QC11Y-20×2500 Gate Shearing Machine

USE MANUAL

QC11Y-20×2500

Gate Shearing Machine

CUTTING THICKNESS: 20 mm
CUTTING WIDTH: 2500 mm

The People's Republic of China

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 QC11Y-20×2500 Gate Shearing Machine

PREFACE

Thank you for your choosing our product of QC11Y series producing line. For the
safety’s sake, the Manual should be followed carefully.
The purpose of the Manual is to provide the technical guide, explain the
installation, commission, operation, maintenance and the simple fault solving of the line.
Supposed you have any doubts and problems, please contact our technician or
after sales service .
If the line is transferred to others, please provide the Manual together with the line.
The line is subject to Chinese standard. If it is used out of China, the clients are
kindly requested to follow the requirements of safety standards of his own country.
With the principle of improving the quality of the products, our company will
reserve the rights for improvement, and the changes of Manual will not be notified in
advance.

☆ Thank you for purchasing our product

☆ In order to properly use the machine that you bought, please read this manual
carefully before use.

☆ Please be sure to pass this manual to the actual user of the machine.

Safety Information

Before installation, operation, maintenance and check, please be sure to read up this use manual for
correct use. Operation is allowed only after fully understand the machine principle, safety condition
as well as all the precautions.

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Indications:

Warning!
Indicate that wrong-operation may get an electric shock.

Caution!
Please don’t put your hands or other things into the dangerous range to avoid accidents.

Warning!
Grounded before operating the machine, the type of grounded should in line with the national
standard or related international standard. Otherwise it may get an electric shock.

Warning!
Be sure not to put hands or any part of the body into the danger zone.

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Contents

1. Basic parameters of the machine…………………………………… 5

2. Main usage of the machine………………………………………… 6
3. Hydraulic systems of the machine ………………………………… 6
4. Constructions of the machine………………………………………… 9
5. Electrical control of the machine …………………………………………13
6. Lubrication of the Machine ………………………………………… 17
7. Suspension and installation……………………………………………18
8. Adjusting & preparing work before installation …………………………20
9. Safety technical and maintenance of the machine………………………… 21

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Ⅰ、Basic parameter of the machine

Name Data Unit Remarks

Max cutting thickness 20 mm

Max cutting width 2500 mm

Intensity of the sheared material 450 N/mm2

Shearing angle 0.5～2°30′

Max stroke of backgauge 20-800mm

Times of stroke 8-12 Per/min

Distance between vertical columns 2750 mm

The length of blade 2600 mm

Height of the work bench 900 mm

Main motor Model Y2-180L-4B35

Power 30 KW

Speed 1440 rpm

Backgauge motor Model Y1602-6 B5

Power 0.55 KW

Speed 900 rpm

Gear Pump Model CP1-63-01R

Power 63 L/min

Pressure 31.5 MPa

Dimensions Length 3250 mm

Width 2100

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Height 2500

Ⅱ、Main Functions and Characteristics of the Machine

This machine is suitable for shearing the plate that the thickness is1-20mm,
width≤2500 mm, The strength of sheets is 450N/mm2. The more strength of the
plate to be sheared, the more thickness should be decreased.
Our machine adopts plates welding construction, hydraulic driving, and
accumulator return stroke. The machine is of steadiness with small volume,
lightweight, rigidity and lower noise.
It′s fast and convenient to adjust the blades clearance. It has front gauge. Front
gauge adopts staff counter and gauge orientation. It has also equipped with light to
overlapping the draw line on the plate. So it’s convenient to draw the line and
shear. The stroke of the upper knife carrier can be adjusted stepless.

Ⅲ、 Hydraulic system of the machine

The hydraulic system of the machine consists of HG1-63-01R gear pump, one
way valve (18), system electro-magnetic overflow valve (7、8、9) , one way order
valve and accumulator(14) .
The needed pressure oil is supplied by HG1-63-01R gear pump. The max
pressure is 25MPa. It is adjusted by system electro-magnetic overflow valve (8).
Attention pls. , it is not necessary for the users to adjust hydraulic values, for
each of them has been adjusted before leaving the factory.
Working principle:( See drawing 1)
After oil pump start, treat down foots switch, YV1 gains power, then hydraulic
system builds pressure . Some of the pressure oil enters into press plate oil
cylinder, and the plate is pressed, the others enters into left(main cylinder) upper
champed of cylinder through one way order valve 22 and sphere valve . while the
low champers of the left cylinders oil enters into upper champers of the right
cylinder, area of left lower champers of the left oil cylinder is equal to area of
upper champers of the right cylinder, so it makes a series synchronic circuit to
drives the blades move down . While oil of lower champers of the right oil cylinder
is pressed into the accumulator .
Returning of the machine

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After return point is arrived, YV1 losses power, oil pump release the pressure.
Blades return to upper point because of effect of accumulator pressed oil. Oil of
upper champers of the left cylinder are flowed into the oil tank through one way
valve (23) and sphere valve .
Cutting angle adjustment
Cutting angle reduce is realized by left cylinder keeping no movement while oil
being into upper chamber of right cylinder. At first the sphere valve of tube of
upper cylinder must be shut up, The oil pump is in running, push cutting angle
increasing button, YV2 gains power at the same time. Oil from upper left cylinder
is flowing YV2 into oil tank. Press decreasing button YV1 , YV2 gain power at
the same time ,YV1 works is ensure that the pressure oil enters into upper chamber
of the right cylinder.
(Before adjusting angle the sphere valve should be shut up. Normally the sphere
valve should be open)
1.Fueling of the accumulator: open valve gate 21, Push filling button , valve
YV1 gains power , Pressure oil entres into the accumulator through valve gate 21
and make sure the valve of the accumulator pressure. Then close the valve gate
and release the fueling button of the accumulator, then blades return to the upper
dead point because of effect of pressure oil, Fueling pressure is lower than
13MPa.
2.Specially note: The accumulator is only allowed to fill with N2! The other
gases is not allowed! Otherwise it causes blast!!! The pressure is lower than 9
Mpa
(Fueling of accumulator is finished by two persons)

Fig1:hydraulic principle drawing

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Ⅳ、The Construction of Machinery

1、Framework: The machine adopts all-steel welding structure that ensures

fine rigidity. Two oil cylinders are formed on the left and right top. The workbench
is linked to framework by welding. The lower blade is fixed on the workbench and
adjusted subtly to keep the distances between the two neighbors-able blades equal.
2 、 The upper carrier: It is steel welding structure which ensures fine
rigidity .It moves up and down with the support of fulcrum eccentric sleeve to
fulfill shearing.
3、Plate - press equipment: It consists of several pressed cylinders fitted on
the support plate in front of the framework.
When pressure oil enters into plate – press cylinder you will find that the
plastic cover overcomes pulling-force of spring and pressing the plate tightly. With
the help of the pulling force the plastic cover returns to the original position after
the shearing ends.
4、Gauge equipment
Front Gauge:
Front gauge adopts staff counter and gauge orientation.

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Figure3: Pressing cylin

Figure4 : Backgauge drawing

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Ⅴ、 Electrical control of the machine

The machine adopts three-pha 380V, 60Hz power electricity. The input circuit
of controlling transformer employs 380V while output is 24V. The main motor
employs three-pha 380V while the controlling part; hydraulic valve and indicating
lamps adopt 24V DC power together with coordinating lamp and main contact
KM1 adopt 24V.
The electric box is placed on the left of the machine. The controlling buttons
are fixed in front of the machine so as to be operated conveniently.
The lead wire of foot-switch (SA3) is connected with the electrical box
directly.
Its operating details are as follows:
Open the door of the electric box with key, turn air-circuit breaker (QF1) to its
“on” position; the machine’s power is on. Turn on the key button (SA1) to put on
the controlling circuit at this moment. Indicating lamp is on to show the power is
on.
Press the button switch (SB2) or (SB3) to make the back gauge to the required
dimension (the counter will show its value). If it is not moved accurately, you can
adjust it through hand regulation device. There are safety switches on the max and
min dimension. The adjusting range of (SQ3 SQ4) backgauge is 600mm.
Press the switch (SB4), the oil pump motor is staring. The (HL2) lights at the
same time indicating that the oil pump motor is in the state of working.
Turn the combined switch on the position ‘11’, the shearing mode means
‘single stroke’. The foot switch (SA3) is actuated. The top knife carrier shears
downward and the combined switch is on the position’111’, the machine keeps on
cutting when shearing model is on ‘continue’.
The shearing length of this machine can be changed through rotary the button.
Revolve rotary switch (SA1) and move the plate after turn on the coincided

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lamp to make the working line coinciding with the machine’s projection line, then
the required results can be got.
Be sure that the key switch (SA2) is locked and the air-circuit breaker has
been turned off before operator left. Locking the electric box is also necessary.

Electrical components

Code Name Specifications remark

QF1 Air circuit breaker C65D25A/3P

QF2 Air circuit breaker C65D6A/3P

M1 Motor Y2-180L-4B5 30KW

M2 Motor Y1602-6 0.55KW

Alternating current LC1
KM1
contactor D11610/3160V+DN20
KA2KA6KA5 Medium contactor LC1D0601/3160V

KT3 Time relay LA2DT0

FR Thermal relay LR2D1321+ LA7D1066

FU1 FU2 Fuse C65D6A/2P

FU3 Fuse C65D6A/1P

TC Transformer JBK3-250 3160/220V

TC1 Transformer BKC-50 3160/220V

SA1 Key switch XB2BG21+BE101

SQ16 Door switch JW6M-11

SA3 Foot switch YDT1-11

SA2,6,5,6 Tumbler LW6-6/1

SB1 Sudd-switch XB2BS562+BE102

SB2-SB5 Button XB2BA21

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SQ1,3 Safety switch JW2-11A/L

SQ,6,5 Safety switch JLXK1-6111

HL16 light

HL1-HL6 Signal light XB2BVM1-24V

Ⅶ、Lubrication

Every main lubricating point is lubricated in oil-gun pouring point

Oil-adding Type-number
Number Lubricating point
distance of lubricating

1 Articulating fulcrum on the left-right oil

Every day
cylinder Calcium
lubricating
grease
2 The rod screw of the back Gauge

3 Every duty Mechanical

Detective light pole of back gauge
oil

Calcium
6 The swing fulcrum of the top blade beam
lubricating
(one point on the left and right)
grease

Notes: 1.use by the mixture of 50%calcuium lubricating grease and 50%

technical oil
2.use by the mixture of graphite Li grease adds 30% technical oil.

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Ⅵ、Suspension and Installation

1. While the machine being transported, the ways given on the hoisting
diagram (See fig5) should be taken.

Figure4: hoisting and installation for the machine

2. The machine’s foundation
(1) The dimension of the foundation may refer to the installation
diagram of the foundation (see fig7).

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(2) The earth around the foundation must be rammed. The depth of the
foundation depends on soil texture.
3. The installation
While the machine being installed and fixed, the crisscross level should be
checked with the level meter. It is not more than 0.2mm on the crisscross level
within 1000mm in every direction.

Figure7: foundation drawings

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Ⅷ. The prepare work and adjustment before under

working

1.preparation before operation

(1) Clean the parts of machine pour lubricating oil into every part.
(2) Add66# low-coned sated hydraulic pressure oil into the oil box, according
to the liquid level in the liquid level gauge.
(3) The machine must have ground connection connect with the mains and
examine the coordination of each electric, equipment’s action.
2.Adjustment of the even degree of the clearance between edges.
While composite change-over switch is located at“zero”, that is, start oil
pump in one-way condition, the tool carrier returns to the top dead point. locate
the composite switch at“1”,that is button-start pedal switch “SA3”to make top tool
carrier to down dead point. Locate composite change-over switch at“3”,that is
button –start top point. change to button-start“SA3”,little by little goes up the top
tool carrier in the whole stroke at the same time adjust the clearance between the
edges part by part keep the coherently of the clearance between the edges in the
length of the whole blade, get the even degree of clearance between the edges by
pulling or pushing the screw nails on the adjustment working bench.
3.Adjustment of the clearance between edges
Correct ways to adjust the clearance between edges are the important factors
which affect the shearing quality and service life of the blades. Refer to the
following chart for adjusting clearance value. The clearance between edges (mm)
4. Adjustment of hydraulic system pressure
The adjustment of the pressure value has been calibrated before leaving the
factory.

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After the check –repair of the machinery or the change of hydraulic element,
the user can refer to the following recommend manner to adjust system pressure if
needed.
Push oil-filling button (spot) that is equipped on the control board, electro-
magnetic reversing valve (7) is acting. Pressure gauge (13) will display pressure
value. Adjusting order valve (8) until the display value is about 5-5.5Mpa at the
same time. After all, fasten the adjusting nut of the order valve (8), shut down
valve (9). When the filling pressure is more than 5.5Mpa, discharging oil through
valve (9) and repeat above adjusting process. （NOTE: in normal situation, valve
(9) must shut down; otherwise, the storage energy will be damaged!）

Ⅸ、Safety Technique and Maintenance

1. The operators of the machine should be familiar with its main structure and
function.
2. When many people operate the machine, the foot-switch can be step on

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only after the safety is confirmed.

3. Re-adjust each valve is not necessary when the machine is used in normal
state.
4. Check the sharpness of the edge at a regular period. Use another edge or
grind the thickness surface of the blade if the edge is blunt.
5. Check and clean oil pump and net-oil filter constantly, or the noise of oil
pump will louder and influence normal usage of hydraulic system.
4. Check electrical system equipment fluently to ensure the electric works
well.
7.all the pipe joint sealing adopt “O” type. It is very easy aging or damage
under pressure oil. You should change the oil sealing as soon as found the
pipe joint leakage. (See fig 11)
8.You should keep the shear cleaning. If you find any unusually problem,
stopping it and checking it immediately.

Ⅹ. The normal faults and its elimination

1、 no oil from the pump.

Reason ：(1) turning direction of the motor is not correct.
(2)pump break down
(3)pump not running
Method：(1) check the incoming line phase (but can not change the wire in
the electricity box)
(2)change the new pump
(3)check the joint spindle between pump and motor.
2、 the hydraulic circuit can not establish pressure, can not cutting.
Reason：(1) leakage of oil pump.

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(2) the No 7 electro-magnetic valve spool lock.

(3) the No 4 electro-magnetic valve spool lock.
Method ： (1) check if the joint of oil pump loosen or not, change the oil
sealing.
(2) check if the electro-magnetic plugs loosen or not.
(3) clean No 7 valve
(4) clean No 4 valve.
3、blade come down and can not return back.
Reason： no pressure from the storage energy.
Method： filling oil to the storage energy (the method see p13).after blade go
up , if the pressure increase to high, then need to fill gas to storage energy up to 5
Mpa pressure.
4、many noise while cutting.
Reason: oil dirty , oil filter block or not enough oil.
Method: change clean oil, clean oil filter and filling enough oil.
5、shaking of the machine and pipe.
Reason：(1)oil in oil tank not enough.
(2)oil filter block.
(3)oil dirty.
Method：(1)filling oil till the oil tank mark.
(2)clean oil filter.
(3)change the oil.
4、leakage of the oil cylinder, joint of parts and pipe.
Reason: oil sealing damage or aging
Method: change new oil sealing.
7、blade can not come down to down dies point.

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Reason: the time of time relay is too short.

Method: extend working of time relay.
8、press cylinder can not press plate.
Reason: oil cylinder dirty inside.
Method: clean oil cylinder.
9、press cylinder can not return back.
Reason: the spring not good.
Method: remove press cylinder and change new spring
10、blade come to down dies point can not return back quickly.
Reason: down limited switch loosen
Method: fix down limited switch.
11、machine can not work continue
Reason: upper limited switch loosen.
Method: fix upper limited switch.

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Technical demand
1.heat treatment : (1)back out (2)HRC55-60
2.fault localization
3.edge abate is not necessary
6.the tolerance of constant thickness of two big edges is 0.03mm

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5.the tolerance of constant thickness of two small edges is 0.03mm

QC11Y-20×2500

Gate Shearing Machine

Quality certification

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QC11Y-20×2500 Gate Shearing Machine

The People's Republic of China

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 QC11Y-20×2500 Gate Shearing Machine

This machine has passed its final quality audit.

Inspector:
Date:

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