Scotchman 6509-24FF User manual

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MODEL
6509-24FF
IRONWORKER
PRINTED AUGUST 2014

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE #
1.0 INTRODUCTION 4
2.0 SAFETY PRECAUTIONS 5
2.1 WARRANTY 7
3.0 WARNING LABELS 8-9
4.0 INSTALLATION & SET-UP 10-19
4.1 Physical Dimensions 11
4.2 Machine Moving Procedures 12
4.3 Physical Inspections 13
4.4 Electrical Requirements 14
4.5 Machine Start Up 17
4.6 Machine Stroke Inspection & Adjustment 18
5.0 MAINTENANCE 20-23
5.1 Lubrication 20
5.2 Routine Lubrication 20
5.3 Scheduled Maintenance 22
6.0 MACHINE OPERATION 24-35
6.1 Punch Operation 24
6.1B Stripper Adjustment 29
6.2 Bar Shear Operation 30
6.2A Shear Arm Adjustment (Ser. # 7815 & Up) 32
6.2B Shear Blade Adjustment (Ser. # 7815 & Up) 34
7.0 OPTIONAL TOOL OPERATION 36-61
7.1 6 x 6 Angle Shear 38
7.2 Rod Shear 40
7.3 6 x 6 Ninety Degree Notcher 42
7.4 Rectangle Notcher 44
7.5 12 & 24 Inch Brakes 46
7.6 Angle Iron Brake 48
7.7 Channel Shear 50
7.8 Pipe Notcher 52
7.9 Picket Tool 55
7.10 Square Tube Shear 56

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE #
7.10A Square Tube Shear Installation 56
7.10B Square Tube Shear Operation 56
7.11 Optional Punch and Die Holders 58
7.11A 2-1/2" & 3" Die Inserts 58
7.11B Offset Die Holder 58
7.11C 6 x 6 Die Holder 58
7.11D # 45 Punch Retaining Nut 58
7.11E Heavy Duty Split Ring Retaining Nut 59
7.12 Optional Gauging Equipment 60
7.12 48 Inch Deluxe Back Gauge 60
7.13 Urethane Stripper 60
8.0 TROUBLE SHOOTING GUIDE 65-69
8.1 Electrical Trouble Shooting-Motor 65
8.2 Limit Switch Inspection 66
8.3 Control Valve Inspection 66
8.4 Hydraulics 67
8.5 Cylinder Seal Replacement 68
9.0 IRONWORKER PARTS LISTS 70-89
9.1 Shear Arm Assembly (Ser. #7815 & Up) 70
9.2 Punch Assembly 72
9.3 Stripper Assembly 74
9.4 Upper Arm Assembly 76
9.5 Stroke Control Assembly 78
9.6 Hold Down Assembly 80
9.7 Cylinder Assembly 82
9.8 Connecting Link Assembly 83
9.9 Power Unit 84
9.10 Electrical Unit 86
9.11 Urethane Stripper 88

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1.0 INTRODUCTION
The Scotchman 6509-24M is a versatile, multi-purpose, shearing, punching and forming machine
engineered for trouble free operation. The design of the machine combines simplicity of operation with
smooth, full stroke control. The ability of the operator to control the machine’s direction of movement at
any point in the stroke (stop, jog or reverse) gives the Scotchman 6509-24M Ironworker a tremendous
advantage over mechanical ironworkers. There is no chance of the Scotchman being "accidentally
tripped". The hydraulic system operates at a maximum pressure of 2,500 PSI and is protected from
overload by a pilot operated relief valve. The Scotchman 6509-24M Ironworker lends itself to a variety
of special purpose tools that can be mounted on the tool table where a selection of power and stroke
potentials are available.

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2.0 SAFETY PRECAUTIONS
1) The operators of this machine must be qualified and well trained in the operation of the machine.
The operators must be aware of the capacities of the machine and the proper use of the hold down
devices, strippers and guards provided with the machine.
2) All of the guards, adjustable restrictors and awareness barriers must be installed on the machine
and kept in good working order. Promptly replace worn or damaged parts with authorized parts.
3) Never place any part of your body into or under any of the machine’s moving parts, strippers or
hold devices.
4) Wear the appropriate personal protective equipment. Safety glasses are required at all times,
whether operating, setting up or observing this machine in operation. Since heavy pieces of metal
with sharp edges can be processed on this machine, the operator should also wear steel-toed shoes
and tight fitting leather gloves.
5) Strictly comply with all warning labels and decals on the machine. Never remove any of the
labels. Replace worn or damaged labels promptly.
6) Always disconnect and lock out the power when performing maintenance work or setting up any
tooling on the machine. Follow the procedures outlined in the operator’s manual for setting up,
changing or aligning any tooling on this machine.
7) Never operate this machine with dull or damaged tooling. Replace worn punches, dies and blades
promptly.
8) Practice good housekeeping. Keep the area around the machine clear and well lit. Do not
obstruct the operator’s position by placing anything around the machine that would impede the
operator’s access to the machine.
9) Never modify this machine in any way without the written permission of the manufacturer.
10) Never leave this machine running unattended.
11) Always operate the punch station facing the station, standing. Never operate any of the work
stations from a sitting or kneeling position.

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12) Set up a program of routine inspections and maintenance for this machine. Make all repairs and
adjustments in accordance with the manufacturer’s instructions.
13) A safety CD or VHS tape was mailed to you or shipped with the machine. If you did not receive it,
please contact the factory or your local dealer immediately and one will be sent to you at no
charge. If this machine was purchased used, please contact the factory for a safety CD or VHS
tape.

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2.1 WARRANTY
Scotchman Industries Inc. will, within three years of date of purchase, replace F.O.B. the factory or
refund the purchase price for any goods which are defective in materials or workmanship, provided that
the buyer returns the warranty registration card within thirty days of the purchase date and, at the
seller’s option, returns the defective goods freight and delivery prepaid to the seller, which shall be the
buyer’s sole and exclusive remedy for defective goods.
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, changed or
modified in any way or subjected to abusive and abnormal use, inadequate maintenance and lubrication
or subjected to use beyond the seller’s recommended capacities and specifications.
In no event shall seller be liable for labor cost expended on such goods or consequential damages.
The 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 officer, employee or agent of the 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 the seller.
Any electrical changes made to the standard machine due to local electrical code variations must be paid
by purchaser.
As we constantly strive to improve our products, we reserve the right to make changes without
notification.

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3.0 WARNING LABELS
ITEM QTY PART # DESCRIPTION
A 1 003100 LARGE SAFETY GLASSES
B 1 003105 FINGERS BEYOND BAR GUARD
C 1 003110 PUNCH & DIE WARNING
D 1 003120 DANGER VOLTAGE LABEL
E 2 003140 FINGER BEYOND TOOL SHEAR
F 1 019127 U.S. FLAG DECAL
G 1 003195 3 X 3 X 1/4 MAX STICKER
H 1 010117 27” SCOTCHMAN DECAL
I 1 019138 65T CAPACITY DECAL
J 4 019103 LUBRICATE DECAL
K 9 019105 GREASE POINT DECAL
L 1 003175 CAUTION CONTAMINATION
(Not shown.)
M 1 019102 RESERVOIR CAPACITY
(Not shown.)
O 1 003530 65T DECAL PACKAGE

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FIGURE 1

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4.0 INSTALLATION & SET UP
⌦CAUTION: THIS SECTION DISCUSSES INSTALLATION AND SET-UP PROCEDURES.
PLEASE READ THOROUGHLY BEFORE OPERATING THIS MACHINE.
FIGURE 2

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4.1 PHYSICAL DIMENSIONS
INCHES CM
A. Floor to punch ram 43-1/4 109.8
B. Floor to top of die holder 39-1/2 100.3
C. Floor to punch bolster 35 88.9
D. Floor to bottom rail 3 7.6
E. Floor to Bar Shear 27-1/2 69.8
F. Floor to tool table 41-1/2 105.4
G. Height 64-1/2 163.8
H. Length 60-3/4 154.3
I. Punch stroke 2 5
J. Width 30 76.2
K. Weight 2,750 LBS. 1,250 KG.

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4.2 MACHINE MOVING PROCEDURES
This machine is designed to be moved with a forklift. The weight of this machine is 2,750 pounds (1,250
Kg.). Check the capacity of the lifting equipment before attempting to move the machine.
THIS MACHINE IS TOP HEAVY AND SHOULD BE MOVED WITH CARE AND ON FLAT
SURFACES ONLY.
This is the quickest and safest means of moving the machine. The forks of the lift should be spread so
that they fit inside the lifting channels provided.
FIGURE 3

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4.3 PHYSICAL INSPECTIONS
After the machine has been located, remove the side shrouds and inspect the interior of the machine for
possible shipping damages.
CHECK SPECIFICALLY THE FOLLOWING ITEMS:
A. Stroke control handles and limit switches.
B. Pump and motor assembly.
C. Hydraulic hoses and fittings.
D. Starter box and control box.
E. Electrical connections.
F. Control valve.
The reservoir is full of oil. The recommended oil is a lightweight, non-foaming, anti-wear, hydraulic oil
such as Mobil DTE-25, with a minimum ISO cleanliness code of 20/18/15, or equivalent.
The reservoir holds 14 U.S. gallons (53 liters).
⌦CAUTION: DO NOT OVER FILL!

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4.4 ELECTRICAL REQUIREMENTS
FIGURE 4

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FIGURE 4B

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FIGURE 4C

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⌦CAUTION: TO PREVENT DAMAGE TO THE MOTOR AND DANGER TO THE OPERATOR,
ALL ELECTRICAL CONNECTIONS SHOULD BE MADE BY A LICENSED ELECTRICIAN.
All machines are wired for three phase electrical power unless otherwise specified.
To insure satisfactory machine performance, the supply voltage should be (+ or -) 10% of the motor
voltage rating. Check the motor data tag for full load current requirements. The electrical diagram
for the machine is inside the cover of the control box. The diagram is also in FIGURE 4 ON PAGE 15.
For electrical supply lines ten feet (3m) or shorter, we recommend at least 12 gauge, and preferably, 10.
For longer electrical supply lines, use at least 10 gauge, and preferably, 8. We do not recommend supply
lines longer than twenty five feet (7.5m).
POWERREQUIREMENTS:
Motor frame 3PH = 182T 1PH = 184T
MOTOR VOLTAGE FULL LOAD CURRENT
(VAC) (AMPS)
208 15.5
230 14
460 7
575 5.9
230 (Single Phase) 23.5
Motor Power Rating: 5hp Speed 1,750 RPM
KVA Power Rating: 5.6 KVA Frequency 60 HZ
Starting Current: 210% Full Load
4.5 MACHINE START-UP
Before starting this machine, take time to thoroughly review the safety dvd and the operator’s
manual. This machine is equipped with a lock-out, disconnect switch. We strongly urge you to follow
OSHA directive CFR-1910.147 (effective 09-01-90) regarding lock-out, tag-out procedures. Before
powering the machine, be sure that all packing materials and tools have been removed from the machine
and that the work stations are clear.
TO POWER THE MACHINE, place the disconnect switch in the ON position and the selector switch in
the START position. Power the machine by pushing the green START button. If the machine does not
operate when the selector switch is moved, the motor rotation is not correct and the electrician will have
to switch two of the three supply line wires to change the direction. Once the machine has been powered,
it will not move until the selector switch has been placed in either the punch or the shear position.
Placing the selector switch in the PUNCH position will cause the arms to move down. Placing the selector
switch in the SHEAR position will cause the arms to move up. Any time that the power to the machine
has been turned off, the selector switch must be placed in the START position to restart the machine.

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4.6 MACHINE STROKE INSPECTION & ADJUSTMENT
The stroke setting is important for the proper operation of the machine. If this setting has changed, the
machine may over-travel and cause the cylinder to "bottom out". This continued condition will
eventually cause the starter overload to open. It can also cause the hydraulic oil to overheat and damage
hydraulic system components. A slight change in the stroke setting can result in inadequate stroke to
operate the tooling. A check of the machine’s stroke setting is made at the punch station. SEE FIGURE 5
ON THE FOLLOWING PAGE. Set the stroke control handles (A) out to their farthest position away
from the metering boss (C). Turn the selector switch (G) to the START position and power the machine.
Place the selector switch in the PUNCH position. Measure the distance from the punch ram to the top of
the bolster. The distance should be 8-13/16 inches (224mm). Switch the selector switch to the SHEAR
position and measure the distance. The distance should be 6-13/16 inches (173mm). If the stroke is out of
these limits, use the following procedure.
1. Loosen the two mounting plate screws (D) that hold the mounting plate to the machine.
SEE FIGURE 5 ON THE FOLLOWING PAGE.
2. Move the plate vertically, up or down. Moving the plate up will bring the distance up and a
movement down will bring the distance down. Moving the plate 1/8 of an inch (3mm) will move
the dimension approximately 1/8 of an inch (3mm).
3. Tighten the screws and re-check the dimensions. Repeat, if needed.
A. STROKE CONTROL HANDLES
B. SCALE - STROKE CONTROL
C. METERING BOSS
D. MOUNTING PLATE SCREWS
E. JOG CONTROL
F. JOG/RUN/PROBE SWITCH
G. PUNCH/START/SHEAR SWITCH
H EMERGENCY STOP SWITCH
I START BUTTON

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FIGURE 5

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5.0 MAINTENANCE
The Scotchman Ironworker is an exceptionally rugged machine designed for long life with a minimum
amount of maintenance. A regular program of servicing will extend the life of the machine and prevent
costly down time.
5.1 LUBRICATION
IMPORTANT: Before operating the 6509-24M, apply oil to the angle shear blades, bar shear blades
and the punch and die. Re-oil punches and dies every 5 to 10 holes and blades every 10 to 15 cuts. The
oil will allow the machine to shear, punch and strip more easily and increase tool life considerably.
(We recommend cutting oil or motor oil swabbed on with a brush or applied with a squirt can or a spray
applicator.)
5.2 ROUTINE LUBRICATION
Grease the main pins (A & B) and the punch ram (C) daily.
(SEE FIGURE 6 ON THE FOLLOWING PAGE.)
Grease all other fittings twice per week.
A multi-purpose, Molybdenum Disulfide (Dow Corning BR-2 or equivalent) high pressure bearing grease
is recommended.
Check the oil level in the reservoir at least once a month. It should be 1-1/2 inches below the top of the
reservoir.
Change the hydraulic oil and filter at least once a year; more often under adverse conditions.
TO CHANGE THE HYDRAULIC OIL, TURN THE MACHINE’S POWER OFF.
Remove the drain plug from the bottom of the reservoir. Allow the oil to drain.
Replace with 14 U.S. gallons (53 liters) of lightweight, non-foaming, hydraulic oil such as Mobil DTE-25,
with a minimum ISO cleanliness code of 20/18/15, or equivalent.