Mini Pod Press Model - #78H-M2 SN - Year - JLT Clamps 108 Parker Ave. Poughkeepsie, NY 12601 Tel: (800) 901-8037 Fax: (845) 452-0764 E-mail: clampguys@jltclamps.com Web: http://www.jltclamps.com
TABLE OF CONTENTS Table of Contents INTRODUCTION...3 Company Introduction... 4 Limited Warranty... 5 Machine Requirements and Layout... 6 RULES FOR SAFE OPERATION...7 Types of Warnings... 8 General Safety Rules... 9 Machine Safety Decals... 10 INSTALLATION...12 Receiving & Unpacking... 13 Position the Machine... 14 Connecting Air... 14 OPERATION...15 Safety & Training... 16 Operating Controls... 17 Main Disconnect Valve... 17 Dial Pressure Regulator(s)... 17 Air Lock Valves... 18 Adjusting the Platens... 18 Loading the Press... 19 Applying Pressure... 19 Calculating Glue Line Pressure... 20 Opening the Press... 21 TROUBLESHOOTING...22 Operational Troubleshooting... 23 MAINTENANCE...24 Maintenance Checklist... 25 PARTS & SERVICE...26 Model & Serial Plate Location... 27 Recommended Spare Parts... 28 Parts Order Form... 29
INTRODUCTION INTRODUCTION INTRODUCTION 3
INTRODUCTION Company Introduction We at JLT Clamps would like to thank you and your company for selecting the JLT Mini Pod Press. With proper care, your Mini Pod Press will provide you with many years of reliable service and high quality production. INTRODUCTION This manual contains important information about the installation, operation and maintenance of your Mini Pod Press. We urge you to read it carefully, become familiar with the components and features it describes, and follow its recommendations, to help make your machine as trouble-free and productive as possible. This manual is intended for use by anyone working with this machine. It should be kept available for immediate reference so that all operations can be performed with maximum efficiency and safety. Do not attempt to perform maintenance or operate this machine until you have read and understand the information contained in this manual. 4
INTRODUCTION Limited Warranty (This supersedes all previous warranties) JLT Clamps guarantees all products of its manufacture to be free of defects in workmanship or material when properly installed, serviced and maintained under normal conditions. JLT Clamps' obligation under this warranty is limited to repair ing or replacing any part or parts thereof which shall within one (1) year after shipment to the original user, be returned to its factory, transportation charges prepaid, and which JLT Clamps' examination shall disclose to be defective. INTRODUCTION JLT Clamps assumes no liability for labor charges incidental to the adjustment, service, repairing, or removal or replacement of parts or other losses, or for ex pense of repairs made outside of its factory, except when made pursuant to JLT Clamps' PRIOR written consent. JLT CLamps does not guarantee equipment furnished by us, but manufactured by others, such as belts, electric motors, starters, controls or other electrical equip ment or accessories, as they are guaranteed separately by their respective manufacturers. JLT Clamps assumes no liability whatever for any of these parts claimed to be defective or for damages or delays caused by defects beyond making such repair or furnishing duplicate parts within the manufacturer s warranty, nor shall we be liable for any defective material repaired or replaced without our consent. The foregoing shall constitute the fulfillment of all of our obligations under this warranty and there are no other warranties or guarantees, expressed or implied except as stated herein. 5
INTRODUCTION Machine Requirements and Layout The Mini Pod Press requires 100 psi air pressure. INTRODUCTION 42 5/8" 85 1/4" 127 7/8" XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX Three Individual Top Platens 10'-8" Platen Single Lower Platen 15" Opening 12" Platen 36" 6'-4" Height XXXX XXXX XXXX XXXX XXXX XXXX 6
INTRODUCTION INTRODUCTION Air Connection: 1 CFM @ 100psi (28 l/min @ 6.9 Bar) Load/Unload Area Operator Control #78H- Lower Platen Height Adjustment #78H- Manual Layout MATERIAL NAME: Description: Created: 1/12/2012 by: Jacob D. Greenfield Modified: 3/7/2012 by: Administrator DWG. NO. #78H- SCALE: 1:20 James L. Taylor Mfg. Co. Poughkeepsie, NY, USA WEIGHT: 1351.53256 REV SHEET 1 OF 1 7
RULES FOR SAFE OPERATION RULES FOR SAFE OPERATION RULES FOR SAFE OPERATION 8
RULES FOR SAFE OPERATION Types of Warnings This is the safety alert symbol. It is used to alert you to potential injury hazards. Obey all safety messages that follow this symbol to avoid possible injury.! RULES FOR SAFE OPERATION DANGER in white letters on a safety red background with a safety red exclamation point. This indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING in black letters on a safety orange background with a safety orange exclamation point. This indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. CAUTION in black letters on a safety yellow background with a safety yellow exclamation point. This indicates a potentially hazardous situation which, if not avoided, COULD result in minor or moderate injury.!!! DANGER WARNING CAUTION 9
RULES FOR SAFE OPERATION General Safety Rules Follow lockout procedure before servicing. Read and understand manual before operating machine. Wear eye protection. See the plant supervisor to determine what protective equipment each job requires. Follow electrical and fire codes. RULES FOR SAFE OPERATION Do not wear loose clothing, jewelry or long hair around operating equipment. Keep guards in protective position when machine is operating. Keep clear of belts, chains, saw blades and moving parts.! DANGER Lockout ALL energy sources before servicing. 10
RULES FOR SAFE OPERATION Machine Safety Decals The following warning stickers are used on your machine. Over time, these stickers can become worn and illegible. New stickers can be obtained from: James L. Taylor Mfg. Co. 108 Parker Ave. Poughkeepsie, NY 12601 Tel: (845)-452-3780 Fax: (845)-452-0764 E-mail: clampguys@jamesltaylor.com RULES FOR SAFE OPERATION Part Number: Description: PLA37.206 Read Manual Warning Sticker Location: On the Lower Platen. 11
RULES FOR SAFE OPERATION Part Number: Description: Sticker PLA78.404 Pinch Point Warning RULES FOR SAFE OPERATION Facing Operator on Up- Location: per Platen Part Number: Description: Sticker PLA.190 Pinch Point Warning Facing Operator on Up- Location: per Platen 12
INSTALLATION INSTALLATION INSTALLATION 13
INSTALLATION Receiving & Unpacking Inspect the skid and its boxes for shipping damage. If any shipping damage has occurred, notify the shipping company immediately. The Mini Pod Press has been quality inspected and tested at our factory. INSTALLATION 14
INSTALLATION Position the Machine Move the machine off the skid and position it in a flat, level area. Make sure all four corners of the foot pads rest securely on the floor so the machine doesn't rock. Make sure the operator controls are easily accessible and that there is plenty of room for getting material into and out of the press. Connecting Air Connect an air line to the main shutoff valve provided. The Mini Pod Press requires 100 psi air. It will work at lower air pressures, but it won't generate full clamping pressure. Make sure your air supply never surpasses 120 psi, or the machine may be damaged. If your air pressure surpasses 120 psi, install an air pressure regulator before the Mini Pod Press. INSTALLATION 15
INSTALLATION Dismantling To dismantle the machine, reverse the Installation (Assembly) instructions. Resell or dispose of the components according to your local regulations. INSTALLATION 16
OPERATION OPERATION OPERATION 17
Safety & Training OPERATION According to many OSHA, ANSI, STATE, and LOCAL CODES it is the EMPLOYER'S RE- SPONSIBILITY to: Permit only trained and authorized employees to operate equipment. Inspect and maintain guards, safety devices, and start/stop controls. Instruct, train, and supervise the safe method of work! Be sure personnel are properly trained and safety rules are clearly understood before operating or performing maintenance! OPERATION 18
OPERATION Operating Controls The following are the necessary controls for the general operation of the Mini Pod Press. Familiarize yourself with the location, operation, and purpose of each control before proceeding to operate the machine. Main Disconnect Valve Located on side of the machine. Rotate the handle on this valve to supply air to the system or exhaust the air in the system. Keep in mind that to exhaust all air from the system, the Air Lock Valve(s) also need to be opened (see below). Dial Pressure Regulator(s) Single station presses have a single dial pressure regulator. Larger machines have independent dial regulators for each upper platen. These regulators should be used for the primary operation of the machine. To energize the upper platen, dial the regulator to the desired pressure (see chart in a later section). The higher the dial is set, the higher the force generated. OPERATION To release the press pressure, dial the regulator back to zero. 19
OPERATION Air Lock Valves Each dial regulator is accompanied by an air lock valve. Under normal operation, these valves will not be used. When a press is going to remain energized over night, these valves can be energized to trap the air in the machine regardless of whether the air supply is cut off (the air compressor is shut down for the night). Cylinder Shutoff Valves Each cylinder is accompanied by an air shut off valve. These valves are used to turn off air cylinders that are not needed for a particular clamping job. Specifically, you should use these valves when there is no material below a particular cylinder. Failure to use these valves could result in damage to your product and/or your machine. OPERATION Adjusting the Platens Both the upper and lower platens are vertically adjustable to accommodate a wide range of laminating projects. Platen adjustment is designed for quick changeovers. To adjust the lower platen, first make sure that the lifting mechanism is properly supporting the weight of the lower platen. Next, remove the bolts attaching the platen to the machine frame. Reposition the platen using the adjusting mechanism. Note that you may need to change the position of the lower pin multiple times if you are making a large adjustment. Reinstall and fully tighten all of the bolts. Open Closed 20
OPERATION Using a forklift, you can also adjust the height of the upper platens if desired. OPERATION Loading the Press When loading the press, make sure to center the material on the platens. Failure to do so will result in uneven clamping pressure and may damage the machine. To simplify the loading of longer machines, it may be desirable to place a simple roller conveyor at the end of the machine. Material can be laid up on the conveyor, then rolled into the press. 21
OPERATION The upper platen has a stroke of 2 1/4" and achieves maximum force toward the middle of this stroke. It is best to load the machine so that there is around 1" of clearance between the material and the upper platen before the pressure is applied. Applying Pressure To apply clamping pressure, slowly turn the dial pressure regulator in the clockwise direction. Continue to turn the regulator until the upper platen begins to move and then makes contact with the material to be glued. Continue to turn the regulator until the desired glue line pressure is achieved (see below). Calculating Glue Line Pressure Glue manufacturers will recommend a particular glue line pressure for their glues. They typically recommend pressures that are higher than necessary for materials that are properly prepared. This being said, their numbers are often a good starting point. OPERATION The air pressure shown on the dial regulator is not the same as the glue line pressure. To calculate glue line pressure, you need to know the surface area of the material 22
OPERATION you are gluing. If the material being glued is 36" long by 6" wide, then the surface area is 36" times 6", or 215 square inches. This is the surface area regardless of how many pieces are stacked. You also need to know the total force generated by the press. Use the chart at the right to determine the press force for a particular dial regulator setting. To calculate the glue line pressure, divide the total press force by the material surface area. To work backward, start with the recommended glue line pressure. Multiply this by the material surface area to get the total force required. Use the chart at the right to determine the proper dial regulator setting. Opening the Press OPERATION To open the press, turn the dial regulator all the way counter clockwise. 23
TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING 24
TROUBLESHOOTING Operational Troubleshooting Problem Solution. TROUBLESHOOTING 25
MAINTENANCE MAINTENANCE MAINTENANCE 26
Maintenance Checklist (Photocopy for use) MAINTENANCE Comments Date Initials Daily Maintenance Checklist Monthly Maintenance Checklist MAINTENANCE "Three Month" Maintenance Checklist 27
PARTS & SERVICE PARTS & SERVICE PARTS & SERVICE 28
Model & Serial Plate Location PARTS & SERVICE You will find the Model plate on the front of the Mini Pod Press. You will need this information for ordering spare or replacement parts. PARTS & SERVICE 29
PARTS & SERVICE Recommended Spare Parts The following are recommended spare parts for your machine. You may want to stock the noted quantity of these items to prevent any down time due to shipping: QTY PART NAME DESCRIPTION 1 CYL.BE.20 Type 30 Service Chamber 1 SPGC35.207.1 Spring-2.1875 x 8 x.207 1 78-400-8 Plate-Guide-Poly PARTS & SERVICE 30
PARTS & SERVICE Model Sheet Config Shown: -12-42-40-M2 7 8 9 10 4 14 6 11 3 2 15 13 1 12 5 78-400- -12-42-40-M2 ITEM NO. PartNo Description QTY. 1 78-400-11- Channel-Frame Stiff 2 2 78-400-12- Sheet-Leg 2 3 78-400-12- Sheet-Leg 2 5 78-400-14 Sheet-Foot 2 7 78-400-4 Plate-Spring 2 8 78-400-8- Plate-Guide-Poly 4 9 821-100- Weldment - Cylinder Frame 10 SPGC35.207.1 Spring - 2.1875 X 8 X.207 2 1 11 78-400-A1 Upper Platen 1 12 821-101- Welded Platen-Lower 1 13 78-405- Welded Jack-Pod Press 1 14 CYL.BE.40 Type 20 Service Chamber 15 78-402- Plate-Poly 2 6 #78H- Model Sheet - Pod Press MATERIAL NAME: Description: Created: 1/10/2012 by: Jacob D. Greenfield Modified: 3/7/2012 by: Administrator DWG. NO. 78-400- -12-42-40-M2 SCALE: 1:24 James L. Taylor Mfg. Co. Poughkeepsie, NY, USA WEIGHT: 675.76628 REV SHEET 1 OF 1 PARTS & SERVICE 31
PARTS & SERVICE Parts Order Form 1. Sold to: Company Address Address City State Zip Your Name Phone # Fax # Purchase Order # 3. Parts Needed: 2. Ship to: Company Address Address City State Zip Attention: Phone # Fax # Purchase Order # Quantity Part Name (see parts list) Description Price (each) 4. Preferred Shipping Method: (check one) UPS Regular Truck Customer Pickup UPS Next Day Air Carrier: Other: Air Freight 5. Fax, Mail, or Phone your Order to: JLT Clamps 108 Parker Avenue Poughkeepsie, NY 12601 Phone: (800) 901-8037 Fax: (336) 375-1112 PARTS & SERVICE 32