Operation and Maintenance Manual for GINGINNAT TNUTET emt aD atst:] TV Cote CINCINNAT CINCINNATI INCORPORATED CINCINNATI, OHIO 45211HYDRAULIC PRESS BRAKE CAPACITIES Mild Steel—90° Air Bends ‘The chart below enables you to determine quickly the approximate sizes of machines required for bending mild steel of various thicknesses over typical die openings. fou, eC DIE OPEN, CoeneTR BANC eenperennsytnfennayrfc DIE OPEN. 8 10 15 20 25 30 38) wa" armen re ne emg 2" DIE OPEN. 300 400 500 600 750 3/8" Ss 10" 15° 20 25° 30° 35° 300 400 500 600 750 1000 "DIE OPEN. Ss 10° 15° 20° 28° 30° 35° 300 ©6400 500 600 750 1000 2 MA TT 5" DIE OPEN. s 10° 18° 20° 2s" 30° 35° 300 400 500 600 750 1000, 5/8" S"DIE OPEN. st 10° 15° 20° 25° 30° as 1 300 400 500 600 750 1000 5/8 6"DIE OPEN, s 10" ist 20° 25° 30° 35° 3/4" 400 500 600 750 1000 6°DIE OPEN. 5 O° . . : 7 7 sod enh 0 2 30 3 3/4" 300 500 750 10.00 8" DIE OPEN. ¥ a 7 " c " ¥ So aay 20 2 2 35 " 0 8"DIE OPEN. 400 500 600 750 1000 lo" DIE OPEN. 30° vor COPYRIGHT CINCINNATI INCORPORATED. roma 700TABLE OF CONTENTS SECTION 1 IDENTIFICATION, .......... SECTION 2] INSTALLATION ............. SECTION 3] LUBRICATION .......................... 2 SECTION 4] OPERATION...................0........ 4 STARTING MACHINE........... RAM STROKE CONTROL... eed 14 RAM SPEED CONTROL, TWO SPEED MACHINE.... 15 RAM SPEED CONTROL, THREE SPEED MACHINE.. 15 TONNAGE CONTROL. RAM LEVELING AND RAM TILT CONTROL ...... 17 SECTION 5] MAINTENANCE & ADJUSTMENT ....... 1s HYDRAULIC OIL... ..eee eee eee eee eee eee 18 OIL FILTERS... eee ee eee eee eee 20 MAGNETIC TRAP... 0... eee ee eee eee eee eee 22 OIL COOLER .........4 eoqpog00p0Rd0 ay 22) PISTON VEE PACKING ...........0200005 oy ea2o PISTON | CUESPACKINGS tee etter rer (425) TO REPLACE THE PISTON CUPS.............. 25 LEVELING eee ee eee 27 REPLACING THE LEVELING BAND ............ 28 CHECKING AND SETTING HYDRAULIC PRESSURES. 28 ERRATIC LEVELING OF THE RAM............ 31 GCINGININATH once senseeree SINCINNATH ONO wearsCINCINNAT INCORPORATED Foot Switch Bed Ram Ram Tilt Adj. Crank Tonnage Indicator Cylinder Piston Rod Top Stroke Stop Speed Change Cam IDENTIFICATION Figure 1 SERIAL NUMBER 10, Bottom Stroke Stop 11. Tonnage Control 12, Drive Motor Start-Stop Button 13, Electrical Control Box and Starter 14, Bottom Stroke-Stop Register 15, Bottom Stroke-Stop Adj. Crank 16. Ram Direction Indicating Lights 17, Die ClampsSection-1 Identification 5 Figure 2 1. R.H, Housing 7, H-Beam 2, Main Drive Motor 8, Housing Brace 3, Hydraulic Pump 9. L.H. Housing 4, Hydraulic Manifold 10, Ram Slide 5, Hydraulic Tubing 11. Ram Guide 6. Hydraulic Fluid Reservoir 12, Leveling Band CINeNNAT! INCORPORATED] SECTION-2 | INSTALLATION UNLOADING Upon receipt of your Cincinnati Hydraulic Press Brake, carefully remove contents of the one or more packing boxes with the machine. All loose parts, such as wrenches and tools, are in these boxes. Remove all shipping paper from the wrapped parts of the Press Brake. Leave skids in position until location is reached. 500H Series and larger Cincinnati Hy- draulic Press Brakes are shipped dis- mantled. The five main members are generally put on two flat cars. One car usually contains the left-hand housing, the bed and the tool box which contains the shipping papers. The other car con- tains the right-hand housing, the ram and the housing brace which has the hydraulic unit attached to it. Each of the main members canbe handled by a crane of sufficient capacity with chains or cables of adequate size. Ship- ping weights of the five members (R.H. Housing, L.H. Housing, Bed, Ram and Housing Brace) are clearly listed on the bill of lading for the shipment and on the packing which is contained in the tool box attached to the bed. Check these weights carefully before lifting or handling. Safety precautions will prevent damage to the machine and injury to personnel. LIFTING AND MOVING 400H Series and smaller Cincinnati Hy- draulic Press Brakes are shipped as sembled on skids. They are readily handled by a crane of sufficient capacity, with chains or cables adjusted to proper length for even lifting. A typical hitch is shown in Figure 3. When cranes are of insufficient capacity, or are not available, rig the machine into final location. With assembled machines, be careful tokeep the support even. Guard carefully against tipping.Disassembled machines can be lifted di- rectly from the cars if crane facilities are sufficient. The right and left-hand housings should be lifted by using the lifter hole as shown in Figure 4, If a clevis, as illustrated, is not available, an adequate cable shouldbe used in the same housing hole. The bed and ram should be lifted with a cable through the large lifting holes provided. Be sure to protect finished surfaces from damage. Where crane facilities are insufficient, the handling of the five main parts is done by using jacks and roller bars. Care should be exercised to prevent damage to finished surfaces and parts attached to main members of the machine. Once the main parts have been moved to the area where the Press Brake will be located, all miscellaneous parts, pro- tective covers and paper can be removed. Leave skids on housings until they are erected. Remove skids from bed and ram before assembling to housings. Carefully remove contents of the one or more pack- ing boxes. All loose parts, such as wrenches and tools, are in these boxes. Check parts received against packing list contained in tool box. Claims for short- ages or damaged parts should be made within ten days. FOUNDATION A rigid foundation is essential. It must be able to support the machine without settling. Money spent on a proper founda- tion is a good investment. For details of foundations refer to certified plan pre- viously furnished. As a final check, see that the anchor bolts in your foundation coincide with the bolt hole spacing in the housing feet. Section-2 Installation ERECTION—ASSEMBLED MACHINES WITH BED REMOVED ‘The 300H and 400H Series Press Brakes are usually shipped with the bed bolted on the rear of the machine. Lift the machine with a crane to remove skids. If no crane is available, secure against tipping as soon as the skidded machine is placed on the foundation and before skids are re- moved. Use block and tackle running from the top of the machine both front and back. To remove skids, raise the ma~ chine approximately 2" steps with the aid of blocking and jacks of sufficient capacity. Jacks should be placed under the housing as near the bed or the front of the ma- chine as possible. Block up housings alternately, about 2" at a time, until there is enough clearance to remove the skids. Lower the machine by removing the block- ing approximately 2" at a time from alternate housings. Temporarily bolt the machine in place on the foundation. Carefully wipe off the bed shoe seats and the bearing shoes. Place the bed and shoes into position on the housings in ‘accordance with the markings. Carefully wipe the top of the bed shoes and the vertical surfaces of the housings where the bed will make contact. Front vertical faces of the housings must be plumb. Shim both housings and use the level in ‘the squaring head of an ordinary machin- ists' combination square, or with any level that can be used on vertical sur- faces. Shim both housings so they are plumb, Remove bed from the rear of housings and clean all matching surfaces thoroughly. Place bed in position and pull up the bolts that hold the bed to the hous~ ings only until they are snug. Adjust the jack screws to pull the bed down tightly against the bed shoes and then pull up bed bolts tight. Use a 6 ft. length of pipe on the wrench handle.Section-2 Installation Check your work with feelers. There should be no clearance between the verti- cal bearing surfaces of the housings and bed. There should be no clearance at the bed shoe where it contacts the bed and bed shoe seat. If there is clearance, either the bolts have not been pulled up tight, or there is grit between the bearing surfaces. Reassemble the bottom stop control by bolting the bracket "A", Figure 5, to bed making sure the shipping block has been removed from "B", Connect the shafts by means of coupling "C". With the bottom stroke stop #10, Figure 1, at the bottom (against the set screw), the Bot tom Stroke—Stop Register should read 0.000". This setting will provide the minimum closed height when the ram is at the bottom of the stroke. Connect the electrical wires in box "D" in accordance with the coded marking. ERECTION— MACHINES SHIPPED DISASSEMBLED Before setting up the housings, place a suitable flat steel shim adjacent to each foundation bolt so the top surface of all ‘CINCINNATI INCORPORATED ie q Fe Figure 6 shims is approximately level. Either housing may be set up first. To lift either housing a clevis, as shown in Fig- ure 4, is used. If this is not available, a wire cable should be attached to the lifter hole in a similar manner. Raise the housings and rest them on two blocks as illustrated to provide clearance for re- moving skids. Once the housing is verti- cal, remove the eight nuts holding the long skids, then pull the skids from the bolts. Next take off the two cross timbers. Place the housing over the foundation bolts on top of the shims. Set up the other housing in the same manner. ‘The front and side vertical surfaces of the housings must be plumb. Shim both housings and use the level in the squaring head of an ordinary machinists’ combina- tion square, or any level that can be used on vertical surfaces.Stretch line across bothhousings against the vertical front faces as shown in Fig- ure 6. Set vertical faces to the line by shifting the housings as required. A straight steel bar or wooden straight edge can be used to advantage instead of the line. Carefully wipe off the bed seat of the housing and bearing shoes. Place the shoes into position on the housing in accordance with the markings. Carefully wipe the top of the bearing shoes and the vertical bearing surface of the housing. Wipe off the matching surfaces onthe bed. Place the bed in position on the housings and pull up the bed bolts only until they are snug. Adjust jack screws to pull the bed down tightly against the bed bearing shoes and then pull up the bed bolts tight. Use a 6 ft. length of pipe on the wrench handle. Check your _work with feelers. There should be no clearance between the verti- cal bearing faces of the housings and the bed. There should be no clearance at the bed shoe where it contacts the bed and bed seat. If there is clearance, either the bolts have not been pulled up tight or there is grit between the bearing surfaces. Figure 7 Section-2 Installation Reassemble the bottom stop control, shown in Figure 5, by bolting bracket "A' to thebed, making sure the shipping block has been removed from "B". Connec' the shafts by means of coupling "C" With the bottom stroke stop #10, Figure 1. at the bottom (against the set screw), the Bottom Stroke—Stop Register should read 0.000", This setting will provide the minimum closed height when the ram. is at the bottom of the stroke. Connect the electrical wires in box "D" according to the code marking. To lift the housing brace assembly, a sling, as shown in Figure 7, is used. This brace acts as a spacer between the two housings. Install the four tubes to the cylinders making sure the tubes are fitted to their designated ports. The tubing has flanges at either end and "0" Ring seals are provided. Loosen the clamps from the ram slides and swing the ram slides out enough to remove the formica sheet from between slides and guides. Lower the slides until the pistons are at the bottom of the cylinders. Clean and replace the clamps. Before mounting the ram make sure all matohing and bearing surfaces are thor- oughly clean. Attach ram and tighten all bolts securely. Be careful that dowel pin holes match up, Drive in dowel pins. Be sure that pins are driven in with stamped word "UP" to the top. When driving dowels, have a jack between the bed and the ram, placed under each pin (at the housings). Install the leveling band and adjust if necessary. Refer to "Section 5 — Maintenance and Adjustments, Leveling Control", CINCINNATI INCORPORATED10 Section-2 Installatie CLEANING Block the ram with jacks at each end. Loosen the clamps from the ram slides and pry ram slides out just enough to re~ move formica sheet from between slides and guides, if not previously removed. This formica sheet must be removed be- fore running. Thoroughly clean protective grease from all parts of the machine with kerosene. Go over the grease with a rag wet with kerosene and allow to soak. Use rags instead of waste, A stiff brush will get into the corners. Do not use an air hose—pressure will drive dirt and grit into the bearing surfaces. Loosen the Jacks evenly and check ram to see that it remains fairly level. After cleaning the machine thoroughly, wipe dry and make sure no dirt or grit is left, then oil lightly. Periodic cleaning of the machine after installation is advisable. LEVELING Cincinnati Hydraulic Press Brakes are leveled by placing flat steel shims of proper thickness under the Press Brake housings as required. Use a precision level, not a carpenter's or machinist's CINCINNATI INCORPORATED level. See Figure 8. Always wipe level and surface clean before placing level. Give the bubble of the precision level a half minute to come to absolute rest. Level the brake lengthwise with the level placed parallel to the length of the bed and in the center, Raise the housing with steel driving wedges as shown in Figure 9, Place the required flat steel shims under the low housing at the front and at the back. Let the press brake down and recheck the level. Repeat as often as necessary. Level the machine front to back, with the level crosswise on the bed, first at the right end of the bed near the housing and then at the left end. Use steel driving wedges to insert or remove the flat steel shims under the rear feet of both hous~ ings, as required. Recheck and repeat until level. Check the slides with feeler gauges as shown in Figure 10 to make sure there is no twist in the ram, due to the machine being out of line. If all the clearance, approximately .005" to .008", is at the TOP FRONT and BOTTOM REAR on one housing slide and the reverse condition, Figure 9Section-2 Installation Figure 10 all clearance at the TO? REAR and BO’ TOM FRONT, on the ocher housing, there is a twist in the ram. Regardless of level of bed, if this condition is not corrected, slides may score, Raise or lower the rear of either housing to relieve twist in yam so some clearance appears at the points which have been tight. If bed in~ dicates far out of level crosswise when there is proper clearance in slides, the bed is usually not seated against housing properly, and should be pulled into place. The slide clearances are considered to be the final and most important check on the _level_of the machine since these clearances are between the actual running parts. After the machine is level, tighten nuts on foundation bolts. Also tack weld cap screws on housing brace or spacer. Re- check slide clearances. Do not remove shims. Alignment may not be permanent. Recheck level in a few weeks. When grouting is used, grout under housings only. Do not grout under bed of machine. Leave bed pit empty and cover with steel plate. N CINcINNAT! INCORPORATEDLUBRICATION LUBRICATION Proper lubrication is of extreme impor- tance if the equipment is to have long life and trouble-free operation. Strict ob- servance of all lubrication instructions given here will pay dividends in lower maintenance costs of your Cincinnati Hydraulic Press Brake. Cincinnati Hydraulic Press Brakes are lubricated with the same oil used in the hydraulic system. The type of ofl used as well as maintenance of the hydraulic sys- tem is described in detail in the "Mainte- hance and Adjustments, Section 5". Figure 11 LUBRICATION POINTS The following lubrication points should be checked at regular intervals to assure proper operation. See Figures 11 and 12 for location of lubrication points. OIL RESERVOIR See Figure 11. Keep oil reservoir filled with hydraulic oil as specified in the "Maintenance and Adjustment, Section 5", CINcINNATT INCORPORATED RAM SLIDES See Figure 11. The ram slides are automatically lubricated with clean, filtered oil from the hydraulic system. On the up stroke of the ram, oil is forced through Bijur fittings on each ram guide to give approximately one drop per minute. Before starting the machine, the exposed part of the guides should be wiped clean and oiled.CLEVIS PINS See Figure 11. Service the clevis pin grease fittings every 12 months. STROKE ADJUSTMENT See Figure 11. Put a few drops of ofl on the exposed threads and guide rod weekly. DRIVE MOTOR See Figure 11, Lubricate the drive motor in accordance with the motor manufacturer's recommendations. Do not over-lubricate. Section-3 Lubrication LEVEL CONTROL See Figure 12. Put a few drops of oil on the leveling control slide and ways and on the exposed threads of the screw. OIL FILTER Remove and clean the oil suction filter when vacuum on the suction line reads 12 inches mercury with the machine warmed up and the oil at operating temperature. ‘The cartridges in the micronic filters, located on the hydraulic manifold, should be replaced once a year. See "Maintenance and Adjustments — Oil Filters". LEVEL CONTROL REGISTER TONNAGE INDICATOR LEVEL CONTROL HANDLE Figure 12 CINCINNATI INCORPORATED. 134 OPERATION STARTING MACHINE After completing installation and lubrica~ tion procedure you are readyto start your Cincinnati Hydraulic Press Brake. Care should be taken the first time the machine is operated to see that the ram slides are well lubricated, With the foot switch in "Up" position, jog the motor with the start stop button "Hl", Figure 13, and see that direction of rotation of the pump is in the direction of the arrow on the pump. Now press the start button and bring the pump up to full speed. Run the ram in full tonnage press speed on a full length stroke for a number of sirokes to force all the air out of the system. eee ee RAM STROKE CONTROL, Figure 13 The bottom stop "F" is set by turning the crank "J" and the position of the bottom stop is indicated by the reading of regis- ter "I", This register reading indicates in inches and thousandths of inches the distance between the bed top and the bot- tom reversal point of the ram minus the closed height of the ram. The top stop "B" is adjusted by the locking handle "C", The top stop controls the upper reversal point or stopping point of the ram. This top stop may be set independently of the bottom stop.RAM SPEED CONTROL, TWO SPEED MACHINES, Figure 13 Two down speeds and one up speed are provided on the two speed machines. The down speeds are "Full Tonnage Press" and"Fast Press" which has approximately 40% of the tonnage available and twice the speed of "Full Tonnage Press". ‘The amount of "Full Tonnage Press" stroke is controlled by the amount of stroke the cam roller "A" is actuated by the speed change cam "D", The speed change cam is adjusted by the locking handle "E", The speed change cam may be adjusted independently of either the top or bottom stops to provide either a full stroke in "Fast Press" or a full stroke in Section-4 Operation "Full Tonnage Press" or any combination of the two speeds in the stroke. RAM SPEED CONTROL, THREE SPEED MACHINES, Figure 14 ‘Three down speeds and two up speeds are provided on the three speed machines. The down speeds are "Rapid Advance", "Fast Press" and "Full Tonnage Press". No tonnage is provided in the "Rapid Ad- vance" speed. "Fast Press" provides 40% of "Full Tonnage Press" and approximately twice the speed. A combination of any two of the three speeds can be made with the down stroke speed selector switch "P". The amount of stroke provided in the slower of the 516 Section-4 Operation two speeds selected is controlled by the amount of stroke the cam roller "A" is actuated by the speed change cam "D", The speed change cam is adjusted by the locking handle "E", The speed change cam may be adjusted independently of either the top or bottom stops. The up speeds are "Fast" and "Slow". An up speed selector switch "0" has three Slow The "Fast" and "Slow" positions provide the full up stroke at fast speed and slow speed respectively without, regard to the "Fast"! ‘Slow on the selector switch provides a slow up speed while the cam roller is actuated by the speed change cam and a fast up speed when the cam roller is off the speed change cam. positions: "Fast", "Slow" and position of the cam. The position ‘The indicator lamps "L" and "M", Figure 13, located beneath the bottom stop crank indicate the direction the ram is moving, if the ram is in motion, or the direction the ram will move by stepping on the foot switch if the ram is stopped. The upper lamp "L" is green and it indicates an upward direction of ram travel. The lower lamp "M" is red and it indicates a downward direction of ram travel. ‘The selector switch "K" has inch and run positions. ‘This switch, in combination with the foot switch "N" and the top and bottom stops, controls ram movement. ‘The foot switch "N" is a three-position foot switch, see Figure 15. With the selector switch on "inch", the ram will respond as follows: Up Position — ram stops Center Position — ram stops Down Position — ram runs in di- rection as dictated by the top and bottom stops. Continues to run as long as depressed. Upon releasing the foot switch to either center or up position the ram will stop and upon depressing the switch again to the down position, the ram will re sume the direction itwas previously going, With the selector switch on "run"', the ram will respond as follows: Up Position — ram returns to the top setting and stops Center Position — - ram stops Down Position — ram runs in di- rection dictated by the top and bot- tom stops. Continues to run as long as switch is depressed. Upon re- leasing to center the ram stops. Upon releasing to "Up" position the ram returns to the top setting and stops. Up Position Center Position. Down Pe Figure 15 “CINCINNATI INCORPORATEDTONNAGE CONTROL The tonnage control is composed of a pressure switch "G", Figure 13, with a calibrated dial and adjusting screw and tonnage indicator, Figure 12, The cali- brated dial on the pressure switch indi- cates the tonnage in full tonnage press speed at which the ram will reverse. The load must be centered between the two cylinders in order to be accurate since the pressure switch automatically selects the higher pressure of the two cylinders on an off center load. The pressure switch of the tonnage control is wired in series with the down limit switch of the bottom stop so that actuation of the pres- sure switch by a load in the press brake will cause the ram to reverse as if it had operated the bottom stop. Many forming jobs may be run by using the tonnage control instead of the bottom stop. CAUTION: ALTHOUGH THE HYDRAULIC COMPONENTS AND THE MACHINE FRAME MEMBERS ARE SAFEGUARDED AGAINST OVERLOAD BY BOTH THE TONNAGE CONTROL AS WELL AS THE RELIEF VALVE IN THE CIRCUIT, CARE MUST BE TAKEN TO PROVIDE SUFFI- CIENT AREA UNDER MALE AND FE- MALE DIES TO PREVENT SINKING THE BED TOP OR RAM NOSE DUE TO HIGH- LY CONCENTRATED LOADS. ‘The minimum areato prevent sinking may be calculated by this formula: - Bt poo Maximum Tonna e An example for a 400 ton machine, the Area S = 20 square inches This minimum area should be provided ‘on all dies that might be subjected to this tonnage. Section-4 Operation RAM LEVELING AND RAM TILT CONTROL ‘The leveling control for your Cincinnati Hydraulic Press Brake is entirely auto- matic, maintaining the ram either paral- lel to the bed or at a predetermined angle with respect to the bed. A manual control is provided to tilt the ram one inch either direction and a register will show the amount and direction of the tilt; that is, the register will show the amount in thousandths of inches that the right-hand end of the ram is above or below the left- hand end of the ram. Actually this vertical distance is not at the ends of the ram, but instead at the points of attachment of the leveling band, this length being somewhat shorter than the distance between housings. To operate the Hydraulic Press Brake with the ram level (parallel to the bed), the level control handle, Figure 12, should be turned until the register reads 0. 000 inches. ‘To set a desired tilt on the ram with the right-hand end of the ram lower than the left-hand end, the level control handle should be turned counterclockwise as viewed from the bottom, until the desired tilt is reached. In most cases, the tilt will be set by trail and error on the workpiece. The exact tilt may be set by observing the level control register, Fig- ure 12, which reads increasingly, that is, 0.000, 0.001, 0.002, and 0,003 for a tilt of 001" and . 002" and . 003" respectively with the right-hand end of the ram lower than the left-hand end, To set the tilt with the right-hand end of the ram higher than the left-hand end, the Level Control Handle should be turned clockwise, as viewed from the bottom. ‘The register will read decreasingly from 0,000; that is, 9.999, 9,998, and 9.997, to indicate a tilt of .001", .002", and - 003" respectively with the right-hand end of the ram higher than the left-hand end. V18 Section-4 Operation When the register reads 0.000 the ram is parallel with the bed. The tilt control will operate more easily if the ram is cycled while making the adjustment. CAUTION: When operating at the TREME limits of stroke, THE FULL LENGTH OF STROKE SHOULD BE RE- DUCED BY THE AMOUNT OF THE RAM To maintain the exceptionally accurate performance of your Cincinnati Hydraulic Press Brake there are certain mainte- nance practices that should be followed. This section of the manual will deal with the maintenance and adjustments of Cincinnati Hydraulic Press Brakes. LUBRICATION Proper lubrication is of the utmost im- portance to obtain long life and trouble- free operation. The lubrication points and procedure are covered in Section 3. of this manual. HYDRAULIC OIL, The hydraulic reservoir “H”, Figure 16, should be filled to the top of the oil level gauge “G” with the ram at the top of its stroke. The oil filling cap “F” is shown in Figure 16. Use light hydraulic oil. Viscosity 150 seconds at 10°F, with anti-rust, oxida- tion and anti-wear additives. The following chart shows capacity of Cincinnati Hydraulic Press Brakes. [CINCINNATI INCORPORATED MAINTENANCE & ADJUSTMENT TILT FOR OPERATION IN A TILTED POSITION TO PREVENT THE LEFT- HAND PISTON FROM STRIKING THE TOP OR BOTTOM OF THE CYLINDER. The maximum allowable tilt is 1" in the length of the machine. If this tilt is ex- ceeded, the out of level limit switch will stop the ram by stopping the main pump motor. See "Maintenance and Adjustments, Section 5". oll ‘Machine Size Capacity 300H, 400H, 500H, 600H (Two Spee, 125 Gal. 300H, 40H, 500H, 600H (Three Speed), 750 H, 1000H, 1250H, 1500H, 2000H It is very important that the oil be clear All precautions should be taken to keep the oil clean, free from chips, grit, water, sludge, coolants, cutting oils, ete. The oil should be strained when put in the reservoir and replaced when sludge is evident, The oil level should be checked daily. ‘The oil should be drained and re- placed after 2 to 3 years service or sooner if it becomes contaminated. The drain plug is located in the bottom of the reservoir.Section-5 Maintenance & Adjustment 19 Figure 16 Hydraulic Components on Two Speed Machine Figure 17 Hydraulic Components on Three Speed Machine20 Section-5 Maintenance & Adjustment OIL FILTERS There are two types of filters provided on your Cincinnati Hydraulic Press Brake, The main Suction-Filter "C", Figure 18, consists of one or two Marvel sump type filters (Marvel A-3-100) with 100 mesh monel filter element. When a separate pilot pump "L", Figure 22, is provided, it has a Marvel sump type filter (Marvel C-1-10). One main suction filter is used on the 300H, 400H, 500H and 600H Series Press Brakes. On 750H, 1000H, 1250H, 1500H, and 2000H Series machines, two main suction filters are provided. In all cases the suction filter is located inside the reservoir. To inspect the filter or re~ plate the filter element, the filter can be lifted out of the reservoir as follows. See Figure 18. Remove the screws from the Suction Cover "B" and from the Pump Suction Flange, "A". The Pump Suetion Pipe with Suction Filter "C" attached may be lifted out of the reservoir to have the element cleaned or replaced when the vacuum gauge reads 12 inches mercury. VACUUM GAGE. Figure 18 CINcINNAT: INCORPORATED Lat. couNTERBALANCE VALVE. riurée There are two Waterman #1700-6 mi- cronic filters "A", Figure 19, provided on each side of the Leveling Servo Valve. These filters are located onthe Hydraulic Manifold as shown in Figure 19, The filter cartridges, Waterman Engineering Co. #110421, should be replaced once each year. The suction filter (see Figure 22) for the pilot pump is located inside the reservoir. To inspect or replace the filter element, the four cover screws over the filter cover "A" should be removed, the union "B" uncoupled and the suction filter lifted out similarly to the way the main suction filter is removed. AIR CLEANER The hydraulic reservoir "J", Figure 22, is provided with an Air Cleaner "D" on the breather hole. The filter element, Purolator Products Inc. #30315-1 should be replaced once each year. PILOT PRESSURE PILOT PRESSURE ‘ ° a5 ‘RH. COUNTEREALANCE Figure 19Section-5 Maintenance & Adjustment 2] Figure 20 Hydraulic Manifold ‘On Three Speed ‘Machine (Front View) LM. COUNTERBALANCE ‘GAUGE PLUG 300s! © check vawve © OIFFERENTIAL vaLvE. LM. COUNTERBALANCE VALVE ‘© MAIN RELIEF VALE ‘©onecr vaive ‘AUXILIARY RELIEF GAUGE PLUG —~MAIN RELIEF GAUGE PLUG AUXILIARY RELIEF PRESSURE MAIN RELIEF PRESSURE 2250 PS! 600 Pst MICRONIC FILTER RM, COUNTERBALANCE PRESSURE 3OOPSI MICRONIC FILTER Figure 21 Hydraulic Manifold ‘CHECK VALVE ‘On Three Speed Machine ‘CONTROL VALVE (Rear View) R.H.COUNTERBALANCE VALVE ‘CHECK VALVE LH. AUXILIARY RELIEF VALVE R.HLAUXILIARY VALVE RELIEF VALVE CINcINNAT! INCORPORATED2 Section-5 Maintenance & Adjustment MAGNETIC TRAP A magnetic trap "L", shown on Figure 17, is provided in the oil reservoir. This trap should be removed and cleaned once each year. OIL COOLER - Refer to Figure 22. When required, a water-type oil cooler, "K", may be provided. The ofl cooler pump "I" supplies oil to the cooler direct, from the reservoir. This ofl circulates around the tubes of the cooler and dis- charges back to the reservoir. The cool- ing water passes through a water strainer “F", and temperature control valve "G", through the tubes of the oil cooler and is then discharged. A thermostat bulb "H" is connected to the temperature control valve by a capillary tube"C". This capil- lary tube should be handled carefully be~ cause a sharp bend or kink may prevent it from operating correctly. ‘The temperature of the oil is controlled by the setting of the temperature control valve, Adjustment is made by turning the calibration screw "E"' on the temperature control valve. Turn the screw clockwise for higher temperature and counterclock- wise for lower temperature. This is a modulating control. It does not open wide and shut tight like an electrical control device. It opens gradually wider and wider, in relation to the difference be- tween the actual bulb temperature and the bulb temperature at which the valve is closed. In normal operation, the control valve remains in a constant, partially open position which is automatically ad- justed whenever conditions require it. The only servicing normally required is to keep the control clean, The valve can be inspected and cleaned by access through the inlet and outlet, without dis~ assembly. The bulb must not become coated with any substance which inter- feres with the transmission of heat. Figure 22Section-5 Maintenance & Adjustment 23 PISTON VEE PACKINGS ‘The piston rod packings are fabricated vee-type packings (Houghton S-3. VIX- SYN Fabricated "V" Packing). ‘The pack- ings are adjustable by a large gland nut or a packing flange with a series of screws around it. The surface of the piston rod should have a thin film of oil. If the rod is too dry or if the packing squeals the gland nut or the packing flange should be loosened slightly. If the packing leaks the gland nut or packing flange should be tightened. To tighten the gland nut "A", Figure 23, use the special wrench "B" furnished with the machine. ‘To tighten the packing flange "A", Figure 24, use the socket screw key furnished with the machine. It is recommended that a scale be used at a number of points around the packing flange to assure an even tightening or loosening of the pack- ing. When further tightening fails to stop leakage, another vee ring should be added or the packing replaced. To add or replace a vee ring: 1. Run the ram to the bottom of the stroke and block each end of it. 2, Remove the screw "'C" and lock plate "D" and run the adjusting screw. nut "E" up until it hits the bottom of the piston. See Figure 23. 3. Repeat step No. 2 to the opposite end of the ram even though the vee rings are not being replaced in that end. 4, With the control selector on "inch", jog the pistons up slightly and again loosen the adjusting screw nuts on each side. This should be repeated until the nuts are free of the ram slide "F", 5, Run the pistons up to the top of the cylinders. Figure 24 VEE PACKING Figure 25 CINEINNATY INCORPORATED24 Section-5 M 6. Hang the new vee packings over the ram slide and block under pistons to prevent the pistons from coming down. See Figure 25. 7. Turn off all power tothe machine and lock the electrical disconnect. Loosen bottom flange on lower cylin- der head and drain the oil from under the piston, 9, Remove the gland nut or packing flange "A", Figure 25, and female adapter "J", Figure 25, and remove the old vee packing. These may be fished out if care is taken not to scratch the sealing surfaces or they may be blown out with air pressure applied to the lower drain hole. 10. Cut the old vee packings and discard. Pron CUP PACKING Figure 26. CINCINNATI INCORPORATED on 12. 13. tenance & Adjustment Pass one new vee packing through the gland nut or packing flange "A", Figure 25, and the female adapter and use the female adapter as a pusher. (Note: 1/4" screws should be inserted in the puller holes pro- vided in the female adapter and these serews used when tapping the pack- ings into place. It may be necessary to relieve trapped air pressure by inserting a thin steel scale or smooth wire along the packing. Care should be taken to avoid damaging either the piston rod or the edges of the vee packing. Inspect each packing when in place to see that it is seated properly. Repeat step 11 for each vee packing inserted. Piston AssemblySection-5 Maintenance & Adjustment 14. Replace female adapter and remove 1/4" screws. 15, Replace the gland nut or packing flange and pull up snug. (Do not overtighten. ) 16. Replace lower drain plug. 17, Remove the block from under each piston and wipe out the ball socket with a clean rag. 18. Turn on power to the machine and start the main motor. 19, Jog the pistons down to the ball sockets. 20, Fill the ball sockets with clean oil. 21. Start the adjusting screw nut on each side and run each down, jogging the pistons down when necessary. 22, Tighten the adjusting screw nut until it is tight and back off one notch. Replace the lock plate and screw. 23, Refill the ofl tank to the top of the sight glass. See Section 5, Hydraulic Oil, page 18. PISTON CUP PACKINGS ‘The piston cup packings, see Figure 26, are synthetic rubber impregnated leather (Houghton #1243-3), If these cup packings leak, they must be replaced, To check the cups on the upper side of the pistons, first place the inch-run control on the inch cycle, full tonnage press speed and bottom the ram on dies or blocks. Set the tonnage control on maxi- mum tonnage and back off the relief valve "EN, Figure 16, one full turn so the re lief valve will pass the oil and the tonnage control will not reverse the ram. Loosen both return line flanges (from the bottom of the cylinder to the manifold) at the Hydraulic Manifold. With the ram still in the down cycle (red light on) step on the foot switch to momentarily apply pressure to the cylinders. If either return line passes more than a very small amount of oil, that cup is leaking and should be re- placed. After testing, set relief valve back at the previous setting and set tonnage control as desired. ‘To check the cups on the lower side of the piston, place the control on the inch cycle and run the ram to 1” above the bottom or 1" between blocks. Stop the machine (green light on) and have pump running and observe if either side of the ram settles readily. If one side is sink- ing, shut off all power to the machine and observe if this stops ram sinking, If sinking stops, this indicates the counter- balance valve is leaking and not the lower cup packing. If the ram continues to sink, a double check can be made by removing the differential valve "D", Figure 16, from the hydraulic manifold. If this does show oil leakage while the ram is sinking, it indicates that one of the counterbalance valves, Figure 19, is either set wrong or is leaking, Recheck counterbalance pres- sure and replace valve as necessary. If the test with differential valve removed shows no oil leaking but the ram still settling rapidly on one side, the piston cups must be replaced in the side that is leaking. TO REPLACE THE PISTON CUPS: 1. Run the ram to the bottom of the stroke and block each end of it. 2. Remove the screw "C"" and lock plate "p" and run the adjusting screw nut “E" up until it hits the bottom of the piston. Figure 23. 3. Repeat step No. 2 to the opposite end of the ram even though the piston cups are not being replaced in that end. % CINCINNATI INCORFORATED26 Section-5 Maintenance & Adjustment With the control selector on "Inch", jog the pistons up slightly and again Joosen the adjusting screw nuts on each side. This should be repeated until the nuts are free of the ram slide "F", Figure 23. Run the pistons up to the top of the cylinders and block the ball ends temporarily. Turn off all power to the machine and lock the electrical disconnect. ‘Loosen bottom flange on lower cylin- der head and drain lower part of each cylinder. Disconnect the cylinder line flanges at top and bottom of the eylinder. Hitch a rope around the piston rod at the neck above the ball end. 10, Swing cylinder and piston assembly out and lift it into 2 horizontal plane. See Figure 27. 11. Block cylinder in this horizontal position, 12, Hold air hose over top flange part so that air pressure forces the piston to the bottom of the cylinder. Wrap the piston rodwith masking tape adjacent to the head to prevent the piston from sliding out of the cylinder head during handling, Figure 28. 13. Hitch clean rope around piston rod immediately adjacent to gland ring and take a very light strain on the rope. 14, Loosen head bolts but do not remove them, 15. Again hold air hose over the top flange and blow the piston assembly out of cylinder far enough to put a clevis over the lower cylinder head with the pin through one of the screw holes or, if no clevis is available, put the rope loop on each side of the lower head with a screw passed through it. See Figure 29. Figure 2816. 17. 18. 19. 20. 21. 22, 23. Section-5 M Remove the entire assembly and set the piston and head assembly on a clean paper and put eye bolts in the cup end of the piston. Raise piston by a rope or chain through the eye bolts and allow lower head to slide off piston rod. Remove self-locking screws and fol- lower plates and replace cups. When replacing self-locking screws use 10ft. Ibs. force. Do not overtighten. Remove the vee packings from the lower head. ‘Turn the piston over and slide lower head all the way down on the piston. Replace the vee packings carefully as outlined in the paragraph on re- placing vee packings, inspecting each as it is put into place. Tip the assembled piston and head on its side, on clean paper, and hitch rope through clevis or loop it about the screw as done previously. Figure 29 24, 25. tenance & Adjustment Replace piston in cylinder, being careful to not damage "O" Ring Seal in bottom cylinder head. Pull up lower cylinder head screws tight. Hold air hose over lower flange and blow piston into cylinder. To prevent piston from sliding down when lowering assembly, seal upper flange opening with tape. Lower as- sembly and reassemble ball in ball seat as described previously. Step #18, Piston Vee Packing, page 25. LEVELING The leveling system on your Hydraulic Press Brake is controlled by means of a Servo Valve "A", Figure 30, actuated by a leveling bank "F" which is anchored at the left-hand end of the housing brace and which passes over two sheaves which are attached to the ram. An out of level con- dition which causes the left-hand end of the ram tobe low will shorten the leveling band and cause a spring "B" to move the aSection-5 Maintenance & Adjustment valve spool up in the Servo Valve thus bleeding the upper side of the L. H. cylin- der on the down stroke or the lower side of the R.H. cylinder on the up stroke. Conversely, a low right-hand incidence will lengthen the leveling band and pull the Servo Valve Spool down thus bleeding upper side of the R.H. cylinder on the down stroke or the lower side of the L. H. cylinder on the up stroke. In addition to this control, a microswitch is provided so that an excessive out of level condition will stop the main pump motor, stopping the machine. The microswitch is set to operate at a tilt of 1" either direction in the length of the machine. Should the leveling band break, the ma- chine will stop because of the actuation of the maximum out of level microswitch, ‘The ram should be parallel with the bed, blocked and the leveling band replaced. REPLACING THE LEVELING BAND 1. Parallel the ram with the bed. 2. Block the ram. 3, Remove the old leveling band. 4, Cut the new leveling band tothe same length as the old one. 5. Attach the new leveling band to the L.H. anchor, making sure the band is between the key and the slot, not under the set screw. 6. Pass leveling band over the sheaves and through the protective tube. 7. Turn the level control handle until the level control register reads 0,000. Approximately 1" of thread should be provided between the level control handle and the bottom of the level control support. 8, Turn the level control handle again until the level control register reads 9,047. 9 Attach the right-hand end of the leveling band to the valve rod collar pulling the band as tight as possible when tightening. 10. Now turn the level control handle until . 047" clearance is provided be~ tween the valve rod collar "D" and the bottom of the level control box "CO", See Figure 30. 11, Loosen the lower set screw in the coupling between the adjusting screw and the level control register and reset the register to 0.000, Tighten the set screw. CHECKING AND SETTING HYDRAULIC PRESSURES 1, Main Relief Pressure A gauge plug is provided in the end face of the hydraulic manifold and the correct pressure setting is shown on a tag above the gauge plug. (See hydraulic manifold assembly, FigureSection-5 Maintenance & Adjustment 20.) Remove the gauge plug and in- stall a pressure gauge of a 0-3000 psi pressure range. Adjust top stop to the top position, hold the top stop finger up and inch the ram up (on three-speed machines the "up" selec tor must be on "Slow Return”) until the pistons hit the top of the cylin~ ders. The gauge will read main relief pressure. If the pressure is not the same as shown on the tag, reset by loosening the lock nut on the main relief valve ("E", Figure 16 for two speed machines, and "E", Fig- LH. COUNTERBALANCE VALVE. RLM. COUNTERBALANCE VALVE ure 20 for three speed machines) and turning the adjusting screw. Tighten the lock nut after adjustment. Auxiliary Relief Pressure The auxiliary pressure is provided by the auxiliary pump supplying ofl for "Rapid Advance" and "Fast Re~ turn" on three speed machines only. Auxiliary Relief and Main Relief Gauge Plugs, Figure 20, are pro- vided in each end face of the three speed manifold and the correct pressure setting is shown on a tag TO RH CYLINDER (UPPER) TO R.H. CYLINDER (LOWER) Figure 31. Setting Counterbalance Pressure 9 eeeadjacent to these gauge plugs. Re- move the gauge plugs and install a pressure gauge of 0-300 psi range. Set the speed selector on "Fast Re- turn", Adjust top stop to the top po- sition, hold the top stop finger up and inch the ram up until the pistons hit the top of the cylinders. The gauges will read auxiliary relief pressure. If the pressure is not the same as shown on the tag, reset by loosening the lock nut on the R.H. and L.H. auxiliary relief valves, Figure 21, and turning the adjusting screw. Tighten the lock nuts after adjustment. Pilot Pressure (300H-400H Machines) The pilot pressure on 300H and 400H machines is furnished by imposing a back pressure on the main pump dis charge with the pilot pressure valve. See Figure 19. A gauge plug is pro- vided in the front face of the manifold and the correct pressure setting is shown on a tag above the gauge plug. Remove the gauge plug and install a pressure gauge of 0-600 psi pres- sure range. A shut off valve between the gauge and manifold should be used to protect the gauge from the pressure surge of starting the main pump, Start the main pump but do not run the ram with the shut off valve open. With the main pump running and the ram stopped, the pilot pressure should read as shown on the pressure tag. If the pressure is not the same as shown on the tag, reset by loosening the lock nut on the pilot pressure valve and turning the adjusting screw. Tighten the lock nut after adjustment, Block the ram at each side before removing counterbalance gauge plugs. ‘A shut off valve, as shown, should be used to protect the gauge from pres- sure surges at ram reversal. Open the valve only during the down stroke. 30 Section-5 Maintenance & Adjustment 4, Pilot Pressure (500H and Larger Machines) The pilot pressure on 500H and lar~ ger machines is furnished by a sep~ arate pilot pump "L" and a pilot pressure valve "M", Figure 22. A gauge plug is provided in the tee connection in the pilot line and the correct pressure setting is shown on a tag adjacent to this plug. See Fig- ure 22, Remove the gauge plug and install a pressure gauge of 0-600 psi range. Start the main pump (pilot pump will start with it) and the gauge will read the pilot pressure. If the pressure is not the same as shown on the tag, reset by loosening the Jock nut on the pilot pressure valve and turning the adjusting screw. Tighten the lock nut after adjustment. Counterbalance Pressure Gauge plugs are provided in the hy- draulic manifold and the correct pressure settings are shown on tags above these gauge plugs (300H, 400H, 500H, 600H, Figure 31; 750H and larger, Figure 20), Block the ram at each side before removing coun- terbalance gauge plugs. A shut off valve betweenthe pressure gauge and manifold should be used to protect the gauge from pressure surges at ram reversal. See Figure 31, Re- move the gauge plug and install a pressure gauge of 0-600psi pressure range. With the ram running at Full Tonnage Press speed on the down stroke the shut off valve can be opened and the counterbalance pres~ sure read, Open the valve only on the down stroke and close it before striking the work or the ram rever- sal, The R.H. counterbalance and the L.H. counterbalance pressures should read alike. It is more impor- tant to have these readings precisely alike than it is to have the exact pressure setting as shown on the pressure tag. To reset, loosen theSection-5 Maintenance & Adjustment lock nut and turn the adjusting screw and retighten the lock nut. After resetting counterbalance pressure, cycle the ram a number of strokes and recheck the pressures. ERRATIC LEVELING OF THE RAM In the event of erratic leveling, the fol- lowing things should be checked: 1 Counterbalance Valves ‘The proper pressure setting for the counterbalance valves is stamped on the manifold block just above the valves. This pressure should be checked as shown in Figure 31 and is to be read on the down stroke in Full Tonnage Press Speed. 2, Leveling Band ‘Any binding of the leveling band will cause inaccuracies in leveling. The tube should be examined to see if it is bent or kinked and the covers over the sheaves should be removed to see that the sheaves are free. 3. Servo Valve, See Figure 30 ‘The Servo Valve must be perfectly clean in order to operate satisfac torily. It is protected by two 40 mi- cron filters. With any indication of dirt in the Servo Valve, these mi- cronic filters should be inspected and replaced if dirty. See Figure 19. To replace a Servo Valve, place . 047" feelers between the valve rod collar "D" and the level control box "C", Install the spring and adjust the lock nuts on the valve stem, then bolt the valve to the manifold. Remove the top end cap and adjust the valve spool position, with the adjusting nut, to the dimension stamped on the valve. This dimension, between the end of the valve body and the end of the nut on the valve rod, must be checked with depth micrometers. At this position, the valve spool is centered. Lock the adjusting nut in position with the lock nut, Replace the end cap and remove the . 047" feelers. ORDERING REPAIR PARTS When ordering repair parts, be sure to give this information: Serial number of Press Brake. (located at right end of bed.) ‘The part number and name from assembly drawings included in this book. As complete a description of the part as possible. Delivery required, It is sometimes necessary to furnish sub-assemblies instead of single parts. In such cases, we reserve right to ship and invoice accordingly. 31SPECIFICATIONS FOR THE CINCINNATI HYDRAULIC PRESS BRAKE : 3 3 5 3 Ram Speea 2 3 - 3 3 inches/min. (approx.) 5 s/s] 8] 28 2/3 g & a).8 | Sloe |e 2 Zz 3 a Ele] 3] 2 heal Br 2 8 é 5 13] 3] ¢ elgletsle| |é s|3 3 se] s | alelé bls 3/2 sle e| 2 312) 8) Si] eléle eis] 3)e|els E13 12181 2 seus}®| 3 |g] 2 | ZZ1ElslBlelalelelelglilete| = 3] 6 & a ese la oléel#lz;z2@/e/2]/2/a le & 300» FHS Bie 300] 120] 12 | 20} 8 |...| 77 | 27] 80] ..| 20] a | a | 3° HE 400 4 FS 400] 160] 12 | 20} @ |...| 64] 27] s1|...| 40] a | a | 500 4 800] 200] 12 | 22 10 |....| 55 | 26] 60]....] 50] 5 | a | a 6004 600] 240] 12 | 22 10 |... | 47 | 21 | 45] ...| 50] o | 5° [aston 7504 750| 300] 12 | 22| 10 | 90] 48] 20] 36] 66] co] o | & 00 @ [Hastas 1000 1000] 400} 12 | 24] 12 | 62] 34 | 14] 27] 50] 60] & | 6 12504 1280] 500] 12 | 24] 12 } 56 | 20] 12] 23] 42] 60] & | 7 | 7 [isis -— a see 7 ire 100 1500 4 [4e fiat aero] 42426 1500] 600] 12 | 24 | 12 | a6 | 25 | 10] 19] 24] 60] a | 7 | 7 [ator Hie fresti-|-9- ie fiat peor seis seer CINGINNATI Consul foto for data & mansions ‘2000 Han lerger machines CINCINNATI CINCINNATI, INCORPORATED OHIO 45211