OPERATION AND MAINTENANCE MANUAL

FOR PEMSERTER® SERIES 4® - VERSION M

HARDWARE INSERTION MACHINE

(Original Instruction)

PennEngineering®
99 Middle Chenfeng Road
Kunshan, Jiangsu Province 215300, P.R.China
www.pemnet.com.
PRODUCED IN CHINA BY PEM (CHINA) Co., Ltd
OPERATION AND MAINTENANCE MANUAL

SERIAL NUMBER ________

NOTE: Your New PEMSERTER® Series 4®

Hardware Insertion Machine
has been assigned a Serial Number as indicated above.

This Number Must Be Referenced

In all Correspondence

Part Number 8018760

Revision J (25-FEB-2022)

2
 Read Manual Before Operating Machine!

FOREWORD
Thank you for purchasing a PEMSERTER® Series 4® Hardware Insertion
Machine .With the proper care and maintenance, your machine will install
millions of fasteners safely, quickly and consistently. The machine 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 Hardware Insertion Machine is covered by a one (1) year limited warranty.

Should any questions or problems arise concerning your Series 4® Machine,

contact the PennEngineering® Service Department. Toll-free telephone
number +86(512)5726-9310 (in China) or +1 (209)-848-4000(in America) or
+31(541)-530-230 (in Europe)

Set-up, Training and Repair Service is available to you as long as you own your
Machine. Free telephone instruction and Service is available for the lifetime of
your Machine by calling the PennEngineering® Service Department.

SHIPPING DAMAGE

The PEMSERTER® Series 4® Machine 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
PennEngineering® Service Department.

SPECIFICATIONS:

Ram Force ................................................................

400 to 12,000 lbf (1.8 to 53.4 kN)
Ram Stroke................................ 7/32 inch (5.5mm)
Air Requirements ................................90 to 100 PSI (6 to 7 BAR)
Air Line ................................................................
½” (12mm) I.D. Minimum line flow
Throat Depth................................18” (45cm)
Weight (Insertion Machine ) ................................
485 lbs (220kg)
Weight (Stand ) ................................ 230 lbs (105kg)
Ambient Temperature ................................
-20° 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)

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:
2006/42/EC Machinery Directive
of which only the Essential Health and Safety Requirements of
Annex I apply.
EN ISO 12100 Safety of Machine Tools. Hardware Insertion Machine.

Please read and follow the safety precautions listed below.

GENERAL SAFETY PRECAUTIONS

♦ Always use safety goggles when operating or maintaining the machine.
♦ Always disconnect the air supply before maintaining the machine.(shut-off the pressure relief valve
and should be locked it.)
♦ Ear Protection is recommended.
♦ Before using the machine, 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 machine 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 machine, be sure these instructions are readily available.
♦ Do not use the machine in any way other than for its intended purposes.
♦ Do not modify the machine
♦ The equipment is not allowed to operate in explosive, corrosive or underground environment or
environment containing flammable or poisonous substances.

WARNING:
The PEMSERTER® Series 4® machine 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 B11.1-1982, 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 point-of-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.

4
 IMPORTANT: The setup gap, as explained later in this manual, must
not exceed 7/32 of an inch (5,5 mm) 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). These include standards published by ISO,
ANSI, OSHA, CEN and CSA.

Label Definition

Series 4 Plate

Warning Plate

Warning Label

Warning Label

5
Label Definition
General Warning Label – There are items that require attention.
These are specified in the operator’s manual.

Eye Protection Label – Eye protection must be worn when

operating the press.

Pinch Point Label – Keep hands away from area.

Read Manual Label –Read the content before operation.

OPTION
Label Definition

CAUTION: Laser Radiation. Do not stare into beam.

Class 2 laser product.
Per EN 60825 and ANSI Z136.1: Class 2 lasers are low power
devices emitting visible radiation in the wavelength range
400mm to 700mm. Momentary viewing is not considered
hazardous since the upper radiant power limit on this type of
device is less than the MPE (Maximum Permissible Exposure)
for momentary exposure of 0.25 second or less. Intentional
extended viewing, however, is considered hazardous.

Never aim the spotting light anywhere except at the workpiece.

6
 WARRANTY
PennEngineering® 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 one (1) year 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 PennEngineering®.
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 PennEngineering®. In no event shall PennEngineering®
be liable for the cost of any indirect or consequential damage. In no case shall
PennEngineering®’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 PennEngineering®, its employees, representatives, distributors or agents
shall increase the scope of the above warranty or create any new warranty.

7
 PEMSERTER® SERIES 4® - VERSION M
HARDWARE INSERTION MACHINE
OPERATION AND MAINTENANCE MANUAL

TABLE OF CONTENTS

SECTION TITLES PAGE

1. AIR SUPPLY PREPARATION ................................................................................... 9

2. UNPACKING AND INITIAL SET-UP ......................................................................... 11

3. MACHINE FAMILIARIZATION .................................................................................. 14

4. OPERATOR SAFETY ............................................................................................... 21

AIRBORNE NOISE EMISSIONS ............................................................. 23

5. TOOLING SET-UP .................................................................................................... 24

STANDARD PUNCH AND ANVILS ........................................................... 24

BOTTOM MOUNTED REVERSE FLANGE ANVIL HOLDER.................... 26

TOP MOUNTED REVERSE FLANGE ANVIL HOLDER............................ 28

6. MACHINE SET-UP AND OPERATION ..................................................................... 30

7. MACHINE MAINTENANCE AND ADJUSTMENTS ................................................... 34

8. TROUBLE SHOOTING GUIDE ................................................................................. 42

9. RECOMMENDED SPARE PARTS ........................................................................... 47

10. PNEUMATIC DIAGRAM ......................................................................................... 48

11. APPENDIX 49

8
 SECTION 1

AIR SUPPLY PREPARATION

Recommended Air Supply Hook-Up Arrangement

Proper air supply is very important to the performance and maintenance of the machine.
Following these simple guidelines will ensure good machine 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
machine 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 machine. Shop pressure ranging between 6 to 7
BAR (90 psi to 110 psi) is acceptable. Inadequate air flow will affect machine
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
machine.
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 machine, ensure initial

machine set-up is complete and the ram force is set at the
minimum (Ram Force knob turned completely counter-clockwise).

9
10
 SECTION 2

UNPACKING AND INITIAL SET-UP

Select a clean, well-lit area to place your Series 4® machine. Check that the floor is in
good condition and capable of supporting the weight of the machine, stand and
operator. Provide an area around the machine 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 machine is recommended (Figure 2.0).

Carefully remove the crating and packing materials around the machine and stand.
Remove the box strapped to the crate containing assembly hardware, footswitch,
tooling, etc.

Remove the top cover from the machine. Observe the red warning tags. Follow the
instructions and remove only the items required for shipping.

Air Supply Inlet System The supply of compressed air enters the Hardware Insertion
Machine in frame above the side through a system, which includes a pressure relief
valve (outside the frame--use as a switch) and a main air filter exhaust/supply valve
(inside the frame). The regulator is manually set to control the supply line pressure.
Turning on the pressure relief valve(State – SUP) /supply valve supplies air to the
machine. When the pressure relief valve is turned off the valve closes (State – EXH)
and exhausts all downstream compressed air in the machine quickly, and should be
locked with a padlock.(Figure 3.3)

Value turning on
--SUP

Value turning off

--EXH, and locked
with a padlock

11
 CAUTION: Do not remove the remaining warning tags until all
instructions are read and understood.

Attach shackles and a chain through the (2) machine lifting holes (Figure 3.0). The
machine and stand weigh approximately 715 pounds (325 kg). Unbolt, then lift the
machine and stand from the pallet. Remove the chain and shackles and secure the top
cover.

WARNING: Do not lift the assembled machine and stand by the

stand. The assembled machine and stand is top
heavy and may fall if tilted beyond 10º of vertical.

IMPORTANT: Bolt the stand to the floor. Use appropriate

fasteners for the type of floor. Use steel bolts of
10mm (3/8”) diameter.

Forklift Location In the factory

Fork lift location Fork lift location Fork lift location

12
 RECOMMENDED CLEARANCE FOR MACHINE STAND
NOTE:
Dimension shown in [ ]
Are in Centimeters

STAND PLACEMENT AND RECOMMENDED

CLEARANCES FIGURE 2.0

13
 SECTION 3

MACHINE FAMILIARIZATION

MACHINE FRONT

MACHINE RIGHT SIDE

FIGURE 3.0

Item Description Qty.

1 Spotting Light (Options) 1
2 Ram Bearing 1
3 Ram Bushing & Jam Nut 1
4 Parts Tray 1
5 Control Panel Assy. 1
6 Punch 1
7 Lifting Holes 1
8 Anvil 1
9 Anvil Holder 1
10 Top Cover 1
11 Rear Cover 1
12 Tool Storage Cabinet 1

14
 OPERATOR CONTROL PANEL
FIGURE 3.1

Item Description Qty.

1 Control Panel 1
2 Ram Force/Air Pressure Adjustment 1
3 Set-Up/Cycle Switch 1
4 Pneumatic Totalizer 1
5 OPTICAL SENSOR INDICATOR 1

15
16
17
 27 8004686 MOUNTING BRACKET, ROLLER VALVE 1
26 8002157 LEVER ROLLER VALVE 1
25 8002805 QUICK EXHAUST VALVE 1
24 980035003 ANVIL HOLDER TURRET 1
23 ANVIL-AS REQUIRED 1
22 PUNCH-AS REQUIRED 1
21 980335097 BUSHING RAM 1
20 980335098 RAM JAM NUT ALL PS-4 MODELS 1
19 980039483 SPRING EXTENSION 1
8015019 (Up to S/N 5438)
18 CYLINDER NFPA, 3-1/4 1
8017765 (S/N 5439 & Up)
8015022 (Up to S/N 5438) FITTING
17 1
9800393039 (S/N 5439 & Up) SHUTTLE VALVE

8015511 (Up to S/N 5438)

16 MAIN VALVE 1
9800393037 (S/N 5439 & Up)

15
980445023 (B)FLTR AUX REG.ASSY,PS4 1
14
13 980435103 LEVER 18 TO 1 SERIES 4 PRESS 1
12 980445024 (B) LIFT CYL ASSY 9/16 PS4 1
11 980039015 CLEVIS 10-32 BRASS 1
10 980435060 PLATE CROSS PIN RAM MOD PS4 1
9 980039078 PIN SPRING 1/8 x 3/8 1
8 980435059 LINK CLEVIS LIFT CYL PS4 1
7 980445025 BALL ACT./VALVE KIT 1
6 980435007 PIVOT BLOCK 2
5 980435012 RAM PS4 1
4 980420016 PIN DOWEL 3/4 GROOVED 2IN 1
3 980435008 LINK LEVER 2
2 8002804 VALVE FLOWCNTRL 5/32OD,10/324J 1
1 8005969 VALVE FLOW CONTROL ，5/32 1

ITEM PART NUMBER DESCRIPTION QTY

FIGURE 3.2 (CONTINUED)

MACHINE ASSEMBLY

18
19
TIMER LOCATION (CONTROL BOX REMOVED)
FIGURE 3.4

Item Description Qty.

1 Control Panel 1
2 Pressure Diagnostic Connection 1
3 Control Box(Removed) 1
4 Timer 1

20
 SECTION 4

OPERATOR SAFETY
An important feature of the PEMSERTER® Series 4® Model M machine 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.

Caution: The foot pedal can only be stepped down when the parts is put
on the punch

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).
These include standards published by ISO, ANSI, OSHA, CEN and CSA.

Ball valve location confirmation

While the ram down set the gap between the punch and anvil to .004inch
(0.10mm). Confirm with the feeler that the ball valve can be activated
at .177inch (4.5mm) at 12000 pounds force with the main cylinder extended,
and the ball valve cannot be activated at .217inches (5.5mm) at 12000 pounds
force with the main cylinder extended.

4.5mm Feeler

5.5mm Feeler

21
22
 A AIRBORNE NOISE EMISSIONS

A PEMSERTER® Series 4® - Model M Hardware Insertion Machine 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 machine, near the
installation force cylinder).

Equivalent continuous A-weighted sound pressure = 53.5 dB

Peak A-weighted instantaneous sound pressure = 85.0 dB

Sound pressure was measured at the operator's working level (area in front of the
machine).

Equivalent continuous A-weighted sound pressure = 45.0 dB

Peak A-weighted instantaneous sound pressure = 84 Db

However, If the machine is operated in a room with other machines, the sound
emission level (rated level) can be over 85 dB(A)
If this is the case, improve the acoustics in the room. If you do not, the hearing of
the operators may be damaged.

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: 05563 Serial Number: 5791

23
 SECTION 5

TOOLING SET-UP

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 machine. 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 machine. 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).

5. Set the ram force to OFF. Disconnect the air supply to the machine. 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).

24
25
 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 machine. 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 machine. 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).

5. Set the ram force to OFF. Disconnect the air supply to the machine. 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).

26
27
 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 machine. 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 machine. The ram will
retract.

4. Turn the top anvil holder locking knob (Figure 5.2) 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 machine cycles, a few times,
under installation force.

6. Install the anvil into the Top Mounted Reverse Flange Anvil Holder.

28
29
 SECTION 6

MACHINE SET-UP AND OPERATION

Before operating the machine
Install the tooling (See the TOOLING SET-UP)

Always wear eye protection when operating the machine

Always keep all body parts as far away from moving parts as possible

Test the safety system every day (Refer to Page 34)

1. Set the ram force to OFF by turning the RAM FORCE ADJUSTMENT knob
counter-clockwise (Figure 3.1).

2. Connect the air supply to the machine.

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).
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 (for studs and standoffs). At this point the optical sensor indicator
will be orange. Next turn the punch by hand clockwise until the optical sensor
indicator turns black, then turn the punch counter-clockwise slowly until the
optical sensor indicator just turns back to orange, the press is now set. 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.

30
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.

WARNING: Do not exceed 9,000 lbs. (40 kN) of force if the

machine 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 machine
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 machine 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 MACHINE

31
The footswitch must be depressed until the ram drops and the main cylinder begins to
move.

Laser Spotting with Magnetic Base (Option)

Label enlarge

Pneumatic Totalizer
The 6-digit (0-999,999) totalizer is assembled into Control Panel Assembly. Counter is
incremented with each press stroke. Counter should be reset after safety setup stroke
to Operator manually resets counter.

32
33
 SECTION 7

HARDWARE INSERTION MACHINE

MAINTENANCE ADJUSTMENTS

WARNING: DISCONNECT THE AIR SUPPLY BEFORE

PERFORMING ANY MAINTENANCE .

WARNING: COMPLETE THE FOLLOWING MAINTENANCE EVERY

DAY
Perform the safety stop distance test (5.5mm & 4.5mm feeler testing).

Purpose: To check that the safety system is operating properly.

Why: The safety system of the machine is the most important system. It is designed to
be self-diagnosing and so no single component fault will compromise the system.
However, a check should always be done as a final test of the system.

How Often: Perform Daily and while change the tooling

Tools Needed: 5.5mm & 4.5mm feeler（The final customer must provide it）

• Install Tooling - any punch and anvil set can be used. Standard flat punch and
anvil for a Series 4 are 16mm (.625”) in diameter and 102mm (4.0”) long & 76mm
(3.0”) long .(Ensure that the distance of 0.10mm or only touch the punch and anvil )
• Adjust Force –Adjust Air Pressure Adjustment to 12000lbs.
• Test Safety System - Test that the safety system is functioning properly. Use the
following test:
a) After completing the safety setup step with nothing between the punch and the
anvil. Place a 4.5mm feeler on the anvil.
b) Wear eye protection, keep body parts away from moving parts, as far as
possible.
c) Step on the foot pedal.
d) The ram will extend, the punch will contact the 4.5mm feeler and the machine
appear the high force.
e) Release the foot pedal, than place a 5.5mm feeler on the anvil. Step on the foot
pedal again.
f) The ram will extend, the punch will contact the 5.5mm feeler and the machine
will indicate a safety fault.
g) If the machine appear the high force, the machine has failed the safety test.
Turn the machine off. Lock out the air supply. Contact your service
representative

34
 IMPORTANT: COMPLETE THE FOLLOWING MAINTENANCE EVERY
WEEK.

1. Lubricate all pivot points with a good quality lubricating oil, such as SAE 20-30.
(Refer to Figure 7.0).

Latch

Note: Should open the top cover before lubrication, if done, should lock
latch of the top cover.

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). If an
excessive amount of liquid (over 1/2 inch or 12mm) is in the filter bowl, annual
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 re-install. Never
clean the filter bowl with solvents. Solvents may weaken the bowl material
resulting in bowl deterioration.

35
36
37
 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)
using a socket wrench. Remove the timer assembly from the base (Figure 7.2) 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.

38
39
FLOW CONTROL VALVE ADJUSTMENTS (Figure 3.3)

All FLOW CONTROL VALVES are set at the factory for optimum press performance.
Incorrectly altering these settings may cause machine damage. However, as machine
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 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 - 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 - Fully close VALVE A by turning clockwise. Then, open VALVE A by

turning counter-clockwise approximately 1/4 turn.

VALVE B - 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 machine'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.

40
 LEVER ROLLER VALVE BRACKET ADJUSTMENT
The lever roller valve bracket adjustment is set at the factory for optimum machine
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 machine 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.

41
 SECTION 8
TROUBLE SHOOTING GUIDE

WARNING: DISCONNECT THE AIR SUPPLY BEFORE

PERFORMING ANY WORK THAT REQUIRES
REMOVING OR OPENING THE COVERS.

TROUBLE SHOOTING GUIDE

PROBLEM CAUSE CORRECTIVE ACTION
Punch will not descend. Footswitch not operating. Remove footswitch air
connection from machine.
If machine cycles, replace
footswitch.
Ram Bushing jammed in Unlatch and remove the
Ram Bearing. 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.
Footswitch hose kinked. Unkink Footswitch hose.
Cross Pin Assembly Remove Ram Module
interfering with Bearing from frame. File coined
Plate. area on Bearing Plate.
Ram Module hardware Remove Ram Module.
loose. Apply Loctite #242 to
hardware and reassemble.

Ram will not retract. Broken Plate Cross Pin Replace Plate Cross Pin
Assembly. Assembly.
Clogged Timer Filter. Clean all air filters.
Replace Timer if
necessary.

42
 TROUBLE SHOOTING GUIDE
PROBLEM CAUSE CORRECTIVE ACTION
Ram will not retract
Main Valve jammed. Remove Main Valve
(Continued) Assembly. Disassemble
valve and clean in mineral
spirits. Replace Main
Valve Assembly if
necessary. Clean all air
filters.
Exhaust Muffler clogged Replace Exhaust Muffler.
on Main Valve Assembly.

Fully close Flow Control

Flow control Valve B
adjustment required. Valve B by turning
clockwise. Then, open
valve by turning counter-
clockwise approximately
¼ turns. Ensure Ram
does not slam when
retracting.
Timer adjustment Open tool cabinet.
required. 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.
Set-Up/Cycle switch in Place switch in "Cycle"
"Set-Up" position. position.
No air supplied to Check machine air supply
machine. connections and main air
supply.
Lever roller valve failure. Replace lever roller valve.
Lever roller valve bracket Adjust lever roller valve
out of adjustment. bracket per adjustment
instructions.

43
 TROUBLE SHOOTING GUIDE
PROBLEM CAUSE CORRECTIVE ACTION
Ram Bushing improperly Adjust Ram Bushing per
Fastener will not install. adjusted. Tooling Set-Up and
Operation section.
Workpiece material too Check hardness of
hard. workpiece and compare
with PEM® fastener
catalog specifications.
Punch and anvil lengths Combined length of punch
incorrect. 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.)
Incorrect fastener Measure hole size and
installation hole size in compare with PEM®
workpiece. fastener catalog
specification.
Timer adjustment Open tool cabinet.
required. Remove control box. Set
Timer dial to "A" setting.
Cycle press and readjust if
necessary. Turn dial
clockwise to increase Ram
extension time.
Timer not operating. Remove Timer and clean
Timer filter. Replace
Timer if necessary.

44
 TROUBLE SHOOTING GUIDE
PROBLEM CAUSE CORRECTIVE ACTION
Fastener will not install.
Main Valve jammed. Remove Main Valve
(Continued) Assembly. Disassemble
Valve and clean in mineral
spirits. Replace Valve if
necessary. Clean air
filters.
Punch descends too Ram Module Assembly Clean Ram Module
slowly. dirty. Assembly as described in
Maintenance section.
Ram Bearing damaged. Remove Ram Bearing and
replace. Reassemble and
ensure that the set screws
are fully installed in the
Ram Bushing.
Footswitch not operating. Replace footswitch.
Flow Control Valve A Fully close Flow Control
adjustment required. Valve A by turning
clockwise. Then, open
valve by turning counter-
clockwise ¼ turns. Cycle
press and ensure Ram
does not bounce at bottom
of stroke. Readjust if
necessary.
Ram slams when Flow Control Valve B Fully close Flow control
retracting. adjustment required. Valve B by turning
clockwise. Then, open
valve by turning counter-
clockwise approximately
¼ turns. Cycle press and
ensure Ram does not
slam when retracting.
Readjust if necessary.

45
 TROUBLE SHOOTING GUIDE
PROBLEM CAUSE CORRECTIVE ACTION
Tooling leaves marks on Excessive Ram force. Reduce Ram force. Refer
workpiece. to Tooling Set-Up and
Operation section.
Sharp edge on punch or Break edge of punch or
anvil. anvil .015" X 45E(.38 mm
X 45E) maximum.

Main Cylinder slamming at Main cylinder air cushion Adjust appropriate air
end of stroke. misadjusted. cushion - extend or
retract. (Figure 3.3)

Lever assembly slams

Ram bushing set-up too Adjust ram bushing out
hard on up-stroke.
low. The link levers hitting and set up ram at top of
ram module before lever ball valve per set-up
roller contacts ram cap. instructions.

46
 SECTION 9
RECOMMENDED SPARE PARTS

QUANTITY PART NUMBER DESCRIPTION

1 piece 9800391172 Timer Valve

(Figure 7.2)

1 piece 980335097 Ram Bushing

(Figure 6.0)

1 piece 980335098 Ram Jam Nut

(Figure 6.0)

1 piece 980420081 Cross Pin Plate Assy

(Figure 3.2)

2 pieces 980039077 Socket Set Screw

#10-32 X 1/4 Lg.
(Figure 6.0)

1 piece 8015018 Filter Element-FESTO

(Figure 7.1)

1 piece 980435061 Upper Ram Cross Pin

1 piece 9800391652 Retaining Ring

1 piece 8002157 Lever Valve

(Figure 3.2)

Not included in Spare Parts Kit:

1 piece 8002946 Pressure Diagnostic Gauge Assy

(Optional)

47
 SECTION 10

PENUMATIC DIAGRAM

16 8018733 OPTICAL SENSOR 1

INDICATOR
15 8014151 PNEUMATICS TOTALIZER 1
14 8002804 VALVE FLOWCNTRL 1
13 8005969 VALVE FLOW CNTRL 5/32 FIT 1
12 8002805 VALVE QUICK EXHAUST 1
11 8002157 VALVE LEVER 1
10 8015031 LIFT CYL ASSY 1
9 980039005 VALVE N/C POPPET 1
8 8017545 FOOT PEDAL 1
7 980039016 VALVE TOGGLE AIR 1
6 9800391172 RELAY TIME DELAY 1
8014156 (Up to S/N 5438)
5 8017764 (S/N 5439 & Up)
MAIN CYLINDER ASSY 1

8015511 (Up to S/N 5438)

4 9800393037 (S/N 5439 & Up)
MAIN VALVE 1

3 9800393029 1-TURN REG 3/8NPT ASSY-4J 1

2 8015018 FLT AUX REGU.ASSY 1

1 8024761 PRESSURE RELIEF VALUE 1

ITEM PART NO. DESCRIPTION QTY

48
SECTION 11
APPENDIX

49