AIM Joraco TOCCLE-AIRE HP-16 Accompaniment To The Installation, Operation And Maintenance Manual Download Page 3

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HYDRO-PNEUMATIC SERIES PRESSES

OVERVIEW, INSTALLATION, AND OPERATION

Index

Section I - Press Overview

1.1 - Description
1.2 - Features
1.3

–

Options

1.4

–

Cylinder Components

1.5 - Function

Section II - Valving

2.1

–

Pneumatic Circuit

2.2

–

Valving Connections

Section III - Installation

3.1

–

Un-boxing

3.2 - Synchro-Sig Installation

3.3

–

Mounting Press

3.4

–

Connect Air Supply

3.5

–

Turn On Air Supply

3.6

–

Test the Installation

Section IV - Set-Up and Operation

4.1 - Mounting Tooling

4.2 - Stroke Limitation

Section V - Venting, Purging, Filling

5.1

–

Vent / Fill

5.2

–

Purge / fill

Section VI - Troubleshooting

6.1 - Ram Will Not Extend

6.2 - Ram Will Not Retract
6.3 - Cylinder Will Not Switch to

Power Stroke Cycle

6.4 - Frequent Oil Fills
6.5

–

Press Not Generating Pressure

6.5

–

Ram Will Not Fully Retract

Section VII - Engineering Data

7.1 Standard Specifications

7.2 Cylinder Mounting

7.3 Bolster Plate Mounting

7.4 Cycle Times Charts

7.5 Force

Section VIII

–

Replacement Parts

8.1 Replacement Parts List

Summary of Contents for TOCCLE-AIRE HP-16

Page 1: ... OVERVIEW INSTALLATION AND OPERATION AUTOMATEDINDUSTRIALMACHINE INC TOGGLE AIRE DIVISION 347 Farnum Pike Smithfield RI USA 02917 401 232 1710 www joraco com Installation Operation and Maintenance Hydro Pneumatic Series Bench Presses ...

Page 2: ...pment Because it is impossible to anticipate the conditions under which our equipment will be operated additional safety devices and methods may be required to ensure operator safety Besides conforming to all federal state and local codes the buyer should consider the safety of the entire operation involving any press and see that any additional guarding training and maintenance deemed necessary i...

Page 3: ...3 6 Test the Installation Section IV Set Up and Operation 4 1 Mounting Tooling 4 2 Stroke Limitation Section V Venting Purging Filling 5 1 Vent Fill 5 2 Purge fill Section VI Troubleshooting 6 1 Ram Will Not Extend 6 2 Ram Will Not Retract 6 3 Cylinder Will Not Switch to Power Stroke Cycle 6 4 Frequent Oil Fills 6 5 Press Not Generating Pressure 6 5 Ram Will Not Fully Retract Section VII Engineeri...

Page 4: ... up to power stroke 8 open height 20 between columns and an 8 x 10 precision ground bolster plate Our HP Series Presses cut down on air consumption but still deliver the maximum force required for your application 1 2 Features Self contained Clean Quiet Adaptable No springs Only 3 moving components No external hydraulics 1 3 Options EZ Dial Force Regulator Adjustable Output Filter Regulator Lubric...

Page 5: ... Pressure Advance 2 Rapid Advance 3 High Pressure Intensifier 4 High Pressure Cylinder Head 5 High Pressure Intermediate Cylinder Head 6 Low Pressure Intermediate Cylinder Head 7 Low Pressure Cylinder Head 8 Tie Rod Plate 9 Ram 10 Tie Rod 11 Venting Plug 12 Pressure Gauge 13 4 Way Valve 14 Bleed Fill Valve 15 HP Sensor ...

Page 6: ...to ports A1 and A2 fully retracting the high pressure rapid advance and intensifier pistons Rapid Advance For the cylinder to begin rapid advance compressed air is supplied to port B1 This forces the rapid advance piston down towards the working end of the cylinder forcing oil from the reservoir to the top of the intensifier piston until resistance is met ...

Page 7: ...ract as mentioned above Power Stroke Only Option HP Series Presses are also sold as power stroke only This will simply eliminate the rapid advance section and shorten the total travel of the cylinder For the cylinder to begin the power stroke compressed air is supplied to port B2 This forces the high pressure piston and rod down towards the working end of the cylinder In the power stroke only conf...

Page 8: ...HYDRO AIRE SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE 5 Section II Valving 2 1 Pneumatic Circuit ...

Page 9: ... OPERATION AND MAINTENANCE 6 2 2 Valving Connections Valving Connections Valving Description 1 1 Rapid Advance 2 2 Low Pressure Retract 3 3 High Pressure Retract 4 4 High Pressure Advance 5 5 High Pressure Signal S 6 6 High Pressure Power P ...

Page 10: ...ct the tubing to the appropriate fittings on the actuator See markings on the tubing DO NOT OVERTIGHTEN normally 1 2 turn past finger tight is sufficient for an airtight connection Figure 1 1 B Using the 1 4 20 hex head bolts supplied mount the Synchro Sig to the press as shown Be sure to mount the aluminum lever guard between the actuator and the press at the same time Figure 1 2 NOTE To ensure o...

Page 11: ...he press should be the equivalent of 1 2 minimum B The minimum air pressure for operation is 50 PSI the maximum is 100 PSI The optimum operating range is 60 100 PSI If your application consistently required substantially more than 100 PSI it may indicate the need for a stronger press C Connect air supply to the press at the inlet port NOTE If lower are pressure is required consult factory about EZ...

Page 12: ...EDLY IF HEAVY TOOLING IS BEING USED BE SURE TO PLACE A STOP UNDER TOOLING BEFORE TURNING OFF AIR SUPPLY NOTE When the press is not in use or being serviced or maintained always SHUT OFF the air supply and replace the lockout device Secure with a padlock etc to prevent unauthorized use of the press CAUTION BEFORE PROCEEDING MAKE SURE THE TABLE AND WORK AREA IS CLEAR OF ALL TOOLS FOREIGN OBJECTS AND...

Page 13: ... Mount your tooling A Using the tapped holes in the press platen mount the lower portion of your tooling to the press The platen is machinable and can be drilled and tapped as necessary The standard bore in the press ram is 8125 with a depth of 1 5 Precisely fit your shank to the bore of the ram and lock the shank in with the 5 16 18 hardened lock screw located on the face of the ram The end of th...

Page 14: ...ions the travel of the cylinder must be limited after completing the work required This limitation can be built into the tooling that is being used for the application with the use of die springs Failure to limit the travel of the cylinder in these types of applications may cause damage and premature failure of the cylinder ...

Page 15: ... SO COULD RESULT IN OVERFILLING OF THE CYLINDER WHICH COULD CAUSE DAMAGE MALFUNCTION IT IS RECCOMENDED TO WEAR EYE PROTECTION WHEN PERFORMING THE FOLLOWING PROCEDURES Items Required Hydraulic Oil HF 101 ISO VG 32 AIM Joraco Oil Pump HP 100F Flathead screwdriver 7 16 wrench Shimming material Catch can Eye protection recommended Figure 1 Figure 2 ...

Page 16: ...s in the home position cylinder retracted 2 Place shims between the bolster plate and the ram It is important to get the shims as tight as possible to ensure the correct amount of oil will be added to the cylinder 3 Dump the air to the cylinder by releasing the sleeve valve 4 Open venting plug screw See Figure 1 5 Make sure that AIM Joraco Oil Pump HP 100F is filled with oil 30 fl oz min and vente...

Page 17: ...ome force may be required 9 Continue pumping oil until it begins to flow out of the vent hole and is free of any air bubbles 10 Wait 30 minutes to allow any remaining bubbles in the oil to escape then repeat step 8 11 Turn screw on bleed valve P3 clockwise until it stops valve closed 12 Wipe any excess oil from the cylinder tube making sure the area around the vent hole is clean and dry 13 Replace...

Page 18: ...amount of oil will be added to the cylinder 3 Dump the air to the cylinder by releasing the sleeve valve 4 Open venting plug screw See Figure 1 5 Disconnect hose from port P1 on 4 way valve See Figure 1 6 Disconnect hose from port P2 on 4 way valve See Figure 1 7 Attach Poly flow line to bleed valve P3 See Figure 2 8 Route Poly flow line to catch pan to retain oil being removed from cylinder 9 Tur...

Page 19: ...pen 16 Begin pumping oil from AIM Joraco Oil Pump HP 100F some force may be required 17 Continue pumping oil until it begins to flow out of the vent hole and is free of any air bubbles 18 Wait 30 minutes to let any remaining bubbles in the oil to escape then repeat step 8 19 Turn screw on bleed valve P3 clockwise until it stops valve closed 20 Wipe any excess oil from the cylinder tube making sure...

Page 20: ...to replace Tooling is binding Inspect repair tooling Cause Solution Insufficient air supply Increase air supply pressure Defective valve Contact AIM Joraco to replace Tooling is binding Inspect repair tooling Cause Solution Air lines routed incorrectly Refer to section 2 1 Defective valve Contact AIM Joraco to replace Defective HP sensor Contact AIM Joraco to replace Cylinder low on oil Refer to s...

Page 21: ...n Insufficient air supply Increase air supply pressure Cylinder low on oil Refer to section 5 1 Cylinder out of working range Adjust tooling Damaged worn seals Send cylinder to AIM Joraco Cause Solution Insufficient air supply Increase air supply pressure Tooling is binding Inspect repair tooling Air trapped in oil reservoir Refer to section 5 1 ...

Page 22: ...nting Specifications HP 4 HP 8 HP 16 Force at 100 PSI 9 700 lbs 17 700 lbs 34 200lbs Air Consumption at 80 PSI 0 76 cf 1 15cf 1 80cf Open height 8 0 Total stroke 1 2 Power Stroke 4 0 Working area H frame 20 L R 10 F B Ram mounting 13 16 Bore 1 2 Deep Model AA HP 4 1 2 13 HP 8 1 2 13 HP 16 3 4 16 H Frame Cylinder Mount C Frame Cylinder Mount ...

Page 23: ... Plate Mounting NOTE CUSTOM MOUNTING HOLES AVAILABE UPON REQUEST 7 4 Cycle Times Cycle times vary depending on the volume of air supplied to the unit by the customer the length of the stroke and the weight of tooling applied to the press H Frame Bolster Plate C Frame Bolster Plate ...

Page 24: ...Force Multiplier Pressure Multiplier Approach Force Retract Force HP 2 53 69 x line pressure 8 27 x line pressure 5 71 x line pressure 4 73 x line pressure HP 4 97 53 x line pressure 8 27 x line pressure 11 00 x line pressure 10 00 x line pressure HP 8 177 16 x line pressure 15 02 x line pressure 11 00 x line pressure 10 00 x line pressure HP 16 342 54 x line pressure 29 05 x line pressure 11 00 x...

Page 25: ... HP8 CYL Replacement Cylinder 8T STANDARD HP4 CYL Replacement Cylinder 4T STANDARD HP2 CYL Replacement Cylinder 2T STANDARD HP RAM E Ram Height Extention w 1 Adjustment and Threaded Screw SS PB 18 Puch Button Pneumatic Synchro Sig Two Hand Actuator 18 EZ DIAL Easy Dial Pressure Regulator 270 Sweep PRS 1000 Pressure Return System SCM Speed Control Mufflers HP VPKG HP Valve Package Complete ...

Page 26: ...manufacturer warrants that all TOGGLE AIRE Direct Aire products will be free from defects in material and workmanship for a period of 180 days from the date of shipment to the original purchaser Any claim made against this LIMINTED WARRANTY must be made by contacting the customer service department of the manufacturer At its option A I M will repair or replace any product it deems defective under ...

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