Piranha MegaFab P-120 Technical reference manual

INSTRUCTIONS
AND REPAIR PARTS
MANUAL FOR
IRONWORKER
MODEL NUMBER
P-120
Publication: March, 2010
For Serial Numbers
P120-1054 to Current
Models
www.megafab.com
800-338-5471
Be sure to register your model
and serial number to receive
Piranha Service and Product
Updates.

Piranha Optional Tooling and Attachments
Enhance your Ironworker’s Versatility
Oversize Punch Attachments
•Expand your punching capacity up to 5"
Quickset Gauging Table
Allows you to quickly set-up your punch end
for multiple holes.
Includes an angle gauge bar to index off the
heel of your angle and a plate gauge bar,
which indexes off the end of your plate.
Extensions are available in left and right hand
styles in 5' and 10' lengths.
Backgauge
•Allows you to quickly set-up your machine to
repeat your shearing length by adding a
mechanical backstop.
•Backstop can be positioned in either the
angle, flat bar, or round bar section of the
machine.
•Available in lengths of 3', 6', 9’, or 12'.
•An electronic version is also available, which
cycles the machine automatically when
material makes contact with the backgauge
probe.
Pipe Notching Attachment
•Allows you to single notch Schedule 40 Pipe.
•A must have for handrail jobs.
•Attaches to the punch end of the machine.
•Notching dies available for 3/4", 1", 1-1/4", 1-
1/2", and 2"Schedule 40 Pipe.
•
Oversize Bending Attachments
•Expand your bending capacity to 24"on most
models.
•Includes a 4-way die block for different
thicknesses of material.
***Additional Options Shown on Inside of Back Cover***

INSTRUCTIONS
AND
REPAIR PARTS MANUAL
FOR
IRONWORKER
MODEL NUMBER P-120
Publication: December, 2005
Revised: March, 2010
P.O. Box 1206
Rockford, IL 61105
PH: 800-338-5471
FAX: [phone]
www.megafab.com

TABLE OF CONTENTS
Refer to second section of this manual for information on repair parts breakdown
and ordering repair parts.
Page No.
FORWARD ................................................................................................. 4
WARRANTY ............................................................................................... 4
INTRODUCTION ........................................................................................ 5
SAFETY PRECAUTIONS ........................................................................... 6
MACHINE SPECIFICATIONS .................................................................... 7
FUNCTIONAL DIAGRAM ........................................................................... 8
DIMENSIONAL DATA................................................................................. 9
STANDARDS COMPLIANCE. ................................................................... 10
INSTALLATION ......................................................................................... 11
OPERATING INSTRUCTIONS.................................................................. 12
PUNCH & DIE CLEARANCE CHART........................................................ 18
LUBRICATION........................................................................................... 20
MAINTENANCE......................................................................................... 21
TROUBLESHOOTING............................................................................... 22
PUNCH TONNAGE CHART ...................................................................... 26
TOOL LIST ................................................................................................ 27
ORDERING INSTRUCTIONS.................................................................. RP-1
REPAIR PARTS ILLUSTRATIONS.......................................................... RP-2
REPAIR PARTS ILLUSTRATION INDEX ................................................ RP-3
SERVICE RECORD CHART .................................................................. RP-24

4
FOREWORD
This manual has been prepared for those persons who will operate and maintain the
Piranha Ironworker. It is important that all persons responsible for the care and
operation of this equipment read and understand the information presented in this
publication.
The illustrations and instructions on the following pages were the most recent
available at the time of publication and selection of this material was made based on
a standard machine arrangement. Differences between the machine you received
and the views contained in this manual are the result of design improvement and / or
the addition of optional accessories specified on your order.
WARRANTY
Mega Manufacturing will replace (F.O.B. our factory), or refund the purchase price
for any goods which are defective in materials and workmanship within 12 months of
date of purchase. The buyer must return the warranty registration card within thirty-
(30) days of the purchase date, and at the seller's option, return the defective
materials freight and delivery prepaid to the seller, which shall be the buyer's sole
remedy for defective materials. Seller shall not be liable to purchaser or any other
person for consequential or incidental damages. Hydraulic and electrical
components are subject to their respective manufacturer's warranties. This warranty
does not apply to machines and / or components, which have been altered in any
way, or subjected to abusive or abnormal use, inadequate maintenance, and
lubrication, or to use beyond seller’s recommended capacities and specifications.
Seller shall not be liable under any circumstances for labor costs expended on such
goods or consequential damages. Seller shall not be liable to purchaser or any
other person for loss or damage directly or indirectly arising from the use of the
goods, or from any other cause. No employee, agent, officer, or seller is authorized
to make oral representations or warranty of fitness or to waive any of the foregoing
terms of sale and none shall be binding on the seller.

5
INTRODUCTION
The Piranha Ironworker is a compact hydraulically powered machine that shears,
punches, bends, notches, and copes, all in a low silhouette, efficiently designed unit,
resulting in minimal floor space requirements. The integral lifting lug provides instant
portability and the unit arrives fully assembled, requiring only the addition of
hydraulic oil and electrical power to become operational. A quick-change mounting
assembly, utilizing a split dovetail, allows setup from punching to bending in less
than one minute. The large platen has seventeen 5/8-11 tapped holes giving a wide
base for increased flexibility of attachment sizes. The shearing operation features
an adjustable automatic hold-down allowing the operator to clamp the work piece
with a slight initial adjustment. All workstations are located approximately 44" off the
floor for ease of operation.
The first part of this manual provides operations and maintenance instructions,
including a section on troubleshooting various problems that may occur. The
second part of this manual provides repair parts information and a complete parts list
with their respective part numbers.
Proper understanding and application of the information and procedures given in this
manual will aid in establishing a preventative maintenance program and, provide
assistance for correcting malfunctions that may occur in the machine. The repair
parts list provides information for parts procurement as well as assembly
breakdowns to aid in disassembly and re-assembly for repair part installation.

6
SAFETY PRECAUTIONS
The operator of this machine should view the operational video provided with the
machine, and thoroughly understand this manual before starting any operation.
This machine was designed for use by a single operator only.
Wear eye protection at all times.
Use the proper voltage outlet for your machine.
Make sure that all guards and cover shields are down before starting machine.
CAUTION: Do not remove guards.
Keep hands off working tables and out of the path of moving parts during operation.
Remove all material from the tables except for the work piece.
Remove all tooling from the punch end before starting shearing or coping
operations.
Make sure that all tooling is properly held in position before starting any operation.
The area around the machine should be well lighted, dry, and as free from
obstructions as possible.
All maintenance and repair work should be performed by a person familiar with this
publication.
At the end of the working day, the operator should turn the power off to the machine.
Adjust limit switches when punching or bending to allow 1/4" maximum clearance
between bottom of the stripper foot or bending punch and the top of the material.
Contact the factory for limit switch adjustments on special tooling.
Turn selector switch to the "OFF" position when changing tooling or performing
maintenance work. (Reference Page 12, Figure “B”).

7
MACHINE SPECIFICATIONS
HYDRAULIC SYSTEM
Drive Motor 20HP 230 / 460 Volt / 3 Phase
Hydraulic Tank Capacity 25 Gallons
Hydraulic Oil ISO Grade 32
Consult your local distributor for a cross reference
WORKING SURFACE
Platen Table 14-1/2" x 21"
Coper Table 19" x 19"
CAPACITIES
Punch Maximum 1-1/2" Thru 1" thick material or 120 Tons
Bending Maximum 120 Tons
Punch End Maximum 120 Tons
Bar Maximum 2" Round or 1-3/8" Square
Plate 3/4" x 18" or 20-1/2" with Optional Knifes
Angle Maximum 6" x 6" x 5/8"
Coper-Notcher Maximum 4" x 6" x 3/8"
WEIGHT
Shipping Weight 6,200 Pounds

8
FUNCTIONAL DIAGRAM Rear Control Box
(
OFF SIDE
)
Foot Switch
Angle Table
Coper Guard
Coper Guides
COPER END
Coper Table
Shear TableHold-downStroke Control
Punch
Attachment
PUNCH END
Platen Table
Chip Bucket
Front Control
Box
Chip Bucket
Serial Number
Plate Location
Lifting Lug

9
DIMENSIONAL DATA
35" 90"
44"
68-1/2"

10
Standards Compliance
Electrical System Design/Manufacture:
The machines manufactured in Rockford, Illinois, USA are furnished with electrical /
electronic products that are UL (Underwriter's Laboratory) approved. These
components have the UL numbers printed or stamped on them and can be easily
traced to the point of manufacture. In addition, all of the machines meet the current
"Ontario Hydro" electrical code for proper manufacture of the electrical circuits.
Hydraulic System Design/Manufacture:
Hydraulic components used in Piranha machines are approved by NFPA (National
Fluid Power Association), and those approval numbers can be traced through the
manufacturer's part numbers.
ANSI/OSHA Compliance:
Mega Manufacturing meets the current ANSI construction standards for
manufacturing of ironworkers, press brakes, and shears:
ANSI Bll.5 - Ironworkers, Construction, Care, and Use
ANSI Bll.3 - Power press brakes, Construction, Care, and Use
ANSI Bll.4 - Shears, Construction, Care, and Use
The ANSI B11 standards were developed to establish levels of responsibility for
manufacturing safe products, and for installing, training, and using these products.
The levels of responsibility are evenly distributed between the manufacturer, the
owner/end-user of the equipment, and the operator. Specific guarding requirements
are, in general, assigned to the owner/end-user of the equipment.
With specific reference to Ironworkers, OSHA (Occupational Safety and Health
Administration) made a ruling on March 4, 1991 - under their standard number
1910.212, specific to the OSHA Machine Guarding Standard 29 CFR
1910.212(a)(1). This ruling is stated verbatim below:
"If an employer provides an iron worker machine (at his or her
workplace), which is manufactured in compliance with the safety
requirements specified in ANSI B 11.5-1988, and the guarding is
maintained as required; then that employer meets OSHA's machine
guarding requirements for that machine."
Please understand that this ruling places the primary burden of responsibility for
maintenance of guarding on the owner/end-user of the equipment. Inherent in this
requirement is the responsibility of the owners/end-users of the equipment to
develop and maintain guarding specific to their application for the equipment. These
ANSI safety requirements may be acquired from:
American National Standard Institute 1430 Broadway
New York, New York 10018 Telephone [phone]

11
INSTALLATION
Location
For the best overall performance, install the Piranha in a location that is clean and
well lighted. Provide sufficient space in all directions to allow for the material lengths
of the work pieces to be processed by the Piranha.
Foundation
To maintain the accurate alignment built into the Piranha, and to prevent undue
stress on the moving parts under a load, the Piranha should be placed on a stable
base or floor adequately constructed to withstand the unit weight. NOTE: Use the
leveling bolts provided with the machine.
Wiring
The Piranha is shipped totally wired through the electrical enclosure box. It has
been left to the owner's discretion whether to wire direct to an electrical disconnect,
or to install a cord and plug for mobility of the Piranha.
CAUTION: Compare machine wiring to input voltage prior to connecting
power. Only connect the specified voltage to the machine.
Lifting
The lifting lug on the Piranha is an integral part of the machine. Use a device with
adequate lifting capacity to handle the Piranha.
CAUTION: The unit is exceptionally top heavy! Lifting from the underside
of the machine may cause damage to the cabinet structure.
Assembly
The Piranha is pre-assembled at the factory. The only requirements are the addition
of hydraulic oil and electrical power.

12
Start Button
Green
Stop Button
Red
Four Pole
Receptacle
Toggle
Switch
Selector Switch
Front – OFF - Rear
NOTE: Turn selector
switch to OFF position
when performing
maintenance or
changing tooling.
OFF
Jog Down
Rear Cover
Front Control
Box Only
Front
FIGURE "B"
FIGURE "A"
Rear
FIGURE "E"
View Control Box
Locations FIGURE "D"
Rear Control Box
MACHINE
Jog Down
Fast Up
Fast Down
Front Cover
Front and Rear
Control Boxes
Joystick Operator
Jog Up
Up Stroke
Limit Switch
Down Stroke
Limit Switch
Punch End
Note: Joystick Center
Position is Neutral
FIGURE “C”
Front Control Box
Fast U
p
Jog Up
Joystick Operator
Fast Down
Coper End
"F1"
Foot Switch
Foot Switch Lever Positions
1) Beam Moves Up
2) Beam is Stopped
3
)
Beam Moves Down
Foot Switch Lever
Full Up Position
Beam Elevates
To Limit Settin
g
Foot Switch Lever
Depressed Past Center
Beam Moves Down
To Limit Settin
g
Foot Switch Lever
Neutral Position
Beam Travel
Is Halted
Foot Switch Lever
Depressed Past Center
Beam Moves Down
To Limit Settin
g
Foot Switch Lever
Full Up Position
Beam Elevates
To Limit Settin
g
Foot Switch Foot Switch
Foot Switch Foot Switch Foot Switch
"F""F2"
"F3""F4""F5"
OFF ON

13
OPERATING INSTRUCTIONS
(Refer to drawings on page 12)
The Piranha Ironworker comes pre-assembled and pre-wired, requiring only the
addition of hydraulic fluid in the reservoir to the mark on the fill cap dipstick and a
power source from a disconnect to the electrical enclosure box located inside the
cabinet.
The unit can be started and stopped by the push button operators located on the
front cover of the control boxes on each end of the unit. (Reference Page 12, Figure
“A”). For the Control Box locations, reference Page 12, Figure "E".
The electrical controls have a selector switch to determine which control box controls
the unit. This safety feature is located on the rear cover of the front control box only,
(reference Figure "B"). The legend plate on the selector switch is printed "Front-Off-
Rear". "Front" allows electrical control to the Front Box only. "Off" disconnects
electrical control to both control boxes. "Rear" allows electrical control to the Rear
Box only. The selector switch should be in the "OFF" position when the machine is
not being used, such as, changing tooling, maintenance work, etc. The machine can
only be started from the control box selected via the selector switch. It can be
stopped using either “stop” button.
Joystick Operation
The ironworker is hand controlled by a five-position momentary joystick operator.
When the joystick is released from any of the four positions, it will return to the
neutral (center) position stopping machine movement instantly. The joysticks are
located on top of the control box at each end of the machine (reference Figure "E").
The four controlling positions of the joystick are:
1. Fast Down (pulling the handle forward).
2. Fast Up (pushing the handle away).
3. Jog Down (pushing the handle to the right).
4. Jog Up (pushing the handle to the left). Reference: Figures "C" and "D".
All directions in Figures "C" and "D" are determined by standing at either end and
facing the machine. The jog speed in both positions is a slow speed for alignment of
center punch marks and scribe lines for shearing. The fast cycle should be used for
the work cycle.

14
Footswitch Operation
The ironworker can also be controlled by a footswitch (reference Figure "F"). The
footswitch is used by plugging the 4-pole twist lock cap into the 4-pole twist lock
receptacle located in the front cover of either control box (reference Figure "A"), and
switching the toggle switch (reference Figure "A") from the "OFF" position to the
"ON" position.
The footswitch is a three-(3) position switch allowing hands-free operation.
By fully depressing the footswitch lever, machine movement is downward to
limit setting (reference Figure F2).
By allowing the footswitch lever to elevate to the center position, machine
movement stops (reference Figure F3).
Completion of downward cycle is accomplished by depressing footswitch
lever again. Machine movement is down until limit setting is met (reference
Figure F4).
Removing foot pressure from the switch entirely allows machine movement
upward to limit setting, completing upstroke cycle (reference Figure F5).
The footswitch is used in conjunction with the upstroke and down stroke limit
switches located on the machine side off the front control box only (reference Figure
"C").
The front limit switch (closest to the punch end and the lower switch of the
two switches) controls the down stroke limit.
The back switch (furthest from the punch end and the higher of the two
switches) controls the upstroke limit.
The limit switches are activated by the limit switch arms: Item Number 60,
shown on Page Number RP-3. To set the stroke using the limit switch arms,
use the following procedure:
1) Plug in footswitch.
2) Turn toggle switch to "ON" position.
3) Loosen thumbscrew on down stroke limit-switch arm.
4) Fully depress footswitch lever allowing beam to move downward.
5) Slide limit switch arm until contact with the down stroke switch stops beam
movement at the desired lower limit.
6) Tighten thumbscrew to hold limit switch arm firmly in place.
7) Loosen thumbscrew on upstroke limit-switch arm.

15
8) Allow footswitch lever to elevate allowing beam to rise.
9) Slide limit switch arm until contact with the upstroke switch stops beam
movement at the desired upper limit.
10)Tighten thumbscrew to hold limit switch arm firmly in place.
NOTE: When punching or using the bending attachment, set upper and lower limits
to allow for 1/4" maximum clearance between the bottom of the punch and
the top of the work material. The setting will change when the work material
thickness changes.
NOTE: The down stroke limit switch on the punch end controls the upstroke limit on
the coper end. The upstroke limit is the only switch controlled from the rear
control box footswitch control. The operator controls the downstroke limit by
allowing the footswitch lever to fully elevate after the upper coper knife
passes through the material.

16
STRIPPER ATTACHMENT ALIGNMENT
The alignment of the stripper should be accomplished in the following manner.
(Reference Pages RP-3 and RP-9).
1. Slide the punch stripper assembly on the dovetail-mounting shoe.
2. Tighten the locking shoe by turning the cap screw clockwise (requires 3/8”
Allen wrench). This locks the stripper assembly firmly in place.
3. Remove the coupling nut from the punch stem using the coupling wrench.
4. Insert the punch in the coupling nut and tighten on the punch stem using the
coupling wrench.
5. Insert the female die in the die block.
6. Tighten the setscrew against the female die (requires 3/16” Allen wrench).
7. Slide the die block around the setscrews on the platen table. Do not tighten
the flanged nuts.
8. Switch the front control box toggle switch (reference Figure "A") to the “OFF”
position. Disconnect the foot switch from the receptacle.
9. Start the machine. Use the front control box joystick in the jog down mode
(reference Figure "C"), to move the beam downward. Stop beam movement
when the bottom of the stripper foot is approximately 1/8" above the die block.
10. Align the punch and die visually and by hand movement of the die block. Jog
down again slightly and align. Continue this procedure until the punch has
passed through into the die
.
11. Using the wrench supplied with the machine, tighten the flanged nuts on the
setscrews to hold the die block firmly to the platen table.
12. Set the limit switches to control the length of stroke (reference procedures
previously listed).
13. Start operation.

17
STRIPPER ASSEMBLY ADJUSTMENT
NOTE: The selector switch should be in the "OFF" position until all
tooling changes are complete. (Reference Page 12, Figure “B”.)
The adjustment of the stripper assembly to compensate for varying punch lengths
should be accomplished in the following manner. (Reference Page RP-9 for a visual
reference).
NOTE: The correct adjustment should have the tip of the punch 1/16" below the
bottom of the stripper footplate and the stripper footplate level.
1. Install the stripper assembly on the upper beam (reference instructions
previously listed).
2. Insert punch in the stripper assembly (reference instructions previously listed).
3. Measure the length of the punch relative to the bottom of the stripper foot.
4. If the tip of the punch extends more than 1/16" below the bottom of the stripper
foot, adjustment is required. Remove both dust covers.
5. Turn the two (2)-guide pin adjusting caps counter clockwise until the tip of the
punch extends 1/16" below the bottom of the stripper footplate. The stripper
footplate MUST remain level or parallel to the work material. The punch tip
should be able to line up on a center punch mark before the stripper footplate
engages the material.
6. If the tip of the punch does not extend 1/16" below the bottom of the stripper
foot, or if the stripper footplate is not parallel with the work material, adjustment
is required.
7. Turn the two (2)-guide pin adjusting caps clockwise until the tip of the punch
extends 1/16" below the bottom of the stripper footplate. The stripper footplate
MUST remain level or parallel to the work material. The punch tip should be
able to line up on a center punch mark before the stripper footplate engages the
material.
8. Install the dust covers on the stripper assembly.

18
BENDING ATTACHMENT ALIGNMENT
The alignment of the bending punch and bending die should be accomplished by the
following manner. (Reference Pages RP-3 and RP-11).
1. Slide the bending punch assembly on the dovetail-mounting shoe. The front
edge of the bending dovetail slide should be even with the mounting shoe
2. Tighten the locking shoe by turning the cap screw clockwise (requires 3/8”
Allen wrench). This locks the bending punch assembly firmly in place.
3. Place the bending base holders on the platen table over the setscrews. Do not
tighten flanged nuts.
4. Place the four-way bending die into the bending base holder with the proper
width die opening on the top.
5. Switch the front control box toggle switch (Reference Figure "A") to the “OFF”
position and disconnect the foot switch from the receptacle.
6. Start the machine. Using the front control box joystick in the jog down mode
(Reference Figure "C"), move the beam downward.
7. When contact between the bending punch and the bending die block opening is
made, the bending die block will center itself.
8. Using the wrench supplied with the machine, tighten flanged nuts on the
setscrews to hold the base assembly firmly to the platen.
9. Set the limit switches to control the length of stroke (reference procedures
previously listed).
10. Start operation.

19
SHEAR HOLD-DOWN ASSEMBLY ADJUSTMENT
The adjustment on the hold-down assembly should be accomplished by the
following manner. (Reference Page RP-7)
1. Raise the upper beam to its full upstroke limit.
2. Adjust the three-position hold-down locator per the following instructions:
Locator hole nearest punch end - Plate = 1/4" thick and less, Angle =
3/16" thick and less.
Locator hole center position - Plate = 5/16" to 1/2" thick, Angle = 1/4" to
5/16" thick.
Locator hole nearest the coper end - Plate = 5/8" to 1" thick, Angle =
3/8" to 1/2" thick*
3. Loosen the long hex head nut without removing it from the swing bolt, raising
the hold-down assembly.
4. Assure the hold-down bar has risen until it is directly under the long nut.
5. Insert material to be sheared under the hold-down assembly.
6. Tighten the long hex head nut to allow for approximately 1/8" clearance
between the bottom of the shear urethane and the top of the material to be
sheared. The material should move freely and not be held by the hold-down
assembly at this point.
7. Lower the beam using the front control box joystick in the jog mode (reference
Figure "C") until the hold-down assembly firmly clamps the material.
NOTE: The hold-down assembly must firmly clamp the material before the
shear knives engage the material surface.
8. If the foot switch is to be used during the operation, adjust the limit switches
to control the length of stroke (reference procedures previously listed).