CustomCrimp CC4-50 User manual

1Page
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]

3Page
CRIMPER COMPONENT PARTS
AccuCrimpCONTROL
PANEL-SEESEPARATE
PAGE
CRIMPERHEAD
OILFILLERCAP
OILLEVEL
SIGHTGLASS
TANK DRAINAND OIL
COOLERPORTS
FOOTSWITCH
FOOTSWITCH
PLUGINPORT
MASTER
POWER
SWITCH

4Page
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.

5Page
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.

6Page
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

7Page
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

8Page
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”.

9Page
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)

10Page
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

11Page
TROUBLESHOOTING
PROBLEM:CRIMPER WILLNOTRUNATALL


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(ProgrammableLogicControl)mustbereset.
PROBLEM: CRIMPER RUNS BUT IS SLOW OR NON-FUNCTIONAL


Check supply voltage to see that it matches the voltage specified on the tag
attachedtothe crimper.


Checkmotor rotationand becertainthat themotor rotatesin the directionof the
arrowon themotor housing. For threephase units rotationcan bereversedby
switchinganytwowiresintheplug.
PROBLEM:CRIMPERWILL CLOSEON FITTINGBUTDOES NOTDEVELOP
POWERTOCOMPLETETHECRIMP


Fitting is to large for selected crimp die. Select a crimp die that is closer to final
crimpdiameter. Machinehasbuilt-in safetyby-pass toprotectinternalcomponents
fromdamage dueto incorrect dieselection.


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
32or46 weighthydraulic oil.
Ifproblem(s) persistcontact CustomerService foradditional troubleshootingassistance

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30
27
7
31
25
14
13
12
11
21
8
26
1
16
15
11
12
13
25 14
29
28
20
24
22
22
18
19
17
23
5
10
9
6
4
2
3
COMPONENT PARTS BREAKDOWN

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1101537 CC Crimper Reservoir 1
21116K22 Sight Glass Assembly 1
34534K43 3/8-18 NPTF Hex Socket Pipe Plug 2
4ABS-40FillerAssy Vented Cap Filler Neck 1
5101715 CC38 Pump/Motor Assembly 1
5101714 CC60/CC4-50 Pump/Motor Assembly 1
6101734 Output Hose Assembly 1
7101733 Suction Strainer Hose Assembly 1
8SS-008P012 Suction Strainer 1
991102A033 1/2 Lock Washer 4
10 92865A714 1/2-13 X 1 1/4 Hex Bolt 4
11 101537-04 CC38 Intermediate Plate 1
11 101537-05 CC60/CC4-50 Intermediate Plate 1
12 91102A031 3/8 Lock Washer 6
13 92865A626 3/8-16 X 1 1/4 Hex Bolt 6
14 101548 CC38 Head/Manifold Assembly 1
14 101550 CC60 Head/Manifold Assembly 1
14 101833 CC4-50 Head/Manifold Assembly 1
15 90126A031 3/8 Flat Washer 4
16 91310A536 M8-1.25 X 40mm Hex Bolt - Class 10.9 4
17 101689 Anti-Rotation Guide Pin 1
18 91253A542 1/4-20 X 1 HSFHS 1
19 101790 CC38 Potentiometer Bracket 1
19 101688 CC60 Potentiometer Bracket 1
19 101836 CC4-50 Potentiometer Bracket 1
20 M10-1.5 X 120 CC38 M10-1.5 X 120mm SHCS 1
20 91290A643 CC60/CC4-50 M12-1.75 X 120mm SHCS 1
21 101687 Potentiometer Mounting Plate 1
22 91290A228 M5-0.8 X 12mm SHCS - Class 12.9 3
23 101719 Linear Position Sensor 1
24 91290A230 M5-0.8 X 14mm SHCS - Class 12.9 1
25 101732 PLC Housing Assembly 1
26 92323A512 1/4-20 X 1/2 SHFCS 4
27 101599 Electrical Panel 1
28 101537-03 Reservoir Front Cover 1
29 98065A135 10-32UNF Spring Clip Nut 4
30 6759K23 (Yel/Red) Main Disconnect Switch 1
31 91255A265 10-32 X 1/2 BHCS 4
CC38 (101547) / CC60 (101551) / CC4-50 (101832) Crimper Assembly
Item Part Number Description Qty
COMPONENT PARTS BREAKDOWN

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7
8
2
3
4
5
6
1
1101538 PLC Housing 1
2EZ-420 PLC Display 1
3E22LLB2B/E22B1 Emergency Stop Switch 1
4E22PB3A Pushbutton Switch 2
59600K11 Grommet - 1/8" 1
69600K24 Grommet - 1/4 " 2
769915K65 Cable Strain Relief 1
8502-N-111 Foot Pedal Jack W/Nut 1
969915K57 Cable Strain Relief 1
10 92949A144 6-32 X 1/4 BHCS 4
PLC Housing Assembly (101732)
Item Part Number Description Qty
9
10
COMPONENTPARTS BREAKDOWN

15Page
1101539 Mounting Flange 1
2101539-01 Flange Gasket 1
3101713 8cc Gear Pump 1
3101542 11cc Gear Pump 1
490126A031 3/8 Flat Washer 2
591102A031 3/8 Lock Washer 2
692865A626 3/8-16 X 1 1/4 Hex. Bolt 2
7101543 Shaft Coupling 1
8101541 5 HP - 220V Motor 1
8101540 7.5 HP - 220V Motor 1
991102A033 1/2 Lock Washer 4
10 92865A714 1/2-13 X 1 1/4 Hex. Bolt 4
CC38 (101715) / CC60 & CC4-50 (101714) Pump/Motor Assembly
Item Part Number Description Qty
8
7
1
310
9
6
5
4
2
Substitute These Components On CC60/CC4-50 Assembly
*
*
*
COMPONENT PARTS BREAKDOWN

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1101244 Die Panel 1
2101246 End Panel 2
390108A030 5/16 Flat Washer 16
491102A030 5/16 Lock Washer 8
592865A581 5/16-18 X 1 Hex Bolt 8
695462A030 5/16-18 Hex Nut 8
7101754 CC Crimper Table Top 1
8101242 99MM Die Holder 16
8101243 84MM Die Holder 16
991255A535 1/4-20 X 3/8 BHCS 64
CC Crimper Table Assembly (101755)
Item Part Number Description Qty
3
4
6
9
8
5
3
72
3
5
2
1
3
4
6
COMPONENT PARTS BREAKDOWN

17Page
NOTES