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Instruction manual

SHEARING UNIT

Shearing unit

Summary
DESCRIPTION OF MACHINE ...................................................................... 3
INTENDED USES...................................................................................... 3
UNINTENDED USES ................................................................................. 3
OPERATING PRINCIPLE ........................................................................... 4

INFORMATION ON SAFETY ........................................................................ 5


SAFETY CRITERIA ................................................................................... 5
PROTECTIONS......................................................................................... 5
ANTIREPETITION DEVICE ........................................................................ 5
OPERATOR PROTECTION DEVICES ........................................................... 5
OUTSTANDING RISKS AND PRECAUTIONS ................................................ 5
NOISE .................................................................................................... 6

TRANSPORT ........................................................................................................... 6
DESCRIPTION OF SUPPLY ........................................................................ 6
INSTALLATION............................................................................................................ 7
FITTING THE WHEELS ............................................................................. 7
POSITIONING .......................................................................................... 7
CHECKING ELECTRICAL DATA ................................................................ 7
EARTHING THE MACHINE........................................................................ 7
CONNECTING UP TO THE MAINS .............................................................. 8

USE ................................................................................................................................ 8
STARTING .............................................................................................. 8
INITIAL STARTUP .................................................................................... 8
CUTTING THE ROD IRONS........................................................................ 9
SWITCHING OFF .....................................................................................10

MAINTENANCE ...................................................................................................10
MAINTENANCE PROGRAMME.................................................................10
TOPPING UP AND CHANGING THE OIL .....................................................10
CHANGING THE BLADES ........................................................................11
ADJUSTING THE ANTIREPETITION DEVICE ..............................................11
LUBE OIL PUMP (OPTIONAL) ..................................................................12
DECOMMISSIONING THE MACHINE .........................................................12

This document contains privately owned information. All rights are reserved. This
document cannot be reproduced, totally or in part, without the written approval of the
manufacturer. Only the user is entitled to use this document.
Edition 1.4

Shearing unit

DESCRIPTION OF MACHINE
Intended u ses
Shearing unit for rod irons
Machine designed for cutting steel bars for concrete industry applications.

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The machine model, serial number and year of manufacture are indicated on the
identification plate.

Table showing specifications of rod iron diameters (in mm) usable for each model. The diameters are specified
according to the hardness of the material and to the number of rod irons that can be cut at the same time for
that particular diameter.
R. 65 Kg/mm2
650 N/ mm2

R. 85 Kg/mm2
850 N/ mm2

C26

24

18

12

20

16

10

C30

26

22

14

22

20

C32

28

22

16

26

C36

30

24

18

C42

36

28

C52

44

C55
C70

mm
Number of
rod irons

Motor
Rpm
HP

kW

115

MF 2,5
TF 2

MF 2
TF 1,5

12

115

2,2

22

14

95

2,2

28

24

16

90

22

34

26

20

90

32

24

40

30

22

40

5,5

44

32

24

40

30

22

40

5,5

60

50

38

7,5

5,5

FeB 38 K (65 kg/mm2)


FeB 44 K (85 kg/mm2)

Un in tended use s
Unintended uses are all those uses not explicitly indicated in Intended uses, especially:
Use of materials different to those specified
Use of materials of different diameter to those intended.
Use of machine in explosive atmosphere.

Shearing unit

Operating pr inc ip le
The machine is driven by an electric motor

By means of a pulley 1, the motor shaft drives the two driving belts.
The belts transfer movement to a flywheel pulley 2 ,that turns the control pinion 3.

The pinion 3 drives the gearwheel 4.


The clutch unit 5, keyed on an eccentric shaft 6, operates the blade connecting rod 7 to which the
blade 8 is fitted.

The clutch cam 9, driven by the antirepetition device 10, by means of lever L or pedal P, enables
engagement of connecting rod movement.

Another blade 11 on the machine body cuts the rod iron.

By adjusting the striker 12 the rod iron can be kept in line with the blades.

Shearing unit

INFORMATION ON SAFETY
Safety criter ia
In designing and building this machine, criteria and measures have been adopted to meet the essential safety
requirements outlined in Machine Directive 98/37/EEC.
Protection s

The structure of the frame and guard prevent access to gears, belts and
moving parts.
The moving guard hinged to the frame mechanically prevents movement
of the antirepetition device as long as the guard is open.
Electric motor protected by thermal magnetic circuit breaker.

An t irepet it ion de vice

By pulling lever A, the equaliser C causes slide B to run axially,


releasing clutch the cam (9 in previous illustration)

at the end of its stroke, the equaliser C releases pin D which is integrated
with slide B

so slide B can return to departure position by means of a spring action.

When lever A is released, it is called by the spring and returns to


departure position, ready to start the cycle again.

Operator protection devices


Use gloves to handle the rod irons and prevent any risk of
abrasion and cuts.

Use protective footwear to prevent feet being crushed by the falling of heavy rod irons.

Outstand ing risks and precaut ion s

Danger of fingers being crushed or cut off!

Precautions

The possibility exists of the antirepetition lever remaining in idle position if this is operated with
the machine off. In case of startup, the antirepetition device remains disengaged and the cutting
blade operates continuously. In this case, pull the lever to engage the antirepetition device.
Never ever try and access the cutting area with your hands.
Keep the rod iron in position using the adjustable striker.
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Shearing unit

Only work on the machine and perform maintenance operations when the machine is shut off, with
power socket disengaged.
Electric shock hazard!
The electric shock protection is based on the correct connection to the earth lead: the power
system to which the machine is connected must comply with applicable legislation.
The socket to which the machine is connected must be protected upstream by the customer using a
residual current circuit breaker (tripping threshold not above 30mA).
Do not use extensions.
Make sure the cables between the plug and the machine are not in transit areas, or subject to
damage or mechanical stress.
Hazard! Tampering with the machine or the removal of guards or machine parts can
cause risks for the machine users and persons in the vicinity.

No ise
Continuous equivalent sound pressure level: 75 dB (A).
Average level at a distance of one metre from the machine.

TRANSPORT
Model
C26
C30
C32
C36
C42
C52
C55
C70

Dimensions
WxDxH
84 x 51 x 69
86 x 51 x 71
94 x 61 x 82
105 x 61 x 82
110 x 71 x 87
130 x 71 x 92
130 x 71 x 92
162 x 81 x 109

Weight
kg
275
275
370
460
680
750
750
1400

The machine is equipped with:


Eyebolt for lifting
Wheels for small movements within the work area.
Models C36, C42, C52, C55 feature four wheels. Models C26,
C30 and C32 have 2 wheels plus a support. Model C70 has a
supporting base, without wheels.

Hazard! Only use the wheels for small movements and for positioning the machine on
a flat and smooth surface. Do not wheel the machine up and down gradients; you
could lose control of it due to its weight.

Descrip t ion of supp ly


The machine is supplied with the wheels not fitted, arranged on a wooden pallet and protected by a sheet of
cellophane. Fixed to the frame are: the wheels, the split pins, two Allen wrenches for maintenance,the smaller
one for the guard screws and the larger one for the blade screws.

Shearing unit

INSTALLATION
Fit t ing t he wheels

Lift the machine by means of the eyebolts

Fit the wheel on the pin

Introduce the split pin into the hole in the pin

Bend outwards with a pair of pliers the two ends of the split pin which
protrude from the opposite side of the hole

Lower the machine to the ground.

Posit ion ing

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Before positioning and after transporting, make sure the machine structure has not
been damaged by knocks or falling during transport that could affect machine
operation and reliability.

Besides the overall dimensions of the machine, always follow the instructions below:

Power sources must be provided near the area where the machine is to stand.

The supporting surface must be such as to withstand the weight of the machine and must be flat and
smooth so the machine is stable.

The working environment must be adequately lit so the machine can be operated and serviced in total
safety.

The area must be of a suitable size for the machine and material to be loaded. To safely operate and
service the machine, this must be placed at a distance of at least one metre from walls. It must always
be possible to easily reach the cutting area with the material to be worked and the control switchboard.

Acceptable operating temperatures go from -5C to +40C.

Acceptable relative humidity: from 30% to 90%( at 20C).

The area must be protected from atmospheric agents, such as rain and snow.

Position stops under the wheels to prevent sudden movements.

Checking electr ical data


The Shearing unit is supplied with an electrical system suitable to customers' requests.
Before connecting up the machine, always make sure that the data on the motor plate correspond to those of
the power system. Special attention in this sense must be given to voltage (V), frequency (Hz) and current (A)
or power (kW). These must always correspond to those of the power system.
Earthing the machine
The power cable and the power plug supplied require connecting to the earth lead.

Shearing unit

Hazard! Electrical machine safety is based on correct connection to the


earth lead.

A specific earth terminal is provided to be used when the earth resistance of the power cable is too high or this
value is unknown.
Connect the end of a naked copper plait (section of at least 16 mm2) to the screw of the switch plate
on the back of the machine and then use a nut to secure.
Connect the other end to an earth lead. The earth lead must be set deep in a rather damp and
conductive area, or can be a copper plate, placed deep underground.
Connecting up to the ma in s
To connect up to the power mains, use a cable with the following specifications:
With a plug suitable for the type of socket installed
Of adequate capacity (each lead should have a minimum section of 2 mm2)
Insulated from the operating environment.

USE
Starting

h
h

Hazard! Make sure the cutting area guard is lowered, that there is no one
in the cutting area and that no rod irons have been loaded.
Hazard! Danger of fingers being crushed or cut!

Start the motor by pressing the black key on


the switchboard on the rear of the machine.

Red

OFF

Black

ON

In it ia l startup
Make sure the direction of rotation corresponds to the arrow on the motor fan guard; otherwise switch over the
two phase wires of the cable connected to the power mains.

Shearing unit

Cutt ing the rod iron s


Precautions:
Never try and reach the
cutting area with your
hands.
Keep the rod iron in
position using the
adjustable striker.

Depending on the size of the pieces to be cut, consider:


The piling up of small pieces under the slide on the unloading side.
Adequate support on the unloading side in the event of cutting very long rod irons.
In the event of the rod iron being long and cumbersome, use the bar slide roller to make it easier to slide
material to the desired point
1. Lift the hinged guard.
2. Fit the rod iron between the two blades, positioning this at the desired cutting point.
3. Adjust the striker so as to keep the material in line with the blades
4. Lower the guard.
5. Pull the lever or press the pedal so the machine performs the cutting operation.
6. Release the lever or pedal. The machine is ready for the next cutting operation.

Electrical data
Diameter of usable rod irons

Pull lever
Direction of rod iron insertion

Shearing unit

Switch ing of f

Turn off the motor by pressing the red key on the switchboard, on the rear of the machine.

Detach the plug to isolate the machine electrically.

Leave the machine with the guard lowered.

MAINTENANCE

Hazard! Maintenance operations must be performed by skilled personnel in


compliance with all applicable safety regulations.

Ma intenance programme
Schedule
Daily
40 hours
200 hours
Once a year

Check
Keep work area clean.
Lubricate point "A" and corresponding point on opposite side of machine,
indicated in the next picture.
Check the oil level in the gear reduction unit by means of the indicator. If
necessary, top up through the filling cap.
Completely change the oil.

T opping up and chang ing the o il

Check the level of the oil with the machine off by means of the indicator on the side of the machine.
Top up through the oil cap on top of the machine.
The oil can be drained off through a cap in the lower part or near the level indicator (depending on
model).
Oil cap

Model
C26
C30
C32
C36
C42
C52
C70
Level

10

Oil quantity
l
1,8
1,8
3,0
3,0
3,5
4,0
8,0

Shearing unit

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Do not dispose of oils and greases into the environment. Deliver to authorised firms for
disposal through approved channels.

Brand
ROL OIL
ESSO
MOBIL
SHELL
AGIP

Ambient temperature up
to 10C
EP 320
SPARTAN EP 320
MOBIL GEAR 632
OMALA 320
BLAS1A 320

Ambient temperature up
to 20C
EP 460
SPARTAN EP 460
MOBIL GEAR 634
OMALA 460
BLAS1A 460

Ambient temperature
above 20C
EP 680
SPARTAN EP 680
MOBIL GEAR 636
OMALA 680
BLAS1A 680

Changin g the b lades


To remove and replace
the blades, these must be
allowed to protrude:

Blade retention
screws

Switch the machine


off.
Make sure the guard is lowered.
Press the start button and then immediately the red off
button.
Repeatedly pull the lever to command a cutting stroke until the
lever is completely out and the retention screws can be reached.
If necessary, repeat the operation.
Detach the power socket before carrying out any work.
Unscrew the retention screws and replace the blades, both on the fixed and moving side, using the
Allen wrench provided.
Fit the two blades so the cutting edges correspond. On models C26, C30, C32 and C36 the cutting side
is the oblique side.

Adju sting the ant irepet it ion de vice


After continuous machine use, the need could arise to adjust the
antirepetition device to improve blade connecting rod stop conditions.
Proceed as follows:

Turn off the machine and remove the power plug.

Loosen the two screws that secure the lever guard and
remove the guard.

Loosen the two V screws.

Adjust in the desired direction and then retighten the two


V screws.

Refit the protection guard.

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Shearing unit

Metering
knob

Lube oil pu mp (opt io nal)


As accessory a manual pump with flow regolator for an easy and
corrected lubrication can be mounted on the shearing unit.
Use mineral oil, with viscosity between 100- 250 cst (tank 200 cm3).
In order to lubricate the machine, press knob of the meternig
cylinder 1 time per day in presence of a daily and regular use of the
shearing unit. At the first use, repeatedly act on the knob until
completely loading the circuit. Regularly check the visible level
from the transparent tank, top up through the oil cap when
necessary.

Oil cap

If after pressuring the knob there is an fast return of the control rod, it means that or
the tank is empty or the pressure circuit is loosing .

Ma intenance
Check the filter periodically in order to avoid clog. If necessary dismounting filter, unscrew the tank from its
bayonet coupling and extract the filter in its center. If necessary wash it with oil or gasoline.
Decommission ing the machine
Once the machine has reached the end of its technical and operating life, it will have to be decommissioned.
Decommissioning and placing the machine in such conditions as to be no longer usable for the purposes for
which it was originally designed and built must nonetheless make possible recycling of raw materials making
up the machine.
To decommission the machine without outstanding risks, follow this procedure:
Turn off the machine.

Drain off the lubricating oil. Run the oil out of the drainage cap under the machine and collect in a
suitable container.
Remove the wheels.
Cut the plug from the power cable.
If transport is required, follow the procedure in the Transport chapter.
Disposal of the machine through an approved waste collection centre.

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Do not dispose of oils and greases into the environment. Deliver to authorised firms for
disposal through approved channels.

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