Cleveland Steel Tool Porta-Punch User manual

Porta-Punch
Manual
474 E. 105th Street
Cleveland, OH 44108-1378
[phone] • Fax [phone]
www.clevelandsteeltool.com •E-mail: [email protected]
800-446-4402

Page
General Information........................................................................................................................................1
Porta-Punch Warranty ....................................................................................................................................2
Safety Precautions
Punching Unit .................................................................................................................................................3
Hydraulic Hoses .............................................................................................................................................3
The Porta Punch
Exploded View Drawing..................................................................................................................................4
.................................................................................................................................................4
Punches and Dies ..........................................................................................................................................5
Punch and Die Installation..............................................................................................................................5
Troubleshooting..............................................................................................................................................6
Pump
Warranty .........................................................................................................................................................7
Safety Precautions .........................................................................................................................................8-10
Troubleshooting..............................................................................................................................................11
Exploded View Drawings................................................................................................................................12-14
TABLE OF CONTENTS
01.20

The information and illustrations in
this bulletin cover The Porta Punch,
Cleveland Steel Tool’s 35-Ton
portable hydraulic punching unit.
Read and carefully follow these
instructions before installation and
use of this equipment. Most problems
and personal injuries can be avoided
with proper installation and operation.
Inspect the equipment upon arrival.
It is the carrier’s responsibility for
any damage resulting from shipment.
800-446-4402
For further information, please
contact your Cleveland Steel Tool
representative.
1
GENERAL INFORMATION

PORTA-PUNCH WARRANTY
2
The Cleveland Steel Tool Company will, within one (1) year of date of purchase, replace or repair F.O.B. the
factory, any goods, which are defective in materials and workmanship provided that the buyer returns the defective
goods, freight prepaid, to the seller, which shall be the buyer’s sole and exclusive remedy for the defective goods.
THIS WARRANTY IS VOID IF YOU ATTEMPT REPAIRS YOURSELF. This warranty is void if the items have
been damaged by accident, neglect, or other causes not arising out of defects in materials or workmanship.
subject to respective manufacturer’s warranties. In no event shall The Cleveland Steel Tool Co. be liable for loss
or damage resulting directly or indirectly from the use of merchandise or from any other cause. The Cleveland
waive any of the foregoing terms of sales and none shall be binding on The Cleveland Steel Tool Co.
Proof of purchase date required
seller be liable for labor costs expended on such goods or consequential damages. Seller shall not be liable
to the purchaser or any other person for loss, downtime, or damage directly or indirectly arising from the use of
the goods from any other cause. The Cleveland Steel Tool Co. reserves the right to make improvements and
_______________________________________________
Company Name
Date of Purchase_________Serial #___________________

Warning!
• Read, understand and follow the operating instructions before using the equipment.
• Failure to observe all warnings and instructions may result in personal injury or
property damage.
• It is the responsibility of the user to set up and use the machine and tooling in accor-
dance with local and national OSHA laws and ANSI B11.5 safety standards.
care at all times.
Punching Unit
• Always wear safety glasses.
• Die must be properly inserted with the
smaller hole facing upward.
• Never exceed the maximum capacity of
this machine.
• Match the punch and die correctly.
• Never use chipped or worn punches
and dies. Replace them immediately.
• Properly align and tighten all tooling.
• Disconnect the power source to the
machine when changing tooling.
Hydraulic Hoses
• Securely tighten all connections to
insure that they are leak-free and peri-
odically check for tightness.
• Periodically inspect the hose for signs
of wear or deterioration. Should a hy-
draulic hose burst, rupture or need to be
disconnected, immediately shut off the
pump.
• Never attempt to grasp a leaking
hose with your hands. The force of
serious personal injury.
• Do not use the hose to move at-
tached equipment. Stress may damage
the hose which can result in serious
injury.
• Keep hoses away from any
extreme heat or cold, sharp surfaces,
corrosive materials and heavy impact.
• Do not allow the hose to kink, twist,
curl or bend so the oil within the hose
compatible with the hose material and
coupler seals. Use Mobil Hydraulic Oil
SAFETY PRECAUTIONS
3

ANGLE BRACKET TYPE PARTS BREAKDOWN
28 Locking Collar Tool
250519
29 Hex Key Wrench (2.5MM)
250520
30 Hex Key Wrench (4MM)
250521
13 Keyscrew 250522
14 Stripper 250508
15 Stopper Nut 250509
16 Punch
17 O-Ring 250510
18 Locking Collar 250511
19 Cotter Pin 250513
20 3/8 NPT Nipple
3/8x3/8FF
250512
21 Coupler
256000
23 Main Frame
13 Keyscrew 250522
24 Set Screw
(M8x14, DP)
250514
22 Die
27 Supporter 250515
26 Lockwasher M6
250516 25 Set Screw (M6x16)
250517
1Handle 250494
2Screw (M10x25) 250495
3Lockwasher (M10)
250496
4Spacer 250497
5Threaded End Cap
250498
6Sealed End Cap
250499
7Back up O-Ring
250500
8Sealing O-Ring
250501
9Piston Rod
250502
10 Spring (481)
250507
11 Spring (405)
250505
12 Lower Spring Retainer
250506
8Sealing O-Ring
250501
7Back up O-Ring
250500
25 Set Screw (M6x16)
250517
26 Lockwasher M6
250516

Proper alignment of the punch over the die
in shaped tooling (oblong, square, rectan-
gular, etc.) must be maintained. A locating
pin is provided with each shaped punch and
locating spots on shaped dies.
The punch ram has two locating holes to
align shapes at 90 . Check for proper align-
ment by slowly advancing the punch into
the die.
Periodically check the coupling nut and set
screw to ensure that the tooling is secure.
Lubrication of punches and dies is recom-
mended but not required. This may extend
the life of the tooling.
Punch and Die Installation
Disconnect the power source to the machine
when changing tooling.
Care should be used in matching the proper
punch to the correct die. Each will be marked
with the hole size required.
The die should be placed in the holder with the
smaller hole facing upward. Tighten the set
screw.
Position the punch in the coupling nut with the
effective working length of the punch facing
downward. Thread the locking collar on to the
piston rod. Tighten with the locking collar tool.
o
PUNCHES AND DIES
5
The Cleveland Steel Tool Company maintains an inventory
of replacement punches and dies for The Porta Punch.
The following round punch sizes and corresponding dies are available for immediate shipment:
5/16" 3/8" 7/16" 1/2" 17/32" 9/16" 5/8" 11/16" 3/4" 25/32" 13/16"
Non-stock sizes of round, oblong, square, hexagonal and
rectangular shapes can be shipped within 48 hours.
For further information, please contact your
Cleveland Steel Tool representative.

Problem Cause Solution
Ram will not advance. Bad hose connections Check hose connections
Material hardness Tool rated for 65,000 psi
tensil strength. Harder
material requires more tonnage.
Power source Unit operates with 10,000 psi
power source. Lower psi re-
duces tonnage.
Ram will not retract. Check clearance between Standard clearance is 1/16"
punch and die. Some materials may require
greater die clearance.
Weak or worn stripper spring. Springs must be replaced.
Stopper nut has loosened. Check to see if there is a 9/16"
gap between the stripper forks
and the top of the die. If less
then 9/16" contact our repair
department
Material is not perpendicular Bevel top dies are available for
to the line of the punch.
channel and “I” beams.
PORTA-PUNCH TROUBLESHOOTING
6

PUMP WARRANTY
7
Warranty Statement
Cleveland Steel Tool Co. pumps are warranted to be free of defects in workmanship
and materials for 1 year from the date of purchase
Any Cleveland Steel Tool Co. pumps proven to be defective in workmanship or
material will be repaired or replaced at no charge. To obtain the benefits of this
warranty, first contact Cleveland Steel Tool Co. at [phone] for a return goods
authorization (RGA) number. Drain all oil from the pump and deliver via prepaid
transportation the complete hydraulic pump with proof of purchase to:
Attn.: Warranty Repair Department
CST/ValPower Hydraulic Products
326 N. County Rd. 400 East
Valparaiso, IN 46383
If any pump product or part sold by Cleveland Steel Tool Co. is found to be defec-
tive by CST/ValPower Hydraulics, CST/ValPower Hydraulics, at its option, will either
repair of replace the defective part or product and return via ground transportation,
freight prepaid.
This warranty does not cover any product or part which is worn or abused, altered
used for a purpose other than for which it was intended, or used in a manner which
was inconsistent with any instructions regarding its use.
Electric motors are separately warranted by their manufacturer under the conditions
stated in their separate warranty.

PUMP SAFETY PRECAUTIONS
8
• All WARNING statements must be carefully observed to prevent personal
injury.
• Always wear eye protection when working with equipment.
General Precautions
• Before operating the pump make sure all hose connections are tightened
properly. Do not overtighten connections. They only need to be secure and leak
free. Overtightening may cause premature thread failure or may cause high
pressure fittings to split at pressures lower than their related capacities.
• In the event that a hydraulic hose should rupture, burst or need to be
disconnected, immediately shut off the pump. Never attempt to grasp a leaking
hose under pressure with your hand(s) as escaping hydraulic fluid could pen-
etrate your skin and cause serious injury.
• Do not subject the hose to potential hazards such as fire, extreme heat or
cold, sharp edges or heavy impact. Do not allow the hose to kink, curl, twist or
bend so that the flow of oil inside can become blocked or reduced. Periodically
inspect the hose for wear because any of these conditions can damage the hose
and result in personal injury.
• Do not use the hose to move the pump, this may result in damage to the
pump and/or hose.
VEP0751-PM-CST ELECTRIC HYDRAULIC PUMP
3/4 hp, 115 volt, 60/50 Hz, single phase, with internal auto dump valve
NOTE: These instructions cover all ‘Automatic Return’ style
pumps. Some units may have different specifications than
others and may have additional items. Electric models with
standard manifold block are illustrated.
ATTENTION:
Inspect pump upon arrival. Make sure that there is no
apparent damage due to handling during shipment.
Cleveland Steel Tool Co. is not responsible for dam-
aged caused by shipper. Report damage to shipper
immediately.
Read and follow instructions carefully. Many problems
are the result of improper installation and use.
WARNING SAFETY PRECAUTIONS

PUMP SAFETY PRECAUTIONS
9
Hose Precautions
•
to their products. Never paint hose couplers. Improper care of
in personal injury.
Pump Precautions
• Do not exceed the hydraulic pressure rating noted on the name plate attached on the
pump. Do not tamper with the internal high pressure relief valve as higher
pressures beyond rated capacities could result in personal injury.
•
retracted. Maintain oil level to the middle of the sight glass located on the side of the tank.
• Never operate the pump in advance at 10,000 psi for more than 1 minute without tool
movement as this might overheat the oil and could damage the pump.
Cylinder Precautions
• Do not exceed rated capacitiesof the cylinder(s) or toolsasexcess pressure mayresult in
personal injury.
• Make sure all hydraulic equipment is properly positioned and aligned before operating
• Jerky or sluggish movement of the tool usually indicates air is trapped in the hydraulic
system and must be bled out before pressurizing system to maximum pressure.
• Bleed air out of the system by placing cylinder(s) or tools lower than the pump. Lay the
tool(s) on their side with the hydraulic coupling in an “up” position. Cycle the pump several
times and this will purge any air out of the system.
General Operation
•
power is terminated. The automatic return valve will allow oil to return to tank.

PUMP SAFETY PRECAUTIONS
10
Electrical Supply Precautions
• Do not use an ungrounded (two-prong) extension cord, and never run the motor on
an extension cord longer than 25 feet.
• Replace any cords that have exposed wiring or show damage. Electrical shock may
cause personal injury.
• Check to be sure the voltage rating on the pump matches the voltage in the electri-
cal outlet that the pump is to be plugged into. Incorrect voltage could cause permanent
damage to the motor. Correct voltage is required for the pump to operate correctly.
• Low voltage may cause the motor to overheat, surge when trying to start, or stall
before maximum pressure is reached.
• Always measure voltage at the motor with pump running at full pressure, voltage will
be at the lowest under these conditions. ( Low Voltage = 10% less than name plate volt-
age.)
Electric Motor
• To help avoid possible personal injury all electrical work must be done by a qualied
electrician.
• Disconnect the power supply before performing repairs any maintenance.
Hydraulic Set-up
1. Clean all areas around the oil ports of the pump and cylinders.
2. Inspect the threads and fittings for sings of wear or damage and replace if necessary.
Clean all hose ends, couplers and union ends.
3. Remove the plastic thread protectors from the hydraulic hose. Connect the hose half
coupler assembly to the valve and connect the hose to the tool.
4. Seal pipe/hose connections with pipe sealant. Teflon tape can be used to seal hydrau-
lic connections provided only one layer of tape is used. Apply the tape carefully to prevent
it from being pinched by the coupler and broken off inside the pipe end. Any loose pieces
of tape could travel through the system and obstruct the flow of oil or cause jamming of
precision fit parts.
5. Remove oil filler cap in cover plate.
6 Fill oil reservoir to within 1-1.5 inches below the cover plate (or so it can just be seen
in the sight glass) with an ISO 46 hydraulic oil or equivalent. Remove vent cap and use a
funnel with a filter screen to add oil.

PUMP TROUBLESHOOTING
11
Maintain Hydraulic Oil
• Check hydraulic oil level every 24 hours of operation or on a daily basis. Add ISO 46
or equivalent if necessary. Oil level should be 1-1.5 inches below cover plate or visible in
sight glass with the tools fully retracted and drained back to tank.
• Change oil every 250 hours or six months and refill with ISO 46 hydraulic oil or
equivalent. Change oil more frequently when used in extremely dusty conditions or when
the oil has been overheated.
• Clean filter screen every 250 hours or six months, this can be performed in conjunc-
tion with periodic oil changes.
WARNING: To help avoid possible personal injury disconnect the
power supply before performing repairs or maintenance.
• Make sure the power cord is plugged in to cor-
rect voltage outlet. Have electrician confirm
correct voltage is available at outlet.
• Check oil level.
• Bleed hydraulic system to remove trapped air.
• Low oil in reservoir. Check oil level.
• Air in hydraulic system. Bleed entire system.
• Dirty filter screen. Clean pump inlet filter
screen.
• Check oil level.
• Clean pump filter screen.
• Internal Leakage…Pump needs service. Contact
Customer Service Department for repair facility
information.
Troubleshooting
PROBLEM ITEMS TO CHECK
Pump will not Start
Sporadic Operation
Noisy Operation
Pump runs but does not build
pressure or will not pump oil

ELECTRIC HYDRAULIC PUMP
12
CST-.75HP/DC Pump Assembly (104006)
QTYDESCRIPTIONPART NUMBERITEM
1
Lifting Handle
1039911
23/4 HP PMDC Motor1040232
1
Electrical Box Subassembly
1038963
4
1/4-20 X 1/2 SHCSSKC2143
4
101/4-20 X 1/2 Flanged HHS92979A110
5
4
1/4-20 X 2 1/4 Serrated Flanged HHS
1013406
13/8-18 NPTF Hex Socket Pipe Plug101377
7
1Port Block1015848
13/8 Pipe Nipple375 PIPE NIPPLE9
1
Quick Connect CouplingTC-371
10
1Quick Connect Dust CoverTR-3711
1
Port Block Gasket
10133712
13/8 Bronze Breathing Plug10400713
1
3/4 HP Pump SubassemblyVEP0751-PM-CST
14
1Reservior Gasket10132915
1
1 Gallon Reservior Tank
10143516
43/8-16 X 7/8 SHCSSKC220017
1
2
3
4
11
10
9
8
6
5
7
14
14
16
17
12
13

ELECTRIC HYDRAULIC PUMP
13

PUMP SCHEMATIC
14