Mr. Blacksmith 9023029 Bedienungsanleitung
MANUAL IRONWORKER
INSTRUCTIONS
9023029
The MANUAL IRONWORKER is a serious, industrial metal working machine designed for
production environments and high-volume fabrication shops.
CONTENTS
(1) Ironworker
(1) Upper handle
(1) Lower handle
(1) M8 x 3/4” bolt, lock washer, and nut
TOOLS REQUIRED (not included)
• 1/2” wrench
• Two 11/16” wrenches
• 1/4” drift or punch
• Medium hammer
• 1/4” wrench (Main blade removal only)
• Medium snap ring pliers (Shear blade removal only)
SPECIFICATIONS
The following material shearing capacities are rated for low-carbon steel, aluminum or other
materials not exceeding a maximum tensile strength of 64,000 PSI.
Exceeding rated material limitations can result in severe personal injury and/or
damage to the unit.
Main blade shear capacity, flat stock: 4” x 5/16”
Round stock capacity: 5/8”
Square stock capacity: 25/32”
Angle stock capacity: 2 3/8” x 2 3/8” x 1/4”
SAFETY INFORMATION
The following explanations are displayed in this manual, on the labeling, and on all other
information provided with this product:
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION used with the safety alert symbol, indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
READ INSTRUCTIONS
• Thoroughly read and understand this manual before using.
• Save for future reference. Thoroughly read and understand this manual
before using. • Save for future reference.
PINCH AND CRUSH HAZARD!
• The Manual Ironworker consists of heavy metal components which can
present a hand/finger pinch hazard and cause potentially serious injuries if
dropped. Avoid pinching hands while handling. The use of safety shoes is
strongly recommended. Keep fingers and hands away from moving parts
when operating.
CUT HAZARD!
• Handling sharp metal can cause serious cuts. Wear thick, well-fitting
work gloves to prevent cuts from handling sharp metal.
EYE INJURY HAZARD!
• Metal particles can be ejected from the tool when bending and cutting.
Sheet metal edges and corners are sharp and can injure eyes.
Always wear ANSI approved eye protection when operating this tool.
• Before beginning ANY work with this tool, it is
absolutely necessary that it be securely bolted to a sturdy workbench
anchored to the
floor or wall.
• Strenuous physical force may need to be applied to the Manual
Ironworker during use. Failure to ensure proper footing can quickly
result in a fall which could inflict serious personal injury or property
damage. Always work in a clean, uncluttered environment.
• Be sure there is sufficient working room around the tool to allow for safe
handling of various sizes of metal.
• The Manual Ironworker was specifically designed to be operated by one
person only. Never have one person operate the
Handle while another feeds the workpiece or serious injury could occur.
• Excessive resistance while operating could indicate a defect with the
workpiece material or broken or damaged Manual Ironworker
components. To avoid injury, stop work immediately and inspect workpiece
material for nicks, dents, welds, excessive scale or
remaining coatings. Clean or repair as necessary or discard and begin with
a new piece. Also inspect Manual Ironworker components
for looseness or damage.
SET-UP
• The Manual Ironworker requires up to several hundred pounds of handle force to
operate and must be securely mounted on a heavy, solid workbench, stand, floor etc.,
capable of holding the static weight of the unit plus the ability to counter the high force
stresses from operation.
• Place the Manual Ironworker over the chosen location then mark mounting hole
locations by tracing holes in the feet.
Check for the presence of electrical, air or other utility lines under the mounting surface
before drilling mounting holes.
The use of 1/2” x 4” through bolts & nuts or longer lag screws with substantial washers
and attachment to a structural member is absolutely necessary.
• The Manual Ironworker is shipped with the actuating
Arm in the downward position (FIG 1) requiring some partial disassembly and
reassembly as follows:
- Using a ¼” Drift or Punch, drive out the partially inserted Roll
Pins and set aside for reinstallation (FIG 2).
Actuating
Arm
FIG. 1
FIG. 2
- Remove the Pivot Pin (FIG 3) then pull the Actuating Arm stub all the way up and over
center to relieve tension of the Handle Return Springs (FIG 4).
- Pull off the two Handle Return Springs (FIG 5) and set aside for reinstallation noting which
one is left and which is right.
- Keep the Actuating Arm in the upward, over-center position (FIG 6).
- Replace the Handle Return Springs making sure the hooked fingers are positioned properly
just ahead of the Drive Posts with the open loops facing rearward (FIG 6).
- Replace the Roll Pins allowing them to contact the Straight fingers of the Handle Return
Springs into a slight tension in the nearest locating holes (FIG 6).
- Drive the Roll Pins into place with a Hammer (FIG 7).
- Replace the Pivot Pin (Fig 8) then allow the Actuating
FIG. 3
FIG. 4
FIG. 5
FIG. 6
FIG. 7
FIG. 8
Arm stub to move forward. At this point it should be under spring tension (FIG 8).
ASSEMBLY
• Assemble the two Handle sections and bolt together with the M8 x 13/16” Bolt (FIG 9).
• Install assembled Handle to the Actuating Arm with The M12 x 2” Bolt, Washer, Lock
washer and Nut (FIG 10).
• The Manual Iron Worker is ready for use.
ADJUSTMENTS
• Pivot Pin
The Manual Ironworker design incorporates a moveable Pivot Pin which modifies the cutting
pivot point.
The factory installed position (rearward hole location) offers the greatest leverage with the
lowest Handle force required while causing greater lever travel (FIG 11). This is best when
shearing thicker materials.
The alternate position (forward hole location) provides shorter lever travel however it requires
significantly greater lever force (FIG 12). This may be used on shearing lighter, thinner
materials.
TO SWITCH PIVOT PIN POSITION:
- Remove Pivot Pin by griping the head firmly and rotating side to side while pulling firmly.
Carefully withdraw Pivot Pin and immediately place it through the alternate pivot position
(FIG 12). Rotate Pivot
Pin side to side while pushing in.
FIG. 9
FIG. 10
FIG. 11
FIG. 12
DO NOT allow any components to move when withdrawing Pivot Pin or Blade Drive Plate
misalignment can occur (Fig 13). Should this occur, use of a screwdriver or magnet is
advisable to move the Blade Drive Plate back into alignment.
DO NOT use fingers!
• Right-Side, Round, Square and Angle Support Plate
The Right-Side Support Plate may be adjusted up or down to accommodate various sizes of
material. To Do So:
- Loosen the 11/16” Nuts (FIG 14).
- Insert material to be sheared into the appropriate left side opening.
- Slide the Support Plate up or down as required to provide support for the protruding
material.
- Tighten the 11/16” Nuts.
Drive Plate
OPERATION
The Manual Ironworker features multiple metal shearing options based on the shape,
thickness and type of metal to be sheared (FIG 15).
- Main Shear (FIG 16) - The Main Shear is intended for most common shearing operations of
flat stock and sheet metal up to 4” x 5/16”.
- Round Shear (FIG 17) - The Round Shear is for round bar stock up to 5/8” in diameter.
- Square Shear (FIG 17) - The Square Shear is for square bar stock up to 13/16”.
- Angle & “T” Shear (FIG 18) – The Angle & “T” Shear is designed to accept most angle and T
profile stock up to 2 3/8” x 2 3/8” x 1/4”.
FIG. 13
FIG. 14
FIG. 15
FIG. 16
SHEARING OPERATION – MAIN SHEAR
• Measure and mark a cut line on the material to be cut.
• Raise the Actuating Arm to the highest position, opening the blades.
• With the Clamping Foot in place, slip the material to be cut under it and through the blades
allowing it to hold the piece to be cut in place (FIG 19).
Do Not Use Hands or Fingers to hold piece to be cut in place while cutting.
• Rotate the Actuating Lever downward firmly in one smooth motion to shear the metal.
• Raise Actuating Lever fully then retrieve cut piece from unit.
SHEARING OPERATION – ROUND, SQUARE AND ANGLE SHEARS
• Measure and mark a cut line on the material to be cut.
• Raise the Actuating Arm to the highest position, opening the blades.
• Insert the material to be cut into the left side of the unit at the proper configured opening
and through the blades allowing the right-side Support Plate to support the material (FIG. 20).
• Rotate the Actuating Lever downward firmly in one smooth motion to shear the metal.
• Raise Actuating Lever fully then retrieve cut piece from unit.
BLADE REPLACEMENT
The Manual Ironworker is designed with hardened steel blades that should last the life of the
Iron Worker. Should damage occur and require Blade replacement, the following procedure
describes the process.
NOTICE: The following steps require precise adjustments, alignment and high attention to
detail. This procedure should only be attempted by users with advanced mechanical skills.
Square
Round
FIG. 17
Angle
FIG. 18
FIG. 19
FIG. 20
MAIN SHEAR BLADES REMOVAL
- Unbolt and remove the entire Handle Assembly.
- With (2) 11/16” wrenches remove the outer blade retaining plate bolts (FIG 21).
- Using the same 11/16” wrenches, remove the 2 bolts securing the
MAIN MOVING BLADE TO THE BLADE FRAME.
NOTE: The Main Moving Blade has 2 finished surfaces and may be reversed if one side is
worn or damaged (FIGS 22 & 23).
- With an 11/16” wrench, remove the bolts on the left side attaching the Main Fixed Blade to
the Main Frame (FIGS 24 & 25).
INSTALLATION
NOTE: The Main Moving Blade Must be installed before the Main Fixed Blade as there is a
preload designed into the Main Moving Blade Frame.
- Hold Main Moving Blade in place, reinstall bolts and nuts then secure with (2) 11/16”
wrenches.
FIG. 21
FIG. 22
FIG. 23
FIG. 24
FIG. 25
- Insert the 2 bolts from the left side of the Main Frame, thread into the Main Fixed Blade and
tighten in place.
- Replace Handle.
ROUND, SQUARE AND ANGLE SHEAR BLADES Removal
- Unbolt and remove the entire Handle Assembly.
- Remove the Material Support Plate from the right side of the unit with an 18mm wrench
(FIGS 26 & 27).
- Remove the Pivot Pin then pull the Actuating Arm stub all the way up and over center to
relieve tension of the Handle Return Springs (FIG 28).
- Pull the Actuating Lever/Sector Gear from the assembly.
The following steps involve components and assemblies that are heavy and will suddenly fall
away! Use extreme care and hold these components securely when withdrawing fasteners!
Take note of the position of the Actuating Lever/Sector Gear position and relation to the teeth
with those of the Rack for re-assembly.
- Remove the left side Snap Ring securing the left Pivot Arm to the Main Shaft (FIG 29). then
move the Main Shaft back slightly then Very Carefully lower the left Pivot Arm (FIG 30).
FIG. 26
FIG. 27
FIG. 28
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