manualshive.com logo in svg

Minster IOI, Service Manual

Share
Download
Minster IOI Service Manual Download Page 36

SECTION E

This Section Contains The Following:

Page

Press Servicing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-2

Lockable Switches & Valves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-2

Servicing The Pneumatic System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-3

Air Lockout Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-3

Air Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-4

Air Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-4

Air Pressure Gauges  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-4

Solenoid Air Valves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-4

Air Pressure Switches  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-5

Air Line Lubricators  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-5

To Fill The Air Line Lubricators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-5

To Adjust The Clutch/Brake Air Line Lubricator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-6

To Adjust The Slide Adjust Motor Air Line Lubricator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-6

Counterbalance System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-7

Theory Of Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-7

Air Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-8

Determining Die Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-8

Alternate Methods Of Air Pressure Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-8

Balancing Slide And Die Weight  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-8

Percent Motor Load  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-8

Effects Of Improper Pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-9

Service And Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-9

Re-applying Air After Shutdown  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-9

To Check For Air Leaks In The Counterbalance System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-9

To Replace Slide Counterbalance Cylinder Air Seal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-9

Flywheel Brake  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
Flywheel Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
Die Cushion  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11

To Check For Air Leaks In The Die Cushion System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
To Replace Rail Mounted Die Cushion System Air Seals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
To Replace Trunion Mounted Die Cushion System Air Seals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12

Air Reservoir Tanks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15
Safety Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15
Fusible Plugs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15
Drain Cocks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15
Air Leaks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15

E - 1

Summary of Contents for IOI

Page 1: ...Manual No 1010C MINSTER 8952 399 15 00 Service Manual OBI OBS SERIES PRESS MODEL...

Page 2: ...Manual No 1010C MINSTER 8952 399 15 00 Service Manual OBI OBS SERIES PRESS MODEL...

Page 3: ...ecifications designs and materials with out notice consistent with sound engineering principles and recognized modern practices IMPORTANT In order to more clearly show details of the Minster Model 101...

Page 4: ...n the press to remind personnel of hazards that may not be obvious when and if improper procedures are followed The objective here is to establish SAFE operating procedures for all personnel associat...

Page 5: ...g Procedure C 7 Digital Speed Meter Calibration C 8 To Calibrate The Digital Speed Meter C 8 Servicing Procedure C 8 Remote Controls C 9 Flywheel Rotation C 9 To Check Flywheel Rotation C 9 Air Supply...

Page 6: ...ubricator E 6 Counterbalance System E 7 Theory Of Operation E 7 Air Pressure Adjustments E 8 Determining Die Weight E 8 Alternate Methods Of Air Pressure Adjustment E 8 Balancing Slide And Die Weight...

Page 7: ...ation F 10 Factor Affecting Parallelism And Vertical Movement F 11 SECTION G Pages G 1 thru G 6 Servicing The Frame And Drive Assembly G 2 Relieving A Slide From A Stuck On Bottom Condition G 2 Using...

Page 8: ...s I 4 Weekly Checks I 4 Monthly Checks I 5 Semi Annual Checks I 5 Pneumatic Components I 7 Weekly Checks I 7 Monthly Checks I 7 Electrical Equipment I 9 Weekly Checks I 9 Monthly Checks I 9 Lubricatio...

Page 9: ......

Page 10: ...SECTION B This Section Contains The Following Page Press Identification B 2 Preparation For Use B 3 Press Safety B 4 B 1...

Page 11: ...IDENTIFICATION Optional Counterbalance Assembly N A On Super Speed Press Main Drive Motor Flywheel Cover Lifting Lug Limit Switch Front Cover Slide Bolster Plate Air Line Lubricator Clutch Solenoid Va...

Page 12: ...ve UNDERSTAND PRESS OPERATING PROCEDURES Read and understand all information provided in the Model 101 OBI OBS Series Press Operation Manual Learn to Inch and Stroke the slide before the dies are inst...

Page 13: ...the applica ble Federal and State Regulations with a safeguarding device Personal protective equipment such as safety hel mets tongs gloves hand pads spats and protec tive sleeves must also be provide...

Page 14: ...Lube Line Installation C 5 Drive V Belt Installation C 5 Electrical Connections C 6 Digital Meters Optional C 6 Digital Percent Of Load Meter Calibration C 6 To Calibrate The Digital Percent Of Load M...

Page 15: ...instructed to use adequate block ing when placing slings around major frame parts to prevent cables from crushing oil lines or damaging electrical conduit and or other exposed components CAUTION NEVE...

Page 16: ...dard threaded fasteners bolts screws etc are used on Minster Model 101 OBI OBS Series presses When assembly torques greater than can be tolerated by Grade 5 hardware are required Grade 8 fasteners are...

Page 17: ...his is required in order to make certain that all four 4 press feet are bearing evenly to avoid twisting the frame 2 Make certain the area of the foundation slab on which the press is to be mounted is...

Page 18: ...g Hex Head Cap Screws and flat washers DRIVE V BELT INSTALLATION The drive v belts transmit energy from the main drive motor to the press flywheel Install the drive v belts fol lowing procedure outlin...

Page 19: ...so if the press is equipped with an Eddy Current Variable Speed Drive the coupling control leads must be connect ed before flywheel rotation can be checked Refer to Flywheel Rotation section page C 9...

Page 20: ...present or is present but erratic 1 Check for loose or broken wires attached to the cur rent transformers 2 Check the current transformers for possible dam age open or shorted windings 3 If the power...

Page 21: ...is position the reading is obtained from the first three digits In the 0 2000 position the digit on the right is a fixed 0 which will require speed changed in increments of 10 S P M before the display...

Page 22: ...of flywheel rotation but DO NOT CYCLE THE SLIDE NOTE Lube reservoir must be filled the lube system must be operational and the air supplied to the press must be clean dry and of sufficient vol ume for...

Page 23: ...inster Model 101 OBI Series presses are inclinable Flywheel presses may be inclined to one of four posi tions 0o vertical 10o 20o or 30o Geared presses may be inclined to one of three positions 0o ver...

Page 24: ...d before stroking the press for the first time All tubing and related fittings in the lubrication system must be checked to make certain they are in good con dition Occasionally tubing is crushed or t...

Page 25: ......

Page 26: ...iness And Control D 5 Waste Disposal D 5 Changing Oil In The Lube System D 5 To Change Oil In The Lube System D 5 Lube System Oil Filter D 6 To Replace The Lube Unit 25 Micron Oil Filter D 6 Lube Dist...

Page 27: ...lly are included in the Press Inspection Check List Maintenance Record in Section H Lubrication system components are included in the comprehensive press inspection check list so that they may be conv...

Page 28: ...the top of the cylinder with Minster Lubricant No 1 See Figure 2D 3 Pour one half pint 0 24 liters into the slide ball box See Figure 2D 4 Fill clutch brake air line lubricator and slide adjust motor...

Page 29: ...ress Normal operating counterbalance pressure is 35 to 45 psi 2 4 to 3 1 Bar 12 Make certain oil is dripping from the gibs 13 Check the entire recirculating lubrication system for leaks Also check for...

Page 30: ...ties unless only approved lubricants are used in our presses and auxiliary equipment The lubricants must be periodically drained at recom mended intervals and replaced with new oil or a reconditioning...

Page 31: ...nd sealing surface of the new filter Install the new filter and tighten it securely by hand 7 After new filter element is installed restore electri cal power to the press and start the main drive moto...

Page 32: ...EVICE To Check The Flow Switch To check flow switch for proper operation perform the following test 1 Turn OFF power to press 2 Disconnect the two 2 flow switch leads from the press electrical system...

Page 33: ...E mode and slide positioned at top of stroke start the lube pump motor Then check for presence of 110 V A C between terminal A1 and press ground See Figure 6D Results required 110 V A C should be pres...

Page 34: ...accordance the manufacturer s recommendations 9 Rotor Seal Lubricate every three 3 months with an approved grease lubricant meeting the specifications of Minster Lubricant No 2 Refer to General Lubri...

Page 35: ...D 10 11 3 2 4 8 12 13 9 1 LUBRICATION AREAS Refer to Summary of Lubrication Areas on page D 9 for lubrication instructions 7 7 14...

Page 36: ...Air Pressure Adjustments E 8 Determining Die Weight E 8 Alternate Methods Of Air Pressure Adjustment E 8 Balancing Slide And Die Weight E 8 Percent Motor Load E 8 Effects Of Improper Pressure E 9 Ser...

Page 37: ...eone is working on the press Some sample WARNING TAGS are shown in Figure 1E LOCKABLE SWITCHES VALVES During service procedures it is sometimes necessary to shut off pneumatic or electrical power to p...

Page 38: ...g pneumatic equipment such as piping pressure regulators pres sure switches varies with the type and number of basic air components installed by Minster and may include optional items needed for the o...

Page 39: ...To adjust the air pres sure turn the regulator handle until the desired pres sure is indicated on the associated air pressure gauge Turn the regulator handle clockwise to increase coun terclockwise t...

Page 40: ...ricator is supplied if the press is equipped with motorized slide adjustment A mist of rust inhibited light turbine oil should be carried by the flow of air into the solenoid valve and slide adjust mo...

Page 41: ...he correct interval the drip rate should be adjusted as outlined in Steps 7 thru 11 7 Stop the main drive motor and place the Stroking Selector Switch in the OFF position Make certain that the flywhee...

Page 42: ...es As the piston travels up in the stroke the volume increases thus decreasing pressure allowing lubrication of the bear ings to occur The counterbalance system assists in the following Maintains and...

Page 43: ...gth x width x height in inches of the upper die and divide by 4 Dividing by 4 is the same as mul tiplying by 0 25 Approx 0 283 LBS in3 minus the holes Alternate Methods of Air Pressure Adjustment Bala...

Page 44: ...er month At the same time check alignment of the cylinder with slide A monthly check should be made of lubrication lines and associ ated fittings connected to the counterbalance Make certain that they...

Page 45: ...alant to the air cylinder head mating surface and install the cylinder on the air cylinder head Wipe away any excess sealant 18 Reinstall the air cylinder cover on cylinder and secure with four 4 375...

Page 46: ...ial is fastened to the brake piston with a single 250 20 x 500 long Socket Low Head Cap Screw NOTE If friction material is replaced use a new screw and apply several drops of Loctite Adhesive Grade 24...

Page 47: ...stopped turning completely Attach a WARNING sign to the press controls to advise other personnel that the press is currently being serviced 4 Remove the cylinder stop from lower cylinder See Figure 9...

Page 48: ...d 16 Reconnect pipe unions in the air supply lines that feed and are directly attached to the die cushion and air cylinder Apply Loctite Hydraulic Sealant H S No 569 Brown Liquid to the threads of the...

Page 49: ...bottoms out in lower cylinder being careful not to damage the seal 13 Place a new gasket on the lower cylinder then install the bottom plate Secure the bottom plate to the lower cylinder with twelve...

Page 50: ...and allows air to escape NOTE A spent fusible plug is not repairable and must be replaced with an identical plug DRAIN COCKS Ref Figure 11 E Drain cocks are used for draining moisture from the air op...

Page 51: ......

Page 52: ...Calibration Of The Shutheight Indicator F 5 To Check Calibration Of The Shutheight Indicator F 6 To Calibrate The Shutheight Indicator F 6 Connection Cap Installation F 6 Slide Ball Box F 7 To Check S...

Page 53: ...de surfaces of the slide Properly adjusted gibs are an important factor in main taining parallelism between the slide face and top of press bed or bolster Loose gibs will cause unsatisfac tory stampin...

Page 54: ...relation to the press bed It is most important that the slide face be par allel with the top surface of the bed or bolster because parallelism affects die alignment and quality of the work produced A...

Page 55: ...ed return the press to the full verti cal position 2 Remove dies or tooling from the press 3 Turn ON the air supply to the press Charge the counterbalance cylinder if applicable with air pres sure tha...

Page 56: ...he last 2 00 of travel WARNING MAKE CERTAIN THAT ALL PERSONS AVOID ANY PINCHING POINTS ASSOCIATED WITH THE OPER ATION OF THE PRESS AND OR ITS AUXILIARY EQUIPMENT 14 Stop the main drive motor Place the...

Page 57: ...Applied jack pressure should never exceed 5 percent of press rated tonnage 8 Using the inside micrometer or other precision mea suring instrument measure the exact distance between the slide face and...

Page 58: ...Stroking Selector Switch in the INCH position Then position the slide at Bottom Dead Center BDC of the stroke WARNING MAKE CERTAIN THAT ALL PERSONS ARE CLEAR OF ANY PINCH POINTS ASSOCIATED WITH THE OP...

Page 59: ...n screw clamp plug and turning the connection screw in through one full rev olution If excessive force is required to turn the screw loosen the set screw and back off the adjust ing nut a small amount...

Page 60: ...cam knockout arrangement is also available as an option This mechanism however requires a special slide and is available only when ordered on a new press or by replacing the complete slide assembly A...

Page 61: ...Clean the slide face and the top surface of the bed or bolster 7 Insert a pry bar between the slide and frame Using the pry bar carefully apply pressure at the center of the slide in order to force t...

Page 62: ...due to usage Set gibs as explained on page F 2 2 Improper setting of gibs Set gibs as explained on page F 2 3 Gibs damaged probably due to lack of oil Repair or replace gib and wear plate if necessar...

Page 63: ......

Page 64: ...Stuck On Bottom Condition G 2 Using The Optional Clutch Bumping Arrangement To Free A Stuck on Bottom Press Flywheel Press Only G 2 Total Bearing Clearance G 3 To Check Total Bearing Clearance G 3 Ind...

Page 65: ...n adjust the clutch air pressure regulator to apply full line air pressure to the clutch 4 Set the SPEED SLOW FAST speed control if applicable to maximum speed 5 Place the POWER OFF ON BAR Selector Sw...

Page 66: ...he INCH position Then position the slide at Bottom Dead Center BDC of the stroke WARNING MAKE CERTAIN THAT ALL PERSONS AVOID ANY PINCHING POINTS ASSOCIATED WITH THE OPER ATION OF THE PRESS AND OR ITS...

Page 67: ...D AND THAT THE POWER HAS BEEN DISCONNECTED FROM THE DRIVE MOTOR BEFORE REMOVING DIES 2 Clean the slide face and the top surface of the bed or bolster 3 Place the POWER OFF ON BAR Selector Switch in th...

Page 68: ...s frame and indi cate to the crankshaft Make certain the indicator is placed on the flywheel or main gear side of the press See Figure 1G Set the indicator dial to 0 reading 11 Energize the hydraulic...

Page 69: ...es reveals the need to replace the main or connection bushings it is most important that the recommended fitting practice be observed These bushings are split and must be pre loaded by squeezing them...

Page 70: ...SECTION H This Section Contains The Following Page Press Application H 2 Tonnage H 2 Tonnage Stroke Relationship H 3 Press Drives H 4 Punch Speeds H 8 Energy Capacity H 8 H 1...

Page 71: ...ably one of the least understood The amount of direct tonnage that a mechanical press is able to exert is at minimum near mid stroke however it increases progressively from that point to its maximum r...

Page 72: ...e at all Assuming that a torque input of 600 inch tons is applied to the shaft which has a crank throw of 6 inch es a force of 100 tons would be delivered by the slide at that point To illustrate how...

Page 73: ...as the flywheel located directly on the crankshaft is called a flywheel type or non geared press In presses of this type flywheel energy which has been spent during each stroke should be recov ered du...

Page 74: ...30 25 20 15 10 5 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 2 Stroke 3 Stroke 4 Stroke OBI 5 Flywheel Distance off Bottom vs Tonnage Available Distance off Bottom inches Tonnage Available U S Tons 0 00...

Page 75: ...10 0 25 0 50 0 75 1 00 1 25 1 50 1 75 2 00 2 25 2 50 2 75 3 00 3 Stroke 4 Stroke 5 Stroke 6 Stroke 7 Stroke OBI 7 Flywheel Distance off Bottom vs Tonnage Available Distance off Bottom inches Tonnage A...

Page 76: ...50 45 40 35 30 25 20 0 50 1 00 1 50 2 00 2 50 3 00 3 50 4 Stroke 5 Stroke 6 Stroke 7 Stroke OBI 7 Geared Distance off Bottom vs Tonnage Available Distance off Bottom inches Tonnage Available U S Tons...

Page 77: ...able for work Energy is supplied by the main drive motor and stored as flywheel energy by rotating the fly wheel mass through a predetermined speed range It should be pointed out that not all of the e...

Page 78: ...t Maintenance Record I 4 Mechanical Press Parts I 4 Weekly Checks I 4 Monthly Checks I 5 Semi Annual Checks I 5 Pneumatic Components I 7 Weekly Checks I 7 Monthly Checks I 7 Electrical Equipment I 9 W...

Page 79: ...ed or replaced after every 1300 hours of operation and critical press parts inspected for cracks worn or broken sections Parts needing replacement should be ordered and time to perform repairs should...

Page 80: ...pecific press from its manufacturing Bill Of Material This type of list has proven to be more valu able than placing a generalized list in the manual because subsequent design improvements specifica t...

Page 81: ...ments of die or dies to be installed Do not exceed tonnage capacity of press If dies are set test press to determine if it is overloaded Do not operate press above maximum rated tonnage I 4 MINSTER Pr...

Page 82: ...attachment pins for loose or broken parts Check motor sheave for looseness on motor shaft Check alignment of motor sheave with flywheel sheave Check motor sheave and flywheel for cracks wear and rough...

Page 83: ...ss of ball box adjustment set screw NOTE Checking procedure explained in manual Check frame for cracked or broken sections Check for loose brackets or components attached to the frame Check for uneven...

Page 84: ...With air pressure turned on turn regulator adjustment knob clockwise and note whether associated gauge reading increases Then turn adjustment screw counterclockwise and actuate the related component...

Page 85: ...I 8 COMMENTS CORRECTIVE STEPS TAKEN Inspected By Press approved for operation Press NOT approved for operation...

Page 86: ...is being used where necessary and that it is func tioning properly Check all point of operation guards to make certain they are in place and secure Make certain that all point of operation guards are...

Page 87: ...I 10 COMMENTS CORRECTIVE STEPS TAKEN Inspected By Press approved for operation Press NOT approved for operation...

Page 88: ...ter pump is stopped before adding oil Never permit oil level to fall below 2 00 from the bottom of the reservoir while press in is operation Quarterly Checks Lubricate as necessary See instructions in...

Page 89: ...I 12 COMMENTS CORRECTIVE STEPS TAKEN Inspected By Press approved for operation Press NOT approved for operation...

Page 90: ...ADDITIONAL COMMENTS I 13...

Page 91: ...MMC0208 MINSTER The Minster Machine Company Minster Ohio 45865 Phone 419 628 2331 Fax 419 628 3517 Distributors strategically located throughout the world...

Page 92: ...MMC0208 MINSTER The Minster Machine Company Minster Ohio 45865 Phone 419 628 2331 Fax 419 628 3517 Distributors strategically located throughout the world...

Reviews:

No comments

Brands by name

Popular brands

Load more brands