Scope of Remanufacturing
The following is a thorough list of what is done to a die cast machine during
remanufacture. For an explanation of why remanufacturing is a good idea, and
why rebuilding is different, please see here.
(A remanufactured Birch 850 machine being loaded)
One - Pressure Wash
- Entire machine washed to remove dirt, grease, oils, and so
Two - Hydraulic Reservoir Drained, Cleaned, and Rust Removed
- Pump shutoffs installed if needed.
- Sump filters replaced.
- Oil level gauge cleaned or replaced.
- All covers secured with new gaskets, new hold-down studs where necessary.
- All tank return check-valves rebuilt/replaced as required.
- Tymac thermocouple installed.
- Reservoir sealed and air vent filter installed.
Three - Heat Exchanger
- Water passages cleaned, flushed and pressure checked. If any leakage
is found, exchanger rebuilt or replaced.
- End caps replaced as required, new gaskets installed.
- Oil Passages cleaned and flow checked.
Four - Hydraulic System
- All components removed from manifolds, cleaned & inspected for cracks,
worn passages, and so on. Replacement quoted if excessive wear.
- Valve mounting surfaces stoned or surface-ground.
- All "O" rings replaced with viton or equivalent.
- All relief valves, pilot-operated valves, sequence valves,
solenoid-operated valves, and pressure-reducing valves, one-half inch
and smaller, replaced with new valves. All other valves rebuilt or
replaced, if necessary, at additional charge.
- All cylinders disassembled and cleaned. Bore honed. If scoring is
excessive, replacement quoted.
- New piston rings, rod packing, rod guide bushing, and end-cap
- Cylinder rod inspected, checked for straightness, polished or
rechromed. Rod replaced if bent.
- Cylinders reassembled.
- Slow-down valve (if applicable) - cam-operated:
- Disassembled, cleaned, inspected for proper operation and/or wear.
- Reassembled with new seals. If wear is excessive, rebuilt.
- Telescopic tubes (if applicable):
- Inside tubes checked for straightness, polished/rechromed if
- Reassembled with new seals and bearings (or with hoses, at Tymac's
- Pressure piping/hoses:
- All piping removed, drained, and cleaned.
- All rust or scale/loose material removed.
- Inspected for wear or washout. Any pipe showing reduced wall
- All welded joints inspected for cracks, pin holes, etc..
- Reclamped or secured to machine as necessary.
- All flexible hose replaced with new.
- Pressure gauges:
- All functional gauges recalibrated.
- All defective gauges replaced. NOTE: Machine to have pressure
gauges in the following locations:
- Low pressure relief valve
- High pressure relief valve
- Shot pressure reducing relief valve
- Pilot pressure reducing relief valve
- All pumps rebuilt, except shot end pump (included with purchase of
Tymac shot end).
- Pump ratings fixed at appropriate level for intended service. Pumps
installed so as to facilitate normal maintenance activities.
- Pump relief valves to be solenoid-controlled with multiple relief
settings to facilitate energy conservation. NOTE: Relief valves to be
sized to match pumps:
- Relief valve 1 - 3-stage if applicable.
- Relief valve 2 - 3-stage if applicable.
- All hydraulic valves not replaced under 4.1.4 (Hydraulic System,
Manifolds) disassembled, cleaned, inspected. All valves rebuilt to
meet OEM specifications. All gaskets, seals, "O" rings etc.,
replaced with viton or equivalent. All rebuilt valves checked under
maximum system operating pressure for external and internal leakage.
- Any valve which does not meet OEM specifications replaced.
Five - Central Lubrication System
- All meter units replaced.
- All piping disassembled and cleaned, inside and out.
- All flexible hoses replaced.
- Pump reservoir cleaned and inspected. All seals replaced.
- Pump cleaned and new filter installed. Pump output tested.
- If pump is unserviceable, new pump quoted.
Six - Machine Base
- Inspected for cracks, and leveled:
- All cracks repaired.
- Base made straight and level.
- Leveling on site by Customer.
Seven - Electric Motor(s)
- Electric motors rebuilt as required:
- Installed so as to facilitate normal maintenance activities. NOTE:
Motor specifications to be determined by pump requirements.
Eight - Electrical System (Optional)
NOTE: Existing relay logic to be
replaced with Omron or A-B PLC controls. Electrical system design and
layout to be compatible with new Tymac end components, and to utilize existing
materials wherever possible.
- All existing relay logic removed.
- All machine wiring replaced:
- All rigid and flexible conduits cleaned and reused where possible.
- Operator station pedestal-mounted:
- Station cleaned, and components inspected and checked for proper
operation. Any defective components replaced.
- All nameplates replaced.
- All limit switches replaced as needed.
- All junction boxes cleaned and secured.
- Additional junction boxes and wiring provided as needed to meet
- Main electrical cabinet. NOTE: Where possible, all electrical
components to be grouped by function. For example, all power components.
Existing cabinet assessed for size and suitability. If new cabinet is
required, Customer to be consulted.
- PLC controller for die casting machine purchased and installed. Must
have enough capacity to control machine and to accomodate future output
signals for auto-ladle, sprayer and extractor (this equipment may be
self-controlled but will still need timing signals from the PLC):
- Programming requirements to be determined during electrical system
- PLC ladder and timing diagram to be provided to Customer upon
completion of the project.
Nine - Clamp Remanufacture
- Cross head and guide bars inspected for cracks:
- Guide bars inspected for roundness, straightness, and fatigue.
Replaced as needed.
- Guide bars inspected for cracks, and replaced if necessary.
Re-polished if needed.
- Fit of clamp cylinder checked. Reworked if necessary.
- All toggle links inspected for cracks.
- All bushing bores inspected and restored to OEM centers. Any bores
tapered/out-of-round, bored oversized and bushings installed:
- All bushings to be replaced with new.
- All bushings to be shrink-fit, not press-fit.
- Any galled faces to be repaired.
- Thrust washers installed where needed to maintain alignment.
- All link pins replaced or remanufactured as required.
- Tie bars checked for straightness, cracks, excessive nicks/high spots.
Length measured and compared with OEM specifications:
- Rework ring grooves as needed.
- Damaged tie bars replaced to OEM specs (at additional cost if required).
- Tie bars gun-drilled for tie bar strain reducers. NOTE: Optional, at
- Ejector bump plate resurfaced, or replaced at additional cost if
resurfacing would remove more than 1/4".
- Platen carriers and rails inspected for flatness and parallelism, and
replaced as needed:
- Rails reground and polished.
- Shoes reworked or replaced.
- All platens cleaned & machined, or ground flat & parallel, as required.
- All "T" slots cleaned & inspected, and re-machined as needed.
- Linkage mounting inspected, and machined flat & parallel as needed.
- All guide bushings replaced. Back-plate tie bar holes inspected, and
reworked as required.
- All bumper pin holes inspected. Any tapered or out-of-round holes
welded up and re-bored.
- Stationary platen welded and re-machined to accept shot heights and
Tymac shot end.
- Clamp reassembled, aligned square and parallel with base. Platen
carriers adjusted for proper bushing clearance.
Ten - Motorized Die Height System
Eleven - Tymac Tie Bar Strain Monitoring System (optional at additional cost)
- System to monitor strain on each tie bar and provide output when
out-of-tolerance condition occurs.
- Total clamp tonnage to be part of SPC data retained for each shot during
- Out-of-Tolerance conditions noted in SPC runoff data (Tymac RTU-9000).
- Requires gun-drilled tie bars option
Twelve - Machine Safety
- Operator-side safety door to be power-actuated at additional cost:
- Door operation selectable for manual or automatic mode.
- Shot safeties include:
- Full hydraulic system pressure on clamp cylinder.
- All guards in proper position.
- Low-pressure close:
- Machine to close under a selectable, low pressure until die faces
nearly touch. At this point full hydraulic pressure is applied.
- Safety rachet rebuilt as required.
- All guards repaired/replaced.
Thirteen - Assembly, Painting, and Runoff Testing
- Painted with Polane in Customer's requested color (custom colors at
- Runoff test to consist of 6-8 hours essentially continuous operation.
- Tymac RTU-9000/LCM-9000 monitor to track machine continuously during
Fourteen - NEW Tymac Shot End Installation
- Includes RTU-9000 Operator Terminal and LCM-9000 Data Acquisition &
Control Unit, for state-of-the-art monitoring.
- Includes Model SuperShot III Shot End with 6-phase (hot-chamber) or
7-phase (cold chamber) Real-Time Velocity Control, filtration system,
and a separate, adjustable, "Intensimax" Hydraulic