Scotchman DO-150-24M Manual
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Scotchman DO-150-24M Manual

Iron worker
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Model DO-150/240-24M Ironworker.
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optional tooling for this machine.
If you would like a tooling manual, please
download our #40 Tooling Manual.
START
PUNCH
MM.
IN.
90
80
3
70
213012
60
201240
2
50
40
080061
RUN
30
1
20
10
10
080061
20
1
213012
30
201240
40
2
50
60
70
3
80
90
MM.
IN.
004085
JOG
033707
80191
80211
80197
037110
201620
113017
113017
037105
80424 F
33018
33176
25525 Raw
010117
LUBRICATE
BEFORE
OPERATING
19103
0481
80156 Sales
WARNING
080174
Assy.
243101
START
TO PREVENT SERIOUS
TOOL
SHEAR
NOTCH
BODILY INJURY
DO NOT PLACE FINGERS
BEYOND THIS GUARD
003140
DUAL OPERATOR
150/240 - 24M
JOG
RUN PROBE
MACHINE CAPACITIES
SPEC. BASED ON MILD STEEL-65,000 PSI TENSILE
PUNCH
FLAT SHEAR
150 TONS
BLADE LENGTH 24" - 600MM
Ø1-7/8 THRU 1.0"
1 X 14" - 3/4 X 24"
Ø47 THRU 25MM
25X300 - 12X600MM
START
THROAT DEPTH
RECT. NOTCHER
12" - 305MM
3"X5"X1/2"
76X127X12MM
PUNCH STROKE
ANGLE SHEAR
6"X6"X1/2"
2.25" - 57MM
150X150X12MM
#037009
11,04
STOP
MODEL
H.P.
VOLT
SERIAL
HZ
FLA
SCOTCHMAN INDUSTRIES, INC.
PH
PSI
PHILIP, SOUTH DAKOTA, U.S.A.
BLADE LENGTH
PH. 605-859-2542
MADE IN U.S.A.
3200
WARNING
TO PREVENT SERIOUS BODILY INJURY
NEVER-
Operate, install tooling, service or adjust machine without
proper instructions and without reading and understanding the
operator's manual and safety film.
NEVER-
Service machine with electrical power connected.
NEVER-
Operate any station without the respective strippers or
hold-downs in place.
NEVER-
Operate machine with protective guards removed.
NEVER-
Place any part of your body under blade, punch or moving
members.
NEVER-
Operate punch station without checking the punch to die
alignment and tightness.
(Check alignment and tightness daily.)
NEVER-
Punch half holes, punch or shear unknown materials, side load
press brakes.
SAFETY GLASSES REQUIRED WHEN
OPERATING OR OBSERVING THIS MACHINE
DO NOT REMOVE THIS SIGN FROM THIS MACHINE
003100
FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC.
AT
1-800-843-8844
REV. 0310
37107 - DO-135 & 150
080430
080435 Assy.
LUBRICATE
BEFORE
OPERATING
19103
0481
Assy.
080174
243101
224205
230 Volts
19121
OFF
11856
EATON
DANGER
ELECTRICAL HAZARD
Turn off power
and lock out
before servicing.
3122
1213
13220 - 3ph 13225 - 1ph
224205
WHEN MITERING
DO NOT EXCEED
3 X 3 X 1/4
003195
0502
17341
13179
13179
201110
M6x12
013180
M6x12
201110
M6x12
201110
013180
201110
M6x12
M6x12
201110
201110
M6x12
201110
M6x12
M6x12
201110
230210
230210
224205
224205
224205
224205
13190
LUBRICATE
BEFORE
OPERATING
19103
0481
80155
080174
Assy.
033047
243101
33149

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Summary of Contents for Scotchman DO-150-24M

  • Page 1 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...
  • Page 2 MODEL DO-150/240-24M IRONWORKER VERSION 5 - SEPTEMBER 2021 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-800-843-8844...
  • Page 3 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE REV. 0310 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 80191 80211 80197 37107 - DO-135 & 150 17341...

  • Page 4: Table Of Contents

    6 x 6 Angle Shear Operation 7.1C 6" A.S. Miter Attachment Assembly Rod Shear 7.2A Rod Shear Installation 7.2B Rod Shear Operation PAGE 3 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
  • Page 5 Heavy Duty Split-Ring Retaining Nut 7.11 48 Inch Back Gauge 7.12 Urethane Stripper 7.12A Installing The Urethane Stripper, Punch & Die PAGE 4 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
  • Page 6 Sheet Metal Parts & Hardware Power Unit 9.10 Electrical Unit 9.11 Notcher Assembly 9.12 Optional Die Holders 10.0 ELECTRICAL SCHEMATICS 11.0 HYDRAULIC SCHEMATICS PAGE 5 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

  • Page 7: Introduction

    The ability of the operators to control the machine’s direction of movement at any point in the stroke (stop, jog or reverse) gives the Scotchman Ironworker a tremendous advantage over mechanical Ironworkers. There is no chance of the Scotchman being "accidentally tripped".

  • Page 8: Warranty

    DVD. 2.1 WARRANTY Scotchman Industries, Inc. will, within three (3) years of the 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 the buyer returns the warranty registration card within thirty (30) 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...

  • Page 9: Machine Decals

    003122 Danger Voltage 003140 Finger Beyond Tool Shear 019127 US Flag Decal 003195 3 x 3 x 1/4 Max Sticker 010117 27" Scotchman Decal 037009 DO 150 CAPACITY DECAL 019103 Decal "Lubricate" 019105 Decal "Grease Point" Jog Decal 003200 Scale Stroke Control...
  • Page 10 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80191 80211...

  • Page 11: Installation And Set Up

    4.0 INSTALLATION AND SET UP ► CAUTION: THIS SECTION DISCUSSES INSTALLATION AND SET-UP PROCEDURES. PLEASE READ THOROUGHLY BEFORE OPERATING THIS MACHINE. 4.1 PHYSICAL DIMENSIONS - SEE FIGURE 2 DESCRIPTION INCHES ITEM Floor to Punch Ram 114.3 Floor to top of Die Holder 40-1/2 102.9 Floor to Punch Bolster...
  • Page 12 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80211 80197 37107 - DO-135 & 150...

  • Page 13: Machine Moving Procedures

    Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...
  • Page 14 Punch half holes, punch or shear unknown materials, side load SAFETY GLASSES REQUIRED WHEN press brakes. OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...

  • Page 15: Physical Inspection

    4.3 PHYSICAL INSPECTION Any damage to the machine during shipment should be reported to the delivery carrier immediately. A damage report must be made so that a claim can be placed. The carrier is responsible for shipping damage, but it is the customer’s responsibility to report damages, external or internal. After the machine has been located, remove the side shrouds and inspect the interior of the machine for possible shipping damages.

  • Page 16: Electrical Requirements

    4.4 ELECTRICAL REQUIREMENTS ► CAUTION: TO PREVENT DAMAGE TO THE MOTOR AND DANGER TO THE OPERATOR, ALL ELECTRICAL CONNECTIONS MUST BE MADE BY A LICENSED ELECTRICIAN. All machines are wired for three phase electrical power unless otherwise specified by customer. To insure satisfactory machine performance, the supply voltage should be (+ or -) 10% of the motor voltage rating.
  • Page 17 SINGLE PHASE INCOMING POWER 13 NO 1 L1 3 L2 5 L3 1 L1 3 L2 5 L3 DISCONNECT _OL_ OVERLOAD TEST ZB32-32 RESET 2 T1 4 T2 6 T3 14 NO TO MOTOR TO MOTOR 3 PHASE INCOMING POWER 13 NO 1 L1 3 L2...
  • Page 18 MOTOR CONNECTIONS HIGH VOLTAGE C0NNECTION 250 KVA ( 440-480 VOLT 3PH ) PRIMARY SIDE FUSE FUSE H1-H2 H1-H4 H1-H5 H1-H3 EATON 250 VA CO250E6U XF-X2 XF-X4 XF-X3 FUSE SECONDARY SIDE WHITE GREEN LINE LINE LINE #1 thru #9 are Wires From the Motor 350VA 208-277v PRIMARY SIDE...

  • Page 19: A Control Panel Functions

    4.4A CONTROL PANEL FUNCTIONS Since this machine can be operated by two people at the same time, it is important that the operators be very familiar with all of the control panel functions and how they affect the operation of the machine. REFER TO FIGURE 5 BELOW.
  • Page 20 This is the RUN/JOG selector switch for the PUNCH/TOOL station of the machine. When this switch is in the RUN position, the station will operate with the foot pedal only. When the switch is in the JOG position, the station will only operate with the jog control. The jog control is very useful for setting the machine’s stroke for various tooling and for finding center punch marks when punching.

  • Page 21: Machine Start Up

    Punch half holes, punch or shear unknown materials, side load SAFETY GLASSES REQUIRED WHEN press brakes. DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...
  • Page 22 START START PUNCH SHEAR TOOL NOTCH PROBE START 3200 STOP 004085 7711 Sales Painted Cover - 33707 Complete Assy. 230 Volts 19121 11856 EATON DANGER ELECTRICAL HAZARD Turn off power and lock out before servicing. 3122 1213 FIGURE 6 PAGE 21...

  • Page 23: Machine Stroke Inspection And Adjustment

    Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 10.53"...

  • Page 24: A Punch & Tool Station

    4.6A PUNCH & TOOL STATION 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.

  • Page 25: B Notch And Shear Station

    4.6B NOTCH & SHEAR STATION A check of the machine’s stroke setting for shearing and notching is made at the notcher station. SEE FIGURE 8 ON THE FOLLOWING PAGE. Shear/Notch/Start Selector Switch Start Switch Stroke Control Handles (2) Mounting Plate Mounting Plate Bolts Metering Boss ►...
  • Page 26 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...

  • Page 27: Maintenance

    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 this machine, apply oil to the notcher, rod shear, angle shear, bar shear blades and the punch and die.
  • Page 28 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...

  • Page 29: Scheduled Maintenance

    5.2 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 some important items that should be included in a scheduled maintenance program. Since this machine can be used for a wide variety of applications with many optional tools, every user must design and implement a scheduled maintenance program that fits his needs.
  • Page 30 Punch half holes, punch or shear unknown materials, side load SAFETY GLASSES REQUIRED WHEN press brakes. OPERATING OR OBSERVING THIS MACHINE 003100 DO NOT REMOVE THIS SIGN FROM THIS MACHINE REV. 0310 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 80191 80211 MAIN PIN 80197 DRIVE BEAM...

  • Page 31: Machine Operation

    6.0 MACHINE OPERATION 6.1 PUNCH OPERATION The first and most important procedure is the proper method of changing and aligning punches and dies. ► ALWAYS WEAR SAFETY GLASSES. ALIGNMENT AND REMOVAL OF PUNCHES AND DIES: ► WARNING: FAILURE TO PROPERLY ALIGN PUNCHES AND DIES CAN CAUSE SERIOUS BODILY INJURY AND/OR DAMAGE TO EQUIPMENT.
  • Page 32 ► PLEASE NOTE: THERE IS AN EMERGENCY STOP PALM BUTTON ON BOTH ENDS OF THIS MACHINE. ► NOTE: THIS SET-UP IS FOR THE STANDARD AND OVERSIZE DIE HOLDERS. IF YOU ARE USING THE OFFSET DIE HOLDER, REFER TO SECTION 7.10A FOR INSTRUCTIONS. With the machine’s PUNCH/TOOL selector switch in the PUNCH position and the ram retracted, turn off the power.
  • Page 33 KEYED PUNCHES. This machine is equipped with a keyed punch ram insert. All shaped punches and dies manufactured by Scotchman are milled for keyed alignment. ► NOTE: IF YOU DO NOT USE A KEY WITH SHAPED PUNCHES, IT MAY BE HELPFUL TO HOLD THE BODY OF THE PUNCH WITH A WRENCH WHILE TIGHTENING THE PUNCH RETAINING NUT.
  • Page 34 007239 FIGURE 12 TO ADJUST THE STRIPPER: The height of the stripper is adjusted using the adjustment bolts (1 & 2). The stripper is opened by pushing up on item (3) and swinging it out toward the front of the machine.
  • Page 35 DO NOT PUNCH ANYTHING THICKER THAN THE PUNCH DIAMETER. This "rule of thumb" can be extended, but the punch supplier or Scotchman should be consulted first; i.e. "Do not punch plate thicker than 1/2 inch with a 1/2 inch diameter punch". This rule of thumb applies to mild steel only and must be reduced when punching alloy steels.
  • Page 36 TONS REQUIRED TO PUNCH MILD STEEL HAVING 65,000 PSI TENSILE STRENGTH 3/16 5/16 7/16 9/16 11/16 13/16 HOLE DIAMETER .1875 .250 .3125 .375 .4375 .500 .5625 .625 .6875 .750 .8125 METAL THICKNESS P R E S S U R E I N T O N S GAUGE INCHES .060...

  • Page 37: Bar Shear Operation

    HOLD-DOWN DEVICE TO ITS DOWN POSITION. When using the bar shear on your Scotchman Ironworker, always use the hold-down device. Never put any part of your body between the hold-down and the material to be sheared. A clearance of 1/8 inch (3 mm) between the hold-down and the material to be sheared is acceptable.
  • Page 38 RECOMMENDED CLEARANCE FOR FLAT BAR SHEAR BLADES UPPER BLADE CLEARANCE LOWER BLADE 1° - 2° CANT BELOW BASED ON A36 MILD STEEL OF 65,000 P.S.I. TENSILE STRENGTH 1° - 2° MATERIAL THICKNESS (in) BLADE CLEARANCE (in) .035 (.030-.040) .026 (.020-.030) .022 (.018-.026) .017 (.012-.022) .013 (.010-.017)

  • Page 39: A Shear Arm Adjustment

    6.2A SHEAR ARM ADJUSTMENT Adjustment on the shear arm is maintained on the front (operator’s) side by the pressure plate (1) and on the rear by rub blocks (3 & 6) in two locations: A & B. USE THE FOLLOWING STEPS TO ADJUST THE SHEAR ARM. SEE FIGURE 15 ON THE FOLLOWING PAGE.
  • Page 40 Cutaway Views 218112 218112 218112 218112 218112 218112 M12 Jam 218120 M12 Jam 218120 FIGURE 15 PAGE 39...

  • Page 41: B Shear Blade Adjustment

    6.2B SHEAR BLADE ADJUSTMENT PROCEDURE CAUTION: Cutting Edge Is Curved On Upper Blade!! It has just TWO cutting edges. IT CAN ONLY BE ROTATED END-FOR-END!! SEE FIGURE 16 ON THE FOLLOWING PAGE. Place the selector switch in the SHEAR position and allow the arms to raise completely. Crank the hold-down devise all the way up and remove the shear table.
  • Page 42 QUICK GUIDE TO CHANGING BAR SHEAR BLADES 1st - REMOVE LOWER BLADE 5th - ADJUST UPPER SET SCREWS 1/8 TURN PAST RESISTANCE 2nd - CHANGE UPPER BLADE 6th - TIGHTEN BLADE BOLTS 1/4 TURN PAST RESISTANCE 3rd - START BOLTS (2) IN LOWER BLADE 7th - ADJUST LOWER SET SCREWS UP TO LOWER BLADE 8th - FINAL TIGHTEN: BLADE BOLTS, THEN SET SCREWS 4th - PLACE DESIRED SHIM BETWEEN BLADES...

  • Page 43: Rectangle Notcher Operation

    6.3 RECTANGLE NOTCHER OPERATION This tool is operated with the SHEAR/NOTCH selector switch in the NOTCH position. ► CAUTION: WHEN THE NOTCHER STATION IS NOT IN USE, BE SURE THAT THE GUARD IS IN THE CLOSED POSITION, TO PREVENT ANYONE FROM STORING TOOLS OR MATERIAL ON THE TABLE OR IN THE BLADE CAVITY.
  • Page 44 Manually align the lower blades to the upper blades, with equal clearance all the way around. A clearance of twenty five thousandths (.025) of an inch (.6mm) is recommended. The lower blades may require shimming to achieve the proper clearance. Tighten the blade holder bolts (5) to approximately 100 foot pounds (136 newton meters) of torque.

  • Page 45: Optional Tools

    On the following page, there is a graphical illustration of the available tonnage at locations along the upper arm. SEE FIGURE 18 BELOW. This graph will be helpful in setting up various Scotchman or custom tooling. TOOL TABLE - AVAILABLE TONNAGE DISTANCE...

  • Page 46: X 6 Angle Shear

    7.1 6 X 6 ANGLE SHEAR The 6 x 6 angle shear is a component tool designed to shear angle iron. It installs in the tool station on this machine and has a maximum capacity of 6 x 6 x 1/2 inch (152 x 152 x 12mm) mild steel angle iron. The selector switch must be in the TOOL position and the upper arm in the UP position to operate this tool.
  • Page 47 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197...

  • Page 48: C 6" A.s. Miter Attachment Assembly

    7.1C 6" A.S. MITER ATTACHMENT ASSEMBLY We have P/N 026737 Miter Attachment for the 6 X 6 Angle Shear that is very helpful in making miter cuts on angle iron. It bolts on to the front of the Angle Shear with (4) bolts and has (2) rest buttons that can be used on either side to help to make quick and accurate miter cuts.

  • Page 49: Rod Shear

    Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197...

  • Page 50: A Rod Shear Installation

    7.2A ROD SHEAR INSTALLATION SEE FIGURE 20 ON THE PRECEDING PAGE. The rod shear mounts in the tool station under the upper arm and is held in place with the finger clamps (1) provided. Since the rod shear requires a short stroke, (approximately 1/2 inch (12mm) and has no slug, it can be operated at any practical location under the upper arm.

  • Page 51: X 6 90° V - Notcher

    7.3 6 X 6 90° V - NOTCHER The 6 x 6 ninety degree notcher is a component tool designed to cut 90 degree vee notches in angle and flat stock. It has a maximum capacity of 5/16 of an inch (8mm) thickness mild steel. 7.3A 6 X 6 90°...
  • Page 52 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 16095 80831 16174...

  • Page 53: C Blade Replacement

    7.3C BLADE REPLACEMENT The lower blades of the 6 x 6 ninety degree notcher are symmetrical. They can be rotated to expose (4) cutting edges. The upper blade has (2) cutting edges. To rotate or replace the blades, use the following steps: ►...

  • Page 54: B Brake Operation

    90 degrees, adjust the down stroke of the machine until the desired bend is obtained. A great variety of standard brake dies can be used with this unit. These are available from Scotchman Industries or brake die suppliers.
  • Page 55 BRAKE TONNAGE CHART PRESSURE IN TONS PER LINEAR FOOT REQUIRED TO MAKE 90 DEGREE AIR BEND IN MILD STEEL THICKNESS WIDTH OF V-DIE OPENING OF METAL GAUGE INCHES 5/16 3/8 1-1/8 1-1/4 1-1/2 2-1/2 3-1/2 .036 .048 .060 .075 .090 .105 10.1 .120...
  • Page 56 026303 - 24" BRAKE W/2" DIES WARNING TO PREVENT SERIOUS BODILY INJURY AND/OR DAMAGE TO MACHINE DO NOT BRAKE ROUNDS LOAD MATERIAL CENTRALLY 0398 003150 TO PREVENT SERIOUS BODILY INJURY AND/OR DAMAGE TO MACHINE REMOVE TOOL WHEN NOT IN USE 003145 LUBRICATE BEFORE...

  • Page 57: Open End Brake

    7.5 OPEN END BRAKE This brake is designed to form box frames out of angle iron. It has a maximum capacity of 1/4" (6mm). 7.5A OPEN END BRAKE INSTALLATION SEE FIGURE 24 ON THE FOLLOWING PAGE. This brake mounts in the punch station and the selector switch must be in the PUNCH position to operate this tool.
  • Page 58 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 Center Under 80191 80211...

  • Page 59: Channel Shear

    7.6 CHANNEL SHEAR The Channel Shear is a component tool designed to shear 2 to 6 inch (51 to 152mm) standard channel on this model. The PUNCH/TOOL selector switch must be in the TOOL position to operate this tool. 7.6A CHANNEL SHEAR INSTALLATION SEE FIGURE 25 ON THE NEXT PAGE.
  • Page 60 DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 1-800-843-8844 REV. 0310 REV. 0310...
  • Page 61 SET THE BOTTOM OF THE STROKE AS LOW AS POSSIBLE. The bottom of the stroke should be set as low as possible, without bottoming any part of the upper blade, blade holder or pressure The upper stroke should be set to allow the workpiece to feed freely through the shear.
  • Page 62 026372 - 6" CHANNEL SHEAR 26212 P/N 26211 65/90/120-CS 026435 026435 DO100/65-BK DO100 RS 201110 M6x12 201110 M6x12 26211 Assy 26209 204225 204225 M10x20 219045 026438 16118 201110 201110 26746 26746 26428 26427 160030 201420 201420 201420 201420 201420 201420 M12x50 M12x50 M12x50...

  • Page 63: Pipe Notcher

    7.7 PIPE NOTCHER The pipe notcher is a component tool designed to saddle cut pipe or tubing for applications such as railings. There are dies available to notch angles in pipe and tubing, also. For prices and availability, Contact your local dealer or the factory. 7.7A PIPE NOTCHER INSTALLATION SEE FIGURE 26 ON THE NEXT PAGE.

  • Page 64: C Pipe Notcher Capacities

    Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 4.12500000 12076 Ram 012077 16096 2.10237500...

  • Page 65: Picket Fence Tool

    7.8 PICKET FENCE TOOL The picket fence tool is designed to put picket fence points on square tubing from 1/2 to 1 inch (12 to 25 mm). This tool is mounted in the punch station and operated with the PUNCH/TOOL selector switch in the PUNCH position.
  • Page 66 PICKET FENCE TOOL START START PUNCH TOOL SHEAR NOTCH 213012 201240 RUN JOG RUN PROBE 080061 START 080061 224205 224205 213012 201240 STOP 004085 GREASE POINT 033707 WARNING DO NOT CHANGE OR ADJUST PUNCH/DIE WITHOUT REFERRING TO THE OPERATORS MANUAL AND SAFETY FILM. 0389 3110 16096...

  • Page 67: Square Tube Shear

    7.9 SQUARE TUBE SHEAR The square tube shear is designed to shear square tubing from 1/4" to 2" (6mm to 51mm). 16 gauge (.060 (1.5mm)) is the maximum material thickness. 7.9A SQUARE TUBE SHEAR INSTALLATION SEE FIGURE 28 ON THE FOLLOWING PAGE. The tool mounts on the tool table in place of the angle shear and is anchored with the finger clamps.
  • Page 68 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197...

  • Page 69: Optional Die Holders & Punch Retaining Nuts

    7.10 OPTIONAL DIE HOLDERS & PUNCH RETAINING NUTS 7.10A OFFSET DIE HOLDER FOR FLANGE PUNCHING The offset die holder is used for punching holes in the flange of structural shapes such as channel, I-beam and H-beam. The offset die holder is installed in place of the standard die holder. Use the same method of installing and aligning punches and dies as outlined in SECTION 6.1, with the following exceptions: The punch retaining nut, punch and die must be inserted in the die holder before the machine is powered...
  • Page 70 OFFSET DIE HOLDER 2-1/2 AND 3 INCH DIE HOLDERS 6 x 6 DIE & HOLDER (up to 4" Dia.) FIGURE 29 PAGE 69...

  • Page 71: D #45 Punch Retaining Nut

    7.10D #45 PUNCH RETAINING NUT The #45 punch retaining nut is of the same design as the #40 and is used in oversize punching applications. FOR REQUIREMENTS, SEE THE #40 TOOLING PARTS MANUAL. 7.10E HEAVY DUTY SPLIT RING RETAINING NUT SEE FIGURE 30 BELOW Remove the six socket head cap screws (1).
  • Page 72 026350 - SQUARE TUBE SHEAR 243101 243101 1302 1309 203217 026350 - Assy. 1313 243101 203217 201210 201210 201210 201210 203217 26306 026500 - HEAVY DUTY RETAINING NUT (punch not included) PAGE 71...

  • Page 73: Inch Back Gauge

    NOTE: There is also an Electric Back Gauge (P/N 026610) available for this machine. Contact your dealer, or call the factory at 1-605-859-2542 for more information. PAGE 72 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
  • Page 74 48 INCH BACK GAUGE Parts List 025603 - Deluxe Back Gauge 48" Description Part Number Item # Length Stop 025324 221420 M16 x 50 SHCS 025317 Length Stop Assembly 219047 M10 x 12 Set Screw 025361 M12 x 50 Adj. Handle 025320 Slide Block Length Stop Stop Bar Assembly...

  • Page 75: Urethane Stripper

    7.12 URETHANE STRIPPER Scotchman does not recommend this unit for all general punching applications. However, using this specially designed "Non Deform" stripper unit does offer a significant advantage over a standard stripper arrangement in reducing distortion when punching a confined pattern or series of holes in flat bar or plate.
  • Page 76 Clean both the punch and die of any foreign material. Insert the proper die in the die insert (7). (If the die has a flat spot in it, align this with the bolt in the die insert.) Tighten the bolt firmly with a wrench. Insert the punch into the punch retaining nut.

  • Page 77: B Changing The Urethane Springs

    7.12B CHANGING THE URETHANE SPRINGS SEE FIGURE 32 If the unit is constantly over stroked or over a period of time, it may be necessary to renew the urethane springs. REFER TO FIGURE 32. The springs should be checked periodically. (A sure sign of over stroking is cracking or splitting of the springs.) Secure the unit in a vise by clamping the bottom plate (14).
  • Page 78 URETHANE STRIPPER PUNCH 221329 M12x70 201620 M16x55 221329 M12x70 221329 M12x70 M12x70 221329 201620 221120 M8 x 25 M16x55 221120 M8 x 25 M8 x 25 221120 221120 221120 M8 x 25 M8 x 25 221120 M8 x 25 M8 x 25 221120 221120 M8 x 25...

  • Page 79: Trouble Shooting Guide

    8.0 TROUBLE SHOOTING GUIDE 8.1 ELECTRICAL TROUBLESHOOTING: PUNCH/TOOL STATION ► CAUTION: ALL ELECTRICAL WORK PERFORMED ON THIS MACHINE SHOULD BE PERFORMED BY A QUALIFIED ELECTRICIAN. MOTOR WILL NOT RUN: Check the PUNCH/TOOL and SHEAR/NOTCH selector switches. The machine will not start unless both selector switches are in the START position.

  • Page 80: A Electrical Trouble Shooting: Shear/Notcher Station

    The solenoid on the control valve is not functioning. REFER TO SECTION 8.3 The foot pedal switch is not functioning properly. A voltage test may be run on the terminal strip in the control box to determine if the foot switch is working properly. WARNING: THERE IS LINE VOLTAGE PRESENT IN THE CONTROL BOX WHEN THE MACHINE IS POWERED.
  • Page 81 ► DO NOT OPERATE THIS MACHINE WITH THE EMERGENCY STOP BUTTONS BYPASSED!! Check to be sure that plant voltage and phase correspond to the machine voltage and phase. Check the line wiring connections at the starter. FOR THE WIRING DIAGRAM, SEE SECTION Check the line voltage at the starter.

  • Page 82: B Limit Switch Inspection Procedure: Punch/Tool Station

    With the pedal depressed, the voltage should read 110 to 120 volts between #21 and Ground. There should be no voltage reading between #20 and Ground. If these readings are not correct, continue on with the following steps. Turn the machine’s power off at the SHEAR/NOTCH station and turn off the disconnect switch. Remove the cover on the foot pedal and check for any loose connections.
  • Page 83 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...

  • Page 84: Control Valve Inspection

    If the machine stops instead of returning when the foot switch is released, the problem is in the limit switch. Check the limit switch plunger to make sure that it is operating freely. The limit switch can be tested with an Ohm meter. The limit switch wires must be disconnected from the terminal block to test it. The switch should have continuity with the plunger out and open with the plunger depressed.

  • Page 85: Hydraulic Cylinder Seal Replacement

    For the SHEAR/NOTCH station of the machine, power the machine and place a thick piece of steel on the far left side of the bar shear furthest away from the pivot pin and clamp it down with the hold down device.
  • Page 86 DO-150 SEAL KITS PUNCH CYL. 034305 - DO150 CYLINDER SEAL KIT SHEAR CYL. 080375 - MULTI 6" CYL SEAL KIT CLEVIS FIGURE 33 PAGE 85...

  • Page 87: Parts List

    9.0 PARTS LISTS 9.1 SHEAR ARM ASSEMBLY ITEM QTY. PART # DESCRIPTION SHEAR BEAM ASSEMBLY 033139 INCLUDES 1, 2, 11, 13, 18 & 19 033205 SHEAR BEAM BUSHING 037006 CONN LINK PIN 033167 BRASS WEAR PLATE 208014 M12 HEX NUT 221435 M16 X 90MM SHCS 214016...
  • Page 88 SHEAR ARM ASSEMBLY M16x65 M16x65 FIGURE 34 PAGE 87...

  • Page 89: A Drive Beam Ass'y & Cylinder

    Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...
  • Page 90 DRIVE BEAM ASSEMBLY FIGURE 35 PAGE 89...

  • Page 91: Punch Assembly

    9.2 PUNCH ASSEMBLY 9.2A PUNCH STRAPS, PUNCH RAM AND GUIDE ITEM QTY. PART # DESCRIPTION see 6A STRAP see 6A STRAP 080192 2.505 BRASS WASHER 080199 PUNCH LINK KIT INC. 1, 2, & 3 033205 SHEAR BEAM BUSHING 080205 LOWER PUNCH PIN (5 & 7 same) 016625 2 1/2"...
  • Page 92 PUNCH ASSY. EXPLODED VIEW P/N 080173 Kit Includes 4, 5, 6 & 19. P/N 010239 Kit Includes 12, 14, 15, 16, 17, 18, 19 & 20. 221120 M8 x 25 221120 M8 x 25 221120 M8 x 25 221120 M8 x 25 221120 M8 x 25 221120...

  • Page 93: B Die Holder, Die Spacer & Punch Table

    9.2B DIE HOLDER, DIE SPACER & PUNCH TABLE ITEM QTY. PART # DESCRIPTION 026618 TEE NUT (M10) 026697 GUIDE FINISHED 230110 M8 X 20 FSHCS 080182 M5 ALLEN WRENCH 037107 DO135/150 PUNCH TABLE 080063 RS/JIG HANDLE 214014 M12 WASHER 219060 M10 X 50 FP SET SCREW 204220 M10 X 30 HHCS...
  • Page 94 DIE HOLDER DO-135 & DO-150 ONLY 230110 230110 230110 201640 M16x90 201640 M16x90 230107 230107 230107 230107 230107 230107 FIGURE 37 PAGE 93...

  • Page 95: Stripper Assembly

    9.3 STRIPPER ASSEMBLY ITEM QTY. PART # DESCRIPTION 007244 RETAINER STRIPPER 230007 M6 X 16 FSHCS 660255 #6 X 3/8" DRIVE SCREW 154006 1/8 STEEL POP RIVET (inc. with 6A) see 6A STRIPPER HINGE see 6A STRIPPER DOOR STRIPPER DOOR ASS'Y Must add 011742 INCLUDES 4, 5, &...
  • Page 96 STRIPPER ASSEMBLY 230007 230007 007239 007239 FIGURE 38 PAGE 95...

  • Page 97: Upper Arm Assembly & Punch Cylinder

    Punch half holes, punch or shear unknown materials, side load SAFETY GLASSES REQUIRED WHEN press brakes. OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 80197 37107 - DO-135 &...
  • Page 98 DO-150 UPPER ARM ASSEMBLY SEE SECTION 9.2A: PUNCH STRAPS, PUNCH RAM AND GUIDE for information on these punch related parts. FIGURE 39 PAGE 97...

  • Page 99: Upper Stroke Control Assembly

    9.5 UPPER STROKE CONTROL ASSEMBLY ITEM QTY. PART # DESCRIPTION 033707 D.O. STROKE ASS'Y 007711 STROKE COVER - INCLUDES 30 077907 SHROUD EDGE 011868 EZ CAM SWITCH 011504 LEGEND SHEAR/START/NOTCH 011503 LEGEND PUNCH/START/TOOL 011862 E-STOP OPERATOR - INCLUDES 9 011500 LEGEND E-STOP 011872 MOUNTING ADAPTER...
  • Page 100 UPPER STROKE CONTROL START START PUNCH TOOL SHEAR NOTCH 213012 201240 080061 START 080061 213012 201240 STOP 004085 M4x16 FIGURE 40 PAGE 99...

  • Page 101: A Shear & Notcher Stroke

    9.5A SHEAR & NOTCHER STROKE ITEM QTY. PART # DESCRIPTION 080061 STROKE ADJUSTMENT HANDLE 004087 POINTER 013190 NOTCHER STROKE BOX 011713 LATCHING CLIP 141010 3/16 X 1/2 ROLL PIN (inc. with 6) 004086 MICRO SWITCH MOUNT (incs. 5) 562112 M.S. LIMIT SWITCH 073450 M4 X 16MM SHCS 014003...
  • Page 102 SHEAR & NOTCHER STROKE CONTROL FIGURE 41 PAGE 101...

  • Page 103: Hold Down Assembly

    9.6 HOLD DOWN ASSEMBLY ITEM QTY. PART # DESCRIPTION 080348 H.D. GEAR CENTER 080347 H.D. GEAR LEFT 080439 H.D. GEAR RIGHT 080338 WHEEL SHAFT H.D. 017430 7 X 7 X 24 KEY SHAFT 080342 HOUSING H.D. 013185 FRONT BAR SHEAR GUARD 221320 M12 X 50MM SHCS 212014...
  • Page 104 HOLD DOWN ASSEMBLY FIGURE 42 PAGE 103...

  • Page 105: Slug Buckets, Fan & E-Stop

    9.7 SLUG BUCKETS, FAN & E-STOP ITEM QTY. PART # DESCRIPTION S L U G B U C K E T S 033161 NOTCHER BUCKET ASS'Y 220016 M6 X 10MM BF - (2) PER BUCKET 046018 HANDLE MT/105 - (1) PER BUCKET 033176 PUNCH BUCKET ASS'Y F A N &...
  • Page 106 FAN & GUARDS SLUG BUCKETS E-STOP DETAIL 213005 15 14 PUNCH SLUG BUCKET (2) FANS & GUARDS 073204 073204 M4x.07 073204 073204 201000 M4x30 073204 M4x.07 M4x30 213005 213005 201000 073204 201000 M4x30 E-STOP ASS'Y 201000 M4x30 M4x30 213005 213005 201000 201000 M4x30...

  • Page 107: Sheet Metal Parts & Hardware

    9.8 SHEET METAL PARTS & HARDWARE ITEM QTY. PART # DESCRIPTION 224205 M10 X 16MM WLCS 033273 PUNCH COVER PAINTED 221005 M6 X 12MM SHCS 013289 SHEAR DOOR ASS'Y 341140 PIPE NOTCHER SLUG RAMP 204222 M10 X 55MM HHCS 214012 M10 REGULAR WASHER 013160 TOOLING SLUG CHUTE...
  • Page 108 SHEET METAL PARTS 341140 221005 033297 224205 224205 224205 224205 FIGURE 44 PAGE 107...

  • Page 109: Power Unit

    9.9 POWER UNIT Description Item Part Number DO120/135/150 RESERVOIR SCH. 40 033403 S/N 1180 & Prior HAS The Cooling Thru Tubes DO70/95/120/135/150 RESERVOIR 033500 S/N 1181 & UP - NO Cooling Thru Tubes 006630 REPLACEMENT FILTER 016088 FILLER BREATHER CAP 013400 SUCTION SCREEN S/N 1180 &...
  • Page 110 Pump Assy. Valve Detail MICROSWITCH FOOT CONTROL (inside Foot Pedals) Green (gnd) (jumper) (com) White (N.O.) Black (N.C.) FIGURE 45 PAGE 109 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

  • Page 111: Electrical Unit

    9.10 ELECTRICAL UNIT ITEM QTY. PART # DESCRIPTION 011861 TRANSFORMER-250VA 011933 1-1/2 AMP PRIMARY FUSE 011835 2 AMP SECONDARY FUSE 011852 3 AMP PRIMARY FUSE 5 AMP N/A: USE GRAINGER 011853 PART # 6F118 011856 DISCONNECT SWITCH 011976 3 PH CONTACTOR DILM 32-10 011977 1 PH CONTACTOR DILM 65 OVERLOAD MOUNTING BASE...
  • Page 112 CONTROL BOX ASS'Y 13 NO 1 L1 3 L2 5 L3 1 L1 3 L2 5 L3 INPUT OUTPUT Fuse Fuse VOLTAGE VOLT (FUSED) H1-H2 H1-H3 H1-H4 H1-H5 XF-X2 XF-X3 XF-X4 Holder Holder EATON VA 250 HZ 50/60 _OL_ CO250E6U DISC OUTPUT 1.92A OVERLOAD...

  • Page 113: Notcher Assembly

    DO150 S/N: 1147M & UP NOTCHER BLADE HOLDER 15A 1 033149 DO150 S/N: 1146M0616 & PRIOR 221327 M12 X 70MM SHCS SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542 PAGE 112...
  • Page 114 NOTCHER ASSEMBLY 230207 230207 230207 230207 221314 M12x35 221314 M12x35 221314 M12x35 221314 M12x35 FIGURE 47 PAGE 113...

  • Page 115: Optional Die Holders

    9.12 OPTIONAL DIE HOLDERS ITEM PART # DESCRIPTION 230207 M10 X 20 FSHCS 004275 OFFSET DIE HOLDER TABLE 201625 M16 X 65 HHCS 113020 5/8" HARD WASHER 013186 OFFSET DIE HOLDER 2" DIE 219050 M10 X 25 SS 003145 REMOVE TOOL LABEL 003135 40 TON OFFSET CAPACITY 230415...
  • Page 116 OPTIONAL DIE HOLDERS 230207 230207 230207 230207 201625 M16x65 201625 M16x65 201625 M16x65 201625 M16x65 201625 M16x65 201625 M16x65 OFFSET DIE HOLDER 203630 M16x80 203630 M16x80 203630 M16x80 203630 M16x80 6 x 6 DIE HOLDER FIGURE 48 PAGE 115...

  • Page 117: Electrical Schematics

    10.0 ELECTRICAL SCHEMATIC (4) Limit Switch's (4) Solenoid's (2) Foot Pedal's (1) Shear Right (1) Shear Black (1) Shear FP (1) Shear Gray (1) Shear Left (1) Fan DO 70-95 (1) Punch Top (1) Punch Black (2) Fan's DO 120-150 (1) Punch FP (1) Fan (1) Punch Bottom...
  • Page 118 GREEN / YELLOW CABLE DETAIL START START NOTCH PUNCH TOOL SHEAR E-STOP START Wire Labels Terminal Strip #'s RUN / JOG RUN / PROBE PAGE 117...
  • Page 119 DO-120, 135, & 150 3PH 1 DISC SEE MOTOR TAG INCOMING SUPPLY FOR DETAILS PN 033221 RATING TABLE (BY CUSTOMER) LINE VOLTAGE (3PH) PROVIDE MAXIMUM MAX. HP UPSTREAM MOTOR FLA 27.6 15.8 12.5 PROTECTION PER N.E.C. OVERLOAD ZB32-32 ZB32-32 ZB32-16 ZB32-16 ZB32-16 CODE 430-52 AND TABLE...
  • Page 120 DO-120, 135, & 150 230V 1PH 1 DISC SEE MOTOR TAG INCOMING SUPPLY FOR DETAILS PN 033225 RATING TABLE (BY CUSTOMER) LINE VOLTAGE (1PH) PROVIDE MAXIMUM MAX. HP UPSTREAM PROTECTION PER N.E.C. MOTOR FLA CODE 430-52 AND TABLE OVERLOAD ZB65-57 430-152.

  • Page 121: Hydraulic Schematics

    9 = DOUBLE ACTING CYLINDER (2) LINE, PILOT 10 = MANUAL SHUT-OFF VALVE 11 = LINE PRESSURE TEST PORT (2) COMPONENT ENCLOSURE PAGE 120 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

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