NEW-LINE NHC-S20 Crimping Machines Instruction Manual

: September 23, 2024
: NEW-LINE

Table of Contents

NHC-S20 Crimping Machines
Specifications:
Product Usage Instructions:
General Information:
Transport:
Storage:
Mounting:
Commissioning:
Operation:
Preventative Maintenance:
- FAQ:
Q: What should I do if I encounter improper die warning?

NHC-S20 Crimping Machines

Specifications:

Product Model: NHC-S20 / NHC-S32
Operation: Electrically operated hydraulic crimping
machine
Motor: Single electric motor (can be equipped with a 3 phase
motor on request)

Product Usage Instructions:

General Information:

New-Line crimping machines are electrically operated hydraulic
crimping machines designed for hydraulic hose assemblies. The
machine consists of a crimping head and a hydraulic unit mounted on
the oil tank, which serves as the machine frame.

Transport:

Handle with care during transportation to avoid any damage to
the machine components.

Storage:

Store the crimping machine in a dry and clean environment to
prevent rust or corrosion.

Mounting:

Ensure the machine is securely mounted on a stable surface to
prevent any movement during operation.

Commissioning:

Follow the instructions provided for oil fill and electrical
connection before operating the machine.

Operation:

Refer to the control panel illustration for NHC-S20/NHC-S32 for
guidance on operating the machine. Follow the instructions for die
sets installation, selecting the die set, and setting the crimping
diameter.

Preventative Maintenance:

Regularly grease the machine components to ensure smooth
operation. Re-calibrate the crimping diameter dial as needed.

FAQ:

Q: What should I do if I encounter improper die warning?

A: Check for possible causes such as incorrect die installation
or wear. Refer to the troubleshooting section in the manual for
detailed steps.

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NHC-S20 / NHC-S32
OPERATION MANUAL

new-line.com

800-661-2208

CONTENTS
GENERAL ……………………………………………………………………….. 3
TRANSPORT ………………………………………………………………………………………………………… 3 STORAGE …………………………………………………………………………………………………………….. 3 MOUNTING …………………………………………………………………………………………………………… 3
WARNINGS …………………………………………………………………….. 4
GENERAL …………………………………………………………………………………………………………….. 4 DANGER ZONES ……………………………………………………………………………………………….. 4-5
e COMMISSIONING ………………………………………………………….. 5
OIL FILL ………………………………………………………………………………………………………………… 5
in ELECTRICAL CONNECTION …………………………………………………………………………………. 5
QUICK FIX-PACKAGE …………………………………………………………………………………………… 5
OPERATION ……………………………………………………………………. 6
l NHC-S20/NHC-S32 CONTROL PANEL ILLUSTRATION ………………………………………… 6-7 – DIE SETS INSTALLATION WARNING ………………………….. 8
SELECTING THE DIE SET S20 & S32 ……………………………………………………………………. 8
w INSTALLING THE DIE SET ……………………………………………………………………………………. 8 QUICK CHANGE MS ……………………………………………………………………………………. 9 CHANGE OF A SINGLE DIE S20 & S32 ………………………………………………………… 9
e SETTING THE CRIMPING DIAMETER MS …………………………………………………………….. 9 n PREVENTATIVE MAINTENANCE …………………………………. 9
GREASING S20 & S32 …………………………………………………………………………………………. 10 RE-CALIBRATION OF CRIMPING DIAMETER DIAL MS-CONTROL ………………………. 10
IMPROPER DIE WARNING ………………………………………….. 11
POSSIBLE CAUSE ………………………………………………………………………………………………. 11
IMPROPER DIE PHENOMENA ……………………………………..12 TROUBLESHOOTING ……………………………………………………13 S20 DETAILS …………………………………………………………………14 S32 DETAILS …………………………………………………………………15

GENERAL
New-Line crimping machines are electrically operated hydraulic crimping machines for hydraulic hose assemblies. The crimping machine comprises a crimping head and a hydraulic unit mounted on the oil tank which serves as machine frame. Normally delivered with a single electric motor. On request it can be equipped with a 3 phase motor.
TRANSPORT
The packed machine is transported on a pallet, which is easy to move and lift by a forklift truck. After unpacking, the machine can be lifted using a hoisting belt. Size of package for P51-models: x = 102, y = 82, z = 113cm. Size of package for other models: x = 77, y = 62, z = 81cm.
STORAGE
The manufacturer has protected the machine against the ma-
e chine against corrosion by using the Zerust method. The ma-
chined parts have been treated with Axxatec 77C protective agent. A Zerust vapor capsule has been put into the electric
in box, and the machine has been packed into a bag made of
Zerust film. The protection is effective for months if the package is not
l 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
w enclosed in the package.
MOUNTING
e The adjacent picture shows an appropriate way to lift the man chine after it has been unpacked. It is recommended to mount
the machine on table. Before mounting, the table must be screwed to the floor with four M12 wedge anchors. Boreholes in the floor: Ø 12mm, depth 55mm. When the machine is mounted on the table, the four shoes under the machine are removed. The table with assembly instructions is packed separately. The crimper may be installed on some other table as well, provided it is sturdy and broad enough or it has been fastened on the floor so that it cannot fall over. Furthermore, there must be a hole in the table to enable emptying the oil tank through the drain plug. S20 & S32 – models x = 558, y = 560.
3

WARNINGS
GENERAL
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. Openings between the dies exceed 6mm, 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.
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COMMISSIONING ine OIL FILL l 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 32 litres.
It is recommended to pump the oil into the tank through a 20 filter, because new oil in drums is not pure.
w OIL FILL
CAUTION! Check that the machine voltage (see type plate) is equal to your supply voltage. For proper
e installation to local code, consult a licensed contractor. n Bring the supply cable in through the hole in the side panel of the electric box. Secure the cable with a
stress relief plug.
1-phase: Connect the phase and the neutral to the retrospective 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.
3-phase: Connect the phase conductors to the respective L1, L2 and L3 terminals in the supply disconnecting the device. Connect the earth connection to the ground terminal on the fixing plate. Check the connection against the wiring diagram enclosed in spare parts list.
Check that the motor rotation is parallel with the arrow on the tank close to the motor. In case the motor rotates in wrong direction, two phase conductors in the supply disconnecting device must be interchanged.
QUICK FIX-PACKAGE
Included with the machine, there is a Quick Fix-Package which has some basic parts for that machine model.
5

OPERATION
S20 – S32 CONTROL PANEL ILLUSTRATION
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OPERATION
S20 – S32 CONTROL PANEL ILLUSTRATION The Control Panel with Counter
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SELECTING THE DIE SET
Use only original die sets in 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 D is marked on each die set. Example: with die set No 18506/10 the minimum crimping diameter is 10 mm.
line INSTALLING THE DIE SET – QUICK CHANGE MS (OPTION)
An optional Quick Change Tool Base enables storing die sets under the machine. Die sets can be installed into the master dies with a quick change tool one set at a time.
w · Before installing dies, make sure that the master dies are clean.
· STOP THE MOTOR PRIOR TO CLEANING DIES.
e · Insert the pins of the tool into the die set in the die table, turn the tool clockwise and pull the whole set out (Image on next page).
n· Hold handle of the quick change tool as shown in Figures 1 and 2, and make sure your hand will not get between the dies. · Mount the die set between master dies (Fig. 2) and start closing the dies. · TO AVOID DAMAGING MASTER DIES, MAKE SURE THAT ALL DIE SET PINS HIT IN THEIR
HOLES. · Close the master dies completely until the pins are locked in their places (Fig 3). Remove the
tool. The dies are now ready for use (Fig 4). · Die set is removed from the master dies in reverse order: close the dies, insert the tool into the
die set, open the master dies and place the set back in the die table.
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QUICK CHANGE MS (OPTION)

· Start the motor and depress the retraction button until

maximum retraction is reached. Stop the motor.

CAUTION | THE MOTOR SHALL ALWAYS BE

STOPPED DURING INSTALLATION OF DIES.

· Prior to installing dies, clean the contact surfaces of

both the die set and master dies properly to avoid

damaging the surfaces.

· Pull the pull pin in the master die with the tool delivered

together with the machine (see figure).

· Insert the die with the retaining pin into the master die,

die number always towards you. Release the pull pin.

· After installing all the dies, make sure they are straight

and properly seated in the master dies.

SETTING THE CRIMPING DIAMETER MS
new-line The crimping diameter chart S32

EXAMPLE: Manufacturer has specified a crimping diameter of 20.6 mm for the fitting. Select die set No 20-19 (min crimping diameter 19 mm) according to the die chart. Turn the dial to position 1.60 (upper scale 1, lower 60). This setting will give the crimping diameter 20.6 mm (19 + 1.6 mm)
The machine has been calibrated at the factory with 40 bar pressure. This means that when you are crimping a fitting requiring 44 bar pressure, the measuring scale of tte crimping diameter dial provides an accurracy of +/- 0.1 mm (possible elastic recover of the ffitting not

regarded).

PREVENTATIVE MAINTENANCE
· The following maintenance operations can be performed by the operator according to the instructions below. However, electrical works and repairs like changing seals or the pump must only be carried out by a qualified specialist.
· PRIOR TO ANY SERVICING OPERATION, TURN THE SUPPLY DISCONNECTING DEVICE TO POSITION `0′.
· BEFORE CHANGING THE MOTOR CIRCUIT BREAKER OR UNDERVOLTAGE TRIP, DISCONNECT THE PLUG OR SUPPLY CABLE FROM THE MAINS!
· Open the dies to maximum retraction before servicing.

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GREASING S20 & S32
· Lubricate the inner surface of the conical flanges daily with pressure-proof grease like Molub Aloy OG-H or equivalent.
· Apply the grease to the conical surfaces at the front and back of the die with small brush. · Lubricate often with a small amount of grease rather than seldom with much grease. · Do not grease the piston rod.
e RE-CALIBRATING OF CRIMPING DIAMETER DIAL MS -CONTROL in NOTE: The crimping diameter dial has been calibrated at the factory during test run.

Re-calibrate the crimping diameter with ferrule
l (seamless steel tube) Ø 25 mm; wall 2 mm, by us-
ing the die set No 20-19 (S20) or the die set 32-19
– (S32)
Set the dial at 1.0, so that the crimping diameter
w will be 20 mm (see adjacent picture) and lock the dial.
Crimp the ferrule and measure the real diameter.
e 3) Remove the control dial (avoid turning the dial n shaft at the same time).
Open the dial lock and set the real diameter into it (diameter of ferrule) relock it and reinstall. 5) Turn the dial to right diameter and crimp another ferrule. Now the machine has been calibrated and the real diameter should be the same as the diameter on the dial. If not, repeat from point 2 and be more careful when handling the dial. 6) After the adjustment, the crimping result should be the minimum nominal crimping diameter of each die set with the dial at 0.0.
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IMPROPER DIE WARNING
Improper die set may have the effect similar to the picture shown on the next page. The die set protrudes outward and the rear part of the master die is off the cone track. You can observe the phenomenon quite easy when crimping if this happens. Please view these pictures carefully. When you encounter the same issue, please stop crimping immediately. You need a proper die for your fitting. This machine requires a balanced crimping. If you experience an improper die – stop crimping immediately and change a die set or contact us for a replacement die set.
POSSIBLE CAUSES

The die diameter is not correct, you chose a smaller die (the difference between the die diameter and coupler diameter shall be less than 10 mm). If exceeding 10 mm before crimping, you must check the die sets and change to the one closest. 2) The die set is too long compared to the length of the ferrule needing to be crimped. This makes the crimping part too forward to be abel to crimp evenly or balanced. This will cause the problems shown
e in the pictures on the next page. Normally this is casued by one piece fitting, as one piece fitting is very
short compared to the normal fittings. Our standard die set is designed to crimpe the most fittings, thus
in it is usually longer. But when you encounter these phenomena, please stop crimping and request prop-
er die sets from us. Please stop crimping when you experience these issues. If you proceed you will have serious conse-
l quences like but not limited to: breaking the jaw of the master die and damaging the front and back new- cone surface, which will eventually make the machine useless.
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IMPROPER DIE PHENOMENA
STOP CRIMPING IF YOU ENCOUNTER THESE PHENOMENA!
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TROUBLESHOOTING
Troubleshooting is to be carried out by a serviceman.

TROUBLE
Machine will not start.

POSSIBLE CAUSE
1. No electric supply. 2. Motor protection tripped.
3. Switch broken. 4.Low supply voltage.

ACTION
1. Check fuses and supply cable connections. 2. Reset if tripped again, check motor and pump connection. 3. Check the voltage up to the motor. 4. Check the voltage.

Motor runs but no piston

1. Wrong rotation direction.

1. Interchange two phases in the supply

e movement.

2. Low oil level. 3. Fuses/rectifier/transform out of order. 4. Dial broken (MS). 5. Valve out of order.
6. Pump or coupling broken.

disconnecting device. 2. Check, refill. 3. Check, replace. 4. Check, replace. 5. Check movability of valve stream. Check the solenoids. 6. Check, replace.

lin Insufficient crimping force.

1. Insufficient lubrication. 2. Low oil level. 3. Pressure relief valve stuck. Pilot check valve leaking. 4. Leaking pump/pressure pipe 5. Coupling between motor and pump slipping.

1. Lubricate the dies. 2. Check, refill. 3. Check, clean. Replace if broken.
4. Check, tighten, replace. 5. Check, replace.

new- Crimping diameter varies.

1. Insufficient lubrication. 2. Set value changed. 3. Dial knob loose (MS). 4. Dial loose or broken (MS). 5. Sliding potentiometer. 6. Valve sticking.

1. Lubricate the dies. 2. Check. 3. Check, calibrate, tighten. 4. Check, tighten, replace. 5. Check, tighten, replace. 6. Check, clean.

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NHC-S20 DETAILS

Benefit:
· Digital Precision Control · Quick Change Tool and Die Rack · Energy Saving and Safety Operation · TUV, CE, CSA Approved

w-line Main Specifiation ………….. NHC-S20
Max Hydraulic Hose .. 1-1/4 4 Spiral
e Crimping Range …………….. 4-60 mm
Die Type ……………………………….. S20
nMaster Die Length ……………. 80 mm

Voltage …………….. 220V 1ph 20 amp Foot Pedal …………………….. Included Die Rack ……………………….. Included Quick Change Tool ………… Included Backstop Device ……………. Optional

Max Opening ………………….. +25 mm

Control By Pressure ………. Optional

Motor …………………………………. 4 KW

Noise Level ……………………… 65 dBA

Crimping Force ……………… 1370 KN

Protection Class ………………….. IP56

Crimpings Per Hour …………….. 1200

LWH ……………… 6806001400 mm

Control ………………… Digital Control

Weight …………………………….. 270 KG

Standard Die Sets Included:

Die No. Length

6 8 10 12 14 16 19 22 26 30 34 39 45 51* 60 60 60 60 60 60 60 75 75 75 80 80 90 90

*Optional Die Sets Available.

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NHC-S32 DETAILS

Benefit:
· Digital Precision Control · Quick Change Tool and Die Rack · Energy Saving and Safety Operation · TUV, CE, CSA Approved

w-line Main Specifiation ………….. NHC-S32
Max Hydraulic Hose …….. 2 4 Spiral
e Crimping Range …………….. 4-87 mm
Die Type ……………………………….. S20
nMaster Die Length ……………. 80 mm

Voltage …………….. 220V 1ph 20 amp Foot Pedal …………………….. Included Die Rack ……………………….. Included Quick Change Tool ………… Included Backstop Device ……………. Optional

Max Opening ………………….. +32 mm