Greenlee Gator Intelli-PUNCH User manual

INSTRUCTION MANUAL
Gator® Intelli-PUNCH™
Battery-Hydraulic
Knockout Driver
52085706 © 2018 Greenlee Tools, Inc. 12/18
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
Español............... 13
Français.............. 25

Greenlee Tools, Inc. 2
Intelli-PUNCH™Knockout Driver
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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 this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee tool:
Intelli-PUNCH™ Battery-Hydraulic Knockout Driver
Keep this manual available to all personnel.
Replacement manuals are available upon request at
no charge at www.greenlee.com.
Do not discard this product or throw away!
For recycling information, go to www.greenlee.com.
All specications are nominal and may change as design
improvements occur. Greenlee Tools, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Kwik-Stepper, Slug-Buster, Slug-Splitter, and SPEED PUNCH
are registered trademarks and Intelli-PUNCH™ is a trademark of
Greenlee Tools, Inc.
KEEP THIS MANUAL
Table of Contents
Description ..................................................................... 2
Safety ............................................................................. 2
Purpose of this Manual .................................................. 2
Important Safety Information ..................................... 3–5
Identication and Illustration .......................................... 6
Specications................................................................. 6
Setup and Operation.................................................. 7–8
Capacity ......................................................................... 9
Maintenance................................................................. 10
Troubleshooting............................................................ 11
Description
The Greenlee Intelli-PUNCH™ Battery-Hydraulic
Knockout Driver is a hand-held, self-contained knockout
driver intended to be used with Greenlee punches,
dies, and drawstuds for punching holes through mild
steel, stainless steel, brass, copper, aluminum,
berglass, and plastics.
This tool is designed to be used with the following
Greenlee accessories:
• Standard punches, dies, and drawstuds
• Slug-Buster®punches, dies, and drawstuds
• Slug-Splitter®punches, dies, and drawstuds
• SPEED PUNCH®Knockout System
• Electronic connector panel punches
• Special shape punches, dies, and drawstuds
(“D”, Double “D”, Key, Square, Rectangular, and
Oiltight with notches)
Standard and Slug-Buster, Electronic Connector Panel
Punches, and special shape punches can punch holes
through mild steel, brass, copper, aluminum, berglass,
and plastics, with limited stainless steel capability.
Slug-Splitter punches, dies, and drawstuds are capable
of punching through all of these materials and are
optimized for stainless steel. Refer to the “Capacity”
section in this manual for detailed information on
maximum driver rating. Do not exceed the rated
capacity of the punch or driver.
This tool is protected by U.S. Patent No. 6,276,186,
6,401,515, 7,086,979, and 7,254,982.

Greenlee Tools, Inc. 3
Intelli-PUNCH™Knockout Driver
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
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, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
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.
Electric shock hazard:
This tool is not insulated. When
using this unit on or near energized
electrical lines, use proper personal
protective equipment.
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
ying debris or hydraulic oil.
Skin injection hazard:
Do not use hands to check for oil
leaks. Oil under pressure easily
punctures skin. If injured, seek
medical attention immediately to
remove oil.
Failure to observe this warning
could result in serious injury, gan-
grene, or death.
Do not use solvents or ammable
liquids to clean the tool body.
Solvents or ammable liquids could
ignite and cause serious injury or
property damage.
Pinch points:
• Remove battery before changing
dies, adapters, or jaws.
• Keep hands away from the tool
head when punching.
Failure to observe these warnings
could result in severe injury or death.

Greenlee Tools, Inc. 4
Intelli-PUNCH™Knockout Driver
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
IMPORTANT SAFETY INFORMATION (cont'd)
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.
Do not attempt to punch a hole
through two or more layers of
material. This will bend or break the
drawstud, and could throw 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.
• Use only Greenlee punches, dies, and drawstuds.
Other manufacturers’ components might not with-
stand the forces generated by this punch driver.
• Manual Punch Setup: The punch must be
threaded completely onto the drawstud. All of the
punch threads must be engaged by the drawstud
threads. Incomplete assembly could cause a com-
ponent failure.
• Hydraulic Punch Setup: The drawstud must be
threaded completely into the driver head. The
punch must be threaded completely onto the
drawstud. All of the punch threads must be
engaged by the drawstud threads. Incomplete
assembly could cause a component failure.
• SPEED PUNCH Setup: The drawstud must be
threaded completely into the driver head. The
SPEED LOCK must fully engage and completely
close on the drawstud. Incomplete assembly
could cause a component failure.
Failure to observe these warnings could result in
severe injury or death.
• Inspect tool for wear or damage. Replace any
worn, damaged, or missing components with
Greenlee replacement parts. A damaged or
improperly assembled tool can break and strike
nearby personnel with sufcient force to cause
severe injury or death.
• Inspect the punch, die, and drawstud for wear or
damage. Replace any worn or damaged items
with Greenlee replacement parts. Replace any
punches that have dull cutting surfaces.
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.
Do not dispose of batteries in a re. They will vent
fumes and may explode.
Failure to observe this warning could result in
severe injury from harmful fumes or burns from
ying debris.
Use this tool for the manufacturer's intended
purpose only. Use other than that which is
described in this manual can result in injury or
property damage.
Ensure the punch cycle is stopped after a hole is
made. Failure to do so could cause a part collision
which could throw broken parts.
Failure to observe this warning could result in severe
injury or death.

Greenlee Tools, Inc. 5
Intelli-PUNCH™Knockout Driver
4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
IMPORTANT SAFETY INFORMATION (cont'd)
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.
• Do not use this tool for continuous use. After 30 to
40 cycles, allow the tool to cool for 15 minutes.
• Do not secure this tool in a vise. This tool is
designed for hand-held operation.
• This tool may be used in damp or wet environ-
ments; however, air-drying is recommended before
use if the tool becomes soaked. Damage may
result when the tool is operated prior to thorough
drying when electrical components are soaked.
• Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions may result in
injury or property damage.
Do not allow anything to contact the battery
terminals.
• Do not immerse the batteries in liquid. Liquid may
create a short circuit and damage the battery.
If batteries are immersed, contact your service
center for proper handling.
• Do not place the battery into a pocket, tool pouch,
or tool box with conductive objects. Conductive
objects may create a short circuit and damage the
battery.
• Do not place a battery on moist ground or grass.
Moisture may create a short circuit and damage
the battery.
Failure to observe these precautions may result in
injury or property damage.
• Do not store the battery at more than 122 °F
(50°C) or less than –4 °F (–20 °C). Damage to the
battery can result.
• Do not use another manufacturer’s charger. Other
manufacturers’ chargers may overcharge and
damage the battery.
• Do not attempt to open the battery. It contains no
user-serviceable parts.
Failure to observe these precautions may result in
injury or property damage.
Do not perform any service or maintenance other
than as described in this manual. Injury or damage
to the tool may result.
Failure to observe this precaution may result in injury
and property damage.
Note: Keep all decals clean and legible, and replace
when necessary.