Service manual

Maintenance of AMADA
Tools
Standard and
ps:®beta-V2®

These operating instructions:

- contain general and special instructions which must be complied with,
- contain technical instructions which must be observed when handling the machine,
- must be read by the responsible technical personnel or operator before setting up and taking into use,
- must be continuously available at the installation site of the machine.

Retain for future use!

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List of contents

1 General comments............................................................................................... 3
1.1 Maintenance intervals........................................................................................... 3
1.2 Regrind length....................................................................................................... 4
1.2.1 Regrind length, CU-Profi....................................................................................... 4
1.2.2 Regrind length, CU-WK II...................................................................................... 4
2 Disassembly ........................................................................................................ 5
2.1 Disassembly standard tool.................................................................................... 5
2.2 Disassembly ®beta-V2® tool.................................................................................. 7
2.3 Disassembly cutting tool..................................................................................... 10
2.3.1 Disassembly disc springs................................................................................... 11
3 Assembly............................................................................................................ 12
3.1 Assembly Standard tool...................................................................................... 12
3.2 Assembly ®beta-V2® tool..................................................................................... 13
3.3 Assembly cutting tool.......................................................................................... 15
3.3.1 Assembly disc springs cutting tool..................................................................... 17
4 Drawings and lists.............................................................................................. 18
4.1 Drawings and lists cutting tool 60 x 8 mm.......................................................... 18

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General comments

1 General comments

This kind of tool contains moveable and dynamically strained parts.

Therefore we recommend that the punch unit should be maintained regularly as there is
the possibility that abrasive swarfs can come into the guide.
Particularly the cleaning of the sliding surfaces and the greasing are required.
Punching swarfs can come into the inner side of the tool guide especially by working with
aluminium or cinc-plated sheets. According to that a regularly check of the tool is recom-
mended in order to avoid damages on the sliding surfaces.

We are not able to give a long-life guarantee when these maintenance rules are not obser-
ved. This is a kind of guide called “steel on steel-guide” and will be damaged inevitably
without the necessary maintenance (see the following picture showing the possible
damage).

1.1 Maintenance intervals

Working with foiled Aluminium-sheet (after approx. 160.000 hits without maintenance)

- The tool, the cutting station and the dies must be inspected monthly for damage and
contamination.
- After about 1 million strokes, the disc springs must be replaced.

Recommended maintenance intervals

Steel or stainless steel approx. all 50.000 to 100.000 hits
Aluminium sheet approx. all 30.000 to 50.000 hits
cinc-plated steel approx. all 20.000 to 30.000 hits

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General comments

1.2 Regrind length

1.2.1 Regrind length, CU-Profi

CU-Profi Regrind length

Station B Standard, 10 mm 1,5 mm
Station B Standard, 15 mm 3,5 mm
Station B ps:®beta-V2®, 10 mm 2,6 mm
Station B ps:®beta-V2®, 15 mm 4,6 mm
Cutting tool, 10 mm 10,5 mm
Cutting tool, 15 mm 5,5 mm
Die for cutting tool without washer 0,5 mm
Die for cutting tool with washer 1,5 mm
Station C Standard, 10 mm 8,5 mm
Station C Standard, 15 mm 3,5 mm

1.2.2 Regrind length, CU-WK II

CU-WK II Regrind length

Station A Standard, 10 mm 0.9 mm
Station B Standard, 10 mm 1.5 mm
Station B Standard, 15 mm 3.5 mm
Station B ps:®beta-V2®,10 mm 2.6 mm
Station B ps:®beta-V2®,15 mm 4.6 mm
Station D Standard, 10 mm 8.5 mm
Station D Standard, 15 mm 3.5 mm

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Disassembly

2 Disassembly

2.1 Disassembly standard tool

- Remove the tool upwards from the tool box

- Remove the grub screw with a 2,5 mm Allen key.

Attention!
Two grub screws can be screwed on top of
each other!

- Clamp the tool in a vise.

- Loosen and remove the upper part of the tool

(head screw) with a 50 mm open-end wrench.

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Disassembly

- Remove the disc springs

- Remove the intermediate piece (tin)

Disassembled tool
(punch body)

- Check punch and disc springs for wear and

damage.

Attention!
Replace the disc springs completely,
not individually !!

Spare part no.: 4092B11-CU

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Disassembly

2.2 Disassembly ®beta-V2® tool

- Remove the tool upwards from the tool box

1 2

- Remove the punch guide (1)

- Unscrew the punch body (2)

- Remove the grub screw with a 2,5 mm Allen key.

Attention!
Two grub screws can be screwed on top of
each other!

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Disassembly

- Clamp the tool in the vice, at the thread

Attention!

Be sure to use protective aluminium jaws!

- Loosen and remove the upper part of the tool

(head piece) with a 50 mm open-end wrench

- Remove the disc springs

- Remove the intermediate piece (tin)

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Disassembly

Disassembled tool

- Check punch and disc springs for wear and

damage.

Attention!
Replace the disc springs completely,
not individually !!

Spare part no.: 4090B10-CU-1

head unit (head, disc springs, tin)

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Disassembly

2.3 Disassembly cutting tool

- Use an Allen key size 10 mm and loose the screw.

- Take out the tool from the machine adaptation.

- Turn the tool and open the 4 screws with Allen key
size 4 mm.

- Remove the stripper.

- Now loose the screw on the top complete.

- Take out the punch body.

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Disassembly

2.3.1 Disassembly disc springs

- Clamp the cutting tool in the vice

Attention!
Be sure to use protective aluminium jaws!

- Remove the three screws (M8 x 30) of the punch

head with a 6 mm Allen key.

- Remove the punch head and the disk springs.

- Check punch head and disk springs for wear and

damage

Attention!
Replace the disc springs completely,
not individually !!

Spare part no.: 409211CU

- Assembly, see page 17

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Assembly

3 Assembly

3.1 Assembly Standard tool

- Check punch and disc springs for wear and

damage.
Attention!
- Replace the disc springs completely,
not individually !!
Spare part no.: 4092B11-CU

- Clamp the tool in a vise

- Mount the intermediate piece (tin)

- Mount disc springs as shown in the picture

- Screw on the head screw and tighten with a 50 mm

open-end wrench.

- Screw the two grub screws over each other with

a 2,5 mm Allen key (the longer screw first)

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Assembly

3.2 Assembly ®beta-V2® tool

- Check punch and disc springs for wear and damage.

Attention!
Replace the disc springs completely,
not individually !!

Spare part no.: 4090B10-CU-1

head unit (head, disc springs, tin)

- Clamp the tool in a vise

- Mount the intermediate piece (tin)

- Mount disc springs as shown in the picture

- Screw on the head piece and tighten with a 50 mm

open-end wrench.

- Screw the two grub screws over each other with

a 2,5 mm Allen key (the longer screw first)

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Assembly

1 2

- Screw on the punch body (1)

- Mount the punch guide (2)

Attention
Pay attention to the correct seat during
installation!

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Assembly

3.3 Assembly cutting tool

- Spray the punch with TOP 2000 grease

- Pay attention to set the punch

driver into correct position!

- Insert punch body

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Assembly

- Tighten a little bit the screw back to hold the punch.

- Put on the stripper

- Tighten the 4 screws.

- Enter the parting tool to the machine adapter

- Tighten the screw strongly.

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Assembly

3.3.1 Assembly disc springs cutting tool

- Place three of the 39 disc springs on top of each

other.
- Place two of these packs of 3 on top of each other
with the curved side facing out. One package of 3
is left over.

- Starting with the single 3 spring pack (curved side

up), place all 6 spring packs on top of each other.

- Reassemble the punch head with the three M8 x 30

screws and tighten with the 6 mm Allen key.

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Drawings and lists

4 Drawings and lists

4.1 Drawings and lists cutting tool 60 x 8 mm

9
15

11

13

10

12

6
5

8
4

14 1

2 8

Pos. Part name Piece Part number

1 Guide 1 409281CU
2 Stripper 1 404203CU
3 Die 1 405203CU
4 Guide holder 1 409251CU
5 Tin 1 409221CU
6 Punch body 1 402203CU
7 Punch drift 1 409291CU
8 Fillister head screw M5 x 16 8 –
9 Punch head 1 409231CU
10 Spring unit (39 pieces) 1 409211CU
11 Cylinder screw M12 x 170, M12 x 170 DIN 912, 12.9 1 409241CU
12 Straight pin 5 x 16 1 –
13 Countersunk screw M6 x 50 4 –
14 Straight pin 4 x 10 4 –
15 Fillister head screw M8 x 30, DIN 912, 12.9 3 –

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