Piranha IRONWORKER P90 Operation Manual
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Piranha IRONWORKER P90 Operation Manual

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IRONWORKER MODEL NUMBER P90
For Serial Numbers P90-3001 to Current Models
Publication Date: May 3, 2022
Call us: 800-338-5471

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Summary of Contents for Piranha IRONWORKER P90

  • Page 1 IRONWORKER MODEL NUMBER P90 For Serial Numbers P90-3001 to Current Models Publication Date: May 3, 2022 Call us: 800-338-5471...
  • Page 2 Piranha Optional Tooling and Attachments Enhance your Ironworker’s Versatility Oversize Punch Attachments • Expand punching capacity up to 5" Quickset Gauging Table • Allows you to quickly set-up your punch end for multiple holes. • Includes an angle gauge bar to index off the heel of your angle and a plate gauge bar, which indexes off the end of your plate.
  • Page 3 Ironworker Manual Model P90 Be sure to register your model and serial number to receive Piranha Service and Product Updates. Support Please have the serial number or model ready when calling. For technical support: Via Phone: 815.490.0473 Via Email: service@piranhafab.com For ordering parts and consumables: Via Phone: 800.338.5471...

  • Page 4: Table Of Contents

    Table of Contents Refer to second section of this manual for information on repair parts breakdown and ordering repair parts. Table of Contents ......................4 Foreword ......................... 5 Warranty .......................... 5 Introduction ........................6 Safety Precautions ......................7 Machine Specifications ....................8 Functional Diagram ......................

  • Page 5: Foreword

    Warranty Piranha / MegaFab will replace (F.O.B. our factory) or refund the purchase price for any goods which are defective in materials and workmanship within 12 months of date of purchase. The buyer must return the warranty registration card within thirty-(30) days of...

  • Page 6: Introduction

    About Piranha Piranha is a subsidiary of MegaFab, based in Rockford Illinois. MegaFab is a manufacturer of metal fabrication machinery, including laser cutting machines, plasma cutting machines, ironworkers, press brakes, bending rolls, combination punching and cutting machines, and structural steel punching equipment.

  • Page 7: Safety Precautions

    Contact the factory for limit switch adjustments on special tooling. Turn selector switch to the "OFF" position when changing tooling or performing maintenance work (Reference page 13, figure B). Piranha Ironworker P90...

  • Page 8: Machine Specifications

    Machine Specifications Hydraulic System Drive Motor 10 Hp 230 / 460 Volt 3 Phase Hydraulic Tank Capacity 25 Gallons Hydraulic Tank - Initial Fill 18 Gallons Aw-32 Or Equivalent Iso Grade 32 Hydraulic Oil Consult your local distributor for a cross reference. Working Surface Platen 12"...

  • Page 9: Functional Diagram

    Rear Control Box (OFF SIDE) Angle Table Lifting Lug Shear Table Stroke Control Punch Hold-down Attachment Coper Guard Coper Guides COPER PUNCH Coper Table Platen Table Chip Bucket Chip Bucket Serial Number Plate Location Front Control Foot Switch Piranha Ironworker P90...

  • Page 10: Dimensional Data

    Dimensional Data 64" 42" 31" 79" Dimensional Data...

  • Page 11: Standards Compliance

    In addition, all of the machines meet the current "Ontario Hydro" electrical code for proper manufacture of the electrical circuits. Hydraulic System Design/Manufacture: Hydraulic components used in Piranha machines are approved by NFPA (National Fluid Power Association), and those approval numbers can be traced through the manufacturer's part numbers.

  • Page 12: Installation

    Foundation To maintain the accurate alignment built into the Piranha, and to prevent undue stress on the moving parts under a load, the Piranha should be placed on a stable base or floor adequately constructed to withstand the unit weight.

  • Page 13: Operating Instructions

    Operating Instructions The Piranha Ironworker comes pre-assembled and pre-wired, requiring only the addition of hydraulic fluid in the reservoir to the mark on the fill cap dipstick and a power source from a disconnect to the electrical enclosure box located inside the cabinet.
  • Page 14 Joystick Operation The ironworker is hand controlled by a five-position momentary joystick operator. When the joystick is released from any of the four positions, it will return to the neutral (center) position stopping machine movement instantly. The joysticks are located on top of the control box at each end of the machine.
  • Page 15 ▪ Completion of downward cycle is accomplished by depressing footswitch lever again. Machine movement is down until limit setting is met (reference Figure F4). ▪ Removing foot pressure from the switch entirely allows machine movement upward to limit setting, completing upstroke cycle (reference Figure F5). Piranha Ironworker P90...
  • Page 16 Footswitch Limit Switches The footswitch is used in conjunction with the upstroke and downstroke limit switches located on the machine side off the front control box only, see figure C. ▪ The front limit switch (closest to the punch end and the lower switch of the two switches) controls the downstroke limit.
  • Page 17 11. Using the wrench supplied with the machine, tighten the flanged nuts on the setscrews to hold the die block firmly to the platen table. 12. Set the limit switches to control the length of stroke Reference previous page. 13. Start operation. Piranha Ironworker P90...
  • Page 18 Stripper Assembly Adjustment NOTE: The selector switch should be in the "OFF" position until all tooling changes are complete. Reference page 13, figure B. The adjustment of the stripper assembly to compensate for varying punch lengths should be accomplished in the following manner. See page 36 for a visual reference. NOTE: The correct adjustment should have the tip of the punch 1/16”...
  • Page 19 8. Using the wrench supplied with the machine, tighten flanged nuts on the setscrews to hold the base assembly firmly to the platen. 9. Set the limit switches to control the length of stroke (reference procedures previously listed). 10. Start operation. Piranha Ironworker P90...
  • Page 20 Shear Hold-Down Assembly Adjustment The adjustment on the hold-down assembly should be accomplished by the following manner. Reference page 34. 1. Raise the upper beam to its full upstroke limit. 2. Adjust the three-position hold-down locator per the following instructions: a.

  • Page 21: Lubrication

    Hold-down Bar (2 Places) Hold-down Pin Stripper Assembly (2 Places) Clevis Pin Lower Pull Arm Hinge Pin Crank Arm Hinge Pin Drive Motor One shot One shot from Multi-purpose per year grease gun grease Drive Motor Piranha Ironworker P90...

  • Page 22: Maintenance

    Hydraulic Oil Level The Piranha ironworker is equipped with a dipstick indicator on the fill cap located inside the access door. The dipstick is marked to help maintain proper fluid level. This should be checked as part of your normal maintenance cycle.

  • Page 23: Reference Charts

    Die Clearance (Add to Punch Size) 0.089 – 0.125” 0.01” 13 thru 11 0.126 – 0.190” 1/64” (0.016”) 10 thru 7 0.191 – 0.500” 1/32" (0.032”) Over 7 thru 1/2" Plate Over 1/2” Plate Over 0.500” 1/16" (0.063”) Piranha Ironworker P90...

  • Page 24: Tonnage Required For Punching Holes In Mild Steel

    Tonnage Required for Punching Holes in Mild Steel This table shows the tons of force required for punching round holes in mild steel derived by the formula: Force = hole diameter x material thickness x constant 80. All figures shown are in U.S. tons. For holes larger than 1 inch, the punching force can be calculated per the following example: What pressure is required to punch a 2-1/4"...

  • Page 25: Troubleshooting

    Many of these problems can be solved by following a step-by-step procedure for isolating the issue. Take notes on the steps tried, and the outcomes. This way if you are not able to fix the issue, you can pass on what has been done and tried already to the Piranha technician.
  • Page 26 P2: Machine Starts but Will Not Operate Determine if the problem is electrical or hydraulic by using the manual override buttons located on the Rexroth directional valve top and bottom sides. Refer to Valve Body Assembly Illustrated, pages 44 and 45, item 9. If the machine operates, the problem is electrical.
  • Page 27 Knives may have been ground. Shim to recommended clearance. 2. Knives may be dull and are creating a pulling effect on the shearing edge. 3. Material may be too hard. 4. Material may be thicker than rated capacities. Piranha Ironworker P90...
  • Page 28 P6: Machine Leaves Burr When Shearing 1. Knife clearance: .007" to .010". If not, follow procedure in P5. 2. Check shear knives for sharpness 3. Check that the automatic hold-down is adjusted to clamp the material securely. P7: Bent or Broken Shear Hold-Down Swing Bolt 1.

  • Page 29: Ordering Repair Parts

    The following assembly parts lists are shown in four columns. In the first column are the index numbers of the parts illustrated. The second column contains the Piranha part number, followed by the description in the third column. The last column shows the quantity of parts required for the assembly.
  • Page 30 Repair Parts Table of Contents P90 Whole Machine Illustrated ..................31 Shear Hold Down Assembly Illustration ................ 34 Stripper Assembly Illustrated ..................36 Bending Assembly Illustrated (Optional) ............... 38 Bending Die Capacities ....................39 Electrical Enclosure Assembly ..................40 Electrical Diagram ......................40 Front Box Assembly ......................

  • Page 31: P90 Whole Machine Illustrated

    P90 Whole Machine Illustrated Piranha Ironworker P90...
  • Page 32 Whole Machine Part Numbers Figure and Part Number Description Qty. Index No. 0250100 Upper Beam Assembly 0250101 Lower Beam Assembly 0250112 Crank Arm Assembly 0250113 Platen Support-On Side 0250114 Platen Support-Off Side 0250115-1 Coper Side Plate-On Side 0250116-1 Coper Side Plate-Off Side 0250110 Pull Arm-On Side 0250111...
  • Page 33 1/4" Hex Nut 0250124 Coper Table Assembly 0531715 Jergens Handle 0531307 1/2" Flat Washer 0330128 Coper Table Guide 0531088 1/2" x 1-1/2" Carriage Bolt 0531086 1/2" x 1-3/4" SHCS 0541155 3/4" x 2-1/4" SHCS 0250415 Shear Guard Assy. Piranha Ironworker P90...

  • Page 34: Shear Hold Down Assembly Illustration

    Shear Hold Down Assembly Illustration Ordering Repair Parts...
  • Page 35 0250201 Hold Down Pin 0340215 Hold Down Pin Key 0350215 Locator Plate 0541393 Locator Pin Knob 0340213 Locator Pin Housing 0340216 Locator Pin Spring 0340212 Locator Pin 0531270 1-1/2" NF Jam Nut 0350210 Hold Down Bar Bushing Piranha Ironworker P90...

  • Page 36: Stripper Assembly Illustrated

    Stripper Assembly Illustrated Ordering Repair Parts...
  • Page 37 Stripper Guide Pin Slip Sleeve 0340408 Stripper Guide Pin Adjusting Cap 0531360 1610 Zerk 0241410 Coupling Wrench 0340400 Punch Guard 0531012 Punch Guard Rivets 0531013 Punch Guard Spacer 0541045 W-17N Ball Plunger 1/4" - 20" 0531350 1/4" x 3/4" RP Piranha Ironworker P90...

  • Page 38: Bending Assembly Illustrated (Optional)

    Bending Assembly Illustrated (Optional) Ordering Repair Parts...

  • Page 39: Bending Die Capacities

    Die Holder with Pins 0350505 Die Holder without Pins 0531351 3/8" x 1" Roll Pin 0531251 5/8" FLDG Nut 0541127 5/8" x 3-1/2" SSS Bending Die Capacities "V" Width Maximum Material 3" 3/8" 2" 1/4" 1-1/2" 3/16" 7/8" 10 Gauge Piranha Ironworker P90...

  • Page 40: Electrical Enclosure Assembly

    Electrical Enclosure Assembly Assembly Part Number 02316402-1 Figure and Part Number Description Qty. Index No. 0521634 Rear Wiring Harness Receptacle 0521634 Front Wiring Harness Receptacle 0521636 Valve Body Harness Receptacle 0531641 Starter T2253 Auxiliary Contact 05316261 220 / 440 Volt Transformer 05316271 575 Volt Transformer 05316281...

  • Page 41: Electrical Diagram

    Electrical Diagram Piranha Ironworker P90...

  • Page 42: Front Box Assembly

    Front Box Assembly Assembly Part Number 02316292-1 Figure and Part Number Description Qty. Index No. 05316291 Front Control Box - With Covers 0531608 Joystick 9001 K35 0531609 KA-1 Contact Block 0531644 KA-2 Contact Block Joystick Assembly including items 2, 3, and 4 0531608-1 (for ordering as a repair part) 05316451-1...

  • Page 43: Rear Box Assembly

    Contact Block with base N.C. ZB4BZ102 05316121-1 (Contact Number ZB4BE102) 0531618 4 Pole Receptacle 0531619 Toggle Switch 0531654 Liquid Tight Connector 3/8" 0531657 JIC Grey Conduit Flexguard Quick Disconnect Plug Contact Block with base ZB4BZ101 (Contact 0531696-1 Number ZB4BE101) Piranha Ironworker P90...

  • Page 44: Valve Body Assembly Illustrated

    Valve Body Assembly Illustrated Assembly Part Number 0231530-2 0.109 Orifice Disk Ordering Repair Parts...
  • Page 45 0541505 6802-12 Fitting 0541505 6802-12 Fitting 0551522 48" Hose To Filter Assembly 0531543 32" Hose To Tank 0551521 55" Hose To Cylinder 0551520 40" Hose To Cylinder 03316512-2 Valve Body Wiring Harness (not shown) 0.109 Orifice Disk Piranha Ironworker P90...

  • Page 46: Motor Assembly

    Motor Assembly Assembly Part Number 0231600-2 Figure Part and Index Description Qty. Number 05316612 10 HP Motor 220/440V (Hollow Shaft) 05316652 10 HP Motor 575V (Hollow Shaft) 05316702 10HP Motor Single Phase (Hollow Shaft) 0533539 6801-16 Hydraulic Fitting 0531596-3 Hydraulic Pump 0531050 3/8"...

  • Page 47: Cylinder Assembly

    16105 Zerk 1/8" P Thread 0250152 Cylinder Clevis 0531085 1/2" x 1/2" SSS 0541310 5108-200 Snap Ring 0531531 6801-12 Fitting 0531538 6801-12-16 Fitting 0551521 55" Hose to Valve Body 0551520 40" Hose to Valve Body 05415001 Seal Kit Piranha Ironworker P90...

  • Page 48: Foot Switch Assembly

    Foot Switch Assembly Assembly Part Number 0231628 Figure and Part Number Description Qty. Index No. 0531655 Foot Switch 0531636 Cord Grip 0531637 16 - 4 SEO Cord (sold by the foot) 6 ft 0531617 4 Pole Plug NOTE: Limit Switches in Foot Pedal are not a stock item but can be obtained. Ordering Repair Parts...
  • Page 49 5/8" Sq Bar Knife - Tall 2402841 3/4" Sq Bar Knife - Short 0240284 3/4" Sq Bar Knife - Tall 2402851 7/8" Sq Bar Knife - Short 0240285 7/8" Sq Bar Knife - Tall 2402861 1" Sq Bar Knife - Short Piranha Ironworker P90...

  • Page 50: Knives

    Knives Continued Figure and Part Number Description Qty. Index No. 0240286 1" Sq Bar Knife - Tall 2402871 1-1/8" Sq Bar Knife - Short 0240287 1-1/8" Sq Bar Knife - Tall 2402881 1-1/4" Sq Bar Knife - Short 0240288 1-1/4" Sq Bar Knife - Tall 2402891 1-3/8"...

  • Page 51: Service Record Chart

    Service Record Chart Piranha Ironworker P90...
  • Page 52 Service Record Chart...
  • Page 53 Piranha Optional Tooling and Attachments Enhance your Piranha’s versatility! Pressbrake Tooling Holders • Allows you to use pressbrake punches and dies in your ironworker for higher precision bending. Roller Feed Tables • Available in 5' lengths. • Includes rollers for angle and flat bar sections.

This manual is also suitable for:

P90P90-3001

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