Sunrise IW-45M User manual

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [email protected]
Fax: [phone]
www.sunriseiw.com.tw
SUNRISE
HYDRAULIC IRONWORKER
SINGLE CYLINDER MODELS
IW-45M, IW-50A, IW-60H
OPERATION &
MAINTENANCE MANUAL
Original Instructions
632EG013
12-2012

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [email protected]
Fax: [phone]
www.sunriseiw.com.tw
i
TABLE OF CONTENTS
Introduction ……………………………………………….…… 1
Safety Precautions ……………………………………………… 2
Transport …………………………………………..…………… 6
Installation ………………………………………………………7
Lubrication …………………………………………………..… 9
Standard Equipment ………………………………..……….… 10
Control Switches …………………………………………….… 11
Low pressure tool alignment with JOG mode……...…………. ..14
Foot Switch …………………………………………………… 15
Optional Electric BackGauge ……………..………………..… 16
Stroke Adjustment …………………………………..………… 17
Adust the Main Central Shear Slide ………….……..………… 19
Adjust the Punch Ram (IW-50A Only) ……………..………… 19
Punching Station …………………………………….………… 20
Standard Equipment ……………………………………… 20
Alignment of Punch and Die ………………..…………… 20
Punch and Die Clearance ………………..……………… 21
Adjusting Stripper ………………………….…………… 21
Actual Punching Force ………………………..………… 22
Precaution ……………………………………….……… 22
Punch and Die Lubricant ………………………….…… 22
Punch Operation ……………………......…………….… 23
Punching Station Assembly ……………………………. 26
Flat Bar Shearing Station ………………..…………….……… 27
Blades ……………………………………….………..… 27
Cutting Clearance ………………………………………. 27
Precaution ……………………….……………………… 28
Flat bar Shear Operation ………….….………………… 29
Angle Flange Shear Operation ……….………………… 29

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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Angle Shearing Station ………………..……………………… 30
Blades …………………………………...……………… 30
Cutting Clearance ……………………………………… 30
90 Degree Shear Operation …………………..………… 31
45 Degree Internal Miter Shear Operation
(on IW-45M and IW-50A) ……………………..… 32
45 Degree Internal/External Miter Shear Operation
(on IW-60H only) ………………..…….………… 32
Square/Round Bar Shear Station …………….……..………… 34
Cutting Clearance ……………………….…..…………. 34
Precaution …………………………………...…………. 34
Bar Shear Operation ………………………….………… 34
Notching Station (On IW-50A and IW-60H) ………..………… 36
Blades ………………………………………..……………36
Bolster Adjustment …………………………..………… 36
Notching Operation ……………………….….………… 37
Maintenance …………………………………………………… 38
Trouble Shooting ………………………………..…….……… 40
Hydraulic Circuit Diagram ……………………..……………… 42
Hydraulic Parts List …….…………………………………….… 43
Electrical Circuit Diagram IW-45M ………………………….… 44
Electrical Parts List IW-45M…………………………………… 45
Electrical Circuit Diagram IW-50A, IW-60H…………..…….… 46
Electrical Parts List IW-50A, IW-60H………………………… 47
Electrical Circuit Diagram IW-50A, IW-60H with sensor…...… 48
Electrical Parts List IW-50A, IW-60H with sensor .…………… 49

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [email protected]
Fax: [phone]
www.sunriseiw.com.tw
- 1 -
INTRODUCTION
The Sunrise Ironworker is a hydraulically powered punching and metal
shearing machine. The machine is equipped with Punching, Flat Bar
Shearing, Angle Shearing, Round Bar / Square Bar Shearing, and Notching
stations (on IW-45M, the notcher is an optional tooling installed at the
punching station). This multi-function aspect allows the Sunrise
Ironworker to meet the diversified needs of the metal forming industry.
There are many optional accessories that will further increase the versatility
of the machine, contact our dealer for details.
Each machine has been individually tested in the factory and under-gone an
extensive pre-delivery check to ensure that the machines meet the highest
quality standard. The ironworker has been designed to be a reliable and
dependable machine with excellent performance. We know the working
quality of the machine will confirm that you have made a good choice by
selecting Sunrise products for your facility.
In order to have a better understanding of the operating procedures, to
obtain maximum benefits from the machine, and to minimize the
maintenance cost of the equipment, please have the operators and engineers
read this Manual thoroughly and carefully before operating the machine.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [email protected]
Fax: [phone]
www.sunriseiw.com.tw
- 2 -
SAFETY PRECAUTIONS
IMPORTANT:
It is the duty of both employer and employees to acquaint themselves
with the safe working practices contained in this manual and ensure
that all operators adopt these practices.
While every effort has been made to furnish sufficient safe guards, this
equipment, if not operated and maintained properly, has the potential to
cause serious injury or death. A thorough knowledge of the machine and
operating with carefulness is the best protection against accidents.
All operations are controlled by either the foot switch or by the optional
electric backgauge. The operator should be familiar with the control and
function of the switch/backgauge before perform the operation.
Many warning labels are fixed on the machine. NEVER REMOVE THESE
LABELS. Be sure to follow these warnings to avoid injury.
Please also pay attention to the following general rules:
1. Do not operate the machine unless all safety guards and hold-downs are
in place. Use of optional attachments/tooling should also have proper
hold-downs and guards installed. If any guards are damaged or worn
out, replace immediately with new guards.
2. On the single cylinder models, only one operator is allowed to operate
the machine. Before each operation, make sure no other person is near
the machine.
3. Operator must wear Protective Glasses during operation to protect
the eyes.
4. Keep hands clear of all moving parts at all times. Fingers must not
go under or inside the danger zone established by the safety guards,
stripper, and/or holddowns.
5. On IW-50A and IW-60H which has a notcher, the nature of the station

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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requires opening the notcher safety cover during notching operation for
processing different shape and sizes of materials. This creates a
potential risk to the operator. The notcher safety cover is interlocked
by the SHEAR/NOTCH selection switch. Notcher safety cover must
be closed when not using the notching station. During notching
operation, keep fingers away from moving parts. Do not notch material
that operator cannot hold firmly during notching. Exercise caution and
be alert to potential risks.
6. Any maintenance/repair of electrical/hydraulic circuit; change/adjust of
blade/tooling; and alignment of punch-die should be done only by
qualified engineers or personnel.
7. Always turn off power and disconnect electric supply before doing any
tool change or maintenance work.
8. After tool changes, always check punch & die alignment and blade
clearances before operation.
9. Do not punch, shear, or notch parts that are too small to fit under the
safety hold downs.
10. If any problem or abnormal condition arises during operation, stop the
machine immediately and report to a supervisor. Do not turn on the
machine again until the problem is rectified by qualified personnel.
11. The machine should never be left under power when not in operation or
unattended. Always isolate the machine after turned the power off.
12. After completion of operation, all slugs and waste materials must be
cleaned away from the machine.
13. Regularly check all stations and tooling for defects and wear to ensure
safety and maintain good condition.
14. Heavy materials should be supported.
15. Use handling equipment when lifting heavy tooling and materials.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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16. Do not punch partial holes as this creates a side load force on the punch
and can result in tool breakage. Special tooling may be available for
this purpose.
17. Do not punch material thicker than the diameter of the punch.
Doing so can overload and break the punch and create a hazard.
18. Never exceed the rated capacity of the machine. Refer to the
specification chart for details for each model.
The manufacturer shall not be held for any liability for damages/body
injuries or other consequences to machine, material, and persons
caused by the non-compliance of the above safety precaution
procedures, in particular for the following situations:
1. Removing or disabling any guards or hold-downs is a violation and
will result in the termination of your warranty.
2. Place of any body part under or inside the danger zone established
by the safety guards, stripper, and/or holddowns.
3. Did not wear protective glasses for the eyes.
4. Did not close the stripper during operation.
5. Did not close the notcher safety cover when using other workstations.
6. Did not properly adjustment the clearance resulting the
punch/die/blades hitting each other.
7. Did not interrupt the main electric power supply before any
maintenance work.
8. Damage of electric parts or risk of fire due to incorrect electric
power supply.
9. Damage of pump or other hydraulic parts due to incorrect setting of
the limit switches.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [email protected]
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- 5 -
DANGER
zKEEP HANDS CLEAR OF ALL MOVING PARTS.
zALL GUARDS AND HOLD-DOWNS MUST BE IN POSITION
BEFORE OPERATING THE MACHINE.
zALWAYS POSITION MATERIAL UNDER A CORRECTLY SET
HOLD-DOWN. NEVER ALLOW THE MATERIAL TO FEED
BEYOND THE HOLD-DOWN.
CAUTION
zTHOROUGHLY READ THE OPERATION MANUAL BEFORE
OPERATION.
zTURN OFF POWER AND ISOLATE THE MACHINE WHEN
CHANGING TOOLING OR DOING MAINTENANCE.
zALL MAINTENANCE/REPAIR WORK MUST BE DONE BY
QUALIFIED PERSONNEL.
zIF ANY PROBLEM OR ABNORMAL CONDITION OCCURS,
STOP THE MACHINE IMMEDIATELY. DO NOT OPERATE
THE MACHINE AGAIN UNTIL THE PROBLEM IS FIXED.
Opertators’s working positions:

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [email protected]
Fax: [phone]
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- 6 -
TRANSPORT
When transporting the machine by a crane, hook the crane to the eye bolt on
top of the machine. Do not use slings under the machine. Pay special
care if lifting / transporting the machine with forklifts. The forks should
extend fully to cover the width of the machine. Do not put the forks from
either end.
NOTE: As the top of the machine is heavy, the high center of gravity can
cause the machine to tip over if machine is not in good balance.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [email protected]
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- 7 -
INSTALLATION
The machine only requires the normal industrial concrete foundation. If the
ground is uneven and the machine vibrates during operation, use foundation
bolts to tighten the machine firmly to the ground or alternatively mount the
machine on anti-vibration pads.
IMPORTANT:
zMaintain a spacious working area around the machine for safety.
zHave the work area well illuminated with proper lighting.
zClean the scraps and waste materials regularly, and make sure the work
area is free of obstructing objects.
zKeep the ground free of oil and make sure it is not slippery.
zIf long lengths of material are to be fed into the machine, make sure that
they will not extend into any gangways.
Crowded, poorly illuminated or slippery area are often causes for accidents.
Remove all anti-corrosion grease after installing the machine. Check that
the oil reservoir, located in the machine base, has been properly filled.
When refilling oil, use recommended oil and fill the reservoir to the upper
level of the oil level gauge.
Connecting Power Supply
Electrical wiring must be done by a qualified electrician. Before connecting
the electrical supply, make sure the voltage and current is compatible to the
electrical components in the machine. Check the data shown in the
electrical control box.
IMPORTANT: Turn off Supply Electricity at your facility's circuit
breaker before making electrical connections to the machine.