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You have downloaded a manual for our Model Porta-Fab 45 Ironworker. This manual does not include all of the optional tooling for this machine. If you would like a tooling manual, please download the #20 Tooling Manual. MADE IN THE USA...
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MODEL PORTA-FAB 45 TON IRONWORKER JANUARY 2025 S/N 2900 & UP SCOTCHMAN IND. - 180 E US HWY 14 - PO BOX 850 - PHILIP, SD 57567 Phone: 605-859-2542.
The ability of the operator to control the machine’s direction of movement at any point in the stroke, (i.e. stop, jog or reverse) gives the SCOTCHMAN IRONWORKER a tremendous advantage over mechanical ironworkers. There is no chance of the SCOTCHMAN IRONWORKER being accidentally tripped.
A safety video for this machine is available online at Scotchman.com. You can use the camera on on your smart phone to view it via the QR code below. Scotchmans also has many other helpful and informative videos posted on YouTube related to this machine.
4.0 INSTALLATION AND SET-UP CAUTION: THIS SECTION DISCUSSES INSTALLATION AND SET-UP PROCEDURES. PLEASE READ ALL SECTIONS OF THIS MANUAL THOROUGHLY BEFORE OPERATING THIS MACHINE. 4.1 PHYSICAL DIMENSIONS WITHOUT STAND WITH STAND INCHES INCHES Floor To The Top Of Die Holder 22.04 39.54 1004...
4.2 MACHINE MOVING PROCEDURES CAUTION: BE SURE THAT ANY LIFTING DEVICE HAS ADEQUATE CAPACITY BEFORE ATTEMPTING TO MOVE THIS MACHINE. The weight of this machine is 605 pounds (274.42 kg) without the stand and 635 pounds (288.03 kg) with the stand. FIGURE 3 ON THE FOLLOWING PAGE DEMONSTRATES THE USE OF AN OVERHEAD LIFT OR A FORK LIFT.
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 WITHOUT STAND 012351 Tool...
HZ: 60 4.5 MACHINE START-UP Before starting this machine, take time to thoroughly review the safety video at scotchman.com and the operator’s manual. Scotchmans also has many other helpful & informative videos posted on YouTube related to this machine. We strongly urge you to follow the OSHA directive CFR-1910.147 (effective 09-01-90) regarding lock-out, tag-out procedures.
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 machine's life and prevent costly downtime. 5.1 LUBRICATION IMPORTANT: Before operating the Porta-Fab Ironworker, apply oil to the THREE IN ONE TOOL blades and the punch and die.
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 important items that should be included in a scheduled maintenance program: EVERY 250 HOURS OR THREE MONTHS Check the clearance between the punch barrel (A) and the punch barrel guide (B).
6.0 MACHINE OPERATION 6.1 CONTROLS SEE FIGURE 5 ON THE NEXT PAGE EMERGENCY STOP: This button will stop the machine in the event of an emergency. The machine cannot be restarted until the button has been manually reset but pulling it out. START BUTTON: Pressing this button will start the machine.
Please read carefully and understand the following method. It would also be helpful to refer to the safety video on scotchman.com for a visual reference. Scotchmans also has many other helpful & informative videos posted on YouTube related to this machine. You can scan the QR code below to see our video on how to align a punch and die for this machine.
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ALIGNMENT AND REMOVAL OF PUNCHES AND DIES. REFER TO FIGURE 6 ON THE PRECEDING PAGE. With the punch in the down position and the arm up, turn the machine’s electrical power OFF. Remove the stripper (B) by pressing down on the tab (A) and pulling the stripper toward you. Loosen and remove the bolts (G) holding the die holder (C) and remove the spacer (D) from under the die holder (C) and then the die holder can be lowered off the punch and removed Loosen the set screw holding the die.
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Align the punch to the die so that there is equal clearance on all sides of the punch in the die. Tighten both the die holder bolts (G) firmly. Check to be sure that the punch and die are still in alignment. Realign, if necessary. Replace the stripper (B).
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strap iron, the material will tend to draw up into the stripper. To prevent this, a plate or large washer can be attached to the bottom of the stripper, to reduce the size of the opening. This type of stripper will also allow you to punch in the corners of material. There is an oversize stripper available for oversize punching applications.
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(.032) thousandths of an inch. Under normal punching conditions, a punch will use a corresponding die stamped the same size. A 3/8 inch punch will use a die stamped 3/8 inch. All Scotchman #20K punches and dies are stamped with the size. All dies have a larger hole in the bottom side for slug relief.
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DO NOT PUNCH MATERIAL THICKER THAN THE DIAMETER OF THE PUNCH. This "RULE OF THUMB" can be extended, but the punch supplier or Scotchman should be consulted first; (i.e. do not punch material thicker than 1/4 inch with a 1/4 inch diameter punch).
6.3 THREE IN ONE COMBINATION TOOL The Three In One tool is a component tool designed to shear angle iron, round stock and plate. It installs on the tool table and has a maximum capacity of 3" x 3" x 5/16" inch (76x76x8mm) mild steel angle iron, 3/4"...
THE THREE IN ONE SHEAR MOUNTS ON THE TOOL TABLE AS SHOWN ON PREVIOUS PAGE ► NOTE: REMOVE THE PUNCH AND DIE BEFORE MOUNTING THIS TOOL. The arm must be in the up position. Slide the tool under the arm with the Warning Label and the (2) thumb screws facing the operator's side of the machine.
IN ADDITION TO THESE BASIC STEPS, the operator should be familiar with the following: A. MAINTAIN PROPER BLADE CLEARANCE. Do not work with dull or damaged blades. If the blades are chipped or dull, they should be replaced. The movable blade for the multi tool is designed to fit only one way. Installing the blade backwards will cause damage to the tool.
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Moving Blade must be positioned in the tool as shown below or damage will result!! 12359 12355 201215 201215 (2)Thumb Screws Adjust Down to Material Shear Shear Angle Shear 012351 Tool FIGURE 9 Page 27...
7.0 OPTIONAL TOOLING CAUTION: WHEN USING THE TOOL STATION REMOVE THE PUNCH AND DIE FROM THE PUNCH STATION. AS WITH ALL FUNCTIONS ON THIS MACHINE, SAFETY GLASSES ARE REQUIRED WHEN USING OPTIONAL TOOLS OF ANY TYPE. Each self contained tool has its own stroke and tonnage requirements. This section will cover the installation, operation and maintenance of each tool.
7.1 ROD SHEAR The rod shear is a component tool designed to shear solid sections of round and square stock. It has a maximum capacity of 3/4 inch (19mm) in round or square. 7.1A ROD SHEAR INSTALLATION SEE FIGURE 11 BELOW. The rod shear mounts on the tool table in place of the Three in One shear and is anchored with the bolts provided.
7.2 SIX INCH BRAKE The six inch brake is a component tool designed to bend and form mild steel. The six inch brake mounts in the punch station. 7.2A SIX INCH BRAKE INSTALLATION SEE FIGURE 12 ON THE FOLLOWING PAGE. Remove the die holder, stripper and punch retaining nut.
7.3 EIGHT AND TWELVE INCH BRAKES The eight and twelve inch brakes are component tools designed to bend and form mild steel. They mount on the tool table in place of the angle shear. The brakes are shipped with standard dies to accommodate material up to 1/4 inch (6mm) thick.
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8" Brake 433003 2-3/8 INCH FROM FRAME MOUNTING BOLTS 12" Brake 433000 1-3/4 INCH FROM FRAME MOUNTING BOLT FIGURE 13 Page 33...
If parts require bends less than 90 degrees, adjust the stroke 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 your local dealer. CAUTION: ALWAYS REMOVE THIS TOOL WHEN IT IS NOT IN USE.
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B R A K E T O N N A G E C H A R T 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 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1-1/8 1-1/4 1-1/2...
7.4 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 tubes and pipe, also. For prices and availability, contact your local dealer or the factory. 7.4A PIPE NOTCHER INSTALLATION SEE FIGURE 15 ON THE FOLLOWING PAGE.
Never remove the M10 set-screw from the upper die. Generally, it should not be necessary to remove the set screw that holds the insert in the top die (Scotchman product). Check the alignment of the unit. After cleaning the unit, always check the alignment of the punch and die.
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UPPER DIE LOWER DIE PROPER ALIGNMENT OF PIPE NOTCHER DIES CORRECT WRONG FIGURE 16 Page 39...
7.5 RECTANGLE NOTCHER The rectangle notcher is a component tool designed to make rectangle and vee notches in angle iron and flat stock. The maximum capacity of this tool is 2 x 1-3/4 inch (51 x 44mm) rectangle notch in 1/4 inch (6mm) material or a 1-1/2 inch (38mm) vee notch.
7.6 PICKET FENCE TOOL The picket fence tool is designed to make picket points on square tubing for ornamental fence applications. The tool has a maximum capacity of 1 inch (25mm), 16 gauge tubing. 7.6A PICKET FENCE TOOL INSTALLATION SEE FIGURE 18 ON THE FOLLOWING PAGE. This tool mounts on the tool table in place of the Three in One tool and is anchored with the same bolts.
7.7 6 x 6 NINETY DEGREE NOTCHER The six inch (152mm) ninety degree notcher is a component tool designed to make square and vee notches in angle iron and flat stock. The maximum capacity of the tool is 3 x 3 x 1/4 inch (76 x 76 x 6mm) or 6 x 6 x 1/8 inch (152 x 152 x 3mm).
7.7B 6 x 6 NINETY DEGREE NOTCHER OPERATION Lubricate the blades before starting and every 10 to 15 cuts, thereafter. Oil the pressure block every two hours of operation. Do not attempt to shear material thicker than 1/4 inch (6mm) and never side load the notcher.
7.8 SQUARE TUBE SHEAR The square tube shear is designed to shear square tubing from 1/4" to 1". 16 gauge is the maximum material thickness. 7.8A SQUARE TUBE SHEAR INSTALLATION SEE FIGURE 20 ON THE FOLLOWING PAGE. The tool mounts on the tool table in place of the Three-In-One Tool and is anchored with the same bolts (C).
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1307 203212 1309 1350 Assy. 1307 203212 1309 1350 Assy. NOTE: If tool ever jams or gets stuck - REMOVE THE TOOL FROM THE MACHINE BEFORE ATTEMPTING TO FREE IT. FIGURE 20 Page 47...
7.10 MULTI-SHEAR TOOL The Multi-Shear Tool is designed to shear standard Unistrut profiles, as well as many other specialty profiles. 7.10A MULTI-SHEAR TOOL INSTALLATION SEE FIGURE 21 ON THE FOLLOWING PAGE. If the punch and die are mounted on the machine, remove them. Run the Punch Beam above the too table, up to its highest setting.
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NOTE: See-Thru Guard is for Clarity 201420 M12x50 201420 M12x50 243101 243101 GUARD 221210 M10 x 25 221210 M10 x 25 Tool Table FIGURE 21 Page 49...
7.11 WELD COUPON BENDER TOOL The Weld Coupon Bender Tool is designed to bend welded test coupons into "U" and "V" shapes for the purpose of testing soundness and ductility of welds. The maximum size of a test clip is 7" long x 2" wide x 3/8"...
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201417 M12x45 "V" 201417 M12x45 "U" Setting The Stroke Set stroke with bottom of Ram V-Die Stroke U-Die Stroke FIGURE 22 Page 51...
7.12 OPEN END BRAKE The Open End Brake is a tool designed to bend notched angle iron into a "picture frame" corner. It can bend flat metal as well. Please scan the QR Code on the following page with the camera on your phone to see this tool in use.
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The "OPEN" end of brake is facing the operator. 201417 M12x45 001362 201417 M12x45 The "OPEN" end of brake is facing the hydraulic cylinder. 1365 Scan QR Code below to see a video of this tool. FIGURE 23 Page 53...
8.0 TROUBLE SHOOTING GUIDE 8.1 ELECTRICAL - MOTOR CAUTION: ALL ELECTRICAL WORK PERFORMED ON THIS MACHINE SHOULD BE PERFORMED BY A QUALIFIED ELECTRICIAN. A. MOTOR WILL NOT RUN: Check to be sure that the power service supplying the machine is turned on and properly rated for the load.
Check the voltage at the motor contact coil. The START/STOP switch is comprised of a small relay to create a latching circuit that supplies constant power to the starter contactor after a single button press. Press the START button, then check the voltage between X2 on the terminal strip and A2 terminal of the motor contactor (where red wires attach).
MOTOR RUNS, BUT THE MACHINE WILL NOT MOVE IN ONE OR BOTH DIRECTIONS WHEN DEPRESSING THE FOOT PEDAL: ► NOTE: MAKE SURE THE CORD FROM THE FOOT PEDAL IS IN GOOD CONDITION. IF IT HAS BEEN PINCHED OR CUT - REPLACE IT!! Check the motor rotation.
Using an ohm meter, check the continuity between the black and red wire when the LEFT pedal is depressed. If the reading shows open, the foot pedal or foot pedal cord is defective and must be replaced. 8.4 LIMIT SWITCH INSPECTIONS The limit switch is a sealed unit and can not be taken apart.
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FRONT COVER MUST BE REMOVED TO GAIN ACCESS TO CIRCUIT BREAKER AND/OR TEST PORT CIRCUIT BREAKER FIGURE 24 TEST PORT REMOVE DUST CAP AND INSTALL GAUGE P/N 001144 PRESSURE GAUGE MANUAL VALVE CONTROL KNOB FIGURE 25 Page 58...
GAUGE WITH A MINIMUM OF THREE THOUSAND (3,000) P.S.I. (207 BAR) IS REQUIRED. A PRESSURE GAUGE WITH TEST PORT ADAPTOR IS AVAILABLE FROM SCOTCHMAN INDUSTRIES AS P/N 001144 (See Fig. 25). THE MOST COMMON HYDRAULIC PROBLEMS ARE: A. LOW LEVEL OF HYDRAULIC FLUID IN THE RESERVOIR: The reservoir holds 2 U.S.
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C. CYLINDER LEAKING INTERNALLY: If the pressure setting does not respond to changes to the relief adjustment screw, check the cylinder for internal leaks. NOTE: A -06 JIC plug and a -06 JIC cap will be needed for this procedure. Move the beam to the bottom of its stroke, then raise slightly.
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FOR CLARITY, BELOW REMOVE SHOWN WITH REAR COVER LOCKING REMOVED - CAN BE ACCESSED FROM FRONT OF MACHINE ADJUST SCREW AS NECESSARY: DO NOT EXCEED 2,500 P.S.I.!! TAKE CARE TO NOT LOSE COPPER SEAL PRESSURE RELIEF ADJUSTMENT FIGURE 26 VIEWED PLACE BLOCK FROM BACK UNDER BEAM...
8.7 CYLINDER SEAL REPLACEMENT Use the following steps to replace the seals in the hydraulic cylinder: SEE FIGURE 28 ON THE FOLLOWING PAGE. With the arm up, turn the machine’s power OFF. Block the arm up on the tool table (A). Remove the hoses from the cylinder and allow the fluid to drain.
9.0 MACHINE PARTS LISTS The Following Sections Contain The Ironworker And Optional Tooling Parts Lists And Drawings. For Your Own Convenience, Always Give Your Complete Serial Number When Ordering Parts. 9.1 PUNCH ASSEMBLY DESCRIPTION ITEM PART # 012305 Punch Beam (Includes B, F, G, H, I, & J) 012304 Bushing 012331...
9.2 STAND ASSEMBLY ITEM PART # DESCRIPTION 012343 Leg Ass'y 45 Stand 012349 Shelf 012440 PF Brace Base 201210 M10 X 20MM HHCS 215012 M10 Greer Nut 201410 M12 X 25MM HHCS 215014 M12 Greer Nut Complete Stand Assy. 012342 FULLY ASSEMBLED STAND Page 66...
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HYD. HOSE ROUTING HOSE 16 Top Port of Cylinder to C2 (outside) Port on Power Unit HOSE 8 Bottom Port Cylinder to C1 (inside) Port on Power Unit 12 17 NOTE: Tighten Nut to no more than 40 in-lb (4.5 N •...
9.6 CONTROL BOX PARTS LIST ITEM PART # DESCRIPTION 000202 1/2" Cord Grip 000205 1/2" Large Cord Grip 003122 Danger Voltage Sticker 006540 DIN Connector (A) Black 006545 DIN Connector (A) Grey 011780 Screwless End Stop 011781 Ground Terminal Block 011782 Terminal Block 011783...
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COMPONENTS MOUNTED IN CONTROL BOX FIGURE 34 Page 75...
PN 012460 RATING TABLE 10.0 WIRING DIAGRAM LINE VOLTAGE (1PH) MAX. HP MOTOR FLA INCOMING SUPPLY PROVIDE MAXIMUM BLK - T1, T3, T5 WHT - T2, T4, T8 UPSTREAM PROTECTION PER GRN - GND N.E.C. CODE 430-52 AND TABLE 430-152. 1MOT SEE MOTOR TAG FOR DETAILS...
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