ContiTech Continental Perma-Crimp PC150 Series

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Summary

PC150 Component Identification

PC150 Quick Start Guide

Safety Precautions

Review instructions, identify parts, keep hands away from pinch points, and wear eye protection before use.

Installation and Setup Instructions

Position crimper on workbench, ensure clearance, check oil level, plug into appropriate outlet, install pressure plate and die set.

PC150 Calibration Instructions

PC150 Crimping Procedure

Hose Assembly Position

Instructions on positioning the fitting into the die set for a full length crimp, including specific guidance for T7 and T8 fittings.

Additional PC150 Features

Coupling Stop Feature

Easily removable coupling stop provides automatic stop for straight fittings without needing to sight alignment.

Adjustable Retraction Stop

Limits hydraulic ram retraction for faster removal of hose assembly, speeding up production jobs.

Troubleshooting

Crimper Will Not Run

Checks for tripped circuit breaker, correct outlet, and functioning stop switches; warns against extension cords.

Crimp Diameter Too Large

Addresses issues with calibration, incorrect die set, micrometer setting, pump pressure, and lubrication.

Crimp Diameter Too Small

Covers checking diameter, recalibrating, incorrect die selection, and micrometer adjuster settings.

Dies Sticking

Identifies inadequate lubrication of the compression ring and die surfaces as the cause.

Part Numbers

Die Components and Dies

Lists part numbers for die springs, screws, and various die sets with their corresponding IDs.

Options and Replacement Parts

Details part numbers for optional accessories like storage shelves and replacement components like pushers and rings.

Warranty

CustomCrimp No Nonsense Warranty

Covers defects in workmanship and materials for one year; specifies exclusions like wear, abuse, or alteration.

The Continental Perma-Crimp™ PC150 Hydraulic Hose Crimper is a robust and efficient machine designed for creating reliable hose connections. This manual covers the PC150-1 (110V) and PC150-2 (220V) models, which are identical in componentry, crimping, and calibration procedures, differing only in their electrical power requirements. The crimper is part of an engineered system that works with Continental ContiTech hose and fittings to ensure optimal performance.

Function Description:

The primary function of the PC150 crimper is to securely crimp hydraulic hose fittings onto hoses, forming a durable and leak-free assembly. It achieves this by applying up to 60 tons of hydraulic force to compress a die set around the fitting and hose. The crimper is designed for precision, allowing for accurate crimp diameters as specified in the Continental ContiTech Crimp Specification Manual. It is crucial to use Continental ContiTech components with this crimper, as the manufacturer does not warrant assemblies that do not incorporate their hose and fittings or are not crimped according to their process specifications.

Important Technical Specifications:

Hydraulic Cylinder: 80 Ton Hydraulic Cylinder, indicating its powerful crimping capability.
Power Requirements:
- PC150-1: 110V electrical source, requiring a 15 amp wall outlet.
- PC150-2: 220V single-phase power supply, requiring a 220V single-phase 15 amp wall outlet.
- Caution: The crimper should not be run on an extension cord or from a portable power source, as low voltage can damage the motor.
Weight: The crimper weighs 275 lbs, necessitating a sturdy workbench for installation.
Die Sets: A variety of color-coded die sets are available, each with a specific ID (Inner Diameter) etched on the OD (Outer Diameter) of the die ring, representing the fully closed diameter in millimeters. The die sets have a limited range of diameters for which a satisfactory crimp can be obtained, typically around 3mm (.120 in.) above the closed diameter.
- Available die IDs include: 8.5mm, 12mm, 14mm, 16mm, 19mm, 23mm, 27mm, 31mm, 34mm, 41mm, 45mm, 50mm, and 56mm.
Hydraulic Oil: Requires ISO viscosity grade 46 hydraulic oil. The oil level in the electric pump should be approximately 1.5 inches below the fill plug.
Pump Pressure: When correctly adjusted, the pump should generate approximately 10,000 psi. Adjusting the pump to produce in excess of 10,000 psi can cause damage to components or personal injury.

Usage Features:

Micrometer: A metric micrometer (readings 0 to 10) provides direct readings for precise crimp diameter adjustments. The micrometer setting is added to the die ring's etched diameter to determine the final crimp diameter.
Adjustable Ram Retraction Stop: This feature allows the operator to limit the hydraulic ram's retraction, opening the die set just enough to remove the hose and fitting assembly. This significantly speeds up production jobs by eliminating the need for the ram to fully advance and retract on every cycle.
Removable Coupling Stop: An easily removable coupling stop provides an automatic stop for straight fittings, eliminating the need to visually align the fitting for each crimp, thus increasing accuracy and productivity for repeat crimps.
Automatic Stop Switch: The crimper is equipped with an automatic stop switch that shuts off the electric pump approximately 1 second after the die set reaches its fully closed position or minimum ID.
Manual Pneumatic Start/Stop Switch: This switch controls the crimping cycle.
Power On/Off Circuit Breaker Switch: Serves as both a power switch and a circuit breaker, protecting the motor from electrical overloads.
Die Storage Shelf (Optional): An optional accessory for convenient storage of die sets.
Hose Assembly Position: Fittings should be positioned into the die set for a "full" length crimp, with the fitting hex up to but clear of the die during crimping. Specific instructions for T7 and T8 fittings are provided in the Crimp Specification Manual.

Maintenance Features:

Calibration: Regular calibration is critical for accurate crimp diameters. The calibration procedure involves adjusting a calibration screw with a 5/32 hex key wrench while holding the micrometer with a 5/16" open-end wrench. Each complete turn of the calibration screw affects the finished crimp diameter by approximately 0.5mm. Calibration should be checked prior to first-time operation and whenever the pump shut-off time is significantly different from 1 second.
Lubrication: Proper lubrication of the die segments, compression ring, and pressure plate is essential to prevent dies from seizing and to ensure smooth operation. High-pressure grease (PN900-grease-3 oz. or PN900-grease-1lb.) or an aerosol lubricant (PN900-aerosol lube) should be applied sparingly to the contact surfaces. Lubrication should be performed each time the die set is removed from the crimper. Failure to lubricate can damage the die set and the crimper.
Oil Level Check: The hydraulic oil level should be checked regularly and replenished with ISO viscosity grade 46 hydraulic oil as needed.
Troubleshooting Guide: The manual includes a troubleshooting section to address common issues such as the crimper not running, incorrect crimp diameter (too large or too small), and dies sticking in the compression ring, providing solutions like checking circuit breakers, recalibrating, verifying die selection, and ensuring proper lubrication and oil levels.

The Perma-Crimp™ PC150 is designed for ease of use and reliability, providing a comprehensive solution for hydraulic hose assembly. Adherence to the instructions in this manual and the Continental ContiTech Crimp Specification Manual is crucial for safe and effective operation and to maintain the product warranty.