Hydraulic Shearing Machine Operation Manual

This is one complete operation manual for the swing beam shearing machine, which is also very popular hydraulic shearing machine. You can check out the Hydraulic Guillotine Shears Operation Manual in another post.

Standard features of hydraulic shearing machine

The hydraulic shearing machine is provided for cutting metal-steel plate, and capacity is based on plate strength of 450N/mm2. Please correct the plate thickness if cut other material plate with different strength.

Sheet plate welded structure is adopted, easy operation and reliable performance. Cutting is driven by hydraulic pressure, and return is by nitrogen gas cylinder, which can protect the machine from overload. Fitted with digital display system or numerical control system as customer’s request.

Blade gap with indicator for a handy and prompt adjustment. Alignment device with lighting, cutting stroke can be adjusted to improve the efficiency of cutting narrow plates. Front support arms and back gauge are equipped. The back gauge is mechanic transferring, position is numerically displayed or positioned by NC controller through the encoders, with micro-adjustment by hand-wheel. The front supporting arms are ruler counted. Rolling material support ball is provided on worktable to minimize fish tail with sheet bar and to reduce frictional resistance.

Installed safety fence, ensure the operation safety.

Frame of hydraulic shearing machine

Machine frame

Steel-welded plate, high rigidity. Two cylinders are fixed on left and right vertical pole. Installed vice cut-board on worktable conveniently adjust low-cut board. Keep the gap between up-cut and low-cut coincidence. Install feed ball on worktable, operation convenient and fast.

Cutting frame

Welded plate, high rigidity, is support at eccentric socket (9), by left and right cylinders and stroke cylinder drive, finish cutting by pendulum repeat. (See Fig. 1)

The vertical surface of up-cut support is curve, keep the gap between up-cut and low-cut coincidence.

Pressure device (Hold down)

It is consisted of some pressure feed cylinders installed at support board in front of machine frame. Oil flow in pressure feed cylinder, pressure head press down against the pull force of stress spring (18), press plate tightly. Finish cutting, the cylinders are reset by the pull force of stress spring. The pressure is bigger as thicker as the thickness of plate. (See Fig. 3)

Front gauge and back gauge

Front gauge: fixed on worktable, valve display on ruler, adjust mobile bar to necessity valve. When cut thin steel plate, cut it conveniently on front gauge.

Back gauge (see picture5) fixed on up-cut board, pendulum up and down as up-cut board. Adjust back gauge by 0.55Kw motor, reduce through gear, and drive by control rod. Brake down the button “+” (or”_”), can adjust gauge to front or back. When mechanic adjustment cannot get the necessity valve, turn hand-wheel (50) to demand valve, the adjustment of back gauge is convenient and reliability.

The standard range of back gauge is 20-750mm. When the length of cutting plate is longer than the max distance of back gauge, remove the back gauge (43) to the least place, lift up the board by the incline surface of support frame (47), then can cut any length of plate. (See Fig. 4)

shearing machine cutting frame structure and blades gap

shearing machine oil tank and stroke cylinder

shearing machine hold down cylinder

shearing machine backgauge

Installation of hydraulic shearing machine

Packing / Shipment of hydraulic shearing machine

All machines leaving the factory are packed with squaring arm and foot panel tied to the hand guard. Working tools and operation manual are packed into one box.

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

 

Lifting the hydraulic shearing 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. (See Fig. 5)

shearing machine installation

Foundation

All our shears are designed to use the foundation. Details please check the attached foundation drawing.

 

Installation

This hydraulic shearing 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.

 

Electrical Installation

Be sure that the local power supply is suitable for this hydraulic shearing machine before any electrical power up. Connect power cable to the bottom left of the electrical panel.

 

Some machine may require N (Neutral) wire.

 

Electrical diagram of hydraulic shearing machine

Shearing Machine Electric Diagram

4.1 The following steps are to be cared for by the owner and must be carried out by specialized personnel.

  • Check the hydraulic shearing machine nameplate and confirm that the wiring of the machine
  • Corresponds to the available power in your facility.
  • If the required power does not meet the requirement of the machine please contact your electrical supplier.
  • The power incoming to the machine should be fused so that the machine can be fully disconnected for repair.
  • The Electric drawings check the following attachments, the different controller has different drawings.

4.2 All the operating buttons fixed on controller panel at front except foot switch SF. The symbol of each function is displayed on the above of buttons.

Detail operation steps of the digial display system as follows:

Open the door of the electric box, close the power switch QF1, QF2, the machine is wiring on, close the electric box. Push the key button SA1 (  ), switch on the control circuit. Indicating light HL1 ( ) lighting shows the machine power on.

Push button SB4 or SB5 (), can run the back gauge to the front or go back. The position of back gauge displayed on the SICK mechanical displayer, at the max. and min. travel of back gauge, installed limit switches (SQ3 SQ4), standard max. travel is 500mm-750mm; min travel is 20mm.

Push lighting button SB3 (), lighting shows the pump motor start to work, at the same time, you can hear the working voice.

Switch the button SA3 (), select cutting mode. At (), it is manual mode. At (), it is auto mode.

( ) is the Illumination Light. Turn SA4 to (1), start to count. To (0) place, stop counting.

 

Hydraulic System

Clean the hydraulic Oil

The hydraulic system has the high requirement for the cleanliness of hydraulic oil. The clean of the oil tank is very important.

When replacing the hydraulic oil, you must discharge the cover of the oil tank. Use the towel to clean the bottom of the tank (do not use cotton yarn), then wash with cleaning coal oil gasoline. For limitation of tank cover, the arm cannot reach the end of the tank; you can wrap the towel on the bamboo or stick to wipe each corner. Loosen the leaking plug or brake valve to leak out the dirty oil.

Use the cleaning towel to dry the sides and bottom of the tank until it’s clean. If necessary, roll the dough at the welding seam or difficult cleaning places to cling the dirt, and then put on the cover.

Choose the hydraulic oil

The mark value of hydraulic oil is equal to the average value of viscosity when the temperature is 40℃.

If the working pressure and temperature of the hydraulic system are higher, and the working speed is slower, the chose hydraulic oil mark is higher.

It is recommended to use antiwar hydraulic oil ISO VG46# (the average value of viscosity is 46mm2/s when the temperature is 40℃). If the machine operates under 5℃ for a long period, you can choose hydraulic oil ISO VG32#.

It is also recommended not to use the machine at very low temperatures (below -5°). However, should this occur, and then let the machine run idle for a while. An oil heater can be fitted in the circuit if required.

Under the normal working conditions, the oil temperature must not exceed 70℃. Under special conditions, oil cooler can be fitted necessary.

Fill the oil

The using oil must clean. Screw the nut of air filter, filling through the air filter. If using the filling equipment with filter, you can open the cover of the oil tank and fill directly. Observe oil gauge, when ram stops at Top Dead Spot, the hydraulic oil fills at 80~90% of interspaces.

Make the machine work, first idling then at the maximum stroke to expel any air bubbles in the hydraulic circuit.

  • Hydraulic schematic drawing checks the following fig..

Shearing Machine Hydraulic Diagram

The hydraulic system’s working rule as follows:

The cutting frame goes down:

When the magnetic discharge valve 3 is electricity working on, the hydraulic oil drew out by pump 2 and flows through magnetic discharge valve 3, go into the hold downs and the up-area of main oil cylinder, the piston of hold downs go down to press the metal-plate after against the pull force of the spring, and the oil pressure starts to rise. When the pressure get against the nitrogen gas pressure in stroke cylinder, the cutting frame goes down to cut.

The cutting frame returns up:

When up-cut frame goes down at the down-dead spot, magnetic iron YV1 of magnetic discharge valve 3 lost electricity by a limit switch, the cutting frame goes up by the pressure from nitrogen gas cylinder. At the same time oil of up-area in the main cylinder flow back oil tank through the magnetic discharge valve. Also, the piston of hold downs goes up by the pull force of the spring and oil return back to oil tank through magnetic discharge valve 3. When the cutting frame come at the up-dead spot, one cutting is finished.

 

6. Standard control equipment

 

6.1Start button:To start the main motor running and Control circuit.
6.2Stop button:To stop the main motor running and Control circuit.
6.3Auto/Man mode selector switch:Select the working mode
In Auto mode
-One step on the foot switch, the cutting frame will cut continues.
 -Can command cut by foot pedal only.
 In Manual mode
 -One step the foot switch, the cutting frame will only do once cutting.
 -Adjust the cutting stroke by return the rotating button on the panel.
6.4Foot pedal:Push to command cutting blade down and release to have top blade carrier rise in AUTO mode.
6.5Illumination Light:Working light to shine at cutting blade area, operating at single phase power supply at 220V, 50Hz.

 

Adjustment and operation of hydraulic shearing machine

Adjust the gap between blades of hydraulic shearing machine

The blade gap is very important to the quality of cutting and the life of blades, please according to the gap adjusting table below.

Adjust the gap between blades

When adjusting the gap (see picture 2), need to loose the tight screw (4), then turn the handwheel (3) to the requested value after calculated by the thickness of the plate, then tight (4).

There is a ball valve (on right side of the machine, outside of cylinder). It is used to measure the coincidence gap between up and low blade.

Detail ways: at manual mode, when cutting frame go to down-dead spot, close the oil circuit rapidly, the cutting frame will stay at the down-dead spot, then turn on the ball valve a little by a little, the cutting frame will go up step by step on the all stroke. And then can measure the coincidence value of the gap between blades.

Operation of hydraulic shearing machine

7.2.1 Preparation of machine

(1) 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.

(2) Clear the dirty oil on components, pay attention that the ball valve should be at the open position.

(3) Lubricate all the necessary spots.

(4) Supply HL46 hydraulic oil in the oil tank (about 200L each machine under 12mm model).

(5) Connect the earth line, switch on, and check the working action of all electrics.

7.2.2 Starting the machine

Push ‘START’ button and release.

Motor “on” indicator light turns on.

Put mode selector from MAN to AUTO position.

Step the foot switch, the cutting frame will go down to cut.

If not, that means the motor is running in the wrong direction. Switch off the power supply. Reverse starts the motor again, any of the two phase wires.

The top blade carrier will rise and stop when it hit the limit switch.

7.2.3 Motorized Back gauge

The motorized back gauge readout is accurately set in the factory and it should correspond 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 decreased and stops when hitting minimum travel limit switch L/S 4.

The parallelism of the back gauge is set in the factory; however, it can be calibrated when necessary.

Bring back gauge bar to the rear for removing anti-rust coating prior to cutting.

Note: (1) The pressure table should be on during cutting, and check the pressure if it shows wrong, may adjust the overflow valve.

(2) During the operation, if there is deviant noise or the oil tank over temperature, should stop the machine immediately, and the temperature of the oil tank should not exceed 60℃

 

Trouble shooting of hydraulic shearing machine

Machine Cannot Start

  • Check incoming power supply.
  • Check that Emergency Stop is release.
  • Check transformer output.

Machine Cannot Cut

  • Check that limit switch is engaged.
  • Check that motor is rotated in a correct rotation.
  • Check that foot paddle cable is not broken.
  • Check that micro-switch inside foot paddle is working.

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

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.

 

The fault and resolve of hydraulic system

FaultCauseResolve
The hydraulic system no pressure and cutting frame no action1.      The plug of magnetic exchange valve is a bad connection.

2.      The valve core is jammed by waste or becoming rude. All throttle valve hole of coincidence valve cannot flow.

1.      Inspect the plug.

2.      Disassemble the valve and clean.

1.Cutting frame return slowly or cannot go up at up-dead spot

2. The action of cutting frame and hold downs is inharmonious

 

The pressure of nitrogen gas is not enough.Supply nitrogen gas for adding pressure

 

Maintenance of hydraulic shearing machine

Lubrication and Hydraulic Oil

This machine uses hydraulic oil grade 46, refill or replace only with the same grade of oil as follow:

FIAT-HTF 46, ENERGOL HLP 46, ESSO NUTO H46, SHELL-TELLUS S68, TOTAL-AZOLLA 46

Lubrication program

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

shearing machine frame

No.nameflowInternal time(h)Kind and type brand
1A top point and a bottom point on each return cylinder.Small16Ca-lubrication Oil

ZG-3

GB491-65

Mechanical oil

N46GB443-84B

2A point on the left and a point on the right of the rear stop sliding nutMedium8
3Two fulcrums for the oscillation of the upper knife frame, one on the left and other on the rightSmall24
4One on the left and the other on the right of the clearance shaft sleeveSmall48
5Each spot on piston rod of left and right cylindersMedium84# carbon-lithium

Q/SY1000-65

6Each one on the padding block of the left and right cylinderMedium8

 

Note: 1. Ca-Lubrication 50%, mechanical oil 50%, mixing for use.

  1. Carbon-lithium lubrication oil must mix with 30% mechanic oil.
  2. Exchange oil of tank one times per half year.

Changing of Shear Blade

Both top and bottom shear blades are identical and inter changeable. Use the ball valve to make the cutting frame go down at the lower dead spot,

The 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 the 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 the small set screw to close up blades when require.

CAUTION: Always engages a qualified and experienced personnel to do this job, otherwise damage to shear blades/machine or personal injuries may result.

Grinding of Shear Blade

The Shear blade is rectangular in shape and the upper blade has two cutting edges, the lower blade has four cutting edges.

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

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

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

Upper and lower blades

(Tooling drawings See the attached drawings)

 

Safety preventing and hydraulic shearing machine main construction

Note

—The section is used in the machine with special demands; it is only referenced to other machines.

For preventing the safety of people and equipment, we design the safety equipment. The operator must not change, remove or discharge the safety equipment.

10.1 Light Beam/Laser Beam

There is a light beam or laser (according to customer’s request), If the operator wards off the light of curtain, the safety module will work. The ram cannot move downward. To avoid the operator injured.

10.2 Safety grid

There is safety grid at side and back of the machine. It can keep the operator away from dangerous areas. Safety grid connects electrical system by the safety switch. When opens the safety grid, the electrical system starts, the machine cannot operate.

10.3 Emergency stop

There is an emergency stop button on the handle control station, hanging control station. When there happens error operation or other accidents, push the emergency stop button, the machine will stop all actions.

10.4 Hydraulic system

Ram’s falling is very dangerous. To avoid its falling, the system adds the safety lifting valve. The valve cores of exchanging valve and safety lifting valve have checking signal. If the valve core is abnormal, the checking signal will stop the electrical system to avoid the falling injury.

If the valve cores of exchanging valve and safety lifting valve cannot reset, check the valve.

10.5 Troubleshoot

The normal operation is safety.

If it happens any strange accidents, or when you maintain or repair the machine, you lock in the safety grid, push the emergency stop button, which inside the uprights, then call for help.

If your hands or other parts of the body are clamps by the punch or sheet, push the emergency button; check the condition then restarts the machine. Switch the operating mode to “inch” position.

Then pushes the handle return button, the ram returns pulls the clamped parts out.

 

2018-01-16T17:22:24+00:00

One Comment

  1. Jordan Champ September 26, 2017 at 6:25 pm - Reply

    This look very understandable as you represent it with the use of diagrams and other materials thanks for sharing all this.
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