CustomCrimp CC200 User manual

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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 rell 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-disulde 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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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 specications
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 specications.
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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Innovating SMART Hose Assembly Solutions Since 1979
PROBLEM: CRIMPER RUNS BUT IS SLOW OR NON-FUNCTIONAL
• Check supply voltage to see that it matches the voltage specied on the tag attached to the crimper.
• If the crimper is connected to a three phase circuit, check all three legs of the circuit to be certain that all legs are hot.
• Measure the voltage to the crimper when the crimper is under load. Voltage should be a minimum of 90% of line voltage
when the crimper is under load.
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.
• The circuit in the crimper is protected by a thermal overload relay. If the relay trips after resetting it from the master pow-
er switch, call for technical service.
PROBLEM: MOTOR RUNS BUT FOOT SWITCH WILL NOT OPERATE
• Power to the secondary circuit is supplied from a 24 volt step down transformer. If the motor runs normally but the foot
switch will not function check the 2 amp slo blow fuse located in the control box as shown in the photo below.
PROBLEM: CRIMPER WILL CLOSE ON FITTING BUT DOES NOT DEVELOP POWER TO
COMPLETE THE CRIMP
• Fitting is to large for selected crimp die. Select a crimp die that is closer to nal crimp diameter. Machine has built-in
safety bypass to protect internal components from damage due to incorrect die selection.
• 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.
If problem(s) persist contact Customer Service for additional troubleshooting assistance
TROUBLESHOOTING

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Innovating SMART Hose Assembly Solutions Since 1979
Dial Micrometer Assembly
CC200 Crimper P/N:102941-450
CC400 Crimper P/N:102941-60
Die Lock Pin For 84S/99S
Die Series P/N:101582
CustomCrimp® Notched Digital
Caliper IN/MM P/N:CC-Caliper
Mini Grease Gun w/ CRIMPX Die
Lubricant 3 oz mini grease tube
P/N:103889
CRIMPX Die Lubricant 3 oz mini
grease tube P/N:103887
CRIMPX Die Lubricant 14 oz
large grease tube P/N:103888
Foot Pedal Assembly
P/N:104118
99mm Quick Change Tool
P/N:102571
Crimper Stand 16 Station
Die Holders P/N:101247-99
Die Rack 9 Station Die Holders
P/N:102616-99mm
Intermediate Die Removal Tool
P/N:5691A13
Protective Master Die Foam Pad
CC200 Crimper P/N:102529
CC400 Crimper P/N:102530
Adapter Die Set 130mm OD to
99mm ID P/N:101575
Die Lock Pin For 130S/145S
Die Series P/N:101403
Adapter Die Set 145mm OD to
99mm ID P/N:103726
Manual Back Stop
P/N:MBS-60
CC200 / CC400 REPLACEMENT ACCESSORIES

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Innovating SMART Hose Assembly Solutions Since 1979
CC150/200/400 Assembly (103052)
QTYDESCRIPTION
PART NUMBERITEM
1
CC Crimper Reservoir
102618-WELD1
1
CC-60 Head Assembly
1028002
1
CC-450 Head Assembly
1025133
1CC-38 Head Assembly102594
4
1Front Die Panel102946
5
5
99MM Die Holder1012426
5
84MM Die Holder1012436
201/4-20 x 3/8" SHCS91251A535
7
4
1/4-20 x 1/2 BHCS
91255A5378
1Electrical Box Assembly1030539 4
1/4-20 x 1/2 SHFCS
92323A51210
1
Dial Micrometer Assembly
10294111
14 Pin Plug/12 Foot Cord10306112 1Foot Switch10305813 1Full Guard for Foot Switch10305414 15 HP/3 Ph/8cc Motor and Pump101714-5-8-315 1
5 HP/1 Ph/8cc Motor and Pump
101714-5-8-116
14
13
12
65
8
7
11
9
234
1
10 15 16
COMPONENT PARTS BREAKDOWN

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Innovating SMART Hose Assembly Solutions Since 1979
CC-150/200/400 Electrical Box (103053)
ITEM PART NUMBER DESCRIPTION STOCK NUMBER QTY
1 102945 Electrical Box Metal Assembly 102945 1 2 69915K65 Cable Strain Relief 69915K65 1 3 69915K56 3/4 NPT Cord Grip 69915K56 1 4 7807K64 Multi-Wire Cord Grip 7807K64 1 569915K51 3/8 NPT Cord Grip 69915K51 1 6 103060 4 Pin Receptical 1R4004A20A120 1 7 91251A537 1/4-20 x 1/2 SHCS 91251A537 2 8 3.125LDIN 3.125 Length DIN Rail 3.125LDIN 1 9 90675A029 1/4-20 Nut with Tooth Washer 90675A029 3
10 103057-2303 Manual Starter with Overload - 230V 3Ph BM3RHB-016 1 11 103057-2301 Manual Starter with Overload - 230V 1Ph BM3RHB-032 1
CC-150/200/400 Electrical Box (103053)
ITEM PART NUMBER DESCRIPTION STOCK NUMBER QTY
12 103057-4603 Manual Starter with Overload - 460V 3Ph BM3RHB-004 1 13 103059-LINK1.355L Starter Switch Linkage BZ0VYRL 1 14 103059 External Starter Handle and Linkage BZ0VYRL 1 15 90273A197 #8-32 x 3/4 CS Screw 90273A197 2 16 103055 230/460-24VAC Transformer PT50QG 1 17 90480A009 #8-32 Nut 90480A009 2 18 MEN2 Time-Delay 2 Amp Fuse MEN2 1 19 103056 Bridge Rectifier MP1505 1 20 91251A541 1/4-20 X 7/8" SHCS 91251A541 1 21 91255A190 #8-32 x 1/4 BHCS 91255A190 5
7
9
5
420
3
2
10 11 12
13
8
1
6
14
21
15
17
18
19
16
COMPONENT PARTS BREAKDOWN

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Innovating SMART Hose Assembly Solutions Since 1979
CC Motor and Pump Assembly (101714)
QTYDESCRIPTIONPART NUMBERITEM
15 HP 1800 RPM Motor1015411
17.5 HP 1800 RPM Motor1015402
110 HP 1800 RPM Motor1029943
1Motor Mounting Flange1015394
4
1/2 Lock Washer
91101A0335
4
1/2-13 x 1 1/4" Bolt92865A7146
1Motor Coupling101543-01
7
1
Coupling Spider Insert
101543-038
1
8cc Gear Pump
1017139
1
11cc Gear Pump
10154210
1
14cc Gear Pump
10299211
23/8 Washer98023A3112
23/8 Lock Washer91102A03113
23/8-16 x 1 1/4" Bolt92865A62614
1
3/4" Shaft Coupling
101543-0215
1
Flange Gasket
101539-0116
1
8 JIC 37 M to 12 SAE Adapter
6400-8-1217
18 JIC 37 M to 10 SAE Adapter6400-8-1018
123
15
8
7
4
16
5
6
17
91011
18
12
13
14
FINAL ASSEMBLY PART NUMBER CREATION:
101714-"MOTOR HP"-"PUMP SIZE"-"PHASE (IF REQ'D)"
EX. 7.5 HP MOTOR WITH 11cc PUMP: 101714-7.5-11
EX. 5 HP MOTOR WITH 8cc PUMP, SINGLE PHASE:101714-5-8-1
COMPONENT PARTS BREAKDOWN

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Innovating SMART Hose Assembly Solutions Since 1979
CC Crimper Table Assembly (101755)
Qty
DescriptionPart NumberItem
1Die Panel1012441
2End Panel1012462
165/16 Flat Washer90108A0303
8
5/16 Lock Washer
91102A0304
8
5/16-18 X 1 Hex Bolt
92865A5815
8
5/16-18 Hex Nut
95462A0306
1CC Crimper Table Top101754
7
1699MM Die Holder1012428
1684MM Die Holder1012438
641/4-20 X 3/8 BHCS91255A5359
3
4
6
9
8
5
3
7
2
3
5
2
1
3
4
6
COMPONENT PARTS BREAKDOWN

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Innovating SMART Hose Assembly Solutions Since 1979
CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT
All Custom Crimp® Products are warranted to be free of defects in workmanship and materials for one
year from the date of installation. This warranty ends when the product becomes unusable for reasons
other than defects in workmanship or material.
Any Custom Crimp® Product proven to be defective in workmanship or material will be repaired or replaced
at no charge. To obtain benets of this warranty, rst, 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.
318 North Co. Rd 400 East
Valparaiso IN 46383
If any product or part manufactured by Custom Crimp® is found to be defective by Custom Crimp®, at
its option, Custom Crimp® 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 inconsistent with any instructions
regarding its use.
Electric motors are separately warranted by their manufacturer under the conditions stated in their separate
warranty.

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Innovating SMART Hose Assembly Solutions Since 1979
For support: [email protected]For sales: [email protected]Visit us at: www.customcrimp.com
CUSTOM CRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS.
CUSTOM CRIMP®|Custom Machining Services, Inc.
326 North 400 East Valparaiso, IN 46383
[phone]Custom Crimp®www.customcrimp.com
Innovating SMART Hose Assembly Solutions Since 1979