Metallkraft HPS DS, HPS 55 DS, HPS 65 DS, HPS 85 DS, HPS 115 DS Operating Instructions Manual
...
HPS
DS
Series
Operating Instructions
Hydraulic section steel shears
HPS 55 DS, HPS 65 DS, HPS 85 DS
HPS 115 DS, HPS 175 DS
INDEX Page
General notes 1-2
Readjustment 3
View of the delivery side 4
Setting up the machine 5
Technical specifications 6-8
Additional tools 9
Five work stations 10-11
Safety explanations 12-14
Operation of the machine 15
Arrangement of the punch tools 16-18
Safety precautions on each of the work stations 19
Angle cutting installation 20
Mitring angle 45 degrees 21
Profie cutting station 22
Shearing, profile section cutting 23
Notching station 24
Stroke adjustment 25
Hydraulic system 26-27
Machine rod and lever readjustment 28
Punch tools 29
Punch tool part list 30
Part and parts list of the cutting frame 31
Blade adjustment / blade change 32
Blade part list 33
Notching parts 34
Special accessories 35
True punching 36
Hydraulic plan 37
Transportation 38
EC Declaration of Conformity 39
GENERAL NOTES
1.
Introduction
Thank you for choosing a METALLKRAFT Metal Working Machine. We are proud to have you
in our long list of satisfied customers all over the world.
This User’s Manual is absolutely for your safety and is essential for the machine to have a
long production life. As long as you keep up with our Manual you will be able to run your machine
smoothly and safely. Keep in mind that the machine is designed absolutely to perform maximum
safety and for efficient working.
In this Manual you can find instructions and inform ation about:
Correct installations of the machine
Description of the functional parts of the machine
Set-up and start-up adjustments
Correct standard and scheduled maintenance
Simple safety regulations and accident prevention.
Therefore, as far as the user’s safety is concerned, in this handbook the possible risks con-
nected with machine operation are pointed out as follows:
Attention: Showing the risks of accident, if instruction s are not followed.
Warring: Showing the probable damages to the machine or equipment, if the
instructions are not strictly followed.
Note: It gives useful information.
It is certainly necessary that the operator should read and understand all the Attention,
Warring, Note specified in this Manual before starting with operation of the machine and before any
lubrication or maintenance intervention
On all steps of installation, operation and maintenance safety must be your first concern for
the protection of yourself, other users and the service of the machine. In case of any failure please first
refer to this Manual, and then if a solution cannot be found contact first of all the distributor where you
purchased our product. Do not forget to refer to the drawings and the numbers for any spare part
needed or to define any problem. Make sure you have the serial number and production year of the
machine.
Our technical staff will make their best to help yo u in the most convenient way.
- 1 -
2.
Transport
As soon as you receive the machine, check for any visible transport damages. Should there
be any visible damages; report it straight away to the transporter company and of course Stürmer
Maschinen GmbH or your supplier.
Remove any protective crates around the machine and read the instructions on related chapters of this Manual carefully to set up the machine. If the machine is damaged while transport, imme-
diately take some photographs for insurance claims.
Take precautions while loading / unloading or moving the machine to avoid any injuries. Refer
also to related chapter of this Manual for the best way of handling the machine.
3.
Electrical Information
All necessary connection procedure can be found on this Manual. Do not try to connect the
machine before reading these procedures and fully understanding the drawings. For any unclear
matters get in touch with Stürmer Maschinen GmbH. Have the machine connected by a qualified
electric technician. For, as we made clear in the “general conditions of guarantee”, under no
circumstances installing mistakes, including electrical connection mistake, can’t be covered by
guarantee agreement. Always turn off power before making any connections or disconnecting the
machine.
4.
Maintenance
Your machine is designed and produced to work efficiently and smoothly. To achieve this you
should also take care while operating the machine. Regard Maintenance sections to have the longest
life from your machine. Try and use original spare parts where necessary and most importantly do not
overload the machine or do not make any unauthorized modifications.
5.
Safety
Take all precautions possible to avoid any personal injury while using the machine. Keep in
mind to protect the third party people around the machine. Refer to safety directives.
- 2 -
1
3 2
READJUSTMENT
The adjustment of the shear levers should be carried out before any adjustment of the shear blade. The
adjustment explain as shown below.
Explanation of figure
1.
Adjustment screw
2.
Safety nut
3.
Bronze pressure plate
- 3 -
Punch unit
Punch unit
Driver set hydraulic
VIEW OF THE DELIVERY SIDE
Lever group
Punch cylinder
VIEW OF THE EXIT SIDE
- 4 -
SETTING UP THE MACHINE
Ask for the help of an experienced and qualified technician while setting up the machine.
1)
Fundamental Plan of the Machine
Four holes (Refer to the drawing below) Dia.15mm
2)
Instructions
For an effective machine, the position and the base of the machine are important. Be careful
on these points while placing the machine:
The machine must be placed on a flat, preferably cement base. To fix the machine use bolt s.
There must be plenty of room all around the machine for easy working.
The machine height is ideal for any workingman.
There must be plenty of Light on top of the machine
- 5 -
- 6 -
mm)
TECHNICAL SPECIFICATIONS
General Information
Motor Power 5,5 kW 5,5 kW 7,5 kW
Pressure 55 t 65 t 85 t
Operating Voltage 400 V/50 Hz 400 V/50 Hz 400 V/50 Hz
Machine Dimensions
L x B x H [mm]
Weight 1520 kg 1600 kg 2315 kg
Noise Level L
Punching
Ø max. x Thickness Ø 100 x 3 mm Ø 110 x 3 mm Ø 110 x 4 mm
Ø x max. Thickness Ø 20 x 20 mm Ø 26 x 20 mm Ø 33 x 20 mm
Ø x Thickness Ø 40 x 10 mm Ø 57 x 10 mm Ø 57 x 12 mm
Stroke 60 mm 55 mm 80 mm
Stroke count (20
Throat depth 255 mm 305 mm 355 mm
Working height 900 mm 900 mm 9040 mm
Steel Bar Shearing
Round / Square Ø 40 / 40 mm Ø 45 / 45 mm Ø 50 / 50 mm
Angle Shear
Angle section 90° 120x120x12 120x120x12 150x150x15
Angle section 45° 70x70x10 70 x 10 80 x 8
Working height 1130 mm 1140 mm 1200 mm
Sheet Metal Shear
WA
HPS 55 DS HPS 65 DS HPS 85 DS
1500 x 950 x
1880
96,9 dBA 96,9 dBA 96,9 dBA
25 25 25
1700 x 950 x
1880
1920 x 950 x
2040
Sheet thickness max. 200 x 20 mm 300 x 20 mm 380 x 20 mm
Sheet size max. 300 x 15 mm 375 x 15 mm 480 x 15 mm
Blade lenght 317 mm 380 mm 482 mm
Shearing with angle 80 x 15 mm 100 x 15 mm 120 x 15 mm
Working height 900 mm 900 mm 940 mm
Notching
Thickness max. 10 mm 10 mm 13 mm
Width (L) 45 mm 45 mm 52 mm
Depth (P) 90 mm 90 mm 100 mm
Working height 900 mm 900 mm 940 mm
- 7 -
Optional Tools
U-I Section bl ades 120 x 58 mm 120 x 58 mm 160 x 74 mm
T- Section blades 80 x 9 mm 90 x 11 mm 100 x 11 m m
V-notching
tooling[mm]
V-bending Press brake:
Bar bend max. 250 x 12 mm 250 x 15 mm 250 x 20 mm
Sheet bend max. 500 x 3 mm 500 x 3 mm 500 x 4 mm
Punching on
notcher:
Bar bend max. 125 mm 125 mm 125 mm
Capacity max. 38 x 8 mm 38 x 8 mm 38 x 10 mm
HPS 55 DS HPS 65 DS HPS 85 DS
100 x 100 x 10 100 x 100 x 10 100 x 100 x 13
General Information
Motor Power 11 kW 11 kW
Pressure 115 t 175 t
Operating Voltage 400 V/50 Hz 400 V/50 Hz
HPS 115 D S H PS 175 D S
Machine dimensions
L x B x H [mm]
Weight 2920 kg 6000 kg
Noise Level L
Punching
Ø max. x thickness Ø 110 x 5 mm Ø 125 x 5 mm
Ø x max. thickness Ø 34 x 26 mm Ø 40 x 32 mm
Ø x thicknes s Ø 55 x 16 mm Ø 57 x 22 mm
Stroke 80 mm 80 mm
Stroke/min (20 mm) 25 22
Throat depth 355 mm 625 mm
Working height 935 mm 1130 mm
Steel Bar Shearing
Round / Square Ø 55 / 50 mm Ø 65 / 55 mm
WA
2040 x 950 x
2180
96,9 dBA 96,9 dBA
2730 x 1150 x
2280
Angle Shear
Angle section 90° 150x150x16 200x200x20
Angle section 45° 80 x 10 80 x 10
Working height 1215 mm 1130 mm
- 8 -
Sheet Metal Shear
Sheet thickness max. 380 x 25 mm 380 x 30 mm
Sheet size max. 600 x 15 mm 600 x 20 mm
Blade lenght 610 mm 610 mm
Shearing with angle 120 x 15 mm 120 x 15 mm
Working height 935 mm 810 mm
Notching
Thickness max. 13 mm 16 mm
Width (L) 60 mm 60 mm
Depth (P) 100 mm 100 mm
Working height 935 mm 910 mm
Optional Tools
HPS 115 D S H PS 175 D S
U-I Section bl ades 200 x 90 mm 300 x 125 mm
T-Section blades 120 x 13 mm 150 x 15 mm
V-notching
tooling [mm]
V-bending Press brake:
Bar bend. max. 250 x 22 mm 250 x 25 mm
Sheet bend. max. 700 x 3 mm 700 x 3 mm
Punching on
notcher:
Bar bend max. 125 mm 125 mm
Capacity max. 38 x 12 mm 38 x 13 mm
100 x 100 x 13 100 x 100 x 16
- 9 -
ADDITIONAL TOOLS
BENDING
Maximum bar size
PUNCHING AT THREADING STATION
Maximum capacity
Groove depth
NOTCHING
Maximum thread surface
PIPE NOTCHING
Maximum tube diameter
Based on material strength 45 [kg/mm2]
500x3 [mm2]
38x8 [mm2]
85 [mm2]
100x100x6 [mm3]
83 [mm]
The maximum punching pressure of this machine is 650 kN ( 65 ton )
The following tools are included in the basic equipment of the machine;
1 C – Spanner 80/90
3, 4, 5, 6, 8, 10, 14, 19 mm. Allen keys
Punch adapter
Punch holder
Stamp and matrix (22 mm)
Scraper
Round square blade (1 set)
Angle cutting blade (1 set)
Profile cutting blade (1 set)
Notching tools
- 10
FIVE WORK STATIONS
1.
1-PUNCHING STATION
All punching operating are processed by means of hydraulic power thus giving the machine
the ability to punch very efficiently and silently. It can either be used to punch thick materials
or thin materials in layers together. Punching is silent, powerful and efficient. The waste
materials in layers together. The punching table consists two parts. First is the punching
flange. The second is holder. The holder is a device that holds the material after punching not
to come back with the punch. It must be equally adjusted or it can break the punch. There are
different holders for different materials. However the standard holder which we supply is
suitable for punching is between 6-38 mm.
SAFETY PRECAUTIONS
All power and depth and other adjustment m ust be done under full control of an
experienced technician
Please check all the moving parts before working
Check the punch and die that they are in the same direction
Adjust the holder equally and according to the material
always use the protective plastics
on small and accuracy needing works use special protection
while replacing the punch or die or holder shut the main switch
never leave the machine unattended
do NOT overload the machine
2.
SHEARING STATION
The shearing unit has been equipped with a simple and robust fixing installation, which can be
adjusted for any material thickness within the cutting the cutting capacity of the machine. A
shearing up to 45
0
for flat bars or the cutting of the flanges of angle profiles, which have
previously been cut at inclined-angle cutting stat i ons.
The shearing blades constructed for mass production can be used on both sides ( the upper
blade has 2 cutting edges, the lower blade has 4 cutting edges ) and ensure a clean cutting
with the minimum deformation, from the full capacity till a material thickness of only 2 mm.
SAFETY PRECAUTIONS
Always use the bolder
Never place any part of your body under the blade
Do NOT overload the machine
3.
CUTTING STATION
This station enables the cutting of big angles with a capacity of up to 90
up to 45
0
. The angle between 45
0
and 900 will be obtained, these will be cut first at 900and then
0
and smaller angles
at the shearing station of the flange will be cut at the required angle. The fixing installation
supports the material in a manner to provide a corr ect cutting.
SAFETY PRECAUTIONS
Never place your hand or fingers inside the blade.
Do NOT overload the machine
Use holder fitted on this station for a better work
- 11
4.
5.
PROFILE CUTTING STATION
The machine are equipped as standard with the blades for cutting round and quadrangle bars.
Through additional equipment, it is possible to cut at the machine U-section, I-section and T-
section profiles in this clearance. The blades are held by simple squeezing jaws which ensure
an easy equipment arrangement at the machine without any detailed adjustment.
SAFETY PRECAUTIONS
Never place your hand or fingers inside the blade.
Do NOT overload the machine
Use holder fitted on this station for a better work
NOTCHING STATION
The notching station has been equipped as standard with a rectangle unit and threading table
having adjustable counter holders, which enable a repeatable positioning. Additional
installations are available for narrow widths or V notching of angles up to 45
it is possible to have units for forming at bar en ds and for easy notching works.
SAFETY PRECAUTIONS
Never put any part of your body under the blade
Use protective gloves or protective cages for very small works
Do NOT overload the machine
SHOWS OF THE FIVE WORK STATIONS
0
(V). Furthermore,
STANDARD SPECIFICATIONS
Punch and die Ø22
Punch holder
Flange cutting blade
Notching blade
Centralized lubrication
Crescent key
User's manual
- 12
SAFETY EXPLANATIONS
The Machine is equipped with a hydraulic check valve system in order to relieve the excess
pressure when the machine is overloaded, thus preventing serious damage to the machine and the
worker. All safety precautions are for your safety, which we believe will be obeyed by our customers
unasked.
SAFETY UNITS
Quick stop button use on the panel and main body
Protective barriers
In this manual are summarized the important i nformation for work safety. The following
security explanations and instructions are considered as the essential information for your s afety.
Any and all persons who must operate the machine should be firstly trained well in terms of the
operation and safety information and instructions. For this purpose, more copies of this manual shall
always be asked from the supplier. It should be clearly fixed out that which persons will have the
responsibility to change and arrange tools and blades. These persons need to be essentially trai ned
in terms of this subject.
All the METALLKRAFT machines are delivered as standard with a safety equipment,
such equipment is for a high and general work safety. For this purpose, the machine should only be
used in accordance for those purposes for which it has been constructed.
The most dangerous and probable deviations as to the construction limits of the machine are estimated to be as follows:
1.
Machining of other materials as unalloyed steel (45 kg/mm2)
2.
Erroneous use of the fixing installation
3.
Punching or fixing very small work pieces, as these will easily cause the operators be subject
to danger zones.
Should the additional tools be necessary to be used on the machine, which are not foreseen
by the producer, it should be re-verified whether or not there is sufficient safety and security against
work accidents. For this purpose, the producer should be contacted for advice when deemed
necessary. All the maintenance works should be carried out by sufficiently qualified expert personnel.
Particular attention should be paid to the correct assembly and arrangement of the hole stamps,
cutting cases, blades and other tools. In order to enable us and yourselves to fulfill our mutual and
common responsibility for all people, we request you to read this manual very carefully before putting
the machine into operation and to obey all the saf ety information and instructions.
Attention: All the parts of the machine dyed in r ed are danger zones and particular
attention should be paid in such zones!
All the operators should be instructed in order not to place their fingers or other body parts
near, in or under the parts of the machine colored in red. There is the risk of losing the body parts
when these are placed in such zones!
- 13
All the safety components and fixing installations that should be removed for maintenance
purposes, should be remounted again before the machine is reoperated. The operators should wear
the clothing described by the employer. The producer recommend the use of protection eyeglasses
against eventual stamp breaks and shoes with steel covering in order to prevent foot of the operator
against falling materials.
SAFETY RULES
1.
The assembly and adjustment works, tool changes and maintenance services shall only be
realized by the technical personnel qualified for this purpose, who should strictly obey the
instructions of the producer.
2.
Remove any oil remaining, cuttings and other impurities from the working zone where such
remaining might be left the previous operator.
3.
Before the starts working on the machine, the operator should make sure that all the tools are
in a perfect condition.
4.
Any leakage and order of hole stamps and cutting cases, blade tolerances etc. should be
checked after each tool change and be readjusted i f necessary.
5.
The scraper should always be adjusted according to the material resistance to be machined.
Unequal scraping forces can easily result with t ool breaks.
6.
Never punch any material which stronger than the diameter of the hole stamp. In this case, the
hole stamp can be overloaded and easily break.
7.
Always punch trough holes. Never punch base holes, unless the tool is clearly foreseen for
this purpose. The lateral elongation force, which occurs during punching of the base holes,
might excessively press the hole stamp against the cutting case and consequently an easy
break might result.
8.
The machine has been designed in a manner to work with the pieces which can be placed
without having subjected the fingers or hands into the danger zone. For punching, mortising
and profile cutting of the short pieces ( for instance small sheet metal parts ), special tools,
scrapers and security components are pieces should be placed into the machine and taken
back suitable holding tools.
9.
Regularly check the screw connections and other fixings of all the blades and other parts as
well as the safe seating of the hole stamp and cutting cases. For example, should the hole
stamp ( punch ) get loose during the operation, there occurs the danger that the hole stamp
inclined over the cutting case so that the tool might break.
10.
Before each tool change, make sure that the machine is disconnected from main switch.
11.
Completely disconnect the machine from the net before you carry out any maintenance work.
12.
Never let the machine function without any inspection.
- 14
13.
When you perform works where big forces are existing, the work piece should be additionally
protected through a block having an assembled roll or similar installation, which is to be
placed on the machine.
14.
The machine capacity shall never be exceeded. For this purpose, check the" technical data"
on this rules and compare the values with the information given on the manufacture plate. All
the capacity information is based on a material having a resistance of 45 kg/mm
2
15.
Should the hydraulic circuit flow be overloaded, the hydraulic oil will be led back to the reserve
tank over the overload valve until the pressure gets down again to the normal level.
Attention: HOWEVER, IT IS. NECESSARY TO UNDERLINE THAT IT MIGHT BE
DANGEROUS TO USE THE OVERLOAD VALVE AS A "SAFETY VALVE" IN O RDER TO
EXCEED THE MACHINE CAPACITY.
The producer presents all the instructions for a work protection and safety and hopes to have
a good and full calibration with you, the users, in order to ensure that the maximum Level of safety
could be obtained.
CONTROLS BEFORE PUTTING INTO OPERATION
1.
Press on the green " START " button in order to start the machine. In order to ensure this,
make sure that the red off button (" STOP") rotates clockwise (or directly to draw).
2.
Make sure that the entries for hole stamp and cutting case are safety fixed.
3.
At the command table, change the status from "NORMA" to "ADJUSTMENT" ( Consider that
the readjustment course is not automatic at this position. When you leave the foot pedal
loose, the machine does not return to standby, rather it simply gets left).
4.
Make sure that the course limiter allows a maximum course. Now, press on the foot pedal so
often that the hole stamp stays in the cutting case. Take care that the hole stamp is regularly
arranged with the cutting case.
5.
Change the position from “ADJUSTMENT” to “NORMAL” at the command board. No w t he
machine gets automatically back to the standby position.
6.
Check whether or not single cylinder perf orm, full course. Make sure that, no-hydraulic pressure occurs at the and of related course. In order to ensure that there is no air available in the
hydraulic system, repeat the process several times (air might enter here during transport).
7.
Verify all tubes, hoses connections, branching and reserve tank for eventual hydraulic
leakage.
8.
Fix again all the protection parts and remove al l loose subjects from the working zone of the
machine
The machine is now ready for your job.
- 15
OPERATION OF THE MACHINE
Operation elements
All the electrical delivery of the machine passes through the main switch. In order to connect
this, rotate the switch clockwise. To confi rm this, check that the control lamp starts lighten.
By pressing on the green “START” button, connect the motor (for the motor to be able to
function, the “STOP” button should be disconnected. This can be realized by rotating the red button
clockwise (or drawing this).
By pressing on the red “STOP” button, the motor will be stopped. The lightly pressed “STOP”
button gets locked at command. In order to loosen the button and to cause the machine to function
again, the “STOP” button will be turned clockwise ( or drawn ).
Note: The machine has two
pedals and double pistons. We
designed two workstations to work at
the same time; two operators can
make two operations at the same
time.
The pedal switch has three positions:
Over position
central position
lower position
If pedal is driven till the lower position and there remains fixed, the machine gets into the
deepest punching position. Nevertheless, the machine doesn’t turn back to the standby position until
the pedal is left loose.
The central pedal position allows the operator to effect unlimited positioning including over and
down course. This central position is very practical because it allows the operator to carry out touching
so that the work piece can be optimally positio ned.
The switch “NORMAL / ADJUSTMENT” ensures that the machine is operated at touch
operation or performs production at norm al functioning.
When the switch is arranged on “NORMAL”, the machine performs a normal and full work
cycle at each action of the foot pedal, that means the punch moves to the lowest position and then
gets again into the standby.
When the switch is arranged to “ADJUSTMENT” the
machine stops. When the pedal is left loose, the automatic
back course at this position has been cancelled.
REGULAR LUBRICATION INST ALLATION
The machine is equipped with a central lubrication
pump under pressure which is located at used, the system
should be adjusted to a pressure of 1-3 bars. When the
machine is at operation, a suitable pressure would be
maintained, through which the system will get back into the
previous filling pressure (approximately each 30 to 60
minutes).
- 16
ARRANGEMENT OF THE PUNCH TOOLS
IN GENERAL
The big punch bearing surface and the
removable front block have been constructed in
manner to allow a very wide range punch works:
Through the optionally obtained tools, the
big holes in any form up to the diameter / quadrate
as it is indicated in the capacity table can be
produced. In addition, machining at overhanging
position, with the removed front in addition, during
machining at overhang, with the removed front
block, the of U profiles of double T supports having
diameters or eventually diagonals up to 38mm
highest capacity can be punched.
The punching stamp is held though a
holding ring, according to the size of the stamp
(punch) one or two of the delivered adapters can b e
used. The matrixes are fixed to the tensioning pl ate
through a positioning screw. When the filled punch
stamps and matrixes are be arranged, it should be
paid attention to the screw is correctly placed on
the machined surface of the matrix. In order to allow
a suitable play area and to ensure that the material
is taken out, the punch stamp scraper plate should
be correctly adjusted, however it should not effect
the stamp course. Attention should be paid to that
the lower course limiting switch has been adjusted
as per the instructions. When the holes are punched
with sufficient material, a flat contact occurs at both
sides of the scraper plate. The scraper forces can
be important and unbalanced scraper forces can
lead to the break of the punch stamp through the
contact with a side of the scraper.
No material should be punched which is
thicker than the stamp diameter. The quality of the
hole is a direct finger appearance on the situation of
the punch stamp and matrix.
When the scraper fingers are used for very
big holes or irregular forms, the fingers should be
equally position and adjusted in order to prevent and
unbalanced scraper load.
Additional tools at this multi purpose wor k
station allow bar and sheet metal bending wor ks,
edge threading, tube threading, tube threading and
general column positioning works.
- 17
In order to install or change the punch tools you will need the following tools:
Hook key
Soc. head cap bolt key ( 6 mm )
Screw key ( 24 mm )
WHILE ORDERING SPARE STAMPS AND MATRIXES, PLEASE ALWAYS INFORM OF THE
FOLLOWING: MODEL, TYP E AND MANUFACTURING NUMBER O F T HE MACHINE.
Below we explain step by step now the hole stam p and cutting case are changed:
1)
In order to take out the cutting case, move the machine to a position where there is enough
2)
Disconnect the machine at machine switch
3)
Open the scraper, loose the coupling nut, fixing screws of the cutting case delivery plate a nd the
M12 screws, which hold the cutting case. Remove the coupling nut together with the hole
stamp and adapter. Remove the cutting case.
4)
Place the required punch tool set. Make sure th at the hole stamp and cutting case are correctly
fixed.
5)
Connect the machine and than position at “adjustment”.
6)
Move the hole stamp slowly towards the cutti ng case. Push the cutting case delivery plate
correctly so that the hole stamp and cutting case are completely arranged.
7)
Adjust the cutting case delivery plate in a manner that the cutting distance which remains
between the hole stamp and cutting case is fully equal and draw the delivery plate fixed in this
station.
8)
Check whether or not the receiving plate has been deviated during the drawing. If the cutting is
not equal, you should repeat the point 8. as soon as the plate is fixed the cutting distance is
equal, adjust the machine to “normal”.
9)
Take the scraper back then adjust the distance between the scraper and cutting case according
to the thickness of the material to the machined.
10)
Adjust the course adjustment in such a manner t hat the shortest possible way should be left
back.
11)
In order to protect the operations, fix the macralon protection before you start working.
- 18
PUNCH CAPACITY
The diagram shows the punch capacity curves of the XS-series depending on the material
thickness and stamp diameter. (Based on a construction steel having a traction resistance of
45kg/mm
2
).
Diameter of the punch stamp D (mm). During calculation of the punch capacity it should
proceeded according to the following formul a:
P = SHEARING SURFACE x TRANTION RESISTANCE
P = ∏×D × S ×TRANTION RESISTANCE
A calculation example:
A 20 mm hole will be necessary in a 12 mm thick homogenous steel sheet metal having 45kg/mm
traction resistance.
This is valid the following:
Punching pressure = Shearing surface x tracti on resistance x 0.0098 and
Shearing surface = Volume of the punch stamp x material thickness ( so the traction resistance
Amounts to 45kg/mm2, 0.0098 is the fixed value for the calculation of kg/ m m
2
on KN
accordingly : 20x 3,142x12x45x0,0098 = 333 K N ( 33,3 Tons )
2
Attention :
Never punch with a hole stamp which is thinner than the material to be machined.
- 19
SAFETY PRECAUTIONS ON EACH OF THE WORK STATIONS IS WRIITEN UNDER
ITS NAME
WRONG CORRECT
Wrong sized punch holder
Wrong sized part
Wrong distance
Normal punching
Very small punching, which requires
special eccentric die and tool
FLANGE PUNCHING
You can use the standard tool for all kind of punching, however for flange punching like pictured above
(right side), you have to order us a new set of eccentric die and tool.
- 20
ANGLE CUTTING INSTALLATION
This work station allows the cutting of big angles of 900 as well as cutting of the angles smaller
than 45
In order to cut angle profiles, the material is placed into the cutting zone through the fixing
installation and the support screw is adjust ed to the corresponding material thickness.
0
.
Nevertheless, one should pay attention here in that longitudinal move of the profile still remains
possible.
For the inclined cutting at 450, the angles should be first cut on the length where the delivery for
the cutting of edges is also foreseen.
Please the first and in the blade, here the highest support position will be used.
Now cut about 6 mm from the end of the material, while you mountain 450 at vertical position.
Now place the other and in the blade, here the left support position is used and then cut the
material longitudinally. For this purpose, 45
machine.
0
should be maintained for from surface position of the
In order to obtain other cutting angles between 450 to 900 first cut the angle profile at length and
then cut the flange as per the required angle at the sheari ng station.
The cavity in the shear fixing installation allows that the angle profiles can be positioned for left or
right side cutting. Here, attention should be paid to that the fixing installation gets adjusted to the
related thickness.
Each blade has four cutting edges and is held by the simple fixing screws. These blades should
not be sharpened. After four rotation these should be replaced by new blades.
WHILE ORDERING SPARE BLADES , ALWAYS STATE THE FOLLWING: MODEL, TYPE AND MANUFACTURING NUMBER OF THE MACHINE
- 21
MITRING ANGLE 45 DEGREES
Since the introduction of the requirements for heal th and safety, the accessibility and distance
between hold-downs and blades have been amended.
To this effect the operation cutting angle i n the angle cutting station requires the following
simple hold-down adjustment.
Once the hold-down is secured for cutting as posit i on 3, it is also possible use the hold-down
for cutting angle at 90 degrees if required.
STANDARD HOLD-DOWN
POSITION
REMOVE THREE SECURING
SCREWS & INVERT
HOLD-DOWN AS ABOVE
ROTATE AND SECURE THE
HOLD-DOWN TO THE
MACHINE FOR CUTTING
- 22
PROFIE CUTTING STATION
SHEARING INSTALLATION
Blade adjustment / Blade Change:
During the installation of the new blades, pay attention to that the mobile blades fully approach onto
the shear lever. While the machine is disconnected, pull blades together with the soc. head cap bolts
(Nr.1) totally onto the shear lever.
In order the adjust the blades, more the shear lever so wide towards down that both blades
get aligned. Now disconnect the machine. Adjust the mobile blade in such a manner that there
remains a cutting distance of 0.1 mm. Pull the blade having conserved the right cutting distance
(bolts, part no. 2 ).
Note : Both blades can be used on both sides. Y ou have four cutting edges.
- 23
SHEARING, PROFILE SECTION CUTTING
The shearing unit has been equipped with a simple and strong fixing installation that can be
arranged at any material thickness within the cutting capacity of the machine. A shearing delivery table
having adjustable quides has been const ructed in order to allow a correct delivery of the material. The
guiding can be arranged in a manner to allow the angle cuts up 45
of flange of angle profiles, which have been previously cut at the inclined cutting station. Alwa ys place
the material from the entry side of the machine and make sure that the material gets fixed by a
correctly adjusted fixing installation. If a full a full cutting is required, the biggest possible dimensions
for the material to be cut at angles, amount to 70x70x10.
In case the shear blade should be grounded, grin d only the cutting surfaces. A re-grinding is
possible up to a maximum depth of 0.8 mm. After the grinding the blades should be adjusted to a play
of 0.1 mm.
Shows special section blades available
0
for flat bar material or the cutting
- 24
Front distance
NOTCHING STATION
The threading station has quadrangles punch stamp as a standard equipment element and is
delivered with a threading table complete with adjustable lateral and rear counter holders, which
essentially simplify the repeatable positioni ng of the material.
The sharp notching tools can also be constructed at t hi s wo rk station. Optionally, the units for
narrower width of quadrangles or forms can also be delivered. Various uni ts are also available for the
forming of bar ends.
A special feature of this work station is the possibility to fix some punch end units, that means
tools for smaller punching works up to a punch pressure of 40 t ( characteristics can be supplied upon
request ).
In case the grinding of the notching stamp is necessary, only grind the side and front surfaces
of the stamp. The matrixes have four cutting edges and should be turned in order to require
new cutting.
NOTCHING TOOLS – ADJUSTMENT
The below described steps should be followed for the change of the notching (threading) blade set :
1.
Move the stamp to the exit position (that means fully open)
2.
Disconnect the machine at the main switch
3.
Remove the scraper finger and the stamp
4.
Remove the hole stamp and loosen the support
5.
Fix the new stamp
6.
Correct the machine and adjust it to “ADJUSTMENT” position. Fully lower the st amp and
disconnect the machine
7.
Take the hole ring into the support. Secure the fro nt hole ring, then adjust the distance as
illustrated in the below sketch
8.
Secure the support on the machine after the adjustment of the front distance. Then adjust the side
distances as illustrated in the sketch
9.
Secure the side hole rings on the support. Check again the distances for safety
10.
Connect to machine to loosen the stamp. Remount the scraper finger.
adjust the machine course in order to have motion as small as possible.
Note :
The lateral distances of the stamp should be adjusted as per the adjustments illustrated in the
sketch. Then the limiter will be arranged in such a manner that the lower edges of the hole ring will be
touched by the bas.
Lateral distance
NOTCHING ADJUSTMENT
Adjustment
the lowering
ated bending
screws
he stropper A
0.1-0.2 mm
0.1-0.2 mm
- 25
STROKE ADJUSTMENT
In order to lock the lowering stroke ( that
means repeated bending etc. ) you must
adjust the stropper A towards side.
In order to lock the upper stroke B, use
the punch stamp with the foot pedal and
hold this in the lower position. Now lift the
foot up in order to verify the position. If
necessary, a readjustment shall be
foreseen now.
Attention:
All the adjustments to be made on the
stroke limiter, can also be carried out
by using, the leading mode. For this
purpose, the punch and / or shear
position is arranged in such a manner
that the required position is obtained
by the foot pedal and then the
stoppers are adjusted upon request.
After the adjustment process, you
must cause the machine to function
under normal tempo in order check the
stoppers.
In order to lock the back stroke of the shearing unit, use the shears with the foot pedal and hold
them in closed position. Now you can sadjust the stopper arrangement C. Then lightly lift the foot in
order to check the position. If necessary, carr y out a readjustment.
- 26
HYDRAULIC SYSTEM
A 5.5 KW motor drives a hydraulic pump, which supplies the power cylinders on each end of
the machine through regulation valves. The punch cylinder is directly connected to the punching unit,
where the shear cylinder is connected through a turning lever.
Hydraulic oil
For this purpose are advised the oil types indicated in the machine plate. The oil filling and
ventilation supports are located in the tank where access is provided after removal of the protection
having cooling cavities located on machine base.
Absorption filter
The oil filter should be checked every twelve months. Access to the filter can be ensured after
having dismantled the screws of the tank protect i on. If necessary the filter can be washed in paraffi n.
Impurity section
After having taken out the lower machine body protection, the section located under the main
chassis should be checked each year for dirt and i mpurities.
Cleaning
Under normal operation conditions, all the visible working parts should be regularly cleaned
from foreign substances that can prevent a st andard use of the machine.
REGULAR MAINTENANCE
Daily Maintenance;
Before starting machine
Check full level in tank – top up us necessary
Check oil level in oil pump – top up us necessary
Check condition of all blades, punch and die
Check surrounding work area is tidy, remove and off-cuts, slugs from floor area
Clean off any mill scale which may have collected around the cutting apertures
Weekly maintenance;
But depending on work load
Examine power cable and food pedal cable for damage or chafing
Check movement of machine is smooth when running under no load condition
Monthly maintenance;
Check arm adjustment for any slackness
Yearly;
Change hydraulic fluid, check the oil absorption filter for any dirt and impurities
- 27
32 Grade Mineral Oil
46 Grade Mineral Oil
Agip
HYDRAULIC LUBRICATION HYDRAULIC FLUID
Fill to top level of inspection glass. Use only mineral oil as recommended or equivalent. You
can select a oil at the table 1
OILING LUBRICANT
Check oil level in pump reservoir daily, operat e pump 2/3 times daily.
Castrol Magna DR220
Shell Tomma T220
B.P.
Mobil Vactra oil No. 4
Esso Febis K220
Energol GHI 220
Lubrication check
Before operating machine, the following important checks should be made.
The hydraulic fluid is at top level of inspection glass.
The oil pump has been operated, and that there is oil pressure indicated, check oil level in pump
HYDRAULIC OIL LIST
On most of our machines hydraulic systems we use Grade 32 Hydraulic Oil and Grade 46
Hydraulic Oil Generally we recommend the use of Shell Tellus Nr.46 and BP Energol Nr.46 for
hydraulic systems
Brand
BP Energol HLP 32 Energol HLP 46
Castro Hyspin AWS 32 Hyspin AWS 46
Elf Elfolna 32 Elfolna 46
Esso Nuto H 32 Nuto h 46
Fina Hydran 32 Hydran 46
IP Hydrus 32 Hydrus 46
Mobil DTE 24 DTE 25
Q8 Haydn 32 Haydn 46
Shell Tellus 32 Tellus 46
Texaco Rando HD 32 Rando HD 46
Total Azolla ZS 32 AzollaZS 46
DIN 51524 Specification
OSO 32 OSO 46
Table 1
DIN 51524 Specification
- 28
MACHINE ROD AND LEVER READJUSTMENT
After a preliminary working period (about 5 to 6 days), it will be necessary to carry out arran-gement
adjustments on the machine.
Punch rod
The arrangement of the rod will be realized with t he hel p of a “rod leading plate”.
This plate should be readjusted.
The related adjustment screws are located at the exit side of the machine.
In order to adjust the rod, proceed in the following manner :
Remove the punch stamp
Loosen the safety nuts
Readjust the rod adjustment screw
(not to tighten too much)
Lock the screws with a safety nut
The adjustment control is to be made through a few in and out movement ( about 6 times ) of
the rod. Then the machine should be checked in adjustment mode. If the rod does not move here, the
plate should be readjusted and the process m ust be repeated.
Shear lever
The machine should be disconnected before car rying out any readjustment works on the shear lever.
The readjustment of the pressure lines shoul d be carried out from the delivery side of the machine.
For this purpose, proceed in the following manner:
Loosen the safety nuts ( M24 ) only of the three pressure line positions
Until alight pressure is obtained, rotate the adjustment screws clockwise
Tighten the safety nuts again and check the m ovement ability
Attention: The grooving stamp and matrixes are now not any more arranged. Please adj ust
these again before the use of the machine.
- 29
PUNCH TOOLS
The part numbers in the above given figure 1belong to the standard equipment.
- 30
Assembly
No
1
1
Punch support
2
4
Soc. Head cap bolt
3
1
Stamp 4 1
Adapter
5
1
Specific nut
6
1
Top scraper plate
7
1
Distance piece
8
1
Spring
9
1
Washer
10
2 Soc. head cap bolt
11
2 Scraper support
12
1 Scraper head
13
2 Washer
14
2 Spring ring
15
2 Counter washer
16
6 Soc. head cap bolt
17
6 Counter washer
18
1 Washer
19
1 Matrix holder
20
6 T nut
21
1 Set screw
22
1 Matrix
23
1 Fixing wheel
24
1 Set screw
25
1 Hook key
PUNCH TOOL PART LIST
The parts indicated in the below given table belong t o the standard equipment. Some different
hole stamps and cutting cases are illustrated on t he lateral drawing.
As standard material, a Ø22 mm hole and cutting case delivered (the maximum diameter
amounts to 38 mm). Adjust the hole stamp centrally so that an equally rotating cutting distance of 5 %
of the material thickness remains. Never punch a material that is thicker than the diameter of the hole
stamp.
Quantity
Part Identification
LUBRICATION OF THE PUNCH TOOLS
In order increase the service lives of the hole stam p and cutting case, we recommend you to use one
of the below listed lubrications;
Shell Garia 927
BP Servora 68
Castroll llobroach 219
Duckharns Adfomol EP7
Joseph Batson LB 733
- 31
1
Mobile profile blade
1
2 Fixed profile blade
1
3 Hook 2
4 Soc. head cap bold
4
5 Set screw 1
6 Set screw 4
7 Counter nut
4
PART AND PARTS LIST OF THE CUTTING FRAME
PART DESCRIPTION QUANTITY
- 32
Description
1 1
Mobile angle blade
2 2
Fixed angle blade
3 3
Hex. soc. head cap bolt
4 8
Set screw
5 4
Hex. soc. head cap bolt
6 4
Spring washer
BLADE ADJUSTMENT / BLADE CHANGE
During the installation of the new blades, pay attention to that the mobile blades fully approach
onto the shear lever. While the machine is disconnected, pull blades together with the internal
hexagonal screws (3) totally onto the machine body, without the thread pins (4) press against the
blade.
In order the adjust the blades, more the shear lever so wide towards down that both blades
get mobiles and fixed blades) get aligned. Now disconnect the machine. Adjust the mobile blade in
such a manner that there remains a cutting distance of 0.1mm ( the thread pins, part no.4 serve for the
adjustment ). Pull the blade having conserved the right cutting distance (screws, part no. 5).
Note: Both blades can be used on both sides. Y ou have four cutting edges.
No
Qty.
- 33
NO
PART DESCRIPTION
QUANTITY
1
Upper blade
1
2 Lower blade 1
3
3
4
3
5 Spring washer
3
6
3
7 Set screw 9
8 Hex. soc. head cap bolt
3
9 washer 3
SPECIAL
BLADE PART LIST
Set screw
Washer
Nut
- 34
1
Scraper finger
2
2 Upper blade
1
3 Lower blade
2
4
Lower blade
1
5 Holder 1
6 Tensioning 2
Hex. Screw M12x65
4
Spring disc 12mm
4
Flat disc 12 mm
4
8 Nut M12 4
9 Internal hex. Screw M10x25
2
10
Internal hex. Screw M10x30
4
11
Maden screw M8x20
6
12
Internal hex. Screw M16x40
2
13
Flat disc M16
2
14
Nut M16 2
NOTCHING PARTS
PART DESCRIPTION QTY.
7
- 35
NO
PART DESCRIPTION
QUANTITY
1 Hole ring ( 5 – 38 ) usable with stamp
1
2 Hole ring ( 3 – 19 ) usable with stamp
1
3 Hole ring holding plate
1
4 Hole ring holding plate
1
5 Adapter plate
1
6 Adapter plate
1
7 Support tensioning
2
8 Matrix support
1
9 Hex. soc. head cap bolt
6
10
T nut 6
11
Set screw 1
12
Set screw 1
13
Soc. head cap bolt
2
SPECIAL ACCESSORIES
Drilling of the I and U profiles
During punching of the I profiles, change the st andard scraper head with the lengthened type.
Min. profile size 65 for I or U profile
Max. profile size 120 for I or U profile
Note :
These article are already available in the standard kit
- 36
Figure 1
Figure 2
A B
TRUE PUNCHING
This machine is equipped with a single piston. When you work with the machine on shearing station
with max shearing and then change to punching station the overtravel may cause the holding nut (A) to
contact the scraper(B) and damage these components. (Figure - 1)
To avoid this, after working with the shearing tool you must make sure that its adjusted back to
working with punching tools.
Re-adjust the stroke so that when the punch goes down it does not contact the scraper. This means
that you must adjust the stroke as shown in Fi gure - 2 by l eaving enough travel stroke (4 – 5 mm is sufficient)
shown in Figure – 3. Remember that, at this adjust ment if you work with the punch you will
damage the scraper and the tool holder
Figure 3
If you will work with max stroke of the SHEAR only then you must adjust it to full stroke as
.
- 37
HYDRAULIC PLAN
- 38
TRANSPORTATION
There is a ring mounted on top of the machine for t ransport purposes. You mount the chain or rope to
this ring for all kind of displacement purpose s
DAMAGES
As soon as you receive the machine, make a general check on the machine anal inform the
transporter and the manufacturer in case of any visible damage. Especially be careful on these points;
a)
Visible mounted tools
b)
Tools in the
c)
Safety guards
d)
Oil gauge
e)
Main power knob
f)
Foot pedal cable
Attention:
If you see any visible damage on electric components, do NOT connect the machine to power.
Inform the manufacturer as soon as possible. Ask a qualified electric engineer for connect ing the
machine. STÜRMER MASCHINEN GMBH WILL NOT BE RESPONSIBLE FOR DAMAGE CAUSED
BY IMPROPER CONNECTION OF ELECTRICS.
-39-
EC Declaration of Conformity
EC Declaration of Conformity
According to Machinery Directive 2006/42/EC Annex II 1.A
Manufacturer/distributor
hereby declares that the following product
Product Group:
Description of the machine:
Machine typ:
Serialnumber:
Year of manufacture:
corresponds to all the relevant provisions of the abovementioned Directive and other Directives applied (below)including their amendments valid at the time of the declaration.
Relevant EU Directives:
The following harmonized standards have been applied:
DIN EN ISO 12100:2010
DIN EN 60204-1:2007-06
DIN EN ISO 13857:2008
Responsible for documentation:
Hallstadt , 15.04.2016
Stürm er Maschinen Gm bH
Dr.-Robert-Pfleger-Straße 26
D-96103 Hallstadt
Metallkraft® Metallbearbeitungsmaschinen
HPS 55 DS, HPS 65 DS, HPS 85 DS
HPS 115 D S, HPS 175 DS
Hydraulic section steel shears
20
2014 / 35 / EU
2014 / 30 / EU
Safety of machinery - General principles for design - Risk assessment
and risk reduction (ISO 12100:2010)
Low Voltage Directive
EMC Directive
Safety of machinery. Electrical eq uipment of machines. Specifi cation for
general requirements
Safety of machinery - Safety disctances to prevent hazard zones being
reached by upper and lower limbs
Engineering Department, Stürmer Maschinen GmbH,
Dr.-Robert-Pfleger-Str. 26, D-96103 Hallstadt
Kilian Stürmer
Managing Director
www.metallkraft.de
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