Quick Draw® Hydraulic Punch Drivers
Contents
1. 1 15 905 0168 3 O ring 364 x 500 x 068 nitrile 1 16 503 1878 0 Decal punch release see see ke ee ee a ee ee ee ee Ek ee ee ek ee ed ee 1 18 905 1130 1 O ring 1 50 x 1 62 x 062 nitrile 1 19 502 3258 4 Grip TUDDer e AE pte Sen eee e d de 1 20 503 2488 8 Plug bladder ie n t teens 1 21 905 4186 3 Retaining ring 217 Truarc ee ee ee ee Re Re ee ee ee 4 22 501 0388 1 Retainer coupler in ouam HS AERE EH 1 23 905 3845 5 Spring compression 152 x 180 x 380 1 24 503 7715 9 ae oe tee den cater tt ee rece eb ad aste ON 1 25 905 3503 0 Retaining ring 562 Truarc see ee ee ee AR Re Re ee ee Re ee 1 26 501 0386 5 Coupler AE RE EE Ge avete Pd dq 1 27 503 6886 9 Knob release valve a a aa 1 28 503 6893 1 Stem release valVe tu S n US ee Su SQ ua Q u Cuba 1 29 503 4269 0 Bladder rubber eo SEE rev cte SS aG a iE C Eee t 1 30 503 7714 0 Pin handle san RO etes 2 31 503 6899 0 Filtet ilix eu eta t eoe ik Sa etal f aet us 1 32 905 0678 2 Ball steel 187 diameter 2 33 905 3854 4 O ring 3250 3 75 OBP inier tei fete e gd 2 34 905 0458 5 aI SE EE EE N EE N 1 35 905 0376 7 O ring 1 125 x 1 375 x 12 nitrile oo eee cence cece u2. EZ LZ GI EL 1 8 s senbs xoe q ui pe a Swan sepnjour Hy Ated ti S Ine p H Z7 ZZv0 LOS m r EE JO euo ZE 8Z ZZ OL ZL So 9JI9 YOR G ui pa o suJei sepnjoul Wy eday Hun anen aseajay 90917 coc S aeday 21 Rockford IL 61109 2988 USA 815 397 7070 4455 Boeing Dr 8 Greenlee Textron Subsidiary of Textron Inc GREENLEE Quick Draw Hydraulic Punch Drivers Parts List 7704SB 7706SB Key Part No Description Qty 1 503 6889 3 Handle reservoir re ive haat dede exec 1 2 503 6887 7 Handle od ARE AE OE ER EE OE deedecead 1 3 503 6890 7 Seat inlet clieck EE RE ES EE GE RM 1 4 503 4271 1 Cylinders hydraulic 1 2 s ce e eti Dee bete 1 5 501 0390 3 Block weld assembly pump seem 1 6 501 0384 9 Rr aec ci rose dae eet tg re reb dece ede ducem ED 1 7 503 4272 0 Spring compression 1 07 x 1 37 x 3 18 1 8 905 3847 1 Backup ring spiral 1 00 x 1 24 x 027 sse 1 9 905 1316 9 O ring 1 50 x 1 75 x 125 nitrile esses 1 10 905 3849 8 Backup ring spiral 1 50 x 1 74 x 027 1 11 905 1330 4 O ring 1 00 x 1 25 x 125 nitrile ee ee Re Re Re ee Re 1 12 905 5281 4 Screw set 48 32 x 312 cup point ee ee ee Re Re ge ee 1 13 905 3761 0 Retaining ring 125 Truarc sees ee ee RR Re ee ee ee 1 14 905 5121 4 Backup ring spiral 373 x 479 x 056
3. block sections Clean or replace filter 31 Refer to Ram Travel Inspection in the Inspection and Adjustments section Refer to Maintenance cylinder and pump block sections Refer to Release Valve inspection in the Inspection and Adjustments section 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers Disassembly 1 Remove reservoir handle 1 and bladder plug 20 drain oil from the rubber bladder 29 2 Remove O ring retainer 35 and the rubber bladder 29 Remove retaining rings 21 from one end of both handle pins 30 and disassemble handle pins and lever handle 2 3 Grasp plunger 24 with pliers pull and twist to remove Loosen set screw 12 from release valve knob 27 remove knob Unscrew release valve stem 28 to remove from pump block 5 Ball 32 is also accessible 4 Loosen set screw 12 from cylinder 4 and unscrew cylinder from pump block 5 5 Remove compression spring 7 retaining plate 22 and ram coupler 26 Spring 23 and ball 37 can also be removed 6 Screw a draw stud into end of ram 6 push the ram out of the cylinder 4 7 Remove retaining ring 25 and filter 31 Remove seat 3 and ball 32 Retaining ring 13 will also be accessible You have now disassembled the punch driver Thoroughly clean all parts and inspect the three ball seats intake discharge and release valve stem f
4. ee Re sS 1 36 905 4230 4 Backup ring spiral 265 x 318 x 050 Re ee 1 37 905 0452 6 Ball steel 218 diameter 1 38 503 6894 0 Cap reservoir handle u 1 39 501 0392 0 FloS u EATA ti es 1 40 501 0387 3 Retainer Spring ie einen retten m tere dees ett eden pede spe ts 1 41 905 4142 1 Ring retaining 2 EE EE BE ote e i ce ene 1 42 501 0393 8 Cover hose eee tee eee EINE 1 43 500 1592 3 Decal identification neiet ara eer en aiara eaan apa e s 1 Greenlee Textron Subsidiary of Textron Inc 9 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers Illustration 7804SB 7806SB g L8 SZ EZ LZ BL GL EL 11 8 sojenbs xoe q ui p y Swan sepnjour HY Ated ti onneapAH p L9LZ 06 m ve EE JO euo ZE ez ZZ OL ZL So 9JI9 YOR G ui p y suJei sepnjoul Wy eday Hun anen aseajay 90917 coc syy aeday Rockford IL 61109 2988 USA 815 397 7070 4455 Boeing Dr 10 Greenlee Textron Subsidiary of Textron Inc GREENLEE Quick Draw Hydraulic Punch Drivers Parts List 7804SB 7806SB Key Part No Description Qty 1 503 6889 3 Handle reservoli socrii inier RE EE OE decus 1 2 503 6887 7 Handle od AE AE dete eren 1 3 503 6890 7 Seat inlet clhieck iR RR LR el ads 1 4 503 4271 1 Gylinder hydraulic i tei tp cce g
5. this Manual This manual is intended to familiarize all personnel with the safe service procedures for the following Greenlee tools 7704SB 7706SB Serial Code AHJ 7804SB 7806SB Serial Code YZ Keep this manual available to all personnel Replacement manuals are available upon request at no charge Other Publications Instruction Manual Publication 999 4730 7 All specifications are nominal and may change as design improve ments occur Greenlee Textron shall not be liable for damages resulting from misapplication or misuse of its products Quick Draw Flex is a trademark and Quick Draw is a registered trademark of Greenlee Textron Loctite and 242 are registered trademarks of Loctite Corporation KEEP THIS MANUAL Greenlee Textron Subsidiary of Textron Inc 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers IMPORTANT SAFETY INFORMATION SAFETY AWARNING ALERT Wear eye protection when operating or servicing this tool SYM BOL Failure to wear eye protection can result in serious eye injury from This symbol is used to call your attention to hazards flying debris 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 A WARNING after the signal word provides information for preventing or avoiding the hazard Inspect tool for wear or damage Replace any worn d
6. this tool for the manufacturer s intended pur pose only Use other than that which is described in Do not use this tool near live circuits np this manual can result in injury or property damage This includes but is not limited to the following Near circuit breaker panels or fuse Note Keep all decals clean and legible and replace boxes with energized circuits when necessary Near junction boxes with ener gized circuits Failure to observe this warning can result in severe injury or death Greenlee Textron Subsidiary of Textron Inc 3 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers Maintenance Maintenance and repairs should be performed in a dust free area by qualified technicians This unit requires minimum maintenance because it I has a closed hydraulic system and all internal parts Reservoir Handle are lubricated by the hydraulic fluid Lubricate lever pins lightly Keep contaminants away from the ram and cylinder Store with the lever down and hydraulic pressure released Adding Hydraulic Oil Bladder Plug 1 Place the driver in a vise in a vertical position with the handles up Unscrew the reservoir handle and remove the bladder plug Open the release valve knob to assure the ram is fully extended 2 Fill the rubber bladder to the point of overflow with Greenlee hydraulic oil 3 Purge air from the system Pump the lever handle several
7. 8 8 Spacen 7607 X 1 97 SI N 1 1614SS 503 0043 1 Screw 3 8 short adapter ee ee ee ke Re ee ge 1 33967 503 3967 2 Adapter stud 3 8 24 x 3 4 16 1 GREENLEE DARCI Greenlee Textron Subsidiary of Textron Inc 4455 Boeing Drive Rockford IL 61109 2988 USA Customer Service International 815 397 7070 Fax 815 397 9247 Customer Service North America 800 435 0786 USA Fax 800 451 2632 815 397 1865 Canada Fax 800 524 2853 www greenlee textron com Printed in the USA
8. SERVICE MANUAL GREENLEE 7804SB 7806SB Quick Draw 7704SB 7706SB Quick Draw Flex Quick Draw Hydraulic Punch Drivers Serial Codes AHJ and YZ Read and understand all of the instructions and safety information in this manual before operating or servicing this tool 999 4732 3 2002 Greenlee Textron 8 02 GREENLEE Quick Draw Hydraulic Punch Drivers Table of Contents Safely E E EE las a dats ET 2 Purpose of this Manual eene 2 Other Publications 22 eti Ecce PR pendet 2 Important Safety Information 3 Maintenance ee Ee Re RA Ee ee ee ee Ge RA Re ee ee ee ee 4 Troubleshooting u de ee 5 BEE ed AE EE ehe dd 6 Ball Seat Repair ani a Ru RA gu AA ee ee 6 Reassembly uuu uw a Ee ee ee ee ee ee s 7 Inspection and Adjustments 7 Illustrations and Parts Lists 8 11 7704SB 7706SB 8 9 7804SB 7806SB sse 10 11 Draw Studs and Accessories 12 Safety Safety is essential in the use and maintenance of Greenlee tools and equipment This 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
9. amaged or missing components with ADANGER Greenlee replacement parts A damaged or improperly assembled tool can break and strike nearby personnel with sufficient force to cause Immediate hazards which if not avoided WILL TR ld or death result in severe injury or death Inspect the punch die draw stud and spacers for wear or damage Replace any worn or damaged A WARNING items with Greenlee replacement parts Replace any punches that have dull cutting surfaces Hazards which if not avoided COULD result in severe injury or death A ACAUTION a Do not exceed the rated capacity of this tool Hazards or unsafe practices which if not avoided Exceeding the rated capacity could cause a MAY result in injury or property damage component failure which could throw broken parts with great force Failure to observe this warning can result in severe A WARNING injury or death Read and understand all of the instructions and safety information in A WARNING this manual before operating or vA servicing this tool Refer also to the Do not operate the pump lever after the ram motion instruction manual which is listed stops Continuing to operate the pump lever after the under Other Publications ram motion stops will damage the driver and could propel internal parts with great force striking nearby personnel GA Failure to observe this warning can result in severe injury or death A CAUTION Electric shock hazard Use
10. cted Measure ram travel distance difference between ram completely extended and completely retracted Adjust cylinder 4 so travel distance is 0 830 21 1 mm to 0 930 23 6 mm Tighten set screw 12 23 6 mm 21 1 mm Rotate cylinder 930 f to make adjustment 830 Piston i Travel 1 33967 Adapter Set Screw 12 Pump Section Inspection Intake Check Valve Close the release valve knob and operate lever handle 2 until ram 6 bottoms and handle resistance increases f the ram bottoms in 30 strokes or less the intake check valve is operating properly More than 30 strokes indicates an intake check leak Re seat re drill or replace the intake check seat Discharge Check Valve If the lever handle 2 returns to the raised position by itself the discharge check valve is leaking Re seat or re drill the discharge check seat and replace the discharge compression spring 23 Release Valve Pump the handle until the ram bottoms Gently apply and maintain additional force on lever handle 2 If the lever handle remains solid the release valve ball 82 is operating properly If the lever handle 2 goes down slowly the release valve is leaking Re seat or re drill the release valve stem seat and replace O ring 33 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers Illustration 7704SB 7706SB LE LE Ge
11. e 1 26 503 6891 5 Coupler AE RE EE Ge EE Ge mu SR Ge Ge 1 27 503 6886 9 Knob release valve iese ee ee ee ee Ee Ee ee ee ee RR ER a ee ee ee ee Ee ee 1 28 503 6893 1 Stem release valve tu S n ee ee ee ee ee ee Su SQ ua Q u ER ee ee ee 1 29 503 4269 0 Bladder rubber ea eo i reete itn Fe AR DE Ee a iE t EE ER t 1 30 503 7714 0 Pin handle RE IR N be e s 2 31 503 6899 0 Filters Oil eis se ited eta t eoe fecere e f aet N 1 32 905 0678 2 Ball steel 187 diameter 2 33 905 3854 4 O ring 2503375 X062 wicca aiming tetti eee gd 2 34 905 0458 5 aI SR N OE RE nee N ER 1 35 905 1741 5 O ring 1 31 x 1 56 x 125 Nitrile s nenne 1 36 905 4230 4 Backup ring spiral 265 x 318 x 050 ee Re ee Re 1 37 905 0452 6 Ball steel 218 diameter 1 38 503 6894 0 Cap reservoir handle ee ee ee Re ee Re Re Re Re ee ge ee 1 503 7622 5 Decal identification not SHOWN a a 1 Greenlee Textron Subsidiary of Textron Inc 11 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers Draw Studs and Accessories Cat No Part No Description Qty 29451 502 9451 2 Draw stud 7 16 stainless steel optional 1 31872 503 1872 1 Draw stud 3 4 16 x 4 12 eek RR Re ER Re Re ee Re ee Re ee 1 1924AA 503 324
12. e Remedy Does not punch hole Requires excessive lever force Pump does not build pressure Excessive number of strokes are required to punch hole Does not return piston External oil leaks Greenlee Textron Subsidiary of Textron Inc 5 Improper assembly or use of punch die or accessories Low oil level Improper assembly or use of punch die or accessories Material being punched is too thick or too hard Air in system Inoperative intake check valve Inoperative discharge check valve Leaking release valve Damaged piston piston extension pump plunger seals or mating surfaces Clogged filter Weak or damaged return spring excess oil in unit Damaged piston piston extension pump plunger seals or mating surfaces Damaged release valve stem seal Refer to Operation and Capacity and Draw Stud Selection Guide Refer to Adding Hydraulic Oil in the Maintenance section Refer to Operation and Capacity and Draw Stud Selection Guide Refer to Capacity and Draw Stud Selection Guide Refer to step 3 of Adding Hydraulic Oil in the Maintenance section Refer to Intake Check Valve inspection in the Inspection and Adjustments section Refer to Discharge Check Valve inspection in the Inspection and Adjustments section Refer to Release Valve inspection in the Inspection and Adjustments section Refer to Maintenance cylinder and pump
13. e t ettet eee bene 1 5 503 6900 8 Block pUMPs ec eh TERRIER REIS 1 6 503 6896 6 Rte aoa aec aam d e e e e dum ceed tes 1 7 503 4272 0 Spring compression 1 07 x 1 37 x 3 18 ee RR Re Re 1 8 905 3847 1 Backup ring spiral 1 00 x 1 24 x 027 see 1 9 905 1316 9 O ring 1 50 x 1 75 x 125 nitrile esses 1 10 905 3849 8 Backup ring spiral 1 50 x 1 74 x 027 1 11 905 1330 4 O ring 1 00 x 1 25 x 125 nitrile Re Re 1 12 905 1032 1 Screw set 8 32 x 187 socket cup RR Re ee ke 2 13 905 3761 0 Retaining ring 125 Truarc sees ee ee ee RR Re ee ee ee ee 1 14 905 5121 4 Backup ring spiral 373 x 479 x 056 sse 2 15 905 0168 3 O ring 364 x 500 x 068 nitrile 2 16 503 1878 0 Decal punch release see see din ke ee ek ee He dee 1 18 905 1130 1 O ring 1 50 x 1 62 x 062 nitrile 0 2 eee Re RR RR RA RA 1 19 502 3258 4 Grip TUDDOr e AE ies eA eee ed de 1 20 503 2488 8 Plug bladder ie t eee RD 1 21 905 4186 3 Retaining ring 217 Truarc see ee ee Re Re ee ee ee ee 4 22 503 6892 3 AREA RE ME EE EUR RE cad 1 23 905 3845 5 Spring compression 152 x 180 x 380 1 24 503 7715 9 ae EE N OER ER ad aste ON 1 25 905 3503 0 Retaining ring 562 Truarc sees ee ee Re Re ee ee ee e
14. or nicks scratches or other damage Greenlee Textron Subsidiary of Textron Inc 6 Ball Seat Repair Re seating Minor seat imperfections may be corrected by re seating Use a soft brass rod and hammer to tap the ball against its seat A WARNING Wear eye protection when operating or servicing this tool Failure to wear eye protection can result in serious eye injury from flying debris Re drilling Badly worn or damaged seats may be reworked by re drilling and then re seating The pump block is manufactured with seats of 118 the standard drill point angle Use standard drills for re drilling To re drill the 3 16 ball seat for release valve stem 28 Use an l drill and a 9 64 diameter reamer To re drill the 7 32 ball seat for the discharge check Use an I drill and a 5 32 diameter reamer To re drill the 3 16 ball seat for the intake check Use a 1 4 drill and a 1 8 diameter reamer When drilling remove a minimum of material to obtain maximum seat life Re seat the balls before reassembly Drill ma Discharge Check Std Drill to Acceptable Drill m 5 32 Ream Release Valve 9 64 Ream Stem Intake B Drill Check 9 64 Ream 4455 Boeing Dr Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers Reassembly Reassembly is done in reverse sequence of disassembly 1 Use one of the following repair kits to
15. replace all O ring seals balls and springs e 77048B 7706SB Repair kit 501 0477 2 e 7804SB 7806SB Repair kit 503 7161 4 2 Inspect drilled oil passage in ram 6 be sure this passage is not blocked 3 Before reinserting ram 6 in cylinder 4 lightly coat O ring seals and bores of the cylinder with clean hydraulic oil 4 Coat discharge check spring 23 with petroleum gel and insert it into the counter bore of the ram coupler 26 5 Fill plunger bore in pump block 5 with clean oil Then coat plunger O ring seals with clean oil and reinsert in the pump block with release valve knob 27 closed 6 Fill unit with clean oil and purge air Refer to Adding Hydraulic Oil in the Maintenance section of this manual Greenlee Textron Subsidiary of Textron Inc 7 Inspection and Adjustments After reassembly check the following Ram Travel Inspection Ram Extended With the draw stud removed and release valve knob open observe whether end of ram 6 is flush to 1 64 0 396 mm below the end of cylinder 4 If it is not the rubber bladder 29 contains too much oil To remove excess oil 1 Remove reservoir handle 1 and bladder plug 20 2 Slowly open release valve knob 27 excess oil should come out of the rubber bladder and the ram should move to become flush to 1 64 0 396 mm below the end of cylinder 4 3 If excess oil does not come out replace the compression spring 7 Ram Retra
16. times to remove air from the pumping chamber Close the release valve knob and pump the lever handle until the ram completes its full travel Repeat as necessary Note Open the release valve knob slowly so the Oil Leaks ram extends slowly Rapid return of oil and air may Check for external oil leaks cause the oil to overflow the rubber bladder Rubber Bladder Release Valve Knob Check that the release valve knob and stem are If this procedure fails to remove air remove the closed tightly and seating properly bladder plug and open the release valve knob Place Remove the reservoir handle and check for oil leaks thumb over the plug hole in the bladder and squeeze h ladd d bladder pl the bladder while pumping the lever handle several argunas pora aid blader plae times Close the release valve knob and pump the lever handle until the ram completes its full travel Repeat as necessary If this procedure does not remove air remove the plunger 24 and fill the plunger cavity with clean oil as described in the Reassembly section of this manual 4 Fill the rubber bladder to the point of overflow and replace the bladder plug Wipe the bladder clean of excess oil and reassemble the reservoir handle Greenlee Textron Subsidiary of Textron Inc 4 4455 Boeing Dr e Rockford IL 61109 2988 USA 815 397 7070 GREENLEE Quick Draw Hydraulic Punch Drivers Troubleshooting Problem Probable Cause Probabl
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