INSTRUCTION MANUAL
776
Ratchet ACSR Cutter
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
99949598 REV 3
© 2007 Greenlee Textron Inc.
1/07
776 Ratchet ACSR Cutter
Table of Contents
Safety
Description...................................................................... 2
Purpose of this Manual................................................... 2
Important Safety Instructions.......................................... 3
Identification.................................................................... 4
Specifications.................................................................. 4
Operation......................................................................... 5
Maintenance
General..................................................................... 6
Cleaning the cutter................................................... 6
Lubricating the cutter............................................... 6
Disassembly.................................................................... 7
Assembly
Cutter head............................................................... 8
Stationary handle...................................................... 9
Movable handle........................................................ 9
Movable handle to stationary handle..................... 10
Cutter head to stationary handle............................ 10
Cutter head to movable handle.............................. 11
Tighten pivot screws.............................................. 11
Illustration...................................................................... 12
Parts Lists.................................................................13-14
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.
Purpose of this Manual
This instruction manual is intended to familiarize
personnel with the safe operation and maintenance
procedures for the Greenlee 776 Ratchet Cutter.
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge.
Description
The Greenlee 776 Ratchet Cutter is a non-insulated
cutting tool intended to cut ACSR through 636 kcmil
with steel core diameter less than 0.32".
Specifically cuts:
• all 336.4 kcmil and smaller ACSR
• 397.5 kcmil – Brant, Chickadee, Ibis
• 477.0 kcmil – Pelican, Flicker, Hawk
• 566.5 kcmil – Osprey, Parakeet
• 605.0 kcmil – Peacock
• 636.0 kcmil – Kingbird, Swift, Rook
This tool is equipped with fiberglass handles and rubber
grips to limit operator fatigue.
This tool is not intended to cut guy wire, rebar, or steel rod.
The Greenlee 776 Ratchet Cutter is protected by U.S.
Patent No. 6,766,581.
All specifications are nominal and may change as design improvements occur. Greenlee Textron Inc. shall not be liable for damages
resulting from misapplication or misuse of its products.
Molykote is a registered trademark of Dow Corning Corporation.
Loctite is a registered trademark of Loctite Corporation.
KEEP THIS MANUAL
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
Keep hands away from closing
blades.
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 preventing or avoiding the hazard.
Pinch points:
Keep hands away from moving
parts.
Immediate hazards which, if not avoided, WILL
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.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
• This tool is intended for two-handed operation. Maintain a firm grip on both handles during
operation.
• Do not cut guy wire or steel rod.
• 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.
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.
Electric shock hazard:
This tool is not insulated. Do not use
this tool near energized electrical
lines.
Failure to observe this warning could
result in severe injury or death.
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Identification
Movable
handle
Link
Grips
Speed
pawl
Movable
blade
Stationary
blade
Stationary
handle
Keeper
Release
knob
Specifications
Mass/Weight.............................................................................................2.8 kg (6.2 lb)
Length ................................................................................................ 505 mm (19.87")
Width
at blades............................................................................................. 127 mm (5.0")
at handles.......................................................................................... 159 mm (6.25")
Thickness............................................................................................... 68.5 mm (2.7")
Jaw opening (minimum).......................................................................... 29 mm (1.15")
Handle force at Maximum Capacity.......................................................... 267 N (60 lb)
Capacity —cuts ACSR through 636 kcmil with steel core diameter less than 0.32"
Specifically cuts:
• all 336.4 kcmil and smaller ACSR
• 397.5 kcmil – Brant, Chickadee, Ibis
• 477.0 kcmil – Pelican, Flicker, Hawk
• 566.5 kcmil – Osprey, Parakeet
• 605.0 kcmil – Peacock
• 636.0 kcmil – Kingbird, Swift, Rook
Do not attempt to cut ACSR cable that is not listed, or ACSR cable with a
steel core diameter greater than 0.32".
Failure to observe this precaution may result in damage to the tool.
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Operation
1. Check to see that the release knob is against the link.
release knob
Electric shock hazard:
This is not an insulated tool.
Contact with live circuits could
result in severe injury or death.
link
engage
Wear eye protection when using this
tool. Failure to wear eye protection
could result in serious eye injury
from flying debris.
2. Place the cable to be cut between the cutting blades.
3. Open and close the handles until the cable is cut.
Note: The automatic rapid advance mechanism will
advance the movable blade by 3 teeth each time
the handle is opened. The blade advances 1 tooth
for each closing of the handle. The rapid advance
mechanism is spring-loaded to disengage when
maximum leverage is needed to cut the cable.
4. When the cut is complete, the automatic blade
mechanism automatically returns the blade to the
open position and resets the reverse lever to cut
cable.
Note: To open the blade before the cut is complete,
move the release knob away from the link and press
the handles together. The blade spring will return the
blade to the open position.
• 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.
release knob
link
disengage
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR 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.
Note: The blade lock nut (43) may require tightening
after making several initial cuts on a new or repaired
unit. Always maintain proper adjustment on all pivot
screws. For adjustment procedures, see Assembly—
Tighten pivot screws.
Lubricating the cutter
Keep hands away from closing
blades.
Cleaning the cutter
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.
Close the blades and apply Molykote lubricant or
equivalent between the blades. Lubricate the teeth on
holding pawl (6) and drive pawl (7). Lubricate the four
pivot shoulder screws (13, 16 and 17) and area between
pivoting surfaces. Operate the cutter to spread the
lubricant.
Disassemble, clean, and lubricate the tool if it does not
operate smoothly.
Blow dirt and/or cable particles out of the ratchet
mechanism with compressed air.
Lubrication points
—use Molykote®
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Disassembly
Cutter head
1. Open the movable blade to release tension on the
blade return spring (36).
2. Remove two shoulder screws (16) and remove the
cutter head assembly from the handle assemblies.
Note: Holding pawl (6), torsion spring (40), drive
pawl unit (7), washer (22) and spacer (19) may fall
free during disassembly.
3. Remove shoulder screw (17), spacers (27 and 20),
links (4), release lever (3) and bushing (29).
4. Remove screw (15) and separate cover (10) from
stationary blade (2).
5. Remove screw (41) and spring (36).
This tool consists of three subassemblies: the cutter
head, stationary handle, and movable handle subassemblies (see figure).
1. Cutter head assembly: movable blade (1),
stationary blade (2), release lever (3), links (4),
keeper (18), spring cover (10), reverse lever pin (12),
spring (37), bushing (29), return spring (36), shoulder
screw (17) and related hardware.
2. Stationary handle assembly: handle unit (39),
handle plates (5), holding pawl (6), torsion spring
(40), shoulder screw (16) and related hardware.
3. Movable handle assembly: handle unit (38),
handle plates (8 and 9), speed pawl (11), spring
(35), drive pawl (7), shoulder screws (13 and 16) and
related hardware.
The disassembly procedure is divided into sections of
the tool. Disassemble only the section(s) necessary to
complete the repair.
Disassemble the tool on a flat, clean surface. Take care
not to lose or damage any parts that may fall free during
disassembly.
Stationary handle
6. Remove shoulder screw (13) and movable handle
assembly.
7. Remove two screws (30) and stationary handle
plates (5).
Movable handle
8. Remove two screws (31), left handle plate (8), right
handle plate (9), speed pawl (11) and spring (35).
cutter head
assembly
movable handle
assembly
17
16
13
stationary handle
assembly
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Assembly
4. Install end of spring (36) over roll pin (14) and
assemble spacer (25), and cover (10). Apply Loctite
242 thread adhesive to screw (15) and assemble
to stationary blade (2). Roll pin (14) should be flush
with top of cover (10).
5. Install optional screw guide (46) onto shoulder screw
(17) to help guide the screw through components.
6. Lubricate components and assemble shoulder
screw (17), two links (4), bushing (29), reverse
lever (3), movable blade (1), stationary blade (2),
spacer (20), cover (10), link (4), spacer (27)—with
counterbore toward link. Remove guide (46) if
used and install lock nut (43). Tighten lock nut so
gap between blades does not exceed .004 inches.
Tighten set screw (44).
7. Apply Loctite 242 thread adhesive to screws (28)
and install screws through keeper (18) and into
stationary blade (2).
Refer to the Exploded View and Parts List for correct
orientation and placement of parts. Inspect and replace
any worn or damaged parts. Wherever the assembly
results in metal-to-metal contact, coat the surfaces with
Molykote or equivalent lubricant.
Cutter head
1. Apply Loctite 680 retaining compound to two dowel
pins (32) and install into movable blade, if necessary.
The dowel pins should be flush with the flat side of
the blade. Remove excess Loctite.
2. Apply Loctite 271 thread adhesive to screw (41)
and install screw through end of spring (36) and into
movable blade. Adjust until end of screw is flush
with the angled side of the blade. Allow Loctite to
cure for 10 minutes and remove excess adhesive.
3. Install roll pin (14) into stationary blade (2), if
necessary.
Apply
Loctite 271
Apply
Loctite 242
41
28
43
44
36
2
18
4
27
20
1
15
3
29
46
(optional)
Apply
Loctite 242
10
4
25
14
32
17
Greenlee / A Textron Company
Apply
Loctite 680
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Assembly (continued)
Stationary handle
8. Assemble handle plates (5) to handle unit (39),
but do not tighten hex screws (30).
9. Insert shoulder screws (13 and 16) to align handle
plates (5) and tighten hex screws (30) to 170-190
in-lb. Remove shoulder screws.
Movable handle
10. Assemble right and left handle plates (8 and 9) to
handle unit (38), but do not tighten hex screws (31).
Orient handle plates so slotted hole is opposite the
chamfer in the handle adapter.
slot
9
5
13
16
39
38
chamfer
11. Install roll pin (34) into right and left handle plates.
12. Install roll pin (33) into speed pawl (11), if necessary.
The roll pin should protrude .20 inches from each
side of the speed pawl.
13. Install spring (35) between handle plates.
14. Spread the right and left handle plates and install
speed pawl so the roll pin fits into the slot in the
handle plates. Use the speed pawl to compress
spring (35).
30
.20"
11
9
33
31
8
34
35
38
15. Insert shoulder screws (13 and 16) to align handle
plates and tighten hex screws (31) to 170-190 in-lb.
Remove shoulder screws.
Greenlee / A Textron Company
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Assembly (continued)
Movable handle to stationary handle
16. Install movable handle assembly between the
stationary handle plates and align 3/8" pivot holes.
17. Install optional screw guide (46) onto shoulder screw
(13) to help guide the screw through components.
18. Lubricate shoulder screw (13) and install it through
the handle plates (5 and 8), handle plates (9 and
5) and spacer (26). Remove guide (46) if used and
install lock nut (23).
Cutter head to stationary handle
19. Install torsion spring (40) onto holding pawl (6)
and locate them between the handle plates on the
stationary handle (39) as shown.
2
24
4
19
47
(optional)
10
16
6
5
5
stationary handle
assembly
40
26
5
5
46
(optional)
39
13
23
9
movable handle
assembly
Note:
Ends of torsion spring should be
against handle and pawl as shown.
8
20. Install head assembly between handle plates on the
stationary handle and around the holding pawl (6).
21. Install optional screw guide (47) onto shoulder screw
(16) to help guide the screw through components.
22. Lubricate shoulder screw (16) and install it through
link (4), handle plate (5), torsion spring (40), holding
pawl (6), stationary blade (2), second handle plate (5),
cover (10) and spacer (19). Remove guide (47) if used
and thread on lock nut (24), but do not tighten.
Greenlee / A Textron Company
10
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Assembly (continued)
Cutter head to movable handle
23. Lubricate the ID and teeth on drive pawl unit (7).
Install drive pawl unit between right and left handle
plate (8 and 9) with teeth toward speed pawl. Install
a 5/16 x 1-1/4" pin through the handle plates, pawl
unit, washer (22) and spacer (19) to keep it in place.
4
3
37
12
4
47
(optional)
7
16
9
19
24
19
22
22
Tighten pivot screws
28. Tighten lock nut (43) and set screw (44) on
shoulder screw (17) so gap between blades does
not exceed .004 inches. Spring (36) must open
movable blade freely.
29. Tighten lock nuts on three shoulder screws (13 and 16)
and adjust until components pivot freely.
30. Operate the cutter without cutting cable (see
Operation) and check for proper function. At the
end of the cutting cycle, the spring (36) should
automatically return the movable blade (1) to the
fully open position. Pin (32) should hit and reset
reverse lever (3) into the cutting position. Pin (32)
should remain against the reverse lever as shown.
Note: Tighten the lock nut (43) on screw (17) if there
is a gap between the pin and reverse lever. Loosen
the lock nut (43) if the movable blade returns slowly
or the reverse lever does not reset to the cutting
position. Tighten set screw (44).
8
24. Lubricate release lever pin (12) OD and spherical
end. Install spring (37) and release lever pin (12) into
release lever (3).
25. Rotate cutter head to align 5/16" diameter holes in
links (4) with handle plates (8 and 9).
Note: Spherical end of release lever pin should nest
into one of the two pockets in drive pawl unit.
26. Install optional screw guide (47) onto shoulder screw
(16) to help guide the screw through components.
27. Lubricate components and install shoulder screw (16)
through link (4), washer (22), right handle plate (8),
drive pawl unit (7), left handle plate (9), spacer (19),
link (4) and spacer (19). Remove guide (47) if used
and thread on lock nut (24), but do not tighten.
44
43
17
3
Greenlee / A Textron Company
9
8
5/16 x 1-1/4 pin
11
1
32
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Greenlee / A Textron Company
17
46
(optional)
12
13
16
4
47
(optional)
29
30
3
Apply Loctite 680
Retaining Compound
37
12
22
5
32
18
39
1
40
6
Apply
Loctite 242
28
42
31
2
21
36
7
41
8
14
Apply
Loctite 271
20
38
11
19
26
23
4
27
33
35
5
23
25
43
23
44
21
9
10
19
34
15
19
24
Apply
Loctite 242
24
776 Ratchet ACSR Cutter
Illustration
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Parts List
Key
Part No.
1
2
3
50105213
4
50105248
5
50105264
6
50105280
7
50106317
8
50105310
9
50105337
10
50028251
11
50105370
12
50106252
13
90553764
14
90513479
15
90501110
16
F023194
17
90552229
18
50028278
19
50106279
20
50106287
21
50223003
22
90516567
23
F009550
24
90541200
25
50018671
26
50018663
27
50109901
28
90507967
29
50106295
30
90553853
31
90552652
32
33
90506995
34
90517822
35
90553780
36
90539850
37
90553802
38
50106716
39
50106724
40
50106309
41
F017344
42
90553799
43
50028286
44
90513746
Greenlee / A Textron Company
Description
Qty
Blade assembly, movable (includes key 32)........................................1
Blade, stationary..................................................................................1
Lever, release.......................................................................................1
Link......................................................................................................3
Plate, stationary handle.......................................................................2
Pawl, holding.......................................................................................1
Pawl unit, drive (includes key 42)........................................................1
Plate, right handle................................................................................1
Plate, left handle..................................................................................1
Cover, spring.......................................................................................1
Pawl, speed.........................................................................................1
Pin, reverse lever.................................................................................1
Screw, shoulder, 3/8" x 1.50" x 5/16-18..............................................1
Rollpin, .125" x .50".............................................................................1
Screw, cap, #10-24 x .50" button head...............................................1
Screw, shoulder, 5/16 x 1.75 x 1/4-20.................................................2
Screw, shoulder, 3/8" x 1.75 x 5/16-18...............................................1
Keeper.................................................................................................1
Spacer, .315" x .62" x .286"................................................................3
Spacer, main pivot...............................................................................1
Grip, rubber 0.995" x 1.50" x 5.09".....................................................2
Washer, 5/16 flat..................................................................................1
Nut, locking, 5/16-18...........................................................................5
Nut, locking, 1/4-20.............................................................................2
Spacer, .203" x .50" x .179"................................................................1
Spacer, .377" x .62" x .230"................................................................1
Spacer, .377" x .62" x .187"................................................................1
Screw, 1/4 - 20 x 1/2 button, head cap...............................................2
Bushing................................................................................................1
Screw, cap, 5/16-18 x 1.75" hex head................................................2
Screw, cap, 5/16-18 x 1.25" hex head................................................2
Pin, dowel, .2503" x .50".....................................................................2
Rollpin, .187" x 1"................................................................................1
Rollpin, .094" x 1"................................................................................1
Spring, compression...........................................................................1
Spring, extension.................................................................................1
Spring, compression...........................................................................1
Handle kit—one handle and hardware (includes keys 38, 21, 31, 23) . ..1
Handle kit—one handle and hardware (includes keys 39, 21, 30, 23) . ..1
Spring, torsion.....................................................................................1
Screw, cap, #10-24 x 1/2, socket head...............................................1
Bearing, bronze, .312" x .437" x .625"................................................1
Nut, lock, 5/16-18................................................................................1
Screw, #10-32 x 1/8" set ....................................................................1
13
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
776 Ratchet ACSR Cutter
Repair Parts List
Key
Part No.
Description
Qty
50106260
Bolt kit (includes keys 13, 16, 19, 23, 24, 26)......................................1
50113976
Blade assembly (includes keys 1, 2, 32)..............................................1
Optional Repair Parts
50114603
46
47
Service kit, screw guides (includes keys 46, 47).................................1
Guide, 3/8 screw.................................................................................1
Guide, 5/16 screw...............................................................................1
USA
800-435-0786
815-397-7070
Canada
800-435-0786
International +1-815-397-7070
Fax:
800-451-2632
Fax:
815-397-1865
Fax:
800-524-2853
Fax: +1-815-397-9247
4455 Boeing Drive • Rockford, IL 61109-2988 • USA • 815-397-7070
An ISO 9001 Company • Greenlee Textron Inc. is a subsidiary of Textron Inc.
www.greenlee.com
Greenlee / A Textron Company
14
Printed in USA
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070