Norlok SL III User manual

26 Adams Blvd., Brantford, Ontario, Canada N3S 7V2
OPERATION AND MAINTENANCE MANUAL SL III
ORIGINAL INSTRUCTION
519.759.5896
Fax [phone]
E-mail [e-mail]
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Document No: 110011 Rev. No: 5.0
CONTENTS
SECTION 1.0 - Safety Guidelines..............................................................................................................................2
Safety Precautions Before Operating The Machine.............................................................................................2
Operator Safety Notice ......................................................................................................................................4
Risk Assessment.................................................................................................................................................5
SECTION 2.0 - Surelok III Information......................................................................................................................6
Surelok III Press Layout and General Description ................................................................................................6
Specifications –Surelok III..................................................................................................................................7
SECTION 3.0 - Installation and Operation................................................................................................................9
Installation.........................................................................................................................................................9
Initial Testing...................................................................................................................................................10
Measurement Of CLinch Quality –Non-Destructive Testing..............................................................................10
Tooling Adjustment Procedure.........................................................................................................................13
Safety Stroke Adjustment................................................................................................................................. 16
Pressure Switch Adjustment............................................................................................................................. 17
SECTION 4.0 - Clinchlok Basics .............................................................................................................................. 18
Clinchlok Principle............................................................................................................................................ 18
Tooling Adjustment.......................................................................................................................................... 19
Materials To Be Joined..................................................................................................................................... 19
Die Selection.................................................................................................................................................... 19
Joint strength...................................................................................................................................................20
SECTION 5.0 - Clinching Terminology .................................................................................................................... 21
Views of the Clinchlok Joints............................................................................................................................22
Joint Failure.....................................................................................................................................................23
Section 6.0 - Tooling Maintenance & Replacement ...............................................................................................24
Standard Reversible Tooling –Punch Replacement...........................................................................................24
Optional P-Tooling –Punch Replacement......................................................................................................... 24
Replacing Die................................................................................................................................................... 25
Die Insert Assembly ......................................................................................................................................... 26
SECTION 7.0 - Maintenance.................................................................................................................................. 27
Preventative Maintenance............................................................................................................................... 27
Maintenance - Pressure Adjustments.............................................................................................................28
Maintenance - Regulator Draining & Filter Cleaning........................................................................................28
Maintenance - Lubrication of Upper Tooling................................................................................................... 28
SECTION 8.0 –Trouble Shooting Guide ................................................................................................................. 28
Operation Troubleshooting.............................................................................................................................. 28
Joining Issues...................................................................................................................................................29
Joint Quality .................................................................................................................................................... 29
SECTION 9.0 - DOCUMENT REVISION HISTORY...................................................................................................... 31
SECTION 10.0 - Warranty Information................................................................................................................... 32

OPERATION AND MAINTENANCE MANUAL SL III ORIGINAL INSTRUCTION
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Document No: 110011 Rev. No: 5.0
SECTION 1.0 - SAFETY GUIDELINES
Before operating the machine, study and follow all safety guidelines in this manual, these precautions are intended
to prevent injury to you and your fellow workers. Please use EXTREME CAUTION before performing any procedure
or operation.
WARNING
This equipment is designed to be operated with all covers secured in place. Operation without these safeguards
may result in conditions that are hazardous to the operator and observers.
Follow Lockout Procedure to disconnect air and drain all air from the system when:
Doing any kind of maintenance to the machine
•During any set-up changes
•Moving the machine
•When leaving machine unattended
SAFETY PRECAUTIONS BEFORE OPERATING THE MACHINE
Protect yourself. Keep your work area clear of all scrap, oil spills, rags, tools, and other obstructions, which could
cause you to slip, trip or fall.
Always use safety glasses that conform to ANSI Z87.1
and CAN/CSA Z94.3
Always wear proper personal hearing protection that
conforms to ANSI S12.6 (S3.19)
•Look for the knob with lockout point sticker which shown
in image below push and turn it counterclockwise to match
hole on the valve body which will turn off the main air
supply.
•Follow standard lock-out tag-out procedure before
removing any guards to avoid injury.
Make sure pneumatic pressures are at specified level
before operating this equipment.
Table 1

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Document No: 110011 Rev. No: 5.0
Be sure all guards and covers are in place
Keep fingers and hands away from pinch point areas:
Between the punch stem and die, i.e., upper and lower
tooling
Keep this equipment properly maintained
Check for worn or broken parts. Do not attempt to
operate machine with broken parts present or if it is
making unusual noises.
Note the location of Reset buttons.
Keep this manual near the machine for the operator’s
reference when necessary
Table 2

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Document No: 110011 Rev. No: 5.0
OPERATOR SAFETY NOTICE
The Surelok III is designed as a safe and reliable machine.
However, as with any punching machine, the critical danger area is the pinch point between the punch and die.
•Keep fingers and limbs away from this critical pinch point.
•Never operate this machine without all covers and guards in place.
•Use 6mm Nylon disc to test safety feature, refer to Initial Testing section on page 7 of this manual
THE NATIONAL SAFETY COUNCIL REMINDS US THAT MANY ACCIDENTS ARE CAUSED BY
FAILURE TO FOLLOW FUNDAMENTAL SAFETY RULES.
This is the reason that a careful operator is the best guarantee of an accident free work
place.
a. Disconnect and drain air before making any adjustments or servicing any Surelok components.
b. Always be alert whenever operating any machinery.
c. Only one person should control the machine(s). Never allow anyone to operate the controls
while you are working on this equipment. In addition to disconnecting power, always use
lockouts and warning signs to indicate that you are working on the machine(s).
d. Keep your hands and arms away from internal workings of the machinery when starting, running
or stopping.
e. Never override or disable any safety switch or safety interlock.
f. Use extreme caution if maintenance or adjustments must be performed with power on and the
machine in operation.
g. Always wear eye protection when operating or maintaining machinery.

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Document No: 110011 Rev. No: 5.0
RISK ASSESSMENT
Hazard Type
Description
Mitigation
Mechanical
Top heavy machine tipping
during transportation, lifting or
installation
•¾” Threaded hole for lifting
at highest point
•Wide stand and wide skids
for transportation
•Warning decals included
Pinching and crushing hazards
during operation and
maintenance
•Safety stroke mechanism
that only permits power
stroke to activate at opening
of 6mm or less
•Control circuit only permits
operation by foot pedal and
tooling sensor activation
Pinching and crushing hazards
between main cylinder and
internal moving parts during
operation and maintenance
•Mechanical fixed guarding
•Air shut off valve
Stored energy (gravity) –tooling
drop when foot pedal is pressed
•Shock absorber to reduce
tooling drop impact
Pinching and crushing hazards
during tooling switch over and
adjustments
•Air shut off valve
•Maintenance instructions
Stored air in power cylinder and
stored air in control circuit
•Compliant pressure vessels
•Mechanical fixed guarding
•Air shut off/exhaust ports to
release stored air when not
in use
Noise hazards
Whistling pneumatics
•Exhaust mufflers
Ergonomic
Repetitive activity
•Low impact foot pedal
•Ergonomic machine height
of 35 to 45”
•Laser pointer to ease
repeatability
Radiation
Optical laser pointer can cause
eye damage
•Warning decal and
classification
•On/off switch for when not
in use
Table 3

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Document No: 110011 Rev. No: 5.0
SECTION 2.0 - SURELOK III INFORMATION
SURELOK III PRESS LAYOUT AND GENERAL DESCRIPTION
Figure 1 Surelok III Layout
General Description of Equipment
Norlok Technology Inc. is a machine tool manufacturing company with wide range of clinching products.
The Surelok series is developed for sheet metal joining process and available in different sizes.
Intended Use:
The Surelok III (SL III) is Floor Mounted Pneumatic Mechanical Press designed for sheet metal
operations such as clinching, punching, and riveting depending on the tooling applied. The tooling applies
a high force to perform these sheet metal forming operations. The machine can also be utilized to perform
high force press operations with modified tooling. SL III can perform such operations within rated
performance limits and under standard industrial environment as mentioned below.
Operating Condition
Storage Condition
Transportation
Temperature
-10 to 40° C
-10 to 40° C
-10 to 40° C
Humidity
70%
70%
70%
Altitude
1000m
1000m
1000m
Table 4

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Document No: 110011 Rev. No: 5.0
SPECIFICATIONS –SURELOK III
Designation: Pneumatic mechanical press
Press Design: Solid 3” steel "C" frame.
Features: Advanced power unit
Regulator and Shut-off Valve
Foot pedal operated
Stroke: 2 1/2” max (adjustable)
Throat: 25”
Work Height: 45"
Approx. Weight: 1250 lbs
Noise Level: A-Weighted: <70 dBA
Upper Tooling: Quick change adjustable punch
Lower Tooling: Quick change die
Capacity: MAX: Two ply 0.075” mild steel.
MIN: Two ply 0.010” mild steel.
MAX: Two ply 0.050” Stainless.
MIN: Two ply 0.010” Stainless.
Cycle speed: 60-80 cycles/min
Up to 150 cycles/minute with options and adjustment
Air Requirements: 80psi to 100psi (90psi recommended)
Approx. 0.2 cuft free air per cycle
2 HP @ 60 clinches per minute
Reach
Pipe
Diameter
Die reach into
Pipe
3” Ø
1 3/8”
4” Ø
3 1/4”
5” Ø
5”
6” Ø
12 1/4”
7” Ø
13 5/8”
8” Ø
15 7/8”
9” Ø
18 1/8”
10” Ø
20 1/2” *
11” Ø
22 3/4” *
12” Ø
25” *
Table 5 *SLIII 25 only
•Both the punch and die are of special design and should not be sharpened.
•Under normal operation both punch and die should last for approximately 200,000 to 300,000 cycles.

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Document No: 110011 Rev. No: 5.0
NORLOK’S EC DECLARATION SL III
NOTE: NORLOK’S SURELOK III IS CE CERTIFIED NOW FROM SERIAL NUMBER 22007 AND LATER. ONLY
APPLICABLE IF MACHINE NAME PLATE STATES AND CONFIRMS CE.

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Document No: 110011 Rev. No: 5.0
SECTION 3.0 - INSTALLATION AND OPERATION
INSTALLATION
UNCRATING:
1. The press can be lifted using the forklift cutouts in the stand, using a ¾”NC eye bolt inserted into the top of the
frame or using a chain hoist near the centre of mass which is in line with the ¾” hole on the top.
2. Locate the following items that may have been packed separately;
a) Manual
b) Laser pointer (if ordered)
c) Spare punch and die
d) Foot Pedal
3. Check the condition of the press and record the serial number for reference.
SERIAL # __-____
LEVELING AND BOLTING DOWN MACHINE:
I. Level the machine
II. Lag the machine to the ground if necessary.
INSTALLING AIR SUPPLY:
1. Make sure that the foot pedal is not activated.
2. Make sure that the main air supply valve is turned OFF.
3. Supply the inlet with 125 psi (max) - 80 psi (min) of clean dry air. Use an additional filter / regulator on
the inlet line if necessary. We recommend a minimum of 1/2" diameter airline.
CAUTION TOP HEAVY
Fa

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Document No: 110011 Rev. No: 5.0
INITIAL TESTING
A. The machine is shipped already set up for your material. This can be confirmed easily and it is recommended.
B. Ensure that all guards are in place.
C. Slowly open the main air supply valve and check the pressure at the regulator
on the machine.
The main Filter Regulator should be set at 100 psi. If the gauges do not
read the correct pressure, adjust and lock the regulator.
WARNING! THIS ACTION ACTIVATES THE HIGH PRESSURE
CLINCHING STROKE.
D. To test the clinch safety feature, place the supplied 6mm Nylon disc between
the upper and lower tooling
E. Press the foot pedal and verify that the high-pressure clinching stroke does not
operate. If it does, refer to Safety Stroke Adjustment section on page 14 of this
manual.
F. With the safety feature verified, place 2 pieces of your material on the die plate
keeping your hands clear.
G. Operate the foot pedal labeled “clinch”.
H. Inspect the connection. Refer to Measurement of Clinch Quality and Tooling
Adjustment sections.
MEASUREMENT OF CLINCH QUALITY –NON-DESTRUCTIVE
TESTING
1. The two best ways to verify a Clinchlok joint are measuring the BD (Button Diameter) and the CT (Clinch
Thickness)
2. A measurement of either of these parameters gives a very strong correlation to actual clinch strength

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Document No: 110011 Rev. No: 5.0
Go/NoGo Gauge Part#
Suitable material
07763.238.246
30ga
07763.250.260
22ga-28ga
07763.265.275
18ga-20ga
07763.275.290
14ga-16ga
07763.280.300
0.280-0.300
Table 6 Go/No-go Gauge Chart
Figure 2 Measuring a Button Diameter (BD) using Vernier calipers
Figure 3 Measuring a Button Diameter (BD) using a Norlok GoNoGo Gauge
Norlok’s GoNoGo Gauges, part# 07763,
are a quick and simple inspection tool.
They may not identify the ideal clinch in
different material but they provide a
starting guideline for clinch inspection.
Further testing and more accurate gauges
can be developed.

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Document No: 110011 Rev. No: 5.0
Figure 5 Trouble Shooting Quick View
Figure 4 Measuring a Clinch Thickness (CT)

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TOOLING ADJUSTMENT PROCEDURE
SQUEEZE ADJUSTMENT
1. The tooling must be adjusted to produce the correct amount of "squeeze" between the punch and die
when the joint is made.
2. As described earlier, the correct tooling adjustment is very important for producing a good joint and to
maximize punch and die life.
3. The aim of tooling adjustment is to produce minimum "squeeze" that will produce a good joint.
4. The basic procedure is to set the tooling too high (not enough "squeeze") to produce a good joint and
then to slowly lower the tooling by 1/6th of a turn (or less) to produce a good joint.
5. Make sure that the correct die has been selected for the material to be fastened.
6. Make sure that the pressure on the inlet filter is set correctly.
Figure 6 Removing Tooling Guard
7. Remove guard screw and
swing guard open to reveal
power unit and upper
tooling blocks

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Figure 7 E Tooling Adjustment
•Loosen set screw
•Using an Allen key, rotate the
adjuster block
•Rotating right increases squeeze
•Rotating left decreases squeeze
•SEE DECAL FOR REFERENCE

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RESET SQUEEZE SETTING AFTER EVERY TOOLING SWITCH OVER
OBSERVE ALL SAFETY PRECAUTIONS, AND MAKE SURE ALL GUARDS AND COVER PLATES ARE
IN PLACE.
8. Make a sample clinch joint using the correct material.
9. The joint should be too weak because the tooling will be too high (not enough "squeeze").
10. Turn the adjuster block clockwise 1/4 turn, lowering the punch.
11. Make a joint and check the joint strength.
12. If the joint is still weak lower the tooling by 1/4 turn and repeat the procedure.
13. Once a good joint has been made the tooling should be raised by 1/16th of a turn, and the joint strength
checked.
14. If the joint produced at this new setting is weaker than the original reset the tooling downward by 1/16th
turn.
15. If the joint produced at this new setting is as strong as the original, raise the tooling by another 1/16th
turn and repeat the process.
16. Tighten the tooling adjuster set screw and replace the cover.
17. REMEMBER - SET THE TOOLING TO THE HIGHEST SETTING THAT WILL PRODUCE A GOOD JOINT. THIS
ENSURES MAXIMUM TOOL LIFE.

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STROKE ADJUSTMENT FOR SLIII
Figure 8 Stroke Adjust for SLIII
SAFETY STROKE ADJUSTMENT
Figure 9 SLIII Safety Stroke Adjust
The stroke is the maximum distance
between the punch and die at the
beginning of a clinch cycle, or when the
tooling is at rest.
It can be adjusted using adjustment screw
at the top of the SLIII.
Loosen the locking setscrew, then turn the
shock absorber using the allen key
provided.
The Safety Stroke mechanism is factory
set and is ready to operate.
The tooling will drop when the foot pedal
is pressed but the clinch cycle will only
operate if the material thickness is 3/16”
or less.
NEVER BYPASS THE SAFETY
STROKE AND NEVER OPERATE
THE MACHINE WITH A SAFETY
STROKE GREATER THAN 0.25”
ADJUSTING THE SAFETY STROKE IS NOT
RECOMMENDED AND MAY RESULT IN
SERIOUS INJURY
Only if necessary, the maximum tooling
opening at which the clinch cycle
operates can be adjusted by moving the
button head screw up or down.
Moving the screw down increases the
tooling opening at which the clinch cycle
will operate.

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PRESSURE SWITCH ADJUSTMENT
Figure 10 Pressure Switch
•The standard pressure switch is located at the back of the frame.
•Turning the knob clockwise increases the pressure at which the clinch cycle resets –but may increase
the cycle time and if set too high the clinch cycle will not restart.
•Turning the knob counter-clockwise decreases the pressure at which the clinch cycle resets –but may
reduce clinch quality.
•The pressure switch is factory set for consistent clinching at the quickest cycle time.
WARNING: OVER ADJUSTMENT OF PRESSURE SWITCH CAN CAUSE TOOLING DAMAGE

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SECTION 4.0 - CLINCHLOK BASICS
CLINCHLOK PRINCIPLE
WHAT IS “CLINCHING”?
Clinching is a method of fastening sheet metal together without the use of heat, rivets, fasteners or adhesives.
It is fast, clean, and reliable and does little or no damage to painted surfaces.
It is ideal for fastening galvanized, aluminum, pre-painted & coated mild steel, as well as brass, copper & stainless
steel.
Clinching can fasten two-ply from 10 gauge (0.130”) to 32 gauge (0.012”), with a strong, leak-proof joint.
HOW DOES IT WORK?
•The clinchlok joint is formed when the punch squeezes the two-ply material between itself and a
special die.
•As the punch squeezes the material the two layers “mushroom” out, forming a strong joint.
•The die features spring-loaded “blades” that allow the material to be drawn down by the punch, and
then expand outwards to form the joint.
STEP-BY-STEP CLINCHING METHOD:
CLAMP
1. Two-ply material is laid on the die in desired location.
i. Punch stripper and die holder clamp material.
DRAW
2. Punch begins to penetrate.
i. The material is drawn down into the die.
CLINCH
3. Material is squeezed between the punch & die anvil. This causes an outward flow of material. The die
blades spread to allow extrusion to occur.
STRIP
4. Punch and stripper retract, and material can now be easily removed from the die.

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TOOLING ADJUSTMENT
1. The amount of joint squeeze is controlled by adjusting the upper tooling (punch) either towards the die or away
from the die with the tooling adjusting screw.
2. For thin material the punch will have to be lowered (moved towards the die) and for thick material it will have
to be raised (moved away from the die).
3. The correct tooling adjustment is the most critical adjustment on the Surelok II. Please read the tooling
adjustment instructions in a later section of this manual.
MATERIALS TO BE JOINED
1. The Surelok II is capable of joining commercial quality mild steel up to two ply 10 gauge mild steel.
2. For best results both ply of material should be of the same or similar thickness.
3. If different thicknesses are to be joined the best results will normally be found with the thicker material on the
upper (punch) side of the two ply although this is not always possible.
4. The thicker material should not be more than twice the thickness of the thinner material and the combined
thickness of the two-ply should not exceed 0.276”.
5. Other materials can be joined with the Surelok II as long as they are not harder than commercial quality mild
steel. In most cases both ply should be of the same hardness, but if a different hardness is used for each ply
(not recommended) the harder material should be on the upper (punch side) if possible.
DIE SELECTION
1. There are three sizes of dies required to cover the complete range of material that the Surelok II can handle.
2. The punch in the upper tooling is not changed for different material thicknesses.
3. The die selection chart can be used to find which die will be most suitable for your application, however the
chart is a guide only, different types of material may require a different size of die.
OTHER OPTIONS MAY BE AVAILABLE, PLEASE CONSULT FACTORY FOR DETAILS.
Table 7 Medium Duty Machines (3/16” Punch Diameter, 5/8” Die Diameter)
Die size
Material thickness
MD #50
0.075” + 0.075”
0.063” + 0.063
0.063" + 0.052"
0.063" + 0.040"
0.052” + 0.052”
0.052” + 0.040”
MD #40
0.040" + 0.040"
0.040" + 0.034”
0.034" + 0.034"
0.034" + 0.028"
0.034" + 0.022"
0.028" + 0.028"
0.028" + 0.022"
MD #30
0.022" + 0.022"
0.022" + 0.018"
0.022" + 0.014"
0.018" + 0.018"
0.018" + 0.014"
0.014" + 0.014"
0.010” + 0.010”

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JOINT STRENGTH
Figure 11 Pull - Peel Layout
1. There are two ways to measure the strength of a Clinchlok joint, pull and peel (see Figure 11 Pull - Peel Layout).
2. Pull is almost always stronger than peel and is less sensitive to die adjustment.
3. Typical joint strengths for properly adjusted tooling are given for commercial quality mild steel.
4. These should be used as a guide only; different material will affect the joint strength.
5. If the material is softer than mild steel these strengths will be reduced according to the strength of the material.
Material thickness
Button strength (lbs)*
RECOMMENDED DIE
Two Ply
PULL
PEEL
0.075”
550
190
#50
0.060”
475
175
#50
0.050”
430
150
#50
0.040”
400
120
#40
0.030”
375
100
#40
0.020”
285
70
#30
*These strength numbers are a guideline only and should be validated with actual samples
Table 8 Clinch Strength Chart Medium Duty