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SERVICE REPORT

7025 FIRESTONE BOULEVARD, BUENA PARK, CALIFORNIA 90621 + PHONE: (714) 739-2111 + FAX: (714) 739-4099

Co. Name: Account #: Job Type:THERMO FISHER SCIENTIFIC INC. 13701 01 Service

Address: SR#: Billable:100 MILLCREEK ROAD 1666-284 N

City: Machine Model: Install Date:MARIETTA VIPROS368K

State

Zip: Country:

Machine S/N:OH 36840037

45750 US

Warranty Type End DateStart Date

AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015

Itemized Time Charges

Date Type Start End Hours

07/11/2013 01 Work 10:30 15:00 4.50

07/11/2013 02 Travel 6.00

Services Performed

Problem: Bad punches with station 201

Bad punches with station 201

Cause: tooling wear

tooling wear

Action: I came in because it looked like the auto index station 201 needed an alignment done. I put the alignment tool in and saw

that the alignment was good. The customer showed me what was happening to their sheets when punching this station. It

was leaving pretty bad burs. They are punching 22 gauge high spring stainless. I had them get me a new tool and I

punched my own test program. There was no burring. After inspection of the original tool I found that the die clearance

measured .002" larger than it should have been and the punch was worn. We put in a new tool and the result was much

better.

I came in because it looked like the auto index station 201 needed an alignment done. I put the alignment tool in and saw

that the alignment was good. The customer showed me what was happening to their sheets when punching this station. It

was leaving pretty bad burs. They are punching 22 gauge high spring stainless. I had them get me a new tool and I

punched my own test program. There was no burring. After inspection of the original tool I found that the die clearance

measured .002" larger than it should have been and the punch was worn. We put in a new tool and the result was much

better.

Comments:

Engineer Name:

Service Charge Policy: For weekday service, Monday thru Friday, labor and travel charges will be invoiced at the rate of $120.00 per hour for labor and $120.00 per hour for travel. A

minimum charge of 2 hours for labor and 1 hour for travel will be charged. Airfare and administiative expense will be charged, based on distance to customer location. Ground transportation

will be invoiced at $65.00 per day. Living expense will be invoiced at $150.00 per day. Contact the service representative for weekend and holiday rates. A copy of the complete policy will be

provided upon request. All rates are subject to change without notice.

Date:

Customer PO:

Customer Name:

Andrew Comuzie

07/11/2013 Duaine Berg

Report Generated on 5/15/2014 of 1

SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



06/27/2013 01 Work 00:00 00:00 0.00

06/27/2013 02 Travel 0.50

06/26/2013 01 Work 00:00 00:00 0.00

06/26/2013 02 Travel 0.50

06/27/2013 01 Work 07:30 12:30 5.00

06/27/2013 02 Travel 4.00

06/26/2013 01 Work 12:00 16:30 4.50

06/26/2013 02 Travel 4.00

Services Performed

Problem: -intermittent "2092 - SD RESET" alarm usually followed by a "1050 - T-axis in position" alarm

Cause: Turret Chain tension unbalanced left to right, top to bottom. Lower turret chain tension was main problem.

Action: -Adjusted chain tension for upper and lower turrets, left to right, upper to lower.

-Monitored DIAGNOSTICS #300 servo load while adjusting chain tension and adjusted PARAMETER #1850, T-axis, until

servo load was rfeduced to less than 100 as monitored on Diagnostics #300.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax


Report Generated on 5/15/2014 Page 1 of 1

SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



02/11/2013 01 Work 00:00 00:00 0.00

02/11/2013 02 Travel 0.50

02/11/2013 01 Work 11:30 17:30 6.00

02/11/2013 02 Travel 4.50

Services Performed

Problem: -414 Servo Alarm: C-axis Detection relared Error, A/I stations 201 & 230.

Cause: C-axis Torque Command "FILTER" value was incorrect.

Action: -Arrived and met/worked with FANUC Service Technician.

-Made Machine Origin.

-I removed load from c-axis motor by removing upper A/I drive shaft from coupler and removed sync belt.

-Started A/I test program to activate c-axis motor; FANUC tech found that servo motor vibrated more without load attached.

-FANUC found C-axis Torque Command "FILTER" value, parameter 2067, was incorrect. It was set to 2486. Fanuc set

value to 0.

-I reattached A/I drive shafts to c-axis motor and ste c-axis grid shift, Parameter 1850, to minimum servo load and restarted

A/I test program. We were able to run Test program for about 1 hour without any further alarms or problems.

-Replaced all covers and closed cabinet doors and returned machine over to customer for production.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



02/08/2013 01 Work 00:00 00:00 0.00

02/08/2013 02 Travel 4.50

02/07/2013 01 Work 00:00 00:00 0.00

02/07/2013 02 Travel 0.50

02/06/2013 01 Work 00:00 00:00 0.00

02/06/2013 02 Travel 0.50

02/07/2013 01 Work 08:00 15:00 7.00

02/07/2013 02 Travel 0.50

02/08/2013 01 Work 08:00 16:00 8.00

02/08/2013 02 Travel 0.50

02/06/2013 01 Work 11:00 18:00 7.00

02/06/2013 02 Travel 4.50

Services Performed

Problem: -Intermittent 410 servo alarm: C-axis excess error; A/I station 230.

-Intermittent 414 servo alarm: C-axis detection related error; A/I station 230.

-Intermittent 414 servo alarm: C-axis detection related error; A/I station 201.

Cause: Inconclusive; T/S to continue Monday.

Action: -T/S found A/I station 230 driven clamp slightly off of home position after drive clamp retracted; A/I brake not locked in.

--Put A/I station 230 to home position then adjusted driven clamp position to home and brake locked in after drive clamp

retracted. Also adjusted c-axis limit switch and dog to correct position.

-Now only getting intermittent 414 sevo alarm on A/I stations 201 and 230.

--started checking Both stations for binding. dissasembled A/I stations and found no sluggs binding worm gear, no bent or

worn parts, no bearings catching, brass ring gear good; reassembled A/I stations 201 and 230 and made sure perfect

home alignment and aligned stations upper to lower.

-Ran A/I test program and 414 alarm continues to occur. Can however run on F3 for quite awhile without alarming out but

eventually get 414 alarm.

***When 414 alarm happens, it is usually when the c-axis is being returned home, the c-axis motor will oscillate very fast

and eventually alarm out. Classic symptom of mechanical binding but when alarm happens, and c-axis motor kicks out, I

can turn A/I drive shafts easily without any binding???

-Removed upper and lower A/I drive mechanisms and checked bearings and gears for whear or binding; no excessive wear

and no binding found. No sluggs stuck in mechanisms. Shafts to coupler before motor not bent either.

***Contacted FANUC for service. Suspect bad c-axis motor or servo amplifier. FANUC will arrive Monday morning. I will

return then to continue T/S w/ FANUC.


SERVICE REPORT


Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



11/29/2012 01 Work 12:00 14:00 2.00

11/29/2012 02 Travel 4.00

Services Performed

Problem: -A/I station #144 is step punching.

Cause: Parameter needs adjusted.

Action: -Adjusted parameter #16433 from 4 to 55, to correct for stepping.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



Services Performed

Problem: -A/I station #144 is stepping.

Cause:

Action: -Adjust Parameter #16433 from 4-55 to correct for stepping.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



Services Performed

Problem: -A/I station #144 is stepping.

Cause:

Action: -Adjust Parameter #16433 from 4 to 55 to adjust for stepping.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



10/17/2012 01 Work 00:00 00:00 0.00

10/17/2012 02 Travel 0.50

10/18/2012 01 Work 00:00 00:00 0.00

10/18/2012 02 Travel 4.00

10/18/2012 01 Work 06:30 12:30 6.00

10/18/2012 02 Travel 0.50

10/17/2012 01 Work 11:30 19:00 7.50

10/17/2012 02 Travel 4.00

Services Performed

Problem: -Parts arrived to rebuild upper and lower A/I, station #144.

continued

Cause: Worn Parts

Action: -Removed upper and lower A/I assy and rebuild sub-assys.

-Removed upper and lower worm screw assy and rebuild.

-Replace Upper and lower A/I parts and align.

-reinstall surrounding stations that were previously removed and align.

-Test punch grid pattern using gang punch = no burrs.

-Ran production job several times = no burrs or other issues.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



10/08/2012 01 Work 11:00 18:30 7.50

10/08/2012 02 Travel 7.00

Services Performed

Problem: Replace ram bushings.

Cause: Parts in.

Action: Worked with Mike Truax.

We replaced both front/rear ram bushings. Both bushings spun freely in ram pockets. Evidence of previous bushing

service. Old bushings are undersized by .002". Heavy rust in machine frame. Cleaned and polished. Found broken lube line

for ram pins. Piping repaired, ram pins and bushings lubed.

Production resumed.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Ryan



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



10/08/2012 01 Work 00:00 00:00 0.00

10/08/2012 02 Travel 0.50

10/09/2012 01 Work 00:00 00:00 0.00

10/09/2012 02 Travel 0.50

10/09/2012 01 Work 08:00 16:00 8.00

10/09/2012 02 Travel 4.00

10/08/2012 01 Work 11:30 20:30 9.00

10/08/2012 02 Travel 4.00

Services Performed

Problem: -Ram pin/Bushings worn out and need replaced.

(continued from yesterday, 10/08/2012)

-Burrs on material when punching w/ c-punch.

Cause: worn out, excessive deflection during deflection test. Found grease fitting conduit broken and no grease was getting to ram

pin bushings.

Looks like tooling issue but A/I station #144 should be re-built, upper/lower to isolate any station slop from any tooling

issues.

Action: -Worked with Mike Ryan.

-R/R Ram pins and bushings.

-Repair broken grease fitting.

-Align Station #230.

Check A/I station #144 alignment = OK

-Removed backlash, upper/lower, station #144, stilkl burr, same spot, c-punch.

-Test Punched grid Pattern using c-punch, in A/I station #115; Burr in same spot as when punched in station #144.

-Put 3" square in A/I station #144 and punched grid; no burr.

-Punched Grid pattern, c-punch, at 0,90,270 degrees; burr remained at same spot following turns.

-Put custer punch in A/I station #144 & punched grid pattern; No Burrs.

Comments:


SERVICE REPORT


Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



09/28/2012 01 Work 00:00 00:00 0.00

09/28/2012 02 Travel 4.00

09/28/2012 01 Work 08:00 13:30 5.50

09/28/2012 02 Travel 0.50

Services Performed

Problem: -2091 PHNC alarm and Ram runaway.

Cause:

Action: -Remove/Replace Flow Valve and wire connections.

-warm start.

-Perform Ram Tune-up.

-Test punch.

***Customer states they will not use cluster punch while waiting for Ram pins and Bushings to be replaced in order to

hopefully save the flow valve from damage. Customer will use a single punch instead.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



09/20/2012 01 Work 00:00 00:00 0.00

09/20/2012 02 Travel 4.00

09/20/2012 01 Work 08:30 13:00 4.50

09/20/2012 02 Travel 0.50

Services Performed

Problem: -PHNC 2093 alarm

-RAM slamms down to BDC and stays. Ram will also runaway.

Cause: -Faulty Flow Valve

Action: -R/R flow valve

-Perform Ram Tune-up

-Test punch = good

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



09/18/2012 01 Work 00:00 00:00 0.00

09/18/2012 02 Travel 0.50

09/18/2012 01 Work 12:30 15:30 3.00

09/18/2012 02 Travel 4.00

Services Performed

Problem: Customer states A/I station #115 needs alignment due to sheet pulls and pre-mature wearing out of tooling sharpness.

Cause: -Worn out 3" square Die; ground down past max grind life; no more inside land surface, grinding into inside taper/out of

clearance dimension causing burrs and likely causing sheet pulls.

Action: -Arrived and immediately checked A/I station #115 alignment with alinment tool; station was aligned/alignment punch

dropped into alignment die.

-Measured 3" square Die that operator was using in machine when I arrived and found it was ground past its useable life;

measured 1.140".

-Went ahead and got new "E" station alignment tool from main building and aligned station.

-Input grid pattern program and ran program to test. Used a newer 3" square Die that was onhand and test punched

several 4'x4' sheets of 0.029" thickness, stainless steel; had NO sheet pulls and NO burrs present on punched sheet.

-Turned machine over to customer for production.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



09/13/2012 01 Work 11:00 14:30 3.50

09/13/2012 02 Travel 4.00

Services Performed

Problem: -414 C-axis Detect Error.

-Several 410 c-axis detect errors

Cause: -C-axis lmit switch, station #230, grounding out to upper turret.

-Turret chains needed tightened.

Action: -Found upper A/I station #230, c-axis limit switch was grounding out to upper turret due to wire insulation broken, exposing

wires; Repaired wiring.

-Tightened chains for upper and lower turrets.

-Adjusted T-axis servo error to minimum and C-axis servo error to minimum.

-Had customer run production; no problems detected.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



08/27/2012 01 Work 00:00 00:00 0.00

08/27/2012 02 Travel 0.50

08/28/2012 01 Work 00:00 00:00 0.00

08/28/2012 02 Travel 0.50

08/29/2012 01 Work 00:00 00:00 0.00

08/29/2012 02 Travel 4.00

08/28/2012 01 Work 08:30 20:00 11.50

08/28/2012 02 Travel 0.50

08/29/2012 01 Work 08:30 12:30 4.00

08/29/2012 02 Travel 0.50

08/27/2012 01 Work 12:00 18:30 6.50

08/27/2012 02 Travel 4.00


SERVICE REPORT


Services Performed

Problem: -Getting PHNC #2091 & #2093 servo Amp alarms; LSVAMP1 alarming out with 2093 PHNC alarm.

-Ram Slamms Down and stays down; Have to cycle power to get Ram to move Back up to T.D.C./ RAM Runaway.

(Continued from yesterday, 08/27/2012)

Need to perform RAM Deflection Test due to excessive shock and vibratiuons that have been damaging flow valve.

Cause: -Excess Backlash in Lower A/I stations #230 & #144 caused Die to misalign just enough to cause excessive shock which

contributes to breaking flow valve voice coil spool shaft and pre-mature wear of tooling and caused excess burrs on

worksheet.

-Ram Bushings and pin worn and need replaced; also contributing to excess shock through RAM causing Flow Valve Voice

coil spool shaft to break.

-Upper guide key needed replaced on A/I station #230 due to punch was sloppy/excess movement; Future may dictate that

Turret is bored and resleaved to get rid of excess slop and movement of punches in upper turret.

Action: -Removed Fixed Stations around A/I station #144 & #230, to gain access to worm shaft housing and A/I brake assy.

--Adjusted worm housing to remove excess backlash between lower worm shaft and brass ring gear; removed most all of

backlash so dies can't move around and wear prematurely, especially with the tight 0.006" die clearance used by this

customer. This will also aleviate some excessive vibrations/shock through RAM to flow valve, especially when punching

with cluster punch Station #144.

-Checked Brass ring gear, worm gear, and all associated A/I brake parts for wear; no wear on any lower A/I parts Stations

#230 & #144.

-Started replacing fixed stations previously removed and aligned them using alignment tools.

-Aligned all A/I stations.

***Will return tomorrow to continue repair.

-Finished replacing fixed stations previously removed and aligned.

-Removed Replaced Flow Valve & Tuned.

-Test punched grid pattern with Cluster Punch, A/I station #144; Most of burrs have been eliminated from worksheet. As a

note, the customer has decided to purchase and use cluster punch w/ die clearance increased to 0.009".

--went back and removed even more backlash from Lower A/I station #144 & re-aligned with alignment tool.

-Test punched grid pattern again, a/i station #144 again and found that premature tool wear and burrs virtually eliminated.

***All test punching, A/I station #144, performed with brand new punch and die, 0.009" clearance.

-Test punched A/I station #230, grid pattern, 0.030" stainless steel; Found worksheet still had bad burr; found Punch was

sloppy in upper turret.

-Replaced upper guide key, A/I station #230, which helped remove slop and excessive punch movement in holder. Test

punched grid pattern again and achieved good results; minimal/acceptable burr and no sign of premature tool wear.

-Found A/I station #230 lower driven clamp not locked into home position when drive clamp retracted; re-aligned driven

clamp to home position and brake locked in when drive clamp retracted.

-Performed RAM Deflection Test.

***Dial indicator placed on top left of Ram Block:

--Order Value = 19.00mm

--Actual Position = 18.16mm

--Deflection = 00.30mm/0.0118"

--Tonnage = 22 Tons

***Dial Indicator placed on top right of Ram Block:

--Order Value = 19.00mm

--Actual Position = 18.16mm

--Deflection = 00.53mm/0.0208"

--Tonnage = 22 Tons

-Test results that Ram Bushings and pin are worn to point of needing replaced. I will inform customer of parts required and

explaine repair job requirements.


SERVICE REPORT


Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



08/16/2012 01 Work 00:00 00:00 0.00

08/16/2012 02 Travel 0.50

08/17/2012 01 Work 00:00 00:00 0.00

08/17/2012 02 Travel 4.00

08/17/2012 01 Work 07:30 12:30 5.00

08/17/2012 02 Travel 0.50

08/16/2012 01 Work 12:00 19:30 7.50

08/16/2012 02 Travel 4.00


SERVICE REPORT


Services Performed

Problem: -PHNC Alarms #2091 & #2093; Customer/operator states During punching, cluster punch, station #144, RAM slammed

down and operator hit e-stop and ram runaway occured and RAM cycled by itself a couple times until servo amplifier

alarmed out stayed down; Recycled power and RAM went up, warm start good, tried to run program again but same bad

results from RAM.

(continued from Yesterday,08/16/2012)

Cause: -Bad Flow Valve.

Action: -Arrived and first looked at station #144 to check for any slop in upper or lower A/I assy which may have caused tooling to

misalign during punching allowing for excessive vibratons that may have taken out/damaged flow valve; I found upper and

lower A/I assy to be mechanically sound with no excessive play; installed tooling and was not able to move punch or die

around while installed which may have indicated worn out A/I assy; Station #144 mechanically sound w/ tooling installed.

-Next started looking at cluster punches and dies that were at machine when I arrived. I found a cluster punch die, 0.009"

clearance that showed damage in two of four holes as if die was not seated in die holder and punch was made

damamaging die.

-Next found a second cluster punch die, 0.006" clearance, that had one of four holes good when measured w/ calipers and

other three holes were oblong at diferrent points in holes measuring outside 0.006" clearance; worn out dies.

-Cycled machine power and noticed ram surge down slightly and then go back up to TDC when airdown reset/S.D. Reset

pressed.

-Origined all axis ok.

-Removed punch, for 3 1/2" station, and placed under striker, performed warm start; all good.

-Ran test program to punch at 3 1/2" station w/ tooling removed and punch slammed down and ram runaway occured after

e-stop pressed until servo amplifier alarmed out; Flow Valve is bad and needs replaced.

-Removed/Replaced flow valve.

-Performed Ram tune-up.

-performed warm start (x3); no problem.

-created program to punch grid program using cluster punch, station #144, using only tooling available whose condition is

described above.

-asked operators to sharpen tooling and found out that Grinding wheel on TOGU III was worn completely out and has been

needed replaced for several months.

-operator took tooling to top of hill and sharpened there on TOGU III w/ good grinding wheel.

-Test punched 1st 4x4 sheet, stainless steel, 0.030" thickness, and noticed while punching that sheet was pulling up on

punch, due to worn out tooling, and sheet eventually did pull out of clamps.

-At this point I will return tomorrow when cluster punch tooling being used on Vipros at top of hill can be brought down and

tested on this machine.

-Arrived and waited for operator to go get tooling from up on hill that was being used to keep up w/ work usually punched on

this machine.

-Operator brought tooling down and I used calipers to measure cluster punch die holes and all four holes measures good

w/0.006" clesrance. Die thickness was ground down to 1.125", which is past its grind life. Was able to shim die to 1.181"

and install in machine, Station #144. Installed Puch.

-Ran several more test sheets, punching grid pattern full sheet with no issues.

-Informed Duaine Berg that they need to order new cluster punches and a grinding wheel for TOGU III.

-I dis-assembled Bad valve and found voice coil spool shaft broken.

***As befor, once decent tooling is installed, there are no punching issues. It seems to be worn out/Dull tooling that is

causing excessive shock to Ram, which ends up breaking voice coil spool shaft in valve.

Comments:


SERVICE REPORT


Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



06/18/2012 01 Work 00:00 00:00 0.00

06/18/2012 02 Travel 0.50

06/19/2012 01 Work 08:00 15:30 7.50

06/19/2012 02 Travel 1.00

06/18/2012 01 Work 10:30 18:00 7.50

06/18/2012 02 Travel 4.00


SERVICE REPORT


Services Performed

Problem: -NC control displayed a PHNC warning when in middle of program run, punching a gang punch on station #144 (4 1/2"

station). Operator reset alarm and re-origined all axes re-started job from beginning; on first punch, which happened to be

on a 1/2" tool, Ram came all the way down and broke tool and stuck in down position at B.D.C.

(Continued from Yesterday)

Cause: Defective Flow Valve.

Action: -Arrived and powered up machine, striker was over an empty station (Punch removed).

-Tried to run "Warm Start" and Ram immediately slammed down hard to BDC and stayed down. Both LSVAMP #1 & #2

alarmed out. I shut machine down and waited a while before powering machine back up. When powered back up, RAM

went back up to TDC when S.D. Reset Pressed and hydraulic unit came on.

-Tried to run "Warm Start" again and had same results as above except the Ram kept cycling on it's own, slamming down to

BDC and back up slowly until Amps alarmed out.

-Recycled power again and too voltage measurements from input power to Power supply voltages = all good.

-Forced H/L switching valve to high tonnage and checked Idle tonnage doubled and voltage feedback on LSVAMP#2 =

-2.5vdc = good.

-checked all cable connections at valves and amps = good.

-Came to conclusion that Flow valve was Defective again.

-I informed my Manager and he is having a new Flow Valve sent to customer overnight to arrive tomorrow.

-Arrived on-site, Part not arrived yet, wait for part to arrive.

--Removed defective flow valve and prepare to install new Flow valve.

-Part arrived; installed new Flow valve & wired up.

-Performed "Warm Start" (x3) to force air out of hydraulics after valve change; Warm Start ran correctly to completion, no

problems indicated.

-Performed a Ram Tune-up.

-John Felice of Amada National Service arrived.

-Input a test program to run a grid pattern using gang punch (cluster tool), station #144; ran 6 sheets of test material without

fail or issue.

-Handed off machine to customer to set up and run production job while we observed; no punching problems w/ eception of

lancing forms needed adjusted but all ran good overall.

***Will check back in morning to see how machine ran overnight.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



06/07/2012 01 Work 08:30 12:00 3.50

06/07/2012 02 Travel 4.50

06/06/2012 01 Work 11:00 15:30 4.50

06/06/2012 02 Travel 4.50

Services Performed

Problem: Parts need to be assigned RMA#'s, placed on pallet, shrink wrapped, weighed and staged to be picked up for shipment

back to Amada Parts returns.

-Customer trying to align A/I station #144 with alignment tool and are in need of assistance.

Cause:

Action: -worked with Amada Parts to get final RMA's; all parts have RMA#'s assigned.

-placed parts to be returned on pallet and shrink wrapped, weighed and measured.

-Parts staged for pick-up for shipment back to Amada Parts Returns.

-Assisted Dennis Ward and operator on how to correctly perform station alignment on A/I station #144.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



05/29/2012 01 Work 00:00 00:00 0.00

05/29/2012 02 Travel 0.50

05/29/2012 01 Work 11:00 15:30 4.50

05/29/2012 02 Travel 4.00

Services Performed

Problem: -Punching Problem; intermittent not punching through material when using gang punch, station #144.

Cause: -Tooling; cluster punches customer has on hand are worn out and need replaced. The gang punches and dies on hand

are worn to different sizes in diameter. I was informed by Duaine Berg that new tooling has been ordered.

Action: -Initially arrived to get Parts that were used for previouse repair packed, palleted, shrink wrapped and assigned RMA #'s,

but, ended up rehashing punching issues due to worn tooling with customer.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



05/01/2012 01 Work 07:30 19:30 12.00

05/01/2012 02 Travel 0.50

05/02/2012 01 Work 07:30 19:30 12.00

05/02/2012 02 Travel 0.50

05/03/2012 01 Work 07:30 18:00 10.50

05/03/2012 02 Travel 0.50

05/04/2012 01 Work 07:30 10:00 2.50

05/04/2012 02 Travel 3.00

04/30/2012 01 Work 10:00 18:00 8.00

04/30/2012 02 Travel 3.00


SERVICE REPORT


Services Performed

Problem: The customer was having a problem with the ram running away.

Cause: switching and flow valves

Action: I came in with John Felice and Mike Truax to fix the problem the customer was having with the ram running away and getting

stuck down. The first action we took was to switch out lsv amp 2 for a new amp. The problem did not go away. We then

installed a new switching valve. That caused both amps to go into alarm. We then switched the cables phh21 and HQ7 to

see if we could isolate the problem to one of the cables but there was no change.

We came back and replaced the phnc board. The ram still ran away. We went back and started checking voltages and

found that the main line coming into the machine was only supplying 400 volts so we had the customer change the power

supply . We were then getting over 480 volts. The ram still ran away. We changed both the switching and flow valves. the

ram was stuck down. We changed the flow valve again and the ram moved up and stayed. We changed the flow valve again

and got the machine to warm start. We shut the machine down and took the drain line off of the mechanical accumulator.

When we restarted the machine a large quantity of oil came out of the drain that we took off. We then rebuilt the

accumulator.

We came back in and tried to start the machine to check the operation of the mechanical accumulator but the hydraulics

would not start. We finally got the hydraulics on and the ram runaway still occurred. We changed the flow valve again. We

still could not get the hydraulics to turn on unless the machine sat with the power off for a period of time. When the machine

came on we began punching test pieces. The machine ran well with small tools but had a problem when high tonnage was

required.

Thursday we came in and tried to troubleshoot the issue of the hydraulics not turning on. We found that the ka3 switch had

contacts that were burnt. We jumped those contacts and the hydraulics came on when the machine came on. We then

changed the switching valve and adjusted the tonnage settings. The customer was still having problems with one large

tool, so we had them sharpen the tool and that fixed the issue.

We came back to check on how the machine ran the previous night. the customer had problems with another tool so we

had them sharpen that tool and the problem went away. We stayed to watch the machine run for a while to make sure they

had no more problems arise.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Andrew Comuzie



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



04/22/2012 01 Work 00:00 00:00 0.00

04/22/2012 02 Travel 4.50

04/23/2012 01 Work 07:00 18:30 11.50

04/23/2012 02 Travel 1.00

05/01/2012 01 Work 07:00 19:30 12.50

05/01/2012 02 Travel 1.00

05/02/2012 01 Work 07:00 19:00 12.00

05/02/2012 02 Travel 1.00

04/27/2012 01 Work 07:00 12:30 5.50

04/27/2012 02 Travel 4.50

04/24/2012 01 Work 07:30 17:30 10.00

04/24/2012 02 Travel 1.00

05/04/2012 01 Work 07:30 12:30 5.00

05/04/2012 02 Travel 4.50

05/03/2012 01 Work 07:30 18:00 10.50

05/03/2012 02 Travel 1.00

04/25/2012 01 Work 08:00 14:30 6.50

04/25/2012 02 Travel 4.50

04/26/2012 01 Work 11:00 18:00 7.00

04/26/2012 02 Travel 4.50

04/30/2012 01 Work 11:30 18:00 6.50

04/30/2012 02 Travel 4.50


SERVICE REPORT


Services Performed

Problem: -"2093" PHNC Alarm.

-RAM Run away/gets stuck down.

-Both Servo Amplifiers Alarmed out.

(continued from 04/23/2012)





-RAM Runaway when punching material with larger 3 1/2",4 1/2" tooling, primarily Gang Punch; RAM Getting stuck at BDC

and PHNC 2093 Alarm





Cause: -Inconclusive at this time.


SERVICE REPORT


Action: -Sunday Travel to hotel

-Power-up Machine, Begin "Warm Start"; Ram Drops to BDC, Goes back up then drops back down and goes back up.

Re-cycle power and try warm start again; same results. Went up top to check valve cable connections , LVDT and LVDT

cable. re-cycle power and Ram Comes down and stays down as soon as hydraulic unit comes up after pressing "S.D.

Reset". Called Amada National Service.

-Checked AVR1,2,3,4 power supplies; all good voltages at machine idle. Powered down and re-checked LVDT Connector

and cleaned.

-Powered up machine and RAM went back up to TDC when hydraulics came up. Initiated "warm start" & it ran to completion.

Re-ran "warm start" and while it was running went up top to LVDT and Cable and moved wires around to see if problem

would re-occur while warm start running; warm start ran to completion.

-input short test job program, no material, removed tooling. started program and on first hit, RAM slammed down & stayed

down; recycled power and Ram came up when hydraulics came up.

--Removed both Flow valve and switching valve, to gain access to LVDT and removed LVDT.

--Had customer order a new LVDT, LVDT cable, all Cables going to Flow valve (HQ3, HQ4, HQ7)

-Waiting on parts to arrive.

--Parts arrive; Received LVDT and LVDT cable, cables HQ3,4 & 7 are on back order.

-R/R LVDT & LVDT cable.

-Re-install flowvalve & switching valve.

-Perform RAM Tune-Up.

-Ran "warm start" to completion.

-Ran test program, no tooling, no material; Ram went down to BDC & stayed down on first hit.

-Re-installed each LSVAMP#1 that had been previously removed; problem remains.

-Called My manager Chuck Savage & he is shipping out another Flow valve and LSVAMP#1 to arrive tomorrow.

-Wait on parts to arrive from UPS

--Flow valve arrives but amp does not. Part tracking finds amp is sitting at UPS and will be delayed until tomorrow

(Thursday).

-R/R Flow Valve.

-Warm start to completion.

-RAM Tune-Up.

-Test program; RAM came down on fist punch and stayed down

-Called Amada National Sevrvice & John Felice will be flying in on Thursday to help.

-Re-tried used servo amps; no change.

***Will return tomorrow w/John Felice from Amada National service to Continue T/S.

Arrived and took receipt of parts that John Felice of Amada National Service had shipped (AVR1,AVR2,AVR3, SPHNC Board

& LSVAMP#1). Also Received LSVAMP#1 that was delayed at UPS yesterday.

-John Felice arrives. RAM Is Stuck down & will not go back up even after many power re-cycle attempts. We end up

removing Flow valve I installed yesterday and re-installing flow valve I removed yesterday. Powered up machine and when

hydraulics came on after pressing "S.D. reset", RAM Moved up to TDC.

-Performed warm start and ran test program, punch on, no tooling, no material, for about 10 minutes befor symptom

returned; RAM runaway and RAM ended up stuck down.

-Istalled new AVR2, AVR3 and AVR1 Power supplies, one at a time; No change. Installed and re-initialized new SPHNC

Board; no change, RAM remains stuck down.

-tried different things for awhile to get RAM to come back up.

--Going to hotel for night, will return tomorrow to continue T/S.

-Arrived, Powered up machine, pressed "S.D.reset" & hydraulic unit came on & RAM went up.

-initiated "warm start" & it ran to completion.

-Performed Hit rate Test for low & high tonnage; Ram cycled smoothly without any issues.

-John Felice input a test program,grid pattern, starting with 1/2" station, no material, ran for quite ahwile without fail. Then

Ran program with material and punched grid pattern several times, 100's of hits, without fail.

--continued above sequence of events utilizing 1 1/4" then 2" tooling which ran without fail.

--Ran above program with 3 1/2" tooling and RAM ran away and would get stuck down. We were able to Recycle Power and

get RAM to move back up to TDC. Tried this several times and have a better understanding that Flow Valve and LSVAMP#1

are good and problem more than likely exists in either or both the switching valve or switching amplifier (LSVAMP#2).


SERVICE REPORT


--John Felice has ordered a switching valve and switching amp to be shipped for Monday when we return.

-R/R Switching Valve

-R/R Switching Amplifier

-R/R and re-initialize SPHNC Board

--Able to run punching program, without material, up to 4 1/2" station; try to punch material w/ 4 1/2" tool & RAM would

Runaway & get stuck down at BDC w? PHNC 2093 Alarm.

-Swapped cables between Switchin & Flow Valves and LSVAMP#1 & LSVAMP#2; Problem stayed same, nothing conclusive

determined, swapped cables back to origional position.

-Measured input voltage & found reading too low; 418 vac at idle with drop to as much as 399 vac when punching. Found

that incoming power supply cable too long causing too much pwr loss at machine. Informed customer & they

moved/connected input power cable to a 480 vac distibution box w/ 60 amp breaker located on wall near machine. Now

have 490 vac incoming to machine.

--Also found T1, 100 vac transformer was outputting too low of voltage until 490 input power was supplied to machine as

described above. was getting barely 90 vac, now getting 106 vac. The 100 vac circuit is directly related to hydraulic circuit

including valves, motor, contacts, ect.

*** still having problems but power problems described above are a contributing factor to why servo valves and LSV AMP's

were being taken out/damaged.

-After power issue was rectified, swapped out all flow valves we suspected of being defective and proved that they were in

fact bad.

-Removed lower line from mechanical accumulator & powered up machine and hydraulics; dry ran punching program & oil

flowed from bottom side of mechanical accumulator with each punch/ram cycle; should only be puffs of air coming out, not

oil.

--Removed mechanical accumulator & disassembled. Flipped cylinder sleeve and reassembled and re-installed in

machine. Will test tomorrow.

-Powered up machine and tested mechanical accumulator function; mechanical accumulator functions properly now.

*** John Felice of Amada National Service ordered another new flow valve yesterday and it arrived and was installed.

-Started having problems with hydraulic motor not coming on as it should when S.D restet pressed during start up.

Extensive T/S in progress.

-Continued T/S hydraulic motor not coming on issue. Found magnetic contactor KA3 faulty; charred and melted contacts

directly related to inputpower issue described previously. KA3 Contacts that carry 100 vac voltage to T1 timer for star to

delta motor starting sequence were melted and no voltage sent out of contact; jumped wires for now and researching

contact part info. Contact in this European machine not part of or in stock but I will try to find comparable magnetic contactor

to order.

-T/S found switching valve not switching properly and Switching amplifier (LSVAMP#2) switcing voltage was not high

enough; could only get max -2.401 vdc when switching valve forced to high tonnage. Requires 2.5 vdc. Tried to adjust null

pot on amp up to get required voltage but maxed out at -2.401 vdc

--Replaced switching amp and was able to adjust switching voltage to -2.498 vdc, within tolerance.

-with origional switching valved forced to high tonnage, could punch large 4 1/2" gang punch, and any other punch size, with

material, without fail. Once switching valve was not forced to high tonnage, Ram had trouble punching through Stainless

steel intermittently with gang punch so, replaced switching valve.

-arrived to find overall machine ran throughout night shift without punching problems. There was a couple of alarms that

ended up being attributed to programming issues. I provided some training on setting up forming tools and how the

M510/M5ll info affects forming. Also showed operator and Dennis Ward how to properly access PHNC to get secondary

alarm codes and info when a "PHNC ALARM" occurs. Also found that when gang punch did not punch through, the tool was

dull and needed sharpened. Once sharpened, machine ran and punched using gang punch without issue. I

re-emphasized the importance of sharpening Gang punch and lage tools especially. May have to sharpen large tools and

gang punch a couple times a shift but, at least at beginning of each shift or when problem punching through. Die also

needs to be properly shimmed.

Comments:


SERVICE REPORT


Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax

04/22/2012 Butch Wright


SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



04/09/2012 01 Work 00:00 00:00 0.00

04/09/2012 02 Travel 0.50

04/10/2012 01 Work 00:00 00:00 0.00

04/10/2012 02 Travel 0.50

04/10/2012 01 Work 08:00 11:30 3.50

04/10/2012 02 Travel 4.00

04/09/2012 01 Work 10:00 18:30 8.50

04/09/2012 02 Travel 4.00

Services Performed

Problem: 2093 Servo Amp alarm. During punching, customer states Ram continued to cycle up and down even after stop button

pressed.

***LSVAMP#1 & Linear Servo Valve was just recently replaced for similar problems.

(continued from yesterday)

Cause: Failure of LSVAMP#1 and Linear Servo Valve.

LSVAMP#1 & Linear servo valve.

Action: -T/S LSV Amplifiers and Valves using LSV AMP Maintenance Manual Trouble shooting flow chart. This consisted of wringing

out all cables and connectors associated with LSVAMP#1 and LSVAMP#2 as well as both Linear flow valve and hi/low

switching valve connectors and cabling. All cables and connectors ohmed out good. Had Thermo Maint suprvsr, Bitch

Wright assisting. T/S Flow chart indicated a defective LSVAMP#1 and Flow Valve.

-Remove/replace Linear servo Amp #1 and Flow Valve.

-Performed Ram Tune-up.

-Ran Warm Start

-Ran Test job that Test Punches all Tool Stations in turret; all Good.

-Turned Machine over to customer to Run Production; Machine running without failures. I will return in morning to audit

machine performance further.

-Arrived to find Machine running. Operator stated that Machine ran fine all night, no problems.

-I stayed to audit machine performance for 4 1/2 hours. Watched machine run several programs without fail, all looked

good.

Comments:


SERVICE REPORT


Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



03/27/2012 01 Work 08:00 13:30 5.50

03/27/2012 02 Travel 0.50

03/28/2012 01 Work 10:30 14:30 4.00

03/28/2012 02 Travel 4.00

Services Performed

Problem: -Part arrived; Linear servo Amplifier #1 (LSVAMP#1)needs installed/replaced.

-Part arrived; 2nd linear servo valve needs installed to replace defective 1st valve.

Cause: -Unstable tuning; voltages fluctuating excessively during Tune-up; does not hold idle position.

1st newly installed linear servo valve is defective.

Action: -Remove/Replace LSVAMP#1 & perform tune-up.

--Powered machine up and when hydraulics kicked on, noticed RAM moving slowly up and down until LSVAMP#1 alarmed

out and a "2093" sevo amp alarm was displayed on NC control.

--T/S found recently installed new linear servo valve is defective.

***I called my manager, Chuck savage, and he is having a new Linear Servo Valve shipped overnight to customer at no

charge.

I will return and replace when it arrives tomorrow.

-R/R linear servo valve and wire up.

--Perform RAM Tune-up.

-Test punch all stations; all look good.

-I observed customer run production job without issue for a couple hours without fail.

-closed all cabinet doors and replaced all covers.

-Turned machine over to customer.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



03/26/2012 01 Work 00:00 00:00 0.00

03/26/2012 02 Travel 0.50

03/26/2012 01 Work 12:30 15:30 3.00

03/26/2012 02 Travel 4.00

Services Performed

Problem: Linear servo valve recently replaced; need to check on machine performace.

Cause:

Action: -Stopped in to check on machine performance. talked to Dennis Ward and operator; machine has been running without

issue since last wednesday when servo valve was replaced.

-servo amp has beed ordered as I suggested; I will replace and tune-up when it arrives and production time permits.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



03/20/2012 01 Work 00:00 00:00 0.00

03/20/2012 02 Travel 0.50

03/21/2012 01 Work 00:00 00:00 0.00

03/21/2012 02 Travel 4.00

03/21/2012 01 Work 08:00 15:30 7.50

03/21/2012 02 Travel 0.50

03/20/2012 01 Work 12:00 18:30 6.50

03/20/2012 02 Travel 4.00

Services Performed

Problem: Punching problems

-2008 PHNC alarms (intermittent)

--Inconsistent forming heights and gang punch not punching through (Intermittent)

(Continued from yesterday)

Cause: Failing Linear Servo Valve and Pressure Transducer.

Action: -R/R pressure transducer.

- R/R Linear servo Valve & wired.

--Powered up machine and Ram started rapid punching on its own when hydraulic unit came up.

--Checked and re-checked wiring of new Linear valve; could not find any problems.

***Going to Hotel for night. Will return in morning to countinue repair.

-Arrived & disconnected all cable wires going to linear servo valve wired yesterday.

--Cut back cable wires to ensure no brittle wire insulation and rewired linear servo valve.

--Powered machine up & hydraulic unit up; no problems encountered.

-Forced RAM to High Tonnage by jumping wires #416 & P2 in electrical cabinet; Idle pressure doubled as it should;

removed jumper.

-Performed RAM Tune-Up

--Ran test program that punches each station.

-Re-checked idle position in PHNC monitor; noticed idle position was off from previously tuned position.

-Re-tuned Linear Servo amp #1.

--Ran Test job ok; ran production while i observed for several hours with no more punching problems encountered.

***I did inform customer (Butch Wright) that LSVAMP#1 is beginning to be unstable and that a new LSVAMP#! should be

ordered and installed in near future. I provided Butch Wright w/ part info.


SERVICE REPORT


Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



03/05/2012 01 Work 00:00 00:00 0.00

03/05/2012 02 Travel 0.50

03/05/2012 01 Work 12:30 15:30 3.00

03/05/2012 02 Travel 4.50

Services Performed

Problem: -Punching problems

Customer states they have been getting PHNC alarm again

--PHNC Alarm = 17 B.D.C. Error - Servo tolerance is over the Limit, while hitting BDC. Check worksheet, hydraulic unit, servo

valve & servo amplifier.

Cause: Inconclusive at this time. Linear servo/spooling valve may be sticking. Problem does not appear to be linked to

accumulators at tghis time.

Action: Arrived to find Machine was running without any issues for now. Talked to Dennis and he will continue to monitor.

-I checked accumulator pressures:

--Low Pressure (10L) = 5.7 Mpa

--High Pressure (6L) = 11.7

--Pilot Pressure (1L)= 7.5

*** Accumulators were within operating pressures and did not leak off any pressure since the last time I checked, but

accumulator pressures were not to exact specs. I charged accumulators to specified Pressures:

--Low Pressure (10L) = 6.7 Mpa

--High Pressure (6L) = 12.9 Mpa

--Pilot Pressure (1L)= 6.7 Mpa

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



02/17/2012 01 Work 07:00 10:00 3.00

02/17/2012 02 Travel 0.50

Services Performed

Problem: Customer states they have been getting PHNC alarm again

--PHNC Alarm = 17 B.D.C. Error - Servo tolerance is over the Limit, while hitting BDC. Check worksheet, hydraulic unit,

servo valve & servo amplifier.

Cause: inconclusive at this time. Linear servo/spooling valve may have been fouled by particulates that eventually worked itself out.

Action: -stopped in and talked to Dennis about PHNC problems. He stated that machine has been running without fail for several

days. He said that they had manipulated some tooling data then ran the machine in full stroke mode for a shift, then put

machine to run in hover heighth mode. the machine ran without failing so he put all tooling data info he had changed back

to specified settings after measuring punches and dies. Machine hasn't stopped running since.

Comments: Before I left to travel home, I also checked to make sure that the PEGA-357 I worked on yesterday was still running and it

was. Customer ran it all night without fail.

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



02/07/2012 01 Work 00:00 00:00 0.00

02/07/2012 02 Travel 0.50

02/08/2012 01 Work 07:30 14:30 7.00

02/08/2012 02 Travel 0.50

02/07/2012 01 Work 12:00 20:30 8.50

02/07/2012 02 Travel 4.00


SERVICE REPORT


Services Performed

Problem: (02/08/2012)

Parts arrived for override detection and need replaced.

(02/07/2012)

-Getting A/I clamp alarms.

-Station 144 not at home position.

-A/I drive clamps wont retract.

Cause: Override Detection Plate bent due to front turret cover brackets broke and cover fell and jammed up on override plate,

bending it down to where work holder detection rollers no longer made contact with detection Plate.

Faulty C-axis limit switch.

Action: -checked with operator to see if any further problems with A/I station 144; no problems encountered, ran through the night.

--I did adjust T-axis grid shift parameter due to excessive servo load when turret pins locked in.

-Remove and rebuild override detection plate and test override detect; functions correctly.

-Replaced covers and turned machine over to operator for production.

-Align A/I station 144 upper and lower to home position.

-origin station 144.

-loosen A/I drive timing belt; too tight.

-loosen upper and lower A/I drive shaft couplers and turn shafts until upper and lower drive clamps retracted fully.

-tighten A/I drive shaft couplers.

-origin c-axis and then check for excessive servo load when A/I drive clamps retracted onto keyway.

-adjusted c-axis grid shift parameter #1850 until not servo load present when A/I clamps retracted.

-manually input A/I program that turns c-axis 90,270,180 and 0 degrees,each A/I station, continually, to verify that A/I clamps

engauge and retract without failure and that each A/I station returns to home position.

--Test ran without fail for over an hour. had operator load job that was running when problem started. Ran job and A/I station

144 failed; did not return home and clamps did not retract; machine stopped with C-limit switch alarm.

-replaced c-axis limit switch on A/T station 144 and adjusted prox distance.

-re-ran A/I test program without fail for long time.

-turned machine over to operator for production.

*** Will check back in morning to see if any further issues.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



01/26/2012 01 Work 00:00 00:00 0.00

01/26/2012 02 Travel 4.00

01/26/2012 01 Work 08:00 17:00 9.00

01/26/2012 02 Travel 0.50

Services Performed

Problem: X-axis override detection plate needs replaced/rewired.

Cause: -Detection Plate bent.

-Wire insulation worn off, exposing wires and grounding out detection plate.

Action: -Removed Override detection plate to rebuild and rewire; discovered that customer had ordered wrong detection plate. I

went ahead and re-used original detection plate and rewired, installed new isolation strip, and re-installed plate to

machine.

***During testing, found out that original detection plate was bent and work clamp roller heads would not touch detectors on

plate. Informed customer that they would have to order the correct Detection plate for this VIPROS-368KII (EU). I looked up

the part info and provided to Butch Wright, Supervisor of Maintenance. He will order parts and I will return to replace

Detection Plate.

Comments:

Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



SERVICE REPORT





State

Zip: Country:


45750 US


AMP 12/14/2009 12/13/2010

AMP 01/02/2011 01/01/2012

AMP 01/02/2012 01/01/2013

AMP 02/01/2013 04/21/2013

AMP 05/01/2013 07/25/2013

AMP 08/01/2013 10/25/2013

AMP 11/01/2013 01/26/2014

AMP 01/27/2014 01/26/2015



01/16/2012 01 Work 00:00 00:00 0.00

01/16/2012 02 Travel 0.50

01/17/2012 01 Work 00:00 00:00 0.00

01/17/2012 02 Travel 0.50

01/17/2012 01 Work 06:30 08:00 1.50

01/17/2012 02 Travel 0.00

01/16/2012 01 Work 12:00 18:00 6.00

01/16/2012 02 Travel 4.00

Services Performed

Problem: Punching problems - 2008 PHNC alarm

Continued from 01/16/2012

Cause: Combination of:

-Improper oil used (Mobil DTE 25, should have been Mobil DTE Excel 46) when hydraulic unit oil was changed.

-worn tooling (punches and dies not shimmed in stations where alarms happen most (T258 &229).

-LVDT twist lock connector dirty w/oil.

-overcharged pilot accumulator

Action: -Checked PHNC Monitor, idle tonnage and idle position = within specs.

-forced switching valve to high tonnage and idle tonnage doubled as it should.

-checked LSVAMP1 & 2 for alarm; amps were not alarming out.

-Checked High, Low and Pilot Accumulator pressures; found pilot accumulator overcharged; I drained Nitrogen down until

Pilot Accumulator was within specs.

-Checked LVDT twist lock connector and found it dirty w/ oil. I cleaned plug on LVDT and twist lock connector.

***Customer will continued to run production through the night and record any failures or alarms. I will return in morning to

check on status of machine.

-Arrived to check on machine status after operator ran production through night shift; No further errors, alarms or punching

problems detected

Comments: This service report to be closed as no charge to customer. Customer has renewed AMP on this machine.


SERVICE REPORT


Engineer Name:





Date:

Customer PO:

Customer Name:

Michael Truax



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