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.