PUNCH PRO™ ELECTRO-HYDRAULIC HOLE PUNCHER 75004R OPERATOR’S MANUAL with Power Retract IMPORTANT SAFETY INSTRUCTIONS WARNING: When using electric tools, basic safety precautions should always be followed to reduce the risk of fire, electric shock, and personal injury, including the following. 1. READ ALL INSTRUCTIONS 5. Consider Work Area Environment Do not expose tool to rain 2. Grounding Instructions Do not use tool in damp or wet 2a. This tool should be grounded while in use to locations. Keep work area well lit. protect the operator from electric shock. The Do not use tool in presence of flammable tool is equipped with a 3-conductor cord and liquids or gases. 3-prong grounding type plug to fit the proper 6. Guard Against Electric Shock grounding type receptacle. The green (or green and yellow) conductor in the cord is the Prevent body contact with grounded grounding wire. Never connect the green or sufaces. For example: pipes, radiators, ranges, refrigerator enclosures. green and yellow wire to a live terminal. If your unit is for use on 115V, it has a plug that Keep Children Away looks like that shown in sketch (A). An adapter, 7. Do not let visitors contact tool or extension see sketches (B) and (C), is available for cord. All visitors should be kept away from connecting sketch (A) type plugs to 2-prong work area. receptacles. The green-colored rigid ear, lug, or the like extending from the adapter must be Store Idle Tools connected to a permanent ground, such as a 8. When not in use, tools should be stored in properly grounded outlet box. a dry high or locked-up place-out of reach NOTE: Use of a grounding adapter is of children. prohibited in Canada by Part 1 of the Canadian Electrical Code. 9. Do Not Force Tool It will do the job better and safer at the rate for which it was intended. 10. Use Right Tool Do not force small tool or attachment to do the job of a heavy-duty tool. Do not use tool for purpose not intended. 11. Dress Properly Do not wear loose clothing or jewelry. They 2b. 3. Extension Cords Use only 3-wire extension cords that have 3-prong grounding type plugs and 3-pole receptacles that accept the tool’s plug. Replace or repair damaged cords. Make sure the conductor size is large enough to prevent excessive voltage drop causing loss of power and possible motor damage 12. Always wear safety glasses or goggles. 13. Do Not Abuse Cord. Never carry tool by cord or yank it to disconnect from receptacle. Keep cord from heat, oil and sharp edges. LENGTH OF CORD IN FEET FOR ALL DOUBLE-INSULATED TOOLS When servicing use only identical replacement parts. 4. Keep Work Area Clean Cluttered areas and benches invite injuries. can be caught in moving parts. Rubber gloves and non skid footwear are recommended when working outdoors. Wear protective hair covering to contain long hair. 2 115V (Amps) 25 FT. 50 FT. 100 FT. 5-6 18 16 6-8 18 16 150 FT. 200 FT. 250 FT. 300 FT. 14 12 10 10 8 12 10 10 8 6 8-10 18 14 12 10 8 8 6 10-12 16 14 10 8 8 6 6 12-14 16 12 10 8 6 6 6 14-16 16 12 10 8 6 6 4 SAFETY FIRST Always wear eye protection while using punching tools, or in the vicinity of punching. CAUTION! Risk of pinching or crushing. Keep away from moving parts when unit is in use. CAUTION! The slug is ejected at the end of the punch. Do not aim the unit so that ejected slug may hit someone around, or below you. CAUTION! To prevent electric shock, do not use power tools near wet areas, or where power tool may become wet. PRINCIPLES OF OPERATION The Hougen-Ogura Electro-hydraulic Hole Puncher is an integrated unit, containing the electric motor, hydraulic pump, and "C"-frame punching unit. It uses hydraulic power to force the punch through the workpiece, and a strong spring to return the punch piston to its "home" position. The patented design includes an automatic valve that releases the hydraulic pressure when the punch piston is at the bottom of its stroke. The automatic valve remains open until the punch piston has fully returned to the home position. As a result of this design, the piston will not return to its home position automatically unless the full stroke has been completed. Also, the punch will not begin another stroke unless the punch has fully returned to the home position, resetting the automatic valve. In the event that the punch does stick in the material, keeping the punch piston from returning to the home position, the 75004R now features a power return. Leaving the manual return valve closed and depressing the trigger, the punch piston will now be powered back to the home position. To allow the punch piston to be manually returned in the event that the punch cycle is stopped prior to completion, a manual return valve is provided. Trigger Oil Port Manual Return Valve Punch Handle Die Hole Locator Gauge Work Stand Stripper 3 75004R CONTENTS Hydraulic Oil................................................................................................ 75376 11/16" Diameter Punch................................................................................ 75492 11/16" Diameter Die - Type S - For material 1/8" to 1/4".............................. 75516 11/16" Diameter Die - Type T - For material 1/4" to 3/8".............................. 75517 Pin Spanner................................................................................................. 75903 10mm Open End Wrench............................................................................ 75771 Foot Switch.................................................................................................. 75110 Work Stand.................................................................................................. 75194 M3 Hex Key.................................................................................................. 75742 M4 Hex Key.................................................................................................. 75743 M5 Hex Key.................................................................................................. 75744 M6 Hex Key.................................................................................................. 75745 M8 Hex Key.................................................................................................. 75746 OPERATING PROCEDURES Read, understand and follow all safety instructions and operating procedures. If you do not understand the instructions or if conditions are not correct for proper operation, do not operate the machine. Consult your supervisor or other responsible person. *Check that the trigger switch is not locked on. *Check that the manual return valve is closed. *Make sure that the proper punch and die are installed correctly. See Die Selection and Proper Punches and Dies in this Manual *If you are using the hole locator gauge, adjust it to the proper distance. See Hole Locator Gauge Adjustment in this manual. *Plug the power cord into the proper power supply. *Position the puncher at the proper location on the workpiece using the hole locator gauge or by locating the point on the end of the punch into a center punch mark on the piece. With everything in proper order, the switch can be activated to start the electric motor. The punch piston will move out and push the punch through the material. Keep the switch on until the punch has reached the end of its stroke and stops. Release the switch. The automatic return valve will open at the end of the stroke allowing the punch piston to retract to its home position. The punch piston must return completely before another hole can be punched. If the punch stops in the midst of its stroke or does not come out of the material, open the manual return valve. Once the punch piston has returned to its home position, tighten the manual return valve. INSTRUCTIONS -- FOOT SWITCH Although the foot switch is guarded against inadvertent operation, it is best to position the foot pedal away from normal standing position. Place it in a position that requires deliberate effort to reach and activate the switch. The trigger switch should be locked on only when ready to punch. Release the trigger switch immediately after punching to prevent operation by inadvertent actuation of the foot switch. HOLE LOCATOR GAUGE ADJUSTMENT The Hole locator Gauge can be set to hold the Hole Punches at a constant distance from the edge of the workpiece. The gauge is held in place by one or two socket head caps screws. Before making any adjustment, first, unplug the power cord. To adjust the position of the gauge, loosen the cap screw(s), tap the gauge into the desired position and retighten the cap screw(s). 4 REMOVING AND INSTALLING PUNCHES Prior to removing a punch, jog the punch piston down until it puts pressure on a piece of material that is of the appropriate thickness. With a pin spanner, loosen the retaining nut. Manually release the punch piston with the manual release valve, disconnect the unit from the power supply and then remove the retaining nut and punch. Prior to installing a different punch, check for debris in the retaining nut and punch piston. Clean if necessary. Prior to installing a punch, verify the "O" ring on the punch piston is clean and not damaged. Place your punch into the retaining nut, properly align the punch within the punch piston and hand tighten the retaining nut. Plug in power, jog the punch piston down until it makes contact with your work surface. Tighten the retaining nut with the pin spanner. Manually release the punch piston. Your now ready to punch your material. Failure to align your punch properly could result in serious damage to your machine. It is not necessary to remove your die to install the punch piston. SELECTING PROPER DIES Proper die selection is essential. Other than the obvious necessity of matching shaped punches and dies, there are two other basic selection factors that must be considered. The first is die clearance. Different material types and different material thicknesses require different clearances between the punch and die. In order to maintain the best possible hole while remaining within the tonnage capacity of the machine, it is essential to choose the die with the proper clearance. The second is the die angle. Most structural shapes can be punched with the standard flat dies, but "I" -beams and most channels which have a 2-in-12 taper require the use of special 9-1/2 degree angled dies. Car and ship channel flanges and other structural shapes with a 2 degree taper can be punched with flat dies. Materials with a flange taper of less than 5 degrees can also be punched with the flat die, however, the hole will be slightly angled. Refer to specific information and tables within this manual for the proper punch and die combination. IMPORTANT NOTES: REMOVING THE NEW DIE 1. To make it easier, please remove the strippers 3. Pull the die up to the tip of the punch 2. Unscrew the nuts and set screws that hold the die in place PUNCH STRIPPER Your Hougen-Ogura punch unit has been equipped with a new die configuration. Please review this information prior to operating your machine 4. Remove the die from the “C”- frame, inclining it to remove. SET SCREW NUT STRIPPER INSTALLING A PUNCH 1. 2. 3. 4. 5. To make the operation easier, first remove the strippers on both sides. Reference your Operators manual and remove your punch and the die. Install a new punch and punch retaining nut. Install the die (Reference the steps above and work in reverse) Tighten the punch retaining nut according to the Instructions in your Operators manual. New Die Hougen-Ogura Punches are designed to be used in Structural Steel. If used in harder or higher tensile strength materials, performance will be impeded and serious damaged could occur to your unit. Old Die NOTE : 75004R utilizes the "old" style die. 5 PUNCH AND RETAINING NUT Pin Spanner Retaining Nut Punch IMPORTANT NOTE PERIODICALLY CHECK THE RETAINING NUT, MAKING SURE IT IS TIGHTENED PROPERLY. O-Ring USING THE WORK STAND All models can be used with an accessory work stand for bench or table mounting of the Hole Puncher. The stand is standard with all models. To install the stand, first unplug the power cord., then mount the unit to the stand with the supplied hardware. When using the stand, periodically check to make sure that the punched material (slugs) are not stacking up between the exit hole in the "C"-frame and the stand. Keep this area clear of accumulated slugs. ADDING OIL Use of the correct hydraulic oil is essential. Approved oils are Shell "TELLUS Oil" and Exxon "TERESSTIC" (Part No. 75376). Grade #46 viscosity must be used. Check the unit specifications. Make sure that the work area and all equipment are clean so that no dirt, dust or other foreign material can get into the hydraulic oil or pump area. 1. Locate the socket head cap screw that plugs the oil port. It is just above the manual return lever on the right hand side of the Hole Puncher. 2. Lay the Hole Puncher on its left side so that the oil port is facing up. 3. Turn on the switch to move the punch piston almost to the bottom of its stroke. If necessary, cycle the punch several times to determine where the bottom of the stroke is, and to correctly position the punch piston. In this position, the maximum amount of oil has been drawn from the pump and the correct fill can be obtained. 4. Carefully open the oil port by removing the sockethead cap screw. 5. Using the small squeeze bottle supplied with the Hole Puncher, carefully add hydraulic oil to completely fill the reservoir. Rock the Hole Puncher back and forth slightly several times to free any trapped air bubbles, then add additional oil if necessary. 6. Replace the cap screw and wipe up any excess oil. 7. Cycle the Hole Puncher several times with the Manual return Valve open, and again with the valve closed, to work any trapped air out of the system, then repeat the above procedure, making sure that the punch piston is almost at the bottom of the stroke before removing the cap screw from the oil port. 8. Add additional oil as necessary. If the unit was extremely low on oil, it may be necessary to repeat HELPFUL HINTS FOR HOLE PUNCHING Each of the punches is provided with a sharp point at its center. If the hole locations are center punched, the point on the end of the punch may be used to "find" the center punched spot. Also, for accurate and easy positioning of the punch to a hole location, the switch can be intermittently pulsed on and off to jog the punch down to the work surface. If the position is not satisfactory, open the manual return valve to retract the punch for another attempt. This operation can also be performed with the manual return valve "cracked" open slightly to prevent full punching pressure from being developed. In this manner, the punch can be easily brought right down to the surface without beginning to punch the hole. If the location is satisfactory, close the valve and finish the operation. 6 TROUBLESHOOTING PROBLEM MOTOR RUNS BUT PUNCH PISTON DOES NOT COME OUT PUNCH PISTON COMES OUT, BUT PUNCHING POWER IS TOO WEAK TO PUNCH MOTOR DOES NOT ROTATE OR POOR ROTATION OF MOTOR OIL LEAKING BETWEEN "C" FRAME AND CYLINDER OR BETWEEN CYLINDER AND PUMP HOUSING OIL LEAKING AROUND PISTON OR FROM INTERNAL AREA PUNCH DOES NOT STRIP OUT OF WORKPIECE AFTER PUNCHING CAUSE SOLUTION MANUAL RETURN VALVE IS OPEN CLOSE MANUAL RETURN VALVE OIL IS INSUFFICIENT ADD OIL PISTON HAS NOT RETURNED COMPLETELY TO ITS HOME POSITION DUE TO STEEL CHIPS, DIRT OR OTHER DEBRIS ON THE EXPOSED PUNCH-HOLDER POSITION. CLEAN DEBRIS FROM EXPOSED PUNCH-HOLDER PORTION OF PISTON ROD. PUSH PUNCH PISTON BACK TO ITS HOME POSITION. PUNCH PISTON RETURN SPRING IS TOO WEAK TO RETURN PUNCH ROD HAVE MACHINE SERVICED BY THE FACTORY MANUAL RETURN VALVE IS NOT COMPLETELY CLOSED CLOSE MANUAL RETURN VALVE OIL IS INSUFFICIENT OR AIR IS TRAPPED IN RESERVOIR ADD OIL INTERNAL PUMP OR PISTON PARTS ARE WORN, DIRTY OR DAMAGED AND NOT FUNCTIONING PROPERLY HAVE MACHINE SERVICED BY THE FACTORY OPEN POWER CIRCUIT CHECK PLUG, EXTENSION CORD, CIRCUIT BREAKER IMPROPER VOLTAGE CHECK POWER SOURCE EXCESSIVE VOLTAGE DROP EXTENSION CORDS ARE OF INSUFFICIENT WIRE SIZE FOR THE LENGTH OF THE CORD. WORN OR DAMAGED CORDS OR PLUGS. WORN CARBON BRUSHES. DAMAGED INTERNAL MOTOR PARTS HAVE MACHINE SERVICED BY THE FACTORY BOLTS ARE NOT TIGHT TIGHTEN BOLTS GASKET IS DAMAGED HAVE MACHINE SERVICED BY THE FACTORY INTERNAL SEALS OR SURFACES ARE DAMAGED. OIL LEVELER SACK IS BROKEN HAVE MACHINE SERVICED BY THE FACTORY PUNCH OR DIE IS WORN REPLACE IMPROPER DIE FOR MATERIAL OR THICKNESS CHECK FOR PROPER PUNCH AND DIE SELECTION WORKPIECE WAS NOT UNDER BOTH STRIPPERS AND IS BINDING OR PUNCH MAKE SURE THAT THE MATERIAL IS FULLY SEATED IN THE PUNCHING AREA 7 8 MODEL 75004R PARTS LIST Det # Part # Qty Det # Part # 1 75358 Hole Locator 1 59 75209 Roll Pin 1 2 75156 SCR-Set Screw 6 X 15mm 5 60 75255 Pump Cylinder 1 Description Description Qty 3 75157 Flat Washer 2 61 75054 Magnet 3 4 75063 Punch Carry Handle 1 62 75220 Gasket 1 5 75192 SCR-Set 10 X 10mm 1 63 75256 Retaining Ring 1 6 75191 Steel Ball 1 64 75086 Ball Bearing 1 7 75175 SCR-Wing M6 X 15mm 1 65 75055 Spacer 2 8 75162 Lock Washer 2 66 75088 Roller Bearing 1 9 75119 Strippers 2 67 75257 Retaining Ring 1 10 75908 O-Ring 1 68 75258 Pump Housing 1 11 75907 Retaing Nut 1 69 75090 Seal Washer 1 13 75091 Hex Nut M6 2 70 75107 SCR-SHC M10 X 15MM 1 14 75120 SCR-Set 6 X 15mm 2 71 75872 Washer 6mm 4 15 75121 “C” FRAME 1 72 75871 Screw SHC 6 X 50 mm 4 16 75122 Set Screw 6 X 6mm 2 73 75259 Oil Seal 1 17 75123 Steel Ball 2 74 75327 Ball Ring 1 18 75236 Set Screw 8 X 30mm 12 75 75874 Sub Plate 1 19 75159 Washer 8mm 14 76 75821 Armature 115v 1 21 75124 Back Up Ring 2 77 75328 Flat Washer 4mm 4 22 75909 O-Ring 2 78 75826 Screw SHC 4 X 20mm 4 23 75233 Back Up Ring 1 79 75822 Paper Washer 1 24 75234 Packing Rod Seal 1 80 75823 Ball Ring 1 25 75195 O-Ring 1 81 75824 Thrust Washer 16mm 1 26 75137 Oil Bladder 1 82 75825 Rubber Pin 1 27 75138 Bladder Screw 1 83 75827 Fan Guide 1 28 75190 O-Ring 1 84 75828 Screw 5 X 65mm 2 29 75188 Bladder Screw Bushing 1 85 75829 Field 115v 1 30 75155 Lock Washer 10mm 1 86 75830 Field Support Set 1 31 75138 Bladder Retaining Screw 1 87 75831 Brush Cap 2 32 75099 Roll Pin 2.5 X 10mm 1 88 75832 Carbon Brush (pair) 1 33 75135 Punch Piston Key 1 89 75864 Warning Tag 1 34 75196 Punch Return Spring 1 90 75834 Anti Vibration Rubbers (B) 2 35 75197 Punch Piston 1 91 75865 Caution Tag 1 36 75198 Valve Seal Nut 1 92 75835 Flat Washer 5mm 4 37 75199 Valve Seal Bolt 1 93 75836 Lock Washer 5mm 4 38 75200 O-Ring 2 94 75837 Screw SHC 5 X 25mm 4 39 75235 Packing 1 95 75329 Name Tag 1 40 75201 Spool Release Valve 1 96 75838 Motor Housing Set 1 41 75202 Valve Return Spring 1 97 75839 Handle Set 1 42 75203 Stopper Plate 1 98 75840 Label 1 43 75204 Release Valve Spring 1 99 75841 Pin 3mm 2 44 75205 Screw SHC 4 X 6mm 2 100 75842 Compression Spring 1 45 75206 Back Up Ring 1 101 75843 Rock Button 1 46 75207 Set Screw 5 X 5mm 9 102 75844 Switch 1 47 75208 Steel Ball 9 103 75845 Spacer 1 48 75241 Screw SHC 8 X 25mm 2 104 75846 Switch Lever 1 49 75048 A-J Pump Pistons are replaced by size and fit. The Pump Cylinder will need to be returned to Hougen Mfg. to determine the correct part. 105 75850 Anti Vibration Rubber (A) 4 106 75847 Runner Plate 1 50 75053 Piston Return Spring 3 107 75848 Cord Clamp 1 51 75050 CHECK VALVE 3 108 75849 Screw 4 X 18mm 2 52 75052 CHECK VALVE SPRING 3 109 75851 Screw 4 X 25mm 5 53 75325 Rubber Packing Seal 3 110 75852 Strain Relief 1 54 75326 O-Ring 3 111 75870 Power Cord 1 55 75160 Set Screw 6 X 8mm 2 112 75330 Work Stand 1 113 56 75047 Return Lever 1 57 75046 Return Valve 1 58 75085 O-Ring 1 75110 Foot Switch 1 75903 Pin Spanner 1 9 ROUND PUNCHES AND DIES 10 OBLONG PUNCHES AND DIES 11 Commercial / Industrial Limited Warranty Hougen Manufacturing, Incorporated warrants its Portable Magnetic Drills, Electro-hydraulic Hole Punchers for a period of (1) one year and other products for ninety (90) days from date of purchase against defects due to faulty material or workmanship and will repair or replace (at its option) without charge any items returned. This warranty is void if the item has been damaged by accident or unreasonable use, neglect, improper service, or other causes not arising out of defects in material or workmanship. No other expressed warranty is given or authorized. Hougen Manufacturing, Inc. disclaims any implied warranty of MERCHANTABILITY or FITNESS for any period beyond the expressed warranty and shall not be liable for incidental or consequential damages. Some states do not allow exclusions of incidental or consequential damages or limitation on how long an implied warranty lasts and, if the law of such a state governs your purchase, the above exclusion and limitation may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. To obtain warranty service, return the item(s), transportation prepaid, to your nearest Factory Authorized Repair Center or to Hougen Manufacturing, Inc., 3001 Hougen Drive, Swartz Creek, Michigan 48473. Hougen Drills (Rotabroach Cutters) are warranted against manufacturing defects only. Subject to Hougen Manufacturing inspection. THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE © 2012 Hougen Manufacturing, Inc. HOUGEN - OGURA PATENT NOTICE Photographs and Specifications shown are accurate in detail at time of printing. Manufacture reserves the right to make improvements and modifications without prior notice. Hougen, Hougen-Edge, Rotabroach, Punch-Pro, Trak-Star and the Hougen logo are proprietary trademarks of Hougen Manufacturing, Inc. Ogura and Ogura logo are proprietary trademarks of Ogura & Co., Ltd. Factory Warranty Repair Services can be obtained by sending your product to: Hougen Manufacturing, Inc. 3001 Hougen Drive Swartz Creek, MI 48473 Attn: Repair Department Hougen Manufacturing, Inc. 3001 Hougen Drive • Swartz Creek, MI 48473 Phone (810) 635-7111 • Fax (810) 635-8277 www.hougen.com • [email protected] © 2012 Hougen Manufacturing, Inc. OM75004R1111 Printed in U.S.A.
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