BLACK a WEBSTERAIR PRESS

MODEL AP1200

INSTALLATION) OPERATING)& MAINTENANCE INSTRUCTIONS

Black & Webster Assembly Equipment Division545 Hupp Ave. • P.O. Box 831 • Jackson, Michigan 49204

Phone: (517) 787-9444 • Fax: (517) 787-7585

FORM REV. 199704

TABLE OF CONTENTSInstallation and set up ........••....••.....••••••••• 1

Maintenance and disassembly •••••••..........••.•.•••• 2

Troubleshooting guide 3Pneumatic circuit •.••.••.•..•.••••............••...•• 4Parts list........................................... 5

Parts drawing........................................ 6

MACHINE GUARDINGMachine guarding is the responsibility of the user. Provisionsmust be made to protect the operator and other employees frominjury as a result of contact with work in progress, moving parts,mechanical motions of the press, etc. Air-Hydraulics cannotprovide "standard" guards for its products due to the variety oftooling used by its owners. However, Air-Hydraulics will be happyto install guards and similar safety devices for operatorprotection. These safety devices must be produced at the requestof, and with design approval of purchaser.

WARRANTYWe warrant to the original user that all products of ourmanufacture will be free from defects in material and workmanshipand will possess the characteristics represented in writing by us.Claim for breach of the above warranty must be made within a periodof one (1) year from date of delivery to the user. Uponsatisfactory proof of claim, we will make any necessary repairs orcorrections, or, at our option, replace defective parts at thefactory, transportation charges prepaid. Charges for correctingdefects will not be allowed, nor can we accept goods returned forcredit unless we are notified in writing and the return correctionis authorized by us in writing. THE FOREGOING IS IN LIEU OF ALLOTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTIESTHAT EXTEND BEYOND THE DESCRIPTION OF THE PRODUCT. This paragraphsets forth the extent of our liability for breach of any warrantyin connection with the sale or use of our products. It isunderstood we will not be liable for consequential damages such asloss of profit, delays, or expense, whether based on tort or contract.

INSTALLATION1. Place press on rigid bench or table at a convenient height for

operator. Bolt securely to bench.

2. Connect 100 P.S;I. filtered shop air supply (40 micron min) to3/8 N.P.T. inlet port of pressure regulator.

SET UP AND OPERATION1. Loosen locknut and adjust pressure regulator until pressure

gage reads desired pressure (100 P.S.I. max ), CAUTION: Do notoperate at pressure greater than 125 P.S.I.

2. Adjust speed control valve to slow decent of shaft by turningouter hex sleeve.

3. Check to be sure safety sleeve assembly is ln correct positionon the press before operating.

4. Keeping hands clear of shaft, actuate press by depressing handvalve pedal(s).

5. Release pedal (s), shaft should return to fully retractedposition.

6. Remove safety sleeve from press.

7. Loosen locking nut and adjust stop nut to obtain desiredstroke. Distance between bottom of stop nut and top surfaceof stop cap or frame is the stroke of the shaft. CAUTION: Donot back off locking nut beyond top of threaded shaft. Doingso may damage packings.

8. Replace safety sleeve and re-actuate press.9. If necessary, re-adjust stop nut, speed control and pressure

regulator to obtain desired setting. CAUTION: Never operatepress unless safety sleeve is in place and hands are clear ofshaft.

10. Install tooling into hole provided in shaft, securing with setscrew.

11. Install dies, nests or anvils onto base using tapped holesprovided.

12. Make any final stroke, speed and pressure adjustments toobtain desired workpiece configuration with tooling in place.

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MAINTENANCE

LUBRICATIONAir-Hydraulics presses are lubricated at the factory and shouldrequire no additional lubrication. However, if a press isdisassembled for service or replacement of parts, all internalsurfaces should be coated with a light bearing grease such asLubriko M6 (Master Chemical Co.) or equivalent.

PRESS DISASSEMBLYShould press disassembly become necessary, use extreme CAUTION.This press has a heavily compressed return spring under the piston.When removing cylinder end cap, the cap should be securely held inposition until retaining screws are removed and then raised veryslowly until spring compression is fully released. Failure to doso will result in various parts separating abruptly, possiblycausing injury to personnel. Re-assembly should be approached inthe same cautious manner.

Air-Hydraulics, Inc. maintains complete facilities, at all times,for repair of presses. If qualified maintenance personnel are notavailable at a customer's facility, the press may be returned tothe factory for service.

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ProblemTROUBLESHOOTING GUIDE

CauseA. Shaft fails to 1. Insufficient alr

extend after pressure.hand valveactuates, orfails to return 2. Speed control valveto rest position. closed or clogged.

B. Ram moveserratically.

C. Excess shaftrotation.

D. Reduced forceat a givenpressure.

3. Power valve notshifted.

4. Hand valve clogged.5. Shaft bent.

6. Anti-rotation keyjammed.

7. Return spring jammedor broken.

1. Insufficientlubrication.

2. Air leaking pastpackings.

3. One or more valvesclogged or leaking.

1. Anti-rotation keyworn.

1. Air leaking pastpackings.

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Remedy1. Check air supply,

adjust or cleanregulator.

2. Open speed controlvalve or cleanvalve of dirt.

3. Check for adequatepilot air from handvalve, and forjammed spools.

4. Clean hand valve.

5. Replace shaft.

6. Disassembly key,check for wear ordamage, replaceif necessary.

7. Free spring orreplace.

1. Re-lubricatepress (seemaintenance).

2. Replace packings.

3. Clean or repairvalves.

1. Inspect key,replaceif required.

1. Replace packings.

PNEUMATIC DIAGRAM

SINGLE ACTING CYLINDER WITHDUAL PALMS & ANTI- TIE DOWN

FlL TER/R£GULATOR

SA CYlJNDER

P8 1

AN17-nEDOWN

DIRECnONALVALVEP82

AP 1200

Length of stroke • •• • ••.•••• 0-2" adjustableThroat depth. • • • • . • • • •• •• 5.00"Opening of ram to base 6.00"Tool hole in ram. . . • • • • • . .18 dia. x 1.50 dp.Force at 100 p.s.i. . . . . . .. Up to 1200 lbs.Ram style . . • • • • • • KeyedNet weight (less controls) ......•. 100 lbs.Controls (optional). • . . • . Flow control valve

Pressure regulatorPressure gaugeHigh flow power valveExhaust air muffler

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Part #

20303520335120335220335520335402203364203360203363203230203358203359203357203368203362203107203065

203356

203382

* Not shown

PARTS LISTAP1200 AIR PRESS

Description 2iYBase 1Frame 1Cylinder 1Shaft 1Stop cap 1Retaining ring 1Bottom cup washer 1Cup washer 1Key 1Packing 1Cup packing 1Retaining washer 1a-ring 1Return spring 1Safety sleeve 1Straight base (optional) 1S.H.S.S. #10-32 x 1/4" Lg 1S.H.S.S. 5/16-18 x 1/2" 19 1S.H.C.S. 1/2-13 x 2-1/4" 19 4Downstop nut 1Lock washer 3/4" 1Bolt square head 4(5/16-18 x 5-1/2" long)Self-locking nut 1" - 14 1Repair kit (203358,59,64,68) 1

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