Marvel Spartan ironworker User manual

Sales and Service

Centers and

Warehouses:

Oshkosh, Wisconsin

Toll Free: 1-800-472-9464

Fax: 1-920-236-4156

Fort Worth, Texas

Phone: 1-817-535-2183

Fax: 1-817-531-1163

Kent, Washington

Phone: 1-360-575-9917

Fax: 1-360-575-9706

Manufacturing

Facilities:

Oshkosh, WI

Direct Sales

Managers and

Technical Specialists

in Ma or Cities

IRONWORKER

For IW66D/DX, IW88D/DX, IW110D/DX, IW135DX

and IW180 DX

Safety

Installation

Operation

Maintenance

Parts Catalog

Part No. PL/OMIW-2CYL_V2 06/14

Corporate Office and Service Center:

3501 Mar el Dri e

Oshkosh, WI 54902

Phone (920) 236-7200

Fax (920) 236-4156

Toll Free 1-800-4-SAWING (1-800-472-9464)

www.sawing.com

Record your machine’s serial number here:

________________________________________

A MESSAGE OF SAFETY SPARTAN IRONWORKER

ii

IMPORTANT MESSAGE

While Marvel Manufacturing Co. Inc.

machinery an equipment is engineere for

safety an efficiency, a high egree of

responsibility must be place upon the

machine operator to follow safe practices,

base primarily on common sense, upon

which true safety epen s. Any machine

with a potential safety hazar must be

operate accor ing to the instructions in the

instruction manual, within the equipment’s

capacity, an in a careful an eliberate

manner. All guar s must be in place, an

safety glasses an other applicable safety

clothing must always be use . The machine

must be inspecte an maintaine regularly.

Any questions regar ing the safety,

con ition, or operation of this equipment

must be imme iately referre to supervisory

or engineering personnel.

The warning sign repro uce below is

attache to the machine in plain view of the

operator to constantly remin the operator

that only s/he can make this machine safe by

following safe operating proce ures. This

sign must not be remove or isfigure . The

sign must be replace if it becomes

unrea able. Replacement signs can be

obtaine from Marvel Manufacturing Co.

Inc.

SPARTAN IRONWORKER TABLE OF CONTENTS

iii

A MESSAGE ON SAFETY ..................................................................................................................... ii

CONTENTS.............................................................................................................................................. iii

SAFETY ................................................................................................................................................. S-1

WHO MAY USE THIS MACHINE? .......................................................................................... S-2

FOLLOW THE INSTRUCTIONS .............................................................................................. S-2

RECOGNI E SAFETY INFORMATION .................................................................................. S-2

SAFETY SIGNAL WORDS ....................................................................................................... S-3

WEAR PROTECTIVE EQUIPMENT ........................................................................................ S-3

STAY CLEAR OF MOVING PARTS ........................................................................................ S-3

HANDLE CHEMICALS SAFELY ............................................................................................. S-4

REMOVING DEBRIS ................................................................................................................. S-4

SAFE MATERIAL HANDLING ................................................................................................ S-5

ELECTRICAL HA ARDS ......................................................................................................... S-5

HA ARDOUS METALS ............................................................................................................ S-6

HIGH PRESSURE FLUIDS ........................................................................................................ S-6

PUNCHING & SHEARING EQUIPMENT ............................................................................... S-6

KEEP THE MACHINE SAFE .................................................................................................... S-7

KEEP THE WORK AREA SAFE ............................................................................................... S-7

OPERATE THE MACHINE SAFELY ....................................................................................... S-7

SERVICE THE MACHINE SAFELY ........................................................................................ S-8

INSTALLATION .................................................................................................................................. A-1

GENERAL SPECIFICATIONS ...........................................................................................................B-1

MACHINE DESCRIPTION ................................................................................................................ C-1

PUNCHING STATION ........................................................................................................................ D-1

NOTCHING STATION ........................................................................................................................E-1

ANGLE SHEARING STATION .......................................................................................................... F-1

BAR SHEARING STATION ............................................................................................................... G-1

FLAT BAR SHEARING STATION ................................................................................................... H-1

MAINTENANCE ................................................................................................................................... J-1

REPAIR PARTS .................................................................................................................................... P-1

A MESSAGE OF SAFETY SPARTAN IRONWORKER

iv

THIS PAGE LEFT BLANK INTENTIONALLY

SAFETY SPARTAN IRONWORKER

S-1

In ustrial Machinery can be Dangerous.

Rea the safety messages on the following pages as well as the instructions in

the operator's manual an those poste on the machine before attempting to install,

operate, or maintain this machine.

While Marvel Manufacturing Co., Inc. has made every effort to eliminate the

potential dangers in its equipment through careful design and guarding, this equipment, if

not operated and maintained properly, has the potential to cause serious injury or death.

A thorough knowledge of the operation of this machine and the hazards it presents

is your best protection against injury.

Attention Users of Ol er Marvel Equipment:

Marvel equipment is ruggedly built and many machines are still operating well

beyond their anticipated useful life. Older equipment may not meet current standards and

may have been modified outside the control of Marvel Manufacturing Co., Inc. While we

are happy to support your use of this equipment, we ask that you take whatever means

necessary to safeguard your operators. Please contact Marvel Manufacturing Co., Inc. for

the availability of safety retrofit kits for your particular machine.

3501 Marvel Drive • Oshkosh, WI 54902

Ph. (920) 236-7200 • Fax (920) 236-7209

Toll Free: 1-800-4-sawing (1-800-472-9464)

www.sawing.com • email: abinfo@sawing.com

S-1

SPARTAN IRONWORKER SAFETY

SPARTAN SAW SAFETY

S-2

WHO MAY USE THIS MACHINE?

Machinery sold by Marvel Manufacturing Co., Inc. is to

be installed, operated, and maintained by people

familiar with industrial machinery, the hazards

associated with industrial machinery and the

environment in which it is used, and the accepted

methods of safeguarding against those hazards.

FOLLOW THE INSTRUCTIONS

Read and follow all of the safety and operating

instructions supplied with your machine. This includes

the operator's manual, any safety signs on the machine,

all Material Safety Data Sheets (MSDS), vendor

literature, etc.

• Keep safety and operating instructions in good

condition and located where the machine operator

can refer to it. Replacement signs and literature are

available from Marvel Manufacturing Co., Inc.

• Do not allow anyone to operate or repair the

machine without proper instructions.

• If you need information not supplied in the

operator’s manual or accompanying literature,

contact Marvel Manufacturing Co. Inc.

RECOGNIZE SAFETY INFORMATION

• This safety-alert symbol signals important safety

information to prevent personal injury or death.

• Safety messages are highlighted with bol words.

• Always obey safety messages which accompany the

safety-alert symbol.

Note: The safety-alert symbol is a relatively new device

which does not appear in older Operator's Manuals.

Please review manuals which do not contain safety-

alert symbols carefully to identify safety information.

S-2

SAFETY SPARTAN IRONWORKER

SPARTAN IRONWORKER SAFETY

S-3

SAFETY SIGNAL WORDS

A safety signal word always accompanies the safety-

alert symbol. The safety signal words - DANGER,

WARNING, and CAUTION - identify the severity of

a hazard.

• DANGER indicates a situation which, if not

avoided, will result in serious injury or death.

• WARNING indicates a situation which, if not

avoided, could result in serious injury or death.

• CAUTION indicates a situation which, if not

avoided, can result in damage to the machine.

WEAR PROTECTIVE EQUIPMENT

• Wear safety glasses, safety shoes and hearing

protection.

• Do not wear gloves except when handling work

stock. Gloves can get caught in the machine's

moving parts and cause serious injury or death.

STAY CLEAR OF MOVING PARTS

• Contact with moving and rotating parts can cause

serious injury or death.

• Wear close fitting clothing, secure apron and

garment strings, and tie back long hair so they can

not get caught in moving parts.

• The machine may have automated movements. Be

familiar with the machine's operation before

operating the controls.

• Turn off the machine's power at its main electrical

disconnect switch and lock it in the "Off" position

before adjusting, servicing, or cleaning the saw.

S-3

SPARTAN IRONWORKER SAFETY

S-4

HANDLE CHEMICALS SAFELY

• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used

with this machinery includes lubricants and

hydraulic fluid.

• The Material Safety Data Sheets (MSDS) provide

specific details on these chemical products

including the specific hazards, safety procedures,

and emergency responses.

• Consult the MSDS before operating the machine to

become familiar with the specific hazards and how

to avoid them.

• MSDS sheets for chemical products supplied with

your machine are available from Marvel

Manufacturing Co., Inc. These may be different

from the actual chemicals present in your machine.

Contact the chemical manufacturer for the MSDS of

the products you are using.

• Protect the environment. Dispose of used and

unwanted chemicals properly.

REMOVING DEBRIS

• Never use compressed air to remove debris from the

machine. The flying debris can cause serious

personal injury. Remove debris with a brush.

S-4

SAFETY SPARTAN IRONWORKER

SPARTAN IRONWORKER SAFETY

S-5

SAFE MATERIAL HANDLING

Loading and unloading material from the machine

presents safety hazards of its own.

• Wear appropriate safety equipment including safety

shoes, hard hat, safety glasses, etc.

• Do not allow any part of your body to come

between the material and any other surface. Serious

or fatal crushing injuries can result.

• Never stand underneath the material while it is

being handled.

• Always use equipment, in good, serviceable

condition, capable of safely handling the material.

This includes cranes, hoists, chains, and straps with

a lifting capacity greater than the weight of the

material being lifted.

• Never lift the material higher than necessary.

ELECTRICAL HAZARDS

Contact with high voltage will cause death.

• Never perform any maintenance on or near

electrical components until the machine’s power

source has been disconnected. Lock out power

before servicing.

• The only way to be sure the machine’s electrical

circuits are safe is to turn off the machine’s power

supply at your facility’s circuit panel and lock it out.

• The “All Stop” pushbutton oes not disconnect the

machine’s power supply. Hazardous electricity is

still present in the machine’s electrical circuits.

• The machine’s main electrical disconnect switch

will remove electricity from the machine’s circuits,

however, deadly voltage is still present inside the

main electrical panel at the infeed (line) side of the

main fuses. Keep han s an tools away from the

top of the electrical panel’s main fuses.

S-5

SPARTAN IRONWORKER SAFETY

S-6

HAZARDOUS METALS

Your machine was designed specifically for metal

working. However, some metals, such as beryllium,

magnesium and lead, have characteristics which, if not

handled properly, will cause serious injury or death.

• Know the material you are working with and the

hazards it presents.

• Do not work materials which require specialized

equipment or a controlled atmosphere unless your

machine has been specifically designed and

installed for that purpose. Stan ar machines sol

by Marvel Manufacturing Co. Inc. o not meet

those special requirements.

HIGH PRESSURE FLUIDS

• Fluid escaping under pressure can penetrate skin

and cause serious injury and death.

• Avoid the hazard by relieving pressure before

disconnecting hydraulic lines.

• Look for leaks with a piece of cardboard. Protect

your hands and body from exposure to the fluid.

• If an accident occurs, see a doctor immediately and

inform them of the nature of the accident. Injected

fluids must be surgically removed within a few

hours or gangrene will result.

PUNCHING AND SHEARING

EQUIPMENT

• Always wear gloves when handling stock which has

been punched or sheared. The edges can be

extremely sharp.

• Never place your hands inside the safety guards.

• Keep fingers and hands away from the tooling.

• Always use the holddowns supplied with the

machine to clamp the material.

• Turn off the machine before changing the tooling.

S-6

SAFETY SPARTAN IRONWORKER

SPARTAN IRONWORKER SAFETY

S-7

KEEP THE MACHINE SAFE

• Do not alter the machine in any way.

• Do not remove protective guards, covers or safety

signs.

• Perform regular maintenance to keep the machine

operating safely and efficiently.

• Immediately replace worn, missing or damaged

parts, including safety signs attached to the

machine.

KEEP THE WORK AREA SAFE

• Keep the machine and the area around the machine

clean, well lighted, and free of debris and spills.

• Immediately clean up lubricants and hydraulic fluid

from the floor. These create serious slipping

hazards.

• Keep air hoses, power cords, etc., off the floor.

These create serious tripping hazards.

OPERATE THE MACHINE SAFELY

• Use the machine only for its intended use and

within its specified capacity.

• Do not operate the machine if it has been altered in

any way, is defective, or has worn, missing or

broken parts.

• Operate the machine in a careful and deliberate

manner.

• Remove rings, watches, bracelets, necklaces and

other jewelry. These can get caught in the machine

and cause serious injury or death.

• Refer to the machine’s data charts and operating

instructions for the proper punch and die

combinations.

• Stop the machine before reaching into the cutting

area or any area with moving parts.

• Always use the tooling guards.

• Report unsafe conditions to your employer.

S-7

SPARTAN IRONWORKER SAFETY

S-8

SERVICE THE MACHINE SAFELY

Review all safety information provi e with your

machine before servicing the machine. A itionally,

important safety information which the service

technician shoul be aware of is locate throughout

this safety section.

• Turn off the machine’s power and lock it out before

adjusting, servicing, or cleaning the machine.

• Read and understand a service procedure before

performing the service.

• Never lubricate or service the machine while it is

running. Keep your body, clothing, and tools away

from power-driven parts.

• The machine may have automated movements.

Become familiar with the machine’s operation

before operating the controls.

• Turning off the machine’s main electrical

disconnect switch does not remove electrical power

from the input side of the machine’s main fuses. To

eliminate all electrical power at the machine, turn

off the machine’s electrical supply circuit at your

facility’s circuit breaker and lock it out.

• Some parts, particularly malfunctioning hydraulic

parts and parts subject to high friction, can become

hot. Allow the machine to cool before servicing.

• Whenever possible, avoid climbing on any of the

machine’s components. If it is necessary to climb

on the machine’s components, use extreme care!

Always turn the machine’s power off an lock it

out before climbing on the machine. Cutting

lubricants and debris can make the machine’s

surfaces slippery. Always maintain a safe footing, a

firm hand hold, and never jump off the machine.

S-8

SAFETY SPARTAN IRONWORKER

SPARTAN IRONWORKER SAFETY

S-9

THIS PAGE LEFT BLANK INTENTIONALLY

INSTALLATION SPARTAN IRONWORKER

A-1

IMPORTANT

Before completing any steps in this section, read

the entire safety section (the yellow pages

numbered S-1 through S-8). The safety section

contains important information which will

safeguard both yourself, and the machine, during

installation.

It is extremely important to read through the

entire installation section to familiarize yourself

with the installation procedure before performing

any steps in this section.

HANDLING

IMPORTANT: Equipment capable of safely

han ling the weight of the machine is require .

Always use cranes, hoists, chains, straps, etc.,

with a lifting capacity greater than the weight of

the object being lifted.

Avoi personal injury. Never

push, pull, or lift the shipping

crate to move the machine.

Move the machine only by

pushing or lifting the ski with

a forklift, or by lifting with the

eyebolt provi e in the top of

the machine.

Avoi serious personal injury.

Never place any part of your

bo y un er the machine while

it is suspen e .

Avoi serious personal injury.

The machine is top heavy an

will tip if tilte too far.

When transporting the machine with a crane, hook

the crane to the eye bolt on top of the machine

(A).

Refer to the following chart for the weight of your

particular machine.

An eyebolt A) is provided at the top of the machine for

lifting the machine with an overhead crane.

MACHINE NET WEIGHTS

Machine lbs kg

IW66D 3,969 1,804

IW66DX 4,851 2,205

IW88D 4,807 2,185

IW88DX 5,.844 2,656

IW110D/2 6,505 2,956

IW110DX/2 7,608 3,458

IW135D 7,365 3,347

IW135DX 8,710 3,959

IW180DX 10,915 4,961

POSITIONING

Consider these items when selecting a position for

the machine:

Foun ation - The foundation must be a dry,

level, concrete floor in good condition.

Lighting - The entire machine must be well

lighted for operator safety and maintenance.

Stock Movement - Leave space around the

machine for loading and unloading stock.

WARNING

A

SPARTAN IRONWORKER INSTALLATION

A-2

Maintenance - The machine must be placed to

allow easy access to all areas for maintenance and

repairs. Make sure all doors and panels can be

opened easily.

LEVELING AND ANCHORING

Four leveling screws (A) are provided to level the

machine. After the machine has been leveled the

position of each leveling screw can be locked in

place with the lock screw (B) provided on each

leveling screw.

Anchoring bolts can be installed if needed.

Anchor the machine to the floor by drilling holes

in the floor through the four holes in the

machine's base (C) and installing anchor bolts,

washers, and nuts.

Leveling screw A), locking screw B), and anchor bolt hole

C).

ASSEMBLY

The Ironworker is shipped fully assembled with

the exception of the electric back gauge. To

assemble the back gauge:

1. Attach the length rod (A) to the discharge

side of the machine with the three screws

provided (B).

Assembling the electric back gauge.

2. Slide the collar (C) onto the length rod.

3. Install the cross-arm (D).

4. Unscrew the cap from the back gauge's

electrical socket (E, above and below) and

insert the gauge's electrical connector (F).

Secure the connector by turning the

knurled ring on the end of the connector

clockwise until it stops.

Connecting the back gauge's electrical connector.

CONNECTING POWER

IMPORTANT: Electrical wiring must be one

by a qualifie electrician in conformance with

the prevailing electrical stan ar s of your area.

Hazar ous voltage. Will cause

serious injury or eath. Turn

off supply electricity at your

facility’s circuit breaker before

making electrical connections to

the machine.

DANGER

C

A

B

A

C

E

B

D

F

E

INSTALLATION SPARTAN IRONWORKER

A-3

1. Open the electrical panel door and remove

the panel directly below the door.

The electrical panel door and access panel must be removed

to connect a power cord. The cord is then passed through

the hole in the end of the machine A) and up into the

electrical enclosure B). See step 2, below.

Avoi amaging the machine.

Make sure the supply voltage

an phase matches the voltage

the machine has been wire for.

Refer to the ata plate on the

electrical enclosure.

2. Bring a three-phase power cord into the

electrical enclosure through the entrance

hole on the end of the machine (A) and

then up through the hole in the floor of the

electrical enclosure (B).

3. Connect the power cord's three power

leads to terminals L1, L2, and L3 at the

bottom of the terminal strip (See photo).

The main power leads L1, L2, and L3 C) connect to the

terminals at the bottom of the terminal strip. The ground

wire connects to the yellow and green terminal next to the

power lead connections D).

4. Attach the power cord's grounding wire to

the grounding terminal (D, see photo).

The importance of a properly groun e

machine cannot be over emphasize - both for

the safety of the operator an the epen able

operation of the machine.

The machine must be grounded, by a qualifie

electrician, in conformance with:

a. National Fire Protection Association

(NFPA) No. 79, "Electrical Standard for

Metal Working Machine Tools".

b. National Fire Protection Association

(NFPA) No. 70, "National Electrical

Code".

c. The prevailing national, state, and local

electrical codes.

LUBRICATION

The lubrication points and intervals must be

checked before operating the saw. Refer to

"Lubrication", page J-2.

ELECTRICAL CHECK

IMPORTANT: Rea steps 1 through 6 before

performing this electrical check.

This electrical check ensures the leads of the

power cord are properly connected.

Avoi amaging the machine.

Make sure the hy raulic flui

level is correct before operating

the machine. Refer to

"Checking the Hy raulic Flui

Level", page J-2.

1. Set the following switches as indicated:

• Auto / Manual switch - Manual

• Turn the Emergency Stop pushbuttons

clockwise to reset them.

CAUTION

B

A

C

D

SPARTAN IRONWORKER INSTALLATION

A-4

• Normal / Jog switch - Normal

• Shear /Notch switch - Notch

2. Turn the Main Electrical Disconnect

switch on.

3. Open the notching station's guard and

make sure all other guards and covers are

in place.

The hy raulic pump can be

amage if the main power

lea s are not connecte

properly. Do not operate the

pump more than 3 secon s

uring this check.

4. While stepping firmly on the notching

station's foot switch, press the "Pump On"

pushbutton, briefly observe the notching

station for movement, and then press the

"Pump Off" pushbutton.

5. If the notching station moved, continue

with step 6.

If the notching station did not move, the wires to

the main electrical disconnect switch are

improperly connected. To change the connections:

a. Turn off the Main Electrical Disconnect

switch.

Hazar ous voltage.

Will cause serious injury or

eath. Turn off supply

electricity at your facility’s

circuit breaker before making

electrical connections to the

machine.

b. Turn off the machine's supply voltage at

your facility's circuit breaker.

c. Open the machine's electrical panel door.

d. Reverse power leads L1 and L2, or L2 and

L3, not both.

e. Repeat steps 1 through 5 above.

Reverse L1 and L2 or L2 and L3 if the punching does not

move during the electrical check.

6. Turn the Main Electrical Disconnect

switch off.

FINAL INSPECTION

After the machine has been installed, a final,

thorough inspection should be performed. The

following checklist will help locate any items that

may need further attention:

• Loose components, guards or panels

• Loose fasteners and fittings

• Loose hoses and conduit

• Missing or damaged items

• Hydraulic leaks

• Tools and other material left on the machine

• Overall condition and readiness for use

CAUTION

DANGER

L2

L1

L3

GENERAL SPECIFICATIONS SPARTAN IRONWORKER

B-1

Note: Specifications given are for standard machines. Available options may alter these specifications.

All specifications are subject to change without notice.

Specifications specific to each work station are given in the sections which describe each work station.

Hy raulic Motor AMP Loa

230V/460v

Net Weight Airborne Noise

IW66D 7-1/2 HP 20.5A/10.25A 3,969 lbs 75Db +/- 5dB

IW66DX 7-1/2 HP 26.5A/13/25A 4,851 lbs 75Db +/- 5dB

IW88D 10HP 26.5A/13.25A 4,807 lbs 75Db +/- 5dB

IW88DX 10HP 26.5A/13.25A 5,844 lbs 75Db +/- 5dB

IW110D/2 10HP 26.5A /13.25A 6,505 lbs 75Db +/- 5dB

IW110DX/2 10HP 26.5A/13.25A 7,608 lbs 75Db +/- 5dB

IW135D 15HP 37.5A/18.75A 7,365 lbs 75Db +/- 5dB

IW135DX 15HP 37.5A/18.75A 8,710 lbs 75Db +/- 5dB

IW180DX 20HP 50.5A/25.25A 10,915 lbs 75Db +/- 5dB

SPARTAN IRONWORKER MACHINE DESCRIPTION

C-1

SECTION CONTENTS

Machine Overview - Operator's Side C-2

Machine Overview - Discharge Side C-3

Machine Overview - Operator's Panel C-4

Important C-5

Main Electrical Disconnect Switch C-5

Auto / Manual Switch C-5

Shear / Notch Switch C-5

Pump On Pushbutton C-6

Pump Off Pushbutton C-6

Normal Jog Switch C-6

Door Lock C-6

Emergency Stop Pushbutton C-6

Punching Station Foot Switch C-6

Notching / Shearing Foot Switch C-7

Electric Back Gauge C-7

MACHINE DESCRIPTION SPARTAN IRONWORKER

C-2

Machine Overview - Operator Si e

Model IW110DX/2 shown

1. Operator's Pushbutton Panel and Electrical Panel Door,

see page C-4

2. Access Panel

3. Punching Station Foot Switch (see page C-6)

4. Punching Station (see page D-1)

5. Stripper (see page D-3)

6. Moveable Worklight

7. Angle Shearing Station (see page F-1)

8. Bar Shearing Station (see page G-1)

9. Flat Bar Shearing Station (see page H-1)

10. Notching Station (see page E-1)

11. Slug Bin

12. Notching / Shearing Foot Switch (see page C-7)

13. Emergency Stop Pushbutton (see page C-6)

8

5

4

11

13

9

10

11

2

3

2

1

12

13

6

7

Marvel SPARTAN IRONWORKER User manual

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