Page 1: ... 1 _ _ _ __ MECHANICAL SHEAR OPERATOR S MANUAL CMAD ...
Page 2: ... to acquaint you with the installation oper ation and maintenance procedures of your Amada machine It is urged that this manual be read carefully for a thorough understanding of the machine to ensure long life and safe efficient operation I ...
Page 3: ...ton 2 3 Side gauge and front support 2 3 Beam light 2 3 Automatic shearing limit switches 2 4 SECTION 3 OPERATION Blade clearance adjustment 3 1 Single mode operation 3 3 Continuous mode operation 3 4 Automatic shearing mode operation 3 4 SECTION 4 MAINTENANCE Daily maintenance 4 1 Periodic maintenance 4 2 Removing and installing the blade 4 3 Lower blade height adjustment 4 7 Adjustment of backga...
Page 4: ...EMERGENCY STOP BUTTON TABLE 1 I CLEARANCE ADJUSTING DEVICE FRONT FOOT SWITCH SUPPORT FRONT VIEW ELECTRICAL ENCLOSURE I HYDRAULIC OIL TANK REAR VIEW BACKGAUGE MOTOR ...
Page 5: ...sed with a worn cutting edge the machine will be overloaded even if the thickness of the plate to be cut is kept within the cutting capacity of the machine In addition the accuracy will become poor and the blade regrinding will become more expen sive It is therefore economical to change the blade edge a little early 5 ADJUSTMENT OF BLADE CLEARANCE Improper clearance will result in damage or early ...
Page 6: ...o maintenance procedures assign a person responsible for the operation and maintenance of the machine including the power ON OFF switch 10 AVAILABILITY OF THIS OPERATOR S MANUAL To help prevent anyone from operating the machine in any other way than described in this manual keep this manual near the machine as a ready reference at any time ...
Page 7: ...ifting lugs on the left and right frames of the machine Photo 1 See the table below CAUTION Be careful to protect the machine from any impact Model Weight kg lb Model Weight kg lb M 1245 2700 5952 M 1260 3700 8157 M 2045 4600 10141 M 2060 4700 10361 M 2545 M 3045 M 4045 5300 11684 7100 15653 11000 24251 M 2560 M 3060 M 4060 5500 12125 8400 18519 14000 30865 CLEANING After the machine has been set ...
Page 8: ...en obtained anchor the machine with anchor bolt nuts Photo 2 ELECTRICAL CONNECTIONS To make electrical connections proceed as follows 1 Remove the screws that secure the electrical enclosure door move the door lever to Reset Open and open the door Photo 3 2 Connect the power supply cable to the input terminal of the circuit breaker and the ground wire to the ground terminal Photo 4 Spirit levels A...
Page 9: ...kgauge motor 0 4 0 4 0 4 0 4 0 4 Total power consumption 7 9 7 9 11 4 11 4 11 4 Recommended cable data The following data is the cross sectional area of cables to be used when your machine is operated on 200 volts ac Use the data as a guide in determining the appropriate cables according to your power supply M 1245 M 1260 5 5 mm2 0 00853 sq in M 2045 M 2060 M 2545 M 2560 M 3045 8 mm2 0 0124 sq in ...
Page 10: ...ermal relay CAUTION To protect personnel from an electrical shock and the machine from possible damage all electrical work should be done by a qualified electrician CHANGING WIRING CONNECTIONS AT TRANSFORMER TERMINALS Machine transformer Photo 5 0 0 0 0 0 0 V 0 V LC 0 N N 0 N N V u n rn co E ct 400V 50Hz l 11 l co 0 C 0 u Cl 0 0 0 0 0 0 Backgauge transformer Photo 6 gg x s gg gg gg gg 1rrrrWrrrrwr...
Page 11: ... MOTOR TERMINALS M 1245 M 1260 M 2045 and M 2545 models Photo 7 R S T R S T 230V 50 60Hz 400V 50Hz 460V 60Hz M 2060 M 2560 M 3045 M 3060 M 4045 and M 4060 models Photo 8 R S T I MS2 Z Y X W V U R S T 230V 50 60Hz 400V 50Hz 460V 60Hz 1 5 ...
Page 12: ...e arrow on the motor If it rotates in the reverse direction immediately press the emergency stop button to stop the motor turn the circuit breaker and factory s main power off and then interchange any two phase connections of the power supply cable Photo 9 After confirming that the main motor rotates in the correct direction install and tighten the screws which hold the electrical enclosure CONNEC...
Page 13: ...ith the groove in the table Adjust the side gauge support so that the stopper slides smoothly along the slide groove 3 Tighten the nuts to secure the side gauge support Photo 11 4 Tighten the bolts to secure the side gauge to its support Photo 12 IMPORTANT Prior to actual shearing operations shear test pieces to make sure the square ness of the side gauge in relation to the blades is correct If it...
Page 14: ... table so that the stopper can slide along the groove smoothly 3 Tighten the nuts to secure the front support Photo 13 NOTE The three meter front support is a standard accessory on model M 4060 Install the front support on the table using a crane then attach the front support stand to the support Make sure the front support is level after installation CHECKING THE HYDRAULIC OIL LEVEL Check the lev...
Page 15: ... on the oil signal units 3 Move the pump lever down 3 or 4 times until the float balls are higher than the lower red lines Photo 15 NOTE a Do not forcibly move the pump lever up It will gradually return to its original position b While the machine is operating move the pump lever 3 or 4 times every one hour to provide proper lubrication Photo 15 1 9 ...
Page 16: ...n the switch is turned OFF 2 DRIVE button When this button is pressed the main motor will start 3 Motor drive light This light is on while the main motor is operating 4 Emergency stop button When this button is pressed all machine operations will stop immediately To resume machine operation press the DRIVE button 2 raise the ram near its TDC in the INCH mode and then make one complete stroke of ra...
Page 17: ...ot move even if the foot switch is INCH pressed 6 LIGHT BEAM switch When this switch is turned ON the beam light will come on The light beam is used to align the I ine scribed on the worksheet for accurate shearing 7 CONTACT switch This switch is used for automatic shearing operation without pressing the foot switch Auto matic shearing is performed by butting the worksheet against the auto shearin...
Page 18: ...e worksheet cannot be sheared at that angle Refer to Installing the Side Gauge on page 1 7 outlined in Section 1 for instructions The side gauge and front support stoppers determine the cutting width of the worksheet on the operator side Photo 18 BEAM LIGHT Beam lights are used for shearing the worksheet by aligning the line scribed on the worksheet with the cutting edge of the upper blade Beam li...
Page 19: ...on can be performed without pressing the foot switch With the mode select switch set to SINGLE set the CONTACT switch to SHORT or LONG depending on the cutting width of the worksheet and butt the worksheet against the affected limit switches Shearing operation will start Photo 19 LIMIT SWITCH r 0 L _ _ _ _ _ __ _ _ n f ____ l_BACKGAUGE SHORT LONG Photo 19 2 4 ...
Page 20: ... 1 6 0 0 236 Blade clearance mm in 0 04 to 0 09 0 0016 to 0 0035 0 08 to 0 16 0 0032 to 0 0063 0 12 to 0 24 0 0047 to 0 0094 0 20 to 0 32 0 0079 to 0 0126 0 25 to 0 40 0 0098 to 0 0157 0 36 to 0 48 0 0142 to 0 0189 When adjusting the blade clearance use the following procedures 0 OO L 2 I I J J 0 L HK 1 Remove the finger protector Photo 20 9 2 Turn the circuit breaker ON 3 Turn the POWER ON OFF sw...
Page 21: ...ry to adjust the blade clearance loosen the table retaining bolts Photo 22 10 Move the table back or forward as required while measuring the blade clearances at the left center and right until the required clearances are obtained Photos 23 and 24 11 Tighten the table retaining bolts 12 Install the finger protector Photo 21 Photo 22 I I M 1245 M 2045 M 2545 M 3045 and M 1260 M 2060 M 2560 M 3060 an...
Page 22: ...our machine 5 Set the mode switch to SINGLE 6 Place the worksheet on the table and butt it against the side gauge Photo 25 7 With the worksheet held in that position move the worksheet toward the backgauge until its front end extends 5 to 25 mm 0 2 to 1 in beyond the blade for proper trim ming NOTE The trimming width should be at least twice the thickness of the worksheet and more than 5 mm 0 2 in...
Page 23: ...es one stroke of operation to shear the work sheet each time the worksheet butts against the automatic shearing limit switches built into the backgauge The foot switch need not be pressed To operate the machine in this mode proceed as follows 1 Repeat steps 1 through 8 outlined under Single Mode Operation 2 Set the mode switch to SINGLE 3 Set the CONTACT switch to SHORT or LONG in relation to the ...
Page 24: ... lower red lines on the oil signal units Photo 27 For details refer to Initial Lubrication on page 1 9 3 Add oil to the threads of the carriage through the upper hole by using an oiler Photo 28 Recommended oil Mobil Vactra Oil No 2 Shell Tanna Oil T68 4 Check the hydraulic oil level for the holddowns and add oil if necessary Recommended oil Mobil Hydraulic Fluid 56 Shell Tellus C56 5 Check the upp...
Page 25: ...fts when pressed midway between the motor pulley and the flywheel Photos 29 30 31 2 Check the level of the machine and adjust it if it is incorrect Refer to Leveling and Anchoring on page 1 2 for adjustment procedures 3 Check the backgauge to make sure it is parallel with the blades If it is not adjust it Refer to Adjustment of Backgauge Parallelism on page 4 8 for adjustment procedures M 1245 M 1...
Page 26: ... replaced with a new one NOTE a Before removing or installing the blade make sure the circuit breaker is OFF b To ensure safety always remove the lower blade first then the upper blade When installing the blades install the upper blade first then the lower blade Removing the lower blade 1 Open the blade to blade clearance as wide as possible Refer to Blade Clearance Adjust ment on page 3 1 2 Remov...
Page 27: ...e 7 Slide the lower blade along the surface of the lower frame and remove it from either frame gap Removing the upper blade 1 Place a wooden block and bar on the left and right sides of the table in order to support the weight of the upper blade UPPER BLADE I j L WQODEN BLOCK LOWER FRAME 2 Remove all bolts except for the two on both ends of the upper blade 3 While supporting the weight of the uppe...
Page 28: ... all the bolts starting with the middle one and work toward the outer ends of the blade IMPORTANT Do not ighten the bolts the other way around This will cause the middle of the blade to have poor contact with the ram Installing the lower blade 1 Clean the mating surface of the table to the lower blade and polish it with an oil stone 2 Insert the blade through the frame gap and slide it on the lowe...
Page 29: ... under Lower Blade Height Adjustment on page 4 7 LOWER BLADE LOWER FRAME PROPER IMPROPER IMPROPER 6 Adjust the blade clearance Refer to Blade Clearance Adjustment on page 3 1 for adjustment procedures 7 Shear several test pieces of worksheet to make sure the blades are properly installed 8 I nstal I the finger protector 9 Install the frame gap covers r 4 6 ...
Page 30: ...e through hole in the main gear is aligned with the jack bolt Photo 35 3 Loosen the lock nuts of the table jack bolts and loosen the jack bolts Photo 36 4 Loosen the mounting bolts which hold the lower frame onto the left and right frames Photo 37 5 Loosen the lock bolts and adjust the jack bolts on the lower frame so that the lower blade is flush with the upper surface of the table 6 Turn the tab...
Page 31: ...ine is wider than the one at the right proceed as follows 1 Turn the circuit breaker to OFF 2 Remove the connecting rod cover from the backgauge 3 Mark the location of the bolts which connect the couplings and remove the bolts ALIGNMENT MARK 2 HOLE COUPLING 6 HOLE COUPLING 4 Turn the six hole coupling in the direction of the arrow in the figure above to relocate the bolt holes while the two hole c...
Page 32: ...utt a straightedge against the backgauge and check to make sure the 50 mm point on the straightedge corresponds with the beam line of the beam light 4 If they are not aligned properly loosen the bolts which hold the bulb holder and move the holder back and forth to adjust the beam light position Photo 38 5 After properly adjusting the beam light move the backgauge backward Shear test sheets to mak...
Page 33: ...cam is set at a 50 to 60 shown in the following figure 3 Set the clutch cam at r 80 to 90 4 If the ram stops after TDC set the clutch cam mounting angle r slightly larger than the specified angle If the ram stops before TDC set the angle 3 slightly smaller than the specified angle In either case ensure the angle 3 falls within the 60 to 100 range NOTE If the ram stops significantly off TDC and the...
Page 34: ... is 5 mm 0 2 in or thereabouts Shearing thin worksheets requires a wider clearance before the shearing width is set Electromagnetic sheet support Photo 40 This device attracts the worksheet with an electromagnetic roll which eliminates the pos sibility of worksheet deflection between the backgauge and blades so that the worksheet can be sheared accurately to the desired width To activate this devi...
Page 35: ...he backgauge and blades so that the worksheet can be sheared accurately to the desired width To activate the device turn the ON OFF switch ON Automatic release backgauge This backgauge automatically reverses itself at the backward end so that it will not interrupt the feeding of the worksheet to be sheared NOTE This device is a standard accessory on models M 3060 and M 4060 5 2 I I ...
Page 36: ...2300 90 5 2800 110 2 3380 133 0 4430 174 4 Type of blade Four edged blade Gap depth 65 2 56 300 11 81 65 2 56 Rake angle 1 28 1 18 1 28 1 18 1 28 1 18 1 28 1 18 1 28 No of strokes spm 75 60 50 52 Main motor kW HP 3 7 5 5 5 7 5 7 5 10 11 0 15 Backgauge motor kW HP 0 4 0 5 Machine weight kg lb 2700 3700 4600 4700 5300 5500 7100 8400 11000 14000 5952 8157 10141 10361 11684 12125 15653 18519 24251 308...
Page 37: ...AMADA COMPANY LTD 200 Ishida lsehara Kanagawa JAPAN DEC 1985 ...
