NCCER Certified Ironworker Study Guide, Exams of Welding Technologies

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NCCER Certified

Ironworker Study

Guide

TABLE OF CONTENTS

1.0 INTRODUCTION

The SCOTCHMAN IRONWORKER is a versatile, multi-purpose, shearing, punching and forming machine engineered for trouble free operation.

The design of the machine combines simplicity of operation with smooth, full stroke control.

The ability of the operator to control the machine’s direction of movement at any point in the stroke, (i.e. stop, jog or reverse) gives the SCOTCHMAN IRONWORKER a tremendous advantage over mechanical ironworkers.

There is no chance of the SCOTCHMAN IRONWORKER being accidentally tripped.

The hydraulic system operates at a maximum pressure of 1,500 PSI (103 BAR) and is protected from overload by a built in relief valve.

2.0 SAFETY PRECAUTIONS

1. The operators of this machine must be qualified and well trained in the operation of the machine. The operators must be aware of the capacities of the machine and the proper use of the hold down devices, strippers and guards provided with the machine.
2. All of the guards, adjustable restrictors and awareness barriers must be installed on the machine and kept in good working order. Promptly replace worn or damaged parts with authorized parts.
3. Never place any part of your body into or under any of the machine’s moving parts, strippers or hold devices.
4. Wear the appropriate personal protective equipment. Safety glasses are required at all times, whether operating, setting up or observing this machine in operation. Since heavy pieces of metal with sharp edges can be processed on this machine, the operators should also wear steel-toed shoes, tight fitting leather gloves and snug fitting protective clothing.
5. Strictly comply with all warning labels and decals on the machine. Never remove any of the labels and replace worn or damaged labels promptly.
6. Always disconnect and lockout the power when performing maintenance work or setting up any tooling on the machine. Follow the procedures outlined in the operator’s manual for setting up, changing or aligning any tooling on this machine.
7. Never operate this machine with dull or damaged tooling. Replace worn punches, dies and blades promptly.
8. Practice good housekeeping. Keep the area around the machine clean and well lit. Do not obstruct the operator’s position by placing anything around the machine that impedes the operator’s access to the machine.

9. Never modify this machine in any way without the written permission of the manufacturer.
10. Never leave this machine running unattended.
11. Always operate the flat bar shear and tooling station from the operator’s side (the side the electrical control is mounted on). Always operate the punch station facing the station, standing.

 Never operate any of the work stations from a sitting or kneeling position.

12. Set up a program of routine inspections and maintenance for this machine. Make all repairs and adjustments in accordance with the manufacturer’s instructions.

2.1 WARRANTY

SCOTCHMAN INDUSTRIES, INC. will, within one (1) year of the date of purchase, replace F.O.B. the factory or refund the purchase price for any goods which are defective in materials or workmanship, provided the buyer returns the warranty registration card within thirty (30) days of the purchase date, and, at the seller’s option, returns the defecti ve goods freight and delivery prepaid to the seller, which shall be the seller’s sole and exclusive remedy for defective goods.

Hydraulic and electric components are subject to their respective manufacturer’s warranties.

This warranty does not apply to machines and/or components which have been altered, changed or modified in any way or subjected to abuse and abnormal use, inadequate maintenance and lubrication or subjected to use beyond the seller’s recommended capacities and specifications.

In no event shall the seller be liable for labor cost expended on such goods or consequential damages.

The 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 the seller is authorized to make any oral representations or warranty of fitness or to waive any of the forgoing terms of sale and none shall be binding on the seller.

Any electrical changes made to the standard machine due to local electrical code variation must be paid by purchaser.

As we constantly strive to improve our products, we reserve the right to make changes without notification.

4.0 INSTALLATION AND SET-UP

 CAUTION: THIS SECTION DISCUSSES INSTALLATION AND SET-UP PROCEDURES.

PLEASE READ ALL SECTIONS OF THIS MANUAL THOROUGHLY BEFORE OPERATING

THIS MACHINE.

4.1 PHYSICAL DIMENSIONS

INCHES CM

A Floor To The Top Of Die Holder 36.5 93

B FLoor To Punch Bolster 33.5 85

C Throat Depth 6 15

D Floor To Bar Shear 26 66

E Floor To Tool Table 35 89

F Floor To Angle Shear 36.5 93

G Punch Stroke 15/16 2.

H Height 53 132

I Length 48 122

J Width 26 65

K Weight 1,170 LBS. 532 KG.

4.2 MACHINE MOVING PROCEDURE

 CAUTION: BE SURE THAT ANY LIFTING DEVICE HAS ADEQUATE CAPACITY BEFORE

ATTEMPTING TO MOVE THIS MACHINE.

The weight of this machine is 1,170 pounds (532 KG).

FIGURE 3 ON THE FOLLOWING PAGE DEMONSTRATES THE USE OF AN OVERHEAD LIFT

OR A FORK LIFT. These are the only two recommended methods of moving this machine.

When using a fork lift, spread the forks of the lift as wide as possible for stability.

Lift only on the tubing side rails or under the skids provided. Do not back away from the machine with

the forks tilted up. This may cause damage to the interior components of the machine.

4.3 PHYSICAL INSPECTION

Any damage to the machine during shipment should be reported to the delivery carrier immediately

and a damage report made out so a claim can be placed. The carrier is responsible for shipping

damage, but it is the customer’s responsibility to report damages, external or internal, immediately.

After the machine has been positioned, the shroud on the operator’s side should be removed and an

inspection made of the interior for missing or damaged parts.

CHECK SPECIFICALLY:

1. The foot pedal linkage should operate freely, all pins and keys in place.
2. The spool should work freely in the valve.
3. Check all fasteners, especially on the motor and pump, to be sure they are tight.
4. Check the motor base and foot pedal for damage.
5. Check the re-pack box for all accessory items ordered with the machine.

SERIAL # 4678M691 & UP

FIGURE 4

FIGURE 4A (SWITCH BOX WIRING DIAGRAM)

4.6 STROKE CONTROL ADJUSTMENT

The stroke adjustment is important for the proper operation of the machine. If the setting has

changed, the machine may over travel and cause the hydraulic cylinder to "bottom out". This

continued condition will cause the starter overload to open. It can also cause the hydraulic oil to

overheat and damage hydraulic system components. A slight change in the setting can result in

inadequate stroke to operate optional tools.

A check of the stroke setting is made at the connecting link pin (D). SEE FIGURE 5 ON PAGE 19.

1. Place the stroke control handles (A) in their outermost position.
2. Place the disconnect switch (B) in the ON position and power the machine.
3. Place the selector arm (F) in the SHEAR position and allow the arms to travel to the up position.

Turn OFF the power to the machine.

4. Measure the distance from the top of the tool table (E) to the center of the connecting link pin (D).

The measurement should be 11-15/16 inches (30 cm).

REFER TO FIGURE 5 FOR A VISUAL REFERENCE.

5. If this measurement is not correct, turn the adjustment clevis (C) on the hydraulic control valve.

Turning the clevis clockwise will move the measurement up; turning the clevis counterclockwise will

bring the measurement down.

6. After turning the clevis, power the machine and cycle it once with the foot pedal.

Turn the machine’s power OFF and recheck the measurement. Repeat, if needed.

• 1.0 INTRODUCTION SECTION DESCRIPTION PAGE #
• 2.0 SAFETY PRECAUTIONS 4 -
  • 2.1 Warranty
• 3.0 WARNING LABELS 6 -
• 4.0 INSTALLATION AND SET UP 8 -
  • 4.1 Physical Dimensions 8 -
  • 4.2 Machine Moving Procedure 10 -
  • 4.3 Physical Inspection
  • 4.4 Electrical Requirements 12 -
  • 4.5 Machine Start-up
  • 4.6 Stroke Control Adjustment 16 -
• 5.0 MAINTENANCE 18 -
  • 5.1 Lubrication 18 -
  • 5.2 Scheduled Maintenance 20 -
• 6.0 MACHINE OPERATION 22 -
  • 6.1 Punch Operation 22 -
  • 6.2 Angle Shear 28 -
  • 6.3 Bar Shear Operation 32 -
• 7.0 OPTIONAL TOOLS 38 -
  • 7.1 Rod Shear 38 -
  • 7.2 Six Inch Brake 40 -
  • 7.3 Eight And Twelve Inch Brakes 42 -
  • 7.4 Pipe Notcher 44 - SECTION DESCRIPTION PAGE #
  • 7.5 Rectangle Notcher 48 -
  • 7.6 Picket Fence Tool 50 -
  • 7.7 6 x 6 Ninety Degree Notcher 52 -
  • 7.8 Optional Die Holders & Strippers
  • 7.9 Optional Gauging Equipment
• 8.0 PUNCHES AND DIES 58 -
• 9.0 TROUBLESHOOTING GUIDE 56 -
• 10.0 PARTS LISTS 60 -
  • 10.1 4014C And 4014CM Punch Assembly
  • 10.2 4014C And 4014CM Main Assembly
  • 10.3 Linkage Assembly
  • 10.4 4014C And 4014CM Base Assembly
  • 10.5 Angle Shear
  • 10.6 Hold Down Assembly
  • 10.7 Electrical Controls
  • 10.8 Die Holders And Strippers
• 11.0 SUPPLEMENT FOR NEWER MODELS 76 -
• FIGURE
• FIGURE
• FIGURE
• FIGURE
• FIGURE

5.2 SCHEDULED MAINTENANCE

A program of scheduled maintenance should be set up and documented according to your application and the frequency you use this machine. The following is a list of important items that should be included in a scheduled maintenance program:

1. EVERY 250 HOURS OR THREE MONTHS:

A. Check the clearance between the punch barrel (A) and the punch barrel guide (B). FOR PARTS IDENTIFICATION, SEE FIGURE 7 ON THE FOLLOWING PAGE.

TO CHECK THE CLEARANCE:

1. With a punch and die properly installed following the instructions in SECTION 6.1 ON PAGES 24-29, place the selector arm in the shear position.
2. With the punch in the die, jog the machine with the foot pedal, watching for lateral movement of the punch in the die.
3. If lateral movement is noted, turn the machine’s power off. Remove the punch barrel (A) and punch barrel guide (B) from the machine and check the tolerance between the two parts.
4. If the tolerance exceeds three (.003) thousandths of an inch (.07mm), replace both parts.

 5. CAUTION: WHEN REPLACING THESE PARTS, DO NOT OVER TIGHTEN THE DRAG

LINK BOLTS (C). THE BOLTS SHOULD BE TIGHT ENOUGH TO RESTRICT THE PUNCH

BARREL FROM ROTATING, BUT NOT SO TIGHT THEY WON’T ALLOW THE DRAG LINKS

(D) TO ROTATE AS THE ARM TRAVELS DOWN.

2. EVERY 500 HOURS OR SIX MONTHS:

Check the condition of the shear blades, angle shear blades and any component tools for wear. Replace worn parts promptly.

3. EVERY 1,500 HOURS OR ONE YEAR:

Change the hydraulic oil once a year; more often under adverse conditions.

TO CHANGE THE HYDRAULIC OIL, turn OFF the power to the machine. Remove the drain plug from the bottom of the reservoir. Allow the oil to drain. Replace with 3.5 U.S. gallons (13 liters) of a light weight, nonfoaming, hydraulic oil such as CENEX ROA 200, MOBIL DTE 16, SHELL PELLUS 46, TEXACO RANDO 46 or equivalent.