Greenlee 39693 Guide

OPERATION, SERVICE AND PARTS
INSTRUCTION MANUAL
999 0703.8 © 1997 Greenlee Textron IM 1139 REV 3 8/97
39693
BUS BAR PUNCH
WITH TABLE
Read and understand this material before
operating or servicing this tool. Failure to under-
stand how to safely operate the tool could result
in an accident causing serious injury or death.
37736 X-Y Table
(Optional)
37735 Ram Unit
37902 Punch Unit

2
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Table of Contents
Additional copies of this manual are available upon request at no charge.
A person who has not read and does not understand all
operating instructions is not qualified to operate this tool.
Failure to read and understand safety instructions may
result in injury or death.
Introduction and Purpose of this Manual..............................................................2
Safety Information.................................................................................................3
Specifications and Capacity .................................................................................4
Description ............................................................................................................4
Setup................................................................................................................. 5-6
Operation ..............................................................................................................7
Punch, Die and Stripper Plate Selection ..............................................................9
Troubleshooting ..................................................................................................10
Ram Unit .............................................................................................................11
Yoke Pin..............................................................................................................12
Alignment Table..................................................................................................13
X-Y Table (optional)............................................................................................14
Mounting the X-Y Table to the Bus Bar Punch Unit ......................................14
Punch Unit
Disassembly / Assembly ................................................................................15
Exploded View ...............................................................................................16
Parts List ........................................................................................................17
Introduction
The Greenlee 39693 Bus Bar Punch with Table consists
of a punch unit, hydraulic ram, and an alignment table.
The 39693 is intended to punch copper or aluminum
bus bar up to 12mm x 120mm. Two separate die sets
are furnished with the punch unit - one set for laminated
bus bar and one set for solid bus bar.
The 39693 is intended to be used with any Greenlee
hydraulic pump capable of developing 10,000 psi
(690 BAR), such as:
Manual Pump: 755
Electric Pump (120-volt): 960, 975, 980
Electric Pump (220-volt): 976-22 FS, 976-22-PS,
980-22 FS, 980-22 PS
An optional X-Y Punch Table (catalog number 37736) is
available for repetitious punching of standard 2-bolt and
4-bolt hole patterns.
Purpose of this Manual
This instruction manual is intended to familiarize
operating and maintenance personnel with the safe
operation and maintenance procedures associated with
the 39693 Bus Bar Punch with Table.

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Safety Information
SAFETY
ALERT
SYMBOL
Hazards or unsafe practices which, if not avoided, COULD
result in minor personal injury or property damage.
Hazards or unsafe practices which, if not avoided, COULD
result in severe personal injury or death.
Immediate hazards which, if not avoided, WILL result in
severe personal injury or death.
The symbol above is used to call your attention
to instructions concerning your personal safety.
Watch for this symbol. It points out important safety
precautions. It means “ATTENTION! Become alert!
Your personal safety is involved!” Read the
message that follows and be alert to the possibility
of personal injury or death.
Safety is a critical factor in the design of Greenlee equipment. The best program starts with a safety-conscious
operator. The information highlighted in this bulletin describes operating practices for the benefit of the workers
who will use our equipment in their daily jobs. Comments from users are appreciated.
• Disconnect electric pump from power supply
before changing accessories, making adjust-
ments, or servicing. Accidental start-up could
result in severe injury.
• Inspect the tool before using. Replace any
worn, damaged, or missing parts with Greenlee
replacement parts. A damaged or improperly
assembled tool can break and strike nearby
personnel with sufficient force to cause severe
injury or death.
• The punch unit is not designed to completely
support longer bus bar. Use additional support
when punching bus bar 1 meter long or longer.
Failure to support bus bar may damage punch unit.
• Use the Die Alignment procedure frequently.
Through normal use of the bus bar punch, the die
may become out of alignment. Using the bus bar
punch with the die misaligned will produce burrs
on the bus bar and may eventually damage the
punch and the die.
Failure to observe these precautions could result in
injury or property damage.
• The yoke pin unit must fully engage the punching
yoke. An improperly assembled tool could break
and components could strike nearby personnel.
• The punch unit is heavy, weighing over 90 lbs.
(40.9 kg), and may require more than one person
to lift or assemble. Injury could result from lifting
alone. If in doubt, get help.
Failure to observe these warnings could result in
severe injury or death.
Pinch points. Do not remove
guards. Keep hands away from
moving parts.

4
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Description
Hydraulic Ram, Punches, and Dies
The hydraulic punching action is accomplished with a
single-acting ram. Hydraulic pressure advances the ram
to drive the punch and an internal spring retracts the
ram after the hole is made.
The punches are designed to punch through solid and
laminated bus bar. Punches larger than 8mm have a
spring-loaded centering pin for precise alignment. Two
sets of dies are supplied with the bus bar punch: dies
with a black finish for punching laminated bus bar, and
dies with a bright zinc finish for punching solid bus bar.
Alignment Table
The alignment table is adjusted vertically to support the
bus bar at the working level of the punch. The adjust-
able handle allows the top plate to be moved from side
to side.
The bus bar punch operator can set precise hole
locations using the alignment top plate, the side align-
ment guide, and the depth stop. These have scales to
indicate the distance from the edge of the bus bar to the
center of the hole.
Hydraulic Pumps (Electric/Manual)
The bus bar punch is intended to be used with any
Greenlee hydraulic pump capable of developing 10,000
psi (690 BAR). See the manual supplied with the pump
for specific instructions concerning its use.
X-Y Table (Optional)
An optional X-Y Table is available for quick set-up and
repetitious punching of standard 2-bolt and 4-bolt hole
patterns. See catalog number 37736.
Specifications
Ram Unit:
25-Ton Single-Acting Hydraulic Ram
Bore Diameter........................................................................2.500" (63,5mm)
Rod Diameter...........................................................................1.25" (31,7mm)
Maximum Stroke ......................................................................2.00" (50,8mm)
Maximum Pressure ........................................................10,000 psi (690 BAR)
Weight .......................................................................................13 lbs. (5,9 kg)
Punch Unit:
Hole Size, Minimum .................................................................... .236" (6mm)
Hole Size, Maximum .............................................................. .658" (16,7mm)
Weight .....................................................................................90 lbs. (40,9 kg)
X-Y Punch Table (optional):
“X” Dimension ..................................................... 26mm, 40mm, 50mm, 60mm
“Y” Dimension .......................................................................... 26mm or 40mm
Weight .......................................................................................19 lbs. (8,7 kg)
Hose Assembly (optional):
Inside Diameter..........................................................................1/4" (6.35mm)
Length ...........................................................................................6' (182.9cm)
Maximum Pressure ........................................................ 10,000 psi (690 BAR)
Sizes and Types of Bus Bar
Maximum Thickness .................................................................... .47" (12mm)
Maximum Width ....................................................................... 4.72" (120mm)
Lamination Thickness, Minimum .............................................. .020" (0,5mm)
Lamination Thickness, Maximum ................................................ .040" (1mm)
Number of Laminations, Minimum ...................................................................2
Number of Laminations, Maximum ................................................................24
Capacity

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Figure 1
The yoke pin unit must fully engage the punching
yoke. An improperly assembled tool could break
and components could strike nearby personnel.
Setup
Bus Bar Punch Unit Placement
The punch unit is heavy, weighing over 90 lbs.
(40.9 kg), and may require more than one person
to lift or assemble. Injury could result from lifting
alone. If in doubt, get help.
The Bus Bar Punch Unit should be set up in a well-lit
and uncluttered work area. Select a work location with
plenty of clearance around the punch unit. Use four
large screws to attach the bus bar punch unit to a
workbench or other work surface sturdy enough to
support the weight of the bus bar punch unit and the
bus bar.
Die Alignment
• Inspect the tool before using. Replace any worn,
damaged, or missing parts with Greenlee
replacement parts.
• Disconnect electric pump from power supply
before changing accessories, making adjust-
ments, or servicing. Accidental starting could
result in severe injury.
Alignment Punch
Alignment Die
Die Holder
1. Remove the yoke pin unit (C) and ram unit (A).
Raise the guard (M). See the exploded view.
Note: If a punch, die and stripper plate have been
installed, remove them before proceeding.
See Changing the Punch, Die, and Stripper
Plate under Operation in this manual.
2. Loosen the four socket-head cap screws (R) on the
die holder (T).
3. Place the alignment die into the die holder (T).
Press the die firmly into place. Lower the guard (M).
4. Insert the alignment punch through the top of the
punching yoke (G). See the exploded view and
Figure 1.
5. Install the ram unit (A) into the punching yoke (G).
Fully insert the yoke pin unit (C) into the punching
yoke (G). See the exploded view.
Note: The yoke pin unit is fully inserted when the ball
plungers have gone completely through the
punching yoke and are visible at the back side
of the punching yoke.
Pinch points. Do not remove
guards. Keep hands away from
moving parts.
6. Connect one end of the hose unit (B) to the
coupler. Connect the other end of the hose to a
hydraulic pump capable of developing 10,000 psi
(690 BAR).
Note: Refer to the manual supplied with the pump.
Note: If using an electric pump, plug it in to an
adequate power supply. Place the release
lever in the MANUAL RELEASE position.
7. Use the hydraulic pump to advance the ram until
the alignment punch and alignment die are fully
engaged.
Note: If using an electric pump, disconnect the pump
from the power supply.

6
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Figure 2
Punch
Die
Die Holder
Stripper Plate
4. Place the die (Q) into the die holder (T). Press the
die firmly into place. Lower the guard (M).
5. Insert the punch (II) through the top of the punching
yoke (G). See the exploded view.
6. Install the ram unit (A) into the punching yoke (G).
Fully insert the yoke pin unit (C) into the punching
yoke (G).
Note: The yoke pin unit is fully inserted when the ball
plungers have gone completely through the
punching yoke and are visible at the back side
of the punching yoke.
The yoke pin unit must fully engage the punching
yoke. An improperly assembled tool could break
and components could strike nearby personnel.
Hydraulic Connection
Connect one end of the hose to the coupler. Connect
the other end of the hose to a hydraulic pump capable
of developing 10,000 psi (690 BAR).
Note: If using and electric pump, connect the pump to
an adequate power supply. Refer to the manual
supplied with the pump.
8. Tighten the four socket-head cap screws (R) on the
die holder (T).
9. Release the hydraulic pressure to retract the ram.
10. Disconnect the hydraulic hose (B) from the coupler.
11. Remove the yoke pin unit (C) and the ram unit (A)
and raise the guard (M).
12. Place the flat edge of a screwdriver against the
bottom edge of the punch. Press the punch upward.
Lift the punch up and out of the yoke (G).
13. Lift the alignment die out of the die holder (T).
Punch, Die, and Stripper Plate Installation
1. Select punch, die and stripper plate according to
the type of bus bar to be punched and the size
of hole required. See table: Punch, Die, and the
Stripper Plate Selection.
2. Remove yoke pin unit (C) and ram unit (A). Raise
the guard (M).
3. Install stripper plate (EE) by pushing it into the
stripper plate holder (FF). See Figure 2.
Note: The stripper plate snaps into place and is
retained by two ball plungers.
Setup (cont’d)

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
3. Use the hydraulic pump to advance the ram.
Note: Refer to the manual supplied with the pump.
4. Release the hydraulic pressure. Move the bus bar
to the next punching position. Repeat steps 2- 4.
TO SET X-Y PATTERN:
•
Locate shoulder screw on underside of table
position screw in either slot A or B
TABLE SCALE (-100 mm thru 100 mm): Indicates distance
from punch center
•
BACK STOP SCALE (0 thru 100 mm): Indicates distance
from end of work piece to punch center
•
Place pin in either slot 1, 2, 3, or 4
DECAL NO. 503 9710.9 REV 1
PUNCH CENTER
BACK STOP SCALE
SLOT 1
SLOT 2
SLOT 3
SLOT 4
PIN SLOT A SHOULDER SCREW
SLOT B
TABLE
SCALE
AB
C
Y
X
"X" DIRECTION "Y" DIRECTION
PIN
POSITION
Slot 1
Slot 2
Slot 3
Slot 4
DIM
"A"
17 mm
(.67")
30 mm
(1.18")
25 mm
(.98")
20 mm
(.74")
DIM
"B"
26 mm
(1.02")
60 mm
(2.36")
50 mm
(1.97")
40 mm
(1.57")
SHOULDER
SCREW
POSITION
Slot A
Slot B
Slot A
Slot B
Slot A
Slot B
Slot A
Slot B
DIM
"C"
26 mm (1.02")
40 mm (1.57")
26 mm (1.02")
40 mm (1.57")
26 mm (1.02")
40 mm (1.57")
26 mm (1.02")
40 mm (1.57")
Figure 5 — Hole Patterns for X-Y Table
Operation
Punching Bus Bar
Figure 4
Centering Guide
0-120 mm
Alignment Guide
80-220 mm
Reads distance from
punch center
Back Stop Scale
0-12 cm
Reads distance from
punch center at rear edge.
Figure 3
Pinch points. Do not remove
guards. Keep hands away from
moving parts.
Use the Die Alignment procedure frequently.
Through normal use of the bus bar punch, the die
may become out of alignment. Using the bus bar
punch with the die misaligned will produce burrs
on the bus bar and may eventually damage the
punch and the die.
Failure to observe this precaution could result in
damage to the tool.
1. Insert the bus par into the bus bar punch.
2. Use the alignment table or the X-Y table (optional)
to set the bus bar in the appropriate location.
Note: The scale on the back stop, alignment guide,
and centering guide measure the distance to the
center of the punch. If using the alignment table,
see Figures 3 and 4. If using the X-Y table, see
Figures 4 and 5: Hole Patterns for X-Y Table.

8
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Operation (cont’d)
Changing the Punch, Die, and Stripper Plate Using the X-Y Table (optional)
The X-Y Table allows the operator to precisely punch
standard 2-bolt and 4-bolt patterns.
The table scale indicates the distance from the edges of
the work piece to the punch center, and the back stop
scale indicates the distance from the end of the work
piece to the punch center. See Figure 5: Hole Patterns
for X-Y Table for the various patterns and correspond-
ing pin settings.
1. Set the back stop to the required distance.
2. Choose the desired pattern. See Figure 5: Hole
Patterns for the X-Y Table.
3. See the exploded view of the X-Y Table.
4. Thread the shoulder screw (56) into the appropriate
slot under the table. Insert the pin (50) into the
appropriate slot in the bus bar guide (47)
5. Insert the bus bar into the bus bar punch.
Disconnect electric pump from power supply
before changing accessories, making adjust-
ments, or servicing. Accidental starting could
result in severe injury.
1. Release the hydraulic pressure to retract the ram.
Note: If using an electric pump, disconnect the pump
from the power supply.
2. Disconnect the hydraulic hose from the coupler.
3. Remove the yoke pin unit (C) and the ram unit (A).
Raise the guard (M).
4. Place the flat edge of a screwdriver against the
bottom edge of the punch. Press the punch upward.
Lift the punch up and out of the yoke (G).
5. Lift the die out of the die holder (T).
6. With a firm grip, pull downward on the stripper
plate (EE). Lower the guard (M).
7. Replace the ram unit (A) and fully insert the yoke
pin unit (C).
Note: The yoke pin unit is fully inserted when the ball
plungers have gone completely through the
punching yoke and are visible at the back side
of the punching yoke.
6. Push the table forward and to the right, until it
contacts the stops.
7. Hold the bus bar against the side guide (47) and the
back stop, and tighten the clamp (49) to hold the
bus bar in place.
8. Punch hole #1. Move the table to the left stop, and
punch hole #2.
9. Pull the table straight back until it contacts the back
stop. Punch hole #3. Move the table to the right and
punch hole #4.
The punch unit is not designed to completely
support longer bus bar. Use additional support
when punching bus bar 1 meter long or longer.
Failure to support bus bar may damage punch unit.
Failure to observe this precaution could result in
injury or property damage.
The yoke pin unit must fully engage the punching
yoke. An improperly assembled tool could break
and components could strike nearby personnel.
8. To install another punch, die, and stripper plate;
see Punch, Die, and Stripper Plate Installation
under Setup in this manual.

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Punch, Die and Stripper Plate Selection
(1) Punch sizes 10mm and larger are furnished with a spring-loaded centering pin.
(2) Black oxide finish dies are for use with laminated bus bar only.
(3) Bright zinc-plated dies are for use with solid bus bar.
PUNCH (1)
• Do not use black laminated dies when punching
solid bus bar. Increased punching forces may
damage the punch unit.
• Do not use bright zinc-plated dies when punching
laminated bus bar. The punch and die may
become jammed together.
Failure to observe these precautions could result in
injury or property damage.
NOM. HOLE SIZE ACTUAL BLACK (2) BRIGHT ZINC STRIPPER
mm inches INCHES LAMINATED DIE SOLID DIE (3) PLATE
M6 1/4 .276 37790 37772 37288 38556
M8 5/16 .339 37791 37773 37316 38557
M10 3/8 .417 37802 37774 37317 38558
M11 7/16 .465 37798 37768 37318 38559
M12 1/2 .524 37799 37775 37320 38560
M14 9/16 .587 37804 37776 37646 38561
M16 5/8 .657 37805 37777 38273 38562

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Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Troubleshooting
PROBLEM PROBABLE CAUSE POSSIBLE REMEDY
Ram will not advance. Poor hydraulic connection. Release hydraulic pressure at the
pump. Tighten the hydraulic connec-
tions by hand.
Pump is faulty. Refer to Troubleshooting section of
pump manual, or send pump to an
authorized service center.
Ram will not retract fully. Weak or broken return spring. Replace return spring (10).
Worn internal parts. Replace backup ring (8) and O-ring (7).
Ram and punching yoke are Spring plungers (13) do not extend Partially unscrew the spring plungers
not properly aligned. beyond the surface of the cylinder (13), so that they extend from the
base (12). cylinder base (12).

Greenlee Textron / Subsidiary of Textron Inc. 11 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System

12
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Punch Unit—ExplodedView
A
B
II
HH
GG
J
FF
EE
DD
CC
BB
AA
Y
V
W
V
U
T
S
R
Q
P
O
N
M
L
K
J
C
I
H
G
F
E
X
Z
D
}

Greenlee Textron / Subsidiary of Textron Inc. 13 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Parts List - Hydraulic Hose Unit
Punch Unit—Parts List
Key Part Number Description Qty
A 503 7735.3 Ram Unit................................................ see Ram Unit Parts List
B 503 8513.5 Hydraulic Hose Unit, 1/4" x 6' ....... see Hydraulic Hose Parts List
C 503 7861.9 Yoke Pin Unit.......................................... see Yoke Pin Parts List
D 503 9021.0 Punch Alignment Table ............................... see Table Parts List
503 7736.1 X-Y Table (Optional)............................. see X-Y Table Parts List
503 7902.0 Bus Bar Punch Unit (consists of the following):......................... 1
E 905 2760.7 Drive Screw.......................................................................... 2
F 503 7945.3 Serial Plate Decal................................................................. 1
G 503 7754.0 Punching Yoke ..................................................................... 1
H 905 2012.2 Shoulder Screw, 1/4" x 1/2" ................................................. 2
I 503 8554.2 Punch Guide Plate ............................................................... 1
J 905 4150.2 Self-lubricating Bearing ........................................................ 4
K 905 4278.9 Spring................................................................................... 2
L 905 4354.8 Ball Plunger.......................................................................... 2
M 503 7866.0 Punch Guard ........................................................................ 1
N 503 7950.0 Instruction Decal .................................................................. 1
O 503 7755.8 Punch Frame Spacer ........................................................... 2
P 905 4200.2 Punch Guide Return Spring ................................................. 2
Q Die......................................................... see Accessories List
R 905 3654.1 M6 x 10 Socket Cap Screw.................................................. 4
S 905 4222.3 Washer, Belleville................................................................. 4
T 503 7760.4 Die Holder ............................................................................ 1
U 503 7811.2 Mounting Plate ..................................................................... 2
V 905 4208.8 M6 x 10 Button-Head Cap Screw......................................... 8
W 905 4204.5 M20 x 80 Socket Cap Screw................................................ 2
X 503 7818.0 Bus Bar Punch Yoke ............................................................ 1
Y 905 4207.0 M6 x 16 Flat-Head Screw..................................................... 2
Z 503 7763.9 Punch Scale ......................................................................... 1
AA 503 7821.0 Back Stop............................................................................. 1
BB 905 2346.6 Threaded Knob .................................................................... 1
CC 503 7824.4 Back Stop Angle .................................................................. 1
DD 905 4201.0 M4 x 12 Flat-Head Screw..................................................... 2
EE Stripper Plate ........................................ see Accessories List
FF 503 8553.4 Stripper Plate Holder............................................................ 1
GG 905 4277.0 Shoulder Screw, 1/2" x 3-1/2" .............................................. 2
HH 905 4202.9 M20 x 60 Socket Cap Screw................................................ 2
II Punch .................................................... see Accessories List
B 503 8513.5 Hydraulic Hose Unit, 1/4" x 6' .................................................... 1
905 4170.7 Dust Cap, 1/4" Male ............................................................. 2
905 4169.3 Coupler, 1/4" Male ............................................................... 2
503 8528.3 Hydraulic Hose..................................................................... 1

14
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
5. Clamp the punch guide plate (I) into the vise. Press
the four self-lubricating bearings (J) into the two
large bores, installing the first bearings to the
bottom of the counterbores and the second bear-
ings flush with the surface.
6. Place the two shoulder screws (GG) into the two
smaller counterbored holes. Slip the two springs (K)
over the bolts, and capture the springs with the
stripper plate holder (FF). Thread the two shoulder
screws into the stripper plate. See the exploded
view.
7. Thread the two ball plungers (L) into the stripper
plate. Place any stripper plate into the center hole
of the stripper plate holder. Twist the two ball
plungers clockwise until they contact the stripper
plate, then back out both ball plungers 1/4 turn.
8. Remove the punch guide plate subassembly from
the vise. Put the bus bar yoke subassembly back
into the vise.
9. Slide the punch guard unit (M) over the punch
frame spacers.
10. Slide the punch guide plate subassembly over the
punch frame spacers (O); the punch guide plate
subassembly fits inside the punch guard unit (M),
and the frame spacers protrude slightly from the
punch guide plate.
11. Set the punching yoke (G) into place on the two
punch frame spacers. Attach the punching yoke
with two M20 socket-head cap screws (HH).
Note: You will need to compress the punch guide
return springs.
12. Torque all four M20 socket-head cap screws (W)
and (HH) to 225-275 foot-pounds (305-373 Nm).
13. Install the two shoulder screws (H) through the
guard unit (M) and into the punching yoke (G).
14. Attach the assembled alignment table (D) to the bus
bar punch yoke (X) with four button-head screws
(V) as shown in the exploded view. Place any die in
the die holder (T). Adjust the alignment table so that
the table top is level and at the same height as the
top of the die.
15. Tighten the four button-head screws (V).
16. Attach each mounting plate (U) to the bus bar
punch yoke (X) with two M6 button-head screws
(V). Set the assembly on a flat surface and tighten
the screws.
17. Attach the serial plate (F) to the punching yoke (G)
with two drive screws (E). Attach the self-adhesive
instruction decal (N) to the guard unit (M). Attach
the self-adhesive caution decal (37) to the side of
the punch alignment table (D). See exploded view
for decal locations.
Punch Unit
Disassembly
1. Remove yoke pin unit (C) and ram unit (A) from the
punching yoke (G).
Note: If a punch, die and stripper plate are on the
punch unit, remove them before proceeding.
See Changing the Punch, Die, and Stripper Plate
in this manual.
2. Clamp the bus bar punch yoke (X) into a vise.
3. Remove the mounting plates (U) by unscrewing four
button-head cap screws (V).
4. Remove the alignment table (D) from the by un-
screwing four button-head cap screws (V).
5. Unscrew the shoulder screws (H).
6. Remove the M20 socket-head cap screws (HH)
from the punching yoke.
Note: With your free hand, maintain a downward
pressure on the punching yoke (G). The punch
guide return springs (P) are under pressure, and
they will spring the punching yoke upward when
the socket-head cap screws are removed.
7. Lift the punch guide plate (I) subassembly off of the
two punch frame spacers (O). Set the punching
yoke subassembly aside.
8. Lift the guard unit (M) up and off of the punch unit.
9. Slip the two punch guide return springs (P) off of the
punch frame spacers.
10. Unscrew two M20 socket-head cap screws (W) from
the bus bar yoke (X). Remove the punch frame
spacers.
11. Remove the bus bar yoke (X) from the vise.
Assembly
1. Place the bus bar yoke (X) into a vise with the small
drilled and tapped holes pointing upward.
2. Press the two punch frame spacers (O) firmly into
the two counter bores. Install the two M20 socket-
head cap screws (W) through the bus bar punch
yoke and through the frame spacers (O). Slip the
two punch guide return springs (P) over the punch
frame spacers.
3. Attach the punch scale (Z) to the bus bar punch
yoke (X) with two M6 flat head screws (Y). Slip four
Belleville washers (S) over four M6 socket-head cap
screws (R); insert the cap screws through the die
holder (T) as shown. Thread, but DO NOT
TIGHTEN, the cap screws.
Note: These cap screws will be tightened during the
die alignment procedure.
4. Remove the bus bar yoke subassembly from the
vise.

Greenlee Textron / Subsidiary of Textron Inc. 15 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Ram Unit (503 7735.3)
3
4
5
6
7
8
10
2
1
11
12
13
9
Key Part No. Description Qty
1 503 7948.8 Serial Plate...............................1
2 905 2760.7 Drive Screw..............................2
3 905 4168.5 Dust Plug..................................1
4 905 4167.7 Threaded Coupler ....................1
5 503 7739.6 Cylinder .................................... 1
6 503 9050.3 Caution Decal...........................1
7 905 4191.0 O-Ring......................................1
8 905 4190.1 Backup Ring.............................1
9 503 7738.8 Piston .......................................1
10 503 7740.0 Return Spring ...........................1
11 905 4340.8 Self-Lubricating Bearing...........1
12 503 7737.0 Cylinder Base...........................1
13 905 4164.2 Spring Plunger .........................2
Disassembly
1. Clamp the cylinder base unit (12) into a vise and
unthread the cylinder (5).
2. Carefully lift the cylinder from the cylinder base.
3. Remove the spring (10).
4. Carefully remove the piston (9) from the cylinder
bore. Do not scratch the bore surface.
5. Remove and replace the O-ring (7) back-up ring (8).
6. Unscrew the spring plungers (13).
7. Slide the bearing (11) out of the cylinder base (12).
8. Unthread the coupler (4).
9. Serial plate (1) is riveted with two drive screws (2).
Assembly
1. Press the bearing (11) into the bore of the cylinder
base (12).
2. Thread the two spring plungers (13) into the base.
The body of each spring plunger must be below the
surface of the base.
3. Use an O-ring lubricant to lubricate the O-ring (7)
and backup ring (8), and assemble to the piston (9);
slide the piston into the cylinder (5) bore.
4. Clamp the cylinder base (12) into a vise.
5. Slip the spring (10) over the piston in the cylinder.
Position the cylinder (5) over the cylinder base (12)
so that the piston (9) is aligned with the bearing (11).
6. Compress the spring by pressing the cylinder down
over the base. Thread the cylinder onto the base.
Torque to 150 foot-pounds (203.36 Nm).
7. Attach the serial plate (1) with two drive screws (2).
8. Slide the key ring of the dust plug (3) over the
threaded end of the coupler (4). Apply a hydraulic
thread sealer such as BAKERSEAL to the pipe
threads of the coupler (4), and thread the coupler
into the end of the cylinder (5).

16
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Yoke Pin Unit (503 7861.9)
Disassembly
1. Remove the “T” handle (20) by unscrewing the
button-head cap screw (21).
2. Remove the remaining two button-head caps
screws (21). Remove the yoke pins (22) from the
pin holder (24).
3. Unscrew the two ball plungers (23) from the two
yoke pins (22).
Assembly
1. Thread the two ball plungers (23) into the two yoke
pins (22) until the ball extends 0.020" - 0.030"
(0.508mm - 0.762mm) above the pin surface.
2. Attach the two yoke pins (22) to the pin holder (24)
with the two button-head cap screws (21). Tighten
both screws with an Allen wrench. Back off one
screw 1/8 to 1/4 of a turn so the pin slides freely on
the holder (24).
3. Mount the “T” handle (20) with a button-head cap
screw (21) and tighten securely.
Key Part No. Description Qty
20 905 4218.5 “T” Handle .................................. 1
21 905 1588.9 Button-Head Cap Screw ............ 3
22 503 7819.8 Yoke Pin..................................... 2
23 905 4057.3 Ball Plunger................................ 2
24 503 7859.7 Pin Holder .................................. 1
21
20
22
24
23

Greenlee Textron / Subsidiary of Textron Inc. 17 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
Key Part No. Description Qty
30 503 8153.9 Busbar Alignment Plate............1
31 503 8534.8 Scale Pointer............................1
32 905 2760.7 Drive Screw ..............................2
33 905 4275.4 Adjustable Handle ....................1
34 905 4193.6 M6 Button-Head Screw ............2
35 503 9020.1 Punch Alignment Guide ...........1
36 503 9022.8 Alignment Top Plate.................1
37 503 7742.6 Decal ........................................1
38 503 7325.0 Clamping Strip..........................1
39 905 3448.4 #10 Shoulder Screw.................2
5. Attach the assembled alignment table to the bus bar
punch yoke (X) with four button-head screws (V) as
shown in the exploded view.
6. Place any die in the die holder (T).
7. Adjust the alignment table so that the table top is
level, and at the same height as the top of the die.
8. Tighten the four button-head screws (V).
Assembly
1. Place the punch alignment guide (35) on the
alignment top plate (36). Thread, but do not tighten,
the two button-head screws (34) through the end
slots of the guide and into the top plate (36).
2. Place the alignment top plate (36) on top of the bus
bar alignment plate (30). Insert the adjustable
handle (33) through the middle slot of the punch
alignment guide, through the alignment top plate,
and through the bus bar alignment plate; thread the
handle into the clamping strip (38).
3. Apply a drop of Loctite®242 or equivalent on the
threads of the shoulder bolt (39). Insert the shoulder
bolt through the clamping strip (38) and into the bus
bar alignment plate (30). Thread the shoulder bolt
into the hole in the alignment top plate.
4. Attach the scale pointer (31) to the bus bar align-
ment plate (30) with the two drive screws (32).
AlignmentTable (Standard) (503 9021.0)
36
35
34
33
32
31
38
39
30
37

18
Greenlee Textron / Subsidiary of Textron Inc. 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System
X-YTable (optional) (503 7736.1)
Assembly
1. Apply Loctite®242 or an equivalent to the threads
of two flat head screws (54). Use these screws to
attach one table track plate (53) to the positioning
table (40).
2. Apply Loctite 242®to two more flat head screws
(54). Attach the track spacer (52) and other table
track plate (53) to the bottom side of the “Y” posi-
tioning table (46). Use two button-head cap screws
(48), attach the bus bar guide (47) to the top side of
the “Y” positioning table (46). Slip the loop of the pin
lanyard (50) over the threaded screw of the short
revolving clamp (49), and mount the revolving
clamp (47) to the top of the bus bar guide (6).
3. Apply Loctite 242®to the remaining flat head screws
(54) and two socket head cap screws (44). Attach
adjustment plates (42 & 43) to the positioning base
plate (41) with the ten flat head screws (54). Mount
the positioning table decal (45) to the adjustment
plate (43) with the two socket head cap screws (44).
4. Place the positioning base plate assembly (41) over
the table track plate (53) mounted to the positioning
table (40). Secure with shoulder screw (56). Slide
“Y” positioning table assembly (46) into the slot on
the positioning base plate assembly (41). Insert the
pin with lanyard into one of the four holes in the bus
bar guide (47).
5. Attach the table operating decal (55) to the side of
the table.
Mounting the X-Y Table to the Bus Bar Punch Unit
1. Remove yoke pin unit (C) and ram unit (A).
2. Clamp the bus bar punch yoke into a vise. Remove
the mounting plates (U) from the bus bar punch
yoke by removing four button-head screws (V); see
the exploded view.
3. Remove the punch alignment table (D) by removing
four button-head screws (V).
4. Attach the X-Y positioning table (40) to the bus bar
punch yoke (X) with the four button-head screws (V)
that were removed in step 3. Do not tighten the
screws.
5. Place any die in the die holder (T).
6. Adjust the X-Y table so that the table top is level,
and at the same height as the top of the die.
7. Tighten the four button-head screws (V).
8. Remove the bus bar punch unit from the vise.
Install the ram unit (A) and the yoke pin unit (C).
The yoke pin unit must fully engage the punching
yoke. The ball plungers of the yoke pin unit must
be visible at the back side of the punching yoke.
Key Part No. Description Qty
40 503 7743.4 Positioning Table...................... 1
41 503 7747.7 Positioning Base Plate ............. 1
42 503 7746.9 Adjusting Plate ......................... 1
43 503 7745.0 Adjusting Plate ......................... 1
44 905 4205.3 Socket Head Cap Screw .......... 2
45 503 7752.3 Positioning Table Decal............ 1
46 503 7748.5 “Y” Positioning Table ................ 1
47 503 7749.3 Bus Bar guide........................... 1
48 905 4193.6 Button-Head Cap Screw........... 2
49 905 4195.2 Short Revolving Clamp............. 1
50 503 7837.6 Pin with Lanyard....................... 1
51 905 1434.3 3/8 Flat Washer ........................ 2
52 503 7751.5 Track Spacer ............................ 1
53 503 7750.7 Table Track Plate ..................... 2
54 905 4201.0 Flat Head Screw...................... 14
55 503 9710.9 Table Operating Decal ............. 1
56 905 4194.4 Shoulder Screw ........................ 1
57 503 7752.3 Decal ........................................ 1
49
50
51
5253
54
54
53
55
56
41
40
42
43
44 45
46
47
48
57

Greenlee Textron / Subsidiary of Textron Inc. 19 4455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Bus Bar Punch System

Printed in U.S.A.
Greenlee Textron / Subsidiary of Textron Inc.
4455 Boeing Drive, Rockford, IL 61109-2988 USA
General Offices: 815/397-7070
Customer Center and Field Service: 800/435-0786
Fax (24 Hour) Customer Center: 800/451-2632 • 815/397-1865
Canada Fax (24 Hour) Customer Center: 800/524-2853
GREENLEE