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Piranha MegaFab P-110 Instruction And Repair Parts Manual

Ironworker
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For Serial Numbers
P110-3001 Current
Models
www.megafab.com
800-338-5471
INSTRUCTIONS
AND REPAIR PARTS
MANUAL FOR
IRONWORKER
MODEL NUMBER
P-110
Publication: April, 2013
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 P-110

  • Page 1 INSTRUCTIONS AND REPAIR PARTS MANUAL FOR IRONWORKER MODEL NUMBER P-110 Publication: April, 2013 For Serial Numbers Be sure to register your www.megafab.com P110-3001 Current model and serial number to Models receive Piranha Service and 800-338-5471 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 heel of your angle and a plate gauge bar, which indexes off the end of your plate.
  • Page 3 INSTRUCTIONS REPAIR PARTS MANUAL IRONWORKER MODEL NUMBER P-110 Publication: April, 2013 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 10 HP 230 / 460 Volt 3 Phase Hydraulic Tank Capacity 25 Gallons Hydraulic Oil AW-32 or Equivalent ISO Grade 32 Consult your local distributor for a cross reference. WORKING SURFACE Platen 14-1/2" x 21" Coping 19"...

  • Page 9: Functional Diagram

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

  • Page 10: Dimensional Data

    DIMENSIONAL DATA 66-1/2" 44" 35" 90"...

  • 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 STRIPPER ATTACHMENT ALIGNMENT The alignment of the stripper should be accomplished in the following manner. (Reference Pages RP-3 and RP-7). 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 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-7 or a visual reference).

  • Page 19: Punch & Die Clearance Chart

    BENDING ATTACHMENT ALIGNMENT The alignment of the bending punch and bending die should be accomplished by the following manner. (Reference Pages RP-3 and RP-10). 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-6) 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-17, 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 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 27: Punch Tonnage Chart

    TONNAGE REQUIRED FOR PUNCHING HOLES IN MILD STEEL The table below shows the tons of pressure required for punching round holes in mild steel derived by the following formula: Tons of pressure required = Hole Size x Material Thickness x a Constant of 80.

  • Page 28: Tool List

    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-6 Stripper Assembly ..................RP-8 Bending Assembly .................. RP-10 Electrical Enclosure ................RP-12 Electrical Schematic ................RP-13 Front Control Box ..................RP-14 Rear Control Box ..................RP-15 Valve Body Assembly ................RP-16 Hydraulic Schematic ................
  • Page 31 P-110 BASIC MACHINE RP-3 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 32 P-110 BASIC UNIT Figure And Part Description Qty. Index No. Number 0240142 Coper Guard 0531352 1/2" x 1-1/2" Roll Pin 0240117-1 Coper End Knife Support 0541200 1" - 8 PTI x 9" HH GR-5 0581265 1" - 8 TPI Jam Nut 0240155 Black Pipe Spacer 0240144...
  • Page 33 P-110 Basic Unit – Continued Figure And Part Description Qty. Index No. Number 0531084 1/2" x 4" SHCS 0240130 Locking Shoe Bearing 0531069 7/16" x 1-1/2" SHCS 0240131 Locking Shoe 0340189 Locking Shoe Bolt 0240132 Mounting Foot 0541090 7/16" -14 x 1" SHCS 0230145 Bronze wear Plate 0531062...
  • Page 34 P-110 Basic Unit – Continued Figure And Part Description Qty. Index No. Number 0541130 5/8" - 11" x 3-3/4" HH GR2 0531051 3/8" x 1-1/4" SHCS 0541185 3/4" - 10 JN Lifting Lug 0240278 Lower Coper Side Knife 0240276 Lower Coper End Knife 0531069 7/16"...
  • Page 35 P-110 SHEAR HOLD-DOWN ASSEMBLY PART NUMBER 0240200 RP-6 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 36 P-110 HOLD DOWN ASSEMBLY PART NUMBER 0240200 Figure And Part Description Qty. Index No. Number 0340200 Hold Down Bar 0240206 Swingbolt Block 0541160 3/4" x 2-3/4" SB 0531250 5/8" Nylock Nut 0541395 3/4 x 7 CL-76 Swingbolt 0340217 Swingbolt Spring 0541396 CL-4 Coupling Nut 0340205...
  • Page 37 P-110 STRIPPER ASSEMBLY Part Number 0240401 RP-7 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 38 P-110 STRIPPER ASSEMBLY PART NUMBER 0240401 Figure And Part Description Qty. Index No. Number 0240400 Die Block 0531002 1/4" X 3/4" SSS 0541085 7/16" - 14" x 3/4" SSS 0541127 5/8" x 3-1/2" SSS 0531251 5/8" FLGD Nut 0340401 Stripper Foot Assembly 0531356 3/8"...
  • Page 39 P-110 BENDING ASSEMBLY (OPTIONAL) PART NUMBER 4441648 RP-9 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 40 P-110 12" BENDING ASSEMBLY (OPTIONAL) PART NUMBER 4441648 Figure And Description Qty. Index No. Part Number 0340500 Bending Dovetail Slide 0531039 3/8" x 3/4" SHCS 0340501 Bending Side Plates 0531114 3/4" x 3" Shoulder Bolt 0531250 5/8" - 11" Nylock Nut 0340502 12"...
  • Page 41 P-110 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 05316271 575 Volt Transformer 05316281...
  • Page 42 RP-12 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 43 P-110 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 P-110 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 P-110 VALVE BODY ASSEMBLY PART NUMBER 0231530-2 & 0.109 ORIFICE DISK BEGINS WITH S/N xxxx RP-15 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 46 P-110 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...
  • Page 47 P-110 MOTOR ASSEMBLY PART NUMBER 0231600-1 Figure And Part Description Qty. Index No. 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 0531596-2 Hydraulic Pump 0531050 3/8"...
  • Page 48 P-110 CYLINDER ASSEMBLY Figure And Part Description Qty. Index No. Number 0541503 Cylinder #13150 0240171S Cylinder Clevis Pin 0531360 0610B Zerk 1/8" P Thread 0240152 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"...
  • 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-19 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 50 P-110 KNIVES Part Index No. Description Qty. Number 0240250 16.625 Shear Knives 0240251 20.5 Shear Knives 2402631 1/2" Rd Bar Knife - Short 0240263 1/2" Rd Bar Knife - Tall 2402641 5/8" Rd Bar Knife - Short 0240264 5/8" Rd Bar Knife - Tall 2402521 3/4"...
  • Page 51 P-110 KNIVES – Continued Part Index No. Description Qty. Number 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 52 REMARKS RP-22 ALWAYS PROVIDE THE COMPLETE SERIAL NUMBER FOR PARTS AND SERVICE...
  • Page 53 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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