Continental Refrigerator PC150 Manual de usuario
2PC150 Operators Manual
2
PC150 Operators Manual
Perma-Crimp™ Hydraulic Hose Crimpers
PC150 Double Angle Die Crimper
Operators Manual
Including PC150-1 and PC150-2
www.contitech.us
PC150 Operators Manual 1
Proper assembly of Continental ContiTech hose and ittings
Continental ContiTech hose, ittings and crimping equipment work together to provide an eicient and reliable hose connection.
Continental ContiTech hose and ittings are part of an engineered system and are to be used in accordance with Continental
ContiTech speciications. Using non-Continental ContiTech components may produce an assembly that does not meet rated
performance. Continental ContiTech does not warrant, expressly or by implication, hose assemblies that do not incorporate
Continental ContiTech hose and ittings, or are not crimped in accordance with Continental ContiTech process speciications.
Buyers may elect to attach additional or non-standard parts or equipment, or to use diferent manufacturing speciications as
necessary to meet the requirements of the buyer or the customer’s application. In such cases, the buyer has sole responsibility to
qualify the hose for the applications as necessary to ensure performance capability.
For guidance in the assembly of Continental ContiTech hose and couplings, please refer to the Continental ContiTech Crimp
Speciications Manual. Information in this catalog is believed to be accurate, but is not warranted and is subject to change
without prior notice. For the most current product information, check the Continental ContiTech website at www.contitech.us.
For technical assistance, call customer service at 18002354632.
Rev Date: 8/2014
Table of Contents
Component Identiication 2
Crimper Quick Start Guide 3
Calibration Instructions 4
Crimping Procedure 5
Additional PC150 Features 7
Troubleshooting 8
Part Numbers 9
Warranty 10
Equipment Warning
2PC150 Operators Manual
PC150 Component Identiication
Double Angle Top Compression Ring
Double Angle Die Set
Double Angle Base Ring
Standard Compression Ring
Standard Die Set
Standard Pressure Plate
80 Ton Hydraulic Cylinder
Removable Pusher
Adjustable Ram
Retraction Stop
Micrometer
Calibration
Adjustment Screw
Power On/Of
Circuit Breaker Switch
Automatic Stop Switch Manual Pneumatic
Start/Stop Switch
Oil Fill and Vent Plug
Do not operate the Continental ContiTech Perma-Crimp™ PC150 until you have read and fully understand this manual
and proper use of the crimper. This manual is applicable to both the Perma-Crimp™ PC1501(110V) and the PC1502(220V)
crimpers. Crimpers are identical in componentry, crimping and calibration procedures. Note that the PC1501 requires a 110V
electrical source and the PC1502 requires a 220V single phase power supply.
PC150 Operators Manual 3
Safety precautions
› Review instructions and identify all component parts before using crimper.
› Crimper can produce 80 tons of force. Keep both hands away from pinch points.
› Consult the Continental ContiTech Crimp Speciication Manual for correct crimper
settings and crimp measurements.
› Always wear eye protection.
PC150 Quick Start Guide
Follow these steps before using the crimper for the irst time.
Installation and setup instructions
Step 1: Position the crimper on a sturdy workbench in a well-lit area. Workbench
should be able to support the crimper weight of 275 lbs.
Step 2: Locate the crimper close enough to the edge of the work surface so that
the hose will not contact the bench or work surface while crimping. There must be
enough clearance for the hose to align perpendicular with the cone base, or the dies
will not seat properly and the crimps will not be accurate.
Step 3: Check the oil level in the electric pump and ill if necessary to approximately
1½ inches below the ill plug. Only use ISO viscosity grade 46 hydraulic oil.
Step 4: Plug the PC1501(110V) crimper directly into a 15 amp wall outlet or plug
the PC1502(220V) crimper directly into a 220V single phase 15 amp wall outlet
Caution: Do not run the crimper on an extension cord or from a portable power
source as low voltage can damage the motor.
Step 5: Place the pressure plate, any die set and the compression ring onto the
bottom lange of the crimper in the order shown.
Step 6: Set the micrometer at zero.
Step 7: Slide the pusher onto the stud of the hydraulic ram.
Step 8: Press and hold the start/stop switch until the
electric pump shuts of. If the time from which the pump
starts to build pressure (the sound will change) and the
time that the pump shuts of is approximately 1 second,
the crimper is properly calibrated. If the pump does not
shut of or if the time is signiicantly diferent, the crimper
must be recalibrated. A calibration check is recommended
prior to irst-time operation to ensure that the crimper
is operating properly.
Step 5
Step 7
Step 5
4PC150 Operators Manual
PC150 Calibration Instructions
Many problems associated with incorrect crimp diameters are caused by
incorrect calibration.
The calibration procedure can be accomplished without a hose and itting assembly.
Step 1: Lubricate the inside of the compression ring as well as the bottom and
tapered sides of each die segment with the high pressure grease included with each
crimper. An optional aerosol grease is also available (PN900-aerosol lube). As it is
important to lubricate the bottom of each die segment and the tapered sides of the
die ingers, do so each time that the die set is removed from the crimper.
Step 2: Set the micrometer at “0”. At the “0” setting the crimper should completely
close the dies to the ID of the die set, which is etched on the OD of the die ring.
Step 3: With the pusher installed and the micrometer set at “0”, depress the
pneumatic start/stop switch bringing the ram and pusher down on top of the
compression ring. Hold the start/stop switch until the pusher has compressed
the die set to its fully closed position or the minimum ID. The bottom of the
micrometer will make contact with the automatic stop switch and will shut of the
electric pump approximately 1 second after the die set has reached its fully closed
position. If the die set does not reach a fully closed position or the pump runs for
signiicantly longer than 1 second after the die set is fully closed, the crimper must
be recalibrated. Proceed to Step 4.
Refer to Page 2 images of the PC150 for the location of the pusher, micrometer,
start/stop switch, automatic stop switch and calibration adjustment screw.
Step 4: If recalibration is necessary, hold the bottom of the micrometer with a 5/16”
open end wrench and adjust the calibration screw with a 5/32 hex key wrench.
Turn the adjusting screw either in or out as necessary to adjust the contact with the
automatic stop switch to allow full closure of the die set and pump shut of within the
recommended time frame. Turning the adjusting screw out will shut the pump of
sooner, and turning the screw in will let the pump run longer and allow the die set
to close further. Note that each complete turn of the calibration screw will afect the
inished crimp diameter by approximately 0.5mm. After adjustment, lock the jam nut
and repeat Step 3 to check calibration.
When the above conditions are met, the crimper is properly calibrated and ready
for use.
PC150 Operators Manual 5
PC150 Crimping Procedure
Double Angle dies double the radial crimping force of the die set allowing
heavier ittings to be crimped. Due to the doubling of the radial crimp
force, they are efective for a smaller range of diameters than a standard
die set. Also, the itting must be approximately centered axially along the
crimping face to avoid taper in the inal crimp.
Step 1: Remove the standard lat Pressure Plate and replace it with
the DBL BASE bottom compression ring. The bottom Pressure Plate may
be held in place with a set screw. Access to this set screw is through the
hole in the hand hazard decal.
Note: The angles are not the same on standard and double angle dies
and the standard compression rings are not interchangeable with
double angle compression rings.
Step 2: Lubricate the contact surfaces of both the upper and lower
compression rings and the outer surfaces of the double angle dies with
the die lubricant furnished with the crimper.
Step 3: Seat the appropriate size double angle die in the conical recess of
the DBL BASE lower compression ring and align the itting as speciied by
the Continental ContiTech Crimp Spec Manual.
6PC150 Operators Manual
Step 4: Place the DBL TOP compression ring on top of the die set and
manually compress the die set until it contacts the itting.
Step 5: Slide the Pusher onto the cylinder stud and set the Micro-Crimp
Adjuster at the appropriate setting.
Step 6: Press and hold the Start/Stop switch until the crimper shuts of.
Step 7: When the crimp cycle is complete, check the itting diameter
to make certain that it is within the Continental ContiTech Crimp Speciications.
PC150 Operators Manual 7
Additional PC150 Features
The PC150 crimper comes with standard features to increase accuracy and improve
productivity for jobs that require repeat crimps of similar or identical assemblies.
The easily removable coupling stop provides an automatic stop for straight ittings
without the need to sight the alignment of the itting on every crimp.
The adjustable retraction stop allows the operator to limit the retraction of the
hydraulic ram at the point where the die set is open only enough to remove the hose
and itting assembly. This feature can greatly speed up crimping on production jobs
since the ram does not have to fully advance and retract on every cycle.
8PC150 Operators Manual
Troubleshooting
Problem: Crimper will not run at all.
› The white rocker switch is also a circuit breaker. Check to see that the circuit breaker has not been tripped.
› Check the wall outlet. The crimper comes from the factory wired for a 220 volt single phase circuit. An optional 110 volt 1 HP
unit is available, and this unit must be run on a 15 amp circuit. Use of extension cords or outlets with inadequate power can
damage the motor. Do not run the crimper from a portable power source.
› Check the stop switch mounted to the switch bracket under the Micro-Crimp Adjuster. This is a normally closed switch and if it
does not close the crimper will not operate. CAUTION: Do not operate the crimper with this switch jumpered as the pump will
not shut of and the brackets can be damaged.
› Check the pneumatically actuated switch in the electrical box, mounted on the motor. This switch controls power to the motor
and is actuated with air pressure from the bulb on the end of the hose going into the box.
Problem: Crimp diameter too large.
› Check the calibration and recalibrate if required.
›Incorrect die being used. Each die has a range of approximately 3mm (.120 in.) above the closed diameter of the die. The closed
diameter is the die size stamped on the die ring.
› Incorrect setting of the micrometer adjuster. Check the Continental ContiTech Crimp Speciication Manual for the correct
settings.
› Inadequate pump pressure. Check oil level in the pump. It should be 1f” to 2” below the ill plug. Replenish with ISO viscosity
grade 46 hydraulic oil.
› Inadequate lubrication of the dies and compression ring, causing the pump to work harder than normal to reach the required
diameter.
› Inadequate pressure being generated by the pump. This is most likely if the crimper can crimp the smaller size hose and not the
larger hose. When correctly adjusted, the pump should generate approximately 10,000 psi. Do not adjust the pump to produce
in excess of 10,000 psi, as damage to components or personal injury may result.
› No pressure being generated by the pump. There should be a deinite change in pitch of the pump as it cycles into high
pressure mode and begins to “work” harder.
Problem: Crimp diameter too small.
› Check crimp diameter and recalibrate if necessary.
› Incorrect die being used. Verify the correct die set has been selected.
› Incorrect setting of the micrometer adjuster. Check the Continental ContiTech Crimp Speciication Manual for the correct
settings.
Problem: Dies sticking in the compression ring.
› Inadequate lubrication of the compression ring and die surfaces.
PC150 Operators Manual 9
Part Numbers
Die components Part #
1) Die spring PC150Die spring
2) Die screw PC150Die screw
3) Dies See below
Part # ID Part # ID
PC1508.5 Black 8.5 mm PC15031 Silver 31 mm
PC15012 Black 12 mm PC15034 Purple 34 mm
PC15014 Red 14 mm PC15041 Orange 41 mm
PC15016 Blue 16 mm PC15045 Black 45 mm
PC15019 Green 19 mm PC15050 Black 50 mm
PC15023 Yellow 23 mm PC15056 Black 56 mm
PC15027 Brown 27 mm
PC1501 and PC1502 dies
3
4
1
2
Double Angle Die Componets Part #
1) Die ring pusher PC150Die Ring
2) Die Fingers Varies with die set
3) Die Springs PC150Die Spring
4) Die Screw PC150Die Screw
Double Angle Die Set Part # Part # SAP #
PC15049 MM DS Die 49 mm 20294365
PC15053 MM DS Die 53 mm 20294366
PC15058 MM DS Die 58 mm 20294367
PC15062 MM DS Die 62 mm 20294368
PC15069 MM DS Die 69 mm 20294369
PC15074 MM DS Die 74 mm 20294480
PC15078 MM DS Die 78 mm 20294481
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