Continental Refrigerator PC150HD User manual

2PC125 and PC125M Operators Manual
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Hydraulic Hose Crimpers
PC125 and PC125M Operators Manual
www.contitech.us
Perma-Crimp™Hydraulic Hose Crimpers
PC150HD Series Operators Manual
Including PC150HD-1HP-1P and PC150HD-2HP-1P
www.continental-industry.com

2
• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER.
• CRIMPER CAN PRODUCE 240 TONS OF FORCE. KEEP BOTH HANDS AWAY FROM PINCH POINTS.
• CONSULT THE CONTINENTAL CONTITECH CRIMP SPECIFICATION MANUAL FOR CORRECT
CRIMPER SETTINGS AND CRIMP MEASUREMENTS.
• ALWAYS WEAR EYE PROTECTION.
SAFETY PRECAUTIONS
Safety Precautions
Equipment Warning
Proper assembly of Continental ContiTech hose and ttings
Continental ContiTech hose, ttings and crimping equipment work together to provide an e󰀩cient and reliable
hose connection. Continental ContiTech hose and ttings are part of an engineered system and are to be used in
accordance with Continental ContiTech specications. Using non-Continental ContiTech components may pro-
duce 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 ttings, or
are not crimped in accordance with Continental ContiTech process specications.
Buyers may elect to attach additional or non-standard parts or equipment, or to use di󰀨erent manufacturing
specications 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 Con-
tiTech Crimp Specications 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 1-800-235-4632.

3
Table of ContentsSafety Precautions
SAFETY PRECAUTIONS----------------------------------------------------------------------------------------------------------------2
EQUIPMENT WARNING-------------------------------------------------------------------------------------------------------------------2
COMPONENT IDENTIFICATION---------------------------------------------------------------------------------------------------------------------4
FOOT SWITCH OPEN / CLOSE FUNCTION-----------------------------------------------------------------------------------------------------5
CRIMPER SPECIFICATIONS-------------------------------------------------------------------------------------------------------------------------6
DIE PART IDENTIFICATION---------------------------------------------------------------------------------------------------------------------------7
INITIAL CRIMPER SETUP-------------------------------------------------------------------------------------------------------8
HYDRAULIC DIE INSTALLATION-----------------------------------------------------------------------------------------------------9
CRIMPING PROCEDURE-------------------------------------------------------------------------------------------------------------10
MANUAL BACK STOP SETUP-------------------------------------------------------------------------------------------------------11
CALIBRATION CHECK--------------------------------------------------------------------------------------------------------------12
LUBRICATION AND MAINTENANCE--------------------------------------------------------------------------------------------------13
TROUBLESHOOTING-------------------------------------------------------------------------------------------------------------14
WARRANTY INFORMATION-------------------------------------------------------------------------------------------------------------15

4
Component Identication
Crimper Head
Manual
Back Stop
Metric Dial
Micrometer
Reservoir
Open/Close
Foot Switch
Crimper
Mounting Holes
Foot Switch Plug-in Port Serial Tag Location Oil Level Sight Glass Reservoir Drain Ports
Oil Filler Cap
On/O󰀨
Power Switch
Close/Open buttons
Electrical Enclosure
Small Footprint for
minimum use of space
Continental QR code
Electrical Cord
Voltage Tag
Do not operate the PC150HD until you have read and fully understand this manual and the proper use of
the crimper. This manual is applicable to the PC150HD-1HP-1P and PC150HD-2HP-1P crimpers. Crimpers are
identical in component and crimping procedures. Note that the PC150HD-1HP-1P and PC150HD-2HP-1P require
di󰀨erent electrical hookups as power requirements di󰀨er from 110V to 220V, respectively.

5
Foot Switch Close Function:
The foot switch permits dies to be
“jogged” into position and accurately
position the tting prior to crimping.
Foot Switch Open Function:
Allows the user to open the crimper
head the amount needed to remove
the crimped assembly.
The foot switch allows the user to operate the crimper head, while keeping both of their hands free to
provide a quick and accurate crimp. Keeping both hands free the user can make crimps fast, accurate
and much easier.
Foot Switch Open / Close Function

6
Crimper Specications
Standard Dies
Part # ID Part # ID
PC150H-8.5 8.5mm PC150H-31 31mm
PC150H-12 12mm PC150H-34 34MM
PC150H-14 14mm PC150H-41 41MM
PC150H-16 16mm PC150H-45 45MM
PC150H-19 19mm PC150H-50 50MM
PC150H-23 23mm PC150H-56 56MM
PC150H-27 27mm
Crimping Force.........................................................
Hydraulic Hose Capacity.........................................
Crimper Dimensions...............................................
Crimper Weight........................................................
Electrical Requirements..........................................
Hydraulic Die Series................................................
Adapter Die Series..................................................
Adjustability...............................................................
Opening w/o Dies....................................................
Master Die Inside Diameter.....................................
Master Die Travel......................................................
Motor..........................................................................
Reservoir Capacity..................................................
Oil Type.....................................................................
240 Tons
¼" through 2" ID, 2-braid hose
1-¼" 6-spiral hose
L: 17-½" x W:25" x H:25"
400 lbs.
220V - 1PH (Standard)
110V - 1PH (Optional)
PC150H
N/A
Metric Dial Micrometer
120mm / 4.72"
84mm / 3.31"
38mm / 1.5"
1.5HP (110V-1PH / 220V-1PH)
6 US Gallons
ISO 46 Hydraulic Oil
PC150H-DCT
84mm Die Change Tool
PC150H-Rack
9 Station Die Storage Rack
PC150H Die Stud
Hydraulic Dies
Miscellaneous Parts
PC200-MBS – Included Manual Back Stop
PC900-Aerosol Lube – Available High Pressure Grease in aerosol can

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Die Part Identication
B) 84mm Hydraulic Die
A) Master Die
A
B

8
Initial Crimper Setup
Follow these steps before using the crimper for the rst time
› Review instructions and identify all component parts before using crimper.
› Crimper can produce 240 tons of force.
› Keep both hands away from pinch points.
› Consult the Continental ContiTech Crimp Specication Manual for
correct crimper settings and crimp measurements.
›Always wear eye protection.
Installing crimper
› Mount the crimper on a sturdy surface. Workbench should be
able to support crimper weight of 400 lbs. Do not lift machine by
the crimper head. Using a fork lift, lift the crimper under the tank.
› Check reservoir oil level with sight glass at the rear of the crimper.
The reservoir requires 6 gallons of ISO 46 hydraulic oil for a complete
ll. If necessary, oil can be drained from either of the two ports on the
rear of the reservoir.
› Check electrical circuit to be certain that it matches the crimper
requirements shown on the tag attached to the crimper cord.
› Make certain that the motor rotates in the direction of the arrow
shown on the motor housing.
#1
#2
#3
#4

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Hydraulic Die Installation
› Bring the crimper head to fully opened position as shown in
photo #1.
› Select the correct die set for the combination of hose and tting
being crimped as shown in photo #2. The correct die set can be
found in the Continental ContiTech Crimp Specication Manual.
› Install the Hydraulic Dies with the quick change tool as shown
in photo #3.
› Align the studs of the Hydraulic Dies with the holes in the Master
Dies and SLOWLY close the crimper head on the die set as shown
in photo #3.
› Bring the crimper head to a fully closed position, then remove the
quick change tool.
› Bring the crimper head to a fully opened position as shown in photo
#4.
Note: The dies may also be inserted manually with the crimper head
in the fully open position.
› Proceed to the Crimping Instructions to set up the crimper for the
hose and tting being crimped.
#1
#2
#3
#4

10
Select the correct hose and tting for your project as shown in
photo #1.
Note: Refer to the Continental ContiTech Crimp Specications
Manual.
Set the dial micrometer as shown in photo #2 to the setting as
shown in the most current Continental ContiTech Crimp Spec-
ications Manual for the combination of hose and tting being
crimped, then lock the micrometer.
Micrometer Setting Example:
Each 100 on the Micrometer represents 1 mm above the closed
diameter of the die set. For example, with a 50mm die installed
and the Micrometer set at 250 as shown, the nished crimp
diameter would be 52.5 mm. (50mm + 2.5mm)
Insert the hose assembly from either direction into the crimper,
taking care not to disturb the die set. Hold the assembly in place
until the crimp is complete as shown in photo #3.
› Activate the crimp cycle by pressing and holding the green close
button or the foot switch, until the crimp is complete.
› After the dies retracted remove the hose assembly.
Check the crimp diameter of the nished assembly with calipers
or micrometers as shown in photo # 4, to be certain that it is within
the specications as outlined in the Continental ContiTech Crimp
Specications Manual.
Crimping Procedure
#1
#2
#3
#4

11
Manual Back Stop Setup
The Manual Back Stop eliminates guesswork, allowing the
operator to visually observe exactly where the crimp will be
positioned on the tting without the need for trial and error and
product scrap due to poor crimp positioning.
With the Manual Back Stop retracted, load the appropriate set
of dies and set crimp diameters as required.
With the dial micrometer at 0, bring the dies to a fully closed
position.
Loosen the Coupling Stop Clamp
and position the Coupling Stop
against the back face of the dies.
Slide the Coupling Stop Guide
against the Coupling Stop Arm.
Hold the tting against the Coupling
Stop Arm withdraw the Coupling Stop
Rod such that the Guide is aligned
with the desired crimp position. Lock
the Coupling Stop Clamp.
Position the tting against the Coupling
Stop and actuate the crimper in the
normal manner.
The dimension from the face of the
tting to the crimp position will now
be the dimension established in the
previous step.
Coupling Stop
Coupling Stop
Clamp
Coupling
Stop Guide

12
The PC150HD Crimper is calibrated at factory using the correct hose,
tting, and die set outlined in the Continental ContiTech Crimp
Specications Manual.
Note: All settings are approximate, for minor adjustment adjust the
dial as needed.
Due to variations in hose and tting tolerances, some “o󰀨set” may
required to achieve the correct crimp diameter for specic hose
and tting combinations across the range of hose and ttings being
crimped. If crimp diameters are consistently too large or consistently
too small, the crimper should be recalibrated.
For example, with a 50mm die set installed and the Micrometer set
at 250, the nished crimp diameter would be 52.5mm.
(50mm + 2.5mm).
Step 1. Select the correct hose, tting, and die set.
Note: Refer to the Continental ContiTech Crimp Specications
Manual.
Note: While the crimper can be calibrated using any recommended
hose and tting combination, using a hose and tting combination
close to the size most frequently crimped will minimize the o󰀨set
required for other sizes and combinations of hose and ttings.
Step 2. Set the dial micrometer to the setting as shown in the most
current Continental ContiTech Crimp Specications Manual for the
combination of hose and tting being crimped.
Step 3. Check the crimp diameter of the nished assembly with cal-
ipers or micrometers, to be certain that it is within the specications
as outlined in the Continental ContiTech Crimp Specication Manual.
Calibration
Note: If the above conditions are not met, the crimper requires
recalibration.
› Make a crimp with the hose and tting combination most commonly
used, and measure the nished crimp diameter.
› If necessary, loosen the set screw on the adjustment knob with a
.050’ hex key wrench.
› Rotate the adjustment knob so that the number on the dial matches
the actual diameter of the nished crimp.
› Tighten the set screw and make another crimp to conrm that the
crimper is set correctly.
Calibration Check
#1
#2
#3
#4 Set Screw (.050 hex wrench)

13
Lubrication and Maintenance
Proper lubrication is essential to prevent damage to the machine
and to assure accurate crimping.
› Use the mini grease gun with ush tting adapter with grease
(supplied with the crimper) or a high-pressure moly grade grease
can be used as well.
› Failure to lubricate the crimper can cause premature failure,
loss of accuracy and may result in damage to the crimper.
› Lubricate the crimping head after each 250 - 400 crimping
cycles or at the start of each shift if the crimper is used in a
production setting.
› To begin, rst bring the master dies to the fully opened position
and lubricate the die ngers through the 8 lubrication ttings in the
front ange face.
›Next, bring the master dies to the fully closed position, and lubricate
the master dies through the 8 lubrication ttings again.
Note: Use only a high-quality moly-disulde grease. Failure to do so
may result in damage to the wearing surfaces.
Front ange bolts: Periodically, every 6-12 months depending upon
usage, the front ange bolt torque should be checked. The correct
torque is 199NM (147 ft-lbs).
Front Flange Bolts
#1
#2
#3
#4

14
PROBLEM: CRIMPER RUNS BUT IS SLOW OR NON-FUNCTIONAL
• Check supply voltage to see that it matches the voltage specied on the tag attached to the crimper.
• If the crimper is connected to a three phase circuit, check all three legs of the circuit to be certain that all legs
are hot.
• Measure the voltage to the crimper when the crimper is under load. Voltage should be a minimum of 90% of
line voltage when the crimper is under load.
Note: Many performance problems are the result of low voltage or inadequate electrical service.
• Check motor rotation and be certain that the motor rotates in the direction of the arrow on the motor housing.
For three phase units rotation can be reversed by switching any two wires in the plug.
• The circuit in the crimper is protected by a thermal overload relay. If the relay trips after resetting it from the
master power switch, call for technical service.
PROBLEM: CRIMPER WILL CLOSE ON FITTING BUT DOES NOT DEVELOP POWER TO
COMPLETE THE CRIMP
›Fitting is to large for selected crimp die. Select a crimp die that is closer to nal crimp diameter. Machine has built-in
safety bypass to protect internal components from damage due to incorrect die selection.
›Check oil level. Position dies to the fully open position and check oil sight gage in rear of machine. Be sure the oil level
is in the middle of the sight glass. Use ISO 32 or 46 weight hydraulic oil.
If problem(s) persist contact Customer Service for additional troubleshooting assistance
Troubleshooting

15
For technical assistance, call customer service at 1-800-235-4632. The Continental ContiTech branded crimper
is covered under the warranty below.
CustomCrimp® “No Nonsense” warranty
All CustomCrimp® products are warranted to be free of defects in workmanship and materials for one year from
the date of invoice. This warranty ends when the product becomes unusable for reasons other than defects in
workmanship or material.
If any product or part manufactured by CustomCrimp® is found to be defective by CustomCrimp®, at its option
CustomCrimp® will either repair or replace the defective part or product and return via ground transportation,
freight prepaid.
This warranty does not cover any product or part which is worn out, abused, altered, used for a purpose other
than for which it was intended or used in a manner which was inconsistent with any instructions regarding its use.
Electric motors are separately warranted by their manufacturer under the conditions stated in their separate
warranty.
Warranty

Continental. Smart Solutions Beyond Rubber
The ContiTech division of the Continental Corporation
is one of the world’s leading industry specialists. As
a technology partner, our name is synonymous with
expertise in development and materials for components
made of natural rubber and plastics and also in
combination with other materials such as metal, fabrics
or silicone. By integrating electronic components, we are
also generating solutions for the future.
Beyond products, systems and services, we also provide
holistic solutions and have a formative inluence on the
industrial infrastructure. We see digitalization and current
trends as an opportunity to work with our customers to
add sustainable value – for both sides and for good.
Rev: 04/29/2020
The content of this publication is not legally binding and is provided
as information only. The trademarks displayed in this publication are
the property of Continental AG and/or its ailiates. Copyright © 2018
ContiTech AG. All rights reserved. For complete information go to:
www.contitech.de/discl_en
Industrial Fluid Solutions
Market segment
Hydraulic Hose
Contact
ContiTech
703 S. Cleveland Massillon Road
Fairlawn, OH 443333023 U.S.A.
1800 2354632
www.contitech.us
Your local contact
www.contitech.de/contactlocator
Canada
18882754397
Mexico
18004397373