Textron Greenlee 763 User manual

763 & 764M4

Ratchet Cable Cutters

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

INSTRUCTION MANUAL

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Greenlee / A Textron Company 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

Description ..................................................................... 2

Purpose of this Manual .................................................. 2

Important Safety Instructions ......................................3-4

Identification ................................................................... 5

Specifications ................................................................. 5

Operation ....................................................................... 6

Maintenance

General ...................................................................... 7

Cleaning the cutter..................................................... 7

Lubricating the cutter ................................................. 7

Disassembly .............................................................. 8

Assembly ..............................................................9-11

Exploded View ............................................................. 12

Parts List ...................................................................... 13

Table of Contents

Description

Greenlee 763 and 764M4 Ratchet Cable Cutters are

non-insulated cutting tools intended for use on copper

and standard aluminum electrical cable. The 763 will

accommodate up to 500 MCM copper or 795 MCM

aluminum cable. The 764M4 will cut up to 750 MCM

copper or 795 MCM aluminum cable.

Both cable cutters ratchet and are equipped with fiber-

glass handles and rubber grips to limit operator fatigue.

They are not intended for use on ACSR (aluminum

cable, steel-reinforced) cable.

Purpose

This instruction manual is intended to familiarize person-

nel with the safe operation and maintenance procedures

for the following Greenlee 763 and 764M4 Cable Cutter.

Keep this manual available to all personnel.

Replacement manuals are available upon request

at no charge.

Safety

Safety is essential in the use and maintenance of

Greenlee tools and equipment. This instruction manual

and any markings on the tool provide information for

avoiding hazards and unsafe practices related to the

use of this tool. Observe all of the safety information

provided.

KEEP THIS MANUAL

All specifications are nominal and may change as design improve-

ments occur. Greenlee Textron Inc. shall not be liable for damages

resulting from misapplication or misuse of its products.

Loctite is a registered trademark of Loctite Corporation.

416 Super Bonder is a registered trademark of Loctite Corporation.

Molykote is a registered trademark of Dow Corning Corporation.

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Greenlee / A Textron Company 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

IMPORTANT SAFETY INFORMATION

This symbol is used to call your attention to hazards

or unsafe practices which could result in an injury

or property damage. The signal word, defined below,

indicates the severity of the hazard. The message

after the signal word provides information for prevent-

ing or avoiding the hazard.

Hazards or unsafe practices which, if not avoided,

MAY result in injury or property damage.

Hazards which, if not avoided, COULD result in

severe injury or death.

Immediate hazards which, if not avoided, WILL result

in severe injury or death.

SAFETY

ALERT

SYMBOL

Read and understand all of the

instructions and safety information

in this manual before operating or

servicing this tool.

Failure to observe this warning could

result in severe injury or death.

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Greenlee / A Textron Company 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

IMPORTANT SAFETY INFORMATION

Electric shock hazard:

This is not an insulated tool.

Contact with live circuits could result

in severe injury or death.

• This tool is intended for two-handed operation.

Maintain a firm grip on both handles during

operation.

• Do not cut ACSR or steel.

• Do not exceed the rated capacity of this tool.

• Inspect before use. Replace any worn or damaged

parts.

• Do not perform any service or maintenance other

than as described in this manual.

Failure to observe these precautions may result in

injury or property damage.

Pinch points:

Keep hands away from moving

parts.

Wear eye protection when using this

tool. Failure to wear eye protection

could result in serious eye injury

from flying debris.

Keep hands away from closing

blades.

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Greenlee / A Textron Company 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

Specifications

763 764M4

Mass/Weight ...................................................................................2.15 kg (4.75 lb) ............................ 2.4 kg (5.25 lb)

Length ............................................................................................ 349 mm (13.75") ........................ 486 mm (19.125")

Width at blades .............................................................................. 102 mm (4.03") ............................ 102 mm (4.03")

at handles ............................................................................ 132 mm (5.19") ................................. 152 mm (6")

Thickness ........................................................................................... 63.5 mm (2.5") ............................. 63.5 mm (2.5")

Jaw opening (minimum).................................................................... 30 mm (1.188") ............................ 30 mm (1.188")

Handle force at Maximum Copper Capacity......................................... 334 N (75 lb) ................................ 267 N (60 lb)

Maximum Rated Capacity

Copper (600-Volt Building Wire) .............................................. 240 mm2(500 Kcmil) ................... 400 mm2(750 Kcmil)

Aluminum (600-Volt Building Wire).......................................... 400 mm2(795 Kcmil) ................... 400 mm2(795 Kcmil)

Communications Cable.............................................................30 mm (1.188") O.D. ....................30 mm (1.188") O.D.

Frequent Use

Copper (600-Volt Building Wire) ...............................................170 mm2(350 MCM) ....................240 mm2(500 MCM)

Aluminum (600-Volt Building Wire)...........................................240 mm2(500 MCM) .................... 400 mm2(750 MCM)

Identification

Grips

Stationary

handle

Stationary

Jaw

Release

knob

Release

Movable

handle

Movable

Jaw

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Greenlee / A Textron Company 64455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

Operation

• This tool is intended for two-handed operation.

Maintain a firm grip on both handles when using

this tool.

• Inspect before use. Replace any worn or damaged

parts.

Failure to observe these precautions may result in

injury or property damage.

1. Place the cable to be cut between the jaws.

2. Press the handles together until the ratchet clicks

once.

3. Open the handles until the ratchet clicks again.

4. Repeat steps 2 and 3 until cable is completely cut.

5. To open the blades, lift the movable handle until it

stops. Press the release knob outward as shown.

Electric shock hazard:

This is not an insulated tool.

Contact with live circuits could result

in severe injury or death.

Wear eye protection when using this

tool. Failure to wear eye protection

could result in serious eye injury

from flying debris.

Release

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Greenlee / A Textron Company 74455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

Maintenance

General

Maintain the tool with care. Keep the blades sharp

and the tool clean for better and safer performance.

Follow instructions for lubricating the cutter; lubrication

prolongs the tool life and enables the tool to cut with less

force. Keep grips dry, clean and free from oil

and grease.

Cleaning the cutter

Blow dirt and/or cable particles out of the drive

mechanism with compressed air.

Lubricating the cutter

Close jaws and place 3-in-1 oil or equivalent on the

blades. Oil the jaw bolt (25), spacer (4), and jaw areas

around them. Also oil the master gear (16) and pawls (15)

at their respective shafts (19) and contact surfaces. Oil

the inside of the housing plates (13, 23) where contacted

by the lever handle plates (14, 22). Open and close the

cutter to spread the oil.

Disassemble, clean, and lubricate the tool if it does not

operate smoothly.

Wear eye protection when using this

tool. Failure to wear eye protection

could result in serious eye injury

from flying debris.

Pinch points:

Keep hands away from moving

parts.

Keep hands away from closing

blades.

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Greenlee / A Textron Company 84455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

Disassembly

This tool consists of three basic operating mechanisms

(see Figure 1).

1. Cutter jaw mechanism: stationary jaw (1), movable

jaw (3), jaw bolt (25), jaw spacer (4), return spring (5),

and related hardware.

2. Jaw drive mechanism: master drive gear (16),

master gear shaft (26), drive pawl (15), pawl spring

(12), pawl shaft (19), top and bottom handle plates

(14, 22) and operating lever.

3. Jaw holding mechanism: holding pawl (15), pawl

spring (17), pawl shaft (19) and pawl release pin

(27).

Maintenance (cont’d)

Both the jaw mechanism and drive mechanism can

be removed and serviced without disassembly of the

housing.

1. Remove cap screw (21). Release tension on exten-

sion spring (5) by opening the operating lever and

rotating release pin (27) outward.

2. Remove nut (6).

3. Remove bolt (25) and spacer (4).

4. Disconnect spring (5) from housing (13).

5. Remove retaining ring (9) from gear shaft (26).

Also remove two screws (8) from stop pin (20).

6. Remove shaft (26) and gear (16).

7. Remove the operating lever assembly.

8. Remove rubber bumpers (10) from release pin (27).

9. Remove two housing screws (11). Lift housing from

tool.

10. Remove two screws (11) to disassemble operating

lever assembly and remove pawl (15), pawl spring

(12) and pawl shaft (19).

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Greenlee / A Textron Company 94455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

Assembly

Maintenance (cont’d)

Figure 1

2,8

35,7 16 13 20 14

28 29

6,25

9,26 10

11*

JAW HOLDING

MECHANISM

LUBRICATION

POINTS -

USE MOLYKOTE®

SPRING

ANCHOR PIN

JAW DRIVE

MECHANISM

OPERATING

LEVER

*Note: Tighten to 19.2 - 21.4 Nm

(170-190 in-lb)

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Greenlee / A Textron Company 10 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070

763 and 764M4 Ratchet Cable Cutter

Note: Use Loctite

262 Threadlocker on all screws

and tighten all 5/16" diameter screws to 190/170 in-lb.

Use Loctite 416 Super Bonder

(cyanoacrylate) to attach

release pin bumpers (10). Lubricate moving parts with

Molykote

grease (see Figure 1).

Assembly (cont’d)

Assemble handle assembly (39) to bottom of housing

plate (13) using two screws (11).

2. Install stop pin (20). Place a spare 3/8" x 1.500"

screw through the master gear hole in bottom

housing plate (13) and place assembly on bench

with screws up (see Figure 2).

3. Lubricate pawl shaft (19) and assemble pawl shaft,

pawl (15) with pin (33) projecting from pawl surface,

spring (12), bottom handle plate (14) and top handle

plate (22) to handle assembly using two screws (11).

The long leg of the spring goes against the bottom

handle adapter (28) and the short leg goes under the

pawl (see Figure 3).

4. Insert master gear (16) between top and bottom

handle plates against drive pawl (15) and assemble

over spare screw in bottom housing plate (see

Figure 4).

5. Place holding pawl (15) with release pin (27) and

spring (17) over hole in bottom housing plate and

insert lubricated pawl shaft (19). The pawl will

engage the master gear. The long leg of the spring

goes against the handle adapter (28) where it

touches the bottom housing plate and the short leg

goes under the pawl (see Figure 4).

6. Thread housing cover (35) between handle plates

above the master gear—between spring (17) and

handle adapter (28) (see Figure 4).

Maintenance (cont’d)

Figure 3

13 20

Figure 2

15 27 19 17 28

Figure 4

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