PULLMAX 201-204 Before you start use your new Pullmax Machine, may we suggest that you read this manual carefully. tt contains the information you need to use and maintain your machine to its best advantage. If your follow the instructions given, the life of the machine will meet the requirements which you have the right to expect from a machine of this kind and, at the same time, the work it will produce will be of the highest quality.Table of contents Technical data P201, P202 ‘Technical data P203, P204 Dimensions Unpacking Electrical installation Control, cabinet Control panel Wiring diagram Operation Stroke lenght adjustment and tool lift Pneumatic tool lift P202, P204 Setting of number of strokes Lower toolholder Adjustment of lower tool holder Adjustment of cutting tools Feeding the plate Tool grinding Straight cutting Circle cutting Slot cutting Cutting of small radius Cutting of stainless steel Cutting of soft materials Free- hand cutting Beading Joggling Doming Louvering Flanging Bige bending, 45° and 90° Punching 19, 20 21,22 23 23 23 23 24 24 25 26 27 28 29Table of contents Nibbling Nibbling tool Oil mist lubrication unit Service manual Lubrication To change the V- belt Adjustment of variable speed drive Spare parts Stroke mechanism P201, P203 : a 202, P204 Pneumatic tool Lift P202, P204 Driving transmission Guide rails Tower toolholder Circle attachment Straight guide NibbLing tool O41 mist lubrication Lists Page 30, 32 32 33 34 35 36 37 38, 40, 42 39, 41, 42 43 44 45 46 47 48 49 50 51-61Technical data Maximum thickness of plate Tensile strength of plate N/mm? / tons p.s.i. cutting Start from edge of plate, strip width maximum 20 mn, 3/4" Start from edge of plate, strip width above 20 mm, 3/4" Start in center of plate, without starting hole Nibbling Start from edge Start in center Slot cutting Start from edge Start in center Joggling Beading Doming Louvering Flanging Edge bending 45° Edge bending 90° Punching, Capacity for 9 30 mm Cuts per minute Stroke length, mn of of of of plate plate plate late Electric motor, kW at 50 Hz Depth of throat, mm/inch Circle cutting Maximum diameter, mm/inch Minimum diameter, mm/inch Minimum diameter with extension for small circles, mm/inch Segment out: mn/inch Strip cutting with straight cutting g, Maximum radius, Largest width, ma/inch Smallest width, mm/inch 390/25 590/38 mn/inch mn/inch 7* 9/32" 6 7/32" 6 7/32" Be eye 5 3/16" 4,5 3/16" 3/16" 4 5/32" 4 5/32" due 2agel 4 5/32" 3,5 10 ga 3 12 ga 2,5 12 ga 3,5 10 ga 3 12 ga 3,5 10 ga 30 i2ga 3 12 ga 2,5 12 ga 3 12 ga 2,5 12 ga 2,5 12 ga 2 14 ga 3 12 ¢a 2,5 12 ga 2,5 12 ga 2 14 ga 2,5 12 ga Ziel aicay 400 = "4000 1,7- 7,0 0.067" ~ 0.276" 1,5 1070 42" 1050 41 5/16" 1355 5/16" 502" i 104s 41 1/8" attachment 1035 40 3/4 20 13/16" * Maximum @ mm/5/16" to be limited to short periodsDimensions y | H £ obs - Ly " Ta] % | Dimensions in mm/inch ...... |__p201, 202 7 |_P203, P204 a 1965 77 3/8" | 2260 30" 8 1708 67 1/2" 1785 70 1/2" c 800 31 1/2" 800 31 1/2" D 1070 42" 1250 49" g 1000 4o" 1000 40" F 220 8 11/16" 220 8 11/16" 6 an 7/16" 1 7/16" K 1115 4a 1380 54 5/16 a 183 7asae 125 47/8" K 730 28 3/4" 730 28 3/4" L 9 24 s/s" | 9 24 15/16 Weight 1040 kg 1260 kg | 2290 ibs 2775 lbsUnpacking Remove the top- and side walls of the packing if the machine is packed into a wood case. Loosen the machine and the bases from the bottom girder. Put the bases on a suitable place. Lift the machine in the lifting holes by means of hooks or tube pieces through the frame. Place the machine on the bases. Tighten the fitting screws. Level the machine vertically and horizontally with a spirit level. - Use machine shoes, compressed mashine felt or similar materiel, to absorb vibration. Electrical installation Check that the rated voltage of the motor and wiring agree with main voltage. The starting apparatus only protects the motor against overloadinc Fuses must therefore be connected in the power line before the machine, Correct rotation of the motor is anti clockwise when seen from the shaft end. Changing of motor voltage direct on the motor connec terminal board in the controlboxTa a Tere 3 4 al a is 3 on oa (NE Dat sau i bux ti 0 Gita y 5 me Dis aa «4 ww 8 m7 | rl | Al 1 obs t | pany omen a , y i y yp T 5 1 eA T 5 T faa Q ‘Aoqtpera-uette Aa{petd-uet tw Kajpeta-uatte Kalperg-uay ly AeTperg-uet Ty AeTpetg-ue ty AaTpesd-uaT Ty Ao[pead-uaT tv Ao Tpead-uaT Iv seTpexa-uaTTw Saypeag-vaTTw Satpera-ust Tw AsTpetg-ueT iy Aa [perd-uaT tw AoTpetd-uattw Ao [peag-usT Tw AoTpead-usT1y saTpera-uat Te A PESTS, AaTperd-uaTTw Aa[peag-uat ty Ae tpeaq-ust Tw aeinjoeynuey, Lo’eo"a0 eqed Tr #30 1 :ebed USTT LNSNOdWOD ZTTMAST-3008 Tox¢-9008 TOXe-d008 Tox¢-d008 "Izw-4008 vySIH-aa008 ‘Tcw-4008 oTxe-8008 Z4-S9008 ya-S4008 Toxe-g008 Tzv-s008 ¢TIMAST-3008 TOxe-a008 Tox¢-a008 Toxe-a008 ‘T2¥-4008 bpSLH-aa008 Te LOT OLee 90L9 99-€SLT-SZW-aP6T MISS*O BZ-TLOS €¥N6OH-OOT epeorie OTTEO6L satwa-€6T adAL, T prs ubts doqs Aouebzows YEOTA JeIUCD yEOTA FORINOD yBoTq WoeIUOD ayun qoequo3 woqyng doys Asuabzeumg qqyun yoeqU09 yeoTq 39e3U0D uoqang ysna uoqang ysng 4BOTA JORIOD ajun qaequ0D u6ts doqs Aouebzeug yeoTq eID 4ooTq WoRIUOD yeotq Jaequoy qqun 30RqU0D uoqang doys Aouebrowg doutoysuery, aayearq yTNo1TD yoayfus yoauuoasta tO30W qoqoequE9 pTa MSZ AOPZ QING QUBTT WIE qeyoos duet W6°2-0°T Aver yuarmmoIeAd uoTJeuTuOUET ge eo00EEe 68Zo00eEe 6gZ000E62 68 Z000E6e gecoonEsz SEEOODESZ B8zo00eEz LEZO00Ese zez000esz cezo00eee 68Z000E62 Bezo00eEz 9EEDNESZ 68Z000€67 68Z000E62 68z000E6z e8zo00cec Seeoo0eez gegtooeez PSpoooesz EOD EST Nzpoa0ese oseoovEsz nozsaveee NeT9O0Ce@ GOT TOOLEZ ow ANS: s- es- zs- s~ Tsb- 20- 10- THe a TH- Ta- weqE LEQOOONA:werberp 3pNozTo qstunp seuT tnd :q9afoza :zeui0y st) YaTMLSOGNT AWSAeqpera-uatty Aoqpeag-uat Tw Se|petg-uat Ty Aa [pexd-uat tw orxe-s008 ToOxZ-a008 "Tzw-a008 cens-Sa008 z eprs ret eoTq JoRIUOD yeoTq FOROS atun yoequ0D you Ts, LEZooueez 6gzo00Ese agzooorEz gecoo0eez ss~Operation Hand wheel for variator Stroke length lever. Tool lift P 201, P 203. Start and stop control buttons. Collet nuts for locking tools. Locking screw for lower tool holder. Sideway adjustment of lower tool holder. Screw for height adjustment of lower tool. Locking screw for guide rails. Guide rail adjusting screw for side ways adjustment. Lower tool holder adjusting screw. Control box. a Terminal box.Stroke length adjustment and tool lift Position Length Tool of lever of stroke Lift Rn inch mm inch aA 1 1,7 +067 0 2 2 +079 3 3 2118 4 4 +157 5 5 1197 6 6 +236 7 7 +276 B 2 079 c 5 +197 D 9 354 z 15 +590 a 201 203Setting of number of strokes The number of strokes per minute is adjusted by means of the hand wheel for the variator on the right side of the machine, The Red Scale is for short-stroke length and the Green Scale is for long-stroke length. The Scale for setting the stroke length is colourmarked accordingly. Green scale: 400 - 1500 strokes/min. Red scale: 1500 - 4000 strokes/min. Valid for 50 and 60-cycle. Choice of number of strokes For last pass, in order to planish. Opera Number 0 | strokes per minute | Bea * | creen CUEEIng, thin plate 3000 heavier plate 1000 | Nibbling 400 | Slot cutting, | : thin plate 3000 | | heavier plate 1000 Joggling 3000* 1500 Beading 3000* 1500 Oo: Doming 3000* 500 Louvering 3000* | 1500 Flanging 3000* | 700 Bdge bending 3000* 700 | Lock forming 1000 iLower tool holder There are two different lower tool holders for Pullmax P201-204. The tool holder as shown in figure 1:1, is used for the cutting tool. This holder can be fitted with the lower tool outside (1:1 a) or inside (1:1 b) the upper tool. See also under "Straight cutting" and "Circular cutting". This tool holder is known as the standara block. For all other working operations the tool holder shown in figure 1:2 is used and this is known as the centre block. om] neh oO. Fig. 1:lbAdjustment of lower toolblock and tool block holder Front and back adjustment. To obtain side clearence between the cutting tools, the adjusting screw on the left hand of the tool block holder is screwed in or out. igure top left. It is then locked in position by a locking screw on the raight hand of the tool block holder. Figure bottom left. Side ways adjustment. Certain tools requiré very accurate setting and to ensure that this is possible, the tool block holder has been designed to have sideways adjustment. This is carried out by loosening the four retaining screws and turning the ecceritric Figure top right. fter the correct position has been obtained, the four retaining screws should be tightened. Figure bottom right.PULLWAX IN USE Adjustment of Cutting Tools Different types of plate require a different amount of side~clearance (a). The gap between the upper and lower tool (b), and the appropriate strokelength, {c) has also the be worked out. The below table gives a guide to the combinations of settings, t, a, b and c for edge cutting of mild steel. For inside cutting of tougher and softer materials, a reduction of the a and b measurements and an increase of the stroke length c is necessary. t mm inch “| a b c T 0,05 [0,5 | 1,7 20ga | 0,002 | 0,020 | 0,067 2 0,4 fi,0° J 1,7 14ga 0,004'| 0,040 | 0,067 3 0,2 11,5 | 2/0 1/3" 0,008 | 0,060 | 0,079 as 4 0,3 [2,0 | 2,0 SSS 5/32" | 0,012 | 0,080 | 0,079 # 5 0,4 12,5 13,0 3/16" | 0,016 | 0,100 | 0,118 6 05 |3,0 |3,0 7/32" | 0,020 | 0,120 | 0,118 7 0,6 3,5 | 4,0 9/32" | 0,024 | 0,140 | 0,157 8 0,7 | 4,0 15,0 5/16" | 0,028 | 0,160 | 0,197 Feeding the plate The plage should be tilted at an angle of 1° to 2°.this applies to all cutting operations when using the standard type of cutting tools, Tool Grinding The cutting edges of the tools should be kept sharp. The cutting angle has been carefully worked out and should be maintained when regrinding. The angle can be checked by means of a grinding gauge. Grinding should be carried out with care, ensuring that tools are not overheated, which would cause a lose of hardness through annealing. Use a medium grade grinding wheel and stone the cutting edge after grinding.