Greenlee Quick draw 7804sb User manual

SERVICE MANUAL

Read and understand all of the instructions and

safety information in this manual before operating

or servicing this tool.

Quick Draw®

Hydraulic Punch Drivers

Serial Codes AHJ andYZ

7704SB / 7706SB

Quick Draw Flex™

7804SB / 7806SB

Quick Draw®

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

Table of Contents

Safety .............................................................................2

Purpose of this Manual ..................................................2

Other Publications..........................................................2

Important Safety Information..........................................3

Maintenance...................................................................4

Troubleshooting .............................................................5

Disassembly...................................................................6

Ball Seat Repair .............................................................6

Reassembly ...................................................................7

Inspection and Adjustments ...........................................7

Illustrations and Parts Lists ......................................8–11

7704SB / 7706SB ...................................................8–9

7804SB / 7806SB ...............................................10–11

Draw Studs and Accessories .......................................12

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.

KEEPTHIS MANUAL

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 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

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815/397-7070

IMPORTANT SAFETY INFORMATION

Note: Keep all decals clean and legible, and replace

when necessary.

Electric shock hazard:

Do not use this tool near live circuits.

This includes, but is not limited to,

the following:

•Near circuit breaker panels or fuse

boxes with energized circuits

•Near junction boxes with ener-

gized circuits

Failure to observe this warning can

result in severe injury or death.

Read and understand all of the

instructions and safety information in

this manual before operating or

servicing this tool. Refer also to the

instruction manual, which is listed

under “Other Publications.”

Failure to observe this warning can

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

Use this tool for the manufacturer’s intended pur-

pose only. Use other than that which is described in

this manual can result in injury or property damage.

Do not operate the pump lever after the ram motion

stops. Continuing to operate the pump lever after the

ram motion stops will damage the driver and could

propel internal parts with great force, striking nearby

personnel.

Do not exceed the rated capacity of this tool.

Exceeding the rated capacity could cause a

component failure, which could throw broken parts

with great force.

Failure to observe this warning can 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 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.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris.

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Maintenance

Maintenance and repairs should be performed in a dust-

free area by qualified technicians.

This unit requires minimum maintenance because it

has a closed hydraulic system and all internal parts

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

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 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

ram extends slowly. Rapid return of oil and air may

cause the oil to overflow the rubber bladder.

If this procedure fails to remove air, remove the

bladder plug and open the release valve knob. Place

thumb over the plug hole in the bladder and squeeze

the bladder while pumping the lever handle several

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.

Oil Leaks

•Check for external oil leaks.

•Check that the release valve knob and stem are

closed tightly and seating properly.

•Remove the reservoir handle and check for oil leaks

around the rubber bladder and bladder plug.

Release Valve Knob

Rubber Bladder

Bladder Plug

Reservoir Handle

Lever Handle

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Problem Probable Cause Probable Remedy

Troubleshooting

Does not punch hole. Refer to “Operation”and “Capacity and Draw

Stud Selection Guide.”

Improper assembly or use of punch,

die, or accessories.

Low oil level. Refer to “Adding Hydraulic Oil”in the

“Maintenance”section.

Requires excessive lever

force. Improper assembly or use of punch,

die, or accessories. Refer to “Operation”and “Capacity and Draw

Stud Selection Guide.”

Material being punched is too thick or

too hard. Refer to “Capacity and Draw Stud Selection

Guide.”

Pump does not build

pressure. Air in system. Refer to step 3 of “Adding Hydraulic Oil”in

the “Maintenance”section.

Excessive number of strokes

are required to punch hole. Inoperative intake check valve. Refer to “Intake Check Valve”inspection in

the “Inspection and Adjustments”section.

Inoperative discharge check valve. Refer to “Discharge Check Valve”inspection

in the “Inspection and Adjustments”section.

Leaking release valve. Refer to “Release Valve”inspection in the

“Inspection and Adjustments”section.

Damaged piston, piston extension,

pump plunger seals, or mating

surfaces.

Refer to “Maintenance,”cylinder and pump

block sections.

Clogged filter. Clean or replace filter (31).

Does not return piston. Weak or damaged return spring;

excess oil in unit. Refer to “Ram Travel Inspection”in the

“Inspection and Adjustments”section.

External oil leaks. Damaged piston, piston extension,

pump plunger seals, or mating

surfaces.

Refer to “Maintenance,”cylinder and pump

block sections.

Damaged release valve stem seal. Refer to “Release Valve”inspection in the

“Inspection and Adjustments”section.

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

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) for

nicks, scratches, or other damage.

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 “I”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.

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.

Wear eye protection when operating

or servicing this tool.

Failure to wear eye protection can

result in serious eye injury from

flying debris.

“I” Drill

Std. Drill

Acceptable

“I” Drill

Release

Valve

Stem

“B” Drill

5/32" Ream

Discharge

Check

9/64" Ream

Intake

Check

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

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 Retracted

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).

33967

Adapter Set Screw

(12)

Piston

Travel

Rotate cylinder

to make adjustment.

.930"

.830"

(23.6 mm)

(21.1 mm)

Pump Section Inspection

Intake Check Valve

Close the release valve knob and operate lever

handle (2) until ram (6) bottoms and handle

resistance increases.

•If 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 (32) 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).

Reassembly

Reassembly is done in reverse sequence of

disassembly.

1. Use one of the following repair kits to replace all

O-ring seals, balls, and springs:

•7704SB / 7706SB: Repair kit 501 0477.2

•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.

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Illustration—7704SB / 7706SB

33 33

33 36

14 15 3232

3232

Repair Kits

503 7160.6 Release Valve Unit Repair Kit

includes items keyed in black circles

(12, 16, 27, 28, 32, one of 33, 34)

501 0477.2 Hydraulic Repair Kit

includes items keyed in black squares

(3, 8–11, 13–15, 21, 23, 25, 31–37)

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Parts List—7704SB / 7706SB

1 503 6889.3 Handle, reservoir ............................................................................... 1

2 503 6887.7 Handle, pump .................................................................................... 1

3 503 6890.7 Seat, inlet check ................................................................................ 1

4 503 4271.1 Cylinder, hydraulic............................................................................. 1

5 501 0390.3 Block weld assembly, pump .............................................................. 1

6 501 0384.9 Ram................................................................................................... 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 .............................................. 1

9 905 1316.9 O-ring, 1.50 x 1.75 x .125 nitrile ........................................................ 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 ........................................................ 1

12 905 5281.4 Screw, set #8-32 x .312 cup point ..................................................... 1

13 905 3761.0 Retaining ring, .125 Truarc................................................................ 1

14 905 5121.4 Backup ring, spiral, .373 x .479 x .056 .............................................. 1

15 905 0168.3 O-ring, .364 x .500 x .068 nitrile ........................................................ 1

16 503 1878.0 Decal, punch release......................................................................... 1

18 905 1130.1 O-ring, 1.50 x 1.62 x .062 nitrile ........................................................ 1

19 502 3258.4 Grip, rubber ....................................................................................... 1

20 503 2488.8 Plug, bladder ..................................................................................... 1

21 905 4186.3 Retaining ring, .217 Truarc................................................................ 4

22 501 0388.1 Retainer, coupler ............................................................................... 1

23 905 3845.5 Spring, compression, .152 x .180 x .380 ........................................... 1

24 503 7715.9 Plunger .............................................................................................. 1

25 905 3503.0 Retaining ring, .562 Truarc................................................................ 1

26 501 0386.5 Coupler, ram...................................................................................... 1

27 503 6886.9 Knob, release valve........................................................................... 1

28 503 6893.1 Stem, release valve........................................................................... 1

29 503 4269.0 Bladder, rubber.................................................................................. 1

30 503 7714.0 Pin, handle ........................................................................................ 2

31 503 6899.0 Filter, oil............................................................................................. 1

32 905 0678.2 Ball, steel, .187 diameter................................................................... 2

33 905 3854.4 O-ring, .250 x .375 x .062.................................................................. 2

34 905 0458.5 Pin, roll, .125 x .375........................................................................... 1

35 905 0376.7 O-ring, 1.125 x 1.375 x .12 nitrile ...................................................... 1

36 905 4230.4 Backup ring, spiral, .265 x .318 x .050 .............................................. 1

37 905 0452.6 Ball, steel, .218 diameter................................................................... 1

38 503 6894.0 Cap, reservoir handle ........................................................................ 1

39 501 0392.0 Hose .................................................................................................. 1

40 501 0387.3 Retainer, spring ................................................................................. 1

41 905 4142.1 Ring, retaining ................................................................................... 1

42 501 0393.8 Cover, hose ....................................................................................... 1

43 500 1592.3 Decal, identification ........................................................................... 1

Key Part No. Description Qty

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 10 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Illustration—7804SB / 7806SB

534

Repair Kits

503 7160.6 Release Valve Unit Repair Kit

includes items keyed in black circles

(12, 16, 27, 28, 32, one of 33, 34)

503 7161.4 Hydraulic Repair Kit

includes items keyed in black squares

(3, 8–11, 13–15, 18, 21, 23, 25, 31–37)

Quick Draw®Hydraulic Punch Drivers

Greenlee Textron / Subsidiary of Textron Inc. 11 4455 Boeing Dr. •Rockford, IL 61109-2988 USA •815/397-7070

Parts List—7804SB / 7806SB

1 503 6889.3 Handle, reservoir ............................................................................... 1

2 503 6887.7 Handle, pump .................................................................................... 1

3 503 6890.7 Seat, inlet check ................................................................................ 1

4 503 4271.1 Cylinder, hydraulic............................................................................. 1

5 503 6900.8 Block, pump....................................................................................... 1

6 503 6896.6 Ram................................................................................................... 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 .............................................. 1

9 905 1316.9 O-ring, 1.50 x 1.75 x .125 nitrile ........................................................ 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 ........................................................ 1

12 905 1032.1 Screw, set, #8-32 x .187 socket cup ................................................. 2

13 905 3761.0 Retaining ring, .125 Truarc................................................................ 1

14 905 5121.4 Backup ring, spiral, .373 x .479 x .056 .............................................. 2

15 905 0168.3 O-ring, .364 x .500 x .068 nitrile ........................................................ 2

16 503 1878.0 Decal, punch release......................................................................... 1

18 905 1130.1 O-ring, 1.50 x 1.62 x .062 nitrile ........................................................ 1

19 502 3258.4 Grip, rubber ....................................................................................... 1

20 503 2488.8 Plug, bladder ..................................................................................... 1

21 905 4186.3 Retaining ring, .217 Truarc................................................................ 4

22 503 6892.3 Plate, retaining .................................................................................. 1

23 905 3845.5 Spring, compression, .152 x .180 x .380 ........................................... 1

24 503 7715.9 Plunger .............................................................................................. 1

25 905 3503.0 Retaining ring, .562 Truarc................................................................ 1

26 503 6891.5 Coupler, ram...................................................................................... 1