Crimping　Machine

Manual　Operation

ＰＧＣ１５００

日本オートマチックマシン株式会社

JAPAN AUTOMATIC MACHINE CO.,LTD.

1. Specifications　
　

1. Model ＰＧＣ１５００

2. Crimping ability １５０ｋＮ

3. Stroke length ３０～１００ｍｍ

4. Pressurizing method Hydraulic cylinder

5. Maximum use pressure １５．６ＭＰａ

6. Daylight ２５０ｍｍ

7. Shank hole φ ２５×６０

8. Bottom dead point

７０ｍｍ（electric adjuster）
　adjustment quantity
9. Power supply ３ φ　ＡＣ２００Ｖ　５０／６０Ｈｚ　１５Ａ（Power supply change: Within ±10%）

10. Motor pump output ＡＣ２００Ｖ　２．２ｋＷ

11. Hydraulic oil capacity ３２

12. Machine dimensions Refer to “General view”.

13. Weight Approx. 800kg

14. Accessory devices ①Electric adjuster

②Oil cooler

③Foot switch

④Safety cover

⑤Limit switch for safety cover

⑥Press safety limit switch

⑦Applicator one-touch base

2. General view
3. Installation of machine

(1) Put the level blocks under the machine (both sides of the caster). Fix the machine with the level jack to
set it horizontally.

(2) Check the oil level in the tank with the oil level gauge from the left side of the machine. The oil quantity
is sufficient when the oil reaches the middle of the level gauge. If the oil quantity is insufficient, supply
the oil.
Use the oil ISO VG-56 or its equivalent.

(3) Supply the main air of 5kgf/cm² or more to the air joint (20PM) on the right side of the machine (under
the control box).

(4) Connect the foot switch to the metal connector on the bottom of the control box.

(5) Connect the power cord to the power supply and set the circuit protector to “ON”. Check the power input
with the lamp.

(6) Apply the radio pliers to the radio pliers interlock. Make sure that the emergency stop button is not
pressed and that the safety cover is closed.
Set the key switch to “jog operation” and the motor to “ON”.

(7) Set the continuous terminal switch to “OFF” (lamp does not light) and press the original position reset
switch to reset the ram to the top dead point.
Depress the foot switch, and the ram lowers.
If the motor rotates reversely, the ram does not operate. Change two of the three wires, which are
connected to “R”, “S” and “T” of the terminal board in the control box.
Before changing the wires, remove the receptacle.
After making sure that the ram lowers, press the original position reset switch to return the ram to the
top dead point. Press the motor OFF switch to stop the motor.
　　
(8) The signal tower lights up when the hydraulic motor is ON.
4. Operation

４-１　Layout of operation panel

　　　
　　　1：Electric adjuster counter
　　　2：Emergency stop push-button switch
　　　3：Pressurizing timer
　　　4：Counter ON-OFF switch
　　　5：Production quantity counter
　　　6：Digital pressure controller
　　　7：Power switch
　　　8：Electric adjuster
“up ↔ down” switch
　　　9：Electric adjuster
“high speed ↔ low speed” switch
　　　10：Electric adjuster operation switch
　　　11：Hydraulic motor ON switch
　　　12：Hydraulic motor OFF switch
　　　13：Cylinder applicator selector push-button switch
　　　14：Original position reset switch
　　　15：Terminal feed original position indicator lamp
　　　16：Terminal feed switch
　　　17：Top dead point indicator lamp
　　　18：Pressurization indicator lamp
　　　19：Buzzer
　　　20：One process indicator lamp
　　　21：Jog operation indicator lamp
　　　22：OFF indicator lamp
　　　23：Mode selector key switch
24：Power indicator lamp
 4 - 2 Changing the air cylinder applicator/pin terminal applicator

Change the applicator by setting the air cylinder applicator push-button switch to “ON/OFF” on
the operation panel. When the switch is turned on, the air cylinder applicator mode is set.
When the switch is turned off, the pin terminal applicator mode is set.
When the slide type applicator is installed, access the air cylinder applicator mode.

4 - 3 Pin terminal applicator mode

(1) OFF
The hydraulic motor does not operate in this mode. During operation, if you set the key
switch to the “OFF” mode, the motor stops.

(2) Jog operation

Depress the foot switch, and the ram lowers at the pressurizing speed. Release the foot switch,
and the ram stops. To raise the ram, press the original position reset button.

(3) One process

　When the ram is at the top dead point, insert the wire and depress the foot switch. The ram of
the crimping machine performs the following one process: Lowers at high speed, →
Lowers as pressure is added, → Time is up, → Rises.

(4) Installation/removal of applicator

①Set the toggle clamp to the right side on the one-touch base.
　 　 　 ② Put the applicator on the one-touch base from the front of the crimping machine as
inserting the applicator’s shank into the ram bolt.
　　　③ Align the notch of the applicator with that of the one-touch base and set the lever of the
toggle clamp to the left side. Make sure that the applicator is installed without play.
④The installation of the applicator is completed.
Remove the applicator in the reversed procedure.

4 - 4 Air cylinder applicator (Operation of the slide type applicator)

 (1) OFF
The hydraulic motor does not operate in this mode. During operation, if you set the key
switch to the “OFF” mode, the motor stops.
The air cylinder cannot operate.

(2) Jog operation

Depress the foot switch, and the ram lowers at the pressurizing speed.
Release the foot switch, and the ram stops. To raise the ram, press the original position
reset button.
Unless the anvil of the applicator is at the crimping position, the ram does not lower.
When the crimping machine is at the top dead point, the anvil can be returned by the
toggle switch.

(3) One process

The operation start position is set when the crimping machine is at the top dead point and the
anvil is at the operator side.
Put the terminal on the anvil and push the anvil to the press-fit position as pushing the
terminal with the wire. Depress the foot switch, and the ram
performs the following one process: Lowers at high speed → Lowers as pressure is
added → Time is up → Rises. If the pressurizing sensor is ON while the ram is
lowering at high speed, the speed is changed to the pressurizing speed and the
pressurizing timer is ON.
After time is up, the anvil of the applicator returns to the operator side. When one
process is finished, the value on the counter is increased by “1”.

　　　(4) Installation/removal of applicator

① Set the toggle clamp to the right side on the one-touch base.
② Put the applicator on the one-touch base from the front of the crimping-
machine as inserting the applicator’s shank into the ram bolt.
③ Align the notch of the applicator with that of the one-touch base and set the lever of the
toggle clamp to the left side. Make sure that the applicator is installed without play.
④ Connect the air pipes of the applicator cylinder and the wires of the sensor.
⑤ The installation of the applicator is completed.
Remove the applicator in the reversed procedure.

4 - 5 Other operations

(1) Setting the top dead point of ram

①Lower the ram by jog operation to the desired position. Press the emergency stop button to
stop the motor.
 ②There is the knob (upper side), which fixes the top dead point sensor, on the left side of the
machine. Loosen this knob. Lower the sensor until the top dead point lamp lights up
and then fix it.
③When you want to raise the top dead point position, fix the sensor at the upper side and
press the original position reset switch.

(2) Setting the pressurizing timer

①There is the knob (lower side), which fixes the pressurizing sensor, on the left side of the
machine. Loosen this knob. Fix the sensor where you want to apply pressure.
　　　　② When the pressurizing sensor is ON in the one-process mode, the
pressurizing timer operates.
③Set the pressurizing time with the timer’s dial.

(3) Adjustment of pressurizing force

①Loosen the lock nut of the pressure adjustment bolt.
②Add pressure in the jog operation mode to set the indication of the pressure gauge to the
desired pressure.
③Tighten the pressure adjustment bolt, and the pressure rises.
④After setting the pressure, lock the bolt with the lock nut.

(4) Adjustment of flow

①Loosen the lock nut of the flow adjustment bolt.
②Tighten the flow adjustment bolt. The flow is decreased and the ram speed is slowed.
③The protruded length of the bolt should be 17mm in the 50Hz area, and 16.5mm or less in
the 60Hz area.
Pressure adjustment
bolt

Flow adjustment
bolt

5. Operation of the accessory devices

5 - 1 Electric adjuster
This adjuster can operate only when the ram is at the top dead point. Press the operation push
button when the toggle switch is at the “Up” side, and the crimp height is higher. When the
toggle switch is at the “Down” side, the mechanical stopper moves up and down to lower
 the crimp height.
The display unit of counter is 0.01mm.

5 - 2 Digital pressure controller

This controller displays and compares the oil pressure.
This controller measures the oil pressure when the set time of the crimping machine is up. If
the pressure exceeds the set value, the controller shows this
status with buzzer. Reset the machine with the original position reset button.

6. Maintenance

6 - 1 Replacing the cylinder packing

Polyurethane rubber is used as the material of the hydraulic cylinder’s packing because it is
not easily affected by heat or by the deteriorated hydraulic oil. You can use the packing
for 2 to 7 years without disassembling/inspecting. The standard for replacing the packing
 is approx. 500 ~ 1000km of the sliding distance, or 3 ~ 5 years of the use time. This
standard is changed according to the use conditions.

6 - 2 Replacing the oil

To keep the operation stable and the press performance normal, you must replace the
hydraulic oil.
First, replace the oil after three months since you purchased the machine and, thereafter,
replace the oil once a year.
Use the oil ISO VG-56 or its equivalent.
Replace the oil as follows.

① Open the rear cover of the crimping machine body. Remove the oil drain screw from the
oil tank and drain away the oil from the tank.
② After draining away, wind the seal tape around the screw and tighten it.
③ Supply the new oil into the tank through the oil filler port until it reaches the middle of the
oil level gauge.
④ Set the hydraulic motor to “ON” and, after a few seconds, set it to “OFF”. Repeat this
procedure two or three times to exhaust air from the pipes.
⑤ Check the oil level gauge. If the oil quantity is insufficient, supply it.

6 - 3 Lubrication
If the machine is oilless, not only its life will be shortened but also its parts will be damaged.
Be sure to lubricate the machine.

Lubricating point＿Open the front cover and lubricate the four grease nipples.
Interval of lubrication＿Every 3 ~ 4 months
Type of oil＿Grease

Grease Nipple

6 - 4 Set values of the electric adjuster counter

Input mode ： Ud-C

Output mode ： L
Counting speed ： 5kHz
Minimum reset time ： 20ms
Decimal point position ： ---------
 Prescale value ： 0.013
Key protect ： KP4
Input mode ： nPn
Display color change ： rEd

SET1 ： 7000
SET2 ： 　　0

6 - 5 Set values of the electric adjuster inverter

No01 ： 0 (Set it last.)

No02 ： Operation method 1
No06 ： Multi-function input 4
No11 ： Speed 1 6.0
No12 ： Speed 2 30
No20 ： Acceleration time 0.5
No21 ： Deceleration time 0.1
No37 ： Carrier frequency 1

7. Electrical Circuit Diagram

8. Arrangement on operation panel
 1 ：H7CR-CW
2 ：AVD301NR
3 ：ADX110E2
　ADX18002
4 ：8C2011
5 ：H7CE-NV
6 ：AP-V85
7 ：BAB3215311
8 ：8C2011
9 ：8C2011
10 ：A16-JGM-1
　A16ZJ-5050
11 ：A16-AGM-1
12 ：A16-ARM-1
13 ：A16L-ARA-24D-1
14 ：A16-AYM-1
15 ：DO-9HJT-24-G
16 ：8C2061
17 ：DO-HJT-24-G
18 ：DO-HJT-24-G
19 ：M2BJ-B24C
20 ：DO-9HJT-24-G
21 ：DO-9HJT-24-G
22 ：DO-9HJT-24-O
23 ：S-3-180-ABC-3
24 ：LMS-9JP-220-W

9. Arrangement in the control box panel

10. Hydraulic circuit diagram
 Prefill
valve

Solenoid valve

Ram Cylinder
ﾗﾑｼﾘﾝﾀﾞ

Pilot check Solenoid valve

Counterbalance valve
valve

Motor
Pressure gauge pump

Oil level
Oil cooler
gauge
Oil filler port breather
Thermometer Suction
　　 filter

Oil tank

11. Consumable parts list

Hydraulic cylinder unit
Part Name Type Q’ty
Packing *USI95 2
Packing *USI105 1
Dust seal *LBI10511568 1
O-Ring *G125 2
O-Ring *G105 1
O-Ring *G55 1
O-Ring *P65 1
O-Ring *P34 1
O-Ring *P30 1
O-Ring *P28 2
O-Ring *P22A 1
O-Ring *P16 1
O-Ring *P12 1
Backup Ring *T3G105 1
Sleeve *WPB-110 1

Control unit
Part Name Type Q’ty
Relay *G2R-2-SND-DC24V 7
Timer *ADX110E2 1