NC40-640 Crimping Machine

Operation manual
 Contents

1. Structure and work principal.

2. Specification details.

3. Electric control.

4. Operation

5. Maintenance

6. Safety

7. trouble shooting.

8. appendix.
1. Structure and work principal.

7 8 9
1
2 NEKON
construction

TIMEREGUIATOR
（DIE-BACKING)

3 On

Off
POWER
AUTO MANUAL

1. ring cylinder 2. Sliding block 3. Ring spring 4. Pressing dies 5. Positioning

magnetic plate 6. Oil tank 7. Control panel 8. Pressure Meter 9. Electric box

Work Principal：
The annular piston pushes the sliding block sliding in the conical sliding path on the
inner wall of the annular cylinder, they taper fit with each other so when the sliding
blocks move forward, they also push the pressing dies into the axis direction which
press on the work piece.
2. Major specifications
rebar sizes for the couplers Ø12 -Ø40
Pressing die moving distance ±15MM
Hydraulic pressure 31.5Mpa
Pump capacity 90L/Min
Oil type 46# hydraulic oil
Oil Tank volume 480L
Cooling system Air cooling
Moter power 11kW
Power Supply 380V 50Hz
Machine weight (kg) 1800 kgs
Machine dimensions 1320x850x1500mm

3. Electric control
3.1 Control Panel:
1 2 7 8

NEKON
construction
3

MOTOR

4
On Off TIMEREGUIATOR
（DIE-BACKING)
CYLINDER
5
On

6 PRESS RELEASE

Off

POWER
AUTO MANUAL

1. Motor On 2.Motor Off 3.Release (dies open) 4.Press (Dies close) 5. Manual
mode 6. Automatic mode 7. Die release meter 8. Main power Switch

3.2 The electric principal refers to the attached electric diagram.

4. Operation
4.1 input oil；input 480L 46# hydraulic oil into the tank (The oil level meter should be
above 2/3)
4.2 Power switch on；Switch on main power. Press the motor on button, check
whether the motor rotates along the direction of its arrow to make sure the motor
rotation direction is correct.
4.3 Test the button；test each button on the control panel to see they work correctly.

4.4 install the pressing dies and the positioning device；

After finish the above initial check up, ensure the machine is in “manual mode”,
press the release button to move the sliding blocks backword to the end of its
position (biggest opening of the sliding blocks), then stop the motor and start
installing the pressing dies as follows:

Select the correct dies, check the dies are Move the sliding blocks to its max.
intact and no cracks, the handle is not loose, opening by manually operate the
to make sure they are in good condition. release button and then stop the motor.

Put the pressing dies on the sliding blocks

by the sequence from the bottom to the top,
make sure the handle sit in the positioning
Use 17mm spanner to loosen the 8 fixing hole on the sliding block.
bolts

Put all the 8 pressing dies in, tighten the
fixing bolts a little bit and make sure the 8
dies are in good position.
Switch on the motor, operate manually to
(press the “press button) close the sliding
blocks so the press dies close to its
minimum opening. Stop the motor and
tighten the fixing bolts.

Set up the positioning device

Release the fixing bolts of the positioning Take out the positioning device.
device on the back of the machine.

Change the positioning bar (different

length) according to the coupler size.
This positioning bar stops the rebar in the
coupler when the coupler end touches
the positioning plate. So this is to set up Install it back on the machine.
how much length the rebar goes into the
coupler.

Release the positioning lock bolt so the
positioning device inside can move
easily.
Switch on the motor, put in a coupler, close
the pressing die a little by manual
operation, then adjust the position of the
positioning plate by moving the whole
positioning device forward or back work till
the right position reached. This is to set up
the length of pressing on the coupler.

Insert the coupler with the rebar inside,

After position calibration, tighten the lock
bolt to lock the positioning device.
make sure the coupler touches the
positioning plate and the rebar touches the
positioning bar, then the right pressing can
be reached.

4.5 Adjust the hydraulic pressure；Press down the red knob on the pressure meter
and at the same time turn the pressure indicator (hand) to the desired position, then
release holding down the red knob so the desired pressure is set.
4.6 Adjust the release timer；

It’s not necessary to let the pressing dies (sliding blocks) always return to their very
beginning position as this would waste time if the opening is already big enough to
receive the certain size of the coupler. The release timer is to set the time for the
cylinder to return so a proper time for the cylinder to return means once the opening
is big enough for the certain coupler, the pressing dies will stop open more and the
next press can start automatcically (This function works only in automatic mode).

Enter into automatic mode by pressing the

Auto button. Set up the desired release time
(the time for the cylinder to return). Please
refer to the attached table to choose the
proposed release time.

4.7 Automatic mode.

Once the manual operation (pressing “press” button in manual mode) reaches the
satisfactory result of coupler pressing and the release timer is properly set, the
machine can enter into Automatic mode by pressing “automatic” button. In
Automatic mode, after put in the coupler and rebar in place in the machine, just
press the foot pedal then the pressing and release process shall complete
automatically.

5. Lubrication and maintenance.

5.1 The machine must be placed on ground horizontally.
5.2 Important: Before each batch production, lubricating the sliding paths (the 8
sliding paths on the inner wall of the annular cylinder, just lift the sliding block a
little it can be seen) and the sliding blocks with grease. Set the pressure to the
minimum, release the sliding blocks (pressing dies) to the maximum, apply the
grease on the inner wall of the cylinder, also lift the sliding block a little bit so the
grease can be put into the sliding path with a grease gun. Then close and open
the pressing dies several times without any load. After proper greasing, wipe out
all the grease outside to ensure the pressing dies are clean.
5.3 In case of leakage of the hydraulic oil, replace the hydraulic seals.
5.4 The hydraulic oil is 46#. The best temperature should be around 30℃~35℃.
5.5 Check the sliding blocks and pressing dies regularly, ensure they are in good
position and condition..
5.6 Clean the oil system, electron valve, overflow valves regularly.
6. Safety check up.
6.1 after switch on the motor, check around the machine to ensure no leakage of the
oil before starting work.
6.2 Stop the motor before change dies.
6.3 during pressing process, never inert hands into the dies.
6.4 The machine can only be maintained by professional personnel.
6.5 Don’t press the machine without load, don’t work long time with pressure more
than 30 Mpa (Max. 31.5Mpa)

7. Trouble shooting and solution

Problem Cause Solution
The motor rotates the wrong Change the phase of the power supply
direction
No hydraulic pressure restriction hole of the overflow valve clean the restriction hole
or low pressure jammed
overflow valve damaged repair or replace the overflow valve
pump damaged repair or replace the pump
oil level lower than the required refill the oil
The noise of the pump is
pump damaged repair or replace the pump
too big
shaft coupler damaged repair or replace the shft coupler
problem of the power supply for the check the power supply to the
electromagnet electromagnet.
Reversing valve does the reversing valve stuck or repaire or replace the reversing valve
not work damaged
no pressure of the hydraulic system adjust the overflow valve to increase
the pressure
big noise during bad lubrication in the sliding path proper lubrication.
pressing (dies, sliding
blocks)
Appendix 1. Recommended parameters for standard couplers:

L* L*
L L

D*

D*
d1

d1
D
D
d

d
f f
e e

Thread Before Recomd.

Rebar Recomd. Recomd. After pressing Die Ø
Coupler M Pressing Pressure
Ø
d D L e f D* L* （Mpa) (mm)
DSD10 10 12 17.5 47 28 23 14.3-14.6 52 2.3-2.6 12
DSD12 12 16 22 58 34 30 17-17.5 64 3-3.3 14
DSD14 14 18 26 68 38 34 20.5-21.5 74 4-4.5 16
DSD16 16 20 28 77 46 38 22-23 84 5.5-6 20
DSD18 18 22 31 87 50 41 24.5-25.5 95 6.5-7 20
DSD20 20 24 34 94 53 44 27-28 103 7.5-8 24
DSD22 22 27 38 101 58 48 32-33 110 8-9 24
DSD25 25 30 42 114 67 54 34-35 122 9.5-10.5 30
DSD28 28 33 46 125 70 58 39-40 132 12-12.6 36
DSD30 30 36 50 138 80 65 41-42 147 13.5-14.5 36
DSD32 32 42 57 149 81 55 49.5-50.5 160 16-17 45
DSD34 34 42 57 157 89 74 49.5-50.5 169 18-19 45
DSD40 40 48 67.5 182 104 85 59-60 194 22-23 55
The above parameters are recommended according to our couplers and the normal
conditions of our machine, tests are needed for the client to determine the best
parameters for their work.
 Appendix 2. Electric diagram for 11kw hydraulic station.:

L1 24V
LA

LB
L3 0.5mm2 thermal relay
LC Red
Circuit
AC380V breaker 1
0.4mm2 AC contactor
Red
0.5mm2
AC contactor SB1
emergency Blue
L2 stop
control
transformer 2

thermal relay electric

bridge
relay-1
SB2
start relay-2 4
U V W
3

M
button with button wit
~ AC contactor relay
lamp Green lamp Red
pump motor
11KW
0V motor start/stop

motor start/stop
 manual auto- Die Die electro release
matic close open connection time
(Press) (Release) pressure
gauge
24V

button button button button electro Time

with with with with connection relay2-1 relay3-1 relay2-2 relay3-2
pressure
relay
lamp lamp lamp lamp gauge

COM X01 X02 X03 X04 COM X05 X06 X07 X08 COM X09 X10 X11 X12

5 6 7

Controler eletro- eletro- eletro-

magnetic magnetic magnetic
valve1 valve2 valve3

diode diode diode

24+ 0V 24+ Y01 Y02 Y03 Y04 24+ Y05 Y06 Y07 Y08

0V
24V 0V eletro-magnetic valve eletro-magnetic valve eletro-magnetic valve
HL3 HL4 HL5 HL6 Time relay relay2 relay3 for die close for die open for overflow valve

24V
indicator of indicator of relay of
automatic die open die close
indicator of indicator of release relay of
manual die close time die open

Electric diagram for 11kw hydraulic station.

 list of connecting terminal

Note:COM,X3 connect to the pedal switch

COM

COM

24V
1 2 3 4 0V X1 X2 X3 X4 X5 X6 Y1 Y2 Y3 Y4 Y5 5 6 0V 7 0V

buttons on the panel pressure gauge lamps on the panel overflow

Valve Valve valve
for for
die Die
close open

manual automatic release time adjustment

24V Y1 24V Y2
COM X1 COM X2
Y5
24V

Die close (Press) Die open (Release)

24V Y3 24V Y4 COM X6
COM X3 COM X4

Start Stop
0V 3 0V 4
2 3 1 2
panel diagram
Appendix 3. Hydraulic diagram:

Check Valve

1DT 2DT

pressure gauge

4DT overflow
valve
air cooler

M3
motor air filter
M

shaft coupler

oil level
indicator
oil tank:480L