SteelBeast HP110 User manual
Contents
1. GENERAL INFORMATION............................................................................................... 3
1.1. Application................................................................................................................. 3
1.2. Technical data............................................................................................................ 3
1.3. Maximum plate thicknesses depending on the material type and diameter/dimensions
of the hole to be made....................................................................................................... 5
1.4. Selecting punches for the most common inch plates.................................................. 8
1.5. Design ......................................................................................................................10
1.6. Equipment included ..................................................................................................11
1.7. Transportation...........................................................................................................12
2. SAFETY PRECAUTIONS.................................................................................................13
3. STARTUP AND OPERATION..........................................................................................15
3.1. Unpacking.................................................................................................................15
3.2. Installing the punch and die.......................................................................................16
3.3. Connecting the hydraulic power pack........................................................................18
3.4. Positioning................................................................................................................19
3.5. Punching...................................................................................................................20
3.6. Replacing the die and punch.....................................................................................20
3.7. Replacing the restrainer............................................................................................21
3.8. Troubleshooting........................................................................................................22
4. ACCESSORIES...............................................................................................................24
4.1. Punches and dies .....................................................................................................24
4.2. Balancer....................................................................................................................25
4.3. Crane........................................................................................................................26
4.4. Stationary work set ...................................................................................................29
4.5. Guide........................................................................................................................31
4.6. Tool box....................................................................................................................33
5. WIRING DIAGRAM..........................................................................................................34
6. DECLARATIONS OF CONFORMITY...............................................................................35
7. QUALITY CERTIFICATES...............................................................................................37
8. WARRANTY CARDS.......................................................................................................39
JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH
This document is protected by copyrights.
Copying, using, or distributing without permission of JEI Group Ltd is prohibited.
3
1. GENERAL INFORMATION
1.1. Application
The Puncher is designed to punch circular holes with diameters of 7–27 mm and oblong
holes in metal plates using acylinder driven by the HPP 700/1.5 Hydraulic Power Pack.
1.2. Technical data
148 mm (5.8’’)
379 mm (14.9’’)
HP60
335 mm (13.2’’)
HP110
135 mm (5.3’’)
479 mm (18.9’’)
388 mm (15.3’’)
84 mm (3.3’’)
60 mm (2.4’’)
26 mm (1’’)
77 mm (3.0’’)
68 mm (2.7’’)
110 mm (4.3’’)
26 mm (1’’)
128 mm (5.0’’)
JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH
This document is protected by copyrights.
Copying, using, or distributing without permission of JEI Group Ltd is prohibited.
4
HP60
HP110
Throat depth*
60 mm (2.36’’)
110 mm (4.33’’)
Maximum hole diameter
27 mm (1.06’’)
27 mm (1.06’’)
Maximum plate thickness**
for S235JR mild steel
with a shear strength Rm< 490 MPa (70,000 psi)
13 mm (0.51’’)
16 mm (0.63’’)
Pressing force
35 T
47 T
Punching time
5 s (50 Hz, 230 V)
6 s (60 Hz, 230 V)
6 s (60 Hz, 115 V)
6 s (50 Hz, 115 V)
8 s (50 Hz, 230 V)
9 s (60 Hz, 230 V)
9 s (60 Hz, 115 V)
10 s (50 Hz, 115 V)
Weight
20 kg (44 lbs)
35 kg (77 lbs)
HPP 700/1.5 Hydraulic Power Pack
Voltage
1~ 220–240 V, 50 Hz
1~ 220–240 V, 60 Hz
1~ 110–120 V, 50 Hz
1~ 110–120 V, 60 Hz
Power
1500 W
Flow rate
1.5 l/min
Pressure
700 bar (10,000 psi)
Oil reservoir capacity
10 l
Weight
82 kg (181 lbs)
* With the depth stop removed.
** Depends on the material type and diameter/dimensions of the hole to be made.
520 mm (20.5’’)
594 mm (23.4’’)
1082 mm (42.6’’)
JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH
This document is protected by copyrights.
Copying, using, or distributing without permission of JEI Group Ltd is prohibited.
5
1.3. Maximum plate thicknesses depending on the material type
and diameter/dimensions of the hole to be made
Circular holes using circular punches with metric sizes
Ø
[mm]
Inch equivalent
Maximum plate thickness
S235JR mild steel
Rm< 490 MPa
(70,000 psi)
355J2 G3 hard steel
Rm= 490–630 MPa
(70,000–90,000 psi)
stainless steel
Rm= 630–750 MPa
(90,000–110,000 psi)
Decimal
Fractional
mm
Inch equivalent
mm
Inch equivalent
mm
Inch equivalent
Decim.
Fract.
Decim.
Fract.
Decim.
Fract.
HP60
7
0.276
9/32
5.6
0.220
7/32
3.5
0.138
9/64
2.8
0.110
7/64
8
0.315
5/16
6.4
0.252
1/4
4.0
0.157
5/32
3.2
0.126
1/8
9
0.354
23/64
7.2
0.283
9/32
4.5
0.177
11/64
3.6
0.142
9/64
10
0.394
25/64
8.0
0.315
5/16
5.0
0.197
13/64
4.0
0.157
5/32
11
0.433
7/16
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
12
0.472
15/32
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
13
0.512
33/64
10.4
0.409
13/32
6.5
0.256
1/4
5.2
0.205
13/64
14
0.551
35/64
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
15
0.591
19/32
12.0
0.472
15/32
7.5
0.295
19/64
6.0
0.236
15/64
16
0.630
5/8
12.8
0.504
1/2
8.0
0.315
5/16
6.0
0.236
15/64
17
0.669
43/64
13.0
0.512
33/64
8.5
0.335
21/64
6.0
0.236
15/64
18
0.709
45/64
13.0
0.512
33/64
9.0
0.354
23/64
6.0
0.236
15/64
19
0.748
3/4
13.0
0.512
33/64
9.5
0.374
3/8
6.0
0.236
15/64
20
0.787
25/32
13.0
0.512
33/64
10.0
0.394
25/64
5.0
0.197
13/64
21
0.827
53/64
13.0
0.512
33/64
10.5
0.413
13/32
5.0
0.197
13/64
22
0.866
55/64
13.0
0.512
33/64
10.3
0.406
13/32
5.0
0.197
13/64
23
0.906
29/32
12.4
0.488
31/64
9.9
0.390
25/64
4.0
0.157
5/32
24
0.945
15/16
11.9
0.469
15/32
9.5
0.374
3/8
4.0
0.157
5/32
25
0.984
63/64
11.4
0.449
29/64
9.1
0.358
23/64
4.0
0.157
5/32
26
1.024
1-1/64
11.0
0.433
7/16
8.7
0.343
11/32
4.0
0.157
5/32
27
1.063
1-1/16
10.6
0.417
27/64
8.4
0.331
21/64
4.0
0.157
5/32
HP110
7
0.276
9/32
5.6
0.220
7/32
3.5
0.138
9/64
2.8
0.110
7/64
8
0.315
5/16
6.4
0.252
1/4
4.0
0.157
5/32
3.2
0.126
1/8
9
0.354
23/64
7.2
0.283
9/32
4.5
0.177
11/64
3.6
0.142
9/64
10
0.394
25/64
8.0
0.315
5/16
5.0
0.197
13/64
4.0
0.157
5/32
11
0.433
7/16
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
12
0.472
15/32
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
13
0.512
33/64
10.4
0.409
13/32
6.5
0.256
1/4
5.2
0.205
13/64
14
0.551
35/64
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
15
0.591
19/32
12.0
0.472
15/32
7.5
0.295
19/64
6.0
0.236
15/64
16
0.630
5/8
12.8
0.504
1/2
8.0
0.315
5/16
6.0
0.236
15/64
17
0.669
43/64
13.6
0.535
17/32
8.5
0.335
21/64
6.0
0.236
15/64
18
0.709
45/64
14.4
0.567
9/16
9.0
0.354
23/64
6.0
0.236
15/64
19
0.748
3/4
15.2
0.598
19/32
9.5
0.374
3/8
6.0
0.236
15/64
20
0.787
25/32
16.0
0.630
5/8
10.0
0.394
25/64
6.0
0.236
15/64
21
0.827
53/64
16.0
0.630
5/8
10.5
0.413
13/32
6.0
0.236
15/64
22
0.866
55/64
16.0
0.630
5/8
11.0
0.433
7/16
6.0
0.236
15/64
23
0.906
29/32
16.0
0.630
5/8
11.5
0.453
29/64
6.0
0.236
15/64
24
0.945
15/16
16.0
0.630
5/8
12.0
0.472
15/32
6.0
0.236
15/64
25
0.984
63/64
16.0
0.630
5/8
12.5
0.492
31/64
6.0
0.236
15/64
26
1.024
1-1/64
15.1
0.594
19/32
12.0
0.472
15/32
6.0
0.236
15/64
27
1.063
1-1/16
14.5
0.571
37/64
11.5
0.453
29/64
6.0
0.236
15/64
JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH
This document is protected by copyrights.
Copying, using, or distributing without permission of JEI Group Ltd is prohibited.
6
Oblong holes using oblong punches with metric sizes
Dim.
[mm×mm]
Inch Decimal
Equivalent
Maximum plate thickness
S235JR mild steel
Rm< 490 MPa
(70,000 psi)
355J2 G3 hard steel
Rm= 490–630 MPa
(70,000–90,000 psi)
stainless steel
Rm= 630–750 MPa
(90,000–110,000 psi)
mm
Inch equivalent
mm
Inch equivalent
mm
Inch equivalent
Decim.
Fract.
Decim.
Fract.
Decim.
Fract.
HP60
16×8
0.630×0.315
6.4
0.252
1/4
4.0
0.157
5/32
3.2
0.126
1/8
18×9
0.709×0.354
7.2
0.283
9/32
4.5
0.177
11/64
3.6
0.142
9/64
18×11
0.709×0.433
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
20×10
0.787×0.394
8.0
0.315
5/16
5.0
0.197
13/64
4.0
0.157
5/32
20×12
0.787×0.472
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
20×14
0.787×0.551
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
22×11
0.866×0.433
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
22×14
0.866×0.551
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
24×12
0.945×0.472
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
25×9
0.984×0.354
7.2
0.283
9/32
4.5
0.177
11/64
3.6
0.142
9/64
25×12
0.984×0.472
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
25×13
0.984×0.512
10.4
0.409
13/32
6.5
0.256
1/4
5.2
0.205
13/64
25×14
0.984×0.551
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
25×18
0.984×0.709
13.0
0.512
33/64
9.0
0.354
23/64
6.0
0.236
15/64
HP110
16×8
0.630×0.315
6.4
0.252
1/4
4.0
0.157
5/32
3.2
0.126
1/8
18×9
0.709×0.354
7.2
0.283
9/32
4.5
0.177
11/64
3.6
0.142
9/64
18×11
0.709×0.433
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
20×10
0.787×0.394
8.0
0.315
5/16
5.0
0.197
13/64
4.0
0.157
5/32
20×12
0.787×0.472
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
20×14
0.787×0.551
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
22×11
0.866×0.433
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
22×14
0.866×0.551
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
24×12
0.945×0.472
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
25×9
0.984×0.354
7.2
0.283
9/32
4.5
0.177
11/64
3.6
0.142
9/64
25×12
0.984×0.472
9.6
0.378
3/8
6.0
0.236
15/64
4.8
0.189
3/16
25×13
0.984×0.512
10.4
0.409
13/32
6.5
0.256
1/4
5.2
0.205
13/64
25×14
0.984×0.551
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
25×18
0.984×0.709
14.4
0.567
9/16
9.0
0.354
23/64
6.0
0.236
15/64
JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH
This document is protected by copyrights.
Copying, using, or distributing without permission of JEI Group Ltd is prohibited.
7
Circular holes using circular punches with imperial sizes
Ø
[’’]
Decimal
equivalent
Maximum plate thickness
S235JR mild steel
Rm< 490 MPa
(70,000 psi)
355J2 G3 hard steel
Rm= 490–630 MPa
(70,000–90,000 psi)
stainless steel
Rm= 630–750 MPa
(90,000–110,000 psi)
mm
Inch equivalent
mm
Inch equivalent
mm
Inch equivalent
Decim.
Fract.
Decim.
Fract.
Decim.
Fract.
HP60
5/16
0.3125
6.4
0.252
1/4
4.0
0.157
5/32
3.2
0.126
1/8
3/8
0.3750
8.0
0.315
5/16
5.0
0.197
13/64
4.0
0.157
5/32
7/16
0.4375
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
1/2
0.5000
10.4
0.409
13/32
6.5
0.256
1/4
5.2
0.205
13/64
9/16
0.5625
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
5/8
0.6250
12.8
0.504
1/2
8.0
0.315
5/16
6.0
0.236
15/64
11/16
0.6875
13.0
0.512
33/64
9.0
0.354
23/64
6.0
0.236
15/64
3/4
0.7500
13.0
0.512
33/64
9.5
0.374
3/8
6.0
0.236
15/64
13/16
0.8125
13.0
0.512
33/64
10.5
0.413
13/32
5.0
0.197
13/64
7/8
0.8750
13.0
0.512
33/64
10.3
0.406
13/32
5.0
0.197
13/64
15/16
0.9375
11.9
0.469
15/32
9.5
0.374
3/8
4.0
0.157
5/32
1
1.0000
11.0
0.433
7/16
8.7
0.343
11/32
4.0
0.157
5/32
1-1/16
1.0625
10.6
0.417
27/64
8.4
0.331
21/64
4.0
0.157
5/32
HP110
5/16
0.3125
6.4
0.252
1/4
4.0
0.157
5/32
3.2
0.126
1/8
3/8
0.3750
8.0
0.315
5/16
5.0
0.197
13/64
4.0
0.157
5/32
7/16
0.4375
8.8
0.346
11/32
5.5
0.217
7/32
4.4
0.173
11/64
1/2
0.5000
10.4
0.409
13/32
6.5
0.256
1/4
5.2
0.205
13/64
9/16
0.5625
11.2
0.441
7/16
7.0
0.276
9/32
6.0
0.236
15/64
5/8
0.6250
12.8
0.504
1/2
8.0
0.315
5/16
6.0
0.236
15/64
11/16
0.6875
14.4
0.567
9/16
9.0
0.354
23/64
6.0
0.236
15/64
3/4
0.7500
15.2
0.598
19/32
9.5
0.374
3/8
6.0
0.236
15/64
13/16
0.8125
16.0
0.630
5/8
10.5
0.413
13/32
6.0
0.236
15/64
7/8
0.8750
16.0
0.630
5/8
11.0
0.433
7/16
6.0
0.236
15/64
15/16
0.9375
16.0
0.630
5/8
12.0
0.472
15/32
6.0
0.236
15/64
1
1.0000
15.1
0.594
19/32
12.0
0.472
15/32
6.0
0.236
15/64
1-1/16
1.0625
14.5
0.571
37/64
11.5
0.453
29/64
6.0
0.236
15/64
JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH
This document is protected by copyrights.
Copying, using, or distributing without permission of JEI Group Ltd is prohibited.
8
1.4. Selecting punches for the most common inch plates
HP60
Plate thickness
[’’]
S235JR mild steel
Rm< 490 MPa
(70,000 psi)
355J2 G3 hard steel
Rm= 490–630 MPa
(70,000–90,000 psi)
stainless steel
Rm= 630–750 MPa
(90,000–110,000 psi)
Punch type
Circular
metric
[mm]
Oblong
metric
[mm×mm]
Circular
imperial
[’’]
Circular
metric
[mm]
Oblong
metric
[mm×mm]
Circular
imperial
[’’]
Circular
metric
[mm]
Oblong
metric
[mm×mm]
Circular
imperial
[’’]
1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
1/8
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
8–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
3/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
10–27
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×12,
25×13, 25×14,
25×18
3/8 –
1-1/16
12–27
20×12, 20×14,
22×14, 24×12,
25×12, 25×13,
25×14, 25×18
1/2 –7/8
1/4
8–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
13–27
20×14,22×14,
25×13, 25×14,
25×18
1/2 –
1-1/16
N/A
N/A
N/A
5/16
10–27
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×12,
25×13, 25×14,
25×18
3/8 –
1-1/16
16–27
25×18
5/8 –
1-1/16
N/A
N/A
N/A
3/8
12–27
20×12, 20×14,
22×14, 24×12,
25×12, 25×13,
25×14, 25×18
1/2 –
1-1/16
20–23
N/A
13/16 –
7/8
N/A
N/A
N/A
7/16
14–25
20×14, 22×14,
25×14, 25×18
9/16 –1
N/A
N/A
N/A
N/A
N/A
N/A
1/2
16–22
25×18
5/8 –7/8
N/A
N/A
N/A
N/A
N/A
N/A
9/16
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
5/8
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11/16
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
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HP110
Plate thickness
[’’]
S235JR mild steel
Rm< 490 MPa
(70,000 psi)
355J2 G3 hard steel
Rm= 490–630 MPa
(70,000–90,000 psi)
stainless steel
Rm= 630–750 MPa
(90,000–110,000 psi)
Punch type
Circular
metric
[mm]
Oval
metric
[mm×mm]
Circular
imperial
[’’]
Circular
metric
[mm]
Oval
metric
[mm×mm]
Circular
imperial
[’’]
Circular
metric
[mm]
Oval
metric
[mm×mm]
Circular
imperial
[’’]
1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
1/8
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
8–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
3/16
7–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
10–27
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×12,
25×13, 25×14,
25×18
3/8 –
1-1/16
12–22
20×12, 20×14,
22×14, 24×12,
25×12, 25×13,
25×14, 25×18
1/2 –
1-1/16
1/4
8–27
16×8, 18×9,
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×9,
25×12, 25×13,
25×14, 25×18
5/16 –
1-1/16
13–27
20×14, 22×14,
25×13, 25×14,
25×18
1/2 –
1-1/16
N/A
N/A
N/A
5/16
10–27
18×11, 20×10,
20×12, 20×14,
22×11, 22×14,
24×12, 25×12,
25×13, 25×14,
25×18
3/8 –
1-1/16
16–27
25×18
5/8 –
1-1/16
N/A
N/A
N/A
3/8
12–27
20×12, 20×14,
22×14, 24×12,
25×12, 25×13,
25×14, 25×18
1/2 –
1-1/16
20–27
N/A
13/16 –
1-1/16
N/A
N/A
N/A
7/16
14–27
20×14, 22×14,
25×14, 25×18
9/16 –
1-1/16
23–27
N/A
15/16 –
1-1/16
N/A
N/A
N/A
1/2
16–27
25×18
5/8 –
1-1/16
N/A
N/A
N/A
N/A
N/A
N/A
9/16
18–27
25×18
11/16 –
1-1/16
N/A
N/A
N/A
N/A
N/A
N/A
5/8
20–25
N/A
13/16 –
15/16
N/A
N/A
N/A
N/A
N/A
N/A
11/16
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
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1.5. Design
Fig. 1. View of the Puncher
Fig. 2. View of the hydraulic power pack
Die
Punch
Depth stop
Restrainer
STOP/UP
DOWN
Status LED
Control
connector
Low-pressure hydraulic socket
High-pressure hydraulic socket
Safety strap for
puncher transportation
High-pressure
hydraulic socket
Control socket
Low-pressure
hydraulic socket
Oil plug
Transport cap
Power ON/OFF switch
Air vent
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1.6. Equipment included
The Puncher includes the following elements.
Punching head
1 unit
Metal box
1 unit
5 m (16.5 ft) hydraulic hoses and control cable
1 set
Wrench
1 unit
Die drift
1 unit
Tool container
1 unit
1.5 m (5 ft) chain
1 unit
4 mm hex wrench
1 unit
5 mm hex wrench
1 unit
6 mm hex wrench
1 unit
27 mm flat wrench
1 unit
30 mm flat wrench
1 unit
The Hydraulic Power Pack is supplied on a pallet and includes the following elements.
700/1.5 Hydraulic Power Pack
1 unit
Transportation jacket
1 unit
Tool box
1 unit
Safety strap
1 unit
5 mm hex wrench
1 unit
8 mm hex wrench
1 unit
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1.7. Transportation
Before transporting, fix the machine to the hydraulic power pack by catching the
safety strap on the lugs 1and 2(Fig. 3), and then place the oil plug and the transport
cap as shown in the figure (3, 4).
Never bend the high-pressure hydraulic hose to a radius less than 80 mm (3.2’’)
or damage to the hose will result. If the hose is bent to a smaller radius, replace the
hose immediately.
Fig. 3. Transporting the machine
1
2
4
3
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2. SAFETY PRECAUTIONS
1. Before beginning, read this Operator’s Manual and complete proper occupational
safety and health training.
2. The machine must be used only with HPP 700/1.5 Hydraulic Power Pack.
3. The machine, hydraulic power pack, cables, and hoses must be used only in
applications specified in this Operator’s Manual.
4. The machine and hydraulic power pack must be complete and all their parts must
be genuine and entirely operational.
5. The electrical supply specifications must conform to those specified on the rating
plate of the hydraulic power pack.
6. The hydraulic power pack must be plugged into a properly grounded (earthed)
socket-outlet. The electrical supply must be protected with a C25 A fuse for 230 V or
a C32 A fuse for 115 V.
7. Do not cover the air vents of the hydraulic power pack.
8. Never crush or pull cables and hoses as this may damage them and result in
serious injury.
9. Arrange hoses so that there are no tripping hazards. Wrap the hoses around the
power pack if possible.
10. Thebendingradiusof the high-pressure hose must neverbe less than 80mm(3.2’’).
If the hose is bent to a smaller radius or has any signs of wear or damage, replace
the hose immediately.
11. Untrained bystanders must not be present near the machine and hydraulic power
pack.
12. Before beginning, check the condition of the machine, hydraulic power pack, and
electrical supply, including cables and hoses, connectors, sockets, plugs, punch,
and die. Make sure the high-pressure hydraulic hose is securely attached to the
machine and power pack.
13. Keep the machine, hydraulic power pack, cables, and hoses dry. Exposure to
direct sunlight, rain, snow, or frost is prohibited.
14. Keep the work area well lit, clean, and free of obstacles.
15. Never use machine near flammable liquids or gases, or in explosive environments.
16. Use only punches and dies specified in this Operator’s Manual.
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17. Use dies with parallel surfaces for plates with parallel surfaces, while 5° inclined
dies for plates with one surface inclined by 5°.
18. Mount punches and dies securely. Remove adjusting keys and wrenches from
the work area before powering the hydraulic power pack.
19. Before every use, inspect the machine and hydraulic power pack to ensure they
are not damaged. Check whether any part is cracked or improperly fitted. Make
sure to maintain proper conditions that may affect the operation of the machine
and hydraulic power pack.
20. Always use a face shield, hearing protection, protective footwear, gloves, and
protective clothing during operation. Do not wear loose clothing.
21. Do not put hands near the restrainer during operation as this may lead to serious
injury.
22. Cover steel parts with a thin anti-corrosion coating to protect the machine from
rust when not in use for any extended period.
23. Maintain the machine and mount/dismount punch, die, and restrainer only with
the power ON/OFF switch set to position ‘O’.
24. Repair only in a service center appointed by the seller.
25. If the machine falls from any height, is wet, or has any other damage that could
affect the technical state of the machine, stop the operation and immediately
send the machine to the service center for inspection and repair.
26. Neverleave the machine or the hydraulic power packunattended duringoperation.
27. Remove the machine and power pack from the worksite and store in a secure and
dry location when not in use.
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3. STARTUP AND OPERATION
3.1. Unpacking
Open the box, unscrew the lock using the 5mm hex wrench to remove the machine,
and screw in the front handle. Next, use six M8x12 screws and the 5 mm hex wrench
to attach the handle to the power pack in the position shown in Fig. 4.
Fig. 4. Assembling the machine and the power pack after unpacking
Adhere to all safety precautions.
M8x12 screws
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3.2. Installing the punch and die
Set the power ON/OFF switch to the position ‘O’. Then, insert the nut joined with the
punch into the machine (1, Fig. 5), and screw the nut manually in the direction 2.
Next, insert the wrench into the hole (3) and lock the nut by rotating the wrench in the
same direction. If an oblong punch 4is used, before locking the nut the punch pin
must snap into the socket, which will be indicated by a snap sound.
Fig. 5. Installing the punch
Select a proper die for the plate to be punched: use dies with parallel surfaces for
plates with parallel surfaces, while 5° inclined dies for plates with one surface inclined
by 5° (Fig. 6a). Never use dies with parallel surfaces for plates with one surface
inclined, or inclined dies for plates with both surfaces parallel (Fig. 6b).
Fig. 6. Selecting a die for the plate used
1
2
3
4
a)
b)
CORRECT ✓
INCORRECT
CORRECT ✓
INCORRECT
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Retract the restrainer as far as possible (1,Fig. 7a), rest the die onto the drift (2),
and lower the drift to insert the die into the socket (3). Then, tighten the die with the
4mm hex wrench (4). The diameters (dimensions) of the punch and die installed
must be the same. Position inclined dies 5and oblong dies 6and 7 in such a way to
align the groove with the set screw 4. Always install oblong dies and oblong punches
in the same orientation (Fig. 7b).
Fig. 7. Installing the die (a); correct orientation of the oblong punch and die (b)
2
1
4
5
6
7
a)
b)
g)
3
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3.3. Connecting the hydraulic power pack
Connect the machine with the hydraulic power pack using the hydraulic hoses and
control cable. To do this, remove the caps from the hydraulic sockets of the machine,
use the 27 mm and 30 mm flat wrenches to firmly screw the high-pressure connector
into the socket 1(Fig. 8), and then plug the low-pressure connector into the socket 2
until it snaps into place. Next, connect the control cable to the connector 3and plug
the power cord of the hydraulic power pack into an appropriate power source.
Every time the power pack is connected and the power ON/OFF switch is set to
position ‘I’, the status LED will flash every 0.5 seconds indicating the need to press and
hold the STOP/UP button for about 3 seconds. This will cause the punch to retract
fully if it is not already in this position.
Then, use the 8 mm hex wrench to unscrew the transport cap 4of the hydraulic
power pack and place the oil plug in cap’s position 5.
Fig. 8. Connecting the machine to the hydraulic power pack
3
1
2
4
5
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3.4. Positioning
Hang the machine on the chain. Then, position the machine on aplate as shown in
the detail from Fig. 9, with the restrainer located above the plate and the punch tip
placed into a center-punch mark indicating the center of the hole to be made, and
press the machine down to the plate. The restrainer must be rotated such that to be
above the plate, but not outside the plate, to allow the entire support of the restrainer
during rectraction of the punch. Next, loosen four depth stop screws using the 6 mm
hex wrench, adjoin the depth stop to the plate, and tighten in this position.
Fig. 9. Positioning the machine on the plate
STOP/UP
DOWN
Depth stop screws
INCORRECT
CORRECT
✓
Restrainer above the plate
Restrainer outside the plate
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3.5. Punching
Operate the machine by holding the handles with both hands. The continuous LED
light indicates the machine is ready to operate. Press and hold the DOWN button to
move the punch toward the plate. This will be indicated by the LED flashing every
0.25 seconds. When the punch reaches the plate, the automatic punching process
should start, indicated by the LED flashing every 0.1 seconds. After the end of the
punching process the punch will return to the initial position. Punching thin plates may
require the DOWN button to be held until the hole is established. To interrupt the
motion at any time, press the STOP/UP button. Pressing the STOP/UP button again
will retract the punch. If penetrating the material fails because of excessive thickness,
the motion will stop. To avoid this, do not exceed the maximum plate thickness or the
value of the shear strength Rmspecified in “Maximum plate thicknesses…” section.
After establishing the first hole, and then after every 100 holes, check whether
the punch and die are tight, and re-tighten as necessary.
To establish a second hole, move the machine to a next center-punch mark.
Once the work is finished, toggle the power pack ON/OFF switch to the position ‘O’.
Maintain a proper oil level indication on the gauge of the hydraulic power pack.
Change oil after 3,000 operating hours. Use HLP 46 oil.
3.6. Replacing the die and punch
Set the power ON/OFF switch to the position ‘O’. To dismount the die, retract the
restrainer fully (1, Fig. 10) and use the 4 mm hex wrench to loosen the set screw 2.
Then, use the drift (3) and remove the die (4).
Fig. 10. Dismounting the die
1
4
3
2
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1
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