INSTRUCTION MANUAL
38456, 38520, 7306/7306SB,
7310/7310SB, 7506, 7606SB, 7610SB,
7625/7625Pg/7625PgSB,
7646/7646Pg/7646PgSB
Read
and
understand
all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
99996065
© 2013 Greenlee Textron Inc.
IM 1066 REV 9 12/13
Hydraulic Punch Driver
Hydraulic Punch Driver
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Important Safety Information .....................................3–4
Setup and Operation Instructions ................................. 5
Illustrations and Parts Lists ........................................6–9
Maintenance ................................................................ 10
Repair .......................................................................... 10
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.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee hydraulic punch driver kits:
• 38456
• 38520
• 7306/7306SB
• 7310/7310SB
• 7506
• 7606SB
• 7610SB
• 7625/7625Pg/7625PgSB
• 7646/7646Pg/7646PgSB
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge at www.greenlee.com.
Description
The Greenlee hydraulic punch driver sets combine
the 746 Hydraulic Ram with the 767 Hand Pump or
the 1725 Foot Pump. These hydraulic driver sets
are intended to be used with either standard or
Slug-Buster
®
punches and dies to punch holes through
plastic, fiberglass, aluminum, and steel. Greenlee
Slug-Splitter
®
punches, dies, and draw studs are
capable of punching through all of these materials and
stainless steel.
Round punches are available for punching holes from
12.7 mm through 144 mm (1/2" through 5-5/8") in
diameter, including 1/2" through 5" conduit and pipe
sizes. Other shapes are available — square, special
square, rectangular, “D”, double “D”, electronic connec-
tor, oiltight with notches, and key.
The maximum thickness of material that the punch can
penetrate depends on the size and shape of the punch.
Refer to the instruction manual supplied with the punch
for individual punch capacities.
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.
Kwik-Stepper, Slug-Buster, and Slug-Splitter are registered
trademarks of Greenlee Textron Inc.
KEEP THIS MANUAL
Greenlee / A Textron Company
2
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Hydraulic Punch Driver
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
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 pre-
venting or avoiding the hazard.
Electric shock hazard:
Do not use this tool near live circuits.
This includes, but is not limited to, the
following:
• near circuit breaker panels or fuse
boxes with energized circuits
• near junction boxes with energized
circuits
Failure to observe this warning could
result in severe injury or death.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Skin injection hazard:
• Hand-tighten all couplers com-
pletely before operating the pump.
Do not use tools to tighten the
couplers.
• Do not use hands to check for
leaks.
• Do not hold hose or couplers while
the hydraulic system is pressurized.
• Release the hydraulic pressure
before disconnecting the hoses or
couplers, and before servicing the
pump or accessory.
Oil under pressure easily punctures
skin causing serious injury, gan-
grene or death. If you are injured by
escaping oil, seek medical attention
immediately.
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.
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.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from flying
debris or hydraulic oil.
Greenlee / A Textron Company
3
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Hydraulic Punch Driver
IMPORTANT SAFETY INFORMATION
A component failure could throw
broken parts.
• Do not allow anyone to stand in
front of the punch or behind the
hydraulic ram.
• Close access doors or covers on
any equipment that is in line with
the punch or ram.
Failure to observe this warning could
result in severe injury or death.
Replace worn, damaged or missing components
with Greenlee replacement parts. Worn or damaged
components can fail, resulting in injury or property
damage.
• Inspect the pump, hoses, couplers, and fittings for
wear or damage.
• Inspect all punch components (punch, die, draw
stud, etc.) for wear or damage.
Failure to observe these warnings could result in
severe injury or death.
Do not attempt to punch a hole
through two or more layers of mate-
rial. This will bend or break the draw
stud, and could throw parts with great
force.
Failure to observe this warning could
result in severe injury or death.
Do not exceed the rated capacity of this tool.
Exceeding the rated capacity could cause a com-
ponent failure, which could throw broken parts with
great force.
Failure to observe this warning could result in severe
injury or death.
Set up the tool properly. An improper setup could
cause a component to fail and strike nearby person-
nel with great force.
• Thread the punch completely onto the draw stud.
All of the punch threads must be engaged by the
draw stud threads. Incomplete assembly could
cause a component failure.
• Use only Greenlee punches, dies, and draw studs.
Other manufacturers’ components might not with-
stand the forces generated by this punch driver.
Failure to observe these warnings could result in
severe injury or death.
The punch driver will fall free when the punch is
complete.
• Support the weight of the tool when punching.
• Do not allow anyone to stand beneath an overhead
punch.
Failure to observe this warning may result in injury or
property damage.
Use this tool for the manufacturer’s intended purpose
only. Any other use may result in injury or property
damage.
This punch system was designed for a maximum
operating pressure of 450 bar (6500 psi).
• Use this punch system with the Greenlee 767 Hand
Pump or 1725 Foot Pump only.
• Connect the pump to the ram with Greenlee hoses
and couplers only.
Use of any other hoses or couplers could result in
injury from a component failure.
Greenlee / A Textron Company
4
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
Hydraulic Punch Driver
Setup and Operation Instructions
1. Remove the dust caps from the couplers; attach the
hose to the ram and to the pump. Thread the dust
caps together.
Note: Hand-tighten the couplers completely until all
threads are engaged. Do not use tools.
2. Select the punch, die, and draw stud that will make
the appropriate size hole.
3. Determine and mark the exact location for the hole.
Using a drill bit that is slightly larger than the draw
stud, drill a hole. This is the
pilot hole.
4. Thread the 3/4" piston shaft (B) completely into the
ram (A). Refer to the illustration.
Note: For a punch and die with a 3/8" center hole,
thread the 3/8" adapter draw stud (F) into the end of
the piston shaft. For a punch and die with a 1-1/8"
center hole, thread the screw sleeve (E) onto the
piston shaft.
5. Install spacers as necessary. Refer to the illustra-
tions on this page.
6. Slide the die over the draw stud with the open end
of the die facing away from the ram.
7. Insert the draw stud through the pilot hole.
8. Thread the punch onto the draw stud with the
cutting surfaces of the punch facing the material.
Tighten the punch by hand until the spacers, die,
material, and punch are snug.
Note: All of the punch threads must be engaged by
the draw stud threads. If any of the punch threads
are not engaged, dis-assemble the setup, remove
one of the spacers, and reassemble the setup.
Do not operate the pump after ram motion stops.
Continuing to operate the pump lever after the ram
stops will damage the ram.
Note: If the ram stops before the hole is complete,
stop pumping. Check that the setup is correct
and that you have not exceeded the tool’s capac-
ity. Refer to the setup instructions. If necessary,
disassemble the setup and add a spacer.
9. Activate the pump. For specific instructions, refer to
the operating manual supplied with the pump.
Note: Support the weight of the ram when operat-
ing the pump. This will prevent the ram from falling
when the punch is complete.
10. Release the pressure at the pump.
Punch
Die
3/8" Adapter
Draw Stud
Spacer
Material
Punch
Die
Spacer
as needed
Material
Punch
Material
1-1/8" Sleeve
3/4" Draw Stud
Ram
Completed Assembly
Die
Greenlee / A Textron Company
5
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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