SAMWAY P20NMS User manual

SAMWAY
OPERATING INSTRUCTIONS
P20NMS / P32NMS
SAMWAY
SAMWAY
Released 01/2019
WUXI SAMWAY CO.LTD
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SKYPE : samway.company
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Copyright 2019 by SAMWAY International Business Limited. All rights reserved.
Translation of the original instructions.
Keep this manual for future needs.
The machine has been designed for crimping hose fittings. SAMWAY shall not be held liable
for any product which has been crimped on the machine. The machine has been designed to
operate in room temperature, in dry indoor conditions and in sufficient illumination. Using the
machine for any other purpose in not allowed without written consent from the factory.
No part of this documentation may be reproduced,copied or transmitted in any from,or by any
electronic, digital or other means, without permission in writing from SAMWAY. This includes
photocopying and information storage and retrieval systems. The material in this
documentation is subject to change without notice.

CONTENTS
CONTENTS............................................................................................................................. 5
GENERAL............................................................................................................................... 6
TRANSPORT...................................................................................................................................... 6
STORAGE........................................................................................................................................... 6
MOUNTING......................................................................................................................................... 6
HELP PROTECT OUR ENVIRONMENT................................................................................. 7
DISPOSAL OF THE PACKING MATERIAL....................................................................................... 7
DISPOSAL OF YOUR OLD MACHINE .............................................................................................. 7
WARNINGS............................................................................................................................. 7
GENERAL........................................................................................................................................... 7
DANGER ZONES............................................................................................................................... 8
COMMISSIONING................................................................................................................... 9
OIL FILL.............................................................................................................................................. 9
ELECTRICAL CONNECTION............................................................................................................. 9
RUNNING IN......................................................................................................................................10
GREASING........................................................................................................................................10
QUICK FIX-PACKAGE......................................................................................................................10
OPERATION ..........................................................................................................................11
CONTROL IDENTIFICATION............................................................................................................11
TESTRUN.........................................................................................................................................11
SELECTING THE DIE SET, P20 MODEL........................................................................................ 12
SELECTING THE DIE SET, P32 MODEL........................................................................................ 12
INSTALLING THE DIE SET.............................................................................................................. 13
QUICK CHANGE......................................................................................................................................... 13
CHANGE OF A SINGLE DIE....................................................................................................................... 13
SETTING THE CRIMPING DIAMETER........................................................................................... 14
CRIMPING........................................................................................................................................ 15
FOOTPEDAL.............................................................................................................................................. 15
PREVENTIVE MAINTENANCE ............................................................................................ 17
IF THE MACHINE DOES NOT WORK....................................................................................... 16
CLEANING........................................................................................................................................ 17
GREASING....................................................................................................................................... 17
CYLINDER PROTECTION INSERTS .............................................................................................. 18
OIL CHANGE.................................................................................................................................... 18
FILTER CHANGE............................................................................................................................. 18
MASTER DIE SPRING CHANGE..................................................................................................... 19
PRESSURE PIPES........................................................................................................................... 19
RE-CALIBRATION OF CRIMPING DIAMETER DIAL ......................................... 19............................
MAINTENANCE HISTORY / HUOLTOHISTORIA................................................................ 23
GUARANTEE........................................................................................................................ 20
TECHNICAL DATA............................................................................................................... 21
TECHNICAL DATA P20 ................................................................................................................... 21
TECHNICAL DATA P32 .............................................................................................................................. 22

6
MOUNTING
The adjacent picture shows an appropriate
way to lift the machine after it has been
unpacked.
It is recommended to mount the machine on a
table. Before mounting, the table must be
screwed on the floor with four M12 wedge
anchors. Boreholes in the floor: Ø 12 mm
depth 55 mm.
When the machine is mounted on a
SAMWAY table, the four shoes and fixing
plates under the machine are removed.
The table with assembly instructions is
packed separately.
The Crimper may be installed on some other
as well, provided it is sturdy and broadenough
or it has been fastened on the floor so that it
cannot fall over. Check the machine weight
from the type plate.Furthermore there must be
a hole in the table to enable emptying the oil
tank through the drain plug.
Mount the machine in a location that gives
enough working space, 900 mm ( 3 ft ) round
themachine.The sufficient lightning in machine
surroundings is also needed to ensure safe
working.
GENERAL
SAMWAY crimping machines are electrically operated hydraulic crimping machines for hydraulic hose
assemblies. Machines are designed for single piece- and low production.
The crimping machine comprises a crimping head, a hydraulic unit which serves as machine frame.
SAMWAY crimping machine is normally delivered with a 3-phase electric motor.
TRANSPORT
The packed machine is transported on a pallet,
which is easy to move and lift by a fork-lift
truck. After unpacking, the machine can be
lifted using a hoisting belt.
Size of package: x = 75, y = 60, z = 78 cm.
STORAGE
The manufacturer has protected the machine
against corrosion by using the Zerust method.
The machined parts have been treated with
Axxatec 77C protective agent. A Zerust vapor
capsule has been put into the electric box,
and the machine has been packed into a bag
ade of Zerust film.
m
The protection is effective for months if the
package is not opened. After opening it, the
protection of the wrapping film ceases. If the
machine is not yet brought into use, it must be
reprotected against corrosion. The machine is
to be stored in dry indoor conditions.
Remove the protective agent according to the
instructions enclosed in the package.
Pakkaus1.eps

7
HELP PROTECT OUR ENVIRONMENT
DISPOSAL OF THE PACKING MATERIAL
The transport and protective packing is mostly manufactured from the recycled or recyclable
materials. Please check local environmental regulations before disposing of packing materials. Rather
than throwing these materials away, please take them to your community recycling center.
DISPOSAL OF YOUR OLD MACHINE
Old machines contain materials which can be recycle
Use only original SAMWAY die sets in your SAMWAY crimping machines. Installing and using
third party die sets are voiding any warranties, and all liability what so ever nature is rejected.
Using third party dies sets will be done solely on users own risk and recourse.
d. Please contact your recycling center of scrap
merchant before discarding the appliance.Handle the waste oil and filters according to law.
WARNINGS
GENERAL
Read the instructions thoroughly to secure safe and correct operation of the machine.
Test the function of the emergency stop push buttons every day!
The machine is intended for professional use. It is to be operated only by a trained operator who has
understood the dangers involved in the operation. The machine is designed to operate in room temperature,
n dry indoor conditions and in sufficient illumination.
i
Openings between the dies exceed 6 mm, thus being large enough to let fingers go between the dies and
get crimped. It is, therefore, ABSOLUTELY necessary to follow operating instructions and warnings
indicated by the stickers on the machine when changing dies and crimping fittings.
The cover- and protection plates protect the operator from crimping- and other possible hazards.
It is recommended to use appropriate protective eyewear, gloves and safely shoes during operation and
maintenance.

8
DANGER ZONES
LABEL
WARNINGS 1 AND 2
WARNINGS 3
WARNINGS 4
WARNINGS 5(P32 model)
CAUTION: DANGER OF SQUEEZE
DEFINITION
General Warning label.There are items that require attention.
When crimping a fitting, hold the hose far enough to avoid crimping
your hand!
WARNING: HIGH VOLTAGE
The electric box is to opened only by a professional electrician!
Disconnect the machine from the mains before opening.
CAUTION: DANGER OF SQUEEZE
The rear of the crimping head is covered by a housing protecting
the operator from the crimping hazard under the housing between
Do not remove this housing！
Do not put your hands inside the dies while the machine is set on!
Dies open and close by depressing the hand emergency push-
buttons at both ends of the valve. Do not touch these push-buttons
during normal operation!

9
COMMISSIONING
OIL FILL
Fill the oil tank to centre line of the indicators in the dipstick with hydraulic oil like Shell Tellus T46 or
equivalent. Volume of the tank is 30 litres.
It is recommended to pump the oil into the tank through a 20 filter, because new oil in drums is not pure.
If any oil has run out on the floor, wipe it away.
ELECTRICAL CONNECTION
CAUTION! Check that the machine voltage (see type plate) is equal to your supply voltage.
For proper installation to local code, consult a licensed contractor.
Bring the supply cable through the hole on the rear of the machine and guide it through the hole on the
rear of the electric box. Secure the cable with a stress relief plug. The minimum size for the cable:
3-phase: Connect the phase conductors to the respective L1, L2 and L3 terminals in the supply
disconnecting device. Connect the earth connection to the ground terminal on the fixing plate. Check the
connection against the wiring diagram enclosed in the spare parts list.
Check that the motor rotation is parallel with the arrow close to the motor. In case the motor rotates in
rong direction, two phase conductors in the supply disconnecting device must be interchanged.w
1-phase: Connect the phase and the neutral to the respective terminals in the supply disconnecting device.
Connect the earth connection to the ground terminal on the fixing plate. Check the connection against the
wiring diagram enclosed in the spare parts list.
SAMWAY 20 SAMWAY 32
Voltage Cable Voltage Cable
400 V / 460 V
230 V / 240 V
400 V / 460 V
230 V / 240 V
2.5 mm² (AWG 13)
4 mm² (AWG 12)
4 mm² (AWG 12)
6 mm² (AWG 10)

10
RUNNING-IN
Recommended running in period for a new machine is 50 000 crimps. It will be enough if the greasing cycle
is halved during the running in period. The purpose of frequent greasing is to ensure that there is always
grease enough between the sliding surfaces. Due to the surface pressure the grease sinks in to the metal
pores ensuring good sliding properties for the machine’s lifetime. During the running in period grease the
machine affter every 1000 crimps.
GREASING
The master dies of the machine has been greased at the factory after the final testing. However, the grease
may have dried during the transportation and storing and therefore the machine should be greased
according to the operating instructions before commissioning.
Greasing of the master dies is an important maintenance procedure which should be made regularly. The
adverse working environment and crimping volume have a special effect on the need for maintenance.
Preventive maintenance and proper use help to ensure trouble-free operation of the machine. It is
recommended to grease the machine after every 2000 crimps, except during the running in period when
the greasing should be done after every 1000 crimps.
QUICK FIX-PACKAGE
Included with the machine, there is a Quick Fix-package which has some basic parts for this machine
model.

11
OPERATION
The crimping machine is switched on by turning the supply disconnecting device. However, the motor won’t
run until the crimping- or retraction -push button is pressed. The motor stops automatically and the indicator
light starts flash, if the machine is not used in 6 seconds. The motor springs to life when the crimping- or
retraction -button is repressed.
CONTROL IDENTIFICATION
1. Supply disconnecting device for starting and stopping the motor. The device is used to separate
the machine from power supply. However, the machine can be made only by disconnecting the plug or
supply from the mains.
2. As long as the crimping push-button is depressed, the dies will close until the button is released
or the preset crimping diameter is reached.
3. Retractionbutton. When depressed and held down, the dies will open until the button is released
or themaximum mechanical retraction is reached.
Holder for die change tool.
4. Crimping diameter dial.
5. Emergenty stop.
6.
7.
Foot pedal (option). Crimping pedal 8.1 and retraction pedal 8.2. See page 15.
8.
Die chart with crimping diameter range for each die set and corresponding dial adjustment
values is delivered together with the machine.
The main operating area of the machine is in front of the controls.
TEST RUN
Start the machine.
Set the crimping diameter dial to 0.0.
During the first crimping cycles air in the cylinders may make the piston/dies move irregularly and at high
speed. Cycle the press a few times till the motion becomes even.
To avoid accidents, make sure that there are no foreign objects between the dies.
In case the dies do not move in either direction, the motor rotates in wrong direction. Correct by
interchanging two phase conductors in the supply disconnecting device.

12
SELECTING THE DIE SET, P20 MODEL
Use only original SAMWAY die sets in SAMWAY crimping machines.
Refer to the fitting manufacturer's specifications for proper crimping diameter for the fitting.
Each die set has its own crimping range. Follow it to assure the roundest possible crimping result.
he minimum crimping diameter Dis marked on each die set.T
Example: with die set No 18013/10 the minimum crimping diameter is 10 mm.
D L Die set No Crimping range
D L Die set No Crimping range
10 55 18013/10 10...12 mm
12 55 18013/12 12...14 mm
14 55 18013/14 14...16 mm
16 55 18013/16 16...19 mm
19 55 18013/19 19...23 mm
23 55 18013/23 23...27 mm
27 70 18013/27 27...31 mm
31 70 18013/31 31...36 mm
36 75 18013/36 36...41 mm
41 75 18013/41 41...47 mm
47 85 18013/47 47...54 mm
54 85 18013/54 54…61 mm
In addition to the standard die sets, a wide range of special die sets is available on request.
SELECTING THE DIE SET, P32 MODEL
Use only original SAMWAY die sets in SAMWAY crimping machines
Refer to the fitting manufacturer's specifications for proper crimping diameter for the fitting.
Each die set has its own crimping range. Follow it to assure the roundest possible crimping result.
The minimum crimping diameter Dis marked on each die set.
Example: with die set No 18506/10 the minimum crimping diameter is 10 mm.
10 55 18506/10 10 ... 12 mm
12 55 18506/12 12 ... 14 mm
14 55 18506/14 14 ... 16 mm
16 55 18506/16 16 ... 19 mm
19 55 18506/19 19 ... 22 mm
22 70 18506/22 22 ... 26 mm
26 70 18506/26 26 ... 30 mm
30 70 18506/30 30 ... 34 mm
34 75 18506/34 34 ... 39 mm
39 75 18506/39 39 ... 45 mm
45 90 18506/45 45 ... 51 mm
51 90 18506/51 51 ... 57 mm
57 100 18506/57 57 ... 63 mm
63 110 18506/63 63 ... 69 mm
69 110 18506/69 69 ... 75 mm
74 110 18506/74 74 ... 80 mm
78 110 18506/78 78 ... 87 mm
In addition to the standard dies, a wide range of special dies is available on request.