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SteelBeast HP110 Operator's Manual

Puncher hydraulic power pack
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OPERATOR'S MANUAL
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Unit 21 Empire Business Park, Enterprise Way
Burnley, Lancashire, BB12 6LT
Phone: 00 44 1706 229490, Fax: 00 44 1706 507347
www.steelbeast.co.uk
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e-mail:
sales@jeisolutions.co.uk
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  • Page 1 OPERATOR’S MANUAL r HP60/HP110 Unit 21 Empire Business Park, Enterprise Way Burnley, Lancashire, BB12 6LT Phone: 00 44 1706 229490, Fax: 00 44 1706 507347 www.steelbeast.co.uk e-mail: sales@jeisolutions.co.uk...

  • Page 2: Table Of Contents

    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.

  • Page 3: General Information

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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 a cylinder driven by the HPP 700/1.5 Hydraulic Power Pack.
  • Page 4 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 520 mm (20.5’’) 594 mm (23.4’’) HP60 HP110 60 mm (2.36’’) 110 mm (4.33’’) Throat depth* 27 mm (1.06’’) 27 mm (1.06’’) Maximum hole diameter Maximum plate thickness** 13 mm (0.51’’) 16 mm (0.63’’)

  • Page 5: Maximum Plate Thicknesses Depending On The Material Type And Diameter/Dimensions Of The Hole To Be Made

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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 Maximum plate thickness Inch equivalent S235JR mild steel...
  • Page 6 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Oblong holes using oblong punches with metric sizes Maximum plate thickness S235JR mild steel 355J2 G3 hard steel stainless steel Inch Decimal Dim. < 490 MPa = 490–630 MPa = 630–750 MPa (70,000 psi) (70,000–90,000 psi)
  • Page 7 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Circular holes using circular punches with imperial sizes Maximum plate thickness S235JR mild steel 355J2 G3 hard steel stainless steel Ø Decimal < 490 MPa = 490–630 MPa = 630–750 MPa (70,000 psi) (70,000–90,000 psi)

  • Page 8: Selecting Punches For The Most Common Inch Plates

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 1.4. Selecting punches for the most common inch plates HP60 S235JR mild steel 355J2 G3 hard steel stainless steel < 490 MPa = 490–630 MPa = 630–750 MPa (70,000 psi) (70,000–90,000 psi) (90,000–110,000 psi)
  • Page 9 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH HP110 S235JR mild steel 355J2 G3 hard steel stainless steel < 490 MPa = 490–630 MPa = 630–750 MPa (70,000 psi) (70,000–90,000 psi) (90,000–110,000 psi) Punch type Circular Oval Circular Circular Oval...

  • Page 10: Design

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 1.5. Design STOP/UP DOWN Status LED Depth stop Control Restrainer connector Punch High-pressure hydraulic socket Low-pressure hydraulic socket Fig. 1. View of the Puncher Oil plug Transport cap Power ON/OFF switch Air vent...

  • Page 11: Equipment Included

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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...

  • Page 12: Transportation

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 1.7. Transportation Before transporting, fix the machine to the hydraulic power pack by catching the safety strap on the lugs 1 and 2 (Fig. 3), and then place the oil plug and the transport cap as shown in the figure (3, 4).

  • Page 13: Safety Precautions

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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.
  • Page 14 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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.

  • Page 15: Startup And Operation

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 3. STARTUP AND OPERATION Adhere to all safety precautions. 3.1. Unpacking Open the box, unscrew the lock using the 5 mm 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.

  • Page 16: Installing The Punch And Die

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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.
  • Page 17 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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 4 mm hex wrench (4).

  • Page 18: Connecting The Hydraulic Power Pack

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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.

  • Page 19: Positioning

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 3.4. Positioning Hang the machine on the chain. Then, position the machine on a plate 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.

  • Page 20: Punching

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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.

  • Page 21: Replacing The Restrainer

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Mount the die as shown in Fig. 7a. To dismount the punch, insert the wrench into the hole (1, Fig. 11), unscrew the nut by rotating it in direction 2, and remove the nut joined with the punch (3).

  • Page 22: Troubleshooting

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 3.8. Troubleshooting Problem Cause Solution Punch stuck in the Die with parallel surfaces used Use a die with parallel workpiece during up for an inclined plate, 5° surfaces for a plate with...
  • Page 23 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Problem Cause Solution Punch does not move down Machine not restarted once Press and hold STOP/UP while DOWN button is held. connected to a supply, which button for about 3 seconds. is indicated by the status LED LED flashing should turn into flashing every 0.5 seconds.

  • Page 24: Accessories

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 4. ACCESSORIES 4.1. Punches and dies Maximum plate thickness [mm] HP60 HP110 Ø Circular punch Circular die 5° inclined circular die [mm] – STM-0507-20-18-00-0 MTY-0507-40-18-00-0 – STM-0507-20-17-00-0 MTY-0507-40-17-00-0 STM-0507-20-16-00-0 MTY-0507-40-16-00-0 3.6 MTY-0507-50-16-00-0...

  • Page 25: Balancer

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Maximum plate thickness [mm] HP60 HP110 Ø Decimal Circular punch Circular die equivalent [’’] 5/16 0.3125 STM-0507-20-33-00-0 MTY-0507-40-33-00-0 0.3750 STM-0507-20-32-00-0 MTY-0507-40-32-00-0 7/16 0.4375 STM-0507-20-31-00-0 MTY-0507-40-31-00-0 0.5000 STM-0507-20-30-00-0 MTY-0507-40-30-00-0 10.4 10.4 9/16 0.5625...

  • Page 26: Crane

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 4.3. Crane Allows suspending the machine, balancing its weight, and moving the machine along with the power pack. Part number: ZUR-0517-15-00-00-1 1108 mm (43.6’’) 1337 mm (52.6’’) This document is protected by copyrights.
  • Page 27 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH The included equipment consists of: Crane base with arm 1 unit Left support 1 unit Right support 1 unit M8x16 screw 16 units 8.5 mm round washer 16 units Gas spring unit...
  • Page 28 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Mount the gas spring unit between the crane arm and the crane base as shown in Fig. 14. Place the unit in such an arm socket (1) to set a force that will balance the weight of the machine.

  • Page 29: Stationary Work Set

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 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.
  • Page 30 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Machine control connector Machine control connector Control cable connector Fig. 16. Connecting the foot switch to the machine and hydraulic power pack This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 31: Guide

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 4.5. Guide Allows guiding the machine along the workpiece. Part number (for PRO 110 HP): PRW-0507-90-00-00-0 (two special washers and 10 mm hex wrench included) Loosen the wing screws (1, Fig. 17) fully and use the 10 mm hex wrench to loosen the upper bearings 2.
  • Page 32 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Fig. 18. Mounting the guide on the machine Position the machine the right way up on the plate in such a manner to place the punch above a previously center-punched mark indicating the center of the hole to be made.

  • Page 33: Tool Box

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Punch through the plate and once the punch is retracted, move the machine in the direction 6 to a next center-punch mark, pressing the machine against the plate face. If the mark is at a different distance from the plate face than is the center of the first hole, loosen the four screws 3, adjust the position of the guide, and tighten the screws in this new position.

  • Page 34: Wiring Diagram

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 5. WIRING DIAGRAM This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 35: Declarations Of Conformity

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 6. DECLARATIONS OF CONFORMITY EC Declaration of Conformity JEI Group Ltd Unit 21 Empire Business Park Enterprise Way Burnley, Lancashire, BB12 6LT, UK declare with full responsibility that: Puncher HP60, HP110 are manufactured in accordance with the following standards: •...
  • Page 36 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH EC Declaration of Conformity JEI Group Ltd Unit 21 Empire Business Park Enterprise Way Burnley, Lancashire, BB12 6LT, UK declare with full responsibility that: HPP 700/1.5 Hydraulic Power Pack is manufactured in accordance with the following standards: •...

  • Page 37: Quality Certificates

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 7. QUALITY CERTIFICATES Machine control card PUNCHER □ PRO 60 HP □ PRO 110 HP Serial number ................Quality control ..........Adjustments, inspections Quality control ..........This document is protected by copyrights.
  • Page 38 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH Machine control card HPP 700/1.5 HYDRAULIC POWER PACK □ 230 V / 50 Hz □ 230 V / 60 Hz □ 115 V / 50 Hz □ 115 V / 60 Hz Serial number ..............

  • Page 39: Warranty Cards

    JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH 8. WARRANTY CARDS WARRANTY CARD No..................in the name of Manufacturer warrants the Puncher to be free of defects in material and workmanship under normal use for a period of 12 months from the date of sale.
  • Page 40 JEI Drilling & Cutting Solutions Ltd HP60/HP110 PUNCH WARRANTY CARD No..................in the name of Manufacturer warrants the HPP 700/1.5 Hydraulic Power Pack to be free of defects in material and workmanship under normal use for a period of 12 months from the date of sale.

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