,eAFlv, ,€,1 ' {'* s-GtEKA -;,

'-'#5iIl*- r GEI(A laa-M '"3ffi-g READ THIS AND THE MANUAL BEFORE USING

HOW THE HOLD DOWN SYSTEM PAY NXTIL{ CAIIE HOLD-DOWNS USE EXTREME PIIDSSUIIE

how each This machine is equipped with hydraulic holddowns for the punclr, plate, or angle sectiom. Following is system works and how to a{u$ or take care of any malfturctions that may occur.

Punch Section

plate down The punch section contains 2 hydraulic holddowns to hold the plate in place md to h.old th9 switch located on during the rtripp*g action. You can manually move the hold-down up and down by the 3 posilion yourself clearance to tt *v"r.-you witt need to make this adjustment when changing dies to give enough "yii"ao a return shoke of approx ."-*"" the die. The machine is set up using timei ff t in the electrical box to only allow to the top of its l/g,,. When punching a newthickness plate-use the manual up svritch to raise the holddown all the way The hold-downs shoke and then punJh your first hole. After this has been done the shoke will only retum approx U8". pressure is controlled by pressrre switch SPI - It is preset for 30 mpa'

Problem\ that m4v occur

the otler is These two cylinders work on the principle of a series connection. I cylinder is a double sided ram come out of parallel- a single ended. Due to leakage arormd the seals oiboth cylinden you canlnve the cylinders punch Wneir ttris lapens it is im$rtant to remedy this problem as soon as possible. On the left hand side of the the manual switch to cylinder coveiis a guard hetA on with 4 suews ti"ttloO tttir cover is a ball valve. While holding become level ttre Oowl positioo o]"n th" bull valve and then close. You should then see that the holddown cylinders uluil. n*.ni"g with ttre hold-down out of level can and will damage the pistons. It is the responsibility of the operator to check this point.

P

RYAN J. VORSTEG coMEQ INC. PH: 410-933-8500 ex. 170 [email protected] FAX: 410-933-1600 .o-i''9A8* F-

GEKAA1r./ raY-Mh ffi@fr/

Shear Section

To activate the hold-doum firnctions &e switchthat mys manuaUautomatic must tre switched over to automatic. If the switch remains on the manual selection the machine will work like a nonnal GEKA IRONWORKtrR with no hold downs. Use the machine this way when you are using the otlrcr sections with no hold-downs. The shear retpm is controlled by a timer in the electrical box called KT. This timer is set to rehrn the hotrddovms ap'gox l/8"- When a thicker plateis to be sheaed use the up trrow button located near the shear side energency stop to raise the hold-down. After the new plate thickness is sheared the holddown will only retum l/8". The hold-downs will work with either the foot peclal or the electric length gauge. The key switch on the electrical box door must be turn to the guard down position and the yellow notcher guard must be completely down. When a fiurction is activated and the f,olddown builds pressure it will activate the shear action. If you want to stop the shear from descending simply remove your foot iom the pedal and the shem will rekact" When working with the electrical length gauge press the merpencv stoo.

MachineswitkbothAngle and Plate hold dnwt

When the switch is furned to the manual mode of operation the selector valve must be furned to the plate shear section for before for added safety. The plate shear hold down will descend on its own to close the opening ofthe plate shear section to insure that it is not used. The plate shear and mgle shear section are not to be used without the hold doun.

Plale Section

The plate section uses a hydraulic cylinder to move the holddown against the plate to be sheared. NEVER PLACE A PLATE BEYONII IIIE IIOLD-.DOWN.

Ansle SqcFon

The angle section uses a hydraulic motor to actuate a screw that will hold the angle at the fillet' Never cycle the angle shear hotd down without material in place . It is possible to jam the screw in the dorrun position. It should be possible to release the screw by holding the up arrow button on the shear cylinder cover.

I\TEVEB PI"ACE A AIYGLE BEYOND THE X'RONT GIIIDES.

Problems that m4v occ*r

The shear side holddowns work on a pressure switch. When the foot pedal or electric length gauge is triggered the holddowns will hold the material nntil a set pressure is built and then lrigger the shqryg action- Over tlre coirise of the machines life this switch will need to be adjusted. This pressure switch is located in the hydraulic section. It will be nea the secondary manifold. This prressue switch is marked SP. It is peset to 40 mpa

06/08/06 11848-PULL-80X-2137

RYAN J. VORSTEG coMEQ INC. PH: 410-933-8500 ex. 170 [email protected] FAX: 410-933-1600 NOTE. SUBJTCT T[ CHANGT VITHIUT NITICT

GIKA IRINVIRKIR MITIR HIRSIPIVTRS AND AMP DRAV

MODIL H.P 220 VOLTS 440 VILTS MIN STRVICE EEOV MIN. SIRVICT 44OV HYDRACROP 55A-AD 8,5 e0 t0 50 25 HYDRACRIP 55S-SD 8,5 20 l0 50 25 HYDRACRIP BOA-AD 8,5 20 l0 50 25 HYDRACROP BOS-SD t? 32 t7 BO 40 HYDRACRDP IIOA-AD 8,5 ? 0 i0 50 e5 HYDRACRIP IIOS-SD 1? 3a t7 80 40 ca HYDRACROP 155S-SD ct J( ?6 125 6 0 HYDRACRIP 22OS-SD ?? 52 ?6 les 50 MICRICRt]P 4,5 16 I 40 ? 0 MINICRIP 4,5 l6 B 4 0 ( 0 P,P, 50 8,5 ? 0 10 50 a5 PUMA 55 t-500/750 8,5 ? 0 10 50 e5

PUMA 80 E-500/750 1? 3? 17 BO 4 0

PUMA 110 t-500/750 1? 32 17 BO 4 0 PUMA 155 E-500/750 cc 5a ?6 125 60 PUMA aaO t-500/750 (( 5e ?6 r25 60 BENDICRIP 8,5 ? 0 10 50 e5 M]CR[ SINGLI PHAST 5,0 ? J N.A 50 N,A.

SUGGTSTTD SIRVICT IS CALCULATTD BY AMP RATING [N MOTIR TIMES 2.5 TO 3. THIST FIGURTS ARt THTRORITICAL AND TIGURTD AT THE MACHINT.

DAIE HISTnY m txsruAMilo{ r rEVIsl06 HAR0r{SS { VARIAl{I )

MACHINT TLTCTRICAL BIX BITTIM LtFT HAND CIRNTR

PE LI LE L3

0[F o o o

LiG I

LE6 2

LE6 3

IF THIRT ISA HIGH LIG PRTSINT INSURT IT IS PLACTD IN THI TTRMINAL MARKTD 12, PRTMATURT FAILURT Ir THT TRANSFIRMIR IS PISSIBLI,

AN IPTNING IS PRIVIDID AT THT BITTIM [F THt TLICTRICAL BIX FI]R FIt DING [F PIVIR.

4ff"* I I wenw IJ rU. r{t}: A o II,58B KGI gzasr D I rs I 27$l X 75 ?43 36.6r \_ NOTCHIN6 X 43.07 44,49 PUNCHIN6 ANGLE 36,6r 49.4t FLATS BARS + 0&@

3.937 oo o.-.

N @ (:) ni \i o (') s \t rf) HYD.BO S n $ q + q s ru 0/) ru

+ + rf @ ..! 14 54.331 1.969 ('

58.268 8.189

68.?24 GRTASI POINTS

o n

\_ +

UST MID GRADT BTARING GRIASI HARtlrtss { Rtvtsttl,rs v v @@mnE@ [NG" h xrffiirffirutEtnnr|@L HYMffRP STRIES GREASE PtIINIS w v Hl nE E.EtrIrUrUt rm fiur TiFifir uxEt lr *t!f, m L nil. cu s u oac E rit I r(lt clrt$tl t lle ilt llrtsor r IlEtr w'7 v Er& afrttm-K }r rt0wFrlmrltsrwffi[E Ermulr rt8[tmgorLtauoE ru w v ru ING PLAOUE

CLEARANCE PLAOUE SATEIT TLECIRIC LIIIGIH ({'AGE

TEY GLASSES CONTACT

TEY GLASSES -STOP

TAGE PRINT NUMBER

PHASE

ZED USERS ONLY

HANIIISS t".t { RtvtstOts XI ISITRIAL v v G@nmE@ [NG" h SIAI{DARI} SAFITY SIICKERS L w v vAtatAdl ru I SU& IXXX-XXXX.XXXX \Z\P v ru \m v nlu PAPfII 85XII1 [AIt: $l-07-0{ t[mtro u] 6-t(r-1il .G SO21 s82 }lIH'l g .aE] so3/ S05 Dt SBI SO4 D. ..E 506

so8

+

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@

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HYDl65/aaoS-SD HYD80/ll0s-sD YV5 HYD55S-SD YV5 HY D55./80/l l0A-AD YV5 YVA YVE YVI YVI YVA YV2 YVE YVA YV3 YV3 YV3 YV3

YV3 TRANSFIRl'4tR 9 Pt[I zlBv I0 250v l? P{lsT ?08v r0 250v

v? v? t6 V6 v5

U? v? v?

5 posr a8v r0 ?50v

U? v? va iF v5 u5 tJs y5

vt vt u vl vt

}IIIVE VIRE 4E IO CL[]SESI INC[]IIING VOL]A6E

CNC }.IACHINE VILL HAVI I{OR[ THEN ONT IRANSFORI4IR tlf,utxo r[{s Ir{1il16 Llr{s lilc0{r6 Llilts REIlt1VABLE AUX CI]NTACT 9 P(NT llov I0 lglv t? Ptlr {40v T0 .&v \@@@ I,P v? v? &-6 & & 1.6 V6 v6 Ar9 ADJUSIIII{I !

ue v? v? sro 6 P0SI {10V I0 1&)V !

U2 v? v2 919895% 1,6 v5 v5 U5 v5 @a 6a @@@ a@@ UI vl vl vt vl UI Gvo?fi SERIIS LRD SIIIES

IVTRL[AD INFIRMATION tif,0{r6 Llr€5 lM:t1il6 Llrfs Ir{cillNc LIiltS

DATE I HISIInY M EXSPTAMIIII tr RtvtStD6 HARI}ESS { VANIAIT I )(t mrLilA_ lllru @@nntr@ v v uru tNG, h .Irllu 6TKA VII-IATI INf I]RXAIIT}{ w v .[III[I ultall IOI: [flfl {t} xxxxxx st*xxxxx lmatltp: pyax tvrp\Trri I w v ltttIru NTN XA tFtfJlfre PYN tvn9rTrn w v llul[a ]L'ILL: ItA. lxt' xx-xx-xx ltG t-VtllAff-m llro PAtf9: nSlll lhlLt lllg4lut B 5 ?4 35 05 5 25

PUNC H SHiAR

gz gz gz 4v Vh 4v 8Z VA !t ON ON \t g t]N \t t]N \t bI TI EI TI 5 05 nm- ?gtn nqlt- -;sein nm- ;slTl neF- e @ @ ;'gtn

JN 3N 3N IE te ra

1 1 LlV SPITD HIIH SPITD LlV SPtiD HIIH SPTTD

STAGT 1 STAGI ? STAGT 1 STAGT ?

6-B=N0 6-?4=N0 05-35=N[ 5-25=NI 5-19=NC 06-13=NC

IIAIE I HISINY tn TXSPTAMIIil tr REvtstB6 HARsfss I { VARIAI{T lXI ilAtEnr[ .[lm @@nnE@ I I r2-rpt: v v [NG" h I I I lA-'F HYDRACRIP 'S' FOOIPEI}AL VIRIItr I-I-7fr:riF v ult[l IELII€CAI{IOU FMT PEDAL xPE-il7I5645 I I {8-52Rt llll|ru ltAI:69g XXXXI Sl+ XXXXX lnPAf,ItP! eYAx t\tD\ItG v ulru N|+ '*tut tFtrinftR eYN rvrp(rrfi 51-56nC I I ffi ILALL: TI fitr XX-XX-XI llrl TF0nta-FPrt-Yr7rstuq I I i(:m \7\7W v ru LII{II SVIICH LII{II SVIICH

REIURN LIXII SVIICH ruSI BE IRIPPID VEN CTLIilDTR IS FUIY RETI*MD M DAr{A6t T0 HynAU_lc sysrEr{ ts mssln t

o o l{ry8 I,P IO II{CRTASI IRAVTL MVHVARDS }IWE UP IO DTCREASI ffIMI IRAVEL rovE IIUN IO DTCREASE TRAVEL IXM{VARDS I[]VT D[)VI{ Tt] IiIRTASE RETURI{ TRAVEL o @ @

IRAVEL CN1 LIilITIrc CEfi

LIHIIIIG CAI{ TRAVTL CAII

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IRAVEL CAI{ LllilIIN6 CAn

IIqVI UP Tt1 IISREASE IRAVEL DI]VNVARI}S I[]VE I}tlVII IO D€CRTASE IRAVEL IX]VIIVARDS

XOVE IP IO UCRTASI REIURN IRAVTL ilOVE MVN TO II{CREAST RTIURI{ TRAVET

IRAVTL CAII ffINil LIIflI SVITCH IIUST BT IRIPPTD VITI{ CYLII{If,R IS FULLY RTTURI€D t1R DAIIAGT Tt] HYIMI|-IC SYSIEI{ IS POSSIH-E

LIIIITIttr CNI

BO-TS

RETM'{ LIHIT SVIICH

LIIIII SVIICH

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s03 AND Soe RIVTRSED t]N --A HYD 55 STRIES

o o Y- -[ N.A. HYD55 - (a @ oo o Detoit A o I

A A o

o o@ Detoil B I I It t1 @ o o

HY0 55-80

o o HYD 110-165 HYD 110-165 o

qA Section A-A

DAIE HISIBY m txsPtAl{Altu tr ntvlstt]G HARsfss I r- VARIAI{I ={ .lm G@nnE@ v =V ru [N@" h f TT:'T HYINACRI]P SERIES PU{CHIN6 PARIS RETEruICE I lro-r.f w =V !sE I I rA-srer T T sz:atf w=9 P: I'A Itt5nf tR RYAI -r-vfPslFri I I 51-56RC riwv mtr 0llllru St-A F, l:l = V rllrnt l-8

o {

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f

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l-48t l-48B l-48C l-48A 1-48D 1-7

nnn HANNESS REvtSt0{s v =v @@nnE@ [N@" h HYMACRI]P STRIES PI'{HIIE CYLINIf,R PARI LISI Er.lmrln r$tlI rtr! n nr|@ n =v I[ n|6 E .Itt$ruD r | (Il cDc|l vAtatAl{I FIlrt ruq.00riAng(.rr $[w E Hr I |Clt (trltu r na m!. lErftr o ntr6 ru I )U} IIIIIIII"IIM tne tTte: 9YN r\,Ipttrr, =y EE X HIt tlN. ffi n,I I rrul:ourt tr t0grrlm|tlos|nm eru t( ru w nm[cnlta6rl^tmE fru =v ru lt Slxtrt 0AIt:01,-0l-lx Itflf o tfl l{-lr-t-ln-pl HYDRACR(IP IIOA/S.SD

}II8 ILAI VASHIR FABNRY I,II8 NUT I AHilt{Y ilt8 r l.{t \l[:Kt I \[ilt I ABORY il18 rLAt vASHtR FABIRY }II8 NUI FABNRY I,II8 X IM HFX HFAI} I ABI[{Y 7 HI(} X ?O SNCKFT NTT T I AIIIII?Y t{t I t A8I1RY TII4 NUI FABNRY HI4 X I{t) HEX HFAD BN T FABNRY I,i33 THICK VASHFP I ABURI r{33 X 150 HLX 8[Lt fABORY STANDARD DIE BLOCI( I'tKA /-l mslTI0r,l OUANT. DISCRIPI ION REFERENCE

HYDRACRIIP 8OA/S-SD

4 HI6 FI AT VASHFP I AEtlRY 1il6 Nlil FABMY r{15 x lz0 sucKtl sTU0 FABIRY }tI5 FLAI VASHTR FABIRY I{16 NUI FABNRY t{t5 x 70 Htx HEAD FABNRY I Hl(l x m snc(FT nn I I A RI II?Y I r,il0 x 80 s0cl(Er B0Lr FABDRY I{I4 NUI FABNRY

4 I r4t1 x l?0 HFx HFAn nfi T I AtsURY 3 }l;,/ IHII]X VA\HFP FABORY t{?/ x t00 Htx BnLI FABNRY ,';';{:;: STAilNARN DIF H NCK bLKA /-I r PosmoN OUAlT DESCRIPIION REFTRTNCE

HYDRACRIIP ssA/S-SD

I 4 il14 tLAr vAsHtR TABDRY ilt4 NUI FABNRY 4 -,Vfu lll4 x I00 sucKET SIUD H!6 FI AI VASHFR I'ABNRY AtsURY n6 NUT I AEBRY '%^r* 8c4 , l{t5 x /0 Htx HtA0 FABTIRY ilo x al s0cKtl BILT FABORY MIOXMSOCKEIETII FABNPY HARIrcSS r-r= { REVtSttlts I r,fl? Nt I I ABURI XI IIAILI(IAL G@nnE@ tNG" h I HIE X I()() HIX HEAD BNLI FABNRY V= v HYmACRIP StRttS PUNCHlltG Dtt H.0Ct( HAn0vARt 1121 IHICI( UA\HFP I AtsURY *rlmtricmEUtrt w: v m5nvtr[.mtrilutrr0uo[annurlmn -wmr l,r?4 x 100 HLx EuLI TABt]RY fitErnn|n@Hw0suut f, 9{r I |{t' (9UllI r ffi r$. t[rt&. ! ffi ru I SIANDARD DIE BLICK 6F(A 7-l Vw= v EF{ffi|:IM.[tffi5rrt{sdD ru t swBrJmuf,srtrmltEm&gImE [s mF E PIISIIIt]N OUAIT. DESCRIPIITIN REFEREIICT w7= v ru It 85xlt1 lAIt: l]!}-07-01 t[Irf,fJ ln H-7-r-p 30 TINS l4AX MAX MATERIAL THICKNISS = I/4' l4AX PUNCH 3/4'

3l

t'

I t- -J 17 '-l- 3-l l HYD 55-80 PUMA 55-80 - I /NUT

I I

) 7-

50

!AIE HISIMY B EXSPLAIIAIIII{ tr ffVISIIIIS HARII{SS I l-1 { VASIAIII I I)

6?7,3 64 n,0751 t1,587

SHAPT I4AX DI|{ SHAPE ilAX DIt.| SHAPT }IAX DIl{

ROUND 1.075' ROUND 1.e60' ROUND 1.587',

SOUARE 0.750' SOUARI 0.875', SOUART 1.1??'

t]BLEN6 1.062' x 0.8t2' tlBLt]N6 t250' x 0.812' OBLtlN6 1.562', X l'

RtCTAN6LE t'x 0.375' RECIAN6LE r.l?2' )( 0.5' RECTAN6LE 1.5' x 0.5'

Htx 0.941' Htx r.091' HEX 1.37 4',

TRIAN6LE 0.806' IRIAN6LE 0.945', TRIAN6LE Ll90'

PENTA6RA}I 0.97?', PENTA6RAI.I Lt40' PENIA6RAIl 1.435',

B B

s t s E PINTAGRAM TRIAN6LI HTX SOUART RICTANGLI IBLING MEASURTMINT MEASURTMENT MEASUREMINT MIASURTMTNT MIASURIMENT MIASURTMTNT

!AIT HISIInY tn EXSPTAIIAIITT tr REVISIilS HASDr[SS { VARIAilT ru G@nnE@ v v l|ro [N@. h trJmrq,t smI S{rat tnrofl I l[lllry HYDRACRtr/PU{A 55-&}.IIl) w v mEW[.mmrurrxrm PIIIH CLA}P SLTTVE I$M{ATItI{ ruIrttnm@uru@ucfi! W E*IElmUrEmilsn!ffi lM I'T.T XIIIIX \ITXXXXX IMAFIFR PYAT IVTN\T'Ii w v xm&ffilifrr.E MEaES.r[ r s0lormllmtlm rs nE6 [ 6UI[t np tct lftfillftR PYAX rVfp(IrC fryurrrmmqnaDor L, l:l UKJ IX-XI.U It{t t-Hxxx-7-st: v tluft -44 1-4t 1-4C 4D -4A I- 4l I

tffSD|ESS { Rfvtsltt{s XI IIAIT,IIIAL @@nnE@ I ?2-1pt v v tNG" h rrJsr&tsHI Eruttnx|@! HYMACRI]P SIRIES I{[}ICI{R CTLINI)ER PARIS LISI w: v [t El6 F a rFlwrur rt|tr ff{rIrrrn&silro@LIm ffi T&mr f, n r l(utt!3ru r lle rllstrr D st6t vw= v EEE ryIITIN. M f,[ 6'EIUT! trsryrrlmrtttsmmMsE clu StAl-E, l,l I RtF: XXXLXXXX.XXXX lfrfilltrtR eyar rvrp(rrfi SiIW. v riru[ tr nI!. eBr l^ | (uo : ru FttrllAT: DV6 I oRG XX-XX-XX lPApt Nn driflflmffimm olru 'APtft E5xll1 0ArE: 09-07-0a lct]l{o l$ H-ll-l-1-Pt HrRortss t-] .{ Rtvlsttl6 G@nnE@ V =v tNG" h HYDRACRIP III]ICHTR STCIIIN HARDVART tl w =v vA{Aa{ I [I] w =v OIru Itt' ll lRtF, XXXX.XXXXJXXX lfMlisFP: PYrrr{ rvrfiIrr, ru rwat: uvu I utu u-xr-xx IPAPI N} flmtnnflflnm w .v Eru "F tr o s (:= PARIS LI6EI'ID HYDRACRI]P 55 =) l4 1 I{IO LICK VASHER I AUut{Y I - l.J 4 ilo x e5 HLx FABMY 2n a I IIE ruAVY FLAI VASHTR AUIJI(I I uq -d IIIC ILAI VA\HLR I AtsUI'Y I UltHlNtr \lUL ILAUL bLKA q 2 I{I4 ILAI VASHTR I AEIX

PARTS LE6TND HYDRACR[]P &} 4 I'I4 LULI( VASHLR P9 l{t4 x 35 ttrx III2 HTAVY FLAT VASIJFR fAffNY III4 FI AT UA\HFP I AtsIRY 9-AA I\ ICHING \IOt BI AIF 6fl(A t0 { NUr FARTPY I bLKA 'ABORY 1il2 x ?0 stfxFl 4 ITHING SIIF ELADE 6IKA xtu x 55 ttrx FANNRY I bLKA t{10 x /5 Htx I AEIIiY H8X: RULL PIN FABt]RY A Ht4 X 40 HtX FABNRY I I n?x X c) KLYSIIILK } AtsURY I{I{ X 60 HFI FABORY K VAS}ILR FABI]RY llt4 x 50 Htx FABNRY I I U SUI,KLI I ABTJRY 4 }il1 x 70 HFt TABI}RY l8 }II? X x 30 KtY sI[tK TAEORY Hl4 X 50 StT SCREV FABNRY I IrLHlriu JtUP t LKA Hl2 X 9n Sft:KFT 6 KA >+Dbb 'ANNPY r{0lcHlN6 Dtt BL0CK 6tKA 4 1fl4 Ft I I VASHIR T AtstJI(Y

mslII0l'l 0tl4NI DTSCRIPIIIN RIFTRTNCI PtlstItur/ Ot,ANT I}ESCRIPTITI'I REFTRINCI r" B F F PARTS LT6TND HYDRACRIIP IIO 4 I{I4 ]LAI VASHTR FABMY t4 III{ LIJLK YASHLI( } ABURY I 3 4 n4 x 35 t{tx FABNRY ?8 I I,II? HEAVY FLAT VASI{R I AtstIRY I iil4 lLAt vAsHtR FABIRY I 6tKA I I HI4 NUI I AUIRY I bLKA lilz x ?0 sucKtl FABTIRY 6IKA Hto x 65 Htx I AUU(I :HIN6 IIPPFR H AI}F 6E(A 4 1il0 x /5 HLx TABORY fA8[RY Ht4 X 45 HFX I AtsUTT Hlz X x 25 KIYSIT]K FABORY 4 HI4 X )0 HLX FAEMY I ] AEURY 4 Ht{ x 60 Htx I AETKI l{t5 x / sflcKt I FABORY :l Ht4 X 5l' slt SCRLV 1 ABUIIY JI' KLT sIIIK I AEIJRY iltz x 90 smKET I AIIJKI I TCHING STIP KA I NIJILHINb UIL tsLUIK bIKA lr LTKA

PtlSIIItlN flJANT. DESCRIPTItlN REFTRTISI P0stil0N OLIANI DtScRIPTID'l REFIRENCE

PARTS LT6TNI} HYDRACRtr 165 ?EO t1 4 }II4 LOCK VASHTR l3 4 1il4 x 35 HLX 2R HI? HTAVY FLAI VASHTR I 4 Ifl6 tLAt VASHU{ 6 TJLKA lt 1 I{I4 ILAI YASHTR :HIN6 FRfNI H AIIF 6t(A l0 1 ilt{ rut ?1 I[KA ' x ?0 sncKFT :HINti I,IPPFR il ANF IJLKA 4 HIU X /) HtX ? X JU RULL PIN } AtsI-]RY HIo X 85 HFX x I x 25 KtYSItfK FABTRY 6 nb x 4t fiLx I ABIJRY 4 1fl4 x 50 Htx l{t6 x / sutKt I FABORY 1 ? 1il6 r /5 rft.x I I X 30 KEY STtlCK } ABURY 1il6 x 50 stl scRtv 3-48 i IIHINI SIIP 6IKA ? r,[c x lcl, SuLKLr ll I LHlt{tr \lUP U-KA MIITHINI DIt BLI]TK 6tKA I { FABIIRY

PtlSITItlN RJANI I}ESCRIPIIIII RTFERENCI P0slil0N OtJANT. DESCRIPTITI'I RErtffNCt R

USID V]TH MATTRIAL [F 3/B' AND UNDTR

VHIN RTMIVING tl_BO] AND RTINSTALLING THt UPPTR BLADT MAKI SURI IT STATS ALL THT \/AY AGAINST THt MIVING BLAII HILDTR [R DAMAGI MAY ICCUR T! THT MACHINI UStD VITH MATTRIAL IHICKTR THTN 3/B' ilII

I)AIE HISIInY M EXSPLAMIIOI tr ffVISIITS HAStXttSS t"l { VASINI XI IIAITI'IAL v lM G@nnE@ [NG" h v aollr0t g} xrffincsu{5tut rw@[ !0lllru HYMACRIP \F v [lM!aEsrEraJum o0ll!ru RII{I]VAL tr BLAIE SIPPLIIIII ututtm|n(anuun@!0m Eru Iromu t EmtgBrEcs6 0nlru v xffiE Crcllrilr ru nf!.msrr! r$wmltrn!fir&ffiEEIE ILA tu! IFNGIiFFft RYAI.I .I VtN\IFTI retlrrrnx5@LtffcE .L: It Uatr II-IX-XX ti& t-Hgt-t-t5flr]{-0t v$w v l@ POINIS

THIS 6UIDE LEFI ltl RI6HT TO 6IVE HORIZONAL LE6 OF AN6LE 90'cuTs.

J U fu= r-..t [rJ>5 r

HORIZONTAL o GUIDE o

INSURE 6UIDES ARE VITH AN6LE ADJUSI IHIS 6UIDE UP OR DOVN LEVEL BLADES TO 6IVE VERTICAL LE6 t]F AN6LE 90'culs.

r{ARU{tSS { Rtvts1tl6 IIAITRIIL @@nfiE@ [N@" h V= v ADJUST}INI r 6ul[s FoR AtsLE sEcllo'l FOR HYMACRIP SERIES IRII{U$ffiR5 w: v VARIAI{T rld W: v ru ru w= v [m Slixlll MIt:09-13-& lCOt0 lG |N-1-5-HIA0 ATTACHED DOCTTMENTS

SPECIFIC OR GENERIC MACHINE CATATOGUE - DIES AND PUNCHES CATALOGUE - ATTACHMENTS CATATOGUE - MArN COMPOTTENTS LrST (4 VIEWS) PARTS LIST OF ETECTRIC STOP INSPECTION AI.ID CTIECK.UP CARD FOT'NDATION PLAT.I - WIRING DIAGRAI,I LIST OF CONTROTS - I{YDRAULIC DIAGRAM PARTS LIST OF IIMRAULIC I'NIT - GREASING POINT PLAI{

- APPE}TDIX - DIRECTIONS FOR USE OF ATTACHT{ENTS ON GEKA MACHINES

t{a

DATE OF ISSttE: L994-t Z-30

DATE OF LAST REVISION:i.994-L2-30

EOUIPIIIENT:

NAME: Universal Shearing and punching Machine. }IARK: GEKA MODEL: IIYDRACROP- KPs SERIAT NTIMBER: I.{It,-} 'a I

I4AKER: MAQUINANIA GEKA 9 .A. , POL. I}ilD. UGATDETXO S/N, OIARTZUN ( SPAIN) TEt. +94.-43-490034 - FA:( +34-43-49L237 _ TELEX t

DISTRIBUTOR:

GEI(iA

/ SECTION 0:PRELIMINARIES

SECTION 1:DESCRIPTIoN

L .1.. GENERAT FEATURES L .2. crossARY

SECTION 2:INSTALIATION

2.L. PREREQUISTTES 2.2. TRANSPORT AND UNPACKING 2.3. INSTALLATION LAYOUT 2.4. INSTALLATION INSTRUCTIONS

SECTION q:OpERATTON AND SETTINGS 3'1' 3:tTT'." E3*ilfi31'8,,**,, o 3.2. DESCRIPTION OF EACH WORKSTATION FT'NCTION 3.2. t . PUNCHING 3.2.2. FTATS AND PTATES SHEARING 3.2 .3. ANGTE IRON SHEARING 3.2.4. ROUND AND SQUARE BAR CROPPING 3.2. s. I{OTCHING

3.3. SETTINGS AND TOOL CENTRING 3.4. START-UP

SECTIOI.I 4 : I'IAINTENAI{CE

4.L . MAINTENANCE OPERATIONS 4.2 . LUBRICATION AT.ID CLEAI{ING o SECTION 5:PARTS LIST

SECTION 6:TROUBLES AND REI{EDIES

SECTION 7:$AFETIES

GEI(A

l SECTION O - PRELIMINARIES

This TNSTRUCTION MANUAL ains at giving GEI{A machine's users a clear and efficient document for a.i e"s! installation, start-up, operation, maintenance and. repair of tire machine, as welr -" source of information on the machine safeties "" Io. this purpose, two identicar copies of this Manual, in your langruage, have been supplied with tire machine: one of them should be accessible to the machine production operator, while the second one is to be kept by the l"lanager. rn'any case, the opera.tor and the Production Manager shall be responsible for the safe upkeep of their respective copy. This document has been prepared with reference standards: to the following * UNE 66-L00-8L (Technical Principles for preparing Technical Manuals of Industrial Equipment); rr UNE-EN 292-2 (Basic concepts and General principles of Desigm o and Engineering); * Real Decree-Law No. J-4gs/L992 of zTttr November, 1^ggz which enforces the applicable provisions of the EEC CounciL's Directive No . 89 /392 /r,Ee . In- additionr w€ received advice from both INVEMA (Machine-Tool rndustriar Research and Development Association)' and A.F.M. (spanish Association of Machine-Tool Manufacturers;. You are kindly requested to read this Manual carefully for a safe operation and proper use of the machine which was bui-It, like its accessories, with the desire of supplying you with an equipnrent _of optimum prlce-guarity ratio. rn trtis ielpect, if you slould however detect any fault or wantage of the irachine, pLease feel free to advise us, indlcating your suggestions of inrpiovmrent. While reading this document, you will come across the following abbreviation and slzmbol:

: (?g".drwg) according to drawing. The d,rawing reference used I in all the documents. rt t I control elements.

A1I _ the operations described in this INSTRUCTION MAI{UAL must be performed by an authorized and qualified personnel having been trained to operate the mactrine.

Training with regard to this INSTRUCTION ldN{UAt is your right, as an operator of the machine. Do exercise it ! -

GEKA rf you shourd not recsive a proper training, do not hesitate to contact your supplier or the rnanufacturer on the other hgrrd,.-we sharr be gratefur to you for reporting, to your Distributor/Supplierr dny error, orniision and/br lack of clarity you may encounter in this franuaf, Finally, we wish to thank you once more for your attention and reading this Manuall ps a prerequisite to ensure the good running of the machine, which, eventuafty, ah"ii result in maintaining excellent maher-user relations. flfiwX yOU.

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All the characteristics specified in this INsTRucrIoN MANUAT and its ANIIEXES concern nrateiial with a resistance of 45 kg/mmz and standard GEKA machines.

MAOUTNARTA GEKA s.A. rese-rves the right to modify any iten of this Instruction Manual without prior iotice. o

GEKA

I SECTION 1. - DESCRIPTION

We refer you to the four enclosed pictures showing the machine you have just acquiredr of any representative of its fanrily, both with and without front and rlar |uards. These pictures strltr be the graphic support for rNsiRucrroN I this I{AT.IUAL and are called MAIN COMPONENTS LIST' .

The red-coloured figures at the end of the signalling arrours represent the technical reference of the component (acc.drwg), allowing you to trace its name and the quantily of same on each machine. Your machine has been designed to operate, preferabty, in forge miIls, sheet metal shops, structurar enginieiing workihops, eti. and, generalry, in any industry in the line of metar lnormally unaLloyed iron) processing, in need for punching, cutting and forming equipment. However, this machine has muitipte applications which shall depend on its adaptation to the speciiic industrial activity. The standard machine is prepared to process metal parts preferably over 3 mm in thickness.

o ]..1. GENERAL FEATURES All GEKA HYDRACROP machines present the following features: * Sandwich-tlrye, monobloc frame structure. * Electric foot-operation. ?t Five working stations and two adjustable-stroke cylinder hydrauric drive: one of the cyrinders (1/+a acc.drwg) actuates the punching equipment, while the other one G/A acc. dr:i$.g} actuates the tool-holder ( 1/i.g acc.drwg) ttrat moveS,:-' reciprocatively ttrrough all the other working stations. * colours: beige RAt 1oLs (other, exceptionally upon request) and orange RAL L007 for working areas. The working stations available on your machine can be seen on the o relevant CATATOGUE and are briefly deseribed below: :- Punch (sge cATAtoGUE): working station for making hores in the material by pressing a punch (7/4 acc.d*g) into i aie acc.drwg). U/z

_ Anqles Shear (See CATALOGUE): Working statj.on for cutting angle sections of different sizes, thioug*r the compensated movement of the rotary blade (LS/S acc.drwg) over two stationary blades (15/3 and L5/4 acc.drwg).

GEI(A

1 1 for cutting fLats by operating two blades: a stationaiy one (1 acc.drwg) and a movable one (L/46A acc.drwg). /46

and Bare er (See CATALOGUE): tilorking station for shearing soLid round and square various sizes. bars in

NoFcher (see cATAtoGUE) :-__rrbiting" " _ ; working station for removing ( ) material from the worhpiece itarting from one end oi same (sometimes referred to as 'dinking die').

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GEKA

1 2 L.Z. G.LOSSARY - l'lAll$ COMPONENTS

FRAIIE (see..cATAtoGUE): part of the machine. supporting arl the r^rorking stations. rt is welded onto the BED. The cyli,nders are secured to this frame which houses the tooL-holder. * BED (see cATALocuE) (L/a7 acc.drwg) : Bottom part of the machine supporting the frame,. It houses [,tre nyaraulii rmit which is accessible after opening the guard(s) (r/g1 - 1/g1A acc.drwg). * - .CYLINDER oR Prgrotl (see cATAtocuE) (t/4-L/48 acc.drwg): The machine component that applies a force to the material. Ii is the double-acting tree and basically consists in four elements: jacket, piston, seals and guid'€t. Concerning the HIDRACROP series, it is essential to differentiate at alL times the punch cyrinder (L/49 acc.drwg) from the notcher cylinder (t/4 acc.drwg) IgotflolPER (see cATAtocuE) (t/ta acc.drwg): The cast steel arbor that slides in the middle of the frame under the action of a cylinder (L/4 acc.drwg) ana carries the rnovable cutting and o notching too1s. * ELECTRIC OR CONTROL CSBII{ET (See CATATOGUE): a chest that accornmodates' most of the eLeciric components of the machine (fuses, relays, transformer, contactorl etc.). The cabinet or control panel is permanent).y accessible and is mounted on the front of the bed. ?k InrDRAuLrc tNrr (see cATAtoGuE): rts function is to control the movement of the cylinders according the actuation pedal to of the Thg purnp driving motor and the electrovalves that ,dispense' the oil delivered by the pump are mounted on the oil tank. The reference of the hydrauJ.ic unit of your machine is ind.icated on the INSPECTION AND COilTROL CARD. * (See -PEDAL CATATOGUE): The actuator switch controlling the up and dovrn movements of the cutter cylinders, and hence tools of the machine. There are two tlpes of pedars: single and double, o which are d.escribed in section 3.1.1. coNTRoL ET.EMENTS i PgNcH (see cATALocuE) (7/4 acc.drwg): Treated steer tool desigmed to pierce hores (to punch). rt Ean be of any shape. As standard, round, sqluare, rectangular and oblong -shapls are avaiLable. ry (See CATALOGUE) (7/2 acc.drwg): Fixed treated steel tool placed in a horizontal prane with respect to the punch, at a given distance called clearance or gap.

GEI(A

't 3

!- * BLAI}ES OR IffIvEs (See CATALOGUE): Treated steel toolg for cutting sections. According to the shipe tlpes available: of sane, there are four 4lgfe shear knives: see assernbly drawing No. 15 Flat shear knives: (1/46A + t/4:6 acc.drwg) Bar cropper -blades: (t/41 acc.drwg) Notcher blades: see assembly drawing No. 9

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GEI(A

1 I SECTION 2 - INSTALI.,ATIOT{

2.t. PREREOUTSTTEg

Prior to instarring any GEKA IfimRAcRop machine, make sure that the minimum infrastructure are fulfilled:_following and rocation requirements + The machine will be installed. ln a moisture-free, ventilated roofed area, at a room temperature varying from 0o t; 3so c and will not be subject to weathering + The floor i.s made of concrete and 1evel1ed. + The machine will be placed outside access and traffic zones. + The machine will be placed away from any wall and tlrere wilt be a sufficient crearance for thl feedini discharge of workpieces. The risks for any person passinf by""a and/or stinding at either side of the machine shall be calcuratla at all times. + Anchoring the machine into the floor is recomrnendable in all ll cases and is imperative for arl rnachines equipped with such attachments as feeders, copying tables, pArry systems, etc. For anchoring the machine into the froo-r, use the holes drilled in thE machine bed, which become apparent after removing the packing skids. + The electric cables (3 leads + earth) to the control cabinet will be laid in ulderground or overhead protective cableways anA their section U1l be appropriate for the instalred powei (see cATALocItE/FottNDATroN DRAWTNG). check that the mains voltage coincides with the motor, transformer and wiring vortale requirements.

The power supply and electrical installation shaLl compLy with the electric safety regruJ-ations in force and the voltage range shaIl be the rated voltage t 5 ?. o 2.2. TRANSPORT AI{D T'NPACKING Lifting and carrying the machine must ALWAYS be made by IIANGING same ffg* the eyebott(s) (L/94 acc.drwg) provided for this purpose at the top of the urachinb. The machlne rreight is indicated on the transport instruction label sticked on the outsid,e_of the packing material. If missfng or when in doub!, please refer to tLe CATILOGUE or contact yot i distributor or the manufacturer Never lift the machine hording it by the bed (L/97 acc.drwg) only, since you would then run the risk of its overturning GEI(IA

1

--- For its transport from the factory, the machine is supported by two skids (wood planks) which should not be used as a Bermanent base for the macfiine, since they could cause injuries to anybody stunbling on same. The skids should therefore be removed. whiLe the machine is hanging from the crane, at an adequate height from the floor. After placing the machine on the floor, proceed as follows: + Cut the packing ropes and remove the pLastic filn protecting the machine during its transport. + Next' remove the paper or cardboard packages which are leaning against tbe rnachine and contain accessories, pedals and tools praced in that position for easier transport. unpack these components and keep them in a safe p1ace.

2.3. TNSTATLATION I,AYOUT Refer to the rNsrAtLATroN tAyour of your machine, which is attached hereto and shows the dimensional characteristics of the o specific model you have acquired. 2.4. INSTALTATTON IITSTRUCTTONS Installing the machine shall be made, complying with the instructions and verifications detailed below: + Verify if the machine bed is perfectly flat on the f1oor, i.e. it is not rocking. Otherwise, level and wedge the machine appropriately. + Mount the different attachments previously unpacked, following the instructions given in the relevant ATTACHMENT INSTRUCTION APPENDIX. + The punching and notching worktable as well as the electric stop are very usual (and reconmended) attachnents. Installing them is, therefore, described below: The tables are suppl ied pre-mounted from factory and the o straightedges only shouLd be mounted on site, proceeding as follows: L.- Install ttre (long) cross straightedge l4Z/Z g/4 acc. drwg)r placing it on the worktable and pushing it, by both ends simultaneously, into the gap of the workstation and then lock it with the relevant attabhing flanges 2.- The (short) longitudinal straightedge (43/3 - gltZ acc. drwg) is mounted on the croas straightedge (43/Z g/4 acc, drwg). In all cases, verify that it is secured in place.

GEICA /2 r.nstarling the erectric stop shourd be made following the procedure described below: 1.- Prace the longitudinar stop bar (6/L acc.drwg) ulth the nillimeter rule upwards; tighten securely the Allen sciews ("A") in the threaded, holes provided. for in the punch-holder rotation bort area {L/lt acc.drwg) at the back of thl machine. 2.- Slide the crankpin (6/2 acc.drwg) fixed to the crosis bar (6/5 acc.drwg) arong the longitudinal itop bar (6/L acc.drwg) and lock it using the lower clanrping lever. 3.- Connect to the socket outlet provided for this purpose at the rear of the machine, verifying that aII parts are fixed properly. The adjusting procedure for this accessory is described in paragraph 3.3.G. - ADJUSTMENT OF ELECTRIC STOP. + The ped.al protection casing is fitted with a knobbed rod for easier transportation. Tighten the nuts at the threaded end. + The magrnetic lanp must obligatorily be plugged in the LZ V socket provided for this purpose at the top rear guard of the o machine + Clean the nachine thoroughly, remove all grease from the notcher and lubricate the machine (See 4.2 TUBRICATION AND CTEANING) . + Check the oil leveI. The machine is dispatched from factory with the oil tank filled up to the appropriale level. (see 4.1.A: - MAINTENA],TCE OPEBATIONS: OIt). + Flake sure the voltage of the motor, the motor wiring and the connections to the transformer is the same as the mains voltage. + Proceed with wiring the machine, as follows: L, Open the machine bed guard and the electric cabinet, 2. Introduce the poller cable in the hole at the bottom of o the electric cabinet. 3. Connect the power cable wires to the terminals as indicated below:

Earth terminal > ground wire (green-yellow) (green-ye11ow) . R terminal ------> PHASE conductor

S terminal > PHASE conductor

T termi.nal > PI{ASE conductor

2 3 4. Close the machine bed guard. and the electric cabinet door. 5. tllake sure the emergency stop pushbuttons (red mushroom- headed button on yerlow base) are not rocked up, by turning then anti-clockwise until the mrshroom head is totally clear at the top of the yelIow base. 6. Remove the punch. To do so, retract the punch stripper (L/47 acc. dr*g), pushing downwards with a 1BO" turnl then using the spanner supplied with the machine, slightly undo the nut (7/6 acc.drwg)r turn the bayonet-socket (7/S acc.drwg) which can then be taken out together with the punch. 7. Turn the main switch tAl clockwise (45")r the white power-on indicator t50I on the control panel must turn on. ( See paragraph 3.1,1. - CONTROL ETEMENTS). 8. Electric wiring shall be considered to be conrpleted, after checking tlre motor d.irectj.on of rotation, in accordance with paragraBh 3.3.4. - START-UP. o UAn!{IITG ! The machine is nor ready to work, but m No|f put it in operation without readl.ng first Section 3 conpletely: OPERATION (3.tf?), SETTINC'.S (3.3) and START-IIP (3.4) and., ahove all, understand,ing perfectly the content of Section 7 - SAI'ETIES.

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GEI(A

2 I SECTION 3 - OPERATION. A}ID SETTINGS

3. ].. OPERATING PRINCIPLE Assuming you are familiar with the definitions of the components set forth in paragraph L.2 - GLOSSARYT w€ shall now explain how those elements actuate in order that the machine can operate. By pressing the green pushbutton, you nake the main switch that starts up the motor and, then, when you apply on the pedal(s), the electric control, depending on its selectors, generates the commands to the electrovalves of the hydraulic unit for distributing the oil delivered by the pump to the cylinders. The cylinders, in their turn, transmit the notion to the punching head and the shearing knife-holder, complete with their cutting tools. The fixed knives or b1ades as well as the cylinders are mounted on the machine frame. Schematically, the operat5.ng sequence c€ut be established as follows:

SWITCHING ON o I MOTOR il ITYDRAULIC PTIMP I OPERATION OF PEDAL I ELECTROVALVES t ITYDRAULIC CYTINDERS cuTTINGIToots

Bel-ow is a guiding list of materials classified by their nature: * IilTRAUIIC ELEMENTS (Refer to PARTS IIST OF ITYDRAULIC UNIT) IIYDRAULIC IINIT: Electrovalves o Safety valve Bloch Pump Oil tank CYTTNDER(S): Guide Rod Piston SeaLs (gasket, retainers, O-rings) MruRAULIC flOgES * ELECTRIC EtE!{E}cfS (Refer to IIST OF CONTROLS) GEI(A

3 1 ELECTRIC CABINET: Transformer ReLays Switches

LIMIT SWITCIIES EMERGENCT STOP PUSHBUTTONS ELECTRTC FOOT-CONTROLS (PEDATS) MOTOR

:t L{ECEA}IICAI ELEMENTS

Att oTHER PARTS, NOT ITSTED ABOVE.

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GEI(iA

3 2 3.1.1. CONTROTS The next tabre will enable you to d.etermine which controls are available on your machine. These controls described hereafter. are individually

MACIIINE coNTROTS ITYDRACORP 'IAII L-L-A-K- J-23-24-26-P-50- 6 (* ) H.YDRACOPR "S-SD' z-L-A-K- J-23-24-26-P-50- 6 (* )

K P

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A @ o 50

* THE Er,EcTR_rq srop t6l is suppried as an .optional accessory, although it is highly reconmended-, tll sruPr.E PELAL As can be seen on the irlustration, positione: it has two operating o

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o-46r

3 i- l-. STOP, When the pedal is in this position, the punch-head rises up to the up-stroke lirnit switch which is then activated and no electric impulse is sent.

2. RUN. With the pedal in this position, the punch-head moves down, allowing the process to be carried out.

T2 JDOIIBLE PEDAL As c€rn be seen on the illustration, it has three operating positions:

o o-x rL6r o-3

1. STOP. llhen the pedal is in this position, the punch-head rises up to the up-stroke limit switch which is then activated and no electric impulse is sent. 2. INCHING. Irilith the pedal in this intermediate position, the punch-head is lowered at low speed (jogged). 3. RIIN. With the pedal in this position, fuII pressure is applied to the punch-head that moves down at ful1 speed, allowing o the process to be carried out. Passing directly from STOP (1) to RUN (3) is possibte. The IIYDRACROP A-S-SD rnodels are supplied with a punch control Peda1 whose cable comes out near the electric cabinet and a shear controL pedal wlrose cable entry is in the notcher area. Each pedal is identified by means of the reLevant symboJ.. t I GEKA

3 4 ttl APPROACH I{ODE SELECTOR

IT H T ti TT- ii I It operates as follotrrs: + Left position (A). The autornatic return of the punch asserrbly to the top position is inhibited. The tool remains where it i; when the pedal is released. rt is recorunended to place the selector in this position for easier centering of the -workpi-ece and adjusting/centering the tools. + Right position (c) . rt has the same frrnction as positj.on (A), except that it concerns the workstations associaled with the knife-holder (t/18) acc.drwg), i.e. frat and angre shears, f,ound and square bar crofper and notcher. + In order to work on all stations at the same time, the selector has to be in the central position (C) which enables the automatic o return of the tool to its upper position when the pedal is released rn relation to the above, mind that the machines are provided with TWO LIMIT SWITCHES controlling the stroke of the cytinder. Therefore, in spite of this selector being in either the ilpltNcH APPROACH" (A) or t'PtArE AppRoAcH" (c) position, when the bottom Iinit switch is activated, the headit6c-fr will rise to the stop of the top lirnit switch, as the pedal is released.

lrlhen working in the 'tAPPRoAcH MODE" (PLATE or puNcH), the pressure in the other workstations IS NOT NECESSARILY THE FULI PRESSURE, BUT CAN BE THAT APPTIED TO THE WORKSTATION OPERATING IN THE APPBOACII MODE. lAl r,rArN suITcH Power oN/oFF switch. tfith the switch in the ,r0,, position, no power is supplied to the nachine; with the switch in the- tr. position, the machine is power-supplied and the white pilot lanp o t50l turns on, indicating that condition. tKl GREET{ PUSTTBUTTON Machine start pushbutton" The motor gets started with no pressure build-up in the hydraulic group. The machine waits ior the relevant erectric signal from Bedal t1l tz] or erectric stop in order to start working. [6],

tJI RED PUSHBTTTTON Machine stop pushbutton. The maehine continues to be power- supplied, although the motor stops. GEKA

3 5 t23I EMERGENCY STOP(S) Red (mushroom-headed) pushbutton on ye1low base, in visible areas of the nachine. Utren operatedr the machine i.nstantly stops working and, the button remains interlocked. In order to restalt the machine, it is necessary to unlock the emergency stop button (by rotating the mushroom head) and to pres6 the green start pushbutton tKI. t241 LrttrT SHITCffiS srditches adapted to control the stroke (travel) of the piston(s). Paragraph 3.3.A - SETTINGS: PITNCII-ro-DIE DISTAIICE/SETTTNG OF trMrT shtrTcHEs gives full details on such switches. we urge you to read said paragraph carefurly, because correct setting is one of the most important elements for optinizing your job. tPI ilCIrcHER GUARD SAFEIY LATCEKST It aims at protecting the operator or third persons against the potential. risk of injury that may arise from working with the protective sriding guard of the notcher (L/s4 acc.drwg) Iifted.

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Left turn position (A). (The key is removed and kept by the shop Leader). The machine can work only if the sliding guard of tha notcher {L/54 acc.drwg) is closed Rj"ght turn position (B). (The key is inserted into the key switch, by authorization of the shop leader). This position ia provided for o-ceptional use, wtren it is absolutery necessary to lift the sliding gruard of the notcher (!/54 acc,drwg) in order to $o the iob. On completion of the operaiion, the key rnrust be given back to the shop leader. For further d,etails on this item, refer to section 3.2.5 o NOTCHTNG.

GEKA

3 6

--. [26] ELECTRTC STOP ,/ PEDAL SELECTOR

It is desigrned to unify the electric control of the machine, so that: When in left position (A), the machine is actuated through the eleetric stop on1y. lUhen in right position (B), the machine is actuated through the pedal only If latchkey tPl is in the (B) position, the electric stop will not actuate at all, even though the sliding gruard of the notcher o (t/54 acc.drwg) were closed. tsol [ruTE PILOT LA!{P It indicates'that the machlne is power-supplied (refer to "[A] -Main Switchr') . 161 ET,ECTRTC STOP It becomes a control when the ELECTRIC STOP/PEDAI SETECTOR [26] is j.n the (A) left position and the workpiece presses against (hits) the electric stop end (6/8 acc.drwg). On receiving the electric impulse, the notching head moves to the rower linit switch, thus performing the job, and then returns to the upper position, thus conpleting the process cycle. Never generate the electric impulse manuallyr ds this night endanger the safety of any operator at the other side of the machine, who would not expect the machine start-up. Before proceeding with any setting or maintenance operation of o the machine, turn it off and Blace the pedals t1l tz] behind seune, making sure that nobody wilL use them.

Paragraph 3.2.2 - 'TDESCRIPTION OF EACII WORKSTATION FI'NCTION: FLAT SHEARING" provides further Lnformation about this accessory.

GEKA

3 7 Schematically and by way of sunmary, the operative steps sequence would be as follows:

STEP CONTROT Switch: Lng on of machine tAl

I I s' :art tKl

t s I lection tLl

,1r".r". IPI tz6J I \ Actuation of the pedal/ against electric stop t1] Lzt t 6l

I C)* I I I o rlI I s1 :OP 1231 IJI I Swi tch ,Il9 off tAI

o

GEKA

3 I 3.2. DESCRIPTION OF EACH WORKSTATION FIJNCTION

GENERAL PRELIMINARIES Please read and take note of, the warning/instruction plates affixed to the machine. Fo1low those instruciions exactly aid do not remove the plates for no reason whatsoever. Remenber that the nameplate ratings for all workstations are maximum values which are valid for any material with a resistance up to 45 kg,/nm2. when processing material with greater resistances' the maximrrm thickness of that material should be calculated according to the following equation:

45 NEW MAX. THICK. = TIIICK. FOR 45 kglrnmr x ------NEW MATERIAT RESIST. (*)

(*) TIIE MATERIAL RESISTANCE IIAS TO BE CONFIRI{EDICERTIFIED BY THE SUPPLIER. By way of an illustration and application of the a,m. equation, the machine capacity (NEW TIIICIfiESS) for stainless steel of 75 o kg/mnz resietance (NEhf MATERIAL RESISTANCE) would be equal to 6Ot of the nameplate rating (608 being obtained fron the quotient: 45/75 = O.6).'. For any subject related to the use and optimiration of the cylinder stroke, refer to paragraph 3.3.A PI'NC}I-TO.DIE DrSTANCE/SETTING OF LIMrr SI0TTCHES.

Tahe good note of our reconmendations about SAFETY in Section 7 and care for your health at alt times (that's a value we can neither sell you nor replace I ). You are kindly requested to wear goggles, gloves, a safety cdp, an apron in ord,er to protect your body and, specially, your eyes, face, head, hands and arms. o

GEI(rA

3 I DESCRIPTION OF EACH WORKSTATIOH FUNCTION 3.2.L PIINffiING I

o

o {E

t6 1/118 o eo 0e

+ Before starting punching, the two requisites described below must be complied with, namelY: 1-- FrRST REQUTSTTE (TIITCSNESS COIITROL) In order to determine the l{A:(IMttM ADMISSIBLE THICKNESS for all sorts of materials, use the following equation: 45 l4N(. TIIICK. (rmr) = PITNCH DIA. (nm) x ------MATERIAT RESIST . ( * ) ( kglmm2 )

(*) THE MATERTAI RESISTANCE HAS TO BE CONFIR!4EDICERTIFIED BY TIIE o SUPPLIER. IiIhen the RESISTA}ICE OF THE MATERIAI TO BE PU!{CITED (KgINN2) iS equal to 45 kglmmz, then the IIAICIMUM ADMISSIBTE TffICI(NESS IS gdUel TO THE pUi,tCt* DIAMETER. As a result, never t5V to punch a nofe in a plate whose thickness is greatgr !h"1 the punch diasreter ("nledle effectt'-risk of punch breakage). For exanqlle, DO NOT TRY to punch a 10 rnm dia, hole in a plate LL nn in thichness. As for shaped punches, the PTINCH DIANIETER value is derived from the smallest side of the design.El(Alt{PtE 1-L: GEI(A

3 r0 can a 4 mm dia. hore be punched in a 3 mm thick stainless steel plate with a resistance of 70 kg/rsnz ?

MAiK. ADMISSIBTE THICKNESS = 4 x ---1:---- = 2.57 mm 70 Hence, rr cANNor, the maximum admissibre thickness under the mentioned conditions being z.s? nm (which is less than 3 nm) and, the punch running the risk of shattering.

EXAl,lPtE 1-2:

Can you punch a L0 mnr dia. hoLe in a 5 mm thick steel plate with a resistarrce of 6O kg,/rnn2 ?

45 I{N(. ADMISSIBTE THICK$IESS = 10 x = 7.50 mm 60 Hence, YOU CAI{ since the maximun punchable thickness und.er the l!^ mentioned conditions is 7.50 mnr (which is more than 5 nun).

EXAMPLE 1-3:

Can 20x5 nun square holes be punehed in 4 mrn thick stainLess steel plates with a resistance of 45 kg/run" ?

45 II{AX ADMISSIBLETIIICKNESS=5x =5nm 45

Hence, rHEY cAtit, the thickness of the prate to be punched (4 nm) being inferior to the maximurn admissible thickness (s mn).

2-- SECOT{D REQUTSTTE (COllTnOr OF TOtrS nEQUTRED) In order to determine the ntunber of TONS RE9UIRED, whatever the o tpe of material, use the following equation:

DIA. (run) x 3.L416 x TIIICK. (rnn) x r{AT.RESIST.1*;ktS/nnz TONS = REQUIRED 1000

(*) TIIE MATEBIAT RESISTATCE HAS TO BE CONFIRMED/CERTIFIED BY TIIE SUPPLIER If the TONS REQUIRED calculated according to the specified GEI€A equation are not available at the puNcHrNG srATroN of your machine (Refer to IIIACHINE CATATOGITE), REFRAIN FROM DOrNG THE JOB CONCERNED. For punches of any shape, but round, the product of DIAIIIETER (nnr) x 3.L4L6 in the equation shourd be replaced by the perimeter.

EIGMPLE 2-Lz what is the punching force required to punch a 23 nm diameter hole in a 17 mm thick material with a resist€rnce of 4E kgrrmnz ? 23 x 3.1.416 x 17 x 45 = 55.276 MT required L000

EXAMPTE 2-22

What is the punching force you need in order to punch a 23 nm dia. hole in a 12 mm thick stainless steel plate of 70 kg/mnra 2

o -31-l-3:11y-:-13-i-l:- = 60.6e rar required 1000

E]XAMPLE 2-3:

what is the punch5.ng force required to punch a 12 mm dia. hore in a 17 nun thick material with a resistarrce of 45 kglnm2 ?

THIS JOB CANNOT BE DONE. RE!,TEMBER THAT, FOR ANY MATERIAL I"ITII A RESISTAT{CE FROM 45 KG/MM2 UPIdARDS, SIIE THICIG{ESS MUST BE EQUAT TO OR LESS THN{ THE PUNCH DIAMETER. (Refer to FIRST REQUTSTTE - TTTICKIIESS CONTROT. ) o Ht(Ar{PtE 2-4: hfhat is the punching force you need. in order to punctr a 28x10 nm oblong hole in a 3 rnm thick material with a resistance of 60 hglnmz ? Perimeter of the oblong hole'?(a-b) + (3.L416 x b) = 36 + 31..4j. = 67.41 where (axb) = (28x10) ----> a=28 i b=10. 67.41 x 3 x 60 --- = l2.L3 MT required. L000

GEKA

3 12

L t( Check with the suppLier if the material is suitable for your punching conditions. ?k When punching, always use the punch stripper (t147 acc.drwg) correctly rnount€d on its supports (l-l1Lg acc.drwg) and levelled as far as possible. Otherwise, you would run the risk of the punch breaking when being removed from the workpiece. (sEE prATE NTTMBER 6 SECTTON 7 -SAFETTES) * Ag an accident-preventive measure, enclose the punch peripherally by lowering the prrnch stripper (L/47 acc.drwg) toa distance of 1 mm from the workpiece, using, to this end, its supports (L/LLg acc.drwg) 't Do not use the punching station to make holes bit by bit; always punch the hole through at once. * For easier working and SAFETYTs sake, we recommend to use the worktable in the punching station. The relevant instructions are included at the end of this seetion. * Check the down-stroke of the punch for correct length, making sure that the punch body will interfere with neither the die nor the workpiece. In any case, verify if the punch path is o free from obstacles. rr For punching angle sections near the Ieg, use eccentric punches and dies. In this e,vent, the maximum punchable thickness is equal to half the diameter of the hole to be made. ?t SmaLl angle sections &oy, sometimes, be punched with the legs "upwards". In this event, insert the section through the rear vertical opening in the punch stripper (l/47 acc.drwg) and verify clearance at nut (7/6C acc.drwg) and socket (7/5C acc.drwg). * When punching small parts with areas smaller than the area of the punch stripper (L/47 acc.drwg) complete with its guards and roIls (3/t9 - 3/LgP acc.drwg), do not position them with your fingers, but use the positioning rods or any appropriate tool (except your hands ! ). * tubrifying the punch will contribute to a longer service o Iife and eaEier operation. For this purpose, any tlpe of oi} can be used. However, always lube with a direct-pump oilcan to preserve your hands rt In order to change the punch-die assenbly, proceed as follows, using the special rCr-spanrrer supplied in the toolkit. 0. Stop the machine by pressing the red pushbutton tJl, 1. Conceal the punch stripper-protection (1/47 acc.drwg) by pushing i,t downwards and turning to 180 degrees.

GEKA

i3

- 2. Remove the punch. To d,o so: ease the punch fixing nut (7/6C acc.drwg), - detach the bayonet socket (1/sc acc.drwg) by turning the nut l/4 o.f a turn anti-clockwise, the punch then coming off . 3. Remove the die. To do so: - undo the die lockscrew from the die-holder (7/L acc. drwg) and remove the die. 4. clean the punch and die seats. verify if the key and all residues of the last punch used have been removed fron Lhe punch base (7/3C acc.drwg). 5. choose the new punch and die. verify if the cutting face of the punch can enter the die with some play. check the punch for proper working conditiorr, i.e. the entire cutting edge must.be sharp-edged and free from roundness and notches. Furthermore, verify if the cutting-edge diameter is greater than the diameter of any part of the punch that wirl o possibly penetrate into the workpiece 6. put the new die in prace with the cutt5.ng edge upwards and push it downwards until it perfeetly fits in the seat (7/L'tire acc. drwg). Then, fix it by tightening the lockscrew against external groove of the die. 7. Reprace the punch, proceeding in the inverse order of its dismantllng (steps 2-1-0) . When the shape of the cutting tool is not round, but sguare, rectangrrlar, obrong, etc., make sure that the punch and die assembl"y positions are identicar. on the other Land, insert the pun,ch head positioning key into the punch key,vay and into the punch-horder (7/3c asc.drwg). Before tightening-the nut (7/6c acc.drwg) sgcurely, verify if the punch head -is fully seated on the punch-holder (7/3 acc. drwg) by correctry pJ.acin! the key inside same. Prevent the punch irom rotaling whei tightening the nut (7/6c acc.drwg) and make sure th;t its o positioning coincides exactly with that of the die. 8. verify the punch-die arignment each time you change the tool and make sure both componexrts rernain aligned throughoit the punching process, by checking them for correct centering at regrular intervals. When working under hard eonditions (trard material, small diarueter, great thickness), increase the nr:mber of verifications. (Refer to paragraph 3.3.8 pItNcH-To- DrE CLEARAI,ICE AltD ALIGNMENT. ) (sEE PLATE NLMBER 3 SECTION 7-SAFETTES)

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3 14

E {r Directions for use of the worktable Frace the part !o !e punched against the cross straightedge (43/z acc.drwg) and the longitudinar straightedge (43/3 aci.dr-g), both having been previously positioned by iross-reference -to the nillimeter rules and secured by their iespective blocking levers. The coordinates are read on the front of cross straightedge t43/2 acc.drwg) and 010 side of rongitudinat straightedge (43/3 acc.drwg). The drop (tracing) worktable (43/st acc.drwg) can be concealed by releasing th.e clarnping levers located under same and removing thL tabre fixing bar {43/53 acc.drwg). rt is necessary to drop the table in order to punch holes in the leg of an angle.

*OPERATION PI.ACE THE HORKPIECE IN Tffi PTINCSING STATION FOLLOT{IITG THE DIRECTIONS FOB U,SE OF lgE WORKTABI,E OR PLACE TsE PRFVIOUSLY IRACED WORKPIECE ENSTIRING THAT TEE MARK COINCIDES HITH lEE PT'NCII POIITTER. 1

ACTTIATE THE COI{TROI'S DESCRIBED AT TEE BEGINITING OF TEIS SECTION o (3.1.1), TAXIilc ItrTO ACCOUIIT OttR INSTRUCTIOIIS FOR: 3.2.1 & DIE CHAr{GING 3.2.L GNI,IENT 3.3.8

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GEKA

3 i5 3 .2.2 . FI.ATS AND PLATES SHE,ARING

+ 00[il

r. When cutting flats, always use the flat stop (L/L24 acc. drwg) which shalI be adjusted proceeding as follows: o (sEE prATE NLI.{BER 4 SECTTON 7 -SAFETTES)

90"

WRONG I{RONG RIGIIT

1. Undo the fixing butterfly nuts (4/3 acc.drwg). 2. Raise or lower the stop (t/t24 acc.drwg) by turning the thumbscrew (L/1?,2 acs.drwg) until the entire bearing face of same o Ieans against the workpiece. 3. Wtren this is achieved, slightly lift the stop (t/L24 acc. drwg) (1 nrm) to allow introducing the workpiece and tighten the fixing butterfly nuts- The guide need not be adjusted while processing ah'rays the same material width. Any abuse of or failing to use this stop nay cause serious d.anages. Therefore' we urge you to use it ProPerIY. * The upper face of the flats support table (42/L acc.dr-wg) has guide marks for miter-cuts. Besides, it is reconmended to use the giuide bars (42/2 acc.drwg) in order to "emprison" the workpieCe, in such a way that sane ie held down by the stop G/t}+ acc.drwg) and lateraLly by the gruide bars (42/2 acc.drwg). GEI(A 3t

--. * For correct sizing of the material to be cut, we recommend the use of the electric stop described, as to its operation, at - the end of this section. tr The nurnber of cutting edges of each blade is specified in the table below:

MACITINE NITMBER OF CUTTING EDGES

TOP BLADE BOTTOM BLADE (L/46A acc,drwg) (L/46 acc.drwg)

ITYDRACROP 50 z 4 ITYDRACROP 70 2 4 I{YDRACROP 1.OO L 4 HYDRACROP 150 2 4

tr For good guality cutting and a longer service life of both machine and toolsr'd correct use of the wedges and positioning of the blades is required. IIYDRACROP 50-70-150 models are supplied, from factory, with o an insert on the top b1ade, This insert (L/80 acc.drwg) is used for cutting flats less than 13 mn in thichness. Prior to cutting flats over 13 mm in thickness, it is necessary to dismount the top blade (L/46A acc. drwg) and to renove the insert (1/80 acc.drwg).

On I{YDRACROP 100 nachines, the top blade {1/46A aec.drr,rg) is provided with a wedge {L/80 acc-drwg) which should be mounted in either positionr os follows:

A B

Position {A), for cutting plates less than L3 mm in thickness, o Position (B), for cutting plates over 13 mm in thickness. - On this model, the top blade (L/464 acc.drwg) can be mounted in one position only, as illustrated below:

+++++

GEI€A

3 17

L ?k In order to replace the fLat shear follows: blades, proceed as 0. stop the machine by pressing the red pushbutton tool-holder operating cyrindei is tJl wtren the travel. at trre highest point of its

1. Remove the BorroM BTADE (L/46 acc.drwg). To do so: unscrew the fixing butterfty nuts of the stop (t/tz[ acc.drrg) and take it out. undo the hex-headed screws DrN g33 (T) onty, with their respective washers, which hold down the blade. these screws are at the same revel as the plate support tabre (42/l acc.drwg) (which can be removed, if necessaryll 2. Remove the TOp BLADE (L/46A acc.drwg). To do so: Lift the rear gruard. (3/4 acc.drwg) of the flat shear. undo the hex-headed screws DrN 033 (T) only, with their respective washers and remove the bIade. 3- Clean the housings thoroughly and proceed the other lcay round o in order to install new blades-or to change the cutting iage ;i the existing gnes. 4. check thd clearance, adjust stud bolts DrN 913 (E) if necessary and tighten thern securery. (Refer to paragraph g.g.c CLEARANCE BETWEEN FLAT SHEAR BLADES. . . I . 5- Replace the stop (L/LT acc.drwg) and tighten the butterfry nuts (4/3 acc.drwg). DO NOT START THE MACIITNE ITNLESS you ARE QUrrE SURE THE SLADES ARE CORRECTLY MOT'NrED. The operation of t$e electric stop is identical at all cutting stations. To work with the el.ectril stop, proceed as forlowsz ' 0. Adjust the electric stop following the instructions under paragraph 3.3.G - ADJUSTMENT OF ELECTRIC STOP. o L. Bring the end of the cross stop bar face to face with the clrtting station to be used, by actuating the clamping lerers of the crankpin (6/2 acc.clricg). Make sure that the bar end in eontact with .the workpiece is slightly incLined to allow falling of the cuttings. free 2. serect the desired cuttirg length, which sharl be given by the intersectirg point of the adjustable thunbscrew rc/5 and the millimeter rule. """.ir-gl 3. Put selector t26l in posLtion (A).

GEI(A

J/

-_ 4. rnsert the workpiece until it hits the electric stop head, previously centred with respect to same. At that moment, the machine wilL start working, without need for applying on the peda1.

*OPERATION - IUTRODUCE THE TIORKPIECE LENTING Oil TUE SIIPPORS TABLE (42/L acc.drwg) rltTo Tm F'r,aT oR PLATE gHEjARs, GUTDTNG SA!{E Hrls rHE sroP BARS (42/2 acc.dnrg), ErrHEn IrNTil rr rrrrs rHE ELECTRIC STOP OR UNTIT TIIE PRESET NEFERENCE !{ANK IS RE.ACIIED. IN THIS I'ATTER CASE, IIOLD TEE WORKPIECE HITU TEE GUIDE (1./L24 acc.dnrg) AIED ACIrUATE TUE RELErratlT co![TRoLg, AS DESCRTBED A]rD TAKIITG IIITO ACCqTNT OTIR INSTNUSTIONS AITD RECO!,TMEIIDATIONS.

o

o

GEI(lA 3t 3.2 - 3. AHGTE IRON SHE;ARING

F

o rr As on arI workstations, the use of the guide-stop (4/5 acc.drwg) together with the cramping bort (4/7 acc.drwg) is essential for. good performances. proceed as fo110ws: Turn the knurred head clarnping boLt (4/7 acc.drwg) associa'ted with the guide-stop (4/s acc.drwg) in order to broiir the angle iron. Then, srightly turn the -bolt in the other direction, so that the workpiece wirl novb freely. This setting shall be kept as.Iong as angles of same thickness are processed.

tr For correct sizing of the materiar to be sheared, we reconmend the use of the electric stop whose operating prlnciple is described at the end of paragraph 3.2.2. - FLATS tA![D ptATEs SHEARING. * rf the cut in the legs of the angle iron should not be at right angle (90"), correct it by using the horizontaL and verticaL guide bars (4/6 acc.drn"g). The horizontal, gruide bar (4/6 acc. drwg) serves to correct the cutting angle of the vertical leg of the angre iron, whereas the vertical gruide bar (4/6 o acc.drwg) serves to correct the cutting angle of the horizontal leg of the angle section * &lhen cutting angles at 45", it often trappens that cuttings rernain caught in the workstation. Never try to remove them wittr your hand, while the machine is in operation. rnstead, introduce the workpiece qt 90o or press the red button tJl in order to stop the machine and then remove the cuttings.

GEKA ?t rn order to change angle shear blades, proceed as forlows: 0. stop the mac!'ine by pressing the red pushbutton tJl when the notching punch (9/3 acc.drwg) is in its top position.

l llt,.

o N A r | 151t, I T-

I I I I I I I L J o - -r- - - 1lt'\ 15t3

1-. undo the hex-head screw DrN 93L/1 fixing the guide (4/s acc.drwg) to the machine frame and remove said guide. 2. Take off the cramp (t/89 acc.drwg) in order to be able to remove ttre movable triangrular b}ade ( j.5/5 acc.drwg). 3. On all models, except IIYIIRACROP-SO, introduce the extractor, suppried with the toolkit, in hole (A) and puIl in order to remove tlre movabLe blade (15/5 acc.drwg) 4. Release the fixing screws DrN 931/t (T) of the fixed brades (L5/3 and 15/4 acc.drwg) and remove the blades. Arl four cutting edges of said brades can be used. To do So, interchange blade (L5/3) and blade (15/4) and overturn them. o 5. clean all seating areas thoroughry and repLace the brades, Broceeding as follows: Install the fixed blades (L5/3 and 1S/4 acc.drwg), without driving the screws hone. Put the movable blade (r5/5) in its housing, replace cranqr (L/89 acc.drwg) and tighten ecrews (r-J) securely. Then, srightry release central screw (J) and, with a thickness gauge, check if there is a small clearance between clamp (Ll9g acc.drwg) and movable blade (15/5 acc.drwg). GEI(iA Adjust the play between movable and fixed bLades, by lowering the movable triangular bLade (ls/s acc.dnryg) and acting on the stud borts DrN 913 (E) and respective nuts (N). (Refer ta paragraph 3.3.C - CTEARANCE BETWEEN FLAT SIIEAR BLADES AND PLAY BETWEEN MOVABLE AlrD FIXED BLADES OF ANGTE SIIEARS. ) DO NOT START THE MACHINE ITNLESS YOU ARE QUITE SURE TIIE BLADES ARE CORRECTLY MOT'NTED.

?TOPERATIOT{ FOR CUTTIilG AI{GLES AT 9O", INTRODUCE Tffi ITORKPIECE PERPEIIDICULAR TO GUIDE (4/5 acc,drug), FRONTALLY, SO TSAT IT PASSES TIIBOTIGTI TEE I,TACHIIIE AIID IS GUIDED BY CI,A!.IPING BOLT (4/7 acc.dnrg). ADJUST TEE tEilGtE EITEER BY USil,IG TIIE ELECTRIC STOP OR PUSEING TIIE ANGI.E TO TEE PNEDETER!{IIIE NEFEREIICE UARI(. roR oFF-cuTTrl{G ailGLES AT 45", IITfRODUCE TIIE HORXPTECE rttTo SLOTS ilArr AIID nBn (I"ATERAL Al[D TOP) IN cItIDE (4/5 acc.dmg) AIID I,ET TIIE OPPOSITE END NEST ON TIIE CTITTING EDGES OF TEE I'IXED BI.AIIE$ (15/3 e L5/4 acc-drug). IN TEIS tlAY, OFF-CtIfTIilG CAr{ BE PERFOBIiED ITTIIEOIIT NEED FOR Tffi ANGLE TO BE GUIDED BY ITElii (4/7 acc.drrg).

IN AI.L CASES, ACTUATE TITE COIrTROLS DESCRIBED AT TIIE BEGINilIilG OF TSIS SECrION, FOLLOSING OUR INSTRUCTIOI{S AI{D o NECSil,IEIIDATIOilS.

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GEKA 3/ 3.2.4. ROUIID AND SQUARE BAR CROPPLNG

?k Always use stop-guide (4/4 acc.drwg) throughout ttre cropping process o * For almost d,istortion-free cuts, the openings in the blades must be well suited to the diameter/perirneter of the bar to be cropped * For correct sizing of the bar to be cropped, ure recommend you to' use the electric stop, whose operating principle is described at the end of paragraph 3.2.2. FLATS AND PLATES SHEARING tr By changing the blades and guides (1 complete set per size), the cropper can also be used to cut UNP/INP sections. All the explanations given herein also applies to the cutting of said sections. * In ord,er to change the blades of round, square and other sections cropper, proceed as foLlows (referring to the MAIN coMPoNENTS rrST): First of all, make sure that both cropper blades are perfectly o paralleS.. This condltion is ful.f iLled when the notcher operating cylinder is at the highest point of its stroke. When the blades are in said position (i.e. when the front one only can be seen), proceed as follows: 0. Press the red pushbutton tJl ln order to stop the nachine. 1. Remove gruide plate (4/4 acc.drwg). To do so, undo the wing screws fixing it to the nachine frame (4/3 acc.drwg). 2. Back off the ALlen screws DIN 912 (f) and take off the blade retaining blocks (L/44 acc,drwg). 3. Remove the first blade (L/43 acc.drwg).

GEKA lrr*f| 4. Lift the rear guard and gently tap the back of the second (movable) blade {L/43) to push it out of the housing at the front of the machine. 5. Clean the seating areas thoroughly and replace the blades, inserting them from the front of the machine. Verify if the blades will not get stuck. To do so, secure the blade retaining blocks (l/44 acc.drwg) and., with a thickness gaufte, check the clearance between those blocks (L/44 acc. drwg) and the front blade. Final1y, replace the guide plate (4/4 acc.drwg).

DO NOT START THE MACITINE ITNTESS YOU ARE QUITE SURE TIIE BLADES ARE CORRECTTY MOUNTED.

WORKPIECE FEEDING PROCEDURE: 1. Insert the bar or section in the corresponding opening in guide plate (4/4 acc'drwg). 2. Hold ttre bar horizontally, J-oosen the wing nuts (4/3 acc. drwg), lower the' guide plate (4/4 acc.drwg) down to the top surface of the bar, by turning the thumbscrew (L/L22 acc. drwg), 3. Secure the wing nuts (4/3 acc.drwg) in order to maintain that o position until the next change of bar,/section tlpe or size. ?TOPERATIO$ FOSITION TUE BAR/SECTIOH EITHER BY USING TIIE ELECTRTC SI:OP (RETER TO APPEIIDIX DIRECTIOI{S FOR USE OF ATTACHTTENTS) OR AT THE PREDETEm{Iil8D nEFERENCE l'lARK. ASTUATE THE COIITROLS I'ESCRIBED AT THE BEGII{NI}{G OF TEIS SEETIOfi, TAKING INTO ACCOUNT OUR IilSTRUCTIOITS AITD AECOI.TIIEITDATIOI{S.

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GEKA 3t 3.2.5 HOTCEING

o e e o e o h \$

o o o

* tilhen working at this workstation, always mind that the workpiece should never be supported by one blade only, as shown on Fig. C, because this would inply shearing and would have to be done on the relevant workstation. As a rule, when notching, always lean the workpiece against two (fig. B) or ttrree (Fig. A) bottom blades at a time. (sEE PLATE NUI{BER 5 SECTTON 7 -SAFETTES)

\ \ v I o I I

I I I / \

FIG.A FIG.B FIG. C RIGHT RIGHT WRONG GEKA * Always use the notching punch strippers (3/47 and 3/48 acc. drwgl for easier extraction of punch and workpiece. (sEE prATE NITMBER 6 SECTTON 7 -SAFETIES) rk For easier working and SAFETY'S sake, we recommend to use the worktable in the notching station. The relevant instructions are included at the end of this paragraph. * In any case, use the sliding protection guard (1"/54 acc.drwg) provided at this workstation, making sure the Lock of the latchkey, allowing to exceptionally inhibit this safety, is in position (A). (See instructions for use of latchkey tPI below. ) I I o POSITION A - CLOSED POSITION B - OPSN When notbhing or working at this workstation in general, the sliding protection guard (L/54 acc.drwg) must be closed (Position A). If for 'any reason, intentionaL or unintentj.onal, the guard should get open (Position B), the machine would then stop working. If there should be any good reason for operating the machine with the guard in the retracted position (B ), then the following procedure would have to be applied: 1. Ask the shop leader for the latchkey. The latchkey must always be kept by the shop leader, away from the machine. 2. Under the responsibility of the shop leader and your own, as an authorized operator, i.nsert the latchkey into the lock and turn it to position (B). As a resuJ.t, the detector is inhibited. o 3. Do the job that has been previously authorized. 4. Then, cLose the protection guard (t/54 acc.drwg). 5. Turn the.latchkey tPl to Bosition (A) agrain and renove the key. (As a resuJ-t, the machine will operate only if the gruard is closed. ) 6. Give the key back to the shop leader. The key must not be left in the lock, except if a.bsolutely necessary.

GEI€A

r2g * As indicated in the operating instructions of the flat shears, any abuse of this workstation may cause serious damages to the machine. * In order to change tJre punch and blades, proceed as follows, after verifying if the notching punch is in its most retracted position. 0. Press the red pushbutton tJl in order to stop the machine. L. Back off the fixing hex-head screws and remove the blades (9/2 acc.drwg) from the die-holder (9lL acc.drrg). 2. Remove the guards, if necessary. 3. Back off the notching punch (9/3 acc,drwg) fixing screw at the bottom face of same. 4. Clean all seating areas thoroughly and replace the punch and. blades, proceeding in tlre reverse order.

:r How to use the support table ? PLace the part to be notched against the cross straightedge (9/4 acc.drwg) and the Longitudinal straightedge (g/tZ acc.drwg), both having been previously positioned by cross-reference to the millimeter rules and secured by their respective clamping levers. The coordinate read on the front of cross stralghtedge (9/4 acc. o drwg) indicatee the distance to the cutting edge of the blade on the front die-holder, while the coordinate read on the 0lO side of longitudinal straightedge (9/I2 acc. drwg) represents the distance to the centre of the notching punch. For correct centering of the tool, refer to paragraph 3.3,D CLEARAI{CE BETWEEN NOTCHING PT'NCH AND BTADE DIE.HOLDER.

DO NOT START THE MACHINE UNTESS YOU ARE QUITE SURE THE BLADES ARE CORRECTLY I4OI'NTED.

TcOPERtrTION USIIIG THE SUPPORT TABLE (REFER TO APPEIIDIX DrnEcTroNs FoR usE oF ArrAcalrENTs) oR r{cf, pLAcE TIIE WORKPIECE ril THE NOTCHTilc HOnKSTaTION .IIiID ACTUATE TIIE CONTnOLS DESCRIBED At TEE BEGTilHIilG OF TIIIS SBCTTON, TAKTNG rmo ACCOUilT OUR INSTNUCTIONS AND RECOIIIGNDATIONS. o 3,3 .SETTINGS For maintaining the process parameters on and on, we recommend a series of settings as stated below. These adjuetments should be made by an authorized and skilted personnel familiar with the operation of the machine, taking all necessarY precautions, since gruards and safeties are inhibited,.

3.3.A.- PUNCH-TO-DIE DISTAI{CE/SETTING OF LIMIT SWITCIIES At the punching workstat5.on, the recommended punch-to-die dj-stance is equal to the maximum punchable thickness specified for the mactrine plus 6 mm. When punching large series, without changes in thickness, the linit of th€ punch up-stroke can be set at 3 srm above the workpiece/stripper (1/47 acc,drrrg) contact Ievel. At the notching and other stations, a gap enabling the free introduction of the workpiece would be sufficient. On the other hand, we reconmend that, on its down-stroke, the punch wouLd not go more than 1 mm in the die, after passing o through the workpiece. This is intended to reduce possible serious damages in the event of faulty centering of punch and die. The Linit swit,ches should interrupt the cylinder travel before an internal mechanical stop at either the uBper end or the farthest lower end occurs. The adjustment is achieved by meana of the two stops (L/65-A acc. drwg) placed on each cylinder. These stopo (L/65-A acc.drwg) can be released with a 4 nm Allen wrench. Take care not to remove the sealed capped backstops (L/658 acc.drwg) provided to impede overrunning the maximum allowable travel

The function of each stop is specified in the follovring table: o PUNC}IING CYTINDER MACHINE THE UPPER STOP TIIE tOIrtER STOP CONTROTS THE CONTROLS THE

I{YDRACORP 50 UP-STROKE DOhIN-STROKE

TfYDRACROP 70-100-150-200 DOhIN-STROKE UP-STROKE

GEKA

2 28

-- NOTCHING CYLINDER

MACHINE THE UPPER STOP THE LOWER STOP CONTROLS THE CONTROTS THE

rryDRAcRop 50-70-l_00-150-200 DOWN-STROKE UP-STROKE

o

o

GEKA 3.3. B. PT]NCH-TO-DIE CLE.ARATiICE . ITOW TO CENTER TTrEM ? For a given punch and its corresponding die, the cLearance l-s f ixed. Acceptable quality punching can be achieved, when the punch-to- die clearance is approximately L/LO of the plate thickness- Clearance less than 0.5 nm are however not recomne,nded. For workpieces from 3 to 5 mn in thj,ckness, the recornmended punch-to-die clearance is 0.5 mm; for all other thicknesses over 5 rnm, the recommended clearance is as said above, i.e. abt. L/lO of the plate thickness. Always use genuine GEI(A punches and dies. Refuse any imitations. For further information, refer to the attached PTNCH AND DIE CATALOGUE. When ordering replacement parts, alwavs quote the punch or die reference nurnber or, if'not available, the model of your machine, as well as the desired clearance, otherrrsise we shall consider that the clearance required is as per the catalogue sBecifications. o PT'NCH AITD DIE CEITTERING PROCEDTIRE: HARHIITG I BE VERY CAREF"UL, BECAUSE YOU AnE HORKING HITHOTIT SAFEIY GIIARDS. DO IIOT PT'T YOIIR EAITDS OR YOI'R FACE IN OR I{EAR TgE PTTNGIII|G AREA FON NO REASOil WHATSOSITER. o

{a o o r o o

L. With selector tt] in the PITNCH APPROACII position and the punch stripper (L/47 acc.drwg) concealed' apply on the pedal at very sbort intervals in order to lower the punch gradually until it is at a distance of 3 sur from the die. In this position, centering of both tooLs can be verified easily at f,irst sight. If clearLy unsatisfactory, proceed directly with point 3. If centering is found to be correct, proceed as said above in order to bring the punch nearer to the die, without touching it. GEKA

/30 2. Visually inspect the clearance for evenrress all- around the punch. If correct, let the punch get 1 mm in the die' as explained 5.n paragraph 3.2.L - DESCRIPTIOII OF EACH WORKSTATION FIINCTION: PIINCIIING, and proceed with point 4. Otherwise, proceed as follows: 3. Stop the machine and slightly back off the screws or nuts marked (A). Consequently, the die-holder can be moved in order to be centered. To this end, remember that items (B) are used to move the die-hoLder {7/L acc.drwg) for its eentering parallel to the machine axis, while items (C) permit its centering perpendicular to the machine axj.s. 4. giltren punch and die are correctly centered, secure the fixing parts (A-B-C) in the reverse order.

Punch a3d die centering should be made at each tool change. TooI charrging instructions are given ln paragraph 3.2.t - PIINCHING. (sEE PLATE NI'MBER 3 SECTTON 7 -SAFETTES) 3. 3. C. CLEARAT{CE BETWSEN FLAT SHEAR BrrypES ANp PIAY BETI|EET o MOVABLE A}'ID FIXED BLADES OF AI{GLE SHEARS

E.N

*-:'^.- -.Jr-

\ o

For material thickness over 4 mm, aceeptable guality cutting is achieved with 0.3 nfn blade clearance. The following stepe are required in order to adjust the blade cLearagce: 1. tower the (f1at/angle) shear blades until the cutting edges meet.

GEK/A

3 31 2. Press the red pushbutton tJl in order to stop the machine and, then, remove the gruide from the reLevant workstation. 3.Slightly back off the hex-headed screws DIN 933 (T) fixing the blades. 4. Undo the hexagonal nuts (N) which lock the clearance setting Allen studbolts (E). 5. Tigbten or loosen the Allen studbolts (E) according as the clearance must be decreased resp. increased. (See illustration on previous page.) 6. Retighten partly the hex-headed fixing screws DIN 933 (T) (refer to point 3) and, with a thickness gtauge, verify if the clearance is correct. 7. tock the hexagonal nuts (N) fixing the Allen studbolts (refer to point 4). 8. Tighten the hex-headed screws (T) securely (but raithout excess, to avoid any risk of blade breakage). 9. Check the clearance once more and, if correct, replace the guide removed at the beginning of the adjustnent process.

3.3.D. CTEANANCE BETTJEEN NOTCHING PUNCIT AND BIADE DIE-HOLDER.. o

tS 9/3 I I I I I 912A s I

E 9/Z

c

9/1 o D

D For any material thickness over 3 nm, acceptabJ.e quality notching can be achieved if the clearance between the punch (9/3 acc.drwg) and the front notching bLade (9/2 acc.drwg) is 0.4 mm. In order to readjust the clearance between punch (9/3 acc.drwg) and front blade (9/2 acc.drwg) and to center the tools, proceed as follows: GEKA

J 32 0. Press the red pushbutton tJl to stop the machlne, when the cyrinder is at the up-stroke end. Ask the shop leader for the safety latchkey [P] and lift the sriding guara (r/s+ acc.d*g). L. Check studbolt (E) for correct tightening, make sure the cutting edges are correctly positioned and verify if notching punch (9/3 acc,drwg) is perfectly blocked. 2. Turn latchkey lock tPl to the right position (B) and switch selector ttl to the right position (C).- press the machine start pushbutton tKl and, applying on the pedal at strort intervals, lower the blade-holder until the punch is at a short distance from the cutting edges of the blades mounted on the die-holder. 3. Inspect the arrangenent visually and, if satisfactory, continue lowering the punch, by jogging it very slowly, and verify visually the correct aLigrnment of the tools, until the punch finally enters the die-holder (9/L acc.drwg). Then, with thickness gauges, verify if the punch-to-blade clearance is evenly distributed laterally and the clearance between the punch and the front blade is equal to 0.4 mm. 4. If the die-holder shoul,d be offset (the punch colliding with the blades on the die-holder), stop the machine by pressing the red pushbutton tJl and slightly back off the hex-headed o screws/studbolts marked (A-B-C-D) on the iLlustration on the previous pagfe, As a result, the die-holder is released. and can be centered. 5. Note that screws (A) are provided for lateral centering of die-base, while Allen screws/studbolts (B-D) serve to adjust the clearance between punch and front blade Restart the machine as indicated in point 2 and nrove the die- holder {9/t acc.drwg) as may be necessary for punch (e/3 acc.drwg) to get in. 6. Stop the machine by pressing the red pushbutton tJl and, verifying the cLearance with thickness gauges, retighten screws (A) (side clearance) ?ndr then, screws,/studbolts (B-D) (front clearance). When the tool has been satisfactorily centered, simultaneously drive (C) home and tighten screws,/studbolts (A-B- D ) securely, taking care not to mo\re the die-hol.der (9 /1 o acc.drwg) previously centered. 7. Close the sliding giuard (L/54 acc.drwg), turn the latchkey [PJ into position (A) and give the latchkey back to the shop leader. (sEE PLATE NLMBER 5 SECTTON 7 -SAFETTES)

GEI(A

3 33

--- 3.3,E. APJUSTMENT OF BLApE_HOLpER The blade-holder can be adjusted by meaxls of the Allen studbolts situated on the machine frame, near the greasing points marked i.n red circles on both sides of the machine and shown on the GREASING POINT PtAN. The factory-set play is 0.L nm. If you should want to change this setting, you would be urise to contact your dealer and/or the manufacturer.

3. 3 . F. PRESSURE OF ITYDRAULIC UNIT See enclosed tab1e.

MACHINE FAMITY PRESSURE (BARS)

I{YDRACROP 250

The pressure need not be readjusted, except if the machine capacity is not sufficient to do the jobs it is intended for o according to the catalogrue and,/or nameplate specif ications. The pressure.. is adjusted by means of the safety valve of the hydraulic unit (refer to HYIDRAUTIC UNIT PARTS LIST) as follows: 1. Open the panel(s) (t/gL L/9LA acc.drwg) of the machine bed (L/87 acc.dr*g) .

2. Open ttre pressure gauge cut-of f valve ( refer to IIYDRAULIC ttNIT PARTS I,IST). 3. Press the red pustrbutton tJl to stop the machine and, then, verify if the pressure gauge read.ing is 0 (zero). 4. Press the green start pushbutton tKl and lower the blade- hoLder (1/18 asc.drwg) or the punch (7/4 acc.drwg) until it Eets stuck, unable to continue the operation. At that time, note the pressure gauge reading. o 5. If the reading is inferior to the maximum pressure (according to table), renove the safety valve Locknut and introduce the internal regulating studr so that the pressure of the hydraulic unit can buiLd up. On the contrary, Lf the hydraulic unit pressure should be reduced, the internal regulating stud would have to be taken out. 6. Check the hlzdraul.ic unit pressure again, It should now be equal to or sligthly Lowet than that specified in the table. 7. Retighten the internal regulating stud fixing nut" 8. Close the pressure gauge cut-off valve, naking sure the GEI(A

3 34 presgure is correct. 9. Close the paneL(s) of the machine bed.

3 . 3. G. ADJUST},IENT OF ELECTRIC STOP Adjusting this accessory sha1l be made in accordance with the following procedure (refer to PARTS IIST OF ELECTRIC STOP): L. Insert plug ("No) in the socket provided for this purpose at the back of the nachine and turn selector t26I into position (A). 2. Start the machine and feed the workpiece to be cut at any size you require. 3. Stop the machine and measure the length of the cutting. 4. The meaeurement might be different frorn the value initially set by means of the milLimeter rule. In order to take up the difference, ease the thumbscrew (6/3 acc.drwg) and slide it to the adequate reading. Then, block the studbolt (rDn) of the thumbscrew, As a result. the electric stop has been adapted to o the workstation concerned. If any additional guide bar (6/LA acc.drwg) need be assembled, aligm it properly, using the exteneion module coupling bolt (6/tD acc.drwg) which has various threads that have to be conrbined in order to obtain a perfect alignment of the millimeter rule. When such alignment is obtained, block the assesrbly by means of the Al1en stud bolt ('P") When using one or more extensi.on modules, it is necessary to provide then with a support (stand) in order to Brevent those modules from "sagging", which would have a negative effect on their support on the machine.

3.4. GETTING STARTED Machine wiring has been made following the instructions under o Section 2.4 INSTALTATION INSTRUCTIONS and should be checked before starting-up the machine, proceeding as foLLows: O. The rnachine is power-supplied (as prepared in accordanee with Section 2 - INSTATLATIOT{). 1. Turn the PIINCII-PLATE selector [H], if any, on the electric cabinet into 'PITNCH' Position. 2. Turn the aPproach selector ttl on the electric cabinet into position 0 (zero), 3. Apply the prrnching pedal fulI on' GEKA /35 4. Press the green pushbutton and verify if the machine starts. tKl 4-YES' IT DOES. If the pgnch-holder (7/3 acc.drug) moves, the direction of rotation of the motor is rioht andr hence, the machine i.s ready to operate. 4-NO, IT DOES NOT. If no movement of the machine takes place, CAUTION: Release the oedal inmediatelv in order not tg dgmatre the hpdraulic pumr and stop the machine bv preesinq the red STOP puslrbutton [J]. In this event, the direction of rotation of the motor is wronq and must be inverted, proceeding as follows: 4-NO-A: Switch off the machine, by turning the naj.n switch tAl on the eleetric cabinet until the white pilot lamp t50I turns off. 4-NO-B: Interrupt the power supply so that the machine feeder is not Live. 4-NO-C: Open the electric panel. o 4-NO-D: Invert cables at terminals R and T. Consequently, the corrnections will result in: * Earth terrninal - unchanged (green,/ye11ow wire) ?k Terminal R - PHASE conductor-(formerly connected to T) * Terminal S - PIIASE conductor (unchanged) rt Terminal T - PHASE conductor (formerly connected to R), 4-NO-E: Close the electric panel and repeat steps O-l-2-3-4. The direction of rotation of the motor must now be correct (4- Y:ES). Otherwise, refer to Section 5 - TROUBTES AI\ID RE!{EDIES. o

GEKA SECTION 4 - MAINTENANCE

AI.t THE OPER4:TJ:0!{S DE99RIBED IN TIIIS SEcTIoN MUsr BE PERFORMED WITH TIIE MACHINE AT REST AND pOIrrER OFF. l!!_= THE TNTERVENTToNS HBnsrN MUST BE PERFORMEp By A DULY AUTHORIZED AI.ID OUAI.TFffi FAI{ILIAR WITH THE OP.ERATIO}I OF TIIE MACIIINE.

4.T. MAINTENAI{CE OPERATIONS The maintenance operations recommended by the machine manufacturer are described below: 4.1.A. Oil By means of the external oil sight of the tank, check if the oil level is appropriate. Change hydraulic oil every 3000 working hours, proceeding as follows: o - Stop the machine by pressing the red pushbutton [J]; turn main switch tAI off and remove the panel(s) from the machine bed in order to reacll the hyd.raulic unit. Remove the filling plug from the hydraulic oil tanh and empty the tank with a suction pump. rf you should not have such a pump, undo the draining plug at the bottom of the tank and rernove ttre waste oiI. Then, replace the draining ptug. FilL the tank with hydraulic oil ISO TR3498-IIII{46 until a sufficient level is reached. Refer to the tank capacity tab1e.

MACHINE TAI.IK CAFACITY

I{YDRACROP 50 80 I ITYDRACROP 70 L00 I IITrDRACROP 100 ro0 I FTYDRACROP 1.50 200 r o ITTDRACROP 200 200 I Replace the filling pLug and the panel(s) of the machine bed.

GEKA

4 1 4.1.8. Inlet Strainer The inlet strainer [J or D] (refer to pARTS IIST OF I{yDRAULIC uNrr) should be changed every L00o worki.ng hours, proceeding as follows: Stop the machine by pressing the red pushbutton [J], tur:n main switch tAl off and renove the panel(s) from the machine bed in order to reach the hydraulic unit. If you have a IIYD ?OS/SD or IIYD IOOS/SD machine equipped with a VICI(ERS hydraulic unit, open the hatch on the top cover. If you have any other model, unlock and slightly lift tlre top cover of the oil tank at one Eide. Unscrew the inlet stralner and replace it by a new one according to the following table:

},TODEL FLOW THREAD SIEVE RAfE

vrcKERs (rryD 50s/sD, rrY:D 70AlN, 3s 3/4" 90p o HINE r{YD 100A/N) vrcKERs (rryD 70s/sD, nyD 100s/so1 65 1" 9ou HINE VICKERS (IIYD 150 - r{YD 200) L30 L*" 90U

REXROTH 100 1*'1L25u GOIMENDI - Close the hatch or cover of the tank. Replace the panel(s) of the machine bed.

4.L.C. Wear Parts

TOOLS * Punching Head: (7 /4 acc.drwg) Punch. o (7 /2 acc.drwg) Die. (7 /3C acc.drwg) Punch-ho L der,/punch-bas e . (7 /5C acc.drwg) Bayonet socket. (7 / 6C acc. d*g) Punch fixing nut. (L/47 acc.dnug) Punch stripper. fr Cutting knives or blades: (t/46) Flat shear knives. ( L,5 / ) Ang1e shear knives. (L/43) Round and square bar cropper blades. (e/ ) Notcher blades.

GEI(iA

4 2 It is recommended to inspect all wear parts frequently. More particulary: FLat, angle and round and square bar knives and blades shall be subjected to a visual inspection evsry I working hours in order to detect any wear of their cutting edge and, if necessary, they shalL be changed in accordance with the instructions under paragiraph 3.2 DESCRIPTION OF EACII WORKSTATION OPERATING PRINCIPTE . Check punch (7/4 acc.drwg) and die (7/2 acc.drwg) for correct centering, making sure the . setting remains unchanged throughout the punching process. If any unusual wear shouLd be noti.ced, replace the component. Pay especial attention to this point when punching hard materials or thick workpieces. - Check parts (7/3C, 7/5C, 7/6C and I/47 acc.drwg), i.e. the punching head, for proper working conditions and, if necessary, replace thesl. Verify especiaLly if (i) the punch stripper (L/47 acc. drwg) is Ievelled and crack-free and (ii) the punch bearing surface of punch-holder (7/3C acc.drwg) is smooth and the kelnrvay in good o condition. 4. L.D. Safetv Guards Before starting working, inspect all safety guards and stops visually for correct positioning. If in doubt, refer to Section 7 SAFETIES and check all and any items described in sane.

ALWAYS USE PERSONAL AIID MACIIINE PROTECTIONS WTTEN WORKING. THESE ARE YOUR BEST ACCIDENT PREVENTION WEAPONS.

4.2. IUBRTCATTqN ANp CIEAI.ITNG Every 40 working hours, lubricate with abundant grease all greasing points marked in red circles on both sides of the machine and shown on the GREASING POINT PLAN (See attached docunents). o To do so, refill with grease ISO TR3498-XCCHB2, using the grease grun supplied with the machine. Cleaning the outside of the machine and coating the bare parts of the nraihine with rust-preventive fLuids are always profitable practices whose periodicity is, of course, dependent upon the machine user's goodwill.

4 3 SECTION5.PARTSLIST

The I,IAIN PARTS LIST ( four views of the machlne) is attached hereto, as an APPENDIX to this Instruction Manual and clearly identify all the machine components. Pictures of the trlzdraulic unit (IIYDRAUTIC PARTS LIST) and eLectrie cabinet (COI{TROI PARTS IIST) are also enclosed. When ordering or asking for information about any part, please quote the reference number (acc.drwg in this MANUAT) indicated on the illustration, as weLl as the model / version and serial number of your nachine, as stated on the narneplate. Referring to the said docr:rnents will obviate possible confusions and errors when placing enquiries or orders for reBlacement parts. Please, consult then !

o

o

GEKA

5 1 SECTION 6 - TROI'BLES A!{D REI,TEDIES

This Section describes the most frequent troubles you can face as weLl as the way to repair them. Unless otherrnrise specified, aIl the actions described below must be carried out with the nachine completely stopped and power off.

ALt THE ONS REFERRED TO TIERETN MITST PERFORMED BY A DUIY AUTHORIZED AND OUALIFIED PERSONNEL FAMILIAR IIIITH THE OPERATION OF TTIE MACHINE

Jh TROT'BLE # 1 - THE I.IO|[OR DOES ITCIT START

POSSIBI,E CAUSES: - CAUSE A: Emergency stop interlocked. CAUSE B: Tripping of thermorelay. CAUSE C: Fuse blown. CAUSE D:' Control panel not closed properly. REMEDIES: o REMEDY 1-A: Check and release the emergency stops. REMEDY L-8: Reset the thermorelay and wait for a few seconds, befo{e restarting. REMEDY L-C: Check the fuses and reptace the faulty one by a new' one gf same amperage. REMEDY 1-D: In fact, the machine has not been set in motion. Close the control panel and turn the main switch on again

* TROTTBLE * 2 - THE I{ACIIME IS UOT pOWEn SUppLrE:D I'HEN THE uAltr SHITCII IS TT'RIIED ON. TIIE NPOIIE:R ON" WHITE PILOT LEilP DOES NOT TURN Oil.

POSSIBLE CAUFES:

- CAUSE A: The nains voltage i.s cut off . CAUSE B: Ttre transformer output fuse is blown. CAUSE C: The cabinet is not closed properly. o CAUSE D: The nPOWER ON'r lanp is burnt out. REMEDIES:

REI4EDY 2-A; Check the circuit-breaker and electric installation of the workshop. REMEDY 2-Bz Check the fuses and replace the faulty one by a new one of same anperage. REMEDY 2-C: Close the electric cabinet correctly. - REIIEDY Z-Dz Change the bulb.

GET(A

6 1 * TROUBTE # 3 - TIIE IIOTOR STARTS, B{tr pREssuRE DOES NOT BUrLD Up IN THE MACEIilE

POSSIBLE CAUSES: - cAusE A: Direction of rotation of the motor inverted. CAUSE B Safety valve deregulated. CAUSE c Failing hydraulic pump. CAUSE D The slide of the electrically-operated valve does not operate. CAUSE E: Piston seal damaged. CAUSE F: The pedal does not work properly. CAUSE G: The pedal-machine electric cable is danaged. CAUSE H: Limit switch out of adjustment. CAUSE I: OiI level too low. CAUSE J: Motor-punp coupling broken.

REilIEDIES I

REMEDY 3-A: Proceed as indicated in paragraph 3.4 START- UP. REI,IEDY 3-Bi Readjust the safety valve. REMEDY 3-C: Replace the pump. o REMEDY 3-D:Energize the electrically operated valve as indicated in the diagnostic test at the end of this section. Should the problem persist, change the electro-valve. REIIIEDY 3-E: Remove the cylinder and replace the seal(s) where appropriate. For this purpose, contact servicemen familiar with hydrauJ.lc problems. REMEDY 3-F: Check .its connection; visually inspect the interior and repJ.ace the internal microswitch if the problem persists. REMEDY 3-G: Restore the connection in the damaged area and. protect with insulating tape. REMEDY 3-I{: Re-adjust the lirnit-switch in accordance with the recommendation in paragraph 3.3 - SETTINGS. REMEDY 3-I: Add oil to reach the required leve1r ds indicated in paragraph 4.1.A - MAINTENANCE OPERATIONS: OIL. REMEDY 3-J: Replace the coupling. To do so, 1t is necessary to unfasten the motor flange and/or feet. o * TROI'BLE # 4 - Irc-PHASE TARTIT{G POSSIBLE CAUSES:

CAUSE A: Faulty wiring.

REMEDIES: REMEDY 4-A: Check wiring and correct according to the instructions given in Section 2 INSTALLATION.

GEKA * TROUBLE # 5 - TIIE I.{OTON STARTS, THE PRESSTIRE BUILDS UP TO 25O OR 180 BARS (ACC. TO ITODELS) AlrD Tffi UOTOR STOPS AFTER A FE'n SECONDS DTIE TO THE TRI,PPING OF Tffi TEERI{ORELAY

POSSIBLE CAUSES:

CAUSE A: Linit switch out of adjustment.

REMEDIES:

REMEDY 5-A: Readjust, by sliding the stop through the rod until making the lisrit switch.

* TNOUBLE # 6 . TEE UOTON STARTS AND STOPS AF'TEN A FE:N MIMTTES

POSSIBLE CAUSESI CAUSE A: timit-switch out of ad.justment, it sticks at the top leve1 of the strokd. REI{EDIES:

o REMEDY 6-A: Readjust, by sliding the stop through the rod until making the Limit switch,

rk TROUBLE * 7 - IINCLEAII CUT

POSSIBTE CAUSES:

CAUSE A: Cutting tools with excessive play or duLl-edged.

REMEDIES: REI,IEDY 7-A: Adjust the play as indicated in paragraph 3.3 SETTINGS or change the cutting tool (paragraph.3.2 DESCRIPTION OF EACH WORKSTATION OPENATING PRINCIPTE).

* TROI'BLE * 8 - AilGLE-CT'TTIIIG IS }ICf SOPARE o POSSIBLE CAUSES: CAUSE A: Wrong guide position.

REI"TEDIES: REMEDY 8-A: Adjust the lnlet angle by means of guide (4/5 acc,drwg) and adjusters (4/2 acc.drvg), following the instructions in paragrah 3.2.3. Al{GtE SHEAR.

GEI(IA

6 3 * TROUBLE # 9 I}ISUFFICIETET OPENING

POESIBLE CAUSES: CAUSE A: Stroke-end stop out of adjustment. RE}IEDIES:

REMEDY 9-A: Relocate the top stroke-end stop.

* TROUBLE # 10 - ffiE F?DRAULIC GROI'P VIBNA?ES ABNOSTTIALIY DT,RI}IG THE CTI,I!$DER BACK UOTION

FOSSIBTE CAUSES: CAUSE A: Transfo:rmer voltage failure (+/- 5 8). REMEDIES:

RE}{EDY 10-A: Check the line or instaLl a speciaL transformer that will compensate for the line failures.

o * TROUBLE # 1L (On nodels with DOI|BLE PEDAT) - FAULTY SLOII SPEED (rorf PREssttRE) AilD FAST SPEED (rurt r0Arr) OPERATTON

POS$rBrE CAUSES: CAUSE A: The internal microswitch of pedal lzJ has moved. REI{EDIES: REMEDY Ll-A: Check the inside of the pedal and adjust the nicroswitch.

* TROUBLE * LZ - (On nodels with work area lighting) - TIIE LAl,tP BT'NNS OT}T WEEil TUR$ED OT{.

POSSIBLE CAUSESI CAUSE A: The lamp is connected to the mains instead of the o mashine outlet (12 V),

REMFDIES:

REMEDY 1.2-A: Change the lamp and conneet correctly.

GEKA

4 If the trouble still exists, carry out the following diagnostic test (not applicable to troubles # L and Z), proceeding as follows:

1 - Start the machine. 2 Remove the panel(s) of the machine bed, (Llgt /gLA acc.drwg). 3 Refer to the IIYDRAULIC ttNIT PARTS LIST and energrize the electically operated vaIve, using a screwdriver or similar tool and pushing the ends (black cap) of the si.des of the electrovalve. In this wBy, the slide inside the valve will nove. As a rul-e, if the machine works, the failure is of electric origin; if it does not, the failure is hydraulic. Contact the maintenance technician of the company that supplied the machine to your stating the following:

MODEL OF TITE MACHINE SERIAL NT'MBER IIYI)RAUIIC GROUP DATA RESULT OF DIAGNOSTIC TEST (electric or hydraulic failure). o

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GEKA

6 tr SECTIOII 7 - SAFETI.ES Throughout the preced,ing sections, advices, instnrctions and warnings have been given in order to ensure a perfectly safe operation of the machine, under both correct use and foreseeable malfunction conditions. this section is meant to sumarize, wittrout limitation, the vital safety recomendations : The machine nnrst exclusivelv be operated by duly authorized' qualified anrd trained Bersons, under ttre responsibility of the Corpany's Uanagenent. This inply they trave read and understood the INSTRUCTION DlAltUAL, conplete with its APPENDICES. In addition, they must be familiar with the jobs to be performed on the mashine equipped with both its standard and optional attachments. - Never leawe the machine ssitched on and unattended. Always turn the main switch tAI off when completing the job. Do not remove or damage the waraing plates affixed to the machine. Those plates concern: o T-GENENAL USE PT"ATE 2-IIIACHIITE RATINGS PLATE 3-CENTERING PTINCII STATIOT{ PLATE. 4-FLAT SffEAR STOP PLATE. s-CEITTERII{G & USING NOTCIIING STATION PLATE. 6-STOPS & SAFEIY GUARDS PLATE. ?-'rCE[ I.IARI(. Should any of these plates be nissing or damaged, feel free to advise us; it will be replaced free of charge for you. - Yellosr/orange-painted areas are potentiaL danger areas. In order to protect the operators of our machines" all workstations are fittgd rith mrards and protecti-ons, as described hereafter. $aid qirards .and protections must be kent in qood ordgr at all times; thev should never be removed shile the machine is operatinq and the, machine should nevErr be put in ooeration, o without al-I protgctions beinq in place * PIINCH Safetv Guard (Refer to PARTS LIST) The PIIIICEING workstation is provided with front and rear guards (3/L7-3118 acc.drug) mounted on rolls (3/Lg acc.drug). In addition, mind the following safety instmctions: L- Check tbichness for punchability, against the '!{Alil![tt!t THICKNESS ' equation. 2- Ask your supplier to confirm the resistance of the material to be punched. GEI(/A

7 I o o o o lnffDEmtlEttXmm[lfll EDnEInptssrE il.1,t5?s rptm.rEIq,rmt5!EFnnD IHIXL A ffif,rTIrfllotm.ttrlrTE.[ (f,rEutoElu. l- rmmtlslExtrEmmcrru rulXmmlffixsnrmrr! l= Ht- lGGoffifltlu.ngffim e rffisl[?@ITREBL &FInCffiXfrm.EIBIN* & ilFrrllEflnnlfinl soFlrurnnmuEm$?n o am, n 3EmFrEilrtrr[f nntln8m, ffiTHEl, tlurltrA @(^ sr' t-tEaantmtiltfinifSllxo llllrctt 20r qnnuil iluzlo 1 }EEIEffiNNKI!XNfiINE EPIf,I o o o

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WHEN I,IORKING ON THIS STATION, ALWAYS USE F THE 6UIDE STOPS AND 6UARDS. \J 3

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-- 3. Enclose the punch area as much as you can. 4. Use the punching table. 5, Never put your finger under the stripper. 6. Frequently check tool for correct centering. 7. Always punch holes through at once (not bit by bit). 8. Consult the punch maker about any risk of breaking/ shattering, before starting arry job. 9. Take all injury preventive measures.

tt FLAT SIIE.AR $afetv Guari (Ref,er to PARTS LIST) Front gruard: composed of gruide (L/L24 acc.drwg) and grating around sane (3/L4 acc.drwg). - Rear gruard, i.e. plate with iaclined plane inpeding its opening (3/4 acc.drwg). * AI{QLE SHEAB SafetY GuArd (RCfEr to PARTS LIST). Front guard: composed of oversized gruide (415 acc.drwg) and grating arormd Eame (3/8-3/L5 acc.drrrg). - Rear guard, i.e. plate with inclined plane inpeding its opuring o (3/2 acc.drvg).

* ROIIND & SQUARE BAR CRO?PER Safetv Guard (Refer to PARTS tIST) . Front gnrard: overdimensioned giuide protected by ttre other workstations or gratings arormd its perimeter (3/L3-3/L4 acc.dnrg). - Rear giuard, i.e. plate with inclined plane inpeding its opeoing (3/3 acc.dncg).

* I|OTSIER Safgtv Guard (Refer to PARTS LIST). S1iding gruide (l/54 acc.dmg) fixed by me.rrrs of bahelite thumbscrens and safety latchkey tPI. In addition, samambss the following: f.l 1- Always worh with tbe safety sliding guard lowered- 2- Use the notching support table 3- Do not put your hands in the notching area for no reason whatsoever. 4- Frequently verify if the tool components are correctly aligned. 5- Take all injury preventive neasures. 6- Use protective screens when doing special jobs or for special applications

GEKA

7 2 The cylinders and hoses are protected against possible damages due to burst or leakage, by means of safety gruards. DO NOT REI'IOVE THESE GUARDS.

For your own security, compl-y with all Hygiene and Safety at lorh Regrurlations and, pirtieutaity, those relating to using injury preventive means. You are kindly requested to wear goggles, gloves, a safety cdP, an apron in order to protect your body and, specially, your eyes, face, head, ams and hands.

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