CustomCrimp CC38 User manual

CC38 General Production Hose Crimper
Updated 09/12/2017
CC38 CRIMPER OPERATORS MANUAL
WITH ACTTM CONTROLLER
The CC38 Series hose crimper with the Patented ACT™ Controller and 240
tons of crimping force has the capability to crimp up to 2" industrial hose.
UNIQUE USER FRIENDLY PATENTED ACTTM CONTROLLER
• Fully adjustable crimp to diameter.
• Production capabilities.
• Pressure Compensation uses pressure to eliminate “trial and error”.
• Memory capacity for accurate repeatability.
• Automatically converts inch to mm and mm to inch so that no calculation is ever
required.
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Max Head Opening
W/O Dies
Max Head
Opening
120mm
4.72"

CC38 General Production Hose Crimper
2
SAFETY PRECAUTIONS
• READ INSTRUCTIONS AND IDENTIFYALL COMPONENT PARTS BEFORE USING CRIMPER.
• CRIMPER CC38 CAN PRODUCE 240 TONS OF CRIMPING FORCE.
• KEEP BOTH HANDSAWAY FROM PINCH POINTS.
• CONSULT HOSE AND FITTING MANUFACTURER FOR CORRECT MACHINE SETTINGS
AND CRIMP MEASUREMENTS.
• ALWAYS WEAR EYE PROTECTION.
SAFETY PRECAUTIONS
! !

CC38 General Production Hose Crimper
3
SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2
COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4
INITIAL SET UP & MAINTENANCE--------------------------------------------------------------------------------------------------------5
AccuCrimp ACTTM CONTROL PANEL------------------------------------------------------------------------------------6
AccuCrimp ACTTM CONTROL PANEL QUICK START---------------------------------------------------------------------------------7
HYDRAULIC DIE INSTALLATION----------------------------------------------------------------------------------------14
AccuStopTM COUPLING STOP-------------------------------------------------------------------------------------------15
PLC RESET / RELAY REPLACEMENT------------------------------------------------------------------------------------16
TROUBLESHOOTING------------------------------------------------------------------------------------------------17
CC38 CRIMPER REPLACEMENT ACCESSORIES----------------------------------------------------------------------------------18
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------19
CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------24
CUSTOMCRIMP® CONTACT INFORMATION--------------------------------------------------------------------------------------25
TABLE OF CONTENT

CC38 General Production Hose Crimper
4
COMPONENT PARTS & TECHNICAL DATA
Technical Data
240 Ton
Max 2SP: 2", 4SP: 1-½", 6SP: 1-¼"
Max Industrial: 2"
L: 20" x W: 29" x H: 28"
Weight: 495 lbs
Power: 5HP / 230V / 3Phase (Standard)
5HP / 440V / 3Phase (Optional)
5HP / 230V / 1Phase (Optional)
1HP / 12VDC (Optional)
1HP / 24VDC (Optional)
Die series: 84S
Adjustability: Inch / Metric
Opening w/o dies: 120mm / 4.72"
Master die inside diameter: 84mm / 3.31"
Master die travel: 38mm / 1.5"
Reservoir capacity: 8 US Gallons
Oil type: ISO 46 Hydraulic Oil
Adapter dies: N/A
29"
20"
Patented ACTTM Controller
Easy to use push buttons
Power Switch
Foot Pedal for use in Semi
and Full automatic mode
The 5 HP motor delivers the
power needed to get the job
done quickly
Small Footprint for
minimum use of space
Manual Back Stop
Oil Filler Cap
28"
Reservoir
Pressure
Compensation

CC38 General Production Hose Crimper
5
INITIAL SET UP & MAINTENANCE
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:
220 Volt 3 Phase Current (Standard)
440 Volt 3 Phase Current (Optional)
DO NOT RUN CRIMPER ON AN EXTENSION CORD.
Check to be certain that the motor rotates in the direction of the arrow
shownonthemotorhousing. Ifmotorrotationisoppositeofthedirection
of the arrow, reverse any two hot wires in the electrical plug.
(NOTE: THIS ISAPPLICABLE 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 refill 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,thefrontflangebolttorqueshouldbechecked.Thecorrecttorque
is 199NM (147 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
fingers through the 8 lubrication fittings in the front flange face.
• Bringthediestothefullyopenpositionandlubricateall8fittingsagain.
Use only a high quality moly-disulfide grease. Failure to do so may
result in damage to the wearing surfaces.

CC38 General Production Hose Crimper
6
EMERGENCY STOP
MANUAL MODE FUNCTION: CLOSE DIES
AUTO MODE FUNCTION: CYCLE START
MANUAL MODE FUNCTION: OPEN DIES
AUTO MODE FUNCTION: CYCLE STOP
NOTE:
IF THE CRIMPER IS IN MANUAL MODE,THE GREEN OPEN/CLOSE BUTTONS WILL OPEN AND CLOSE THE
CRIMPER HEAD.
IF THE CRIMPER IS IN AUTO MODE, THE BUTTONS FUNCTION AS CYCLE START AND CYCLE STOP BUTTONS.
IF THE CRIMPER IS IN SEMI-AUTO MODE, PRESSING THE FOOT SWITCH OR THE CLOSE BUTTON WILL
CLOSE THE CRIMPER HEAD AND RELEASING WILL HALT THE CLOSING ACTION.
AccuCrimp ACTTM CONTROL PANEL
Products covered by all or some of these Patents:
US 7,383,709; US 8,230,714; EP 1,909,987 and Patents Pending.
6" TOUCH SCREEN
STYLUS PEN
USB PORT

CC38 General Production Hose Crimper
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AccuCrimp ACTTM CONTROL PANEL QUICK START
While the ACTTM crimper has the ability to perform a number of
fully automatic functions, manual operation is also possible.
To make a manual crimp, two numbers are needed:
The closed diameter of the die (in either inches or mm).
The finished crimp diameter (in either in or mm)
That’s all you need to know. ACTTM does the rest.
TO MAKE A MANUAL CRIMP:
• Press START Button.
• Select CRIMP TO DIAMETER.
• Enter the closed diameter of the die set in either in or mm
and press ENTER. Note: for a 25mm die, enter 2500.
ACTTM will add the decimal point.
Decimal point entry:
For 1.56 inch entry, enter 1560 (Controller supplies 3
places for entries in inches).
For a 50.0 mm entry, enter 5000 (Controller will supply 2
decimal places for entries in mm).
• Enter the finished crimp diameter and press ENTER.
• From the ENTER CRIMP screen, press the MANUAL button
to put the crimper in manual mode.
• Confirm that the die and finished crimp diameters are correct
and that MANUAL MODE is displayed.
• Press and hold the green CLOSE button until the crimper
stops closing.
• Check the final crimp diameter. If a minor correction is
required see HOW TO MAKE MINOR CORRECTIONS.
Tip: Pressing the CHANGE DIES button allows the crimper
head to be fully opened or closed with the green OPEN-CLOSE
buttons on the controller front panel When the CHANGE DIES
button is blinking the dies can be opened and closed manually
without altering any of the crimper settings.

CC38 General Production Hose Crimper
8
HOW TO MAKE MINOR CORRECTIONS
• Due to variations in hose and fitting tolerances a minor crimp
adjustment may be required if the measured diameter of the final
crimpisnot within the hose and fitting manufacturer’sspecifications.
ACTTM technologymakesminor corrections a simple processwhich
requires no addition or subtraction.
Ifthe finishedcrimpdiameter is notwithintherequired specifications:
• Press the ADJUST CRIMP button.
• Enter the measured diameter of the fitting in either inches
or mm (Do not enter the amount of correction)and press
ENTER.
• Press OK.
• Make another crimp and verify that the fitting is within
specifications.
EXAMPLE: If the hose and fitting manufacturer specifies that the
finished crimp should measure 1.500 to 1.520 and the measured
crimp diameter was 1.530, simply enter the measured diameter
(1530 - Controller will supply 3 decimal places) and press SAVE.
The finished crimp diameter can be entered in either in or mm and
ACTTM will make the conversion.
While a single correction will usually bring the hose and fitting into
specifications, the process can be repeated as many times as is
required.
PATENTED ACTTM TECHNOLOGY
On crimpers equipped with ACTTM controllers the sensors which
sense the position of the dies are supplemented by a pressure
transducer which senses the “effort” required to make a crimp and
compensates for variations in hose and fitting combinations. This
uniquefeaturemeans that the operator canenter the finishedcrimp
diameter and will seldom, if ever, have to enter an offset to achieve
the correct finished crimp diameter.
AccuCrimp ACTTM CONTROL PANEL QUICK STARTAccuCrimp ACTTM CONTROL PANEL QUICK START

CC38 General Production Hose Crimper
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HOW TO ADD A SAVED DIE
Up to 50 different dies can be saved in the computer memory.
These dies can be recalled in the set up process eliminating the
need to re-enter the die size each time.
To enter a saved die:
• From the OPTION screen, press SETUP MODE.
• Select SAVED DIES.
• Select the save position (1-50) where the die is to be saved
and press the EDIT button.
• Enter a die description (up to 12 alpha/numeric characters).
• Enter diameter units (inch or metric).
• Enter the closed diameter of the die.
• Press SAVE and EXIT.
• The saved die will now appear on the SELECTED DIE
screen. From this screen individual dies can be cleared or
edited.
HOW TO RECALL A SAVED DIE
• SelectCRIMP TO DIAMETER,and from the OPTION screen,
select USE SAVED DIE.
• Select the saved die (1-50) and press LOAD and then OK.
The die parameters will now be used for the crimp process.
From the ENTER CRIMP screen press MANUAL.
• The saved die will now be shown on the crimp parameters
screen.
AccuCrimp ACTTM CONTROL PANEL QUICK STARTAccuCrimp ACTTM CONTROL PANEL QUICK START

CC38 General Production Hose Crimper
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HOW TO ADD A SAVED CRIMP
• Adjust the die diameter and crimp diameter as required and
place the crimper in MANUAL mode.
• Press SAVE.
• Select a location (1-100) and press EDIT.
• Enter a description (up to 12 characters).
• Press SAVE and EXIT.
• The die and crimp setting can now be recalled from the
saved location as required.
TO RECALL SAVED CRIMP
• Select USE SAVED CRIMP from the option screen.
• Select a previously saved crimp from location 1-100.
• Press LOAD.
• Press OK.
• The saved crimp will appear on the manual screen.
AccuCrimp ACTTM CONTROL PANEL QUICK START

CC38 General Production Hose Crimper
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AccuCrimp ACTTM CONTROL PANEL QUICK START
FULL AUTO MODE
With the crimper in FULL AUTO mode additional functions are available:
• The crimper will cycle automatically from the CRIMP button
on the touch screen, the green CYCLE START button on the
panel, or the foot switch.
•To set the position to which the dies will retract, close the
crimper to the desired retract position prior to pressing the
FULL AUTO button.
Note: The retraction position must be set a minimum amount above the
finished crimp diameter or the crimper will not retract. The minimum
retraction diameters are:
CC38 - Crimp Diameter plus 2 mm
CC4-50 - Crimp Diameter plus 2 mm
CC60 - Crimp Diameter plus 3 mm
• Pressing the FULL AUTO button will toggle the crimper into
SEMI-AUTO mode. In SEMI-AUTO mode, pressing the FOOT SWITCH
orthe CLOSE button will closethe crimper headand releasing itwill cause
the head to stop closing. This mode allows the crimper to be jogged into
position allowing more precise positioning of a fitting in the dies.
Pressing the SEMI AUTO button will toggle the crimper back to FULL
AUTO mode
InFULLAUTO mode pressing the footswitch willstart thecrimp cycleand
the dies will stop closing when the crimp cycle is complete.
• The COUNT function is activated allowing the operator to
monitor the number of crimps made.
• A measurement can be required after a preset number of
crimps. See SET REQUIRED MEASUREMENT
SET REQUIRED MEASUREMENT
• Press the PRODUCTION button.
• Determine if 1 or 2 crimps will count as a crimp
• Toggle the CRIMP ADJUSTMENT REMINDER to ON.
• Set the COUNTS BETWEEN CRIMP MEASUREMENTS
to the desired number and press OK.
• At the set interval, the ADJUST CRIMP screen will come up
and the operator will be asked to measure the last crimp and
enter a correction if required.

CC38 General Production Hose Crimper
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AccuCrimp ACTTM CONTROL PANEL QUICK START
ADJUST CRIMP COUNT
If a production operation is interrupted for some reason, it is
possible to reset the counter to where the operation was at the
point of interruption.
• Press the Adjust Count button from the auto crimp screen.
• Press the Crimp Counter and reset the count to the desired
point.
ACTTM ADDITIONAL FEATURES
• Additional features and functions of the ACTTM controller can
beaccessed by pressing the MORE buttonon theMACHINE
SET UP screen.
• When “Allow Crimp to Diameter” is set to “YES”, all of the
adjustment functions of the crimper are available. When
“Allow Crimp to Diameter” is set to “NO” only the settings
entered as a saved crimp can be used.
• English or Spanish language options are available.
• The “Use Pressure Compensation” is set to “YES” for all
crimpers equipped with a pressure transducer. A security
code is required to turn this function on or off.

CC38 General Production Hose Crimper
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AccuCrimp ACTTM CONTROL PANEL QUICK START
ACTTM ADDITIONAL FEATURES
Pre-Loaded Crimp Specifications
In addition to the ability to store up to 50 user entered dies and
150 user entered crimp settings, the ACT™ Controller has the
capability of accepting pre loaded manufacturer’s crimp specifi-
cations.
CustomCrimp® does not maintain these specifications as they
are proprietary to the individual hose and fitting manufacturer.
If, however, your ACT™ Controller was pre loaded with a manu-
facturer’s crimp specifications or if they are available to you, they
are accessed in the following manner:
• Press the Crimp Memory Table Button.
• Press the access button to bring up the stored crimp specifi
cations.
• Scroll through the crimp specifications to select the correct
one. The right hand rocker button moves through the crimp
specs one line at a time and the left hand rocker button moves
one screen at a time.
• When the correct crimp specification is selected, press the
highlighted selection and then the Load button and select OK
to write the data to the ACTTM Controller.
• This will bring up the familiar crimp screen and the crimper
can then be operated in the normal manner.

CC38 General Production Hose Crimper
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HYDRAULIC DIE INSTALLATION
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
Master Dies and SLOWLY close the crimper head on the
die set as shown in photo B.
Bring the crimper head to a fully closed position as shown
in photo C.
Remove the quick change tool as shown in photo D.
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 fitting being crimped.
For Hydraulic Die removal, bring the crimper head to the
fully closed position as shown in photo D.
Insert the quick change tool and open the crimper head
releasing the Hydraulic Dies form their spring retention
holes as shown in photo E.
Press the CHANGE DIES button on the controller to
easily open and close the master dies without affecting
crimper settings.
A
B
C
D
E

CC38 General Production Hose Crimper
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AccuStopTM COUPLING STOP
Coupling Stop
Coupling Stop
Clamp
Coupling
Stop Guide
The AccuStopTM coupling stop eliminates guesswork
allowingthe operator tovisuallyobserveexactly where
the crimp will be positioned on the fitting without the
need for trial and error and product scrap due to poor
crimp positioning.
WiththeCouplingStopretracted,loadtheappropriate
set of dies and set crimp diameters as required.
WiththecrimperintheMANUAL 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 fitting against the Coupling StopArmwithdrawthe Coupling Stop
Rod such that the Guide is aligned
withthe desired crimp position. Lock
the Coupling Stop Clamp.
Position the fitting against the Cou-
pling Stop and actuate the crimper
in the normal manner.
The dimension from the face of the
fitting to the crimp position will now
be the dimension established in the
previous step.
An electronic Coupling Stop is avail-
able. Setupis identical, but whenthe
fittingtouches the Coupling Stop, the
crimp cycle will start automatically.
CAUTION: When using an electronic Coupling Stop, disconnect it from the controller prior to setup.
Failure to do so will cause the crimper to actuate during the set up process.

CC38 General Production Hose Crimper
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The PLC (Programmable Logic Controller) requires a relatively constant source of electrical power.
Power surges, outages or drops in power can cause the PLC to lose its settings.
This may result in missing or misplaced information on the controller screen.
Resetting the PLC to its original settings is a simple procedure
• Turn the main power switch to OFF.
• Remove the 4 screws holding the front panel in place and set the panel aside without disconnecting any wires.
• Power up the crimper from the main power switch. The crimper must be powered on during the PLC reset procedure.
• Move the three position toggle switch on top of the PLC right to the STOP position and then left to the RUN position.
• Return the toggle switch to the center TERM position.
• Turn the main power switch to OFF and replace the front panel.
• The PLC and the crimper should now operate normally.
Relay Replacement
• There are 3 relays which control the motor operation and dies open and dies close functions of the crimper. If one of
these functions is inoperable these relays can be replaced.
• If the pilot light adjacent to the “R1”, “R2”, and “R3” is lit and the function does not operate. This indicates that the relay
is receiving power but not performing its function.
• All 3 relays are identical and interchangeable.
Electrical Panel (Front Cover Removed)
Programmable Logic
Controller (PLC)
Motor Relay
Dies Open Relay
Dies Close Relay
PLC RESET / RELAY REPLACEMENT

CC38 General Production Hose Crimper
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TROUBLESHOOTING
PROBLEM: CRIMPER WILL NOT RUN AT ALL
• Check the E-Stop switch to be certain that it is not depressed. A slight twist is required to release switch
after it has been depressed.
• PLC (Programmable Logic Control) must be reset. See instructions on the following page.
PROBLEM: CRIMPER RUNS BUT IS SLOW OR NON-FUNCTIONAL
• Check supply voltage to see that it matches the voltage specified on the tag attached to the crimper.
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.
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 final 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.
PROBLEM: CRIMPER WILL NOT OPEN TO RETRACT POSITION IN AUTO MODE
• Retract position must be at least 3 mm larger than the final crimp diameter.
If problem(s) persist contact Customer Service for additional troubleshooting
assistance

CC38 General Production Hose Crimper
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CC38 REPLACEMENT ACCESSORIES
CC-Foot Switch
P/N:CC-FOOTSWITCH
6" Touch Screen Panel
P/N:102600-ACT
Electronic Back Stop
P/N:EBS-60 Crimper Stand 16 Station Die Holders
P/N:101247-84
Protective Master Die Foam Pad
P/N:102531 Die Lock Pin For 84S/99S Die Series P/N:101582
CustomCrimp®Notched Digital
Caliper IN/MM P/N:CC-Caliper
Manual Back Stop
P/N:MBS-60
84mm Quick Change Tool
P/N:102572
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
Die Rack 9 Station Die Holders
P/N:102616-84mm

CC38 General Production Hose Crimper
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Touch Panel Housing Assembly (102633) QTYDESCRIPTION
PART NUMBERITEM 13/4" NPT Straight Flex Cord Grip69915K6512Grommet - 1/4"9600K2421
Grommet - 1/8"
9600K1131Foot Pedal Jack W/Nut103874
411/2" NPT Cord Grip69915K57
510
#10 Sheet Metal Screw
90935A24061USB Connector103792
71USB Cable4974T781Receptacle6897K3891
Touch Panel Housing Assembly
102508-BT10 16" Touch Screen Text PanelEA7-S6M-R11 2
Green Push Button101545-GREEN
12 1
Emergency Stop Button
101545-RED13
10
11
3
2
5
1
7
10 11 4
9
12
13
12
COMPONENT PARTS BREAKDOWN

CC38 General Production Hose Crimper
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DETAIL A
A
4243
3839
36
44
4
17
21 22 23
6
28
2930
15
15
14
32
32
45
25
24
19
18
2
5
3
26
27
46
13
12
10
11
16
32
31
32
20
34 35
37
33
40 41
1
789
COMPONENT PARTS BREAKDOWNCOMPONENT PARTS BREAKDOWNCOMPONENT PARTS BREAKDOWN