Greenlee GATOR CLS60GL User manual

INSTRUCTION MANUAL
999 4507.0 © 2002 Greenlee Textron IM 1516 REV 01 8/02
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
GATOR®
CLS60GL Punch Driver
120 Volt and 230 Volt

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
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.
GATOR, Kwik Stepper, Slug-Buster, and Slug-Splitter are registered
trademarks of Greenlee Textron.
AVIA is a registered trademark of Avia International.
Mobil is a registered trademark of Mobil Oil Corporation.
NUTO is a registered trademark of Exxon Corporation.
Tellus is a registered trademark of Shell Oil Company.
KEEPTHIS MANUAL
Table of Contents
Description .....................................................................2
Safety .............................................................................2
Purpose of this Manual ..................................................2
Important Safety Information......................................3–5
Identification ................................................................... 6
Specifications ................................................................. 6
Operation .................................................................7–11
Capacity and Draw Stud Selection Guide ....................12
Maintenance.................................................................13
Troubleshooting ...........................................................14
Disassembly.................................................................15
Assembly......................................................................16
Illustrations .............................................................17–18
Parts List ................................................................19–20
Description
The CLS60GL Punch Driver is a hand-held, self-
contained tool intended to be used with Greenlee
punches, dies, and draw studs for punching holes
through plastic, fiberglass, aluminum, and steel.
The CLS60GL is designed to be used with the following
Greenlee accessories:
• Standard punches, dies, and draw studs
• Slug-Buster®punches, dies, and draw studs
• Slug-Splitter®punches, dies, and draw studs
• Electronic connector panel punches
• Special shape punches, dies, and draw studs
(“D”, Double “D”, Key, Square, Rectangular, and
Oiltight with notches)
Standard, Slug-Buster, electronic connector panel
punches, and special shape punches can punch holes
through plastic, fiberglass, aluminum, and steel.
Slug-Splitter punches, dies, and draw studs are capable
of punching through all of these materials as well as
stainless steel. Refer to the “Capacity and Draw Stud
Selection Guide” in this manual for detailed information
on punch sizes and maximum material thickness. Do not
exceed the capacity of the punch.
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 tools:
CLS60GL11 120 Volt Punch Driver
CLS60GL22 230 Volt Punch Driver
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge.

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
IMPORTANT SAFETY INFORMATION
Read and understand all of the
instructions and safety information in
this manual before operating or
servicing this tool.
Failure to observe this warning will
result in severe injury or death.
• Do not expose to rain.
• Do not use in wet or damp
locations.
Failure to observe these warnings
can result in severe injury or death.
Electric shock hazard:
• Connect the power cord to a
receptacle of proper voltage for the
tool in use on a ground fault-
protected circuit only.
• Do not modify the power cord or
plug.
• Inspect the power cord before use.
Repair or replace the cord if
damaged.
• Do not pull or carry by cord, use
the cord as a handle, close a door
on the cord, run over the cord, or
pull the cord around sharp edges
or corners. Keep the cord away
from heated surfaces.
• Do not unplug by pulling on the
cord. To unplug, grasp and pull the
plug—not the cord.
• Disconnect from power before
servicing.
Failure to observe these warnings
can result in severe injury or death.
Do not use this tool in a hazardous
environment. Hazards include
flammable liquids, gases, or other
materials. Using this tool in a
hazardous environment can result in
a fire or explosion.
Failure to observe this warning will
result in severe injury or death.
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.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Hazards which, if not avoided, COULD result in
severe injury or death.
Immediate hazards which, if not avoided, WILL
result in severe injury or death.
SAFETY
ALERT
SYMBOL
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 can
result in severe injury or death.

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
IMPORTANT SAFETY INFORMATION
Keep hands away from the tool head
when in use.
Failure to observe this warning can
result in severe injury or death.
Do not operate the tool while wearing loose clothing.
Loose clothing can get caught in moving parts.
Failure to observe this warning can result in severe
injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying 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 can
result in serious injury, gangrene, or
death.
Do not use solvents or flammable
cleaners to clean the tool body.
Solvents could ignite, causing
serious injury or property damage.
Do not allow anyone to stand directly in front of the
punch. A component failure could propel parts that
could strike nearby personnel with sufficient force to
cause severe injury or death.
• Inspect the punch, die, draw stud, and spacers
for wear or damage. Replace any worn or
damaged items with Greenlee replacement parts.
Replace any punches that have dull cutting
surfaces.
• 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 punch failure, which could propel parts
that could strike nearby personnel with sufficient
force to cause severe injury or death.
• Use only with Greenlee punches, dies, and draw
studs. Other manufacturers’ components may not
withstand the forces generated by this punch
driver and may break and strike nearby
personnel, causing severe injury or death.

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070
Note: Keep all decals clean and legible, and replace
when necessary.
Extension cords:
•Use only 16, 14, or 12 AWG
extension cords.
•Do not use extension cords that
are longer than 30 m (100').
•Repair or replace damaged
extension cords.
Failure to observe these warnings
can result in severe injury or death. 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 can result in
injury and property damage.
IMPORTANT SAFETY INFORMATION
Inspect tool before use. Replace any worn or
damaged parts with Greenlee replacement parts. A
damaged or improperly assembled tool can break
and strike nearby personnel.
Failure to observe this warning can result in severe
injury or death.
•This tool is not designed for continuous use.
After 30 to 40 cycles, allow the tool to cool for
15 minutes.
•Do not place the tool in a vise. The tool is
designed for hand-held operation.
•Ensure that all bystanders are away from the
work area when operating the tool.
•Ensure that the work area is clean, dry,
uncluttered, and well-lit.
•Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions can result in
injury or property damage.

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Identification
Specifications
CLS60GL
1. Housing
2. Retract Button
3. Power Cord
4. Trigger
5. Ram
6. Ram Housing
7. Oil Reservoir
8. Oil Plug
Length
Ram Retracted................................................................................262 mm (10.31")
Ram Extended ................................................................................284 mm (11.18")
Width ............................................................................................................76 mm (3")
Height....................................................................................................292 mm (11.5")
Mass/Weight .............................................................................................. 3 kg (6.6 lb)
Maximum Punch Force ........................................................................60 kN (6.7 tons)
Maximum Punch Diameter in 10 ga. (3 mm) Mild Steel.........................63.5 mm (2.5")
Maximum Ram Travel .............................................................................22 mm (0.87")
Punching Time
1/2" Conduit in 10 ga. (3 mm) Mild Steel ..................................................5 seconds
2" Conduit in 10 ga. (3 mm) Mild Steel ...................................................12 seconds
Sound Level ...............................................................................< 75 dB (A) at 1 meter
Vibration ........................................................................................................ < 2.5 m/s2
Motor Voltage
CLS60GL11 .......................................................................... 120 VAC, 60 Hz, 2.1 A
CLS60GL22 .......................................................................... 230 VAC, 50 Hz, 1.1 A
Hydraulic Oil.........................................................50 ml (0.1 pint) of Shell Tellus®T 15
2
4
1
3
7
8
6
5

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Operation
Keep hands away from the tool head
when in use.
Failure to observe this warning can
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 can
result in severe injury or death.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying 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 can
result in serious injury, gangrene, or
death.
•This tool is not designed for continuous use.
After 30 to 40 cycles, allow the tool to cool for
15 minutes.
•Do not place the tool in a vise. The tool is
designed for hand-held operation.
•Ensure that all bystanders are away from the
work area when operating the tool.
•Ensure that the work area is clean, dry,
uncluttered, and well-lit.
•Use this tool for the manufacturer’s intended
purpose only.
Failure to observe these precautions can result in
injury or property damage.

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
1. Select the punch, die, and draw stud to make the
appropriate size hole. Refer to the illustrations on the
following pages.
2. Determine and mark the exact location for the hole.
Use a Greenlee Kwik Stepper®drill bit to drill a hole
that is slightly larger than the draw stud. This is the
pilot hole.
3. Push the retract button to fully retract the ram.
4. Thread the 3/4" draw stud or 3/4" adapter completely
into the punch driver. Refer to the illustrations on the
following pages.
Note: For a punch and die with a 3/8" center hole,
thread the 3/8" draw stud into the end of the 3/4"
adapter.
5. Install a spacer, if necessary. Refer to the illustra-
tions on the following pages.
6. Slide the die over the draw stud with the open end of
the die facing away from the punch driver.
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 spacer, die, material,
and punch contact each other.
Note: All of the punch threads must be engaged
by the draw stud threads. If any of the punch threads
are not engaged, disassemble the setup, remove the
spacer, and reassemble the setup.
9. Pull the trigger. Release the trigger as soon as the
hole is completed.
Note: A “popping”sound indicates that the
CLS60GL has reached relief pressure. This may
indicate that the operation attempted is
beyond the capacity of the tool.
10. Release the trigger. When the punch is completed,
the ram retracts completely.
Note: At any time during the punching cycle,
pushing the retract button will result in a complete
return of the ram.
11. Unscrew the punch. Remove slugs from the die.
Remove the spacer and unscrew the draw stud.
Operation (cont’d)
Pull trigger to punch
Push to retract ram
Release the trigger when the punch completes the
hole. The tool will not sense when a hole is made.

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Operation (cont’d)
Punching with Round Punches
Metric: 22.5 mm
Conduit Size: 1/2"
Actual Size: 0.885"
Punching with Round Punches
Metric: 28.3 mm to 61.5 mm
Conduit Size: 3/4" to 2"
Actual Size: 1.115" to 2.416"
Material Being Punched
Die
7/8" (22.2 mm)
Pilot Hole
3/4"
Draw Stud
Punch
Die
1/2" (12.7 mm)
Pilot Hole
30043
3/8" Draw Stud
Punch
33967
3/4" Adapter
03248
Spacer
Material Being Punched
03248
Spacer

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Operation (cont’d)
Punching with Square and
Rectangular Punches
Metric: 12.7 mm square
Inches: 1/2" square
Metric: 11.1 mm x 22.2 mm rectangular
Inches: 7/16" x 7/8" rectangular
Punching with Square and
Rectangular Punches
Metric: 15.9 mm to 24.0 mm
square
Inches: 5/8" to 0.945" square
Metric: 17.0 mm x 19.0 mm
rectangular
Inches: 0.670" x 0.749"
rectangular
Punching with Square and
Rectangular Punches
Metric: 25.4 mm square
Inches: 1" square
Metric: 19.1 mm x 29.0 mm to
31.8 mm x 35.1 mm
rectangular
Inches: 0.750" x 1.140" to
1.250" x 1.380"
rectangular
03248
Spacer
End with Long Threads
Threads with Flats
Die
Pilot Hole
Punch
60258
1/2" Counter Nut
60167
1/2" Adapter
60117
3/8" Draw Stud
03248
Spacer
End with Long Threads
Threads with Flats
Die
Pilot Hole
Punch
04638
3/8" Counter Nut
33967
3/8" Adapter
60116
3/8" Draw Stud
03248
Spacer
End with Long Threads
Die
Pilot Hole
Punch
05244
1/4" Counter Nut
60114
1/4" Adapter
60115
1/4" Draw Stud

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 11 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Operation (cont’d)
Punching with Square and
Rectangular Punches
Metric: 46.0 mm to 68.0 square
Inches: 1.811" to 2.677" square
Metric: 33.3 mm x 66.7 mm to
35.0 mm x 65.0 mm rectangular
Inches: 1.312" x 2.625" to
1.378" x 2.559" rectangular
Punching with “D”,
Double “D”, and Key
Punches
Punching with Electronic
Connector Panel Punches
03248
Spacer
End with Long Threads
Threads with Flats
Die
7/16" (11.1 mm)
Pilot Hole
Punch
04638
3/8" Counter Nut
33967
3/8" Adapter
34421
3/8" Draw Stud
03248
Spacer
End with Long Threads
Die
Pilot Hole
Punch
Counter Nut
Adapter
Draw Stud
End with Long Threads
Die
Pilot Hole
Punch
60235
3/4" Counter Nut
60118
3/4" Draw Stud

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 12 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
1234
1
23
4
1
23
4
1234
123456
1
2345
6
1
2345
6
1
2345
6
123456
1234567
1
23456
7
1
23456
7
1
23456
7
1
23456
7
1
23456
7
1234567
1234567890123456789012
1
23456789012345678901
2
1
23456789012345678901
2
1
23456789012345678901
2
1
23456789012345678901
2
1
23456789012345678901
2
1234567890123456789012
12345678901
1
234567890
1
1
234567890
1
1
234567890
1
1
234567890
1
12345678901
Capacity and Draw Stud Selection Guide
Includes optional step-saver adapter
1/2"
con.
ø 0.885"
22.5 mm
3/4"
con.
ø 1.115"
28.3 mm
1-7/32"
con.
ø 1.210"
30.5 mm
1"
con.
ø 1.362"
34.6 mm
1-1/4"
con.
ø 1.701"
43.2 mm
1-1/2"
con.
ø 1.951"
49.6 mm
2"
con.
ø 2.416"
61.5 mm
1/2"
con.
ø 0.885"
22.5 mm
3/4"
con.
ø 1.115"
28.3 mm
1-7/32"
con.
ø 1.210"
30.5 mm
1"
con.
ø 1.362"
34.6 mm
1-1/4"
con.
ø 1.701"
43.2 mm
123456789012345678901
1
2345678901234567890
1
1
2345678901234567890
1
1
2345678901234567890
1
1
2345678901234567890
1
123456789012345678901
➀29451 included with CLS60GL11A and CLS60GL22A units only.
1-1/2"
con.
ø 1.951"
49.6 mm
2"
con.
ø 2.416"
61.5 mm
Stud and Accessories
123
1
2
3
1
2
3
1
2
3
123
Electronic Connector Punches
RS-232, 229, 231, 234, 238
12345
1
234
5
1
234
5
1
234
5
1
234
5
1
234
5
12345
123
1
2
3
1
2
3
123
➀
16 ga. (0.0598" [1.5 mm])
Mild Steel and 1/8" Soft Aluminum
10 ga. (0.1345" [3 mm])
Mild Steel
10 ga. (0.1345" [3 mm])
Stainless Steel
12 ga. (0.1046" [2.5 mm])
Stainless Steel
Standard and Slug-Buster Punches Slug-Splitters
31872
3/4" Draw Stud
1614SS
Draw Stud
1924AA
Spacer
33967
Adapter
1924AA
Spacer
29451
7/16" Draw Stud
1924AA
Spacer
31872
3/4" Draw Stud
33967
Adapter
1924AA
Spacer

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 13 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Maintenance
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection can
result in serious eye injury from
flying 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 can
result in serious injury, gangrene, or
death.
Do not use solvents or flammable
cleaners to clean the tool body.
Solvents could ignite, causing
serious injury or property damage.
Daily
Before use:
1. Inspect the tool for damage or leaks.
2. Inspect the punching components and replace any
worn, damaged, or missing components with
Greenlee replacement parts:
•Punch must be sharp.
•Die must be in good condition.
•Draw stud must be straight, and threads must be
in good condition.
After use:
1. Use a damp cloth and mild detergent to clean the
housing. Allow the housing to dry.
2. Fully retract the ram. Place the tool in the carrying
case and store in a cool, dry place.
Monthly
1. Thoroughly clean all surfaces.
2. Check the oil level.
Annually or After 10,000 Punches
1. Replace the hydraulic oil.
2. Send the tool to an authorized Greenlee service
center for inspection.
Checking the Oil Level
1. Remove the two screws that retain the tank housing
cover. Remove the tank housing cover.
2. Point the tool head downward and remove the oil
reservoir plug. Fill reservoir if necessary.
3. Replace the oil plug and tank housing cover.
Recommended Hydraulic Oils
AVIA®HVI 15
Shell Tellus T 15
Mobil®DTE 15
NUTO®H 15

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 14 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Troubleshooting
Tool is inoperative. Dirt, contaminants, etc., in ram area Clean tool.
of tool.
Tool components worn or damaged. Return tool to an authorized
Greenlee service center.
Ram stops during operation. Oil level is low. Check oil level. Refill reservoir.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately
10 seconds.
Ram stops before punch is Ram has reached end of travel. Press retract button. After ram is fully
completely through material. retracted, tighten punch or draw stud.
Die, material, and punch must be snug.
Proceed to punch.
Spacer needed. Disassemble setup. Add spacer.
Reassemble and punch.
Air in hydraulic system. Pull trigger and hold retract button
simultaneously. Hold for approximately
10 seconds.
Rated capacity of tool has been Reduce size of punch, thickness of
exceeded. material, etc.
Tool loses oil. Damaged internal seal. Return tool to an authorized
Greenlee service center.
Oil plug not installed properly. Refill reservoir and replace plug.
Probable CauseProblem Probable Remedy

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 15 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Disassembly
Main Components
1. Unscrew two tank cover screws (52) and remove the
tank cover.
2. Remove the hydraulic reservoir plug (74) and drain
the hydraulic fluid.
3. Reinstall the plug.
4. Loosen two screws (23). Unscrew and remove the
punch head assembly (20).
5. Unscrew three screws (24). Remove the ram (25),
three spacers (26), compression spring (28), and
piston (27). Replace the piston O-ring (21) and
backup ring (22).
6. Remove the remaining housing screws (52).
7. Remove the housing half.
8. Remove the trigger cover (51) and spring (56).
9. Lift the pump/motor assembly and circuit card from
the housing half.
10. Slide a plastic bag over the circuit card and elec-
tronic subassemblies. Tape the bag shut to protect
the subassemblies from hydraulic oil and other
contamination.
11. Unscrew the shoulder bolt (30) and remove the
release lever (34).
12. Remove screws (102) and separate the gear
housing/motor subassembly from the pump housing.
Pump
1. Use a hooked tool to remove the reservoir O-ring
(78). Gently tug it over the reservoir.
2. Remove the reservoir (72).
3. Remove the pump piston (150).
4. Remove the screw plug (151), O-ring (152), washer
(153), and spring (154). Replace the sealing washer
(153).
5. Use a piece of tape to mark the side of the relief
that is facing up. (This is a reference point for
reassembly.) Remove the unloading valve by
unscrewing the plug (126).
6. Remove the feeder tube subassembly by unscrew-
ing the feeder tube (76). Replace the oil filter (75).
Remove metal chips from the magnet (80).
7. Remove the threaded bushing (70) and replace the
O-ring (71).
Motor, Gearbox, and Bearing
1. Remove the tamper-proof paper seal (96).
2. Remove two screws (92). Remove the end cap
(100).
3. Apply pressure evenly at three points around the ball
bearing (91) and gently pry the bearing up to remove
it.
4. Remove the eccentric (101), grooved ball bearing
(99), and snap ring (98) subassembly from the shaft.
5. Remove four screws (93). Remove the mounting
block (103) from the gear housing (94).
6. Use a snap-ring removal tool to remove the snap
ring (98).
7. Unscrew four bolts (not numbered) and hex nuts
(97) from the gear housing (94). Separate the gear
housing from the motor flange (104). Unscrew two
flat head screws (106) to separate the flange from
the motor (90).

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 16 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Motor, Gearbox, and Bearing
1. Install four hex nuts (97) into the motor flange (104).
2. Install two flat head screws (106) into the motor
flange (104) and motor (90). Tighten the screws.
3. Install four screws (not numbered) and hex nuts (97)
into the gear housing (94). Tighten the screws.
4. Install four screws (93) into the mounting block (103)
and gear housing (94). Tighten the screws.
5. Replace the grooved ball bearing (99) and snap ring
(98).
6. Replace the eccentric (101). Use a fiber mallet to tap
the eccentric onto the shaft. Replace the ball bearing
(91).
7. Align the end cap (100). Use a fiber mallet to tap the
cover until it is flush on the mounting block (103).
Install two screws (92).
8. Align the gear housing/motor subassembly so that
the pump piston (150) extends through the mounting
block (103) and makes contact with the grooved
bearing (99). Locate and start the screws (102)
through the mounting block and into the pump
housing. Tighten the screws.
Pump
1. Insert the seal (122) and unloading valve subassem-
bly into the pump housing. Grasp the needle valve
subassembly by the plug (126) and twist it several
turns clockwise. Stop when the piece of tape is
facing up.
2. Assemble the O-ring (152) to the pump piston (150).
Assemble the screw plug (151), spring (154), and
sealing washer (153) to the pump housing. Install
the pump piston (150).
3. Install the release lever (34) so that the forked end
engages the unloading valve subassembly between
the pressure relief (126) and the support ring (127).
Install the screw (30) and washer (31).
4. Insert the threaded bushing (77) and feed tube
subassembly (75, 76, 80). Screw in until snug.
5. Install the reservoir (72). Slip the O-ring (78) over
the reservoir. Using a hooked tool, carefully slip the
O-ring over the lip of the pump housing.
6. Insert the plug (74) into the reservoir.
Assembly
Main Components
1. Remove the protective plastic bag from the
electronics subassembly.
2. Lay the gear housing/motor subassembly into the
right half of the housing. Insert the circuit board into
the circuit board recess.
3. Lay the wires into the case. Be sure that the wires
will not be pinched.
4. Guide the wires for the power cord so that the cord
lays on top of the electronics box.
5. Install the switch cover (51) and spring (56). Press
and release the trigger to be sure that it operates
freely.
6. Locate the right housing half on the top of the left
housing half. Check for pinched wires.
7. Install the housing screws (52).
8. Install the piston (27) and compression spring (28).
9. Replace the punch head assembly. Screw the ram
housing (20) until it stops; back off 3/4 of a turn and
tighten the screws (23). Be sure that the ram hous-
ing rotates freely approximately 350°.
10. Rotate the ram housing until the three M4 threaded
holes in the piston are aligned with the three ø0.18"
(4.5 mm) holes in the ram housing. Install the three
spacers (26), ram (25), and three screws (24).
Tighten the screws.
11. Clamp the head assembly into a vise with the
reservoir plug facing upward. Remove the fill plug
(74) and fill the reservoir with hydraulic oil.
12. Plug the power cord into a live receptacle.
13. Squeeze the trigger while pressing the release lever
for 45 to 60 seconds. Fill the reservoir with hydraulic
oil. Replace the fill plug (74).
14.
Replace the tank cover and tank cover screws (52).

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 17 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Illustration
21
2
52
50
52 50
1
50
50
51
56
55
4
3
54
22
27
28
20
23
26
25
24

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 18 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Illustration
70 71
81
77
79
72
80
73
75
76
153 151 154 152 150
128
129
122 123
124
121
130 125
126
127
96
92
91
99
93
100
101
98
102
103
33
32
34 31 30
106
97
95
105
94
104
90
12 11
120
78
74

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 19 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Parts List
Key Part No. Description Qty
1 500 1551.6 Decal, identification ........................................................................... 1
2 500 1425.0 Decal, safety, 120 volt ....................................................................... 1
500 1527.3 Decal, safety, 230 volt ....................................................................... 1
3 500 1560.5 Plate with microswitch, 120 volt ........................................................ 1
500 1689.0 Plate with microswitch, 230 volt ........................................................ 1
4 500 1561.3 Power cord, 120 volt.......................................................................... 1
500 1627.0 Power cord, 230 volt.......................................................................... 1
500 1559.1 Engine accessories kit (includes items 11–13)
11 500 1582.6 Capacitor ........................................................................................... 3
12 500 1581.8 Cable tie ............................................................................................ 1
13 500 1583.4 Tap, 4.8 x 0.5 (not shown)................................................................. 1
500 1682.2 Punch drive unit (includes items 20–28)
20 500 5828.2 Ram housing ..................................................................................... 1
21* 500 4192.4 O-ring ................................................................................................ 1
22* 500 4194.0 Backup ring ....................................................................................... 1
23 500 4168.1 Button head screw............................................................................. 2
24 500 4929.1 HSC screw ........................................................................................ 3
25 500 4926.7 Ram................................................................................................... 1
26 500 4927.5 Spacer ............................................................................................... 3
27 500 5827.4 Piston ................................................................................................ 1
28 500 7019.3 Compression spring .......................................................................... 1
30 500 4163.0 Screw, socket head ........................................................................... 1
31 500 4922.4 Lock washer ...................................................................................... 1
32 500 4125.8 Spring ................................................................................................ 1
33 500 5872.0 Screw ................................................................................................ 1
34 500 5879.7 Release lever .................................................................................... 1
50 500 1563.0 Housing kit......................................................................................... 1
51 500 1564.8 Switch cover ...................................................................................... 1
52 500 4207.6 Screw .............................................................................................. 14
54 500 1565.6 Cable clip........................................................................................... 1
55 500 1567.2 Protective cable cover ....................................................................... 1
56 500 1569.9 Compression spring .......................................................................... 1
57 500 1571.0 Film insulation (not shown)................................................................ 1
58 500 1566.4 Plug (not shown) ............................................................................... 1
500 1354.8 Pump housing, reservoir assembly (includes items 70–81)
70 500 4144.4 Threaded bushing ............................................................................. 1
71* 500 4143.6 O-ring ................................................................................................ 1
72 500 5861.4 Hydraulic reservoir ............................................................................ 1
73 500 4198.3 Ring ................................................................................................... 1
74 500 4122.3 Reservoir plug ................................................................................... 1
75 500 5880.0 Filter .................................................................................................. 1
76 500 5882.7 Filter adapter ..................................................................................... 1
77 500 5885.1 Threaded bushing ............................................................................. 1
78* 500 5886.0 O-ring ................................................................................................ 1
79 500 5829.0 Attachment ring ................................................................................. 1
80 500 5898.3 Magnet .............................................................................................. 1
81 500 1355.6 Pump housing ................................................................................... 1

CLS60GL Punch Driver
Greenlee Textron / Subsidiary of Textron Inc. 20 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070
Parts List (cont’d)
Key Part No. Description Qty
500 1683.0 Motor assembly, 120 volt (includes items 90A and 91–106)
500 1684.9 Motor assembly, 230 volt (includes items 90B and 91–106)
90A 500 1577.0 Motor, 120 volt................................................................................... 1
90B 500 1606.7 Motor, 230 volt................................................................................... 1
91 500 4138.0 Ball bearing ....................................................................................... 1
92 500 4155.0 Screw ................................................................................................ 2
93 500 4157.6 Screw ................................................................................................ 4
94 500 4133.9 Gearbox............................................................................................. 1
95 500 1575.3 Insulating sleeve................................................................................ 1
96* 500 4153.3 Seal ................................................................................................... 1
97 500 1579.6 Hex nut .............................................................................................. 4
98 500 4151.7 Retaining ring .................................................................................... 1
99 500 4139.8 Grooved ball bearing ......................................................................... 1
100 500 4108.8 End cap ............................................................................................. 1
101 500 4123.1 Eccentric............................................................................................ 1
102 500 8403.8 Screw ................................................................................................ 2
103 500 8402.2 Eccentric case ................................................................................... 1
104 500 1573.7 Motor flange ...................................................................................... 1
105 500 1574.5 Gear .................................................................................................. 1
106 500 1580.0 Screw ................................................................................................ 2
500 1593.1 Relief valve assembly (includes items 120–130)
120 500 5860.6 Washer .............................................................................................. 1
121* 500 4134.7 O-ring ................................................................................................ 1
122* 500 5862.2 Seal ................................................................................................... 1
123 500 5363.0 Valve seat.......................................................................................... 1
124 500 5864.9 Plunger .............................................................................................. 1
125* 500 5869.0 O-ring ................................................................................................ 1
126 500 5871.1 Adjusting nut...................................................................................... 1
127 500 5875.4 Support ring....................................................................................... 1
128* 500 5876.2 Retaining ring .................................................................................... 1
129 500 5877.0 Needle valve...................................................................................... 1
130 500 5894.0 Spring ................................................................................................ 1
500 1685.7 Piston pump assembly (includes items 150–154)
150 500 5892.4 Pump piston ...................................................................................... 1
151 500 1688.1 Box for pump ..................................................................................... 1
152* 500 5897.5 O-ring ................................................................................................ 1
153* 501 0366.0 Sealing washer.................................................................................. 1
154 500 4147.9 Spring ................................................................................................ 1
* 500 5904.1 Seal kit (includes items marked with an asterisk)
500 1686.5 Case with inserts
Printed in the USA
Greenlee Textron / Subsidiary of Textron Inc.
4455 Boeing Drive, Rockford, IL 61109-2988 USA
Customer Service (International): 815/397-7070 •Fax: [phone]
Customer Service (North America): 800/435-0786 •USA Fax: [phone]
Canada Fax: [phone]
www.greenlee.textron.com