HYDRAULICSHEET METAL PUNCH

SET Model 94745

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011Visit our Web site at: http://www.harborfreight.com

Copyright 2006 by Harbor Freight Tools®. All rights reserved. No portion of thismanual or any artwork contained herein may be reproduced in any shape or form

without the express written consent of Harbor Freight Tools.

For technical questions, please call 1-800-444-3353.

®

©

TO PREVENT SERIOUS INJURY,READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Due to continuing improvements, actual product may differ slightly from the product described herein.

PRODUCT SPECIFICATIONS

SAVE THIS MANUALYou will need this manual for the safety warnings and precautions, assembly, operating,inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keepyour invoice with this manual. Write the invoice number on the inside of the front cover.Keep this manual and invoice in a safe and dry place for future reference.

UNPACKING

GENERAL SAFETY RULES

IMPORTANT SAFETY INSTRUCTIONS

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONSFailure to follow all instructions detailed in this manual may

result in serious personal injury.

SAVE THESE INSTRUCTIONS

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 2

WORK AREA

1. Keep your work area clean and well lit. Cluttered and dark work areas inviteaccidents.

When unpacking, check to make sure all the parts shown in the Parts List on page 10are included. If any parts are missing or broken, please call Harbor Freight Tools at thenumber shown on the front cover of this manual as soon as possible.

Item Description Punching Capacity Punching capacity: .118” thick sheet metal and stainless steel sheet (up to

2.4” diameter). Working Pressure 1,100 lbs. Maximum Hydraulic Oil Capacity

4.4 Oz. (130ml)

Stroke Length .09” Bolt Dimensions (2 Included)

19 x 9.5 (3-13/16” L x 7/16” ~ 3/4” Diameter) 19 x 19 (3-7/8” L x 3/4" Diameter)

Die Dimensions (2 Included)

1” Die = 2-1/16” Outside Diameter x 1-3/16” High (1” Inside Diameter) 1-3/4” Die = 2-5/16” Outside Diameter x 1-3/16” High (1-3/4” Inside Diameter)

Punch Dimensions (2 Included)

1” Punch = 2-1/16” Outside Diameter x 7/8” ~ 1” High 1-3/4” Punch = 1-3/4” Diameter x 1-1/4” ~ 1-3/8” High

Die & Punch Hardness

55 ~ 60 HRC

Overall Dimensions 14-1/4” L x 2-3/4” W x 4-7/8” H Unit Weight 17.75 Pounds

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 3

2. Keep bystanders, children, and visitors away while operating the HydraulicSheet Metal Punch Set. Distractions can cause you to lose control.

PERSONAL SAFETY

3. Stay alert. Watch what you are doing, and use common sense when operating apower tool. Do not use a power tool while tired or under the influence of drugs,alcohol, or medication. A moment of inattention while operating power tools mayresult in serious personal injury.

4. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keepyour hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, orlong hair can be caught in moving parts.

5. Do not overreach. Keep proper footing and balance at all times. Proper footingand balance enables better control of the tool in unexpected situations.

6. Always wear eye and hand protection. Wear ANSI approved safety impactgoggles and heavy duty work gloves when assembling and using this product.

TOOL USE AND CARE

7. Do not force the Hydraulic Sheet Metal Punch Set. Use the correct productfor your application. The correct product will do the job better and safer at therate for which it is designed.

8. Store idle tools and equipment out of reach of children and other untrainedpeople. Tools and equipment are dangerous in the hands of untrained users.

9. Maintain this product with care. Keep this product clean. A properly maintainedtool is easier to control. Do not use damaged tools and equipment. Tag damagedtools and equipment “Do not use” until repaired.

10. Check for misalignment or binding of moving parts, loose or broken parts,and any other condition that may affect the Hydraulic Sheet Metal PunchSet’s operation. If damaged, have the product serviced before using. Manyaccidents are caused by poorly maintained tools and equipment.

11. Use only accessories that are recommended by the manufacturer for yourmodel. Accessories that may be suitable for one product may become hazardouswhen used on another product.

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 4

SERVICE

12. Hydraulic Sheet Metal Punch service must be performed only by qualifiedservice technician. Service or maintenance performed by unqualified personnelcould result in a risk of injury.

13. When servicing the Hydraulic Sheet Metal Punch Set, use only identicalreplacement parts. Follow instructions in the “Inspection, Maintenance, AndCleaning” section of this manual. Use of unauthorized parts or failure to followmaintenance instructions may create a risk of electric shock or injury.

SPECIFIC SAFETY RULES

2. Maintain labels and nameplates on the Hydraulic Sheet Metal Punch Set.These carry important information. If unreadable or missing, contact HarborFreight Tools for a replacement.

3. Use the right product for the job. There are certain applications for which thisproduct was designed. Do not use small tools, equipment, or attachments to dothe work of larger industrial tools, equipment, or attachments. Do not use thisproduct for a purpose for which it was not intended.

4. Avoid moving parts during operation. Keep fingers and hands away fromdies, punches, and all moving parts.

5. .118 Inch (3mm) Gauge limit. Do not use the Hydraulic Sheet Metal Punch Seton metal thicker than .118 inch (3mm).

6. Industrial applications must follow OSHA requirements.

8. WARNING! The warnings and cautions discussed in this manual cannotcover all possible conditions and situations that may occur. It must be understoodby the operator that common sense and caution are factors which cannot be builtinto this product, but must be supplied by the operator.

7. Store idle tools. When not in use, store the Sheet Metal Punch Set in a clean,dry, safe location out of reach of children.

1. CAUTION! Always wear ANSI approved safety impact eye goggles whenusing the Hydraulic Sheet Metal Punch Set. Also, wear heavy duty workgloves and steel toe boots or shoes to avoid injury.

SAVE THESE INSTRUCTIONS

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 5

ASSEMBLY AND OPERATING INSTRUCTIONS

1. Hold the Oil Chamber (21) of the Sheet Metal Punch Set upward. Then, unscrewand remove the Oil Fill Knob (23). (See Figure A.)

2. Fill the Oil Chamber (21) with up to 4-1/2 ounces of hydraulic oil (not included).Then, replace the Oil Fill Knob (23). (See Figure A.)

OIL CHAMBER(21)

OIL FILL KNOB(23)

FIGURE A

3. Select the desired size of Punch (51, 52) to be used. (See Chart on page 9.)

4. Drill the Proper hole size for the punch to be made, depending on the materialused (steel sheet metal or stainless steel sheet metal).(See Chart on page 9.)

5. Select the proper size Bolt (54, 55) for the Punch (51, 52) to be used.(See Chart on page 9.)

6. Use the Bolt Tightener (53) provided to tighten the shorter, threaded end of theBolt (54, 55) into the Piston Rod (3). (See Figure B.)

FIGURE B

BOLT(54, 55)

BOLT TIGHTENER(53)

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 6

7. Insert the corresponding size Die (49, 50) over the Bolt (53, 54).(See Figure C.)

FIGURE C

8. Place the previously drilled sheet metal over the Die (49, 50). (See Figure D.)

FIGURE D

9. Tighten the Punch (51, 52) onto the Bolt (53, 54). (See Figure E.)

FIGURE E

PUNCH(51, 52)

DIE(49, 50)

SHEET METAL(NOT INCLUDED)

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 7

ACTIVE ROLLER (3)

10. Turn the Release Valve (7) clockwise to close. (See Figure F.)

FIGURE FRELEASE VALVE (7)

11. Use the Handle (24) to operate the Sheet Metal Punch Set. (See Figure G.)

FIGURE G

12. After punching the hole, release pressure by turning the Release Valve (7)counterclockwise. (See Figure F.)

13. Unscrew and remove the Punch (51, 52). Then, remove the sheet metal blank.(See Figure E.)

14. Repeat the previous Steps to make additional holes.

15. When finished, make sure to store the Sheet Metal Punch Set in its CarryingCase (56) and keep the Carrying Case in a dry, clean, safe location out of reachof children and other unauthorized people.

HANDLE(24)

INSPECTION, MAINTENANCE, AND CLEANING1. Before each use: Inspect the general condition of the Hydraulic Sheet Metal

Punch Set. Check for misalignment or binding of moving parts, damaged orloose parts, dull or worn Cutting Dies and Punches, and any other condition thatmay affect the tool’s safe operation. If a problem occurs, have the problemcorrected before further use. Do not use damaged equipment.

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 8

2. Periodically: Use grease to lubricate all moving parts of the Hydraulic SheetMetal Punch Set.

3. To fill the Oil Chamber: After frequent use, the Hydraulic Oil level within the OilChamber (21) may become low. And indication of this is when the unit does notextend to its full length. To add Hydraulic Oil to the Oil Chamber, open theRelease Valve (7). Raise the unit with its Oil Fill Knob (23) up. Unscrew andremove the Oil Fill Knob. Top off the Oil Chamber with Hydraulic Oil. Close theRelease Valve. Pump the Handle (24) slowly until Hydraulic Oil (and excess air)begins to flow out of the Oil Chamber. Then, firmly retighten the Oil Fill Knob.(See Assy. Diagram.)

4. To clean, use a clean cloth and mild detergent or non-flammable solvent. Then,dry.

5. CAUTION! All maintenance, service, and repairs not discussed in thismanual should only be performed by a qualified service technician.

TROUBLESHOOTING

Problem Possible Cause Possible Solution Unit not collapsing completely. 1. Air under Ram. 1. Open Release Valve. Pump rapidly

several times to bleed air out. Then, close Valve. Handle stroke only partly effective.

1. Air in Pump Chamber. 1. Open Release Valve. Pump rapidly several times to bleed air out. Then, close Valve.

Handle raises without effort. 1. Sticky or leaking Release Valve. 1. Remove and clean the Release Valve. Handle snaps back. 1. Sticky Delivery Valve. 1. Open Release Valve. Pump rapidly several times. Then,

close Valve. Unit not raising to full height. 1. Lack of Hydraulic Oil.

2. Sticky Delivery Valve.

1. Refill, and check for leaks. 2. Remove Pump from Base. Remove Valve unit. Clean or replace Ball Valves.

During each stroke Socket rises and falls.

1. Leaking Delivery Valve. 1. Tighten Pump, or replace steel Ball and/or Brass Seat and Copper Washer in Valve.

Socket not raising. 1. Release Valve open. 2. Sticky or leaking Intake Suction Valve. 3. Sticky or leaking Delivery Valve. 4. Lack of Hydraulic Oil. 5. Air under Ram.

1. Firmly close Valve. 2. Remove Pump, and clean Valve. 3. Remove Pump from Base. Remove Valve unit. Clean or replace Ball Valves. 4. Refill, and check for leaks. 5. Open Release Valve. Pump rapidly several times to bleed air out. Then, close Valve.

Unit not reaching capacity load. 1. Leaking Release Valve. 2. High pressure leaks at Pump or Valve.

1. Clean Release Valve. Then, firmly tighten. 2. Clean Release Valve. Then, firmly tighten. Remove and replace Pump.

Unit will not hold up to load. 1. Leaking Release Valve. 1. Clean Release Valve. Then, firmly tighten. 2. Remove Ram, and replace its Seal.

Unit will not lower the load. 1. Damaged Release Valve. 2. Bent Ram.

1. Remove, and replace Release Valve. 2. Remove, and replace Ram.

SPECIFICATIONS FOR HYDRAULIC SHEET METAL PUNCH SET

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 9

ST

EE

L S

HE

ET

STA

INL

ES

S S

TE

EL

SH

EE

T

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 10

PARTS LIST

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLYDIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER ORDISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HEOR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURERAND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULDBE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYERASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINALPRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OFREPLACEMENT PARTS THERETO.

NOTE:Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Part # Description Qty. Part # Description Qty. 1 Socket 1 29 O-Ring 1 2 Body 1 30 B/UP Ring 1 3 Piston Rod 1 31 B/UP Ring 2 4 Washer 1 32 O-Ring 2 5 Sleeve (I) 1 33 Circlip 1 6 Nipple (I) 1 34 Main Body 1 7 Release Valve 1 35 B/UP Ring 2 8 Plug 1 36 O-Ring 2 9 Washer 1 37 Spring 1 10 Ball (#3) 1 38 Ball (#4) 1 11 Sleeve (II) 1 39 B/Up Ring 1 12 Dowel Pin 1 40 O-Ring 1 13 Pin 1 41 O-Ring 1 14 Pipe (ERW) 1 42 Spring 1 15 Retainer 1 43 Tube 1 16 E-Circlip (I/D-5) 4 44 Mesh 1 17 Circlip (I/D-13.5) 1 45 O-Ring 1 18 Plunger 1 46 O-Ring 1 19 Ball (#4) 1 47 B/UP Ring 1 20 Nipple (II) 1 48 Washer 1 21 Oil Chamber 1 49 Die (1-3/4”) 1 22 Oil Filter 1 50 Die (1”) 1 23 Oil Fill Knob 1 51 Punch (1-3/4”) 1 24 Handle 1 52 Punch (1”) 1 25 Pin 1 53 Bolt Tightener 1 26 Spring 1 54 Bolt (19 x 9.5) 1 27 B/UP Ring 1 55 Bolt (19 x 19) 1 28 O-Ring 1 56 Carrying Case 1

ASSEMBLY DIAGRAM

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 11

NO

TE

:S

ome

part

s ar

e lis

ted

and

show

n fo

r ill

ustr

atio

n pu

rpos

es o

nly,

and

are

not

avai

labl

e in

divi

dual

ly a

s re

plac

emen

t pa

rts.

28

32

29

30

8

36

15

38

46

7

632

533

14

431

93

53

7

17

11

25

16

13

24

12

47

10

34 4

21

94

3

40

3918

48

20

41

21

22

44

45

12

5

27

23

SKU 94745 For technical questions, please call 1-800-444-3353 PAGE 12

WARRANTY

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards,and warrants to the original purchaser that this product is free from defects in materials and workmanship forthe period of ninety days from the date of purchase. This warranty does not apply to damage due directly orindirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, or to lack ofmaintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent,special or consequential damages arising from the use of our product. Some states do not allow the exclusionor limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

To take advantage of this warranty, the product or part must be returned to us with transportation chargesprepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If ourinspection verifies the defect, we will either repair or replace the product at our election or we may elect torefund the purchase price if we cannot readily and quickly provide you with a replacement. We will returnrepaired products at our expense, but if we determine there is no defect, or that the defect resulted fromcauses not within the scope of our warranty, then you must bear the cost of returning the product.

This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-33533491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-33533491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-33533491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-33533491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353

LIMITED 90 DAY WARRANTY