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Greenlee 30T User manual

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Page 1
INSTRUCTION MANUAL
Shear 30T
Shearing Station
Read and understand all of the instructions and safety information in this manual before operating or servicing this tool.
52084433 REV5 © 2019 Greenlee Tools, Inc. 11/19
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Greenlee Tools, Inc.
Table of Contents
Description .................................................................... 2
Purpose of this Manual ................................................. 2
Safety ............................................................................ 3
Identication .................................................................. 4
Caster Mounting ............................................................ 5
Die Loading/Changeover ............................................... 6
Setting the Measurement Stop ..................................... 7
Operation ..................................................................8–10
Cutting Strut Channel ............................................... 8
Cutting Threaded Rod .............................................. 9
Cutting Angle Iron and Rebar ................................. 10
Maintenance ................................................................ 11
Available Dies .........................................................11–12
Cutting Unit Mounting ................................................. 13
Angle Iron and Rebar Support Installation .................. 14
Angle Iron and Rebar Support Mounting .................... 14
Exploded Views and Parts Lists .............................15–19
Cutting Unit ........................................................15–16
Service Cart .......................................................17–18
Angle Iron and Rebar Support ................................ 21
Shear 30T Shearing StationShear 30T Shearing Station
Description
The Greenlee Shearing Station is used to shear commonly branded, mild steel strut channel, threaded rod, angle iron and rebar products. This tool is not designed to be used with stainless steel, aluminum or berglass strut or threaded rod workpieces.
Purpose of this Manual
This manual is intended to familiarize all personnel with the safe operation and maintenance procedures for the Greenlee Shearing Station.
KEEP THIS MANUAL
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Greenlee Tools, Inc.
IMPORTANT SAFETY INFORMATION
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, dened below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result in severe injury or death.
Shear 30T Shearing Station
Strut channel and threaded rod ends can be sharp. Gloves are recommended when handling these materials.
Skin injection hazard. Do not use hands to check for oil leaks. Oil under pressure easily punctures skin. If injured, seek medical attention imme­diately to remove oil. Failure to observe this warning could result in serious injury or death.
Hazards which, if not avoided, COULD result in severe injury or death.
Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.
Read and understand all of the instruc­tions and safety information in this manual before operating or servicing this tool.
Wear eye protection when operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from ying debris or hydraulic oil.
Pinch points: Keep hands away from the cutting unit during the shearing process. Failure to observe this warning could result in severe injury or death.
Do not overload cart
If operating the tool continuously for more than 2 hours hearing protection is recommended. Longterm exposure to high noise levels could result in hearing damage.
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Greenlee Tools, Inc.
Identification
Shear 30T Shearing StationShear 30T Shearing Station
4
5
6
1. Service Cart
2. Cutting Unit
3. Front Material Rest
4. Rear Channel Rest
5. Rear Rod Rest
6. Rear Arm Knob
7. Measurement Stop Knob
8. Extension Arms
2
3
1
9
8
7
13
12
14
15
16
11
17
10
11. 30 Ton Hydraulic Ram with Universal Coupling
12. Die Retaining Rails
13. End Stop
14. Mobile Die
15. Stationary Die
16. Swing Arm
17. Die Spacer
9. Measurement Stop
10. Alloy Steel Cassette Frame
Specifications
Cutting Unit and Dies
For cutting 18, 16, 14 and 12 gauge mild steel strut channel of various nishes. For cutting Grade 2 mild or low carbon steel threaded rod of various nishes. For cutting mild or low carbon steel angle per ASTM A36. For cutting carbon steel rebar, maximum capacity: #6 (3/4”) grade 60.
The dies are not designed to cut stainless steel workpieces. Expect reduced die life if cutting this material.
Maximum Force ................................................................................................. 30 tons
Hydraulic Pressure ........................................................................................10,000 psi
Service Cart
Dimensions .................................................................................. 19” W x 44” H x50” L
Shelf Size ....................................................................................... 2” H x18” W x 36” L
Load Rating ......................................................................... 800 lbs, evenly distributed
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Greenlee Tools, Inc.
Caster Mounting
Shear 30T Shearing Station
Rotate the Service Cart on its side.
Cart is heavy, advise having two persons when turning cart.
Attach the Rigid and Swivel Casters to the bottom shelf of the Service Cart with the included caster mounting hardware. Torque the nuts to 25 ft lbs. Reposition the Service Cart with casters in its upright position.
Transporting and Storage
Remove all dies from the Cutting Unit. Lower the Rear Rod Rest and Measurement Stop. Center both Extension Arms; lock the arms by tightening the Rear Arm Knob and Measurement Stop Knob.
Connecting to Power Source
Attach your 10,000 psi rated pump to the Hydraulic Ram’s universal coupler with a similarly rated hydraulic hose. The Service Cart has an opening in its upper shelf for the hose to feed through if the pump is seated on the lower shelf. Tighten the hydraulic tting and test cycle the Cutting Unit unloaded to conrm a proper connection.
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Greenlee Tools, Inc.
Die Loading/Changeover
If a die set is already loaded in the cutting unit, pull the Swing Arm out of the Mobile Die and rotate it onto the Die Spacer. Pull back the End Stop and slide out the Mobile Die within the Cassette Frame, then push the Stationary Die forward and slide it out also. Load the new die set in a reverse matter. Be sure to reengage the Swing Arm before beginning cutting.
Note: if having difculty removing or inserting dies, clear debris from the Cassette Frame die pockets.
Note: it is recommended to apply a moly-base spray lubricant to the die and frame working surfaces whenever changing dies.
Shear 30T Shearing StationShear 30T Shearing Station
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Setting the Measurement Stop
The Measurement Stop can be set to repeatedly cut lengths from 12 to 48 inches. Turn the Measurement Stop Knob holding down the Extension Arm counter­clockwise to unlock. Set stop to required cut length by moving the arm left or right as needed, then retighten the knob. Raise or Lower the stop such that the workpiece being cut just makes contact.
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Operation
Engage caster brakes before operating unit.
Cutting Strut Channel
When cutting strut channel, the work piece must always be supported by the Front Material Rest. Do not cut total channel lengths of less than 7.5” as they cannot be properly supported and can cause a die to fracture.
Place the workpiece on the Front Material Rest and Rear Channel Rest (if long enough) and push through the Stationary and Mobile dies up to the Measurement Stop (if being used) or to desired nished length. The Rear Rod Rest should be lowered out of the way. Activate the hydraulic pump to begin the cut cycle. Wait for the strut to shear then release the hydraulic pressure. The Mobile Die will return to its original position to begin another cut. Lower the Measurement Stop and unload the nished workpiece, then return the stop for the next cut.
Shear 30T Shearing StationShear 30T Shearing Station
Note: cutting nished lengths of less than 2 inches may warp the channel prole.
Note: the Rear Channel Rest was designed to support up to 10ft workpiece lengths. Additional support may be required when cutting lengths longer than this.
When cutting short pieces of strut channel the nished workpiece can pop out due to the shock of the cutting cycle, always wear safety glasses.
Shearing across holes and slots can leave sharp points on nished workpieces.
Do not cut single box strut workpieces with the double strut dies, the dies will fail quickly.
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Greenlee Tools, Inc.
Operation (cont’d)
Cutting Threaded Rod
Push the workpiece through the Stationary and Mobile Dies up to the Measurement Stop (if being used) or to desired nished length. The Rear Rod Rest can be raised to support longer workpieces. Firmly seat the rod against the threads of the Stationary Die and keep the workpiece perpendicular to the dies. Activate the hydraulic pump to begin the cut cycle. Wait for the rod to shear then release the hydraulic pressure. The Mobile Die will return to its original position to begin another cut. Lower the Measurement Stop and unload the nished workpiece, then return the stop for the next cut.
Note: The threaded rod dies have been designed so that the nut threads onto the cut rod by hand. Thread quality, surface nish (i.e., galvanized or plated), dirt and scale could affect the ability of the nut to thread freely onto the cut rod.
Filing of the rod end or use of a pliers may be necessary if nut does not easily thread on due to these factors.
Shear 30T Shearing Station
Note: The Rear Rod Rest was designed to support single workpieces up to 10ft lengths. Additional support may be required when cutting lengths longer than this or multiple pieces at once.
Tip: If a nut begins to thread and locks up, tapping it on a surface will often loosen it and allow continued threading.
Finished workpiece length should not be less than .25”.
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Operation (cont’d)
Engage caster brakes before operating unit.
Cutting Angle Iron (Steel Angles) and Rebar
Note: When cutting angle iron and rebar, the reaction force on the ends of the workpiece can be severe. Always use the Rear Support to secure the workpiece when cutting angle iron and rebar. The current Rear Channel Rest will not provide sufcient support and damage to the Rear Channel rest will occur if not properly supported.
Lower the Rear Channel Rest and push the angle iron or rebar through the Rear Support and then through the Stationary and Mobile Dies up to the measurement stop (if being used) or to the desired nished length. Provide support to the free end of the angle iron or rebar, keeping it perpendicular to the dies, to prevent the piece from falling. Activate the hydraulic pump to begin the cut cycle. Wait for the angle iron or rebar to shear then release the hydraulic pressure. The Mobile Die will auto­matically return to its original position to begin another cut. Lower the Measurement Stop and unload the n­ished workpiece, then return the stop for the next cut.
Note: The Rear Channel Rest was designed to support up to 10 foot workpiece lengths. Additional support may be required when cutting lengths longer than this.
Note: Cutting angle iron and rebar will require more frequent cleaning in the track portions of the Cassette Frame and Die Retaining Rails. Scale on the surface of the angle iron and rebar will fall during cutting and accumulate in the unit. See maintenance instructions for cleaning.
Note: To remove the Rear Support when it is not in use, disengage the plunger by pulling up the key ring and slide the Support Frame out. To use the Rear Support again, lift the key ring and slide the Support Frame into the Support Base. Release the key ring and make sure that the Support Frame is secure in place.
Shear 30T Shearing StationShear 30T Shearing Station
Rear Support
Rear Support
When cutting short pieces of angle iron or rebar the nished workpiece can pop out due to the shock of the cutting cycle, always wear safety glasses.
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Greenlee Tools, Inc.
Shear 30T Shearing Station
Maintenance
Lock out power to the Cutting Unit before performing any maintenance. Change the hydraulic oil annually or after 10,000 cycles. Use ASTM 215 hydraulic uid (or equal). At least monthly, clean the inner track portions of the Cassette Frame and Die Retaining Rails. Apply a moly based, spray
lubricant to the working surfaces. A dry lm lubricant such as Molykote 557 is recommended. The material cutting dies are wear parts and will fail over time. Order additional dies through Greenlee distributors. The unit experiences a shock during each cutting cycle which can loosen bolt connections over time. Periodically check all
fasteners on the Cutting Unit and retighten where needed.
Available Dies
KEY CAT NO. DESCRIPTION COMPATIBILITY
1 1316SSTRT 13/16 X 1-5/8 Single box prole B-Line B52, B54, & B56
Unistrut P4520, P4100, & P4000 Powerstrut PS 520 & PS 500 Superstrut B-1200 & B-1400
2 78SSTRT 7/8” x 1-5/8 Single box prole Unistrut P3300
3 158STRDSTRT 1-5/8 x 1-5/8 Single box prole B-Line B22, B24, & B26
Unistrut P1000, P1100, & P2000 Powerstrut PS 200 & PS 210 Superstrut A-1200 & A-1400
4 158SSTRT 13/16 x 1-5/8 & 1-5/8 x 1-5/8 Single
box proles
5 1316DSTRT 13/16 x 1-5/8 Double box
back-to-back prole
6 78DSTRT 7/8 x 1-5/8 Double box
back-to-back proles
7 158DSTRT 1-5/8 X 1-5/8 Double box
back-to-back proles
8 4STRT21 1-1/16 x 2-1/8 Single box 4D proles B-Line 4D21 9 4STRT22 2-1/8 x 2-1/8 Single box 4D proles B-Line 4D22 10 1458TROD 1/4-20, 3/8-16, 1/2-13 & 5/8-11
Threaded Rod 11 GSDR15 32 x 15mm G-Type DIN Rail proles TS-32 (G) 12 THDR7515 35 x 7.5mm & 35 x 15mm DIN Rail
Combo proles 13 3000SSRB 3000 Series Steel Raceway Base prole Legrand G3000B, V3000B 14 3000SSRC 3000 Series Steel Raceway Cover prole Legrand G3000CE, V3000B 15 14ANG-KIT Angle Iron dies with Rear Support Mild steel in sizes up to 2”x 2” and 1/4” maximum thickness 16 26RBR-KIT Rebar dies with Rear Support Grade 60 Rebar in sizes up to #6 (3/4”)
B-Line B22, B24, B26 & B52, B54, B56 Unistrut P1000, P1100, P2000 & P4520, P4100, P4000 Powerstrut PS 200, PS 210 & PS 520, PS 500 Superstrut A-1200, A-1400 & B-1200, B-1400
B-Line B52A, B54A, B56A Unistrut P4001, P4101, P4521 Powerstrut PS 500 2T3, PS 520 2T3, PS 560 2T3 Superstrut B-1202 & B-1402
Unistrut P3301
B-Line B22A, B24A, B26A Unistrut P1001, P1101, P2001 Powerstrut PS 200 2T3, PS 210 2T3 Superstrut A-1202 & B-1202
All mild steel rod
TS-35 (7.5mm), TS-35 (15mm)
*Support required for angle iron and rebar dies **See replacement parts for individual angle iron and rebar dies (page 21)
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Available Dies (cont’d)
Shear 30T Shearing StationShear 30T Shearing Station
1
7
13 14
Note: The hot-dipped galvanized nished available from many manufacturers will often leave beads of nish on the product and can be more difcult to get through dies.
2
8
3
9
15
10
16
4
5 6
11 12
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Greenlee Tools, Inc.
Cutting Unit Mounting
To mount the Cutting Unit to another surface, rst unfasten the three 3/8-16 by 5/8” long hex bolts underneath the top shelf of the service cart to free the unit.
The following bolt pattern will be required on the new surface. Longer bolts may be needed if attaching the unit to a surface thicker than 12 gauge (.105 steel).
8.500
1.125
Shear 30T Shearing Station
1.125
14.619
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Greenlee Tools, Inc.
Installation Instructions – Angle Iron and Rebar Support
Please follow the directions below to create the mount­ing holes for the Rear Support. If your service cart already has holes drilled for the Rear Support please skip to the mounting instructions.
Use the base as a template and locate the base 8.75” from the left side of the cart (see below). Line up the left side of the base with this line. Mark a line .25” from the front of the cart (see below). Line up the front of the base with the 0.25” mark.
Using a marker/pencil, trace the holes on the Support Base. Drill the four holes using a 13/32” drill bit.
Shear 30T Shearing StationShear 30T Shearing Station
9.125”
8.750”
0.250”
Angle Iron and Rebar Support Mounting
To mount the Angle Iron and Rebar Support to the cart, rst line up the Support Base with the holes on the cart and bolt the Support Base down using four 3/8-16 by
1.25” socket head cap screws and four 3/8-16 hex nuts. See the image below.
Using the Loctite threadlocker capsule, apply thread­locker to each screw and tighten down to a torque of 35 ft-lbs.
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Greenlee Tools, Inc.
Exploded Views and Parts Lists
Exploded View – Cutting Unit
1A
Shear 30T Shearing Station
2F
2E
2D
2C
1B
1C
2B
2A
1D
1E
3N
3M
3L
3K
5
4A
3A
3B
3C
3D
3E
3F
3G
3H
3I
3J
Note: Torque 3/8 screws to 35ft lbs and 1/4 screws to 10ft lbs.
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Exploded Views and Parts Lists (cont’d)
Exploded View – Cutting Unit
Key Part No. Description Qty
1 52084465 Material Rest Kit ....................................................................................1
1A Socket Head Cap Screw, 3/8-16 x 7/8 L ...............................................3
1B Bellville Washer, .38 ID x 3/4 OD ...........................................................3
1C Front Material Rest ................................................................................1
1D Standoff, 3/8-16 x 4 L ............................................................................3
1E Socket Head Cap Screw, 3/8-16 x 1-1/4 L ...........................................4
2 52084466 End Stop Kit ..........................................................................................1
2A End Stop ................................................................................................1
2B Compression Spring, .36 OD x 1 L ........................................................ 2
2C Slide Block .............................................................................................1
2D Bellville Washer, .38 ID x 3/4 OD ...........................................................2
2E Socket Head Cap Screw, 3/8-16 x 1-1/2 L ...........................................2
2F* Lobed Knob, 3/6-16 x 11/16 L ..............................................................1
Shear 30T Shearing StationShear 30T Shearing Station
3 52084467 Working Components Kit.......................................................................1
3A Faceplate ...............................................................................................1
3B Bellville Washer, .38 ID x 3/4 OD ........................................................... 8
3C Socket Head Cap Screw, 3/8-16 x 3/4 L ...............................................4
3D Identication Decal, Upper .................................................................... 1
3E Piston Rod Adapter ............................................................................... 1
3G Flat Head Screw, 1/4-20 x 1/2 L ............................................................ 2
3H Flanged EGL Screw, 3/8-16 x 1-5/8 L ...................................................1
3I Compression Spring, .455 OD x 1-1/4 L ...............................................1
3J Swing Arm Assembly .............................................................................1
3K Socket Head Cap Screw, 3/8-24 x 7/8 L ...............................................4
3M Die Retaining Rail ..................................................................................2
3N* SEMS Screw, ¼-20 x 1-1/4 L ................................................................1
4 52084464 Cylinder Kit ............................................................................................1
4A Hydraulic Cylinder, 30 Ton ..................................................................... 1
5 Cassette Frame .....................................................................................1
6 52084463 Cylinder Seal Kit ....................................................................................1
Seal Kit for Hydraulic Cylinder ...............................................................1
6A**
*Fastened with threadlocking adhesive .................................................................................................................
**Not shown
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Greenlee Tools, Inc.
Exploded Views and Parts Lists (cont’d)
Exploded View – Service Cart
Shear 30T Shearing Station
1G
1D
1E
1F
1C
1B
1A
2
1N
1H
1M
1L
1I
1J
1K
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Exploded Views and Parts Lists (cont’d)
Exploded View – Service Cart
Key Part No. Description Qty
1 52084468 Cart Components Kit .............................................................................1
1A Grommet, 1-1/2 ID x 2-3/8 OD ..............................................................1
1B Screw, Spade, 3/8-16 x 3/4 L ................................................................1
1C* Carriage Bolt, 3/8-16 x 1 L ....................................................................3
1D* Extension Arm Weldment ......................................................................1
1E* Rectangular Plug, 1 W x 2 L ..................................................................2
1F* Hex Head Flange Screw, 3/8-16 x 1 L ...................................................1
1G* Disc Spring, .480 ID x .6 OD ..................................................................1
1H* Rear Rod Rest / Measurement Stop .....................................................1
1I* Hex Lock Nut, 3/8-16 x 17/64 W ........................................................... 1
1J Hex Nut, 3/8-16 x 9/16 W ......................................................................3
1K* Lock Washer, .385 ID x .665 OD ............................................................3
1L* Slide Plate .............................................................................................. 1
1M Measurement Decal ...............................................................................1
1N Fluted Knob, 3/8-16 x 2 L ......................................................................1
1O Branding Decal ......................................................................................1
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2 Cart Weldment .......................................................................................1
3 52082768 Caster Kit ...............................................................................................1
3A** Locking Swivel Caster, 6 D .................................................................... 2
3B** Rigid Caster, 6 D ....................................................................................2
3C** Carriage Bolt, 3/8-16 x 1 L .................................................................. 16
3D** Flat Washer, .39 ID x 5/8 OD ............................................................... 16
3E** Hex Lock Nut, 3/8-16 x 9/16 W ........................................................... 16
*These parts can be used in either Extension Arm position, order two Cart Components Kits if both Arms must be replaced
**Not shown, see Caster Mounting section of the manual
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Exploded Views and Parts Lists (cont’d)
Exploded View – Angle Iron and Rebar Support
Shear 30T Shearing Station
Key Part No. Description Qty
52087961 Support Frame and Base Kit (includes items 1+2) .................................
1A Screw-Cap 3/8-16 x 1.25 SKT BTN HD ................................................4
1B Nut-Hex 3/8-16 ......................................................................................4
1C Base Weldment......................................................................................1
1D Plunger ..................................................................................................1
1E Spring Compression .............................................................................. 1
1F Key Ring ................................................................................................ 1
1G* Threadlocker Capsule ............................................................................1
2 52087876 Rear Support Frame ..............................................................................1
52087877 Plunger Repair Kit (includes items 1D, 1E, 1F) .......................................
Replacement Dies
52086316 Angle Iron Dies .......................................................................................
52086401 Rebar Dies ..............................................................................................
*Not shown
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