Shear Machine Operational Manual

operational Manual

BST Factory Warning!

When using the machine tool, basic safety precautions should always be followed to reduce the risk

of fire, electric shock and personal injury.

Read all instructions before attempting to operate this machine and keep these instructions.

1. Operator must know about the construction and feature of the machine and must carefully read

the relative prescribe and request in Operation Manual before operating. If more than one

person operates the machine, a director must take charge of the producing!

2. Don’t run the machine when your hands or any other parts of your body enter the machine.

3. Prohibited the hands enter between the upper and lower dies, in order to avoid any accident!

4. Separately add lubrication according to the lubricating diagram.

5. Keep the machine and around ground clean and the lines isolating! Especially keep the

worktable area clear, avoid something enter between the blades making accident!

6. Inspect all parts of the machine usually; make sure there is no hidden danger!

7. The max working pressure is 23 MPa: it has been adjusted before outing the factory, the user

can adjust it according to the actual situation.

8. Opening the electric cabinet by not authorized service personnel is prohibited! Please make sure

the Power switch is on the OFF position before opening the door of electric cabinet!

BST Factory Introduction!

We suggest all users and operators to read this operation manual carefully before using this

machine.

This manual is designed for specialized and qualified personnel. It comes completes with diagrams

and all the documentation necessary to lift, move and place the machine and instructions for the

safe use and maintenance of this machine. All information contain in here are accurate at the time

of print. However, our company reserves the rights to modify and improve specifications without

prior notice.

This machine should be properly installed as instructed; regular inspection and faithful maintenance

service should be carried out so that good performance can be maintained.

Any incorrect and irresponsible usages may cause irreparable damage to the machine and nullify

the safety protection for the operator.

We do not assume any responsibility for improper services or modifications or connections made

by unauthorized personnel.

We suggest that all user to read and understand this manual before using this machine.

 Operational Manual

2

Catalogue

1. Standard features

2. Construction of the machine

3. Installation of the machine

4. Standard control equipment

5. Adjustment and Operation

6. Safety technology

7. Maintenance

8. Lubrication

9. All bearing detail sheet

10. Gear detail sheet

11. The easy spoiled parts sheet of customer self make

12. Trouble shooting

13. Drawings

14. Packing list

15. Certificate of Conformity

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1. Standard features

The machine is provided for cutting steel plate, cutting plate strength according to 450N/mm 2 . If

cut other material strength plate, correcting the plate thickness.

The machine is steel plate welded frame and sliding block. The frame and sliding block is vibration

to eliminate stress of welded and mechanic making, keep the accuracy of the machine. Shearing by

sliding block is drive by hydraulic, nitrogen gas stroke cylinder, can protect the machine from

excess gas load; the machine work is reliability, small volume, light weight, good rigidity.

Adjust the blade gap conveniently and rapidly. The machine is installed front and back gauge rod.

The back gauge rod is mechanic transfer, turn times is numerically displayed, and hand can be tiny

adjustment, conveniently. The front gauge rod is ruler count, gauge rod positioning. The stroke of

up-cut frame can be correct to any data, add up the efficiency of cutting slit plate. Installed safety

fence, ensure the operation safety.

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2. Construction of the machine

1. Machine frame： Steel-welded plate, high rigidity. Two cylinders fix on left and right vertical

pole. Installed vice cut-board on worktable conveniently adjust low-cut board. Keep the gap

between up-cut and low-cut coincidence. Install feed ball on worktable, operation convenient and

fast.

2. Cutting frame: welded plate, high rigidity, is support at eccentric socket (9), by left and right

cylinders and stroke cylinder drive, finish cutting by pendulum repeat. (See picture2)

The vertical surface of up-cut support is curve, keep the gap between up-cut and low-cut

coincidence.

3. Pressure device: it is consisted of some pressure feed cylinders installed at support board in

front of machine frame. Oil flow in pressure feed cylinder, pressure head press down against the

pull force of stress spring (18), press plate tightly. Finish cutting, the cylinders are reset by the

pull force of stress spring. The pressure is bigger as thicker as the thickness of plate.

4. Front gauge and back gauge:

Front gauge: fixed on worktable, valve display on ruler, adjust mobile bar to necessity valve.

When cut thin steel plate, cut it conveniently on front gauge.

Back gauge (see picture5) fixed on up-cut board, pendulum up and down as up-cut board. Adjust

back gauge by 0.55Kw motor, reduce through gear, and drive by control rod. Brake down the

button “+” (or”_”), can adjust gauge to front or back. When mechanic adjustment cannot get the

necessity valve, turn hand-wheel (50) to demand valve, the adjustment of back gauge is

convenient and reliability.

The standard range of back gauge is 20-750mm. When the length of cutting plate is longer than

the max distance of back gauge, remove the back gauge (43) to the least place, lift up the board by

the incline surface of support frame (47), and can cut any length of plate.

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3. Installation of the machine

3.1 Packing / Shipment of machine

All machines leaving the factory are packed with squaring arm and foot panel tied to the hand

guard. A bag of working hand tools and operation manual is lock inside the electrical panel.

All exposed surfaces on machine are coated with rust guard, easily removable by kerosene or

solvent.

3.2 Lifting the machine

Use only approved and safe wire rope to lift this machine from two lifting point which is

located at both side frame of the machine.

3.3 Foundation

All our shears are designed to be free standard. However, a good quality reinforced concrete

floor with a minimum thickness of 150mm should be used.

3.4 Installation

This machine must be properly leveled to give a good cut. Leveling is done by putting a good

leveling gauge at the plate hold down area. Always pre-prepare five pieces of base plate

(dimension 150 x 150 x 9mm, minimum) below machine footing to prevent leveling screw

from digging into the concrete floor.

On completion of leveling, a cement grout mixture must be packed under and around the feet

to maintain correct leveled position.

3.5 Electrical Installation

Be sure that the local power supply is suitable for this machine before any electrical power up.

Connect power cable to the bottom left of electrical panel to R.S.T.E. terminal.

Some machine may require N (Neutral) wire.

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4. Standard control equipment

4.1 Start button : To start the main motor running and Control circuit.

4.2 Stop button : To stop the main motor running and Control circuit.

4.3 Auto/Man mode

selector switch

: Select the working mode

In Auto mode

-One step on the foot switch, the cutting frame will cut

continues.

-Can command cut by foot pedal only.

In Manuel mode

-One step the foot switch, the cutting frame will only do

once cutting.

-Adjust the cutting stroke by return the rotating button

on the panel.

4.4 Foot pedal : Push to command cutting blade down and release to

have top blade carrier rise in AUTO mode.

4.5 Illumination Light : Working light to shine at cutting blade area, operating at

single phase power supply at 220V, 50Hz..

 Operational Manual

5. Adjustment and Operation

5.1 Adjust the gap between blades

The blade gap is very important on the quality of cutting and the life of blades, please according

to the gap adjusting table below.

When adjusting the gap (see picture 2), need to loose the tight screw (4), then turn the

hand-wheel (3) to the requested value after calculated by the thickness of plate, then tight (4).

There is a ball valve (on right side of machine, out side of cylinder). It is used for value the

coincidence gap between up and low blade.

Detail ways: at manual mode, when cutting frame go to down-dead spot, close the oil circuit

rapidly, the cutting frame will stay at down-dead spot, then turn on the ball valve a little by a little,

8

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the cutting frame will go up step by step on the all stroke. And then can measure the coincidence

value of gap between blades.

5.2 Operation

5.2.1 Preparation of machine

(1) Remove the squaring arm and foot pedal from hand guard area. Set up the squaring arm on

left hand side (Close to electrical panel) by bolting down to the machine table and two side holes.

(2) Clear the dirty oil on components, pay attention that the ball valve should be at open position.

(3) Lubricate all the necessary spots.

(4) Supply HL46 hydraulic oil in oil tank (about 200L each machine).

(5) Connect the earth line, switch on, and check the working action of all electrics.

5.2.2 Starting the machine

Push ‘START’ button and release.

Motor “on” indicator light turns on.

Put mode selector from MAN to AUTO position.

Step the foot switch, the cutting frame will go down to cut.

If not, that means motor is running in wrong direction. Switch off power supply. Reverse starts

motor again, any of the two phase wires.

The top blade carrier will rise and stop when it hit limit switch.

5.2.3 Motorized Back gauge

The motorized back gauge readout is accurately set in factory and it should be corresponds to the

distance measure from back gauge bar to the cutting edge.

Push ‘+’ button to bring back gauge bar to the rear, reading is increase and stops when hitting

maximum travel limit switch L/S 3.

Push ‘-’button to bring back gauge bar to the front, reading is decrease and stops when hitting

minimum travel limit switch L/S 4.

The parallelism of back gauge is set in factory; however it can be calibrated when necessary.

Bring back gauge bar to the rear for removing anti-rust coating prior to cutting.

Note: (1) The pressure table should be on during cutting, and check the pressure, if it shows wrong,

may adjust the overflow valve.

(2) During the operation, if there is deviant noise or the oil tank over temperature, should stop the

machine immediately, and the temperature of the oil tank should not exceed 60℃

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6. Safety technology

(1) Workman must know the construction and feature. When many workmen operate on same

time, one expert must be duty on the machine.

(2) Strictly forbidden put hand between up and down blades.

(3) Forbidden putting other things and tools on worktable.

(4) Inspection sharpness of blade if dull of blade, mill or replace blade.

(5) Usually inspection all section of the machine, keep the machine and ground clean, keep

good isolating.

(6) Usually inspect and clean net filter, keep common flow. If filter jammed, will reduce the oil

flow, and make the pump empty, then will short the life of pump.

(7) Nitrogen bomb forbidden supply oxygen, pressure air or other easy-burn gas, supply

nitrogen gas slowly.

(8) Supply nitrogen gas by tools, the work pressure is 8 MPa.

(9) Loose out the nitrogen gas before disassemble nitrogen bomb.

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7. Maintenance

7.1 Lubrication and Hydraulic Oil

This machine uses hydraulic oil grade 68, refill or replace only with same grade of oil as

follow:

FIAT-HTF 68, ENERGOL HLP 68, ESSO NUTO H68, MOBIL-DTE OIL 26,

SHELL-TELLUS S68, TOTAL-AZOLLA 68

7.2 Lubrication program

- Oil change after initial 1500 working hours. All the oil must be chained from oil tank to

eliminate all impurities which could have enter during assembly.

- Oil filter should be changed. Use the same grade of oil filter.

- Subsequently, should have oil change every 5000 working hours.

- Grease all grease nipple points every two weeks. These are found on the back gauge

assembly.

7.3 Changing of Shear Blade

Both top and bottom shear blades are identical and inter changeable. Use the ball vale to make

the cutting frame go down at the lower dead spot,

The OFF the machine. Remove bottom blade first then the top blade.

Release all small set screw on top blade carrier.

Clean blades and blade housing / sitting.

Fix back top blade first then bottom blade.

Tighten the small sets screw on top blade carrier if necessary to close in blade clearance.

Remember to check for minimum clearance, adjust small set screw to close up blades when

require.

CAUTION: Always engages a qualified and experiences personnel to do this job, otherwise

damage to shear blades/machine or personnel injuries may result.

7.4 Grinding of Shear Blade

The Shear blade is rectangular in shape and the upper blade has two cutting edges, the lower

blade has four cutting edges.

Only after all two edges or four edges are used up then you require regrinding of blade.

REMEMBER: Grind only the thickness and not the height of blade.

May require to close in top blade carrier by screw in tensioning bolt as a result of the loss of Grind-off

thickness of the shear blades. (next to quick blade clearance lever).

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8. Lubrication

1. Major lubrication spot is division lubrication by oil gun. All lubrication spots are below:

No. name flow

Internal

time(h)

Kind and type

brand

1

Up and down each spot on left and right return

cylinders

small

16

2

Left and right each spot on swing spot of cutting

frame

small

24

3

Left and right each spot on gap axial socket small

48

4

Each spot on right and left piston rod middle

8

Ca-lubrication Oil

ZG-3

GB491-65

Mechanical oil

N46GB443-84B

5

Each spot on bars of left and right cylinders middle

8

4 # carbon-lithium

Q/SY1000-65

Note: 1. Ca-Lubrication 50%, mechanical oil 50%, mixing for use.

2. Carbon-lithium lubrication oil must mix with 30% mechanic oil.

3. Exchange oil of tank one times per half year.

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9. All bearing detail sheet

No

Bearing

name

Bearing name

scale Accuracy

class

quantity Install place

7 3518

Double series gravity

ball bearing

d=90 D=160

H=40

2 Up-cut board

24 80202

Cap single series

gravity ball bearing

a=15 D=35

H=11

2 Back gauge

27 80205

Cap single series

gravity ball bearing

a=25 D=52

H=15

4 Back gauge

28 8305

Single push ball

bearing

a=25 D=52

H=18

2 Back gauge

36 180502

Dense ring single series

gravity ball bearing

a=15 D=35

H=14

2 Back gauge

40 180502

Dense ring single series

gravity ball bearing

a=15 D=35

H=14

2 Back gauge

31 941/12

Only punch out ring

ball-nickel bearing

a=12 D=17

B=12

2 Back gauge

 Operational Manual

10. Gear detail sheet

No. Name B a m Z da fa H

Accuracy

Class

Material Quantity

Heat

treatment

5

Small

gear

20 20° 2 25 50 1 4.5

9FHGB1

0095

45 2

6

Fan

gear

18 20° 2

25

0

1 4.5

9FHGB1

0095

45 2

25 Gear 18 20° 2 17 34 1 4.5

8GJGB10

095

45 1

26 Gear 16 20° 2 68 136 1 4.5

8GJGB10

095

45 1

37

Chain

gear

20° 14 57.1 1 45 2

HRC38-

43

38

Bevel

gear

10 20° 1 20 20 1 9-8-8DC 45 1

39

Bevel

gear

10 20° 1 50 50 1 9-8-8DC 45 1

11. The easy spoiled parts sheet of customer self make

No.

name Scale or symbol Belong to parts quantity note

13 Clean rim D95 Stroke cylinder 2 amilan

16 Clean rim D65 Stroke cylinder 2 amilan

O ring seal GB1235-76 Pressure cylinder 10/12/15 35*3.5

O ring seal GB1235-76 cylinder 1 110*5.7

O ring seal GB1235-76 cylinder 1 100*5.7

14

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12. Trouble shooting

- 12.1 Machine Cannot Start

- Check incoming power supply.

- Check that Emergency Stop is release.

- Check transformer output.

- 12.2 Machine Cannot Cut

- Check that limit switch is engage.

- Check that motor is rotation in a correct rotation.

- Check that foot paddle cable is not broken.

- Check that micro-switch inside foot paddle is working.

- 12.3 Ram Chattering on Down Stroke

- Counter balance setting pressure is a little too high

- Just release the set screw a little to lower the setting

- 12.4 Machine Operates By Its Self

- Be sure that the Micro-switch inside foot paddle is not damaged.

- Foot paddle cable may be shorted to each other.

-

The fault and resolve of hydraulic system

Fault Cause Resolve

Oil circuit make

pressure up-cut frame

no action

The plug of magnetic exchange valve is

badly connection. The valve core is jammed

by waste or becoming rude. All valve core

mouth of coincidence valve cannot density.

All throttle valve hole of coincidence valve

cannot flow.

Inspection the plug.

Dismantle and

clean.

Up-cut frame stroke

slow or cannot get at

up-dead spot the action

duty between up-cut

frame and pressure

plate cylinder.

The pressure of nitrogen gas in bomb is

not enough.

Supply nitrogen gas

for pressure

becoming bigger.