AIM Joraco TOCCLE-AIRE HP-4 Owner's manual

HYDRO-PNEUMATIC SERIES PRESSES
OVERVIEW, INSTALLATION, AND OPERATION
AUTOMATEDINDUSTRIALMACHINE,INC
TOGGLE-AIRE DIVISION
347Farnum Pike
Smithfield, RI, USA 02917
401-232-1710
www.joraco.com
Installation, Operation and Maintenance
Hydro-Pneumatic SeriesBenchPresses

HYDRO-PNEUMATIC SERIES PRESSES
OVERVIEW, INSTALLATION, AND OPERATION
IMPORTANT
It is the responsibility of the employer/purchaser to provide
his or her employees with proper point of operation guards,
and to ensure that this equipment is used in 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
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 is developed andenforced to protect the wellbeing
of the operator.
THINK SAFETY . . .
. . .WORK SAFELY
COPYRIGHT 2019
by
AUTOMATEDINDUSTRIALMACHINE,INC.
Smithfield, RI, USA All rights reserved

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

HYDRO-PNEUMATIC SERIES PRESSES
OVERVIEW, INSTALLATION, AND OPERATION
1
Section I: Press Overview
1.1 Description
The Hydro-Pneumatic (HP) Series Press is a completely self-contained, air-over-oil unit that
is cost-effective and can be used in a variety of assembly and forming applications including
punching, marking, staking, cutting, crimping and flaring. Our HP presses are available in
sizes from 2 to 16 tons and the standard specifications are: 4” stroke with up to ½” 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, Lubricator (FRL) –clean room compliance
•Dwell Timer
•Non-Rotating Ram
•Can be PLC ready for automated setups and force monitoring packages
*** Custom Features may be quoted upon request
*** C-Frame option also available upon request
*** HP Series Cylinders also sold separately

HYDRO-PNEUMATIC SERIES PRESSES
OVERVIEW, INSTALLATION, AND OPERATION
2
1.4 Cylinder Components
Item No.
Description
1
High 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

HYDRO-PNEUMATIC SERIES PRESSES
OVERVIEW, INSTALLATION, AND OPERATION
3
1.5 Function
Cylinder Retracted
For the cylinder to retract, compressed air is supplied 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.

HYDRO-PNEUMATIC SERIES PRESSES
OVERVIEW, INSTALLATION, AND OPERATION
4
Power Stroke
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. The high pressure piston
and rod travel until reaching the high pressure seal, which will be the point at which pressure begins
to build. As the rod and piston continue traveling, oil that was displaced during the rapid advance is
compressed and builds pressure. Once the work has been completed the cylinder will then retract 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
configuration the high pressure piston and rod are always in contact with the high pressure seal. This
means that as soon as compressed air is supplied to port B2 the cylinder will begin building pressure.
As the high pressure piston and rod continue traveling the oil is compressed and builds pressure. The
cylinder will retract when compressed air is supplied to ports A1 and C1.

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
5
Section II: Valving
2.1 Pneumatic Circuit

HYDRO-AIRE SERIES PRESSES
INSTALLATION, 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)

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
7
Section III: Installation
3.1 Un-boxing
Carefully remove the press from the crate, taking note of
separately packed items such as the "Quick Exhaust
Unit"(Optional), FRL Unit (Optional) and "Synchro-Sig"
Actuator.
Synchro-Sig may come mounted on some models
3.2 Synchro-Sig Installation
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. (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 operator safety some applications may
require that you locate the "Synchro-Sig" actuator further
away from your tooling.
-PICTURES ARE FOR REFERENCE ONLY-
SOME SECTIONS OF THIS MANUAL MAY NOT APPLY
TO YOUR PRESS UNIT.

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
8
3.3 Mounting Press
A. Select a bench of suitable size and strength.
B. Bolt the press to the bench using the holes located
in the press frame below the platen area. Never
operate the press unless it is securely mounted on
a bench or stand. (Figure 1.3)
3.4 Connect Air Supply
A. The air supply must be clean and conditioned.
Preferably, a Filter, Regulator, Lubricator Unit,
(Joraco Part No. FRL-HP) should be located within
6 feet of the press. For optimum results all air lines,
fittings, and hoses used to supply the 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-Dial option
NOTE: A three way Shut Off Valve like the one supplied
must always be used to ensure complete bleeding
of the press circuits when air supply is off.
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!
Inlet
(Figure 1.3)
(FRL Unit)
(Inlet)

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
9
3.5 Turn On Air Supply
A. 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 "Synchro-Sig"
actuator the connections are incorrect. Correctly
reconnect the tubing, taking note of the tubing
labels.
CAUTION: ENSURE HANDS ARE CLEAR OF ANY TOOLING BEFORE
TURNING OFF AIR SUPPLY. THE WEIGHT OF A HEAVY
TOOL MAY CAUSE IT TO DROP UNEXPECTEDLY. 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 BODY PARTS.
3.6 Test The Installation
A. Test the "Synchro-Sig" Two Hand Actuator by
simultaneously depressing the levers on the Model
SS-PB 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.
OFF
ON

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
10
Section IV: Set Up and Operation
NOTE: Prior to installing any tooling in the 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 ADJUST THIS
MACHINE WITHOUT PROPER INSTRUCTION.
NEVER SERVICE THIS MACHINE WITHOUT FIRST
SHUTTING OFF AIR SUPPLY.
NEVER OPERATE THIS MACHINE WITH SAFETY
GUARDS REMOVED.
4.1 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 the ram should bear against the
upper portion of your tooling.
NOTE: 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 in the tool before placing
tooling into production.

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
11
4.2 Stroke Limitation
For punching and piercing applications, 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.

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
12
Section V: Venting / Filling
DO NOT DEVIATE FROM THE FOLLOWING PROCEDURES. DOING
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

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
13
5.1 Air Venting/Adding Oil Procedure
To remove any air pockets from hydraulic cylinder, perform the
following procedure.
1. With air still supplied to the cylinder make sure the ram is
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 vented completely of any air
(no air bubbles in the hose)

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
14
5.1 Air Venting/Adding Oil Procedure (continued)
6. Attach ¼” Poly-flow line from AIM Joraco Oil Pump HP-
100F to the bleed valve (P3)
*See Figure 2*
7. Turn screw on bleed valve (P3) counterclockwise until it
stops (valve open)
8. Begin pumping oil from AIM Joraco Oil Pump –HP-100F
(some 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 venting plug screw and hand tighten lightly
14. Remove AIM Joraco Oil Pump –HP-100F from bleed valve
(P3)
15.Cylinder is ready for operation

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
15
5.2 Replacing Oil
Do not perform Replacing Oil procedure unless
recommended by an AIM Joraco technician.
To fully purge and replace oil in hydraulic cylinder, perform
the following procedure.
1. With air still supplied to the cylinder make sure the ram is
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. 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 ¼” Poly-flow line to bleed valve (P3)
*See Figure 2*
8. Route ¼” Poly-flow line to catch pan to retain oil being
removed from cylinder
9. Turn screw on bleed valve (P3) counterclockwise until it
stops (valve open)
10.Supply air to port (P2) to begin forcing the oil out of the
cylinder
11.Continue supplying air to port (P2) until oil stops flowing
from ¼” Poly-flow line
12.Turn screw on bleed valve (P3) clockwise until it stops
(valve closed)

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
16
5.2 Replacing Oil (continued)
13.Remove ¼” Poly-flow line from bleed valve (P3)
14.Make sure that AIM Joraco Oil Pump –HP-100F is filled
with oil (30 fl oz min) and vented completely of any air
(no air bubbles in the hose)
15.Attach ¼” Poly-flow line from AIM Joraco Oil Pump
HP-100F to the bleed valve (P3)
16.Turn screw on bleed valve (P3) counterclockwise until it
stops (valve open)
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
the area around the vent hole is clean and dry.
21.Replace venting plug screw and hand tighten lightly
22. Remove AIM Joraco Oil Pump –HP-100F from bleed valve
(P3)
23.Replace lines to ports (P1) and (P2)
24.Cylinder is ready for operation.

HYDRO-AIRE SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
17
Section VI: Troubleshooting
6.1 Ram Will Not Extend
6.2 Ram Will Not Retract (stuck in down position)
6.3 Cylinder Will Not Switch to Power Stroke Cycle
6.4 Frequent Oil Fills
Cause
Solution
Air is not on
Turn on air supply
Insufficient air supply
Increase air supply pressure
Defective valve
Contact AIM Joraco 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 section 5.1
Air trapped in oil reservoir
Refer to section 5.1
Cause
Solution
Damaged / worn seals
Send cylinder to AIM Joraco
Defective bleed / fill valve
Contact AIM Joraco to replace