Uni-Hydro PRO 56 User manual

“A Cut Above The Rest”
Uni-Hydro, Inc
PRO 56 Owners Manual
The Uni-Hydro PRO 56 Ironworker is a precision engineered ironworker.
Uni-Hydro customer’s demand reliability, durability and excellence from each of our products.
To ensure an unparalleled legacy we encourage our clients to be fully versed and
knowledgeable about the intricate workings of this model.
To ensure this heritage, we have included complete part and assembly layouts and included are
its accessories with tooling.
Phone: [phone]
Toll: 800-328-0036
Fax: [phone]
Email: [email protected]
310 East Gemini Avenue
Cosmos, MN 56228
Uni-Hydro, Inc
Serial Number ______________________

TABLE OF CONTENTS
PAGE
FOREWORD 1
MACHINE SETUP INSTRUCTIONS 2-3
Machine Location 2
Machine Pre aration 2
Electrical Connections 2
Lubrication 3
OPERATING INSTRUCTIONS 3-6
Pre-O erating Instructions 3
Practice O erations 3-4
O erating the Model PRO56 Ironworker 4
Stroke Control Adjustment 4
Punching O eration 4-5
Sever Angle Shear O eration 5
Notcher Station O eration 5
Bar Shear O eration 5-6
MAINTENANCE 6-7
Punch Installation 6
Double Locking the Punch 6
Removing and Re lacing Angle and Bar Blades 7
Standard Angle Shear 7
Machine Maintenance 8
LUBRICATION 8-9
Machine Com onents 8
Hydraulic System 8
Oil Level 8
Lines and Fittings 8
Hydraulic Oil Change 9
Tonnage Chart 10
TROUBLE SHOOTING 11
Pro er Care of Punches and Dies 12
Lining u Punch and Die 12
Lubrication 12
Stri ing 12
Loose Nuts and Shank 12
WARRANTY
13
General Wiring Schematic 14
GE Control Box 15

Revised - January 2009
- i -
TABLE OF CONTENTS
MAIN BODY ASSEMBLIES
ASSY #
PAGE
Punch Station PRO56-01 16-17
Power Cavity Station PRO56-02 18
Notcher Station PRO56-03 19
Main Body Assembly PRO56-04 20
Body Assembly with Arms PRO56-05 21-22
Bar Shear Station Hold-Down PRO56-06 23-24
Base and Cover Assembly PRO56-07 25
Foot Pedal Linkage Assembly PRO56-08 26
Power Unit Hydraulics PRO56-09 27-28
POWER UNIT ELECTRICAL
3 Phase, 480 Volt - Direct Drive PRO56-10 29
3 Phase, 240 Volt - Direct Drive PRO56-11 30
1 Phase, 240 Volt - Direct Drive PRO56-12 31
ACCESSORIES & TOOLING
Slug Ty e Angle Shear 3" X3" X .375" 4406 32
Sever Shear Housing 2615 33
Sever Angle 4 x 4 x 3/8" Blade Set with Hardware 2730 34
Sever Rod Blade Set with Hardware 2756 35
Sever Channel 2' x 3" Blade Set with Hardware 4431 36
Sever Channel 4" Blade Set with Hardware 4432 37
Square Notcher 1-3/4" x 2" x 1/4" 1276 38
Co er Notcher 3 x 3 x 1/4" Angle 1277 39
Pi e Notcher Assembly 3080 40
Punch & Die Chart 41
6" Punch Station Brake 3212 42
6" Power Cavity Brake 2591 43
Punch Adjustable Jig Table 2549 44
Bar Shear Table Com lete 2394 45
Standard Stri er Com lete 2479 46
Standard Die Stand Com lete 2969 47
Oversize (1 1/2") Stri er Com lete 2482 48
Oversize (1 1/2") Die Stand Assembly Com lete 4762 49
Oversize (1 5/8") Stri er Com lete 2483 50
Oversize (1 5/8") Die Stand Assembly Com lete 4761 51
Die Stand Assembly 150 Series Com lete 2752 52
Die Stand Assembly 500 Series 4409 53
Offset Die Stand (S-Series) Com lete 2748 54
Bar Shear Sto 2540 55
Deluxe Back Gauge 6 ft 2521 56
Punch Rack Assembly 3389 57
Steel Bin Catcher 4144 58

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TABLE OF CONTENTS
ACCESSORIES & TOOLING (cont)
ASSY #
PAGE
Grease Bank Kit 1341 59
Remote Mechanical Foot Control Com lete 2555 60
L-100 Series Punch Nut Wrench 4797 61
Retainer Nut Wrench 0669 62
Decal Placement 63
Decal Kit 4849 64
Tonnage Chart
PRO 56 S ecification Chart
Accessories
Tooling

PRO 56 Uni-Hydro Manual
Page - 1 -
FOREWORD
As the model PRO 56 ironworker is a high quality product, Uni-
Hydro, Inc. is concerned about future use of the machine and safety of
the user. Therefore, all persons involved with the machine should
read this manual and become familiar with proper set-up, operation
and maintenance instructions.
SAFETY
Throughout this manual, safety, mechanical and some general
information is emphasized. WARNING or CAUTION identify safety
messages and indicate a safety message follows that must be read and
thoroughly understood.
HELP
If help concerning set-up, operation, maintenance or safety is needed,
contact your local Uni-Hydro dealer or Uni-Hydro, Inc., 800-328-
0036, for assistance.
IMPORTANT: To gain full warranty benefits, immediately fill out
and return the enclosed warranty registration form upon delivery of
your machine.

PRO56 Uni-Hydro Manual
Page - 2 -
MACHINE SETUP INSTRUCTIONS
MACHINE LOCATION
For best performance, locate the ironworker on a stable, level surface. If a level surface is not available,
level the machine as necessary. Use the built-in forklift slots located at the base of the ironworker to ease
movement of the machine. Leave enough room around the machine to ease material handling while
operating and ensure the area is well lighted for maximum safety conditions.
MACHINE PREPARATION
The machine is delivered in one of four (4) different configurations. Check your packing list for the item
number ordered.
1. Remove all protective shipping material from:
a. Bar Blades
b. Angle Blades
c. Angle Plunger
d. Punch
e. Cylinder
2. Inspect the ironworker for damage that may have occurred during shipment. If damage is found,
notify the shipper that made final delivery immediately. They are solely responsible for all
shipping damages.
3. Locate the punch and dies (snap ring attached) and install the Punch and Die assembly; refer to
Punch Installation.
IMPORTANT: Modifications made to the machine not authorized by Uni-Hydro, Inc., shall serve
as just cause for all warranty to be voided.
ELECTRICAL CONNECTIONS
NOTE: To ensure proper hook-up of your ironworker and to meet local safety codes, we recommend
that all electrical wiring of the ironworker be performed by a licensed electrician.
IMPORTANT: (3 Phase wiring hook-ups only)
If the ironworker fails to function when the start switch is first switched to ON, immediately return the
switch to OFF or hydraulic pump damage may occur. The wiring connections might be reversed causing
the motor and hydraulic pump to run counter-clockwise. Correct by disconnecting all electrical power to
the ironworker and reversing the wiring hook-up. The ironworker is running properly when the motor
shaft is rotating in the same direction as the arrow indicated on the pump.

PRO56 Uni-Hydro Manual
Page - 3 -
OPERATING INSTRUCTIONS (Cont)
LUBRICATION
Use No. 2 General Purpose Lithium grease to lubricate all EIGHTEEN (18) grease fittings on the
ironworker before beginning operation. The fittings are in the following locations:
1. Punch SLEEVE
2. All pivot pins (grease every four (4) hours)
3. Above and below Angle Shear
4. Above and below arms
OPERATING INSTRUCTIONS
IMPORTANT: Never operate more than one work station at a time of the machine may be
damaged and the warranty voided.
PRE-OPERAION INSTRUCTIONS
Before beginning operation, become familiar with the contents of this manual so you understand proper
control operation, proper safety procedures and machine functions. Learn the procedures well before
starting so as to either reduce or eliminate machine downtime due to incorrect operation. Chance of
personal injury will also be minimized.
PRACTICE OPERATION
CAUTION
Always wear safety glasses during operation and use any other safety related equipment that contributes
toward prevention of personal injury.
1. Ensure others are clear of the ironworker and press the “ON” button in the switch box to start the
electric and hydraulic systems.
2. Position yourself in front of the work station and depress the foot petal at the machine base until
the hydraulic cylinder shaft extends approximately six (6) inches. Release the petal. Note the
ironworker components stop in mid-cycle and returns to normal open position when the petal is
released, a desired safety and operational factor.
3. Depress and release the petal through a dozen or more short operational strokes until you feel in
complete control of the ironworker.
4. When satisfied that the ironworker will be operated properly, refer to Operating the PRO56 Model
Ironworker section and use it as a guide to proper operation.
OPERATING THE MODEL PRO56 IRONWORKER
1. The Uni-Hydro Ironworker is designed to perform bar shearing, angle shearing, and punching of
mild steel only.

PRO56 Uni-Hydro Manual
Page - 4 -
OPERATING INSTRUCTIONS (Cont)
2. Like any machine, there are limits to the work performance of an ironworker. Maximum
operational limitations which should not be exceeded are as follows:
a. Bar Shear – flat bars of 3/8” x 14”, 3/8” x 22”, ½” x 10” and 3/4’ x 6”
b. Angle cuts – 3 x 3 x 3/8”
c. Punch – 56 ton; see schedule of punch limitations
d. Notching Station – 1/4” material
3. To avoid damage to the ironworker and voiding of the warranty, NEVER perform more than one
type of machine operation at one time.
4. Before beginning punch operation with a different size punch than previously used, refer to the
schedule listing of punch and material limitations located on the side of the machine, or on page
10 of this manual.
WARNING
To prevent personal injury, always keep hands clear of the bar shear, angle shear and punch work areas
during operation Keep bystanders away while operating and stop the ironworker before leaving it
unattended.
STROKE CONTROL ADJUSTMENT
1. Locate the stroke control handles on the left side cover of machine.
2. To limit down stroke of machine locate the appropriate handle (Decal down stroke). Rotate
handle clockwise to decrease and counter-clockwise to increase.
**This handle is the one to use for braking and specialty punching applications.
3. To limit return stroke of machine, locate the appropriate handle (Decal return stroke). Rotate
handle clockwise to decrease and counter-clockwise to increase.
NOTE: Each revolution of either handle adjusts stroke 1/16 of an inch, half turn 1/32”, etc.
PUNCH OPERATION
1. Due to manufacturing deviations, some types of mild steel may be harder than normal. Apply a
small amount of oil on the steel to help smooth the punching operation. During production
punching, apply oil to the punch and die after every 5 to 10 holes are punched.

PRO56 Uni-Hydro Manual
Page - 5 -
OPERATING INSTRUCTIONS (Cont)
2. Whenever a change of operation is performed, check for proper alignment between the punch and
punch hole in the die. Inadvertent movement of the die block may have caused punch
misalignment.
3. Always remove the punch from the ironworker whenever the punching operation is completed.
SEVER ANGLE SHEAR OPERATION
1. To avoid crooked cuts, adjust the hold-down bolt on the front of the housing so material to be
sheared is level.
2. Be sure there are no obstructions in the shearing area before beginning operation.
NOTE: The severing angle shear does not remove a slug (large amount) of material, thus material
loss is minimal.
NOTE: If the blades finish the return stroke slowly, remove the blades. Clean all slag from the
housing, coat the blades with a light film of oil and re-install; refer to Removing and
Replacing Sever Angle Blades.
NOTCHER STATION OPERATION
CAUTION Never cut less than half the width of top blade, this will cause side pressure.
1. Adjustment of table: Loosen six (6) jam nuts, back off six (6) 7/16 x 3/4 set screws. Loosen
eight (8) 7/16 x 1-1/4 locking bolts. Fine adjust clearance by running top blade down 1/32 into
bottom blades, shut machine off. Adjust 7/16 x 3/4 set screws up until clearance is the same on
both sides of the top blade. Clearance on front of notcher should be approximately .005. Lock
jam nuts on set screws. Tighten top two (2) table bolts and six (6) side bolts. Run machine up and
recheck clearance of blades.
BAR SHEAR OPERATION
NOTE: Rotate the blades as they dull so all four (4) cutting edges may be used. To help achieve
maximum protection, adjust the stroke control to match material thickness. Maximum cut
in the bar shear is:
3/8” x 14”
½” x 10”
5/8” x 6”

PRO56 Uni-Hydro Manual
Page - 6 -
OPERATING INSTRUCTIONS (Cont)
1. Rest the material to be sheared on the base of the bar shear table.
2. To avoid distortion and avoid ironworker damage, firmly secure the bar holder onto the material to
be sheared.
3. Align the scribed mark with the outer edge of the bottom blade.
4. When making maximum cuts, position the material as close as possible to the apex of the throat
opening.
MAINTENANCE
CAUTION To prevent personal injury, disconnect electrical power to the ironworker before
performing maintenance procedures. Should power be required during maintenance, take
care to protect yourself and others from injury.
PUNCH INSTALLATION
1. Loosen two (2) 3/8” bolts and swing stripper to side. Remove punch jam nut, insert punch into
one (1) inch hole, replace the jam nut and tighten securely.
2. With indentation on the die aligned with the die stand Allen screw; tighten the side set screw with
an Allen wrench.
3. With stamped die size facing upwards, insert die into die holder and tighten the side set screw with
an Allen wrench.
4. Completely loosen 1/2 x 1-1/2 inch bolts (2) securing the die block.
5. Pull knob release button at top of punch plunger up and lower handle. Adjust punch block so
punch enters die and clearance is equal on all sides of the punch.
6. Tighten 1/2 x 1/2 inch bolts (2), install stripper and place punch adjustment handle in locked
position.
7. Operate ironworker to check punch and die alignment, correct if necessary.
DOUBLE LOCKING THE PUNCH
After alignment, punches can be double locked to prevent them from turning.
1. Run the punch into the die either manually with the manual punch aligner or by starting the
ironworker. Refer to Punch and Die Alignment procedure above.
2. Facing the punch, with the punch in the down position, locate a 3/8” NC threaded hole at the front
side of the exposed punch plunger. Part # 4213
3. Install a 3/8” x 3/8” set screw (not provided) to double lock the punch shank.

PRO56 Uni-Hydro Manual
Page - 7 -
MAINTENANCE (Cont)
IMPORTANT: If the side lock setscrew is not used, the 3/8 inch setscrew MUST be removed or it
may vibrate loose and damage the plunger and jug.
REMOVING AND REPLACING ANGLE BLADES
Severing Angle Shear
The severing angle shear assembly consists of two (2) shearing blades and housing. Other optional
blades are:
Channel Shear blades
Round, Square and Hexagonal blades
To change blades:
1. Loosen three (3) 3/8” socket set screws on the side of housing.
2. Remove the 5/16” bolts and block securing the moveable blades to remove blades.
3. Install the replacement blades; block, mounting bolts and set screws. Tighten all fasteners to
secure assembly.
NOTE: A spacer plate is required with ½” blades. Install in front of housing and tighten swing clip on
top of the spacer.
Standard Angle Shear
To remove blades:
1. Remove 7/16 inch linkage bolts.
2. Remove four (4) base mounting bolts.
3. Pull spade blade through top of angle shear.
4. Unscrew 7/16 x 1 inch blade bolts and remove blades.
To install blades:
1. Locate relief stamped inside of blade. Install blades so the relief (set of four) face one another.
2. Install and tighten all bolts to secure assemblies.
3. Install spade blade between two (2) blades. Connect spade blade linkage to center plate. Secure
four (4) mounting bolts.

PRO56 Uni-Hydro Manual
Page - 8 -
MAINTENANCE (Cont)
MACHINE MAINTENANCE
After every forty (40) hours of operation:
Inspect the ironworker for wear, damaged components and loose fasteners. Repair as
necessary.
LUBRICATION
MACHINE COMPONENTS
1. Use No. 2 multi-purpose Lithium base grease to lubricate grease fittings after every twenty (20)
hours operation.
2. Eighteen grease fittings are located on:
a. The punch jug.
b. All pins (grease every four (4) hours).
c. Above and below Angle Shear
d. Above and below arms.
3. Use a hand or powered grease gun. If using a hand gun, apply three (3) strokes to each fitting to
ensure adequate lubrication.
HYDRAULIC SYSTEMS
WARNING: Be careful working around hydraulic systems as components may be under extreme
pressure. Fluid escaping under pressure from a very small hole can be almost invisible and have
sufficient force to penetrate the skin. Search for suspected pressure leaks by using a piece of cardboard or
wood. DO NOT USE HANDS. If injured by escaping fluid, consult a doctor immediately. Serious
infection can result if proper medical treatment is not promptly administered.
Oil Level
After every forty (40) hours operation, remove the reservoir filler cap and check oil level. If the oil level
is below two (2) inches from the top of the tank, add No 36 Viscosity non-foaming hydraulic oil until it’s
at proper level.
Lines and Fittings
After every twenty (20) hours operation, inspect system lines and fittings for wear and/or leakage. Repair
as necessary.

PRO56 Uni-Hydro Manual
Page - 9 -
LUBRICATION (cont)
Hydraulic Oil Change
After every two thousand (2000) hours operation, drain and replace oil in the reservoir.
1. Flush the reservoir and add approximately 3.8 gallons of No 36 Viscosity non-foaming hydraulic
oil or equivalent.
2. When fresh oil has been added, start and briefly run the machine to circulate oil through the
system.
3. Operate the controls to purge air from the system.
4. Stop the machine and check the oil level. Add oil as necessary.

PRO 56 Uni-Hydro Manual
TONNAGE CHART
APPROXIMATE PRESSURE FOR PUNCHING ROUND HOLE IN MILD STEEL
HOLE DIAMETER 3/16" 5/16" 7/16" 1/2" 9/16" 5/8" 11/16" 3/4" 13/16" 7/8" 15/16" 1" 1-1/8" 1-1/4" 1-1/2"
THICKNESS
PRESSURE IN TONS
18 GA 0.5 0.7 1.6 1.9 2.1 2.4 2.6 2.8 3.1 3.3 3.5 3.8 4 4.2 5.6
16 GA 0.6 0.9 2.1 2.3 2.6 2.9 3.2 3.5 3.8 4.1 4.4 4.7 4.8 6 7
14 GA 0.7 1.2 2.6 2.9 3.3 3.7 4 4.4 4.8 5.1 5.5 5.9 5 7.2 10
12 GA 1 1.5 3.6 4.1 4.6 5.1 5.7 6.2 6.7 7.2 7.7 8.2 7 10 12
10 GA 1.3 2 4.6 5.3 5.9 6.6 7.3 7.9 8.6 9.2 9.9 10.6 10 13 15
5/32" * 2.3 5.4 6.1 6.9 7.7 8.4 9.2 10 10.7 11.5 12.3 11 16 19
3/16" * 2.8 6.4 7.4 8.3 9.2 10.1 11 12 12.9 13.8 14.8 17 19 23
1/4" * * 8.6 9.8 11.1 12.3 13.5 14.7 16 17.2 18.4 19.7 23 25 30
3/8" * * 12.8 14.8 16.5 18.5 20.2 22.1 23.8 25.8 27.5 29.5 33 38 45
1/2" * * * 19.7 22 24.6 26.9 29.5 31.8 34.4 36.8 39.4 45 50 60
5/8" * * * * * 30.8 33.7 36.9 39.9 43 46 49.2 56 63 75
3/4" * * * * * * * 44.3 47.7 51.7 55.2 59 68 75 90
1" * * * * * * * * * * * 80 90 100 120
* MATERIAL THICKNESS SHOULD NOT EXCEED PUNCH DIAMETER
** RATED 65,000 PSI TENSILE STRENGTH A36 MILD STEEL
Page - 10 -

PRO 56 Uni-Hydro Manual
Page -11-
TROUBLESHOOTING
SYMPTOMS TROUBLE SHOOTING CAUSES CORRECTIONS
Machine runs, but
doesn’t function Electrical wiring problem Have electrician check and correct
Machine lacks power Low hydraulic oil level, faulty
hydraulic pump linkage, faulty
hydraulic spool valve, pump or
electric motor
Isolate and correct as
necessary
Machine leaks oil Faulty hose and or hose ends,
reservoir overfilled, damaged
O-ring, cracked piston or
scarred piston wall
Isolate and correct as
necessary
Machine will not
complete stroke Foot pedal not fully released Adjust stroke control; See Stroke control adjustment
Punch keeps breaking in
shank Stripper Assembly Assure stripper is not bent or misaligned
Punch tip shatters Bar not being held level
with die stand
Punch jam nut shatters Stripper Assembly Operating stripper is not
installed on machine
Loose punch plunger Adjust front set screws on
punch jig

PRO 56 Uni-Hydro Manual
Page -12-
THE PROPER CARE OF PUNCHES AND DIES
PLEASE NOTE:
Too often the failure of a punch is attributed to poor material or workmanship, when in
reality the cause in most cases is due to the following:
LINING UP PUNCH AND DIE
It is of the utmost importance that the punch be aligned
correctly with the die. This is easy to accomplish; at
regular intervals during the day the punch can be
lowered by hand to check if it is centered with the hole
in the die. If this is not centered with the die, this needs
to be corrected. The constant jarring and vibration of
continuous punching is sufficient to cause a slight shift
in either the punch holder or die socket. This is the
MOST prevalent cause of all punch and die failure.
LUBRICATION
One of the main causes of punch flaking off is due to
dry stripping. Dry stripping is when dry particles of
punched material adhere or cling to the surface of the
punch. These particles build up on the surface of the
punch which then causes the punch to strip hard and
finally break.
It is necessary to lubricate or “swab” the punch. This
facilitates easy punching and stripping and prolongs the
life of the punch.
STRIPPING
Strippers that are rough and uneven on the bottom, or
cocked, so that the stripping surface is not parallel with
the plates, are the cause of a large percentage of
premature punch failure. Very often the stripper is set
too far back from the punch, which will cause the
material to cock and also result in the destruction of the
punch.
LOOSE NUTS AND STEMS
Special attention needs to be given to the fit of the
coupling nut. If it is too free on the plunger it will
not grip sufficiently and will work loose. In this
case the punch will also be loose and is liable to
strike the material in a cocked position. This is a
dangerous situation and may result in snapping
the punch. Punch plungers need to be given
periodic inspections.

PRO 56 Uni-Hydro Manual
Page -13-
WARRANTY
UNI-HYDRO INC WILL, WITHIN ONE (1) YEAR OF DATE OF PURCHASE, REPLACE
F.O.B. THE FACTORY, OR REFUND THE PURCHASE PRICE FOR ANY GOODS
WHICH ARE DEFECTIVE IN MATERIALS AND WORKMANSHIP PROVIDED THAT
THE BUYER RETURNS THE WARRANTY REGISTRATION CARD WITHIN THIRTY
(30) DAYS OF PURCHASE DATE, AND, AT THE SELLER’S OPTION, RETURNS THE
DEFECTIVE GOODS FREIGHT PREPAID TO THE SELLER, WHICH SHALL BE THE
BUYER’S SOLE AND EXCLUSIVE REMEDY FOR DEFECTIVE GOODS.
HYDRAULIC AND ELECTRICAL COMPONENTS ARE SUBJECT TO THEIR
RESPECTIVE MANUFACTURER’S WARRANTIES. PUNCHES, DIES, AND/OR
BLADES ARE WARRANTED TO BE FREE OF DEFECTS IN MATERIALS AND
WORKMANSHIP. THIS WARRANTY DOES NOT APPLY TO MACHINES AND/OR
COMPONENTS WHICH HAVE BEEN ALTERED, CHANGED OR MODIFIED IN A
WAY, OR SUBJECTED TO ABUSIVE AND ABNORMAL USE, INADEQUATE
MAINTENANCE AND LUBRICATION, OR SUBJECTED TO USE BEYOND SELLER
RECOMMENDED CAPACITIES AND SPECIFICATIONS. IN NO EVENT SHALL
SELLER BE LIABLE FOR LABOR COSTS EXPENDED ON SUCH GOODS OR
CONSEQUENTIAL DAMAGES. SELLER SHALL NOT BE LIABLE TO PURCHASER
OR ANY OTHER PERSON FOR LOSS OR DAMAGE DIRECTLY OR INDIRECTLY
ARISING FROM THE USE OF THE GOODS OR FROM ANY OTHER CAUSE. NO
OFFICER, EMPLOYEE, OR AGENT OF SELLER IS AUTHORIZED TO MAKE ANY
ORAL REPRESENTATIONS OR WARRANTY OF FITNESS OR TO WAIVE ANY OF
THE FOREGOING TERMS OF SALE AND NONE SHALL BE BINDING ON SELLER.
NOTE: UNI-HYDRO FLAT BAR SHEAR BLADES CARRY AN UNCONDITIONAL ONE
(1) YEAR WARRANTY.