Cleveland Steel Tool 55 Ton User manual

55 Ton Ironworker
Manual
800-446-4402
www.clevelandsteeltool.com
474 E. 105th St. • Cleveland, OH 44108
Serial #__________________________

1 Company Profile, Warranty
2 Operator and Supervisor Information
3 Requirements
4-5 Signal Panel Information
6 Installation
7 Machine Front View
8 Machine Back View
9 Machine Side Views
10 Maintenance Precautions and Schedule
11 Operations Diagram
12 Control Panel
13 Electric Stroke Control
14 Flat Bar Shear Station
15 Flat Bar Shear Station Maintenance
16 Angle Shear Station
17 Angle Shear Station Maintenance
18 Optional Tooling - Auto Cut
19 Optional Accessory Light
20 Punch Station
21 Punch Operation
22 Optional - Oversize Punch
23 Optional - Oversize 241 Punch
24 Punch Station Maintenance
25 Punch and Die Styles
26 Optional - Angle Notcher
27 Angle Notcher Maintenance
28 Optional - Press Brake
29 Press Brake Maintenance
30 Optional Coper Notcher
31 Coper Notcher Maintenance
32 Optional Pipe Notcher
33 Pipe Notcher Maintenance
34 Optional - Rod Shear/Multi-Shear
35 Rod Shear/Multi-Shear Maintenance
36 Optional - Hydraulic Accessory Package
37 Exploded View
38 Parts List
39 Troubleshooting
Table of Contents

55 Ton Ironworker
STANDARD FEATURES
Technical Specifications
Rated capacity
**Rated at 65,000 psi tensile strength
55 Ton
Number of work stations 4
Throat depth 7-1/2"
Maximum capacity 1-1/16" dia. thru 5/8" plate
Largest standard punch 1-1/16" punch
Open height 8-1/8"
Closed height 6-7/8"
Stroke 1-1/4"
Table size 6" x 10"
Hydraulic system 7 gallon reservoir
2,500 PSI, 2-1/2" cylinder
Standard motor 5 HP, 3 phase 208V or 230V - 14amp
Optional motors 5 HP, 3 Phase, 460V - 7 amp
5 HP, 3 Phase, 575V - 6 amp
5 HP, 1 Phase, 208 or 230V - 23 amp
Dimensions Base 44-3/8" W x 36-1/8" D x 55-1/4" H
Shipping Weight 2,480 lbs.
Punch Station with
pedestal die table
219 Punch and 413 Die
Angle Shear
3" x 3" x 3/8"
4" x 4" x 1/4"
mild Steel
Flat Bar Shear
3/8" x 14"
1/2" x 12"
3/4" x 4"
mild Steel
• Fully guarded
• Gauge table
• Adjustable steel strippers
• Fully charged hydraulic system
• Electric stroke control
• Shear blades reversible for extra long life
• Direct drive pump
• Open station for optional tooling

1
Company Profile
The Cleveland Steel Tool Company offers a full
line of high quality, low maintenance hydraulic
ironworking machines, associated tooling and
accessories that are used in the steel fabrication
industry. With proper operation, care, and
maintenance, your Cleveland Steel Tool Ironworker
will provide years of safe, trouble-free ironworking
service. Please take time to study this manual
carefully to fully understand Ironworker safety
procedures, set-up, operation, maintenance,
troubleshooting and warranty coverage prior
to putting the machine into production. Any
questions not answered within this manual can
be directed to The Cleveland Steel Tool Company
or visit www.clevelandsteeltool.com for more
information.
474 E. 105th St.
Cleveland, OH 44108
800-446-4402 ph
216-681-7009 fx
[email protected]
Machine Identification
Your Cleveland Steel Tool Ironworker has been
serialized for quality control, product traceability
and warranty enforcement. Please refer to the
aluminum identification tag with the engraved serial
number and electrical and power specifications
when ordering parts or filing a warranty claim.
Record the serial number on the front of this
manual for easy reference.
Warranty
The Cleveland Steel Tool Company will, within
one (1) year of date of purchase, replace F.O.B.
the factory, any goods, excluding punches,
dies, and/or blades, which are defective in
materials and workmanship provided that the
buyer returns the defective goods, freight
prepaid, to the seller, which shall be the buyer’s
sole and exclusive remedy for the defective
goods. Hydraulic and electrical components
are subject to their respective manufacturer’s
warranties. The Cleveland Steel Tool Company
will, within thirty (30) days of date of purchase,
replace F.O.B. the factory any punches, dies,
and/or blades that prove to be defective in
material and workmanship. Proof of purchase
date required.
This warranty does not apply to machines
and/or components which have been altered,
changed or modified in any way, or subjected
to abusive and abnormal use, inadequate
maintenance and lubrication, or subjected to
use beyond seller recommended capacities
and specifications. In no event shall seller be
liable for labor costs expended on such goods
or consequential damages. Seller shall not
be liable to the purchaser or any other person
for loss, downtime, or damage directly or
indirectly arising from the use of the goods or
from any other cause. No officer, employee,
or agent of seller is authorized to make any
oral representations or warranty of fitness or to
waive any of the foregoing terms of sale and
none shall be binding on seller.

Installation Requirements
This manual provides installation information for the
following Cleveland Steel Tool Ironworker: 55 Ton
2
Operator and Supervisor Information
This manual includes information on:
• Installation
• Safety
• Operation
• Maintenance
READ ALL INSTRUCTIONS BEFORE OPERATING
MACHINERY. Operating machinery before reading and
understanding the contents of this manual greatly
increases the risk of injury.
This manual describes ‘best practices’ in handling,
installing, operating and maintaining your machine.
The contents are subject to change without notice
due to improvements in the machinery or changes in
National or International standards.
All rights reserved. Reproduction of this manual in any
form, in whole or in part, is not permitted without the
written consent of Cleveland Steel Tool.
Keep this manual close to the machine to allow for
easy reference when necessary.
Provide operators with sufficient training and education
in the basic functions of the machine prior to machine
operation.
Do not allow for operation of the machine by unqualified
personnel. Cleveland Steel Tool is not liable for
accidents arising from unskilled, untrained operation.
Do not modify or change the machine without written
authorization from Cleveland Steel Tool. Unauthorized
modification to a machine may result in serious
operator injury, machine damage and will void your
machine warranty.
Never leave a powered machine unattended. Turn
machinery OFF before walking away.
This machine is manufactured for use by able bodied
and able minded operators only. Never operate
machinery when tired or under the influence of drugs
or alcohol.
Do not resell, relocate or export to a destination other
than to the original point of sale. Cleveland Steel Tool
has designed this machine to meet the standards
of the original receiving country and is not liable for
meeting any governing body or performance standards
beyond those of the original receiving country.
Signal Word Definition
Indicates a hazardous situation that, if not avoided, will
result in death or serious injury.
Indicates a hazardous situation that, if not avoided, could
result in death or serious injury.
Indicates a hazardous situation that, if not avoided, could
result in mild or moderate injury.
Indicates information considered important, but not hazard
related.
Signal Word Panel on Machine
Critical machine safety information is identified on
signal word labels. Labels are attached adjacent to
the potentially hazardous locations of the machine.
Reference safety instructions for additional information
regarding the potentially hazardous condition identified
on the label.
Review ALL labels on the machinery, reference the
operational precautions and safe operations sections
within this manual before any operation activity is
initiated.
Failure to read and understand the signal word labels
affixed to the machinery may result in operator death
or injury.

Environmental Requirements
The work station environment for your Cleveland Steel
Tool Ironworker must meet the following minimum
requirements:
• Floor area: Assure that the machinery work area
provides for a stable, adequately sized and load
rated floor area for material movement to and from
the machinery work stations.
• Shelter: Cleveland Steel Tool Ironworkers are
designed for indoor use only. Protect your Iron-
working machinery from water, salts and corrosive
elements.
• Lighting: 60 Watts (500LUX or 50 footcandles)
minimum.
• Operating Temperature: This equipment will op-
erate correctly in its intended ambient, at a mini-
mum between 41° F -104° F.
• Relative Humidity: This equipment will oper-
ate correctly within an environment at 50% RH,
41° F - 104° F. Higher RH may be allowed at lower
temperatures. Measures shall be taken by the Pur-
chaser to avoid the harmful effects of occasional
condensation.
• Altitude: This equipment will operate correctly up
to 3,281 feet above mean sea level.
• Transportation and Storage: This equipment
will withstand, or has been protected against,
transportation and storage temperatures of -13° F
to +131° F and for short periods up to 158° F. It
has been packaged to prevent damage from the
effects of normal humidity, vibration and shock.
Environmental Requirements
Locate your Cleveland Steel Tool Ironworker directly
adjacent to your power supply. Confirm that power supply
is not connected in series with other machinery. Provide
dedicated electrical socket and circuit breaker for each
Ironworker installed. Cleveland Steel Tool Ironworkers are
protected from voltage variations provided the variation
does not exceed +/- 10% machine rating.
3
Electrical Performance Specification
Machine Motor # Type Brand 60Hz/V FLA 50Hz/V FLA
55 132089 5Hp 1~ Leeson 60 Hz 230 19 50 Hz 208-220 23-22
Porta-Power 132077 5Hp 3~ Leeson 60 Hz 208-230/460 14/7 50 Hz 190/380 16/8
CEM3615T-5 5Hp 3~ Baldor 60 Hz 575 5

4
Danger Panel Warning Panel
Electrical Hazard
High voltages present inside the enclosure of
this product. ONLY qualified, authorized, mainte-
nance, service or Certified Electricians should gain
access to electrical panel. Do not operate this
equipment from any power source that does not
match the voltage rating stamped on the equip-
ment. Refer to the Manufacturer’s Identification
Label for operational requirements.
Lockout Power
Danger circuits are live. Lockout/Tagout the
upstream power source. Lockout/Tagout machin-
ery according to Employer procedures.
Voltage (Varies by consumer requirement)
Indication of operating power requirements. This
product should be operated only from the type of
source indicated on the manufacturer’s identifica-
tion label. Installation should be in compliance with
applicable sections of the National Electric Code.
Consult your local building code before installing.
Phase (Varies by consumer requirement)
Indication of electrical phase requirements. This
product should be operated only from the type of
source indicated on the manufacturer’s identifica-
tion label. Installation should be in compliance with
applicable sections of the National Electric Code.
Consult your local building code before installing.
Horsepower
Indication of horsepower requirements. This prod-
uct should be operated only from the type of
source indicated on the manufacturer’s identifica-
tion label. Installation should be in compliance with
applicable sections of the National Electric Code.
Consult your local building code before installing.
Hertz
Indication of electrical cycles per second. This
product should be operated only from the type of
source indicated on the manufacturer’s identifica-
tion label. Installation should be in compliance with
applicable sections of the National Electric Code.
Consult your local building code before installing.
Shear/Crush Hazard
Moving parts can cut and crush. Keep hands
clear while operating. Lockout power before
servicing. Immediately replace guards after
adjustment, repair or service.
Wear Personal Protective Equipment
To avoid physical hazard, always wear personal
protective equipment. Wear protective eye-
wear, clothing, gloves, footwear, head-gear and
hearing protection while operating or servicing
this machinery.
Fluid Injection Hazard
Hydraulic hoses and cylinders are under
pressure. Pressurized fluid can pierce skin and
cause severe injury. To avoid physical hazard,
always wear personal protective equipment.
Keep hands clear while operating. Lockout
power before servicing. Immediately replace
guards after adjustment, repair or service.
Do Not Operate With Guard Removed
Physical barriers and guards have been
designed and installed to protect the opera-
tor from moving parts that can pinch, cut and
crush. Keep hands clear while operating.
Lockout power before servicing. Immediately
replace guards after adjustment, repair or ser-
vice to moving parts.
Heat Hazard
To avoid physical burn hazard, always
wear personal protective equipment. Wear
protective clothing and gloves while working
adjacent to or on the affected surface.
Visit our website to view our Ironworkers in action.
https://www.clevelandsteeltool.com/catalog-and-literature/videos
208 V
230 V
460 V
575 V
1
5 hp
60 Hz

5
Electronics
Electronic equipment must be recycled as required
by local environmental law. Do not dispose of by
adding to the municipal waste stream.
Metal
Metal components must be recycled as required
by local environmental law. Do not dispose of by
adding to the municipal waste stream.
Notice Panel
Ironworker Operation
This manual outlines the basic functions
associated with typical Ironworker operations and
is neither intended to create a comprehensive
list, nor describe every operation possible with an
Ironworker tool. Ironworker machines are designed
to punch, shear and notch mild steel (A36) plate,
barstock and angle. A wide range of accessories
are available to fabricate rod, square stock, sheet
metal and pipe. Cleveland Steel Tool Ironworkers
operate by applying hydraulic force to a moving
center. The center moves within a frame in a
simple, vertical path and exerts force through
Shear Blades, Punches and Dies, Notchers,
Press Brake dies or Rod/Multi-Shear tooling upon
A36 mild steel. Cleveland Steel Tool Ironworkers
are designed for single operator use only. DO
NOT USE THIS EQUIPMENT FOR ANY PURPOSE
NOT DESCRIBED IN THE MANUAL. Ironworker
machines are dangerous and require extreme care
and caution in the safe installation, operation and
maintenance of the machinery. Cleveland Steel Tool
strongly suggests reading and understanding the
manual associated with the machinery as well as
obtaining certified, technical, industrial machinery
operations and maintenance training to reduce
the risk of injury. Regardless of the contents of the
machinery manual, Cleveland Steel Tool will not be
held liable for accidents caused by lack of training.
Wear Personal Protective Equipment
To avoid physical hazard, always wear personal
protective equipment. Wear protective eyewear,
clothing, gloves, footwear, head-gear and hearing
protection while operating or servicing this
machinery.
Forklift Location
This machine is equipped with rated forklift move-
ment points. Do not attempt to lift the machinery
by any other means. Inappropriate movement of
the machinery may result in serious operator injury,
machine damage and will void machine warranty.
Consult the installation manual for equipment
weight ratings. Provide rated forklift and certified
forklift operator to move machinery to appropriate
location.
Safety, Installation, Operations and
Maintenance
This manual contains critical instructions regarding
proper procedures for your machinery. Understand
the contents thoroughly. Failure to follow proper
procedures may result in serious operator injury,
machine damage and will void your machine
warranty. Keep the manual close to the machine
for easy reference.
Safety Ground
Safety earth ground location.
Do Not Use Non-Approved Lubricants
This machine requires lubrication of moving
mechanical parts (grease) and the maintenance of
hydraulic fluids. Refer to maintenance sections for
specific lubrication requirements and application
or maintenance schedules.
PE
‘Protective earth’, electrical grounding location.
Additional Graphic Information
Conformité Européenne
Conformity with all legal requirements pertaining
to the equipment with the European Economic
Area.
Hydraulics
Hydraulic fluids must be recycled as required by
local environmental law. Do not dispose of by
adding to the municipal waste stream.
Electric Motor Rotation
Identification of proper electrical motor rotation.

6
Installing the Ironworker
Receiving the Ironworker
Cleveland Steel Tool Ironworking machinery is fully
assembled and is shipped either by palletized custom
wooden crate or by shrink–wrapped wooden pallet for ease
of transport and receiving.
Inspect the packaging for damage and follow shipping/
receiving instructions as listed on the packaging prior to
receiving the Ironworker into your facility.
When receiving your Ironworker, be prepared to safely
move your machinery with a fork-lift rated for the following
equipment weights:
Minimum Machinery Weights
55 Ton 1,124.9 kg / 2,480 lb
Utilize best practices for fork-lift operation. Handle material
as close to the drive surface as possible with the wid-
est spread and deepest penetration of forks effective to
service the pallet. Forks should be adjusted and locked
into the safety detent closest to the maximum available
fork spread.
Unpacking/Moving the Ironworker
Your Cleveland Steel Tool Ironworker includes surface and
remotely mounted electrical cabling and hydraulic lines. Ex-
ercise caution when removing the factory supplied packag-
ing. Do not cut electrical wires or hydraulic hoses.
1. Unbolt/unpack Ironworker from its pallet using a
3/4" (19.05mm) socket. Wear appropriate personal
protective equipment.
2. Lift Cleveland Steel Tool machinery using the
designated fork lift locations and appropriately rated
lifting equipment.
3. Move the Ironworker to the prepared workstation.
Anchoring the Ironworker
Anchor the base of the Ironworker to the workstation floor
using four 1/2" (12.7 mm) wedge anchor bolts. Anchorage
points are the front and rear of the fork-lift tubes. Secure the
machinery with lock-nuts. In the event the machinery needs
to be relocated, reverse procedure.
Electrical Connection
Confirm with a certified electrician that the electrical
supply to the terminal location powering your Ironworker
meets the operating specifications of the machine prior to
electrical connection.
Confirm your electrical supply with the electrical
specifications of the machine located on the Ironworker
starter box. It is critical that a qualified electrician install your
machinery as your Warranty protection does not cover
incorrect wiring of electrical components at your site.
Prior to connecting your machine to the dedicated,
protected power supply, match work station wiring to the
power supply cable (Owner supplied) and the starter-box/
motor specifications on the machinery. Install connections
appropriately. Check for stability of connections.
If wiring through a plug/socket connection at the work station,
match work station wiring to the socket (Owner supplied),
plug (Owner supplied) and the power supply cable (Owner
supplied) to the starter-box / motor specifications on the
machinery. Install connections appropriately. Check for
stability of connections.
Wire according to the electrical diagrams located
within the control box.
Starter Box Wiring
Provide the electrical schematic wiring diagram (located
within the Ironworker control box) to your Electrician prior to
initiating the electrical hookup of the machine.
Power up the Ironworker
With all stations clear of tools, tooling or debris, power
up the Ironworker by depressing the green button on the
starter box. With the power on, your machine will return to
a neutral position.
Cycle the machinery by depressing the foot pedal. If pres-
sure is released at the foot pedal prior to completing a full
stroke, the operating center of the machinery will return to
a neutral position.
If the machinery fails to cycle the motor may be rotating
incorrectly. To ensure the machinery cycles properly, simply
reverse two of the phase wires on the machine starter box.
If the machine fails to cycle, power down the Ironworker
by depressing the red button on the starter box, Lockout /
Tagout the upstream power and consult the trouble shoot-
ing section of this manual.

KEEP OUT
Lockout
power before
servicing.
Hazardous
voltage inside.
7
Signal Word Panel • Machine Front

8
Signal Word Panel • Machine Back
Keep guards
in place.
Hydraulic
uid is under
pressure.
Hydraulic
uid powers
moving
parts.
FLUID
INJECTION
HAZARD

9
Signal Word Panel
Machine Left Machine Right
Keep
guards
in place.
Moving
parts can
cut and
crush.
SHEAR/
CRUSH
HAZARD

10
Your Cleveland Steel Tool Ironworker will benefit from
reasonable care and periodic maintenance. Reasonable
care includes daily visual observation, general maintenance
daily, weekly, monthly and at hourly milestone intervals by
operator/maintenance personnel. Perform inspections and
maintenance of the electrical, hydraulic, and mechanical
systems of the Ironworker and any optional Cleveland Steel
Tool hydraulic accessory connected to the Ironworker as
follows:
Daily/Shift Change Visual Observation
Electrical System
Visually inspect incoming power and exposed surface
conduit or cabling on the Ironworker for signs of damage.
Cut, abraded or crushed electrical cords may present an
electrical hazard to the Operator and damage the machinery.
Replace fuses as necessary with same type and rating.
Fuses located behind control box. See Figure 1 below.
Hydraulic System
Visually inspect exposed or surface mounted hydraulic
hoses and fittings for signs of damage. Cut, abraded or
crushed hydraulic hoses or leaking fittings may present
a hydraulic fluid hazard to the Operator and damage the
machinery.
Plug hose ends when working with hydraulic fluids and
clean up spills near the machinery in a timely manner to
reduce the likelihood of spills, trips and falls.
Mechanical System
Visually inspect guards and material hold-downs protecting
moving parts. Guards and material hold-downs must
remain on the machine for safe operation. Clear any material
obstructions at the work stations prior to visually inspecting
moving parts of the machine. Cycle the machine. Machine
should operate smoothly in hydraulic extend and retract
mode.
Observe mechanical operating clearances. Punches, dies,
angle shear, notchers and bar shear blades should be
evenly gapped and free of nicks, chips or burrs on their
surface.
Ironworker operation creates small concussive shocks and
vibration that may loosen hardware and fasteners over time.
Inspect fasteners and fittings and tighten where loose.
Slipping, Tripping and Falling
During routine maintenance hydraulic fluid could spill outside
of the machine footprint. Plug hose ends when working with
hydraulic fluids and clean up spills near the machinery in a
timely manner.
Maintenance Precautions
LOCKOUT POWER TO MACHINE FOR ALL MAINTENANCE
General Maintenance - Daily
Clean your Ironworker daily with a compressed air nozzle
and soft cloth lighly moistened with a mild, water based
detergent solution. Remove filings, dirt, dust and grime and
excess lubricant from working surfaces. All clean surfaces
must be fully dry before powering up machine. Grease all
machine guides and pins supplied with a GREASE DAILY
designation with NLGI Grade 2 (NLGI Service GC-LB) or
equivalent premium, heavy duty lubricant.
General Maintenance - Weekly
Check blade tolerance per maintenace section of each
attachment.
General Maintenance - Monthly
Check gib-pins for lubrication and snugness to the operating
center. Tighten gib-pins and locking nuts to maintain blade
clearance as indicated above. Gib-pins are wearing parts.
Order replacement gib-pins through Cleveland Steel Tool.
Check the ISO Viscosity 46 hydraulic fluid level monthly.
Maintain the correct volume of hydraulic fluid in the reservoir
as indicated. Contaminated fluid will compromise your cutting
operation.
General Maintenance - First 30 Hours
Replace the oil filter on your Ironworker after your first 30 hours
of use. External oil filters are available through Cleveland Steel
Tool. When working on the hydraulic power, use plugs to
cap hose ends during maintenance procedures to minimize
fluid loss. Clean up spills near the machinery to reduce the
likelihood of slips, trips and falls.
General Maintenance - Every 1,000 Hours
Replace the oil filter on your Ironworker after your first
1,000 hours of use. External oil filters are available through
Cleveland Steel Tool. When working on the hydraulic power,
use plugs to cap hose ends during maintenance procedures
to minimize fluid loss. Clean up spills near the machinery to
reduce the likelihood of slips, trips and falls.
General Maintenance - Every 5,000 Hours
Drain used hydraulic fluid, dispose of according to local or
jurisdictional guidelines and replace with ISO Viscosity 46
hydraulic fluid to the volume specified on the hydraulic fluid
Figure 1 - Fuses
Part # Volts Phase Hertz FLA Fuse Part # Voltage Amperage SC/IR Class Qty.
213197 230 V 1~ 60 Hz 19.2 FLA Littelfuse JTD040 600 VAC 40 A 200 kA J 2
213198 230 V 3~ 60 Hz 13.6 FLA Littelfuse JTD025 600 VAC 25 A 200 kA J 3
213201 460 V 3~ 60 Hz 6.8 FLA Littelfuse JTD012 600 VAC 12 A 200 kA J 3
213202 575 V 3~ 60 Hz 5.7 FLA Littelfuse JTD010ID 600 VAC 10 A 200 kA J 3
Maintenance Schedule
Failure of any element of the daily/shift change visual
observation will require maintenance of the affected
Ironworker or accessory component. Please follow the
following maintenance procedures.

11
Grease Daily
Punch Station Open Tooling Station
Foot Pedal
Angle Shear
Control Panel
Grease Daily
5 Locations
Flat Bar Shear
Electric Stroke
Control
Front Cylinder
Guard
Operations Diagram
Visit our website to view our Ironworkers in action.
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12
Cleveland Steel Tool Ironworkers feature a centrally located,
integrated Control Panel. Hazardous voltage is present
within the control panel. The panel should only be opened
and serviced by authorized personnel. An external power
source enters this panel and is distributed to the various
working components of the machine.
Push to Start
This button energizes the machine. When energized this
recessed button is internally illuminated and will glow green.
If the machine does not start when pressed an emergency
palm stop button may have been previously pressed and
will need to be reset to allow for the start button to energize
the machine.
Emergency Palm Stop
This button de-energizes the machine and contains a
manual, safety reset function. The projecting, red, palm
stop style button is set within a safety yellow bezel and is
pushed to de-energize the machinery. Once de-energized
the machine requires the palm stop to be re-set prior to
energizing the machine. Simply rotate the emergency
palm stop button clockwise. The button will retract and the
machine will be available for powered operation.
Operations Control
This three-position switch allows the ironworker operation to
shuttle between Ironworker, hydraulic accessory (optional)
or auto-cut (optional) mode.
Ironworker
Power the Ironworker by rotating the three position switch
counter-clockwise. This function allows for operations of
the Ironworker only.
Lockout/Tagout
This round, safety red switch is set within a square, safety
yellow housing. The switch allows for proper procedures
to be followed when de-energizing, isolating, and ensuring
the energy isolation of the Ironworker. The Lockout/Tagout
switch is used, in conjunction with Owner safety and
maintenance programs to ensure that equipment and
machinery is de-energized and isolated from unexpected
start-up by physically locking machinery in a state of zero
energy.
To lockout the Ironworker turn the red switch counter-
clockwise until the black tagout bar is horizontal. Pull the
black, spring-loaded tagout mechanism to install the
maintenance/safety lock and tag provided by the Owner
of the machinery. The machine is now de-energized and is
available for authorized personnel to maintain and service
the machinery.
To open the control panel for servicing, gently pull the
‘hopper-style’ hinged cover. The cover will not open fully until
a safety yellow thumb slide located within the safety yellow
housing is rotated clockwise. Reverse operation following
service to resume Ironworking.
Control Panel

13
Electric Stroke Control
Electric stroke control is standard on all Ironworker models
with the exception of the 25 Ton Ironworker. Stroke control
enables the Ironworker operator to shorten up and down
stroke with minor adjustment of two hand screws. Utilize
stroke control for precision bending with your brake
tooling, when using embossing or bump dies or to simply
increase production from your punch, notch or shear
stations.
Setup
Electric Stroke control is factory installed and arrives fully
set up for immediate use.
Safe Operation
Observe the following guidelines when using and adjusting
the electric stroke control function:
• Read, understand and follow punching, notching and
shearing tolerances as described in this manual.
• Never exceed the capacities of the machine or tooling
as described in the Ironworker specifications or listed
at the tooling station.
• Keep limit switches free of dirt and grime.
• Never remove stroke retention nuts from factory
setting.
• Never reverse stroke limit switches.
• Confirm that red light is illuminated. If not illuminated,
machine cyle is not complete and potential heat build-
up may occur.
Electric Stroke Control Operation
Set upstroke for rapid cycling of your punching,
shearing and notching stations.
1. Power machine on and use the jog function of your
electric foot pedal to bring tooling down to rest just
above the material being worked.
2. Turn machine off.
3. Adjust upper handle with tapered collar to engage limit
switch.
4. Power machine on. Tooling will stay in set position.
Top limit switch will be showing a red light.
5. Remove material from tooling station and cycle
machine. Tooling should return to pre-set position.
Red light will be on.
6. Place material in tooling station and cycle machine.
Set downstroke for Optional Tooling operation
1. Power machine on and use the jog function of your
electric foot pedal to bring ram down to engage
tooling. Jog ram to push tooling to the specified depth.
2. Turn machine off.
3. Adjust lower handle with tapered collar to engage limit
switch.
4. Power machine on. Ram will return to top of stroke.
5. Cycle machine to insure proper stroke depth.
6. Place material in tooling station and cycle machine.
Set downstroke for brake operation
1. Power machine on and use the jog function of your
electric foot pedal to bring ram down to engage tooling
with material.
2. Jog ram to push brake die tooling to the specified
depth / brake angle.
3. Turn machine off.
4. Adjust lower handle with tapered collar to engage limit
switch.
5. Power machine on. Ram will return to top of stroke.
Red light will be on.
6. Place test material in tooling station and cycle machine
to insure proper stroke depth and material brake.

14
Flat Bar Shear Station
Your Ironworker includes a flat bar shear as a standard
feature. The flat bar shear will provide a distortion and burr
free shear cut to mild steel bar stock as listed in the machine
specifications as well as described on the capacity labels
positioned at the Flat Bar Shear Station. The Flat Bar Shear
allows for straight or angled cutting operations. The material
hold down adjusts with a simple hand crank to safely restrain
the material being cut.
The Flat Bar Shear is factory set to proper clearances and
is ready to begin shearing operations. Clearances should
not be altered.
Shear blades are wearing parts and will need to be
maintained or replaced over time. Refer to page 15 for blade
maintenance, removal and replacement.
Safe Operation
Observe the following guidelines when operating the Flat Bar
Shear Station:
• Never exceed the capacities of the machine or tooling as
described in the Ironworker specifications or listed at the
tooling station.
• Fully engage the material hold-down with the material
being cut.
• Do not stack material to cut in the shear station.
• Perform complete shear operations only – partial shear
cuts may jam the drop off side of the frame and could
result in breakage and operator injury.
• Use shearing aids when working with small items at the
shear station.
Bar Shear Operation
1. Clear bar shear station of any tools or debris prior to
powering the machine on.
2. Turn machine on. The shear blades will be in their neutral
position. Place bar stock on the feed table and push
the material under the material hold-down. Position your
desired cut mark adjacent to the moving shear blade.
3. Secure the bar stock in the material hold-down by
engaging the handscrew into the material.
4. Clear your hands from the working area and depress the
foot pedal to activate the shear station.
5. When the cut is complete, release the foot pedal to
automatically return the shear blades to their neutral
position. Reverse the hand screw to raise the manual
material hold-down and remove your material.

15
Turn off power to machine by depressing the red stop/off button and
lockout upstream power at the main electrical panel.
Clearances should not be altered. When all 4 cutting
edges are worn, replace blades.
Remove and replace stationary blade:
1. Remove the material hold-down assembly from the Iron-
worker frame by removing the return spring and bolts that
secure the assembly to the Ironworker frame.
2. Remove blade bolts located under the feed table. Re-
move the stationary blade.
3. With blade removed, clean blade pocket of any dirt or
debris.
4. Your shear blades have multiple cutting surfaces that
can be flipped and rotated prior to full replacement of the
part. Rotate the stationary blade to new cutting surface
and reinstall in blade pocket.
5. Tighten the stationary blade back into the blade pocket.
Remove and replace moving blade:
1. Remove the drop-off guard from the rear of the Ironwork-
er frame.
2. Power on the machine and inch the moving center down
to reveal blade bolts for the moving blade.
Maintenance - Flat Bar Shear
3. With bolts exposed, turn machine off and disconnect
from power source.
4. Remove blade bolts and remove blade from the blade
pocket.
5. With blade removed, clean blade pocket of any dirt or
debris.
6. Your shear blades have four cutting surfaces that can be
used prior to full replacement of the part. Rotate the mov-
able blade to new cutting surface and reinstall in blade
pocket.
7. Tighten the movable blade back into the blade pocket.
8. Replace the drop-off guard to the rear of the frame.
9. Return the machine to power and turn on to automati-
cally return the moving center to its neutral position.
10. Replace and secure guarding removed in the mainte-
nance procedure.
11. Replace the material hold-down assembly to the Iron-
worker frame.

16
Angle Shear Station
Your Ironworker includes an angle iron shear as a standard
feature. The angle shear will provide a distortion and burr
free shear cut to mild steel angle stock as listed in the
machine specifications as well as described on the capacity
labels positioned at the Angle Shearing Station. The Angle
Shearing Station on the Cleveland Steel Tool Ironworker
allows for straight cutting applications. An oversized material
hold down adjusts with a simple thumb crank to safely
restrain the material being cut.
Integrated angle shears are factory set to proper
clearances and are ready to begin shearing operations.
Clearances should not be altered.
Shear blades are wearing parts and will need to be
maintained or replaced over time. Refer to page 17 for blade
maintenance, removal and replacement.
Safe Operation
Observe the following guidelines when operating the Angle
Shear Station:
• Never exceed the capacities of the machine or tooling
as described in the Ironworker specifications or listed at
the tooling station.
• Fully engage the material hold-down with the material
being cut.
• Do not stack material to cut in the shear station.
• Perform complete shear operations only – partial shear
cuts may jam the drop off side of the frame and could
result in breakage and operator injury.
• Do not shear angle smaller than the hold-down will
accommodate.
Angle Shear Operation
1. Clear shear station of any tools or debris prior to
powering the machine on.
2. Turn machine on. The shear blades will be in their
neutral position. Place angle iron into the material
hold-down and position your cut mark adjacent to the
moving shear blade.
3. Secure the angle iron in the material hold-down by
engaging the handscrew into the material.
4. Clear your hands from the working area and depress
the foot pedal to activate the shear station.
5. When the cut is complete, release the foot pedal to
automatically return the shear blades to their neutral
position. If equipped with the hydraulic hold-down
feature, the hold-down will retract when pressure on
the foot pedal is released at the end of the cut cycle.
6. Reverse the thumb screw to raise the material hold-
down and remove your material.
To eliminate distortion
with “light” angle iron,
use this cutting edge.