HANDY PUNCHER SERIES

Transcription

1 OPERATING/SAFETY ORIGINAL INSTRUCTIONS HANDY PUNCHER SERIES EP-1406V EP-1475V EP-19V EP-20S EP-2110V EPC-1518V EP-1475V EP-19V EP-2110V TO REDUCE THE RISK OF INJURY, YOU MUST READ AND UNDERSTAND THIS INSTRUCTIONS I KK CO., LTD , Ashitaka, Numazu-City, Shizuoka Pref. Japan Tel: Fax: international@diamond-ikk.com

2 CONTENTS PAGE GENERAL SAFETY RULES PARTS NAME SPECIFICATIONS PRE-SUE CHECKS RESTRICT USE TO PROPER MATERIALS TYPE OF WORKPIECE PRE-SUE CHECKS PUNCH/DIE SIZE AND MAX. MATERIAL THICKNESS EP-2110V EP-19V/EP-20S EP-1406V/EP-1475V REPLACE PUNCH AND DIE ADJUST WORKPIECE GUIDE BASE SAND RETURN VALVE LEVER (POSITON STOPPER) OPERATING INSTRUCTIONS POINT OF ATTENTION CLEANING OIL-LEVEL CHECK (ADD OIL) BOLT TIGHTNESS CARBON BRUSHES OVERHAUL THESE TOOLS ARE FOR INDUSTRIAL USE ONLY. 1

3 GENERAL SAFETY RULES WARNING: REARD AND UNDERSTAND ALL INSTRUCTIONS. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. The term power tool in all of the warnings listed below refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. WORK AREA SAFETY - Keep work area clean and well lit. Cluttered or dark areas invite accidents. - Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. - Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. ELECTRICAL SAFETY - Power tools plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. - Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. - Do not expose power tools to rain or wet conditions. Water entering a power tools will increase the risk of electric shock. - Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. - When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. - Do not use AC only rated tools with a DC power supply. PERSONAL SAFETY - Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. 2

4 - Use safety equipment. Always wear eye protection. Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. - Avoid accidental starting. Ensure the switch is in the off-position before plugging in. Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents. - Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. - Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. - Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. - If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. User of these devices can reduce dust-related hazards. - Keep handles dry, clean and free from oil and grease. Slippery hands cannot safely control the power tool. POWER TOOL USE AND CARE - Do not force the power tool. Use the correct power tools for your application. The correct power tool will do the job better and safer at the rate for which it was designed. - Do not use the power tool if the switch does not turn in on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. - Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. - Do not cover air vents or operate the tool on dirt. Use a plywood base under the tool to keep armature and fan clean. If the vents are covered, the motor will overhear and may burn out. - Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. 3

5 - Maintain power tools. Check for misalignment or binding or moving parts, breakage of parts and any other condition that may affect the power tools operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. - Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. - Use the power tool, accessories and tool bits etc., in accordance with these instructions and in the manner intended for the particular type of power tool, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. SERVICE - Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. SPECIFIC SAFETY RULES - Hold power tool by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a live wire will make exposed metal parts of the tool live and shock the operator. - Use clamps or other practical way to secure and support the workpiece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. - Never leave the trigger locked ON. Before plugging the tool in, check that the trigger lock is OFF. Accidental start-ups could cause injury. - Keep hand away from cutting area and moving parts. - Do not use dull or damaged blades, cutter blocks and rollers. Damaged part(s) can break easily or could cause injury. - Maintain labels and nameplates. 4

6 GROUNDING - WARNING: Improperly connecting the grounding wire can result in the risk of electric shock. Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded. Do not modify the plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the cord or plug is damaged. If damaged, have it repaired by a DIAMOND service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician. Grounded Tools (Single Insulated Tool): - Tools with Three Prong Plugs Tools have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet. If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock. The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool s grounding system and must never be attached to an electrically live terminal. Your tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. Double Insulated Tools: - Tools with Two Plugs. Tool marked Double Insulated do not require grounding. They have a special double insulation system. EXTENSION CORDS - Grounded tools require a three wire extension cord. Double insulation tools can use either a two or three wire extension cord. As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting loss of power and possible tool damage. Refer to the table shown to determine the required minimum wire size. Recommended Minimum Wire Gauge for Extension Cords 110 / 115V (50/60Hz) 230V (50/60Hz) Cable length Cable size (AWG) Nominal diameter Up to 10 m (25 ft.) mm² Up to 15 m (50 ft.) mm² Up to 30 m (100 ft.) mm² 5

7 PARTS NAME (EP-2110V) (EP-1475V) 1. Motor 2. Carbon brush (cap) 3. Switch 4. Safety switch lock 5. Pump case 6. Oil-plug bolt 7. Cylinder 8. Return valve lever (Position stopper) 9. Housing 10. Workpiece guide 11. Workpiece stopper 12. Punch 13. Die 14. Side handle 15. Base stand 16. Mount for side handle 6

8 SPECIFICATIONS MODEL EP-1406V EP-1475V Power Supply 100V/115V/230V AC 100V/115V/230V AC Wattage 1020 W 1020W Motor Double Insulated motor Double Insulated motor Max. hole size (round) 15 mm 15 mm Max. hole size (elliptical) 11x16.5 mm 11x16.5 mm Max. material thickness Fe 6 mm 6 mm Max. SUS 304 thickness 5 mm 5 mm Dimensions (LxWxH) 124x175x 381 mm 124x175x421 mm Weight 9.6 Kg 11.8 Kg MODEL EP-19V EP-20S Power Supply 100V/115V/230V AC 100V/115V/230V AC Wattage 1050 W 2500W Motor Double Insulated motor Double Insulated motor Max. hole size (round) 20 mm 21 mm Max. hole size (elliptical) 14x21 mm 14x21 mm Max. material thickness Fe 6 mm 8 mm Max. SUS 304 thickness 5 mm 6 mm Dimensions (LxWxH) 133x195x 484 mm 138x217x554 mm Weight 16.1 Kg 15.0 Kg MODEL EP-2110V EPC-1518V Power Supply 100V/115V/230V AC Rechargeable Battery * Wattage 2500 W Motor Double Insulated motor DC18V Max. hole size (round) 22 mm 15 mm Max. hole size (elliptical) 18.2x22 mm 11x16.5 mm Max. material thickness Fe 10 mm 6 mm Max. SUS 304 thickness 6 mm 5 mm Dimensions (LxWxH) 138x217x 554 mm 460x98x246 mm Weight 9.6 Kg 7.6 Kg Fe: SS400 *Recommended rechargeable battery: EB1830H (Ni-MH) 3.0Ah (Hitachi) 7

9 Models & Dimensions (mm) EP-1406V EP-1475V EP-19V EP-20S EP-2110V EPC-1518V A B * C * D E EP-2110V B C * AH Punch & Die: mm * W Punch & Die: * WH Punch & Die: RESTRICT USE TO PROPER MATERIALS These punchers are intended to cut holes in iron (SS400), stainless steel (SUS304) and soft metal (límite de elasticidad 216N/ mm², fuerza de tensión 520N/ mm²). No las utilice para perforar otros materiales, incluyendo madera, vidrio o plásticos. Intentar cortar materiales aparte de metales blandos puede resultar en lesiones para el operador o para otros en las cercanías. ADVERTENCIA: Siempre existe la posibilidad de que el material perforado se rompa o salga disparado, especialmente si el material es más duro de lo especificado. Exceder las especificaciones designadas del material incrementa sumamente el riesgo y también dexceeding designated material specifications greatly increase this risk and will also damage the tool. Do not attempt to use the tool for material harder, thicker or thinner 8

10 than those specified. TYPE OF WORKPIECE Flat Bxt(mm) EPC-1518V EP-1406V EP-1475V EP-19V EP-20S EP-2110V 25x6 B B B B B B 50x6 B B B B B B 65x6 B B B B 75x6 B B B B 100x6 B B 125x6 B 125x9 B Angle AxB(mm) EPC-1518V EP-1406V EP-1475V EP-19V EP-20S EP-2110V 25x25 A & B A & B A & B 30x30 A & B A & B A & B 40x40 A & B A & B A & B A & B A & B 50x50 A & B A & B A & B A & B A & B A & B 65x65 A & B A & B A & B A & B A & B 75x75 A & B A & B A & B A & B A & B 90x90 A & B A & B A & B 100x100 A & B 130x130 A & B Channel 9

11 HxB(mm) EP-1406V EP-1475V EP-19V EP-20S EP-2110V 75x40 B H & B B B H 100x50 B B H & B 125x65 H & B 150x75 B Lip Channel HxB(mm) EP-1475V EP-19V EP-20S EP-2110V 60x30 H H H H 75x45 B B H 90x45 B B H & B 100x50 B B H 120x60 H & B 150x75 B H Beam (10t) HxB(mm) EP-2110V 100x50 100x100 B 125x125 H & B 150x75 H 150x150 H & B 175x90 H 200x100 H & B 250x125 H & B 300x150 H & B 346x174 H & B 10

12 PRE-SUE CHECKS 1. WARNING: Do not expose the tool to rain or wet conditions. Water entering a power tools will increase the risk of electric shock. 2. Wear safety goggles, safety glasses with side shields or a face shield when using these tools. 3. Check that the power source is appropriate to the tool. CARE: If voltage is too high, the motor will burn out. If voltage is too low, insufficient power will be generated. 4. WARNING: Avoid accidental starting. Ensure the switch is in the off-position before plugging in.. Do not attempt to punch material by locking the ON/OFF switch to the ON position. This locking procedure is to be used only to warm the tool in cold climates. This is a safety issue and may cause damage to your tool. Always pull the ON/OFF switch by hand for each individual bend. 5. Check that cord is undamaged and that plug is not loose. CAUTION: Cut or abraded covering could result in a short and electric shock to operator. 6. Check and keep work area clean and enough work space. 7. Check condition of punch and die. Tighten up the set screw and nut for the punch and die, if loosen it. - CHECK FOR CRACKS OR DAMAGE, LOOSEN BOLTS, LOCK NUTS. 8. CAUTION: Inspect punch and die before each application. Faulty or loose punch and die could result in personal injury as well as damage to the tool. PUNCH/DIE SIZE (PARTS #.) AND MAXIMUM MATERIAL THICKNESS EP-2110V Round hole - iron (SS400) Standard Punch and Die Available on request (Refer page #.8) Thickness Size Punch Punch Die AH Punch W Die W AH WH Die WH P1104L 6P1164B P1105L 6P1165B 6P1105W 6P1165W 6P1105 6P1165L 11

13 P1106L 6P1166B 6P1106W 6P1166W 6P1106 6P1166L P1107L 6P1167B 6P1107W 6P1167W 6P1107 6P1167L P1108L 6P1168B 6P1108W 6P1168W 6P1108 6P1168L P1109L 6P1169B 6P1109W 6P1169W 6P1109 6P1169L P1110L 6P1170B 6P1110 6P1170L P1111L 6P1171B 6P1111W 6P1171W 6P1111 6P1171L P1112L 6P1172B 6P1112W 6P1172W 6P1112 6P1172L P1114L 6P1174B 6P1114W 6P1174W 6P1114 6P1174L P1117L 6P1177B 6P P11745L P1115L 6P1175B 6P1115W 6P1175W 6P1115 6P1175L P1116L 6P1176B 6P1116W 6P1176W 6P1116 6P1176L Max. thickness: 10mm (SS400), 6mm Stainless steel( SUS 304) EP-2110V Elliptical hole - iron (SS400) Thickness Size Punch AH Die AH P11225L 6P12025B 6 9 x P1124L 6P1204B 6 9 x 16 6P1125L 6P1205B 9 10 x 15 6P1126L 6P1206B 9 10 x 18 6P1127L 6P1207B 9 10 x 20 6P11272L 6P12072B 9 10 x 25 6P11271B 6P12071B 9 11 x P1128L 6P1208B 9 11 x 18 6P11280L 6P12081B x 25 6P1129L 6P12082B 9 12 x 20 6P1134L 6P1213B 9 13 x 19 6P1130L 6P1209B x 18 6P11311L 6P1216B x P1131L 6P1210B x 21 6P11318L 6P12161B x 22 6P11310L 6P1214B x P11312L 6P1217B x 22 6P11325L 6P12115B x 20 6P1132L 6P1211B x 22 6P1133L 6P1212B 12

14 Max. thickness: 10 mm (SS400), 6 mm Stainless steel( SUS 304) EP-19V /EP-20S Round hole - iron (SS400) Thickness Size Punch B Die A Die CB Die P P P P P P P P P1100 3P1160 3P P1101 3P1161 3P1141 3P1161C P1102 3P1162 3P1142 3P1162C P1103 3P1163 3P1143 3P1163C P P P P1104 3P1164 3P P1105 3P1165 3P1145 3P1165C P1106 3P1166 3P1146 3P1166C P1107 3P1167 3P1147 3P1167C P1108 3P1168 3P1148 3P1168C P1109 3P1169 3P1149 3P1169C P1110 3P1170 3P1150 3P1170C P1111 3P1171 3P P1112 3P1172 3P1152 3P1172C P1113 3P1173 3P1153 3P1173C P1114 3P1174 3P1154 3P1174C P1115 3P1175 3P1155 3P1175C EP-19V - Max. thickness: 6 mm (SS400), 5 mm Stainless steel( SUS 304) EP-20S - Max. thickness: 6 mm (SS400), 6 mm Stainless steel( SUS 304) A Dies are used for thin work piece (2.0~3.2mm) and B Dies are used for thick work piece (3.2~6.0mm). CB dies are for the channel bars. 13

15 EP-19V /EP-20S Round hole - iron (SS400) Thickness Size S Punch SB Die SA Die TB Die P1101S 3P1240 3P P1102S 3P1241 3P P1103S 3P1242 3P1222 6(8) P P P11630TB 6(8) P1104S 3P1243 3P1223 3P1164TB 6(8) P1105S 3P1244 3P1224 3P1165TB 6(8) P1106S 3P1245 3P1225 3P1166TB 6(8) P1107S 3P1246 3P1226 3P1167TB 6(8) P1108S 3P1247 3P1227 3P1168TB 6(8) P1109S 3P1248 3P1228 3P1169TB 6(8) P1110S 3P1249 3P1229 3P1170TB 6(8) P1111S 3P1250 3P1230 3P1171TB 6(8) P1112S 3P1251 3P1231 3P1172TB 6(8) P1113S 3P P1173TB 6(8) P1114S 3P P1174TB 6(8) P1115S 3P P1175TB EP-19V - Max. thickness: 6 mm (SS400), 5 mm Stainless steel( SUS 304) EP-20S - Max. thickness: *8 mm (SS400), 6 mm Stainless steel( SUS 304) (*Please use the S punch and TB die. Those punch and die are used only for EP-20S.) EP-19V SA Dies are used for thin stainless work piece (1.0~2.3mm). SB Dies are used for thick stainless, work piece (3.0~5.0mm) EP-20S SA Dies are used for thin stainless work piece (1.0~2.3mm), SB Dies are used with S punch for thick stainless work piece (3.0~6.0mm).. 14

16 EP-19V /EP-20S Elliptical hole - iron (SS400) Thickness Size Punch B Die A Die CB Die S Punch TB Die x 10 4P1120 3P1200 3P x 13 4P1121 3P1201 3P x 13 4P1122 3P1202 3P1182 3P1202C x 17 3P1123 3P1203 3P1183 6(8) 9 x P1124 3P1204 3P1184 3P1204C 3P1124S 3P1204TB 6(8) 9 x 18 3P1125 3P1205 3P1185 3P1125S 3P1205TB 6(8) 10 x 15 4P1126 3P1206 3P1186 3P1206C 3P1126S 3P1206TB 6(8) 10 x 20 3P1127 3P1207 3P1187 3P1127S 3P1207TB 6(8) 11 x P1128 3P1208 3P1188 3P1208C 3P1128S 3P1208TB 6(8) 12 x 18 3P1129 3P1209 3P1189 3P1209C 3P1129S 3P1209TB 6(8) 14 x P P P P11301S 3P12101TB 6(8) 14 x 21 3P1131 3P1211 3P1191 3P1211C 3P1131S 3P1211TB EP-19V - Max. thickness: 6 mm (SS400), 5 mm Stainless steel( SUS 304) EP-20S - Max. thickness: *8 mm (SS400), 6 mm Stainless steel( SUS 304) (*Please use the S punch and TB die. Those punch and die are used only for EP-20S.) A Dies are used for thin work piece (2.0~3.2mm) and B Dies are used for thick work piece (3.2~6.0mm). CB dies are for the channel bars. EP-1406V/EP-1475V/EPC-1518V Round hole - iron (SS400) Thickness Size Punch B Die A Die CB Die SB Die SA Die P P P P P P P1099 4P1159B 4P1159A P1100 4P1160 4P P1101 4P1161 4P1141 4P1240 4P P1102 4P1162 4P1142 4P1241 4P P1103 4P1163 4P1143 4P1163C 4P1242 4P

17 P P P P11635C P1104 4P1164 4P1144 4P1243 4P P1105 4P1165 4P1145 4P1165C 4P1244 4P P1106 4P1166 4P1146 4P1166C 4P1245 4P P1107 4P1167 4P1147 4P1246 4P P1108 4P1168 4P1148 4P1168C 4P1247 4P P1109 4P1170 4P1152 4P1169C 4P1249 4P1228 EP-1406V/1475V - Max. thickness: 6 mm (SS400), 5 mm Stainless steel( SUS 304) EPC-1518V - Max. thickness: 6 mm (SS400), 4 mm Stainless steel( SUS 304) A Dies are used for thin work piece (1.6~3.2mm), and B Dies are used for thick work piece (3.2~6.0mm). SA Dies are used for thin stainless work piece (1.0~2.3mm), and SB Dies are used for thick stainless work piece (3.0~5.0mm). CB dies are for channel bars. EP-1406V/EP-1475V/EPC-1518V Elliptical hole - iron (SS400) Thickness Size Punch B Die A Die CB Die x 9 4P P x 11 4P P x 10 4P1120 4P1200 4P x 13 4P1121 4P1201 4P1181 4P1201C x 13 4P1122 4P1202 4P x P1124 4P1204 4P1184 4P1204C 6 10 x 15 4P1126 4P1206 4P x P1128 4P1208 4P1188 4P1208C EP-1406V/1475V - Max. thickness: 6 mm (SS400), 5 mm Stainless steel( SUS 304) EPC-1518V - Max. thickness: 6 mm (SS400), 4 mm Stainless steel( SUS 304) A Dies are used for thin work piece (1.6~3.2mm), and B Dies are used for thick work piece (3.2~6.0mm). CB dies are for channel bars. CAUTION: Do not exceed maximum material thickness indicated in the tables as above. Do not punch stainless steel less than 1.0mm in thickness nor iron (or other soft metals) less than 0.8mm thick. 16

18 REPLACE PUNCH AND DIE WARNING: To avoid accidents always disconnect the tool from the power supply before replace Punch and Die or performing any maintenance. 1. Remove pre-fixed Punch and Die. The tool installed 14mm round AH punch and die for EP-2110V (11mm round punch and die for other models) from our factory. (unless this combination is required). To remove punch: 1Remove workpiece stopper. 2Loosen lock nuts for the punch. 3Using hexagonal wrench (allen key). Loosen retaining bolts (set bolts). 4Slide punch out. 17

19 To remove die: 1Loosen set screw for die. 2 Using hexagonal wrench (allen key). Loosen retaining screw (set screw). 3Slide die out. 2. Select and fit the appropriate punch and die (refer to preceding section P.11-16). CAUTION: Elliptical Punch and Die There are convex and concavity on the Punch, Piston end and Die. Don t smash the corner (edge). To fit die: 1 Slide die into housing. The side with the beveled edge and nomenclature should be facing outward make sure that die is properly seated on horizontal surface or lower housing and rear side is parallel to lip on housing. 2Using hexagonal wrench, tighten both retaining bolts (set bolt). 3Tighten both lock nuts. 18

20 To fit punch: 1Side punch into upper housing. Make sure that punch is properly seated with the nomenclature facing outward. To ensure proper alignment of elliptical punches and dies, elliptical punchers have a stepped upper surface which must fit properly into the channel (convex and concavity) in the upper housing. 2Using hexagonal wrench, tighten retaining bolts (set bolt) and tighten lock nuts. 3Then replace workpiece stopper. WARNING: Failure to correctly set the Punch and Die will result in quickly damage of Punch and Die and smash Piston end. ADJUST WORKPIECE GUIDE WARNING: To avoid accidents always disconnect the tool from the power supply before adjust workpiece guide. Adjust workpiece guide so that workpiece is positioned correctly. (Note that there are two bolts on the guide.) When positioning an angle bar or H-beam, it is important to leave a clearance of about 2mm between the inner vertical surface of the workpiece and the front vertical surface of the lower housing (jaw). See illustration below. If this clearance is not provided, movement of the workpiece during the cutting operation might cause the workpiece to become jammed. 19

21 Incorrectly positional workpiece Correctly positional workpiece BASE STAND If the puncher is being used mounted on the base stand, check the die surface is parallel to the stand. If necessary adjust the two level fix bolts and a support bolt located on the underside of the housing. RETURN VALVE LEVER (POSITION STOPPER) Check that Return valve lever (position stopper) is in the CLOSE position. (see photo below) Insert workpiece, making sure that it is perpendicular to the punch, and press switch. The punch will advance while the switch is depressed and stop when the piston is fully extended. Releasing the switch at this time shuts off the motor and cause the punch to return to its starting position. Releasing the switch before the piston is fully extended stop the punch at an intermediate position. Pressing the 20

22 switch again causes the punch to continue advancing. This feature enables the operator to precisely position the workpiece by stopping the punch just as it contact the workpiece and before it commences to cut. To retract the punch if the workpiece is misaligned, move the Return valve lever (position stopper) to the OPEN position. You can easily confirm the hole position. And adjust the punch throat depth by workpiece guide so that workpiece is positioned correctly. Also, In the event that the piston should fail to return automatically for any reason (jam), OPEN the release valve then gentry take out workpiece. OPERATING INSTRUCTIONS 1. Check the combination of Punch and Die. 2. Check that position stopper (pressure relief valve) lever is in the CLOSE position. 3. Adjust workpiece guide so that workpiece is positioned correctly. 4. Make sure the unit is plugged into the proper outlet 115V/230V 50/60Hz, (Please check the voltage of your Handy Puncher.) DIAMOND Handy Punchers are double insulated for operator safety but, to avoid possible electric shock, do not handle with wet hands or use tool in rain pr damp locations 5. WARM-UP: In low ambient temperatures, the unit should be warmed up before actual use. Simply press the switch and keep depressed for about 30seconds so that the hydraulic oil reaches the proper viscosity. 6. Insert workpiece, making sure that it is perpendicular to the punch, and pull the trigger-switch and keep depressed while the piston (punch) advances and cut workpiece. (If the switch is released at an intermediate point, the piston (punch) will stop.) WARNING: Keep hands away from moving parts while operating. 21

23 7. When the cut is complete, release the switch. The piston (punch) retracts automatically. (Note that the switch cannot be re-activated until the piston has fully retracted.) The Foot Switch is convenient to punch many. 8. WARNING: DIAMOND Handy Punchers are designed in such as way that the core will drop gently and not fly out. However, when cutting stainless steel, the core may be forcefully ejected. That use of safety barriers is strongly recommended. 9. Remove core from stand. Allowing core to pile up on the stand could prevent the punch from fully advancing. 10. Switch OFF. Disconnect tool from power outlet when not in use and before cleaning, adjusting or servicing. Do not disconnect plug from outlet by pulling the cord. Always check that the switch is OFF before plugging in. POINTS OF ATTENTION 1. If hydraulic oil exceeds 70 degrees C (158 degrees F) in temperature, power will drop. Allow tool to cool before resuming operation. [Be particularly careful in summer, when the pump case heats up quicker.] 2. Do not cover air vents. CARE: If vents are covered, motor will overheat and may burn out. 3. If a drop in power is observed and the motor is unusually hot, check the carbon-brushes. (See CARBON BRUSHES.) 4. If the piston should ever fail to retract completely. Unplug the tool. OPEN the release valve then gentry take out workpiece. Check the punch and die for accumulated dirt and iron filings that may be jamming the piston. If, after cleaning, the punch and die still does not automatically retract when fully extended, the piston itself may be damaged. Return the tool to an authorized distributor for repair. CLEANING Clean your tool every day, preferably immediately after use. WARNING: To avoid accidents always disconnect the tool from the power supply before cleaning or performing any maintenance. CAUTION: Wear gloves to protect hands from metal splinters. Do not use an air gun: blasting with air can cause metal filings and/or dust to get into eyes and respiratory system. Disconnect the unit. Wipe or brush away all dirt and metal 22

24 filings. Pay particular attention to the lower half of the piston, where dirt is more easily accumulated. OIL-LEVEL CHECK (ADD OIL) As the tool is hydraulically operated, the oil-level must be checked at preferably once a year. Failure to maintain the oil at the proper level results in a drop in pressure and loss of power. If there is no oil leak and oil level is too low, it is thought that there is the damage or shriveled of the Air bag. Replace new air bag. CAUTION: Hydraulic oil is highly flammable. Keep away from sparks and naked flame. Do not smoke. Hydraulic oil may cause inflammation of the eyes and skin. If ingested, it could cause diarrhea and vomiting. In case of eye contact, rinse in clean water for at least 15 minutes and consult a physician. In case of skin contact, wash thoroughly with soap and water. In case of ingestion, consult a physician immediately. Do not induce vomiting. 1. Oil should be warm but not hot. 2. If a piston still works, move piston and stop it just before the materials cut (a punch) off. (It is 2/3 movement of the piston.) 3. Unplug tool from the power source. 4. Remove oil-plug and seal-washer (packing). CAUTION: Never remove oil-plug when unit is hot or oil will spurt out. (EP-2110V) (EP-1475V) 5. Check that oil is level with bottom of plug hole (i.e. that pump case if full to the brim). If oil level is low, top up with fresh hydraulic oil with anti-foam and anti-abrasion properties (ISO viscosity grade VG46, e.g. Tellus46 (Shell), DTE-25 (Mobil) or Uni-Power VG46 (Esso). 6. After topping up, extract air from system. Gently tilt tool lengthwise and return it to a level position. Top up again and tilt in the opposite direction. Repeat this process 23

25 until all air has been extracted. CARE: Tool cannot function properly if oil contains air bubbles. 7. Replace oil-plug. The operation is now complete. 8. If oil level is too low, replace the plug and lightly tighten. Then connect the tool to power outlet. Switch ON to extend piston then release the switch when it has reached its full stroke. 9. When the piston is completely retracted in the start position. Disconnect the tool from the power supply. And remove the oil-plug to let overflows oil with air (bubbles). 10. Gently tilt tool lengthwise and return it to a level position. Slowly fill the tool with fresh oil again. Replace the plug and lightly tighten, connect the tool to power supply and advance the piston a few millimeters. Again remove the oil-plug. Top up oil-level and replace the plug. 11. Repeat this process until the pinch a workpiece, stopping just before it cut (punch) off. (It is a 2/3 movement of piston.) Then check that oil is level with bottom of plug hole. This is full level of oil. CARE: Be careful not to pour too much oil. CARE: Tool cannot function properly if oil contains air bubbles or too much oil. 12. Replace the oil plug and tighten it. 13. The operation is now complete. NOTE: Dispose of hydraulic oil in accordance with local regulations. Do not pour into the sea, a river, a lake or drains. BOLT TIGHTNESS Once a week, or after every 500 cuts (punch), check the tightness of all bolts. Especially those bolts fitting screw and nuts for the Punch/Die and securing the housing to the cylinder. Loose bolts will damaged part(s) can break easily or could cause injury. CARBON BRUSHES Inspect the two carbon brushes at least once every two months. (Nominal brush life is 200 hours). 24

26 (EP-20S, EP-19V and EP-2110V) (EP-1406V and EP-1475V) CARE: Worn brushes will result in power loss; cause the motor to run hot and irreparably damage the armature. 1. Disconnect tool from electrical outlet. 2. Unscrew both brush caps and pull out carbon brushes. 3. Replace brushes if less than 6mm in length. (We recommend the automatic stop carbon brush for the Model: EP-19V, EP-20S and EP-2110V.) Automatic stop carbon brush Parts #.7HTK999073B Standard carbon brush Parts #.7HTK999043B OVERHAUL Return the unit to an authorized distributor for overhaul at least once every two years, sooner if subject to heavy use. Ignorance of proper operating procedures can lead to accidents. If you have any other questions about any procedures, please contact the nearest authorized distributor. *Specifications are subject to change without prior notice. 25

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