CustomCrimp CC1200 User manual

1
CC1200 CRIMPER OPERATORS MANUAL
WITH ACTTM CONTROLLER

2
COMPONENT PARTS IDENTIFICATION -------------------------------------------------------------3
SPECIFICATIONS AND INITIAL SET UP -------------------------------------------------------------4
ACTTM CONTROL OPERATION -------------------------------------------------------------------------5
INDUSTRIAL CRIMP CALCULATOR --------------------------------------------------------------------13
ADAPTER DIE INSTALLATION--------------------------------------------------------------------------14
INITIAL SET UP AND MAINTENANCE --------------------------------------------------------------15
TROUBLE SHOOTING -----------------------------------------------------------------------------------------16
EXPLODED PARTS BREAKDOWN ------------------------------------------------------------------------17
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
CC1200 Crimper Operators Manual With ACT™ Controller (Revised 03/11/2016)
For Parts and Service, Contact:
Custom Machining Services, Inc.
Valparaiso, In 46383
[phone]

3
COMPONENT PART IDENTIFICATION
Hydraulic Power Unit
and Controls
CC1200 Hose Crimper
Cabinet Storage Shelves
160S Series Dies
381mm-275mm Adapter Die
275mm-160mm Adapter Die
Master Dies
381mm-275mm Adapter Die
275mm-160mm Adapter Die
Pressure Hose
Return Hose
Die Release Pins
Reservoir Sight Glass

4
CRIMPER SPECIFICATIONS AND INITIAL SET UP
SPECIFICATIONS:
MAX HEAD OPENING W/O DIES ------------------------------------------------------------------------489MM (19.25IN)
MASTER DIE INSIDE DIAMETER -------------------------------------------------------------------------381MM (15IN)
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 ----------------------------------------------------------381MM TO 275MM AND 275MM TO 160MM
HOSECAPACITY----------------------------------------------------------------------------------------3INTO 12IN 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.

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AccuCrimp ACTTM CONTROL PANEL
EMERGENCY
STOP
STYLUS PEN
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.

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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 decimal 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.

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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.

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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 specifi cations. CustomCrimp® does not maintain these
specifi cations as they are proprietary to the individual hose
and fi tting manufacturer. If, however, your ACTTM Controller
was pre loaded with a manufacturer’s crimp specifi cations 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
specifi cations.
• Scroll through the crimp specifi cations 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 specifi cation 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
• 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.
• Press either MEASURE HOSE OD or HOSE WALL
THICKNESS to toggle between the options where hose
OD is known and wall thickness measurements are
required.
• If the hose outside 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.
• 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
ADAPTER AND DIE INSTALLATION
Adapter Die Installation
381MM to 275MM and 275MM to169MM die adapters are available.
With the proper combination of dies and adapters industrial hoses
from 3 IN to 12 IN can be crimped. Adapter dies as well as crimping
dies are removed and installed by pressing the release pins (Red
Arrow) and sliding the adapter or the die horizontally out of the
crimper.
The I.D. of intermediate adapter dies must match the O.D. of the
corresponding adapter die or accurate crimps can not be made.
Two adapter series are available.
The 381S dies will fi t the Master Die contour without adapters. A
381MM to 275 MM adapter is required for the 275S dies, and the 275
MM to 160 MM adapter will fi t into the 381 MM to 275 MM adapter for
the 160S dies. All dies and adapters slide in and out from either side
with the press of the release button. Die options are shown in the
table below with “standard” dies shown in yellow.
Industrial Die Sizes 160S Die 275S Die 381S Die
Die Size
Eff ective
Crimp
Range
(MM)
Die Length (MM)
74 MM 74-78
78 MM 78-83
84 MM 84-92 130
92 MM 92-100 130
100 MM 100-108 130
108 MM 108-116 130
114 MM 114-122 130
116 MM 116-124 130
118 MM 118-124 130
126 MM 126-134 130
135 MM 135-143 130
166 MM 166.178 205
178 MM 178-190 205
190 MM 190-202 205
215 MM 215-245 205
245 MM 245-275 203
281 MM 281-310 203
310 MM 310-345 203

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INITIAL SET UP, LUBRICATION 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 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 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. Aslight 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
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EXPLODED PARTS VIEW

1 8
EXPLODED PARTS VIEW

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EXPLODED PARTS VIEW

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EXPLODED PARTS VIEW