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MECHANICAL SHEAR

· , OPERATOR'S MANUAL

CMAD«
 FOREWORD

This manual has been prepared to acquaint you with the installation, oper-
ation and maintenance procedures of your Amada machine. It is urged that
this manual be read carefully for a thorough understanding of the machine to
ensure long life and safe, efficient operation.

I
 CONTENTS

SECTION 1 - INSTALLATION
Placement 1-1
Carrying 1-1
Cleaning 1-1
Leveling and anchoring 1-2
Electrical connections 1-2
Connecting the foot switch 1-6
Installing the side gauge 1-7
Installing the front support 1-8
Checking the hydraulic oil level 1-8
Initial lubrication 1-9

SECTION 2 - CONTROLS
Control panel 2-1
Emergency stop button ~ 2-3
Side gauge and front support 2-3
Beam light 2-3
Automatic shearing limit switches 2-4

SECTION 3 - OPERATION
Blade clearance adjustment 3-1
Single mode operation 3-3
Continuous mode operation 3-4
Automatic shearing mode operation 3-4

SECTION 4 - MAINTENANCE
Daily maintenance 4-1
Periodic maintenance 4-2
Removing and installing the blade 4-3
Lower blade height adjustment 4-7
Adjustment of backgauge parallelism 4-8
Beam light adjustment 4-9
Ram stop position adjustment 4-1 O

ACCESSORY GUIDE
Special accessory 5-1

SPECIFICATIONS 6-1
 EMER GENCY
STOP BUTTON

TABLE

1~
.......'I'----.----

CLEARANCE
ADJUSTING
DEVICE FRONT
SUPPORT
\ FOOT SWITCH

[FRONT VIEW]

ELECTRICAL
ENCLOSURE

HYDRAULIC
OIL TANK

BACKGAUGE
[REAR VIEW] MOTOR
 PRECAUTIONS FOR TROUBLE-FREE AND SAFE OPERATION

1. CHECK THE LEVEL OF THE MACHINE:

To maintain accuracy of the machine and to ensure safety, always check that the machine
is level and that all anchor bolts are well tightened.

2. USE AND REPLENISHMENT OF RECOMMENDED OIL:

For lubricating and other oils, always use the recommended oil. Always check the quantity
of oils for lubrication, holddown mechanism, etc. to keep them adequate.

3. STRICT OBSERVANCE OF THE CUTTING CAPACITY:

The cutting capacity of this machine is a maximum cuttable thickness of steel plate with
tensile strength of 45 kg/mm2 • Consult with your serviceman when any materials other than
the above plates or any heat-treated materials (including plates with tensile strength of 45
kg/mm2 ) are to be cut.

4. CHECK THE BLADE FOR WEAR AND EARLY REPLACEMENT:

If the blade is used with a worn cutting edge, the machine will be overloaded even if the
thickness of the plate to be cut is kept within the cutting capacity of the machine: In
addition, the accuracy will become poor and the blade regrinding will become more expen-
sive. It is therefore economical to change the blade edge a little early.

5. ADJUSTMENT OF BLADE CLEARANCE:

Improper clearance will result in damage or early wear of the cutting blade, frequent forma-
tion of burrs, jamming of material, etc. Adjust if the clearance is improper.

6. IMPERATIVE USE OF THE HOLDDOWNS:

To make sure of safe operation, never proceed with the cutting until the material has been
secured with the holddowns.

7. NEVER OPERATE WITH SAFEGUARDS REMOVED:

It is strongly suggested to never operate the machine with finger protector, frame gap cover
and other safeguards removed, since it is very dangerous with these safeguards removed.

8. RIGID EXECUTION OF RETIGHTENING OF ALL BOLTS AND NUTS:

Check periodically that all bolts and nuts are secure and, if necessary, retighten them.
9. ASSIGN A PERSON TO BE COMPLETELY RESPONSIBLE FOR OPERATI ON
AND MAINTENANCE:

To prevent an accident due to mis-operation or non-adherence to maintenance procedures,

assign a person responsible for the operation and maintenance of the machine, including the
power ON/OFF switch.

10. AVAILABILITY OF THIS OPERATOR'S MANUAL:

To help prevent anyone from operating the machine in any other way than described in this
manual, keep this manual near the machine, as a ready reference at any time.
 SECTION 1 - INSTALLATION

PLACEMENT
The foundation should be constructed of concrete, and must be flat and level. Ensure that
there is sufficient space around the machine to afford easy material handling as well as easy
access for inspection and maintenance.

CARRYING
Unpack your machine carefully, and set it in position with a crane. When lifting the machine,
attach the lifting cables securely to the lifting lugs on the left and right frames of the
machine [Photo 1]. See the table below.
CAUTION: Be careful to protect the machine from any impact.
Model Weight kg (lb) Model Weight kg (lb)
M-1245 2700 (5952) M-1260 3700 (8157)
M-2045 4600(10141) M-2060 4700(10361)
M-2545 5300 ( 11684) M-2560 5500 ( 12125)
M-3045 7100 ( 15653) M-3060 8400 (18519)
M-4045 11000 (24251) M-4060 14000 (30865)

CLEANING
After the machine has been set in position, thoroughly remove the rust preventive coating
with a suitable solvent. Apply a coat of machine oil to the surface of the table and other
areas where rust formation might occur.

[Photo 1]

1-1
LEVELING AND ANCHORING
Place three spirit levels on the table as shown in the photo, and adjust the left-and-right and
fore-and-aft levels of the machine with level adjustment bolts located on the legs of the
frames. Machine level should be within a tolerance of 0.05 mm per meter in any direction.
After the proper level position has been obtained, anchor the machine with anchor bolt nuts
[Photo 2].

ELECTRICAL CONNECTIONS
To make electrical connections, proceed as follows:
(1) Remove the screws that secure the electrical enclosure door, move the door lever to
"Reset Open" and open the door [Photo 3].

(2) Connect the power supply cable to the input terminal of the circuit breaker and the
ground wire to the ground terminal [Photo 4].

Spirit levels A and C: fore-and-aft direction

Spirit level B: left-and-right direction
00 HOT OPERATE.
WHEN THE'.
000111 ,SOPOI

[Photo 2] [Photo 3]

[Photo 4]

1-2
Max. power consumption kW
M-1245 M-1260 M-2045 M-2060 M-2545

Main motor 3.7 5.5 5.5 5.5 5.5

Backgauge motor 0.4 0.4 0.4 0.4 0.4

Total power consumption 4.1 5.9 5.9 5.9 5.9

M-2560 M-3045 M-3060 M-4045 M-4060

Main motor 7.5 7.5 11.0 11.0 11.0

Backgauge motor 0.4 0.4 0.4 0.4 0.4

Total power consumption 7.9 7.9 11.4 11.4 11.4

Recommended cable data

The following data is the cross-sectional area of cables to be used when your machine is
operated on 200 volts, ac. Use the data as a guide in determining the appropriate cables
according to your power supply.

M-1245, M-1260 5.5 mm2 (0.00853 sq-in)

M-2045, M-2060, M-2545, M-2560, M-3045 8 mm2 (0.0124 sq-in)
M-3060, M-4045, M-4060 : 14 mm2 (0.0217 sq-in)

1-3
The power supply of your machine should agree with the voltage indicated on the label
attached to the electrical enclosure. If the power line voltage is changed fro m those indicated
on the label, change the wiring connections of the motor and transfo rmer and reset or replace
the thermal relay.
CAUTION: To protect personnel from an electrical shock and the machine from possible
damage, all electrical work should be done by a qualified electrician.
CHANGING WIRING CONNECTIONS AT TRANSFORMER TERMINALS
Machine transformer [Photo 5]
0 0 0 0 0
LC')

u.n rn
0 ('V') 0 ('V')
0 N N 0 N N ('V')

~
co
E
ct 400V-50Hz
~co
-0

u
C
0
Cl)
(/)
l
0
11 l
0
0)
0
0
0

Backgauge transformer [Photo 6]

>~gg x s ~gg gg ~gg gg

1rrrrWrrrrwrr
~l 1 r 1
rrw
C 0 0 0 0 0 0
8a, 0
N
0
N
0
N
(/)
T1 S1 T1

(400V)

( 460V)

[Photo 5] [Photo 6]

1-:--4
CHANGING WIRING CONNECTIONS AT MAIN MOTOR TERMINALS
M-1245, M-1260, M-2045 and M-2545 models [Photo 7]

R S T R S T

230V-50/60Hz 400V-50Hz
460V-60Hz

M-2060, M-2560, M-3045, M-3060, M-4045 and M-4060 models [Photo 8]

R S T R S T
I

Z, Y, X,W, V, U,

MS2

230V-50/60Hz 400V-50Hz, 460V-60Hz

1-5
(3) After making the proper wiring connections, close the electrical enclosure door and move
the door lever to ON to turn on the circuit breaker. Next, turn on the POWER ON/OFF
switch on the control panel and press the DRIVE button. Check to make sure the main
motor rotates in the direction indicated by the arrow on the motor. If it rotates in the
reverse direction, immediately press the emergency stop button to stop the motor, turn
the circuit breaker and factory's main power off, and then interchange any two phase
connections of the power supply cable [Photo 9].
After confirming that the main motor rotates in the correct direction, install and tighten
the screws which hold the electrical enclosure.

CONNECTING THE FOOT SWITCH

Connect the foot switch cable plug to the receptacle [Photo 10].

[Photo 91 [Photo 10)

1-6
INSTALLING THE SIDE GAUGE

(1) Insert the "T" bolts (furnished with the machine) into the "T" groove at the front of the
table, and position the side gauge support by aligning its mounting holes with the "T"
bolts. Temporarily tighten the side gauge support with the nuts.

(2) Align the stopper slide groove in the side gauge support with the groove in the table.
Adjust the side gauge support so that the stopper slides smoothly along the slide groove.

(3) Tighten the nuts to secure the side gauge support [Photo 11].

(4) Tighten the bolts to secure the side gauge to its support [Photo 12].
IMPORT ANT: Prior to actual shearing operations, shear test pieces to make sure the square-
ness of the side gauge, in relation to the blades, is correct.
If it is not correct, loosen the bolts and adjust the position of the side gauge
with the adjusting bolts.

[Photo 11] [Photo 12]

1-7
INSTALLING THE FRONT SUPPORT
(1) Insert the "T" bolts (furnished with the machine) into the "T" groove at the front of the
table, and position the front support by aligning its mounting holes with the "T" bolts.
Temporarily hold the front support with the nuts.

(2) Align the stopper slide groove in the front support with the groove in the table, so that
the stopper can slide along the groove smoothly.

(3) Tighten the nuts to secure the front support [Photo 13).
NOTE: The three-meter front support is a standard accessory on model M-4060. Install the
front support on the table using a crane, then attach the front support stand to the
support. Make sure the front support is level after installation.

CHECKING THE HYDRAULIC OIL LEVEL

Check the level of oil in the hydraulic tank with the sight gauge. The oil is used for the hold-
down mechanism [Photo 14).

[Photo 13] [Photo 14]

1-8
INITIAL LUBRICATION
(1) Check the level of oil in the lubrication oil pump.

(2) Check the float balls to make sure they are lower than the lower red lines on the oil
signal units.

(3) Move the pump lever down 3 or 4 times until the float balls are higher than the lower red
lines [Photo 15].
NOTE: a) Do not forcibly move the pump lever up. It will gradually return to its
original position.
b) While the machine is operating, move the pump lever 3 or 4 times every one
hour to provide proper lubrication.

[Photo 15]

1-9
 SECTION 2 - CONTROLS

CONTROL PANEL

I]] MADA

STATION CUTTING WIDTH

•
START

I
INCH

• OR•GIN
SE~ mm
COUNTER :
o,sP ON•
!"
.....,
7

1
8

" "
2
-
0

3
STOP

OFF 1
' 0 ......
[Photo 16]

1. POWER ON/O FF switch (w/key)

When this switch is turned ON, power will be on. Power will off when the switch is turned
OFF.

2. DRIVE button
When this button is pressed, the main motor will start.

3. Motor drive light

This light is on while the main motor is operating.

4. Emergency stop button

When this button is pressed, all machine operations will stop immediately. To resume
machine operation, press the DRIVE button (2), raise the ram near its TDC in the INCH
mode, and then make one complete stroke of ram operation in the SI NG LE mode.

2-1
5. Mode switch

This switch is used to set the machine in any of the fo llowing modes.

SI NG LE - When the mode switch is set to SI NG LE and the fo ot switch is pressed, the ram
will ma ke one stro ke of operation. To perfo rm the next stroke, release the
fo ot switch and press it again.

CONT. When the mode switch is set to CONT. and the fo ot switch is pressed, the ram
will lower and raise repeatedly.· When the fo ot switch is released, the ram will
complete the stro ke in pro gress, return to TDC and stop.

INCH. When the mode switch is set to IN CH and the fo ot switch is pressed, the ram
will lower. When the fo ot switch is released, the ram will stop at that position.

OFF When the mode switch is OFF, the ram will not move even if the fo ot switch is
pressed. -

6. LIGHT BEAM switch

When this switch is turned ON, the beam light will come on. The light beam is used to align
the I ine scribed on the worksheet for accurate shearing.

7. CONTACT switch
This switch is used for automatic shearing operation without pressing the foot switch. Auto-
matic shearing is performed by butting the worksheet against the auto-shearing limit switches
built into the backgauge. The switch should be set to SHORT or LONG in relation to the
length of the worksheet. This switch is effective only when the mode switch is set to SIN-
G LE.
NOTE: When automatic shearing is not required, be sure to turn the CONTACT switch off.

8. Backgauge control panel

For the description of the buttons and switches and operational procedures of the back-
gauges, refer to the "Programmable Backgauge Operating Instructions" furnished with your
machine.

2-2
EMERGENCY STOP BUTTON
When this button is pressed, all machine operations will stop immediately. This button has
the same function as the emergency button (4) on the control panel. To resume machine
operation, press the DRIVE button (2), raise the ram near its TDC in the I NCH mode, and
then perform one complete stroke operation of the ram [Photo 17].

SIDE GAUGE AND FRONT SUPPORT

The side gauge is used to align the worksheet so that it can be sheared at a right angle (90°).
It is necessary to adjust the position of the side gauge if the worksheet cannot be sheared at
that angle. Refer to "Installing the Side Gauge" on page 1-7 outlined in Section 1 for
instructions.
The side gauge and front support stoppers determine the cutting width of the worksheet on
the operator side [Photo 18].

BEAM LIGHT
Beam lights are used for shearing the worksheet by aligning the line scribed on the worksheet
with the cutting edge of the upper blade. Beam lights come on when the LIGHT BEAM
switch is turned ON. The mode switch should be set to SINGLE.
NOTE: If the backgauge obstructs the feeding of the worksheet, move it backward and then
reverse it. For the reversing procedure, refer to "Programmable Backgauge Operating
Instructions" furnished with the machine.

I
I,

·- [Photo 17) [Photo 18)

2-3
AUTOMATIC SHEARING LIMIT SWITCHES
When these limit switches, built into the backgauge, are pressed by butting the worksheet
against the backgauge, shearing operation can be performed without pressing the foot switch.
With the mode select switch set to SINGLE, set the CONTACT switch to SHORT or LONG
depending on the cutting width of the worksheet and butt the worksheet against the affected
limit switches. Shearing operation will start [Photo 19].
LIMIT SWITCH

-r-,-L-_-_-_-_-_-
0 __-_-_-n f
____.
l_BACKGAUGE

LONG SHORT

[Photo 19]

2-4
 SECTION 3 - OPERATION

BLADE CLEARANCE ADJUSTMENT

The optimum blade clearance varies with the type and thickness of the worksheet to be
sheared. In the case of mild steel plates, for example, the best shearing will be obtained by
setting the blade clearance to within 5 to 7% of the worksheet thickness. The following table
furnishes information which is helpful in determining the optimum blade clearance by thick-
ness of mild steel plates.
Optimum blade clearance (mild steel)
Worksheet thickness Blade clearance
mm (in) mm (in)
1/3 J .0 (0.039) 0.04 to 0.09 (0.0016 to 0.0035)
OO L( -=- ;) 2;, .. I I (,,.J.., J. /0,).,,
/4z?.O (0.079)
3 0.08 to 0.16 (0.0032 to 0.0063) 0

1/g3.0 (0.118) 0.12 to 0.24 (0.0047 to 0.0094) , L-[ :: ¼ HK.

½ ,..4.0 (0.157) ·0.20 to 0.32 (0.0079 to 0.0126)
:Yc,,5.0 (0.197) ·,
0.25 to 0.40 (0.0098 to 0.0157) , ',
½1 6.0 (0.236) 0.36 to 0.48 (0.0142 to 0.0189)
-
When adjusting the blade clearance, use the following procedures:
( 1) Remove the finger protector [Photo 20].
~/~/9~'
(2) Turn the circuit breaker ON.

(3) Turn the POWER ON/OFF switch ON. ,,. :) -=~ (. DI O )

(4) Press the DRIVE button. 0

,( (5) Set the mode switch to INCH.

(6) Press the foot switch to lower the ram until the left end of the upper blade overlaps
approximately 30 mm (1.2 in) with the lower blade.
CAUTION: Never allow the blades to jam with each other. If there is any possibility
of jamming, the table should be moved toward the operator.

[Photo 20]

3-1
 (7) Insert a thickness gauge between the upper and lower blades to measure the blade clear-
ance [Photo 21].

(8) Press the foot switch to lower the ram further, and measure the blade clearances at the
center and the right end of the blade.

(9) If it is necessary to adjust the blade clearance, loosen the table retaining bolts [Photo
22].

(10) Move the table back or forward, as required, while measuring the blade clearances at the
left, center and right, until the required clearances are obtained [Photos 23 and 24].

(11) Tighten the table retaining bolts.

(12) Install the finger protector .

.-
•
•

[Photo 21] [Photo 22]

M-1245, M-2045, M-2545, M-3045 and M-1260, M-2060, M-2560, M-3060 and
M-4045 models M-4060 models
I
I'.

[Photo 23] [Photo 24]

3-2
SINGLE MODE OPERATION
In the single mode, the ram makes one stroke of operation each time the foot switch is
pressed.
To set the machine in this mode, proceed as follows:
(1) Turn the circuit breaker ON.

(2) Turn the POWER ON/OFF switch ON.

(3) Press the DRIVE button. The MOTOR DRIVE light will come on.

(4) Move the backgauge to the required shearing width position. (For backgauge operation,
refer to the "Programmable Backgauge Operating Instructions" furnished with your
machine.)

(5) Set the mode switch to SINGLE.

(6) Place the worksheet on the table and butt it against the side gauge [Photo 25].

(7) With the worksheet held in that position, move the worksheet toward the backgauge
until its front end extends 5 to 25 mm (0.2 to 1 in) beyond the blade for proper trim-
ming.
NOTE: The trimming width should be at least twice the thickness of the worksheet
and more than 5 mm (0.2 in).

(8) Press the foot switch to trim the worksheet.

(9) Move the worksheet toward the backgauge along the side gauge and butt the trimmed
surface against the backgauge.

( 10) Press the foot switch to shear the worksheet to the required shearing width.

[Photo 25]

3-3
 CONTINUOUS MODE OPERATION
In the continuous mode, the ram will continue to move up and down while the foot switch
is being pressed. When the foot switch is released during operation, the ram will rise to TDC
after the cycle of operation in progress has been completed.
To operate the machine in this mode, proceed as follows:
(1) Repeat steps (1) through (8) outlined under "Single Mode Operation".

(2) Set the mode switch to CONT.

(3) Butt the trimmed surface of the worksheet against the backgauge and press the foot
switch. Worksheet will be sheared to the same size by butting it each time against the
backgauge, in relation to the movement of the ram, while pressing the foot switch.

AUTOMATIC SHEARING MODE OPERATION

In the automatic shearing mode, the ram makes one stroke of operation to shear the work-
sheet each time the worksheet butts against the automatic shearing limit switches built into
the backgauge. The foot switch need not be pressed.
To operate the machine in this mode, proceed as follows:
(1) Repeat steps (1) through (8) outlined under "Single Mode Operation".

(2) Set the mode switch to SINGLE.

(3) Set the CONTACT switch to SHORT or LONG in relation to the length of the worksheet.
NOTE: Labels are attached to the front surface of the machine which indicate the posi-
tions of the three limit switches built into the backgauge. When the CONT ACT
switch is set to SHORT, the ram will move down and up by pressing the limit
switches shown by labels A and B; when the switch is set to LONG, the ram will
move down and up by pressing the limit switches shown by labels B and C
[Photo 26].

(4) Each time the worksheet butts against the backgauge, the ram moves down and up to
perform shearing operation.

, I

[Photo 26]

3-4
 SECTION 4 - MAINTENANCE

DAILY MAINTENANCE

Before each day's operation, perform the following maintenance operations:

1. Check the oil level in the lubrication oil pump. If it drops close to 1/3 the full level, add
oil up to the full level.
Recommended oil: Mobil Vactra Oil No. 2
Esso Febis K68
Shell Tanna Oil T68

2. Push the pump lever three to four times until the float balls rise above the lower red lines
on the oil signal units [Photo 27]. For details, refer to "Initial Lubrication" on page 1-9.

3. Add oil to the threads of the carriage through the upper hole by using an oiler [Photo
28].
Recommended oil: Mobil Vactra Oil No. 2
Shell Tanna Oil T68

4. Check the hydraulic oil level for the holddowns, and add oil if necessary.
Recommended oil: Mobil Hydraulic Fluid 56
Shell Tellus C56

5. Check the upper and lower blades for wear or breakage. If worn or broken, replace the
faulty blade. For replacement procedures, refer to "Removing and Installing the Blade"

I on page 4-3.

[Photo 27] [Photo 28]

4-1
PERIODIC MAINTENANCE

Once a month, perform the following maintenance operations:

1. Check the V belt of the main motor for proper tension. If necessary, adjust it. The belt
should be adjusted so that it can deflect 1.6 mm (0.06 in) for a distance of 100 mm (3.9
in) between the rotary shafts when pressed midway between the motor pulley and the
flywheel [Photos 29, 30, 31].

2. Check the level of the machine, and adjust it if it is incorrect. Refer to "Leveling and
Anchoring" on page 1-2 for adjustment procedures.

3. Check the backgauge to make sure it is parallel with the blades. If it is not, adjust it.
Refer to "Adjustment of Backgauge Parallelism" on page 4-8 for adjustment procedures.

M-1245, M-1260, M-2045, M-2060, M-2545,

M-2560 and M-3045 models

[Photo 29] [Photo 30]

[Photo 31]

4-2
 REMOVING AND INSTALLING THE BLADE

Use of a worn or broken blade tip adversely affects the performance of the machine as well as
the shearing accuracy of the worksheet. The position of cutting edge shou Id be changed so
that the other cutting edge of the blade (the blade has four cutting edges on its corners) will
be set in position or the blade should be replaced with a new one.
NOTE: a) Before removing or installing the blade, make sure the circuit breaker is OFF.
b) To ensure safety, always remove the lower blade first, then the upper blade.
When installing the blades, install the upper blade first, then the lower blade.

Removing the lower blade

(1) Open the blade-to-blade clearance as wide as possible. Refer to "Blade Clearance Adjust-
ment" on page 3-1 .

(2) Remove the left and right frame gap covers [Photo 32].

(3) Remove the finger protector.

(4) Remove the chute from the rear of the machine [Photo 33].

[Photo 32) [Photo 33)

4-3
 (5) Remove all bolts except fo r the two located on both ends of the lower blade. To do this,
one operator holds the bolts with a screwdriver at the rear of the machine and the other
loosens the nut with a wrench at the front.
WRENCH

LOWER BLADE
TABLE

SCREW-
DRIVER BLADE FIXING BOLT •

(6) Remove the remaining two bolts from the lower blade. Be careful not to drop the blade.

(7) Slide the lower blade along the surface of the lower frame and remove it from either
frame gap.

Removing the upper blade

(1) Place a wooden block and bar on the left and right sides of the table in order to support
the weight of the upper blade.
UPPER
BLADE

WQODEN BLOCK

I
~.
j,,,L
LOWER FRAME

(2) Remove all bolts except for the two on both ends of the upper blade.

(3) While supporting the weight of the upper blade, remove the bolt from each end of the
blade. -. ____

(4) Gradually lower the wooden bar to lower the blade to the lower frame, and withdraw it
from the frame gap.

4-4
I

Installing the upper blade

(1) Clean the mating surface of the ram to the upper blade then polish it with an oil stone.

(2) Insert the upper blade through the frame gap and slide it on the lower frame until it
reaches the mounting position.
UPPER BLADE

I I
I I

l_v-' LOWER FRAME

NOTE: When sliding the upper blade, be careful not to drop it.

(3) Place a wooden bar under the upper blade. Raise it to align the mounting holes, as shown
in the figure, in order to contact the mating surface.
UPPER
BLADE

LOWER FRAME

(4) Install and temporarily tighten the mounting bolts. i

(5) Tighten all the bolts, starting with the middle one and work toward the outer ends of the
blade.
IMPORTANT: Do not ighten the bolts the other way around. This will cause the
middle of the blade to have poor contact with the ram.

Installing the lower blade

(1) Clean the mating surface of the table to the lower blade and polish it with·an oil stone.

(2) Insert the blade through the frame gap, and slide it on the lower frame until it reaches
the mounting position.

(3) Install the blade mounting bolts and temporarily tighten them with the nuts.

(4) Tighten all the bolts, starting with the middle one and work toward the outer ends of
the blade. I' I
IMPORTANT: Do not tighten the bolts the other way around. This will cause the
middle of the blade to have poor contact with the table.

4-5
(5) Make sure the upper surface of the table is flush with the upper surface of the lower
blade. If it is not, adjust the height of the lower blade as outlined under "Lower Blade
Height Adjustment" on page 4-7 ..
LOWER BLADE

LOWER
FRAME

PROPER IMPROPER IMPROPER

(6) Adjust the blade clearance. Refer to "Blade Clearance Adjustment" on page 3-1 for
adjustment procedures.

(7) Shear several test pieces of worksheet to make sure the blades are properly installed.

(8) I nstal I the finger protector.

(9) Install the frame gap covers.

.,
(r

4-6
LOWER BLADE HEIGHT ADJUSTMENT

After installing the lower blade, check to see if the upper surfaces of the blade and table are
flush. If not, adjust the lower blade height as follows: ·
NOTE: If the blade is higher than the table, the worksheet will not be fed in properly; if it
is lower than the table, an undue bending force will be applied to the worksheet,
resulting in a deflected end of the worksheet.

(1) Remove the drive unit cover [Photo 34).

(2) Rotate the main gear in the INCH mode until the through-hole in the main gear is aligned
with the jack bolt [Photo 35).

(3) Loosen the lock nuts of the table jack bolts, and loosen the jack bolts [Photo 36).

(4) Loosen the mounting bolts which hold the lower frame onto.the left and right frames
[Photo 37).

(5) Loosen the lock bolts and adjust the jack bolts on the lower frame so that the lower
blade is flush with the upper surface of the table.

(6) Turn the table jack bolts until their bolt heads firmly contact the lower surface of the
table.

(7) Tighten the lock bolts used with the lower frame and table jack bolts. Also tighten the
lower frame mounting bolts securely.

(8) Install the drive unit cover.

[Photo 34) [Photo 35)

=--- r.
•I

-·~
-·-

[Photo 36) [Photo 37)

4-7
,
\~•;,''i~
.,
ADJUSTMENT OF BACKGAUGE PARALLELISM ·

If the width of a worksheet which has been sheared on the left and right sides of the back-
gauge are not the same, the backgauge should be adjusted for proper parallelism. Prior to
adjustment, perform steps (1) and (2) below:

(1) Move the backgauge so that the CUTTING WIDTH display shows "50" mm (or "2.00"
in).

(2) Butt a 1.6 mm (0.063 in) thick test piece (approx. 200 mm wide and 500 mm long or
8 inch wide and 20 inch long) against the left, middle and right of the backgauge and cut
the test piece, respectively. Measure the widths of the three cut-off pieces.
NOTE: To provide the best result for backgauge adjustment, data obtained by shearing
a test sheet of 50 mm (or 2 in) in width and 1.6 mm (0.063 in) in thickness
should be used.

If the sheet which has been sheared at the left of the backgauge (as viewed from the front of
the machine) is wider than the one at the right, proceed as follows:

(1) Turn the circuit breaker to OFF.

(2) Remove the connecting rod cover from the backgauge.

(3) Mark the location of the bolts which connect the couplings and remove the bolts.
ALIGNMENT MARK

2-HOLE 6-HOLE
\
COUPLING COUPLING

(4) Turn the six-hole coupling in the direction of the arrow in the figure above to relocate the
bolt holes, while the two-hole coupling is kept stationary. Movement of one bolt hole
makes the backgauge move forward approximately 0.07 mm (0.003 in). In this way,
adjust the bolt hole position as required until correct adjustment is made.

(5) Align the bolt holes in the six-hole coupling with the two-hole coupling, and tighten them
with two connecting bolts.

If the width of the sheet cut on the right of the backgauge is greater than that cut on the·
left, turn the two-hole coupling in the direction shown by the arrow in the figure above.
After properly positioning the coupling, shear a test sheet and adjust the indication value on
the CUTTING WIDTH display to the measured value.

4-8
 BEAM LIGHT ADJUSTMENT

If shearing cannot be accurately performed by aligning the scribed line with the light beam,
adjust the position of the beam light as follows:

( 1) Move the backgauge to an optional cutting width (50 mm, for example).

(2) Turn the beam light on.

(3) Butt a straightedge against the backgauge and check to make sure the 50 mm point on
the straightedge corresponds with the beam line of the beam light.

(4) If they are not aligned properly, loosen the bolts which hold the bulb holder and move
the holder back and forth to adjust the beam light position [Photo 38].

(5) After properly adjusting the beam light, move the backgauge backward. Shear test sheets
to make sure the alignment of the beam I ine is correct.

I
\

[Photo 38]

4-9
RAM STOP POSITION ADJUSTMENT

If the ram stops before or after its TDC, use the following procedure to adjust the ram so
that it will stop at TDC.

(1) Remove the cover from the electromagnetic clutch located on the left side frame of the
machine. The clutch and brake cams will be exposed [Photo 39).

(2) Check that the brake cam is set at "a"> 50° to 60° (shown in the following figure).

. 1·

(·3) Set the clutch cam at "r = 80° to 90°.

(4) If the ram stops after TDC, set the clutch cam mounting angle "r slightly larger than
the specified angle. If the ram stops before TDC, set the angle "{3" slightly smaller than
the specified angle. In either case, ensure the angle "{3" falls within the 60 to 100° range.
NOTE: If the ram stops significantly off TDC and the holddown device remains acti-
vated, it is necessary to adjust the mounting position of' the brake cam.
. .

[Photo 39]

4-10
 . '

ACCESSORY GUIDE

SPECIAL ACCESSORY

Front support w/scale

The front support is provided with a scale to determine the required shearing width of the
worksheet without using the backgauge.

To set the required shearing width of the worksheet using the stopper, proceed as follows:

(1) Position the stopper in relation to the required shearing width of the worksheet, using
the scale as a guide. Tighten the stopper with the lock bolt.

(2) Turn the adjustment nut to make a fine adjustment of the shearing width.
NOTE: The normal clearance between the stopper and the adjustment nut is 5 mm (0.2
in) or thereabouts. Shearing thin worksheets requires a wider clearance before
the shearing width is set.

Electromagnetic sheet support [Photo 40]

This device attracts the worksheet with an electromagnetic roll, which eliminates the pos-
sibility of worksheet deflection between the backgauge and blades, so that the worksheet
can be sheared accurately to the desired width. I

To activate this device, turn the ON/OFF switch to ON, and set the adjustment dial to
· /
correspond to the weight of the worksheet. When the dial is turned clockwise, the magnetic
force increases; when the dial is turned counterclockwise, the magnetic force decreases.
NOTE: The electromagnetic sheet support cannot be used with the machine equipped with
· an automatic release backgauge.

[Photo 40)

5-1
 Pneumatic sheet support [Photo 41]

This device is operated by pneumatic pressure to hold the worksheet to the support, which
eliminates the possibility of worksheet deflection between the backgauge and blades, so that
the worksheet can be sheared accurately to the desired width.
To activate the device, turn the ON/OFF switch ON.

Automatic release backgauge

This backgauge automatically reverses itself at the backward end so that it will not interrupt
the feeding of the worksheet to be sheared.
NOTE: This device is a standard accessory on models M-3060 and M-4060.

5-2

I .I
 SPECIFICATIONS
Unit: mm (in)

~I M-1245 M-1260 M-2045 M-2060 M-2545 M-2560 M-3045 M-3060 M-4045 M-4060
m

Max. thickness of worksheet

[Tensile strength: 4.5 (0.18) 6.5 (0.26) 4.5 (0.18) 6.5 (0.26) 4.5 (0.18) 6.5 (0.26) 4.5 (0.18) 6.5 (0.26) 4.5 (0.18) 6.5 (0.26)
45 kg/mm 2 (64000 psi)]

4080 4100
Max. cutting length 1240 (48.82) 2000 (78.74) 2500 (98.43) 3060 (120.4)
(160.6) (161.4)

Blade length 1340 (52.7) 2300 (90.5) 2800 (110.2) 3380 (133.0) 4430 ( 174.4)

0)
Type of blade Four-edged blade

.....I Gap depth 65 (2.56) 300(11.81) 65 (2.56)

Rake angle 1°28' 1° 18' 1°28' 1 ° 18' 1°28' 1° 18' 1°28' 1 ° 18' 1°28'

No. of strokes (spm) 75 60 50 52

Main motor kW (HP) 3.7 (5) 5.5 (7.5) 7.5 (10) 11.0 (15)

Backgauge motor kW (HP) 0.4 (0.5)

2700 3700 4600 4700 5300 5500 7100 8400 11000 14000
Machine weight kg (lb)
(5952) (8157) (10141) (10361) (11684) (12125) (15653) (18519) (24251) (30865)

Holddown type Hydraulic

No. of holddown units 6 9 11 13 16

Light beam
40W x 2 40W x 3 40W x 4 40W x 5
(No. of bulbs)

Specifications are subject to change without notice.

AMADA COMPANY, LTD.
200, Ishida, lsehara, Kanagawa, JAPAN

DEC. 1985