The Perma-Crimp™ Hydraulic Hose Crimpers PC125 and PC125M are robust machines designed for creating reliable hose connections by crimping hydraulic hoses and fittings. These crimpers are part of an engineered system by Continental ContiTech, ensuring optimal performance when used with their specified hoses and fittings.
Function Description
The primary function of the PC125 and PC125M crimpers is to apply a precise amount of force to a die set, which in turn compresses a fitting onto a hydraulic hose, creating a secure and leak-free connection. The crimpers utilize a hydraulic cylinder to generate significant force, ensuring consistent and accurate crimps. The PC125 model is equipped with an integrated electric pump, while the PC125M model is designed to be powered by external manual, pneumatic, or electric pumps, offering greater flexibility in power source options.
Important Technical Specifications
The PC125 and PC125M crimpers share several core specifications, highlighting their capability and capacity:
- Die Series: PC125 Series
- Maximum Cylinder Force: 60 Tons, indicating substantial crimping power.
- Maximum Hose Diameter (2 Wire): 1 1/4 Inch
- Maximum Hose Diameter (4 Wire): 1 1/4 Inch
- Maximum Hose Diameter (6 Wire): 1 Inch
- Oil Type: ISO Viscosity Grade 46 hydraulic oil is recommended for optimal performance.
- Reservoir Capacity (PC125 Series): 1 Gallon
Model-Specific Specifications:
PC125 Crimper Series:
- Crimper Depth: 22.5 Inches
- Crimper Width: 13 Inches
- Crimper Height: 22.5 Inches
- Weight: 140 Lbs
- Pump: Electric (integrated)
- Pump HP: 1 HP (110V)
- Electric Power Requirement: 110V-15 Amp
PC125M Crimper Series:
- Crimper Depth: 17 Inches
- Crimper Width: 10.25 Inches
- Crimper Height: 21 Inches
- Weight: 72 Lbs
- Pump: Not included – Manual, Pneumatic, or Electric pumps are available as optional accessories.
Usage Features
Both models are designed with features that enhance ease of use, accuracy, and safety:
- Micrometer Style Adjustment: This allows for precise crimping of a wide variety of hoses and fittings, ensuring accurate crimp diameters. The metric micrometer provides direct readings (0 to 10), which are added to the die ring's etched number to determine the final crimp diameter.
- Adjustable Retraction Stop: This feature limits ram retraction to only the necessary amount, saving time during multiple crimps by reducing the distance the ram travels.
- Removable Coupling Stop: An easily removable coupling stop makes repetitive crimps faster by eliminating the need for visual alignment of the fitting before each crimp.
- Notched Compression Ring: The notched compression ring ensures proper die set seating and consistent crimping.
- Die Sets: A range of color-coded die sets are available, with numbers etched on the OD of the die ring representing the fully closed diameter in millimeters, simplifying selection.
- Pusher with Magnets (PC125 Series): Powerful magnets in the pusher retract the notched compression ring with the ram on each cycle, allowing for "hands-free" operation.
- Automatic Stop Switch (PC125 Series): This switch automatically shuts off the pump when the crimp cycle is complete, preventing over-crimping and ensuring consistent results.
- LED Indicator Light (PC125M Series): A LED light warns the operator when the crimp cycle is complete, providing a visual cue for the end of the process.
- Safety Precautions: The manual emphasizes critical safety measures, including reading instructions, identifying components, keeping hands away from pinch points (the crimper produces 60 tons of force), consulting the crimp specification manual, and always wearing eye protection.
Maintenance Features
Proper maintenance is crucial for the longevity and accurate operation of the crimpers:
- Lubrication Procedure: A detailed lubrication procedure is provided, emphasizing the importance of applying CrimpX oil or high-pressure molybdenum grease to the pressure plate, die contact surfaces, and the inner diameter of the notched compression ring. This prevents dies from seizing and ensures smooth operation. Lubrication is typically recommended after every 100 crimps.
- Oil Level Check: For the PC125, the oil level in the pump should be checked regularly, ensuring it is 1-1/2 to 2 inches below the vent plug when the cylinder is retracted. ISO 46 weight hydraulic oil should be used for replenishment.
- Calibration Check: Both PC125 and PC125M models have a calibration check procedure to ensure accurate crimp diameters. This involves setting the micrometer to "0" and observing the ram's extension and pump's pressure build-up. If recalibration is needed, the micrometer barrel can be adjusted with a wrench and hex key.
- Vent Plug: The shipping plug in the pump reservoir must be replaced with the supplied vent plug before operation.
- Troubleshooting Guide: The manual includes a troubleshooting section to address common issues such as the crimper not running, crimp diameter being too large or too small, and dies sticking. This guide helps operators diagnose and resolve problems efficiently.
- Replacement Parts: A list of replacement parts is provided, including die ring pushers, pressure plates, notched compression rings, switches, micrometers, and lubricant oil, facilitating easy ordering and repair.
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