Piranha P120 Ironworker Manual

INSTRUCTIONS
AND
REPAIR PARTS MANUAL
FOR
PIRANHA
IRONWORKER
MODEL NO. P-120
Publication December, 2004
For Serial Numbers
P120-1054 to Current
www.piranhafab.com
800-338-5471
Be sure to register your
model and serial number to
receive Piranha Service
and Product Updates.
Piranha Optional Tooling
Enhance your Piranha’s versatility!
• Oversize Punch Attachments
o Expand your punching capacity up to 5”
•
Quickset Gauging Tables
o Allows you to quickly set up your punch end
for multiple holes.
o Includes an angle gauge bar to index off of the
heel of your angle and a plate gauge bar which
indexes off of the end of your plate.
o Extensions are available in left and right hand
styles in 5’ and 10’ lengths.
•
Backgauges
o Allows you to quickly set your machine up to
repeat your shearing length by adding a
mechanical backstop.
o Backstop can be positioned in either the angle,
flat bar or round bar section of the machine.
o Available in lengths of 3’, 6’, 9’ or 12’
o An electronic version is also available, which
cycles the machine automatically when
material makes contact with the backgauge
probe.
•
Pipe Notching Attachment
o
o
o
o
•
Allows you to single notch Schedule 40 Pipe.
A must have for hand rail jobs.
Attaches to the punch end of the machine.
Notching dies available for ¾”, 1”, 1 ¼”, 1 ½”
and 2” Schedule 40 Pipe.
Oversize Bending Attachments
o Expand your bending capacity to 24” on most
models.
o Includes a 4-way die block for different
thicknesses of material.
***Additional Options Shown on Inside of Back Cover***
INSTRUCTIONS
AND
REPAIR PARTS
MANUAL FOR
PIRANHA
IRONWORKER
MODEL NO. P-120
Publication December, 2005
MEGA MFG. INC.
P.O. Box 457
Hutchinson, KS 67504-0457
Ph 800-338-5471
FAX 620-669-8964
www.piranhafab.com
1
TABLE OF CONTENTS
Refer to second section of this manual for information on repair parts breakdown and ordering repair
parts.
Page No.
PIRANHA OPTIONAL TOOLING (PAGE 1) .................................................................. INSIDE FRONT COVER
FORWARD ........................................................................................................................................................3
WARRANTY .......................................................................................................................................................3
SAFETY PRECAUTIONS .....................................................................................................................................4
ANSI INFORMATION ........................................................................................................................................5
INTRODUCTION .................................................................................................................................................6
MACHINE SPECIFICATIONS .............................................................................................................................7
FUNCTIONAL DIAGRAM ..................................................................................................................................8
DIMENSIONAL DATA ........................................................................................................................................9
INSTALLATION ................................................................................................................................................10
Location ......................................................................................................................................................10
Foundation....................................................................................................................................................10
Wiring ......................................................................................................................................................10
Lifting
......................................................................................................................................................10
Assembly ......................................................................................................................................................10
LUBRICATION .................................................................................................................................................11
General ......................................................................................................................................................11
Lubrication Diagram...................................................................................................................................11
MAINTENANCE................................................................................................................................................12
Hydraulic Filter Element ............................................................................................................................12
Fasteners and Connections .........................................................................................................................12
Hydraulic Oil Level .....................................................................................................................................12
TROUBLE SHOOTING................................................................................................................................ 13-15
PUNCH TONNAGE CHART ..............................................................................................................................16
TOOL LIST ......................................................................................................................................................17
PUNCH & DIE CLEARANCE CHART ..............................................................................................................17
OPERATING INSTRUCTIONS .................................................................................................................... 18-22
ORDERING INSTRUCTIONS ............................................................................................................................23
REPAIR PARTS ILLUSTRATIONS................................................................................................................ RP1
SERVICE RECORD CHART ....................................................................................................................... RP25
PIRANHA OPTIONAL TOOLING (PAGE 2) .................................................................... INSIDE BACK COVER
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
REPAIR PARTS ILLUSTRATIONS
BASIC UNIT
................................................................................................................................................. RP2
HOLD DOWN ASSEMBLY ........................................................................................................................... RP7
PUNCH ASSEMBLY ...................................................................................................................................... RP9
12” BENDING ATTACHMENT ................................................................................................................... RP11
ELECTRICAL ENCLOSURE ....................................................................................................................... RP14
ELECTRICAL SCHEMATIC ....................................................................................................................... RP15
FRONT BOX ASSEMBLY ........................................................................................................................... RP17
REAR BOX ASSEMBLY ............................................................................................................................. RP18
VALVE BODY ASSEMBLY ......................................................................................................................... RP19
HYDRAULIC SCHEMATIC ......................................................................................................................... RP20
MOTOR, PUMP AND FILTER ASSEMBLY................................................................................................. RP21
CYLINDER ASSEMBLY .............................................................................................................................. RP22
ELECTRIC FOOT PEDAL ASSEMBLY ....................................................................................................... RP23
KNIFE LIST ............................................................................................................................................... RP24
RP-1
RP-2
RP-3
RP-4
RP-5
*** This Page Intentionally Left Blank ***
RP-6
RP-7
RP-8
RP-9
RP-10
RP-11
RP-12
RP-13
RP-14
RP-15
*** This Page Intentionally Left Blank ***
RP-16
FRONT BOX ASSEMBLY
PART # 02316292-1
Figure And
Index No.
Part
Number
RP -1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
05316291
0531608
0531609
0531644
05316451-1
0531616
05316101-1
05316111-1
05316121-1
0531618
0531619
05316461
0531654
0531657
05316781-1
0531678-1
0531696-1
Description
Front Control Box - With Covers
Joystick 9001 K35
KA-1 Contact Block
KA-2 Contact Block
Selector Switch ZB4BD3
Microswitch
Start Button ZB4BA3
Stop Button ZB4BL4
Contact Block w/base N.C. ZB4BZ102 (Contact # ZB4BE102)
4 Pole Receptacle
Toggle Switch
Legend Plate, Front-Off-Rear, ZB2BY2002
Liquid Tight Connector, 3/8"
JIC Grey Conduit
Flexguard
Quick Disconnect Plug
Contact Block ZB4BE101
Mtg Base w/2 ea N.O. Contacts * ZB4BZ103
Contact Block w/base ZB4BZ101 *
Qty.
1
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
* Replacement contacts for item # 18 requires 2 ea. # ZB4BE101, item # 19 requires 1 ea.
RP-17
REAR BOX ASSEMBLY
PART # 02316302-1
Figure And
Index No.
RP -1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
Part
Number
Description
Qty.
05316301
0531608
0531609
0531644
05316101-1
05316111-1
05316121-1
0531618
0531619
0531654
0531657
Rear Control Box - With Covers
Joystick 9001 K35
KA-1 Contact Block
KA-2 Contact Block
Start Button ZB4BA3
Stop Button ZB4BL4
Contact Block w/base N.C. ZB4BZ102 (Contact # ZB4BE102)
4 Pole Receptacle
Toggle Switch
Liquid Tight Connector 3/8"
JIC Grey Conduit
Flexguard
Quick Disconnect Plug
Contact Block w/base ZB4BZ101 (Contact # ZB4BE101)
1
1
2
3
1
1
1
1
1
1
1
1
1
1
0531696-1
RP-18
RP-19
VALVE BODY ASSEMBLY
PART # 0251530-1
Figure And
Index No.
Part
Number
RP - 1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
T3572
T3570
0531559-1
0551567-1
0531558-1
0541568-1
0551559-1
0551561-1
T3574
0541535-1
0541530-1
0351635
Description
Pilot Valve 2-way
Counterbalance Valve
Pressure Relief Valve 35/12.5
Check Valve
Single Pilot Piston Valve
Directional Control Valve 4-Way
Pressure Relief Valve 35/26
Solenoid Valve N.C.
Solenoid Coil 115V AC
Shuttle Valve
Valve Body
Valve Body Wiring Harness (not shown)
RP-20
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
P120 MOTOR ASSEMBLY
PART #0261600-1
Figure And
Index No.
Part
Number
RP - 1
-OR
-OR
-2
-3
-4
-5
AND 5
-6
-7
-8
-9
-10
-11
-12
-13
-14
0571660-1
0571662-1
0571665-1
0533539
05915701-1
0531081
0551511
0551512
0521550-1
0521551-1
0551507
0541532
0541534
0541542
0551523
0551521
0351635
Description
Qty.
20 HP Motor 220/440V (Hollow Shaft)
20 HP Motor 208V (Hollow Shaft)
20 HP Motor 575V (Hollow Shaft)
6801-16 Hyd Fitting
Hydraulic Pump
1/2 x 1 1/4 SHCS
6402-12-12 Hyd Fitting
6400-12-12 Hyd Fitting
Filter Assy 4" Pall
Filter Element 4" Pall
6803-12 Hyd Fitting
304-C-12 Hyd Fitting
6503-12-4 Hyd Fitting
Pressure Gauge PGD-25-5000S
30" Hose To Tank
55" Hose To Valve Body
Valve Body Wiring Harness (not shown)
LOW VOLTAGE
HIGH VOLTAGE
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
CANADIAN 600V
6
5
4
6
5
4
9
8
7
9
8
7
3
2
1
3
2
1
3
2
1
RED
WHT
BLK
RED
WHT
BLK
RED
WHT
BLK
RP-21
RP-22
FOOT SWITCH ASSEMBLY
PART # 0231628
Figure and
Index No.
RP-1
-2
-3
-4
Part Number
0531655
0531636
0531637
0531617
Description
Foot Switch
Cord Grip
16-4 SEO Cord
4 Pole Plug
RP-23
Qty.
1
1
1
RP-24
RP-25
Piranha Optional Tooling
Enhance your Piranha’s versatility!
•
Pressbrake Tooling Holders
o Allows you to use pressbrake punches and
dies in your ironworker for higher precision
bending.
•
Roller Feed Tables
o Available in 5’ lengths.
o Includes rollers for angle and flat bar sections.
o 20” wide flat rollers and 6” angles.
•
Channel Shear
o Attaches to the punch end of the machine.
o Removes a ½” slug for each cut.
o Slug must be slid out the front of the channel
shear after each cut.
o A pinned slide block is adjusted to
accommodate different widths of channel.
•
Channel Die Block
o Enables you to punch into the legs of channel
and other structural shapes.
o Mounts in place of your standard die block.
o Still utilizes your urethane punch attachment.
o Can be used in conjunction with offset dies to
punch very near to the web of your material.
RP-26
Additional
Fabricating Equipment
Single Operator
Ironworkers
36 to 120 tons
3 & 4 Roll
Manual/Hydraulic
Portable Presses
Dual Operator Ironworkers
35 to 140 tons
Punch Plasmas
Punch Presses
35 to 140 tons
Section Bending Rolls
Plasma Tables
Press Brakes
25 to 500 tons
Precision Press Brakes
25 to 500 tons
Hydro-Mechanical Shears
1/4˝ to 1/2˝
800-338-5471
www.piranhafab.com