Ironworker - How to	Metal Slitter	Box Brake	Ironworker	Plate Roll	Bore Repair
Radial Drill Press	Hydraulic Press	Lathe machine	Pittsburgh	Band Saw	Press Brake

How To Use a Hydraulic Ironworker Machine:

These instructions are written for an Edwards HYDRAULIC IRONWORKER MACHINE but may also be useful for understanding how to use many other brands of Ironworkers. These instructions are written for Hydaulically operated not Mechanical operated machines, though many procedures will be the same.

Often called the swiss-army-knife of machine tools; Ironworker machines are designed to punch, shear, bend and notch mild steel plate, barstock, angle iron and pipe. A wide range of accessories are available to fabricate rod and square stock, sheet metal and pipe. While many of these machines have a pivot arm system that is pulled down by a hydraulic cylinder, the American made Edwards Ironworkers operate by applying hydraulic force to a moving center plate. The center moves within the machine frame in a simple, vertical path and exerts downward force through shear blades, punch and dies, notchers, press brake dies or bump-die tooling to work with steel. Vertical travel of the moving center allows the operator to perform multiple operations on an Edwards Ironworker without always needing to remove adjacent tooling. Though there are some dual operator machines, due to their high cost most Ironworker machines are designed for single operator use only.

IMPORTANT COMMON SENSE SAFETY PRECAUTIONS

Your Ironworker uses hydraulic pressure and moving shear blades to cut steel products. To operate this tool safely, please review the following safety precautions.

· Read and understand your Ironworker Operator Manual, Installation Manual, Machine Safety Manual and Maintenance Manual.
· Use the tool ONLY for its intended operation.
· Wear approved eye protection.
· Wear protective gloves and clothing.
· Use safety guards, material hold-downs and punch stripper supplied with your Ironworker. Removal, modification or improper use of these safety devices may result in serious injury and will void your machine warranty.
· Keep away from moving parts during operation.
· Always be ready to lift your foot off the foot pedal to stop a mistake from seriously injuring you.
· Unplug or lock-out/tag-out your Ironworker before performing and maintenance or adjustment activities.
· Any maintenance, adjustment or changes in tooling for your Ironworker must be performed by a qualified individual with the processes and procedures describes in the Operator Manual.
· Maintain a clean machine. Remove any obstructions, slugs, cut-offs and fillings from the work area.
· Adequately support the steel material being worked.
· Turn your Ironworker off when not in use-never leave a powered Ironworker unattended.

MACHINE SETUP

Your Ironworker was bagged, palletized, and shipped from the factory to your dock. Remove the protective packaging and bolts from the tubular legs that secure the machine to its pallet. Move your Ironworker to its fabrication location by inserting your forklift forks within the tubular Ironworker legs. Do not move the machine by any other means! Locate your Ironworker directly adjacent to your power supply. See instructions for elctrical hookup written down below.

CARE AND PERIODIC MAINTENANCE
Your Edwards Ironworker will benefit from reasonable care and periodic maintenance.

· Provide clean ISO Viscosity 46 hydraulic fluid (or equal) to the cylinder in the Ironworker. Contaminated fluid will compromise your cutting operation.
· Grease all machine guides and pins daily. Your Ironworker is labeled with all grease locations that require maintenance.
· Maintain .010 clearance between fixed and movable shear blades on 40, 50, 55, 60 and 65 Ton models at all times. Maintain .015 clearance between fixed and movable shear blades on 75, 100, 100D and 120 Ton models at all times. Insert a feeler gauge between fixed and movable blades to verify proper blade clearance and shear tolerance. Adjust tolerance of shear blades by relieving the locking nuts that secure the gib-pins to the Ironworker frame. Once loose, rotate gib-pins to push the operating center against the frame. Gap the angle and bar shear blades with the specified clearance and tighten the gib-pin lock nuts. Failure to maintain proper clearance will result in lower quality cuts, damage to blade, blade pockets and potential to damage the Ironworker frame.
· Periodically check gib-pins for lubrication and snugness to operating center. Tighten gib-pins and locking nuts to maintain blade clearance as indicated above. Gib-pins are wearing parts. Order replacement gib-pins through your Edwards Distributor or through Edwards Mfg.Co.
· The blade set for your Ironworker is crafted from S7, heat treated steel. These are wearing parts that will fail over time. Order additional blade sets through your Edwards Distributor or through Edwards Mfg. Co.
· Check the hydraulic fluid level regularly. Replace the external oil filter on your Ironworker after your first 30 hours of use and every 1000 hours thereafter. Change your hydraulic oil every 5000 hours.
· Periodically clean your Ironworker with a compressed air nozzle and soft cloth. Remove filings, dirt, dust and grime from working surfaces.
· Periodically check tooling for wear. Replace worn tooling* according to manufacturers literature. If in doubt, call Edwards for advice.

PUNCHING

Your Ironworker is capable of punching materials as listed in the Ironworker Specifications section of this Manual as well as described on the capacity labels positioned at the Punch Station. The punch station on the Edwards Ironworker allows for a wide variety of punching, stamping or embossing applications. The removable table allows for flange or leg down punching of standard channel and angle sections.

Setup
Your Edwards Ironworker has been shipped with a punch and die installed within the punch station. When changing the punch and dies its important to make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. To setup your punch station, please observe the following steps.
1. Swing the Punch Stripper up from the punch by loosening the stripper assembly bolts.
2. Remove punch by loosening the punch nut assembly with factory supplied wrench.
3. Remove die by loosening the set screw at the front edge of the punch table and then lifting die from the die holder. If the die resists removal gently tap the die from the underside of the punch table to loosen the die for removal.
4. Install new die and tighten set screw. If loading a shaped die, align the whistle spot with the set screw and tighten.
5. Install new punch and tighten punch nut with wrench. If using a shaped punch, align the locating keystock of the punch with the corresponding slot within the punch stem assembly and tighten the punch nut with the wrench.
6. Check for punch and die alignment by powering up the machine and inching down the punch to meet the die with the foot pedal. Check to see that the punch is centered in the die.
7. In the event that the punch and die are not aligned, loosen the bolts under the table allowing the table to be moved to center the die. When aligned, tighten the table bolts to secure the table.
8. Swing the stripper bar back in place allowing for minimal clearance between the top of the material and the bottom of the stripper and tighten the stripper bolts.

Punch Operation
When familiar with the setup and safe operation of the punch station, clear the punch station of any tools or debris prior to powering the machine on. When clear, power the machine on and place the material to be punched between the punch and die. Check to see that your material is spanning the stripper plate and that adequate material is available beyond the stripper area to safely position the material. Clear your hands from the working area and depress the foot pedal to move the punch through the material and into the die. When the punch is complete, release the foot pedal automatically strip the material from the punch and return the punch to its neutral position.

Recommended Punch and Die Operating Clearances

Punching Capacities
You can determine the tonnage required to punch A36 mild steel (yield strength 32,300 psi, 65,000 psi tensile) by applying the following formulas for round or shaped holes. For materials other than mild steel please refer to the multiplier table.
Round Holes:
Punch Diameter x Material Thickness x 80 = Tons of pressure required
Example:
How many tons of force do I need to punch a 3/8" hole in ¼" mild steel?
.375 x .25 x 80=7.5 tons
Shaped Holes:
1/3 Punch Perimeter x Material Thickness x 80= Tons of pressure required
Example:
How much force do I need to punch a 3/8" x 1" rectangular hole in ¼" mild steel?
(.33 x 2.75) x .25 x 80=18.2 tons
Click for Chart for Tonnage to Punch a Hole

Material Multiplier
When punching materials other than mild steel first calculate tonnage as shown above then apply the multiplier for the listed material.
Material Multiplier
Aluminum: 0.38
Brass (1/4 hard): 0.70
Copper (1/2 hard): 0.52
Steel (50% carbon): 1.50
Steel (cold rolled): 1.24

Important Hole Punching Recommendations:
* Punches normally get dull faster than the die so if you are planning to punch many holes it would be wise to order extra punches at a ratio of about 3 punches for 2 dies.
* Punching holes in stainless steel will dull your punches extra fast. It helps if you spray some cutting oil on the spot before you punch the hole.
* Punching holes in type A36 steel can be unpredictable because A36 is made with recycled steel. The A36 that was made when the steel mill was recycling sheet metal is easier to work with than the A36 that was made when the steel mill was recycling ball bearings.
* For repeat punching in the same position it is recommended that you add a Gaging Table to your machine so you can accurately position your workpiece where you want it over and over again with little effort.
* If you a planning on punching hole patterns with holes that are less than 4 inches apart then you should consider buying a custom made multi-punch and die set that can punch multiple holes simultaneously perfectly spaced everytime. You will need the extra large 241 or 48XX type of punching assembly to do this.
* If you are planning on punching holes for wrought iron fencing or some other reason that requires holes to be evenly spaced on many pieces, then you should consider a CNC feed system.
* If you are punching holes in copper or soft aluminum or very thin steel then you should consider buying a Urethane Stripper to hold the metal down firmly while punching for a nice distortion free hole.
* If you are puching holes in thin metal you should consider using the stroke control to save time on the up and down cycle.

BAR/PLATE SHEARING

Your Ironworker machine will include a bar/plate shear as a standard feature. The bar/plate shear will provide a distortion and burr free shear cut to mild steel bar or plate stock as listed in the Ironworker Specifications section of this Manual as well as described on the capacity labels positioned at the Shearing Station. The Shearing Station on the Edwards Ironworker allows for straight or angled cutting applications. The material hold down adjusts with a simple hand crank to safely restrain the material being cut.

Setup
Standard bar/plate shears are factory tuned to proper clearances and are ready to begin shearing operations. Shear blades are wearing parts and will need to be maintained or replaced over time. When maintaining or replacing your shear blades it is important to make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. To setup bar/plate shear station when maintaining or replacing blades, please refer to the following steps.

Remove and replace stationary blade:
1. Remove the material hold-down assembly from the Ironworker frame by removing the return spring and bolts that secure the assembly to the Ironworker frame.
2. Remove blade bolts located under the feed table. Remove the stationary blade.
3. With blade removed, clean blade pocket of any dirt or debris
4. Your shear blades have multiple cutting surfaces that can be flipped and rotated prior to full replacement of the part. Rotate the stationary blade to new cutting surface and reinstall in blade pocket.
5. Tighten the stationary blade back into the blade pocket.

Remove and replace movable blade:
1. Remove the drop-off guard from the rear of the Ironworker frame.
2. Power on the machine and inch the moving center down to reveal bade bolts for the moving blade.
3. With bolts exposed, turn machine off and disconnect from power source.
4. Remove blade bolts and remove blade from the blade pocket.
5. With blade removed, clean blade pocket of any dirt or debris.
6. Your shear blades have four cutting surfaces that can be used prior to full replacement of the part. Rotate the movable blade to new cutting surface and reinstall in blade pocket.
7. Tighten the movable blade back into the blade pocket.
8. Replace the drop-off guard to the rear of the frame.
9. Return the machine to power and turn on to automatically return the moving center to its neutral position.
10. With a feeler gauge, check shear blade for correct operating clearance. See the Care and Periodic Maintenance section of the Owners Manual for tolerance adjustment instructions. Failure to maintain clearance will damage shear blades and support brackets.
11. Replace and secure the material hold-down assembly and return spring to the Ironworker frame.

Safe Operation
Please observe the following guidelines when operating the Bar/Plate Shear Station

· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Check shear blade clearance at every tooling change or extended shear operation. Maintain correct operating clearance at bar shear and angle shear stations. See the Care and Periodic Maintenance section of your Owners manual for tolerance adjustment instructions. Failure to maintain clearance will damage shear blades and support brackets.
· Tighten the clamp handle to fully clamp the material hold-down on the material being cut.
· Do not stack material to cut in the shear station.
· Perform complete shear operations only- partial shear cuts may jam the drop off side of the frame and could result in breakage and operator injury.
· Use shearing aids when working with small items at the shear station.

Bar Shearing Operation
When familiar with the setup and safe operation of the Shear Station, clear the feed table of the shear station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be sheared on the feed table. Push the material under the material hold-down and into the blade area. Position your material to the desired cut and lower the material hold-down. Tighten the hand-wheel to secure the material in the feed table. Clear your hands from the working area and depress the foot pedal to activate the shear station. When the cut is complete, release the foot pedal to return the shear blades to their neutral position. Reverse the hand-wheel to raise the material hold-down and remove your material.

ANGLE SHEARING
Your Ironworker may include an angle iron shear as a standard feature. The angle shear will provide a distortion and burr free shear cut to mild steel angle stock as listed in the Ironworker Specifications section of this Manual as well as described on the capacity labels positioned at the Angle Shearing Station. The Angle Shearing Station on the Edwards Ironworker allows for straight cutting applications. An oversized material hold down adjusts with a simple thumb crank to safely restrain the material being cut.

Setup
Standard angle shears are factory tuned to proper clearances and are ready to begin shearing operations. Shear blades are wearing parts and will need to be maintained or replaced over time. When marinating or replacing your shear blades it is important to make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. When maintaining or replacing blades please refer to the following.

Remove and replace stationary blade:
1. Remove the material hold-down assembly from the Ironworker frame by removing the bolts that secure the guard/hold-down assembly to the Ironworker frame.
2. Remove blade bolts located behind the guard. Remove the stationary blades.
3. With blades removed, clean blade pocket of any dirt or debris.
4. Your shear blades have multiple cutting surfaces that can be used prior to full replacement of the part. Rotate the stationary blades to new cutting surface and reinstall in blade pocket.
5. Tighten the stationary blades back into the blade pocket.
6. Replace and secure the material hold-down and guarding to the Ironworker frame.

Remove and replace movable blade:
1. Remove the angle shear drop-off guard from the rear of the Ironworker frame.
2. Power on the machine and inch the moving center down to reveal blades bolts for the moving blade.
3. With bolts exposed, turn machine off and disconnect from power source.
4. Remove blade bolts and remove blade from the blade pocket.
5. With blade removed, clean blade pocket of any dirt or debris.
6. Your shear blades have multiple cutting surfaces and tow radius options that can be used prior to full replacement of the part. Rotate the movable blade to the appropriate radius and new cutting surface and reinstall in blade pocket. See fig. For correct radius designation.
7. Tighten the movable blade back into the blade pocket.
8. Replace the drop-off guard to the rear of the Ironworker frame.
9. Return the machine to power and turn on to automatically return the moving center to its neutral position.
10. With a feeler-gauge, check shear blade for the correct operating clearance. See the Care and Periodic Maintenance section in your Owners Manual for tolerance adjustment instructions. Failure to maintain clearance will damage shear blades and support brackets.
11. Replace and secure the material guard and hold-down assembly to the Ironworker frame.

Safe Operation
Please observe the following guidelines when operating the Angle Shear Station

· Never exceed the capacities for the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Check shear blade clearance at every tooling change or extended shear operation. Maintain proper operating clearance at bar shear and angle shear stations. Failure to maintain clearance will damage shear blades and support brackets.
· Fully engage the material hold-down with the material being cut.
· Do not stack material to cut in the shear station.
· Perform complete shear operations only- partial shear cuts may jam the drop off side of the frame and could result in breakage and operator injury.
· Do not shear angle smaller than the hold-down will accommodate.

Angle Shearing Operation
When familiar with the setup and safe operation of the Angle Shear Station, clear station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be sheared into the material hold-down. Push the material through the angle hold-down and into the blade area. Position your material to the desired cut and lower the material hold-down. Tighten the thumb screw to secure the material in the angle shear. Clear your hands from the working area and depress the foot pedal to activate the shear station. When the cut is complete, release the foot pedal to automatically return the shear blades to their neutral position. Reverse the thumb screw to raise the material hold-down and remove your material.

Safety Guard pulled up for photo purposes

COPER-NOTCHER TOOLING (IF STANDARD EQUIPMENT)
Notch tooling will provide a distortion and burr free, three sided shear cut to mild steel bar, plate or angle stock as listed in the Ironworker Accessories section of this Manual as well as described on the capacity labels positioned at the Notching Station. The Notching Station on the Edwards Ironworker allows for shaped, straight or angled notch cutting applications.

Setup
When installing or adjusting notch tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. Your Notching Station is equipped with one, three sided top notcher blade and three, four sided bottom blades. The top blade is mounted to the moving "center" of the Ironworker, while the bottom three blades are secured into a base housing. If ordered as a factory installed option, your notcher assembly is setup for immediate operation. To setup your Notching station please observe the following steps.

1. Swing the notcher guard assembly up and away from the notcher table.
2. Install the top notcher blade with the keyway up and the "foot" of the blade facing the center of the machine. Secure the top blade using the two ½" socket head cap screws. Tighten bolts.
3. Install the notcher table assembly to the base table. The notcher table includes three blades secured within the table housing. Install with the open "U" facing the center of the machine. The guide foot of the top blade should be centered within the base table blades.
4. Loosely secure the table from the underside of the base with four ½" bolts and washers (provided).
5. Check for top and bottom blade alignment by powering up the machine and slowly inching down the top blade to meet the bottom blades within the foot pedal. Power the machine off.
6. Using a feller gauge, adjust the clearance between the perimeter of the top and bottom blades to allow for .010 clearance on all three sides.
7. In the event that the top and bottom blades are not aligned, simply loosen the bolts under the table allowing the table to be moved to center the top blade within the bottom blades. When aligned, tighten the table bolts to secure the table.
8. Adjust the four set screws at the sides of the notcher table to engage the base notcher table to the base table. Lock the four 3/8" nuts in place to secure the set screws in place. These added fixtures are to provide additional support to the base table during the notching operation.
9. Swing the notcher guard back in place.

Safe Operation
Please observe the following guidelines when operating the Notcher Station.

· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Check notcher blade clearance at every tooling change or extended notcher operation. Maintain .010 clearance between top and bottom notcher blades at all times. Failure to maintain clearance will damage blades and support pockets.
· Cut with a minimum two of three sides of the blade surfaces engaging the material being notched. Cutting on one blade surface may overload the blades and result in tooling damage or injury to the Operator. See figures A, B, and C.
· Do not stack material to cut in the notcher station.
· Perform complete notch operations only- partial notch cutes may jam the drop off side of the tooling and could result in breakage and operator injury.
· Use notching aids when working with small items at the notcher station.

Notching Operation
When familiar with the setup and safe operation of the Notcher Station, clear the feed table of the notcher station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be notched on the feed table. Push the material under the tooling guard and into the blade area. Position your material to the desired cut. Clear your hands from the working area and depress the foot pedal to activate the notcher station. When the cut is complete, release the foot pedal to automatically return the top notcher blade to the neutral position.

COPER-NOTCHER TOOLING (IF OPTIONAL)
Optional Notcher tooling will provide a distortion and burr free, three-sided shear cut to mild steel bar, plate, or angle stock as listed in the Ironworker Accessories section of this Manual as well as described on the capacity labels positioned at the Notching Station. The Notching Station on the Edwards Ironworker allows for shaped, straight or angled notch cutting applications.

Setup
Optional tooling and accessories fit within the open station of the machine. When changing any tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. Your Notching Station is equipped with one, three sided top notcher blade and three, four-sided bottom blades. The top blade is mounted to the moving "center" of the Ironworker, while the bottom three blades are secured into a base housing. If ordered as a factory installed option, your notcher assembly is setup for immediate operation. If ordered as an option, the open cavity of the machine must be cleared of any existing tooling, material or debris prior to tooling installation. To setup your Notching Station, please observe the following steps.

1. Swing the notcher guard assembly up and away from the notcher table.
2. Install the top notcher blade with the keyway up and the "foot" of the blade facing the center of the machine. Secure the top blade using the two 3/8" socket head cap screws. Tighten bolts.
3. Install the notcher table assembly to the base table. The notcher table includes three blades secured within the table housing. Install with the open "U" facing the center of the machine. The guide foot of the top blade should be centered within the base table blades.
4. Loosely secure the table from the underside of the base with four bolts and washers (provided).
5. Check for top and bottom alignment by powering up the machine and slowing inching down the top blade to meet the bottom blades with the foot pedal. Power the machine off.
6. Using the feeler gauge, adjust the clearance between the perimeter of the top and bottom blades to allow for .010 clearance on all three sides.
7. In the event that the top and bottom blades are not aligned, simply loosen the bolts under the table allowing the table to be moved to center the top blade within the bottom blades. When aligned, tighten the table bolts to secure the table.
8. Adjust the four set screws at the sides of the notcher table to engage the base notcher table to the base table. Lock the four 3/8" nuts in place to secure the set screws in place. These added fixtures are to provide additional support to the base table during the notching operation.
9. Swing the notcher guard back in place.

Safe Notcher operation
· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Check notcher blade clearance at every tooling change or extended notcher operation. Maintain .010 clearance between top and bottom notcher blades at all times. Failure to maintain clearance will damage blades and support pockets.
· Cut with a minimum two or three sides of the blade surfaces engaging the material being notched. Cutting on one blade surface may overload the blades and result in tooling damage or injury to the Operator. See figures. (right)
· Do not stack material to cut in the notcher station.
· Perform complete notch operations only- partial notch cuts may jam the drop off side of the tooling and could result in breakage and operator injury.
· Use notching aids when working with small items at the notcher station.

Notching Operation
When familiar with the setup and safe operation of the Notcher Station, clear the feed table of the notcher station of any tools or debris prior to powering the machine on. When clear power the machine up and place the material to be notched on the feed table. Push the material under the tooling guard and into the blade area. Position your material to the desired cut. Clear your hands from the working area and depress the foot pedal to activate the notcher station. When the cut is complete, release the foot pedal to automatically return the top notcher blade to the neutral position.

Safety Guard pulled up for photo purposes

V-Notch Tooling (OPTIONAL)
Optional V-Notch tooling will provide a distortion and burr free, two-side, 92 degree shear cut to mild steel bar, plate or angle stock. Common use of this tooling is in the fabrication of angel iron frames. Please review capacity labels positioned at the V-Notching Station.

Setup
Optional tooling and accessories fit within the open station of the machine. When changing any tooling, always wear protective safety glasses and clothing and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. Your V-Notch is equipped with one, two-sided top notcher blade and two, four-sided bottom blades. The top blade is mounted to guide pins and return springs of the tooling base. The moving "center" of the Ironworker, pushes on the top V-Notch blade via the accessory push block. If ordered as a factory installed option, your V-Notcher assembly is set up for immediate operation. If ordered as an option, the open cavity of the machine must be cleared of any existing tooling, material or debris prior to tooling installation. To setup your V-Notching station please observe the following steps.

1. Remove all tooling and guarding from the open station.
2. Install the push back supplied with the V-Notcher assembly. The V-shaped end of the push block should be pointing away from the machine. Secure the push block with bolts provided.
3. Place the V-Notcher assembly on the Ironworker support table with the V pointing away from the machine.
4. Loosely secure the table from the underside base with four ½" bolts and washers (provided).
5. Check for push block and top block and top blade alignment by powering on the machine and slowly inching down the push block to meet the top blade with the foot pedal. Power the machine off.
6. In the event that the push block ands top blade are not aligned, simply loosen the bolts under the table allowing the table to be moved to center the push block centerline to the top blade. When aligned, tighten the table bolts to secure the table.
7. Install the V-Notcher guard with the bolts provided.

Safe Operation
Please observe the following guidelines when operating the V-Notcher Station.

· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Check V-Notcher blade clearance at every tooling change or extended notcher operation. Maintain .010 clearance between top and bottom notcher blades at all times. Failure to maintain clearance will damage blades and support pockets.
· Cut with a minimum of two sides of the blade surfaces engaging the material being notched. Cutting on one blade surface may overload the blades and result in tooling damage or injury to the Operator.
· Do not stack material to cut in the V-Notcher station.
· Perform compete notch operations only- partial notch cuts many jam the drop off side of the tooling and could result in breakage and operator injury.
· Use notching aids when working with small items at the notching station.

V-Notching Operation
When familiar with the setup and safe operation of the V-Notcher Station clear the feed table of the notcher station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material being notched on the feed table. Push the material under the tooling guard and into the blade area. Position your material to the desired cut. Clear you hands from the working area and depress the foot pedal to activate the notcher station. When the cut is complete, release the foot pedal to automatically return the top notcher blade to the neutral position.

Safety Guard removed for photo purposes

OVER SIZE PUNCH TOOLING (OPTIONAL)
Your Ironworker is capable of punching oversize holes in material listed in the Ironworker Accessories section of this Manual. Standard and custom tooling is available to allow for flange or leg down punching of angle sections.

Setup
Optional tooling and accessories fit within the open or standard punch station of the machine. When changing any tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. To setup your Over Size Punch Tooling station please follow the following steps.

1. Swing the Punch Stripper assembly up from the standard punch by loosening the stripper assembly bolts from the Ironworker frame.
2. Remove the standard punch holder from the operating center and the standard die table from the support table base.
3. Secure the oversize punch holder to the operating center with the bolts provided.
4. Place the oversize die tables on the support table base and loosely install 4 bolts (provided) through the underside of the support table into the oversize die tables.
5. Install new oversize die and tighten set screw. If loading a shaped die, align the whistle spot with the set screw and tighten.
6. Install new oversize punch and tighten punch nut with wrench. If using a shaped punch, align the locating keystock of the punch with the corresponding slot within the punch stem assembly and tighten the punch nut with the wrench.
7. Check for punch and die alignment by powering up the machine and slowing inching the punch to meet the die with the foot pedal. Check to see that the punch is centered in the die.
8. In the event that the punch and die are not aligned, simply loosen the bolts under the table allowing the table to be moved to center to the die. When aligned, tighten the table bolts to secure the table.
9. Swing the stripper bar back in place allowing for minimal clearance between the top of the material and the bottom of the stripper and tighten the stripper bolts.

Safe Operation
Please observe the following guidelines when operating the Oversize Punch Station.

· Always use safety glasses and factory supplied guards when operating your Ironworker.
· Read, understand and follow punching tolerances shown in the Punch section of this manual.
· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· The thickness of the material you are punching should not exceed the diameter of the punch being used.
· Follow manufacturers punch and die clearance recommendations as shown in the Punching section of this manual.
· Check punch and die alignment after every tooling change or extended punch operation.
· Adjust the punch stripper supplied with your Edwards Ironworker to allow for material positioning and material stripping.
· Do not stack material to punch in the punching station.
· Use one or two drops of oil at the punch to aid the stripping material from the punch as well as to extend the life of the punch tooling.
· Punch complete holes only- partial holes will side load the punch tooling and could result in punch breakage and operator injury.
· Use punching aids when working with small items at the punch station.

Oversize Punch Tooling Operation
When familiar with the setup and safe operation of the oversize punch station, clear the punch station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be punched between the punch and die. Check to see that your material is spanning the stripper plate and that adequate material is available beyond the stripper area to safely position the material. Clear your hands from the working area and depress the foot pedal to move the punch the material and into the die. When the punch is complete, release the foot pedal to automatically strip the material from the punch and return the punch to its neutral position.

Safety Guard removed for photo purposes

241 & 28XX EXTRA LARGE PUNCH TOOLING (OPTIONAL)
Your Ironworker is capable of punching materials as listed in the Ironworker Specifications section of this Manual as well as described on the capacity labels positioned at the Punch Station. The punch station on the Edwards Ironworkers allows for a wide variety of punching and stamping applications. Standard and custom tooling is available to allow for flange or leg down punching of standard angle sections. Refer to the accessory pages of your manual for further information.

Setup
Optional tooling and accessories fit within the open or standard punch station of the machine. When changing any tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. To setup your 241 Punch Tooling please observe the following steps.

1. Remove the standard punch stripper from the ironworker frame, punch holder from the operating center and the standard die table from the support table base.
2. Secure the 241 punch holder to the operating center by first removing the stud from the holder. Place the holder to the operating center with the tapped hole positioned to the outside of the center. Install holder with two ½" SHCS bolts and tighten. Install stud to holder with four 3/8" SHCS bolts and tighten.
3. Place the 241 die table and slug chute on the support table base and loosely install four ½" bolts (provided) through the underside of the support table into the 241 die table.
4. Install new oversize die and tighten set screw. If loading a shaped die, align the whistle spot with the set screw and tighten.
5. Install new 241 punch and tighten with spanner wrench. If using a shaped punch, align the locating keystock (not provided) of the punch with the corresponding slot within the punch stem assembly and tighten the punch nut with the wrench.
6. Check for punch and die alignment by powering up the machine and slowly inching down the punch to meet the die with the foot pedal. Check to see that the punch is centered in the die.
7. In the event that the punch and die are not aligned, simply loosen the bolts under the table allowing the table to be moved to center the die. When aligned, tighten the table bolts to secure the table.
8. Install and secure the 241 stripper bar to the ironworker frame allowing for minimal clearance between the top of the material to be punched and the bottom of the stripper.

Safe Operation
Please observe the following guidelines when operating the 241 Punch Station.

· Always use safety glasses and factory supplied guards when operating your Ironworker.
· Read, understand and follow the punch size tolerances shown in Fig, 1 (page 7).
· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· The thickness of the material you are punching should not exceed the diameter of the punch being used.
· Follow manufacturer's punch and die operating clearance recommendations as shown on page 7.
· Check punch and die alignment after every tooling change or extended punch operation.
· Adjust the punch stripper supplied with your Edwards Ironworker to allow for material positioning and material stripping.
· Do not stack material to punch in the punching station.
· Use one or two drops of oil at the punch to aid in stripping material from the punch as well as to extend the life of the punch tooling.
· Punch complete holes only- partial holes will side load the punch tooling and could result in punch breakage and operator injury.
· Use punching aids when working with small items at the punch station.

241 Punch Tooling Operation
When familiar with the setup and safe operation of the oversize punch station, clear the punch station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be punched between the punch and die. Check to see that your material is spanning the stripper plate and that adequate material is available beyond the stripper area to safely position the material. Clear your hands from the working area and depress the foot pedal to move the punch through the material and into the die. When the punch is complete, release the foot pedal to automatically strip the material from the punch and return the punch to its neutral position.

Safety Guard removed for photo purposes

PEDESTAL DIE TOOLING (STANDARD)
Your Ironworker will punch materials listed in the Ironworker Specifications section of this Manual as well as described on the capacity labels positioned at the Punch Station. Pedestal Die tooling is available in standard and oversize configurations to allow for 2"x2"x1/4" max. angle to be punched leg down at the punch station. Standard 2"x1/4"max. channel sections may be web punched and special offset dies are available for punching close to web/flange unions. Refer to the accessory pages of your Manual for further information.

Setup
Optional tooling and accessories fit within the open or standard punch station of the machine. When changing any tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. To setup your Pedestal Die Tooling station please observe the following steps.

1. Swing the Punch Stripper up from the punch by loosening the stripper assembly bolts.
2. Remove die by loosening the set screw at the front of the punch table and then lifting die from the die holder. If the die resists removal gently tap the die from the underside of the punch table to loosen the die for removal.
3. Remove standard die table from the fixed table base by removing the four bolts.
4. Install new Pedestal Die Table to fixed table base with the two ½" bolts provided. Loosely secure bolts with the supplied washers and nuts from the underside of the table.
5. Install die and tighten set screw. If loading a shaped die, align the whistle spot with the set screw and tighten.
6. Install punch and tighten punch nut with wrench. If using a shaped punch, align the locating keystock of the punch with the corresponding slot within the punch stem assembly and tighten the punch nut with the wrench.
7. Check for punch and die alignment by powering up the machine and inching down the punch to meet the die with the foot pedal. Check to see that the punch is centered in the die.
8. In the event that the punch and die are not aligned, simply loosen the bolts under the table allowing the table to be moved to center the die. When aligned, tighten the Pedestal Die Table bolts to secure the table.
9. Swing the stripper bar back in place allowing for minimal clearance between the top of the material and the bottom of the stripper and tighten the stripper bolts.

Safe Operation
Please observe the following guidelines when operating the Punch Station

· Read, understand and follow the punch size tolerances shown in Fig.1 (page 7).
· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· The thickness of the material you are punching should not exceed the diameter of the punch being used.
· Follow manufacturer's punch and die operating clearance recommendations as shown on page 7.
· Check punch and die alignment after every tooling change or extended punch operation.
· Adjust the punch stripper supplied with your Edwards Ironworker to allow for material positioning and material stripping.
· Do not stack material to punch in the punching station.
· Use one or two drops of oil at the punch to aid in stripping material from the punch as well as to extend the life of the punch tooling.
· Punch complete holes only- partial holes will side load the punch tooling and could result in punch breakage and operator injury.
· Use punching aids when working with small items at the punch station.

Pedestal Die Operation
When familiar with the setup and safe operation of the Pedestal Die Tooling installed in the punch station, clear the punch station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be punched between the punch and die. Check to see that your material is spanning the stripper plate and that adequate material is available beyond the stripper area to safely position the material. Clear your hands from the working area and depress the foot pedal to move the punch through the material and into the die. When the punch is complete, release the foot pedal to automatically strip the material from the punch and return the punch to its neutral position.

Safety Guard pulled up for photo purposes

PIPE- NOTCH TOOLING (OPTIONAL)
Optional Pipe-Notch tooling will provide a distortion and burr free notch cut to mild steel pipe stock as listed in the Ironworker Accessories section of this Manual as well as described on the capacity labels positioned at the Pipe-Notching Station.

Setup
Optional tooling and accessories fit within the open station of the machine. When changing any tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. Your Pipe-Notch Station is equipped with one, top notcher die and one, bottom notcher die. The top die is mounted within a spring loaded guide housing mounted to the tooling base. The bottom die attaches to the face of the guide housing and is machined with a saddle to aid in centering and guiding pipe sections into the die housing. The moving "center" of the Ironworker, pushes on the top Pipe-Notch blade via the accessory push block. If ordered as a factory installed option, your Pipe Notcher assembly is setup for immediate operation. If ordered as an option, the open cavity of the machine must be cleared of any existing tooling, material or debris prior to tooling installation. To setup your Pipe-Notching station please observe the following steps.

1. Remove all tooling and guarding from the open station.
2. Install the push block supplied with the Pipe-Notcher assembly. Secure the push block with bolts provided.
3. Place the Pipe-Notcher assembly on the Ironworker support table with the bottom die pointing away from the machine.
4. Loosely secure the table from the underside of the base with four ½" bolts and washers (provided).
5. Check for push block and top die alignment by powering on the machine and slowly inching down the push block to meet the top die with the foot pedal. Power the machine off.
6. In the event that the push block and top die are not aligned, simply loosen the bolts under the table allowing the table to be moved to center the push block centerline to the top blade. When aligned, tighten the table bolts to secure the table.
7. Power the machine on and jog the center down. The pipe dies will close or bypass each other. The push block should not come in contact with the die housing.

Safe Operation
Please observe the following guidelines when operating the Pipe Notcher Station.

· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Keep the Pipe Notch tooling clean. When dirt or metal chips accumulate, remove 5/16-18 x 1/2" limit screw located in the center at the rear of punch. Lift out punch holder and two springs. Clean holder with solvent or kerosene.
· Check Pipe Notcher blade clearance and alignment at every tooling change, maintenance cycle or extended notcher operation. Maintain .010 clearance between notcher blades at all times. Failure to maintain clearance will damage blades and support pockets.
· Do not stack material to cut in the Pipe Notcher station.
· Perform complete notch operations only- partial notch cuts may jam the drop off side of the tooling and could result in breakage and operator injury.
· Use notching aids when working with small items at the notcher station.

Pipe-Notching Operation
When familiar with the setup and safe operation of the Pipe Notcher Station clear the feed table of the notcher station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be notcher on the feed table. Push the material under the tooling guard and into the blade area. Position your material for the desired cut. Clear your hands from the working area and depress the foot pedal to activate the notcher station. When the cut is complete, release the foot pedal to automatically return the top notcher blade to the neutral position.

PRESS BRAKE TOOLING (OPTIONAL)
Optional Beak tooling is available in 7", 8", 10" and 12" assemblies for your Edwards Ironworker. Brake tooling will allow for the graduated bending of 1/6", 3/16", 1/8", and ¼" flat, bar or angle stock up to 90 degrees. This tooling is most effective when ordered with the factory installed Electric Stroke Control feature.

Setup
Brake tooling can be accommodated in either the open or punch station of the machine. When changing any tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. Your Brake tooling is equipped with one mounting bracket to secure the "punch" to the center of the machine, one "punch", one "4-way die", and two bottom brackets that secure the "die" to the base table. The moving "center" of the Ironworker, pushed the top punch into the shaped die to bend the specified material. If ordered as a factory installed option, your Brake assembly is setup for immediate operation. If ordered as an option, the open or punch station must be cleared of any existing tooling, material or debris prior to tooling installation. To setup your Brake, please observe the following steps.

1. Remove all tooling and guarding from the open or punch station.
2. Secure the Brake mounting bracket to the "center" with bolts provided. The ½" tapped hole is positioned to the outside of the machine.
3. Position punch in the bracket so that the milled relief in the keyway slips over the bracket bolt. Tighten set screws in the bracket to secure the punch.
4. Place the die assembly on the Ironworker support table.
5. Loosely secure the two support brackets to the support table from the underside of the base with four ½" bolts, nuts and washers (provided).
6. Check for punch and die alignment by powering on the machine and slowly inching down the punch to meet the bottom die with the foot pedal. Power the machine off.
7. In the event that the punch and die are not aligned, simply loosen the bolts under the table allowing the die block to be moved to center the punch. When aligned, tighten the table bolts to secure the table.
8. Select 1/16", 3/16", 1/8", or ¼" test material for bending. Rotate your four-way die to your selected material thickness. Power the machine on and jog the center down until the punch pushes the sample material into the die. If the punch stops before the material has been formed to a 90 degree angle, a small steel shim must be placed between the bottom die and support table.
9. Re-install all guarding to the machine prior to machine use.

Safe Operation
Please observe the following guidelines when operating the Press Brake Station.

· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Keep the brake tooling clean.
· Check Brake clearance and alignment at every tooling change, maintenance cycle or extended Brake operation. Failure to maintain proper clearance may damage punch, die and support brackets or adjacent tooling.
· Brake material towards the center of the brake length.
· Do not stack material in the Brake station.
· Use Brake aids when working with small items at the Brake station.
· When not in use, remove the Brake die from the holder.

Press Brake Operation
When familiar with the setup and safe operation of the Brake, clear the station of any tools or debris prior to powering the machine on. When clear, power the machine up and place the material to be "broken" on top of the bottom die. Bending material to the front or back of the brake die may damage your Ironworker. Position your material for the desired bend in the middle. Clear your hands from the working area and depress the foot pedal to lower the punch the desired amount. You can hold a protractor in front to see what angle you are bending to. If your Ironworker machine has electronic stroke control like an Edwards, you can adjust it to stop the punch at the exact depth you want to repeat the same bend angle, again and again. When the brake operation is complete, release the foot pedal to return the punch to the neutral position.

ROD SHEAR/MULTI-SHEAR TOOLING (OPTIONAL)
Optional "bump-die" shear tooling is available for your Edwards Ironworker. Rod Shear or Multi Shear Tooling will provide distortion and burr free cuts to mild steel rod, square, bar and small angle stock as listed in the Ironworker Accessories section of this Manual.

Setup
Optional "bump-die" tooling and accessories fit within the open or punch stations of the machine. Verify recommended location per Ironworker model below. When changing any tooling, always wear protective safety glasses and make sure the machine is turned off. Failure to power down your machine could result in injury to the operator performing the work. Edwards "bump-die" tooling consists of a housing which holds a stationary blade, a moving blade, return springs and a push block. The moving "center" of the Ironworker, pushes on the top moving blade via the push block to shear the material. If ordered as a factory installed option, your "bump-die" assembly is setup for immediate operation. If ordered as an option, the open or punch cavity of the machine must be cleared of any existing tooling, material or debris prior to tooling installation. To setup your Rod Shear or Multi Shear tooling installation please observe the following steps.

1. If your machine is an Edwards, use the following locations:
25 Ton: open station on right side
50 Ton Pro: punch station
55 Ton: open station on right side or punch station
65 Ton: punch station or open cavity in upper middle
75 Ton: punch station
100 Ton: Deluxe: punch station
120 Ton: open cavity

2. Remove all tooling and guarding from the appropriate open, punch or open cavity station.
3. Place the "bump-die" assembly on the Ironworker support table with the push block in line with the moving center.
4. Loosely secure the table from the underside of the base with four 1/2" blots and washers (provided).
5. Check for push block and moving center alignment by powering on the machine and slowly inching down the center to meet the push block with the foot pedal. Power the machine off.
6. In the event that the push block and top die are no aligned, simply loosen the bolts under the table allowing the bump-die to be moved to center the push block with the moving center. When aligned, tighten the table bolts to secure the table.
7. Power the machine on and jog the center down. The moving blade will close or bypass the fixed blade. The push block should not come in contact with the die housing.

Safe Operation
Please observe the following guidelines when operating any Rod Shear or Multi-Shear bump-die tooling.

· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Keep the tooling clean.
· Check blade clearance and alignment at every tooling change, maintenance cycle or extended tooling operation. Maintain .010 clearance between blades at all times. Failure to maintain clearance will damage blades and support pockets.
· Do not stack cut material.
· Perform complete shearing operation only- partial cuts may jam the tooling and could result in breakage and operator injury.
· Use shearing aids when working with small items at the Rod Shear or multi Shear Tooling station.

Rod Shear/Multi-Shear Operation
When familiar with the setup and safe operation of the Rod Shear or Multi-Shear Tooling, clear the work area of any tools or debris prior to powering the machine on. When clear, power the machine up and insert material through the tooling guard and into the blade area. Position your material for the desired cut. Clear your hands from the working area and depress the foot pedal to activate the tooling station. When the cut is complete, release the foot pedal to automatically return the tooling to the neutral position.

ELECTRIC STROKE CONTROL (STANDARD)
Electric stroke control is standard on most Ironworker machines including all but the Edwards 25 ton. Stroke control enables the Ironworker operator to shorten up and down stroke with minor adjustment of two hand screws. Utilize stroke control to control precision bending with your brake tooling, control stroke when using embossing or bump dies or simply increase production from your punch, notch or shear stations.

Setup
Stroke control is currently offered only as a factory installed option and arrives fully setup for immediate use. Always wear protective safety glasses and make sure the machine is turned off when adjusting the electric stroke control option. Failure to power down machine could result in injury to the operator performing the work.

Safe Operation
Please observe the following guidelines when adjusting the electric stroke control function.

· Always use safety glasses and factory supplied guards when operating your Ironworker.
· Read, understand and follow punching, notching and shearing tolerances as described in related chapters of this manual.
· Never exceed the capacities of the machine or tooling as described in the Ironworker specifications or listed at the tooling station.
· Keep limit switches free of dirt and grime.
· Never remove stroke retention nuts from factory setting.
· Never reverse stroke limit switches.

Electric Stroke Control Operation
Set upstroke for rapid cycling of your punching, shear and notching stations.

· Power machine on and use the jog function of your electric foot pedal to bring tooling down to rest just above the material being worked.
· Turn machine off.
· Adjust upper handle with tapered collar to engage limit switch.
· Power machine on. Tooling will stay in set position.
· Remove material from tooling station and cycle machine. Tooling should return to pre-set position.
· Place material in tooling station and cycle machine.

To Set Upstroke for faster cycle time for punching operation
· Power machine on and use the jog function of your electric foot pedal to bring ram down to engage tooling. Jog ram to push bump die tooling to the specified depth.
· Turn machine off.
· Adjust lower handle with tapered collar to engage limit switch.
· Power machine on. Ram will return to top of stroke.
· Cycle machine to insure proper stroke depth.
· Place material in tooling station and cycle machine.

To Set Downstroke for press brake operation
· Power machine on and use the jog function of your electric foot pedal to bring ram down to engage tooling with material.
· Jog ram to push brake die tooling to the specified depth/ brake angle.
· Turn machine off.
· Adjust lower handle with tapered collar to engage limit switch.
· Power machine on. Ram will return to top of stroke.
· Place test material in tooling station and cycle machine to insure proper stroke depth and material brake.

NOTE: For using other optional equipment such as the various Back Gauges, Angle Gauge, Gaging Tables, Stripper Reducer, Urethane Stripper, Rotating Turret, please see their individual instructions.

IMPORTANT MAINTANENCE FOR YOUR HYDRAULIC IRONWORKER MACHINE
1. Grease your machine minimum of once for every 8 hours of use. This is the most important thing you can do to make your machine last a long time.
2. Change your hydraulic oil a few months after you get your machine to get the break-in oil out of the machine. If you cant change the oil regularly, please change it at least once. It will make a big difference. Heavily used machines should have their oil changed at least once per year. Your hydraulic cylinder, hydraulic pump and hydraulic valve will appreciate it. Edwards recommends using viscosity 46 hydraulic oil.
3. Change your punches and blades when they get dull to prevent from overloading the machine.
4. Make sure you are using your machine on level ground to prevent overloading one side.

TROUBLESHOOTING YOUR HYDRAULIC IRONWORKER MACHINE
Your Edwards Ironworker is designed for years of trouble-free use. In the event of operational problems please refer to the following troubleshooting strategies prior to contacting your Edwards Dealer. All remedial actions are to be performed with the Ironworker powered off and power to the hydraulic supply turned off.

ELECTRICAL HOOKUP

Confirm the electrical supply coming to the terminal location that will power your Ironworker with a certified electrician prior to hooking up your machine. Confirm your electrical supply with the electrical specifications of the machine listed in your Operator Manual and located on the Ironworker starter box. It is critical that a qualified electrician install your machine as your Warranty protection does not cover mis-wiring of electrical components at your site.

ELECTRICAL STARTER BOX

Have your electrician confirm the power supply coming into your facility and to the electrical terminal location. Provide the wiring diagrams to the electrician prior to initiating the electrical hookup of the machine.

Typical 220 volts 1 phase Electrical Diagram shown below

Power wiring of Overload Relay for single phase motors shown above.
The overload relay is designed to speed tripping in case of uneven loading or loss of one phase, therefore all 3 overload heaters must be used on 1 phase.
Incoming power hooks in on top of starter to #3 and #5. It does not matter which lead goes to #3 or 5. But the ground wire does matter. The motor should already be wired for correct rotation at the factory.

Typical 220/380/415/440/480 volts 3 phase Electrical Diagram shown below

For Manual Control with Buttons in Cover.
Incoming power hooks in on top of #1, 3, 5. Motor rotation is clockwise looking at the fan end of the motor. If rotation is wrong, switch line 2 and line 3 around.

Click for Edwards Ironworker Machines

Click for How to use a Lathe Machine

Click for How to use a Milling Machine

Click for How to use a Band Saw Machine

Click for How to use a Surface Grinder Machine

Click for How to use a Drill Press Machine

Click for How to use a Sheet Metal Brake Machine

Click for the American Machine Tool Homepage

Terms and Conditions

Privacy Clause