CustomCrimp CC15 User manual

CC15 HYDRAULIC CRIMPER
OPERATORS MANUAL

2Page
READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS
BEFORE USING CRIMPER
CRIMPER CAN PRODUCE 33 TONS OF FORCE. KEEP BOTH
HANDS AWAY FROM PINCH POINTS
CONSULT HOSE AND FITTING MANUFACTURER’S
SPECIFICATIONS FOR CORRECT MACHINE SETTINGS AND
CRIMP MEASUREMENTS
ALWAYS WEAR EYE PROTECTION
Rev 3/8/2012
SAFETY PRECAUTIONS

3Page
CC15 COMPONENT IDENTIFICATION
CRIMP ADJUSTMENT
MICROMETER
SYSTEM POWER SWITCH
AND CIRCUIT BREAKER
CRIMP HEAD
RESERVOIR DRAIN
START/CLOSE SWITCH
OIL FILL/VENT PLUG
HOLD-RELEASE VALVE
CYLINDER
RETRACTION STOP
FOOT SWITCH
COUPLING STOP

4Page
CC15 SPECIFICATIONS
Crimping Force------------------------------------------------------------------------------------33 Ton
Maximum Hose Diameter (2 Wire)--------------------------------------------------5/8”(15.9mm)
Maximum Hose Diameter (4 Wire) -------------------------------------------------1/2”(12.7mm)
Maximum Hose Diameter (6 Wire)--------------------------------------------------------------N/A
Maximum Die Opening (Die Size Plus)---------------------------------------------------27.5mm
Maximum Opening w/o Dies-------------------------------------------------------------------94mm
Length-----------------------------------------------------------------------------------------------23-1/2”
Width-----------------------------------------------------------------------------------------------------15”
Height-----------------------------------------------------------------------------------------------18-1/2”
Weight------------------------------------------------------------------------------------------------150 lb
Electrical Power Requirement (Std)------------------------------------------------------------110V
Electrical Power Requirement (Optional)----------------------------------------------220V 1 Ph
Pump HP----------------------------------------------------------------------------------------------1 Hp
Oil Capacity-----------------------------------------------------------------------------------------13 Qt
Oil Type----------------------------------------------------------------------ISO Viscosity Grade 46
Manual/Automatic Crimping-----------------------------------------------------------Manual Only
Inch/Metric Settings------------------------------------------------------------------------Metric Only
Custom Crimp Die Series---------------------------------------------------------------------103702

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RELEASE
HOLD
CRIMPING WITH THE CC15 CRIMPER
• Select the correct die set for the combination of hose and
fitting being crimped. Consult the hose and fitting manufacturer’s
specifications for the correct die to use and final crimp diameter
required.
• To insert the dies, open the master dies to the fully open position,
and insert each die finger individually making certain that the die
size (number stamped on the die) is correct. The die should click
into place with the ball detent when it is properly positioned.
• The final crimp diameter is the closed diameter of the die
stamped on the face of the die plus the number shown on the
micrometer. See micrometer setting example below.
Micrometer Setting Example
Each 100 on the metric Micrometer represents 1 mm above
the closed diameter of the die set. For example, with a 10mm
die installed and the Micrometer set at 250, the finished crimp
diameter would be 12.5 mm. (10mm + 2.5mm)
• Insert the hose and fitting in the crimper head and press and hold
the green Start/Close button or press and hold the Foot Switch.
When the crimper reaches the correct diameter, the crimper will
shut off. When possible, the hose fitting should be centered axially
in the die set to assure a uniform crimp with minimum taper.
• When the Hold/Release valve is in the Hold position, the crimper
can be jogged into position to allow for more accurate positioning
of the fitting in the die set. Turn the Hold/Release valve to the
Release position to allow the dies to retract.
• Measure the finished crimp diameter to be certain that it is within
manufacturer’s specifications. If the finished diameter is not within
specifications, see calibration instructions.
Note: Due to tolerance variations in hose and fitting
combinations, some “offset” may be required for specific
combinations of hose and fittings. This does not mean that
the crimper is out of calibration.

6Page
CC 15 CRIMPER CALIBRATION
Calibration Check:
While the CC15 Crimper is calibrated at the factory prior to shipment, a calibration check is recommended
prior to using the crimper. Select a typical hose and fitting and set the CC15 micrometer to the hose and
fitting manufacturer’s recommendation. Insert the hose and fitting and press and hold the Start/Stop switch
until the crimper shuts off. Measure the finished crimp. If the finished crimp diameter is not within the hose
manufacturers specifications, recalibrate the crimper.
Note: Due to variations in hose and fitting tolerances, some “offset” may required to achieve the
correct crimp diameter for specific hose and fitting combinations across the range of hose and fittings
being crimped. If crimp diameters are consistently too large or consistently too small, the crimper
should be recalibrated.
Calibration:
While the crimper can be calibrated using any recommended
hose and fitting combination, using a hose and fitting combination
close to the size most frequently crimped will minimize the offset
required for other sizes and combinations of hose and fittings.
• Select a hose and fitting combination recommended by the
hose manufacturer and continue to adjust the Crimp Adjustment
Micrometer until the correct measured crimp diameter is achieved.
For example, if there is a 10mm die set in the crimper and the
required crimp diameter is 12.5mm the micrometer would be set to
crimp at 10mm + 2.5mm or 12.5mm.
Note: The number on the Crimp Adjustment Micrometer
may not agree with the hose manufacturers specification
at this point.
• If necessary, loosen the set screw on the knob with a .050 hex
key wrench and rotate the knob until the setting on the knob
matches the actual diameter of the finished crimp.
• Tighten the set screw
• Calibration is now complete
Knob Set Screw

7Page
Foam Filler Pads
Grease Fitting Holes
Flush Style Grease
Coupler Required
SPECIAL FEATURES & MAINTENANCE
Coupling Stop
• When making repetitive crimps, setting the Coupling Stop eliminates
the need to visually align the couplings each time.
For repetitive crimps, position the hose and fitting in the correct position
and bring the face of the coupling stop against the fitting. Tighten the
coupling stop in the correct position.
Retraction Stop
• When making repetitive crimps, setting the Retraction Stop at a
point where the hose and fitting can be conveniently withdrawn without
allowing the cylinder to fully retract will greatly reduce the crimp cycle
times.
Lubrication
• Check the tank sight glass for proper reservoir oil level. If additional oil
is required fill with ISO Grade 46 hydraulic oil.
Crimper Head Lubrication
Lubrication passages are drilled in the CC15 die holders. This feature
makes positive lubrication of the wear surfaces much easier assuring
longer life and smoother crimper operation. Foam pads are installed
between the die holders to keep dirt and debris from destroying the die
and piston surfaces.
• Close the die holders to a position nearly flush with the front plate of
the crimper to expose the lubrication fittings in the front of the die holders.
Lubricate with the CrimpX grease furnished with the crimper or a moly-
disulfide lubricant. Failure to use a high quality lubricant can result in
premature wear and possible damage to the master dies and piston
surfaces.
• The foam pads may be removed to make certain that the grease
passages are open and that grease is getting to the wearing surfaces.
Replace the pads as they are critical to protect the wearing surfaces
from damage.
Coupling Stop
Retraction Stop

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TROUBLESHOOTING
PROBLEM: CRIMPER WILL NOT RUN AT ALL
• Thewhiterockerswitch isalso acircuit breaker. Check to see that the circuit breaker has not been tripped.
• Check the wall outlet. Use of extension cords or outlets with inadequate power can damage the motor .
Do not run the crimper from a portable power source.
PROBLEM: CRIMP DIAMETER TOO LARGE
• Check crimper calibration and recalibrate if required.
• Incorrect die being used. Each die has a range of approximately 3mm (.120 in) above the closed diameter
of the die. The closed diameter is the die size stamped on the die face.
• Incorrect setting of the micrometer. Check hose manufacturer’s specifications.
• Inadequate pump pressure. Check oil level in the pump. It should be 1-1/2 to 2 inches below the fill plug.
Replenish with ISO Viscosity Grade 46 hydraulic oil if necessary.
• Inadequate lubrication of the master dies causing the pump to work harder than normal to reach the re-
quired diameter.
• Inadequate pressure being generated by the pump. This is most likely if the crimper can crimp the smaller
size hoses and not the larger hoses. When correctly adjusted, the pump should generate approximately
5000 psi.
Do Not adjust pump to produce in excess of 5000 psi as damage to components or per-
sonal injury could result
• No pressure being generated by the pump. There should be a definite change in pitch of the pump as it
cycles into high pressure mode and begins to “work” harder.
PROBLEM: CRIMP DIAMETER TOO SMALL
• Check crimp diameter and recalibrate if necessary.
• Incorrect die being used (See die range under Crimp Diameter Too Large).
• Incorrect setting of the micrometer. Check hose manufacturer’s specifications.

9Page
CC15 Machine Assembly Directory (103666)
DESCRIPTIONPART NUMBERITEM CC15 Crimper Head Assembly
10295511 HP 110V MotorVEP-1-CMS-CC1521/4-20 x 1/2 Flanged HHS 92323A5123Pump Gasket1013294CC15/CC30 Sheetmetal Assembly 1039055Mounting Bracket Assembly1039066Dial Micrometer Assembly102941-60073/8 High Pressure Tubing1039098Backstop Assembly1039079Electrical Box Assembly10389610
7
6
9
1
2
10
5
4
38
COMPONENT IDENTIFICATION

10Page
CustomCrimp®
Custom Machining Services, Inc.
326 N. County Rd. 400 East
Valparaiso, IN 46383
Ph: [phone]
Fax: [phone]
www.customcrimp.com
NOTES
CustomCrimp “No-Nonsense” Warranty Statement
All CustomCrimp Products are warranted to be free of defects in workmanship and mate-
rials for one year from the date of installation. This warranty ends when the product be-
comes unusable for reasons other than defects in workmanship or material.
Any CustomCrimp Product proven to be defective in workmanship or material will be re-
paired or replaced at no charge. To obtain benefits of this warranty, first, contact Warranty
Repair Department at Custom Machining Services at [phone] and then deliver via
prepaid transportation the complete hydraulic product to:
ATTN: WARRANTY REPAIR DEPT.
Custom Machining Services, Inc.
326 North Co. Rd 400 East
Valparaiso IN 46383
If any product or part manufactured by CustomCrimp is found to be defective by Custom-
Crimp, at its option, CustomCrimp will either repair or replace the defective part or product
and return via ground transportation, freight prepaid. Custom Crimp will not cover any
incoming or outgoing freight charges for machines sold outside The United States.
This warranty does not cover any product or part which is worn out, abused, altered, used
for a purpose other than for which it was intended, or used in a manner which was incon-
sistent with any instructions regarding its use.
Electric motors are separately warranted by their manufacturer under the conditions stated
in their separate warranty.