Norlok Sure-Lok 24 User manual

WARRANTY INFORMATION
Subject to the conditions below, and with the exception of punches and
dies, Norlok Technology Inc. ("Norlok") warrants to the first end user (the "Buyer")
that Norlok equipment and components are free from defects in material and
workmanship for one year from the date of purchase of the equipment or
components. Punches and dies are covered under the same warranty conditions
for a period of thirty days from purchase from Norlok Technology Inc.
Norlok will either repair, or replace defective components, including lowest transportation
costs, but not including installation or any similar charges, provided that;
1) The buyer notifies Norlok in writing of the claimed defect within one year of the shipment
from the Norlok factory (thirty days in the case of punches and dies).
2) Provides a complete explanation of the claimed defect, the application of the product, and
any other information as may be requested by Norlok.
3) Returns the defective component to Norlok in accordance to Norlok's specific written
instructions and authorization obtained from Norlok prior to the return of the product.
4) Norlok's inspection of the product confirms that the product was defective.
This warranty applies only if the product was;
a) used in, and applied correctly under normal operating conditions and good engineering
practice,
b) was installed, operated, and maintained in accordance with all instructions issued or
published by Norlok,
c) was used within the stated pressure, and operating limitations published by Norlok,
d) was not subject to abuse, misuse, or unauthorized modification.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, not withstanding any disclosures to Norlok of the use for
which the product is to be put. The Buyer's SOLE AND EXCLUSIVE REMEDY on any
claim of any kind of loss or damage arising out of the use of Norlok equipment or
components shall be for the repair or replacement of any defective product as provided
herein.
IN NO EVENT SHALL NORLOK BE LIABLE FOR ANY SPECIAL,
INCIDENTAL OR CONSEQUENTIAL DAMAGES. There are no warranties expressed or
implied made by Norlok other than the warranty against defects in material and
workmanship set forth above, and Norlok neither assumes or authorizes any other person
or firm to assume for it any other obligations or liability.
26 ADAMS BOULEVARD
BRANTFORD, ON.
CANADA, N3S 7V2
Ph: [phone]
Fx: [phone]
ISO 9001 Registered E-mail: nlmail @ norlok.com
Web: www.norlok.com

SURELOK MANUAL 2002 1
WARNING
THIS EQUIPMENT IS DESIGNED TO BE OPERATED WITH ALL COVERS SECURED
IN PLACE. OPERATION WITHOUT THESE SAFEGUARDS MAY RESULT IN
CONDITIONS WHICH ARE HAZARDOUS TO THE OPERATOR AND OBSERVERS.
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 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.
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.
Wear safety glasses at all times.
Be familiar with procedures of disconnecting and draining air from system.
Make sure hydraulic and pneumatic pressures are at specified levels before operating this
equipment.
Be sure all guards and covers are in place.
KEEP FINGERS AND HANDS AWAY FROM THE 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.
Be aware of the location of the air shutoff/exhaust valve and electrical disconnects (if
installed) or the emergency stop button in the case of an electrically operated machine.
Keep this manual near the machine for theoperators reference when necessary.
SURE-LOK MD / LD

SURELOK MANUAL 2002 2
Operating Manual #8/02
CONTENTS:
SAFETY PRECAUTIONS: 3
FEATURES: 4
TECHNICAL SPECS: 5
PRESS LAYOUT: 6
INSTALLATION: Uncrating 9
Leveling & bolting down 9
Foot pedal 9
Air supply & regulator 10
Initial operation and testing 10
OPERATION BASICS: Frame. 11
WAMP power unit. 11
Tooling. 12
Air tank. 12
CLINCHLOK BASICS: Clinchlok principle 13
Punch adjustment. 14
Materials to be joined. 14
Die selection. 15
Joint strength. 16
Joint failure. 17
Views of joints 18
Testing joint strength. 19
ADJUSTING PUNCH: 20
SETTING LASER: 23
OPEN HEIGHT ADJUSTMENT: 24
MAINTENANCE: Daily. 25
Replacing die. 26
Replacing die components 26
Replacing punch. 28
Auto return adjustment 30
Pressure adjustments 31
Filter draining. 31
Lubrication of upper tooling 32
TROUBLE SHOOTING: PRESS OPERATION. 33
JOINT QUALITY 34
SPARE PARTS LIST: 37
COMPONENT SPEC SHEETS

SURELOK MANUAL 2002 3
SAFETY INSTRUCTIONS
OPERATOR SAFETY NOTICE:
THE SURE-LOK 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.
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.
1) DISCONNECT AND DRAIN AIR BEFORE MAKING ANY ADJUSTMENTS
OR SERVICING ANY SURE-LOK COMPONENTS.
2) ALWAYS BE ALERT WHENEVER OPERATING ANY MACHINERY.
3) 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 LOCK OUTS AND WARNING SIGNS TO
INDICATE THAT YOU ARE WORKING ON THEMACHINE(S).
4) KEEP YOUR HANDS AND ARMS AWAY FROM INTERNAL WORKINGS
OF THE MACHINERY WHEN STARTING, RUNNING OR STOPPING.
5) NEVER OVER-RIDE OR DISABLE ANY SAFETY SWITCH OR SAFETY
INTERLOCK.
6) USE EXTREME CAUTION IF MAINTENANCE OR ADJUSTMENTS HAVE
TO BE PERFORMED WITH POWER ON AND THE MACHINE IN
OPERATION.

SURELOK MANUAL 2002 4
NORLOK MD SURELOK 24
FEATURES
The SURE-LOK 24 features a one piece steel "C" frame with an 24" throat and
integrated clinch-lok type tooling.
The machine is specifically designed to fasten two ply material together, as used in
the sheet metal and manufacturing industry.
The machine features a replaceable lower arm, and can fasten mild steel,
aluminum, brass, copper and other malleable materials from 16g to 28g. in
thickness
The press is powered by a pneumatic “WAMP” multi-stack air diaphragm unit which
features a fast, low impact, clinching stroke.
The clinching stroke is operated by a guarded foot pedal, and features a "single
shot" operating cycle.
The open height between the punch and die may be easily adjusted to eliminate any
"pinch point" without effecting theClinchlok. This open height may be adjusted from
full stroke to zero with an adjuster screw.
The machine features a fast change punch and die, either of which can be changed
in minutes.
The punch and stripper are located in the upper tooling and operate through the full
stroke of the machine. The height of the punch may be easily adjusted to suit
different material thickness.
The die is located in the lower arm of the press, and may be easily changed to suit
different material thickness.
To cover the complete range of material threedifferent gauge dies are required.
Only one die is supplied as standard and so the gauge of the material to be
fastened must be known.
Only one punch is required to fasten all gauges of material.
The machine is supplied with a stand, punch, die, pneumatic filter / regulator, and
tool kit.
To assure accurate positioning of the clinch-lok button a low power laser pointer is
available as an option, to assist in locating the exact position of the joint.
Unless otherwise requested the machine will be factory set for two ply 22 gauge
material with a #40 die installed.

SURELOK MANUAL 2002 5
SPECIFICATIONS - MODEL MD SURE-LOK 24-1
Press Design: Single steel "C" frame featuring a replaceable lower
arm.
Features: WAMP pneumatic diaphragm power unit.
Air surge tank and filter regulator.
Guarded foot pedal. Single shot auto return.
Stroke: 1" (approx)
Throat: 24”
Work Height: 45"
Upper Tooling: Fast change 0.18" diameter punch.
Replaceable punch stripper.
Adjustable to suit material thickness.
Lower Tooling: Die insert set in a hardened die plate.
Capacity: MEDIUM DUTY
MAX: Two ply 0.062 mild steel.
MIN: Two ply 0.012 mild steel.
LIGHT DUTY
MAX: Two ply 0.032 mild steel.
MIN: Two ply 0.010 mild steel.
Cycle speed: Clinching stroke (1") - 1 second.
100% duty cycle.
Air Requirements: 80 psi (minimum) 125 psi (maximum)
125 psi (recommended)
Air Consumption: Approx. 0.6 cu ft free air per cycle.
(5 HP @ 60 clinches per minute)
Dimensions: Width 36" (overall)
Length 59" (overall)
Height 75" (overall)
Weight 1900 lbs (approx
Typical joint strengths for mild steel are as follows;
Material (mild steel) Pull strength Peel strength
2 x 0.060" 475 lbs 175 lbs
2 x 0.050" 440 lbs 160 lbs
2 x 0.040" 400 lbs 110 lbs
2 x 0.030" 375 lbs 85 lbs
2 x 0.020" 300 lbs 70 lbs
2 x 0.010" 200 lbs 50 lbs

SURELOK MANUAL 2002 6

SURELOK MANUAL 2002 7

SURELOK MANUAL 2002 8

SURELOK MANUAL 2002 9
UNCRATING:
1) Remove the machine from the shippingcrate. It may be picked up with a chain hoist
from either the 2" diameter hole in the top of the frames or by attaching a 3/4" NC
eye bolt to the top of the "C" frame.
DO NOT LIFT BY THE STAND!
2) Locate the following items that will have been packed separately;
a) Foot pedal and hose.
b) Manual.
c) Laser locator (if supplied).
d) Spare punches and dies (if ordered).
3) Check the condition of the press and record the serial number for reference.
SERIAL # ________________
LEVELING AND BOLTING DOWN MACHINE:
1) Locate the machine at its operating position.
2) Level the machine by shimming the legs of the stand.
3) Secure the stand to the floor with the four bolt down holes located on the ends of the
legs.
4) INSTALL ALL GUARDS AND SAFETY DEVICES IF THEY HAVE BEEN
REMOVED.
INSTALLING FOOT PEDAL:
1) Locate the foot pedal at the correct location and attach the two fittings at the hose
end to the foot pedal manifold.
2) The fittings are color coded - red hose fitting to red manifold fitting.

SURELOK MANUAL 2002 10
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) Make sure that the tank drain valve is CLOSED.
4) Supply the air tank inlet with 125 psi (max) - 80 psi (min). of clean dry air. Use a
filter / regulator on the inlet line if necessary. We recommend a minimum of 1/2"
diameter air line.
INITIAL TESTING:
1) Slowly open the main air supply valve and check the pressure at the regulator on the
air tank.
For Medium Duty Tooling the air tank regulator should be set at 100 psi.
For Light Duty Tooling the air tank regulator should be set at 80 psi.
If the gauge does not read the correct pressure, adjust and lock the regulator.
NOTE! The tank pressure must be higher than the required regulator
pressure in order to set the regulator pressure.
2) Making sure all guards are in place, operate the foot pedal.
WARNING! THIS ACTION ACTIVATES THE HIGH PRESSURE CLINCHING
STROKE.
Keep your foot on the foot pedal, and the machine will activate the high speed
clinching stroke and return to the open position automatically.
3) The clinching stroke is factory set for a 1 second automatic return. If the foot pedal
is released before the automatic return the clinching stroke will end as a safety
feature.
If the automatic return is too fast or too slow the automatic return valve must be
adjusted - see maintenance section.
4) The foot pedal must be released and re-activated to repeat the clinching stroke.

SURELOK MANUAL 2002 11
OPERATION BASICS:
FRAME:
1) The SURE-LOK is designed around a very rigid flame cut steel "C" frame.
2) The upper tooling barrel is welded pinned to the frame.
3) The lower arm is bolted and pinned to the frame, this lower arm may be replaced for
a different design if required.
"WAMP" Unit:
1) The press is powered by a multi stacked air diaphragm unit known as a "WAMP"
unit.
2) This power unit is very reliable and is not user serviceable.
If necessary it may be removed from the press and serviced or exchanged by the
factory.
3) The clinching stroke is operated by a guarded foot pedal.
4) The pneumatic system features a single shot automatic return. The machine
operates through a single clinching stroke each time the foot pedal is activated.
5) The automatic return is set to about 1 second on standard machines. If set too fast
a good joint may not be formed. If set too slow, production will be reduced.
Machines fitted with high speedvalving, or Production Controls will operate faster.
6) The clinching stroke will be terminated before the automatic return cycle is complete
if the foot pedal is released before the auto return cycle is complete.
7) The open height (the gap between the upper punch and lower die) may be reduced
by adjusting a screw in the center of the top of the WAMP unit, as described in a
later section of the manual.
8) This adjustment is used to eliminate any "pinch point" between the punch and die
and does not effect any other press adjustments or alter the quality of the Clinchlok
joint.

SURELOK MANUAL 2002 12
TOOLING:
1) The clinching punch and stripper are located in the upper tooling and operate
through the stroke of the machine (Usually 1” or ½”). The punch may be easily
adjusted, through an inspection plate in the front of the barrel, to suit different
material thickness.
2) The clinching die is located in the lower arm of the machine. Different dies may be
selected, and easly installed to suit different material thicknesses.
3) Both the punch and die are of a very special design and should not be sharpened.
4) Under normal operation both punch and die should last for approximately 200,000
to 300,000 cycles.
AIR TANK:
1) The air reservoir tank is located on the back of the machine.
2) The air surge tank features a 3/4" filter/regulator, which is set to 100 psi. for the
Medium Duty tooling and 80 psi. for the Light Duty tooling.
The filter should be drained regularly and cleaned as required.
3) There is a safety blow-out valve mounted on the tank set at 135 psi. Do not remove
this valve. If the valve blows out reduce the inlet pressure to the tank to 125 psi.
4) Drain moisture from the tank daily using the drain valve located at the base of the
tank.

SURELOK MANUAL 2002 13
CLINCHLOK BASICS:
CLINCHLOK PRINCIPLE.
CLAMPS - DRAWS - LOCKS
1) The clinchlok joint is formed when the upper tooling squeezes two layers of material
between the punch and die.
2) The amount of squeeze is very important to the strength of the clinchlok joint and to
the life expectancy of the punch and die.
3) It will be noted that the die is of a very special design that allows the clinchlok to
"mushroom".
4) The punch is also a special design and unlike a normal punch the edge of the punch
is not sharp, but is rounded. This is known as the punch tip radius.
5) Neither the punch nor die can be sharpened.

SURELOK MANUAL 2002 14
PUNCH ADJUSTMENT:
1) The amount of joint squeeze is controlled by adjusting the punch either towards the
punch or away from the punch with the punch adjusting screw.
2) For thin material the die will have to be lowered (moved towards the die) and for
thick material the punch will have to be raised (moved away from the die).
3) The correct punch adjustment is the most critical adjustment on the SURE-LOK.
Please read the punch adjustment instructions in a later section of this manual.
MATERIALS TO BE JOINED:
1) The SURE-LOK is capable of joining commercial quality mild steel as follows;
a) Medium Duty Two ply 0.012" to twoply 0.062".
b) Light Duty Two ply 0.010” to two ply 0.032”
For best results both ply of material should be of the same or similar thickness.
2) 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 twoply although this is not
always possible.
3) The thicker material should not be more than twice the thickness of the thinner
material and the combined thickness of the twoply should not exceed 0.125" for MD
machines and 0.062” for LD machines.
4) Other materials can be joined with the SURE-LOK as long as they are notharder
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.
5) Common materials: Capacity (MD): Capacity (LD):
Stainless steel Not usually possible Not usually possible
High carbon steel Not usually possible Not usually possible
Commercial quality steel 0.062" + 0.062" max 0.032" + 0.032" max
Galvanized steel 0.062" + 0.062" max 0.032" + 0.032" max
Drawing quality steel 0.062" + 0.062" max 0.032" +
0.032" max
Aluminum 0.062" + 0.062" max 0.032" + 0.032" max
Copper 0.062" + 0.062" max 0.032" + 0.032" max
Brass 0.062" + 0.062" max 0.032" + 0.032"max

SURELOK MANUAL 2002 15
DIE SELECTION:
1) There are three sizes of dies required to cover the complete range of material that
the SURE-LOK can fasten.
2) As a general rule the punch in the upper tooling does not need to change when
different material is joined.
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.
4) Two charts are shown below.
One is for Medium Duty machines (3/16” punch diameter, 5/8” die diameter)
One is for Light Duty Machines (1/8” punch diameter, 7/16” die diameter)
4) MD Material thickness LD Material thickness
Die size (punch + die side) Die size (punch + die side)
MD #50 0.062" + 0.062" LD #30 0.032” + 0.032”
0.062" + 0.052" 0.032” + 0.028”
0.062" + 0.040" 0.028” + 0.028”
0.052" + 0.052” 0.028” + 0.022”
0.052" + 0.040" 0.022” + 0.022”
MD #40 0.040" + 0.040" LD #25 0.022” + 0.022”
0.040" + 0.034” 0.022” + 0.019”
0.040" + 0.028" 0.019” + 0.019”
0.034" + 0.034" 0.019” + 0.016”
0.034" + 0.028" 0.016” + 0.016”
0.034" + 0.022"
0.028" + 0.028"
0.028" + 0.022"
MD #30 0.022" + 0.022" LD #20 0.016” + 0.016”
0.022" + 0.018" 0.016” + 0.013”
0.022" + 0.014" 0.013” + 0.013”
0.018" + 0.018" 0.013” + 0.010”
0.018" + 0.014" 0.010” + 0.010”
0.014" + 0.014"

SURELOK MANUAL 2002 16
JOINT STRENGTH:
PULL PEEL
1) There are two ways to measure the strength of a Clinchlok joint, pull and peel (see
diagram).
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.
If the material is softer than mild steel these strengths will be reduced according to
the strength of the material.
MEDIUM DUTY
Material thickness Joint strength Recommended
Each / two ply PULL PEEL Die
0.06" 475 lb. 175 lb. MD
#50 0.05" 430 lb. 150 lb. MD
#50 0.04" 400 lb. 120 lb. MD
#40 0.03" 375 lb. 100 lb. MD
#40 0.02" 285 lb. 70 lb. MD #30
LIGHT DUTY
Material thickness Joint strength Recommended
Each / two ply PULL PEEL Die
0.030" 200 lb. 35 lb. LD #30
0.025" 185 lb. 28 lb. LD #30
0.020" 175 lb. 24 lb. LD #25
0.015" 150 lb. 18 lb. LD #20
0.010" 120 lb. 15 lb. LD #20

SURELOK MANUAL 2002 17
JOINT FAILURE
1) If pulled hard enough any clinchlok joint will pull apart.
2) There are two usual ways for a clinchlok to pull apart;
a) NON TEARING FAILURE
The two halves of the joint will pull apart leaving a male joint half (punch side)
and a female joint half (die side).
b) TEARING FAILURE
The joint will tear out of the punch side layer leaving a hole in it. The joint will
remain in the die side layer.
3) A correctly formed joint will usually fail by tearing (b) in the pull test. The joint
strength usually increases as the punch is adjusted towards the die. However it is
easy to over adjust the punch and overload the punch and die reducing their life.
4) In the peel test, an under adjusted joint (punch too far away from the die) will pull
apart as a non tearing fail (A) and an over adjusted button (punch too close to the
die) will pull apart as a tearing fail (B).
5) The correct adjustment is when the joint fails in peel sometimes as non-tearing and
sometimes as tearing. This will give the greatest peel strength.
6) If the peel strength of a correctly adjusted joint is less that shown in the joint strength
chart, and thejoint tends to fail by tearing apart, the incorrect die (too deep) may
have been selected;
MD: Change #50 die to #40 die. Change #40 die to #30 die.
LD: Change #30 die to #25 die. Change #25 die to #20 die.
If this does not improve the peel strength of the joint, - either, the punch tip radius is
too sharp, or the material is not suitable for clinching (probably too hard).
7) If the peel strength of a correctly adjusted joint is much less that shown in the chart
above, and the joint tends to fail as a non tearing failure, the incorrect die (too
shallow) may have been selected;
MD: Change #30 die to #40 die. Change #40 die to #50 die.
LD: Change #20 die to #25 die. Change #25 die to #30 die.
8) If this does not improve the peel strength of the joint then - either the punch tip radius
is too large, or the material is not suitable for clinching (probably too soft).

SURELOK MANUAL 2002 18
VIEWS OF THE CLINCHLOK JOINTS.
1 2 3 4
TOOLING TOOLING TOOLING TOOLING
UNDER ADJUSTED OVER ADJUSTED CHIPPED
ADJUSTED CORRECTLY OR BROKEN
CROSS SECTION OF JOINT
TOP VIEW OF JOINT (PUNCH SIDE)
BOTTOM VIEW OF JOINT (DIE SIDE)

SURELOK MANUAL 2002 19
TESTING JOINT STRENGTH:
1) The best method of testing joint strength is to pull the joint apart in both pull and peel
and measure the force required with a pull tester.
2) In production however an indication of the joint strength can be found by measuring
the diameter of the button cap (the "mushroom") on the die side of the joint.
3) If a joint is tested in pull and peel with a pull tester and the upper and lower limits of
joint strength are found, the cap diameters for these two limits can be measured.
Calipers or a GO - NOGO gauge can then be used in production to see if the cap
diameter is within the measured limits.
NOTE! a) If the material changes or the die # is changed the cap
diameters will change.
b) When using the button cap diameter shear and peel tests should also
be used occasionally to confirm strengths.
MAX
Checking Button Cap Dia TOLERANCE GAUGE MIN
With a Caliper
Good Joint Not Acceptable
PULL AND PEEL TESTING. TESTING BUTTON CAP DIAMETER.