JH21-SERIES

C-FRAME FIXED TABLE PRESS

OPERATION
MANUAL

MACHINE NO.:

YANGZHOU METALFORMING MACHINE GROUP CO.,LTD.

THE PEOPLE’S REPUBLIC OF CHINA
 FOREWORDS

Forewords

For your selecting and purchasing the “ ” machinery，we feel gratefully .

It´s deeply believed that many technologies of YangZhou Metal forming machine
Group CO.,LTD , will sure to bring many beneficial help for your company.

△
! warning

z Please read this manual carefully before using the machine , please operate,
inspect, debug and maintain the machine following the proper procedures
as this manual guides. Especially after the installation, debugging and
maintaining of the machine must be made by the specialists who have
received special training.

z People who have not received special training or who are disqualified
could not operate this press machine.

z Our company will take no responsibility for the accidents and the troubles
due to ignoring the instructions in the manual.

z Please place this operation manual beside the machine, so as that the
operators can get a consult at any moment.

z If this machine will be transferred , please transfer this operation manual to

the new user at the same time.
 FOREWORDS

<<To operators who is going to use the machine>>

Everyone concerning with the machine must read this operation manual
carefully and understand fully.

<<IF you still have confusion after reading this manual>>

If you still have confusion or any further questions, please contact our service
department or technical department.
Please supply the message about the model, the tonnage, the manufacture date and
the machine number when inquired.

Tel: ++86-514-7849486

Fax: ++86-514-7849479

¾ Our products are improving unceasingly, If have some difference between the
instruction and the machine, Please subject to the machine .
 CATALOGUE

Catalogue
A. Safety

A For the notes, statute and warning of operating press

B. Specification
B For the technical data of the press

C. Installation

C For the preparation, transport, installation and debug of the

press

D. Operation

D For required tools, check daily, manipulation and replacing

moulds.

E. Maintenance

E For the regular check, lubrication and disposal failures.

F. Figure

F For all drawings

 A.SAFETYINSTRUCTION

A. SAFETY INSTRUCTION

1. Warning …………………………………………………………… 2

2. Safety procedures ………………………………………………… 3

3. Safety equipments ………………………………………………… 5

4. Safety notices ……………………………………………………… 7

5. Operations to prevent danger ……………………………………… 12

6. Warning labels …………………………………………………… 13

1
 A.SAFETYINSTRUCTION

1. Warning
z The dangers are classified in three degrees in this operation manual, and indicated
by the warning signs.

¾ △
! Danger in case of this condition, the operator will be severely harmed
even led to death.

¾ △
! Warning in case of this condition, the operator may be severely
harmed even led to death.

¾ △
! Notice in case of this condition, the operator may be mildly wound or
harmed.

Importance: Once the press machine happens as the above-mentioned situation,

the machine won’t keep out of damage!

△
! Warning
z We cannot enumerate all the warnings in the world, the warnings signed or
mentioned in the operation manual are only the lowest limit ones in the safety.
z Please abide and understand the warnings.

z In case that the operator or the press machine is harmed, due to the operator’s
ignoring of the warnings, our company will take no responsibility.

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 A.SAFETYINSTRUCTION

2. Safety procedures

△
! Warning
z The administrator, functionary, trainer for the mould and the repairer must abide
the law and regular of the safety law of labor, prevent to causing the danger.
z Our company will take no responsibility, if you do not abide the safety notice.

The press is suitable for many crafts, but the producing and technical department in
your company decides the production method. Our company does not understand your
special crafts or the safety device you hoped, so we advise your company regulate and
execute the safety device.
Please execute the notice strictly that our company have illustrated as following.

2.1 Administrator should do as follows:

(1) Should supply safety working circumstance, prevent the operator from dying or
being harm.
(2) Should install safety device to prevent the operator being harmed by the moving or
rotating components and spark.
(3) Should install and adjust safety device and forbidden to reconstructive or
disassemble the safety device.
(4) Should assign the functionary, trainer for moulds, operator and repairer, and the
repairer should have the maintain ability.
(5) Should bring up and educate the functionary, trainer, operator and repairer so that
they know how to operate the press machine.
(6) Should institute the brief with the danger of press machine, education of operation,
preparation, maintenance and bring up the administrator, functionary, trainer for
the mould and the repairer
(7) Should check whether the administrator, functionary, trainer for the mould and the
repairer understand the operation process , preparation process and maintenance
process.
(8) Should compile a operation manual as follows, and bring up the administrator,
functionary, trainer for the mould and the repairer, make them operate according
to the operation manual,
① assemble the moulds and try to press
② process
③ operate continuously
④ check daily and operate regularly
(9) Should institute the plan of checking press regularly, barrier and safety device,
besides, ensure the all components, accessory device and safety device should be
in the good working condition. Once there is any problem, please repair it at once,

3
 A.SAFETYINSTRUCTION

and make the repairing record.

(10) Should check the press machine once a week, and maintain, repair the press
machine before starting it.
(11) Should use the mould with safety design
(12) Should let the works know that if the press machine happens accident, they
should stop the machine at once, after settling the problems, than they can start the
machine. It is forbidden to open the machine before settling the problems.
(13) Should translate or interpret the necessary information to the worker who can not
read or understand the operation instruction
(14) Should fulfill other obligation according to the law and stature.

2.2 Functionary should do as follows:

(1) Should check the press carefully before starting it, and check the barrier and safety
device daily and regularly.
(2) Should stop the press machine, if there is any problem, then, inform the
administrators and repairer to settle it.
(3) Should keep the keys of press machine and safety device carefully.
(4) Should carry out the administrators’ order and assignment.

2.3 Trainer for mould and operator should do as follows:

Trainer: Should know how to assemble and train the moulds and below-mentioned
for the operator.

Operator: Should know the damage of press machine, the ways of the barrier, safety
device and the operation process, besides, you should check and maintain the press
machine.

2.4 The repair should do:

(1) Should check press machine, barrier and safety device regularly.
(2) Should stop the press machine immediately and repair it, if there is any problem.

4
 A.SAFETYINSTRUCTION

3. Safety device

3.1 Preventive dangerous

△
! Warning
z Before operate the press machine, the administrators should abide the items as
follows:
(1) The customer should design the safety device according to your company
required.
(2) Before installing decoiler, feeder and other automatic peripherals. it must taking
safety precautions
(3) The device is installed in front of the press machine, if you assign an assistant,
you should adopt necessary steps to prevent operator’s body entering into the
dangerous area.
(4) Should ensure the safety idea, barrier and safety device will not disturb producing.

3.2 Two-hand buttons

When you press the buttons by your hands, the slide starts.
When the slide move down, the operator loose his hands, so the slide stops at once.
There is a distance between the hands button and working area so that prevents the
hands entering into the working area.
When the width of working table is over 1300mm, the hands button do not have
function avoiding danger, therefore, you should install barrier and photo electric
protection device

△
! Warning
z It is forbidden to change the installation position.

z It is forbidden that the size of upper die is over the size of bottom slide, it will
cause body harm when the operator’s body enter into dangerous area.

3.3 Barrier (Optional equipment)

After closing barrier, it will prevent the operator’s hand entering into the working
area.
Besides, except “manual”, “inch”, if the barrier is not closed, the slide can not work
When the width of working table is less than 1300mm, the press can move singly by

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 A.SAFETYINSTRUCTION

hands button when the barrier is opened.

△
! Warning
z It is forbidden to run the press, when the barrier is on the invalid position by the
sensitive switch.
z It is easy to cause an accident, if looses the barrier’s protection.

z It should be replaced, if the plexiglass is cracked.

3.4 Photo electric protector

The photo electric protector can make the press emergency stop which the infrared is
shaded. When the photo electric protector is working, and the slide move singly or
continuously, once the infrared is shaded, the slide will stop at once.

△
! Warning
z It is forbidden to change the installtion position without permission.

z The size of upper mould should be less than the bottom size of slide. It is easy to
make body harm after the operator’s body entering into the dangerous area.
z Before working, the operator should check the photoelectric protector according
to the manual of the photo electric protector whether it is good or not.
z If the operator finds there is in problem, you should stop and repair the press
machine, however, if you ignore the problems, it will maybe make body harm.

3.5 Other auxiliary equipments

Although the following equipments do not belong to safety device, but the device can
prevent the operation mistakes.

3.5.1 Power switch

The power switch is used for cutting the power, when the switch is turn off and pull
out the key, it can make the slide and main motor stop.

3.5.2 Breaker
Turn off the breaker of electrical cabinet to off position, it can cut the current, when
open the electrical cabinet, please turn the breaker to “off” position.

3.5.3 Safety block

When the customer repairs the press machine, please be sure to put the safety block
on the working table, and keep the repairer and press machine safe.

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 A.SAFETYINSTRUCTION

4. Safety notice

4.1 Basic notice

△
! Warning
z It is forbidden to disassemble or reform the press machine and circuit without
permission.
z It is absolutely forbidden to disassemble or reform safety parts, do not have to
change the position of safety device without authorization.
z It is forbidden to operate the press machine in the case of exceeding its
specifications, and it is also forbidden to operate the press machine deviation
specification, otherwise, the safety device will not work normally, and maybe
cause an accident .
z It is forbidden to wear robe and accessory, which can be involved the press
machine, and make body harm. Besides, as the requirement, the operator should
wear safety helmet, protecting glass, safety shoes, gauze mask and gloves etc.
z The operator should be educated and trained safety knowledge.

z It is likely to make body harm if the operator do not know the danger of
operation press, or can not operate correctly.
z It should install, operate and maintain the press machine according to the
operation introduction.
z The customer owns the right of design, produce and usufruct of mould, and the
customer should adopt necessary safety device according to the danger of the
mould and causing by punching.
z The size of upper mould should be less than the bottom size of slide, otherwise,
it maybe make body harm.

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 A.SAFETYINSTRUCTION

4.2 Notice of installment

△
! Warning
z It needs expert to transport, hanger and install press machine. It should
commission special or our service department.
It will make body harm if make the common operator do these.
z It should be connected power by the technical with electrical qualifications
according to the electrical equipments technical standard.

△
! Notice
z The press machine should be installed workshop which there is enough working
lighting and work area.
z The temperature is between 5℃ and 40℃ in the workshop.
If the temperature is less than 5℃, it will cause lubricating badly.
If the temperature is over the 40℃, it will cause bearing and bushing being
damaged, and the function of clutch-brake being reduce.

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 A.SAFETYINSTRUCTION

4.3 Notice during operating

△
! Danger
z It is forbidden to touch the ejector rod, when the slide is moving or adjusted.

△
! Warning
z It is forbidden to run the press machine, when disassemble or open the shield of
flywheel, rotating parts and moving parts, otherwise, the operator’s body will be
involved the press machine and make great harm.
z It is forbidden to put the operator hands under the slide or in between the dies,
when the slide is moving or the press is training, otherwise, it will punch the
hand or other parts of body.
z It is forbidden to enter the body into the press machine during the slide being
moving.
z It is forbidden to run the press machine, when the photo electric protector is
turned off, otherwise, it will make body harm.
z It is forbidden to run the press, when the barrier’s keys are turned to “on”
position, otherwise, it will make body harm.
z It should manage the press and safety device’s keys, when the photo electric
protector is working.
z Before working, the customer should check the press. If find there is problem,
you’d better repair it, otherwise, it will make body harm.
z It should install safety device around the press and the operator to prevent the
waste metal and broken pieces from harming the operator’s body.
z Before start the press machine, there is no other people and any obstacle near it.
Besides, it is forbidden to put any tools on the working table to prevent from
harming the operator.

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 A.SAFETYINSTRUCTION

△
! Warning
z It should operate the press to do single movement with two hands. Besides, you
should install the photo electric protector or barrier, if you make single
movement by pedal.
z It should check whether the safety device is good firstly, when the customer use
outside operation patera. If the safety device is problem, the slide will move
without pressing the “running” button, which will make body harm.
z It is forbidden to operate the press machine exceeding the range of max.
connected times under single operating, otherwise, it will influence the clutch’s
function and will make body harm.
z The press can move singly or continuously, when the operator change the mould
or check the press.
z The barrier or safety device is under invalid condition when the press move
singly or continuously, it is easy to make body harm.
z It should press the two buttons by both hands, if you use other appliance or one
hand to start the press, the operator’s hand or other parts will enter into the
working area, it will make body harm.
z If there are many workers to operate the press machine, it should ensure every
worker if under safety condition during the press running, otherwise, it will make
body harm.
z It should press the “emergency stop” button to stop the slide, when the slide
makes problem, and then settle it under functionary’s instruction.

△
! Warning
z Please stop using, when the crank stops at a angle that more than 30°, you
should adjust and maintain it, or will bring accidents.

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 A.SAFETYINSTRUCTION

4.4 Notice during maintenance

△
! Warning
z It should check the press machine and safety device regularly.
The worker who adjust, operate and maintain electrical equipments should have
electrical qualification, otherwise, it is easy to get an electric shock and make body harm.
z It should cut off the power before open the electrical cabinet, otherwise, it is easy to get
an electric shock and make body harm.
z It should replace the safety device, which reaches its deadline. Besides, the wrong parts
should be replaced instead of repairing to prevent from making body harm.
z It should pay attention the operation’s safety, when check or clear the press machine.

z It should use safety ladder or stair plate to operate the press on the platform of 1.5m
height or above.
z It is forbidden to consider the press’s parts as platform. Besides, the operator should tie
safety belt to prevent him from falling from high above the ground.
z It should move the mould away the press when maintain the mould, otherwise, it is easy
to make body harm.

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 A.SAFETYINSTRUCTION

5. Operation avoiding danger

△
! Warning
z Before the operator operating, checking and maintaining the press machine,
the functionary should do as follows, besides, the operator should keep the
keys after pull it out, otherwise, it will make body harm.

(1) Press the “emergency stop”

button;
(2) Turn the “running” switch
to “off” position, then pull
out the keys;
(3) Turn the “power” switch to
“off” position, then pull out
the keys;
(4) Check the flywheel whether
stop rotating;
(5) Pull out the slotting of
safety piece, then insert the
safety piece between the
upper mould and bottom
mould;
(6) Turn the breaker to the
“off” position, then lock it;
(7) Cut off the power, and
check it, if it can not be
locked, you should hang the
warning label of “stop
operating”
(8) Chose the air outlet valve,
then lock it, and eject the
rest pressure, if it can not
be locked, you should hang
the warning label of “stop
operating”;
(9) Put the “stop running” on
the attractable position;

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 A.SAFETYINSTRUCTION

6. Warning label

△
! Warning
z The warning label record important information, so the operator should do as
follows:
(1) Abide by the contact of warning label;
(2) Forbidden to damage and stain the warning label;
(3) Forbidden to disassemble without authorization.

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 B. SPECIFICATION INSTRUCTION

B. SPECIFICATION
INSTRUCTION

1. Specifications ……………………………………………………… 2

2. Curve chart………………………………………………………… 9

3. Other sizes of the machine ………………………………………… 10

4. Major component names ………………………………………… 14

5. Important Notice ………………………………………………… 18

1
 B. SPECIFICATION INSTRUCTION

1. Specifications
1.1Technical Data
Specifications
Serial Names Unit
number JH21-25 JH21-45

L S L S
1 Nominal capacity KN 250 450

2 Nominal capacity stroke mm 2.8 3.2

3 Stroke of slide mm 80 50 100 70

Single 90 110 80 90
4 Strokes SPM
Variable 70-100 80-130 60-90 70-110
Max. permissible engaging number of
5 clutch in intermittent strokes(per minute) SPM 24 24
6 Max. Die set height mm 250 265 270 285

7 Die height adjustment mm 50 60

8 Distance between center of slide to mm 210 225

frame
9 Size of table(FB x LR) mm 400x700 440x810

10 Thickness of table mm 85 110

11 Distance from table to floor 755 780

12 Size of opening in table mm Φ100 Φ150

13 Bottom size of slide (FB x LR) mm 250x360 340x410

14 Hole for punch shank (diameter x

depth) mm Φ40x60 Φ50x60
15 Distance between uprights mm 450 500
16 Overall dimensions (LR x FB x H) mm 950x1350x2160 1080x1440x2300

single Y132S-6 3KW Y132S-4 5.5KW

17 Main motor KW
(power) Variable YCT160-4B 3KW YCT200-4A
5.5KW
18 Air pressure MPa 0.5 0.5

19 Total weight (approximately) KG 3100 3850

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 B. SPECIFICATION INSTRUCTION

Specifications
Serial Names Unit
number JH21-60 JH21-80

L S L S
1 Nominal capacity KN 600 800

2 Nominal capacity stroke mm 4 4.5

3 Stroke of slide mm 120 80 140 90

Single 70 90 60 80
4 Strokes SPM
Variable 50-80 60-100 40-75 50-90
Max. permissible engaging number of
5 clutch in intermittent strokes(per minute) SPM 24 24
6 Max. Die set height mm 300 320 320 345

7 Die height adjustment mm 70 80

8 Distance between center of slide to mm 270 290

frame
9 Size of table(FB x LR) mm 520x870 560x1000

10 Thickness of table mm 130 130

11 Distance from table to floor 830 830

12 Size of opening in table mm Φ150 Φ150

13 Bottom size of slide (FB x LR) mm 400x480 430x560

14 Hole for punch shank (diameter x

depth) mm Φ50x60 Φ60x80
15 Distance between uprights mm 560 590
16 Overall dimensions (LR x FB x H) mm 1200x1615x2570 1385x1915x2820

single Y132S-4 5.5KW Y132M-4 7.5KW

17 Main motor KW
(power) Variable YCT200-4B YCT200-4B
7.5KW 7.5KW
18 Air pressure MPa 0.5 0.5

19 Total weight (approximately) KG 5500 7500

3
 B. SPECIFICATION INSTRUCTION

Specifications
Serial Names Unit
number JH21-110 JH21-125

L S L S
1 Nominal capacity KN 1100 1250

2 Nominal capacity stroke mm 5 5

3 Stroke of slide mm 160 100 160 100

Single 60 80 55 70
4 Strokes SPM
Variable 35-70 45-80 35-65 45-80
Max. permissible engaging number of
5 clutch in intermittent strokes(per minute) SPM 24 24
6 Max. Die set height mm 350 380 370 400

7 Die height adjustment mm 90 90

8 Distance between center of slide to mm 350 370

frame
9 Size of table(FB x LR) mm 680x1090 720x1120

10 Thickness of table mm 160 160

11 Distance from table to floor 860 860

12 Size of opening in table mm Φ160 Φ160

13 Bottom size of slide (FB x LR) mm 520x620 520x620

14 Hole for punch shank (diameter x

depth) mm Φ70x80 Φ70x80
15 Distance between uprights mm 680 710
16 Overall dimensions (LR x FB x H) mm 1410x2200x3190 1450x2300x3220

single Y160M-4 11KW Y160M-4 11KW

17 Main motor KW
(power) Variable YCT225-4A YCT225-4B
11KW 15KW
18 Air pressure MPa 0.5 0.5

19 Total weight (approximately) KG 9830 12000

4
 B. SPECIFICATION INSTRUCTION

Specifications
Serial Names Unit
number JH21-160 JH21-200

L S L S
1 Nominal capacity KN 1600 2000

2 Nominal capacity stroke mm 6 6

3 Stroke of slide mm 180 110 200 130

Single 50 60 45 50
4 Strokes SPM
Variable 30-55 35-70 25-50 30-60
Max. permissible engaging number of
5 clutch in intermittent strokes(per minute) SPM 20 18
6 Max. Die set height mm 400 435 450 485

7 Die height adjustment mm 100 110

8 Distance between center of slide to mm 390 430

frame 760x1260
9 Size of table(FB x LR) mm 760x1170 840x1390

10 Thickness of table mm 165 200

11 Distance from table to floor 900 1000

12 Size of opening in table mm Φ180 Φ200

13 Bottom size of slide (FB x LR) mm 580x700 650x880

14 Hole for punch shank (diameter x

depth) mm Φ70x100 Φ70x100
15 Distance between uprights mm 720 900
16 Overall dimensions (LR x FB x H) mm 1515x2355x3250 1630x2690x3810

single Y160L-4 15KW Y160L-4 15KW

17 Main motor KW
(power) Variable YCT225-4B YCT250-4B
15KW 22KW
18 Air pressure MPa 0.5 0.5

19 Total weight (approximately) KG 13800 20000

5
 B. SPECIFICATION INSTRUCTION

Specifications
Serial Names Unit
number JH21-250 JH21-315

L S L S
1 Nominal capacity KN 2500 3150

2 Nominal capacity stroke mm 7 8

3 Stroke of slide mm 220 150 250 180

Single 40 45 35 35
4 Strokes SPM
Variable 25-45 30-50 25-40

Max. permissible engaging number of

5 clutch in intermittent strokes(per minute) SPM 18 16
6 Max. Die set height mm 500 535 550 585

7 Die height adjustment mm 110 120

8 Distance between center of slide to mm 450 480

frame
9 Size of table(FB x LR) mm 880x1580 940x1700

10 Thickness of table mm 200 200

11 Distance from table to floor 1150 1050

12 Size of opening in table mm Φ250 Φ250

13 Bottom size of slide (FB x LR) mm 700x930 720x1000

14 Hole for punch shank (diameter x

depth) mm Φ70x100 Φ70x100
15 Distance between uprights mm 950 1050
16 Overall dimensions (LR x FB x H) mm 1750x2830x3930 1950x3400x4100

single Y180L-4 22KW Y200L-4 30KW

17 Main motor KW
(power) Variable YCT280-4A YCT315-4A
30KW 37KW
18 Air pressure MPa 0.5 0.5

19 Total weight (approximately) KG 24000 34700

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 B. SPECIFICATION INSTRUCTION

Specifications
Serial Names Unit
number JH21-400

L S
1 Nominal capacity KN 4000

2 Nominal capacity stroke mm 8

3 Stroke of slide mm 250 180

Single 30 30
4 Strokes SPM
Variable 25-35
Max. permissible engaging number of
5 clutch in intermittent strokes(per minute) SPM 16
6 Max. Die set height mm 550 585

7 Die height adjustment mm 120

8 Distance between center of slide to mm 480

frame
9 Size of table(FB x LR) mm 940x1850

10 Thickness of table mm 200

11 Distance from table to floor 1050

12 Size of opening in table mm Φ250

13 Bottom size of slide (FB x LR) mm 720x1000

14 Hole for punch shank (diameter x

depth) mm Φ70x100
15 Distance between uprights mm 1050
16 Overall dimensions (LR x FB x H) mm 2200x3800X4300

single Y225S-4 37KW

17 Main motor KW
(power) Variable YCT315-4A 37KW

18 Air pressure MPa 0.5

19 Total weight (approximately) KG 43000

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 B. SPECIFICATION INSTRUCTION

1.2 Air cushion specifications(optional equipments)

Model Tonnage for air cushion(ton) Stokes for air cushion(mm)

JH21-25 1.2 40
JH21-45 1.8 50
JH21-60 3.8 60
JH21-80 6 70
JH21-110 8 80
JH21-125 8 80
JH21-160 11.5 90
JH21-200 12.5 100
JH21-250 13.5 110
JH21-315 19.5 120
JH21-400 19.5 120

¾ If the above specification can not meet your demand, please contact the service
department of our company.

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 B. SPECIFICATION INSTRUCTION

2. Curve chart
This page record the specifications in normal.

2.1 Pressure curve chart

ANGLE OF CRANK SHAFT

PRESSURE CURVE CHART

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 B. SPECIFICATION INSTRUCTION

3. Other sizes of the machine

3.1 T-slot size on the bottom of the slide

Parameter Bottom size of slide

Model A B C D E F G H A1
JH21-25 260 360 250 Φ40 18 12 32 30
JH21-45 300 410 340 Φ50 18 12 32 30
JH21-60 300 480 400 Φ50 22 18 40 38
JH21-80 300 560 430 Φ60 22 18 40 38
JH21-110 300 620 520 Φ70 22 18 40 38
JH21-125 300 620 520 Φ70 22 18 40 38
JH21-160 300 700 580 Φ70 28 20 56 46 500
JH21-200 350 880 650 Φ70 28 20 56 46 700
JH21-250 350 930 700 Φ70 28 20 56 46 700
JH21-315 350 1000 720 Φ70 28 20 56 46 700
JH21-400 350 1000 720 Φ70 28 20 56 46 700

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 B. SPECIFICATION INSTRUCTION

3.2 T-slot size on the table (without air cushion)

Parameter Size of table

Model A B C D E F G H A1
JH21-25 250 400 700 Φ100 18 12 32 30
JH21-45 300 440 810 Φ150 18 12 32 30
JH21-60 300 520 870 Φ150 22 18 40 38
JH21-80 300 560 1000 Φ150 22 18 40 38
JH21-110 220 680 1090 Φ160 22 18 40 38 520
JH21-125 220 720 1120 Φ160 22 18 40 38 520
JH21-160 300 760 1170 Φ180 28 20 56 46 600
JH21-200 350 840 1390 Φ200 28 20 56 46 700
JH21-250 350 880 1580 Φ250 28 20 56 46 700
JH21-315 350 940 1700 Φ250 28 20 56 46 700
JH21-400 350 940 1850 Φ250 28 20 56 46 700

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 B. SPECIFICATION INSTRUCTION

3.3 T-slot size of the table (with air cushion)

Model
Sizes JH21-60 JH21-80 JH21-110 JH21-125 JH21-160
A 300 300 220 220 300
BXC 520X870 560X1000 680X1090 720X1120 760X1170
A1 ---------- ----------- 520 520 600
D 24XΦ20 24XΦ20 24XΦ28 24XΦ28 24XΦ28
a×b 75×75 75×75 90×90 90×90 100×100
E 22 22 22 22 28
F 18 18 18 18 20
G 40 40 40 40 56
H 38 38 38 38 46

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 B. SPECIFICATION INSTRUCTION

Model
Sizes JH21-200 JH21-250 JH21-315 JH21-400
A 350 350 350 350
BXC 840X1390 880X1580 940X1700 940X1850
A1 700 700 700 700
D 35XΦ28 35XΦ28 35XΦ28 35XΦ28
a×b 100×100 100×100 100×100 100×100
E 28 28 28 28
F 20 20 20 20
G 56 56 56 56
H 46 46 46 46

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 B. SPECIFICATION INSTRUCTION

3.4 Foundation plan for the machine

Parameter The sizes of foundation

Model A B a1 b1 H h1 F
JH21-25 1320 1110 860 700 600 450 70
JH21-45 1410 1150 950 750 600 450 70
JH21-60 1600 1260 1120 840 700 550 90
JH21-80 1800 1480 1280 980 700 550 145
JH21-110 2090 1560 1560 1040 950 800 140
JH21-125 2225 1590 1645 1070 950 800 145
JH21-160 2320 1660 1690 1140 950 800 130
JH21-200 2590 1880 2020 1360 950 800 205
JH21-250 2850 2080 2150 1480 950 800 220

Parameter The sizes of foundation

Model m1 m2 d K C D MCXL
JH21-25 200 200 4 24 200 560 M24X400
JH21-45 200 200 4 24 200 560 M24X400
JH21-60 200 200 4 24 200 640 M24X500
JH21-80 200 200 4 24 200 760 M24X500
JH21-110 200 200 4 30 200 800 M30X800
JH21-125 200 200 4 30 200 800 M30X800
JH21-160 200 200 4 36 230 900 M36X800
JH21-200 200 200 4 36 250 1220 M36X800
JH21-250 200 200 4 36 250 1220 M36X800

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 B. SPECIFICATION INSTRUCTION

Parameter The sizes of foundation

Model A B a b a/2 F
JH21-315 3200 2400 2430 1600 1215 260
JH21-400 3250 2450 2470 1650 1235 275

Parameter The sizes of foundation

Model H h1 m1 m2 d K MCXL
JH21-315 950 800 200 200 6 42 M42X800
JH21-400 950 800 200 200 6 42 M42X800

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 B. SPECIFICATION INSTRUCTION

4. Major component names

16
 B. SPECIFICATION INSTRUCTION

17
 B. SPECIFICATION INSTRUCTION

5. Important notice

Important
● Before use the machine, the workers must pay attention as follows,
(1) the machine must be used in the pressing capacity, exceeding the range
could damage the slide、the connecting rod、the crank shaft、the frame
etc.
(2) the machine must be used in the range of pressure curve charts ,
exceeding the range could damage the driving parts of the slide and the
clutch-brake.
(3) The machine must be used in the range of working force, exceeding the
range could damage the main motor.

z The pressing machine is suitable for metal sheet cold processing, please pay
attention to the pressure capacity, the torque, the working force and Max. permissible
engaging number of clutch in intermittent strokes(per minute), exceeding the range is
not allowed.
z Notice：this press machine can be used for bending ,lower drawing ,punching and
so on, but not suitable for incuseding .

5.1 Pressure capacity

Pressure capacity means the ability of the press mechanism to safety sustaining the
maximum pressure allowed.
Because the working load can be effected by thickness of material, tensile strength ,
die lubrication or abrasion ,please leave some extra pressing force.
Especially when doing punching or cutting, there exist an additional impact
load ,therefore ,the pressure should be kept under the 60% nominal capacity and 70%
nominal capacity.
Besides, The pressure capacity is measured by the load equally distributed over the
central 60% of the total bolster area. Therefore, avoid the load being concentrated on
a smaller area.

When there is no choice of the load being over-concentrated or of its deviation

from the center, please contact the technical department of our company.

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 B. SPECIFICATION INSTRUCTION

5.2 Torque capacity

Torque capacity means the capacity that is required to produce pressure at the
tonnage rating point between the initial point of nominal capacity and the bottom dead
center

5.3 Pressure curve chart

Pressure curve chart shows the relation between the bottom dead center and torque
capacity

5.4 Working force

Working capacity means the maximum tonnage released in one processing
operation.
Working force will be effected by the capacity of the flywheel and the output power
of main motor.

5.5 Max.permissible engaging number of clutch in intermittent

strokes(per minute)
Max. permissible engaging number of clutch in intermittent strokes (per minute)
refers to the numbers of the stroke to be allowed per minute by single ,inching,
manual. If exceed this range, the clutch will be easy to be damaged.

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 C.INSTALLATION INSTRUCTION

C. INSTALLATION
INSTRUCTION

1. Preparation ……………………………………………………… 2

2. Transport and installation ……………………………………… 4

3. Air-supply ……………………………………………………… 5

4. Power-supply …………………………………………………… 6

5. Oil-supply ……………………………………………………… 7

6. Inspection after installation …………………………………… 8

1
 C.INSTALLATION INSTRUCTION

1. Preparation
1.1 Foundation

Importance
z Before planning the foundation, you are sure to consider carrying capacity of the
foundation.
z The foundation, which press machine will be installed, should be reinforced by
some steel bolts, the whole-concrete foundation will be easy to rupture.

(1) The foundation should be constructed according to the foundation plan our
company submitted.
(2) If the foundation is too soft, some reinforcing steel should be used to strengthen.
(3) Please refer to the weight of press in our catalogue.

1.2 The position of padding-plate

1.2.1 Using foundation bolts

Please refer the diagram of foundation bolts installation.
Before the press machine arrives at the customer’s company, you should do
preparation as follows:
(1) Put the padding-plate on the determined place, according to the foundation plan.
(2) Screw the bolts into the padding-plate.
(3) Adjust the precision of padding-plate.

The horizontal precision ＜0.5mm/1000mm

The height difference between padding-plates ＜3mm

(4) Grout un-shrink mortar under the padding-plates, be sure that the mortar is
adhesive to the padding-plate.
(5) Confirm the horizontal precision of padding-plates again.

1.2.2 Using anti-shock pads

Please refer the 1.3.2

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 C.INSTALLATION INSTRUCTION

1.3 Pre-installation

1.3.1 Using foundation bolts

(1) Pull out the foundation bolts.
(2) Cut off the adjustable bolts on the padding-plates, be sure that the height of
adjustable bolts is lower than the surface of padding-plates.

The diagram of foundation bolts installation

①foundation bolts ②rubber ③padding-plate ④adjustable bolts ⑤the base of press
machine ⑥un-shrink mortar ⑦un-shrink mortar ⑧un-shrink mortar for installation
⑨concrete

1.3.2 Using anti-shock pads

(1) Please lay the anti-shock pads
or make concrete. The
difference height between four
pads is less than 4mm
(2) Put the padding-plates on the
concrete.

① Anti-shock pad device

② Washer
③ Screw
④ Bolt

The diagram of anti-shock device installation

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 C.INSTALLATION INSTRUCTION

2. Transport and installation

Importance
Make sure to install the foundation bolts vertically, otherwise, the bolts will be not
tightened or cause being broken.

2.1 Using foundation bolts

Please refer the diagram of foundation bolts installation.
(1) Clear the antirust grease by the mineral oil, and clear the base of the press
machine.
(2) Install the press on the determined place.
(3) Install the washer and nuts on the foundation bolts.
(4) Put rubbers between the foundation bolts and padding-plates, and adjust the
precision (﹤0.03mm/1m)
(5) Grout the un-shrink mortars, please pay attention to prevent the foundation bolts
from inclining.
(6) After the mortars solidifying, tighten the nuts.
(7) Check the installation precision again.
(8) Pile up the mortars on the base of press to cover the spacers.

2.2 Using anti-shock pads device

(1) Clear the antirust grease by the mineral oil.
(2) Install the anti-shock pads on the determined place, and disassemble the bolts of
anti-shock pads device.
(3) Put the press on the anti-shock pads.
(4) Tighten the disassembled bolts of anti-shock device.
(5) Adjust the horizontal precision of working table( to reach ﹤0.03mm/1m).
(6) Tighten the nuts enough.
(7) Check the installation precision again.
(8) It should prepare to prevent the press from moving when it is punching.

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 C.INSTALLATION INSTRUCTION

3. Air-supply

△
! Notice
z Please supply clear and dry compressed air. If you use the air with waste and
water, it will cause valves damaged, and the air tank will be rusted.
z Please take the air consumption into consideration, according to press machine
and automatic devices.
z If the compressed air consumption is not enough, the press will be abnormal.

3.1 Air connection

(1) Turn off the air cuting
valve, and be connected
to your company’s air
tube,then supply the
compressed air which the
pressure is 0.5-0.7MPa.
(2) If the distance is over
5m from air source to
press machine, the
diameter of pipe should
be up to G3/4.

3.2 Air consumption

Mould JH21-25 ~ JH21-125 JH21-160 ~ JH21-400

Quantity of the air(L/min) 10L per set of machine 15L per set of machine
Air pipe(mm) φ12×φ10 requested

¾ Quantity of the air means the sum of air supply for the clutch in intermittent strokes
and the wastage for blow equipment, but the air for other equipment is not
included.

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 C.INSTALLATION INSTRUCTION

4. Power-supply

Importance
z Once connect L1, L2, L3 wrongly, the main motor will rotate inversely.
z If the press is controlled by frequency transformer, even connect L1, L2, L3
wrongly, the flywheel will not inversely, but the other motor will rotate inversely.

4.1 Connect power and wire

(1) Please refer the Item 4.2 of Chapter A to operate the press machine.
(2) Prepare a power switch for the press. If the press is controlled by the frequency
transformer, the customer should adopt breaker which is suitable for frequency
transformer to prevent from being harmed.
(3) Please turn off the power and then connect the terminal with the power.
(4) The customer should connect the terminal with the power, please connect L1, L2,
L3 correctly.
(5) The customer should connect the terminal with ground wire.

4.2 The capacity of electrical wire

The power of main motor (kW) 5.5 7.5 11 15 22 30 37

Supply voltage 220V Current (A) 25 30 45 60 80 120 140
Ground wire 4 4 6 10 16 25 30
(mm2)
Supply voltage 440V Current (A) 11.6 15.4 21.6 30.3 42.5 56.8 69.8
Ground wire 2.5 2.5 4 6 10 10 16
(mm2)
The capacity of breaker According to the electrical diagram records

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 C.INSTALLATION INSTRUCTION

5. Oil-supply

△
! Notice
z Pour into lubrication oil, hydraulic oil and grease, then run the press, otherwise,
the press will be damaged.
z The customer should adopt necessary measurement to prevent from causing
emergency, leak oil and fire.
z The customer should clean the leaked oil, sometimes, it will lead to damage.
z The customer should pour the oil into the gear box, using safety ladder or stair
plate. It is forbidden to take some high parts as table or ladder, the customer also
should tie safety belt to prevent from dropping.

Please prepare the lubrication oil or grease according to the kinds of lubricant,
quantity refer to Item 2.2 of Chapter E

Supply position Methods of supplying lubricant

Gear box Disassemble the gearbox cover on the top of frame; pour the
pure oil, which height should be reach to the half of the
gauge.
Connecting part of Disassemble the plug on the worm-cover inside slide; pour
slide the pure oil, which height should reach the worm and gear.
Manual pump Open the pump cover, pour the pure oil, which the height
should reach the upper limit of pump.
Automatic pump Pour00# lithium lubrication with special tool.

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 C.INSTALLATION INSTRUCTION

6. Check after installation

Item Methods of adjustment Remedy

1. Check oil-supply Check the oil gauges
Gearbox Check the gauges, then
Connecting part of slide operate the manual pump
Manual pump for 10 cycles.
Connecting rod
Overload protector
Clutch-brake
Auto lubrication pump
2. Check air-supply Within the Air pressure is determined
Turn on the valves slowly, pre-determined range at 0.5-0.7Mpa
check the gauges whether
it reach the predetermined
pressure
3. Check power-supply Check optically Connect the ground wire.
Whether the ground wire Check the power source
is connected?
Whether the voltage is
correct?
Whether the pilot lamps
are light?

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 D.OPERATION INSTRUCTION

D. OPERATION INSTRUCTION

1. Operation ……………………………………………………………2

2. Running………………………………………………………………6

3. Adjustment …………………………………………………………9

4. Settle abnormal condition ………………………………………… 11

1
 D.OPERATION INSTRUCTION

1. Operation
The diagram is standard ordonnance diagram. Our company can decide to change the
position of ordonnance according to the customer’s requirement.

1.1 Main control interface

2
 D.OPERATION INSTRUCTION

1.2 Two-hand buttons’ cabinet

1.3 Function and operation instruction

1.3.1 Main control interface

z Indicator for crank angle ·Angle of crank
·0°the top dead center
·180°the bottom dead center
z Power light (white) ·The power is put through, the light will be
lighting. It indicates that the control circuit and
motor power are on-state.
z Prepare light (green) ·When the light is on, the customer can press the
“ Two-hand starting ” button, the slide can start.
z The top dead light (white) ·When the slide is stopping at the top dead, the light
is on
z Main motor light (green) ·When the main motor is running, the light will be
green.
z Overload light (red) ·If the light is on, the press is overloaded

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 D.OPERATION INSTRUCTION

z Lubrication trouble button (red) ·When the lubrication is in trouble, the light
is on
z Main motor start button (green) ·When press the button of main motor, the
alternating contractor is engaged, the main
motor will start.
z Reset button(blue) ·When press the button at TDC, it will reset or
cancel the trouble.
z Lubrication ·There are three grades of lubrication time
and period.
·The functionary should keep the key
carefully.
z Main motor stop (red) ·When press the stop button of main motor,
the alternating contractor is disengaged,
the main motor will stop.
z Counter · Once the press runs a stroke, the counter
will work one time.
z Ejector ·Once the press runs a stroke, the ejector will
flow one time.
z Control power · Once turns on the control power, the control
interface and buttons’ cabinet can be operated.
Besides, the lubrication pump starts to lubricate.
z Counter reset (blue) ·Once press the button, the counter resets “0”.

z Speed invertor ·Adjust the speed of slide.

1.3.2 Two-hand buttons’ cabinet

z Two-hand button (black) ·Press two buttons by both hands

z Emergency stop button (red) ·During the press machine being running,
once the customer press the button, the slide
stops at once.
z Hand/foot change switch ·Optional accessory

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 D.OPERATION INSTRUCTION

z CONT pre-set button (green) ·Turn the switch to “CONT” position, press this
button, the light is on, press the “two-hand
running” button by both hands, after three
seconds, the light will go out, and then loosen
both hands, the slide will move continuously.
z Stroke-stop button(red) ·While the press moving continuously, once press
this button, the slide will stop at the top dead.
z Slide adjust ·Turn the “slide adjust” button to “on” position,
the slide can be adjusted, and the press cannot
punch.
z Slide up (red) ·Turn the “slide adjust” button to “on” position,
once press this button, the slide moves up at once.
z Slide down (red) ·Turn the “slide adjust” button to “on” position,
once press this button, the slide moves down at
once.
z Foot switch socket ·Optional accessory

z Joint box ·When buttons cabinet is fixed, it is a metal joint.

·When buttons cabinet is movable, it is a socket.

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 D.OPERATION INSTRUCTION

2. Running

△
! Notice
z It is forbidden to punch steel by the “inch” mode. If the clutch is not engaged
completely, it will damage the clutch.
z Before running the press, the customer should prepare procedures following the
Chapter C.
z Before starting or having run for eight hours, you should check the press
machine according to Item 2.2 of Chapter D.
z During operation, once there is abnormal sound,, smell and other situation, you
should stop operating at once, and then check and repair.
z If the press machine has been stopped running for over twenty-four hours, the
customer should check it as follows in order to avoid an accident.
1) Check and operate according to Item 2.2 of Chapter D
2) The press should be firstly trial-run for five minutes, and then the customer
can operate it.
z If the press machine has been stopped running for over one week, the customer
should do as follows,
1) Check and operate according to Item 2.2 of Chapter D, but you should pay
attention to the items as follows.
① Operate the grease pump ten times
② Turn on and off the control power four or five times with interval of 20
seconds
2) Check the press every month.
3) Disassemble the mould, run the press machine for thirty minutes, and check
whether there is abnormal sound, heat and shock and so on.

Before running and operating, be sure to understand Chapter A, if the customer install
photo electric protector, you should read the operation instruction carefully.

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 D.OPERATION INSTRUCTION

2.1 Check before operating

Following as belows:
1) Check “inch” running, please confirm that slide is moved when the customer
press the “two-hand start” button by two hands, stopped once two hands is loose.
2) Check whether the crankshaft, flywheel, slide, connecting rod and adjustable
screw is loose.
3) Check the function of the single stroke
When running the press by single, press the start button by both hands ,if the
angle ranges between 0 and 180 degrees ,loosen the button it will stops at
once ,if the angle ranges between 180 and 360 degrees ,it will stops at the top
dead center
4) Check the function of the emergency stop button
Please confirm that the slide can emergency stop when press the emergency
button during running.
5) Check the function of safety devices
A. Barrier
Please confirm that the hands of the workers can not enter into working area
after the barrier is closed.
B. Photo-electrical safety curtain
Please confirm that the slide will stop moving when the curtain is warded off.
C. Two-hand button
Please confirm that the slide can not move if you have not pressed two buttons
at the same time
6) Check the mould and others
Please confirm that there are not any tools and goods on the table or inside the
mould.

2.2 Check daily and running operation

The item with ☆ must be done by idiographic functionary.

z Clean the press and ground.

z ☆Please check whether all kinds of lubrication reach lower limit, if not, you
should inject lubrication oil. Besides, you should check whether there is oil
leak.
z Manual pump should operated for five times.
z Should check whether there is garbage on the filter.
Once there is dirty, the customer should clean the filter and we suggest the
customer should clean it every week.
z Open the drain valve

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 D.OPERATION INSTRUCTION

Please check by sound method whether there is air leak with pneumatic device.
z ☆Should ensure the pressure of clutch is within the regular limits and the
pressure of balance cylinder is fit for the weight of upper moulds.
z Should ensure there is no water in air pipe. And the customer should also check
the air compressor whether there is water.
z ☆It should have been connected to the electricity supply , and turn breaker to the
“on” position, and the indicator light of “power” should be light.
z ☆It is forbid to pull out the key when the key insert into the switch of control
power and turn it right.
z ☆The customer should make function test of solenoid valve.

z ☆The customer should turn the “emergency” to reset position, and then press the
“emergency”, but the “emergency” button is still on previous condition.
z ☆The customer should check the exhausting voice whether is ringing and
muffler exhaust continuously by pressing two buttons of press run and then loose
them.
z The customer should press the button of “main motor”, and check whether the
indicator light of main motor is light.
z ☆The customer should adjust the strokes without overload referring to the
operation instruction.
There is an arrow at the back of the press machine, which indicate the rotating
direction of flywheel. Besides, the customer should check whether the V-belts skid
and shock abnormally.

2.2 Operate after finishing

The item with ☆ must be done by idiographic functionary
The customer should operate as followings, if the press machine stops running or
the press machine finish punching.
z ☆The customer should pull out the key, when you insert the key into the
running switch, and put it on “OFF” position .
z The customer should press the button of “main motor stop” to stop running .
z ☆The customer should cut off the power and pull out the key.
z The customer should cut off the supply power.
z The customer should drain the water in the every air pipe and in the air
compressor.
z The customer should close the air valve.

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 D.OPERATION INSTRUCTION

z The customer should check whether the mechanism is damaged and the belt is
loose.
z The customer should tidy and clear the press and the ground.
3. Adjustment

△
! Warning
z If the press machine is equipped the ejector, you should adjust the ejector to the
top position or discharge the ejector before rising the slide.
z Because once knockout bar touches the ejector, the press will be damaged or
make an accident

Importance
z Slide adjustment device is forbid to do other things except adjusting the slide .
z The slide adjustment device is not able to press the upper and bottom moulds.
z It will cause the motor being heat and damaging the adjusting part, if the
customer presses the upper and bottom moulds by the adjusting slide.

The shut height of mould is the distance from the bottom of slide to the top of
working table during the slide stopping on the bottom dead center.

3.1 Adjust slide (manual)

z The slide will stop if the customer turns the “’slide adjust” to the “on”
position.
z The slide will move up or down, when the customer presses the “slide up” or
“slide down”. Once the customer looses it, the slide will stop. Besides, the
adjusting slide has maximum. and minimum.
z After adjusting, please turn off the adjusting slide.
3.2 Adjust knockout bar

△
! Danger
z It is forbidden to touch the ejector when the slide is moving or adjust the slide,
otherwise, the operator’s hands will be harmed.
z The customer can adjust the ejector when the slide stops on the top dead.

A. Loose the bolts of the knockout base.

9
 D.OPERATION INSTRUCTION

B. There is a certain distance about 10mm

between the knockout bar and ejector.

C. Tighten the loosen bolts.

10
 D.OPERATION INSTRUCTION

4. Eliminate abnormal condition

△
! Notice
z It should eliminate abnormal condition under the functionary’s
direction.
z It should check the reason of slide stopping, and solve it
z It should operate the electrical part by the electrical quality
technician. Or please contact the service department of our
company

1.1 Trouble and solution

Trouble Possible Cause Solution

It can not run by inch, (1) Is the LED of input port 06,07,08) (1) Check whether
ingle and continuous is on? the circuit is loose or
modes Yes; continuous check broken, if yes, please
No: check the input signal replace the switch
(2) Is the LED of input port within 0.2
seconds 011.100) is on? (2) Check whether
Yes: continuous check the circuit of switch is
No: check the input signal loose, if yes, please
(3) Is the LED of input port replace it
1104.1106) is on ? (3) Adjust the clutch
Yes: check the clutch according to the
No: continuous check manual of clutch.
(4) Is the LED of input port (4) Check whether
(1001.1004) is on? the overload is
Yes: continuous check exceed, the pressure
No: check the PC controller is low, lubrication is
problem.
(5) Check the PC
controller.
Emergency can not (1) The button is in trouble. (1) Replace.
work (2) The circuit is in trouble. (2) Check whether
(3) The auxiliary relay is in trouble. the circuit is loose
(4) The PC controller is in trouble. or broken.
(3) Replace.
(4) Check the PC
controller.

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 D.OPERATION INSTRUCTION

Trouble Possible Cause Solution

Press run can not work (1) Is the LED of input (1) Check the left and
port within 0.2 right switch or
seconds 011.100) is replace.
on?
Yes: continuous check
No: check the left and
right switch
(1) PC controller is in (2) Repair by expert.
trouble
Single is not work (1) Adjust the angle of cam (1) Adjust properly.
inadequately (2) Replace.
(2) The switch of cam is
damaged.
Stopping position is not on (1) Adjusting the angle of (1) Adjust properly.
the top dead center cam is not properly.
(2) Brake friction is worn (2) Replace
in the long-term.
Emergency stop is invalid (1) The circuit is loose or (1) check and tighten the
or emergency stop can not broken. screw up.
reset (2)The switch is in trouble. (2) Replace.
(3) PC controller is in (3) Repair by expert.
trouble.
The adjusting slide by (1) Heat protector protects (1)Reset the heat protector.
electricity is invalid. the protector switch of
motor. (2)Check.
(2) Reach the range of
upper and lower limit. (3)Turn to the “on”
(3) The switch of adjusting position.
slide does not turn to
the “raise or drop ” (4)Check.
position.
(4) Adjusting pressure of (5)Replace.
balancer is disproperly.
(5)Electromagnetic (6)Check the circuit and
contractor is in trouble. electrical material and
(6) The circuit is in check the driving
trouble. sprocket.
(7)The button or (7)Replace.
changeable switch is in
trouble.

12
 D.OPERATION INSTRUCTION

Trouble Possible Cause Solution

The pressure is too high, (1)There is problem (1)Adjust properly.
so the slide stop a certain between the cam and
position switch.
(2)The switch of cam is in (2)Replace.
trouble.
(3)There is problem (3)Adjust properly.
between the wrench and
the switch.
The slide adjust can not be (1)The electromagnetic (1)Replace.
stopped. switch can not be reset.
(2)The circuit is in trouble. (2)Check the circuit.
The man motor can not run (1)The circuit of main (1)Check and tighten the
smoothly. motor is loose or circuit and connect the
broken. circuit.
(2)Heat relay is protected (2)Press the button of heat
or broken. relay and replace the
(3)The button of starting heat relay.
or stopping are broken. (3)Replace.
(4)The contractor is
broken. (4)Replace.
The counter can not work (1)the counter switch does (1)Turn to the “on”
not turn to the “onr” position.
position.
(2)The switch of cam is (2)Replace the switch.
trouble.
(3)The counter is (3)Repair and replace.
damaged.
The light of run (1)The electric bulb is (1)Replace.
preparation is broken damaged.
(2)The pressure is not (2)Check whether the
enough. pressure is leak.
(3)The pressure is too (3)Set the pressure
2
high. 4-5.5kg/cm
(4)The switch of pressure (4)Replace.
is damaged.
(5)The emergency button (5) Reset emergency
can not be reset. button.

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 D.OPERATION INSTRUCTION

4.2 During residual current circuit breaker working

When the residual current circuit breaker is working, the slide will emergent stop ,
and the light of power is light, now please stop punching and investigate the cause
1) Operate and check the press according to the section 5 on the Chapter A
except No.8.
2) Open the door of control disc.
3) Hoist the handle of current leakage breaker to the “ON” position.
4) Close the door of control disc.
5) Operate the press according to No.8 of section 5 on the Chapter A.

4.3 During the heat relay tripped out

Importance
z It is prohibited to adjust rated amperage without permission
z It is prohibited to start and stop motor frequently ,other wise ,the heat relay
will trip out

The slide will emergency stop ,when the heat relay of main motor is tripping out,
please operate according to the followings
1) Press the button of “main motor stop” to stop the press running
2) Please operate and check the press according to the section 5 on the chapterA
except NO.8
3) Open the door of control disc
4) Press the reset button of heat relay ,when you listen to the sound of
“KAKA”. the relay has been reset
5) Close the door of control disc
6) Operate the press according to NO.8 of section on chapter A

7) If the heat relay trips out again ,the machinery parts may be in trouble ,you
should stop punching ,then check

¾ If you can not know the reason ,please contact service department of our company

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 E.MAINTENANCE INSTRUCTION

E. MAINTENANCE
INSTRUCTION

1.Regular checks …………………………………………………… 2

2. Oil supply …………………………………………………… 8

3. Mechanical maintenance …………………………………………12

4. Maintenance of clutch ……………………………………………15

5. Maintenance of pneumatic and hydraulic devices …………………17

6. Electrical maintenance ……………………………………………28

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 E.MAINTENANCE INSTRUCTION

1. Regular checks
z Inspection before operating and daily inspection
z The belowed regular inspection items are minimum items to guarantee long-term
security usage of the pressing machine , Please increase inspection items according to
the situation of your company
z Regular inspection of oil (oil-supply and oil-change),please inspect according to
maintenance instruction (chapter E 2.2)
z The inspectors must inspect the items regularly, please inspect according to safety
instruction (chapter A 4.4), after inspection the inspectors would take certain
corresponding measurement into effect.

1.1 Inspection items of per month (250hours)

If you find any trouble, must solve it in time.

Inspection items Solution

1. Inspect if the plastic vessel of
filter is broken or not Replace
2. Inspect V-type belt
(1) If the tension is within the (1) Adjust tension
set-up range (2) Replace
(2)Whether it is cracked or
damaged
3. Inspect the solenoid valve of
the clutch
(1) If the loop has the abnormal (1)(3) Please contact service department
sound of our company
(2) If the exhaust pipe has (2) Replace
damaged
(3) If water or oil flow out from
the exhaust pipe
(4) The function test by monitor
4. Inspect the air power pump of
hydraulic overload protector
whether it can hear the sound of Please contact service department of our
pump without load every thirty company
minutes to two hours
5. Please inspect the buttons and
switches (1)Please clear the buttons 、 switches
(1) Without any waste or any oil and its surrounding part ,make sure
(2) Throw over switch or button that you can see the sign clearly
is normal (2 ) (3) Replace
(3) Without any damage

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 E.MAINTENANCE INSTRUCTION

Inspection items Solution

6.Please inspect the residual
current circuit breaker Please contact service department of our
(1)press the test button ,stops on company
OFF position
7.Inspect the relay
(1) No shake
(2) If the contact point and loop (1)(2)(3)(6)(7) Please contact the
has burnt service department of our company
(3) The crust has damaged (4) Tighten it up
(4)The fixed position of the (5) Replace
screw becomes loose
(5)Whether it will reach life span
soon
(6)The pin department is not
crooked
(7)the department that welds
does not have welding
8.Check electric wires for
movable parts and sockets of
electric wires outside the move Replace
button station
(1) If the insulating barrier has
been damaged
(2) If the electric wires have been
damaged
9.Checking the guardrail
(1) The screw has become
flexible (1)(2) Tighten it up
(2)Whether the ability of the (3) Please contact the service
atmospheric pressure spring has department of our company
dropped
(30 the wire clip has become
flexible
10.The filter (in the side of the
filter) and the core of the Clear or replace
filter are blocked
11.Whether air cleaner for the
fan in the electric box has Clear or replace
damaged

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 E.MAINTENANCE INSTRUCTION

1.2 Midyear checks and maintenance are effective for 1,500 working

hours per six months

If you find any question , solve it in time

Inspection items Solution

1. Inspect the instruments
(1) Crank angle instrument shows (1)(2) Please contact service
180 degrees when the slide stop at the department of our company
bottom dead center (3) Replace
(2) The shut height of die is the same
as the actual observed value
(3) Pressure gauge
After exhausting completely,
whether
the indicator turn to zero
2.Determine the insulation resistance
normal insulation value Please contact the service department
of our company

3.Inspect whether the solenoid valve Please contact service department of

leaks air our company
it does not leak air when the solenoid
valve was connected

4.Inspect the life-span of electrical

parts
whether electric parts will reach life Replace
span soon

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 E.MAINTENANCE INSTRUCTION

1.3 Annual checks and maintenance are effective for no longer than

3,000 working hours per day

Inspect all the items every month and half a year
If you find any question, must solve it in time

Inspection items Solution

1.Inspect the slide guide clearance Please contact service department of
Inspect if the guide clearance is our company
within standard range

2.Change oil groove of gear case ,

lubricating oil for clutch , pontes of Replace
slide

3.Inspect the strokes of clutch Please contact service department of

Inspect if the strokes is within our company
standard range
4.Inspect the rubber hose of moving
element Replace
the rubber has damaged
5.Inspect the installation accuracy Please contact service department of
of the press machine our company
if the levels for the table is not
correct
6.Replace the paper of filter
and the core of the filter Replace

7.Inspect the solenoid valve outside clutch

The same solution as the solenoid valve of clutch

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 E.MAINTENANCE INSTRUCTION

1.4 Inspection items for three years (overhaul)

After a three-year usage of the machine, you must perform all-around inspection and
maintenance

1.4.1 General inspection and maintenance

The following inspection and maintenance need to disassemble the press machine, please
contact service department of our company
(1) Inspect and adjust the accuracy of the press machine.
(2) Inspect and maintain the ball seat ,adjust screws, worm and chain
(3) Inspect and maintain the drive shaft , other shafts ,tooth surface of
the gear, clearance of the gear.
(4) Inspect and maintain the slide guide rail , bearing and the slide unit so on .
(5) Inspect the seal ring , 0-type ring and so on
(6) Inspect the clutch-brake

1.4.2 Replace the rubber hose and the electric wires.

(1) The rubber hose is installed between the solenoid valve and flywheel ,it must be
replaced once every three years whether it has damaged or not
(2)The rubber hose of moving element and the material for electric wires will become older,
it must be replaced every five years whether it has damaged or not.

¾ For the specification of the accessories、hardware and standard component

please contact service department of our company

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 E.MAINTENANCE INSTRUCTION

1.5 Inspection and maintenance for ambient device of the machines

Please maintain and inspect the ambient device regularly.

For the content of inspection and maintenance, you can consult the instruction

If the following devices are not inspected and maintained in time ,it will cause the accident
or damage the machine.
If you find any question , you must solve it in time .
If you want to inspect and maintain other devices except the followings, please consult the
instruction

Names Regular inspection and maintenance

Per Per Per Three Half A Three
day week month months a year year years
1 Main motor ● ● ● ● ● ●
2 Disk motor ● ●
3 Convertor ●
4 VS controller ●
5 Photo safety ● ● ● ● ● ●
device
6 Die clamp ● ● ● ● ●
7 Quick retooling ● ● ● ● ●
device

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 E.MAINTENANCE INSTRUCTION

2. Supply oil
Please according to the notice of the safety instruction

△
! Caution
z It is Forbidden to use other grease except the No.00.
Or it will damage the moveable parts of press machine.
z It must use the stated grease, it is forbidden to use different kinds of grease.
Or it will lose the lubrication function and damage the moveable parts of
press machine
z In order to use the lubrication oil, hydraulic transmission oil 、grease safely,
you should accept the safety data chart that the manufacturer recommend,
according to the requirements, you should adopt correlative steps. Especially,
you shall pay attention to the emergency, fire and leakage oil and so on.
z Use various oils must be carefully, protect glasses, glove must be used.
Especially the oil that the press machine was just used is often in high
temperature .it may cause the accident if you are not careful, please operate
after it cools.
z If finding metal slice, metal powder or other matters interfuse into the
replaced oil, please contact service department of our company. the internal
part may be damaged.
z It should be wiped away immediately after the oil has flown out, if it flows
into the control parts, it is easy to cause moving mistakes of control parts

2.1 Clear
Clear is a means that prevent the old oil or other matters mixing into the new oil when
replacing the oil.
Please operate as follows when replacing the oil.
When clearing the clutch-brake, after giving enough oil, start main motor, make the
flywheel rotate for twenty to thirty minutes. Then drain out the oil (suit the wet clutch)
(1) Before supplying the new oil, drain out the other matters and dirty oil by injecting the
new oil, clearing the oil –injection device outside oil pump
(2) After discharging the dirty oil, you shall inject the same kind washing oil. And run the
circulated hydraulic device for 20~30 minutes, and clear the interior.
(3)You do not supply the oil until clear the pump

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 E.MAINTENANCE INSTRUCTION

2.2 The types and amount of lubrication oil

The time table of changing the oil is based on the principle of working eight hours every
day .if the actual time exceeds eight hours every day, the time table of changing the oil
must be shortened according to working hours. if working hours is less than eight hours, oil
changing should be made according to the time table of eight hours working

Please lubricate to slide department, screw and chain in time, If the peripheral equipment’s
lubricating is not recorded in the following chart, please consult the operation instruction.

Quantum
Oil position Oil kind JH21-25 JH21-80 JH21-160 JH21 JH21 JH21 Time
JH21-45 JH21-110 JH21-200 -250 -315 -400
JH21-60 JH21-125
Gear box 320#gear Each
oil 20L 45L 70L 105L 135L 150L year,first
time is
three months
Worm and ISO VG 3L Every year
worm wheel 100
Connecting ISO VG 0.1L Every day
rod screw 100
Overloading 32# 4L Semiannally
protection hydrauli
c oil
Mannual pump ISO VG 68 1L Add it when
used out
Thick oil 00#lithi 1.5L Add it when
pump um used out
grease
Alkene Normal 0.1g～0.2g Semiannally
grease
Cylinder Normal 0.4g～0.5g Every month
grease
Wet clutch 6＃or8＃ 3L～8L 适量注入 Refer to
hydrauli Pg.15
c oil
Motor Refer to the motor instruction

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 E.MAINTENANCE INSTRUCTION

2.3 Lubrication position

The following chart shows the normal place of supplying the oil ,it can be changed
according to the special requirements of your company

① Balance cylinder oil inlet Add oil every day

② Gear box oil gauge Check oil daily
③ Overload protector oil tank Change oil once half a year
④ Connecting rod screw oil inlet Add oil every day
⑤ Worm and worm-wheel oil inlet Add grease once three months
⑥ Slide oil outlet Clean up once half a year
⑦ Gear box oil inlet Change oil once half a year
⑧ Gear box oil outlet
⑨ Chains for adjusting the slide Spread grease once half a year
⑩ Air source processing unit Drain water and check oil daily
○
11 Fly wheel Add oil once one month

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 E.MAINTENANCE INSTRUCTION

2.4 Lubrication method

(1) Gear box
Change the oil once a year , remove the gate valve below the gear box ,drain out
all oil in it, then lift the top cover for the frame and fill in cleansing oil up to the
marked line on the left side of the frame .
(2) Worm and worm gear
Change the oil every six months, remove oil plug on the right of the slide ,drain
out all oil in it and cover it ,remove the inlet plug of spherical cover board and fill
in the stated oil .
(3)Connecting rod thread
Refuel every day, inject the cleaning oil from the pouring orifice by oil gun
(4)Hydraulic overload protector device
Change the oil every six months , remove the oil plug on the bottom of the oil
tank ,drain out all the oil in it ,then screw on .then remove the oil plug on the top of
the oil tank and fill in the clean oil and cover it
(5) Manual oil pump
Open the cover on the top ,inject into the thin oil ,then close it .
(6) Grease pump
Forbid using the butter except 00# lithium based grease ,inject into the oil from
pouring orifice by oil gun .
(7)Chain
Grease on the chains with a brush once three months
(8)The bar of the balancing cylinders
Inject the oil once a month ,when the machine stop at the bottom dead
centre ,brushing on the bar of the balancing cylinders directly.

(9)Clutch (wet clutch)

After changing oil for the first time ,it must be changed once when single action use
for 15000 times or continuing action use for 25000 times ,it must be changed once
when use per for 150 million to 200 million times , Make oil drain to the lowest
position when changing the oil, put off oil plug and air exhausting plug ,drain out
the oil in flywheel and make oil drain in the highest position, inject stipulated oil,
until oil reach the oil scale reticle ,screw on oil plug and air exhaust plug .

(10)Main motor
Consult the instruction for main motor

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 E.MAINTENANCE INSTRUCTION

3. Mechanical parts maintenance

Please refer to the notice of safety instruction to maintain machinery parts

3.1 Determine the clearance of slide guide

Importance
z When the measured value for guide clearance deviates from the
appropriate value, please contract the service department of our
company ,adjust the clearance or check precision after adjusting
z If disregard adjustment and continue operating the press machine, it may
affect precision of the products and life-span of the mould, it will
probably cause the slide-guide rail is locked .

1.Debus the die from press machine, make the slide stop on the bottom dead center
2.Execute the introduction as the five point of Chapter A except the NO.8.
3.Determine the clearance from 1 to 6 by gap gauge, there is very small clearance guide
when the gap gauge is inserted above 30mm ,it should supply grease fully after
determining it .

¾ The appropriate clearance :each clearance is under 0.07mm

Opposite clearance and (①add②,④add⑤,③add⑥) :0.03～0.14mm

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 E.MAINTENANCE INSTRUCTION

3.2 Adjust the tension of V-type belt

(1) Please perform preventing

operations according to part 5 of
safety instruction
(2) Check if the tension of v-type
belt is normal
Press the center point of every V-type
belt with the strength of F(refer
to the following chart), the
vertical length of V-belt is 16mm
for 1m, which indicate the
tension is normal.

MOULD LOAD (F)

JH21-25~JH21-160 About 27N
JH21-200~JH21-400 About 20N

(3) If the tension is abnormal, you shall

adjust it.
Loosen the tight bolts ②and the
tight nuts ④ on the four
position, rotate the adjustable bolts
evenly, and strain the V-belt by raising
the motor so that reach the height.
(4) After adjusting, daub the
LOCKTITL NO.242 on the tight
bolts and tight nuts, and then tighten
the tight bolts up.

¾ This motor in the right picture may be don’t like the actual.
¾ Remark: We advise that use a pressure machain to mensurate the tensile force ,please
contact with sell parment of the beltseller or our company.

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 E.MAINTENANCE INSTRUCTION

3.3 Replace the V-shape belts

△
! Warning
● Replace the belts on your own is strictly prohibited
It needs special technologies , then the belts must be replaced by service
department of our company
It needs debus the clutch when replacing the belts ,therefore ,if replaced
by other personnel in place of the service department of our company ,it
may cause trouble to clutch

Importance
● All the old belts must be replaced at the same time
The V-belts with the same nominal length, but the actual length maybe is
different. So you shall measure the actual size, and use the V-belts with
same length.
It will cause stretch and tension asymmetrically, reduce the durability,
when mixing the old belts with the mew ones or using different length
belt .
● It is forbidden that V-type belt touches soil or other matters from the
V-type trench of flywheel, or it will cause slipping
● After three days running, the V-belts will be matched with V oil slots.
Therefore, after the running, belt tension should be reexamined and
regulated once again.
● The spare belts should be put in the cool and drying place

Replace the belts according to the following procedures.

(1) Please operate according to the notice of safety instruction
(2) Loosen the belts according to 3.2 the procedure of adjustment tension
(3) Disassemble the arm board between clutch and frame, and disassemble the rubber
hose between clutch and solenoid valve.
(4) Replace the new belts
(5) Install the rubber hose and the arm board of clutch
(6) Adjust the belts tension according to the 3.2 procedure of adjustment tension.

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 E.MAINTENANCE INSTRUCTION

4. Clutch and brake maintenance

Standard equipment :
JH21-25～JH21-125 DG series clutches(DING JIE COMPANY)
JH21-160～JH21-400 KB series clutches (ITALY OMPI)
JH21-25～JH21-250 can choose wet clutch passably
It may be changed with the requirement of the customer

4.1 Usage and maintenance of (DG series clutches)

(1) It should often be lubricated on the place where the dowel pin cooperated with the
board , in order to friction disc can move smoothly.
(2) Check if the atomized lubricator is normal, guarantee that the seals will be sprayed the
oil .keep lubricating ,prevent unlubricated friction, so as to prolong the life to the
seals ,reduce leaking airs .
(3) The clearance of friction disks must be adjusted in time, when the clutch works for a
while（two or three months ,due to the friction disks will be worn naturally , the
clearance will be increased . Brake effect will decrease gradually , the best clearance is
between 0.7mm and 1.5mm,after two or three months ,the junction plane between
friction disk and resist combination will become well .

4.2 Usage and maintenance of( KB series clutches )

(1) Contact Yang Zhou metal forming machine for the disassembly the clutch brake, never
take the device apart on your own, the manufacturer take no responsibility for
accident .if find the quality problems, please contact the service department of our
company .
(2) The friction disks of clutch will be worn when the machine worked for a while ,it must
be replaced when the friction disks have weared out badly
(3) When connection time for clutch exceeds 0.02 second , and can not reach the rated
ability of clutch-brake ,you should check the friction disks in time .when the friction
exceed the rated level, the user must contact service department of our company in
time .

4.3 Usage and maintenance of (wet clutch)

(1) Before the machine leaves the factory ,the displacement of the clutch cylinder has been
adjusted, when the displacement increase sharply ,the user should contact our service
department and should not take apart the flywheel without permission
(2) During normal usage, the following situations should be carefully noticed :
(a) The clutch sounds abnormal
(b) The clutch cylinder leaks air or the back of the flywheel leaks oil
(c) When the slide stops ,brake angle is so big or the slide does not stop at top dead

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 E.MAINTENANCE INSTRUCTION

centre

4.4 The trouble and solution of clutch

Trouble Cause solution
The clutch is too The clearance of friction disk is too small Adjust the clearance
heat
The friction disk is worn or there is oil in it Replace the friction disk
Brake slips Brake springs are damaged Replace the springs
There are other matters in the double solenoid Clear or replace it
valve
The friction disk is worn or there is oil in it
Replace the friction disk
Slip when The air course is blocked Check the air course
clutching Air pressure is not enough Check air pressure
The seal is damaged Replace the seal
Brake angle is too The friction disk is worn, then the clearance is
Adjust the clearance of friction
big too big disk
Abnormal noise The clearance between the pin and lining is too Replace the pin and the lining,
when the clutch big the gap must be controlled
runs without load The problem does not affect the usage above 0.2mm,it will affect the
normal usage for the clutch if
the gas is too small
Abnormal noise The clearance between the pin and lining is too Replace the pin and the lining,
when the clutch small, the gap must be controlled
working Which leads the problem that the base above 0.2mm
plate unable to move normally, cause the Install the pin of the clutch
base plate to embrace again

4.5 Clutch standard fitting chart

Press
JH21-25 JH21-45 JH21-60 JH21-80 JH21-110 JH21-125
Model
Clutch
DG1 DG1 DG2 DG4 DG5 DG5
Model

Press
JH21-160 JH21-200 JH21-250 JH21-315 JH21-400
Model
Clutch
KB600-6 KB800-3 KB800-9 KB1200-6 KB1200-1
Model

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 E.MAINTENANCE INSTRUCTION

5. Maintain pneumatic and hydraulic device

Maintain pneumatic and hydraulic device, please operate according to the notice of safety
instruction

5.1 Air filter

△
! Caution
● If there is a great amount of water in it , it is necessary to install the drier in the
source of air , guarantee to supply the dry air .
If you use the moist air, solenoid valve will make wrong actions, it may rust in
the cylinder, and it may cause an accident.

5.1.1 Specifications

Model AF40-04
Pneumatic test pressure 1.5MPa
Extreme service 1.0 MPa
pressure
Environment and fluid
-5-60°C
temperature
Filtration precision 5μm
Material Polycarbonate
Manufacturer SMC

5.1.2 Structure
Please refer to the chart in right.

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 E.MAINTENANCE INSTRUCTION

5.1.3 Drain water by manual

Press the drain water button on the bottom of filter by hands and drain the water

5.1.4 Clear interior and the replacing method

Please refers to 5.1.2 in last page

Importance
z Cup components ⑤ are plastic products, when washing with the organic
solvent (dilution, alcohol) ,it will cause crack and chaos ,and it might cause air
leakage

(1) Stop the air source, drain out residual pressure of the machine .
(2) Press the drain water button on the bottom of filter by instrument, then drains water and
residual pressure
(3) Press the lock button, does not loose, rotate the cup components and protecting cover
(4) Then pull to the underside, debus the cup components and the covers of cup
components
(5) Debus the core of the filters and mangers
(6) Put the core of the filters into the kerosene for five to ten minutes, then clear it with
neutral detergent, and dry it
(7) Clear mangers with neutral detergent
(8) Install the components which is cleared or replaced
(9) It must be sure that the lock button is locked, before the air source has been connected

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 E.MAINTENANCE INSTRUCTION

5.2 Atomized lubricator

△
! Caution
● Oil level must be within the upper and lower scales in the oil cup ,if exceed the
upper limit, atomized lubricator may be unable to work normally, so it must
inject lubrication oil in time

5.2.1 Specifications

Model AF40-04
Pneumatic test pressure 1.5MPa
Extreme service pressure 1.0 MPa
Environment and fluid temperature
-5-60°C
Oil type ISO VG 32
Material Polycarbonate
Manufacturer SMC

5.2.2 Structure
Please refer to the chart in the next page

5.2.3 Inject oil

The atomized lubricator can inject oil without stopping air, when it needs to inject oil,
screw off the oil plug, the pressure of oil level drops to the atmospheric pressure, the steel
balls of seat valve and the steel balls of one way valve all pressed on its own valve seat, it
has blocked the inlet of air piping, now you can inject the oil from oil inlet, after lubricating,
then tighten the oil plug up, because there are some small grooves on the seat valve,
compressed air can reach the oil cup by the groove leaks ,make the pressure rise
constantly ,until the steel balls are pushed away from the seat valves , the atomized
lubricator will work normally again .

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 E.MAINTENANCE INSTRUCTION

Atomized lubricator
1-Ligulate valve groupware 2-Ligulate valve 3-window 4-Oil-dripting 5-Oil filler plug
6-Appliance 7-O-ring 8-Oil cup 9-Cover 10-Oil grip cannulation 11-Seat valve
12-Single-line valve 13-Reduce valve

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 E.MAINTENANCE INSTRUCTION

5.3 Automatic grease pump

Importance
● It is forbidden to open the
cover of pump, or it will
interfuse air and rubbish,
besides , you shall fill the
grease up to the upper limit of
oil gage. The operator shall
often fill the grease properly in
order to prevent from lubricating insufficiently. If the grease is interfused
air and dust, it will cause lubricating improperly, the bearing and guide are
too heat, and damage them.
● It is forbidden to adjust the flooding valve. Otherwise, the lubrication
pressure will be changed, the cause the lubrication improper, result in the
bearing and guide is too heat, and damage them.

5.3.1 Specifications

Model SK-505BM-1
Tank capacity 1L
Nominal pressure 14.7Mpa
Nominal flow rate 13ml/min
manufacturer IHI
Applicable grease 00#

5.3.2 The method of injecting grease

No.00# grease must be injected before reaching the lower limit of oil gauge
Open the grease inlet, the grease must be injected to the upper limit by grease gun or grease
box

5.3.3 The method of exhausting air

If a great amount of air mixed into the lubricating oil, it will cause the problem that the oil
separator cannot work, then the press machine cannot work normally, open the exhaust
valve, switch on electric source, make automatic pump operate and drain air fully, close
exhaust valve until lubricating oil can flow out properly

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 E.MAINTENANCE INSTRUCTION

5.3.4 The cause of the trouble and solution

NO. Trouble Cause Solution

1. The motor ●The wires is not connected ●Replace the wires

can not run ●There are other matters in ●Clear the matters
the place of plunger
● Fueling relay could not ●Check the relay and circuit
work normally

2. Oil leaks Main pipeline and others has Replace it or lock it

been ruptured
●There is no lubricating oil ●Inject lubricating oil, press the
3. When you in the pumping main motor start button
press the ●The type of lubricating oil ●Choose NO.00# lithium based
main motor is wrong grease
start button, ●There is plenty of air in ●Open the screw of pumping
detector pumping inlet , make the pumping
switch is operate and drain air fully,
abnormal until lubricating oil can flow
out properly
●The distributor is blocked , ● Check the instruction
stick ,disassemble the outlet
connection of distributor ,if
the butter can not pour
out ,then the distributor is
blocked, replace the
distributor
●The plunger is locked ●Replace the distributor
● The lubrication point is ●Clear the inlet of lubrication
blocked point
●The plug of pumping is ●Replace the pumping ,use the
worn clean lubricating oil
● Detector switch is ● Detect by ammeter ,if it is
damaged damaged ,please replace it

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 E.MAINTENANCE INSTRUCTION

5.4 Manual pump

Manual oil pump is chiefly used for balancing cylinder and other optional equipments

Importance
●When the handle action feels too heavy ,it is generally believed that oil sill
pipe is damaged or oil separator is blocked , repair it immediately
If you ignore it, it will cause the damage to the slide parts

5.4.1 Specifications

Model L-8L
Nominal delivery 2-7ml/CY
capacity
Nominal capacity 0.5Mpa
Volume for tank 0.8L
Applicable oil Thin oil
Manufacturer YONGJIA

5.4.2 Inject lubricating oil by manual pump

Lubricating oil must be injected before it has fallen to the lower limit
Open the cover of the pump, the lubricating oil must be injected to the upper limit

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 E.MAINTENANCE INSTRUCTION

5.5 Hydraulic overload protection device

Hydraulic overload protection device is chiefly used to prevent the damage when the press
machine exceeds the workload capacity.

△
! Warning
● Parameters of hydraulic overload pump are adjusted well before the
machine leaves the factory ,it is forbidden to adjust the pressure
adjustment screw, the manufacturer take no responsibility for accident .

5.5.1 Fundamental circuit

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 E.MAINTENANCE INSTRUCTION

5.5.2 Operation sequence of overload protection device

The press machine

starts working
↓
Overload

↓
Overload protection device starts working, the slide
tank pressure drops, the indicator light is on(red),the
press machine will promptly stops working ,connect
the electrical source ,cut off the air source of overload
protection pump ,the travel switch starts working
↓
Make the slide moves to the top dead center by inching
mode, solenoid valve is broken , connect the air
passage ,hydraulic overload pump will start working

↓
the slide tank pressure reaches the setup
pressure , the travel switch starts
working
↓
Exclude the cause of overload, press
the reset button, the indicator light is
off (red)
↓
The press machines has
finished preparation works

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5.5.3 Oil tank capacity

The oil tank capacity is 3.8L,after supply the slide with lubricating oil , the residual
lubricating oil in the tank should exceed the lower limit ,when all the lubricating oil for
slide tank has come back to the tank ,the tank should have 20% remainder

5.5.4 Eliminate air in hydraulic overload pump.

a) The oil in the tank must reach the upper limit
b) Inject the compressed air from air supply inlet, make the hydraulic overload pump
start working
c) Loosen the air outlet plug, tighten it up after ten seconds
d) The compressed air rising to the stated pressure
e)When the pressure in the slide tank will rise .the hydraulic overload pump stops
working , then finished exhausting air.
f) If the pressure in the slide tank can not rise ,please do c-e again

5.5.5 Travel switch adjustment

Loosen exhaust valve ,stop supplying air, it should leave 0.5mm between screw of
sinker bar and contact point of travel switch ,use the gauge to confirm ,it may through
the set screw to the end ,then return to semi circle ,.locks it with the locknut

26
 E.MAINTENANCE INSTRUCTION

5.5.6 The trouble and solution

NO TROUBLE CAUSE SOLUTION

·No air supply ·Supply air according to stated pressure

Hydraulic ·The pressure of air supply is less than 2kgf/cm ·Supply air according to stated pressure
1. overload pump ·The solenoid can not work normally · Replace it
can not work ·The piston is locked · Loosen the set screw of hydraulic
overload pump ,if it still can not work
normally ,disassemble hydraulic
overload pump and clear foreign
matters

Hydraulic ·The type of hydraulic oil is wrong ·Use the ISO V32 hydraulic oil
overload pump ·The oil in the tank is less than hydraulic lower limit ·Inject the oil
can work, but ·Exhaust air is insufficient ·Exhaust air
the pressure ·The pipeline for sucking oil leaks air ·Tighten it up
2 does not rise ·The filter is blocked ·Clear it
·There are foreign matters in the one way valve, or does not ·Clear it or replace it
seal
Hydraulic ·The work oil is unclean ,it will cause the problem that the ·Clear or replace the work oil
overload pump one way valve ,drain valve ,overflow valve have foreign
3 can work, the matters ,and do not seal
pressure raise, ·It is damaged to sealing surface of one way valve ,drain ·Replace it
but the hydraulic valve ,overflow valve, so it does not seal
overload pump ·Exhaust valve is not tightened up or the seal ring is ·Tighten it up or replace the seal ring
does not stop damaged
·Drain valve has become flexible or the seal ring is damaged ·Adjust seal ring or replace it
·Pipeline or slide cylinder leaks oil ·Repair

The pressing ·The travel switch is wrong ·Confirm it and revise it

machine does ·The position of the travel switch is wrong ·Adjust it again
4 not operate or ·The contact point of travel switch is damaged ·Replace the switch
the alarm signal
is abnormal
When unloading that · the position of adjustment screw is wrong ·adjust it again
the actual · the external circuit is abnormal ·check the circuit
5 atmosphere
pressure is not
accordance with
computed value

27
 E.MAINTENANCE INSTRUCTION

6. Electrical parts maintenance

Maintain electrical parts, please operate according to the regulation of safety
instruction

△
! Caution
z After replacing the parts, carry out the daily inspection. it should be
confirmed that there is no anomaly after the test run ,then start operating
again
z When increasing induction loads, you must take some measures to prevent
noise
z When maintaining electrical parts ,you should try to avoid soiling them with
the rubbish、oil and water

z Besides, except the position where maintaining the inside of control disk ,the
door of the control disk must be closed .
z When electrical parts has soiled with the rubbish、oil and water, it will affect
the life-span or make wrong actions

6.1 Determine with megohmmeter (determine insulation resistance)

△
! Caution
z It is forbidden to determine the megohmmeter under the conditions that the
electrical device and terminal have been connected

z Megohmmeter checks, electrical parts maintenance, it must be performed by

a qualified personnel

For example

A. Please operate according to the notice of safety instruction

B. Debus grounding wires of transformer
C. The ground plate in the control disk must be connected to the earth plate of
megohmmeter. the other should be connected to the terminal of control circuit(4)
② determine it
When the result is above 5MΩ,it is normal value
If the result is less than 5MΩ,please contact the service department of our
company

28
 E.MAINTENANCE INSTRUCTION

6.2 Life –span for electrical parts

Before the life-span has been reached ,it must be replaced ,even it is running
well ,when it was replaced , the parts must used the same form, model and
manufacturer products
It need special technologies to replace the solenoid valve, please contact service
department of our company

The life –span will vary with the circumstance and frequency

Names Manufacturer Life time

Electromagnetic switch Schneider Five years

Relief relay OMRON two years
Terminal relay OMRON two years
Button Schneider Five years
Limit switch DELIXI Five years
Solenoid valve of clutch TACO,ROSE Five years

29
 E.MAINTENANCE INSTRUCTION

6.3 The residual current circuit breaker checks

△
! Danger
z When inspecting the residual current circuit breaker, it is forbidden to touch
the inside of control disk except the residual current circuit breaker, if not,
it will cause an accident

A. Press the test button①

B. Confirm that the residual current circuit breaker make the following operations
·Leak electricity showing button ② jumps out 、convex
·Handle ③ moves to the middle position

C. Confirm that the residual current circuit breaker make the following operations
·Press the handle to the OFF position ,and then put the handle to ON position
·The action will make button into concave , the residual current circuit breaker
has finished a reset
D. After pressing the test button that the residual current circuit breaker still does
not operate , you ought to stop operation and investigate the cause .
When the cause is unknown ,please contact service department of our company

30
 E.MAINTENANCE INSTRUCTION

6.4 Electrical diagrams

△
! Danger
z It is forbidden to amend the circuit diagrams and disassemble it without
permission
z If you amend the circuit diagrams and disassemble it without permission,it
will cause a serious accident .our company take no responsibility for it
z When the pressing machine arrived, if you need amend the circuit
diagrams,please contact the service department of our company

The following diagrams

Please consult from the next page

31
 Type JH21-60 JH21-80 JH21-110 JH21-160 JH21-200 JH21-250 JH21-315 JH21-400
Model JH21-125
O-Ring-1 149.3X5.7 169.3X5.7 174.3X5.7 199.3X5.7 219.3X5.7 219.3X5.7 229.3X5.7 299.3X5.7
O-Ring-2 249.3X5.7 259.3X5.7 289.3X5.7 314.6X8.4 354.6X8.4 374.6X8.4 444X8 470X6
O-Ring-3 179.3X5.7 189.3X5.7 209.6X8.4 244.6X8.4 244.6X8.4 289.6X8.4 354.6X8.4 384.6X8.4
 MODEL JH21-25 JH21-45 JH21-60 JH21-80 JH21-110
O-Ring-1 15.8×2.4 15.8×2.4 17.8×2.4 17.8×2.4 29.4×3.1
O-Ring-2 64.4×3.1 74.4×3.1 84.4×3.1 104.4×3.1 144.4×3.1
Seal-1 60×70×6 70×80×6 80×90×6 95×110×9 136×150×8.5
Seal-2 20×28×5 20×28×5 20×28×5 20×28×5 35×45×6

MODEL JH21-160 JH21-200 JH21-250 JH21-315 JH21-400

O-Ring-1 29.4×3.1 25.7×3.5 25.7×3.5 25.7×3.5 29.4×3.1
O-Ring-2 149.3×5.7 169.3×5.7 189.3×5.7 209.3×5.7 239.3×5.7
Seal-1 145×160×9 165×180×9.5 180×200×12 200×220×12 230×250×12
Seal-2 35×45×6 35×45×6 35×45×6 35×45×6 40×50×6
 CERTIFICATE OF INSPECTION
FOR
JH21-SERIES C-FRAME FIXDE TABLE PRESS

MACHINE NO.:

YANGZHOU METALFORMING MACHINE GROUP CO.,LTD.

PEOPLE’S REPUBLIC OF CHINA
This machine has been tested and
found qualified for dispatch.

Inspector:
Inspection chief:
Date:
 CERTIFICATE OF INSPECTION

NOTES FOR MACHINE ACCURACY TEST

NO. Test to Sketch Tolerance(mm) Testing

≤630KN ＞630KN
be value

applied
Flatness of 100:0.01
top surface
of bolster
1

Flatness of 100:0.01
bottom
surface of
slide
2

Parallelis a: a:
m of 100:0.015 100:0.02
bottom
surface of b: b:
3 slide with 100:0.02 100:0.03
top
surface of
bolster The front of the slide is
a: L-R to incline downward
b: F-B
 CERTIFICATE OF INSPECTION

NOTES FOR MACHINE ACCURACY TEST

NO Test to Sketch Tolerance(mm) Testing

≤630KN ＞630KN
. be value

applied
4 Verticality a) and b)
of shank 100:0.05
hole with Note:100 is the
bottom extended length
surface of the testing rod

5 Verticality a) and b) a) and b)

of slide 100:0.03 100:0.04
stroke
with top
surface of
bolster
a: L-R
b: F-B
 PACKING LIST
FOR
JH21-SERIES C-FRAME FIXED TABLE PRESS

MACHINE NO.:

YANGZHOU METALFORMING MACHINE GROUP CO.,LTD.

PEOPLE’S REPUBLIC OF CHINA
 PACKING LIST JH21-25-ZD Page：1

Serial No.

Dimensions of packing box（L×W×H）：950×1350×2160

Item Name Specification Quantity

1 Press :Model JH21-25 250KN 1 set
2 Foundation bolts(Include nuts and washers) M24×400 4 pcs
3 Spanner 55 1 pcs
4 UHS-ring UHS020 20×28×5 2 pcs
5 UHS-ring UHS060A 60×70×6 2 pcs
6 O-ring P95 94.6×5.7 1 pcs
7 Fuser RT23-16/6A 380V 2 pcs
8 Fuser RT23-16/4A 220V 2 pcs
9 Operation instruction 1 copy
10 Certificate of inspection 1 copy
11 Packing list 1 copy
12 Manual of programmable controller 1 copy
13 Manual of cam controller 1 copy
14 Manual of electrical oil pump 1 copy
15 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-45-ZD Page：2

Serial No.

Dimensions of packing box（L×W×H）：1080×1440×2300

Item Name Specification Quantity

1 Press :Model JH21-45 450KN 1 set
2 Foundation bolts(Include nuts and washers) M24×400 4 pcs
3 UHS-ring UHS020 20×28×5 2 pcs
4 UHS-ring UHS060A 60×70×6 2 pcs
5 O-ring P130 129.6×5.7 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-60-ZD Page：3

Serial No.

Dimensions of packing box（L×W×H）：1200×1615×2570

Item Name Specification Quantity

1 Press :Model JH21-60 600KN 1 set
2 Foundation bolts(Include nuts and washers) M24×500 4 pcs
3 UHS-ring UHS020 20×28×5 2 pcs
4 UHS-ring UHS080 80×90×6 2 pcs
5 O-ring G180 179.3×5.7 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-80-ZD Page：4

Serial No.

Dimensions of packing box（L×W×H）：1385×1915×2820

Item Name Specification Quantity

1 Press :Model JH21-80 800KN 1 set
2 Foundation bolts(Include nuts and washers) M24×500 4 pcs
3 UHS-ring UHS020 20×28×5 2 pcs
4 UHS-ring UHS095 95×110×9 2 pcs
5 O-ring G190 189.3×5.7 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-110-ZD Page：5

Serial No.

Dimensions of packing box（L×W×H）：1410×2200×3190

Item Name Specification Quantity

1 Press :Model JH21-110 1100KN 1 set
2 Foundation bolts(Include nuts and washers) M30×800 4 pcs
3 UHS-ring UHS035 35×45×6 2 pcs
4 UHS-ring UHS136 136×150×9 2 pcs
5 O-ring P210 209.05×8.4 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-125-ZD Page：6

Serial No.

Dimensions of packing box（L×W×H）：1450×2300×3220

Item Name Specification Quantity

1 Press :Model JH21-125 1250KN 1 set
2 Foundation bolts(Include nuts and washers) M30×800 4 pcs
3 UHS-ring UHS035 35×45×6 2 pcs
4 UHS-ring UHS136 136×150×9 2 pcs
5 O-ring P210 209.05×8.4 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-160-ZD Page：7

Serial No.

Dimensions of packing box（L×W×H）：1515×2355×3250

Item Name Specification Quantity

1 Press :Model JH21-160 1600KN 1 set
2 Foundation bolts(Include nuts and washers) M30×800 4 pcs
3 UHS-ring UHS035 35×45×6 2 pcs
4 UHS-ring UHS145 145×160×9 2 pcs
5 O-ring P245 244.5×8.4 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-200-ZD Page：8

Serial No.

Dimensions of packing box（L×W×H）：1630×2690×3810

Item Name Specification Quantity

1 Press :Model JH21-200 2000KN 1 set
2 Foundation bolts(Include nuts and washers) M36×800 4 pcs
3 UHS-ring UHS035 35×45×6 2 pcs
4 UHP-ring UHP180 165×180×9.5 2 pcs
5 O-ring G280 279.3×5.7 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-250-ZD Page：9

Serial No.

Dimensions of packing box（L×W×H）：1750×2830×3930

Item Name Specification Quantity

1 Press :Model JH21-250 2500KN 1 set
2 Foundation bolts(Include nuts and washers) M36×800 4 pcs
3 UHS-ring UHS035 35×45×6 2 pcs
4 USH-ring USH180 180×200×6 2 pcs
5 O-ring G290 289.5×8.4 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-315-ZD Page：10

Serial No.

Dimensions of packing box（L×W×H）：1950×3400×4100

Item Name Specification Quantity

1 Press :Model JH21-315 3150KN 1 set
2 Foundation bolts(Include nuts and washers) M42×800 4 pcs
3 UHS-ring UHS035 35×45×6 2 pcs
4 USH-ring USH200 200×220×12 2 pcs
5 O-ring P355 354.5×8.4 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 PACKING LIST JH21-400-ZD Page：11

Serial No.

Dimensions of packing box（L×W×H）：2200×3800×4300

Item Name Specification Quantity

1 Press :Model JH21-400 4000KN 1 set
2 Foundation bolts(Include nuts and washers) M42×800 4 pcs
3 UHS-ring UHS040 40×50×6 2 pcs
4 UHS-ring UHS230 230×250×12 2 pcs
5 O-ring P385 384.5×8.4 1 pcs
6 Fuser RT23-16/6A 380V 2 pcs
7 Fuser RT23-16/4A 220V 2 pcs
8 Operation instruction 1 copy
9 Certificate of inspection 1 copy
10 Packing list 1 copy
11 Manual of programmable controller 1 copy
12 Manual of cam controller 1 copy
13 Manual of electrical oil pump 1 copy
14 Manual oil gun Three presses or 1 set
less three presses
 OMPI OPERATION AND
MAINTENANCE MANUAL
AIR ACTUATED CLUTCH-PRAKE
UNITS

1
 Contents

1.Structure and operating principle for OMPI pneumatic friction

brake-clutch --------------------------------------------------------------------3

2.The requirement of installment for clutch-----------------------------------3

3.Maintenance of clutch----------------------------------------------------------4

4.Trouble and solution for clutch-----------------------------------------------5

5.Assembly drawing and list of spare parts for clutch-----------------------6

2
1. Structure and operating principle for OMPI pneumatic friction
brake-clutch
Pneumatic friction brake-clutch is consisted of clutch main body 、 clutch otic
placode 、brake otic placode、friction disk、clutch pins、brake pins and lockplate,
which transmitting transfer torques. the unit is keyed on the driven shaft transmitting
the motion to the machine members .

The clutch ears and break ears are connected to the flywheel and frame by the four
pins ,to prevent the pins drunkenness the shape of blocks should be inserted in
through special slots on the disk and fixed by screws

The piston should be moved when the compressed air gets into the cylinder of clutch,
then the clutch engages ,the compressed air should be out when the clutch is braking,
the piston move reversely by the spring ,the clutch of OMPI engages and brakes
within from 0.005 to 0.15 second

2．Installation requirement

1).Install the clutch round pin and square clamp , brake round pin and square cotter
which the allowance should be H7,and the center of hole should be parallel to center
of principal axis .

2).The allowance between central clutch and groove of key ,and roughness should
reach the standard ,the position allowance of principal axis .and fineness should reach
the standard ,to improve assembly efficiency .

3).You can choose the different assembly sequence according to the different
conditions ,in generally ,firstly ,install the clutch and brake pins, and clutch and brake
pin keep plate ,then install the clutch and brake main body

4).The clutch and brake square clamp can eliminate deformation of plate causing by
the different between clutch and brake two pins and the clutch too heat .
Please note :the levels of clutch and brake square clamps should be parallel to axis
of clutch and brake ears

3
5).After assembling the clutch and brake should be moved smoothly ,before supply air
for the clutch ,you should check whether the clutch is moved smoothly

3．Maintenance for the clutch –brake

1).Before selling the clutch should be inspected carefully ,it is prohibited to
disassemble the clutch without agreement ,in case there is trouble in quality ,please
inform manufacturer
2).The friction will be worn for a long time ,you should replace the friction disk ,it is
our most excellence to replace the friction disk conveniently
3).Methods of replacing friction
A-Disassemble the friction disk of clutch ,and clutch ears is loose without
air ,remove the screws fixed the friction disk ,replace the friction ,then tighten
the screws

B- Disassemble the friction disk of brake , the brake ears is loose with air ,repeat
above mentioned

4). When need replace the friction disk

It should check the friction disk of the clutch engages exceeding 0.02 seconds, and
can not reach the capacity of the engagement and braking ,if the friction disk is
worn ,you must contact our service department immediately and replace it.

Model Thickness of friction disk The wear gap of friction disk

New（mm） Min（mm） New（mm） Max（mm）
KB0025 2.9 1.9 0.3~0.9 2.5
BK0050 3.6 1.9 0.3~0.9 2.5
KB0100 4.3 2.3 0.5~1.5 3.5
KB0200 5.8 3.1 0.3~1.5 3.5
KB0400 6.0 3.5 0.3~1.6 4.0
KB0500 7.0 3.5 0.3~1.6 4.0
KB0600 7.0 3.5 0.5~1.7 5.0
KB0800 8.0 4.5 0.5~1.7 5.0
KB1200 8.5 4.5 0.5~2 6.0
KB1700 9.0 5.0 0.5~2 6.0

4
4.Troubles and solutions
Trouble The cause Solution
1.the model of the clutch is Supply the correct model
The clutch is too heat wrong by OMPI company
2. the gap of friction disk Adjust the gap
is too small
3.the pins of clutch is 3.install it again
installed incorrectly
The friction disk is worn Replace the friction disk
Slipping when braking strictly or there is the oil in
it
The spring is damaged Replace the spring
There are foreign matters Clean the double solenoid
in the double solenoid valve or replace it
valve and exhaust the air
anomaly
Clutch slips The friction disk is worn Replace the friction disk
strictly or there is the oil in
it
The air circuit is anomaly Check the air circuit or
when pouring into the replace the gas tank
air ,the capacity if gas tank
is too little
Insufficient air pressure Check the pressure ,keep
the pressure in 5.5kg/cm²
The seals are worn Replace the seals
The braking angle is too The model of the clutch is Supply the correct model
big wrong ,the inertia is too by the OMPI
big
The friction disk is Adjust the gap
worn ,the gap is too big
Make noise when the The gap is too big between Replace the pins and
clutch idling the pins and sleeve sleeve ,keep the gap is
above 0.2mm
Make noise when the The gap is too small Replace the pins and
clutch is operating between the pins and sleeve ,keep the gap is
sleeve ,or the pins of above 0.2mm
clutch is installed
incorrectly

5
5.Assembly drawing

Fig.1a Unit with pins lining Fig.1b Unit with bushing Fig.1c Unit with bushing
stuck on screwed pads lining stuck on discs lining stuck on discs

A) air inlet holes

B) extraintion holes
1) hub-hub disc
2) cylinder disc
3) hub-cylinder disc screws
4) central seal
5) internal seal
6) external seal
7) pins
8i )clutch disc with stuck friction material
8L) clutch disc for friction pads
8t) clutch disc for friction blocks
9i) brake disc with stuck friction material
9L) brake disc for friction pads
9t) brake disc for friction blocks
10) springs, spring-holders, spring-guides

6
11) friction pads
12) bushings
13) clutch round pin
14) clutch square clamp
15) clutch pin keep plate
16) clutch ears
17) clutch ear screws and nuts
18) brake square pin
19) brake square clamp
20) brake pin keep plate
21) brake ear
22) brake ear screws and nuts
23) clutch round pin
24) clutch round clamp
25) clutch round clamp
26) brake round pin
27) brake round clamp
28) brake pin keep plate
29) not provided
30) screws and nuts for friction pads
31) friction blocks
32) bushing for friction block rings

7
DG SERIES DRY FRICTION

CLUTCH/BRAKE

OPERATION MANUAL

1
1.Main specification
1). Stokes of piston (also clearance of friction disk): 0.7mm-0.9mm
2). Air pressure requested: 0.5Mpa –0.6MPa
3). Temperature ≤ 80º
4).Time of clutch-brake ;within 0.005-0.15 seconds
5).The other models of clutches is connected by expansion sleeve, except DG-1 is
connected by key

2.Assembling
1).When mounting the clutch and brake plates, you should keep them parallel and in
the centre of main shaft, especial for mounting the clutch plate.
2).It should be smoothly for the round pins, square pins and sleeves, to prevent the
friction disks from being damaged
3).It should test condition of the clutch pins and flywheel, if the coordination is loose,
the pins will outward move, lead the disks damage, and the temperature will
increase.
4).It should tighten all screws on the expansion sleeve, otherwise the gap will become
big between clutch and main shaft.

3.Notice in usage
1).It should lubricate the pin and sleeve, to make the friction disk moving smoothly.
2).It should check whether the atomized lubricator works normally or not, and make
sure that the seals of clutch cylinder can be lubricated well.
3).It should adjust the gap of friction disk ,when the clutch works for a long time ,due
to the friction disc will be worn ,the gap will increase ,the damping –effect will
decrease ,the optimum gap must be controlled between 0.7mm and 1.5mm.

4.Troubles
1).The brake is in trouble and slip, the main cause: the gap of friction disc is too
big ,exhaust unsmoothly or the spring is loose
2).The temperature is too high , the main cause: inertia is too large ,the friction disc
move unnormally ,the gap is too small
3).The strength of clutch is not enough ,the main cause :the seal is damaged and leak
air ,so the pressure can not reach the requirement of project
4).The clutch makes noise, the main cause :the coordination of square pins and sleeve
is too loose ,and the gear is in trouble.

5.Solution
1).When the temperature of clutch is too high and the clutch is too hot ,you should
check whether the friction disc moves smoothly and the round pin move outside, it
can become smooth by repairing the round pins.
2).When the strength of clutch is not enough ,it will have some difficultly in

2
 starting .then check the air joint .,check whether the clutch is air leakage ,if it
is ,please replace the joint or seals ,if not .please check whether the condition of
supplying air is normally
3).The method of adjusting the clearance
(3.1) The method of DG2—DG8
A. Put a mark on the pressure disc
B. Take the pressure disc and conduit off
C. According to the requirement of reasonable gap ,take the adjustment spacer
off .
D. Make the parts of taking off to recover
(3.2) the method of DG-1
A. Loosen the twelve hex screws of the teeth pressure disc ,but do not take it off
B. Disassemble the spacer ,screw on the bolt ,but do not screw up
C. Assemble the spacer of the same thickness into the screw ,then screw them
up.
D. After adjusting ,check whether the clearance reach the range of
0.7mm-0.9mm

6.Tell the world

After adjusting the friction for many times ,if it has slipped when braking ,the braking
angle is too large or the time of braking is too long ,you should stop operating and
replace the friction disc

7.Service promises
1).Our company guarantee one year for the clutch ,under the normal using conditions
2).After the guarantee period ,our company will sell the wearing parts at the cost price