Scotchman DO-150/240-24M Manual

Ironworker

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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

TOOL

MM.

IN.

213012

201240

RUN

JOG

080061

213012

201240

MM.

IN.

004085

JOG

3200

033707

80191

80211

80197

037110

201620

113017

037105

80424 F

33018

33176

13220 - 3ph 13225 - 1ph

25525 Raw

010117

LUBRICATE

BEFORE

OPERATING

19103

0481

80156 Sales

WARNING

Assy.

080174

243101

TO PREVENT SERIOUS

START

SHEAR

NOTCH

BODILY INJURY

DO NOT PLACE FINGERS

BEYOND THIS GUARD

003140

DUAL OPERATOR

150/240 - 24M

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

2.25" - 57MM

6"X6"X1/2"

150X150X12MM

#037009

11,04

STOP

MODEL

H.P.

VOLT

SERIAL

FLA

PSI

SCOTCHMAN INDUSTRIES, INC.

PHILIP, SOUTH DAKOTA, U.S.A.

BLADE LENGTH

PH. 605-859-2542

MADE IN U.S.A.

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.)

NEVER-

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

37107 - DO-135 & 150

080430

080435 Assy.

LUBRICATE

BEFORE

OPERATING

19103

0481

080174

Assy.

243101

224205

230 Volts

19121

OFF

11856

EATON

DANGER

ELECTRICAL HAZARD

Turn off power

and lock out

before servicing.

3122

1213

224205

WHEN MITERING

DO NOT EXCEED

3 X 3 X 1/4

003195

0502

17341

13179

201110

M6x12

013180

M6x12

201110

M6x12

201110

013180

201110

M6x12

201110

M6x12

201110

M6x12

201110

230210

224205

13190

LUBRICATE

BEFORE

OPERATING

19103

0481

80155

Assy.

080174

243101

033047

33149

Table of Contents

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Summary of Contents for Scotchman DO-150/240-24M

Page 1 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 2 MODEL DO-150/240-24M IRONWORKER SERIAL # 1218 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 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 4: Table Of Contents
TABLE OF CONTENTS SECTION DESCRIPTION PAGE # INTRODUCTION SAFETY PRECAUTIONS Warranty MACHINE DECALS INSTALLATION AND SET UP Physical Dimensions Machine Moving Procedures Physical Inspection Electrical Requirements 4.4A Control Panel Functions Machine Start Up Machine Stroke Inspection And Adjustment 4.6A Punch & Tool Station 4.6B Notch and Shear Station MAINTENANCE...
Page 5 SECTION DESCRIPTION PAGE # 6 x 6 90° V - Notcher 7.3A 6 x 6 90° V - Notcher Installation 7.3B 6 x 6 90° V - Notcher Operation 7.3C Blade Replacement 12 & 24 Inch Brakes 7.4A Brake Installation 7.4B Brake Operation Open End Brake...
Page 6 SECTION DESCRIPTION PAGE # 7.13 Weld Coupon Bender Tool 7.13A Weld Coupon Bender Tool Installation 7.13B Weld Coupon Bender Tool Operation 7.14 Multi-Shear Tool 7.14A Multi-Shear Tool Installation 7.14B Multi-Shear Tool Operation TROUBLE SHOOTING GUIDE Electrical Trouble Shooting: Punch/Tool Station 8.1A Electrical Trouble Shooting: Shear/Notcher Station 8.1B...
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 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 80191 80211 80211 80197 80197 37107 - DO-135 &...
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 80191 80211 80197 37107 - DO-135 &...
Page 13: Machine Moving Procedures
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 14 Punch half holes, punch or shear unknown materials, side load press brakes. SAFETY GLASSES REQUIRED WHEN OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. DO NOT REMOVE THIS SIGN FROM THIS MACHINE 1-800-843-8844 REV. 0310 80191...
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-H5...
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 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 22 START START PUNCH TOOL SHEAR 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 DO NOT REMOVE THIS SIGN FROM THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 80191 80211 MAIN PIN...
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 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
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 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...
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 DO NOT REMOVE THIS SIGN FROM THIS MACHINE OPERATING OR OBSERVING THIS MACHINE REV. 0310 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 16095 80831 16174 201625 113017...
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 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 REV. 0310 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 80191 80211 80197 17341 224205...
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 OPERATING OR OBSERVING THIS MACHINE 003100 FOR MORE INFORMATION CONTACT SCOTCHMAN INDUSTRIES INC. 1-800-843-8844 REV. 0310 12076 Ram 012077 16096...
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 (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 OPERATING OR OBSERVING THIS MACHINE DO NOT REMOVE THIS SIGN FROM THIS MACHINE DO NOT REMOVE THIS SIGN FROM 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.
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" 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
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 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...
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 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...
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
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 87 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 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 DO-150 SEAL KITS PUNCH CYL. 034305 - DO150 CYLINDER SEAL KIT SHEAR CYL. 080375 - MULTI 6" CYL SEAL KIT CLEVIS FIGURE 33 PAGE 89...
Page 91: 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 214017...
Page 92 SHEAR ARM ASSEMBLY FIGURE 34 PAGE 91...
Page 93: A Drive Beam Ass'y & Cylinder
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 MACHINE 80197 37107 - DO-135 &...
Page 94 DRIVE BEAM ASSEMBLY FIGURE 35 PAGE 93...
Page 95: Punch Assembly
9.2 PUNCH ASSEMBLY 9.2A PUNCH STRAPS, PUNCH RAM AND GUIDE ITEM QTY. PART # DESCRIPTION see 3A STRAP see 3A 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 96 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 97: 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 PUNCH TABLE ONLY - SQUARE MOUNT 037018 PUNCH TABLE ONLY - ROUND MOUNT 033050 PUNCH TABLE ASSY.
Page 98 Old Style DIE HOLDER Punch Table DO-135 & DO-150 ONLY Round Mount 230110 230110 230110 201640 M16x90 M16x90 201640 230107 230107 230107 FIGURE 37 PAGE 97...
Page 99: 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 100 STRIPPER ASSEMBLY 230007 230007 007239 007239 FIGURE 38 PAGE 99...
Page 101: Upper Arm Assembly & Punch 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 102: Upper Arm Assembly
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 101...
Page 103: Upper Stroke Control Assembly
9.5 UPPER STROKE CONTROL ASSEMBLY PARTS LIST PARTS LIST ITEM PART # DESCRIPTION ITEM PART # DESCRIPTION 004086 MICRO SWITCH MOUNT 073450 M4 X 16MM DIN912 SHCS 004087 POINTER REV. A 077907 SHROUD EDGE 004521 LEGEND PLATE HOLDER 080061 STROKE ADJUSTMENT HANDLE 004526 RUN JOG LEGEND 145001...
Page 104 UPPER STROKE CONTROL NOTE: #33 is located in the electrical enclosure in the base. FIGURE 40 PAGE 103...
Page 105: 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 106 SHEAR & NOTCHER STROKE CONTROL FIGURE 41 PAGE 105...
Page 107: 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 108 HOLD DOWN ASSEMBLY FIGURE 42 PAGE 107...
Page 109: 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 110 FAN & GUARDS SLUG BUCKETS E-STOP DETAIL 15 14 PUNCH SLUG BUCKET (2) FANS & GUARDS E-STOP ASS'Y PUNCH SLUG BUCKET FIGURE 43 PAGE 109...
Page 111: Sheet Metal Parts & Hardware
9.8 SHEET METAL PARTS & HARDWARE DO-150 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...
Page 112: Sheet Metal Parts
SHEET METAL PARTS 341140 224205 224205 FIGURE 44 PAGE 111...
Page 113: Power Unit
9.9 POWER UNIT DO-150 DO150 CYLINDER SEAL KIT Item Description Part Number 034305 (for the 034310 Punch Cylinder) DO120/135/150 RESERVOIR SCH. 40 033403 013500 1PH MOTOR 10HP 230V 60HZ S/N 1180 & Prior HAS The Cooling Thru Tubes DO70/95/120/135/150 RESERVOIR 013508 ASS'Y MOTOR 10HP 208/230V 033500...
Page 114 Valve Detail Inspect foot pedal to determine if it's a LINEMASTER or SSC before ordering parts for it. FIGURE 45 PAGE 113 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 115: 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 116: 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 117: 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 116...
Page 118 NOTCHER ASSEMBLY 230207 230207 230207 230207 221314 M12x35 221314 M12x35 221314 M12x35 221314 M12x35 FIGURE 47 PAGE 117...
Page 119: 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 120 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 119...
Page 121: 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 122 CABLE DETAIL START START NOTCH PUNCH TOOL SHEAR E-STOP START Wire Labels Terminal Strip #'s RUN / JOG RUN / PROBE PAGE 121 SCOTCHMAN INDS. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Call: 1-605-859-2542...
Page 123 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 124 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 MOTOR FLA PROTECTION PER N.E.C. CODE 430-52 AND TABLE OVERLOAD ZB65-57 430-152.
Page 125: Hydraulic Schematics
11.0 HYDRAULIC SCHEMATIC DO-150 SHEAR CYL PUNCH CYL SOL 1 SOL 2 SOL 3 SOL 4 3500 PSI 3500 PSI 241 BAR 241 BAR 9 GPM 9 GPM (34 LPM) (34 LPM) 1 = TANDEM GEAR PUMP 2 = 10 H.P. AC MOTOR 3 = PRESSURE RELIEF (2) 4 = DO5 4-WAY SOLENOID VALVE (2) 5 = RETURN FILTER...

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