Piranha MegaFab IRONWORKER P-50 Instructions And Repair Parts
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Piranha MegaFab IRONWORKER P-50 Instructions And Repair Parts

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For Serial Numbers
P3-11050 to 13,000
Models
www.megafab.com
800-338-5471
INSTRUCTIONS
AND REPAIR PARTS
MANUAL FOR
IRONWORKER
MODEL NUMBER
P-50
Publication: December, 2010
Be sure to register your model
and serial number to receive
Piranha Service and Product
Updates.

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Summary of Contents for Piranha MegaFab IRONWORKER P-50

  • Page 1 INSTRUCTIONS AND REPAIR PARTS MANUAL FOR IRONWORKER MODEL NUMBER P-50 Publication: December, 2010 For Serial Numbers Be sure to register your model www.megafab.com P3-11050 to 13,000 and serial number to receive 800-338-5471 Models Piranha Service and Product Updates.
  • Page 2 Piranha Optional Tooling and Attachments Enhance your Ironworker’s Versatility Oversize Punch Attachments " • Expand your 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 ...
  • Page 3 INSTRUCTIONS REPAIR PARTS MANUAL IRONWORKER MODEL NUMBER P-50 Publication: December, 2004 Revised: December, 2010 P.O. Box 1206 Rockford, IL 61105 PH: 800-338-5471 FAX: 815-964-0831 www.megafab.com...

  • 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. Page No. FORWARD ....................4 WARRANTY ....................4 INTRODUCTION ..................5 SAFETY PRECAUTIONS ................6 MACHINE SPECIFICATIONS ..............7 FUNCTIONAL DIAGRAM ................8 DIMENSIONAL DATA .................

  • Page 5: Forward

    FOREWORD This manual has been prepared for those persons who will operate and maintain the Piranha Ironworker. It is important that all persons responsible for the care and operation of this equipment read and understand the information presented in this publication.

  • Page 6: Introduction

    INTRODUCTION The Piranha Ironworker is a compact hydraulically powered machine that shears, punches, bends, notches, and copes, all in a low silhouette, efficiently designed unit, resulting in minimal floor space requirements. The integral lifting lug provides instant portability and the unit arrives fully assembled, requiring only the addition of hydraulic oil and electrical power to become fully operational.

  • Page 7: Safety Precautions

    SAFETY PRECAUTIONS The operator of this machine should view the operational video provided with the machine, and thoroughly understand this manual before starting any operation. This machine was designed for use by a single operator only. Wear eye protection at all times. Use the proper voltage outlet for your machine.

  • Page 8: Machine Specifications

    MACHINE SPECIFICATIONS HYDRAULIC SYSTEM Drive Motor 10HP 230 / 460 Volt / 3 Phase Hydraulic Tank Capacity 18 Gallons Hydraulic Oil Mobile DTE 13 or Equivalent (ISO Grade 32) Consult your local distributor for a cross reference WORKING SURFACE Platen Table 10"...

  • Page 9: Functional Diagram

    FUNCTIONAL DIAGRAM Rear Control Box (OFF SIDE) Lifting Lug Angle Table Stroke Control Hold-down Shear Table Coper Guard Coper Guides Punch Attachment COPER END PUNCH END Coper Table Platen Table Chip Bucket Chip Bucket Fixed Hold-down Must be used when shearing 1"...

  • Page 10: Dimensional Data

    DIMENSIONAL DATA 60" 42" 24" 66"...

  • Page 11: Standards Compliance

    "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

    Only connect the specified voltage to the machine. Lifting The lifting lug on the Piranha is an integral part of the machine. Use a device with adequate lifting capacity to handle the Piranha. CAUTION: The unit is exceptionally top heavy! Lifting from the underside of the machine may cause damage to the cabinet structure.
  • Page 13 FIGURE "A" FIGURE "B" Toggle Start Button Switch Green NOTE: Turn selector switch to OFF position when performing maintenance or changing tooling. Stop Button Four Pole Receptacle Front Rear Selector Switch Front – OFF - Rear Front Cover Rear Cover Front and Rear Front Control Control Boxes...

  • Page 14: Operating Instructions

    OPERATING INSTRUCTIONS (refer to drawings on page 12) 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 15 Footswitch Operation The ironworker can also be controlled by a footswitch (reference Figure "F"). The footswitch is used by plugging the 4-pole twist lock cap into the 4-pole twist lock receptacle located in the front cover of either control box (reference Figure "A"), and switching the toggle switch (reference Figure "A") from the "OFF"...
  • Page 16 8) Allow footswitch lever to elevate allowing beam to rise. 9) Slide limit switch arm until contact with the upstroke switch stops beam movement at the desired upper limit. 10) Tighten thumbscrew to hold limit switch arm firmly in place. NOTE: When punching or using the bending attachment, set upper and lower limits to allow for 1/4"...
  • Page 17 PUNCH ATTACHMENT ALIGNMENT The alignment of the punch and die should be accomplished in the following manner. (Reference Pages RP-2 and RP-9). Slide the punch stripper assembly on the dovetail-mounting shoe. Tighten the locking shoe by turning the cap screw clockwise (requires 3/8” Allen wrench).

  • Page 18: Punch Tonnage Chart

    STRIPPER ASSEMBLY ADJUSTMENT NOTE: The selector switch should be in the "OFF" position until all tooling changes are complete. (Reference Page 12, Figure “B”.) The adjustment of the stripper assembly to compensate for varying punch lengths should be accomplished in the following manner. (Reference Page RP-9 for a visual reference).

  • Page 19: Tool List

    BENDING ATTACHMENT ALIGNMENT The alignment of the bending punch and bending die should be accomplished by the following manner. (Reference Pages RP-2 and RP-11). Slide the bending punch assembly on the dovetail-mounting shoe. The front edge of the bending dovetail slide should be even with the mounting shoe Tighten the locking shoe by turning the cap screw clockwise (requires 3/8”...
  • Page 20 SHEAR HOLD-DOWN ASSEMBLY ADJUSTMENT The adjustment on the hold-down assembly should be accomplished by the following manner. (Reference Page RP-7) 1. Raise the upper beam to its full upstroke limit. 2. Adjust the three-position hold-down locator per the following instructions: ...

  • Page 21: Lubrication

    LUBRICATION GENERAL The importance of correct lubrication cannot be over emphasized. Under no circumstances should the machine be operated without complying with the lubrication requirements set forth in this publication. LUBRICATION CHART Lubrication Station Part Lubricated Frequency Instructions Type Upper Pull Arm On Side Every 40 Apply With Mobile MP...

  • Page 22: Maintenance

    HYDRAULIC OIL LEVEL Your 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: Troubleshooting

    TROUBLESHOOTING The following material is a trouble-shooting guide to be followed by maintenance personnel should a problem occur with your machine. Many of these problems can be solved in your shop by following a step-by-step procedure for isolating the deficiency. If the deficiency cannot be isolated and corrected in your shop, any information regarding your effort to isolate the area should be related to the service technician at Mega Manufacturing, Inc.
  • Page 24 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 Page RP-18, Item 9). If the machine operates, the problem is electrical. Follow the procedure below: Determine if problem exists in the front control box only, the rear control box only, or in both control boxes.
  • Page 25 P3 - MACHINE OVERHEATS 1. Check if fluid level in reservoir is low. 2. Check for low line voltage to transformer, causing low control voltage to directional valve solenoid coils. 3. Determine if limit switches are set improperly when using footswitch, allowing cylinder to bottom out at retraction and extension.

  • Page 26: Ordering Instructions

    P6 - MACHINE LEAVES BURR WHEN SHEARING 1. Knife clearance: .007" to .010". If not, follow procedure in P-5. 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 27 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 28 MAINTENANCE TOOLS LIST The following tools are required for performing maintenance and to assist you in troubleshooting your machine: 1. Grease gun with a flexible connection. 2. Open end wrenches - 3/4" thru 1-1/4". 3. Adjustable wrench – 1-1/2" thru 2-1/4" opening. 4.
  • Page 29 Manufacturing part number, followed by the description in the third column. The last column shows the quantity of parts required for the assembly. Electrical wiring diagrams and hydraulic diagrams are shown with the Piranha part numbers. Some of these items shall be considered as an assembly and only one part number will be given, even though they are comprised of component parts.

  • Page 30: Repair Parts Illustrations

    REPAIR PARTS ILLUSTRATIONS Page No. Basic Machine..................RP-3 Shear Hold-down Assembly ..............RP-7 Punch Assembly ..................RP-9 Bending Assembly .................. RP-11 Electrical Enclosure ................RP-13 Wiring Diagram ..................RP-14 Front Control Box ..................RP-15 Rear Control Box ..................RP-16 Valve Body Assembly ................RP-17 Motor, Filter, and Pump Assembly ............
  • Page 31 P-50 BASIC MACHINE RP-3 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 32 P-50 BASIC MACHINE Figure And Part Description Qty. Index No. Number 0230142 Coper Guard 0531351 3/8" x 1" Roll Pin 0230117-1 Coper End Knife Support 0531118 3/4" x 7-1/2" HH 0531255 3/4" Nylock HN 0230155 Black Pipe Spacer 0230144 Coper Dust Cover Plate 0230124 Coper Table Assembly 0531080...
  • Page 33 P-50 BASIC MACHINE – Continued Figure And Part Description Qty. Index No. Number 0531076 7/16" x 4" SHCS 0230130 Locking Shoe Bearing 0531051 3/8" x 1-1/4" SHCS 0230131 Locking Shoe 0330189 Locking Shoe Bolt 0230132 Mounting Foot 0531039 3/8" x 3/4" SHCS 0230145 Bronze Wear Plate 0531062...
  • Page 34 P-50 BASIC MACHINE – Continued Figure And Part Description Qty. Index No. Number 0531060 3/8" x 3/4" HCS GR8 0531253 5/8" JN 0531400 Lifting Lug 0230276 Coper Knife- Lower Side and End 0276274 Angle Knife - Lower 0531050 3/8" X 1" SHCS - Upper Coper 0230277 Coper Knife - Upper 0531330...
  • Page 35 P-50 SHEAR HOLD-DOWN ASSEMBLY RP-7 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 36 P-50 SHEAR HOLD-DOWN ASSEMBLY PART NUMBER 02302001 Figure And Part Description Qty. Index No. Number 0531271 1-1/4-12 JN 02302011 Hold-down Pin 0330202 Hold-down Link 0531300 3/4" Hard Black Fit. Washer 0531255 3/4" Nylock HN 0330214 Locator Plate 03302001 Hold-down Bar 0531104 5/8"...
  • Page 37 P-50 PUNCH ASSEMBLY RP-9 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 38 P-50 PUNCH ASSEMBLY PART NUMBER 02304011 Figure And Part Description Qty. Index No. Number 02304001 1-13/16" Die Block Cast 0531002 1/4" x 3/4" SSS 0531055 3/8" x 1/2" SSS 0531100 5/8" x 3" SSS 0531251 5/8" CL-4 FLDG Nut 03304011 Stripper Foot Cast 0531356 3/8"...
  • Page 39 P-50 8" BENDING ASSEMBLY RP-11 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 40 P-50 8" BENDING ASSEMBLY PART NUMBER 4431648 Figure And Part Description Qty. Index No. Number 0330500 Bending Dovetail Slide 0531039 3/8" x 3/4" SHCS 0330501 Bending Punch Slide Plate 0531114 3/4" x 3" SB 0531250 5/8" Nylock HN 0330502 8" Bending Punch 0330503 8"...
  • Page 41 P-50 ELECTRICAL ENCLOSURE ASSEMBLY PART NUMBER 02316402-1 Figure And Part Description Qty. Index No. Number 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 - or - 05316271 575 Volt Transformer...
  • Page 42 RP-14 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 43 P-50 FRONT BOX ASSEMBLY PART NUMBER 02316292-1 Figure And Part Description Qty. Index No. Number 05316291 Front Control Box - With Covers 0531608-1 Joystick 9001 K35 – With Contact Blocks 0531609 KA-1 Contact Block 0531644 KA-2 Contact Block 05316451-1 Selector Switch ZB4BD3 0531616 Microswitch 05316101-1 Start Button ZB4BA3...
  • Page 44 REAR BOX ASSEMBLY PART NUMBER 02316302-1 Figure And Part Description Qty. Index No. Number 05316301 Rear Control Box - With Covers 0531608-1 Joystick 9001 K35 – With Contact Blocks 0531609 KA-1 Contact Block 0531644 KA-2 Contact Block 05316101-1 Start Button ZB4BA3 05316111-1 Stop Button ZB4BL4 05316121-1 Contact Block with base N.C.
  • Page 45 VALVE BODY ASSEMBLY PART NUMBER 0231530-2 & 0.109 ORIFICE DISK BEGINS WITH S/N RP-17 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 46 VALVE BODY ASSEMBLY PART NUMBER 0231530-2 Figure And Part Description Qty. Index No. Number T3572 Pilot Valve 2-Way 0551566-1 Counterbalance Valve 0551559-1 Pressure Relief Valve 35/26 0531567-1 Check Valve 0531566-1 Single Pilot Piston Valve 0531562-1 Pressure Relief Valve 25/12 0551561-1 Solenoid Valve (N.C.) T3574 115V AC Solenoid Coil...
  • Page 47 P-50 MOTOR ASSEMBLY PART NUMBER 0231600-1 Figure And Part Description Qty. Index No. Number 05316612 10 HP Motor 220/440V (Hollow Shaft) - or - 05316652 10 HP Motor 575V (Hollow Shaft) - or - 05316702 10 HP Motor Single Phase (Hollow Shaft) 0533539 6801-16 Hydraulic Fitting 0531596-2...
  • Page 48 P-50 CYLINDER ASSEMBLY Figure And Part Description Qty. Index No. Number 05315031 Cylinder - Green, Number 600E-3775 0230171 Clevis Pin 0230152 Clevis 0531340 5103-125 Snap Ring 0531362 1652B Zerk Str 1/4-28 0531085 1/2" x 1/2" SSS 02301721 Cylinder Pin 0531509 6802-10 Hydraulic Fitting 0531521 50"...
  • Page 49 FOOT SWITCH ASSEMBLY PART NUMBER 0231628 Figure And Part Description Qty. Index No. Number 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. RP-21 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 50 KNIVES Part Index No. Description Qty. Number 02302501 Flat Shear Knives x 12.125" 0230252 3/8" Round Bar Knife 0230253 Blank Round Bar Knife 0230254 1/2" Round Bar Knife 0230256 5/8" Round Bar Knife 0230258 3/4" Round Bar Knife 0230260 7/8" Round Bar Knife 0230262 1"...
  • Page 51 REMARKS RP-23 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 52 Piranha Optional Tooling and Attachments ***Additional Options Shown on Inside of Front Cover*** 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.

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