CustomCrimp CC4-50 User manual

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CC4-50 CRIMPER OPERATORS
MANUAL

2Page
CC38 Manual (Rev 7-19-2005)
SAFETYPRECAUTIONS
READINSTRUCTIONSANDIDENTIFYALL
COMPONENT PARTS BEFORE USINGCRIMPER
KEEPHANDSAWAY FROM PINCH POINTS
CONSULTHOSEANDFITTINGMANUFACTURER’S
SPECIFICATIONS FOR CORRECT MACHINE
SETTINGSANDCRIMPMEASUREMENTS
ALWAYSWEAR EYE PROTECTION
ForPartsandService,Contact:
Custom Machining Services, Inc.
Valparaiso, In 46383
[phone]

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CRIMPER COMPONENT PARTS
AccuCrimpCONTROL
PANEL-SEESEPARATE
PAGE
CRIMPERHEAD
OILFILLERCAP
OILLEVEL
SIGHTGLASS
TANK DRAINAND OIL
COOLERPORTS
FOOTSWITCH
FOOTSWITCH
PLUGINPORT
MASTER
POWER
SWITCH

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CRIMPER SPECIFICATIONS & SET UP
SPECIFICATIONS:
MAX HEAD OPENING W/O DIES................................................................168 MM (6.62 IN)
MASTER DIE INSIDE DIAMETER..............................................................130 MM (5.11 IN)
MAXIMUM SWAGING RANGE...................................................................130 MM (5.11 IN)
MAXIMUM DIE OPENING ..........................................DIE CLOSED DIAMETER + 38 MM
CRIMPER SIZE.......................................................29 IN LONG X 20 IN DEEP X 32 IN HIGH
WEIGHT...............................................................................................................573LB (269KG)
ELECTRICALREQUIREMENTS......................................220VOLT3 PHASE(STANDARD)
.................................................................................................440VOLT3PHASE (OPTIONAL)
MOTOR.................................................................................................................................7.5HP
RESERVIOR CAPACITY...............................................................................................8 US GAL
OILTYPE..............................................................................................ISO 46HYDRAULIC OIL
MASTER DIES..........................................................145MM I.D. MASTER DIE STANDARD
ADAPTER DIES.......................................................99 MM I.D.ADAPTER DIES INCLUDED
HOSECAPACITY.......................................................................................2INCH 6 SPIRAL
...............................................................................................................2-1/2INCH INDUSTRIAL
INITIALCRIMPERSET UP
CHECKRESERVIOROILLEVELWITHSIGHTGLASSATREAROFTANK
CHECKELECTRICALCIRCUITTOBECERTAINTHATITMATCHESTHECRIMPER
REQUIREMENTSSHOWN ONTHETAGATTACHEDTO THECRIMPER CORD.
MAKECERTAINTHATMOTOR ROTATES INTHEDIRECTIONOFTHEARROW
SHOWNONTHE MOTORHOUSING.
IFMOTORROTATIONIS INCORRECTREVERSEANYTWOHOTWIRESINTHE
CRIMPERPLUG.

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DIE SET UPAND INSTALLATION
IndustrialandHydraulichosediesareavailableforthiscrimper.
Industrial Dies are inserted directly into the Master Dies and
hydraulicdies requirean intermediatedie. Hydraulic Diesare
availablewithan80mm,84mm, 99mmand130mmO.D.
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
Turnon thecrimperatthe masterpowerswitch(SeeAccuCrimp
ControllerInstructions)and gotoManualmode.
Insert the die removal tool in the release hole to release the
retainingspringandattach eitheranIntermediateAdapterDie ora
Hydraulic Die to the Master Die. the numbers stamped on the face
of the die should face the operator.
Mount all 8 dies in a similar manner.
IfIndustrial Diesarebeing used, proceedtotheAccuCrimp
Operatinginstructionsandsetupthe crimperforthe correctcrimp
diameter.
IfHydraulic Dies are being used,seeHydraulic Die Installation
instructions.

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AccuCrimp CONTROLPANELFUNCTIONS
INCH/MMTOGGLE TEXTPANEL MOTORON/OFF
“esc”ESCAPE
CURSOR
SCROLL
BUTTONS
CYCLE
COUNTER
RESET
EMERGENCY
STOP
MANUAL
MODETOGGLE
AUTOMODE
TOGGLE
MANUALMODE FUNCTION:CLOSE DIES
AUTOMODE FUNCTION:CYCLESTART
MANUALMODE FUNCTION:OPEN DIES
AUTOMODEFUNCTION:CYCLESTOP
NOTE:
IF THE CRIMPER IS IN MANUAL
MODE,THE GREENOPEN/CLOSE
BUTTONSWILLOPENANDCLOSETHE
CRIMPERHEAD.
IF THE CRIMPER IS IN AUTO MODE
THEBUTTONSFUNCTIONASCYCLE
STARTANDCYCLESTOPBUTTONS

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AccuCrimpOPERATINGINSTRUCTIONS
Turnonthe crimperMasterPowerswitch. Crimperwillgo
througha“self test”cycle. Atthecompletion ofthe selftest
cycle,the logoandthe “PressESC”instructionwill appear.
Press“ESC”buttononcontrolpanel,andthe“TURNONTHE
HYDRAULICMOTOR” screenwillappear. Pressthered
“MOTORON/OFF”button.
Machine Set up
Presstheblue“MAN”button togointomanualmode
Note: Adjustments can only be made when the
machine is set in “MAN” mode
Presstheyellow“IN/MM” BUTTONtotogglebetween“IN”or“MM”setting.
Scrollupto“CRIMPPOSITION”with theyellowscrollbuttons
andpress “enter”.
Note that at the completion of each step you must press “enter”.
Cursor will move to the number to be changed or adjusted
“CRIMPPOSITION” is thedimension (ininches ormm
depending upon the machine setting) that the finished crimp
diameter will be above the closed diameter stamped on the dies. For example: a setting of
“047” will result in a finished crimp diameter of .547 inches with a .500 die set. The
permissible range for each die set is shown below crimp position.
Withtheyellowscrollbuttons,adjust“CRIMPPOSITION”
numbertotheamountabovethecloseddiameter ofthedieinthe
machinethatis requiredforthefinishedcrimpdiameter.
Press“enter” to completethe setting
Scrolldownto“DWELLTIME(AUTO)”andpress“enter”
Withtheyellowscroll buttons,adjusttheamountofdwell, in
seconds,thatthemachinewilldwell afterreachingthe correct
crimpdiameter.
Press“enter” to completethe setting
The example screen shown at the left is set up with a .500 die and
is set to crimp at a finished diameter of .547 inches with a dwell time of 0.2 seconds at the end
of the crimp cycle before the dies open.
Whilestillin the“MAN”mode movethediesto theopenposition withthegreen “OPEN”(STOP/
OPEN)buttonthatthedieswillreturntoaftercompletionof thecrimpcycle.
Crimper Operation
Goto“AUTO”and press“CYCLESTART”(START/CLOSE). Noadjustmentscanbe changed
while the control in the “AUTO” mode. To change any settings the control must be in “MAN”
mode.
Thecyclecounter canbereset atanypointto maintainarunning countofcrimpcycles.
Tooperatethemachinein“MAN”mode,maketheappropriatesettingsandpressthe“OPENDIES”
(STOP/OPEN)or“CLOSEDIES”(START/CLOSE) buttons

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HYDRAULICDIE INSTALLATION
InstallIntermediateAdapterDiesas shownpreviously making
certainthat the IntermediateAdapterDieI.D. matchesthe
HydraulicDie O.D.
Removethe HydraulicDies fromtheir holderwith themagnetic
dieinsertion tool asshown.
The die size stamped on the face of the die should face toward the
operator
Alignthe studs of the HydraulicDies with the holesin theAdapter
Diesandwith thecrimperinmanual modeSLOWLYclosethe
crimperhead on the dieset.
Bringthe crimperheadto afullyclosed positionand remove the
dieinsertion tool.
Thedies mayalso beinserted manually withthe crimperhead in
thefullyopenposition.
ProceedtotheAccuCrimpoperatinginstructionsto setup the
crimperforthehoseandfittingbeingcrimped.
ForHydraulicDie removal,placethe crimperinmanual modeand
bringthe crimper headto the fullyclosed position. Insert thedie
removaltoolandopenthecrimper headreleasing theHydraulic
Diesform theirspring retention holes.
Quick Tip: When working with metric settings, leave the inch
settings set at “0”. When a die change is required, switch the
crimper to inch and press the close button to quickly bring the
head to a fully closed position. When working with inch settings,
leave the metric setting at “0”.

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INITIALSETUP & MAINTENANCE
FrontFlangeBolts
Donot liftthe machineby the crimperhead. Lift witha fork lift
underthetank.
Mountthe crimperon asturdy surface
ElectricalRequirements:
220Volt3Phase Current(Standard)
440Volt3PhaseCurrent(Optional)
Checkto be certain thatthe motor rotates inthe direction of the
arrowshownon themotor housing. Ifmotor rotationis oppositeof
thedirectionof the arrow, reverseanytwo hot wiresin the
electricalplug.
Damageto the pump canresultif the motor doesnotrotate in the
correctdirection.
Check the oil level in the sight glass on the rearof the crimper. 8
U.S,gallons ofISO 46 hydraulicoil are requiredto completely
refillthe tank.
Oilcan bedrainedfrom eitherofthe twoportsat thebottomof the
tank.
Anadditionaloil cooler,while notnormallyrequired,canbe
plumbedintothe twoports atthe rearof thecrimper
Front Flange Bolts: Periodically,every6-12 monthsdepending
uponuseage, the front flangebolt torque should be checked. The
correct torque is 330NM (243 Ft Lbs)

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LUBRICATION &MAINTENANCE
Properlubrication is essentialto prevent damageto the
machineandto assureaccuratecrimping.
Lubricatethe crimpinghead after each100 crimpingcycles.
Alubricantcontaining60%molybdenumdi-sulphidemustbe
used. Acanoflubricant (P/NDMA-12) is furnishedwith the
machine. Thecan must beshaken for aminute in orderto
assurethat the thicklubricant at the bottomof the canis
thoroughlymixedwiththepropellant.
Close the Master Dies until the face of the die is approximately
17mm(.65 in) above theflange as shown.
Spraythe lubricant intothe front andrearof the diesas well as
into the diffuser hole in the center of the die.
Every400 crimp cycles, removethe soft protective pads from
betweenthe Master Diesand spray lubricant intothe spring
cavityarea.
Becertain to replace the protectivepadsas dirt and chips can
causepermanentdamage tothe crimpinghead