McIntyre 320 User manual

Original Manual as required by: Machinery Directive (2006/42/EC)
320, 407, 500, and 600
McIntyre | Manual
Alligator Shears
[phone] www.nascoop.com

320/407/500/600.41912-ENG
Contents
1. Introduction 1
2. Warnings 2
2.1. Operating Warnings 2
2.2. Warning Labels 4
2.2.1. Positioning of Labels 7
2.3. Important Information 8
2.3.1. Serial Number Plate 8
2.3.2. Electric Motor Rotation 8
2.3.3. Continual Improvement Policy 9
2.4. A Cautionary Tale 9
3. Installation 10
3.1. Lifting & Transporting 10
3.2. Siting & Installation 10
3.2.1. Electrical Power Supply 11
3.3. Hydraulic Fluid 11
3.4. Dimension&TechnicalSpecication 12
3.4.1. 320 Shear 12
3.4.2. 407i & 407CAT Shear 13
3.4.3. 500 LGT and 500 CATCutting Capacity (Mild Steel 43A): 14
3.4.4. 600 LGT and 600 CATCutting Capacity (Mild Steel 43A): 15
4. Operation of the Shear 16
4.1. Starting & Stopping the Shear 16
4.1.1. Start & Stop Buttons 16
4.1.2. Use of the Electrical Isolator Switch 16
4.1.3. The Emergency Stop (E-Stop) Button 17
4.2. Foot Pedal Control 17
4.2.1. Using the Foot Pedal 17
4.2.2. Siting the Foot Pedal 17
4.3. Starting & Stopping the diesel powered 407 Shear 18
4.3.1. To Start the Shear 18
4.3.2. To Stop the Shear 19
4.3.3. The Emergency Stop (E-Stop) Button 19
4.4. Adjusting the Stroke 20
4.5. The Blade Guard 21
4.6. Protective Clothing 21
4.7. Shearing Large Items 22
4.8. Shearing Small Items 22
4.9. Using the CAT Bracket & V-Block 23
5. Periodic, Routine Care & Maintenance 24
5.1. Warnings 24
5.2. Hydraulic Fluid 24
5.2.1. Storage, Handling & Disposal 24
5.2.2. First Aid Measures 24

320/407/500/600.41912-ENG
5.2.3. Fire Fighting Measures 25
5.3. Daily Operator Inspection 26
5.3.1. Diesel Engine version 26
5.4. Weekly Routine Maintenance 27
5.4.1. Additional check for 407, 500, and 600 CAT Shears 27
5.5. Three Month Periodic Maintenance 28
5.5.1. Diesel Engine version 28
5.6. Twenty-Four Month Periodic Maintenance 29
6. Servicing & Repair 30
6.1. Troubleshooting 30
6.1.1. Hydraulic Fluid is getting hot 30
6.1.2. The Shear runs too slowly 31
6.1.3. Loss of power when cutting heavy items 31
6.1.4. The Shear will not repeat stroke. 31
6.1.5. The Hydraulic Fluid becomes aerated or frothy 31
6.1.6. The Motor trips out due to overload or overheating 31
6.1.7. The Motor trips out repeatedly 31
6.2. Electrical Cable Schedule - Three Phase 32
6.2.1. JMC001 32
6.2.2. JMC002 32
6.3. Electrical Cable Schedule - Single Phase 33
6.3.1. JMC001 33
6.3.2. JMC002 33
6.4. Electrical Wiring Diagram 34
6.4.1. Three Phase 34
6.4.2. Single Phase 34
6.5. Hydraulic Circuit Diagram 35
6.6. Shear Blade Turning & Changing 36
6.6.1. Introduction 36
6.6.2. Replacing or Turning the Top Blade 36
6.6.3. Removing side movement from the Main Pivot 36
6.6.4. Replacing or Turning the Bottom Blade 37
6.6.5. Starting the Shear after Changing or Turning the Blades 37
6.7. Resealing the Hydraulic Ram 38
6.7.1. Removing the Ram from the Shear 38
6.7.2. Resealing the Hydraulic Ram 38
6.8. Hydraulic Relief Valve 40
6.8.1. Testing for Over-Pressure 40
6.8.2. Adjusting the Relief Valve Setting 40
6.9. Foot Pedal Cable 42
6.9.1. Renewing the Foot Pedal Cable 42
6.9.2. Adjusting the Foot Pedal Cable 42
6.10. Changing the Suction Filter 43
6.11. Renewing the 407 CAT Shear Jaw Extension 44
6.12. Renewing the CAT Shear V-Block 45

320/407/500/600.41912-ENG
7. Illustrations 46
7.1. Body, Blades & Blade Guard 46
7.1.1. 320 and 407 46
7.1.2. 500 and 600 47
7.2. Hydraulic Tank 48
7.3. Control Valve & Ram Supply 49
7.4. Hydraulic Ram 50
7.5. Stroke Adjuster & Foot Pedal 51
7.6. CAT Bracket & V-Block 52
8. Ordering Spare Parts 53
9. Record Keeping 54
9.1. Useful Contacts 54
9.2. End of Life Disposal 55
9.3. Training, Safety & Ownership Records 55
Operator Training Record 56
Shear Safety Checklist 57
Ownership Registration Form 58
Declaration of Conformity 59

1
320/407/500/600.41912-ENG
1. Introduction
This Manual covers the operation and maintenance of the single and three phase versions
of the 320, 407, 500, and 600 Shears, including the CAT versions and diesel powered
version of the 407 Shear.
McIntyre machines are designed to give long and trouble-free life, provided that simple
maintenance procedures are carried out as described in this Manual. It is recommended
that you take out a service contract with the supplier to ensure the Shear is kept in best
working order.
Remember that scrap metal processing can be hazardous. Before operating the
equipment, it is important that you read and understand the safety instructions contained
in this Manual. Please ensure that your Operators are fully trained in the use of the
Shear and, should you decide against a service contract, that you conduct periodic safety
reviews of the equipment’s safety features and Warning Labels. Replacement Warning
Labels and other items of safety equipment such as the Blade Guard, Foot Pedal and
Tongs can be obtained at cost from the Manufacturer. If you would like more safety or
operating information for this type of scrap metal processing equipment, then this can be
obtained by contacting any one of the organisations listed at the end of this Manual.
If you need any further help or assistance, or wish to order parts or a service contract,
please contact your local agent or the manufacturer:
JMC Recycling Systems Ltd
Unit 2, Harrimans Lane, Dunkirk, Nottingham, England NG7 2SD
Tel: UK [phone] Fax: UK [phone]
www.jmcrecycling.com email: [email protected]

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2. Warnings
Read & Understand this Manual before operating the Shear
2.1. Operating Warnings
BEFORE OPERATING THIS SHEAR ENSURE THAT:
• You, as the Operator, have read and understood this Manual.
• You are fully familiar with the Shear’s Controls.
• TheBladeGuardiscorrectlytted.
• AnyCoversareinplaceandcorrectlytted.
• All Warning Notices are clean and legible.
• The Foot Pedal Cable is free from damage.
• There are no obstructions to any air vents or intakes.
• You are wearing appropriate Protective Clothing.
• The working area around the Shear is clear of metal and debris.
• The Hydraulic Fluid level is correct.
• Visual Daily Operator Inspection Checks have been carried out.
• You have carried out a Shear Safety Inspection using the Shear Safety Checklist.
DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO SHEAR:
• Totally enclosed vessels, sealed cylinders, gas containers, aerosols or any other
pressurised container.
• Vesselscontainingvolatileorammablesubstances,acidsoralkalines.
• Ammunitions, cartridges, or explosive material of any type.
• Hardened or high-speed steels, engine pistons, automotive valves or valve seats.
• AnymetalorsubstancelikelytoyfromthebladesoftheShearwhilstbeingcut.
• Inatedautomobileandlorrytyres.
• Any other substances likely to cause injury to the Operator or bystander.
DO NOT:
• Hold bundles of items whilst shearing.
• Puthandsorngersintoopenendsoftubesorcylinderswhilstshearing.

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320/407/500/600.41912-ENG
• Puthandsorngersintoopensidedsections.
• Attempt to cut small items without the use of pliers or tongs.
• Operate the Shear from the front, back or left hand side of the Shear.
ALWAYS:
• Stand between the material being cut and the Controls of the Shear.
• Use the Shear from the Right (Control Box) side.
• Always hold long lengths of material to the right hand side of the body.
• Use the Blade Guard to clamp material when possible.
DANGEROUS WORKING PRACTICES
• Do Not point items to be sheared towards the body.
• Do Not operate the Shear in the manner shown in the following illustrations:
Material and tools may jerk up or jump out of the closing
blades causing injury.
Always feed material from the Control Box side of the Shear.

4320/407/500/600.41912-ENG
Label B.
2.2. Warning Labels
The Warning Labels illustrated are examples of those attached to all McIntyre Shears.
Keep all notices clean and legible. Replacement labels can be obtained directly from JMC
Recycling Systems Ltd.
UK labels are shown here. Colour and language of other countries labels may differ to
meet appropriate standards.
Label A.

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320/407/500/600.41912-ENG
Label C. Label D.
Label E.
Label F.
Label G.

6320/407/500/600.41912-ENG
Label J.
Label H.
JMC Recycling Systems
Label K.
Label L.
Label M.
Label I.

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320/407/500/600.41912-ENG
2.2.1. Positioning of Labels
Label D
Label F
Label F
Label G
Label K
Serial Number Plate
Label L
Label H
Label A Label F
Label E Label I
Label C
Label M
Label E
Label BLabel ELabel I

8320/407/500/600.41912-ENG
2.3. Important Information
2.3.1. Serial Number Plate
Below is an example of a JMC serial number plate declaring the EEC requirement for a
CE Mark along with the gross weight of the machine and the maximum working pressure
of the hydraulic system.
Note:Theworkingpressureandweightisspecictoeachmachineand
should not be taken as standard for similar machines.
2.3.2. Electric Motor Rotation
Electric Motor rotation is clockwise at the fan end.
Do not run the Motor anti-clockwise as this will result in
Hydraulic Pump damage.

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320/407/500/600.41912-ENG
2.3.3. Continual Improvement Policy
JMC Recycling Systems reserves the right to make changes and/or improvements to our
machines without obligation to incorporate such changes on machines previously sold.
2.4. A Cautionary Tale
The McIntyre 320 model Shear pictured below came into the manufacturer’s works for
reconditioningandresaleinMay2001.IthadbeenoperatingintheeldsinceNovember
1989. At some time during it’s history, the Shear had been refurbished by someone
otherthanthemanufacturer.TheBladeGuardhadbeenremovedandnotre-tted.The
FootPedalhadbeenmodiedbyremovingalargesectionofshielding.Removalofthe
Foot Pedal shrouding could result in accidental operation of the equipment by either the
Operator, someone stumbling onto the Pedal, or even a piece of falling metal. All Warning
Labels had been removed.
Modicationsofthistypecannotbecondonedsincetheycouldresultinseriousinjury
to the Operator. If you see, are offered, or are asked to work on a machine which has
been altered in such a way as to compromise Operator safety, then please contact
the manufacturer, trade organisation, and/or your local Health and Safety Executive.
Replacement Guards, Covers, Foot Pedals, Cables and Warning Labels etc can be
obtained at cost from the manufacturer.

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3. Installation
3.1. Lifting & Transporting
For safe movement of the Shear there are two Fork Lift Channels as shown below. Use
at all times when lifting the Shear and check the capacity of the equipment to be used.
Do not attempt to lift the Shear by any other means
The Shear is also on wheels, however for movement over longer distances or uneven
ground lifting the Shear with a forklift is advisable.
3.2. Siting & Installation
The Shear must be sited on level ground, ideally on sound concrete, and in good ambient
lighting. The Shear must not be allowed to rock back and forth while in operation. Site the
Shear in a position which will allow the Operator to walk freely and unhindered around all
sides. Ensure that the working area around the Shear is kept clear of metal and debris.
The Shear should be sited such that the noise generated is not reverberated or amplified
by the surroundings and does not disturb other Workstations or Operators.
Sound Pressure Level above 70 dBA
Fork Lift Channels

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320/407/500/600.41912-ENG
3.2.1. Electrical Power Supply
The Shear installation requires a 63A single or 32A three phase electrical supply. As part
of the installation, we strongly recommend the use of an earth leakage trip or Residual
Current Detector (RCD).
Ensure that the electrical supply is compatible with the Shear. Use armoured supply cable
complying with local regulations. Route the Supply Lead in such a manner as to leave it
freefromtrappingpointsandareaswhereitislikelytohindertheefcientoperationofthe
Shear, or cause a hazard.
The electrical supply to the Shear must only be installed by
an approved electrician.
3.3. Hydraulic Fluid
DonotruntheShearbeforellingtheHydraulicTankwith
Hydraulic Oil. Do not use a liquid other than Hydraulic Oil.
BeforestartingtheShearensuretheTankislledwithHydraulicOiltotheheavyblack
line on the Level Gauge.
Recommended oil types:
• BPHLP46;
• ShellTellusOil46;
• MobileDTE25;
• EssoNutoH46.
Monitor the oil temperature and do not allow it to exceed 65
Degrees Centigrade

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3.4. Dimension&TechnicalSpecication
3.4.1. 320 Shear
Single Phase Three Phase
Blade Length 320mm (12.5”) 320mm (12.5”)
Tip to Tip Opening 165mm (6.5”) 165mm (6.5”)
Shearing Height 910mm (35.8”) 910mm (35.8”)
Weight (with Oil) 830kg 830kg
Oil Capacity 200 Litres (44 Imp Gal) 200 Litres (44 Imp Gal)
Sound Pressure Level
(Operating Position - normal conditions) TBC 77 +/-3 dBA
Peak Sound Pressure Level TBC 84 dBC
Sound Power Level TBC 83 +/- 3 dBA
Cutting Control Single Cut - Repeating Single Cut - Repeating
Standard Power Supply 63A 1ph 230V 50hz 32A 3ph 380-415V 50hz
Motor Rating 5.5kW (7.5hp) @ 1420rpm 7.5kW (10hp) @ 1450rpm
Max System Pressure 172Bar (2500psi) 172Bar (2500psi)
Max Shear Force 67 Tonnes 67 Tonnes
Cutting Speed (Max Stroke) up to 11 cycles/min up to 16 cycles/min
Cutting Speed (40% Stroke) up to 29 cycles/min up to 41 cycles/min
Cutting Capacity (Mild Steel 43A):

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3.4.2. 407i & 407CAT Shear
Single Phase Three Phase
Blade Length 407mm (16”) 407mm (16”)
Tip to Tip Opening 225mm (8.8”) 225mm (8.8”)
Shearing Height 931mm (36.6”) 931mm (36.6”)
Weight (with Oil) 900kg 900kg
Oil Capacity 200 Litres (44 Imp Gal) 200 Litres (44 Imp Gal)
Sound Pressure Level
(Operating Position - normal conditions) TBC 77 +/-3 dBA
Peak Sound Pressure Level TBC 84 dBC
Sound Power Level TBC 83 +/- 3 dBA
Cutting Control Single Cut - Repeating Single Cut - Repeating
Standard Power Supply 63A 1ph 230V 50hz 32A 3ph 380-415V 50hz
Motor Rating 5.5kW (7.5hp) @ 1420rpm 7.5kW (10hp) @ 1450rpm
Max System Pressure 193Bar (2800psi) 214Bar (3100psi)
Max Shear Force 80 Tonnes 90 Tonnes
Cutting Speed (Max Stroke) up to 8 cycles/min up to 11 cycles/min
Cutting Speed (40% Stroke) up to 21 cycles/min up to 28 cycles/min
Cutting Capacity (Mild Steel 43A):

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3.4.3. 500 LGT and 500 CAT
Single Phase Three Phase
Blade Length 508mm (20”) 508mm (20”)
Tip to Tip Opening 225mm (8.9”) 225mm (8.9”)
Shearing Height 934mm (36.75”) 934mm (36.75”)
Weight (with Oil) 990 kg 990 kg
Oil Capacity 200 Litres (44 Gal) 200 Litres (44 Gal)
Sound Pressure Level
(Operating Position - normal conditions) TBC 76 +/-3 dBA
Peak Sound Pressure Level TBC 82 dBC
Sound Power Level TBC 74 +/-3 dBA
Cutting Control Single Cut - Repeating Single Cut - Repeating
Standard Power Supply 63A 1ph 230v 50hz 32A 3ph 380-415v 50hz
Motor Rating 5.5kW (7.5hp) @ 1420rpm 7.5kW (10hp) @ 1450rpm
Max System Pressure 193 Bar (2800 psi) 241 Bar (3500 psi)
Max Shear Force Up to 96 Tonnes Up to 120 Tonnes
Cutting Speed (Max Stroke) Up to 8 cycles/min Up to 8 cycles/min
Cutting Speed (40% Stroke) Up to 21 cycles/min Up to 21 cycles/min
Cutting Capacity (Mild Steel 43A):