AIM Joraco TOGGLE-AIRE 2530 Series Installation and operating instructions

“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
10 & 16 Ton, 2530 & 3530 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 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
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 wellbeing of the operator.
THINK SAFETY . . .
. .WORK SAFELY
COPYRIGHT 2018
by
AUTOMATED INDUSTRIAL MACHINE, INC.
Smithfield, RI, USA
All rights reserved

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-1-
Section I: Installation
1. Carefully remove the press from the crate,
taking note of separately packed items such
as the "Quick Exhaust Unit", "Synchro-Sig" Two
Hand Actuator or any other accessories you
may have ordered.
2. Attach "Quick Exhaust Unit"
(See photos 1.1 and 1.2)
a. Screw brass nipple into top port of the
main cylinder located at the rear of
the press. Once tight, orient the
assembly as shown in photo 1.2.
b. Locate the poly-flo tubing that runs
from the main valve assembly on the
right side of the press. Connect this
tube to the elbow in the inlet port of
the "Quick Exhaust Unit".
3. Attach "Synchro-Sig" Actuator.
(See photos 1.3 and 1.4)
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.
B. Using the 1/4-20 hex head bolts
supplied, mount the "Synchro-Sig" to
the press as shown.
NOTE: To ensure operator safety some
applications may require that you
locate the "Synchro-Sig" actuator
further away from your tooling.
Photo 1.1
Photo 1.2
Photo 1.3
Photo 1.4

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-2-
4. Mount the press to your stand or workbench
(See photo 1.5)
A. Select a bench of suitable size and
strength.
B. Bolt the press to the bench using the
holes located in the feet of the press
frame below the platen area. DO NOT
operate the press unless it is securely
mounted on a bench or stand.
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!
5. Connect air supply
(See photos 1.6, 1.7, 1.8)
A. The air supply must be clean and
conditioned. Preferably, a Filter,
Regulator, Lubricator Unit, (Joraco
Part No. FRL-2530) 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" NPT
minimum.
B. The minimum air pressure for
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.
C. Connect the air supply to the press at
the inlet port on Part No. G-2530, 3-
way, On-Off Valve (photo 1.7 & 1.8).
NOTE: A three way Shut Off Valve like the
one supplied must always be used to
insure complete bleeding of the press
circuits when air supply is off.
Photo 1.5
Photo 1.6
Photo 1.7
Photo 1.8

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-3-
6. Turn on air supply
(See photos 1.9, 1.10)
A. Remove the yellow lock out device
found on the On-Off Valve (photo 1.9).
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, then the
connections are incorrect. Correctly
reconnect the tubing, taking note of
the tubing labels.
NOTE: When the press is not in use, 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, CLEAR THE
PRESS TABLE AND WORK AREA OF ALL
TOOLS, FOREIGN OBJECTS, AND
BODY PARTS.
7. Test the installation
(See photos 1.11, 1.12)
A. Test the "Synchro-Sig" Two Hand
Actuator by simultaneously depressing
the buttons on the Model SS-PB or by
simultaneously placing a finger in each
sensing "button" on the Model SS-OT. If
the buttons are continuously held
down the press should cycle once,
return to the top of stroke and await
another signal from the actuator (CSR
G2 mode only).
NOTE: If press does not return to top of stroke
when buttons are continuously held
down then depth must be adjusted
(See pg. 6)
Photo 1.9
Photo 1.10
Photo 1.11
Photo 1.12

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-4-
(See photos 1.13, 1.14, 1.15, 1.16)
B. 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 (photo 1.14). Move the
valve lever to the down position (photo
1.15). 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 Section
II, Paragraph 2) return the valve lever
to the up position (photo 1.16). The
ram will immediately return to the top
of the stroke.
NOTE: After using the "Set-Up" valve, always
lock the valve in the up position using
the red locking screw.
CAUTION: THIS VALVE IS NOT DESIGNED FOR
USE IN PRODUCTION AND SHOULD
ONLY BE USED BY AUTHORIZED AND
QUALIFIED PERSONNEL
Photo 1.13
Photo 1.14
Photo 1.15
Photo 1.16

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-5-
(See photo 1.17)
C. Optional Auxiliary Ram Up Valve
(On BEM control systems only)
2530 & 3530 BEM presses are equipped
with an Auxiliary 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 II, paragraphs 2 and 3 for
additional information on the use of
the Auxiliary Ram Up Valve.
(See photo 1.18)
D. Ram Speed Adjustment.
(Optional on 2530 & 3530 Series
Presses)
The ram speed on the down stroke can
be adjusted to suit your application.
Locate the adjustable flo-contol
muffler. Unlock the adjusting screw
and screw it in to slow the ram down,
back it out to increase ram speed.
Lock the adj. screw when speed has
been set.
NOTE: When operating the press with slow
ram speed, special guarding and
control considerations apply.
Photo 1.17
Photo 1.18

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-6-
Section II: Set Up and Operation
(See photos 2.1, 2.2)
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.
1. Mount your tooling
(See photos 2.3, 2.4)
A. Using the tapped holes in the press
platen (photo 2.3), 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.
Photo 2.1
Photo 2.2
Photo 2.3
Photo 2.4

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-7-
2. Adjust the depth setting (end of stroke)
(See photos 2.5, 2.6, 2.7, 2.8, 2.9)
A. Use "Set-Up" valve to bring the ram
to bottom of stroke under power. (See
Section I, Paragraph 7B)
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.
B. Alternatively, 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 top guard.
3. Lower ram by placing appropriate
steel bar between the ram yoke
(JP-710) and the pivot of the lever
(JO-110).
4. Pull the bar towards the front of
the press to lower the ram.
CAUTION: RAM WILL RETURN UP WHEN AIR
SUPPLY IS RESTORED.
C. Adjust the final depth of the press by
loosening the Lock Nut (JP-3310) on
the Ram Adjusting Screw (JP-1110)
located at the top of the press.
1. Rotate the screw up or down to the
desired position. Remember, if
your press has the Standard Ram
Adjustment Screw, one revolution
of the screw is .071" of
adjustment.
Photo 2.5
Photo 2.6
Photo 2.7
Photo 2.8

TOGGLE-AIRE MODEL 2530 & 3530 SERIES PRESSES
INSTALLATION, OPERATION, AND MAINTENANCE
-8-
NOTE: In some cases, with the ram is in
the down position and the air is
on, it may not be possible to
adjust the ram up. To adjust up,
shut off air supply before
adjusting.
2. Final adjustments should always
be made by screwing the ram down
to the desired point.
3. Lock the ram adjusting screw in
place with the lock nut.
NOTE: Once tools have been set, always
replace all press guards before
proceeding.
3. Important principles of set up and
operation.
(See photos 2.10, 2.11, 2.12)
When setting up and operating it is
important to keep in mind that the press is
a pneumatically powered TOGGLE press.
The key element in the machine is the
TOGGLE or KNUCKLE JOINT. A toggle is a
simple machine in and of itself. It is a great
multiplier of force. The press takes the
output of the cylinder, couples it to a 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. The moment that 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-2530).
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 2530 presses this is approx.
5.375" maximum to 4.625" minimum and
in standard 3530 presses this is approx.
6.375” maximum to 5.625” minimum.
Photo 2.9
Photo 2.10
Photo 2.11
Photo 2.12