MODEL 322 HYDRAULIC DIE LIFTER RAIL
N118 W18251 Bunsen Drive Germantown,WI 53022 (262) 250-4410 • Fax (262) 250-4409
pfa-inc.com Copyright Š2020 PFA, Inc. All rights reserved. Reproduction or use in any manner of editorial or graphic content herein without the express written permission of PFA, Inc. is strictly prohibited. Every effort has been made to ensure the information within this publication is complete and accurate at the time of printing.
S3103 DR-322 REV A - 2/20
TABLE OF CONTENTS 1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5. Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6. Drawing 322W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7. Drawing Slots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
pfa-inc.com MODEL 322 | HYDRAULIC DIE LIFTER RAIL | PAGE 3
INTRODUCTION NOTE: This User Guide is written for the knowledgeable mechanic. 1. The Model DR-322 has a double 90 degree cam roller configuration. 2. The Model DR-322 has a T-shaped cross section. 3. The Model DR-322 Die Lifter must be mounted in a T-slot only. 4. It is available in High Profile (HP) and Low Profile (LP) versions to accommodate a range of slot heights. Some sizes may be available in Extremely Low Profile (ELP) versions. 5. Typical Wide Slots are 1” (1.060”) which provide room on the sides for easy movement for a nominal rail width of .995”. See SLOTS drawing for details on T-slot configurations. 6. Lift height is controlled by custom T or tab height. Part numbers state tab height, neck width, profile, and bracket types, as appropriate. 7. Movement: When hydraulic pressure is applied to the die lifter, downward facing pistons extend causing the die lifter to elevate. When the hydraulic pressure is turned off, the weight of the die will cause the die lifter to recess. 8. Lift Capacity: Maximum die weight per pair is 4,000 lbs per foot of die contact. For example a 36 inch die resting on a pair of 48” die lifters must not exceed 12,000 lbs. [36” = 3 ft x 4,000 lbs/ft = 12,000 lbs] 9. Please study drawing 322 for details.
pfa-inc.com MODEL 322 | HYDRAULIC DIE LIFTER RAIL | PAGE 4
INSTALLATION 1. Place the die lifter in the bolster T-slot and check for proper fit. A rectangular slot may be used for the Model 322. The bolster slot needs to be wide enough for unhampered up and down articulation. Also, remove any foreign material in the slot. 2. Check bolster slot for proper depth. When hydraulic pressure is applied the die lifter roller balls should be above the bolster surface by the amount requested at the time of order. Typically lift above surface ranges from .060� to .125� above the bolster surface. In the lowered position, the die lifter roller balls must be below the bolster surface. If existing bolster extensions (pre-rollers) are installed, the die lifter roller balls, when elevated, must be on the same plane with the extensions for a smooth transition. If bolster slot is too deep, a spacer may be placed on the bottom for height adjustment. 3. A end mounting bracket (EBK) on the end of the die lifter rail is often used to keep the die lifter from moving horizontally. An internal to slot bracket (IB) and extension fitting is also available to prevent movement, allowing rails to be centered in the slot for certain applications. 4. For end mounting brackets, please refer to enclosed drawings to drill and tap the 1/4-20 UNC holes in the bolster for mounting the bracket guides. Place the rail centered in the T-slot with the mounting bracket touching the side of the bolster. Make sure that the pistons are recessed. With the mounting bracket as a reference mark the drill point on each side of the mounting bracket using the left/right dimensions shown on drawings.
CAUTION: MAKE SURE THAT THE MOUNTING BRACKET IS RETAINED BY THE SCREWS WHEN THE DIE LIFTER IS IN THE FULL DOWN POSITION AND THAT THE DIE LIFTER IS FREE TO MOVE UP AND DOWN. 5. Secure the mounting bracket using the two screws furnished. Make sure the guide sleeve is placed over the screw prior to installation. 6. After proper positioning of the die lifters, attach the hydraulic hoses. In most cases, the die lifter circuit on PFA Power and Control Module provides the control and hydraulic pressure to operate the die lifters. 7. The die lifters are tested at the factory. Some hydraulic fluid will remain and minimize the amount of air in the die lifter. However, before using the die lifters make sure that the air is purged from the lines by repeatedly pressurizing and depressurizing the die lifters.
CAUTION: WHEN INSTALLING ANY HYDRAULIC EQUIPMENT TAKE CARE TO PREVENT ANY CONTAMINATION FROM ENTERING HYDRAULIC LINES. DO NOT USE BLACK PIPE TO CARRY HYDRAULIC FLUID.
pfa-inc.com MODEL 322 | HYDRAULIC DIE LIFTER RAIL | PAGE 5
OPERATION Please integrate the following steps into your approved QDC procedures. 1. Remove die clamps and make sure that the ram is away from the die. 2. Elevate die lifters by applying hydraulic pressure. 3. Roll die off bolster. 4. Roll next die onto bolster and make positioning adjustments. 5. Lower die lifters by turning off hydraulic pressure. 6. Clamp die.
CAUTION: MAKE SURE DIE LIFTER IS IN THE DOWN POSITION BEFORE CLAMPS ARE APPLIED.
pfa-inc.com MODEL 322 | HYDRAULIC DIE LIFTER RAIL | PAGE 6
MAINTENANCE 1. Should it become necessary to replace ball cartridges, hydraulic seals or pistons follow the steps listed below carefully and refer to illustration D1 and referenced (item) numbers in the spare parts section. 2. To replace a damaged ball cartridge remove the die lifter from the press and place the die lifter rail on a suitable work surface. Remove the steel retaining ring(s) and affected ball cartridge(s). Replace with new. 3. To replace a piston or lower piston seal do the following: a. Remove the SAE hex face plug, which covers the affected cylinder. (Replace it if necessary during reassembly). b. Turn the rail over (rollers down) and push the piston out carefully using a blunt pointed tool. Do not scratch cylinder wall. c. Replace the internal o-ring. d. Reassemble in reverse.
NOTE: If the piston for some very unusual reason has mushroomed on the underside of the rail it will be necessary to remove the enlarged diameter before attempting to push it out of the cylinder. In such a case push the piston all the way out from above and use a saw, file or other tool to cut off the enlarged area. Deburr the cut off end before pushing the piston out. 4. If the die lifter is assembled using two segments they may be separated as follows: a. Refer to illustration D-1 and remove two screws on one end of the plate which secure the two segments. b. Drive out both roll pins which secure the splice on top of the die lifter. c. Separate the two halves by pulling apart. Do not bend. d. O’rings and backup rings can now be replaced on the pipe connecting the two segments. Use an O’ring lubricant. e. Re-assemble carefully in reverse sequence. CONNECTING SPLICE ROLL PIN
O-RING
PISTON SCREW
pfa-inc.com SPLICE PLATE BOTTOM
CONNECTING TUBE
MODEL 322 | HYDRAULIC DIE LIFTER RAIL | PAGE 7
RECOMMENDED SPARE PARTS 322W RAIL – LP (LOW PROFILE) P/N
Description
Qty
6185-100
Piston (specific to rail part number)
6
1783-12
O’Ring for Piston Seal
4
1788-4
Plug
4
1864-12
Roller Bearing
4
1604-16
.125 Roll Pin
4
5655*
Connecting Tube
2
1772-007*
O’Ring
4
1782-007*
Backup Ring
4
6353
Bracket Assembly
1
9046-185
Dowel Pin 1.875
4
* If applicable - only for rails with a splice
322W RAIL – HP (HIGH PROFILE) P/N
Description
Qty
7068-100
Piston (specific to rail part number)
6
1783-12
O’Ring for Piston Seal
4
1788-4
Plug
4
1864-12
Roller Bearing
4
1604-16
.125 Roll Pin
4
5655*
Connecting Tube
2
1772-007*
O’Ring
4
1782-007*
Backup Ring
4
6353 (6868 315N Only)
Bracket Assembly
1
9046-185
1.875 Dowel Pin
4
* If applicable - only for rails with a splice
pfa-inc.com MODEL 322 | HYDRAULIC DIE LIFTER RAIL | PAGE 8
CONFIDENTIAL: The information shown on this sheet is confidential. Permission to use, reproduce or transmit in any way not specifically authorized is expressly withheld.
MODEL# 322W-24 322W-30 322W-36 322W-42 322W-48 322W-54 322W-60 322W-66 322W-72
DIM 'A' 24 30 36 42 48 54 60 66 72
1
# ROLLERS # PISTONS MAX DIE PER RAIL PER RAIL WEIGHT/PAIR 8,000 LBS 14 8 10,000 LBS 18 10 12,000 LBS 22 12 14,000 LBS 26 14 16,000 LBS 30 16 18,000 LBS 34 18 20,000 LBS 38 20 22,000 LBS 42 22 24,000 LBS 46 24 SEE CATALOG FOR OTHER AVAILABLE SIZES
DISCLAIMER: Illustrative drawings, CAD models, and information described herein is proprietary intellectual property of PFA, Inc., accurate to the company’s knowledge at time of printing, and intended for reference only. Specifications are subject to change without notice. If the information obtained from this document is critical to a specific application, it should be confirmed by contacting PFA, Inc. PFA Terms of Sale apply.
RIGID SPLICE N N N N N Y Y Y Y
5 DIRECTION OF TRAVEL
A
2
0.50 FOR LOW PROFILE RAILS, 0.75 FOR HIGH PROFILE RAILS
.995
2.120
2.120 MOUNTNG BRACKET 1/4-20 UNC x .50 DEEP THREAD, (2) PLACES
5 4 3 2
1
1.50
1.495 (LP) 1.709 (HP)
3 1.77
4
.36 MAXIMUM PISTON TRAVEL, LP RAIL (.385 REF.) .58 MAXIMUM PISTON TRAVEL, HP RAIL (.600 REF.)
DIE TRAVEL IS PERPENDICULAR TO THE LENGTH OF THE DIE LIFTER. FLANGE THICKNESS IS MACHINED TO FIT CUSTOMER'S T-SLOTS AND POSITION ELEVATED ROLLERS .080 ABOVE BOLSTER SURFACE. OTHER ELEVATIONS ABOVE THE BOLSTER MAY BE SPECIFIED. THIS DIE LIFTER IS AVAILABLE IN LOW PROFILE (LP) AND HIGH PROFILE (HP). IF T-SLOT IS TOO DEEP ADD SPACER/SHIMS AS NECESSARY. DIMENSION IS FROM BOTTOM OF RAIL TO TOP OF ROLLERS. LENGTHS SHOWN ARE TYPICAL, OTHER LENGTHS AVAILABLE. MODELS LONGER THAN 48" ARE MADE IN TWO OR MORE SECTIONS USING A STAINLESS STEEL SPLICE PLATE FOR A RIGID CONNECTION. MAX DIE WEIGHT PER PAIR IS AT 5,000 PSI. HYDRAULIC PRESSURE, AND ASSUMES THAT THE DIE FOOTPRINT IS PROPORTIONAL TO THE DIE LIFTER LENGTH.
THE MODEL-322 DIE LIFTER HAS A T-PROFILE CROSS SECTION, CYLINDRICAL ROLLERS AND IS HYDRAULICALLY ACTUATED AT 5,000 PSI. MAX.
MODEL 322 HYDRAULIC DIE LIFTER RAIL 322W
PAGE 1 OF 1
REV -
N118 W18251 Bunsen Drive, Germantown, WI 53022 | 262.250.4410 | pfa-inc.com
CONFIDENTIAL: The information shown on this sheet is confidential. Permission to use, reproduce or transmit in any way not specifically authorized is expressly withheld.
DISCLAIMER: Illustrative drawings, CAD models, and information described herein is proprietary intellectual property of PFA, Inc., accurate to the company’s knowledge at time of printing, and intended for reference only. Specifications are subject to change without notice. If the information obtained from this document is critical to a specific application, it should be confirmed by contacting PFA, Inc. PFA Terms of Sale apply.
U-SLOTS (RECTANGULAR)
'A'
'A'
T-SLOTS 'D'
NOMINAL SIZE
'E'
PRESS #
5
4 3
BOLSTER
'A' (±.010)
'E'
'E' (±.010)
3/4"
5 .840
1.510
1"
1.062
1.510
2"
2.030
2.200
'C' (REF)
.03
(ALLOWABLE) 'B'
2
WHEN MACHINING/REMACHINING 3/4" SLOTS USE .840 ±.010 FOR THE 'A' DIMENSION. THIS CREATES OPTIMUM FIT FOR THE DIE LIFTERS. (THE ANSI/ASME "A" DIM OF .812 WILL WORK AND DOES NOT NEED TO BE ENLARGED IN EXISTING SLOTS). THE T AND U SLOTS SHOWN ALLOW USE OF STANDARD PFA, INC. DIE LIFTERS, DIE CLAMPS AND ACCESSORIES. PFA, INC. PART NUMBERS FOR T-NUT SIZES ARE SHOWN. OTHER SIZES, INCLUDING SINGLE PIECE T-BOLTS ARE AVAILABLE.
2
THIS AREA MAY BE USED AS A WORKSHEET TO RECORD ACTUAL SLOT DIMENSIONS.
1
THIS IS A SELECTION OF T-SLOT SIZES WHICH CONFORM TO 'A' DIMENSIONS ESTABLISHED BY ASME B5.1M-1985, REAFFIRMED 2014. DIMENSIONS 'B', 'C' , 'D' AND 'E' ARE WITHIN MIN./MAX. ASME PARAMETERS.
NOMINAL T-BOLT SIZE
'A' (+.010 -.000)
'B' (+.03 -.00)
'C' (REF)
'D' (+.010 -.000)
'E' (±.010)
5/8"
.688
1.22
.50
.750
1.250
3/4"
.812
1.43
.63
.875
1.510
1.062
1.80
.80
1.000
1.805
1"
PRESS #
BOLSTER
PRESS #
RAM
1
2
*
*
* PLUS _______ CUTTER RELIEF, IF ANY. 'A' THREAD SIZE 'D' (REF) 'E' 'C'
'B'
T-NUT
3 PART#
SELECTED T-NUTS NOMINAL THREAD T-SIZE SIZE
'A'
'B'
'C'
'D' (REF)
'E'
1767-1
5/8"
5/8-11
.67
1.13
.42
.33
.75
1755-13
3/4"
3/4-10
.80
1.25
.56
.44
1.0
1755-16
1"
3/4-10
1.03
1.62
.63
.37
1.0
4983-16
1"
7/8-9
1.03
1.62
.69
.31
1.0
COMMON SLOTS T SHAPE & RECTANGULAR PAGE 1 OF 1
REV -
N118 W18251 Bunsen Drive, Germantown, WI 53022 | 262.250.4410 | pfa-inc.com
N118 W18251 Bunsen Drive Germantown,WI 53022 (262) 250-4410 • Fax (262) 250-4409
pfa-inc.com