Hydraulic Guillotine Shears Manual

Hydraulic Guillotine Shearing Machine Manual

Warning!

When using the machine tool, basic safety precautions should always be followed to reduce the risk of fire, electric shock and personal injury.

Read all instructions before attempting to operate this machine and keep these instructions.

1. Operator must know about the construction and feature of the machine and must carefully read the relative prescribe and request in Operation Manual before operating. If more than one person operates the machine, a director must take charge of the producing!
2. Don’t run the machine when your hands or any other parts of your body enter the machine.
3. Prohibited the hands enter between the upper and lower dies, in order to avoid any accident!
4. Separately add lubrication according to the lubricating diagram.
5. Keep the machine and around ground clean and the lines isolating! Especially keep the worktable area clear, avoid something enter between the blades making accident!
6. Inspect all parts of the machine usually; make sure there is no hidden danger!
7. The max working pressure is 23 MPa: it has been adjusted before outing the factory, the user can adjust it according to the actual situation.
8. Opening the electric cabinet by not authorized service personnel is prohibited! Please make sure the Power switch is on the OFF position before opening the door of electric cabinet!

Don’t remove this sign and operation manual!

 

Catalog

 

1. Introduction

 

2. Standard Features of Machine

 

3. Installation

 

4. Standard Control Equipment

 

5. Start up of Machine

 

6. Blade Clearance Adjustment

 

7. Maintenance

 

8. Working System

 

9. Trouble Shooting

 

10. Drawing and Spare Parts List

1. INTRODUCTION

We suggest all users and operators to read this operation manual carefully before using this machine.

This manual is designed for specialized and qualified personnel. It comes completes with diagrams and all the documentation necessary to lift, move and place the machine and instructions for the safe use and maintenance of this machine. All information contain in here are accurate at the time of print. However, our company reserves the rights to modify and improve specifications without prior notice.

This machine should be properly installed as instructed; regular inspection and faithful maintenance service should be carried out so that good performance can be maintained.

Any incorrect and irresponsible usages may cause irreparable damage to the machine and nullify the safety protection for the operator.

We do not assume any responsibility for improper services or modifications or connections made by unauthorized personnel.

We suggest that all user to read and understand this manual before using this machine.

2. STANDARD FEATURES OF MACHINE

• Well proven quality and performance.
• Sturdy frame construction for life-long operation.
• Mono block hydraulic system for minimum piping works with less chance for leakage.
• Double pump hydraulic system provides high speed and independent cutting and hold down force adjustable.
• Hydraulic overload protection as standard built in.
• Illumination light for cutting.
• Quick and accurate blade clearance adjustment with indication of material thickness for a good cut.
• Hydro-electric adjustment for rake angle setting for minimum distortion and maximum thickness of plate to be cut.
• Quality shearing blade made by high chrome, high carbon speedy D2 material in full length, four sided by U.K. manufacturer.
• Standard motorized back-gauge, stroke 750mm with read out and fine hand wheel adjustment.
• Quality electrical component, with built in motor overload
• 1000mm squaring arm with scale and disappearing stop.
• Filled up oil tank, ready for work.
• Set of hand tools for maintenance.

3. 3. INSTALLATION OF MACHINE

3.1 Packing / Shipment of machine

All machines leaving the factory are packed with squaring arm and foot panel tied to the hand guard. A bag of working hand tools and operation manual is lock inside the electrical panel.

All exposed surfaces on machine are coated with rust guard, easily removable by kerosene or solvent.

 

3.2 Lifting the machine

Use only approved and safe wire rope to lift this machine from two lifting point which is located at both side frame of the machine.

 

3.3 Foundation

All our shears are designed to be free standard. However, a good quality reinforced concrete floor with a minimum thickness of 150mm should be used.

 

3.4 Installation

This machine must be properly leveled to give a good cut. Leveling is done by putting a good leveling gauge at the plate hold down area. Always pre-prepare five pieces of base plate (dimension 150 x 150 x 9mm, minimum) below machine footing to prevent leveling screw from digging into the concrete floor.

On completion of leveling, a cement grout mixture must be packed under and around the feet to maintain correct leveled position.

 

3.5 Electrical Installation

Be sure that the local power supply is suitable for this machine before any electrical power up. Connect power cable to the bottom left of electrical panel to R.S.T.E. terminal.

 

Some machine may require N (Neutral) wire.

 

 

5. STANDARD CONTROL EQUIPMENT

5.1	Start button		:		To start the main motor running and Control circuit.
5.2	Stop button		:		To stop the main motor running and Control circuit.
5.3	Auto/Man mode selector switch		:		Select the working mode
	In Auto mode				-Rake angle adjustment function able
					-Motorized back gauge function able
					-Can command cut by foot pedal only.
	In Man mode				-Rake angle adjustment not- Function able.
					-Motorized back gauge not-function able.
					-Command up and down of top blade  carrier by push button ‘­’ or ‘¯’.
5.4	Foot pedal			:	Push to command cutting blade down and release to have top blade carrier rise in AUTO mode.
5.5	Illumination Light			:	Working light to shine at cutting blade area, operating at single phase power supply at 220V, 50Hz..

 

6. START UP OF MACHINE
   • Preparation of machine

Remove the squaring arm and foot pedal from hand guard area. Set up the squaring arm on left hand side (Close to electrical panel) by bolting down to the machine table and two side holes.

• STARTING THE MACHINE
• Push ‘START’ button and release.
• Motor “on” indicator light turns on.
• Put mode selector from MAN to AUTO position.
• Top blade carrier will rise after a few seconds.
• If not, that means motor is running in wrong direction. Switch off power supply. Reverse starts motor again, any of the two phase wires.
• The top blade carrier will rise and stop when it hit limit switch L/S 2.
• RAKE ANGLE ADJUSTMENT
• Put selector switch at ‘AUTO’ mode. Rake angle adjustment works only in this mode.
• Push ‘angle +’ top blade carrier should rise to 3 degree (Three light should light up) and stop upon hitting limit switch L/S 7.
• Push ‘angle –‘top blade carrier should lower to 1 degree (One light should light up) and stop upon hitting limit switch L/S 5.
• The above confirmed that rake angle adjustment system is functioning well.
• SETTING UP SQUARING ARM
• Starts motor and stay on to AUTO mode.
• Push ‘angle –‘button until it reduce the rake angle to 1 degree and stop by hitting limit switch L/S 5.
• Put selector switch to ‘MAN’ mode.
• Push ‘¯’, top blade will come down and intercept with lower blade. See that the interception point is about 300mm to 400mm from start of cut (LHS)
• Use a good tri-square to gauge against the top blade to set the squareness of squaring arm by the two side bolts and nuts.
• BLADE CLEARANCE ADJUSTMENT
• At the rear of machine, there are two blade clearance adjustment level at both side of machine, both are with indication of sheet thickness.
• Factory set them at lowest position during delivery of the machines, which is suitable for cutting mild steel plate 5 to 6mm (1/4”) thick.
• Try to put to other setting by pulling the locking sleeve, then lift upward to 1mm position.
• It would be heavier to put to top position (1mm) than to lower position (6mm) due to spring pot tension. Both side of the blade clearance adjustment is factory set and should have about the same tension.
• MOTORISED BACKGAUGE
• Put selector switch to AUTO mode, motorized back gauge works only in this mode.
• The motorized back gauge readout is accurately set in factory and it should be corresponds to the distance measure from back gauge bar to the cutting edge.
• Push ‘+’ button to bring back gauge bar to the rear, reading is increase and stops when hitting maximum travel limit switch L/S 3.
• Push ‘-‘ button to bring back gauge bar to the front, reading is decrease and stops when hitting minimum travel limit switch L/S 4.
• The parallelism of back gauge is set in factory, however it can be calibrated when necessary.
• Bring back gauge bar to the rear for removing anti-rust coating prior to cutting.

 

7. BLADE CLEARANCE

7.1 Blade Clearance Table

Quick blade      Clearance setting		For material thickness	Blade clearance
Top position	1 to 2 mm	( 1/24’’ to 1/12’’ )	0.05mm	(0.002”)
2nd  position	3 to 4.5 mm	( 1/8” to 3/16’’ )	0.3  mm	(0.012”)
Lowest position	5 to 6.5mm	(5/24” to 13/48’’ )	0.6  mm	(0.023”)

7.2 Check for Maximum Clearance

• Set blade clearance lever to lowest position.
• Put rake angle at 3 degree at ‘AUTO’ mode.
• Switch selector to ‘MAN’ mode.
• Push ‘¯’ button to bring top blade carrier down to have top and bottom blade intercepting point at just before end of blade (RHS)
• Use a feeler gauge to check the clearance at the point of interception, it should be at 0.6mm (0.023”)
• Push ‘­’ button to bring top blade carrier up until the interception point just before start of cut.
• Use a feeler gauge to check, it should be at 0.6mm (0.023”)

7.3 Check for Minimum Clearance

Switch selector switch to ‘MAN’ mode.

Be sure that quick blade clearance levers are set at 2nd position (3mm).

Push ‘¯’ button until top blade carrier goes to the lowest position.

Bring quick blade clearance levers to the top position (1mm).

Push ‘­’ button until interception point at end of cut.

Make measurement with feeler gauge, it should be 0.05mm (0.002”).

Push ‘­’ button until the interception point at start of cut, take measurement, it should read 0.05mm (0.002”).

7.4 Attention

Only experienced and skilled personnel should be allowed to perform blade clearance checking. Recommended having two persons work together. The back gauge should be set to the rear (maximum out).

Greatest care must be exercised when setting / check the blade clearance, otherwise may cause excessive blade damage or injuries to personnel.

8. MAINTENANCE

8.1 Lubrication and Hydraulic Oil

This machine uses hydraulic oil grade 68, refill or replace only with same grade of oil as follow:

 

FIAT-HTF 68, ENERGOL HLP 68, ESSO NUTO H68, MOBIL-DTE OIL 26, SHELL-TELLUS S68, TOTAL-AZOLLA 68

 

• Lubrication program

• Oil change after initial 1500 working hours. All the oil must be chained from oil tank to eliminate all impurities which could have enter during assembly.
• Oil filter should be changed. Use the same grade of oil filter.
• Subsequently, should have oil change every 5000 working hours.
• Grease all grease nipple points every two weeks. These are found on the back gauge assembly.

 

• Back Gauge Calibration

The back gauge is calibrated correctly in our factory. But it can calibrate when necessary. Following describe the method to adjust parallelism of back gauge.

-Always loosen M14 screw before any adjustment

-To reduce back gauge dimension screw in M8 screw, then tighten   two M6 screws.

-To increase back gauge dimension screw out two M6 screws then tighten M8 screw.

-Tighten M14 screws after calibration is done.

 

8.4  Changing of Shear Blade

Both top and bottom shear blades are identical and inter changeable.

Always put blade clearance to the largest (lowest position).

Put machine in ‘AUTO’ mode and remove wires ‘F’ and ‘S’ from terminal block. This is to prevent any unwanted down command of cutting action while working on it.

OFF the machine. Remove bottom blade first then the top blade.

Release all small set screw on top blade carrier.

Clean blades and blade housing / sitting.

Fix back top blade first then bottom blade.

Tighten the small sets screw on top blade carrier if necessary to close in blade clearance.

Remember to check for minimum clearance, adjust small set screw to close up blades when require.

Remember to put back wires ‘F’ and ‘S’ to their original position before putting machine back to working condition.

 

CAUTION: Always engages a qualified and experiences personnel to do

this job, otherwise damage to shear blades/machine or personnel injuries may result.

 

8.5  Grinding of Shear Blade

The Shear blade is rectangular in shape and has four cutting edges.

Only after all four edges are used up then you require regrinding of blade.

REMEMBER: Grind only the thickness and not the height of blade.

May require to close in top blade carrier by screw in tensioning bolt as a result of the loss of Grind-off thickness of the shear blades. (next to quick blade clearance lever).

 

 

9. WORKING SYSTEM

• Hydraulic system (Refer to Hydraulic Circuit – Drg. 9.1 (b) )

• When foot pedal is press and hold there, valve C and valve D energize and plate clamps come down.
• Pressure switch will triggle valve B to energize and top blade descend to cut material.
• At the end of stroke or by releasing of the foot paddle at any point of cut, valve A, valve D and valve G energize and top blade rise to T.D.C. and ready for next cut to be commence.
• To increase rake angle, valve D and valve F are energize.
• To decrease rake angle, valve D and valve E are energize.

9.2 Electrical System

• In Auto mode, contactor R4 energize during idle state.
• Contactor R1 to command plate clamp and blade down when foot paddle is depress and hold there.
• Release foot paddle for up stroke, contactor R2 must energize.
• Contactor R3 (anti- repetition) is energize as long as foot paddle is depress during up stroking of top blade to prevent second stroke of top blade.
• Contactor A1 is for back gauge to move away from cutting edge.
• Contactor A2 is for back gauge to move towards cutting edge.

9.3 Motorized back gauge

• The back gauge serves as a gauging device. When the plate to be cut is push into the Shear, it is stopped by the gauge-bar.
• We can move the gauge bar by powered or by hand wheel. In both cases it is moved by one pair of accurate lead screws.
• In the RAS series machine, the readout is in front of the machine, having setting up to 0.1mm increment.
• The back-stop bar can be adjusted with reference to straightness. It can be aligned by setting bolts and couner-bolt located in the bar itself.
• It is necessary to lubricate at regular intervals-weekly.

10. TROUBLE SHOOTING

• 1 Machine Cannot Start
• Check incoming power supply.
• Check that Emergency Stop is release.
• Check fuse – 3 x 32A, 1 x 10A and 1 x 6A are still not fused.
• Check transformer output.
• 2 Machine Cannot Cut
• Check that selector is at Auto mode.
• Check that limit switch L/S 2 is engage.
• Check that motor is rotation in a correct rotation.
• Check that foot paddle cable is not broken.
• Check that micro-switch inside foot paddle is working.
• 3 Ram Chattering on Down Stroke
• Counter balance setting pressure is a little too high
• Just release the set screw a little to lower the setting
• 4 Machine Operates By Its Self
• Be sure that the Micro-switch inside foot paddle is not damaged.
• Foot paddle cable may be shorted to each other.
• 5 Fuse F2, 10A Fused
• Transformers faulty, replace it.
• 6 Fuse F3, 6A Fused
• Rectifiers faulty, replace it.
• 7 Plate Clamp Come down But Top Blade Carrier Not Working
• Pressure switch not working.
• Wire to pressure switch may be broken.

11.1   Hydraulic Shearing Machine

11.2 (A) FRONT VIEW

11.2 (B) REAR VIEW

11.3 SIDE VIEW

11.4 LIFTING OF MACHINE

11.5 PLACING OF LEVELING GAUGE

NOTE: MAKE SURE THE LEVELING GAUGE, NOT TOUCHING THE BLADE AND PLACE IT AS SHOWN ABOVE

11.6 (A) BACK-GAUGE ASSEMBLY

11.6 (B) SIDE VIEW                                       11.6 (C) REAR VIEW

Pre-adjust inspection

 

No.	graph	Inspection program	Permission error	Inspection tools	Real value	Inspection ways
G1		Coincidence gap between blade and sharp	0.06 I class 0.10/1000 II class 0.02/1000 III class 0.50/1000	Clearance gauge	Inspection clerk	When blade board move between up and down blade coincidence, if two gap of two section is equal, from 50mm, measure the gap & per 150mm. The error is max gap value minus min gap value.
G2		Parallelism Between low-blade and back gauge	I class 0.10/1000 II class 0.02/1000 III class 0.50/1000	Clearance gauge  inside diameter micrometer	Inspection clerk	Adjust the mouth of front feed clamp to max or min, measure the distance between back gauge and low-blade, at least 3 spot per one meter, error value is max reading per one meter.

No.	graph	Inspection program	Permission error	Inspection tools	Real value	Inspection ways
P1		linearity	0.25/1000	Level ruler level table clearance gauge	Inspection clerk	Put test pieces on level table, 1000mm length level ruler depend on cutting surface of test pieces, measure the gap by clearance gauge. Error is max reading value.
P2		Parrel	0.15/1000	Vernier slide calliper	Inspection clerk	Measure the width of test pieces by vernier slide calliper(at least 3spot per one meter), error is max reading value on any 1000mm.

Note: 1.the accuracy test duty according to this rule is not real test duty. For fix and dismantle inspection tools conveniently, can be according to any duty.

2. Forbidden adjusting the frame and parts effecting on accuracy during test accuracy.
3. Test demand of test pieces:

Demand of test pieces to work accuracy

1. The length is cutting plate width.
2. The width is 2times as the thickness, forbidden less 8.0mm.
3. The thickness of test pieces is half as max cutting thickness.
4. The tensile strength &<450Mpa.
5. ii) Quantity of test pieces is not less 3 pieces.

iii) At 10 times as thickness from section, need not test.

4. When real length is shorter than regular length, need correct the measure valve according to GB8170 to 10^-6meter class.