User Manual, Model 3530
Contents
1. 3E UP VALVE 3 Way Toggle Viv A RETURN VALVE 3 W ay Pin Plunger Viv CSR G2 MODULE POWER VALVE Spring Return SHU UTTLE VALVE Pomel Models 1030 1530 2530 amp 3530 13 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE About Control Systems Unless otherwise specified your TOGGLE AIRE press has been shipped complete with all valving necessary for two hand single stroke operation including one of our SYNCHRO SIG series two hand anti tie down actuators The actuators provide state of the anti tie down control The two levers on the SS DM series or the two photo optic buttons on the SS OT series must be simultaneously activated to provide a down signal to the press When one or both are released the down signal is terminated Both levers or buttons must be totally released before the units will allow another down signal The units cannot be locked or tied down to allow single hand operation Standard presses are valved to operate in the impulse or BEM Mode That is once the press has been activated the ram will descend to the bottom of the stroke The ram will not reverse until it has reached maximum strength and travel Repeatability in this mode is plus or minus 001 In some applications i e very slow ram speed special loading considerations etc you may desire to have the ram reverse when the operator2. 11 3500 Cie 12 3500 SS ten teats 13 3500 FrOnt Plate JP 14A 39 Main Pivot Pin with Retaining 8 22 JP 27 PRN CGN ee JP 33 3500 Adj sting Screw JP 90B 0000 IRIVOUPIM JP 39673900 teas 54 3500 PIVO Pi 55 3500 PIN OL Bl 56 3500 3500 Hnkage Beanng Cylinder Parts 3500MC Main Cylinder Complete JP 4 3500 Replacement Cylinder Tubes Std Stroke 5 JP 1 5 3500 PISTON FROG ASSEMDI Y nerse JP 26 Cylinder Screw w lock washer Set Of 4 JP 32 Cylinder Hold Down Screw Set of 2 SK 3500 Oy IG Cl INI eaten Control Parts 3500MVA Main Power Valve A 3500 asidinin ianei ienien 1026B ROUN I
3. The Pneumatic Toggle Press Innovators Since 1947 AUTOMATED INDUSTRIAL MACHINE INC TOGGLE AIRE DIVISION 347 Farnum Pike Smithfield RI USA 02917 401 232 1710 www joraco com Installation Operation and Maintenance 16 Ton 3500 Series Bench Presses IMPORTANT It is the responsibility of the employer purchaser to provide his or her employees with proper point of operation guards and to insure that this equipment is used accordance with the manufacturer s recommendations as well as any OSHA federal or state regulations that are applicable to such equipment Because it is impossible to anticipate the conditions under which our equipment will be operated additional Safety devices and methods may be required to insure 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 is developed and enforced to protect the well being of the operator THINK SAFETY WORK SAFELY COPYRIGHT 2010 y AUTOMATED INDUSTRIAL MACHINE INC Smithfield RI USA All rights reserved TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Section Installation 1 Carefully remove the press from the crate taking note of separately packed items such as the Synchro Sig Two Hand Actuator Filte
4. Replacement Valve 53 00 GK 3500 Rear Guard Kit 2 rear 5 80 00 PC 3500 Pneumatic Electronic Stroke Counter 196 00 L 2 P 3500 One Shot Lube System 459 00 L 2 P 2CC Pump Assembly Only One Shot Lube 150 75 DT 3500 Bottom of Stroke Dwell 250 00 FRL 3500 Filter Regulator Lubricator Unit 249 00 Tooling Components TL 4 6 Punch Toggle Lock PUNCH each 54 00 TL 4 6 Die DIGASSEMDIY 195 00 RD Post Hardened Alignment post 46 00 Call for current prices and availability 1 888 889 4287 12 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Valving Schematic BEM Mode Standard Mode G 3530 On Off Valve 3530 Set Up Valve 3530 Return Valve Aux Ram Up Valve Ti 3530 Cylinder q Hoe c 0 3530 Quick Exhaust Valve 7 Synchro Sig Actuator Valving Schematic CSR G2 Mode Constant Signal Required
5. Section Paragraph 2 return the valve lever to the up position The ram will immediately return to the top of the stroke After using the Set Up valve always lock the valve in the up position using the locking screw THIS VALVE IS NOT DESIGNED FOR USE IN PRODUCTION AND SHOULD ONLY BE USED BY AUTHORIZED AND QUALIFIED PERSONNEL 16 Optional Auxiliary Ram Up Valve On BEM control systems only 2530BEM presses are equipped with an Aux Ram Up Valve It is used to manually reverse the press ram to the up position during set up procedures or in the case of misloaded parts ram set too deep etc all conditions which do not allow the press to toggle out and Stall the press prior to completion of the stroke See Section Il paragraphs 2 and 3 for additional information on the use of the Auxiliary Ram Up Valve and the principles of set up and operation Photo 1 14 Photo 1 16 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Section Il Set Up and Operation See photos 2 1 2 2 NOTE Prior to installing any tooling in the CAUTION press proper point of operation guarding specifically designed for your tooling must be built and mounted on or around your tooling CAUTION NEVER OPERATE SERVICE OR Photo 2 1 ADJUST THIS MACHINE WITHOUT PROPER INSTRUCTION NEVER SERVICE THIS MACHINE WITHOUT FIRST SHUTTING OFF AIR SUPPLY NEVER OPERATE THIS MACH
6. s hand or hands are removed from the SYNCHRO SIG Two Hand Unit This is the new CSR G2 Mode 2nd generation Constant Signal Required Your press can be easily converted to this mode by purchasing the CSR G2 Conversion Kit Part No CSR G2 CON 1030 Existing valving including the SYNCHRO SIG unit remains intact and is utilized Conversion requires approximately 15 minutes and 15 easily accomplished Please contact our engineering department to discuss any questions you may have about control systems modifications and your applications We are glad to supply our presses built to your specifications should you require other than our standard systems 14 Factory Support Our 40 year reputation for providing quality JTOGGLE AIRE presses that meet wide range of special requirements and our 55 years of service and support experience are all available to you with one phone call It s your biggest advantage in dealing directly with our factory Make use of it Please call with any all questions you may have regarding your applications and our equipment WARRANTY A M hereafter referred to as the manufacturer warrants that all TOGGLE 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 op
7. INE WITH SAFETY GUARDS REMOVED Photo 2 2 1 Mount your tooling See photos 2 3 2 4 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 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 the ram should bear against the upper portion of your tooling If your tool incorporates guide pins etc be sure the tooling easily moves along the full length of travel with no binding or misalignment Correct any problems found the tool before placing tooling into production Photo 2 4 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE 2 Adjust the depth setting end of stroke See photos 2 5 2 6 2 7 2 8 A CAUTION Use Set Up valve to bring the ram to bottom of stroke under power See Section Paragraph 6 1 Use the regulator component in your Filter Regulator Lubricator unit to adjust the line pressure to approx 40 PSI NOTE The minimum OPERATING pressure during actual production runs should always be 50 PSI For Set Up purposes however it is acceptable to use lower line pressures to facilitate Set Up See paragraph below for ram adjustment After the break in period if
8. P 3500 Return Valve Impulse B 3500 SEL UD Valve A C 3500 MULE E mica ricer davis heater utes D 3500 QUICK EXNGUSEVAIVG CSR G2M CSR G2 Stroke Completion Module SK D Type II Quick Exhaust Seal Kit New style valves E 3500 A way Power Valve F 3500 PU WAIN Os G 3500 On Off Valve w LOCK Out 11 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Section V Replacement Parts List Continued Control Parts Cont KOS 3500 Key Operated Air Supply Shut 129 95 H 3500 Muter PAGS CAC 13 50 3500 Muffler 51 1 10 50 3500 RaM UD ____ _ _ 72 175 SS PB Std Two Hand Actuator w guard 599 00 SS OT Optical Touch Two Hand Actuator w Power 850 00 PS SSOT Replacement Power Supply for SS OT Actuator 69 00 PK 3500 Plumbing Kit includes all tubing amp fittings std control pkg 59 85 Misc VC 3500
9. air supply and manually move the press or with air supply on actuate the Optional Aux Ram Up Valve See photo 2 14 CSR G2 modes see note below photo This will send the ram back to the up position Re adjust the depth setting so the toggle is allowed to straighten Do not confuse the nature of the force curve in the ram with the Ram Adjusting Screw or depth adjustment The ram force developed by the press is not affected by the Ram Adjusting Screw or where you are set in terms of ram depth The only thing that affects ram force is the air pressure used to power the press The Ram Adjusting Screw is simply an end of stroke adjustment much like the adjusting collar found full revolution mechanical power presses In fabrication jobs like punching piercing and blanking enter the punch only as deep as necessary to clear your blank etc Always set up so that the press is doing the work as close to the end of stroke as possible where the toggle is close to straight and the rated strength of the press is developed Finally once the tools have been set and locked in place using the regulator on the Filter Regulator Lubricator Unit adjust the air pressure to 5 to 10 PSI above the minimum required to do the job Any additional line pressure is wasted and causes unneeded wear and tear on the machine etc Consult the factory if your application requires shorter strokes additional shut height etc Photo 2 13 S
10. at the press is a pneumatically powered TOGGLE press The key element in the machine is the TOGGLE or KNUCKLE JOINT See photos 2 10 2 11 2 12 A toggle is a simple machine and of itself It is a great multiplier of force The press takes the output of the cylinder couples it toa lever which drives the toggle As the toggle straightens it drives the press ram downward creating a powerful squeeze at the end of the stroke At the moment the toggle hits end of stroke the upper toggle link encounters a stop block The press is then reversed when the impulse pin is driven out through the front plate which in turn actuates the return valve A 3500 See photo 2 13 When controlled in this manner the press is very accurate with a repeatability of plus or minus 001 It is crucial that you recognize this relationship Your tooling should be built with a shut height that falls within the shut height range of the press In standard presses this is approx 5 000 maximum to 4 250 minimum a ae Note Press front plate removed for clarity TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Important principles continued Your tooling must be built to allow the toggle to straighten out If the tooling is too high or if you set the ram too deep the press will not be able to complete the stroke and stall If you do stall the press BEM mode only during set up you can either shut off the
11. desired the ram can be lowered manually to allow for alignment of tooling etc To lower the ram manually 1 SHUT OFF AIR SUPPLY 2 Remove the Upper Linkage Guard to gain access to the JO 1 3500 Lever 3 Lower ram by placing appropriate Steel bar between the ram yoke JP 7 3500 and the pivot of the lever JO 1 3500 4 Pull the bar towards the front of the press to lower the ram RAM WILL RETURN UP WHEN AIR SUPPLY IS RESTORED Adjust the final depth of the press by loosening the Lock Nut JP 33 3500 on the Ram Adjusting Screw JP 11 3500 located at the top of the press 1 Rotate the screw up or down as required your tooling Remember if your press has the Standard Ram Adjustment Screw one revolution of the screw is 071 of adjustment Photo 2 8 NOTE 3 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE See photos 2 9 2 In some cases with the ram in the down position and the air on it may not be possible to adjust the ram up Either raise the ram to the up position or shut off air supply before adjusting 3 Final adjustments should always be made by screwing the ram down to the desired point 4 Lock the ram adjusting screw in place with the lock nut Once tools have been set always replace the Upper Linkage guard before proceeding Important principles of set up and operation When setting up and operating it 15 important to keep in mind th
12. ined always SHUT OFF the air supply and replace the lockout device Secure with a padlock etc to prevent unauthorized use of the press BEFORE PROCEEDING CLEAR THE PRESS TABLE AND WORK AREA OF ALL TOOLS FOREIGN OBJECTS AND BODY PARTS 6 Test the installation See photos 1 10 1 11 A Test the 519 Two Actuator by simultaneously depressing the levers on the Model SS DM or by simultaneously placing a finger in each sensing button on the Model SS OT The press should cycle once return to the top of the stroke and await another signal from the actuator If the levers or buttons are continuously held down the press should remain in the down position until one or both levers or buttons are released Photo 1 10 Photo 1 11 _ TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE See photos 1 12 1 13 1 14 1 15 CAUTION See photo 1 oF Test the Set Up Valve The press is equipped with a Set Up valve which allows tool setters or maintenance personnel to lock the ram in the down position to facilitate tool depth adjustment Check the function of this valve To actuate this valve back out the red locking screw from the valve guard Move the valve lever to the down position The press ram will immediately descend to the bottom of the stroke and stay in that position Once the ram depth has been set see
13. oil specifically formulated for use in pneumatic equipment 2 GENERAL 1 Regularly check the function of the Synchro Sig Actuator Set Up and Aux Ram Up Valves Regularly check all mechanical aspects of the press including fasteners pivot pins set screws Tighten any fasteners if loose replace any badly worn or broken pins links Check linkage bushings for wear and replace if necessary 9 Oil Here Daily eS Oil Here Daily Oil Here Daily Oil Here Daily Photo 3 1 Photo 3 4 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Section IV Parts Identification Drawings 1 Linkage Parts See pages 11 amp 12 ____ 12 3500 IMPORTANT NOTE ORIENTATION OF afc TOGGLE LINKS JP 8 3530 WHEN REPLACING See Photos 2 10 2 11 2 12 2 Valving Parts See pages 11 amp 12 Model 2530 and Model 3530 Interchangeable TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Section V Replacement Parts List Linkage Parts JO 1 3500 Lever Standard Steel 3500 JO 2 3500 tr ae en ane JP 6 3500 YOKE saneca 7 3500 8 3500 Toggle Link Set Of 2 JP 10 3500 AGIUSUNG BIOGK
14. r Regulator Lubricator Unit optional or any other accessories you may have ordered 2 Attach 519 Actuator See photos 1 1 1 2 1 3 A NOTE 3 Mount See p A Locate the 1 4 yellow tubing found under the press platen Connect 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 Using the 1 4 20 hex head bolts supplied mount the 5 512 to the press as shown Be sure to mount the aluminum lever guard between the actuator and the press at the same time To insure operator safety some applications may require that you locate the Synchro Sig actuator further away from your tooling the press to your stand or workbench hoto 1 4 Select a bench of suitable size and strength Bolt the press to the bench using the holes located in the press frame below the platen area Never operate the press unless it 15 securely mounted on a bench or stand Photo 1 1 Photo 1 4 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE CAUTION WHENEVER CONNECTING YOUR AIR SUPPLY TO THE PRESS BE CERTAIN TO FOLLOW SAFE OPERATING PROCEDURES AND KEEP ALL PARTS OF YOUR BODY AWAY FROM THE MOVING PARTS OF THE PRESS 4 Connect air supply See photos 1 5 1 6 1 7 A The air supply must be clean and conditioned Preferabl
15. tion A M will repair or replace any product it deems defective under the terms of this warranty If factory service is required transportation costs to and from the factory are to be paid by the purchaser This warranty does not apply to equipment that has been subject to abuse misapplication negligence improper maintenance alteration failure to manufacturer s instructions A M s SOLE OBLIGATION UNDER THIS WARRANTY 15 STATED ABOVE THIS WARRANTY IS IN LIEU OF ALL OTHERS EXPRESSED OR IMPLIED AND UNDER NO CIRCUMSTANCES WILL A I M BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OF TOGGLE AIRE PRODUCTS 347 Farnum Pike Smithfield RI 02917 Call us Toll Free 1 888 889 4287 Visit us online at Www joraco com
16. upplied with control systems only Not req d on CSR G2 systems Photo 2 14 SEE NOTE BELOW IF YOUR PRESS WAS ORDERED WITH CSR G2 CONTROLS lf your press has the CSR G2 Control System you will not require a J 3530 Aux Ram Up Valve In the CSR G2 control system the press ram will always return up when the two hand actuator or B 2530 Set Up Valve released See the addendum to this manual for proper set up and operation in the CSR G2 mode Section 111 1 TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE Maintenance LUBRICATION A components See photo 3 1 3 2 1 One Shot Lubrication Systems Your press is equipped with the L 2 P One Shot Lube System Fill the reservoir with 20 wt general purpose machine lubricating oil With the press ram in the up position pull the plunger all the way up and release The pump will meter the oil to the various points of lubrication Upon filling the reservoir for the first time it may take several pumps to purge the system of air Generally two pulls of the plunger per shift is adequate B Air Supply See Photo 3 3 3 4 1 Follow the instructions provided by the manufacturer of the Filter Regulator Lubricator Unit you are using See Section Paragraph 5A Fill the reservoir with Joraco Air Tool Oil Pt No JO FRL Adjust the drip rate to approx one drop per 100 strokes of the press Only use
17. y a Filter Regulator Lubricator Unit Joraco Part No FRL 3500 should be located within 6 feet of the press optimum results all air lines fittings and hoses used to supply the press should be the equivalent of 1 2 NPT minimum id The minimum air pressure operation is 50 PSI The maximum is 125 PSI The optimum operating range is 80 to 100 PSI If your application consistently requires substantially more than 100 PSI it may indicate the need for a stronger press Connect the air supply to the press at the inlet port on Part No G 3500 3 way On Off Valve Photo 1 7 NOTE A three way Shut Off Valve like the supplied must always be used to insure complete bleeding of the press circuits when air supply is off TOGGLE AIRE MODEL 3500 SERIES PRESSES INSTALLATION OPERATION AND MAINTENANCE 5 Turn on air supply See photos 1 8 1 9 A NOTE CAUTION Remove the yellow lock out device found on the On Off Valve To turn the air on simply move the gold colored sleeve downward until it Stops Slide the sleeve upward to the Stop to shut the supply off With the supply on check for air leaks and be sure all connections you have made are secure and air tight If air leaks from inside the 519 actuator the connections are incorrect Correctly reconnect the tubing taking note of the tubing labels When the press is not in use or being serviced mainta
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