CustomCrimp CC1000 User manual

1
CC1000 CRIMPER OPERATORS MANUAL
WITH ACTTM CONTROLLER

2
COMPONENT PARTS IDENTIFICATION -------------------------------------------------------------3
SPECIFICATIONS AND INITIAL SET UP -------------------------------------------------------------4
ACTTM CONTROL OPERATION -------------------------------------------------------------------------5
DIE SET UP AND INSTALLATION --------------------------------------------------------------------13
INITIAL SET UP AND MAINTENANCE --------------------------------------------------------------14
TROUBLESHOOTING ------------------------------------------------------------------------------------15
EXPLODEDPARTS BREAKDOWN ------------------------------------------------------------------------16
SAFETY PRECAUTIONS
READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS
BEFORE USING CRIMPER
KEEP HANDS AWAY FROM PINCH POINTS
CONSULT HOSE AND FITTING MANUFACTURER’S
SPECIFICATIONS FOR CORRECT MACHINE SETTINGS AND
CRIMP MEASUREMENTS
ALWAYS WEAR EYE PROTECTION
CC1000 Crimper Operators Manual With ACT™ Controller (Revised 03/28/2016)
For Parts and Service, Contact:
Custom Machining Services, Inc.
Valparaiso, In 46383
[phone]

3
Oil Level
Sight Glass
Power Switch
COMPONENT PART IDENTIFICATION
Master Dies
145mm to 99mm
Adapter Dies
99mm Hydraulic Dies
Hydraulic Power Unit
and Controls
145mm to 99mm
Adapter Die
Hydraulic Die
230mm to 145mm
Adapter Die
Master Die
230mm to 145mm
Adapter Dies
Return
Hose
Adjustable Mirror
Hydraulic 99mm Die
Storage Pockets
Industrial Die
Storage Shelves
Pressure
Hose

4
CRIMPER SPECIFICATIONS AND INITIAL SET UP
SPECIFICATIONS:
MAX HEAD OPENING W/O DIES ------------------------------------------------------------------------350 MM (13.7 IN)
MASTER DIE INSIDE DIAMETER -------------------------------------------------------------------------230 MM (9.1 IN)
MAXIMUM DIE OPENING ----------------------------------------------------------DIE CLOSED DIAMETER + 125 MM
CRIMPER SIZE -----------------------------------------------------------------44 IN WIDE X 30 IN DEEP X 74 IN HIGH
WEIGHT ------------------------------------------------------------------------------------------------------6185 LB. (2904 KG)
ELECTRICAL REQUIREMENTS ----------------------------------------------------220 VOLT 3 PHASE (STANDARD)
--------------------------------------------------- 440 VOLT 3 PHASE (OPTIONAL)
MOTOR -------------------------------------------------------------------------------------------------7.5 HP (2 STAGE PUMP)
RESERVOIR CAPACITY --------------------------------------------------------------------------------------------50 US GAL
OIL TYPE ----------------------------------------------------------------------------------------------ISO 46 HYDRAULIC OIL
ADAPTER DIES ----------------------------------------------------------230 MM TO 145 MM AND 145 MM TO 99 MM
HOSE CAPACITY ----------------------------------------------------------------------------------------2-1/2 INCH 6 SPIRAL
--------------------------------------------------------------------------------------10 INCH INDUSTRIAL
INITIAL CRIMPER SET UP
• CHECK RESERVOIR OIL LEVELWITH SIGHT GLASS ON THE FRONT OF THE POWER UNIT.
• CHECK ELECTRICAL CIRCUIT TO BE CERTAIN THAT IT MATCHES THE CRIMPER REQUIREMENTS
AS SHOWN ON THE TAG ATTACHED TO THE CRIMPER CORD.
• MAKE CERTAIN THAT MOTOR ROTATES IN THE DIRECTION OF THE ARROW SHOWN ON THE
MOTOR HOUSING.
• IF MOTOR ROTATION IS INCORRECT REVERSE ANY TWO HOT WIRES IN THE CRIMPER PLUG.
• CONNECT THE PRESSURE AND RETURN HOSES AS SHOWN AND CONNECT THE YELLOW
ELECTRICAL CORD TO THE CONTROL PANEL.
• ALSO SEE ADDITIONAL INFORMATION ON THE INITIAL SET UPAND MAINTENANCE PAGE.

5
AccuCrimp ACTTM CONTROL PANEL
EMERGENCY
STOP
MANUAL MODE FUNCTION: CLOSE DIES
AUTO MODE FUNCTION: CYCLE START
MANUAL MODE FUNCTION: OPEN DIES
AUTO MODE FUNCTION: CYCLE STOP
TOUCH SCREEN CONTROL PANEL
U.S. Patent No: 7,383,709
NOTE:
IF THE CRIMPER IS IN MANUAL MODE, THE
GREEN OPEN/CLOSE BUTTONS WILL OPEN AND
CLOSE THE CRIMPER HEAD.
IF THE CRIMPER IS IN AUTO MODE, THE BUT-
TONS FUNCTION AS CYCLE START AND CYCLE
STOP BUTTONS.
IF THE CRIMPER IS IN SEMI-AUTO MODE,
PRESSING THE FOOT SWITCH OR THE CLOSE
BUTTON WILL CLOSE THE CRIMPER HEAD AND
RELEASING WILL HALT THE CLOSING ACTION.

6
ACTTM CONTROLLER QUICK START
While the ACTTM crimper has the ability to perform a
number of fully automatic functions, manual operation is
also possible. To make a manual crimp, two numbers are
needed:
• The closed diameter of the die (in either in or mm)
• The fi nished crimp diameter (in either in or mm)
That’s all you need to know. ACTTM does the rest.
TO MAKE A MANUAL CRIMP:
• Press START MOTOR.
• Select CRIMP TO DIAMETER.
• Enter the closed diameter of the die set in either in or mm and press ENTER.
Note: for a 25mm die, enter 2500. ACTTM will add 2 decmal places.
for a 1.5 inch die, enter 1500, ACTTM will add 3 decimal places.
• Enter the finished crimp diameter and press ENTER.
• From the ENTER CRIMP screen, press the MANUAL button to put the crimper in manual mode.
• Confirm that the die and finished crimp diameters are correct and that MANUAL MODE is displayed.
• Press and hold the green close button until the crimper stops closing.
• Check the final crimp diameter. If a minor correction is required see HOW TO MAKE MINOR
CORRECTIONS.
Tip: Pressing the CHANGE DIES button allows the crimper head to be fully opened or closed with
the green OPEN-CLOSE buttons on the controller front panel When the CHANGE DIES button is
blinking the dies can be opened and closed manually without altering any of the crimper settings.

7
HOW TO MAKE MINOR CORRECTIONS
Due to variations in hose and fitting tolerances a minor crimp
adjustment may be required if the measured diameter of the final
crimp is not within the hose and fitting manufacturer’s specifications.
ACTTM technology makes minor corrections a simple process which
requires no addition or subtraction.
If the finished crimp diameter is not within the required
specifications:
• Press the ADJUST CRIMP button.
• Enter the measured diameter of the fitting in either inches or
mm (Do not enter the amount of correction)and press
ENTER
• Press SAVE.
• Make another crimp and verify that the fitting is within
specifications.
EXAMPLE: If the hose and fitting manufacturer specifies
that the finished crimp should measure 1.500 to 1.520 and
the measured crimp diameter was 1.530, simply enter the
measured diameter (1530 - Controller will supply 3 decimal
places) and press SAVE. The finished crimp diameter
can be entered in either in or mm and ACTTM will make the
conversion.
While a single correction will usually bring the hose and fitting
into specifications, the process can be repeated as many times as is
required.

8
HOW TO ADD A SAVED DIE
Up to 50 different dies can be saved in the computer memory. These
dies can be recalled in the set up process eliminating the need to re-
enter the die size each time.
To enter a saved die:
• From the OPTION screen, press SETUP MODE.
• Select SAVED DIES.
• Select the save position (1-50) where the die is to be saved and
press the EDIT button.
• Enter a die description (up to 12 alpha/numeric characters).
• Enter diameter units (inch or metric).
• Enter the closed diameter of the die.
• Press SAVE and EXIT.
The saved die will now appear on the SELECTED DIE
screen. From this screen individual dies can be cleared or edited.
HOW TO RECALL A SAVED DIE
• Select CRIMP TO DIAMETER, and from the OPTION screen,
select USE SAVED DIE.
• Select the saved die (1-50) and press LOAD and then OK.
The die parameters will now be used for the crimp process.
• From the ENTER CRIMP screen press MANUAL.
• The saved die will now be shown on the crimp parameters
screen.

9
HOW TO ADD A SAVED CRIMP
• Adjust the die diameter and crimp diameter as required and
place the crimper in MANUAL mode.
• Press SAVE.
• Select a location (1-150) and press EDIT.
• Enter a description (up to 12 characters).
• Press SAVE and EXIT.
The die and crimp setting can now be recalled from the
saved location as required.
TO RECALL SAVED CRIMP
• Select USE SAVED CRIMP from the option screen.
• Select a previously saved crimp from location 1-150.
• Press LOAD.
The saved crimp will appear on the manual screen.

1 0
FULL AUTO MODE
With the crimper in FULL AUTO mode additional functions are
available:
• The crimper will cycle automatically from the CRIMP button on
the touch screen, the green CYCLE START button on the panel,
or the foot switch.
• To set the position to which the dies will retract, close the
crimper to the desired retract position prior to pressing the
FULL AUTO button.
• Pressing the FULL AUTO button will toggle the crimper into
SEMI-AUTO mode. In SEMI-AUTO mode, pressing the
FOOT SWITCH or the CLOSE button will close the crimper
head and releasing it will cause the head to stop closing. This
mode allows the crimper to be jogged into position allowing
more precise positioning of a fitting in the dies. Pressing the
SEMI AUTO button will toggle the crimper back to FULL
AUTO mode.
In FULL AUTO mode pressing the foot switch will start the crimp
cycle and the dies will stop closing when the crimp cycle is complete
• The COUNT function is activated allowing the operator to
monitor the number of crimps made.
• A measurement can be required after a preset number of
crimps. See SET REQUIRED MEASUREMENT.
SET REQUIRED MEASUREMENT
• Press the PRODUCTION button.
• Determine if 1 or 2 crimps will count as a crimp.
• Toggle the CRIMP ADJUSTMENT REMINDER to ON.
• Set the COUNTS BETWEEN CRIMP MEASUREMENTS
to the desired number and press OK.
• At the set interval, the ADJUST CRIMP screen will come up
and the operator will be asked to measure the last crimp and
enter a correction if required.

11
ADJUST CRIMP COUNT
If a production operation is interrupted for some reason, it is possible
to reset the counter to where the operation was at the point of
interruption.
• Press the Adjust Count button from the auto crimp screen.
• Press the Crimp Counter and reset the count to the desired
point.
ACTTM ADDITIONAL FEATURES
• Additional features and functions of the ACTTM controller can be
accessed by pressing the MORE button on the MACHINE SET
UP screen.
• When “Allow Crimp to Diameter” is set to “YES”, all of the
adjustment functions of the crimper are available. When
“Allow Crimp to Diameter” is set to “NO” only the settings
entered as a saved crimp can be used.
• English or Spanish language options are available.
• The “Use Pressure Compensation” is set to “YES” for all
crimpers equipped with a pressure transducer. A security code is
required to turn this function on or off.

1 2
ACTTM ADDITIONAL FEATURES
Pre-Loaded Crimp Specifi cations
In addition to the ability to store up to 50 user
entered dies and 100 user entered crimp settings, the
ACTTM Controller has the capability of accepting pre
loaded manufacturer’s crimp specifications. Custom
Crimp®does not maintain these specifications as
they are proprietary to the individual hose and fitting
manufacturer. If, however, your ACTTM Controller was
pre loaded with a manufacturer’s crimp specifications
or if they are available to you, they are accessed in the
following manner:
• Press the Crimp Memory Table Button.
• Press the access button to bring up the stored crimp
specifications.
• Scroll through the crimp specifications to select the
correct one. The right hand rocker button moves
through the crimp specs one line at a time and the left
hand rocker button moves one screen at a time.
• When the correct crimp specification is selected,
press the highlighted selection and then the Load
button and select OK to write the data to the ACTTM
Controller.
• This will bring up the familiar crimp screen and the
crimper can then be operated in the normal manner.

13
INDUSTRIAL CRIMP CALCULATOR
The Industrial Hose Crimp Calculator is part of the ACTTM
controller package on many Custom Crimp® crimpers capable
of crimping industrial hoses. With a few simple measure-
ments, it takes the guess work out of industrial hose crimping
and eliminates the need for charts and graphs.
Note: Not all ACTTM controllers have the Industrial Crimp
Calculator software. Contact your sales specialist for
information on a specific crimper.
• Press the CRIMP TO DIAMETER button
• Press the INDUSTRIAL CRIMP Button
• Press MEASURE
If the hose diameter is known or a pi tape is being
used, enter the hose O.D.
If hose O.D. is not known,press MEASURE for wall
thickness options
• Measure the wall thickness of the hose. Press the right
arrow and take 2 more measurements of the hose wall
thickness. The Industrial Crimp Calculator will average the
three measurements.
• Enter the stem diameter of the fi tting. For example: If the
stem diameter is 4 inches, you would enter 4000 and the
ACTTM controller would supply the decimal place.
• Measure and enter the wall thickness of the ferrule
• Next enter a compression factor. While this can vary
depending upon the specifi c hose and manufacturer, the
following guidelines are a starting point:
Standard Industrial hose (approximately 1/4 inch
wall thickness): 22%
Standard lay fl at hose: 11%
Note: Contact your hose and fitting manufacturer for the
compression factor to use on a specific hose and ferrule,
• Press PROCESS and enter the die diameter if you have
not already done so.
• Select and install the correct die set for the combination of
hose and fi tting being crimped.
• Press MANUAL and proceed to crimp the hose

1 4
DIE INSTALLATION AND REMOVAL
Adapter Die Installation
230 mm to 145 mm and 145 mm to 99 mm Adapter Dies are available with
the crimper. Adapter dies are held in place by the locking screws as shown in
the illustration. Hydraulic dies can either be installed manually or with the die
removal tool as shown.
The I.D. of intermediate adapter dies must match the O.D. of the
corresponding adapter die or hydraulic die or accurate crimps can not be
made.
Hydraulic Die Installation
• Install the 230mm to 145mm and 145mm to 99mm Intermediate Adapter
Dies as shown making certain that the Intermediate Adapter Die I.D.
matches the Hydraulic Die O.D.
• Remove the Hydraulic Dies from their holder with the magnetic die
insertion tool as shown.
• 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
with the crimper in manual mode SLOWLY close the crimper head on the
die set.
• Bring the crimper head to a fully closed position and remove the die
insertion tool.
The dies may also be inserted manually with the crimper head in the fully open
position.
Proceed to the ACTTM operating instructions to set up the crimper for the hose
and fitting being crimped.
For Hydraulic Die removal, place the crimper in manual mode and bring the
crimper head to the fully closed position. Insert the die removal tool and open
the crimper head releasing the Hydraulic Dies from their spring retention holes.
Press the CHANGE DIES button on the controller to easily open and
close the master dies without affecting crimper settings
Note that on the CC1000, the master dies must be slightly closed in
order to completely insert the die removal tool.

15
INITIAL SET UP AND PLC RESET
Initial Setup
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.
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 front of the tank. 50 U.S. gallons
of ISO 46 hydraulic oil are required to completely refill 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 tank.
Lubrication
Lubricate the crimping head after each 400 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 master
dies through the 8 holes in the protective plates as illustrated.
With the dies still in the fully closed position lubricate the fittings visible through
the 2 bottom lubrication holes in the protective plate of the crimper.
Use only a high quality grease. Failure to do so may result in damage to the
wearing surfaces.
PLC Reset Procedure
The PLC (Programmable Logic Controller) requires a
relatively constant source of electrical power. Power
surges, outages or drops in power can cause the PLC
to lose its settings. This may result in missing or
misplaced information on the controller screen.
Resetting the PLC to its original
settings is a simple procedure
• Turn the main power switch to OFF.
• Open the front of the Control Panel.
• Power up the crimper from the main power switch. The crimper must be
powered on during the PLC reset procedure.
• Move the three position toggle switch on top of the PLC right to the STOP
position and then left to the RUN position.
• Return the toggle switch to the center TERM position.
• Repeat for the other PLC Unit.
• Turn the main power switch to OFF and replace the front panel.
• The PLC and the crimper should now operate normally.

1 6
TROUBLESHOOTING
PROBLEM: CRIMPER WILL NOT RUN AT ALL
• Check the E-Stop switch to be certain that it is not depressed. A slight twist is required to release switch after it
has been depressed.
• PLC (Programmable Logic Control) must be reset. See instructions on the previous page.
PROBLEM: CRIMPER RUNS BUT IS SLOW OR NON-FUNCTIONAL
• Check supply voltage to see that it matches the voltage specified on the tag attached to the crimper.
Many performance problems are the result of low voltage or inadequate electrical service.
• Check motor rotation and be certain that the motor rotates in the direction of the arrow on the motor housing. For
three phase units rotation can be reversed by switching any two wires in the plug.
PROBLEM: CRIMPER WILL CLOSE ON FITTING BUT DOES
NOT DEVELOP POWER TO COMPLETE THE CRIMP
• Check oil level. Position dies to the fully open position and check oil sight gage in rear of machine. Be sure the
oil level is in the middle of the sight glass. Use ISO 32 or 46 weight hydraulic oil.
PROBLEM: CRIMPER WILL NOT OPEN TO RETRACT POSITION IN AUTO MODE
• Retract position must be at least 3 mm larger than the final crimp diameter.
If problems persist contact Customer Service for additional troubleshooting
assistance

17
EXPLODED PARTS VIEW
CC1000 SHEET METAL ASSEMBLY
QTYDESCRIPTION
PART NUMBERITEM
1
CC1000 FRONT PANEL
103204-11
2
CC1000 PROTECTIVE SLIDE PLATE
1032092
1
CC1000 BACK PANEL
1032143
2
CC1000 PROTECTIVE PLATE WRAP
1032364
1
CC1000 TOP FRAME WRAP
1032195
24
M6 X 12 BHCS
91239A3186
2
M6 X 16 BHCS
91239A3217
1599S DIE HOLDER1012428
601/4-20 x 3/4 SHCS91251A5409
2CC1000 BASE LEG10320810
8M12 X 50 SHCS91290A62611
5
4
2
3
6
7
1
8
9
6
2
10
6

1 8
CC1000 WEAR PLATE ASSEMBLY
QTYDESCRIPTION
PART NUMBERITEM
1CC1000 FRAME1031461
1CC 1000 SLIDING V PLATE1031502
4CC 1000 MASTER DIE WEAR PLATE1031573
8M10 X 20 FHCS91294A3284
2CC 1000 STATIONARY WEAR PLATE103163
5
8
M6 X 25 FHCS
91294A2426
1
CC 1000 CYLINDER ASSEMBLY
1031587
1
M16 X 70 SHCS
91290A8378
2
CC1000 LEFT SUPPORT LEG ASMB.
103206-L9
2CC1000 RIGHT SUPPORT LEG ASMB.103206-R10
8M12 X 50 SHCS91290A62611
8M12 WASHER91166A29012
1
2
3
5
6
4
8
7
11
12
9
10
TORQUE TO
305 FT/LBS
EXPLODED PARTS VIEW

19
EXPLODED PARTS VIEW
CC1000 PROTECTIVE PLATES AND GUIDES ASSEMBLY
QTYDESCRIPTIONPART NUMBERITEM
1CC1000 FRAME1031461
4CC 1000 SIDE GUIDE PLATE1031932
68M12 X 35 SHCS91290A6203
8M8 X 25 SHCS91290A4324
8CC 1000 MASTER DIE COVER PLATE1031965
16M8 X 20 FHCS91294A2846
1CC1000 POTENTIOMETER BRACKET1032487
2M12 X 50 SHCS91290A6268
1M16 X 50 SHCS91290A8209
4CC1000 PROTECTIVE PLATE ALIGNMENT TABS10323010
1CC600/1000 ROLLER LIMIT SWITCH10347311
1CC600/1000 ADJUSTABLE BRACKET10334912
4CC1000 PROTECTIVE PLATE KEY10344813
1CC600/CC1000 LINEAR POTENTIOMETER10347214
210-24 x 5/8 SHCS91251A24415
210-24 X 3/4 SHCS91251A34516
210-24 ROUND WASHER91255A54917
4M4 X 25 SHCS91290A17618
8M6 X 14 FHCS91294A23719
3M10 X 100 SHCS91290A54820
3
4
4
65
1
2
9
7
8
16
17
12
15
11
14
20
13
19
18

2 0
EXPLODED PARTS VIEW
CC1000 MASTER DIE ASSEMBLY
QTYDESCRIPTIONPART NUMBERITEM
4CC1000 MASTER DIE CARRIER1031471
40CC1000 MASTER DIE ALIGNMENT NUT1032492
40
M4 X 10 SHCS
91290A1443
8M8 X 45 SHCS91290A4464
8CC1000 MASTER DIE SHOE1031565
24DIE SPRING1034706
2M10 X 100 SHCS91290A5487
4
1
5
3
2
6
7
3
2