Crimping Machine

Please read completely through these insturction before using the crimper.
your DOUGLAS DE 1600 HAND CRIMPER is supplied factory pre-set for quic change-over between most aluminium window systems.

PLEASE NOTE :
The crimping bench should be constructed in such a way as to offer suitable support for the material being crimped, in order to protect material being crimped from damage, it is advisable to cover the bench bearers with carpet to similar and keep the surfaces clear of swarf or objective likely to damage material surfaces.

SETTING UP
Remove crimper from box, locate on corner of suitable bench, which must be a robust and stable comstruction. Secure to bench with four M10 counters unk bolts or screws. Insert handles into handle sockets and secure with loking screws which must locate into dimples provided on handle ends. Remove toggl clamp from packing and fix to top of anvil block with two M6 x 10 socket cap screws which are located in the anvil block.

WARNING :
(1) Do not operate the crimper unless both handles are secured as described above, failure to comply may result in the handles slipping out of the sockets and causing a hazard to the operator.
(2) The punch heads are sharp and must be handled with care.
The DE 1600 hand crimper is designed for two handed operation by one operator only. It is the operators responsibility to ensure that the path of the punch heads are unobstructed are operating the hand lever handles.

TOOLING CHANGES
ANVIL INSERT
(1) Loosen locking screws (R) Fig. 1 and lift of insert (Q)
(2) Slide alternative insert into place, ensure face marked "TOP" is uppermost, locate firmly on bottom face or pins, ensuring that the rear face of the anvil insert sits flat against the anvil block.

CRIMP PUNCH HEADS
(1) Remove completely the retaining screws (J) Fig 1
(2) Pull Punch Heads our of location slots.
(3) Clean all location faces.
(4) Select correct punch heads to match anvil insert, push into location slots, replace retaining screws (J) and screw down.



TOGGLE CLAMP ADJUSTMENT
(1) Select short mitred corner from off-cuts of profile to be crimped, insert correct cleat (s) and corner brance (s) and locate corner on anvil insert.
(2) Adjust clamp spindle (v) Fig 1. so that when clamp lever locks ito forward locked position the test corner is held by the clamp pd, with a pressure equivalent to a firm finger pressure.
(3) Tighten clamp spindle lock nuts.

PLEASE NOTE !
If the clamp pressure is set to high, distortion of profile will occur resulting in poor crimping.

CRIMPING TEST JOINT
Before starting production it is advisable to test toooling changes as follows :-
(1) Leave small sample corner piece in position after setting Clamp.
(2) Bring the handles in towards the centre until Cr5imp Heads touch the profile.
(3) Open box section profiles the crimp action can be performed by applying equal pressure to both handles simultaneously until the Link Ars (F) Fig 1. lock into a straight line with Punch Heads.
(4) When crimping heavy gauge or closed box section profiles it may be found easier to hold one Crimp Punch Head firmly against profile for support whilst the other Head is crimped into it's full depth. Then with a slight alteration in stance, the first head can be pushed to it's full depth.
(5) Both crimp Punch heads should be withdrawn from the profile simultaneously.

PLEASE NOTE !
Under no circumstances should any one Punch Head be used without firm support of the other one. failure to observe this basic rule will result in the profile frame moving on the anvil insert, a poor crimped joint being produced and possible damage to the Crimper.

SETTING CHECK
The crimper is supplied factory set and has been test crimped prior to dispatch if for any reason the setting of the crimpter is in doubt the following procedure should be adopted.
(1) Cut a sample corner of material to be crimped
(2) Carefully check the cut and establish that the cut is a true 45, flat and at 90 to both legs of the section.
(3) Offer the appropriate setting piece to the anvil insert and check that the setting is as shown Fig. 2
(4) The punch heads tips should engage onto the slope of the cleat as shown and should either just "skim" the setting piece or clear with minimal clearance.
(5) The punch heads should ride down the slope until the link arms lock into straight line with the punch heads. The initial setting for the depth to which the punch heads should run is approximaterly two thirds of the full tepth see Fig. 2 The optimum setting is best established by carrying out test crimps and checking results.



PLEASE NOTE
A Setting Piecd can be made up by fixing with a suitable adhesive, two packing strips to the back of a cleat that is to be used in the system. The packing strips must be eqial in thickness to the wall of the profile to be crimped.

ADJUSTMENTS
Should the crimpel require resetting, both the anvil position and the depth of bite of the crimp heads are fully adjustable

ANVIL ADJUSTMENT
1) Remove the clamp assembly (U) by removing 2 screws (T), this will reveal a socket head screw. Slacken this screw.
2) Slacken the four nuts at the extreme rear of the crimper (S).
3) Using the setting piece as a guide, adjust the anvil towards or away from the crimp punch heads by turning the nuts. Set the anvil so that the crimp punch heads ride down the slope of the setting piece as shown in Fig 2.
ADJUSTMENT OF PUNCH HEADS
Each ram assembly is secured tgo the casting by 2 screws (P), slaken to allow the punch head assembly to slide in the casting. By slackenning the lock nut and adjusting screws (N), the position of the punch heads can be adjusted. Adjustments should be initially set so that the crimp punch heads run down the slope on the setting piece to approximately two thrids depth. The assembles must be locked in this position by re-rightening the socket screws (P). The final depth setting is best established by carrying out test crimps and making minor adjustments until satisfactory results are obtained.
NOTE
Setting the bite of the punch heads too deeply is to be discouraged, if set too tight the resulting joits will not necessarily be tight. "bottoming out"on the cleat is not necessary when trying to obtain a good quality crimp.

An indication that the cimper is set over tight, is difficulty encountered when withdrawing crimp punch heads from the crimped material

Ensure that all the bolts and nuts are tightened after adjustment have been carried out to maintained settings.

is it important that when the crimper is finally set, the heads should both run equal depths on the test piece.

It is important that the anvil is set so that the crimp punch heads ride down each slope in the same manner, i.e. the anvil must not be set askew relative to the crimp punch heads.

MAINTENANCE

Standard packing by using wooden box for which we have government policies and standards for safe delivery of the products. we are also arranging the third party inspection for quality of products and packaging which is useful for clearance of goods specifically for Africa.