FPD-1120 Instruction Manual V2 R1 (1-20-2016)

FPD-1120
Safety ◦ Installation ◦ Maintenance ◦ Repair ◦ Operation
Instruction and Control Manual

Version 2, Revision 1 (January 2016)
YD2313052
Our Company...
Peddinghaus Corporation is proud to be serving the steel construction,

plate fabrication, and metal working industries since 1903. Peddinghaus
maintains engineering, customer service, and production facilities in
Bradley, Illinois and Andrews, South Carolina in the
United States, as well as in Gevelsberg, Germany
and Vitoria, Spain. Sales and Service offices are
located throughout the world, specifically in the
UK, the Netherlands, Hong Kong, and Mexico.
Peddinghaus is dedicated to engineering expertise

focused on machine productivity. We maintain the
largest staff of field service technicians and
customer support in the industry. Our extensive
parts inventory assures our customers of next-day
parts shipments.
To discover the many ways that we can help you

make the most of your Peddinghaus partnership,
refer to the Appendix in this manual, visit us at
www.Peddinghaus.com, or call us at 815-937-3800
(USA).
© Peddinghaus Corporation, 2008

All Rights Reserved
© Peddimat Software is a copyright of Peddinghaus Corporation
Peddinghaus Corporation reserves the right to improve or change product design and specifications without prior notice. In addition, Peddinghaus
Corporation assumes no responsibility for damages, injuries or accidents caused by improper or other than normal use of it or any related
equipment. The information in this manual must not be reproduced or distributed for competitive purposes.
i Visit us at www.Peddinghaus.com
… and Your Machine
This manual covers the mechanical operation and maintenance of your machine. Some of the
features described may be for optional equipment, which you may or may not have in your
system. All persons supervising, operating, or servicing this machine must read and understand
this manual.
Optional equipment not covered in this manual will have its own manual. All pertinent manuals
will be provided for the equipment you are receiving. For information on optional equipment that
is available for your machine, contact Peddinghaus Inside Sales.
The FPD-1120 Duplicator by Peddinghaus is designed exclusively for the fabrication of flat plate
and angle detail parts for the fabrication industry meeting AISC standards. The machine consists
of a triple tool punch with a hydraulic drill spindle and Signoscript in-line with the punch. The FPD
-1120 creates multiple series of holes on a variety of flat and structural angle materials.
FPD-1120 ii
Table of Contents
I: Mechanical Unit
1.0 Safety
Warning Systems ································································································· 1.1
Warning Signs ····································································································· 1.2
Safety Features and Protection Systems ····································································· 1.3
Environmental Safety Features ················································································ 1.4
Closed Circuits ··································································································· 1.5
Interlocking ······································································································· 1.6
Lockout/Tag-out Procedure ···················································································· 1.7
Ear Protection ···································································································· 1.8
Safety Guidelines ································································································ 1.9
Conditions for Safe Use ························································································ 1.10
Personnel Qualifications ······················································································· 1.11
2.0 Machine Components

Machine Construction ··························································································· 2.1
Axis Definition ···································································································· 2.2
Layout of Controls ······························································································· 2.3
Electrical Cabinet ································································································ 2.4
3.0 Operation
Preparation Prior to First Use ·················································································· 3.1
Preparation Prior to Start-Up ·················································································· 3.2
Theory of Basic Operation ······················································································ 3.3
Safety for Standard Operational Mode ··················································································· 3.3.1
Safety for Special Operational Modes ···················································································· 3.3.2
Emergency Shutdown Procedures ············································································· 3.4
4.0 Maintenance & Troubleshooting

Inspection and Maintenance Schedule ········································································ 4.1
Daily Inspection and Maintenance············································································· 4.2
Around the Machine········································································································· 4.2.1
Mechanical ··················································································································· 4.2.2
Hydraulic ····················································································································· 4.2.3
Lubrication ··················································································································· 4.2.4
Electrical ····················································································································· 4.2.5
Pneumatic ···················································································································· 4.2.6
Weekly Inspection and Maintenance ·········································································· 4.3
Mechanical ··················································································································· 4.3.1
Computer ····················································································································· 4.3.2
Pneumatic ···················································································································· 4.3.3
Monthly Inspection and Maintenance ········································································· 4.4
Hydraulic ····················································································································· 4.4.1
Lubrication ··················································································································· 4.4.2
Computer ····················································································································· 4.4.3
Six Month Inspection and Maintenance ······································································· 4.5
Hydraulic ····················································································································· 4.5.1
iii Visit us at www.Peddinghaus.com

Annual Inspection and Maintenance ··········································································· 4.6
Mechanical ···················································································································· 4.6.1
Electrical ······················································································································ 4.6.2
Troubleshooting ··································································································· 4.7
General System ·············································································································· 4.7.1
Hydraulics ····················································································································· 4.7.2
Pumps ························································································································· 4.7.3
Solenoid Valves ·············································································································· 4.7.4
Filters ·························································································································· 4.7.5
Drill Bits ······················································································································· 4.7.6
Punches ······················································································································· 4.7.7
Technical Specifications ························································································· 4.8
Screw and Bolt Torque Specifications—Metric ·········································································· 4.8.1
Screw and Bolt Torque Specifications—Standard ······································································· 4.8.2
5.0 Spare Parts

Drill Lubricant ····································································································· 5.1
Primary Spare Parts List ························································································· 5.2
Additional Spare Parts Sources ················································································· 5.3
Ordering Spare Parts ····························································································· 5.4
Returning Spare Parts for Credit ··············································································· 5.5
6.0 Assembly
Handling ············································································································ 6.1
Identification of Components ··················································································· 6.2
Support and Lifting Points ······················································································· 6.3
Positioning and Joining of Components ······································································· 6.4
Shipping Blocks ··············································································································· 6.4.1
XY Table Installation ········································································································ 6.4.2
Hydraulic and Electric Connections ······················································································· 6.4.3
Optional Auxiliary Table Leveling ························································································· 6.4.4
Machine Paint Coverage ···································································································· 6.4.5
Loctite ························································································································· 6.4.6
Optional Structural Angle Clamping Jaws ················································································ 6.4.7
Adjustments ······································································································· 6.5
Punch and Die Alignment ··································································································· 6.5.1
Material Clamp Adjustment ································································································ 6.5.2
Punch TOS, BOS, and Layout Mark Adjustment ········································································· 6.5.3
XY Table Home and Over-travel Prox Switch Adjustment ····························································· 6.5.4
Y-axis Travel Prox Switch Adjustment···················································································· 6.5.5
Hydraulic Drill Full Retract Position Adjustment ······································································· 6.5.6
Gag Cylinder Switch Adjustment ·························································································· 6.5.7
Dismantling, Disposal, and Reassembly ······································································· 6.6
7.0 Installation
Installation Requirements ······················································································· 7.1
Required Installation Materials and Tools ···································································· 7.2
Installation Procedures ·························································································· 7.3
Electrical Connection ······································································································· 7.3.1
Fusing on the Construction Site and Supply Lines ······································································ 7.3.2
Hydraulic Connections ······································································································ 7.3.3
Pneumatic Connections ····································································································· 7.3.4
Assembly and Installation Inspection ·········································································· 7.4
FPD-1120 iv
8.0 Packaging & Storage
Packaging Requirements ························································································ 8.1
Methods of Handling ····························································································· 8.2
Protection from Unwanted Movement ········································································ 8.3
Labeling ··········································································································· 8.4
Storage Requirements ··························································································· 8.5
Storage Space ···································································································· 8.6
II: Control Unit

9.0 Basic Machine Operation
Siemens CNC Control General Information ·································································· 9.1
Operating Modes ································································································· 9.2
Jog Mode ·········································································································· 9.3
Jog Mode—Repos (Incremental Axis Move) ·············································································· 9.3.1
Jog Mode—Ref Point (Manual Axis Reference) ·········································································· 9.3.2
MDI Mode ·········································································································· 9.4
Automatic Mode ·································································································· 9.5
Part Program Selection ····································································································· 9.5.1
Load HD » NC ················································································································ 9.5.2
Unload NC » HD ·············································································································· 9.5.3
Start Cycle ··················································································································· 9.5.4
Stop Cycle ···················································································································· 9.5.5
Single Block Execution ····································································································· 9.5.6
10.0 Machine Operations

Manual Pushbuttons ···························································································· 10.1
Power On ···················································································································· 10.1.1
E-stop Buttons ·············································································································· 10.1.2
Fault·························································································································· 10.1.3
Hydraulic Pump ············································································································· 10.1.4
Tool Mode ··················································································································· 10.1.5
Work Position Switch Override ··························································································· 10.1.6
Material Clamp ············································································································· 10.1.7
Punch Strip + and - ········································································································ 10.1.8
Punch Tool + and - ········································································································ 10.1.9
Spindle Jogging ··········································································································· 10.1.10
Spindle Start ·············································································································· 10.1.11
Feed Override Turn Dial································································································· 10.1.12
11.0 General Configuration Parameters

Parameter Screen ······························································································· 11.1
Miscellaneous Parameters ································································································ 11.1.1
Hydraulic Pump ············································································································· 11.1.2
Punch ························································································································ 11.1.3
Reposition ··················································································································· 11.1.4
Drill ··························································································································· 11.1.5
Drill RPM ····················································································································· 11.1.6
Signoscript··················································································································· 11.1.7
Monitor Screen ·································································································· 11.2
Spindle ······················································································································· 11.2.1
Spindle RPM ················································································································· 11.2.2
v Visit us at www.Peddinghaus.com
12.0 Access Levels
Access Level Retention ························································································ 12.1
Determining Current Access Level ··········································································· 12.2
Raising the Access Level ······················································································· 12.3
Lowering the Access Level ···················································································· 12.4
Changing Passwords ···························································································· 12.5
13.0 Additional Installed Programs

Peddimat Programming System ·············································································· 13.1
Updating Peddimat ····························································································· 13.2
Step7 PLC Program ····························································································· 13.3
14.0 NC Code Listing
Appendix I: Peddinghaus Services
FPD-1120 vi
Table of Images
Safety Features ·································································································· 1-1
Lockout/Tag-out Procedure ···················································································· 1-2
Airborne Noise Emission ························································································ 1-3
Main Machine Components ····················································································· 2-1
Axis Definition ···································································································· 2-2
Control Panel ····································································································· 2-3
Control Console ·································································································· 2-4
Main Machine Electrical Cabinet ·············································································· 2-5
Work Hours Counter ····························································································· 4-1
Drill Assembly ···································································································· 4-2
Punch and Die Replacement 1 ················································································· 4-3
Signoscript Components ························································································ 4-7
Hydraulic Fluid Sight Gauge ···················································································· 4-8
Filter Status Indicators ·························································································· 4-9
Drill Coolant Reservoir ························································································· 4-10
Mist Lubricator ·································································································· 4-11
Filter Regulator Lubricator Assembly ········································································ 4-12
Lubrication Groups ····························································································· 4-13
Material Clamps Lubrication Points ·········································································· 4-14
Punch Lubrication Points ······················································································ 4-15
Drill Lubrication Points ························································································ 4-16
Signoscript Lubrication Points ················································································ 4-17
XY Table Lubrication Points ··················································································· 4-18
Power Unit Components ······················································································· 4-19
Low and High Pressure Filter Elements ····································································· 4-20
Prox Switch ······································································································ 4-21
Triple Tooling Prox Switches ·················································································· 4-22
Hydraulic Drill Prox Switch ···················································································· 4-23
X-axis Prox Switches ···························································································· 4-24
Y-axis Prox Switches···························································································· 4-25
Punch BOS Prox Switch························································································· 4-26
Punch TOS and Layout Prox Switches ········································································ 4-27
Main Machine Lifting Points ···················································································· 6-1
Drill & Signoscript Assembly Lifting Points ·································································· 6-2
Shipping Blocks ··································································································· 6-3
XY Table Installation ···························································································· 6-4
Ball Screw Nut Bracket Connection ··········································································· 6-5
Y-axis Cable Track Connection ················································································ 6-6
Hydraulic Hose Connections ···················································································· 6-7
Electrical Connections ·························································································· 6-8
Auxiliary Table Leveling ························································································ 6-9
Angle Clamping Jaw Installation ············································································· 6-10
Punch and Die Alignment ······················································································ 6-11
Material Clamp Adjustment ··················································································· 6-12
Clamp Lower Jaw Adjustment ················································································ 6-13
Punch BOS Prox Switch Adjustment·········································································· 6-14
Punch TOS Prox Switch Adjustment·········································································· 6-15
vii Visit us at www.Peddinghaus.com

Punch Layout Prox Switch Adjustment ······································································ 6-16
XY Table Home and Over-travel Prox Switch Adjustment ················································ 6-17
Y-axis Travel Prox Switch Adjustment ······································································ 6-18
Drill Full Retract Prox Switch Adjustment ·································································· 6-19
Gag Cylinder Switch Adjustment ············································································· 6-20
Power Unit Electric Enclosure ·················································································· 7-1
Pneumatic Connection ··························································································· 7-2
Main Machine Storage Space ···················································································· 8-1
Auxiliary Table Storage Space ·················································································· 8-2
Machine Control Panel ··························································································· 9-1
FPD-1120 viii
1.0 Safety
1.1 Warning Systems
Warning
All persons involved with the supervising, assembling, installing, operating, or
servicing of your Peddinghaus machine should wear appropriate safety glasses,
safety shoes, hard hats, and protective work gloves.
The control console for your machine notifies the operator of warnings and errors with the system.
Different headings on labels and headings in this manual indicate the severity of the potential hazard.
Note
Notes on operation and safety must be strictly observed and carried out by the operator to
maintain machine performance and protect the work area.
Caution
Refers to operation and maintenance instructions that must be strictly followed
to prevent damage to the machine and the surrounding area.
Warning
Refers to instructions that must be strictly followed to prevent injury or
dismemberment.
Danger
Refers to instructions that must be strictly followed to prevent serious injury or
death.
Failure to acknowledge and follow the warnings provided in this manual and elsewhere may lead to damage, destruction of
property, injury, or death.
1 Visit us at www.Peddinghaus.com
1.2 Warning Signs
Some of the warning signs on your machine apply to overall safety for anyone near the machine and clearly state what actions
need to be taken to prevent injury. Some of these signs are displayed below.
Other signs on your machine are more explicit and apply to a hazard presented by a specific machine part, function, or action
taken by those working on or with the machine.
All those who will operate, maintain, repair, or work near this machine must be aware of these labels, their locations, and the
dangers they represent.
Chapter 1: Safety 2
1.3 Safety Features and Protection Systems
Warning
Prior to putting your machine into operation, whether it be at the beginning of
the shift or start-up after break, the location and functionality of the below-
described safety devices must be confirmed. Failure to do so can cause serious
injury.
There are several safety features incorporated into your system. These features include:
• Emergency Stop (E-stop) push buttons—1 on the Control Console, and 1 on the entry side C-Frame
• Main Power Disconnect—located on the lower half of the Control Console
• Perimeter Light Guard—set around the front of the machine and the material movement area
Perimeter Light Guard

E-stop Push Button
Perimeter Light Guard
E-stop Push Button
Main Power Disconnect
Figure 1-1: Safety Features

Any time your machine is in E-stop mode or electrical power is off, the hydraulic and pneumatic valves switch to blocked centers
to prevent the cylinders from moving. Axis drives will be shut off to prevent movement of material, which also results in a loss of
material position data.
To reset the E-Stop switches after activating them, give the push buttons a clockwise quarter turn or pull them away
from the machine, depending on the model used.
Warning
All operators and personnel in the general area of the machine must be made
familiar with the location and operation of all Emergency Stop buttons and other
safety features.
1.4 Environmental Safety Features

Your machine is environmentally friendly. It is equipped with a vegetable-based oil coolant, which poses no major threat to the
environment.
1.5 Closed Circuits

All E-stops in your system are hooked up in closed circuits. If an E-Stop wire is broken or cut, the machine will automatically shift
into E-Stop mode.
1.6 Interlocking
The main electrical cabinet is designed so that the power to it must be turned off before the cabinet can be opened.
Chapter 1: Safety 4
1.7 Lockout/Tag-out Procedure
Follow these steps to release all hazardous energy before performing maintenance on this machine. For more information on
Lockout/Tag-out, see CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout).
Danger
These steps must be followed before installing, operating, servicing, or
dismantling this machine. Failure to do so can cause serious injury or death.
To lockout/tag-out the machine:

• Shut down the machine.
• Open the main power disconnect switch on the
main panel by turning the handle to the “Off”
position.
• Lockout and tag-out the electrical power at the
supply disconnect. This procedure should be
accomplished yourself. Do not rely on others to
perform this operation. Once this is completed,
verify by trying to re-start the machine to
confirm that all electrical power is off.
• Exhaust, vent, lockout, and tag-out pneumatic
and hydraulic pressure that is stored within the
machine. This trapped energy could cause
dangerous, unwanted machine motion. This is
accomplished by locking and tagging out the red
switch on the FRL unit where the air connects
to the machine. Hydraulic pressure is dumped
when the electrical power is disconnected.
Figure 1-2: Lockout/Tag-out Procedure
1.8 Ear Protection
When the machine is idling, it emits noise measuring between 72 and 78 decibels (db); however, during material processing
operations, the noise level exceeds 85 db within the typical operator’s zone. Ear protection is not required for the operation of
this machine; however, you may use ear protection at your discretion.
65 db @ 7 feet
72 db @ 7 feet
69 db @ 7 feet
72 db @ 7 feet
65 db @ 7 feet
72 db @ 7 feet
67 db @ 7 feet
78 db @ 7 feet
75 db @ 2 feet
86 db @ 2 feet
75 db @ 2 feet
86 db @ 2 feet
68 db @ 7 feet
74 db @ 7 feet
70 db @ 7 feet
80 db @ 7 feet
Key
Plain text = idling level
Underlined text = operating level
Figure 1-3: Airborne Noise Emission
Chapter 1: Safety 6
1.9 Safety Guidelines
• Only persons adequately trained should operate, assemble, maintain, or perform service on your machine.
• Never operate your machine without all safety devices in place and working properly.
• Always perform proper shut-down procedure before performing any service to the machine.
• Do Not try to process materials not intended to be used on this machine.
• Do Not use the machine as a manual drilling or punching device. There are sensors to prevent damage or injury when running
that are not active when the machine is in manual jog mode.
1.10 Conditions for Safe Use

Note
No modifications to your machine are allowed while it is under warranty, unless they are
performed by a Peddinghaus Service Technician.
The operating environment for your machine must have sufficient lighting. Do not operate the machine in areas where the
ambient temperature is less than 40° Fahrenheit (4.4° Celsius) unless it is equipped with an oil heater, or in areas where the
ambient temperature is greater than 110° Fahrenheit (43° Celsius) unless it is equipped with additional oil cooling equipment.
When operating the machine in cold climates, it must warm up before processing material.
The machine must be protected from outdoor elements such as rain, snow, hail, intense sunlight, strong winds, sand, etc.
Always keep the operating instructions in reach of the machine. In addition to the operating instructions, keep to and apply
general legal rules and other mandatory standards regarding accident prevention and environmental protection.
Staff members engaged in performing work at the machine must read the operating instructions before starting their work,
especially the sections on safety. This applies in particular to personnel that infrequently work on the machine, such as those who
equip or service the machine.
Should mechanical or operational changes leading to dangerous situations occur, shut down the machine immediately, secure it
against tampering, and report the malfunction to the person or department responsible. Never carry out any modification or
redesign of the machine, or install additional components, that may affect the safety of the machine without the permission of the
supplier. This also applies to the installation and adjustment of safety devices and safety valves.
Electrical system work may only be performed by electricians or by persons trained to perform electrical work and under the
supervision of an electrician. Work on the electrical system must be performed in accordance with the applicable rules of
electrical codes.
Hydraulic system work may only be performed by experienced hydraulics personnel.
Spare parts must comply with the technical specifications defined by the manufacturer. This is always the case with spare parts
originally supplied by Peddinghaus Corporation.
Note
Peddinghaus Corporation cannot be held responsible for any damage or injury due to the use
of parts, accessories, and/or special equipment that has not been originally supplied by
Peddinghaus Corporation.
All moving parts must be fully supported before performing any work on these cylinders or hydraulic valves.
The safety light curtain uses a Class 1 Laser product, which complies with 21 CFR 1040.10 and 1040.11, except for deviations
pursuant to Laser Notice No. 50, dated 07-26-01. Do not disassemble, repair, or modify this product in any way.
Warning
Never stare directly into the sensor lens. Laser light can damage the eye. Avoid
placing reflective surfaces in the path of the beam.
Note
The location of the laser beam may vary depending on where the safety light curtain is set up
around the machine.
1.11 Personnel Qualifications

Everyone involved with your machine must be properly trained. All personnel must fully read all sections of this manual that are
pertinent to the job they will be performing, and become familiar with the machine before running or working on the machine.
All personnel involved with the machine should have an understanding of general shop practices and your company’s health and
safety policies.
Peddinghaus Corporation’s Customer Service Training Department can assist your with any of your training needs. Call Peddinghaus
Corporation at (815) 937-3800 or visit http://www.peddinghaus.com/Peddinghaus_Training.asp to learn more about training
course offerings.
Chapter 1: Safety 8
2.0 Machine Components
2.1 Machine Construction
C-frame
Punch Cylinder
XY Table
(30x60” capacity)
Electrical Cabinet
Punch Slug Chute
Punch / Punch
Stripper Valve Stack
Hydraulic Drill
Drill Feed Cylinder
Hydraulic Drill
Motor
Hydraulic Power
Unit
Signoscript
Drill Stripper
Material Clamps
Drill Stripper
Cylinder
Figure 2-1: Main Machine Components
Chapter 2: Machine Components 10

2.2 Axis Definition
AXIS DESCRIPTION
X Material Flow Axis
Y Table In and Out Axis
-
is
- ax
Y
+
- X-axis
+
Figure 2-2: Axis Definition
2.3 Layout of Controls
Figure 2-3: Control Panel
Operator Screen
Control Panel
Figure 2-4: Control Console
For more detail and information concerning the control panels on this machine, consult section 10.1 in this manual and the
Siemens or other provided manual.

2.4 Electrical Cabinet
Your machine contains a Puls power supply. It has a three phase input of 320-550 VAC and an output of 24 VDC @ 20 amps.
24V Power Supply X- & Y-axis Servo

Circuit Breaker Contactors & MSP
X- & Y-axis Servo

Drives
Power Unit Contactor
& MSP
Fuse/CB Block Safety/E-stop Relays
24V Power Supply

Hour Meter
Main Power
Disconnect (Supply &
AD14 Module
Ground Location)
(Analog/Encoder)
Siemens PLC
Figure 2-5: Main Machine Electrical Cabinet
3.0 Operation
3.1 Preparation Prior to First Use
Prior to using your machine for the first time:
• Fill the hydraulic reservoir with hydraulic oil.
• Fill drill coolant reservoir with the recommended coolant.
• Check the punch/die clearance.
• Double-check alignment of material through the machine.
• Make sure the machine is properly anchored to the floor.
• Read and understand this entire manual.
• Familiarize yourself with all the components of the machine.
• Check to ensure that the safety light curtain is functioning correctly.
• Clear the area around the machine.
• Make sure all lubrication points are properly lubricated.
• Follow all start-up procedures.
Note
The minimum starting temperature of the hydraulic oil is between 54oF and 57oF (12oC and
14oC). The standard operating temperature is approximately 120oF (50oC). When
temperatures are low and during winter, the system must be allowed to warm up for 15-30
minutes before starting operation. This is required to guarantee proper functioning.
3.2 Preparation Prior to Start-up

Prior to the start-up of your machine, make sure that the following criteria are met:
• Hydraulic reservoir is full of oil.
• Drill coolant reservoir is full.
• All electrical connections are secure and correct.
• Drill bit is installed correctly.
• Punch and die are installed correctly.
• Area surrounding machine is clear.
• Inspect all hoses and tubing for cracks, splits, wear, and abrasions.
• Inspect all high-pressure hoses, paying close attention at the hose-to-hose interface joint for signs of cracking, wear, fraying,
or splitting.
• Inspect all wires for signs of wear, fraying, abrasion, or other damage.
• Check all fasteners to ensure they are secure.
When initiating start-up of your machine:

• All Emergency Stop buttons on the machine must be enabled.
• The Main Power Disconnect located on the electrical cabinet must be “On”.
• Switch on the machine control with the “Power On” push button located on the machine control console. Wait until start-up
screen appears on the video screen. It may take approximately 30-60 seconds for this sequence to occur.
3.3 Theory of Basic Operation
Once the machine is correctly installed and started up, load the part program you want to run. Load the material onto the XY
table. At this point, the material clamps will be open and the retracting datum will be extended to act as a datum stop. Make sure
that the material is pushed firmly against the datum stop and the material clamp edge. Push the Material Clamp button on the
control panel to close the clamp jaws.
Once the operator presses the Cycle Start button, the XY table will move along the X– and Y-axes to perform a homing routine (to
determine the leading edge of the material in relation to the centerline of the punch). The X-axis table and Y-axis table will move
simultaneously to the programmed location of the first punched or drilled hole.
Punch Cycle
If the first hole is to be a punched hole, the punch stripper will move down to hold the material in place; immediately before each
punching stroke, the coolant system lubricates the punch. After punching the first hole, the stripper will retract and the XY table
will move to the next programmed hole location. This sequence will continue until all programmed punched holes have been
processed.
Drill Cycle
If the first hole is to be a drilled hole, the drill stripped will move down to hold the material in place; as soon as the drill makes
contact with the material, the drill feed cylinder will then extend at the programmed rate. The control will turn on the material
sense/breakthrough prox switch, and then the drill feed cylinder will extend at the programmed feed rates for the appropriate
drill sizes. When the drill breaks through the material, the drill activates the material sense/breakthrough prox switch; the drill
feed cylinder will then retract completely until is activates the full retract prox switch. The drill stripper will then retract, and the
XY table will move to the next programmed hole location. This sequence will continue until all programmed drilled holes have
been processed.
Signoscript Cycle
If the operator activates the Signoscript cycle, the parking cylinder will extend fully to bring the air motor close to the material.
Then, the feed cylinder will extend at a preprogrammed rate, and mark the material. The speeds and feeds are preprogrammed,
so the operator does not need to manually adjust these values during the Signoscript marking cycle.
After the program fully executes, and the machine completely processes the material, the X-axis carriage will move left and the Y-
axis will move until the XY table reaches the loading/unloading position. The operator will then push the Material Clamp push
button to release the material clamps, and then unload the finished material from the top of the XY table.
To shut down the machine:

1. Press the “Exit” button shown on the control screen. Select “Yes” when the “Shutdown the entire system?” prompt appears.
Wait for the “Safe to shut off computer” prompt appears.
2. Press the “Off” button on the Control Console to shut off the power to the machine.
Chapter 3: Operation 16
3.3.1 Safety for Standard Operational Mode
Operate the machine only if all protective and safety installations (e.g. removable safety devices, emergency devices) have been
installed and are functioning.
Check the machine at least once every shift for externally visible damage and irregularities. Any changes (including changes in
operation) must be immediately reported to the person/department responsible. If required, stop the machine immediately and
secure it against tampering.
Before switching on the machine, verify that nobody is endangered by the starting of the machine.
Use the machine in accordance with the operating instructions and its intended functional purpose only.
3.3.2 Safety for Special Operational Modes

Always follow the recommended schedule and instructions for maintenance operations, inspection procedures, adjustments, and
part replacement. These operations must be performed only by expert personnel.
Observe the machine activation and deactivation procedures described in the operating instructions as well as the notes on
maintenance—
• For all operations, production adaptation, re-equipping, or adjustment of the machine and its safety installations.
• For all inspection, maintenance, and repair procedures.
Always safeguard the area of maintenance.
Remove oil and other protective agents from the system, especially from couplings and screw connections before starting
maintenance or repair work. Never use corrosive detergents.
Always completely re-tighten screw connections that were loosened for maintenance and repair work. Refer to specific assembly
drawings for torques.
If safety equipment (guards, covers, E-Stops, etc.) need to be removed for maintenance or repair procedures, they must be
remounted and inspected immediately after the work has been completed.
The operating and process materials, as well as replacement parts, must be disposed of in a way that is not harmful to the
environment.
3.4 Emergency Shutdown Procedures
In case of emergency, first trigger one of the Emergency Stop (E-Stop) switches.
Then depending on the severity of the emergency, do all of the following that apply:
• Turn off the hydraulic pump by pressing the pump button on the control console.
• Turn off power to the pump by turning the Main Power Disconnect on the electrical cabinet to the Off position.
• Turn off power to the entire machine.
• Disconnect the air supply to the machine.
Chapter 3: Operation 18
4.0 Maintenance & Troubleshooting
4.1 Inspection and Maintenance Schedule
Symbol “◊” indicates the inspection / maintenance interval.
Note
Faithfully keep a maintenance log to ensure that all the machine’s needs are met. Consult all
other manuals received with this machine to ensure that every part of your machine is fully
maintained.
Inspection/ Maintenance Intervals

Weekly Monthly Every 6 months Every year Refer to
Items Daily
(50 hours) (200 hours) (1250 hours) (2500 hours) Section
Around the Machine
Dispose of corrosion, scale, and drill
chips
◊ 4.2.1
Check for oil and grease spills ◊ 4.2.1

Mechanical
Inspect hoses for leaks ◊ 4.3.1
Check for loose fasteners and
damaged equipment
◊ 4.2.2
◊
Inspect the proximity (prox) switches (when replaced / 4.6.1
adjusted)
Inspect tooling for chips and worn

edges
◊ 4.2.2
Check Signoscript cutter sharpness

and depth
◊ 4.2.2
Hydraulic
Inspect idle system pressure ◊ 4.4.1
Check the power unit fluid level ◊ 4.2.3
Change hydraulic oil ◊ ◊ 4.5.1

(first time)
Replace supply and return filter

element
◊ 4.5.1
Check oil filter status indicators ◊ 4.2.3
Weekly Monthly Every 6 months Every year Refer to
Daily
(50 hours) (200 hours) (1250 hours) (2500 hours) Section
Lubrication
Check all lubrication points ◊ 4.2.4
Grease all lubrication points ◊ 4.4.2
Electrical
Check all terminal connections ◊ 4.6.2
Check Emergency Stop (E-stop)
buttons for correct operation
◊ 4.2.5
Check the functions of the operating

elements
◊ 4.6.2
Check and adjust the control and

auxiliary voltages
◊ 4.6.2
Check electrical lines for mechanical

damage
◊ 4.6.2
Check the shaft encoder attachment

and coupling
◊ 4.6.2
Computer
Create system backup of computer
hard drive
◊ 4.3.2
Clean computer screen & keyboard ◊ 4.4.3

Pneumatic
Check the drill coolant reservoir ◊ 4.2.6
Check the mist lubricator ◊ 4.3.3
Check pneumatic air filter ◊ 4.3.3
Check tubing for damage ◊ 4.3.3
Warning
Before performing any maintenance, repair, or adjustments on this machine,
shut down the machine and follow proper lockout/tag-out procedures. Secure
any parts that are usually held in place by the machine’s hydraulic or pneumatic
power.
Chapter 4: Maintenance & Troubleshooting 20

To check the work hours counter:
• Locate the work hours counter on the main
machine electrical panel.
• Use the work hours counter to determine how
many production hours have passed and when
maintenance and inspection practices should
take place.
Figure 4-1: Work Hours Counter
4.2 Daily Inspection and Maintenance
4.2.1 Around the Machine
Dispose of Corrosion, Scale, and Drill Chips
Place metal scraps in a pre-designated container and dispose of in an environmentally friendly manner.
Warning
Do not touch metal scraps with bare hands, as this could cause injury.
Check for Oil and Grease Spills

Visually assess the machine, hydraulic power unit, hoses, and the machine’s immediate area for any signs of oil leakage or spilling.
If an oil leak or spill is found, it should be cleaned immediately to prevent work surfaces from becoming hazardous. Repair the
source of the spill or leak immediately.
4.2.2 Mechanical
Check for Loose Fasteners and Damaged Equipment
Any loose or damaged equipment must be repaired or replaced before operating the machine.
Inspect Tooling for Chips or Dull Edges

Make sure that the tip of the drill is sharp and not damaged or broken. If any tooling is dull or damaged, replace it before
operating the machine.
To change the drill bits:

• Retract the drill feed cylinder until it reaches
its limit.
• Fully retract the XY table so that the person
performing the maintenance can easily reach
the drill spindle.
• Shut down and logout/tag-out the machine.
• Use a drill drift and a soft-faced hammer to
remove the bit from the spindle.
• Insert the new drill bit into the drill spindle and
tap lightly using a soft-faced hammer. The drill
bit must be securely fixed in the drill spindle.
Note
If the drill bit breaks during a program cycle operation, Drill Spindle
first press the Cycle Stop push button to fully retract the
drill feed cylinder. Then, follow the rest of the steps
listed above.
Drill Bit
Figure 4-2: Drill Assembly

Note: Punches must be replaced after repeated cutting-edge sharpening removes a maximum of 3 mm (1/8”) of punch material, or
if the hole size or quality is no longer acceptable to the user.
Caution
Always remove the punch before changing the matching die.
To replace the punches and dies:

• Position the table as close to the main machine
as possible.
• Move the material clamps away from the punch
assembly.
• Completely raise the punches. Lockout/tag-out
the machine at this point.
• Remove the guard covering the punches by
removing the 2 screws.
• Using a hammer and the spanner wrench
provided, loosen the coupling nuts on the far
left and right punches, unscrew the couplings
completely, and remove the punches. Repeat
the process with the center punch.
Figure 4-3: Punch and Die Replacement 1
Note: When removing directional punches that have keys, make sure to reserve the key when it drops out as you unscrew the
coupling. If the key does not drop out, it no longer functions properly; remove the key manually and replace it with a new key.
• Insert a new punch into the coupling.

- For directional punches, push the punch
and key up into the coupling housing to lock
them into place. Hold the punch in place
when tightening the coupling.
- For non-directional punches, push the
punch up into the coupling housing to lock
it into place, and then tighten the coupling.
• Inspect the punches to ensure they are straight.
Use the spanner wrench and the hammer to
completely tighten the couplings.
• Turn the machine back on, and move the table
as far away from the punches and dies as
possible. Lockout/tag-out the machine at this
point.
• Remove the setscrews securing the dies in
place.
• Using a long Allen wrench or other tool through Setscrews
the setscrew holes, pry the dies out of the
bottom of the assembly. Use caution to avoid
damaging the die.
• Drop the new die into place. When using
directional punches and dies, the dies and
punches should be perfectly aligned, and the
dies’ V-grooves or whistle notches (depending
on the type of dies used) should be centered on
the setscrew hole.
• Replace and tighten the setscrews, making sure
the dies are fully inserted into the die pockets.
V-groove
• After completing the above process, check the

alignment of the punches and dies. Turn the
machine back on.
• In Jog Mode, manually lower the stripper until it
meets the dies. Inspect the dies to make sure
they are centered within the stripper’s holes.
• Manually lower the punches until they just
reach the surface of the dies. Inspect the
punches and dies to ensure that they are
perfectly aligned. If the punches and dies are
properly aligned, the machine can safely
process material.
• Replace the punch guard.

Check Signoscript Cutter Sharpness and Depth
Make sure that the edges of the cutter are sharp and are not chipped or worn. The Signoscript is an optional marking tool available
with this machine that creates characters and layout marks on the work piece. It uses a carbide cutter, driven by a pneumatic
motor, which is pushed into the material and retracted by pneumatic cylinders. The distance that the cutter sticks out beyond the
material reference foot determines the depth of the cut.
Write Cylinder
Position
Cylinder
To change the cutter:
• Loosen the collet nut using the 1-inch wrench
provided, and remove the tool holder and cutter
from the collet.
• Remove the cutter from the tool holder using the
cutter wrench and Allen wrench supplied with the
Signoscript option.
• Install the sharp cutter into the tool holder and
secure.
• When reinstalling the tool holder, slide the tool
holder all the way into the collet for maximum
rigidity.
To adjust the cutting depth:

• Loosen the collet nut and slide the cutter out until Air Motor
the cutter protrudes the desired distance beyond
the material reference foot. Compressed Air Tube
• Retighten the collet nut.
Collet Nut
Tool Holder
Material
Reference Foot
Cutter
Figure 4-7: Signoscript Components
4.2.3 Hydraulic
Check the Power Unit Fluid Level
The level of hydraulic fluid in the power unit must be checked daily to ensure that the unit functions properly.
To check the hydraulic fluid level:

• Look at the sight gauge, located on the side of
the power unit.
• The fluid level should never be higher than
halfway up the gauge.
• The fluid must be replenished when the fluid
level has dropped below the minimum
observable level of the sight gauge.
• Note: The hydraulic fluid will flood the area
surrounding the thermometer. Use the
thermometer to monitor the temperature of the
fluid.
Figure 4-8: Hydraulic Fluid Sight Gauge
Check the Oil Filter Status Indicators

The indicator shows the productiveness of the filter, and when it should be replaced.
To check the return filter status indicator:

• Look at the indicator, located on the top of the Return Filter
tank. Status Indicator
• The needle within the indicator will show the

status of the power unit filter. When the needle
reaches the red area, you must change the
filter to ensure proper functioning of the power
unit.
• Consult the Power Unit manual for more
information on changing the filter.
Pressure Filter
To check the pressure filter status indicator: Status Indicator
• Look at the indicator, mounted on the top of the
filter housing.
• Make sure the machine is running. The visual
indicator device is fully functional only when the
power unit is running.
• Take whatever action is necessary according to
the 2-color indicator. Consult the Power Unit
manual for more information.
Figure 4-9: Filter Status Indicators

4.2.4 Lubrication
Check all Lubrication Points
Watch all moving components that are manually lubricated while the machine is running, to ensure that the parts move smoothly.
If the movement is not smooth, lubricate the necessary points (see section 4.3.2 for lubrication locations).
4.2.5 Electrical
Check all Safety Devices for Correct Operation
Before beginning machine operation, ensure that each E-stop button and safety mechanism functions as it should.
• See section 1.3 of this manual for more details.
4.2.6 Pneumatic
Check the Drill Coolant Reservoir
Visually inspect the Coolant Tank, located on the side of the machine, to ensure that it is sufficiently filled with fluid.
This machine is equipped with an air cooling system for the drill bits, which adds oil to the cooling air. Peddinghaus recommends
using PeddiCool cutting oil for this system.
Reservoir Lid Cap
Drill Coolant Reservoir
To fill the drill coolant reservoir:

• Open the cap on the drill coolant reservoir lid.
• Using a clean funnel, fill the drill coolant
reservoir with PeddiCool cutting oil until the
reservoir is almost full.
• Remove the funnel, and close the drill coolant
reservoir lid cap.
Figure 4-10: Drill Coolant Reservoir
4.3 Weekly Inspection and Maintenance
4.3.1 Mechanical
Inspect Hoses for Leaks
Check all hoses at least once a week and prior to running each new job, especially if the machine goes through heavy-duty and
continuous production cycle. Look for cracks, splits, wear, and abrasion
In particular, inspect all of the high-pressure hoses and the hose-to-hose joints for signs of cracking, wear, fraying, or splitting. If
any hose shows any signs of this kind of damage, replace the hose assembly immediately.
For replacement hoses and hose assemblies, contact the Peddinghaus Service Department.
4.3.2 Computer
Create a System Backup of the Computer’s Hard Drive
This ensures that you will not lose a significant amount of information should outside conditions cause the computer to fail or lose
data.
4.3.3 Pneumatic
Check the Mist Lubricator
The Peddimat PC/CNC system has an intermittent pneumatic usage. Because of this, the lubricator is set to release a steady supply
of oil. The oil is used only when pneumatic movement is required.
Oil details:
• 100-200 SSU viscosity at 100°F (37.8°C) and an aniline point greater than 200°F (93.3°C) - same as SAE No. 10.
• Do not use oils with adhesives or tacky additives. Compounded oils containing solvents, graphite, soaps, or detergents are not
recommended.
Adjusting Screw
To fill the mist lubricator: Fill Plug

• Release the filing-inlet pressure by shutting off
the air supply at the self-venting shut-off valve.
• Remove the fill plug.
• Fill the reservoir to the fill line with oil. Fill Line
• Replace the fill plug firmly and with low force—
excessive torque is unnecessary.
• Repressurize the lubricator.
To adjust the oil delivery:

• Use a slotted screwdriver to turn the adjusting
screw at the top of the lubricator.
• For LESS oil, turn the screw clockwise.
• For MORE oil, turn the screw counterclockwise.
Figure 4-11: Mist Lubricator

Note
This constant density-type lubricator delivers a constant oil-to-air ratio. Therefore, if the air
flow increases or decreases, the oil delivery will be adjusted proportionally. Your needle
valve setting should be changed after the initial setting only when a different ratio is desired.
Gauge the amount of oil delivered by counting the number of drops per minute in the sight dome. Approximately 3% of the drops
seen in the sight dome go downstream. When adjusting the drip rate, consult the following oil volume equation:
25 drops/minute = 1 ounce (.03 liters)/hour
Oil Delivery Conversion

3% of drip rate to downstream
Downstream Delivery (Drops per Minute)
Dome Drip Rate (Drops per Minute)
Check the Pneumatic Oil Filter
Both free moisture and solids are automatically removed by the filter. There are no moving parts.
Manual drain filters must be drained regularly before the separated moisture and oil reaches the bottom of the lower baffle.
The filter element should be replaced when a working pressure of 75 psi (5 bar) can no longer be set with the regulator.
Note
Collect and dispose of the contaminated liquid in an environmentally safe manner.
Regulator Knob
Lockout / Shut-off
Valve
Oil Adjust Screw
Air Filter/Regulator
Fill Plug
Air Pressure Gauge

Mist Lubricator
Locking Tab
Lubricator Bowl
Filter Bowl
Silencer
Push to drain
Figure 4-12: Filter Regulator Lubricator Assembly
To clean the filter elements:

• Shut off the air supply at the self-venting shut-off valve.
• Pull the two locking tabs and give the polycarbonate bowl a quarter turn clockwise to remove the bowl.
• Unscrew the lower baffle and remove the filter element and 2 gaskets.
• Clean all internal parts, bowl, and filter element using mild soap and water only. Do not use cleaning agents such as acetone,
benzene, carbon tetrachloride, gasoline, toluene, etc.
• Install the element and gaskets.
• Attach the lower baffle and tighten firmly.
• Lubricate the bowl seal with only mineral-based oils or grease, and replace it.
• Replace the bowl.
Check Tubing for Damage

Check the coolant system periodically for visible leaks, damage, and sharp bends. Any damaged tubing should be removed and
replaced.

4.4 Monthly Inspection and Maintenance
4.4.1 Hydraulic
Inspect Idle System Pressure
Referencing the gauge on the power unit, make sure that the idle system pressure is at the correct level (1400 psi). Any
adjustment in pressure settings can only be made by a Peddinghaus Service Technician.
4.4.2 Lubrication
Grease all Lubrication Points
Take particular notice of the lubrication schedule, the lubrication intervals, and the list of recommended lubricants. Before initial
startup of the machine, all lubrication points must be supplied with sufficient lubricant.
Lubricant Lubrication Method
Molycote BR2 Grease (or EP Moly D) Applied by grease gun, brush, or hand-packed
(Moly-disulfide paste grease)
Mobil HP (No MoS2 Graphite added) Applied by grease gun or brush
Drill / Signoscript
Punch
XY Table
Material Clamps
Figure 4-13: Lubrication Groups
Molycote BR2
Molycote BR2
Figure 4-14: Material Clamps Lubrication Points
Molycote BR2
Mobil HP
Molycote BR2
Mobil HP
Figure 4-15: Punch Lubrication Points
Figure 4-16: Drill Lubrication Points

Mobil HP
Figure 4-17: Signoscript Lubrication Points

Mobil HP Molycote BR2 Mobil HP Mobil HP
Molycote BR2
Mobil HP
Figure 4-18: XY Table Lubrication Points
4.4.3 Computer
Clean Computer Screen and Keyboard
Use a soft cloth and glass cleaner to clean both the computer screen and the keyboard. Clean these as often as is required based
on usage and operation conditions.

4.5 Six Month Inspection and Maintenance
4.5.1 Hydraulic
Change the Hydraulic Oil
The first hydraulic oil change should take place after six months of use; after that, the oil can be changed annually.
• For normal workplace conditions and temperature, use Mobil DTE 24 or equivalent.
• For extended workplace temperatures below 50° F (10° C), use Mobil DTE 13M or equivalent.
Alternative Hydraulic Oil Specifications:

• Premium oil with a viscosity range between 150-250 SSU (30-50 CST) at 100° F (38° C). Normal operating viscosity range
between 80-1000 SSU (17-180 CST).
• Maximum start-up viscosity of 4000 SSU (1000 CST).
• The oil should have maximum anti-wear properties, including rust and oxidation treatment.
Refer to the Power Unit Maintenance Manual for information on changing oil and inspecting the reservoir.
Cooling Fan
Power Unit Electric

Motor
Filter Status
Indicators
Filters
Sight Gauge
Filler Cap
Fluid Tank
Figure 4-19: Power Unit Components
Replace the Supply and Return Filter Elements
To guarantee trouble-free operation of the hydraulic system, the filters must be checked frequently and the filter elements
replaced every 1,000 operating hours. The supply filter also has an electronic indicator which will display a message on the control
screen when the filter needs changing.
Refer to the Power Unit Maintenance Manual for information on changing and replacing the filter elements.
Supply/Pressure Filter
Return Filter
Figure 4-20: Low and High Pressure Filter Elements

4.6 Annual Inspection and Maintenance
4.6.1 Mechanical
Inspect the Proximity (Prox) Switches
• The Control Panel Computer will indicate if any of the prox switches need to be adjusted.
• If the Prox Switches are dirty, wipe them with a damp cloth to remove any metallic residue that may prevent the switches
from working properly.
• Check all prox switches to make sure that Lock Nut

the switch is secure and the lock nut is in
place. The prox switch gap has been set at
the factory; if all switches are secure and
nuts tightly locked into place, the gap does
not need to be adjusted.
• Any adjustments must be carried out by
Peddinghaus Service Technicians only.
Flat Surface
Figure 4-21: Prox Switch
Figure 4-22: Triple Tooling Prox Switches
1 2
1. Drill Work Position Prox Switch

2. Drill Full Retract Prox Switch
Figure 4-23: Hydraulic Drill Prox Switch
1 2
1. X-axis Over-Travel Prox Switch

2. X-axis Home Position Prox Switch
3. X-axis Maximum Travel Prox Switch
Figure 4-24: X-axis Prox Switches

1 2 3
1. Y-axis Over-Travel Prox Switch

2. Y-axis Home Position Prox Switch
3. Y-axis Maximum Travel Prox Switch
Figure 4-25: Y-axis Prox Switches
Figure 4-26: Punch BOS Prox Switch
1. Punch TOS Prox Switch
1 2
2. Punch Layout Mark Prox Switch
Figure 4-27: Punch TOS and Layout Prox Switches
4.6.2 Electrical
For the following electrical maintenance, employ a Peddinghaus Service Technician or professional electrical technician.
• Check all terminal locations
• Check the functions of the operating elements
• Check and adjust the control and auxiliary voltages
Use an AC voltmeter to measure the secondary voltage of the control transformer, and a DC voltmeter to measure the 24-
volt DC secondary power supply at the corresponding terminal strip.
• Check the electrical lines for mechanical damage
Inspect all electrical lines on the machine to ensure that they have not been cut or otherwise damaged by
machine and shop conditions. Should any wiring need to be repaired or replaced, the work should be performed by a
trained professional.

4.7 Troubleshooting
4.7.1 General System
Problem Possible Causes Corrective Action Refer to
Power unit is operating in direct sunlight, high ambient Cool/ventilate the machine’s
-
temperatures, or poorly circulated air. surroundings
Power Unit
Excessive Heat
The hydraulic fluid has a lower viscosity than required Replace hydraulic fluid Manual,
4.5.1
Cavitation and slippage in a pump Contact Service Department -
Cavitation or air in the hydraulic fluid Contact Service Department -
Contaminated hydraulic fluid or filter Power Unit

Replace hydraulic fluid and/or
Manual,
The hydraulic fluid has a higher viscosity than required filter
4.5.1
Excessive Noise
Power Unit
The reservoir level is low Replenish hydraulic fluid Manual,
4.5.1
A coupling is worn or damaged Replace coupling -
4.7.2 Hydraulics
Power Unit
Components were not cleaned after servicing Replace oil and clean components Manual,
4.5.1
Power Unit
Replace oil and install the breather
Air breather has been left off Manual,
Dirty Oil properly
4.5.1
Hydraulic lines were not covered during service Contact Service Department -
Power Unit
Filter needs to be replaced Replace the oil filter Manual,
4.5.1
Power Unit
Oil level is too low Replenish hydraulic oil Manual,
4.5.1
Power Unit
Oil is contaminated with an incompatible foreign
Replace oil Manual,
material.
Foaming Oil 4.5.1
Suction leaks in the pump are aerating the oil Contact Service Department -
Power Unit
Lack of anti-foaming additives in the oil Replace oil Manual,
4.5.1
Soluble oil solutions have splashed into an unsealed pump
Contact Service Department -
or open fill pipes
Regulate machine’s ambient
Extreme fluctuation of ambient temperatures -
Moisture in the Oil temperatures
Power Unit
Excessive sump sediment in the system Replace hydraulic oil Manual,
4.5.1
Ten Rules of Hydraulic System Maintenance
1. Plug all leaks.

2. Look at the fluid daily to ensure that it is free from contaminants, water, and foam.
3. Listen for unusual noises in the system.
4. Keep fluid at a moderate temperature—preferably between 90° and 120° F (32° and 49° C).
5. Keep the reservoir full of fluid.
6. Clean or change filters, strainers, and magnets when required.
7. Use only fluids that meet pump specifications.
8. Add only clean, new oil using a strainer or filter.
9. Use only clean, well-marked containers for adding oil.
10. Have your fluid tested periodically to see if it needs to be filtered or changed.

4.7.3 Pumps
Vacuum leaks in the suction line or in the pump shaft-
seal
Pumps are not aligned with the drive mechanism
Fluid is not compatible with the system Contact Service Department -
Power Unit
Fluid level is too low Fill to correct level Manual,
4.5.1
Worn or faulty bearings Contact Service Department -
Reversed pump rotation Reverse electrical phase

Pumps Making Excessive Noise
Plugged or restricted suction line or strainer Contact Service Department -
Power Unit
Plugged reservoir filter breather Replace filter breather
Manual
Oil viscosity is too high or operating temperature is too
low
Loose or worn pump parts Contact Service Department -
Air bubbles in the intake oil Contact Service Department -
Pump housing bolts or mounting bolts loose or not

properly torqued
Power Unit
Low fluid level in the reservoir Fill to correct level Manual,
4.5.1
Oil intake pipe’s suction strainer is plugged Contact Service Department -
Oil viscosity is too high or operating temperature is too

Pump Fails to Deliver Fluid Contact Service Department -
low
Broken pump shaft or parts Contact Service Department -
Dirt or debris in pump Contact Service Department -
Reversed pump rotation Reverse electrical phase
Power Unit
Shaft seal is worn Replace pump
Manual
Oil Leakage Around Pump
Pump housing bolts loose or improperly torqued Contact Service Department -
Abrasive dirt or debris in the hydraulic oil Contact Service Department -
Oil viscosity is too low Contact Service Department -

Excessive Pump Wear
Pump is misaligned with the motor shaft Contact Service Department -
Air is being drawn through the inlet of the pump Contact Service Department -
Seizure due to lack of oil Contact Service Department -
Broken Pump Parts Inside the Excessive torquing of housing bolts Contact Service Department -
Housing
Solid matter being drawn in from the reservoir and
getting wedged in the pump
4.7.4 Solenoid Valves
Burnt-out coil caused by low voltage
Both solenoids of a double solenoid valve receiving signals

simultaneously
Iron dust or metallic chips collected within the magnetic
field of the solenoid
Solenoid Failure During Operation
Mechanical damage to the leads caused by a short circuit,
open connections, etc
Mechanical damage to the coils caused by a short circuit,
open connections, etc
Tight spool of other mechanical parts of the valve being
actuated
Lack of electric flow to the solenoid or operating device Contact Service Department -
Foreign matter is jammed in the main spool Replace valve
Solenoid Valve Fails to Operate Fluid media temperature exceeding the recommended
range
Foreign material in the oil causing gumming deposits Contact Service Department -
The system lacks adequate fluid to actuate the load Fill tank to correct level -
4.7.5 Filters
Filter Maintenance
• Establish a filter maintenance schedule and follow it diligently.
• Inspect filter elements that have been removed from the system for signs of failure that may indicate that the service
intervals should be shortened and of impending system problems. Periodic inspection of the filter element in a new machine is
desirable, to determine the proper replacement interval.
• DO NOT return any fluid to the system that has leaked out.
• Always keep the supply of fresh fluid covered tightly.
• Use clean containers, hoses, and funnels when filling the reservoir.
• Use common sense precautions to prevent the introduction of dirt into components that have been temporarily removed from
the circuit.
• Make sure that all cleanout holes, breather caps, and breather cap filters on the reservoir are properly fastened.
• Make sure that the fluid used in the system is a type recommended by Peddinghaus Corporation.
• Before changing from one type of fluid to another (i.e. from petroleum-based oil to a fire-resistant fluid), contact Peddinghaus
Corporation’s Service Department. Hydraulic oil cannot be replaced with fire-resistant fluid on most standard Peddinghaus
power units.

4.7.6 Drill Bits
Uneven cutting angles Regrind drill
Drill point off-center Regrind drill
Hole diameter is too large Drill is bent Replace drill
Drill shanks damaged Replace drill
Replace multiple extensions with

Multiple extension tapers
one long extension
Uneven cutting angles Regrind drill

Poor surface finish
Tool not ground/ground too much Regrind drill
Drill point off-center Regrind drill
Drill is bent Replace drill

Uneven holes produced

one long extension
Metal pushed back but not cut Negative relief angle Regrind drill
Increase of axial load on tool and

Negative relief angle Regrind drill
spindle
Tool not ground/ground too much Regrind drill

Drill overheating
Tip of the drill marked Replace drill
Point off center Regrind drill
Drill bent Replace drill

Wear on drill edges

one long extension
4.7.7 Punches
Lack of cutting coolant Increase coolant, sharpen punch
Premature dulling of punch or die Non-uniform clearance Replace mismatched punch or die
Re-align punch and die, sharpen

Misalignment
punch
Dull cutting edges Sharpen cutting edges

Burrs on punched holes
Improper clearance Reset correct clearance
Misaligned ram of press Align ram of press

Excessive punch breakage
Dull cutting edge Sharpen cutting edge
Problem Possible Causes Description

Punching a small hole through very thick material, exceeding the
compressive strength of the punch, will cause the punch end to
expand and break. The break ordinarily happens before the punch
enters the material, but sometimes a slight expansion during the
Exceeding the Diameter to Thickness Ratio
punch cycle will cause the punch to break as it is being stripped.
Swelling of the punch end can usually be measured to indicate this
type of failure. Refer to the Diameter to Thickness Ratio charts to
determine how to prevent this problem.
Punching exceptionally hard material usually results in a severe
Broken Punch Ends or Punch breakthrough shock that, in some cases, will cause the punch head
Heads to break off. We recommend that material having a tensile
strength greater than 100,000 PSI (6895 Bar) not be punched.
Examples of hard material that we do not recommend punching
would be C-1090, grader and snow plow blade material, and non-
Punching Exceptionally Hard Materials
annealed spring steel. Under special conditions, such material can
possibly be punched, after consulting with Peddinghaus
Corporation’s Customer Service. Special punch units are needed
for this application. We do not guarantee punches being used on
re-rolled rail stock since it is impossible to confirm the presence
or absence of hard spots in the material.
Many punches do not wear out under normal operating conditions,
but punch-die misalignment can damage them. Misalignment
causes the punch to shear into the die, and makes the punch
Misalignment of Punch and Die appear as though it were naturally worn; however, the damage
usually appears on only one side of the punch and die. To correct
this problem, make sure that the punch and die are properly
aligned and tight in the press.
Normal clearance should be approximately 8-10% of the thickness
of the material being punched. Insufficient clearance between the
punch and die for a given thickness of material will cause
Premature Wear on Punches
excessive wear. Proper clearance decreases the amount of force
and Dies
required to strip the material from the punch. If there is
insufficient clearance, the stripping force will be as great as 10-
Insufficient Clearance
20% of the punching force. However, if there is proper clearance,
the stripping force will drop to approximately 3% of the punching
force. Since wear is usually proportional to the applied force, the
proper clearance will greatly increase the life of the punch.
Cutting oil or die lubricant is recommended for punching,
wherever possible, to reduce wear and galling.
Nibbling, or punching just a part of a hole using a standard punch,
Nibbling
will cause the punch to be thrust sideways and shear into the die.

If a hard and/or abrasive material is being punched, a punch made
from a better grade of tool steel (i.e. high-speed steel) should be
used. Call 1-800-PUNCH-IT to order from Peddinghaus
Corporation’s large selection of punches and dies. However, using
a standard steel punch with a good grade of cutting oil will extend
the life of the punch considerably. Cutting oil or die lubricant is
recommended for punching and shearing whenever possible.
Hard and/or Abrasive Materials Shaped punches having sharp corners, such as squares and
rectangles, become duller more quickly at the corners as a result
of punching hard, thick material. Under such conditions, the
corners on the punches should be ground with a radius, or a 45°
chamfer to eliminate the very sharp, sensitive corners. The size of
the radius or chamfer depends upon the hardness of the material
being punched. For example, when punching a 3/4” square hole in
a 1/2” thick C-1045 material, corners of the square should be
broken approximately 1/16”.
Soft material such as copper and aluminum tend to stick to the

punch and gall. Lubricating the material and punch with a good
grade of cutting fluid will increase the life of the punch and die.
Punching Soft Materials
Increasing the die clearance will also prolong tool life and reduce
the stripping force. The various clamps and rollers on the machine
may also damage soft materials.
The number of holes punched between sharpening sessions varies

with the type and thickness of the material being punched. Fifty
thousand holes can be created in thin sheet metal before
sharpening, while as few as 500 holes can be created in heavy
Sharpening the Punch and Die Too Late material (1” or 2.5 cm thick). A punch and die should be
sharpened at a point where a sharp cutting edge can be restored
after grinding .015” or .04 cm. If they are used beyond this point,
the wear increases rapidly and greatly reduces the number of
holes pierced per punch.
Punching Pressure Tonnage Chart
(Use for round holes only)
Tons Pressure Required to Punch ASTM-A36 Structural Steel

Metal Thickness Hole Diameter in Inches
Gauge Inches 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 1 1 1 1
1/16 1/8 3/16 1/4
1/8 (or 0.120 1.4 2.1 2.8 3.5 4.2 4.9 5.7 6.4 7.1 7.8 8.5 9.2 9.9 10.6 11.3 12.0 12.7 13.4 14.1
10)
10 0.135 1.6 2.4 3.2 4.0 4.8 5.6 6.4 7.2 7.9 8.7 9.5 10.3 11.1 12.0 12.7 13.5 14.3 15.1 15.9
3/16 0.187 2.2 3.3 4.4 5.5 6.6 7.7 8.8 9.9 11.0 12.1 13.2 14.3 15.4 16.5 17.6 18.7 19.8 20.9 22.0
1/4 0.250 2.9 4.4 5.9 7.4 8.8 10.3 11.8 13.2 14.7 16.2 17.7 19.1 20.6 22.1 23.6 25.0 26.5 28.0 29.5
5/16 0.312 5.5 7.3 9.2 11.0 12.9 14.7 16.5 18.4 20.2 22.1 24.0 25.7 27.6 29.4 31.3 33.0 34.9 36.8
3/8 0.375 8.8 11.0 13.3 15.5 17.7 19.9 22.1 24.3 26.5 28.7 31.0 33.1 35.3 37.6 39.7 42.0 44.2
1/2 0.500 17.7 20.6 23.6 26.5 29.4 32.4 35.3 38.3 41.2 44.2 47.1 50.0 52.9 55.9 58.9
5/8 0.625 29.5 33.1 37.0 40.5 44.2 48.0 51.5 55.2 59.0 62.6 66.2 69.9 73.7
Material Multiplier Chart

Type of Material Tons per Square Inch Shear Strength Pounds Chart Multiplier
per Sq. In.
Structural ASTM-A7 25.0 50,000 0.83
Firebox Steel & Boilerplate 27.5 55,000 0.92
Structural ASTM-A36 30.0 60,000 1.00
Structural Cor-Ten (ASTM-A2424) 33.0 66,000 1.10
Steel, 50 Carbon 35.0 70,000 1.17
Structural T-1 45.0 90,000 1.50
6061 T-6 Aluminum 15.0 30,000 0.50
Soft Copper 15.0 30,000 0.50
Use of Tonnage Chart/Example

For punching materials with a different shear strength than 60,000 PSI (as listed in the chart). It is necessary to use a multiplier for
calculating the tonnage required for a given hole size.
Example—To punch a 3/4” diameter hole through 1/2” thick 50 carbon steel (70,000 PSI shear strength), the force required
(according to the above table) is 35.3 tons. The multiplier for 50 carbon steel is 1.17; therefore, 35.3 tons x 1.17 = 41.3 tons
(actual force required) to punch the tougher steel.

4.8 Technical Specifications
Type Unit of Measurement FPD-1120
Equipment and Module Weights
Main Machine with Mounted Power Unit Lbs (kg) 10,000 (4536)
Hydraulic Power Unit Lbs (kg) 500 (227)
Auxiliary Table Lbs (kg) 500 (227)
Hydraulic Drill and Signoscript Assembly Lbs (kg) 700 (318)
Operating Power Requirements

Standard Voltage / Phase / Hertz —- (230) 460 / 3 / 60
Power Consumption kva 37
Motor Power Hp 25
Motor Speed RPM 1800
Air Usage Specifications

Air Consumption cu. ft/min 10
Air Pressure psi (bar) 90-100 (6.2-6.9)
Machine Parameters
Power Unit Maximum Relief Valve Setting PSI 3300
System Pressure Adjustment for Punching Cycle Maximum PSI/Operating PSI 3000/3000
System Pressure Adjustment for Drilling Cycle Maximum PSI/Operating PSI 1750/1750
System Pressure Adjustment (Standby or Idle) Maximum PSI/Operating PSI 900/900

Accumulator Pre-charge for Material Clamps and
Maximum PSI 450
Retracting Datum
Drill Stripper Pressure Reducing Valve Maximum PSI/Minimum PSI/
1000/500/500-1000
Adjustment Operating PSI
Punch Stripper Pressure Reducing Valve Maximum PSI/Minimum PSI/
3000/1500/1500-3000
Adjustment Operating PSI
Maximum PSI/Minimum PSI/
Supply Air Pressure 110/80/90
Operating PSI
Minimum cu. feet/min /
Air Flow Rate 10/10+
Operating cu. feet/min
Control System
Machine Control System —- Siemens
Notes for minimum material thickness:

Running thinner material should be done with caution! Thinner full size plates becomes more un-
stable and subject to warping and flexing during processing. When processing thinner material it
may be required to slow the machine to minimize material motion during X/Y axis motion. As with
all materials, punching tight patterns of holes can cause warping of the material and could poten-
tially cause problems when processing. Running thinner material should be done with caution!
Type Unit of Measurement FPD-1120
Capacities, Speeds, and Passlines
Machine Passline Inches (mm) 40 (1016)
Punch Tonnage —- 120 Tons
Max. Material Thickness Inches (mm) 1.25 (31,75)
Min. Material Thickness * (see notes on previous page) Inches (mm) 0.12 (3,2)
60 x 30 x 1.25
Maximum Plate Dimensions Inches (mm)
(1524 x 762 x 31,75)
8 x 8 x 1-1/8
Maximum Angle Dimensions Inches (mm)
(203 x 203 x 28,58)
2-1/2 x 2-1/2 x 1/8
Minimum Angle Dimensions Inches (mm)
(63,5 x 63,5 x 3,18)
Maximum Material Support Table Load Lbs (kg) 640 (290)
Maximum Hole Size with Standard Punch Tooling Inches (mm) 1.25 (31,75)
Material Clamp Mechanism —- Hydraulic
Stripper Type —- Positive (infinitely adjustable)
Punch Stroke Control —- Adjustable Limit Switches
Hydraulic Operating Pressure (Punch Cycle) psi (bar) 3000 (206,8)
Hydraulic Operating Pressure (Drill) psi (bar) 1750 (120,7)
Positioning Range
• Front-to-back and left-to-right Inches (mm) 30 x 60 (762 x 1524)
• Positioning accuracy Inches (mm) 1/32 (0,79)
• Full stroke of press ram Inches (mm) 2 (50,8)
• Part positioning rate Inches/min (meters/min) 500 (12,7)
Optional Drill Information

Number of Spindles —- 1
Tool Holder —- #4 Morse taper with through-tool coolant
Spindle Power Hp 13.5

Spindle Speed (infinitely variable/auto
Approx RPM 0-900
controlled)
Drill Feed Rate Inches/min (mm/min) 2.75-8.00 (70-203)
Drill Rapid Rate Inches/min (meters/min) 192 (5)
Spindle Stroke Inches (mm) 13 (330)
Maximum Hole Diameter Inches (mm) 1 9/16 (40)
Optional Signoscript Information

Standard Cu. Feet/Min Requirement —- 42
Operating Air Pressure psi (bar) 80-90 (5.5-6.2)
Character Depth (variable) Inches (mm) 1/16 (1,6)
Character Rate Characters/min 16

4.8.1 Screw and Bolt Torque Specifications—Metric
Socket Head Cap Screw, Class 12.9 Hex Head Cap Screw, Class 10.9
w/ High Strength
Special Usage (Use when Washers (Use when
General Usage General Usage
specified by Engineering specified by
Engineering
Torque Induced Screw
Stress 32,000 PSI (220 MPa) 100,000 PSI (690 MPa) 20,000 PSI (138 MPa) 90,000 PSI (620 MPa)
Tensile Lubed or Lubed or Lubed or Lubed or

Screw Area Dry Dry Dry Dry
Loctited Loctited Loctited Loctited
Size Pitch (mm2)
13 in-lb 10 in-lb 8 in-lb 6 in-lb
M4 0.7 8.8 N/A N/A N/A N/A
147 N-cm 113 N-cm 90 N-cm 68 N-cm

M5 0.8 14.2 N/A N/A N/A N/A
305 N-cm 237 N-cm 192 N-cm 147 N-cm

M6 1 20.1 N/A N/A N/A N/A
5.2 N-m 4.0 N-m 3.3 N-m 2.5 N-m
M8 1.25 36.6 N/A N/A N/A N/A
13 N-m 9.6 N-m 7.8 N-m 6.0 N-m

M10 1.5 58.0 N/A N/A N/A N/A
25 N-m 19 N-m 15 N-m 12 N-m
32 ft-lb 24 ft-lb 99 ft-lb 76 ft-lb 20 ft-lb 15 ft-lb 90 ft-lb 68 ft-lb
M12 1.75 84.3
43 N-m 33 N-m 134 N-m 103 N-m 27 N-m 20 N-m 122 N-m 92 N-m
M16 2 157
M20 2.5 245
M24 3 353
M30 3.5 561
M36 4 817
Linear Rail Bolt Torque Specifications

Bolt Strength Grade 12.9 (Standard Socket Head Bolt)
DRY (LUBED or LOCTITED)

Bolt Size N-m in-lb ft-lb
M4 5 (4) 44 (33) 4 (3)
M5 10 (8) 88 (66) 7 (5)
M6 16 (12) 142 (106) 12 (9)
M8 40 (30) 354 (265) 29 (22)
M10 81 (60) 717 (322) 59 (44)
M12 95 (70) 841 (630) 70 (52)
M14 166 (124) 1,469 (1,100) 122 (91)
M16 265 (200) 2,345 (2,760) 195 (146)
1. Peddinghaus uses Class 12.9 Socket Head Cap Screws (970 MPa Proof Strength) and Class 10.9 Hex Head Cap Screws (830 MPa
Proof Strength).
2. General Usage is considered bolting of low carbon hot rolled steel in non-fatigue type applications or when not otherwise
specified by Engineering.
3. Special Usage is considered bolting of hardened steels or alloys and/or fatigue type applications. Engineering is to indicate the
torque to be used on the assembly drawings. Ideally, screws should be torqued to a preload of 60- 90% of the proof strength. But,
the maximum preload is limited by the strength of the bolted material. Be sure to check screw head contact stress as discussed
below.
4. Torques for Hex Head Cap Screws w/High Strength Washers (or Hex Flange Bolts) is also considered Special Usage. Again, be sure
to check screw head contact stress as discussed below.
5. For Cadmium plated screws, multiply the tabulated dry torque values by .80
6. For Zinc plated screws, multiply the tabulated dry torque values by 1.1
7. For fine threads, multiply the tabulated torque values by 1.12
8. This table does not apply to shoulder or low head screws.
9. Be certain to follow WI-ENG-022 for correct thread engagement.
10. Be certain to follow WI-ENG-023 for clearance hole size.
11. Do not use fasteners smaller than M12 for critical torque or stress applications.
Calculate compressive stress “Sc” under the bolt head when using “Special Usage” torques or “Hex Head Cap Screws w/High
Strength Washers” torque (See Sheet 3). The compressive stress in the bolted material should not exceed that material’s yield
strength. Use the following formulas to calculate compressive stress and determine the maximum allowable torque:
COMPRESSIVE STRESS UNDER HEAD:
Head Dia. D Head Dia. D
Hole Dia. d Chamfer OD, d
Non-heat Hardened
Treated Steels
Steels
Definitions:
“At” is the screw tensile area, in mm2, as tabulated.

“St” is the screw tensile stress, in MPa, induced by the torque, as tabulated.
“Wt” is the tensile force in the screw, in Newtons, induced by the torque.
“D” is the head diameter, in mm.
“d” is the hole or chamfer diameter, in mm.
“Sc” is the compressive stress in the material under the head, in MPa.
“Sy” is the compressive stress in the material under the head, in MPa.
“Ttab” is Special Usage torque, as tabulated.
“Tallow” is the torque to be used based on the bolted material strength.
Wt = St x A t
Sc = 4 x Wt
x (D2-d2)
To convert MPa to psi, multiply by 145.
If Sc is larger than the yield strength of the material under the screw head, Sy, torque needs to be reduced proportionately, as
follows:
Tallow = Ttab x ( Sy ¸ Sc )

4.8.2 Screw and Bolt Torque Specifications—Standard
Grade 5 Hex
Unbrako-Socket Head
Zinc-Plated
Special Usage
General Shop Usage (use when specified by General Shop Usage
Torque Screw
engineering)
Induced Bolt
Tensile
Stress 32,000 PSI 100,000 PSI 20,000 PSI
Area
Lubed or Lubed or Lubed or
Thread Size Dry Dry Dry
Loctited Loctited Loctited
24 21 IN# 64 IN# 18 IN# .0175 IN2
10 - - -
32 24 IN# 76 IN# 21 IN# .0200 IN2
20 51 IN# 150 IN# 45 IN# .0318 IN2
1/4 - -
28 58 IN# 170 IN# 50 IN# .0364 IN2
18 104 IN# 305 IN# 92 IN# .0524 IN2
5/16 180 IN# -
24 116 IN# 325 IN# 100 IN# .0580 IN2
16 15 FT# 45 FT# 162 IN# .0775 IN2
3/8 30 FT# -
24 17 FT# 48 FT# 185 IN# .0878 IN2
14 25 FT# 70 FT# 22 FT# .1063 IN2
7/16 Use Dry Torque 45 FT# -
20 28 FT# 75 FT# 24 FT# .1187 IN2
to Get
13 38 FT# 50,000 PSI Pre- 108 FT# 34 FT# .1419 IN2
1/2 70 FT# -
20 45 FT# Stress for 114 FT# 38 FT# .1599 IN2
Fatigued
12 55 FT# Applications 155 FT# 48 FT# .1820 IN2
9/16 100 FT# -
18 61 FT# 164 FT# 53 FT# .2030 IN2
11 75 FT# 210 FT# 66 FT# .2260 IN2
5/8 140 FT# 34 FT#
18 85 FT# 222 FT# 74 FT# .2560 IN2
10 133 FT# 360 FT# 118 FT# .3340 IN2
3/4 240 FT# 78 FT#
16 155 FT# 400 FT# 130 FT# .3730 IN2
9 216 FT# 580 FT# 188 FT# .4620 IN2
7/8 385 FT# 126 FT#
14 237 FT# 633 FT# 206 FT# .5090 IN2
8 320 FT# 860 FT# 283 FT# .6060 IN2
1 225 FT# 570 FT# 189 FT#
12, 14 355 FT# 916 FT# 304 FT# .6510 IN2
7 458 FT# 1240 FT# 400 FT# .7630 IN2
1 1/8 320 FT# 825 FT# 266 FT#
12 513 FT# 1383 FT# 449 FT# .8560 IN2
7 650 FT# 1750 FT# 566 FT# .9690 IN2
1 1/4 450 FT# 1150 FT# 378 FT#
12 700 FT# 1883 FT# 626 FT# 1.073 IN2
6 1124 FT# 3041 FT# 984 FT# 1.405 IN2
1 1/2 775 FT# 2028 FT# 658 FT#
12 1265 Ft# 3275 FT# 1106 FT# 1.581 IN2
Zinc Plated
1. Lubricated or Loctited torque = .667 x “Dry” torque. This will give an equal bolt stress to that of “Dry” torque.
2. “General Usage” indicates the use of 1020 type materials.
3. “Special Usage” indicates the use of heat treated materials, alloys, and/or fatigue type applications.
4. For cadmium-plated screws, multiply equivalent zinc-plated torque by 0.53.
5. For bare metal screws, multiply torque by 0.71.
6. This chart does not apply to shoulder or low head screws.
Usage Notes
• Calculate compressive stress “Sc” under bold head when using torque for “Hardened Materials” or for cyclic loading with high
forces. This will ensure that the material being bolted will not deform.
• Do not use fasteners smaller than 1/2” diameter where critical torque and stress is expected.
Head Dia. Head Dia.
Hole Dia. Chamfer OD

Non-heat Hardened
Treated Steels
Steels
Definitions:
“Wt” is the load (or force) in pounds on the screw, induced by torque.
“At” is the “screw tensile area” in inches squared.
“St” is the stress in the screw in PSI, induced by “Wt”.
“Sc” is the contact stress of the bolt head on the mating material. This should not exceed the yield point of the material.
“T” is the recommended torque in “foot #”.
Wt = (T ft#)(60)
(nominal screw size)
St = Wt
At
Sc = _____Wt _____
(head area - hole area)
Or (head area - chamfer area)
Note: actual applied bolt stress can vary by 20%.

5.0 Spare Parts
5.1 Drill Lubricant
This machine uses Peddicool Drill Lubricant, available from the Peddinghaus Inside Sales department. Please contact our Inside
Sales department to order Peddicool.
Peddinghaus Inside Sales / Parts Support

Phone: (815) 937-3800, Extension 259
Fax: (815) 937-4779
Note
The following lists may be edited in the future based on actual parts used on the machine.
5.2 Primary Spare Parts List

These are the most commonly needed spare parts for your machine and should be kept on hand to minimize down time. These are
considered to be wear parts, or are parts that have a history of failing over time.
Description Quantity Part Number

Main Assembly YD180920000000
Cylinder, Punch 120 Tons 0 YD2312814
Key Ram Guide 1 YD180300000002
Triple Tooling Assembly YD180920010000

Cylinder, Pneumatic (Gag) 1 YD2313807
O-Ring (Gag Cylinder Mtg) 1 YD2307754
O-Ring Dash 370 (Housing Seal) 1 YD2312811
O-Ring (Center Mini Ram) 1 YD2304008
O-Ring (Outer Mini Ram) 1 YD2307754
Key Ram Guide (Center) 1 YD180240060004
Key Ram Guide (End) 1 YD180240060005
Punch Coupling Nut (Center-282) 1 YD180240040008
Punch Coupling Nut (End-272) 2 YD180240040009
Spindle Assembly YD180920020100

Seal, Rotary Shaft 45x55x7 1 YD2312953
Rotary Shaft Lip Seal 1 YD2308361
O-Ring Busak 1 YD2312097
Bearing, Turcite Slydring 1 YD2313263
Shaft Key, 10mm x 8mm x 90mm, DIN6885B 1 Y22205260
Prox Switch 1 Y2312100
Signoscript Assembly YD180920020100
Shank, 90 Degree for 10mm Insert 1 YD2310053
Insert, 90 Degree Center Drill 10mm Diameter 1 YD2310052
Drill Support Stand Assembly YD180920020300

Plate, Wear 1 YD180920020302
Stripper Assembly YD180920050000

Proximity Switch—12mm O.D. 1 YD2307271
Stripper Right Cylinder Assembly YD180920050100

Flange Bearing 1 YD2304373
Cylinder, Stripper 1 YD2312816
Stripper Left Cylinder Assembly YD180920050200

Flange Bearing 1 YD2304373
Cylinder, Stripper 1 YD2312816
X-axis Table with Drill Assembly YD180920060000

Pillow Block Bearing 1 YD2307893
Bearing 1 YD2307895
Servo Drive S300 Kollmorgen 1 YD2312740
Servo Motor 1 YD2312869
Ball Transfer Assembly YD180920060200, YD180920060300, YD180920060400

Ball Transfer Unit 10 YD3452127
Shock Mount Spacer 6 YD1702450
Y-axis Drive Assembly YD180920080000

Pillow Block Bearing 1 YD2307893
Bearing, #6205 RS1 1 YD2307895
Servo Drive S300 Kollmorgen 1 YD2312740
Servo Motor 1 YD2312869
Hydraulic Power Unit YD180924500000

Pressure Filter 1 YD2314641
Flow Meter—Lake Monitor 1 YD2314642
Return Filter 1 YD2314643
Proportional Valve 1 YD2314644
Sub Plate 1 YD2314645
Gauge 0-60 1 YD2314646
Pressure Filter Element 1 YD2314647
Return Filter Element 1 YD2314648
Chapter 5: Spare Parts 56

Complete Unist Coolant Kit YD2314323
Reservoir 1 YD2314550
Injector Block Assembly 1 YD2314548
Solenoid Valve 1 YD2314549
Nozzle Assembly 1 YD2314350
5.3 Additional Spare Parts Sources

Hoses and Tubing may be replaced with ones of the same size and strength.
Hydraulic Hoses ASA Steel Tube (Hydraulic)

Hose SAE Rating: Min. Bend Tube Wall
Part Number Hose Description Type Part Number ASA Rating: Work/Burst
I.D. Work/Burst Radius O.D. Thickness
5,000 PSI / 4” 3,850 PSI /

1/4 YD2301340 SAE 100R2 AT 301 1/4 .035 YD2002038
20,000 PSI (101 mm) 15,400 PSI
4,000 PSI / 5” 4,300 PSI /
3/8 YD2301343 SAE 100R2 AT 301 3/8 .049 YD2304381
16,000 PSI (127 mm) 14,400 PSI
3,500 PSI / 7”
1/2 YD2301341 SAE 100R2 AT 301 3,580 PSI /
14,000 PSI (178 mm) 1/2 .065 YD2003682
14,300 PSI
4,000 PSI / 3.5”
1/2 YD2309003 SAE 100R12 721TC 4,000 PSI /
16,000 PSI (89 mm) 3/4 .109 YD2003948
16,000 PSI
3,100 PSI / 9.5”
3/4 YD2301342 SAE 100R2 AT 381 3,300 PSI /
12,400 PSI (241 mm) 1 .120 YD2302180
13,200 PSI
2,500 PSI / 12”
1 YD2302183 SAE 100R2 AT 381
10,000 PSI (305 mm)
4,000 PSI / 7” Pneumatic Hoses
1 YD2304587 SAE 100R12 AT 721TC
16,000 PSI (178 mm)
Hose Part Working
Hose Type Color
3,000 PSI / 8.25” I.D. Number Pressure
1 1/4 YD2304807 SAE 100R12 AT 721TC
12,000 PSI (210 mm)
1/4 YD2304039 200 PSI - Black
150 PSI / 20”
1 1/2 YD2308946 SAE 100R4 381 3/8 YD1701139 200 PSI - Black
600 PSI (508 mm)
1,800 PSI / 20” 1/4 YD2303995 200 PSI Type S
1 1/2 YD2312582 SAE 100R2 AT 381 Green
7,200 PSI (508 mm)
3/8 YD2304051 200 PSI Type S —-
5,000 PSI / 20” Oxygen
Grade RM
1 1/2 YD2312563 SAE 100R13 781 1/2 YD2304003 250 PSI Type H
2 Braid
20,000 PSI (508 mm)

1,125 PSI / 25” 1/4 YD2303998 200 PSI Type S
2 YD2312560 SAE 100R2 AT 301 Red
4,500 PSI (635 mm)
3/8 YD2304052 200 PSI Type S —-
150 PSI / 12” Fuel Gas
2 YD2308447 SAE 100R4 381 1/2 YD2304004 250 PSI Type H
600 PSI (305 mm)
Polyethylene Tube
Tube Wall Working Color

O.D. Thickness Pressure Natural Green
1.4 .040” 120 psi X X
3/8 .062” 125 psi X X
1/2 .062” 90 psi X ——-
Steel Pipe
Pipe Work / Burst Pressure

Size 40 80 (XS) 160 XXS
3500 psi/ 4800 psi/
1/8 ——- ——-
20,200 psi 28,000 psi
4350 psi/
1/4 ——- ——- ——-
26,400 psi
1700 psi/ 3800 psi/
3/8 ——- ——-
16,200 psi 22,500 psi
2300 psi/ 4100 psi/ 7300 psi/
1/2 ——-
15,600 psi 21,000 psi 26,700 psi
3500 psi/ 8500 psi/
3/4 ——- ——-
17,600 psi 25,000 psi
2100 psi/ 3500 psi/
1 ——- ——-
12,100 psi 15,900 psi
1800 psi/ 3000 psi/ 4400 psi/
1 1/4 ——-
10,100 psi 13,900 psi 18,100 psi
1700 psi/ 2800 psi/ 7200 psi/
1 1/2 ——-
9100 psi 12,600 psi 25,300 psi
2500 psi/ 4600 psi/
2 ——- ——-
11,000 psi 17,500 psi
1600 psi/
3 ——- ——- ——-
7400 psi
2400 psi/
3 1/2 ——- ——- ——-
9500 psi
2300 psi/
4 ——- ——- ——-
9000 psi
1300 psi/ 2090 psi/
5 ——- ——-
5500 psi 8100 psi
5.4 Ordering Spare Parts

When dealing with and contacting the Peddinghaus Corporation’s Spare Parts Department, have the appropriate piece part drawing
or assembly drawing in front of you prior to placing the call. Our sales technician will immediately be able to access the same
assembly drawing to synchronize the replacement part requirement.
Warning
Use only authorized Peddinghaus replacement parts. Failure to do so can reduce
the functionality or liability and safety of the system. This can lead to serious
injury or even death, not only to the machine operator, but also to other people
in the area.
5.5 Returning Spare Parts for Credit

No item that is returned to Peddinghaus Corporation will be accepted without prior authorization. The return authorization number
must be written on the outside of the package. If it arrives at our facility without a return authorization number, it will be refused
and returned to the sender.
To receive a return authorization number for a part, contact Peddinghaus Inside Sales for instructions and the number.
Chapter 5: Spare Parts 58

6.0 Assembly
6.1 Handling
Extreme care and safety must be exercised when unloading all components. Always use cranes and forklifts of sufficient capacity
with chains and cables of recommended design (refer to American National Standards Institute B30.9 or European Standards
Committee CEN/TC 168/prEN 818-1, -2, -8). The weights of the various elements are indicated on the Bill of Lading.
The sub-assemblies include many delicate, precision components. Unloading them requires extreme caution and experience.
Peddinghaus Corporation strongly recommends that a professional rigger be employed to unload and place the equipment.
For components lacking lifting eyebolts, straps may be placed around the main frame members.
Some of the components contain linear rails used for measuring position. Store these rails far from magnetic material.
Caution
Threaded holes with or without lifting eyebolts may be provided. Holes are
provided in some plates that are of sufficient strength for lifting those
assemblies. Never use eyebolts or threaded holes located on cylinder assemblies
or electric motors for lifting the entire assembly. These eyebolts or tapped
holes are for lifting only those devices as individual components.
6.2 Identification of Components

To facilitate the shipment and installation, your Peddinghaus machine has been dismantled into sub-assemblies. The various
component groups or sub-assemblies are identified as follows:
• FPD-1120 Main Machine
• Tool box
• Hydraulic Power Unit (mounted on the machine)
• 2 Auxiliary Tables, 1 infeed and 1 outfeed
• Control Console
6.3 Support and Lifting Points
Some of the components of your system may contain lifting eyebolts, or holes for lifting eyebolts. For components lacking lifting
eyebolts, straps may be placed around the main frame parts.
Warning
The crane, ropes, chains, and lifting equipment used in moving the components
must be rated for the specified carrying force. Never walk under hanging loads.
REMOVE WOODEN SHIPPING FRAME FROM VALVE STACK PRIOR

TO LIFTING MACHINE FROM TRUCK. SEE 6.4.1.
CG1 CG2
1 2 3
XY Table
Main Machine Weight: 10,000 lbs (4536 kg)
Figure 6-1: Main Machine Lifting Points
If the XY table is attached to the main machine:

The center of gravity lies along the line labeled CG1. Insert the lifting hooks or straps through lifting holes 1 and 2.
If the XY table is not attached to the main machine:

The center of gravity lies along the line labeled CG2. Insert the lifting hooks or straps through lifting holes 1 and 3.
Use to lift only the drill

and Signoscript assembly
Figure 6-2: Drill & Signoscript Assembly Lifting Point
Chapter 6: Assembly 60
6.4 Positioning and Joining of Components
Caution
All Peddinghaus machines are shipped with a protective rust inhibitor applied to
all unpainted surfaces, bearing rails, and pistons on hydraulic cylinders. This
inhibitor must be removed before machine use. To remove, use mineral spirits,
kerosene-soaked cloths, or vapor degreasing techniques.
After unloading all of the components, position them in accordance with your general arrangement diagram. Do not anchor the
machine at this time.
6.4.1 Shipping Blocks

A wooden shipping frame is added to the machine prior to shipment to protect hydraulic valve stacks. Disassemble or remove this
frame before lifting the machine from the truck.
Shipping Frame;
remove prior to
lifting machine
Figure 6-3: Shipping Blocks
6.4.2 XY Table Installation

During most shipping circumstances, the main machine and the XY table are not connected.
Caution
Make sure that the Signoscript’s position will not interfere with the XY table
installation. Completely raise the Signoscript before installing the XY table.
To install the XY table:
• Using proper lifting equipment, raise the table
and lower it onto the 4 linear bearings. Position
the 4 linear bearings by sliding them along the
rails, and aligning the 4 mounting holes on each
bearing with the 4 mounting holes in the table.
Do not remove the bearings from the rails.
• Use a 6mm Allen Hex Key to tighten the 4 bolts
on each of the 4 linear bearings.
Example Linear Bearing Bolt
Locations
Figure 6-4: XY Table Installation
• Attach the XY table to the Ball Screw Nut

Bracket using the 2 SHCS M12x40mm long
screws provided and a 10mm Allen Hex Key.
Allow the Ball Screw to guide the Ball Screw Nut
Bracket into position, without additional force.
Using additional force may cause machine
misalignment.
Ball Screw Nut

Bracket Screws
Ball Screw
Figure 6-5: Ball Screw Nut Bracket Connection
• Then, attach the Y-axis cable track from the XY

table to the machine bracket, using the 2 SHCS
M6x12mm long screws provided and a 5mm
Allen Hex Key.
Y-axis Cable Track Screws
Figure 6-6: Y-axis Cable Track Connection
6.4.3 Hydraulic and Electric Connections
Once you have installed the XY table and made the Y-axis cable track connection, you must also reattach the material datum and
material clamps hydraulic connections before starting the machine for the first time.
To make the hydraulic connections:

• Use 11/16” and 9/16” hex wrenches to connect the hoses. Both hydraulic hoses have male-to-female fittings, to ensure proper
connection.
Hydraulic
Male Fitting Female Fitting
Connections
Figure 6-7: Hydraulic Hose Connections

8-pin Extension
12-pin Extension
To make the electrical connections:

• Match the 8– and 12-pin connectors—
the 8-pin connector uses only 4 pins,
and the 12-pin connector uses only 8
pins. Hand-screw the electrical
connections together.
To make the Eurofast Junction Box

connection:
• Match the labels on the panel signal
connections with the junction box
Junction Box
labels.
Labels
• Insert each connection into its
corresponding junction.
Panel Signal
Connection Labels
Figure 6-8: Electrical Connections
6.4.4 Optional Auxiliary Table Leveling
The machine and the optional auxiliary tables are both built to the same height; however, uneven flooring and other elements can
create a difference between the height of the machine’s X-axis table and the auxiliary tables. All of these tables must be aligned
and level to ensure proper machine functioning.
To level and align the auxiliary tables:

• Loosen the locking nuts on all four legs of
one of the tables using the 36mm hex
wrench provided.
• Turn the adjusting nuts until the table Locking Nut
reaches the desired height and is level.
• Tighten the locking nuts. Repeat this process
with the other auxiliary table. Adjustment Nut
• Use a mechanical or a laser level to ensure
that the auxiliary tables and the X-axis table
Leveling Pad
are aligned and level.
Figure 6-9: Auxiliary Table Leveling
6.4.5 Machine Paint Coverage

The color scheme of Peddinghaus Corporation systems includes several types of acrylic and acrylic enamel paints. Although it may
not be possible to achieve the same original factory paint appearance, the guidelines below may assist with any general repainting
that may be required:
• Primer applied to all painted surfaces—gray automotive-type primer

• Green paint applied to the machine’s main body—green automotive-type paint
• Orange paint applied to certain moving elements—orange automotive-type paint
• Coating applied over control console panels—clear urethane coating
• Black paint on high-temperature parts—1200° F (649° C) high temperature black paint
(The original machine purchaser may have specified a certain color or paint other than our standard.)
These paints were specifically selected for several reasons:

• The basic color scheme is for Peddinghaus Corp. product registration.
• The quality of the paint product creates an easily cleanable surface over all parts.
• The orange color is used to designate and draw attention to certain moving machine elements.
• The high-temperature black paint offers protection for certain components that operate at above-ambient temperatures. It is
also used where thin-coat paint protection is required.
If repainting is required, follow the original machine paint scheme, and refer to these guidelines:
• Orange machine elements should remain that color for general safety reasons.
• Use high-temperature paints where above-ambient temperatures are encountered.
• Do not allow paint to get into bushings, shafts, rotating or sliding mechanisms, or on guideways. Do not paint on grease fittings
or openings.
• Do not allow paint to get into electrical components, control buttons, limit or proximity switches, or switch light reflectors.
• Do not paint over any warning signs, labels, product information, control tags, instructions, or air filters.
• Paint should never interfere with the intended function of the machine or cause an unsafe operating condition.
6.4.6 Loctite
Fasteners are Loctited to assure proper and safe machine operation. The maintenance department should not neglect these
practices during the repair or reassembly of this Peddinghaus machine. Follow all instructions and safety precautions as stated by
the Loctite Corporation when using their products. Normal machine operation may loosen some fasteners, or maintenance may
require the removal of some fasteners. These may be reassembled with Loctite as follows:
• If the part has been previously Loctited, remove existing Loctite with a wire brush.
• For fasteners smaller than 1/4” thread, use Loctite #222 purple.
• For fasteners 1/4” thread and larger, use Loctite #242 blue. This includes hex, slotted, counter-sunk, flat head, and shoulder
bolts, and with fasteners into aluminum.
• For fasteners 1/4” thread and larger made of high strength alloy (such as UNBRAKO type), use Loctite #262 red if additional
maintenance sheets indicate that this type of Loctite should be used.
• Use pneumatic/hydraulic seal 545 to secure and seal air and hydraulic lines. Do not use Loctite seal 545 or PST on acetylene or
oxygen fittings—use Teflon tape.
6.4.7 Optional Structural Angle Clamping Jaws
Cap Angle FHCS 3/8-16 x 1 1/4

Fixture
Clamp Angle
Fixture
Plate Jaw
Fixture Short Jaw
Angle Fixture
Long Jaw
Angle Fixture
Shoulder Bolt
1/2 x 5/8
Shoulder Bolt
1/2 x 1/2 Figure 6-10: Angle Clamping Jaw Installation
To install the optional structural angle clamping jaws:

• Loosen and remove the 2 recessed 1/2 x 5/8 shoulder bolts at the base of a clamping jaw assembly.
• Remove the plate jaw fixture (already installed on the machine) and replace it with the clamp angle fixture.
• Fasten the clamp angle fixture with the (2) 1/2 x 1/2 shoulder bolts provided, and tighten them securely.
• Determine the necessary height of the mounting fixture, determined by the thickness of the angle to be processed (the
mounting fixture should firmly grip the angle). Install either the long jaw angle fixture, short jaw angle fixture, or cap angle
fixture (with the FHCS 3/8-16 x 1 1/4 screws), depending on the necessary height of the mounting fixture.
• Repeat this procedure with the other clamping jaw assembly.
• Determine and reposition each clamping jaw assembly to properly grip the angle section to be processed (see section 6.5.2 for
more information).
Warning
Avoid positioning the clamping jaws where they could interfere with punch
movement. A clamping jaw and punch collision will result in damage to machine
components and serious injury to personnel.
6.5 Adjustments
6.5.1 Punch and Die Alignment
The triple tooling punch, and the die block with the dies installed, should be aligned after every punch or die change, and before
starting any machine operation.
Socket-Head
Bolts
To align the punches and the die block:
• Loosen the 4 socket-head bolts on the die block.
• Move the die block to align the dies with the
punches.
• Verify the punch-die alignment (see section
4.2.2 for more information).
• Tighten the 4 socket-head bolts to secure the
die block in place.
Figure 6-11: Punch and Die Alignment
6.5.2 Material Clamp Adjustment

The clamping fixtures of this machine can be repositioned laterally. The program logic will dictate where the material clamps
should be placed.
To adjust the material clamps:

• Pull up on the black hold-down handles and
rotate counterclockwise to loosen them.
• Relocate the clamps by sliding them along the
slide to their correct locations; use the scale
along the top of the slide to determine the
correct location for each clamp.
• Turn the hold-down handles clockwise and
tighten to lock the clamps in place.
Clamp Hold- Slide Figure 6-12: Material Clamp Adjustment

Down Handles
If there is a gap between the lower jaw and the bottom face of the material, you must raise the lower jaw until it makes complete
contact with the material.
Set Screw
Jam Nut
To adjust the clamp lower jaw:
• Loosen the jam nut located on the top of the
material clamp.
• Turn the set screw clockwise until the lower
jaw contacts the bottom of the material.
• Tighten the jam nut to lock the set screw in
place.
Material Gap
Figure 6-13: Clamp Lower Jaw Adjustment
6.5.3 Punch TOS, BOS, and Layout Mark Adjustment

Peddinghaus technicians set these prox switches before shipping; they should not be tampered with. If you need to adjust these
switches, first contact the Peddinghaus Service Department for more detailed instructions and assistance.
BOS Actuator
BOS Prox Switch
To adjust the punch TOS (Top of Stroke) and BOS

(Bottom of Stroke) motions:
• Loosen the 2 jam nuts on the appropriate prox
switch.
• Move the prox switch up or down until the full
desired stroke of the punch is registered. Figure 6-14: Punch BOS Prox Switch Adjustment
• When the switch reaches the correct position,
lock it in place by tightening the 2 jam nuts on
the switch.
TOS Prox Switch
Figure 6-15: Punch TOS Prox Switch Adjustment
The punch uses the layout prox switch when the punch is used as a marking tool. The layout mark prox switch should be adjusted
to accommodate varying material thicknesses.
Layout Mark Actuator Disc
Layout Mark Prox Switch
To adjust the punch layout prox switch and use the

punch as a marking tool:
• Load the material, and stroke down the punch
stripper until it makes contact with the top of
the material.
• Loosen the layout mark actuator disc’s set
screw.
• Rotate the actuator disc to move it down until
the tip of the punch penetrates the top of the
material (see diagram below). Each half
rotation roughly equals .021” height change.
• Tighten the set screw to lock the actuator disc
in place. Figure 6-16: Punch Layout Prox Switch Adjustment
Punch
1.00”
0.75”
0.50” Material
0.25”
6.5.4 XY Table Home and Over-travel Prox Switch Adjustment
To adjust the home and over-travel prox switches:

switch.
• Move the prox switch left to right, or left to
right, until the X-axis stops at the desired
position.
the switch.
Home Reference Prox Switch
Over-travel Prox Switch
Figure 6-17: XY Table Home and Over-travel Prox Switch Adjustment
6.5.5 Y-axis Travel Prox Switch Adjustment

Y-axis Maximum Travel Prox Switch
To adjust the Y-axis prox switches:

switch.
• Move the prox switch left to right, or left to
right, until the Y-axis stops at the desired
position.
the switch.
Y-axis Over-travel Prox Switch
Y-axis Home Prox Switch
Figure 6-18: Y-axis Travel Prox Switch Adjustment
6.5.6 Hydraulic Drill Full Retract Position Adjustment
To adjust the drill full retract position:

• Loosen the 2 jam nuts on the full retract prox
switch.
• Move the prox switch up or down until the full
stroke of the cylinder is obtained.
the switch.
Full Retract Prox Switch
Figure 6-19: Drill Full Retract Prox Switch Adjustment
6.5.7 Gag Cylinder Switch Adjustment

The built-in hall effect switches indicate the full extend and full retract positions of the gag cylinders.
Full Retract Hall

Effect Switch
Full Extend Hall

Effect Switch
Figure 6-20: Gag Cylinder Switch Adjustment
6.6 Dismantling, Disposal, and Reassembly
Dismantling
If dismantling the machine to make a repair, take careful note of how parts fit together to aid in the reassembly process.
Warning
When dismantling any part of the hydraulic system, make sure all pressure is
relieved from the system prior to removing any components. Cylinders may drift
down due to gravity after the hoses are removed.
If the machine is taken out of commission and is to be scrapped, all hazardous components, including environmentally hazardous
material, must first be removed and disposed of properly according to local regulations. Care should be taken to sort the
components by the material types.
Material Disposal
Category Hazardous Material Use / Location
Lead (Solder)
Circuit Boards Inside Control Console
Microchips
Hydraulic Hoses Rubber All hoses to cylinders and valves
Hydraulic Reservoir
In Hydraulic Hoses
Hydraulic Fluid Oil
In Hydraulic Cylinders
In Hydraulic Manifolds
Molybdenum Disulfide Grease Sliding Grease Surfaces
Lubricants
Lithium Grease Bearings
Wiring Plastic Insulation All Electrical Wires
Hydraulic Valves
Misc. Electrical Solenoids
Switches
Disposal
Hazardous materials should only be disposed of in a way that is not harmful to the environment. All local regulations must be
followed.
Reassembly
Extreme care must be used for reassembly of components on your machine. All surfaces containing grease must be cleaned off and
coated with new grease. If you need any assistance during reassembly, contact the Peddinghaus Corporation Service Department.
7.0 Installation
7.1 Installation Requirements
Refer to the General Arrangement Diagram (included along with the Peddinghaus price quote) for installation requirements and
foundation guidelines.
Note
Foundation Work is not included in the Peddinghaus scope of delivery.
Check the General Arrangement Diagram and local codes for installation specifications and standards.
Environmental Requirements
Generally, this machine should be installed only under the following conditions. If all of these conditions cannot be met, contact
Peddinghaus Corporation to discuss the discrepancies and how they will affect the machine.
• Supply Voltage: 95% to 105% of nominal supply power voltage

• Source Frequency: ±2 Hz of nominal
• Ambient Temperature: 41° F (5° C) to 104° F (40° C)
• Relative Humidity: 90% or lower (no condensation)
• Altitude: Up to 3,280 ft (1000 m) above mean sea level
• Atmosphere: Free from excess dust, acid fumes, corrosive gases, and salt
• Avoid direct sunlight and/or heat rays, which could alter the ambient temperature of the machine
• Do not expose the machine to abnormal vibration. Vibrations generated by the machine are considered normal and must not
be exceeded.
7.2 Required Installation Materials and Tools

The General Arrangement Diagram lists all materials needed for installation of your machine. Most materials required will be
shipped with the machine; however, you may need to provide some of the materials yourself.
The power unit will be shipped without hydraulic oil; you will need to supply your own oil. The General Arrangement Diagram will
indicate how much is needed for the installation.
You are also required to supply the anchor bolts for your system. The required size and quantity will be indicated on the General
Arrangement Diagram.
You will need the following tools to complete the installation:

• Sight Level (optical transit)
• Power hammer drill, with bit for anchor bolts
• Allen wrenches
• Hydraulic fluid
7.3 Installation Procedures
7.3.1 Electrical Connection
The system location and alignment must be checked by a Peddinghaus Service Technician before any electrical connections are to
be made. At that time, it may only be connected by an electrician. The connection must be made according to the electric
schematics included in the instruction packet. All Federal regulations and any special regulations of your local supplier must be
observed.
Caution
Compare the operating voltage of the system to the available main voltage. The
operating voltage of the system can be found on a label on the switching
cabinet, located on the hydraulic power unit. The voltage noted is phase-to-
phase (i.e., the voltage between the phases L1-L2-L3). The phase-to-phase
voltage must not exceed the maximum permissible value of 480 VAC ±5%.
The machine is designed to operate at 480 VAC by adjusting the primary taps on the supply transformer. If other voltages are
desired, an optional step-up or step-down transformer will be required.
7.3.2 Fusing on the Construction Site and Supply Lines

The fusing and the supply lines on the construction side must be provided and installed by an electrician according to the layout.
All Federal regulations and any special regulations of the local supplier must be observed.
The supply line for a connected load must have sufficient connection length above the floor at the location marked in the layout. A
good earth ground is required to achieve satisfactory operation of PC/CNC systems in an industrial environment. Refer to Federal
and local regulations for acceptable grounding procedures. See the following figure for the grounding location of this machine.
Warning
Do not energize power to the electrical cabinet until the Peddinghaus Service
Technician has checked the installation. This machine must be installed in
compliance with all appropriate local and international codes.
Chapter 7: Installation 74
Supply and Ground
Connection
(Main Power Disconnect)
Figure 7-1: Power Unit Electric Enclosure
7.3.3 Hydraulic Connections

Peddinghaus technicians make all hydraulic connections before the machine is shipped. No extra connections are required.
Caution
This machine is designed to use petroleum-based hydraulic fluid, which is
flammable. Check applicable local fire codes for special precautions you will
need to take when working with the hydraulic system.
7.3.4 Pneumatic Connections

Peddinghaus technicians make all pneumatic connections before the machine is shipped. No extra connections are required.
Pneumatic Connections
Figure 7-2: Pneumatic Connection
7.4 Assembly and Installation Inspection
Once you believe you have the machine assembled correctly and approximately in place (but not anchored), contact Peddinghaus
Corporation to have a Service Technician come out and complete the installation of your machine. He will first ensure that the
electrical power to the system is hooked up correctly. He will then check to ensure the machine is aligned correctly. Once the
machine is in place, and the alignment is approved, the machine can be anchored to the foundation and installation can be
completed.
Chapter 7: Installation 76
8.0 Packaging & Storage
8.1 Packaging Requirements
When packaging your machine for storage or transport, the packaging should be secure and neither it nor any part of the machine
should be allowed to move. Extra care must be taken to ensure the machine is not damaged. The machine should be protected
from moisture.
8.2 Methods of Handling

Exercise extreme care when handling your machine. It is a precise machine and any mishandling can cause a loss of accuracy.
Most components of your system are too heavy to be lifted by hand; therefore, additional equipment should be used. A crane is
recommended for lifting and moving the components of your system. A forklift may be used for some components, but only if it
can be done so safely.
Refer to the Assembly chapter for lifting data and points on this machine.
8.3 Protection from Unwanted Movement

To prevent damage to the machine or injury to those working on or around the machine, protect the machine from sudden impacts
and unwanted movement.
All moveable parts should be blocked or secured to ensure that they don’t move during transport or in storage. Use the red
shipping blocks that originally came with the machine to hold all movable parts in place.
8.4 Labeling
All packages and components should be identified with a label to ensure no parts are lost. In addition, all dangerous and
hazardous objects should be labeled appropriately.
8.5 Storage Requirements

Store the machine in a low-humidity environment to prevent rust from forming. We recommend a protective coating be applied to
all exposed metal surfaces to prevent rust formation.
Do not store your system outside. Only store it indoors where it will be protected from moisture and natural elements.
Drain the hydraulic reservoir to prevent spillage.
Store all encoders and linear rails far from magnetic material.
8.6 Storage Space
132.50 inches (3366 mm)
116.75 inches (2965 mm)
127.25 inches (3232 mm)
Figure 8-1: Main Machine Storage Space
59 inches (1499 mm)

40 inches (1016 mm)
60.25 inches (1530 mm)
Figure 8-2: Auxiliary Table Storage Space
Chapter 8: Packaging & Storage 78

9.0 Basic Machine Operation
9.1 Siemens CNC Control General Information
The Siemens 840Di CNC control is a VERY robust system. A detailed explanation of its many facets far exceeds the scope of this
manual. This manual will try to provide a brief and simple explanation of a few basic concepts needed for general operations. A
complete listing of features w/ descriptions can be found in the supplied Siemens documentation.
One general concept that all 840Di users need to understand is the concept of system memory. The 840Di is a PC based system
complete with a PC type hard disk. There is plenty of extra hard disk space (HD memory) that can be used for part program
storage. In addition, the 840Di has an extra system card not found on a normal PC that provides additional electronic RAM memory
for part program storage and execution. This additional memory is referred to as NC memory. Generally, a part program must be
loaded in NC memory before it can be selected as the active program and executed by the machine.
The Siemens HMI (Human Machine Interface) software treats HD memory and NC memory as one large “virtual” storage container.
The HMI provides the tools to copy, rename and delete program files as well as move them from HD to NC and NC to HD. The only
way to distinguish whether a part program is located in NC memory vs. HD memory is the “Loaded” column in all part program
listings. If an “X” appears in the “Loaded” column the part program is located in NC memory, otherwise the part program is
located in HD memory.
This “dual memory” concept can cause problems for “normal” software applications (such as Peddinghaus’ Peddimat programming
system) that “see” only the HD memory and cannot “see” the NC memory. Example: If a part program is located in NC memory and
Peddimat creates a new part program with the same name in HD memory, there is now a conflict. The HMI will represent this by
displaying an “!X!” in the “Loaded” column in all part program listings. If this situation occurs the 840Di will not allow either of
these part programs to be selected and executed. To correct the conflict the normal HMI tools must be used to delete the file,
which will in fact delete only the part program located in NC memory, leaving the part program in HD memory.
Figure 9-1: Machine Control Panel
Chapter 9: Basic Machine Operation 80

9.2 Operating Modes
The Siemens CNC has 4 different main operating modes that can be selected via appropriately labeled buttons on the machine
control panel. This manual will discuss 3 modes. The 4th mode, “Teach In”, is beyond the scope of this manual:
“JOG” - Manual movement of the machine
“MDI” - Manual creation and execution of programs
“AUTOMATIC” - Execution of programs in a continuous cycle
9.3 Jog Mode

Enter Jog mode by pressing the “Jog” button on the machine control panel. Jog mode has two optional sub-modes: “Repos” & “Ref
Point” - that are available via buttons located to the right of the “Jog” button. “Repos” is used to make manual incremental axis
moves, and “Ref Point” is used to perform manual axis referencing.
To jog an axis manually while in Jog mode:

• Make sure neither sub-mode (Repos or Ref Point) is active by looking at the indicator lamps above the sub-mode buttons. If a
sub-mode is active, press the “Jog” button a second time.
• Next, select the desired axis by pressing the appropriate axis button on the machine control panel.
• Jog the axis by pressing and holding the “+” & “-“ buttons on the machine control panel. To jog at a faster pace,
simultaneously press the “Rapid” button.
9.3.1 Jog Mode—Repos (Incremental Axis Move)

To jog an axis by specific increments:
• Enter Jog mode by pressing the “Jog” button on the machine control panel.
• Select the desired axis by pressing the “X” or “Y” button on the machine control panel.
• Select the desired incremental distance by pressing one of the pre-set distance buttons labeled 1,10,100,1000,10000 (all
distances are in thousandths of millimeters, so 1000 equals one millimeter).
• Last, press the “+” or “-“ button. The axis will move the desired distance in the desired direction.
To move a variable distance:

• Press the “VAR” button.
• Next (with the “Machine” operating area active) set the desired distance by pressing the “INC” softkey, entering a value (in
thousandths of millimeters), and pressing the “Input” key followed by the “+” or “-“ button.
9.3.2 Jog Mode—Ref Point (Manual Axis Reference)

To reference an axis:
• Enter Jog mode by pressing the “Jog” button on the machine control panel.
• Press the “Ref Point” button on the machine control panel to enter the Ref Point sub-mode.
• Select the desired axis by pressing the “X” or “Y” button on the machine control panel.
• Press and release the “-” button on the machine control panel. The axis will then reference.
9.4 MDI Mode
Enter MDI mode by pressing the “MDI” button on the machine control panel (“MDA” button on early versions). If the “Machine”
operating area is active a small editable window titled “MDI” will appear in the lower left quadrant of the display. Programs of any
type can be manually entered and executed here. Program execution is identical to Automatic mode with normal use of the Cycle
Start, Cycle Stop, and Single Block buttons.
An advanced level of understanding of Siemens NC language and machine functionality is required to write fully functional part
programs in MDI mode. This is not recommended. However, only a basic understanding of machine functionality is required to
perform some basic operations.
9.5 Automatic Mode

Enter Automatic mode by pressing the “Auto” button on the machine control panel. Refer to the Peddinghaus HMI software manual
(YD2312997) for a complete description of the HMI and this particular window.
9.5.1 Part Program Selection

Please see Peddinghaus HMI Software Manual YD-2312997 in regards to selecting a part program in Automatic Mode.
9.5.2 Load HD » NC
Please see Peddinghaus HMI Software Manual YD-2312997 in regards to sending a part program from the hard drive to the NC in
Automatic Mode.
9.5.3 Unload NC » HD
Please see Peddinghaus HMI Software Manual YD-2312997 in regards to sending a part program from the NC to the hard drive in
Automatic Mode.
9.5.4 Start Cycle

In Automatic mode, regardless of what operating area is active, pressing the “Cycle Start” button on the machine control panel
will cause the machine to start execution from the current block.
9.5.5 Stop Cycle

In Automatic mode, regardless of what operating area is active, pressing the “Cycle Stop” button on the machine control panel will
cause the machine to stop execution at the current block.
9.5.6 Single Block Execution

In Automatic mode, regardless of what operating area is active, pressing the Single Block button on the machine control panel will
cause the machine to stop execution at the end of each block. Press Cycle Start to start the execution of the next block. Press the
Single Block button a second time to return the control to full automatic execution.
Chapter 9: Basic Machine Operation 82

10.0 Machine Operations
10.1 Manual Pushbuttons
10.1.1 Power On
Use the lighted “Power On” button located between the Display Screen and the Machine Control Panel to reset the E-stop circuitry
(hardware safety relays) after an E-Stop. Use additional machine control panel buttons to clear remaining NC faults.
10.1.2 E-stop Buttons

Pressing any one of these buttons will immediately switch power off to the machine in the event of an emergency.
To restore machine functions after an E-stop event:

• Clear all “tripped” E-stop switches by either pulling firmly on the button or by giving it a slight twist, depending on the switch
type.
• Press the “Power On Reset” button.
• Press and hold the “Fault” button until its lamp goes off.
• Press the “Reset” button.
Note
It is not possible to fully recover from an E-stop event that occurs while processing a part
program in Automatic mode.
10.1.3 Fault
Press to clear most normal status and error messages, including safety curtain and E-stop events. Some events require more steps
and buttons to clear messages.
10.1.4 Hydraulic Pump

Press once to turn the hydraulic pump on, and again to turn it off. The light above the button will indicate the pump status.
10.1.5 Tool Mode

Use this button to select the current tool mode for all tools. The first button press will always select “Off Mode”; subsequent
presses (within 3 seconds) will toggle through the remaining modes. When a new tool mode is selected, a notification message will
display briefly on screen. The LED above the pushbutton also indicates the active tool mode.
• Auto mode (LED on) - All tools function normally.

• Off mode (LED off) - All tool commands are ignored. In addition, entering “Off Mode” from any other mode will cause the
tooling to retract fully.
• Mark mode (LED flashes twice each second) – Drills and Punches will mark the material, the Signoscript will operate normally.
• Test mode (LED flashes once each second) – Drills and Punches will extend for a short time to indicate each start command
and all other tools are ignored.
10.1.6 Work Position Switch Override

Use this pushbutton to simulate the spindle work position switch. Use this button for troubleshooting and machine adjustment
only. There is never a need to press this switch during normal machine operation.
10.1.7 Material Clamp
These buttons, located on the machine control panel and on the machine itself, can be used to pinch and release the material
clamp on the duplicator. The indicator light above the machine control panel button will be on if the material clamp is activated.
10.1.8 Punch Strip + and -

Use these buttons (located on the machine control panel) in Jog Mode to jog the punch stripper up or down. These buttons, along
with the Punch Tool + and – buttons, help align the tool with the die. The hydraulic pump must be on in order for these buttons to
work.
10.1.9 Punch Tool + and -

Use these buttons (located on the machine control panel) in Jog Mode to jog the punch tools up or down. These buttons, along
with the Punch Strip + and – buttons, help align the tool with the die. The hydraulic pump must be on in order for these buttons to
work.
10.1.10 Spindle Jogging

Use this button (located on the machine control panel) in Jog Mode, along with the Jog Plus key, to rotate the spindle manually in
the positive direction. Use this button only to ensure correct spindle function—do not use during operation.
10.1.11 Spindle Start

Use this button (located on the machine control panel) to activate the drill assembly. This button must be pressed before any
drilling is attempted.
10.1.12 Feed Override Turn Dial

Use this dial to override the feedrates of the X– and Y-axes. Set the dial at 100% for standard operational speeds for both axes.
Chapter 10: Machine Operations 84

11.0 General Configuration Parameters
There are a number of parameters that can be adjusted or monitored using the Peddinghaus HMI. Please see Peddinghaus HMI
Software Manual YD2312997 for a complete description of the HMI. Below are descriptions of some of the parameters used in the
FPD1120 Duplicator.
11.1 Parameter Screen

11.1.1 Miscellaneous Parameters
• X-axis Reference Position (mm) - the value at which the X-axis will be set after the axis has been referenced.
• Y-axis Reference Position (mm) - the value at which the Y-axis will be set after the axis has been referenced.
• Default Dimension Mode (2=mm, 3-inches) - indicates whether the axis measurements will be displayed in millimeters (2) or
inches (3).
11.1.2 Hydraulic Pump
• Pump Ramp up Time (ms) - the time after the hydraulic pump is turned on before the idle pressure is set.
• Initial Starting Pressure (0v—10v) - the initial pressure of the hydraulic pump before the hydraulic pump is turned on. Normally
set to 0v.
• Idle Pressure (0v—10v) - the pressure of the hydraulic pump after the pump is turned on and the ramp time has been met.
• Punching Pressure (0v—10v) - the pressure of the hydraulic pump after the pump is turned on, the ramp time has been met,
and a punch command has been issued. This pressure is usually set at the highest available value.
• Drilling Pressure (0v—10v) - the pressure of the hydraulic pump after the pump is turned on, the ramp time has been met, and
a drill command has been issued.
11.1.3 Punch
• Test Time (ms) - in test mode, the punch operations will produce only a small movement. The time set here determines the
amount of movement the punch will be allowed to move.
• Gauge Time (ms) - the amount of time allowed before an error message appears to indicate the gauge device is faulty. The
time measurement begins when a punch command is first issued.
• Stripper Time (ms) - the amount of time allowed for the stripper to come up after the start of the punch return.
• Oil Enable (1=On, 0=Off) - the setting that enables or disables the punch oilers.
• Oil Time Duration (ms) - the duration of a punch lubrication action.
• Oiler Interval—the number of times the punches are lubricated. The smaller the number, the more frequent the lubrication
(example: if the Oiler Interval is set to 3, the punches will be lubricated on every third commanded punch).
• Punch1Current Count—keeps track of the number of the punch1 commands within a part program. This value can be reset to 0
by the operator.
• Punch1 Total Count—the number of times the punch1 is used on the machine. This value cannot be reset within the standard
operator access level.
• Punch2 Current Count—the number of the punch2 commands within a part program. This value can be reset to 0 by the
operator.
• Punch3 Current Count—the number of the punch3 commands within a part program. This value can be reset to 0 by the
operator.
11.1.4 Reposition
• Reposition Stripper Down Time (ms) - the amount of time allowed for the stripper to move downward after the command to
start reposition is given.
• Reposition Stripper Up Time (ms) - the amount of time allowed for the stripper to move upward after the command to stop
reposition is given and the Clamp Close Time has elapsed.
• Reposition Clamp Open Time (ms) - the amount of time allowed for the clamp to open after the command to start reposition is
given and the Stripper Down Time has elapsed.
• Reposition Clamp Close Time (ms) - the amount of time allowed for the clamp to close after the command to stop reposition is
given.
11.1.5 Drill
• Drill Enable (1=On, 0=Off) - enables or disables the drill option for the FPD1120 Duplicators that have the optional drill
attachment
• Drill Coolant Enable (1=On, 0=Off) - enables or disables the drill coolant
• Lubrication Frequency (ms) - determines the duration of each coolant pulse. The greater the number, the longer the pulse.
• Air Off Delay Time (ms) - the amount of time before the air supply shuts off after the drilling latch has been released.
• Drill Count Total—the number of times the drill is used on the machine. This value cannot be reset within the standard
• Drill Count Current—the number of the drill commands within a part program. This value can be reset to 0 by the operator.
• Drill Feed Override (0% - 120%) - adjusts the programmed feedrate of the drill.
• Drill Test Time (ms) - the amount of time the spindle will extend/rotate during a drill cycle when the tool mode is set at
“Test”.
• Drill AntiBounce Time (ms) - the amount of time at the beginning of a drill cycle when the machine ignores the work position
switch.
• Drill Mark Time (ms) - the amount of time the spindle will continue to move forward after the position prox switch is activated
during a Mark cycle. Increase the parameter to make larger marks, and decrease the parameter to make smaller marks.
• Drill Stripper Down Time (ms) - the amount of time allowed for the drill stripper to move downward before the drill spindle
extends.
• Drill Stripper Up Time (ms) - the amount of time allowed for the drill stripper to move upward after the drill spindle has
reached its home position.
• Drill Feed Rapid Advance (%) - the percent of rapid feed used as the spindle approaches the material during a drill cycle.
• Drill Work Speed Calibration—a multiplier used to finely adjust the spindle speed in order to match the requested feed and the
actual feed. Increase the number to increase the actual feedrate, decrease the number to decrease the actual feedrate.
• Drill Feed Rapid Return (%) - the percent of rapid feed used as the spindle retracts after a drill cycle.
11.1.6 Drill RPM
• volt50 (%) - volt850 (%)

Use this screen to adjust the spindle speed calibration parameters used by the machine’s PLC during machine operation. All data is
entered in percentages. These parameters rarely need to be adjusted—only do so when instructed by an authorized Peddinghaus
technician.
Note
Spindle load (and therefore, RPM) can change slightly, depending on the material being
processed and tooling variations.
Chapter 11: General Configuration Parameters 86

11.1.7 Signoscript
• Signoscript Enable (1=On, 0=Off) - enables or disables the optional Signoscript attachment.
• Signoscript Park Time (ms) - the amount of time it takes the Signoscript to fully retract to the top of its stroke and to turn off
the motor.
• Signoscript Mark Time (ms) - the amount of time it takes the Signoscript to extend and to turn on the motor.
• Signoscript UnMark Time (ms) - the amount of time it takes the Signoscript to move between marking characters.
11.2 Monitor Screen
11.2.1 Spindle
• Drill Current Count—the number of the drill commands since the count has last been reset.
• Drill Count Total—the number of times the drill has been used for the life of the machine (or since the time of its last reset).
• Drill Feed Override (%) - adjusts the programmed feedrate of the drill.
• Drill Prog-Feedrate (mm/min) - monitors the drill feedrate set by a part program.
• Feed Rate Override (mm/min) - monitors the drill feed override.
11.2.2 Spindle RPM
• Drill Programmed RPM (rpm) - monitors the programmed RPM from a part program
• Master RPM Override (%) - monitors the RPM override (seen from the dial on the machine control panel).
• Recalculated RPM w/Override (rpm) - monitors the new calculated RPM of the drill, based on the override and programmed
RPMs.
• Drill High Speed—monitors the high speed shift. When the RPM exceeds 400, the indicator should show “1”.
Chapter 11: General Configuration Parameters 88

12.0 Access Levels
There are 3 main password-protected access levels in the Siemens 840Di control. They range from low to high: User, Service, and
Manufacturer. Certain screens and functions are hidden from lower access levels. In reality, there are four additional access levels
all lower than “User” that are determined by the keyswitch on the machine control panel. Peddinghaus has chosen not to use these
access levels. Anyone operating the machine should be at access level “User” as a minimum. The Siemens access level / password
concept and the softkey labels can be confusing and it is important for anyone with an access level higher than “User” to
understand the concepts and labeling of the access levels.
12.1 Access Level Retention

Unlike a normal computer password scheme, the Siemens 840Di control does not forget the current access level when it is shut
down or rebooted, nor does it require a password when the control is restarted. If the control’s access level is “Service” when the
control is shut down or rebooted, it will restart in access level “Service” without the needing the operator to re-enter a password.
Due to this methodology, the person that raises the access level is responsible for lowering the access level when they are finished
with their tasks.
12.2 Determining Current Access Level

• Enter the Start-Up operating area by pressing the “Menu Select” (Area Switchover) button, followed by the “Start-Up” softkey.
• The current access level will appear near the bottom of the screen.
12.3 Raising the Access Level

• Press the “Password…” softkey.
• Press the “Set Password” softkey.
• Enter the password for the higher access level using the alphanumeric keys.
• Press the “Input” key.
12.4 Lowering the Access Level

Unlike raising the access level, you cannot directly lower the access level by simply entering the appropriate password. Instead,
the current password must be “deleted”, and a new one established.
• Press the “Delete Password” softkey. The access level is now reduced to the keyswitch level, and will need to be raised for
machine operation.
• Follow the instructions for raising the access level to establish the new password.
12.5 Changing Passwords
The standard passwords are set by Siemens— Peddinghaus does not change them. If the machine owner decides to change the
passwords and subsequently loses the passwords, Peddinghaus will NOT be able to recover them without a paid visit by a service
technician. For this reason, Peddinghaus HIGHLY recommends keeping the verbally supplied password for access level “Service”
unchanged and strictly confidential. As a rule, Peddinghaus maintains the password for “Manufacturer” access level as private.
If it becomes necessary to change a password:

• Press the “Change Password” softkey.
• On the newly displayed screen, select which access level’s password you wish to change. Only the current access level and
lower levels can be selected.
• Enter the new password using the alphanumeric buttons.
• Confirm the new password and press the “OK” softkey.
The default password for the “User” access level is CUSTOMER
Chapter 12: Access Levels 90

13.0 Additional Installed Programs
In addition to the standard Siemens control software, Peddinghaus also offers several other pieces of software that can be used
when necessary. Some of these applications may only be available at access levels higher than “User”.
13.1 Peddimat Programming System

The Peddimat Programming System is used for the viewing/editing of parts and the creation of part programs. It can be accessed
by pressing the “Menu Select” button, followed by the “Peddimat” softkey. Peddimat can be used at any time, even during part
program execution. Peddimat contains it’s own built in help system and tutorials.
13.2 Updating Peddimat
On occasion it may become necessary to update the version of Peddimat running on the Siemens control. This is accomplished by
placing the update diskette in the diskette drive, pressing the “Menu Select” button, followed by the “ETC” (>) button and finally
the “Peddimat Update” softkey. Follow the on-screen instructions until complete.
Chapter 13: Additional Installed Programs 92

13.3 Step7 PLC Program
The Siemens Step 7 program is used to view/monitor/edit the PLC program running on the machine. Step 7 is a very robust
application with its own documentation and help system, and even its basic use beyond the scope of the manual. Siemens offers
several classes in Step 7 use, and Peddinghaus highly recommends them before attempting to use Step 7 in any capacity.
Chapter 13: Additional Installed Programs 94
14.0 NC Code Listing
Axis Assignments
Material Length X
Punch Gauge Y
Single Tool Machine

Punch M20
Layout M23
Triple Tool Machine

Tool1 (offset –2.375” in X-axis from Punch2) M20
Tool 2 (center tool) M21
Tool3 (offset –2.375” in X-axis from Punch2) M22
Layout with Tool2 M24
Punch Coolant Purge (used in MDA mode only, press MCP Reset to stop) M28
Clamp
Reposition Start (lowered stripper and open clamps) M25
Reposition Stop (closed clamps and raised stripper) M26
Signoscript
On M10
Off M11
Park M9
Drill Spindle
Drill M12
Coolant Purge (used in MDA mode only, press MCP Reset to stop) M27
Miscellaneous Program Codes

Program Stop M00
Alternative End of Program M02
End of Program M30
Traverse Mode G00
Linear Interpolation G01
Clockwise Circular Interpolation G02
Counterclockwise Circular Interpolation G03
Inch Mode G700
Metric Mode G710
Absolute Mode G90
Incremental Mode G91
Reference G74X0Y0
Chapter 14: NC Code Listing 96
Peddinghaus Corporation
300 North Washington Avenue
Bradley, Illinois 60915
(815) 937-3800 ◦ (800) 786-2448 (Toll Free)
(815) 937-4003 (Main Fax) ◦ (815) 937-4146 (Service Fax)
www.peddinghaus.com
Training, Service, and Support

The Service Technician provides a limited amount of training at the time of installation. Refer to the sales quote for more
information about the standard training. Different types of training are provided, such as operator training, supervisor training,
maintenance training and safety. Additional training is also available from Peddinghaus.
For questions regarding training options, obtaining service for your machine, or if you have questions regarding your machine,
contact the Peddinghaus Service Department.
Peddinghaus Service Department

Immediate assistance available Monday-Friday, 7:00 am to 5:00 pm CST
Phone: (815) 937-3800, Extension 328
Fax: (815) 937-4146
Online Assistance and Request Forms:

http://www.peddinghaus.com
http://www.peddinghaus.com/contactus.asp
For questions regarding particular parts of your machine or spare parts, contact the Peddinghaus Inside Sales / Parts Support
Department.
Peddinghaus Inside Sales / Parts Support

Phone: (815) 937-3800, Extension 259
Fax: (815) 937-4779
Visit us at www.Peddinghaus.com

FPD-1120 Instruction Manual V2 R1 (1-20-2016)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FPD-1120 Instruction Manual V2 R1 (1-20-2016)

Uploaded by

Copyright:

Available Formats

FPD-1120

Safety ◦ Installation ◦ Maintenance ◦ Repair ◦ Operation

Instruction and Control Manual

Peddinghaus Corporation is proud to be serving the steel construction,

Peddinghaus is dedicated to engineering expertise

To discover the many ways that we can help you

© Peddinghaus Corporation, 2008

2.0 Machine Components

4.0 Maintenance & Troubleshooting

iii Visit us at www.Peddinghaus.com

5.0 Spare Parts

II: Control Unit

10.0 Machine Operations

11.0 General Configuration Parameters

13.0 Additional Installed Programs

14.0 NC Code Listing

Appendix I: Peddinghaus Services

vii Visit us at www.Peddinghaus.com

Perimeter Light Guard

E-stop Push Button

Main Power Disconnect

Figure 1-1: Safety Features

1.4 Environmental Safety Features

1.5 Closed Circuits

To lockout/tag-out the machine:

Figure 1-2: Lockout/Tag-out Procedure

Figure 1-3: Airborne Noise Emission

1.10 Conditions for Safe Use

Hydraulic system work may only be performed by experienced hydraulics personnel.

1.11 Personnel Qualifications

Punch Slug Chute

Drill Feed Cylinder

Figure 2-1: Main Machine Components

Chapter 2: Machine Components 10

Figure 2-2: Axis Definition

Figure 2-3: Control Panel

Figure 2-4: Control Console

Chapter 2: Machine Components 12

24V Power Supply X- & Y-axis Servo

X- & Y-axis Servo

Fuse/CB Block Safety/E-stop Relays

24V Power Supply

Figure 2-5: Main Machine Electrical Cabinet

3.2 Preparation Prior to Start-up

When initiating start-up of your machine:

To shut down the machine:

3.3.2 Safety for Special Operational Modes

Always safeguard the area of maintenance.

Inspection/ Maintenance Intervals

Check for oil and grease spills ◊ 4.2.1

Inspect tooling for chips and worn

Check Signoscript cutter sharpness

Change hydraulic oil ◊ ◊ 4.5.1

Replace supply and return filter

Check oil filter status indicators ◊ 4.2.3

Check the functions of the operating

Check and adjust the control and

Check electrical lines for mechanical

Check the shaft encoder attachment

Clean computer screen & keyboard ◊ 4.4.3

Check the drill coolant reservoir ◊ 4.2.6

Check the mist lubricator ◊ 4.3.3

Check pneumatic air filter ◊ 4.3.3

Check tubing for damage ◊ 4.3.3