SHIN SUNG

OPERATING MANUAL

Machine Name : CUPPING PRESS.

Model No. : SSC-CSFP80T
 Table of Contents

A. Features & Specifications

B. Safety

C. Transport & Install

D. Operation

E. Periodic Inspection

F. Electric Circuit Diagram

A. Features & Specifications
1. Features of this Machine

This press is designed to fit very various demands of buyers using changeable die set
mold. And 35mm thickness of frame is enough to bear heavy load.
Using an encoder system, precise crank angle control is realized. The limit of
resolution of encoder is 1 degree and these informations from encoder are treated in
a PLC system. Because of this PLC system and touch screen, it is also realized that
the simple changing of program.

2. Specifications

Designation of Series or Type SSC-CSFP80T

Machine Namer CUPPING PRESS

Press Capacity 80 T

Stroke Per Min 100 spm

Die Height 380mm

Slide Stroke Length 140 mm

Main Motor 15.5 Kw

Floor Space 2400 x 1300 mm

Height over all 3320 mm

B. Safety

< WARNING >

This machine is designed well, considering worker's safety. But please read
following before working for your safety and preventing troublesome.

▶ Operate by person in charge

▶ Do not disassemble machine by unskilled worker
▶ Do not adjust electric diagram for machine, we are not responsible for
adjusting without our approval
▶ Do not change structure of machine, we are not responsible for
changing without our approval
▶ Do not make parts yourself without our advise
▶ Do not put the tools on the machine while machine running
▶ Do not feeding lubricant oil, repair while machine running
▶ Do not open any cover while machine running
▶ Keep safety distance while machine running
▶ Check power source before machine running
▶ Do not leave while power source connected
▶ Remove supplied air after operation
▶ Check power source disconnected after operation
▶ Check feeding lubricant oil regularly
▶ Feel free to contact our company when you have machine trouble

When you are not follow our instruction, we are not responsible

for any accidents.

1. MANAGING MACHINE

This machine is designed well, considering worker's safety. But please, read following
before working for your safety and preventing troublesome.
It is important to keep machine clean every day.
Machine will damage by remain dirty, acid, rust.
Use dry clean paper or clean cotton cloth and feed grease, lubricant oil on moving
parts every 4 hours keeping best running condition.

NOTE : DO NOT FEED LUBRICANT OIL AND REPAIR WHILE MACHINE RUNNING

After feeding oil, clean the machine. locate all tools at right position. Remove tools
on the machine.
2. CHECK MACHINE BEFORE OPERATION

After installation machine, before operation, keep clean each parts of machine.

(1) Clean up nearby Cupping Press

(2) Check feed grease on each moving parts
(3) Make sure all components in right position
(4) Remove tools on the machine
(5) Check electricity specification as same as machine
(6) Operate machine by control panel
(7) Check important parts
① Cupping Press Die Set Mold has dirty, abrasion
② Condition of Crank Shaft, Fly Wheel and Ram Slide.
(8) Check operation process
① Leakage of oil on the surface of frame
② Tension of main drive belt
③ Check take-out air blow condition
④ Check air pressure of each regulators

3. CHECK MACHINE ON OPERATION

(1) Check noise while Cupping Press running

(2) Check noise or heat during fly wheel turning
(3) Do not let unskilled worker to operate Cupping Press
(4) Do not put your hand or feet on Cupping Press
(5) Make sure safety around machine
(6) Push red emergency S/W on emergency situation
(7) Do not open cover while Cupping Press running
(8) Check supplied air pressure.
4. CHECK MACHINE AFTER OPERATION

(1) Check power source disconnected

(2) Close air supply
(3) Remove air
- Remove air at the air filter and valve
(4) Check each parts condition
(5) Keep clean
(6) Feed lubricant oil and grease

Please, keep in your mind above instructions for your safety and machine life time.
5. Safety Sticker

OPERATIONAL WARNING STICKER

The operational warning sign will be attached to the right of the machine as a reminder to
machine operators and maintenance personnel that certain procedures must be followed in
order to prevent serious bodily injury. All persons are warned to keep clear the hazardous
area around dangerous position. The sign also serves a warning that no person should
attempt to operate, service or adjust the machine, or install machine unless they have been
properly trained. Operation of the electrical controls, and the resultant movement of
mechanical parts, must be fully understood by all persons using or servicing the machine.

HIGH VOLTAGE WARNING STICKER

The HIGH VOLTAGE warning sticker is located on

the door of the machine electrical control cabinet.
This sign w arns that high voltage, w hich could
be fatal to human life, is present inside the
electrical control panel. If necessary to gain access
to the inside of the control enclosure, the
technician must first make certain that incoming
power has been disconnected. Only experienced
personnel should be permitted to troubleshoot or
service this equipment.

DANGER KEEP HANDS AWAY

WARNING STICKER

The DANGER - KEEP HANDS AWAY warning sticker

is located on or near the cover plates(or guards)
that are placed over various machine components
such as flywheel, gears, sprockets, chains, cams,
belts, levers and other moving parts. The sign
warns all personnel to keep their hands and fingers
clear of those areas containing parts in motion.
Removal of inspection plates or probing through
guard openings while the machine is in operation
could result in injury to the person, or persons,
entering those areas. Always make certain that the
flywheel has stopped turning and that all power
(electric, air, etc.) is disconnected before removing
or probing inside machine guards and covers.
WATCH OVERHEAD WARNING PLATE

The WATCH OVERHEAD warning plates are

located on the interlocking guard sides. This
sign warns all persons to keep their head out
of interlocking guard if opened. WATCH OVERHEAD
AUTHORIZED PERSONNEL ONLY APPROACH(OPERATE), WARNING AND
DANGER WARNING STICKER

The AUTHORIZED PERSONAL ONLY APPROACH

(OPERATE), WARNING AND DANGER warning
sticker is located on or near the carrier cover
plates(inside press electrical control panel) that
are placed over various machine components
such as discharge device, part of electrical and
other important parts. The sign warns all
personnel to keep their hands and fingers clear
of those areas containing parts in motion.
Removal of inspection plates or probing through
guard openings while the machine is in operation
could result in injury to the person, or persons,
entering those areas. Always make certain that
the flywheel has stopped turning and that all
power (electric, air, etc.) is disconnected before
removing or probing inside machine guards and
covers.
 6. A Special Note To Press Operator, Die Setter And Their
Supervisors
You, as a press operator or die setter, are normally more closely associated with the
actual use of mechanical presses than anyone else. It is for this reason that you should
develop a sense of personal safety awareness and understand that by working safety, day
after day, you will be the first to benefit. Of course, the opposite is also true slipshod
and unsafe work habits could result in loss of life or limb; or a machine and its dies
could be wrecked. Safety is the heart of every successful accident prevention program.
This is a real and continuing responsibility which must start at the personal level before
mass participation can be achieved.

Included in this manual are several lists of safety precautions and suggestion. Your
employer may also have some additional safety rules. But, we would like to go beyond
the stark, demanding sometimes bothersome procedures outline herein to explain that
publication of safety information is absolutely useless unless you make it work. You mast
believe in working safety; you must understand the safety regulations and conduct
yourself accordingly. By thinking positively, you may discover additional ways of making
your job safer.

Operator negligence and lack of training have long been regarded as the major direct
causes of press injuries. If you have not been trained for the job to which you are
assigned, see your supervisor. Your supervisor is the person who knows the operation
you are to be doing. Make certain you know how to operate the equipment and how to
operate it safety. The employer is required by law to train press operators and
maintenance personnel.

Many press operators, especially those on incentive rates, place their hands into the die
area to (supposedly) increase their rate of production. Or, when hopping, some operator
might retain a hold on the unfinished end until it reaches a hazardous position, unless a
die guard is used. There are also those persons who may be inclined to reach into the
die area to check sharpness or condition of punches. And other operators might use their
hands, instead of a pick or special tools, to remove scrap material or a finished part
stuck in the die. The practice of placing hands into the die area, for any reason, is very
dangerous and could result in serious injury.

Operators should NEVER place their hands or any part of their bodies under the slide, or
within the die area, unless the main drive motor is turned off, the flywheel has stopped
turning, and the slide or die is blocked. Records show that some operators were injured
when they inadvertently placed their hands into the die area while leaning over to pick up
something. Or, they accidentally placed one of their hands into a danger area as they
paused briefly to talk to another person. Accidents sometimes occur when the operator is
distracted or when his mind is "a thousand miles away." The manner in which the injury
occurred could be one of many, but, it must be emphasized, virtually all press related
accidents would not have resulted in injuries if the operator's hands had never been
placed under the slide.
Always make certain that you are using the proper point of operation safeguarding before
performing any operation. Actually, with safeguard installed and the operator protected,
production rates are usually higher than when unprotected methods are used. The point
of operation safeguarding must, however, be appropriate for the tooling and the method
of operation.

Die setters should be quite knowledgeable about the adjustment and operation of
mechanical presses; therefore, it is difficult to explain why they are involved in many of
the press accidents. Investigations disclose, however, that a significant number of injuries
sustained by die setters resulted from the die setters themselves attempting to install or
remove dies, or to service dies within the point of operation, without first shutting off
power to the press and waiting for the flywheel to stop.

Unless the press is equipped with a flywheel brake(or brake equipped main drive motor)
and the brake is properly actuated, the flywheel will continue to coast long after power
to the drive motor has been turned off. And, as long as the flywheel is turning, it
contains kinetic energy which could create slide movement if the press clutch is
engaged. For this reason, no person should ever attempt to install, adjust, clean,
lubricate or service dies in a press - or remove die from it - while the flywheel is still
turning. Always check visually to make certain the flywheel has stopped and power is
off.

Proper dir setting and/or die setting procedures are somewhat dependent upon size and
configuration of the die. But, in any instance, when you as a die setter are working
within point of operation, or within the pinch point, it is you who must make certain the
flywheel is stopped and that the slide, or die, is blocked. also, when running sample
parts, die setters must use proper point of operation safe- guarding. They are ones
responsible for determining that the proper point of operation safeguard is installed and
that it is functional; furthermore -they must use it.

Care must also be taken when transporting dies. They should be fastened to the truck
before moving. At the press, make certain the die truck is chocked securely to prevent it
from moving away as the die is being transferred. It is also advisable when setting, to
have appropriate die handling tools that are in good condition, conveniently located near
the installation. in some instances, the die setter's truck is designed to include a place
for such tools so that no time will be wasted looking for them.

Press operators and die setters should remember that, no matter how long they have
been associated with the operation of power press equipment, years of service and
experience provide no immunity to accidents. The same is also true of job classification
or title. Cooperate with other employees to promote safe operating procedures, and
make a sustained personal effort to work safety from your very first moment on the job.
 WARNING
Press Operators
NEVER place your hands or any part of
your body under the slide or within the
die area of the press.

NEVER talk to anyone who is engaged

in the operation of a press.

Die Setters
NEVER attempt to install, adjust, service
or remove dies without first shutting off
power to the press, waiting for the flywheel
to stop, and blocking the slide, or die,(or
positioning slide at dead bottom of stroke)
 7. Die Setting Procedure

The total procedure for installing dies in a press comprises several distinct, yet related,
steps. Those steps to be performed include: preparation of the press to receive the die;
actual die installation; securing attachment of the die to the press: necessary adjustments
of the press, die and auxiliary equipment; installation of a point of operation guard and/or
safeguarding device appropriate for the operation to be performed. Press size, stroke
length, speed and capacity must be suitable for the die that will be installed. If additional
components such as die cushions, hopper are required, the press should be arranged for,
and equipped with, these items.

The actual procedure for setting and removing dies may vary slightly, depending upon
press size and the type of operation to be performed. The steps outlined below are of a
general nature and may be amended to suit a particular press and die combination;
however, never should they be amended to the extent that the job is done unsafely.
Observe all warnings.

1) Setting The Die

1. When installing dies, always observe the Die Setter's Safety Precautions included in
this safety manual.

2. Before attempting to set dies, make certain that the main drive motor is turned off, the
press electrical disconnect is locked out to the off position, the flywheel has stopped
turning completely, and then install safety blocks. (If necessary, the slide may be
positioned at bottom dead center of stroke in lieu of installing safety blocks.) Clean
the die, bolster plate and slide face surfaces.

3. Install all necessary bolster inserts, slide and bolster spacer plates, together with any
auxiliary equipment that may be required to obtain proper working height for the die
and material handling components.

4. Make certain that the bolster plate is securely clamped to the press with bolts that are
in good condition. Loose or broken bolts may allow the bolster to shift out of its
correct position during press operation.
A bolster plate that has shifted from its proper position can cause serious die damage
and endanger the safety of the operator.

5. If die cushioning is required, pressurize the cushion and insert pressure pins in
applicable bolster plate holes. Use only clean, straight pressure pins of equal length.
Never use pins that are bent, mushroomed. or otherwise deformed. After inserting the
pins, recheck location and exposed pin length. Plug all of the exposed pressure pin
holes. Lower the die cushion to permit pins to drop below top surface of the bolster.
 WARNING
NEVER PRESSURIZE DIE CUSHION WITHOUT THE BOLSTER PLATE INS-

ALLED AND BOLTED DOWN SECURELY.

6. Remove safety blocks. Provide electrical power to the press control and then INCH or
BAR the slide to bottom dead center of its stroke. If the drive motor was started in
order to lower the slide, turn it off and lockout the press disconnect to the OFF
position. Make certain the flywheel is not turning. Now measure overall height of the die
and height of the opening in the press. Use the press micro shut height indicator if
one is furnished. Adjust the slide to a position that will allow adequate working space
for loading the die into the press. Install and use only dies that are safe. Dies that are
worn or improperly sized can cause injuries to personnel and damage to the press.

WARNING
NEVER INSTALL WORN OR DAMAGED DIES, INSTALL ONLY DIES THAT ARE

IN GOOD CONDITION AND PROPERLY SIZED FOR THE PRESS TO BE USED.

7. Place the die in position for loading into the press. Check top and bottom of the die
for any slugs, metal particles or dirt that may have adhered. Make certain these areas
are clean. Load the die into the press and set it in the desired location. Fasten the
lower die shoe loosely.

8. Check alignment of openings in the die, if applicable, with related openings in the
bolster plate before the die is clamped into position. If these openings are not
properly aligned, stamping, scrap pieces or slugs may catch and pile up inside the
die. This condition could cause the die to fracture and may result in possible injury to
the operator due to flying die particles. Good lighting and a mirror can be quite
helpful when checking alignment. Never use fingers to line up or locate holes.

9. If die cushion will be used, raise pressure pins by pressurizing the cushion. USE ONLY
LOW PRESSURE. Check alignment of pressure pins with the die. If the die is not
located properly, it may be lifted slightly by one or more of the pins; or, pin
misalignment may prevent the cushion from expanding fully. If necessary, reposition the
die slightly or use other safe, convenient means to assure correct alignment of
pressure pins with the die.
 WARNING
IF DIE CUSHION PRESSURE IS EXCESSIVE DURING THE PIN ALIGNMENT

CHECK, AND THE DIE IS MISALIGNED, A HAZARD COULD BE CREATED BY

THE SUDDEN RELEASE OF THE RESTRICTING PARTS. DURING THIS CHECK,

APPLY ONLY THE PRESSURE NECESSARY TO RAISE THE CUSHION

PRESSURE PAD.

10. Adjust the slide down until it nearly touches the top of the upper die. Then bolt the
upper die shoe securely to the slide. If standard nuts are used, the bolt must be
threaded fully through the nut. Use a single washer under every bolt head or standard
nut - never stack washers. Use only bolts that are in good condition.

11. If storage straps are used between the upper and lower dies, they should now be
removed and secured in their proper place either on the die or away from the press.
All other die storage accessories, bolts and other unused components should be
marked for identification and place in a storage area away from the press.

12. Bolt down or clamp the lower die shoe securely to the bolster. If bolts are used, they
must be in good condition. If a clamping arrangement is used, the fulcrum block
should be a single block which is the same height as the die shoe. Do not use shims
or stacked washers for this application; however, commercial type adjustable height
heel block, designed for this purpose, are acceptable. The clamping bolt must always
be located nearer the die shoe than to the fulcrum block. Be sure to use enough
clamps to keep the die in position.

13. Adjust the balance air pressure to properly balance the weight of the slide and upper
die. For instructions on setting balance air pressure.

14. Make certain that no tools, bolt or other obstructions are left in the die area, slide
flange or anywhere else on the press where they could fall and cause damage or an
accident.

15. Restore electrical power to the press ad start the main drive motor and INCH the
slide to the top of its stroke. If separator block, or other die storage components are
used, shut off the main drive motor and lock out the electrical disconnect switch to
the OFF position. Wait for the flywheel to stop turning - then install safety block.
Remove the die storage or separator block, whichever are used, and place them in a
storage area. After the die is cleared and ready for use, remove the safety blocks.
16. Adjust slide for the correct operating height and lock the adjustment. Adjustments
relating to the depth of setting are vitally important because the safety of the operator
is involved as well as stress on the press and tooling. Consequently, a slide that is
set too low may cause damage to the press, or failure in the die-a condition that
could also be hazardous to personnel.

WARRING
DO NOT SET THE SLIDE TOO LOW.

17. Install point of operation safeguards and/or safeguarding devices. Make certain that
the safeguard install is proper for the type of operation being performed and that is
correctly installed and adjusted. Report any defect or malfunction of any safeguard or
safety device to the proper supervisor for immediate correction. Adjust parts chutes, if
used. Install tote pans or other material handling equipment in the proper location. If
additional safety handling equipment or tools are required for a specific job, obtain
the required items and have them placed in a convenient area for the operator's use.

18. Start the main drive motor and INCH the slide through at least one cycle. Then insert
the material and run a few sample parts, preferably an INCH. Inspect the work pieces
and further slide height adjustment if necessary. At this point, all changes in slide
adjustment must be small with special care being taken not to set the slide
adjustment mechanism is locked and that bolster bolts are tight before cycling the
slide. Run several sample parts using the available modes of operation.

19. check the parts produced during the trial run to make certain that they meet
production specifications. Marks on the parts may mean that slugs are accumulating.
Large burrs on the parts can indicate that the punch or die block is dull, or that too
much clearance exists between the punch and die. When inspecting drawn parts, look
for cracked sections especially near the bottom radius. Cracks can develop because
of improper lubrication, improper die clearances, improper die cushion pressure, hard
stock, or a combination of these condition.

20. After all checks and adjustment have been made, observe operation of the machine
for a sufficient period of time to determine that it is working correctly and safety.
Keep the floor area around the press clean and free from obstructions.
2) Die Removal Procedure

1. When removal dies, always observe the Die Setter's Safety Precautions included in this
manual.

2. After stopping slide in the stroke-up position, turn off the main drive motor set the
stroking selector switch in the OFF mode. Wait for the flywheel to stop turning
completely -then install the press safety blocks.

3. Clean the die and thoroughly inspect it for possible damage, wear and general
condition. If the die should require sharpening, servicing or repairs, make certain that it
is routed to the die repair department immediately after removal from the press.

4. If wooden separator blocks (or other type spacers) are to be inserted between the
upper and lower parts of the die, for storage purposes, adjust the slide height upward
at least 1.5 mm more than the thickness of the separator block. install the separator
blocks as required.

5. Remove the safety blocks and return them to the proper storage area. INCH or BAR
the slide down to the bottom of its stroke. If the main drive motor was started, turn it
off and lock out the disconnect switch to the OFF position. Make certain the flywheel
has stopped turning completely. Install die storage straps or clamps, if required. The
slide height may have to be adjusted slightly for this operation.

6. Unbolt the die, making sure that all bolts and clamps are removed. Adjust the slide up
to a height that will permit adequate space for removal of the die from the press.

7. Pull the die from the press and load it onto the die truck. Make certain the die truck
is chocked securely to prevent it from moving away as the die is being transferred.
Fasten die to the truck for safe transport. Be very careful when moving the die; move
the die truck slowly and proceed over solid, level floors only. Route the die to a die
storage area or die repair shop, depending upon the result of the inspection.

8. If a die cushion was used, raise the cushion using low pressure only. Remove the
pressure pins and then exhaust the cushion.

9. Clean the slide and bolster surfaces.

8. Management's Press safety Guide

The following listed steps are intended as a guide as a guide for the user management. It
is hoped that, by pointing out definite areas of responsibility, the entire program of press
safety will receive the leadership and full participation so necessary from the top on down.
A press safety program works best when it has the vigorous backing of management -
where objectives are vividly spelled out, and each employee's responsibilities are clearly
defined. Management must spark such a program by constantly reviewing and evaluating
its effectiveness. Management must nourish such a program by keeping actively involved,
by constantly promoting safety amongst its own personnel, and by exchanging ideas with
others who have demonstrated interest in safety.

Press user management is responsible for meeting applicable safety requirements as set
forth by applicable safety standards. These regulations and standards may cover all
phases of power press usage from in installation through operation, safeguarding,
inspection, maintenance and modification.

(1) Press manufacturers cannot know what day to day use will be made of a press. in
fact, it would be difficult to comprehend the magnitude of potential applications. It is
the press user who determines which dies are going to be installed, the type of
material to be used, the method of loading and unloading the work-pieces, and the
type of point of operation guards or devices that will be user for the job. It is for this
reason that, unless it was especially ordered based upon specifications known only to
the buyer, point of operation safeguarding was usually not furnished as a part of an
original press package. It is now required that the press manufacture or press system
integrator provide the safeguarding as specified by the press user.

Logically then, it becomes the responsibility of the user management to make certain
that point of operation safeguarding is installed, and that it is appropriate for the
operation being performed. All safeguarding must be installed and tested before
releasing the machine for production. After release, a continuing check for proper
usage and effectiveness must be included as a part of the press safety program.

(2) Make certain that press operators, press maintenance personnel and their supervisors
are properly trained. Remember that differences in language and educational
background make it more difficult for some people to understand instructions. Follow
through to be sure the employees know their jobs.

(3) Make certain that die setters are properly trained, and that they understand their
responsibilities must include assuring the integrity of operation safeguarding before
releasing the press for production operation.
(4) Set up a program of press inspections using an itemized checklist of points to be
covered during the daily, weekly, and monthly inspections. Follow through to make
 certain the inspections are being performed correctly and at the specified time
intervals.

(5) Establish a definite preventive maintenance program with checklists for this press. Keep
a historical record of the press maintenance work, repairs and adjustments.

(6) Set up a program to inspect safeguarding equipment. Make a checklist covering any
point of operation safeguarding that is permanently installed on your equipment.
Safeguarding should be inspected as specified. Also perform frequent evaluation
checks during actual production runs. Correct any unsafe practices or conditions
immediately.

(7) Never allow persons under 18 years of age to operate or assist in the operation of a
power press.

(8) Establish safe. convenient material handling systems. If conveyor equipment is

installed. it should conform to recommendations in published standards.

(9) Provide a clean, safe, uncluttered work area around each press.

(10) Provide adequate fire protection equipment throughout your entire plant. Be sure that
all fire extinguishers are adequately charged, carry a valid inspection tag, are clearly
marked and easily accessible.

(11) Provide safety blocks, appropriate for the dies.

(12) If a press malfunction is reported, stop the press immediately and have the problem
corrected before resuming production.

(13) Provide personal protective equipment such as safety glasses, safety helmets, tongs,
gloves, hand pads, spats and protective sleeves to suit the tasks being preformed at
each work operation.

(14) Organize a company safety committee. Schedule periodic meetings to review and
update all safety regulations.

(15) Establish a firm policy an pressroom safety regulations. Publish your objectives and
describe each employee's responsibilities. Make certain all employees know,
unmistakably, what is expected of them.

(16) Thoroughly investigate all accidents, "close calls," equipment misuse or employee
neglect which could have resulted in an accident. Take immediate action to prevent a
recurrence of the incident. Keep records of the investigation and of the corrective
measures that were taken.

(17) Publish a list of names, addresses, and phone numbers of physicians, emergency
rescue squad, fire department, and members of the organization who are to be called
 upon in the event of an accident or emergency.

(18) Make certain that all mechanical presses and associated equipment are properly
connected to earth ground. Grounding should be in accordance with required
electrical equipment standards and consistent with sound local practices.

(19) Never overload the presses.

(20) Never permit any changes to be made in the press control circuitry unless the
changes are designed or reviewed by a recognized competent expert. In this regard,
there are documented instances where field modifications have created hazardous
conditions in press controls because of lack of recognition of the requirements for
proper design. Shin sung, and may other control builders, are available for
consultation. Unauthorized circuit changes could result in an accident or violation of
national or state requirements.

(21) Cooperate and participate. Appoint a safety director who will arrange discussion
group with key personnel in the plant. The group should fully analyze and review
special guarding problems, accidents and the use of all company machinery. Then,
step out and make a concerted effort to communicate with other companies and
groups who have demonstrated an interest in safety. Only by active cooperation can
we lean; not only from own experience, but by the experiences of others as well.
9. Press Operator's Safety Procedures

Each item listed below is related to the operator's safety. It is for his, or her, benefit that
these procedures be observed. The performance of mechanical and electrical repairs is
usually not the responsibility of the operator; however, it is the responsibility of the
operator to report to the proper persons any press, tooling, or auxiliary equipment that re-
quires attention. It is for the operator's own safety - once it has been determined that the
machine needs attention or is malfunctioning - that he immediately turn off the press and
discontinue operation until the equipment has been effectively repaired.

Some experienced press operators may also be asked to perform the duties of a die
setter. Where this is the case, the operator must be instructed in proper die setting
procedures. He should also read, understand and follow the rules listed in the "Die
Setter's Safety Precautions"

(1) NEVER place your hands or any part of your body under the slide or within the die
area of the press.

(2) NEVER operate, service or adjust the press. or install die without proper instructions
and without first reading and understanding the instructions in the press operator's
manual. If you have not been trained for the job to witch you are assigned, see your
supervisor.

(3) NEVER attempt to remove a workpiece or scrap from the die with your hands. If any
material sticks in the die, stop the press and call your supervisor.

WARRING
THE PRESS DRIVE MOTOR MUST BE
TURNED OFF, FLYWHEEL STOPPED AND
SAFETY BLOCK PROPERLY INSERTED
BEFORE PROBING THE DIE(WITH TOOLS)
TO RELEASE THE STUCK PART.
(4) Fingers are precious. Keep all them by keeping them clear of danger areas and pinch
points.

(5) Before starting the press at the beginning of a shift, after die set-up, or after brake
check the following items;

* Make certain that all tools, ladders, and scaffolding used by maintenance
crews have been removed.

* Make certain that safety blocks have not been left between the dies or
between slide and bolster.

* Be sure that no tools, nuts, bolts, clamps and bars were left lying on the
press. (Check die area, slide, bolster and overhead areas.)

* Check slug chutes, feeding and ejection mechanisms for plugged, jammed
or broken sections.

* Check visually to be certain no workpiece or other obstruction was left in

the dies.

* Check all control selector switches to make certain they are set for the
desired mode of operation.

* Check the condition and operation of point of operation safeguarding. Be

sure that all safeguards are in place and functioning correctly.

(6) Whenever the press has been inoperative or left unattended, even for a brief moment,
the setting of all selector switches should be checked before starting the machine.

(7) At the beginning of each shift and after every break, stroke the press several times
and observe carefully to be sure that the clutch/brake and controls are functioning
properly. Also check for proper operation of other press parts, die and auxiliary
equipment at this time.

(8) Check the clutch air pressure gauge and balance gauge(if included) for proper air
pressure regulators as necessary for the particular production run. Refer to the
operator's manual for instructions.

(9) Check slide height setting to be certain that the slide is not set too low for the dies
in use at that time. Setting the slide too low will increase, considerably, the load
applied to the press.

(10) Keep all point of operation safeguarding in place and in good condition.
(11) Safety tongs, vacuum lifters, pliers and other parts handling tools must be kept in
good working order and must be used whenever manual loading or unloading of
parts into and out of the die is required. Turn in worn or defective tools for
replacements that are in good condition.

(12) When charging the setting of press controls for a different mode of operation, make
certain the selector switches are set correctly - then test cycle the press to be sure
it operates as expected. Locking type selector switches should be adjusted only by
authorized persons.

(13) Never talk to another person while engaged in the operation of a press. If talking is
necessary, stop the press and step aside until your conversation is completed.

(14) Report any questionable operation, unusual action, oil leaks, unsafe condition or
improper maintenance of the press and its auxiliary equipment to the proper persons.

(15) Never reach over, under or around press guards and never try to beat, cheat or
modify any point of operation safeguarding.

(16) Always exhaust air pressure from the die cushion, if used, before attempting to
remove a jammed part from the die. Never try to remove a jammed part with your
hands. Always use extracting tools.

(17) Never stand or sit on anything while operating a press that could cause you to fall,
slip or stumble into the press or any auxiliary equipment.

(18) Clean the press daily and inspect carefully for loose, worn, broken or damaged
parts. Also keep the area around the press clean and orderly.

(19) With the main drive and lubrication motors turned off, check sight gauges for
sufficient lubricant level in reservoirs.

(20) Observe press operation for overloading. Accidental or intentional operation above
the maximum rated tonnage will result in excessive wear and abuse of press and
dies, and can also create a hazardous condition.

(21) Improper material handling methods cause accidents. Plan ahead and arrange a safe
method of transferring materials. Use mechanical handling methods (instead of
manual) whenever possible.

(22) NEVER stack parts on the bolster plate or near the die area of the press. Parts
stacked too high could create a pinch point and the press or die could be seriously
damaged if the parts are struck or fall into the die; or the parts could fall onto
control buttons, or into the points of operation with resultant possible forcible
projection during cycling.
(23) All scrap material should be placed in the containers provided. Never allow pieces of
scrap to project over the sides of the container.

(24) Never allow tote pans(for small parts and slugs) to get too full; they become
dangerously heavy and difficult to handle when overloaded.

(25) Never stack blanks or finished stamping so high that there is danger of them
topping. Never stack parts in aisles and passageways.

(26) Never stand, walk or drive under a suspended load. Caution others to keep away
from under the load.

(27) Shut off power to the press when it is not in use. Lock the control panel or
disconnect switch in the OFF position to prevent unauthorized use of the press and
unintentional start.

(28) Develop a sense of personal safety awareness. Observe all safety regulations. Be on
the lookout for hazardous conditions and discuss the control of them with your
supervisor.
10. Die setter's Safety Procedures

Die setting is a very important job - safety of the press, the tools and the operator is
involved. To properly prepare for this job, the Die Setter should have a good working
knowledge of presses, dies and materials. He should also have been instructed in the use
of die trucks and other types of handling equipment. He must remember the importance of
proper die adjustment - how, for example, the press will be subjected to increased shock
and loading simply because the punches of a blanking die are set too low. He must
understand too, how presses can be instantly damaged by coining large areas of metal
with the slide adjusted too low.

Aside from their technical knowledge, die setters must also develop a sense of personal
safety awareness. It is not only important that dies be installed correctly in the proper size
press, but also, the process must be accomplished in a safe manner. The job of setting
dies is not completed until die guards and/or point of operation safeguarding devices -
that are proper for the operation being performed - are correctly installed and tested.

The following precautions are offers as a guide in the development of safe die setting
procedures.

(1) NEVER place your hands or any part of your body under the slide or within the die
area unless the main drive motor is turned OFF, the flywheel has stopped turning and
the slide is blocked. check visually to make certain the flywheel has stopped.

(2) NEVER attempt to install, adjust or remove dies without proper instructions and without
first reading and understanding the instructions in the press operator's manual. If you
have not been trained for the job to which you are assigned, see your supervisor.

(3) NEVER install, adjust, clean, lubricate or service dies in a press - or remove dies
from it - while the flywheel is in motion, drive motor ON, or the slide is in an
unblocked position. (The slide may be positioned at bottom dead center of stroke in
lieu of installing safety blocks.)

(4) Use a brush to bolster plate, slide face and dies before installing the dies. Never use
compressed air to blow off foreign debris from these areas. Misalignment caused by
dirt, chips of metal or other foreign materials could result in injury to the operator or
damage to the press and dies. If die cushion is to be used, check pressure pin holes
in the bolster plate to be sure there is no excessive clearance. If any burrs are found
on the bolster plate surface, remove them with a flat file.

(5) NEVER pressurize a die cushion without the bolster plate installed and bolted down
securely. Accordingly, before removing the bolster plate, ensure that all air has been
exhausted from the die cushion if the press equipped with one.

(6) Have the right tools for the right job. Keep tools clean and good condition.
 (7) Clamp the bolster plate firmly to the press. Be sure the bolts are in good condition
so that constant vibration will not allow the plate to move out of position.

(8) The die setter should know the die's specified clearances and the adjustment,
relationships and the importance of each of these clearances.

(9) Never install worn or damaged dies. Use the proper press size for each die in order
to prevent overloading.

(10) The die should cover at least 2/3(front to back and right to left) of the bolster area.
Operating below this region results in concentrated loading which could result in
damage to the press's bolster, slide and crank components.

(11) Prevent excessive snap through during a powered stroke by ensuring that proper
punch, die alignment and penetration is set correctly and that the tooling is
sharpened. Multiple punches should also have their depths staggered.

(12) After removal from the press, all dies should be securely fastened to the truck before
moving.

(13) When a die set is being installed in a press, the stroke should be down, the drive
motor shut off, flywheel stopped, and the slide adjustment positioned high enough to
adequately clear the die set.

(14) When transferring dies from truck to the press, or from press to the truck, make
certain the truck is chocked securely to prevent it from moving as the die is being
transferred.

(15) If dies are clamped to the press, use enough clamps of the proper size to hold the
dies firmly in position. The clamping bolt must always be nearer the die shoe than the
fulcrum block.

(16) NEVER use your finger to locate or line up holes between the die and bolster. Use a
drift, or sight visually.

(17) Know your die weights, All dies should have their upper die weights marked on them
to assist in setting the balance air pressure setting.

(18) All eye-bolts used to pick up a die should be tightened against the shoulders and
then removed after die installation. All eye-bolts should be examined for fractures,
cross threads, grinded areas, etc., and if doubtful about their condition replace. Do
not use studs or bolts for slinging or transporting dies.

(19) In securing the die, use only safety approved and properly size bolts, nuts, washers
and clamps. The same or a greater number of bolts must be used on a die if the
use of risers is required.
(20) remove and place the die safety block back to its storage location. All dummy plugs
used for check out must be removed and the proper plugs re-inserted.

(21) After the dies are installed, perform all necessary adjustments before stroking the
press. Be sure the slide height setting is correct and locked. If the press is equiped
with slide air balance, reset the counterbalance air pressure to compensate for weight
of the upper die.

(22) When working with another person or crew, be sure that all persons are clear of the
press before inching or stroking the slide.

(23) Check the die area, slide, bolster and overhead area before cycling the press to be
certain that no tools, nuts, bolts, clamps or bars were left during th die installation.

(24) Functional testing of the press control system should be performed before and after
die installation for your safety and that of the operators.

(25) When running sample parts, use the point of operation safeguarding intended for the
operator.

(26) Observe press operation for a sufficient length of time to determine that the press,
die sufficient length of time to determine that the press, die and auxiliary equipment
are working properly.

(27) Before releasing the press for production, replace all guards, covers and applicable
safety devices for production of the operator, and assure their integrity for the
operation.

(28) If manual loading or unloading of parts into and out of the die is required, make
certain that the necessary tools are provided for the operator. The tools must be in
good condition.

(29) Even though the main drive motor is turned off, never install dies or work under the
slide if the press flywheel is still turning. Check visually to make certain the flywheel
has stopped.

(30) When changing the setting on press controls for a different mode of operation, make
certain the selector switches are set correctly - then teat cycle the press to be sure
it operates as expected. If used, locking type selector switches should be set by
authorized persons only and the keys removed after setting to prevent unauthorized
change.

(31) Never actuate the clutch "ON" switch unless you are actually controlling motion of the
flywheel with a "turnover bar"
(32) Install and adjust parts conveyors or chutes; locate tote pans and other material
handling equipment as required. Make certain that all of this equipment is in good
working order.

(33) Report any questionable operation, unusual reaction, oil leaks, unsafe condition or
improper maintenance to the proper persons.

(34) Whenever the press has been inoperative or left unattended, even for a brief moment,
the setting of all selector switches should be checked before starting the machine.

(35) Develop a sense of personal safety awareness. Observe all safety regulations. Be on
the lookout for safety hazards and discuss control of them with your supervisor.

(36) Because you will be working with various kinds of tools around power press
equipment, you, as a die setter, should also read and practice those item listed under
"Safety Tips For Press Mechanics."
11. Press Inspector's and Maintainer's Safety Precautions

An effective press inspection and maintenance program, consistently administered, not only
helps to keep the equipment in good running order, but also helps the user to meet, or
exceed, production schedules, More importantly, when the equipment is operating
correctly, a safe working environment is presented.

As a press inspector or maintenance person, you are expected to perform those activities
outlined in the Press Inspection check list and Maintenance schedule. Those duties should
be performed in a safe manner for your protection and for the safety of others.
Maintenance work can, in itself, present a particular set of hazards. Therefore, it is
imperative (and also required by law) that you receive proper training, and demonstrate
competence in the duties of caring for, inspecting and maintaining power presses.

(1) NEVER operate, service or adjust the press without proper instructions and without
first reading and understanding the instructions in the press service and operating
manual. If you are not sure, check with your supervisor before proceeding.

(2) Always shut off all power (electrical, air etc..) to the press, place safety blocks
between slide and bolster, and wait for the flywheel to stop turning before placing
your hands or any parts of your body under the slide or within the die area.

(3) Always position the slide at the bottom of its stroke before attempting to disassemble
the clutch. brake or any part of the press drive train.

(4) When disconnecting electrical power and/or air sources from the press, disconnect
switch and air valve in the off position and attach WARRING tags to be sure that
power or air cannot be restored without your knowledge.

(5) When disconnecting air and hydraulic pressure from the press, always attach
WARRING tags to the appropriate shutoff valves and lock them out if appropriate.
Also follow the press service manual instructions to be certain that all system
charging pressure are relieved be fore disassembling any air or hydraulically actuated
components.

(6) Make certain that all air and hydraulically actuated components are completely
assembled and properly attached to the press before applying charging pressures.

(7) If the clutch air hose is replaced, make certain that the replacement hose is of the
correct type and length so that it cannot twist or kink due to a slight turning torque
applied by the air distributor whenever the clutch is engaged. If the clutch air hose
becomes kinked, and air passage through it is restricted, the clutch cannot be
immediately disengaged. This action could create a hazardous condition.
 (8) Always make certain that the clutch sir line lubricator is working properly and that the
clutch and its solenoid air valve are receiving the prescribed amount of approved
lubricant.

(9) The clutch air line lubricator must NEVER be turned off completely. Check frequently
to make certain that lubricant is being used.

(10) NEVER install an exhaust muffler on the clutch solenoid air valve that will restrict the
flow of exhaust air. Never install a muffler that is smaller than the valve exhaust port
pipe size.

(11) Make certain that all presses and associated equipment are properly connected to
earth ground with electrical conductors sized to comply with recognized codes.

(12) NEVER remove safety blocks from one press to use in another. Proper safety block
length is dependent upon stroke length and shut height of the press component and
of the dies that are used in that press. Each press must have its own set of safety
blocks.

(13) When working with another man or crew, be sure all persons are clear of the press
before inching or cycling the slide.

(14) Order replacement signs for any WARRING signs that may have been damaged, lost
or defaced. install new sings at the previous or recommended location on the press.

(15) Achieve a zero energy state of the press and its auxiliary equipment before performing
any maintenance work.

(16) Never leave a machine with the power turned on, even for a short period of time.
Lock controls in the OFF position to prevent unauthorized use and accidental starting.

(17) NEVER use your finger to locate or align holes between parts. Use a drift or sight
visually.

(18) NEVER use compressed air to clean off press parts or dies, or to clean out holes of
"T" slots.

(19) The press rotary limit switch is a vital element in the control system. Make certain the
Limit switch and its driving mechanism are inspected regularly and maintained as
recommended in the service manual.

(20) If the press has sustained a serious jam, or a tooling wreck, the press and dies
should be thoroughly inspected for possible damage before permitting them to be
placed back into production. Never release a press for production that has fractured,
broken or damaged parts. Never install or use dies that have damaged or broken
 components.

(21) After repairs have been completed on the press, replace all safeguards and cover
plates. Check for proper operation in each available operating mode - OFF, Tool set,
inch, single stroke/set-up cycle and continuous. Also make certain that the point of
operation guard and/or device is operating correctly. Never release a press for
production operation until you are sure that it, and any auxiliary equipment, are
performing correctly.

12. Safety Tips for Press Mechanics

Federal regulations require competency of those persons caring for, inspecting, and
maintaining power presses. If you, as a press mechanic, have not been trained for the job
to witch you are assigned, see your supervisor. Your supervisor is the persons who knows
the job you are to be doing You must be trained to service all of the presses in you
assigned work area.

In the performance of your duties, you should regularly demonstrate a sense of personal
safety awareness. The "safety tips" presented in this section may be used as guidelines
for the promotion and development of safe work procedures. Note that they have been
grouped into several basic categories for convenience and quick recall; although for
maximum benefit, it is important that you read and understand all of the item listed. Then,
work accordingly and accomplish your job in a safe manner.
C. Transport & Install

1. Transport

(1) When you use crain, please use 20mm diameter wire and shackles
(2) Use wooden pad on the bottom of machine when you use folk lift truck
(3) Do not lay down machine while transport
(4) Do not use the roller
(5) Pay attention for breakable parts on the machine while transport

2. Install

(1) Make clean the floor

(2) Make machine balance even on the floor
(3) Put stabilized device to prevent machine shaking
(4) Fix the machine by leveling bolt
(5) Keep the height even with other device
(6) Install machine by skilled worker
D. Operation
1. CHECK BEFORE OPERATE

(1) FEEDING LUBRICANT OIL

Check oil balance, fill up oil when it is shortage. Important moving part is feed
by oil automatically. You may apply oil by manual hand gun on part which do not
feed automatically. Lubricant oil is very important for machine running. So please
clean all dust before feed oil. Check oil is automatically running. If you leave it
without oil running, it is main reason to break the machine parts.

※ DO NOT USE WASTE OIL

◎ FEED OIL IN AIR SUPPLY UNIT

☞ Feed oil on solenoid valve prevent rusty. Check oil quantity every week
 (2) AIR SUPPLY

Air is connected to air control panel on the bottom of machine. Connection size
is 3/8" Keep air pressure 4kgf/㎠. Before operate please check air pressure gauge is
right position while working.

◉ Connect air after installation

☞ Check air leakage and air control device. Then increase air pressure
◉ Disassemble and clean
☞ Close air supply. Take out air completely before clean
◉ Drain
☞ After clean, take out water while open the air filter and cork

(3) POWER

To connect power, please turn switch first. After connection turn on switch. When
you have overload, please, turn off right away.
 2. INDICATE OF OPERATION

(1) CONTROL PANEL

 (2) Power System and Main Structure

1. Power System

1-1. Auto Feeder

1) Lift Operate
* Hyd' Cylinder → Movable Chain Roller → Chain → Chain Adapter →
Lift Slide Connector → Lift Slide → Lift Up/Down Operate

2) Suction Cylinder Operate

* Carrier Lever → link → Lm Shaft Slide → Suction Cylinder front/rear operate

1-2. Waxing Machine

1) Insert Roller
* Drive Geared Motor → Chain Sprocket → Chain → Chain Sprocket → Insert Roller
Shaft → Insert Roller

2) Waxing Roller
* Drive Geared Motor → Chain Sprocket → Chain → Chain Sprocket → Lower Roller
Drive Sprocket → Lower Roller Drive Gear & Upper Roller Drive Sprocket → Upper
Roller Drive Gear

1-3. Connecting Conveyor

* Worm Reduced Motor → Chain Sprocket → Chain → Chain Sprocket →

Conveyor Drive Shaft → Drive Roller → Urethane Belt
2. Main Structure

2-1. Auto Feeder

1) Suction Cylinder

: So that can install peripheral device and made use of vacuum

pump so that may be suitable before Gosokun and do control
easily to supply Sheet by one, design or manufactured.
2) Two Sheet Detector

: Because done 2 purchase prices so that is exhausted through

automatic discharger if is detected, emphasized in year
attribute of work and design or manufacture.

2-2. Waxing Machine

1) Waxing Roller

: A couple of woolen rollers are wetted with waxing oil and they spread oil to
Oiling Sub-Roller. The clearance of both, upper and lower, sub-roller is very
important.
 (3) PROCESS

① “OPERATION POWER ON / OFF" SWITCH

USE POWER OF SLITTER CONNECT AND DISCONNECT

② “MAIN MOTOR ON" BUTTON.

START MAIN MOTOR

③ “MAIN MOTOR OFF" BUTTON

STOP MAIN MOTOR
IF IN EMERGENCY, PUSH EMERGENCY STOP BUTTON
THEN, PUSH RESET BUTTON IT WILL BE BACK TO OPERATION

④ MAIN MOTOR SPEED ADJUSTING DIAL

THIS DIAL IS ADJUSTING SLITTER'S SPEED
TURN DIAL SLOWLY CLOCK WISE INCREASE SPEED

NOTE : DO NOT TURN DIAL OVER LIMIT OF CAPACITY

⑤ “OIL PUMP ON" BUTTON.

IF SWITCH IS ”ON" WORKING OIL PUMP, ALSO GREEN LIGHT IS ON THIS SIGNAL
IS GOOD WORKING.

<IF WORKING PROBLEM>

◎ RED LIGHT IS ON, JUST CLEAN OIL FILTER

⑥ "CUTTER MOTOR #1,2 ON/OFF" BUTTON.

THIS BUTTON IS WORKING SLITTER CUTTER MOTOR #1, 2
⑦ "VACUUM ON/OFF" SWITCH
IF SWITCH IS ”ON" WORKING VACUUM PUMP, ALSO GREEN LIGHT IS ON, THIS
SIGNAL IS GOOD WORKING.

⑧ “MANU / AUTO" BUTTON

CHECK AUTO FEEDER TIN PLATE SHEET READY
"AUTO" SWITCH "AUTO START" PUSH BUTTON WORKING MACHINE
“AUTO STOP" PUSH BUTTON STOP THE MACHINE
“MANU" SWITCH PUSH BUTTON WORKING EACH PART

⑨ “LIFTER UP" BUTTON

THIS BUTTON IS GO UP TIN PLATE SHEETS ON THE PALLET BY HYD' CYLINDER

⑩ “LIFTER DOWN" BUTTON

THIS BUTTON IS GO DOWN TIN PLATE SHEETS ON THE PALLET BY HYD'
CYLINDER

⑪ “LIFTER CONV' FOR/REV" BUTTON

THIS BUTTON IS TIN PLATE SHEETS ON THE PALLET FEEDING & DISCHARGE
TO AUTO FEEDER, TURN CONVEYOR MOTOR ON
E. Periodic Inspection
○ When you use machine for a long time, you can see short of oil and loose
screw bolt. If you ignore, it cause short of machine life and worker accident.
So please, check carefully followings.

1. DAILY CHECK

ITEM ACTION

LUBRICANT OIL FILL ON SHORT

HEAT CONTACT US

NOISE CONTACT US

LOOSE SCREW BOLT TIGHT UP

SENSOR WORKING CONTACT US

AIR PRESSURE ADJUSTING REGULATOR

AIR PIPING FIX

OIL PIPING CHANGE NEW

GREASE FEEDING FEEDING PER DAY

LUBRICANT OIL PUMP FEED FILL ON SHORT

REGULATOR WORKING CHANGE NEW

Waxing Roller Scratch CONTACT US

MOTOR WORKING CONTACT US

SWITCH WORKING CHANGE NEW

EMERGENCY STOP S/W CONTACT US

SUCTION PAD ABRASION CHANGE NEW

2. MONTHLY CHECK

ITEM ACTION

GEAR WORKING OIL FILL ON SHORT EVERY 6 MONTH

BEARING BREAKING CHANGE NEW

LUBRICANT OIL RUNNING CHECK OIL PIPING

POWER SOURCE FIX

Waxing Roller CONDITION CONTACT US

Waxing Sub-Roller CONDITION CONTACT US

AIR PRESSURE ADJUSTING REGULATOR

AIR CYLINDER WORKING CHANGE NEW

AIR FILTER WORKING CHANGE NEW

SUCTION PAD ABRASION CHANGE NEW

BELT CONDITION CHANGE NEW

3. YEARLY CHECK

ITEM ACTION

BELT PRESSURE CHANGE

CHAIN SPROCKET CONDITION FIX

MOTOR PULLEY CONDITION TIGHT UP

MOTOR NOISE CONTACT US

FRAME CONTACT US

CHAIN SPROCKET SAFETY

FIX
COVER

ELECTRIC CIRCUIT CHECK

WIRING IN THE CONTROL PANEL CHECK

ELECTRIC WIRE FIX

GEAR CONDITION CONTACT US

AIR TANK CONDITION CONTACT US

F. Electric Circuit Diagram