OPERATION AND MAINTENANCE MANUAL PNEUMATIC PRESS SERIAL NUMBER RAM CAP

Transcription

1 OPERATION AND MAINTENANCE MANUAL FOR PEMSERTER SERIES 4 - MODEL J PNEUMATIC PRESS SERIAL NUMBER RAM CAP NOTE: Your New PEMSERTER Series 4 Pneumatic Press has been assigned a Serial Number as indicated above. This Number Must Be Referenced In all Correspondence PEMSERTER PRODUCTS DIVISION PennEngineering PEM Fastening Systems 5161 APPLEBUTTER ROAD BLDG 23 PIPERSVILLE, PENNSYLVANIA PART NUMBER Revised Edition B (3/02) English Version

2 Read Manual Before Operating Press! FOREWORD Thank you for purchasing a PEMSERTER Series 4 press. With the proper care and maintenance, your press will install millions of fasteners safely, quickly and consistently. The press has a maximum 6 ton (54kN) capacity with an 18 inch (450 mm) throat. It is totally pneumatically controlled and operated. No electric power is required. The press is covered by a two (2) year limited warranty. Should any questions or problems arise concerning your Series 4 press, contact the PEMSERTER Products Division Service Department at PENN ENGINEERING. Toll-free telephone number (in North America) or Set-up, Training and Repair Service is available to you as long as you own your press. Free telephone instruction and Service is available for the lifetime of your press by calling the PEMSERTER Products Division Service Department. SHIPPING DAMAGE The PEMSERTER Series 4 press has been shipped to you packaged to withstand normal handling during transit. Upon receipt, the unit should be checked for any damage that may have occurred during shipment due to improper handling. Should any damage be found, the transportation company who delivered the unit must be immediately notified as should the PEMSERTER Products Division Service Department. SECIFICATIONS: Ram Force to 12,000 (1.8 to 54 kn) Air Requirements to 110 PSI (6 to 7.5 BAR) Air Line... ½ (12mm) I.D. Minimum line flow Throat Depth (45cm) Weight lbs (260 kg) Ambient Temperature F to 120 F (-29 C to 49 C) Ambient Humidity... 0% to 80% (Not reflective of inlet air) Air Consumption... Approx. 2.3 liters/sec at 1 atm (4.9 scfm) 20 insertions per minute at 20 kn (4500 lbf) 2

3 SAFETY The Series 4 was designed to conform to applicable ISO, ANSI, OSHA, CEN and CSA safety standards. The Series 4 is compliant to applicable European Union (EU) directives and bears the CE Mark. The Series 4 conforms to the essential requirements of the following directives: EN 98/37/EC (June 22, 1998) Machinery Directive. Please read and follow the safety precautions listed below. SAFETY PRECAUTIONS Always use safety goggles when operating or maintaining the press. Ear Protection is recommended. Before using the press, make sure that a shutoff device has been fitted on the air supply line and the location is easily accessible, so that the air supply to the press can be shut off in an emergency. Check the air hose and fittings regularly for wear. Use only approved parts for maintenance and repairs. Do not use chipped, cracked or damaged accessories and tools. Attach air line securely. Keep body parts away from moving parts. Never wear jewelry, loose clothing or anything that could get caught in moving parts. If a new user is operating the press, be sure these instructions are readily available. Do not use the press in any way, other than for its intended purposes. WARNING: The PEMSERTER Series 4 press is equipped with a point-of-operation safety device to protect the operator from potential injury. A detailed explanation of the safety system can be found in Section 4 Operator Safety of this manual. ANSI specification Number B , Section 5 states "It is the employer's responsibility to ensure the usage of a point-of-operation safety or guard or a properly applied and adjusted pointof-operation safety device on every operation performed on a press production system." It is important that employers ensure that their operators understand and are trained to properly set-up the Series 4 safety system before operation. 3

4 WARRANTY PEMSERTER Products Division warrants that this product, when correctly used according to directions and under normal operating conditions, will be free from defects in material and workmanship for a period of two (2) years from the date of purchase. This warranty shall not apply to any product which has been altered, changed or repaired, normal maintenance excluded, except as authorized by PEMSERTER Products Division. This warranty shall not apply to any product that has been subject to misuse, negligence or accident. The purchaser s exclusive and sole remedy shall be limited to repair, modification or replacement at the discretion of PEMSERTER Products Division. In no event shall PEMSERTER Products Division be liable for the cost of any indirect or consequential damage. In no case shall PEMSERTER Products Division s liability exceed the purchase price of the product. This warranty is exclusive and in lieu of all other warranties. No oral or written information by PEMSERTER Products Division, its employees, representatives, distributors or agents shall increase the scope of the above warranty or create any new warranty. 4

5 PEMSERTER SERIES 4 PRESS OPERATION MANUAL TABLE OF CONTENTS Page AIR SUPPLY PREPARATION...6 UNPACKING AND INITIAL SET-UP...9 PRESS FAMILIARIZATION...12 OPERATOR SAFETY...20 A. AIRBORNE NOISE EMISSIONS...23 TOOLING SET-UP...24 A. STANDARD PUNCH AND ANVILS...25 B. BOTTOM MOUNTED REVERSE FLANGE ANVIL HOLDER...27 C. TOP MOUNTED REVERSE FLANGE ANVIL HOLDER...29 PRESS SET-UP AND OPERATION...31 PRESS MAINTENANCE AND ADJUSTMENTS...35 TROUBLE SHOOTING GUIDE...43 RECOMMENDED SPARE PARTS...49 PNEUMATIC DIAGRAM...51 TOOLING GUIDE

6 AIR SUPPLY PREPARATION 6

7 AIR SUPPLY PREPARATION Recommended Air Supply Hook-Up Arrangement Proper air supply is very important to the performance and maintenance of the press. Following these simple guidelines will ensure good press performance. Air Quality - The quality of the air supply is very important. The air must be clean and dry. Moisture and debris will contaminate the valve systems and lead to press performance and maintenance problems. Air Supply Flow - Use a minimum 12mm (1/2 ) inside diameter line and fittings from the compressed air source to the press. Shop pressure ranging between 6 to 7.5 BAR (90 psi to 110 psi) is acceptable. Inadequate air flow will affect press performance. Air Consumption Average air consumption running at 20 kn (4500 lbf) at 20 insertions per minute is about 2.3 liters/sec at 1 atm. (4.9 scfm). Air Supply Flow requirements are higher than those reflected by these values as air is not being consumed during the entire cycle time. Piping Installation Proper piping hook-up will help achieve the above requirements. See figure 1.0 on the next page. Connect to your supply line with a pipe pointing upwards that curves over and down. This arrangement will help prevent water and compressor oil from entering the press. Connect to that drop with your supply fitting for a 12mm (1/2 ) or larger hose. Continue the end of the drop to a drain valve. This will help collect additional water and oil and allow the system to be purged. If your factory air supply falls short of the above recommendations, an air reservoir tank of an appropriate size for your location can be used. An auxiliary filter/separator installed immediately outside the machine is recommended. CAUTION: Before connecting air supply to the press, ensure initial press set-up is complete and the ram force is set at the minimum (Ram Force knob turned completely counter-clockwise). 7

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9 UNPACKING AND INITIAL SET-UP 9

10 UNPACKING AND INITIAL SET-UP Select a clean, well-lit area to place your Series 4 press. Provide an area around the press that will allow for the removal of the top cover and clearance for opening the back door. A minimum of (2) feet (60 cm) along each side and (2) feet (60 cm) behind the press is recommended (Figure 2.0, Page 11). Carefully remove the crating and packing materials around the press and stand. Remove the box strapped to the crate containing assembly hardware, footswitch, tooling, etc. Position the stand with the press mounting holes as shown (Figure 2.0, Page 11). Bolt the stand to the floor. Remove the top cover from the press. Observe the red warning tags. Follow the instructions and remove only the items required for shipping. CAUTION: Do not remove the remaining warning tags until all instructions are read and understood. Attach shackles and a chain through the (2) press lifting holes (Figure 3.0, Page 13). The press weighs approximately 600 pounds (260 kg). Unbolt, then lift the press from the pallet and attach it securely to the stand with the hardware provided. Remove the chain and shackles and secure the top cover. WARNING: Do not lift the assembled press and stand by the stand. The assembled press and stand is top heavy and may fall. 10

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12 PRESS FAMILIARIZATION 12

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20 OPERATOR SAFETY 20

21 OPERATOR SAFETY An important feature of the PEMSERTER Series 4 Model J press is its "Point of Operation" safety. When the footswitch is depressed, the ram extends by gravity. At the end of the ram stroke, the ram cross pin actuates the ball valve causing the installation force to be applied to the ram assembly and punch. If an obstruction, greater than the set gap between the punch and the anvil, is encountered, the ball valve will not be actuated and the installation force will not be applied. Important: The gap must not exceed 7/32 of an inch (5,5 mm) set gap between the punch and anvil, with the ram fully extended by gravity, to comply with most major safety standards which set the limit at ¼ or 6mm (Figure 4.0, Page 22). These include standards published by ISO, ANSI, OSHA, CEN and CSA. 21

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23 AIRBORNE NOISE EMISSIONS A PEMSERTER Series 4 - Model G pneumatic press was set at the maximum ram force and cycled continuously. Sound pressure was measured at a distance of 1 meter from the surface of the press at a height of 1.6 meters from the floor at a worst case point (behind the press, near the installation force cylinder). Equivalent continuous A-weighted sound pressure = 53.5 db Peak C-weighted instantaneous sound pressure = 79.0 db Sound pressure was measured at the operator's working level (area in front of the press). Equivalent continuous A-weighted sound pressure = 45.0 db Peak C-weighted instantaneous sound pressure = 78.5 db Equipment used during testing: Description: Sound Level Meter Description: Noise Dosimeter Manufacturer: General Radio Manufacturer: Metrosonics Model: 1565-B Model: db307 Class 2A Serial Number: Serial Number: /95 23

24 TOOLING SET-UP 24

25 STANDARD PUNCH AND ANVILS 1. Refer to the tooling guide for the appropriate punch and anvil for the fastener being installed. 2. Set the ram force to OFF. Disconnect the air supply to the press. The ram will extend by gravity. Remove the punch by loosening the (2) set screws in the ram bushing. Install the new punch and tighten the (2) set screws. 3. Set the ram force to OFF. Connect the air supply to the press. The ram will retract. 4. Loosen the set screw in the side of the anvil holder and remove the anvil. Install the new anvil into the anvil holder and tighten the set screw (Figure 5.0, Page 26). 5. Set the ram force to OFF. Disconnect the air supply to the press. Check the alignment of the outside diameters of the punch and anvil. If necessary, align the anvil to the punch. Loosen the bolts in the anvil holder, reposition the anvil holder and then torque the anvil holder bolts to 100 foot pounds (136 Nm). 25

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27 BOTTOM MOUNTED REVERSE FLANGE ANVIL HOLDER 1. Refer to the tooling guide for the appropriate punch and anvil. 2. Set the ram force to OFF. Disconnect the air supply to the press. The ram will extend by gravity. Remove the punch by loosening the (2) set screws in the ram bushing. Install the new punch and tighten the (2) set screws. 3. Set the ram force to OFF. Connect the air supply to the press. The ram will retract. 4. Remove the standard anvil holder. Install the Bottom Mounted Reverse Flange Anvil Holder. Do not tighten bolts (Figure 5.1, Page 28). 5. Set the ram force to OFF. Disconnect the air supply to the press. Position the anvil holder to achieve the alignment of the outside diameters of the punch and anvil. Torque the anvil holder bolts to 100 foot pounds (136 Nm). 27

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29 TOP MOUNTED REVERSE FLANGE ANVIL HOLDER 1. Refer to the tooling guide for the appropriate punch and anvil. 2. Set the ram force to OFF. Disconnect the air supply to the press. The ram will extend by gravity. Remove the punch by loosening the (2) set screws in the ram bushing. Install the new punch and tighten the (2) set screws. 3. Set the ram force to OFF. Connect the air supply to the press. The ram will retract. 4. Turn the top anvil holder locking knob (Figure 5.2, Page 30) counter-clockwise to retract the pin in the T slot mount. Insert the Top Mounted Reverse Flange Anvil Holder into the T slot mount and slide completely forward. Adjustment of the gib plate may be required for more or less clearance in the T slot. If the gib plates are adjusted, retorque to 35 foot pounds (47.5 Nm). With the Top Mounted Reverse Flange Anvil Holder in place, tighten the top anvil holder locking knob. 5. Place the brace assembly against the frame and tighten the leveling pad. It may be necessary to re-tighten the leveling pad after the press cycles, a few times, under installation force. 6. Install the anvil into the Top Mounted Reverse Flange Anvil Holder. 29

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31 PRESS SET-UP AND OPERATION 31

32 PRESS SET-UP AND OPERATION 1. Set the ram force to OFF by turning the RAM FORCE ADJUSTMENT knob counter-clockwise (Figure 3.1, Page 13). 2. Connect the air supply to the press. 3. Place the SET-UP/CYCLE switch to "Set-Up". 4. When installing nuts, place the nut, shank up, in the counterbore of the anvil. Place the fastener installation hole of the workpiece on the shank of the nut. When installing studs or standoffs, place the fastener through the fastener installation hole of the workpiece. Then, insert the fastener with the workpiece into the anvil hole. 5. Depress the footswitch. The ram will extend and will remain extended as long as the footswitch is depressed. Use (2) 3/4 inch wrenches, one wrench on the ram bushing and the other wrench to loosen and tighten the ram jam nut (Figure 6.0, Page 33). If only one wrench is used, the cross pin assembly may break. After the ram jam nut has been loosened, turn the punch by hand clockwise to lower the punch or counter-clockwise to raise the punch. With the ram fully extended and the ram jam nut loose, adjust the punch to slightly contact the panel (for nuts) or the head of the fastener (studs and standoffs). Then, turn the punch clockwise (2) additional turns. Tighten the ram jam nut using the (2) 3/4 inch wrenches as described above. Remove your foot from the footswitch. The ram will retract. NOTE: Caution must be taken not to exceed 7/32 of an inch (5,5 mm) gap between the surfaces of the punch and anvil, with the punch fully extended, to comply with OSHA and CE specifications. Refer to the OPERATOR SAFETY section of this manual for additional information. 6. Turn the RAM FORCE ADJUSTMENT knob to 1,000 to 1,500 lbs. (4.5 to 6.7 kn) of force. Depress the footswitch and hold the footpedal down until the ram is fully extended. Remove your foot from the footswitch, the ram will remain extended. If the ram retracts, check that the SET-UP/CYCLE switch is in "Set- Up" (not "Cycle") and the ram bushing is adjusted correctly. If it is not in "Set- Up" or if the ram bushing is not adjusted correctly, repeat steps 1 through 5. 32

33 WARNING: Do not exceed 9,000 lbs. (40 kn) of force if the press is set-up with a Top Mounted Reverse Flange Anvil Holder or tooling damage will occur. Do not exceed 6,000 lbs. (27 kn) of force, if the press is set-up with a Bottom Mounted Reverse Flange Anvil Holder. Never exceed 12,000 lbs (54 kn). Continue to turn the RAM FORCE ADJUSTMENT knob SLOWLY clockwise, while looking at the fastener and workpiece, until the fastener is properly installed. 7. Place the SET-UP/CYCLE switch to "Cycle". The ram will retract. 8. The press is now set-up for installation of fasteners for nuts. Place the nut, shank up, into the counterbore of the anvil. Place the fastener installation hole of the workpiece over the shank of the nut. Depress the footswitch. The ram will descend, install the fastener and retract. For studs, place the fastener through the fastener installation hole of the workpiece. Then, insert the fastener with the workpiece into the anvil hole. Depress the footswitch. The ram will descend. Install the fastener and retract. FOOTSWITCH OPERATION SERIES 4 PRESS The footswitch must be depressed until the ram drops and the main cylinder begins to move. 33

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35 PRESS MAINTENANCE AND ADJUSTMENTS 35

36 PRESS MAINTENANCE WARNING: DISCONNECT THE AIR SUPPLY BEFORE PERFORMING ANY MAINTENANCE. IMPORTANT: COMPLETE THE FOLLOWING MAINTENANCE EVERY WEEK. 1. Lubricate all pivot points with a good quality lubricating oil, such as SAE (Refer to Figure 7.0, Page 37). 2. Spray the upper and lower portion of the ram with WD-40, CRC 5-56 or equivalent. Wipe clean with a cloth and respray with a light coat. 3. The MAIN AIR FILTER is equipped with an automatic drain (Figure 7.1, Page 38). If an excessive amount of liquid (over 1/2 inch or 12mm) is in the filter bowl, manual draining and cleaning is required to clean the filter bowl. Remove the filter bowl and clean with a clean cloth and soap. Wipe the bowl dry and reinstall. Never clean the filter bowl with solvents. Solvents may weaken the bowl material resulting in bowl deterioration. 36

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39 WARNING: DISCONNECT THE AIR SUPPLY BEFORE PERFORMING ANY MAINTENANCE. IMPORTANT: COMPLETE THE FOLLOWING MAINTENANCE EVERY (6) MONTHS. TIMER FILTER - Open the tool storage cabinet and remove the control box (Figure 3.4, Page 19) using a socket wrench. Remove the timer assembly from the base (Figure 7.2, Page 40) using a straight blade screwdriver. Remove the small "O" ring, then the plastic spacer. Grasp the small brass stem on the filter element and pull straight out. Clean the filter element in solvent, blow dry, and reassemble. 39

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41 FLOW CONTROL VALVE ADJUSTMENTS (Figure 3.3, Page 18) All FLOW CONTROL VALVES are set at the factory for optimum press performance. Incorrectly altering these settings may cause press damage. However, as press components wear or are replaced, the ram may descend too slowly or retract too fast, requiring the following adjustments. FLOW CONTROL VALVE FUNCTIONS VALVE A - VALVE B - VALVE A controls the speed at which the ram descends. VALVE A regulates the amount of air exhausted from the lift cylinder when the footswitch is depressed. VALVE B assists in controlling the speed at which the ram retracts along with cushioning the ram stop. VALVE B regulates the amount of air exhausted from the lift cylinder. ADJUSTMENT PROCEDURE VALVE A - VALVE B - Fully close VALVE A by turning clockwise. Then, open VALVE A by turning counter-clockwise approximately 1/4 turn. Fully close VALVE B by turning clockwise. Then, open VALVE B by turning counter-clockwise approximately 1/4 turn. FINAL ADJUSTMENT An additional adjustment may be required based on the press's actual operation. For example: If, after all adjustments are made, the ram descends too slowly, adjust VALVE A counter-clockwise to increase the amount of air exhausted from the lift cylinder. 41

42 LEVER ROLLER VALVE BRACKET ADJUSTMENT The lever roller valve bracket adjustment is set at the factory for optimum press performance. If during maintenance servicing the bracket is moved it will need to be readjusted. LEVER ROLLER VALVE FUNCTIONS The lever roller valve controls air flow from the foot pedal to the lift cylinder. When the valve is actuated by the lever arm, air flows into the lift cylinder, and the ram is retracted. ADJUSTMENT PROCEDURE Make sure the main cylinder and lever are in the fully retracted position. IMPORTANT: Turn the force regulator off so that the ram will not move. Position the bracket so that the valve is not activated. Tighten the ¼-20 x ½ lg socket set screws that hold down the bracket to the point where the bracket will not move freely but do not tighten completely. Using a hammer gently tap the bracket forward towards the front of the press until the lift cylinder returns to the up position and the ram is retracted. Tighten the ¼-20 x ½ lg socket head cap screws completely. 42

43 TROUBLE SHOOTING GUIDE 43

44 TROUBLE SHOOTING GUIDE PROBLEM CAUSE CORRECTIVE ACTION Punch will not descend. Footswitch not operating. Remove footswitch air connection from press. If press cycles, replace footswitch. Ram will not retract. Ram Bushing jammed in Ram Bearing. Footswitch hose kinked. Cross Pin Assembly interfering with Bearing Plate. Ram Module hardware loose. Broken Plate Cross Pin Assembly. Clogged Timer Filter. Main Valve jammed. Unlatch and remove the top cover. Free Ram by lightly striking top of Ram Assembly. Remove Ram Bearing and replace. Reassemble and ensure that the set screws are fully installed in the Ram Bushing. Unkink Footswitch hose. Remove Ram Module from frame. File coined area on Bearing Plate. Remove Ram Module. Apply Loctite #242 to hardware and reassemble. Replace Plate Cross Pin Assembly. Clean all air filters. Replace Timer if necessary. Remove Main Valve Assembly. Disassemble valve and clean in mineral spirits. Replace Main Valve Assembly if necessary. Clean all air filters. 44

45 TROUBLE SHOOTING GUIDE PROBLEM CAUSE CORRECTIVE ACTION Ram will not retract (Continued) Fastener will not install. Exhaust Muffler clogged on Main Valve Assembly. Flow control Valve B adjustment required. Timer adjustment required. Set-Up/Cycle switch in "Set-Up" position. No air supplied to press. Lever roller valve failure. Lever roller valve bracket out of adjustment. Ram Bushing improperly adjusted. Replace Exhaust Muffler. Fully close Flow Control Valve B by turning clockwise. Then, open valve by turning counterclockwise approximately ¼ turns. Ensure Ram does not slam when retracting. Open tool cabinet. Remove control box. Set Timer dial to "A" setting. Cycle press and readjust if necessary. Turn dial clockwise to increase Ram extension time, and turn dial counter-clockwise to decrease Ram extension time. Place switch in "Cycle" position. Check press air supply connections and main air supply. Replace lever roller valve. Adjust lever roller valve bracket per adjustment instructions. Adjust Ram Bushing per Tooling Set-Up and Operation section. 45

46 TROUBLE SHOOTING GUIDE PROBLEM CAUSE CORRECTIVE ACTION Fastener will not install. (Continued) Workpiece material too hard. Punch and anvil lengths incorrect. Incorrect fastener installation hole size in workpiece. Timer adjustment required. Timer not operating. Main Valve jammed. Check hardness of workpiece and compare with PEM fastener catalog specifications. Combined length of punch and anvil must total 7 inches (178 mm), except when using the Top Mounted Reverse Flange Anvil Holder and the Bottom Mounted Reverse Flange Anvil Holder. (Combined lengths are 3.25 (83 mm) and 8.44 (214 mm) inches respectively.) Measure hole size and compare with PEM fastener catalog specification. Open tool cabinet. Remove control box. Set Timer dial to "A" setting. Cycle press and readjust if necessary. Turn dial clockwise to increase Ram extension time. Remove Timer and clean Timer filter. Replace Timer if necessary. Remove Main Valve Assembly. Disassemble Valve and clean in mineral spirits. Replace Valve if necessary. Clean air filters. 46

47 TROUBLE SHOOTING GUIDE PROBLEM CAUSE CORRECTIVE ACTION Punch descends too slowly. Ram slams when retracting. Tooling leaves marks on workpiece. Ram Module Assembly dirty. Ram Bearing damaged. Footswitch not operating. Flow Control Valve A adjustment required. Flow Control Valve B adjustment required. Excessive Ram force. Sharp edge on punch or anvil. Clean Ram Module Assembly as described in Maintenance section. Remove Ram Bearing and replace. Reassemble and ensure that the set screws are fully installed in the Ram Bushing. Replace footswitch. Fully close Flow Control Valve A by turning clockwise. Then, open valve by turning counterclockwise ¼ turns. Cycle press and ensure Ram does not bounce at bottom of stroke. Readjust if necessary. Fully close Flow control Valve B by turning clockwise. Then, open valve by turning counterclockwise approximately ¼ turns. Cycle press and ensure Ram does not slam when retracting. Readjust if necessary. Reduce Ram force. Refer to Tooling Set-Up and Operation section. Break edge of punch or anvil.015" X 45E(.38 mm X 45E) maximum. 47

48 TROUBLE SHOOTING GUIDE PROBLEM CAUSE CORRECTIVE ACTION Main Cylinder slamming at end of stroke. Main cylinder air cushion misadjusted. Adjust appropriate air cushion - extend or retract. (Figure 3.3) Lever assembly slams hard on up-stroke. Ram bushing set-up too low. The link levers hitting ram module before lever roller contacts ram cap. Adjust ram bushing out and set up ram at top of ball valve per set-up instructions. 48

49 RECOMMENDED SPARE PARTS 49

50 RECOMMENDED SPARE PARTS FOR PEMSERTER SERIES 4 PRESS QUANTITY PART NUMBER DESCRIPTION 1 piece Timer Valve (Figure 7.2) 1 piece Ram Bushing (Figure 6.0) 1 piece Ram Jam Nut (Figure 6.0) 1 piece Cross Pin Plate Assy (Figure 3.2) 2 pieces Socket Set Screw #10-32 X 1/4 Lg. (Figure 6.0) 1 piece Filter Element SMC (Figure 7.1) 1 piece Upper Ram Cross Pin 1 piece Retaining Ring 1 piece Lever Valve (Figure 3.2) Not included in Spare Parts Kit: 1 piece Pressure Diagnostic Gauge Assy (Optional) 50

51 PNEUMATIC DIAGRAM 51

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53 TOOLING GUIDE 53

54 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 PUNCH ASSEMBLY DRAWINGS * Standard Length for Punches is 4 (101.6mm) and Anvils 3 (76.2mm). Most punches and anvils are 5/8 (15.9mm) in diameter. All are designed to fit the 3/8 (9.5mm) punch and anvil adapters of Pemserter presses. All tooling includes yellow shrink tubing in groove as warning for possible pinch point. Page 54

55 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 ANVIL ASSEMBLY DRAWINGS * Standard Length for Punches is 4 (101.6mm) and Anvils 3 (76.2mm). Most punches and anvils are 5/8 (15.9mm) in diameter. All are designed to fit the 3/8 (9.5mm) punch and anvil adapters of Pemserter presses. All tooling includes yellow shrink tubing in groove as warning for possible pinch point. Page 55

56 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 ANVIL ASSEMBLY DRAWINGS ( Continued) * Standard Length for Punches is 4 (101.6mm) and Anvils 3 (76.2mm). Most punches and anvils are 5/8 (15.9mm) in diameter. All are designed to fit the 3/8 (9.5mm) punch and anvil adapters of Pemserter presses. All tooling includes yellow shrink tubing in groove as warning for possible pinch point. Page 56

57 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 IDENTIFY YOUR PRESS THE SERIAL NUMBER IS LOCATED ON THE COVER OF THE INSTRUCTION MANUAL OR ON THE PEMSERTER PRESS NAMEPLATE AS, AC, LAS, LAC PEM SELF-CLINCHING FLOATING BULLETIN ALA 440/M /M /M /M /M Figure P-1 Figure A-4 B, BS PEM BLIND NUT BULLETIN B 440/M /M /M /M /M Figure P-1 Figure A-4 CHA, CHC, CFHA, CFHC PEM CONCEALED-HEAD STUD BULLETIN CH /M M M M Figure P-1 Figure A-3 NOTE: THESE ANVILS ARE SAME AS FH ANVILS CLA PEM ALUMINUM SELF-CLINCHING NUTS BULLETIN CL 256/440/M2/M /M /M /M /M Figure P-1 Figure A-2 NOTE: These anvils are same as CLS, S anvils except for 1032/M5. Page 57

58 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 CLS, CLSS, S, SS PEM SELF-CLINCHING NUTS BULLETIN CL 256/440/M2/M /M /M /M /M /M * M * Anvil ¾ (19mm) dia 0813/M * Punch & Anvil 13/16 (20.6mm) dia Figure P-1 Figure A-2 *Large Nut Anvils instead of counter bore, use protrusion to locate part. CSOS, CSS PEM CONCEALED-HEAD STANDOFF BULLETIN CH 440/M /M /M /M /M Figure P-1 Figure A-3 NOTE: THESE ANVILS ARE DIFFERENT THAN SO ANVILS DPRS, DBRS PEM WAVEGARD GROUNDING BULLETIN DR PACKAGE CONTAINS 2 PUNCHES AND 1 ANVIL Anvil DBRS/DPRS : Punch DBRS : Punch DPRS DSOS, CFN, SLPS PEM CONNECT R WARE FASTENERS BULLETIN CW P125-2 INSERTION PRESS F PEM FLUSH NUTS BULLETIN F 256/M2/M /M /M /M /M /M Figure P-1 Figure A-5 Page 58

59 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 FE, FEO, FEX, FEOX PEM MINIATURE, SELF-LOCKING NUTS BULLETIN FE 440/M /M /M /M /M Figure P-1 Figure A-4 FH, FHA, FHS PEM FLUSH STUDS BULLETIN FH For material.060 +/1.51mm+ Anvil For material <=.059 /1.5mm /M / M M M M M M Figure P-1 Figure A-4 Figure A-9 FHL, FHLS-PEM FLUSH STUDS FOR CLOSE-TO-EDGE & MINIMAL SPACE APPLICATIONS BULLETIN FH For material.060 +/1.51mm+ Anvil For material <=.059 /1.5mm Continued on next page Figure P-1 ½ (12.7mm) dia Figure A-4 - ½ (12.7mm) dia Figure A-9 ½ (12.7mm) dia Page 59

60 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 FHL, FHLS-PEM FLUSH STUDS FOR CLOSE-TO-EDGE & MINIMAL SPACE APPLICATIONS BULLETIN FH (Continued) For material.060 +/1.51mm+ Anvil For material <=.059 /1.5mm M M M M M5 Figure P-1 ½ (12.7mm) dia Figure A-4 - ½ (12.7mm) dia FH4 PEM SERIES 400 STAINLESS FLUSH STUDS BULLETIN FH M M M M Figure P-1 Figure A-6 HFE PEM HIGH STUDS BULLETIN FH For material Figure A-9 ½ (12.7mm) dia Anvil For material.060 +/1.51mm+.040/1mm /1.5mm M M For material.093"+/2.4mm+ For material.060/1.5mm -.093"/2.4mm * *M Figure P-2 Figure A-4 Figure A-9 *INSTALLATION FORCE MAY EXCEED CAPABILITIES OF PEMSERTER PRESSES SHOWN IN THIS TOOLING GUIDE. Punch and Anvil ¾ (19mm) dia. Page 60

61 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 HFH, HFHS, HFHB PEM HIGH STRENGTH STUDS BULLETIN FH Punch ¾ (19mm) dia Punch ¾ (19mm) dia Punch 15/16 (23.8mm) dia M M Punch ¾ (19mm) dia M Punch ¾ (19mm) dia M Punch 15/16 (23.8mm) dia Figure P-2 Figure A-4 TFH, TFHS PEM NON FLUSH THIN SHEET BULLETIN FH For material.030 +/.76mm Page 61 Anvil For material.020 /.51mm /.75mm /M T.B.D M M M M Figure P-2 Figure A-4 Figure A-9 H, HN, HNL PEM SELF-LOCKING AND NON-LOCKING NUTS BULLETIN CL 0420/M /M * 0616/M * Anvil ¾ (19mm) dia Figure P-1 Figure A-2 *Large Nut Anvils use protrusion to locate part instead of counter bore. KF2, KFS2 PEM BROACHING NUTS BULLETIN K 256/440/M2/M2.5/M /M /M /M Figure P-1 Figure A-2

62 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 KFB3 PEM FLARE-MOUNTED THREADED STANDOFF BULLETIN K to to to to M M3-3 to M3-8 to M3-12 to M3-14 to to to to to to M M4-3 to M4-8 to M4-12 to M4-14 to Figure P-4 Figure A-2 KFE, KFSE PEM BROACHING STANDOFF BULLETIN K 440/116-4 to / to / to / to M3-3 to M3-8 to M3-12 to M3-14 to /143-4 to / to / to / to / to Figure P-1 Figure A-2 Page 62

63 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 KFH PEM BROACHING STUDS BULLETIN K M M M Figure P-1 Figure A-4 KPS6 PEM SELF-EXPANDING FOILGUARD FASTENERS BULLETIN K 440 (-4 TO -6) (-8 TO -12) (-16 TO -20) (-4 TO -6) (-8 TO -12) (-16 TO -20) (-4 TO -8) (-10 TO -12) (-16 TO -20) (-4 TO -8) (-10 TO -12) (-16 TO -20) M3 (-3 TO -6) M3 (-8 TO 10) M3 (-12 TO -14) M4 (-3 TO -6) M4 (-8 TO -10) M4 (-12 TO -14) M5 (-3 TO -6) M5 (-8 TO -10) M5 (-12) Figure P-1 Figure A-2 KSSB PEM BROACHING SNAP-TOP STANDOFFS BULLETIN SSA 156 (-8 TO 32) 4mm (-8 TO 25) Figure P-1 Figure A-4 Page 63

64 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 LK, LKS, LKA PEM SELF-LOCKING NUTS BULLETIN LK 2-56/M /M /M /M Figure P-1 Figure A-4 NFPC, NFPA PEM INSERTS FOR PLASTICS BULLETIN SI ALL SIZES Figure P-1 Figure A-1l FLUSH-MOUNTED PANEL SCREW COMPONENTS PF10 COMPONENTS BULLETIN PF PR10 FLUSH-MOUNTED RETAINER 440/M /M /M Figure P-1 Figure A-4 N10 SELF-CLINCHING RECEPTACLE NUTS TOOLING TO BE DETERMINED PF11 PEM PANEL FASTENER BULLETIN PF 440/M /M /M /M /M Figure P-3 Figure A-2 PF30, PF31, PF32, PF50, PF60 PEM LOW PROFILE PANEL FASTENER BULLETIN PF 440/M /M /M /M Figure P-3 Figure A-2 Page 64

65 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 PFC2, PFC2P, PFK, PFS2 PEM PANEL FASTENER BULLETIN PF 440/M /M /M /M Figure P-3 Figure A-2 PFF PEM FLOATING PANEL FASTENER BULLETIN PF 1032/M M Figure P-6 Figure A-10 PFHV PEM PANEL FASTENER BULLETIN PF 440/M /M /M Figure P-3 Figure A-2 PFP PEM PANEL FASTENER BULLETIN PF 440/M /M Figure P-3 Figure A-2 PFS PEM SNAP-IN PANEL FASTENER BULLETIN PF Size Hand Tool Assembly 440/M /M /M PL, PLC PEM-HEX SELF-LOCKING NUTS BULLETIN PL 440/M /M /M /M Figure P-1 Figure A-4 Page 65

66 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 PPB, PFLB, PKB PEM INSERTS FOR PLASTICS BULLETIN SI TOOLING TO BE DETERMINED PTL2 PEM SPRING-LOADED PLUNGER ASSEMBLIES BULLETIN PF Figure P-1 Figure A-4 RAA, RAS PEM R ANGLE CLINCH FASTENER BULLETIN RA M M4 Figure P-1-1 (25.4mm) dia Figure A-8-1 (25.4mm) dia SKC-6060 (SKC 61.5) PEM KEYHOLE SELF-CLINCHING STANDOFFS BULLETIN SK 6060 / Figure P-1 Figure A-4 SL PEM SELF-CLINCHING LOCK NUTS BULLETIN CL 440/M /M /M /M /M Figure P-1 Figure A-2 NOTE: These anvils are same as CLS, S anvils. SMPS PEM SELF-CLINCHING NUT FOR ULTRA THIN SHEETS BULLETIN CL 2/440/M2.5/M /M Figure P-1 Figure A-2 Page 66

67 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 SO, SOA, SOS, SON, BSO, BSOA, BSOS, BSON PEM STANDOFFS BULLETIN SO 2/3/440/M2/M2.5/M /6440/M3/M /8632/M /M Figure P-1 Figure A-4 SOAG, SOSG PEM STANDOFFS BULLETIN K 2/3/440/M2/M2.5/M /6440/M3/M /8632/M /M Figure P-1 Figure A-4 SP PEM 300 STAINLESS STEEL SELF-CLINCHING NUTS BULLETIN CL M M M M M M Pin & Figure P-1 Figure A-7 & Figure A-2 NOTE: These punch & anvils have special geometry for maximum clinch performance into stainless steel and alignment, except for 0420/M6, which does not require the special geometry. SSA, SSS, SSC, KSSB PEM SNAP-TOP STANDOFFS BULLETIN SSA ALL Figure P-1 Figure A-4 Page 67

68 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 TDO PEM CABLE TIE HOOKS-CLINCHING BULLETIN TD (1 dia) Figure P-1 Figure A-11 TPS PEM FLUSH-MOUNTED PILOT PINS BULLETIN FH Size Punch 4 /101.6mm Long Anvil For material.060 +/1.7mm+ Anvil For material / 1mm 1.7mm.125 (.130) (.192) (.255) mm (.161) mm (.201) mm (.290) Figure P-1 Figure A-4 Figure A-9 TSO, TSOS, TSOA PEM THREADED STANDOFFS FOR THIN SHEETS- BULLETIN SO For material Anvil For material /.63mm -.81/.75mm.032 +/0.81mm M M M M M Figure P-1 Figure A-4 Figure A-9 TY-D PEM CABLE TIE-MOUNT SELF-CLINCHING BULLETIN TD Figure P-1 (1 dia) Figure A-8 (1 dia) Page 68

69 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 U, UL PEM MINIATURE SELF-CLINCHING FASTENERS BULLETIN FE Figure P-1 Figure A-5 TURRET ANVILS STUDS FH 4 ¼-20 STANDOFFS SO 4 AND STUDS FH M3 M STANDOFFS SO 4/M3/6/M3.5/8/M4/10/M NUTS S AND CLS 2 ¼-20 / M2 M NOTE: THE BOTTOM AND TOP MOUNT REVERSE FLANGE ANVIL HOLDERS ARE FOR THE SERIES 4 PRESS ONLY! TOOLS FOR SERIES 4 BOTTOM MOUNT REVERSE FLANGE ANVIL HOLDER KIT INCLUDES LONG PUNCH AND FLAT ANVIL PUNCH ANVIL FLAT ANVIL S ANVIL S ANVIL S ANVIL S ANVIL S TOOLS FOR SERIES 4 TOP MOUNT REVERSE FLANGE ANVIL HOLDER KIT INCLUDES PUNCH AND FLAT ANVIL PUNCH ANVIL FLAT NOTE: OTHER ANVILS ARE AVAILABLE FOR TOP AND BOTTOM MOUNT REVERSE FLANGE ANVIL HOLDERS. WORKPIECE ALIGNMENT PLATES KIT PART # CONTAINS: ALIGNMENT PLATE ROUND ALIGNMENT PLATE RECTANGULAR Page 69

70 Manual Tooling Guide For Series 100, 500, 1000, 2000, 4 & TECH2 PRESS ACCESSORIES: Part Number Description Features and Benefits (120V) (US) (220V) (EUROPE) Industrial Work Light Anti-Fatigue Work Mat Industrial Work Seat Flexible, Efficient Coverage of Working Area Bright 20W Halogen Bulb Magnetic Base Mounts to Frame 120V/220V models available Solid polyurethane nodule design increases blood circulation and reduces cumulative trauma disorders associated with prolonged standing. Chemical Resistant Durable and easy to clean Shock absorbent with Tapered Edges 24" by 36" Two Year Wear Warranty Ergonomic design improves comfort and increases worker productivity Four Easy to use Height (16" to 32") and Tilt Adjustments Durable Polyurethane Seat Foot Rest Step Rail Built tough for industrial environment Swivel Stop Feature makes getting on and off the chair easy and safe Five Year, Three shift Warranty Page 70