Scotchman IRONWORKER 6509-24M User manual

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MODEL
6509-24M
IRONWORKER
PRINTED MARCH 2005


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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE #
1.0 INTRODUCTION 4
2.0 SAFETY PRECAUTIONS 5-6
2.1 WARRANTY 7
3.0 WARNING LABELS 8-9
4.0 INSTALLATION & SET-UP 10-17
4.1 Physical Dimensions 10-11
4.2 Machine Moving Procedures 12-13
4.3 Physical Inspections 13
4.4 Electrical Requirements 14-15
4.5 Machine Start Up 15
4.6 Machine Stroke Inspection & Adjustment 16-17
5.0 MAINTENANCE 18-21
5.1 Lubrication 18
5.2 Routine Lubrication 18-19
5.3 Scheduled Maintenance 20-21
6.0 MACHINE OPERATION 22-33
6.1 Punch Operation 22-26
6.1B Stripper Adjustment 27
6.2 Bar Shear Operation 28-29
6.2A Shear Arm Adjustment 30-31
6.2B Shear Blade Adjustment 32-33
7.0 OPTIONAL TOOL OPERATION 34-57
7.1 6 x 6 Angle Shear 36-37
7.2 Rod Shear 38-39
7.3 6 x 6 90 Degree Notcher 40-42
7.4 Rectangle Notcher 42-43
7.5 12, 18 & 24 Inch Brakes 44-45
7.6 Angle Iron Brake 46-47
7.7 Channel Shear 48-49
7.8 Pipe Notcher 50-52
7.9 Picket Tool 53
7.10 Square Tube Shear 54-55

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGE #
7.10 Optional Punch and Die Holders 56-57
7.10A 2-1/2" & 3" Die Inserts 56
7.10B Offset Die Holder 56
7.10C 6 x 6 Die Holder 56
7.10D # 45 Punch Retaining Nut 56
7.10E Heavy Duty Split Ring Retaining Nut 57
7.11 Optional Gauging Equipment 58-59
7.11A 54 Inch Deluxe Back Gauge 58-59
7.11B Miter Table-Bar Shear 58
7.11C Punch Table 58
7.11D Jog Control 58
8.0 TROUBLE SHOOTING GUIDE 60-65
8.1 Electrical Trouble Shooting-Motor 60-61
8.2 Limit Switch Inspection 62
8.3 Control Valve Inspection 62-63
8.4 Hydraulics 63
8.5 Cylinder Seal Replacement 64-65
9.0 IRONWORKER PARTS LISTS 66-81
9.1 Shear Arm Assembly 66-67
9.2 Punch Assembly 68-69
9.3 Stripper Assembly 70-71
9.4 Upper Arm Assembly 72
9.5 Stroke Control Assembly 73
9.6 Hold Down Assembly 74-75
9.7 Cylinder Assembly 76
9.8 Connecting Link Assembly 77
9.9 Power Unit 78-79
9.10 Electrical Unit 80-81
12.0 SUPPLEMENT FOR OLDER MODELS 82-85
12.1 Cylinder Seal Replacement 82-83
12.2 Six Foot Back Gauge 84-85

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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 2,700 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 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 VHS tape.

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2.1 WARRANTY
Scotchman Industries Inc. will, within one year 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 PART # DESCRIPTION
K 003145 REMOVE TOOL
L 003110 PUNCH & DIE WARNING
M 003115 DO NOT REMOVE
N 003125 KEEP HANDS CLEAR
O 003130 30 TON OFFSET
P 019101 HEAVY END DECAL
Q 003100 WARNING LABEL
R 003120 DANGER VOLTAGE LABEL
S 003105 BAR SHEAR WARNING
T 003530 COMPLETE DECAL PKG.

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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 44-7/8 113.9
B. Floor to top of die holder 40-7/8 103.8
C. Floor to punch bolster 36 91.4
D. Floor to bottom rail 3-3/4 9.5
E. Floor to Bar Shear 28-1/2 72.4
F. Floor to tool table 42-1/2 107.9
G. Height 66 167.6
H. Length 61-1/2 156.2
I. Punch stroke 2 5
J. Width 22 55.8
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 12 U.S. gallons (45 liters).
CAUTION: DO NOT OVER FILL!

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4.4 ELECTRICAL REQUIREMENTS
CAUTION: TO PREVENT DAMAGE TO THE MOTOR AND DANGER TO THE OPERATOR,
ALL ELECTRICAL CONNECTIONS SHOULD BE MADE BY A LICENSED ELECTRICIAN.
FIGURE 4
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 ABOVE.
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).

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POWER REQUIREMENTS:
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 1,725 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 VHS safety tape 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. Momentarily power the machine by pushing the green START button and have
someone note the rotation of the motor. Motor rotation should be counterclockwise when viewed from
the shaft end of the motor. If it is not correct, the electrician will have to switch two of the three supply
line wires to change the direction of rotation.
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 overtravel 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 (B). Turn the selector switch (E) 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 (C) 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 down and a
movement down will bring the distance up. 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 (2)
B. METERING BOSS
C. MOUNTING PLATE SCREWS (2)
D. UPPER CONNECTING LINK PIN
E. PUNCH/SHEAR SWITCH

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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 (D) daily.
(SEE FIGURE 6 ON THE FOLLOWING PAGE.)
Grease all other fittings twice per week.
Mobil grease XHP222 Special 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 12 U.S. gallons (45 liters) of lightweight, non-foaming, hydraulic oil such as Mobil DTE-25,
with a minimum ISO cleanliness code of 20/18/15, or equivalent. The filter can be replaced by a Fram
P1653A, Motorcraft FH-10, NAPA 1551, Baldwin BT 839-10 or equivalent.

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FIGURE 6

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5.3 SCHEDULED MAINTENANCE
A program of scheduled maintenance should be set up and documented according to your application
and the frequency you use this machine. The following is a list of important items that should be
included in a scheduled maintenance program:
1. EVERY 500 HOURS OR 6 MONTHS:
A. Check the tolerance between the punch ram and the punch ram bushing.
To check the tolerances, remove the punch ram and the bushing from the machine. For parts
identification, SEE FIGURE 7 ON THE FOLLOWING PAGE.
1. To remove the punch ram and bushing, cycle the machine until the upper punch pin (A) aligns with
the access hole in the frame.
2. Remove the two mounting bolts (B) from the stroke control mounting plate (C) and remove the
stroke control assembly.
3. Remove the die holder and block up the punch ram.
4. Remove the snap ring retainers from the upper punch pin and remove the four mounting bolts (D)
and the grease bolt (E) from the punch ram bushing (F).
5. Remove the punch ram and the bushing. Care should be taken when removing these parts;
THEY ARE HEAVY.
6. Clean all grease and dirt off both parts and check the clearance between the outside diameter of the
punch ram and the inside diameter of the punch ram bushing. If the clearance between the two
parts is five thousandths (.005) or more, replace both parts. Reassemble parts in reverse order.
B. Check the condition of the cutting blades on the bar shear, angle shear and any other component
tool.
C. Check the condition of the bushing in the upper arm and shear arm. This can be done by visually
watching the arms for vertical movement while the machine is in operation.
If vertical movement is noted, block or support the arms with a lifting device and remove the pin
and check the clearance. If the clearance between the pin and the bushing exceeds twelve (.012)
thousandths (.3mm), replace the bushing. Since the 6509-24M can be used for a wide variety of
applications with many optional tools, these may not be all of the items that you need to include in a
scheduled maintenance program.
If you have questions about other applications, contact your local dealer or the factory.