Scotchman DO 95/140-24M Manual

Ironworker

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Model DO 95/140-24M Ironworker.

This manual does not include all of the

optional tooling for this machine.

If you would like a tooling manual,

please download our #40 Tooling Manual.

WARNING

START

PUNCH

TOOL

SHEAR

NOTCH

MM.

IN.

TO PREVENT SERIOUS

BODILY INJURY

DO NOT PLACE FINGERS

BEYOND THIS GUARD

213012

201240

003140

DUAL OPERATOR

RUN JOG

RUN PROBE

080061

95/140 -24M

MACHINE CAPACITIES

SPEC. BASED ON MILD STEEL-65,000 PSI TENSILE

PUNCH

FLAT SHEAR

95 TONS

BLADE LENGTH 24" - 600MM

START

Ø1-3/16" THRU 1"

1X8 - 3/8X 24"

080061

Ø30 THRU 24MM

25X200 - 10X600MM

THROAT DEPTH

RECT. NOTCHER

213012

9.0" - 230MM

3"X5"X3/8"

3"X4"X1/2"

201240

76X127X10MM

76X100X12MM

PUNCH STROKE

ANGLE SHEAR

2.0" - 50MM

6"X6"X 1/2"

STOP

150X150X12MM

#019151

4,07

MODEL

H.P.

VOLT

FLA

SERIAL

MM.

IN.

004085

SCOTCHMAN INDUSTRIES, INC.

PSI

PHILIP, SOUTH DAKOTA, U.S.A.

PH. 605-859-2542

BLADE LENGTH

JOG

MADE IN U.S.A.

033707

TO PREVENT SERIOUS BODILY INJURY

WARNING

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.)

12076 Ram

NEVER-

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

012077

013122

Operators Side

013120

Operator Side

013611 FRAME ASSY

230 Volts

19121

OFF

11856

EATON

DANGER

ELECTRICAL HAZARD

33176

Turn off power

and lock out

before servicing.

3122

1213

13220 - 3ph 13225 - 1ph

25525 Raw

013606 BASE ASSY

WHEN MITERING

DO NOT EXCEED

3 X 3 X 1/4

003195

0502

17341

224205

13179

201110

M6x12

013180

M6x12

201110

M6x12

201110

013180

201110

M6x12

201110

M6x12

201110

M6x12

201110

224205

013261

224205

13190

4113

080174

13267

14119

33046

015075

13137

013609

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Summary of Contents for Scotchman DO 95/140-24M

Page 1 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 012077 17341 224205...
Page 2 MODEL DO 95/140-24M IRONWORKER SERIAL # 1863 M1221 & UP VERSION 9 - JANUARY 2025 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 3 Punch half holes, punch or shear unknown materials, side load 12076 Ram 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 012077 17341 224205 224205...
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
Ironworkers. There is no chance of the Scotchman being "accidentally tripped". The Scotchman DO 95/140-24M is designed as a dual operator Ironworker. On this model, the punch and tooling stations operate independently of the shear and notcher stations.
Page 8: Warranty
CD or VHS tape. 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 019151 95/140 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 12076 Ram 12076 Ram 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 012077 012077 26713 6202 201640...
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 46-11/16 118.6 Floor to top of Die Holder 42-7/16 107.8 Floor to Punch Bolster...
Page 12 Punch half holes, punch or shear unknown materials, side load 12076 Ram 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 012077 6202 201640 113017...
Page 13: Machine Moving Procedures
Punch half holes, punch or shear unknown materials, side load 12076 Ram press brakes. SAFETY GLASSES REQUIRED WHEN OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 REV. 0310 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 012077 17341 224205 224205 13179 13179...
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 012077 17341 224205...
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 18 250 KVA PRIMARY SIDE MOTOR CONNECTIONS FUSE FUSE HIGH VOLTAGE C0NNECTION ( 440-480 VOLT 3PH ) EATON 250 VA CO250E6U FUSE LINE LINE LINE SECONDARY SIDE #1 thru #9 are Wires From the Motor WHITE GREEN LOW VOLTAGE C0NNECTION ( 220-240 VOLT 3PH ) H1-H2 H1-H4 H1-H3...
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. 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 012077 17341 224205...
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 12076 Ram 012077 10.22 8.19...
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 12076 Ram 012077 10.22 8.19...
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 12076 Ram 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 012077 6202 201640 113017...
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 12076 Ram 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 012077 SHEAR BEAM MAIN PIN 6202...
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 15/16 HOLE DIAMETER .125 .1875 .250 .3125 .375 .4375 .500 .5625 .625 .6875 .750 .8125 .875 .9375 1.00 METAL THICKNESS P R E S S U R E I N T O N S GAUGE INCHES .015...
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 DO NOT SET CLEARANCE LESS THAN 0.005" (0.13 mm). For material thickness or blade clearances outside of this chart, consult dealer or factory. FIGURE 14 PAGE 37 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
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 the rub blocks (3, 4 & 7). USE THE FOLLOWING STEPS TO ADJUST THE SHEAR ARM. SEE FIGURE 15 ON THE FOLLOWING PAGE.
Page 40 Cutaway Views FIGURE 15 PAGE 39 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
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 UPPER SET SCREW (2 ea) BLADE BOLT LOWER BLADE LOWER SET SCREW (1 ea) 1°- 2° CANT RIGHT WRONG FIGURE 16 PAGE 41 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
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 N ·...
Page 45: Optional Tools
NOTE: If tool ever jams or gets stuck - REMOVE THE TOOL FROM THE MACHINE BEFORE ATTEMPTING TO FREE IT. 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 12076 Ram 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 012077 17341 224205 224205...
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 012077 17341 224205...
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 Ninety Degree 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 DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 REV. 0310 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 001200 16174 17341 224205 224205...
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 12076 Ram OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 Punch Ram 012077 15030 1385...
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 Punch half holes, punch or shear unknown materials, side load 80445 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 26182 80040 17341 201625...
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 026438 026438 201110 M6x12 001293 - PICKET TOOL HOUSING PAGE 61...
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 DO NOT REMOVE THIS SIGN FROM THIS MACHINE 12076 Ram OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 012077 16096 203225 203225...
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: End View
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 or 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 012077 17341 224205...
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: Probe Placement
48 INCH BACK GAUGE Parts List 025603 - Deluxe Back Gauge 48" Part Number Description Item # Length Stop 025324 221420 M16 x 50 SHCS Length Stop Assembly 025317 219047 M10 x 12 Set Screw 025361 M12 x 50 Adj. Handle Slide Block Length Stop 025320 Stop Bar Assembly...
Page 75: Urethane Stripper
Contact your local Scotchman dealer for advice. Combining this unit with a linear feed repetitive stop system for punching a series of holes in flat bar will significantly increase productivity.
Page 76 8. Select the proper punch and die. Make sure that there is proper clearance between the punch and die. For recommended clearances: GO TO SECT. 6.1 "PUNCH OPERATION" - Letter "I" 9. Clean both the punch and die of any foreign material. 10.
Page 77: B Changing The Urethane Springs
21. Using the M12 hex bolts and large washers, insert the bolts through the large bushing holes of the of the stripper mounting plate, and thread the bolts into the posts. Tighten the bolts all the way, making sure the posts are guided into the bushings correctly.
Page 78 6. Using the M12 hex bolts and large washers, insert the bolts through the large bushing holes of the stripper mounting plate, and thread the bolts into the posts. Tighten the bolts all the way, making sure the posts are guided into the bushings correctly. The bolts should be tightened until they bottom out on the top of the posts.
Page 79: Weld Coupon Bender Tool
After bending the weld test coupon, let the tool return to the resting position. Remove the test coupon and inspect the weld. The tool can be seen in use at www.scotchman.com. NOTE: If tool ever jams or gets stuck - REMOVE THE TOOL FROM THE MACHINE BEFORE ATTEMPTING TO FREE IT.
Page 80 Punch half holes, punch or shear unknown materials, side load 12076 Ram 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 012077 17341 224205 224205...
Page 81: Multi-Shear Tool
7.14 MULTI-SHEAR TOOL The Multi-Shear tool is designed to shear standard Unistrut profiles, as well as many other specialty profiles. 7.14A MULTI-SHEAR TOOL INSTALLATION SEE FIGURE 32B ON THE FOLLOWING PAGE. If the punch and die are mounted on the machine, REMOVE THEM. Turn the machine on and put it in the SHEAR position.
Page 82 Punch half holes, punch or shear unknown materials, side load 12076 Ram press brakes. SAFETY GLASSES REQUIRED WHEN DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE 003100 REV. 0310 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 012077 17341 224205 224205 13179 13179...
Page 83: 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 84: 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 85 ► 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 86: B Limit Switch Inspection Procedure: Punch/Tool Station
If the machine does not stop when the switch is depressed, the limit switch is not functioning properly. Check both limit switches. PAGE 85 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 87 Punch half holes, punch or shear unknown materials, side load 12076 Ram 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 012077 17341 224205 224205...
Page 88: 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 89: 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 90 SEALS IN HYDRAULIC CYLINDERS CLEVIS SEAL KIT P/N 013305 FIGURE 33 PAGE 89...
Page 91: Parts List
9.0 PARTS LISTS 9.1 SHEAR ARM ASSEMBLY (SERIAL #'S 1402 & UP) ITEM QTY. PART # DESCRIPTION SHEAR BEAM ASSEMBLY 013106 INCLUDES 1, 2, 12, 13, 18 & 20 080169 CONNECTING LINK BUSHING 006190 UPPER PUNCH PIN METRIC 013172 M24 X 80 SET SCREW 210024 JAM NUT 033175...
Page 92 SHEAR ARM ASSEMBLY 013325 Assy. 013310 23 23 FIGURE 34 PAGE 91...
Page 93: Punch Assembly
9.2 PUNCH ASSEMBLY 9.2A PUNCH STRAPS, PUNCH RAM AND GUIDE ITEM QTY. PART # DESCRIPTION see 4A STRAP see 4A STRAP 080192 2.505 BRASS WASHER 015131 2.003 BRASS WASHER 4A 1 015132 PUNCH LINK KIT INC. 1, 2, 3, & 4 006172 UPPER PUNCH PIN BUSHING 030625...
Page 94 PUNCH ASSY. EXPLODED VIEW P/N 032074 Kit Includes 5, 6, 7 & 20. P/N 010236 Kit Includes 14, 15, 16, 17, 18, 19, 20, 21 & 22. P/N 015132 Punch Link Kit Includes 1, 2, 3 & 4. 221312 M12x30 221312 221312 M12x30...
Page 95: 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 230107 M8 X 16 FSHCS 080182 M5 ALLEN WRENCH 026713 PUNCH TABLE WITH SCALE 9" PUNCH GAUGING TABLE W/SC 026712 INCLUDES: 1, 2, 4, 5, 6, &...
Page 96 DIE HOLDER & PUNCH GAUGING TABLE 230107 230107 230107 201640 M16x90 201640 M16x90 FIGURE 36 PAGE 95...
Page 97: 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 see 6A 1/8 STEEL POP RIVET see 6A STRIPPER HINGE see 6A STRIPPER DOOR STRIPPER DOOR ASS'Y 6A* 1 011732 INCLUDES 4, 5, &...
Page 98 STRIPPER ASSEMBLY 230007 230007 007239 007239 FIGURE 37 PAGE 97...
Page 99: Upper Arm Assembly & Punch Cylinder
Punch half holes, punch or shear unknown materials, side load 12076 Ram 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 012077 17341 224205 224205...
Page 100 UPPER ARM ASSEMBLY 013320 Assy. 013300 SEE SECTION 9.2A: PUNCH STRAPS, PUNCH RAM AND GUIDE for information on these punch related parts. FIGURE 38 PAGE 99...
Page 101: Upper Stroke Control Assembly
9.5 UPPER STROKE CONTROL ASSEMBLY PARTS LIST ITEM PART # DESCRIPTION 004086 MICRO SWITCH MOUNT 004087 POINTER REV. A 004521 LEGEND PLATE HOLDER 004526 RUN JOG LEGEND RUN PROBE LEGEND (used only 004520 when equipped with Elec. Backgage) 007712 STROKE COVER PAINTED 011200 KRAUS &...
Page 102 UPPER STROKE CONTROL NOTE: #33 is located in the electrical enclosure in the base. FIGURE 39 PAGE 101...
Page 103: 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) 562113 M.S. LIMIT SWITCH 073450 M4 X 16MM SHCS 013191...
Page 104 SHEAR & NOTCHER STROKE CONTROL FIGURE 40 PAGE 103...
Page 105: 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 106 HOLD DOWN ASSEMBLY FIGURE 41 PAGE 105...
Page 107: Slug Buckets, Fan & E-Stop
213005 M5 LARGE WASHER 133313 #8-32 X 3/16 PHILLIPS PAN M/S D070 EMERGENCY STOP ASS'Y 004214 INCLUDES 11 THRU 15 PAGE 106 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 108 FAN & GUARDS SLUG BUCKETS E-STOP DETAIL 16 15 SLUG BUCKET FAN & GUARDS SLUG BUCKET E-STOP ASS'Y FIGURE 42 PAGE 107...
Page 109: Sheet Metal Parts & Hardware
SLUG CHUTE 013261 DO70/95 CYLINDER SHROUD 013628 REAR SHROUD 013267 DO70/95 NOTCHER GUARD 013151 NOTCHER SLUG CHUTE 013629 FRONT SHROUD PAGE 108 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 110: Sheet Metal Parts
SHEET METAL PARTS 341140 224205 224205 224205 FIGURE 43 PAGE 109...
Page 111: Power Unit
9.9 POWER UNIT DO-95 ITEM QTY. PART # DESCRIPTION FOOT SWITCH ASSEMBLY 562453 INCLUDES ITEM 2 011753 168" FOOT CABLE SALES 562451 MICROSWITCH FOR SSC FOOT PEDAL (not shown) *3A 1 562452 MICROSWITCH FOR LINEMASTER FOOT PEDAL (not shown) DO 70/95 CONTROL BOX ASS'Y 013220 INCL.
Page 112 VALVE DETAIL DO-95 POWER UNIT 013320 Assy. 013300 *SEE BALL 003731 003731 VALVE DETAIL 013405 013407 SEE VALVE DETAIL ABOVE 013325 Assy. 013310 *Ball Valve Detail S/N 1773 & After 34 35 (inside foot switch) FIGURE 44 32 33 PAGE 111...
Page 113: Electrical Unit
9.10 ELECTRICAL UNIT ITEM QTY. PART # DESCRIPTION 011861 TRANSFORMER-250VA 011920 1 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 011969...
Page 114: Control Box Ass'y
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 115: Notcher Assembly
M6 X 12MM SHCS 213007 M6 LARGE WASHER 046018 HANDLE MT/105 NOTCHER BUCKET ASS'Y 013168 INCLUDES 19, 20 & 21 PAGE 114 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 116 NOTCHER ASSEMBLY 230207 230207 230207 230207 221314 M12x35 221314 M12x35 221314 M12x35 FIGURE 46 PAGE 115 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 117: Optional Die Holders
6 X 6 DIE HOLDER 080841 6 X 6 DIE HOLDER RISER 230207 230207 230207 230207 201625 M16x65 201625 M16x65 PAGE 116 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 118 201625 M16x65 OFFSET DIE HOLDER 203630 M16x80 203630 M16x80 203630 M16x80 203630 M16x80 6 x 6 DIE HOLDER FIGURE 47 PAGE 117 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 119: Electrical Schematics
PEDAL (FTS-2) (FTS-1) BLACK BLACK SOLENOID SOLENOID GREY GREY SOLENOID SOLENOID BACKGAUGE 18 WIRE PROBE CABLE (PRB) COMPONENT ENCLOSURE 013220 PAGE 118 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 120 CABLE DETAIL START START NOTCH PUNCH TOOL SHEAR E-STOP START Wire Labels Terminal Strip #'s RUN / JOG RUN / PROBE PAGE 119 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 121 TERMINAL PROBE SWITCH BLOCK SOCKET COMPONENT TERMINAL # GRN/YEL GRN/YEL (XO) NORMAL POSITION BROWN BROWN OPTIONAL EQUIPMENT BLUE BLUE COMPONENT PAGE 120 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 122 TERMINAL PROBE SWITCH BLOCK SOCKET COMPONENT TERMINAL # GRN/YEL GRN/YEL (XO) NORMAL POSITION BROWN BROWN OPTIONAL EQUIPMENT BLUE BLUE COMPONENT PAGE 121 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 123: Hydraulic Schematics
9 = DOUBLE ACTING CYLINDER (2) 10 = MANUAL SHUT-OFF VALVE LINE, PILOT 11 = LINE PRESSURE TEST PORT (2) PAGE 122 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...

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