CustomCrimp CC25 User manual

CC25 HYDRAULIC CRIMPER
OPERATORS MANUAL

2Page
READ INSTRUCTIONS AND IDENTIFY ALL
COMPONENT PARTS BEFORE USING CRIMPER
CRIMPER CAN PRODUCE 137 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
Rev3/2/2005
For Parts and Service, Contact:
Custom Machining Services, Inc.
Valparaiso, In 46383
[phone]
SAFETYPRECAUTIONS

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CC25 COMPONENT IDENTIFICATION
CRIMP ADJUSTMENT
MICROMETER
SYSTEM POWER
SWITCH AND CIRCUIT
BREAKER
CRIMP HEAD
RESERVOIR DRAIN REMOTE START/STOP
SWITCH
OIL FILL PLUG
(BEHIND THE MOTOR)

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CC25 SPECIFICATIONS
MasterDieDiameter--------------------------------------------------------------------------80mm
CrimpingForce------------------------------------------------------------------------------137Ton
MaximumHose Diameter (2 Wire)-------------------------------------------------------1-1/4”
MaximumHose Diameter (4 Wire) ------------------------------------------------------1-1/4”
MaximumHoseDiameter (6 Wire)-------------------------------------------------------------1”
Maximum Die Opening (Die Size Plus)-----------------------------------------------18mm
MaximumOpeningw/o Dies--------------------------------------------------------------86mm
Length--------------------------------------------------------------------------------------------------21”
Width----------------------------------------------------------------------------------------------------11”
Weight----------------------------------------------------------------------------------------------195lb
ElectricalPower Requirement (Std)-----------------------------------------------------110V
Electrical Power Requirement (Optional)--------------------------------------220V 1 Ph
PumpHP--------------------------------------------------------------------------------------------1Hp
OilCapacity----------------------------------------------------------------------------------------13Qt
OilType-------------------------------------------------------------------ISO ViscosityGrade46
Manual/AutomaticCrimping-----------------------------------------------------ManualOnly
Inch/MetricSettings-------------------------------------------------------------------MetricOnly
CustomCrimpDieSeries----------------------------------------------------------------------80S

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CRIMPING WITH THE CC25 CRIMPER
LOCKING TAB
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.
Insert each die finger individually making certain
that the die size (number stamped on the face of the
die) faces the front of the machine. The die should
click into place when it is properly positioned.
Release the micrometer locking tab, and adjust the
micrometer to the hose and fitting manufacturer’s
recommended setting.
Note on Micrometer Settings
Each 100 on the Micrometer represents 1 mm
above the closed diameter of the die set. For
example, with a 57mm die installed and the
Micrometer set at 150 the finished crimp
diameter would be 58.5 mm (57mm + 1.5mm)
Insert the hose and fitting in the crimper head and
press and hold the start button. When the crimper
reaches the correct diameter, the crimper will shut
off. Release the start switch and remove the hose
and fitting. When possible, the hose fitting should
be centered axially in the die set to assure a uniform
crimp with minimum taper.
Measure the finished diameter to be certain that it is
within manufacturer’s specifications. If the finished
diameter is not within specifications, see calibration
instructions.

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CC 25 CRIMPER CALIBRATION
Calibration Check:
Set the Micrometer at 000 and press and hold the
start switch. If the dies are fully closed before the
crimper shuts off, the crimper is correctly
calibrated and does not require calibration..
Calibration:
If the crimper needs to be recalibrated, remove
the shoulder bolts holding the Micrometer in
place taking care not to lose the springs.
If the crimper does not shut off when the dies are
completely closed, loosen the jam nut on the end
of the micrometer and turn the set screw out
slightly. Retighten the jam nut and check
calibration.
If the dies are not fully closed when the crimper
shuts off, the set screw should be turned in
slightly and calibration rechecked.
Note that when reinstalling the Micrometer, it
must be free to move slightly on the shoulder
bolts in order to release the micro switch located
in the base of the Micrometer mount.

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Rubber Filler Pads
LUBRICATION AND MAINTENANCE
Check the tank dipstick for proper reservoir oil level. If additional oil is required fill
with ISO Grade 46 hydraulic oil.
Crimper Head Lubrication
Remove the sponge rubber filler pads and spray a moly-disulfide lubricant into the
area between the master die fingers. Be
certain to replace the pads as they prevent
dirt and debris from falling between the
master die fingers and destroying the
finished surfaces of the master dies.
With the die fingers removed, move the
master dies in and out by adjusting the
micrometer setting to expose the sliding
surfaces. Brush a moly disulfide lubricant
in the exposed areas.
P/N DMA-12 Spray Lubricant is available
P/N MTB-10(10 oz can) and MTB-16(16 oz
can) brush lubricant is available

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TROUBLESHOOTING
PROBLEM: CRIMPER WILL NOT RUN AT ALL

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The white rocker switch is also a circuit 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.


Check the pneumatically actuated switch in the electrical box mounted on the
motor. This switch controls power to the motor and is actuated with air pressure
from the bulb on the end of the hose going into the box.


Check the micro switch located in the base of the micrometer. this is a normally
closed switch and must be closed for the crimper to operate.
PROBLEM: CRIMP DIAMETER TOO LARGE


Check crimper calibration and re-calibrate if required.

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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 ring.

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Incorrect setting of the micrometer. Check hose manufacturer’s specifications.

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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.

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Inadequate lubrication causing the pump to work harder than normal to reach
the required 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 5,000 psi.
Do Not adjust pump to produce in excess of 5,000 psi as damage to components or
personal injury may 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 re-calibrate if necessary


Incorrect die being used (See die range under Crimp Diameter too Large)


Incorrect setting of the micrometer. Check hose manufacturer’s specifications.

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NOTES