User Manual, Model 1011RT PLC 3&5 Ton
Contents
1. cccceeeee R 2 Air Ejection System ReQulator ccccccscccccseceeseeeesseeeesseeeesaaeees FRL 1011 Filter Regulator Lubricator Uniit cccceccsececeeeseeeseeeseeeseeees JO FRL Pneumatic Tool Lubricating Oil for use in FRL 1 aft H 2530 M tter Adustable asctad dacicrenetit cetera Guenwen een oud dade aaietnuaouxdodotuendaiaics SS DM 24 24 Two Hand Actuator w Quard cccceccccseeeeceeeeseeeeeseesesaaeess GK SS DM 24 Replacement Aluminum Guard for SS DM 24 ceeceeeeeeees SS OT Optical Touch Two Hand Actuator w Power Supply 086 PS SSOT Replacement Power Supply for SS OT Actuator ccceeee PS 1011 Replacement Power Supply 24VDC for Solenoid Valves Miscellaneous 1011RT Parts VC 1011B Replacement Valve Cover On Base ccceececeeeeeeeeeeeeesaeeeees GK 1030 Rear Guard Kit Press 2 rear covers ccsecceeeceeeseeteeteeeneeenes L 2 P 1011 One Shot Lube System Retrofit Kit cc ceecccsseeeseeeeeeeeeeeseeees L 2 P 2CC Pump Assembly Only One Shot Lube System ccccceeees FRL 1011 Filter Regulator Lubricator Unit e serr cen reeniro ireren JO FRL Pneumatic Tool Lubricating Oil for use in FRL Units 1 Qt RGK 1011C Ram Guard Assembly COMpIete cccceccceeeeceeeeeeesaeeetaeeeeas RGK 1011T Ram Guard Replacement Tube only cccsecceseeeeeeeeeeeeeeeeees Call for quo2. 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 on 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 OMRON D4C 1601 PIN PLUNGER Photo 2 14 Photo 2 15 TOGGLE AIRE MODEL 1011RTPLC INDEXING MACHINE INSTALLATION OPERATIION AND MAINTENANCE Section Ill LCD Operator Interface Functions l Built in Counters A When running in the Manual or Automatic Modes the machine has two built in modes of parts Def
3. of the pump assembly with light to medium weight general purpose machine lubricating oil 20 wt maximum 3 Pull upward on the knob found on the pump assembly and release The pump will lubricate all the pivots etc within the press NOTE After filling reservoir it may be necessary to pull the pump plunger several times to purge the system of air etc There is no need to remove any guarding Always oil the press when the machine is not running and the press ram is in the up position 4 Generally one 2 pulls on the plunger per shift of operation is adequate but you should adjust the frequency of oiling as your application merits 5 NEVER use grease or other viscous lubricants on the linkage of the press The linkage is designed to gravity feed lubricating oil to various points of lubrication and grease will clog the lubricating path within our linkage C Indexer Component 1 Always keep the underside of the tooling plate clean and free of contaminants When mounting tooling to tooling plate please be sure any through holes in the plate are broken and polished Remember the underside of the plate is a bearing surface and must be kept clean of burrs nicks etc Once tooling has been properly aligned and located the tools should be doweled in place on the tooling plate and if possible the press and indexer components should be doweled in place as well 2 From time to time as your application demands lubricate the underside of the
4. switch to RUN and initiate the cycle with the SS DM 24 Two Hand Unit NOTE WHENEVER SWITCHING FROM STOP TO RUN WHILE IN THE AUTO MODE OR FROM MANUAL TO AUTO YOU WILL BE PROMPTED TO VERIFY YOUR INTENTION TO RUN IN THE AUTOMATIC MODE See Photo Below Photo 1 16 Photo 1 17 TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE 5 Additional Controls and Features See photos 1 18 1 19 1 20 1 21 1 22 1 23 Ram Safety Guard A Machine Reset If either one of the Profile the halves of the guard MS 5 Emergency Stop Switches is to clear your tooling activated or if the Ram Safety Guard l Center Guard on detent If this is moved while the machine is guard is ties ie ete prea osition the machine shuts down in Ce the machine will the Same manner as the Emergency immediately stop and dump all air in Stops do Trouble shoot problem the system center the guard again and follow 1 To Reset the 1011RT simply move reset procedure in 7A the MS 1 OFF STOP RUN Switch to the OFF position The machine will be reset to the starting position Trouble shoot the reason the machine was shut down prior to attempting to run again If the Emergency Stop Switch was used you must reset it by rotating the A switch in the direction indicated on Photo 1 18 the button prior to starting up again B Press Ram Speed Controls are located on the left side of the machine 1 Adjust the meterin
5. the the Grand Total Counter Screen press CLEAR CLR to zero the counter 2 Machine Self Diagnostics A The PLC used to control this machine has some limited self diagnostic capabilities See Photo below 1 If the machine should stop running mid cycle in the automatic mode do not shut the OFF STOP RUN switch to OFF immediately Instead wait for approximately 30 seconds until the display screen lists the point at which the sequence was disrupted The screen will display the ID number for the next limit switch in the sequence indicating that the machine stopped prior to that point You can now shut the machine off shut the air supply off and trouble shoot the problem See the valve and switch listing for controls particular to this machine The switch fault numbers displayed correspond to the Limit Switch ID Numbers in the Parts Lists and as labeled on the machine Typical Self Diagnostic Display TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Section IV Maintenance 1 LUBRICATION A Press 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 pO es the reservo
6. 38 58 JP 12 Proso Pil epee cetera one Gaeta ed octet aden R 129 75 JP 13 15 Front Plate Assembly w Stop BIOCK ccccsececeseeeeeeeseeeesenees 61 40 JP 14 39 Main Pivot Pin with Retaining RINGS ccccccesseeeseeeeseeeeeaeeeees 11 15 JP 17 E 6 ear ee Seo Pins ERC eo en E re ree nen 7 14 JP 27 FAG CLOW T E E E A E N E E E 1 79 JP 33 Ram Adjusting Screw Lock Nut Standard c ccscesseeeeeeeees 1 85 JP 33FRA Ram Adjusting Screw Lock Nut Fine Thread c c ccsceeeeees 2 38 JP 35A IW OSs Mel eee dscns eueteseiaee 4 45 JP 35B PVOP apecteeaete cra testa a tatoatkencsctesste A A 4 45 JP 35C ef ALO ca eee re ere ene eee eee re ee eee eee 4 45 JP 36 AMOI PI esaa seeds vawanavaindvaleditaneiicd T 4 45 JP 35 36K Pivot Pin Kit includes all 375 dia pins in linkage c008 26 85 Cylinder Parts 1030MC Main Cylinder Complete recurre 439 00 JP 4 Replacement Cylinder Tube Std Stroke cccsecceseeeeeeeeeeeees 39 59 JP 4SPC Replacement Cylinder Tube Special Lgn Stroke cce 57 24 JP 1 5 PISTON FOG ASSCIMDLY 2ssscetriate tiie sssas tas scon a N 131 85 JP 26 Cylinder Screw w lock washer 4 r Q d ccccssceceeeeeeeeeseeeeeees 2 48 JP 32 Cylinder Hold Down Screw 2 r Q cccsecccseeeeeeeeeeeeeseeeeaeeeeaees 3 16 SK 1000 Cylinder SS Al AM zsrsr E N 17 69 Control Components Manually Operated Switches and or Valves MV 1 All ONEOUASICOVE V QING neste
7. ACE The Ram will however retract to the UP position up whether the guard halves are in place or not 3 Once the ram descends the halves of the guard can be removed to allow work on the tooling 4 The ram will stay in the down position until the MS 3 RAM SET UP switch Is pressed again F Rotary Table Set Up Switch MS 4 This switch allows the toolsetter to operate the indexing table without the press This is useful during the tooling and set up phase of the installation 1 With the MS 1 OFF STOP RUN switch in the STOP position place the MS 4 Table Set Up Switch to TABLE ONLY Use the SS DM Two Hand Actuator to index to each station NOTE Ram Guard must be in place When finished move the switch to the NORMAL position Photo 1 23 TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Section Il Set Up See photos 2 1 2 2 NOTE When installing any tooling on the tooling plate be sure proper point of operation guarding specifically designed for your tooling is installed on the machine at this time If the standard Ram Safety Guard supplied is not suitable for WA your application consult the Photo 2 1 factory for optional guards available CAUTION NEVER OPERATE SERVICE OR ADJ UST THIS MACHINE WITHOUT PROPER INSTRUCTION NEVER SERVICE THIS MACHINE WITHOUT FIRST SHUTTING OFF AIR SUPPLY NEVER OPERATE THIS MACHINE WITH SAFETY GUARDS REMOVED Pho
8. AUTOMATED INDUSTRIAL MACHINE INC J ORACO TOGGLE AIRE DIVISION 47 Farnum Pike Smithfield RI USA 02917 401 232 1710 www joraco com Installation Operation and Maintenance 3 amp 5 Ton 1011RT PLC Series Rotary Indexing Machine 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 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 well being of the operator THINK SAFETY _ WORK SAFELY COPYRIGHT 2005 by Automated Industrial Machine Inc J oraco Division Smithfield Rl USA All rights reserved Section I Installation 1 Carefully remove the crating material from around the 1011RT Leave the pallet the unit was shipped on intact with the machine bolted to it Lift the pallet with a pallet truck or forklift to carefully move the machine to the place it will be installe
9. ODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE CAUTION WHENEVER CONNECTING YOUR AIR AND ELECTRICAL SUPPLY TO THE MACHINE BE CERTAIN TO FOLLOW SAFE OPERATING PROCEDURES AND KEEP ALL PARTS OF YOUR BODY AWAY FROM THE MOVING PARTS OF THE PRESS INDEXING UNIT AND ANY TOOLING INSTALLED 3 Connect air supply See photos 1 6 1 7 1 8 1 9 NOTE Before proceeding check the position of the MS 1 OFF STOP RUN Switch Move the switch to STOP if it is not already in that position A The air supply must be clean and i O conditioned Use of the Filter Photo 1 7 Regulator Lubricator Unit supplied with your 1011RT is crucial For optimum results all air lines fittings CONNECT AIR SUPPLY HERE and hoses used to supply the indexing Te machine should be the equivalent of 77a PT 1 2 NPT minimum ID B The minimum air pressure for operation is 70 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 Model 1011RT at the inlet port on Part No MV 1 Air Supply On Off Sleeve Valve Photo 1 8 Plug the machine s power cord into a Photo 1 9 standard 110 VAC grounded Read and Understand receptacle Cautions on machine NOTE A three way Shut Off Valve like the one supplied must always be used to insure complete
10. ault Total Parts Count Screen E counting 1 Batch Counter with Settable Batch Count Limits 2 General Grand Total Counter NOTE THE CONTROL PANEL OFF STOP RUN SWITCH MS 1 MUST BE SET TO STOP TO SET OR ZERO ALL COUNTERS Upon power up the LCD readout screen displays the current parts count This is the actual number of cycles completed within the current batch run Once you have chosen either Manual or Auto and moved the MS 1 OFF STOP RUN to RUN position you will be asked if you want to a set a Batch Count Limit Press F 1 to choose the Batch Count Option or press F 3 to use the general purpose totalizing counter 1 Batch Counter F 1 The Batch Counter automatically stops machine operation when it reaches the Batch Count Limit you have set see right This counter must then be reset to zero prior to running another batch See photos to right 2 Batch Count Limit The machine will cycle either Manually or Automatically until this count has been reached A batch run can be interrupted end of shift coffee break etc by moving the OFF STOP RUN switch to STOP or OFF Upon restarting the count will continue from the point at which it was halted and complete the batch With control panel mode switch set to stop press F3 to zero the parts counter Batch Count Limit Screen T iv Setting Batch Count Limit At the Batch Count Limit Screen press ENTER ENT then press CLEAR CLR At th
11. bleeding of the press circuits when air supply is off TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE 4 Turn on air supply See photos 1 10 1 11 A NOTE CAUTION Remove the yellow lock out device found on the On Off Valve To turn the air on simply slide the gold colored sleeve to the right until it stops Slide the sleeve to the left 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 When the machine 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 machine BEFORE PROCEEDING CLEAR THE TOOLING PLATE AND WORK AREA OF ALL TOOLS FOREIGN OBJ ECTS AND BODY PARTS MS 1 MS 2 MS 4 1011RT PLC CONTROL PANEL Photo 1 12 INSTALLATION OPERATION AND MAINTENANCE AIR SUPPLY SHUT OFF S68 gt gt gt Photo 1 10 LOCK IN OFF POSITION Photo 1 11 Pictured to the lower left is the 1011RT PLC Control Panel It contains the various mode selector switches used to control the operation of the machine as well as one of the _ two Emergency Stop Switches and the LCD Operator Interface Panel see Section Ill which is used to set vario
12. d See photo 1 1 NOTE Always use extreme care when moving the machine Support the unit properly Do not allow the machine to lean or flip while moving 2 Remove the 1011RT from the pallet See photos 1 2 1 3 1 4 1 5 A B Remove the carriage bolts that hold the machine to the shipping pallet Use a forklift or similar lifting device to lift the Model 1011RT up and off the shipping pallet Note the location of the forks under the lower cross members of the machine base Lift off the pallet in this manner only If your machine was supplied with leveling feet install them in the pads at the bottom of each of the four legs at this time Carefully move and lower the machine into the final installation position 1 If you are using leveling feet adjust them as necessary to keep the 1011RT plumb and leveled in all directions Lock them in position to prevent accidental changes 2 If you are permanently installing the unit use the holes in the pads at the bottom of each leg to bolt the machine to the floor using appropriate fasteners for your flooring system Use shims if necessary to make up for variations in your floor surface TOGGLE AIRE MODEL 1011RT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Photo 1 2 NOTE If desired the front cross member may be removed after installation Remove the valving cover to access the bolts Replace cover when finished TOGGLE AIRE M
13. e flashing zero press the UP arrow to increase this digit to the desired value 0 9 Press the LEFT arrow to move the digit to the left At the next flashing zero use the UP arrow again to set this digit s value Repeat until you have the desired batch count shown Batch Counts Limit can be set up to 9 999 If satisfied with Batch Count Limit setting press ENTER ENT to complete the process TOGGLE AIRE MODEL LOLIRTPLC INDEXING MACHINE INSTALLATION OPERATITON AND MAINTENANCE Section Ill LCD Operator Interface Functions Built in Counters Cont 3 Grand Total General Counter F 3 This counter provides a running total of all cycles run across multiple batches and retains the count until it is reset It can also be used to perform general purpose counting It can record up to 99 999 cycles before it must be reset To access the Grand Total Counter screen from the Default Parts Count Screen Again once you have chosen either Manual or Auto and moved the MS 1 OFF STOP RUN to RUN position you will be asked if you want to a set a Batch Count Limit or a general purpose totalizing counter F 3 to use the general purpose totalizing counter To reset the Grand Total Counter When at the Grand Total Screen press clear CLR to zero the counter See photo to right NOTE YOU CAN NAVIGATE BETWEEN THE COUNTER SCREENS BY USING THE NEXT AND PREVIOUS PREV BUTTONS ON THE DISPLAY Grand Total Counter Screen At
14. ee r3 ND ad ETARA p y7 y TEE W a Peg i gt gt u A a wak Ea lt lt o rry ee ae f O a e te pee OO o mam A a d mran a Pam yde A TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Section V Replacement Parts List Linkage Parts JO 1 Lever SL ANIC Ue test eta a a hh ahd hee Raha 85 95 JO 1L2P Lever for Use with One Shot Lube System ccccessseeeseeeeees 98 35 JO 1ST Lever Heavy Duty Steel sssicsisacdiusaievdiaeaiued poral a 224 80 JO 2 Cap Standard Adjusting SCreW cccccceecececeseeceteeeeseeeseeeeeees 109 39 JO 2FRA Cap Fine Adjusting Screw use with JP 11FRA and JP 33FRA 169 89 JP 6 MINACE OK Gaetan et tae het ene basen ae 69 89 JP 7 Ram Yoke Standard ic ciioe chat ok alte ea dee diate dened dalen deed dio ssh ddde 79 12 JP 7HD Ram Yoke for use with Heavy Duty Links JP 8HD and JP 9HD 79 12 JP 8 Bottom Toggle Link Standard e serr uari rir a e 44 17 JP 8HD Bottom Toggle Link Heavy Duty use w JP 7HD amp JP 9HD 66 27 JP 9 FOD TOGGIEILINK Standal aixsucetscovee be notmencus tsetacaieeed dovtetiensies 44 17 JP 9HD Top Toggle Link Heavy Duty use w JP 7HD amp JP 8HD 66 27 JP 10 Ram AGJUSUNG BIOCK 2 2civetiveice ince ncwsicesien yee eaea a a S 60 49 JP 11 Ram Adjusting Screw Standard ccccccccsscecsseeseeeeseeeeseeeeeeeeeas 24 35 JP 11FRA Ram Adjusting Screw Fine use with JO 2FRA amp JP 33FRA
15. g screw in or out as necessary to adjust the press ram speed as desired Always lock the adjusting screw in place after adjustments are made C Rotary Index Speed Control located on the index cylinder assembly 1 Adjust the knob in or out as necessary to adjust the index speed D Emergency Stop Switches located on the control panel and the right end of the machine base plate 1 Use either one of these to immediately stop the entire 1011RT should the need arise All circuits are exhausted and dumped Use the reset procedure see 5A above to reset the machine after use SECONDARY yEMERGENCY STOP RIGHT END OF MACHINE TOGGLE AIRE MODEL 1011RT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE E Ram Set Up Switch allows the tool setter to lock the press ram in the down position to facilitate the depth setting of your tooling See Section Il Para 2 and 3 for more information about depth setting 1 The Ram Set Up Switch is only usable when the MS 1 OFF STOP RUN switch is in the STOP position 2 With the OFF STOP RUN switch in the OFF position press MS 3 RAM SET UP switch in The amber Photo 1 22 button will light and stay on At this point you must use the SS DM Two Hand Actuator to start the ram s down stroke The ram will stay at the bottom of its stroke until the RAM SET UP SWITCH is pressed again NOTE THE RAM WILL NOT DESCEND UNLESS BOTH HALVES OF THE RAM SAFETY GUARD ARE IN PL
16. iplier 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 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 Press Return Switch LS 4 See photo 2 14 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 machines this is approx 4 570 maximum to 3 820 minimum Photo 2 13 TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE 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 during set up you can use the Machine Reset Proceedure See Section Paragraph 5A and photo 2 15 This will send the ram back to the up position and reset the machine to the start of the cycle Readjust the ram depth setting so the toggle is allowed to straighten Do not confuse the nature of the
17. ir 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 50 strokes of the press Only use oil specifically formulated for use in pneumatic equipment C Indexer Component 1 Always keep the underside of the tooling plate clean and free of contaminants 2 As your application demands lubricate the underside of the tooling plate with a light die grease such as Lubriplate 3 Follow the recommendations of the indexer component found elsewhere in this booklet for the best method of lubricaton for the indexer Oil Here Daily Oil Here Daily Oil Here Daily Oil Here Daily 4 Photo 3 4 TOGGLE AIRE MODEL 1011RT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Section V Parts Identification Photos Drawings and Lists l Linkage Parts See pages 13 and 14 2 4011RT PLC CONTROL PANEL TOGGLE AIRE MODEL 1011RT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE 2 Valving Parts continued See pages 13 and 14 B Under enclosure lower left of machine stand base BRINN 19 CSa E Rat os oF
18. must be totally released before the units will allow another start signal The units cannot be locked or tied down to allow single hand operation Model 1011 Series Indexing Machines are also available controlled with a state of the art PLC control system The new Model 1011PLC offers built in stroke counters parts lot counters and totalizing counters as well as a diagnostic capability all displayed on an LCD programming panel which allows easy setting of various parameters of operation The 1011PLC Control System can be retrofitted to standard Model 1011 machines Contact our sales engineers to discuss any aspect of the control system of your machine We offer a full tooling service as well and are glad to quote you on your tooling requirements Send samples of your job We ll design build and install your tooling in your Indexer or press and ship you a machine ready to make your parts Factory Support Our 40 year reputation for providing quality TOGGLE AIRE presses that meet a 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 and all questions you may have regarding your applications and our equipment WARRANTY A M Joraco Div hereafter referred to as the manufacturer warrants that all TOGGLE AIRE products will be free fr
19. om 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 J oraco Div 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 or failure to follow manufacturer s instructions A M JORACO S SOLE OBLIGATION UNDER THIS WARRANTY IS STATED ABOVE THIS WARRANTY IS IN LIEU OF ALL OTHERS EXPRESSED OR IMPLIED AND UNDER NO CIRCUMSTANCES WILL J ORACO INCORPORATED BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OF TOGGLE AIRE PRODUCTS
20. sure to the minimum required plus 5 10 PSI Running the machine at unnecessarily high pressures only consumes more air Across a long production run the consumption savings can be substantial 4 Lubricate the air supply by filling the Oiler component of the FRL unit with oil that is specifically designed for use in Pneumatic Machinery or Pneumatic Tools Joraco Part No JO FRL available in quarts See the manufacturer s FRL instructions provided elsewhere in this instruction booklet Use of any other type oil may damage seals and packings in the valves and cause the machine to operate improperly 5 Adjust the drip rate of the oil to approximately 1 2 drops per 50 cycles of the press If heavy residues are seen at the machine s various exhausts the oil drip rate should be reduced 6 Always empty the filter bowl of the FRL unit whenever it has accumulated water or other contaminants collected in it If your air Supply is contaminated it may be necessary to change the sintered element inside the Filter from time to time as it may become saturated with contaminants and restrict the air flow to the machine TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Section VI Detailed Installation Maintenance Notes cont B Press 1 The mechanical aspects of the press component of your Model 1011RT are lubricated by use of the One Shot Lube System found on the side of the press 2 Fill the reservoir
21. te on tubes larger than 4 dia TP 1011RT Replacement Tooling Plate Std 18 dia ccccceceeeeeseeeeeeeeees Please Note Call for quote on plates larger than 18 dia Please refer to the manufacturer s documentation provided for the rotary indexing component of your 1011RT Use the parts numbers listed in that literature when ordering replacement parts for the indexer Contact Joraco for price quotes Note that the indexing component is a Model 11F with integral Hyrdo Check Unit Always specify the number of stations your indexer is set up for 386 00 TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Section VI Detailed Installation Maintenance Notes A Air Supply 1 The air supply should always be filtered regulated and lubricated Never operate the Model 1011RT with an air supply that is not running through the Filter Regulator Lubricator Unit supplied with the machine 2 Connect your air supply to the Model 1011RT at the Gold Colored On Off Valve found in the inlet port of the FRL unit at the rear of the machine stand This valve should be locked in the OFF position when the machine is not in use 3 The minimum operating pressure of the Model 1011RT is 70 PSI and the maximum is 125 PSI Once a minimum operating pressure has been established for your particular application regulate the air pressure with the Regulator found in the center of the FRL unit Adjust the pres
22. 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 J P 33 on the Photo 2 6 Ram Adjusting Screw J P 11 located at the top of the press 1 Rotate the screw up or down as required by your tooling Remember if your press has the Standard Ram Adjustment Screw one revolution of the screw is 100 of adjustment If Photo 2 7 your machine was supplied with the Fine Ram Adjustment Option one revolution of the screw is 0625 of adjustment 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 up 3 Final adjustments should always be made by screwing the ram i down to the desired point Photo 2 8 4 Lock the ram adjusting screw in place with the lock nut TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE S NOTE Once tools have been set if you removed any guarding always replace whatever you removed before proceeding IMPORTANT PRINCIPLES OF SET UP AND OPERATION 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 See photos 2 10 2 11 2 12 2 13 A toggle is a simple machine in and of itself It is a great mult
23. to 2 2 1 Mount your tooling See photos 2 3 2 4 A For maximum accuracy each station should be located from the press ram A simple way to locate the centers of each station relative to the ram is to mount an appropriate center punch in the press ram You may need to turn an adaptor holder to get the punch into the shut height range of the machine Be sure the Ram Adjusting Screw JP 11 is adjusted up all the way With the 1011RTPLC set in MANUAL Mode and ia Liss Rotary Table in the NORMAL Photo 2 4 position cycle the 1011RT once with the SS DM 24 Actuator The machine will cycle once Adjust the Ram Adjusting Screw down until the punch marks the plate as necessary for your purposes Continue to mark all stations in this manner See section VI Para C for more information TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE 2 Adjusting the depth setting end of stroke See photos 2 5 2 6 2 7 2 8 2 9 2 10 A Use Ram Set Up Switch MS 3 to bring the ram to bottom of stroke under power See Section I Paragraph 5 E B If desired the ram can be lowered manually to allow for alignment of tooling etc To lower the ram Photo 2 5 manually 1 SHUT OFF AIR SUPPLY 2 Remove the right half of the rear linkage guard 3 Place appropriate steel bar between the ram yoke J P 7 and the pivot of the lever J O 1 4 Pull the bar towards the front of the press to lower
24. tooling plate with a light die type grease similar to Lubriplate The grease should not be too heavy and it should have a high film strength 3 Follow the recommendations of the indexer component mfg found elsewhere in this instruction booklet as to the best method of lubrication and maintenance of the indexer Regularly use the TOGGLE AIRE MODEL 1011RT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE grease fittings found on the base of the indexer to grease this unit as your application demands Section VI Installation Notes Photos 8 PLATE O 10 32 x 1 2 Soc Cay PLATE HOLD DOWN SCREW 32 x 1 2 Soc Cap Screw die makers grease or equiv over the wear plate Automated Industrial Machine Inc J oraco Div 347 Farnum Pike Smithfield Rl USA 02917 Phone 401 232 1710 About Control Systems Unless otherwise specified your TOGGLE AIRE indexer has been shipped complete with all valving necessary for operation as described in this manual If desired or if operator safety so demands you can operate the Model 1011RT utilizing one of our SYNCHRO SIG series two hand anti tie down actuators These actuators provide state of the art 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 initiate any machine cycle When one or both are released the signal is terminated Both levers or buttons
25. us production parameters IMPORTANT Once you have the machine set in the desired mode of operation move MS 1 OFF STOP RUN switch to RUN and initiate any and all cycles of the machine with the SS DM 24 Two Hand Actuator IF YOU DO NOT BEGIN TO CYCLE THE MACHINE WITHIN 30 SECONDS the machine s Self Diagnostic System see Section IlI interprets this as a fault Simply use the MS 1 OFF STOP RUN switch to RESET the machine Start all cycles within 30 Seconds of moving the switch to RUN TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE See photos 1 12 1 13 1 14 1 15 1 16 1 17 B Check the positions of the Mode Selector Switches The machine is shipped with the switches set for Single Cycle Operation In this mode the machine will cycle one complete cycle index one station and one press cycle each time the SS DM 24 Two Hand Actuator is activated C Move the OFF STOP RUN Valve MS 1 to the RUN position The SS DM 24 Two Hand Actuator is used to initiate cycling in either mode by simultaneously depressing the levers of the unit D Cycle the machine in the Single Cycle Operation Mode several times to gain a feel for operation in this mode Move the RUN STOP valve back to STOP when finished in this mode NOTE Always move the OFF STOP RUN Switch MS 1 to the OFF Position when changing settings of the Mode Selector Switch MS 2 Once the desired mode has been set move OFF STOP RUN
26. z ett Retest eed cosas devsicesdeyse eased 27 82 MS 1 OFFS POPS RUN SWIC irar A 89 00 MS 2 Manual Auto Selector SWitch cccccceecceseeceseeeeeteeeeseneeeeee eas 42 00 MS 3 FUR SO VUE eaaa E 86 00 MS 4 Rotary Table Seti OWIE 2 stiveveserneesssvisereesviseraurieecs ieee 19 95 MS 5 Emergency otro WG ecceesee ee cotter aeedes ee cstdenenedetines arabes aseatecnace 92 00 TOGGLE AIRE MODEL LOLIRT PLC INDEXING MACHINE INSTALLATION OPERATION AND MAINTENANCE Section V Replacement Parts List Continued Control Components continued Limit Switches LS 1 Press Actuation SWItCHN cceccccecececececeececececeseeaeaecececeeeeaeaeaeaes LS 2 Rotary Table Advance SWitCh secuiiexectdescewetceaietauitoenistilenscsuetnctece LS 3 RaM GUS WIC Ih co eee oh oe tect oleh do ada habe dake ob Sek ob tik LS 4 Press Return WIC itd atco rcs Sesasaea se AEE AEE AEE LS 5 Rotary Table Return SWO oeeie eE EEEE 24 VDC Solenoid Piloted Valves V 0 Press Power Valve 4 way cccseccsecceceseseeeeceeeseeeseeseeeeaeeseess V 1 Rotary Table POWER VaN G ozcsesee accel en eteye teri enueiue V 2 Emergency Stop Valve 3 Way cccccseeecceeeeeseseeseeeeeseeeesseeeeeas V 3 Al EISCUOM VAIN Gre ar niecievadn a a Miscellaneous Controls RGI 1 Rain Guard InterloCk SansO swsssssescies ieveensetvssdudidvanatededenenees Pl 1 PowenrOn indicator Lamp ASS Versene aoe tee toee R 1 Regulator for Index Table 80 PSI Max setting
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