hydrocam - Ready Technology
Contents
1. OR INJURY TO PERSONNEL e DO NOT SUBSTITUTE ANY COMPONENT IN THIS SYSTEM IMPROPER SUBSTITUTIONS MAY RESULT IN PERFORMANCE PROBLEMS AND OR SAFETY HAZARDS e DO NOT ATTEMPT TO REUSE ANY COMPONENT THAT IS OR APPEARS TO BE DAMAGED THIS CAN RESULT IN POTENTIAL PERFORMANCE PROBLEMS AND OR SAFETY HAZARDS e USE ONLY A PREMIUM ISO V 32 SERIES HYDRAULIC OIL Troubleshooting Tips THE MOST COMMON CAUSE OF A HYDROCAM SYSTEM NOT OPERATING IS AIR CAUGHT IN THE HOSE SYSTEM ENSURE THAT YOU HAVE PROPERLY MOUNTED THE H1 PUMP AVOIDED HIGH SPOTS IN THE HOSE SYSTEM AND BLED THE SYSTEM OF AIR NOTE Indicates repair of the component is in question HYDROCAM components must be replaced with an exact duplicate part Failure to do so may result in serious Injury as well as cause damage to the HYDROCAM system or tool PROBLEM H2 Units Piston Rod is not Extending to its Full Stroke CAUSE There is air in the hose system Air has not been bled from the system There is a high spot in the hose system trapping air The H1 Pump is not mounted above the H2 unit s Adjust and bleed the air from the system See pages 10 and 11 CAUSE M ultiple H2 units are hosed in series Re hose using a single hose from each H2 unit to its own H1 Pump port An excessive number of fittings have been used Eliminate or reduce the number of turning fittings The supplied hose was substituted with a smaller ID hose Use only approved hose and fitting2. 5mm hex wrench and an 11mm thin Wall socket wrench then slowly pull the piston rod up using a dowel puller M8 for a H1 5 Pump M10 for the H1 8 and H1 13 Pumps M16 for a H1 20 Pump M20 for the H1 40 and H1 66 Pumps Check that the hydraulic oil level is centered in the H1 Pump s sight gauge Replace and tighten the fill port plug and exhaust valve CAUSE Hydraulic oil is by passing the H1 Pump base s green O ring seal Rebuild the HLPump See page 16 CAUSE The H1 Pump s piston rod return spring is weak damaged or undersized Replace with a new unpainted return spring PROBLEM Loss of Hydraulic Oil CAUSE Hydraulic oil was accidentally drained The oil level should be centered in the H1 Pump s sight gauge add oil and bleed air from system CAUSE Hydraulic oil fiting s is leaking or breaking The hose fitting s was never tightened or over tightened during assembly Replace any leaking hose or fitting with new Use Blue lock tite on all threads and tie downs on the hose s An excessive number of fittings have been used Eliminate or reduce the number of turning fittings Use only approved hose and fittings CAUSE Scratched H1 or H2 piston rod damaged components seals hoses or fittings are causing a leak Follow standard leak tests to determine the location of leak H1 Pump or H2 unit rebuilt using the wrong or damaged seal kit components causing leaks PROBLEM Loss of Nitrogen Pressure CAUSE Ni
3. HAVE PROPERLY MOUNTED THE H1 PUMP AVOIDED HIGH SPOTS IN THE HOSE SYSTEM AND BLED THE SYSTEM OF AIR Installation continued Required position of H1 as compared to H2 Aun u i L Vent Plug Nitrogen Inlet Port NOTE We understand that a few applications will exceed this guide Contact your representative for application support MODEL HYDROCAM H1 5 HYDROCAM H1 8 HYDROCAM H1 13 HYDROCAM H1 20 HYDROCAM H1 40 HYDROCAM H1 66 Hose Connection H1 to H2 H DIMENSION 21 mm 0 83 in 25 mm 0 98 in 25 mm 0 98 in 25 mm 0 98 in 30 mm 1 18 in 40 mm 1 57 in NOTES uoneJjedo uonejjeisur 11 12 Operation Standard HYDROCAM systems operate using a simple hydraulic driven extension with a nitrogen return and require no special conditions or procedures to operate them Ensure that the PRE IN STALLATIO N GUIDE and INSTALLATION sections of this manual have been followed prior to operation During normal operation occasionally inspect the hydraulic oil level by viewing the sight gauge on the H1 Pump s body The oil level should be centered in the sight gauge In addition check the nitrogen pressure 100 bar 1450 psi in the H2 Piercing Forming unit s front bronze bushing on the control panel or with the RTUAL 04 0 Q DM service tool Note The installation of the RTUAL 04 0 Q DM service tool will automatically lower the nitrogen pressure in the H2 unit as the nitrogen fills the additiona
4. Hydraulic Oil Level in H1 Sight Gauge Appears to be Rising CAUSE Die lubricant is entering the system through the H1 Pump or H2 unit s Eliminate source of the die lubricant and rebuild system PROBLEM The Nitrogen Charge Pressure Indicator on the Control Panel does not rise when the ramy slide is set at Die Closed Position CAUSE The Inlet valve was not removed from the H2 unit during installation of the nitrogen return system s hose assembly Using the RTUAL 04 0 Q DM service tool exhaust all nitrogen from the H2 unit and remove the inlet valve Overhaul Before attempting any service read the sections on INSTALLATION and HAZARD WARNINGS and THIS MANUAL THOROUGHLY Disassembly 1 WITH THE CONTROL PAN ELOR THE RTUAL 04 0 QDM SERVICE TOOL SLO W LY EXHAUST ALL NITROGEN FROM THE SYSTEM BEFORE SERVICING ORHANDUNG ENSURE COMPLETE DISCHARGE OF PRESSURE BEFORE ATTEMPTING TO REMOVE ANY H1 PUMP H2 UNIT S CON TRO L PAN EL HOSES FITTIN GS OR AN Y O THER SYSTEM COMPONENTS 2 To begin disassembly of the HYDROCAM system locate and remove hydraulic oil hose fittings and port plug s from the H1 Pump and H2 unit s Drain the hydraulic oil completely out of the system CAUTION Do notallow the hydraulic oil to drain on to the floor as itis extremely slippery Do not reuse the hydraulic oil as it may be contaminated Consult the M SDS form for the ISO V 32 series hydraulic oil that you are using for additional handling i
5. higher elevation than the H2 unit N ote If access to the H1 Pump is limited final mounting may wait until after hydraulic oil has been added to the system Rotate the H1 Pump prior to mounting to ensure access and viewing of the Pump s sight gauge See page 11 uonejjeisuj 10 Installation continued Connect the H1 Pump and the H2 unit s with hose and fittings providing additional hose length to assure appropriate radius and safe routing Do not allow high spots in the hose routing Use Blue lock tite on all threads and tie downs on the hose s With the H2 unit s piston rod in the full back die open position slowly charge the H2 unit s with 100 bar 1450 psi of nitrogen using the control panel or the RTUAL 04 0 Q DM service tool To install the control panel the cover plug and inlet valve must be removed before installing the adapter fitting on the front bronze bushing of the H2 unit s 1 Adding ISO V 32 Series Hydraulic O il to the System To prevent contamination from entering the hydraulic system loosen the fill port plug on top of the H1 Pump but do not fully remove it Then loosen the vent port plug on top of the associated H2 unit s but do not fully remove it Remove the plugs only when hydraulic oil is being added or air is being bled Depending on the location of the H1 Pump and its H2 unit s two people may be needed to complete the following tasks With a squeeze bottle or the RTAUX
6. pimqeg 7 Lubricate with oil and carefully guide the piston rod into the front bushing and install the bushing assembly in the base Install the four metric socket cap screws in the front of the bushing then install the front plate with its columns Align the columns by indicating them parallel to each other Recheck the parallelism of the columns prior to torquing the metric socket cap screws on the front bushing and centered on the front plate Use blue Lock tite on all threads 8 If the H2 unit is using a self contained nitrogen return and charged using the RTUAL 04 0 Q DM service tool or using the optional oil return system install a new inlet valve in the front bushing s nitrogen port Do not install an inlet valve if the H2 unit will be used with a nitrogen return control panel 9 Refer to the PREINSTALLATION GUIDE IN STALLATIO N and O VERHAUL sections of the IN STALLATIO N AND SERVICE MANUAL for proper guidelines to reinstall this HYDROCAM component in the tool or press Failure to follow those guidelines will result in performance problems damage to the HYDROCAM system equipment and or injury to personnel Venting Piston Front U cup Bush U cup Rod Scraper Plug Guide Ring Seal nitrogen Seal nitrogen Seal Oil Port Piston Plug Rear U cup H2 Body Front Bush Front Bush Piston Seal oil steel Body Seal bronze 19 All Our Products Are Available Globally Our factories and offices U S A Mexi
7. supplied driver Use this measurement to calculate the length of the driver Installation Procedure Pre Assembled HYDROCAM Systems Installation of a PRE ASSEM BLED SYSTEM is the same as the procedure for installing a NO N ASSEM BLED SYSTEM Begin at step 2 of that section noting that the hydraulic oil has previously been added to the system W ith the nitrogen pressure fully discharged the H2 unit s piston rod may be extended by carefully depressing the H1 Pump s piston rod with a manual press installation Procedure Non Assembled HYDROCAM Systems Nitrogen Return 1 Check to see that the system s H1 Pump H2 Piercing Forming unit s hose assemblies and system accessories are not pre assembled see above 2 Locate the H2 unit in the desired position The part number RTAUX 1000 Hand Fill pump can be connected to the H2 unit s hydraulic oil port to move the piston rod easing the alignment of the customer provided piercing or forming station and guidance system Locate the H2 unit againsta thrust key 3 W hen alignments are correct set and tighten four mounting bolts and two dowels in the holes provided on the H2 unit Follow the same procedure for each additional H2 unit N ote If access to the H2 unit is limited final mounting can wait until after hydraulic oil has been added to the system 4 Locate the H1 Pump in the desired position then set and tighten four mounting bolts The H1 Pump must be located ata
8. 1000 Hand Fill pump fill the system slowly with the hydraulic oil through the fill port on top of the H1 Pump W hile one person is adding the hydraulic oil the other will open fully the lowest mounted H2 units vent port until a con tinuous flow of pure hydraulic oil no air bubbles flows from the vent port then replace the port plug Repeat the same with any additional H2 units s moving from the lowest to the highest mounted After all H2 vent plugs are in place add hydraulic oil until it centers in the H1 Pump s sight gauge Do not over fill the system with hydraulic oil Beginning with the lowest mounted separately and carefully reopen the vent ports on each H2 unit Let it open until no air bubbles rise out of the vent port If the hose assembly was properly laid out subsequent to adding hydraulic oil all air bubbles are now out of the system If care was not taken to ensure the smooth fall and rise of the hose assembly the hose system must be adjusted and the process repeated Check the H1 Pump s sign gauge and add hydraulic oil if needed Do not overfill the H1 Pump Center the hydraulic oil in the sight gauge replace and tighten the H1 fill port plug E Check alignments and check to be certain all fittings are tightened 8 Stroke the H1 Pump three times ensuring that the H2 unit s piston rod fully extends and atthe die open position the hydraulic oil level is centered in the H1 Pump s sight gaug
9. 2 units 3 Use O ring style hose fittings Note We understand that a few applications will exceed this guide Contact your representative for application support H1 Pump Driver not supplied Piston Stroke Gauge Ring Fill Port Exhaust Valve Body Sight Gauge Oil Level 4 Oil Supply Ports Nitrogen Inlet Port Anti rotational Pillars Front View Front Mounting Plate plate is machinable Installation Before attempting to install or service READ THIS MANUAL THOROUGHLY PROVIDING A GUIDANCE SYSTEM FOR THE PIERCING OR FORMING STATION IS THE RESPONSIBILITY OF THE CUSTOMER NEITHER THE H2 PIERCIN G FORMING UNITS PISTON ROD NOR ITS FRONT MOUNTING PLATE ASSEMBLY IS DESIGNED TO PROVIDE CAM GUIDANCE Installation Warnings 1 HYDROCAM s H1 Pump must be set in the die or press in a vertical position with the piston rod up and perpendicular to a horizontal ram slide 2 Never stroke a HYDROCAM system unless all components are properly mounted and nitrogen is added to the return system 3 HYDROCAM s H1 Pump must be set above the elevation of H2 Piercing Forming unit s See page 10 4 The tool must include stop blocks to prevent over ra vel of the HYDROCAM s H1 Pump s piston rod 5 Never store the tool in a die closed position or depress the piston rod of the HYDROCAM s H1 Pump s dur ing storage 6 Never loosen a hose fitting if the return system
10. DESCRIPTIO N H 2 3 2 Piercing unit with 25mm stroke and front plate 1 H 1 5 Pump with stroke gauge ring 1 RT 2175 CP Nitrogen Control Panel 2 RT701810670 6 Hydraulic Hose 6 foot long with swivel fittings specify lengths up to 6 foot 2 RT52041JC55 6 Nitrogen Hose 6 foot long with swivel fittings specify lengths up to 6 foot N ote e Nitrogen return is standard oil return can be specified as an option e Front plate is standard direct punch can be specified as an option e Straight fittings will be supplied to connect the hoses when ordered as a system elbow fittings can be specified as an option Pre Installation Guide Selecting the Correct H2 Piercing Forming Unit 1 Determine required cam station tonnage piercing or forming force plus total stripping force plus nitrogen or oil return force Do not exceed 90 of the H2 units rated force listed force less return system force See page 5 2 Determine the number of H2 unit s needed for that tool s applications 3 Select the H2 unit s stroke from those offered A longer stroke could require a larger H2 unit 4 Group identical H2 unit s together tonnage and stroke Group identical cam actions together number size or shape piercing units forming flanging notch ing 5 Determine timing for the extension dwell and retract ing of the H2 unit s piston rod 6 Ball Lock Punch applications Selecta 50 mm or longer stroke H2 unit to provide additional s
11. HYDROCAM HYDRO CAM System Serial No It is important that this manual is read thoroughly prior to removing the HYDRO CAM system from its shipping container begin installation in the tool or operating this product READY Technology Inc 333 Progress Rd Dayton OH 45449 800 543 4355 937 866 7200 fax 937 866 7226 HYDRO CAM is protected by USA and International Patents and Trademarks and is a product of READY Technology Inc Copyright 2001 1998 READY Technology Inc All rights reserved jenue w SdIAJeS pue uonejresur GENERAL DESCRIPTION n onn page 3 CAM SY SUIS xxcxesxshaadesss acude E page 4 RECEIVING INFORMATION nnn nun nnn nnn page 4 H2 SELECTION CHART isua seu aEnRNMNCKREREN FGVECECHER RUNE EIU ME KK Rud page 5 HL SELECTION CHART iiiuiessascsRENM DEAESEEFKKUVREKMER UN KNEE MM E EK R E MEE page 6 PRE INSTALLATION CHART onn nnn nun nnn nnn nn page 7 INSTALLATION iisesskassexvnsSERENERETEEEEELRRER EN E REERARAREERIRERE RR EE TUEE page 9 INSTALULATHON WARNINGS etes const tq pEvaeRGR SEXE CPRI DOR RADI MU IIDE P POYRI PEUPLE page 9 INSTALLATION PRO CEDURE H1 PUMP S PISTON ROD DRIVER enm page 9 INSTALLATION PRO CEDURE PRE A SSEM BLED HYDRO CAM SYSTEMS isssscncriveisacvehountensieuensis page 9 INSTALLATION PRO CEDURE NON ASSEM BLED HYDROCAM SYSTEMS Nitrogen Return page 9 REQ UIRED POSITION OF H1 AS COMPARED TO H2 page 11 HOSE CONNECTIO
12. N H1 TO H2 esee eme page 11 OPERATION sissszoukwskirsxEa xa ENEU EMEN EM MR I RUE RU EadR UN RO DR S page 12 OPERA TON NOC SR REUNY sspe detiediseuqutesot quo etos inaia page 12 gU WANUEUPSQUISOR m page 12 TROUBLESHOOTING TPS as badamidittnb Td Edu i IUDA e a denne page 13 OVERHAUL csssxusuiss s mu REEM EE EN MUN Aa NEN Gu EE ERE E MEER page 15 DISASSEM BLY eeeeeseseenemmememmmemeeh menn nnne nnne nen n rn page 15 CLEANING TAE STOTEN cooemesdtsvat utes vm da Des quM OR FEDT UE DET RI PUR EEUU page 15 POSE BL mc page 15 HYDROCAMY REBUILD noun haurhhununhau nnam page 16 H1 PUMP SEALKITUIN STRUCTION uessaadawksdokbexsad rasa dddtetbkidt andi pate page 16 H2 UNIT SEALKIT IN STRUCTIO N H memmmmmmRenne page 18 MSDS USA SYSTEMS ONLY enn nnn nnn Added to the back of this Manual HYDROCAM CATALOG e Added to the back of this M anual General Description HYDROCAMY systems incorporate patented products and processes that are reshaping the Way metal stamping dies are designed and operated leading to fewer dies required for part manufacture HYDROCAMY is simple to design install and operate HYDROCAM removes complexity from piercing forming and replaces it with simplicity HYDROCANM transfers the vertical action of the press into a precise cam action using patented hydraulic technology Standard compone
13. Rate tons 17 ie Step 5 Read up to the column heading This is the H2 model you Max Rate zi 3 732 5 993 USA tons 1 9 3 need In this example H2 model 3 2 FORCE WARRANTY The minimum force that a H2 Piercing Forming unit is warranted to provide is listed in the maximum rate column If the customer s determined application force for a cam station s tonnage exceeds 90 of the maximum rate force the next larger or multiple H2 unit s must be selected Step 5 Step 4 PIND uon2e es ZH pue TH HYDROCAM H1 Pump Selection Chart This chart determines the appropriate H1 Pump for the H2 unit s selected The chart also lists the H1 Pump s piston rod travel mm CH 2 CH 1 Model Model Model Model Model Model 8 13 20 40 66 next to the number of identical H2 units served You need to know the H2 model number the number of H2 units required and the H2 stroke length before using this chart Always use the Rule of N inety The chart is based On using ninety percent of the total volume VT of the H1 Pumps listed in determining the number of identical H2 units that can be supplied by an H1 pump Different stroke lengths or different H2 models may not be used with the same H1 Pump No more than four H2 units may operate off a single H1 Pump W hen two or more identical H2 units are used to extend a gang pierce bar or forming pad each H2 unit must have its own H1 Pump N O TE Piston rod travel may vary slightly Thi
14. ce at 150 bar 2 175 psi on the H2 unit s f Ideal for multiple piercing applications Max Rate a 2 E NE M MC e ener ee g app USA tons 1 9 3 iu ee m a oL PR CE special shape piercing all forming and flanging Working Example To pierce two holes 0 250 inch diameter through 0 125 thick mild steel with 50 000 psi Model 31 28 817 28 8 63 439 ea 27 121 21 60 989 30 minimum tensile strength W e selected a 25mm stroke length for this example The working example uses piercing as the HYDRO CAM application HYDRO CAM is also ideal for forming flanging and other applications Step 1 Calculate the force Force Hole X x 3 1416 X material thickness X material tensile strength recommended 10 stripping force English example 250 in X 3 1416 X 125 in X 50 000 psi 1096 2 4 909 Ibs 491 Ibs 5400 Ibs 2000 Ibs 2 7 U S tons Metric example 6mm X 3 1416 X 3mm X 40 daN per mm 10 2 262 daN 226 daN 2 488 daN 1000 N 2 5 metric tons Step 2 Select the rate In this example use the standard rate for Example Chart piercing CH 25 Model Model 2 3 2 Step 3 Apply the Rule of Ninety N ever exceed 90 of the rated force 5400 Ibs 0 90 2 6000 lbs daN 1 787 2 885 ot hae Metric tons 1 8 2 9 Step 4 Read across the above chart until the rated force exceeds Step 2 SEEDS Ibf 3 9332 6 346 your Rule of Ninety value In this example 6 346 Ibs EE aN 1 7 exceeds 6000 Ibs Max
15. ckness and to ensure precise travel of the H1 Pump s piston rod Note Machining tolerances may cause the mounting surfaces of the H1Pump and or driver to differ from the drawings Determine the driver thickness from the finished surfaces not the drawings 4 One H1 Pump may serve up to a maximum of four identical H2 units Selecting the Mounting Location for the H1 Pump 1 The H1 Pump s piston rod must be up and perpendicu lar to the ram slide Do not mount the H1 Pump in an inclined press or an inclined special machine 2 Locate the H1 Pump s oil supply ports above the H2 unit s vent port elevation See page 11 3 Locate the H1 Pump anywhere in the die under the ram slide that provides balance and simple hose access to the H2 unit s Avoid areas using spray lubri cation 4 Locate the H1 Pump within 2 meters six feet of the H2 unit s 5 Rotate the H1 Pump prior to mounting to ensure access and viewing of the Pump s sight gauge N O TE As with any air hydraulic or nitrogen cylinder neither the H1 Pump nor the H2 unit is designed to withstand side thrust forces Properly guiding the tool and cam station minimize wear to the cylinders and increase seal life Special Timing of the H2 Unit s Piston Rod Extension Dwell and Retraction Request the help of your representative to select a 1 Larger H1 Pump to begin cam extension later in the stroke 2 Nitrogen cushion to begin cam extension earlier in the
16. co U K France Belgium Germany Sweden Netherlands Singapore READY TECHN OLOGY Inc 333 Progress Rd Dayton OH 45449 800 543 4355 937 866 7200 FAX 937 866 7226 2001 READY TECHNOLOGY INC CATALOG 1101
17. d or sealing surfaces while the body front bushing and piston rod are separated 4 Note the colour size orientation and location of each seal Remove the seals from the piston rod body and front bushing taking care not to damage the sealing surfaces 5 High pressure wash or solventclean the components that will be reused Carefully blow dry the components with filtered compressed air Visually inspect the piston rod body and front bushing sealing surfaces Replace any part that is damaged worn scratched or contains imperfections 6 Carefully install the new seals from the seal kit in their proper location and orientation Check to see that all seals guide rings O rings and sealing surfaces are lubricated before installation Place the front U cup seal in the front top of the front bushing s seal chamber Place grease on the U cup seal leaving the lower portion of the seal chamber open HY DROCAM H2 Unit Rebuild continued H2 Unit PISTON ROD SEAL INSTALLATION TIP Immerse the U cup seals to be installed on the piston rod in hot hydraulic oil for several minutes prior to placing them on the piston rod This will simplify the expansion of the U cup seal as it slides onto the piston rod and into its seal chamber N ote Check that the orientation of the U cup seal is correct prior to placing it on the piston rod The two U cup seals sit on either side of the piston guide ring and must be in opposing directions
18. e Also check that the H2 unit s piston rod returns to its full back die open position Add additional hydraulic oil if need as stated in step 7 Your hydrocam system is now ready for production HYDROCAM systems with the H2 2 unit s or systems with very long Hydraulic Drive Hose Assemblies can be more difficult to fill The following will assist a First discharge the nitrogen return system W ith a pry bar carefully cause the front mounting plate to move it forward about 3 mm 1 8 It is not necessary nor recommended that the front mounting plate be moved open any farther b Complete Steps A D listed above understanding that these systems will take longer to fill Setting the H1 Pump much higher than the H2 unit s while adding hydraulic oil to the system will aid in filling these sys tems After completing Step D above return and com plete Step c listed below c With the H1 Pump s fill port open push the H2 unit s front mounting plate s back into the full back die open position N ext charge the nitrogen return system W ith the H2 unit s front mounting plate s fullback check the oil level in the H1 Pump s sight gauge The oil level may be too high Drain excess oil from the system Complete Step E listed above Complete assistance is available should the need arise contact your representative for details THE MOST COMMON HYDROCAM OPERATING PROBLEM IS AIR CAUGHT IN THE HOSE SYSTEM ENSURE THAT YOU
19. e pump base will exert greater force on the threads making removal difficult 3 Carefully guide the piston rod out the bottom of the pump body Taking care notto damage the piston rod or the pump body bore 4 Note the colour size orientation and location of each seal Remove all seals from the pump body and pump base taking care not to damage the sealing surfaces 5 High pressure wash or solventclean the components that will be reused Carefully blow dry the components with filtered compressed air Visually inspect the piston rod pump body and pump base sealing surfaces Replace any part that is damaged worn scratched or contains imperfections 6 Carefully install the new seals in their proper location and orientation Make sure that all seals O rings and sealing surfaces are lubricated before installation 16 HYDROCAM H1 Pump Rebuild continued 7 Lubricate with oil and carefully guide the piston rod fully into the pump body Install the unpainted return spring in the base of the piston rod and install the pump body assembly on the pump base and tighten firmly Install the two H1 Pump valves on top of the pump body loosely so that hydraulic oil can be added during tool installation Carefully install the sight gauge 8 Refer to the PRE4N STALLATIO N GUIDE IN STALLATIO N and OVERHAUL sections of the INSTALLATION AND SERVICE MANUAL for proper guidelines to reinstall this HYDROCAM component Failure to follow t
20. hose guidelines will result in performance problems damage to the HYDROCAM system equipment and or injury to personnel pimqeg H1 Pump Piston Hod Scraper Port Plug Fill Port as roe Oil Sight Gauge Body Oil Level Black O Seal Green OY Seal Oil Port Fitting Base Spring 17 18 HYDROCAM Rebuild H2 Piercing Forming Unit Seal Kit Instruction BEFORE ATTEMPTING TO SERVICE OR REPAIR A HYDROCAM SYSTEM READ THE INSTALLATION AND SERVICE MANUAL THO ROUGHLY PLACING SPECIAL ATTEN TION TOWARD THE HAZARD AND SAFETY WARNINGS LOCATED THROUGHOUT THE MANUAL IF YOU DO NOT HAVE THIS MANUALCON TACT YOUR REPRESEN TATIVE Before disassembly of the H2 unit s verify that the correct seal kit is on hand and that it is complete Thoroughly review the instruction and drawings included with this seal kit 1 Completely discharge the nitrogen from return system using the control panel or the RTUAL04 0 Q DM service tool If using a control panel with a nitrogen return system remove from the H2 unit s seal kit the inlet valve and discard it 2 Disconnect the hose fitting s and vent plugs attached to the H2 Body and front bronze bushing Remove the front plate with its columns by removing the metric socket cap screw centered on the front plate 3 Remove the four metric socket cap screws on the front of the bronze bushing and carefully separate the front bushing from the body Take care not to damage the piston ro
21. is under nitrogen pressure or the H2 unit s piston rod is extended Installation Procedure H1 Pump s Piston Rod Driver The H1 Pump s piston rod travel is critical to the successful operation of the HYDROCAM system 1 Machine smooth and parallel the tool s mounting surfaces for the H1 Pump lower and the customer sup plied driver upper The diameter of the driver s contact surface is a minimum of twice the diameter of the H1 Pump s piston rod This contact surface must be smooth and parallel with no mounted holes Use a Rockwell 45C plate for the driver 2a If the H1 Pump s stroke gauge ring is available mount and use itto develop the travel of the H1 Pump s piston rod The measurement from the base of the H1 Pump to the top of the mounted stroke gauge ring determines the die closed position of the customer supplied driver s contact surface Use this measurement to calculate the length of the customer supplier driver W e recommend that the stroke gauge ring be removed and stored on the tool prior to stroking the H1Pump OR 2b Use the formula Calculating the H1 Piston Rod Travel from the HYDROCAM catalogue to determine the length of the H1 Pump s piston rod travel See page 6 for the H1 selection and travel of piston The measured height from the base of the H1 Pump to the top of the piston rod extended less the calculated piston rod travel locates the die closed position of the contact surface of the customer
22. l volume in the service tool As with any air hydraulic or nitrogen cylinder neither the H1 Pump nor the H2 unit is designed to withstand side thrust forces Properly guiding the tool and cam station will limit damage to the cylinders and increase seal life THE MOST COMMON CAUSE OF A HYDROCAM SYSTEM NOT OPERATING IS AIR CAUGHT IN THE HOSE SYSTEM ENSURE THAT YOU HAVE PROPERLY MOUNTED THE H1 PUMP AVOIDED HIGH SPOTS IN THE HOSE SYSTEM AND BLED THE SYSTEM OF AIR Complete engineering assistance seminars and service support are available should a need arise for any of our full line of metal forming products Contact your representative for details Hazard Warnings e ONLY PERSONNEL WITH THOROUGH KNOWLEDGE OF HYDRAULIC AND OR NITROGEN CYLINDER SYSTEMS SHOULD ATTEMPT TO SERVICE OR REPAIR THIS SYSTEM e BEFORE ATTEMPTING TO CHARGE OR EXHAUST THIS OR ANY SYSTEM USING HIGH PRESSURE NITROGEN HYDRAULICS OR USE OTHER EQUIPMENT CONTROLLING OR STOR ING ANY COMPRESSED GAS ALWAYS USE APPROVED EYE AND EAR PROTECTION e SLOWLY EXHAUST ALL NITROGEN FROM THIS SYSTEM BEFORE SERVICING MAKE SURE ALL PRESSURE HAS BEEN COMPLETELY EXHAUSTED BEFORE ATTEMPTING TO REMOVE ANY FITTINGS HOSES H1 PUMP H2 PIERCIN G FORMING UNIT S CONTROL PANEL OR OTHER COMPONENTS e EXCEPT FOR AN EMERGENCY ALWAYS SLOWLY CHARGE OR EXHAUST THIS OR ANY NITROGEN SYSTEM RAPIDLY CHARGING OR EXHAUSTING A NITROGEN SYSTEM COULD RESULT IN DAMAGE TO EQUIPMENT AND
23. matically lubricates the cylinder wall on every stroke of the press reducing friction on the H1 Pump and H2 units cylinder seals Reduced friction increases seal life and decreases downtime HYDROCAM s use of any premium ISO V 32 series hydraulic oil extends maintenance free service far superior to any other mechanical cam system on the market W ith HYDROCAM there are no off die tanks hoses or safety problems that result from their use Also there is no wasted time required to assemble dismantle store and find tanks valves fittings and hoses Important Receiving Information NOTE Some HYDROCAM systems are shipped pre assembled with the hydraulic oil already added W ith these systems make sure that the H1Pump is kept upright atall times Failure to do so may result in the loss of hydraulic oil Check the contents of your shipment against the packing list Make sure that all items are accounted for before discarding the container and packaging material O therwise field assembled parts accessories or requested spare parts could be discarded with the packaging material In case of damage advise the carrier who delivered the shipment File a claim with that carrier immediately Do not return damaged components for repair or replacement unless you have contacted your local branch or distributor for instructions and obtained a Returned Goods R G number How To Select a HYDROCAM System for Your Application Ba
24. nformation For cylinder disassembly refer to the instructions included in this manual see H1 Pump or H2 unit s seal kit section pages 16 and 18 Cleaning the System 1 Always remove all plugs fittings and accessories before cleaning the components Using solvent thor oughly clean the disassembled H1 Pump H2 unit s and system components Carefully blow dry the components with filtered compressed air Inspect them for wear as described in the seal kit instructions If in doubt replace a worn component rather than have a premature failure in a newly rebuilt system 2 W hen one major part of the system needs to be rebuilt rebuild them all to assure maximum service life and minimum downtime Assembly 1 Rebuild the H1 Pump and H2 unit s according to the instructions included in this manual See the H1 Pump or H2 unit s seal kit section pages 16 and 18 2 Refer to the PRE IN STALLATIO N GUIDE and INSTALLATION sections in this manual for proper guidelines to reinstall a HYDROCAM system Prior to installation make sure that all seals sealing surfaces and O rings are lubricated Leave the two H1 Pump valves on top of the pump body loose so that ISO V 32 series hydraulic oil can be added to the Pump Failure to follow the INSTALLATION section will result in damage to the HYDROCAM system 3 The H1 Pump was designed to operate in a very specific orientation vertical To avoid loss of hydraulic oil damage to equipmen
25. nts combine into systems easing installation in the tool The H2 Piercing Forming unit can be provided with a machinable front plate that simplifies custom applications HYDROCAM action results from the lowering of the press ram slide to activate the H1 Pump s piston rod Hydraulic pressure or force is transferred through high pressure hose s to one or multiple H2 Piercing Forming units extend ing the H2 unit s piston rod The H2 unit has an adjustable return force using proven nitrogen technology NOTE HYDROCAM s unique design eliminates the thrusting force of the ram slide from the cam station allowing the use of standard L G IBS to position and guide the station Providing a guidance system for a HYDRO CAM driven cam station is the responsibility of the customer N either the H2 unit s piston rod nor its front mounting plate assembly is designed to provide cam station guidance Contact your representative for application support uondi sog eJeuorc Cam Systems Currently we offer two types of cam systems CAMDRIVE and HYDROCAM W ith both systems we eliminate the need for bulky complicated custom mechanical cams W ith our standard HYDROCAM systems you can achieve any angle of movement In addition the designer has greater flexibility in the compo nent placement with any HYDROCAM system Hydraulic oil provides for the continuous performance and long life of the HYDROCAM system The oil auto
26. pace to remove the punch Selecting the Mounting Location for the H2 Piercing Forming Unit s 1 Locate the H2 unit s in any three dimensional orienta tion perpendicular to the work 2 Provide for hose access to the back and right front side of the H2 unit Custom porting is not available 3 Provide a mounting platform that will support three times the total working force of the H2 unit Locate the H2 unit against a thrust key 4 The H2 unit is designed to provide force not guid ance 5 he H2 unit s Piston Rod is designed to extend fully NOTE HYDROCAMY s unique design eliminates the thrusting force of the ram slide from the cam station allowing the use of standard L GIBS to position and guide the station Providing a guidance system for a HYDROCAME driven cam station is the responsibility of the customer N either the H2 unit s piston rod nor its front mounting plate assembly is designed to provide cam sta tion guidance Contact your representative for application support Selecting the Correct H1 Pump 1 The H1 Pump is selected by using the information developed while selecting the H2 unit s See calcula tion pages in the HYDROCAM catalogue See page 25 2 Selectan H1 Pump that provides the H2 unit s volume total within 90 of the H1 Pump s total volume Do not exceed 9096 See page 6 3 The stroke gauge ring can be provided with the H1 Pump to develop the customer supplied driver kiss block thi
27. s CAUSE The H1 Pump s hydraulic oil level is not cor rect The oil level should be centered in the H1 Pump s sight gauge add or remove excess oil and bleed air from system CAUSE The H1 Pump s piston rod is not being travelled the correct distance Recheck using the stroke gauge ring that the H1 Pump s piston rod travel is correct Adjust lengthen or shorten the H1Pump s piston rod travel Contact your representative for support See page 6 CAUSE There is an internal nitrogen leak in the H2 unit causing the hydraulic oil in the system to foam Rebuild the H2 unit CAUSE The H2 unit is undersized for this application Check that the required force piercing or forming force stripping force return force is not beyond 90 of the maximum rated tonnage capacity of H2 unit See page 5 CAUSE The H1 Pump is undersized Volume Total of the H2 unit s is greater than 90 of the HI s Total Volume See page 6 CAUSE The H1 Pump s piston rod has been continuously over stroked weakening the safety relief valve Contact your representative PROBLEM H2 Units Piston Rod is not Returning to its Full Back Die Open Position CAUSE The cam station does not have a guidance system causing the station to bind the H2 unit s piston rod Install a cam station guidance system The H2 unit is designed to provide force not guidance See page 7 CAUSE Check the nitrogen pressure 100 bar 1 450 psi If the nitrogen pressure i
28. s results from normal variations in connecting hose length s and the number and style of the Model 2 Model 3 2 Model 5 Model 7 8 Model 12 5 4 22 26 2 22 26 3 25 57 1 19 55 1 25 57 2 26 48 1 26 48 1 22 33 3 29 64 4 37 02 4 31 60 2 31 60 1 25 57 3 35 96 1 26 48 1 35 96 2 37 17 1 37 17 1 30 92 3 22 79 4 27 88 2 22 79 3 30 43 4 23 55 2 23 55 1 19 54 3 26 32 1 20 05 1 26 32 2 27 31 1 27 31 1 23 52 4 25 59 3 21 74 4 26 49 2 21 74 3 28 86 4 22 35 2 22 35 3 29 77 2 29 77 3 25 08 4 30 94 2 30 94 1 25 08 1 30 94 2 26 45 4 37 19 3 40 90 4 52 04 3 42 65 2 42 65 1 30 94 turning fittings Use only approved hose and fittings mode Working Example aD aen v Model 2 Model 31 Step 4 Step 2 Step 3 lt eq Step 1 Model 3 2 Locate the H2 unit and its stroke In this example model 3 2 stoke 25mm Step 1 and 2 Step 3 Locate the number of H2 units to the right of the stroke length The H1 Pump s piston rod travel in millimeters is listed next to that number in parentheses Step 4 Read up to the column heading This is the H1 model you need In this example H1 model 5 1 26 45 1 35 93 1 22 29 2 37 08 3 51 87 1 37 08 1 51 87 special Here is what you need to order QTY PRO DUCT
29. s low charge the system to 100 bar 1 450 psi and check for nitrogen leaks in the system If nitrogen pressure is very low and or frequent charging is required Rebuild the H2 unit with the appropriate seal kit If the H2 unit is self contained and the inlet valve is leaking replace it with new If the nitrogen pressure is 100 bar 1 450 psi check the H1 Pump see below CAUSE The H1 Pump s hydraulic oil level is too high The oil level should be centered in the H1 Pump s sight gauge Remove excess oil and bleed air from the System PROBLEM H1 Pump s Piston Rod is not Returning to a Full Up Die O pen Position CAUSE The H1 Pump s hydraulic oil level is too high The oil level should be centered in the H1 Pump s sight gauge Remove excess oil and bleed air from the System CAUSE H1 Pump s piston rod is being over travelled causing the 400 bar 5 802 psi safety relief valve to activate on each stroke resulting in hydraulic oil not returning back into the H1Pump s lower chamber W ith the stroke gauge ring adjust shorten the H1 Pump s piston rod travel and bleed air from the system See page 6 sdi 6Bunoousoejqnou s BuiuJeM puezepyy 13 14 Troubleshooting Tips continued CAUSE Hydraulic oil has filled the H1 Pump s upper chamber because the tool was stored in a die closed position See Installation Warnings page 9 Carefully remove the fill port plug and exhaust valve on top of the H1 Pump using a
30. sic Selection 1 Determine tonnage required piercing or forming force plus stripping force per unit to perform the necessary work N ote when using urethane or other mechanical methods for stripping please add the appropriate stripping force 2 After you calculate the forces select the correct H 2 unit s required to do the work Do not exceed 90 of the H 2 units available de rated force rated force less return system force from the chart below Include the proper stroke length needed for each unit 3 Determine the correct size and number of H 1 pump s Group identical H 2 units together tonnage and stroke performing identical work piercing forming of flanging One H 1 pump can operate up to four identical H 2 piercing forming units see chart on page 6 Force of H2 Piercing Forming Unit This chart shows the effect of a nitrogen or oil return Mode Mode sModeg sMarei Mocsi 7 Mocu 2 3 2 5 7 8 12 5 20 system on the force rating of each H2 unit Standard Rate equals the effect of standard daN 1 787 2 885 4 545 7 094 11 319 18 819 minimum return force at 100 bar 1 450 psi on Meticions 18 2 9 4 5 7 113 188 the H2 unit s force Ideal for piercing applications Ib 3 932 6 346 10 000 15 611 24 906 41 40 USA tons 2 3 5 Ue ns that use a customer provided stripper daN 1 698 2 728 4319 6 740 10 742 18 230 Maximum Rate equals the effect of maximum Max Rate otic tons 17 17 13 6 7 107 182 return for
31. stroke 3 Sequenced Solenoid Technology SST for special tim ing requirements uonejjesui d Pre Installation continued 4 Hydraulic or air cylinder pressure system for special machine applications Connecting the H1 Pump H2 Piercing Forming Unit s and Nitrogen Return Control Panel See page 11 1 Minimize the number of fittings in the hose system 2 Do not use a hose system that involves a fitting to fitting to fitting series of connections 3 Hose each identical H2 unit to a H1 Pump with its own hose Do not hose in series Provide simple access for hose routing Use only approved hose and fittings 4 Provide additional hose length to ensure appropriate radius and safe routing Avoid high spots in the oll hose route that will trap and create air pockets 5 Maximum hose length is 2 meters six feet Do not Substitute the supplied hydraulic hose with a smaller or lighter duty hose 6 Rotating the H1 Pump 45 may simplify hose routing 7 Avoid turning fittings If a hose turn requires a turning fitting select a 45 fitting as a first choice and a 90 fitting second Use only BSPP style fittings H2 Unit Oil Supply Port Thrust Key Body Bronze Front not supplied Bushing Mounting Plate Side View Vent Plug Piston Nitrogen Return System 1 Always use a control panel 2 For each H1 Pump use at least one contro panel that connects that H1 s associated H
32. t and or injury to personnel never operate this HYDROCAM component in any other position 4 Use only a premium ISO V 32 series hydraulic oil Substitution can cause performance problems and or safety hazards 5 Prior to operation follow standard leak tests to determine if there is any nitrogen or hydraulic oil leaks 6 Never stroke a HYDROCAM system until all components are properly mounted and tightened NOTES neuJ9AQ Dunoouso qnou 15 HY DROCAM Rebuild H1 Pump Seal Kit Instruction BEFORE ATTEMPTING TO SERVICE OR REPAIR A HYDRO CAM SYSTEM READ THE INSTALLATION AND SERVICE MANUAL THO ROUGHLY PLACING SPECIAL ATTEN TION TOWARD THE HAZARD AND SAFETY WARNINGS LOCATED THROUGHOUT THE MANUAL IF YOU DO NOTHAVE THIS MANUAL CONTACT YOUR REPRESEN TATIVE Before disassembly of the H1 Pump verify that the correct seal kit is on hand and that itis complete Thoroughly review the instruction and drawings included with this seal kit 1 Disconnect the hose fitting s and or port plug s attached to the four pump base sides Using an 11mm thin wall socket wrench and a 5mm hex wrench remove the exhaust valve and fill port plug on top of the pump body Empty the remaining hydraulic oil 2 After carefully removing the sight gauge use a pin spanner wrench to unscrew the pump body from the pump base If a strap wrench is used place it very close to the top of the pump body Placing a strap wrench close to th
33. trogen pressure is low resulting from the normal loss following the installation of the RTUAL 04 0 QDM service tool Recharge system CAUSE Nitrogen pressure was accidentally reduced Recharge system CAUSE f the H2 is self contained and the inlet value is leaking replace it with new Note Nitrogen return systems that use a control panel do not have an inlet valve in the H2 unit CAUSE Nitrogen fitting s is leaking or breaking The hose fitting s was never tightened or overtightened during assembly Replace any leaking hose or fitting with new Use O ring style hose fittings Use Blue lock tite on all threads and tie downs on the hose s An excessive number of fittings have been used Eliminate or reduce the number of fittings Use only approved hose and fittings CAUSE Scratched H2 unit piston rod damaged and or leaking components seals hoses fittings or components on the control panel Follow standard leak tests to determine location of the leak Replace any damaged or leaking part with new H2 unit was rebuilt using the wrong or damaged seal kit components System is in need of general overhaul PROBLEM Rupture Plug Failure CAUSE Nitrogen pressure charged too high maximum pressure is 150 bar 2175 psi A hose has been crushed or has too tight a radius Defective weakened or incorrect rupture plug Die lubricant has entered the system see below Eliminate source and rebuild system PROBLEM
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