HOLEMAKER PRO 60 HP, PRO 110 HP, HPP 700/1.5 Operator's Manual

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PUNCHER PRO 60 HP, PRO 110 HP

HYDRAULIC POWER PACK HPP 700/1.5

OPERATOR’S MANUAL

BEFORE USE, ENSURE EVERYONE USING THIS MACHINE READS AND UNDERSTANDS

ALL SAFETY AND OPERATING INSTRUCTIONS IN THIS MANUAL .

Serial #............................................ Date of Purchase............................

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HOLEMAKER PRO 60 HP, PRO 110 HP & HPP 700/1.5

IMPORTED & DISTRIBUTED BY

INDUSTRIAL TOOL & MACHINERY SALES 18 BUSINESS ST YATALA QLD 4207 AUSTRALIA

07 3287 1114

07 3287 1115

[email protected]

www.industrialtool.com.au

WARRANTY TERMS

In addition to any warranties or conditions implied by applicable Statute or Regulations, Industrial Tool & Machinery Sales warrants all of it’s products against defective workmanship and faulty materials for a period of twelve (12) months from the date of purchase, unless otherwise stated. At our option we will repair or replace, free of charge, any item on the condition that:

• The complete machine or tool is returned, freight prepaid to ITM or one of it’s authorised service agents as directed by ITM, and is found to have a material or constructional defect.

• The machine or tool has not been subject to misuse, neglect or damage by accident.

• The fault is not a result of normal “wear and tear”.

• Written permission has been received from ITM prior to commencement of repair.

• Repairs, tampering or modification carried out by unauthorised personnel will void all warranty.

• Consumable items such as cutting tools, pilot pins, saw blades, grinding wheels etc. are NOT covered by warranty.

Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

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HOLEMAKER PRO 60 HP, PRO 110 HP & HPP 700/1.5

TABLE OF CONTENTS

1. GENERAL INFORMATION - 4 -

1.1. Application - 4 -

1.2. Technical data - 4 -

1.3. Maximum plate thickness - 6 -

1.4. Selecting punches for the most common inch plates - 9 -

1.5. Allowed parameters of extension cords - 11 -

1.6. Design - 13 -

1.7. Equipment included - 14 -

1.5. Transportation - 14 -

2. SAFETY PRECAUTIONS - 15 -

3. START UP AND OPERATION - 16 -

3.1. Mounting the punch and die - 16 -

3.2. Connecting the hydraulic power pack - 17 -

3.3. Positioning - 18 -

3.4. Punching - 19 -

3.5. Replacing the die and punch - 19 -

3.6. Replacing the restrainer - 20 -

3.7. Troubleshooting - 21 -

4. ACCESSORIES - 23 -

4.1. Punches and dies - 23 -

4.2. Balancer - 24 -

4.3. Crane - 24 -

4.4. Stationary work set - 28 -

4.5. Guide - 30 -

4.6. Tool box - 32 -

5. WIRING DIAGRAM - 33 -

6. PARTS LIST - 34 -

6.1. PRO 60 HP Parts List - 34 -

6.2. PRO 110 HP Parts List - 38 -

6.3. HP 700 Parts List - 42 -

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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 a cylinder driven by the HPP 700/1.5 Hydraulic Power Pack.

1.2. Technical data

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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GENERAL INFORMATION

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1.6. Design

GENERAL INFORMATION

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SAFETY INSTRUCTIONS

1.7. Equipment included

1.8. Transportation

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SAFETY PRECAUTIONS

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 speciﬁ ed 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 speciﬁ cations must conform to those speciﬁ ed 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. The bending radius of the high-pressure hose must never be less than 80 mm (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 in the vicinity of 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 highpressure 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 the machine in the vicinity of ﬂ ammable liquids or gases, or in explosive environments.

16. Use only punches and dies speciﬁ ed in this Operator’s Manual.

17. Mount punches and dies securely. Remove adjusting keys and wrenches from the work area before powering the hydraulic power pack.

18. Before every use, inspect the machine and hydraulic power pack to ensure they are not damaged. Check whether any part is cracked or improperly ﬁ tted. Make sure to maintain proper conditions that may aﬀ ect the operation of the machine and hydraulic power pack.

19. Always use a safety helmet with shield, hearing protection, protective footwear, gloves, and protective clothing during operation. Do not wear loose clothing.

20. Do not touch the punch or put hands into its work area.

21. Maintain the machine with care. Cover steel parts with a thin grease layer to protect them against rust when not in use for any extended period.

22. Perform maintenance and replacement of the punch, die, and restrainer only with the power ON/ OFF switch set to position ‘0’.

23. Perform repairs only in a service center appointed by the seller.

24. If the machine falls on a hard surface, from height, is wet, or has any other damage that could aﬀ ect the technical state of the machine, stop the operation and immediately send the machine to the service center for inspection and repair.

25. Never leave the machine or the hydraulic power pack unattended during operation.

26. Remove the machine and power pack from the worksite and store in an isolated and dry location when not in use.

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START UP AND OPERATION

3. STARTUP AND OPERATION

All safety precautions must be closely observed.

3.1. Mounting the punch and die

Set the power ON/OFF switch to position ‘0’. Then, insert the nut joined with the punch into the machine (1, Fig. 4), and screw the nut manually in direction 2, after which insert the wrench into the hole (3) and lock the nut by rotating the wrench in the same direction. If an oblong punch 4 is used, before locking the nut the punch pin must snap into the socket, which will be indicated by a snap sound.

Retract the restrainer as far as possible (1, Fig. 5a), rest the die onto the drift (2), and lower the drift to insert the die into the socket (3). Tighten with the 4 mm hex wrench (4). The diameters (dimensions) of the punch and die installed must be the same. Position inclined dies 5 and oblong dies 6 and 7 in such a way to align the groove with the set screw 4. Mount oblong dies and oblong punches in the same orientation

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START UP AND OPERATION

3.2. Connecting the hydraulic power pack

Connect the machine with the hydraulic power pack using the hydraulic hoses and control cable. To do this, remove caps from the hydraulic sockets of the machine, ﬁ rmly screw the high-pressure connector into the socket 1 (Fig. 6), and plug the low--pressure connector into the socket 2 until it snaps into place. Then, connect the control cable to the connector 3 and plug the power cord of the hydraulic power pack into the power outlet. Every time the power pack is connected and the power ON/OFF switch is set to position ‘I’, the status LED will ﬂ ash 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. Use the 8 mm hex wrench to unscrew the transport cap 4 of the hydraulic power pack and place the oil plug in cap’s position 5.

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START UP AND OPERATION

3.3. Positioning

Hang the machine on the chain and position on a plate with the restrainer retracted above the punch tip as shown in Fig. 7. Set the position of the hole to be made in relation to the edge using the depth stop by loosening the four screws using the 6 mm hex wrench. During the punching process, the bottom surface of the restrainer must be in full contact with the workpiece.

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START UP AND OPERATION

3.4. Punching

Operate the machine by holding both handles. 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 ﬂ ashing every 0.25 seconds. When the punch reaches the plate, the automatic punching process will start and will be indicated by the LED ﬂ ashing every

0.1 seconds. At 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 of the punch at any time, press the STOP/UP button. Pressing the STOP/ UP button again will retract the punch. If entering into the material fails due to its excessive thickness, the down movement will stop. After establishing the ﬁ rst hole, and then after every 100 holes, check whether the punch and die are tight, and re-tighten as necessary. Once the work is ﬁ nished, toggle the power ON/ OFF switch to position ‘0’. 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.

3.5. Replacing the die and punch

Set the power ON/OFF switch to position ‘0’. To dismount the die, retract the restrainer fully (1, Fig. 8) and use the 4 mm hex wrench to loosen the set screw 2. Then, use the drift (3) and remove the die (4).

Mount as shown in Fig. 5a. To dismount the punch, insert the wrench into the hole (1, Fig. 9), unscrew the nut by rotating it in direction 2, and remove the nut joined with the punch (3).

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START UP AND OPERATION

3.6. Replacing the restrainer

Set the power ON/OFF switch to position ‘0’, dismount the punch as shown in Fig. 9, and unscrew the restrainer by rotating it in the direction shown in Fig. 10. Screw the new restrainer by rotating in the opposite direction.

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START UP AND OPERATION

3.7. Troubleshooting

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ACCESSORIES

5° INCLINED ROUND DIE

TO SUIT HOLEMAKER PRO 60 HP & PRO 110 HP

Size Die Part No.

9mm HPRD09A

10mm HPRD10A

11mm HPRD11A

12mm HPRD12A

13mm HPRD13A

14mm HPRD14A

15mm HPRD15A

16mm HPRD16A

17mm HPRD17A

18mm HPRD18A

19mm HPRD19A

20mm HPRD20A

21mm HPRD21A

22mm HPRD22A

23mm HPRD23A

24mm HPRD24A

25mm HPRD25A

26mm HPRD26A

27mm HPRD27A

OBLONG PUNCH & DIE

TO SUIT HOLEMAKER PRO 60 HP & PRO 110 HP

ROUND PUNCH & DIE

TO SUIT HOLEMAKER PRO 60 HP & PRO 110 HP

Size Punch Part No. Die Part No.

7mm HPRP07 HPRD07

8mm HPRP08 HPRD08

9mm HPRP09 HPRD09

10mm HPRP10 HPRD10

11mm HPRP11 HPRD11

12mm HPRP12 HPRD12

13mm HPRP13 HPRD13

14mm HPRP14 HPRD14

15mm HPPR15 HPRD15

16mm HPRP16 HPRD16

17mm HPPR17 HPRD17

18mm HPRP18 HPRD18

19mm HPPR19 HPRD19

20mm HPPR20 HPRD20

21mm HPPR21 HPRD21

22mm HPRP22 HPRD22

23mm HPPR23 HPRD23

24mm HPPR24 HPRD24

25mm HPPR25 HPRD25

26mm HPPR26 HPRD26

27mm HPPR27 HPRD27

Size Punch Part No. Die Part No.

16 x 8mm HPOP1608 HPOD1608

18 x 9mm HPOP1809 HPOD1809

18 x 11mm HPOP1811 HPOD1811

20 x 10mm HPOP2010 HPOD2010

20 x 12mm HPOP2012 HPOD2012

20 x 14mm HPOP2014 HPOD2014

22 x 11mm HPOP2211 HPOD2211

22 x 14mm HPOP2214 HPOD2214

24 x 12mm HPOP2412 HPOD2412

25 x 9mm HPOP2509 HPOD2509

25 x 12mm HPOP2512 HPOD2512

25 x 13mm HPOP2513 HPOD2513

25 x 14mm HPOP2514 HPOD2514

25 x 18mm HPOP2518 HPOD2518

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ACCESSORIES

4.2. Balancer

Allows suspending the machine, balancing its weight, and lifting/lowering the machine. Part number: M7-SP3220 (PRO 60 HP) M7-SP3400 (PRO 110 HP)

4.3. Crane

Allows suspending the machine, balancing its weight, and moving the machine along with the power pack.

Part number: WAD-HPP1010

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The included equipment consists of:

ACCESSORIES

To mount, screw the crane base into top holes on both power pack sides with eight M8x16 screws and 8.5 mm washers (1, Fig. 11) using the 6 mm hex wrench. Use next eight M8x16 screws and 8.5 mm washers (2) to screw the supports with the locking pins placed as shown in detail 3 into lower holes on both sides of the power pack. Then, remove the pins, slightly tilt the power pack backwards, and rotate the supports according to the arrow direction 4 to rest the power pack on the wheels.

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ACCESSORIES

Lock the supports in this position by placing the pins in location 1 from Fig. 12. To join the crane arm to the crane base, put two 44 mm washers (2) between the base and arm, and insert the pivot pin (3). Next, at both sides put 13 mm round washers (4), and place the 9 mm clips (5) into the grooves of the pivot pin.

Then, mount the gas spring unit between the crane arm and the crane base as shown in Fig.

13. Place the unit in a proper arm socket (1) to set such a force that will balance the weight of the machine. Insert the piston rod into the base socket on the required height (2). Hang the machine with the chain on the arm end (3), and lock the chain with the locking plate (4), 6.4 mm washer (5), and M6x20 handlever (6). To set a diﬀ erent force or height, remove the machine with the chain and locate the gas spring unit in an adjacent socket of either comb 1 or 2.

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ACCESSORIES

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ACCESSORIES

4.4. Stationary work set

Allows operating the machine in a stationary position. The dual foot switch functions as the STOP/UP and DOWN machine buttons to allow the punch to stop, raise, and lower.

Part number: WAD-HPP1020

To mount the set, position the machine upside down and attach the support with two M8x20 screws and two 8.5 mm washers using the 6 mm hex wrench (Fig. 14).

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ACCESSORIES

Position the machine the right way up and rotate the restrainer in the direction shown in the Fig. 15 to position the restrainer 2 mm (0.08’’) above the plate. Then, unscrew the front handle and use it to tighten the guard in such a way to level the lower edge of the guard opening with the machine edge indicated in the ﬁ gure.

Plug the machine control connector into the female socket and connect the control cable to the male socket of the foot switch junction box (Fig. 16).

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ACCESSORIES

4.5. Guide

Allows guiding the machine along the workpiece. Part number (for PRO 110 HP): WAD-HPP1030 (two special washers included)

Dismount the depth stop by unscrewing four screws using the 6 mm hex wrench. Then, position the machine on the plate and use DOWN button to slightly penetrate into a previously centerpunched mark on the plate (1, Fig. 17). Use the wrench to facilitate lowering the restrainer as far as possible (2), which will press the plate to the die (3).

Loosen the wing screws (1, Fig. 18) fully and use the 10 mm hex wrench to loosen the upper bearings 2. Next, position the guide on the machine in such a way to bring the lower, upper, and side bearings in close contact with the plate (3). Tighten the upper bearings in this position.

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ACCESSORIES

Attach the guide to the machine with M8x16 screws and washers (4) using the 6 mm hex wrench, then tighten the wing screws 1 to press the die to the plate. Next, raise the restrainer (6) to position it 2 mm (0.08’’) above the plate (7). Retract the punch from the plate and move the machine to the next center--punched mark. If the mark is at a diﬀ erent distance from the plate face than the mark of the base hole is, loosen four M8x16 screws (4), adjust the position of the guide and tighten the screws in this new position. The machine with the mounted guide and positioned on a plate must always be held with both hands. During moving the machine in direction 8, press the machine against the face of the plate.

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ACCESSORIES

4.6. Tool box

Designed for storing tools. Mount on the power pack with two M6x12 screws using the 4 mm hex wrench. Part number: WAD-HPP1040 (two M6x12 screws included)

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