SOP-EQ-004 Rev 1 · Issued 2026-05-24 · Next review 2028-05-24

Geka Hydracrop 55 Ironworker

Equipment: Geka Hydracrop 55 Ironworker (EQ-004)
Location:
Approved by: Marty Howe, Welding Instructor
Approval date: 2026-05-24
Linked records: · ·
Standards basis: OHSA s.25; O.Reg 851 s.24 (machine guarding), s.31 (foot-operated controls), s.85 (lockout), s.105 (PPE); CSA Z460-13 (LOTO — 600V); CSA Z432 (Machine Safeguarding — ironworker / power-press category); CSA Z142 (referenced — mechanical power presses, adjacent guidance for guarding); CSA W117.2 cl. 9; CSA Z94.3; CSA Z94.2.

Machine Specs

MachineGeka Hydracrop 55 Series — Hydraulic Ironworker (confirm exact variant from nameplate)
Punching Power60 US tons (independent punch cylinder)
Shear Power110 US tons (angle, flat bar, bar cutter stations)
Punch SPM~25 strokes per minute
Punch Stroke2-3/8"
Motor4–6.5 HP hydraulic motor (confirm from nameplate)
Electrical230/460V 3-phase (confirm from nameplate)
Work Stations5 — punch, angle shear, notcher, flat bar shear, bar cutter
Simultaneous OperationTwo stations can operate simultaneously (two-cylinder models)
Weight~2,500 lbs
⚠ Danger This machine generates up to 110 tons of force. There are NO second chances at any work station. Hands and fingers must NEVER enter the die area while the machine is powered. One unintended foot pedal activation is enough to cause a fatal crush or amputation injury.

PPE Required

⊙ Safety Glasses + Face Shield — CSA Z94.3. BOTH required — flying slugs, scale, and punch fragments are common.
⊙ Steel-Toed Boots — CSA Grade 1. Slugs and scrap drop to floor level.
⊙ Cut-Resistant Gloves — Wear when handling cut material and tooling ONLY. Never wear gloves when hands are near active die area.
⊙ Hearing Protection — Hydraulic ironworker produces sustained impulse noise — hearing protection required.
⊙ No Loose Clothing — No loose cuffs, drawstrings, or jewelry near any station. Tuck in shirt.

Pre-Use Inspection

Reference

2. THE FIVE WORK STATIONS

Know the capacity and function of each station before using it. Never exceed rated capacity — overloading damages tooling and can cause structural failure.

STATIONCAPACITYMAX MATERIALTHROATNOTES
1 — Punching Station60 US tons1-1/2" Ø in 3/8" mild steel10–20" (confirm from nameplate)Punching holes in plate, flat bar, and structural sections. Independent cylinder — quick tooling change.
2 — Angle Shear (90°)110 US tons4" x 4" x 1/2" (or 5" x 3" x 1/2")—Shears structural angle without deformation. Do not shear material beyond rated capacity.
3 — Notching Station—3/8" thick × 3-1/2" deep × 1-5/8" wide—Rectangular corner notching. Can also be configured for pipe punching and special accessories.
4 — Flat Bar / Plate Shear110 US tons12" x 5/8" or 8" x 3/4" mild steel—Flat stock shearing. Blades on both ends of holder for stability. Radial blade system for high capacity.
5 — Round/Square Bar Cutter110 US tons1-9/16" rounds / 1-9/16" squares—Sections station. Standard blades also handle U, I, T profiles with optional blade sets.

5. OPERATING PROCEDURE → 5.2 Punching Station Operation (table content)

NOTE: If the punch does not strip cleanly and material remains on the punch — STOP. Do not force. Use the manual return if equipped. Notify instructor. Do not attempt to free material by hand while powered.

Overflow: 5.6 Notching Station

5.6 Notching Station

  • Confirm notching dies are correctly installed and aligned for the required notch dimensions.
  • Position material squarely against both gauge stops — X and Y.
  • Confirm hands are clear of both the punch and die faces.
  • Apply foot pedal. Machine notches in one stroke.
  • Remove material carefully — notched edges are sharp.

Operation

5.1 Startup

  1. Confirm pre-op checklist is complete.
  2. Turn main disconnect to ON.
  3. Press START / MOTOR ON button. Hydraulic pump will energize.
  4. Allow the hydraulic system to reach operating pressure before cycling — listen for pump to reach steady state (~10 seconds).
  5. Perform one NO-LOAD test cycle at the active station with no material present. Machine should cycle smoothly and fully return.

5.2 Punching Station Operation

  1. Confirm punch and die are matched and properly seated. Confirm stripper is set.
  2. Position material against the gauge stop. Confirm punch is centred over the desired hole location.
  3. Hands must be on the material, OUTSIDE the throat — not inside the die area.
  4. Apply foot pedal. Machine will punch and automatically strip material.
  5. Wait for full return before re-positioning material.
  6. Clear slugs from die periodically — do not allow slugs to accumulate in the die.

5.3 Angle Shear Station (90°)

  1. Confirm angle shear blades are in good condition — no chips or cracks.
  2. Insert angle iron into the shear guide with both legs seated correctly against the blade guides.
  3. Set the length stop for the required cut length.
  4. Confirm hands are outside the blade path and clear of the shear.
  5. Apply foot pedal. Machine shears in one stroke.
  6. Remove cut section and scrap. Inspect blade condition between cuts.

5.4 Flat Bar / Plate Shear Station

  1. Confirm blade gap is appropriate for material thickness.
  2. Slide flat bar or plate under the blade hold-down to the length stop.
  3. Confirm material is flush against the back gauge — diagonal material causes binding and blade damage.
  4. Hands behind the blade hold-down line before pedal activation.
  5. Apply foot pedal. Shear completes in one stroke.
  6. Support long material on both sides of the cut — unsupported material can pivot and strike the operator.

5.5 Round / Square Bar Cutter

  1. Confirm correct blades are installed for the bar profile being cut.
  2. Insert bar to the length stop. Do not allow bar to extend unsupported behind the machine.
  3. Confirm hands are clear. Apply foot pedal.
  4. Cut sections will drop — have a tray or support in place to catch them.

Prohibitions

Emergency Stop

Emergency Response (1) Press E-STOP. (2) Press STOP / MOTOR OFF — wait for hydraulic pump to fully stop. (3) Turn main disconnect to OFF. (4) For crush or amputation injury: DO NOT pull the injured limb. Apply direct pressure to bleeding. Call 911. Do not free entrapped limbs without EMS — wait for paramedics. (5) Tag-out machine. Do not restart until incident is documented and cleared by instructor.
🚨 For any crush, laceration, or entrapment: E-STOP first. Call 911. Do not move an entrapped limb — wait for EMS. Apply direct pressure to bleeding injuries. Notify instructor immediately.
SITUATIONRESPONSE
Hand / finger crush or amputationDO NOT pull the injured hand. Press E-STOP. Call 911. Apply direct pressure. Do not remove material trapping limb — wait for EMS if limb is trapped. Tag machine out.
Machine cycles unexpectedlyE-STOP immediately. Do not attempt to reset or restart. Tag out. Notify instructor and report the event — unexpected cycling is a serious electrical/hydraulic fault.
Hydraulic fluid leakPress E-STOP. Do not approach pressurized leak — hydraulic injection injuries are life-threatening. Power off at main disconnect. Notify instructor.
Slug / scrap ejectedIf injury: first aid immediately. Inspect work area before resuming. Ensure material is supported and scrap is cleared before next cycle.
Punch or die stuckPress E-STOP. Do NOT use hands to free stuck tooling. Use the stripper or appropriate tool per manual. Notify instructor before attempting removal.
Electrical fault / smoke / burning smellE-STOP. Main disconnect OFF. Evacuate area. Do not restart. Notify instructor immediately.

Lockout / Tagout

Full LOTO Required Before Servicing This equipment has hard-wired power, multiple energy sources, or stored energy. Apply formal LOTO procedure before any cleaning, maintenance, or service. Per CSA Z460-20 and O.Reg 851 ss. 137–139.
  1. Press E-STOP.
  2. Press STOP / MOTOR OFF.
  3. Turn main disconnect to OFF.
  4. Apply personal lock and tag to the main disconnect.
  5. Bleed hydraulic pressure: if equipped with a manual pressure relief, activate it. Otherwise, attempt a no-load pedal cycle with the motor off to exhaust residual pressure.

Post-Use

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Controls Applied — Hierarchy (CSA Z1002)
ELIM
Cannot eliminate. Punching, shearing, and notching at training scale require hydraulic ironworker.
SUB
Plate plasma + drill substitution viable for low-volume punching only. Shear and angle-shear operations have no feasible substitute. Bar cutter station: no substitute.
ENG
Foot pedal guard prevents accidental activation; station guards installed at non-active workstations; tooling alignment verified by station design; hydraulic pressure relief on overload; main disconnect = LOTO point; 600V isolation; two-station simultaneous operation locked out for training use (one-operator rule).
ADM
Pre-use checklist (§2); station-by-station authorization (instructor signs off each station individually before independent use); one-station-per-operator rule even on two-cylinder configurations; foot-off-pedal-when-not-cutting rule; LOTO required for any tooling change; tag-out on tooling defect; absolute no-hands-near-die-while-energized rule.
PPE
CSA Z94.3 + face shield mandatory — flying slugs, scale, punch fragments common; CSA Z94.2 hearing (impulse noise); CSA Grade 1 steel-toe footwear (slugs drop to floor); cut-resistant gloves for handling cut material ONLY — never wear gloves when hands are near active die area; no loose clothing, drawstrings, or jewelry; shirt tucked in.
Before you sign off on this machine

On the next page you will confirm you have:

If you are unsure about any step or any control on this machine, stop and ask the instructor before you sign off.
Sign off on the Geka Hydracrop 55 Ironworker →
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SOP-EQ-004
Confirm training — scan to sign off Scan this code to record your acknowledgment of this SOP. Required before independent operation.
SOP-EQ-004 · Rev 1
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UA Local 46 JTAC