Textron GREENLEE 7646 User manual

USA Tel: [phone]
Fax: [phone]
Canada Tel: [phone]
Fax: [phone]
International Tel: [phone]
Fax: [phone]
56
Holemaking
www.greenlee.com
= REPLACEMENT PART = ACCESSORY
7646
STEEL CAPACITIES FOR CONDUIT SIZES
STANDARD & SLUG-BUSTER®PUNCHES STANDARD SLUG-SPLITTERS®
REQUIRED DRAW STUD AND ACCESSORIES 1/2" 3/4" 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 3-1/2" 4" 1/2" 3/4" 1" 1-1/4" 1-1/2" 2"
3/4" Stud (03294),
3/8" Stud (30043) & Spacers
3/4" Stud (03294),
Long Spacer
3/4" Stud (03294),
Short Spacer
3/4" Stud (03294)
3/4" Stud (03294),
& Sleeve (03170)
7/16" Stud (29451)
3/4" Stud (29452)
10 GA. MILD STEEL 10 GA. STAINLESS STEEL
A
B
FGH
J
L
M
N
R
IK
A
B
FGH
L
R
M
N
K J I
RAM AND HAND PUMP HYDRAULIC DRIVER PARTS IDENTIFICATION
KEY CAT./UPC NO. DESCRIPTION
A 746 / 17091 Ram (includes Item B)
B 2113AA / 03294 Draw Stud–3/4" x 5-3/8"
F 1557AA / 03170 Punch Sleeve
G 1614SS / 30043 Draw Stud–3/8" x 2-13/16"
H 15908 Spacer Group (includes Items I, J and K)
I 1924AA / 03248 Spacer-Short
J 1925AA / 03249 Spacer-Medium
K 1926AA / 06904 Spacer-Long
L 34410 Kwik Stepper Step Bit 1/2"
M 767 / 13284 Hydraulic Hand Pump
N 06302 / 06302 High Pressure Hose–1/4" x 3'
R 30206 Plastic Case
Ram and Hand Pump Hydraulic Driver Kits (Inch and Metric)
• Fast, easy and simple to operate.
• Compact design for field use on construction sites
and maintenance jobs.
• Punches 10 times faster than wrench method.
• Will also drive 751 Cable Cutter head.
• Can be used with most standard round Slug-Buster
and Slug-Splitter®punches (not 1/2", 9/16", 5/8").
• Can be used with non-round punches (adapter may be required).
• 3-foot hose
• Powerful 11-ton hydraulic ram.
WEIGHT
CAT. NO. UPC NO. DESCRIPTION LBS. kg.
7646 15906 Driver with Hand Pump, Draw Studs, 20 9.1
Spacer and Plastic Case
7306 15909 Driver, Hand Pump, Standard Punches, 24 10.9
Dies and Draw Studs for 1/2" through
2" Conduit, Plastic Case
7306SB 34360 Driver, Hand Pump, Slug-Buster Punches, 24 10.9
Dies and Draw Studs for 1/2" through 2"
Conduit, Adapter, Spacers, Kwik Stepper®
Step Bit and Plastic Case
7310 15910 Driver, Hand Pump, Standard Punches, 54 24.5
Dies and Draw Studs and Spacers for
1/2" through 4" Conduit, Steel Case
7310SB 34361 Driver, Hand Pump, Slug-Buster Punches, 54 24.5
Dies and Draw Studs for 1/2" through 2"
and 2-1/2" through 4" Standard Conduit
Size Punches, Dies and Draw Studs,
Adapter, Spacers, Kwik Stepper Step Bit
and Steel Case
7646Pg 27433 Metric – Driver, Hand Pump, Standard 24 10.9
Pg Punches, Dies and Draw Studs and
Spacers for 15.2 mm through 60.0 mm,
Plastic Case
7646PgSB 32799 Metric – Driver, Slug-Buster Pg Punches, 24 10.9
Dies and Draw Studs for 15.2 mm through
60.0 mm, Adapter, Spacers, Kwik Stepper
Step Bit and Plastic Case
7304 02815 Standard Punch and Die Kit (no draw studs) 21 9.5
for 2-1/2" through 4" Conduit, Plastic Case
38456 38456 Driver, Hand Pump, Standard Punches, Dies 48.4 22
and Draw Studs and Spacers for 1/2"
through 3" and 4" Conduit, Steel Case
38520 38520 Driver, Hand Pump, Slug-Buster Punches 48 21.8
and Draw Studs for 1/2" through 3" and 4"
Conduit, Adapter, Spacers, Kwik Stepper
Step Bit and Steel Case

INSTRUCTION MANUAL
999 9606.5 © 2000 Greenlee Textron IM 1066 REV 6 5/00
HYDRAULIC PUNCH DRIVER
38456, 38520, 7306 / 7306SB,
7310 / 7310SB, 7506, 7606SB, 7610SB,
7625 / 7625Pg / 7625PgSB,
7646 / 7646Pg / 7646PgSB
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Greenlee Textron / Subsidiary of Textron Inc. 24455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
Table of Contents
Description .....................................................................2
Safety.............................................................................2
Purpose..........................................................................2
Important Safety Information ......................................3-4
Setup and Operation......................................................5
Illustration.......................................................................6
Parts Lists ...................................................................7-9
Description
The Greenlee hydraulic punch driver sets combine the
746 Hydraulic Ram with the 767 Hand Pump or the
1725 Foot Pump. These hydraulic driver sets are
intended to be used with either standard or Slug-Buster®
punches and dies to punch holes through plastic,
fiberglass, aluminum and steel. Greenlee Slug-Splitter®
punches, dies, and draw studs are capable of punching
through all of these materials and stainless steel.
Round punches are available for punching holes from
12.7mm through 144mm (1/2" through 5-5/8") in
diameter, including 1/2" through 5" conduit and pipe
sizes. Other shapes are available — square, special
square, rectangular, “D”, double “D”, electronic connec-
tor, oiltight with notches, and key.
The maximum thickness of material that the punch can
penetrate depends on the size and shape of the punch.
See the instruction manual supplied with the punch for
individual punch capacities.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction 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
This manual is intended to familiarize personnel with the
safe operation and maintenance procedures for the
following Greenlee hydraulic punch driver kits:
38456
38520
7306/7306SB
7310/7310SB
7506
7606SB
7610SB
7625/7625Pg/7625PgSB
7646/7646Pg/7646PgSB
Slug-Buster®, Slug-Splitter®, and
are registered trademarks of Greenlee Textron.
Keep this manual available to all personnel.
Replacement manuals are available upon request at no
charge.
KEEPTHIS MANUAL

Greenlee Textron / Subsidiary of Textron Inc. 34455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
IMPORTANT SAFETY INFORMATION
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
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.
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.
Skin injection hazard:
Oil under pressure easily punctures
skin causing serious injury, gangrene
or death. If you are injured by
escaping oil, seek medical attention
immediately.
• Hand-tighten all couplers com-
pletely before operating the pump.
Do not use tools to tighten the
couplers.
• Do not use hands to check for
leaks.
• Do not hold hose or couplers while
the hydraulic system is pressurized.
• Release the hydraulic pressure
before disconnecting the hoses or
couplers, and before servicing the
pump or accessory.
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.

Greenlee Textron / Subsidiary of Textron Inc. 44455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
IMPORTANT SAFETY INSTRUCTIONS
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 can
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
draw stud, and could throw parts
with great force.
Failure to observe this warning can
result in severe injury or death.
Set up the tool properly. An improper setup could
cause a component to fail and strike nearby
personnel with great force.
• 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 a component failure.
• Use only Greenlee punches, dies and draw
studs. Other manufacturers’ components might
not withstand the forces generated by this punch
driver.
Failure to observe these warnings can result in
severe injury or death.
This punch system was designed for a maximum
operating pressure of 450 Bar (6500 psi).
• Use this punch system with the Greenlee 767
Hand Pump or 1725 Foot Pump only.
• Connect the pump to the ram with Greenlee
hoses and couplers only.
Use of any other hoses or couplers could result in
injury from a component failure.
Replace worn, damaged or missing components
with Greenlee replacement parts. Worn or damaged
components can fail, resulting in injury or property
damage.
• Inspect the pump, hoses, couplers, and fittings for
wear or damage.
• Inspect all punch components (punch, die, draw
stud, etc.) for wear or damage.
Failure to observe these warnings can result in
severe injury or death.
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.
Use this tool for the manufacturer’s intended
purpose only. Any other use can result in injury or
property damage.
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 can result in injury
or property damage.

Greenlee Textron / Subsidiary of Textron Inc. 54455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
1. Remove the dust caps from the couplers; attach the
hose to the ram and to the pump. Thread the dust
caps together.
Note: Hand-tighten the couplers completely until
all threads are engaged. Do not use tools.
2. Select the punch, die, and draw stud that will make
the appropriate size hole.
3. Determine and mark the exact location for the hole.
Using a drill bit that is slightly larger than the draw
stud, drill a hole. This is the pilot hole .
4. Thread the 3/4" piston shaft (B) completely into the
ram (A). See illustration.
Note: For a punch and die with a 3/8" center hole,
thread the 3/8" stainless steel adapter
screw (G) into the end of the piston shaft.
For a punch and die with a 1-1/8" center
hole, thread the screw sleeve (F) onto the
piston shaft.
5. Install spacers as necessary. See illustrations on
this page.
6. Slide the die over the draw stud with the open end
of the die facing away from the ram.
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 spacers, die,
material, and punch are snug.
Note: If the ram stops before the hole is complete,
stop pumping. Check that the setup is
correct and that you have not exceeded the
tool’s capacity. See the setup instructions.
If necessary, disassemble the setup and
add a spacer.
9. Activate the pump. For specific instructions, see the
operating manual supplied with the pump.
Note: Support the weight of the ram when
operating the pump. This will prevent the
ram from falling when the punch is
complete.
10. Release the pressure at the pump.
PUNCH
1-1/8" SLEEVE
PUNCH
DIE 3/8" DRAW STUD 3 SPACERS
3/4" DRAW STUD
RAM
DIE
MATERIAL
PUNCH DIE SPACER
AS NEEDED
MATERIAL
MATERIAL
Note: All of the punch threads must be engaged
by the draw stud threads. If any of the
punch threads are not engaged, dis-
assemble the setup, remove one of the
spacers and reassemble the setup.
Setup and Operation
Completed Assembly
Do not operate the pump after ram motion stops.
Continuing to operate the pump lever after the
ram stops will damage the ram.

Greenlee Textron / Subsidiary of Textron Inc. 64455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
ExplodedView
502 9451.2
502 9452.0
(for use with Slug-Splitter®punches and dies)
For Punching Stainless Steel:
7646 Hydraulic Punch Driver with 767 Hand Pump
A
B
C
D
EFG
I
K
L
M
N
O
R
HJ
7625 Hydraulic Punch Driver with 1725 Foot Pump
A
B
C
DHIJ
E
F
GK
N
O
P
S
O
D
N
C
Q

Greenlee Textron / Subsidiary of Textron Inc. 74455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
Cat. UPC NO.
KEY No. 78-3310- DESCRIPTION 7646 7306SB 7306 7310SB 7310 7625 7606SB 7610SB 7304 7506
A 746 17091 Ram (includes Keys B, C, D) 1 1 1 1 1 1 1 1
746SS 30387 Ram (includes Keys C, D and 29452) 1
29451 29451 7/16" Stainless Steel Draw Stud 1
29452 29452 3/4" Stainless Steel Draw Stud 1
B 2113AA 03294 3/4" Piston Shaft 1 1 1 1 1 1 1 1
C 54167 54167 1/4" Coupler Unit 1 1 1 1 1 2 2 2 1
D 54168 54168 Dust Plug 1 1 1 1 1 2 2 2 1
E 1557AA 03170 Screw Sleeve 1 1 1 1 1 1 1 1
F 1614SS 30043 3/8" Stainless Steel Adapter Screw 2 2 2 2 2 2 2 2
G 15908 15908 Spacer Group (includes Keys H, I, J) 1 1 1 1 1 1 1 1 1
H 1924AA 03248 Short Spacer 1 1 1 1 1 1 1 1 1
I 1925AA 03249 Medium Spacer 1 1 1 1 1 1 1 1 1
J 1926AA 06904 Long Spacer 1 1 1 1 1 1 1 1 1
K 34410 34410 Kwik-Stepper®Pilot Bit 1 1 1 1 1 1 1 1 1
L 767 13284 Hydraulic Hand Pump 1 1 1 1 1 1
M 38316 38316 1/4" x 3' High-Pressure Hose Unit
(includes Keys N, O) 1 1 1 1 1 1
N 54169 54169 1/4" Coupler Unit 1 1 1 1 1 2 2 2 1
O 54170 54170 Dust Cap 1 1 1 1 1 2 2 2 1
921GB 50386 1/4" x 3' High-Pressure Hose w/ Swivel
(without couplers) 1 1 1 1 1 1
P 1725 31353 Hydraulic Foot Pump
(includes Keys C, D) 1 1 1
Q 37729 37729 1/4" x 10' High Pressure Hose Unit
(includes 2 each of Keys N, O) 1 1 1
52515 52515 1/4" x 10' High Pressure Hose
Replacement (without couplers)
R 30206 30206 Plastic Carrying Case 1 1 1
18402 18402 Metal Carrying Case 1 1
S 23955 23955 Metal Carrying Case 1 1 1
30236 30236 Plastic Carrying Case 1
31068 31068 Metal Carrying Case 1
Parts List
Standard and Slug-Buster®punches, dies and draw studs listed on the
following page are capable of punching a maximum of 10 (.1344", 3 mm)
gauge mild steel. Slug-Splitter®punches, dies and draw studs listed on the
following page are capable of punching a maximum of 10 (.1344", 3 mm)
gauge stainless steel.

Greenlee Textron / Subsidiary of Textron Inc. 84455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
Cat. UPC NO.
KEY No. 78-3310- DESCRIPTION 7646 7306SB 7306 7310SB 7310 7625 7606SB 7610SB 7304 7506
721—1/2 31756 1/2" Slug-Buster®Punch 1111 1 1
14722 14722 1/2" Die 1111 1 1
721—3/4 31757 3/4" Slug-Buster®11 11
123AV 04008 3/4" Standard Punch 1 1
124AV 06972 3/4" Die 1111 1 1
721—1 31758 1" Slug-Buster®Punch 1 1 1 1
125AV 04010 1" Standard Punch 1 1
126AV 04011 1" Die 1111 1 1
721—1-1/4 31759 1-1/4" Slug-Buster®Punch 1 1 1 1
127AV 06974 1-1/4" Standard Punch 1 1
128AV 04013 1-1/4" Die 1111 1 1
721—1-1/2 31760 1-1/2" Slug-Buster®Punch 1 1 1 1
439AV 06978 1-1/2" Standard Punch 1 1
440AV 04061 1-1/2" Die 1111 1 1
721—2 31761 2" Slug-Buster®Punch 1 1 1 1
441AV 04062 2" Standard Punch 1 1
442AV 04063 2" Die 1111 1 1
1429AV 04175 2-1/2" Punch 1 1 1 1
1430AV 04177 2-1/2" Die 1 1 1 1
1431AV 04180 3" Punch 1 1 1 1
1432AV 04183 3" Die 1 1 1 1
2982AV 04653 3-1/2" Punch 1 1 1 1
2981AV 04652 3-1/2" Die 1 1 1 1
2984AV 04655 4" Punch 1 1 1 1
2983AV 04654 4" Die 1 1 1 1
28154 28154 1/2" Slug-Splitter®Punch 1
28155 28155 1/2" Slug-Splitter®Die 1
28156 28156 3/4" Slug-Splitter®Punch 1
28157 28157 3/4" Slug-Splitter®Die 1
28158 28158 1" Slug-Splitter®Punch 1
28159 28159 1" Slug-Splitter®Die 1
28160 28160 1-1/4" Slug-Splitter®Punch 1
28161 28161 1-1/4" Slug-Splitter®Die 1
28162 28162 1-1/2" Slug-Splitter®Punch 1
28163 28163 1-1/2" Slug-Splitter®Die 1
28165 28165 2" Slug-Splitter®Punch 1
28166 28166 2" Slug-Splitter®Die 1
Parts List—Punches

Greenlee Textron / Subsidiary of Textron Inc. 94455 Boeing Dr., Rockford, IL 61109-2988 815/397-7070
Hydraulic Punch Driver
Parts List—Ram
7
6
11
45 3 2 8 12 1 10
Serial No.
Location
9
UPC NO.
KEY 78-3310- DESCRIPTION QTY.
1 500 3294.1 Shaft (746 M-3)...........................................................1*
502 9452.2 Shaft (746 SS) ............................................................1**
2 501 7093.7 Piston ..........................................................................1
3 501 7095.3 Cylinder.......................................................................1
4 501 1251.1 Spring, Compression ..................................................1
5 501 1253.8 Retainer ......................................................................1
6 905 4167.7 Coupler, 1/4" Quick Disconnect..................................1
7 905 4168.5 Plug, Protective...........................................................1
8 905 0338.4 O-Ring, 7/8" x 1-1/8" x 1/8".........................................1
9 905 0389.9 O-Ring, 2" x 2-3/8" x 3/16"..........................................1
10 905 0390.2 Ring, Retainer.............................................................2
11 905 0832.7 Ring, 2" x 2-3/8" x 3/16" Spiral Backup ......................1
12 905 1339.8 Ring, 7/8" x 1-1/8" x 1/8" Spiral Backup .....................1
501 4552.5 Packing Repair Kit (not shown) ..................................1
501 2121.9 Decal, Safety (not shown) ..........................................1
* 500 3294.1 Supplied with the 746 and used with standard punches
and Slug-Buster®punches
** 502 9452.0 Supplied with the 746 SS and used with Slug-Splitter®
punches and dies

Maintenance
The pump and ram require little maintenance. Use the
tool with care to keep dirt and grit out of the hydraulic
system. All internal working parts are lubricated by the
hydraulic oil, so that no other lubrication is necessary.
Repair
All repair work should be performed at an authorized
Greenlee service center. Use only Greenlee replace-
ment parts. Using any parts other than Greenlee
replacement parts may do irreparable damage and will
void the warranty.
Printed in the U.S.A.
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 •Fax: [phone]
Canada Fax: [phone]