CustomCrimp CC200 Manual de usuario
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Innovating SMART Hose Assembly Solutions Since 1979
CC200 / CC400 CRIMPERS OPERATORS MANUAL
WITH DIAL MICROMETER STYLE ADJUSTMENT
Max Head Opening
W/O Dies
160mm
6.30"
Max Head Opening
W/O Dies
182mm
7.17"
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Innovating SMART Hose Assembly Solutions Since 1979
• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER.
• CRIMPER CC200 CAN PRODUCE 340 TONS OF CRIMPING FORCE.
• CRIMPER CC400 CAN PRODUCE 265 TONS OF CRIMPING FORCE.
• KEEP BOTH HANDS AWAY FROM PINCH POINTS.
• CONSULT HOSE AND FITTING MANUFACTURER FOR CORRECT MACHINE SETTINGS
AND CRIMP MEASUREMENTS.
• ALWAYS WEAR EYE PROTECTION.
SAFETY PRECAUTIONS
! !
Rev: 05/2023
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Innovating SMART Hose Assembly Solutions Since 1979
SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2
COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4
INITIAL SET UP & MAINTENANCE--------------------------------------------------------------------------------------------------------5
INTERMEDIATE ADAPTER DIE INSTALLATION-------------------------------------------------------------------------------------6
HYDRAULIC DIE INSTALLATION------------------------------------------------------------------------------------------------7
AccuStopTM COUPLING STOP SET UP------------------------------------------------------------------------------------------------8
CRIMPING----------------------------------------------------------------------------------------------------9
CALIBRATION----------------------------------------------------------------------------------------------------10
TROUBLESHOOTING----------------------------------------------------------------------------------------11
CC200 / CC400 CRIMPERS REPLACEMENT ACCESSORIES------------------------------------------------------------------------12
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------13
CUSTOM CRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------17
CUSTOM CRIMP® CONTACT INFORMATION--------------------------------------------------------------------------------------18
TABLE OF CONTENT
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Innovating SMART Hose Assembly Solutions Since 1979
Notch for clearance
of 90° ttings
Metric Micrometer
Style Adjustment
Manual Back Stop
The Foot Switch permits dies
to be “jogged” into position
and keeps both hands free
The 5 HP motor delivers the
power needed to get the job
done quickly
29"
20"
Small Footprint for
minimum use of space
32"
Built-in die storage panel
keeps frequently used die
sets readily available
Power Switch
Metric Micrometer
Style Adjustment
Manual Back Stop
CC200 Hydraulic Hose Crimper
CC400 Hydraulic Hose Crimper
The Foot Switch permits dies
to be “jogged” into position
and keeps both hands free
The 5 HP motor delivers the
power needed to get the job
done quickly
29"
20"
Small Footprint for
minimum use of space
32"
Built-in die storage panel
keeps frequently used die
sets readily available
Power Switch
Oil Filler Cap
Reservoir
Oil Filler Cap
Reservoir
COMPONENT PARTS & TECHNICAL DATA
CC200 Technical Specifications
Crimping Force: 340 Ton
Hydraulic Hose Capacity: 2 Spiral = 2½",
4 Spiral = 2½", 6 Spiral = 2"
Industrial Hose Capacity: 3"
Crimper Size: L: 20" x W: 29" x H: 32"
Crimper Weight: 635 lbs
Power: 5HP / 230V / 3Phase (Standard)
5HP / 440V / 3Phase (Optional)
5HP / 230 / 1Phase (Optional)
1HP / 12VDC & 24VDC (Optional)
Die series: 99S / 130S
Adjustability: Metric
Opening w/o dies: 160mm / 6.30"
Master die inside diameter: 130mm / 5.12"
Master die travel: 38mm / 1.5"
Reservoir capacity: 8 US Gallons
Oil type: ISO 46 Hydraulic Oil
CC400 Technical Specifications
Crimping force: 260 Ton
Hydraulic hose capacity: 2 Spiral = 2½",
4 Spiral = 2½", 6 Spiral = 1½"
Industrial hose capacity: 4"
Crimper size: L: 20" x W: 29" x H: 32"
Crimper weight: 660 lbs
Power: 5HP / 230V / 3Phase (Standard)
5HP / 440V / 3Phase (Optional)
5HP / 230 / 1Phase (Optional)
1HP / 12VDC & 24VDC (Optional)
Die series: 99S / 145S / 102819
Adjustability: Metric
Opening w/o dies: 182mm / 7.17"
Master die inside diameter: 145mm / 5.71"
Master die travel: 60mm / 2.4"
Reservoir capacity: 8 US Gallons
Oil type: ISO 46 Hydraulic Oil
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Innovating SMART Hose Assembly Solutions Since 1979
Do not lift the machine by the crimper head.
Lift with a fork lift under the tank.
Mount the crimper on a sturdy surface.
Check electrical circuit to be certain that it matches the crimper
requirements shown on the tag attached to the crimper cord.
Electrical Requirements:
230 Volt 3 Phase Current (Standard)
440 Volt 3 Phase Current (Optional)
230 Volt single phase (Optional)
DO NOT RUN CRIMPER ON AN EXTENSION CORD.
Check to be certain that the motor rotates in the direction of the arrow
shown on the motor housing. If motor rotation is opposite of the direction
of the arrow, reverse any two hot wires in the electrical plug.
(NOTE: THIS IS APPLICABLE TO 3 PHASE CIRCUITS ONLY).
Damage to the pump can result if the motor does not rotate in the
correct direction.
Check the oil level in the sight glass on the rear of the crimper. 8 U.S,
gallons of ISO 46 hydraulic oil are required to completely rell the tank.
Oil can be drained from either of the two ports at the bottom of the tank.
An additional oil cooler, while not normally required, can be plumbed
into the two ports at the rear of the crimper.
Front Flange Bolts: Periodically, every 6-12 months depending upon
usage, the front ange bolt torque should be checked. The correct torque
is 332NM (245 Ft-Lbs).
Lubricate the crimping head after each 100 crimping cycles or at the
start of each shift if the crimper is used in a production setting.
• Bring the master dies to the fully closed position and lubricate the die
ngers through the 8 lubrication ttings in the front ange face.
• Bring the dies to the fully open position and lubricate all 8 ttings again.
Use CRIMPX Die Lubricant Grease or high quality moly-disulde grease.
Failure to do so may result in damage to the wearing surfaces.
INITIAL SET UP & MAINTENANCE
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Innovating SMART Hose Assembly Solutions Since 1979
• Dies are available for the CC200 crimper in 84S, 99S and 130S Series
• Dies are available for the CC400 crimper in 84S, 99S and 145S Series
• A set of 130mm O.D - 99mm I.D. Intermediate Dies is furnished with the
CC200 crimper.
• A set of 145mm O.D - 99mm I.D. Intermediate Dies is furnished with the
CC400 crimper.
The I.D. of the intermediate die must match the O.D. of the hydraulic die or
accurate crimps are not possible.
INDUSTRIAL DIE INSTALLATION
INTERMEDIATE ADAPTER DIE INSTALLATION
Turn on the crimper at the master power switch.
Bring the master dies to the full open position as shown in photo A, or to the
position where the die removal tool can be inserted to release the retaining
spring.
Insert the die removal tool in the release hole to release the retaining spring
as shown in photo B.
Attach either an Intermediate Adapter Die or an Industrial Die to the Master
Die as shown in photo C.
Note: The numbers stamped on the face of the die should face the operator.
Note that on some crimpers the master dies must be slightly closed in order
to completely insert the die removal tool.
Mount all 8 dies in a similar manner as shown in photo D.
If 130mm O.D. Dies are being used, proceed to crimping
Operating instructions and set up the crimper for the correct
crimp diameter.
If Hydraulic Dies are being used, see Hydraulic Die Installation
instructions.
A
B
C
D
INTERMEDIATE ADAPTER DIE INSTALLATION
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Innovating SMART Hose Assembly Solutions Since 1979
Install Intermediate Adapter Dies as shown previously making certain
that the Intermediate Adapter Die I.D. matches the Hydraulic Die O.D.
Bring the crimper head to fully opened position as shown
in photo A.
Install the Hydraulic Dies with the quick change tool as shown
in photo B.
Note: The die size stamped on the face of the die should face toward
the operator.
Align the studs of the Hydraulic Dies with the holes in the Adapter Dies
and SLOWLY close the crimper head on the die set as shown in photo C.
Bring the crimper head to a fully closed position as shown
in photo D.
Remove the quick change tool as shown in photo E.
Note: The dies may also be inserted manually with the crimper head in
the fully open position.
Proceed to the Crimping Instructions to set up the crimper for the hose
and tting being crimped.
For Hydraulic Die removal, bring the crimper head to the fully closed
position.
Insert the quick change tool and open the crimper head releasing the
Hydraulic Dies form their spring retention holes.
A
B
C
D
E
HYDRAULIC DIE INSTALLATION
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Innovating SMART Hose Assembly Solutions Since 1979
Coupling Stop
Coupling Stop
Clamp
Coupling
Stop Guide
The AccuStopTM coupling stop eliminates guesswork
allowing the operator to visually observe exactly where
the crimp will be positioned on the tting without the
need for trial and error and product scrap due to poor
crimp positioning.
With the Coupling Stop retracted, load the appropriate
set of dies and set crimp diameters as required.
With the crimper in the MANUAL mode, bring the dies
to a fully closed position.
Loosen the Coupling Stop Clamp
and position the Coupling Stop
against the back face of the dies.
Slide the Coupling Stop Guide
against the Coupling Stop Arm.
Hold the tting against the Coupling
Stop Arm withdraw the Coupling Stop
Rod such that the Guide is aligned
with the desired crimp position. Lock
the Coupling Stop Clamp.
Position the tting against the Cou-
pling Stop and actuate the crimper
in the normal manner.
The dimension from the face of the
tting to the crimp position will now
be the dimension established in the
previous step.
AccuStopTM COUPLING STOP SET UP
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Innovating SMART Hose Assembly Solutions Since 1979
CRIMPING
Select the correct die for the combination of hose and tting being
crimped. Consult the hose and tting manufacturer’s specications
for the correct die to use and the nal crimp diameter required.
The nal crimp diameter will be the closed diameter stamped on the
face of the die plus the number shown on the micrometer gage. See
the micrometer setting example below:
Micrometer Setting Example
Each 100 on the micrometer dial represents 1 mm above the
closed diameter of the die set. For example, with a 57mm
die set installed and the micrometer set at 240 as shown in
the photo, the nal crimp diameter would be 59.4 mm ( 57mm
+ 2.4mm)
Insert the hose and tting in the crimper head to the correct depth
and press and hold the foot switch until the crimper shuts o. If the
AccuStopTM coupling stop is being used make settings according to
instructions.
Check the nished crimp diameter with calipers to be certain that it is
within the hose manufacturer’s specications.
CRIMPING
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Innovating SMART Hose Assembly Solutions Since 1979
Step 1. Use a 0.050" allen wrench to
loosen the set screw on the black knob
to remove the micrometer dial.
Step 2. Rotate the micrometer shaft
counter clockwise until the shaft stops
spinning.
Step 3. Align the numbers on the dial so
that 20 is shown in the black and 75 is
shown in the silver.
Step 4. Align the post on the bottom of the dial to the bottom hole on the micrometer
face as shown.
Step 5. Make sure the dial is sitting at
against the micrometer then retighten
the set screw on the black knob.
20
75
Step 6. Load correct die set into crimper for your test crimp. Put the proper setting into the micrometer then perform test crimp.
If crimp is still tight or loose follow steps 7 thru 10.
Step 7. If the crimp diameter is too tight by 0.004” spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw on
the black knob, spin the dial to 1 at the top and 90 at the bottom and then retighten the set screw. Return the dial to your setting
and crimp another tting.
Step 8. If the crimp diameter is too tight by 0.008" spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw on
the black knob, spin the dial to 1 at the top and 80 at the bottom and then retighten the set screw. Return the dial to your setting
and crimp another tting.
Step 9. If the crimp diameter is too loose by 0.004" spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw on
the black knob, spin the dial to 2 at the top and 10 at the bottom and then retighten the set screw. Return the dial to your setting
and crimp another tting.
Step 10. If the crimp diameter is too loosen by 0.008" spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw
on the black knob, spin the dial to 2 at the top and 20 at the bottom and then retighten the set screw. Return the dial to your
setting and crimp another tting.
Step 11. If your crimp it outside of these numbers, or you need additional assistance please call technical service at
219.462.6128.
CALIBRATION
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