30-8 Manual
Transcription
30-8 Manual
• 4 ½” Open Throat Punch • 8” Bar Shear with 4 Sided bar blades • Power Cavity accommodates various tooling • Fixed or Adjustable bar shear hold-down • Forklift accommodations • Magnetic starter for safety and reliability • • • • • • • PUNCH STATION Coper Notcher Pipe Notcher POWER CAVITY Brake: 6” Angle Shear Channel Shear Rod Shear (Round or Square) Z & T Shear Serial Number -_____________________ • • • • • • Punch nut wrench Bar Shear shop stop for production shearing to 24” Grease Bank for undercover lubrication Punch Rack holds up to 20 sets of Punches & Dies Steel bin catcher catches steel droppings from bar shear Offset die stand for punching close to the web Specify: Size of angle to be punched, largest diameter hole punched, and distance from web to center of hole. TABLE OF CONTENTS FOREWORD PAGE 1 MACHINE SETUP INSTRUCTIONS Machine Location Machine Preparation Electrical Connections GE Control Box General Wiring Schematic Lubrication 2-3 2 2 3 3.a 3.b 3 OPERATING INSTRUCTIONS Pre-Operating Instructions Practice Operations Operating the Model 30-8 Ironworker Punching Operation Sever Angle Shear Operation Bar Shear Operation 3-5 3 3-4 4 5 5 5 MAINTENANCE Punch Installation Punch and Die Alignment Machine Maintenance Machine Lacks Power 6-7 6 6 7 7 LUBRICATION Machine Components Hydraulic System Oil System Lines and Fittings Hydraulic Oil Change 7 7 7 7 7 7 TROUBLE SHOOTING Proper Care of Punches and Dies Lining up Punch and Die Lubrication Stripping Loose Nuts and Shank Troubleshooting Chart 8-9 8 8 8 8 8 9 TONNAGE CHART 10 WARRANTY 11 - Page 2 - TABLE OF CONTENTS ASSY # PAGE MAIN BODY ASSEMBLIES Punch Station Body Assembly with Arms Main Body Assembly Bar Shear Station Hold-down Power Cavity Station Base and Cover Assembly Foot Petal Linkage System Power Unit Hydraulics POWER UNIT ELECTRICS 3 Phase 480 volt 1 Phase 240 volt 3 Phase 240 volt SUB-ASSEMBLIES Sever Shear Housing Complete 1/4 X 3 X 3 Sever Shear Housing Complete 1/4 X 3 X 3 Sever Shear Blade Assembly Sever Angle Shear Blade Assembly Sever Shear Assembly Sever Channel Shear Assembly Sever Channel Shear Assembly - 1" Channel Sever Channel Shear Assembly - 1" Channel Sever Rod Shear Assembly Sever Rod Shear Assembly Coper Notcher 3 X 3 X 1/4 Angle Pipe Notcher Assembly Die Assembly 6" Punch Station Brake 6" Power Cavity Brake Complete Standard 100 Series Die Stand Assembly Stand Stripper Complete Offset Die Stand (S Series) Complete Oversize (1 - 1/2") Stripper Complete Oversize (1 - 5/8") Stripper Complete Punch Adjustable Jig Table Grease Bank L 100 Series Screw On Punch Wrench L 100 Series Punch Nut Wrench Retainer Nut Wrench Decal Kit IE Series Brochure Tooling Brochure Accessories Brochure 30-8-01 30-8-02 30-8-03 30-8-04 30-8-05 30-8-06 30-8-07 30-8-08 12-13 14-15 16-17 18-19 20-21 22-23 24-25 26-27 30-8-09 30-8-10 30-8-11 28-29 30-31 32-33 2609 2606 1922 1817 1820 1895 1819 1894 1896 1818 2579 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 55 56 57 58 59 60 61 62-63 2595 2590 2736 2379 2731 2761 3630 0240 1344 0431 0436 0669 30-8 Uni-Hydro Manual, Page 1 FOREWORD As the model 30-8 ironworker is a high quality product, Uni-Hydro, Inc. is concerned about future use of the machine and safety of the user. Therefore, all persons involved with the machine should read this manual and become familiar with proper set-up, operation and maintenance instructions. SAFETY Throughout this manual, safety, mechanical and some general information is emphasized. WARNING or CAUTION identify safety messages and indicate a safety message follows that must be read and thoroughly understood. HELP If help concerning set-up, operation, maintenance or safety is needed, contact your local Uni-Hydro dealer or Uni-Hydro, Inc., 800-3280036, for assistance. IMPORTANT: To gain full warranty benefits, immediately fill out and return the enclosed warranty registration form upon delivery of your machine. 30-8 Uni-Hydro Manual MACHINE SETUP INSTRUCTIONS MACHINE LOCATION For best performance, locate the ironworker on a stable, level surface. If a level surface is not available, level the machine as necessary. Use the built-in forklift slots located at the base of the ironworker to ease movement of the machine. Leave enough room around the machine to ease material handling while operating and ensure the area is well lighted for maximum safety conditions. MACHINE PREPARATION The machine is delivered with; Customer’s choice of one (1) L (100) series punch and die (not to exceed 1” O.D.) 3” X 3” X ¼” Sever Angle Shear 1. Remove all protective shipping material from: a. Bar Blades b. Angle Blades c. Angle Plunger d. Punch Plunger e. Cylinder 2. Inspect the ironworker for damage that may have occurred during shipment. If damage is found, notify the shipper that made final delivery immediately. They are solely responsible for all shipping damages. 3. Locate the punch and die (snap ring attached) and install; refer to Punch Installation. NOTE: 4. A die block is secured to the plate beneath the punch plunger by two (2) ½” X 1 ¼” bolts. Use a wrench for securing the jam nut and stripper then place in an easy to reach location for future use. IMPORTANT: Modifications made to the machine not authorized by Uni-Hydro, Inc., shall serve as just cause for all warranty to be voided. CAUTION Uni-Hydro has included a punch tonnage chart for this unit. The 30-8 ironworker has been designed for the purpose of shearing and punching Mild Steel Only. As a precautionary measure, please check the tonnage chart before performing any punching or shearing operation. The use of metals other than mild steel will void this ironworker warranty. DO NOT EXCEED 30 TONS. Page - 2 - 30-8 Uni-Hydro Manual MACHINE SETUP INSTRUCTIONS (Cont.) ELECTRICAL CONNECTIONS NOTE: To ensure proper hook-up of your ironworker and to meet local safety codes, we recommend that all electrical wiring of the ironworker be performed by a licensed electrician. IMPORTANT: (3 Phase wiring hook-ups only) If the ironworker fails to function when the start switch is first switched to ON, immediately return the switch to OFF or hydraulic pump damage may occur. The wiring connections might be reversed causing the motor and hydraulic pump to run counter-clockwise. Correct by disconnecting all electrical power to the ironworker and reversing the wiring hook-up. The ironworker is running properly when the motor shaft is rotating in the same direction as the arrow indicated on the pump. LUBRICATION Use No. 2 General Purpose Lithium grease to lubricate all sixteen (16) grease fittings on the ironworker before beginning operation. The fittings are in the following locations: 1. 2. 3. 4. Punch sleeve All arm pins Above and below Angle Shear Above and below arms OPERATING INSTRUCTIONS IMPORTANT: Never operate more than one work station at a time of the machine may be damaged and the warranty voided. PRE-OPERAION INSTRUCTIONS Before beginning operation, become familiar with the contents of this manual so you understand proper control operation, proper safety procedures and machine functions. Learn the procedures well before starting so as to either reduce or eliminate machine downtime due to incorrect operation. Chance of personal injury will also be minimized. PRACTICE OPERATION CAUTION Always wear safety glasses during operation and use any other safety related equipment that contributes toward prevention of personal injury. 1. Ensure others are clear of the ironworker and press the “ON” button in the switch box to start the electric and hydraulic systems. 2. Position yourself in front of the work station and depress the foot petal at the machine base until the hydraulic cylinder shaft extends approximately 4 ½ inches. Release the petal. Note the ironworker components stop in mid-cycle and returns to normal open position when the petal is released, a desired safety and operational factor. Page - 3 - 30-8 Uni-Hydro Manual OPERATING INSTRUCTIONS (Cont) 3. Depress and release the petal through a dozen or more short operational strokes until you feel in complete control of the ironworker. 4. When satisfied that the ironworker will be operated properly, refer to Operating the Model 30-8 Ironworker section and use it as a guide to proper operation. OPERATING THE MODEL 30-8 IRONWORKER 1. The Uni-Hydro Ironworker is designed to perform bar shearing, angle shearing, and punching of mild steel only. 2. Like any machine, there are limits to the work performance of an ironworker. Maximum operational limitations which should not be exceeded are as follows: a. Bar Shear – Flat bars of ¼” x 8” and ½” x 6”; Angle bars of 2” X 2” X ¼” b. Angle cuts – Sever Type: 3” x 3” x ¼” 3. To avoid damage to the ironworker and voiding of the warranty, NEVER perform more than one type of machine operation at one time. 4. Before beginning punch operation with a different size punch than previously used, refer to the schedule listing of punch and material limitations located on the side of the machine. WARNING To prevent personal injury, always keep hands clear of the bar shear, angle shear and punch work areas during operation Keep bystanders away while operating and stop the ironworker before leaving it unattended. Page - 4 - 30-8 Uni-Hydro Manual OPERATING INSTRUCTIONS (Cont) PUNCH OPERATION 1. Due to manufacturing deviations, some types of mild steel may be harder than normal. Apply a small amount of oil on the steel to help smooth the punching operation. During production punching, apply oil to the punch and die after every 8 to 10 holes are punched. 2. Whenever a change of operation is performed, check for proper alignment between the punch and punch hole in the die. Inadvertent movement of the die block may have caused punch misalignment. 3. Always remove the punch from the ironworker whenever the punching operation is completed. SEVER ANGLE SHEAR OPERATION 1. To avoid crooked cuts, adjust the hold-down bolt on the front of the housing so material to be sheared is level. 2. Be sure there are no obstructions in the shearing area before beginning operation. NOTE: The severing angle shear does not remove a slug (large amount) of material, thus material loss is minimal. NOTE: If the blades finish the return stroke slowly, remove the blades. Clean all slag from the housing, coat the blades with a light film of oil and re-install; refer to Removing and Replacing Sever Angle Blades. BAR SHEAR OPERATION NOTE: Rotate the blades as they dull so all four (4) cutting edges may be used. To help achieve maximum protection, adjust the stroke control to match material thickness. Maximum cut in the bar shear is: ¼” x 8” ½” x 6” 1. Hold down must be in place at all times when shearing flat bar. It may be removed when miter cutting angle iron. Use a clamp on bar shear table to hold angle iron in place. 2. Maintain .005 clearance on bar blades. 3. Bar blades have four (4) cutting edges on each blade. Turn blades and readjust to .005 clearances as needed. Page - 5 - 30-8 Uni-Hydro Manual MAINTENANCE CAUTION To prevent personal injury, disconnect electrical power to the ironworker before performing maintenance procedures. Should power be required during maintenance, take care to protect yourself and others from injury. PUNCH INSTALLATION 1. Loosen two (2) 3/8” bolts and swing stripper away. Remove punch jam nut, insert punch into proper adapter, replace the jam nut and tighten securely. 2. With stamped die side facing upwards, insert die into die holder and tighten the side set screw with an Allen wrench. 3. Completely loosen two (2) ½” x 1 ¼” (#4) bolts in die holder. 4. While holding die stand, run punch down making sure it is centered in the hole. Once the punch is through the die stand, shut the ironworker off. 5. Tighten the two (2) ½” x 1 ¼” (#4) bolts. 6. Operate the ironworker to check punch and die alignment. Correct as necessary. If operation is correct, shut machine off. Then proceed to operate ironworker. IMPORTANT: Always check punch and die alignment after replacing the punch. NEVER assume interchangeable punch and dies will properly align. See Punch and Die Alignment Procedures. PUNCH AND DIE ALIGNMENT (For machines without safety manual punch aligner) 1. 2. 3. 4. Completely loosen the two (2) ½” x 1 ¼” (#4) bolts securing die block. Start ironworker, lift die block and fit over secured upper punch. Run punch fully down and stop the ironworker. The hydraulic cylinder will hold the center plate down so proper clearance is achieved between the punch and die. Tighten the two (2) ½” x 1 ¼” (#4) bolts to secure the die in position. Depress foot petal and start the ironworker to hold punch into the die. Let the punch slowly raise and check for proper clearance between the punch and die at the point of entrance into the die. If clearance is incorrect, repeat steps 1 to 4. CAUTION When performing any other operation other than punching, it is recommended the punch be removed for safety and to prevent damage to the machine and or punch and die. Page - 6 - 30-8 Uni-Hydro Manual MAINTENANCE (Cont) MACHINE MAINTENANCE Grease ironworker every eight (8) hours of operation. This prevents steel shaving and slag buildup between the body plates and also reduces friction. Check and wipe all working areas clean before starting each day. MACHINE LACKS POWER 1. Check oil in tank. Oil capacity is fifteen (15) quarts of #303 industrial hydraulic oil. Fill to within 2 inches of top of tank. 2. Check linkage arm on pump unit for loose bolts or if linkage arm is bending. 3. Check V-Belt for slippage; adjust for ¼” space when pulling belt together in center. LUBRICATION HYDRAULIC SYSTEMS WARNING: Be careful working around hydraulic systems as components may be under extreme pressure. Fluid escaping under pressure from a very small hole can be almost invisible and have sufficient force to penetrate the skin. Search for suspected pressure leaks by using a piece of cardboard or wood. DO NOT USE HANDS. If injured by escaping fluid, consult a doctor immediately. Serious infection can result if proper medical treatment is not promptly administered. Oil Level After every forty (40) hours operation, remove the reservoir filler cap and check oil level. If the oil level is below two (2) inches from the top of the tank, add No 303 implement hydraulic oil until it’s at proper level. Lines and Fittings After every twenty (20) hours operation, inspect system lines and fittings for wear and/or leakage. Hydraulic Oil Change After every two thousand (2000) hours operation, drain and replace oil. Filters are also to be replaced. 1. Flush the reservoir and add approximately fifteen (15) quarts of No 303 implement hydraulic oil or equivalent. 2. When fresh oil has been added, start and briefly run the machine to circulate oil through the system. 3. Operate the controls to purge air from the system. 4. Stop the machine and check the oil level. Add oil as necessary. Page - 7 - 30-8 Uni-Hydro Manual, Page 8 THE PROPER CARE OF PUNCHES AND DIES PLEASE NOTE: Too often the failure of a punch is attributed to poor material or workmanship, when in reality the cause in most cases is due to the following: LINING UP PUNCH AND DIE It is of the utmost importance that the punch be aligned correctly with the die. This is easy to accomplish; at regular intervals during the day the punch can be lowered by hand to check if it is centered with the hole in the die. If this is not centered with the die, this needs to be corrected. The constant jarring and vibration of continuous punching is sufficient to cause a slight shift in either the punch holder or die socket. This is the MOST prevalent cause of all punch and die failure. LUBRICATION One of the main causes of punch flaking off is due to dry stripping. Dry stripping is when dry particles of punched material adhere or cling to the surface of the punch. These particles build up on the surface of the punch which then causes the punch to strip hard and finally break. It is necessary to lubricate or “swab” the punch. This facilitates easy punching and stripping and prolongs the life of the punch. STRIPPING Strippers that are rough and uneven on the bottom, or cocked, so that the stripping surface is not parallel with the plates, are the cause of a large percentage of premature punch failure. Very often the stripper is set too far back from the punch, which will cause the material to cock and also result in the destruction of the punch. LOOSE NUTS AND STEMS Special attention needs to be given to the fit of the coupling nut. If it is too free on the plunger it will not grip sufficiently and will work loose. In this case the punch will also be loose and is liable to strike the material in a cocked position. This is a dangerous situation and may result in snapping the punch. Punch plungers need to be given periodic inspections. 30-8 Uni-Hydro Manual, Page 9 TROUBLESHOOTING SYMPTOMS Machine runs, but doesn’t function Machine lacks power Machine leaks oil TROUBLE SHOOTING CAUSES Electrical wiring problem Low hydraulic oil level, faulty hydraulic pump linkage, faulty hydraulic spool valve, pump or electric motor Faulty hose and or hose ends, reservoir overfilled, damaged O-ring, cracked piston or scarred piston wall Foot pedal not fully released Machine will not complete stroke Punch keeps breaking in Stripper Assembly shank Punch tip shatters Punch jam nut shatters Loose punch plunger Stripper Assembly CORRECTIONS Have electrician check and correct Isolate and correct as necessary Isolate and correct as necessary Adjust stroke control; See Stroke control adjustment Assure stripper is not bent or misaligned Bar not being held level with die stand Operating stripper is not installed on machine Adjust front set screws on punch jig 30-8 Uni-Hydro Manual TONNAGE CHART APPROXIMATE PRESSURE FOR PUNCHING ROUND HOLE IN MILD STEEL HOLE DIAMETER 3/16" 5/16" 7/16" 1/2" 5/8" 11/16" 3/4" 13/16" 7/8" 15/16" 1" 1-1/8" 1-1/4" 1-1/2" PRESSURE IN TONS THICKNESS 18 GA 16 GA 14 GA 12 GA 10 GA 5/32" 3/16" 1/4" 3/8" 1/2" 5/8" 3/4" 1" 9/16" 0.5 0.6 0.7 1 1.3 * * * * * * * * 0.7 0.9 1.2 1.5 2 2.3 2.8 * * * * * * 1.6 2.1 2.6 3.6 4.6 5.4 6.4 8.6 12.8 * * * * 1.9 2.3 2.9 4.1 5.3 6.1 7.4 9.8 14.8 19.7 * * * 2.1 2.6 3.3 4.6 5.9 6.9 8.3 11.1 16.5 22 * * * 2.4 2.9 3.7 5.1 6.6 7.7 9.2 12.3 18.5 24.6 30.8 * * 2.6 3.2 4 5.7 7.3 8.4 10.1 13.5 20.2 26.9 33.7 * * 2.8 3.5 4.4 6.2 7.9 9.2 11 14.7 22.1 29.5 36.9 44.3 * 3.1 3.8 4.8 6.7 8.6 10 12 16 23.8 31.8 39.9 47.7 * * MATERIAL THICKNESS SHOULD NOT EXCEED PUNCH DIAMETER ** RATED 65,000 PSI TENSILE STRENGTH A36 MILD STEEL Page - 10 - 3.3 4.1 5.1 7.2 9.2 10.7 12.9 17.2 25.8 34.4 43 51.7 * 3.5 4.4 5.5 7.7 9.9 11.5 13.8 18.4 27.5 36.8 46 55.2 * 3.8 4.7 5.9 8.2 10.6 12.3 14.8 19.7 29.5 39.4 49.2 59 80 4 4.8 5 7 10 11 17 23 33 45 56 68 90 4.2 6 7.2 10 13 16 19 25 38 50 63 75 100 5.6 7 10 12 15 19 23 30 45 60 75 90 120 30-8 Uni-Hydro Manual, Page 11 WARRANTY UNI-HYDRO INC WILL, WITHIN ONE (1) YEAR OF DATE OF PURCHASE, REPLACE F.O.B. THE FACTORY, OR REFUND THE PURCHASE PRICE FOR ANY GOODS WHICH ARE DEFECTIVE IN MATERIALS AND WORKMANSHIP PROVIDED THAT THE BUYER RETURNS THE WARRANTY REGISTRATION CARD WITHIN THIRTY (30) DAYS OF PURCHASE DATE, AND, AT THE SELLER’S OPTION, RETURNS THE DEFECTIVE GOODS FREIGHT PREPAID TO THE SELLER, WHICH SHALL BE THE BUYER’S SOLE AND EXCLUSIVE REMEDY FOR DEFECTIVE GOODS. HYDRAULIC AND ELECTRICAL COMPONENTS ARE SUBJECT TO THEIR RESPECTIVE MANUFACTURER’S WARRANTIES. PUNCHES, DIES, AND/OR BLADES ARE WARRANTED TO BE FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP. THIS WARRANTY DOES NOT APPLY TO MACHINES AND/OR COMPONENTS WHICH HAVE BEEN ALTERED, CHANGED OR MODIFIED IN A WAY, OR SUBJECTED TO ABUSIVE AND ABNORMAL USE, INADEQUATE MAINTENANCE AND LUBRICATION, OR SUBJECTED TO USE BEYOND SELLER RECOMMENDED CAPACITIES AND SPECIFICATIONS. IN NO EVENT SHALL SELLER BE LIABLE FOR LABOR COSTS EXPENDED ON SUCH GOODS OR CONSEQUENTIAL DAMAGES. SELLER SHALL NOT BE LIABLE TO PURCHASER OR ANY OTHER PERSON FOR LOSS OR DAMAGE DIRECTLY OR INDIRECTLY ARISING FROM THE USE OF THE GOODS OR FROM ANY OTHER CAUSE. NO OFFICER, EMPLOYEE, OR AGENT OF SELLER IS AUTHORIZED TO MAKE ANY ORAL REPRESENTATIONS OR WARRANTY OF FITNESS OR TO WAIVE ANY OF THE FOREGOING TERMS OF SALE AND NONE SHALL BE BINDING ON SELLER. NOTE: UNI-HYDRO FLAT BAR SHEAR BLADES CARRY AN UNCONDITIONAL ONE (1) YEAR WARRANTY. PART # 1 2 3 4 5 6 7 2748 1854 1758 1766 1864 1866 1768 1890 DESCRIPTION DECAL KIT FOR 30-8 IRONWORKER CAUTION / TONNAGE CHART 30 TON BLACK SILVER CAUTION / MILD STEEL ONLY FLAG - RED/WHITE/BLUE 2 5/8" X 2 5/8" WARNING / STAND CLEAR IRON EAGLE IRONWORKER PLATE / MODEL & SERIAL - RED/ALUMINUM 3 3/8" X 2 3/4" QTY 1 3 1 1 1 2 1 IRON EAGLE SERIES SPECIFICATIONS 30-8 IRON EAGLE 55 IRON EAGLE Throat Depth 4 ½” 7 ¾” Punch ¾” hole in ½” 1 ¼” hole in 5/16” 1 3/8” hole in ½” 7/8” hole in ¾” Bar Shear ¼” X 8” ½” X 6” ½” X 14” ¾” X 4” 3” X 3” X ¼” 4” X 4” X 3/8” Angle Shear 90° - Slug Type - Server Cut Miter Angle 45° - Bar Shear - Slug Type 2” X 2” standard 1” X 2” standard 1” X 2” combined or 3” standard 5/8” 5/8” 1” 1” Coper Notcher 90° For 3” X 3” X ¼” angle For 3” X 3” X ¼” angle Pipe Notcher Sched 40 or 80 ½”, ¾", 1", 1 ¼", 1 ½", 1 ¾”, 2” ½”, ¾", 1", 1 ¼", 1 ½", 1 ¾”, 2” Brake 6” x ¼” 10” x ¼” Strokes per minute - light material - at max capacity 9 8 Hydraulics 1,000 psi 2,300 psi Oil Capacity 15 quarts 20 quarts Motor - Standard - Optional 3 HP, 1 or 3 phase 5 HP, 1 or 3 phase 24” 27” 50” 38” 43” 58” 880 lbs. 1,500 lbs. Channel Shear Rod Shear - Round (max) - Square (max) Dimensions - Width - Length - Height - Bar shear work ht. - Punch table top ht. - Cavity table top ht. - Notcher station working ht. Weight (net) 1-800-328-0036 For 66 ton & Up Over 20,000 Punch & Die Sets in-stock Punch up to a 4” diameter hole Can be made to your specifications Available for all punch nut sizes Over 20,000 Punch & Die Sets in-stock Holds up to 30 sets of L series Punches & Dies Use when punching with oversize punches ~ Offset die stand is required when punching close to the web on angle. Can be custom built to your specifications if you tell us (a) size of angle being punched, (b) largest diameter hole and (c) how close to the web hole will be located. For shearing up to 24” long pieces Extends table from 3” to 12” For greasing fittings under covers without removing covers For ironworkers up to 50 ton capacity For shearing up to 6’ long pieces For Accurate, High Production Punching Catches drop pieces from the bar shear