Greenlee LS100X11SB4X, LS100X11A User manual

OPERATION MANUAL

Serial Number

Intelli-PUNCH™

Battery-Hydraulic

Knockout Driver

Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.

Español ............... 15

Français .............. 29

52079427 REV 1 © 2016 Greenlee Textron Inc. 9/16

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Intelli-PUNCH™ Knockout Driver

Greenlee / A Textron Company

Table of Contents

Description

Description ..................................................................... 2

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

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

Important Safety Information ..................................... 3–5

Identication ................................................................... 6

Specications ................................................................. 6

Setup and Operation ................................................ 7–11

Capacity and Draw Stud Selection Guide .................... 12

Maintenance ................................................................. 13

Troubleshooting ............................................................ 14

The Greenlee Intelli-PUNCH™ Battery-Hydraulic
Knockout Driver is a hand-held, self-contained punch
driver intended to be used with Greenlee punches, dies,
and draw studs for punching holes through plastic,
berglass, aluminum, and steel.

This tool 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

• SPEED PUNCH® Knockout System

• 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, berglass, 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.

This tool is protected by U.S. Patent No. 6,276,186,
6,401,515, 7,086,979, and 7,254,982.

All specications are nominal and may change as design
improvements occur. Greenlee Textron 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
TextronInnovations Inc.

KEEP THIS 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 operation and maintenance procedures for the
following Greenlee tool:

Intelli-PUNCH™ Battery-Hydraulic Knockout Driver
Keep this manual available to all personnel.

Do not discard this product or throw away!

2

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Intelli-PUNCH™ Knockout Driver

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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 pre­venting 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.

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, gan­grene, 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.

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.

3

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IMPORTANT SAFETY INFORMATION

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 draw
stud, and could throw parts with
great force.

Failure to observe this warning
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, 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.

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 could 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.

• Use only Greenlee punches, dies, and draw studs.
Other manufacturers’ components might not with­stand the forces generated by this punch driver.

• Manual Punch Setup: The punch must be
threaded 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.

• Hydraulic Punch Setup: The draw stud must be
threaded completely into the driver head. The
punch must be threaded 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.

• SPEED PUNCH Setup: The draw stud must be
threaded completely into the driver head. The
SPEED LOCK must fully engage and completely
close on the draw stud. Incomplete assembly
could cause a component failure.

Failure to observe these warnings 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.

4

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Intelli-PUNCH™ Knockout Driver

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IMPORTANT SAFETY INFORMATION

• 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 environ­ments; 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.

5

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Intelli-PUNCH™ Knockout Driver

Greenlee / A Textron Company

Identification

1. Punching Head

2. Return Button

3. LED Indicator (red)

4. LED Work Light (white)

5. Trigger

1

2

3

4

5

Specifications

Knockout driver (without 18V, 3.0 Ah lithium-ion battery)

Length.......................................................................................................... 14.4" (366 mm)

Width ............................................................................................................... 3.1" (80 mm)

Depth ............................................................................................................. 4.8" (122 mm)

Weight .............................................................................................................4.7 lb (2.1 kg)

Force........................................................................................................11.2 tons (100 kN)

Hydraulic Oil ......................................................... 52057878 biodegradable hydraulic uid

Recommended Operating Temperature Range ...................5 °F to 122 °F (–15 °C to 50°C)

Battery Charger ........................................................................Read the instructions supplied

52047087 120 VAC corded adapter
52047088 230 VAC corded adapter
52047083 18V, 3.0 Ah lithium-ion battery

with the battery charger

52049201 120 VAC, 18V charger
52049202 230 VAC, 18V charger
52049204 12 VDC, 18V charger

6

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Intelli-PUNCH™ Knockout Driver

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Setup and Operation

Punching

Note: The Intelli-PUNCH™ driver is a microprocessor­controlled hydraulic punching tool with an automatic
retraction feature that will engage after punch comple­tion to save time and save the operator from having to
manually retract the tool. However, care should be taken
to make sure punches and dies are not bottomed out
and that the tool releases upon punch completion. There
are circumstances that can cause the automatic retrac­tion function to fail.

1. Refer to the illustrations on the following pages for
proper punch, die, spacer, and draw stud setup and
assembly.

2. Select the appropriate punch, die, and draw stud for
the desired hole size.

3. Determine and mark the exact location for the hole.
Use a Greenlee Kwik-Stepper® step bit to drill a pilot
hole slightly larger than the draw stud being used.

4. Depress the Return button to reset the ram to the
starting position.

5. Thread the appropriate draw stud completely into
the ram in the punching head.

6. If needed, place an appropriately sized spacer on
the draw stud.

7. Slide the corresponding die onto the draw stud.
The open end of the die should face away from the
punching head.

8. Insert the draw stud through the pilot hole in the
material being punched.

9. Thread the punch (cutting edge facing the material)
onto the draw stud until the punch assembly is tight
on the material surface.

Note:

• The 3-1/2" to 6" punches require a punch sleeve

prior to assembly to the draw stud.

• All of the punch threads must be engaged with

the draw stud threads. If any punch threads are
not engaged, remove spacer and reassemble the
setup.

• For SPEED PUNCH®, slide the punch onto the

draw stud (cutting edge facing the material) and
secure the SPEED LOCK to the draw stud.

10. Press and hold the trigger to complete the punch
cycle. The Intelli-PUNCH™ driver will automati­cally retract when it senses the punch is completely
through the material.

• Under certain circumstances, such as with thin
sheet steel or very low punch forces, this unit may
not initiate auto-retract or auto-retract may be
initiated prematurely. Care should be taken to not
bottom out punches, which will cause damage
after punch completion. In the event auto-retract is
prematurely activated, retry punching the hole.

• The auto-retract feature can be overridden at any
time to stop ram retraction by depressing the
trigger.

• If overpressure is reached during the punch cycle,
the tool will automatically shut off and return the
ram to the starting position. This may indicate the
operation attempted is beyond the capacity of the
tool. The overpressure condition will also occur
when the tool reaches full stroke. (Care should be
taken to avoid driving this tool to full stroke, as this
may cause damage to the punch and die).

11. Unscrew the punch from the draw stud. Slide the die
off the draw stud and remove any slugs from the die.

Note: For SPEED PUNCH®, remove the SPEED
LOCK. Slide the punch off the draw stud; then slide
the die off the draw stud and remove any slugs from
the die.

Charging the Battery

Read the instructions supplied with the battery charger.

LED Work Light (white)

This LED automatically turns on when the trigger is
pulled. It remains on for 10 seconds after the trigger is
released.

LED Indicator (red)

This tool is equipped with a special circuit board incorpo­rating several important features to inform the user about
the current status of the unit. The LED signals in the fol­lowing cases:

What happens Signal What it means

Constant light for 20seconds
at end of cycle

Tool will not start, and
constant light for 20seconds
when trigger is released

Tool will stop, and constant
light for 20seconds after
trigger is released

Tool will stop, and flashing
light for 20seconds when
trigger is released

Battery charge is below
17V at beginning of cycle

Battery charge is below
16V at beginning of cycle

Battery voltage drops
below 13V during cycle

Motor current exceeds
20A during cycle

Circuit has become too hot

7

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Setup and Operation (cont’d)

STAINLESS STEEL

Note: Refer to “Capacity and Draw Stud Selection Guide”
on page 12 for capacity, draw stud, and hardware.

Material

Being Punched

1/2" (12.7 mm)

Punching Stainless Steel

• 1/2" Conduit Size
(dia. 0.885" / 22.5 mm)

Pilot Hole

Punch

29451

Draw Stud

Die

Punching Stainless Steel

• 3/4" to 3" Conduit Size
(dia. 1.115" to 3.539" /

28.3 mm to 89.9 mm)

Punching Stainless Steel

• 3-1/2" to 4" Conduit Size
(dia. 4.011" to 4.544" /

102.7 mm to 115.4 mm)

Material

Being Punched

Punch

Material

Being Punched

7/8" (22.2 mm)

Pilot Hole

ø 1-3/8" (34.6 mm)

Pilot Hole

Die

29452

Draw Stud

Die

1924AA Spacer

(3/4"–1-1/4" only)

29452

Draw Stud

1557SS

Sleeve

Punch

8

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Greenlee / A Textron Company

Setup and Operation (cont’d)

MILD STEEL

Note: Refer to “Capacity and Draw Stud Selection Guide”
on page 12 for capacity, draw stud, and hardware.

Material

Being Punched

Punching Mild Steel

• 1/2" Conduit Size
(dia. 0.885" / 22.5 mm)

1/2" (12.7 mm)

Pilot Hole

1924AA

Spacer

20963

Draw Stud

Die

Punching Mild Steel

• 3/4" to 3" Conduit Size
(dia. 1.115" to 3.539" /

28.3 mm to 89.9 mm)

Punching Mild Steel

• 3-1/2" to 6" Conduit Size
(dia. 4.011" to 6.375" /

102.7 mm to 161.9 mm)

Punch

Material

Being Punched

Punch

Material

Being Punched

7/8" (22.2 mm)

Pilot Hole

ø 1-3/8" (34.6 mm)

Pilot Hole

Die

2113B

Draw Stud

2113B

Draw Stud

1924AA Spacer

(3/4"–1-1/4" only)

Die

1557AA

Sleeve

Punch

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Setup and Operation (cont’d)

MILD STEEL

Punching Mild Steel

• Square: 1/2" (0.500" / 12.7 mm)

• Rectangular: 7/16"x 7/8"
(0.437"x 0.875" / 11.1 mm x 22.2 mm)

05244

1/4" Counter Nut

Punch

60115

1/4" Draw Stud

Die

Pilot Hole

60114

1/4" Adapter

03248

Spacer

End with

Long Threads

Punching Mild Steel

• Square: 5/8" to 0.945"
(0.625" to 0.945" / 15.9 mm to 24.0 mm)

• Rectangular: 0.670" x 0.749"
(17.0 mm x 19.0 mm)

04638

3/8" Counter Nut

Pilot Hole

Punch

Punching Mild Steel

• Square: 1" (1.000" / 25.4 mm)

• Rectangular: 0.750"x 1.140" to 1.250" x 1.380"
(19.1 mm x 29.0 mm to 31.8 mm x 35.1 mm)

60258

1/2" Counter Nut

60116

3/8" Draw Stud

Threads with Flats

Die

60117

3/8" Draw Stud

Threads with Flats

Die

33967

3/8" Adapter

03248

Spacer

End with Long Threads

60167

1/2" Adapter

03248

Spacer

End with Long Threads

Pilot Hole

Punch

10

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Setup and Operation (cont’d)

MILD STEEL

Punching Mild Steel

• Square: 1.811" to 2.677" (46.0 mm to 68.0 mm)

• Rectangular: 1.312" x 2.625" to 1.378" x 2.559"
(33.3 x 66.7 mm to 35.0 mm x 65.00 mm)

60118

3/4" Draw Stud

End with Long Threads

60235

3/4" Counter Nut

Punching Mild Steel

• “D" Punches

• Double “D" Punches

• Key Punches

Counter Nut

Punching Mild Steel

• Electronic Connector
Panel Punches

Punch

Punch

Pilot Hole

Draw Stud

Die

Pilot Hole

34421

3/8" Draw Stud

Die

Adapter

03248

Spacer

End with Long Threads

33967

3/8" Adapter

03248

Spacer

End with Long Threads

Threads with Flats

04638

3/8" Counter Nut

Punch

Die

7/16" (11.1mm)

Pilot Hole

11

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Capacity and Draw Stud Selection Guide

STAINLESS STEEL

Slug-Splitter and Large Diameter Punches / Draw Studs

Steel Gauge

10 ga. (0.134", 3 mm)

12 ga. (0.104", 2.5 mm)

14 ga. (0.074", 2 mm)

1/2" 3/4" to 1-1/4" 1-1/2" to 3" 3-1/2" to 4"

C, E D, E D

PIPE AND CONDUIT SIZE

MILD STEEL

Standard and Slug-Buster Punches / Draw Studs

Steel Gauge

10 ga. (0.134", 3 mm)
12 ga. (0.104", 2.5 mm)
14 ga. (0.074", 2 mm)

1/2" 3/4" to 1-1/4" 1-1/2" to 3" 3-1/2" to 4" 5" to 6"

A, E B, E B B, F

PIPE AND CONDUIT SIZE

MILD STEEL

Electronic Connector Punches

Steel Gauge RS232, 229, 231, 234, 238

16 ga. (0.0598", 1.5 mm) 33967 adapter, 1924AA spacer

N/A

D, G

N/A

B, F

Key

Item

A 20963 3/8" x 4.8" draw stud
B 2113B 3/4" x 5.38" draw stud
C 29451 7/16" x 4.25" draw stud (stainless steel)
D 29452 3/4" x 5.5" draw stud (stainless steel)
E 1924AA 7/8" spacer
F 1557AA 1-1/8" x 3" punch sleeve
G 1557SS 1-1/8" x 3" punch sleeve (stainless steel)

Catalog No. Description

Draw Stud and Hardware

12

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Maintenance

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, gan­grene, or death.

Daily

Before use:

1. Inspect the tool for wear or damage, such as cracks,
gouges, or chips.

2. Inspect the tool for damage or leaks.

3. Inspect the rotation of the head assembly. Fully
return the ram. The head should rotate freely. If
damage is detected, contact Greenlee customer

After use:

1. Use a damp cloth and mild detergent to clean the
housing. Allow the housing to dry.

2. Fully return the ram. Place the tool in the carrying
case and store in a cool, dry place.

3. If necessary, recharge the batteries. Refer to the
instructions supplied with the battery charger.

Monthly

1. Thoroughly clean all surfaces.

2. Check the oil level.

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.

Annually or After 10,000 Punches

1. Replace the hydraulic oil.

Checking the Oil Level

1. Remove the screws holding the housing cover
together.

2. Point the tool head downward and remove the oil
reservoir plug. Fill reservoir if necessary.

3. Replace the oil plug and housing cover.

Relief valve adjustments must be done by an
authorized service center.

13

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Troubleshooting

Before You Begin

1. Make sure that the battery is charged. Recheck
the battery after several minutes to make sure the
battery is holding its charge.

Problem Possible Cause Probable Remedy

Tool is inoperative. Dirt, contaminants, etc., in

ram area oftool.

Tool components worn or
damaged.

Motor is inoperative. Low or uncharged battery. Try known charged battery. Inoperative battery may be

Broken switch components. Contact Greenlee customer service at 800-435-0786

Motor runs but tool will
not complete a cycle.

Oil level low. Contact Greenlee customer service at 800-435-0786

Air in hydraulic system. Pull trigger and hold return button simultaneously.

2. Use a nonflammable contact cleaner or pencil

eraser to clean the electrical contacts on the battery
and tool.

3. Reinstall the battery and check the tool again.

Clean tool.

Contact Greenlee customer service at 800-435-0786

discharged or may have reached life expectancy.

Run for approximately 10 seconds, and then attempt
to punch. If unsuccessful, contact Greenlee customer

Cold oil. Pull trigger and hold return button simultaneously to

warm oil. Store tool in warm area.

Dies stop during
operation.

LED glows for 20
seconds.

Tool loses oil. Damaged internal seal. Contact Greenlee customer service at 800-435-0786

Oil level low. Contact Greenlee customer service at 800-435-0786

Air in hydraulic system. Pull trigger and hold return button simultaneously.

Hold for approximately 10 seconds.

Battery charge low. Charge or replace battery.

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