CustomCrimp CC4-50 User manual

CC4-50 General Production Hose Crimper
Updated 09/13/2017
CC4-50 CRIMPER OPERATORS MANUAL
WITH ACTTM CONTROLLER
Max Head Opening
W/O Dies
160mm
6.30"
The CC4-50 Series hose crimper with the Patented ACT™ Controller and 340
tons of crimping force has the capability to crimp up to 3" 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.

CC4-50 General Production Hose Crimper
2
SAFETY PRECAUTIONS
• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER.
• CRIMPER CC4-50 CAN PRODUCE 340 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
! !

CC4-50 General Production Hose Crimper
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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
DIE SET UP AND INSTALLATION--------------------------------------------------------------------------------------------------------14
HYDRAULIC DIE INSTALLATION----------------------------------------------------------------------------------------15
AccuStopTM COUPLING STOP-------------------------------------------------------------------------------------------16
PLC RESET / RELAY REPLACEMENT------------------------------------------------------------------------------------17
TROUBLESHOOTING------------------------------------------------------------------------------------------------18
CC4-50 CRIMPER REPLACEMENT ACCESSORIES------------------------------------------------------------------------19
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------20
CC4-50 DIE PART IDENTIFICATION-------------------------------------------------------------------------------------------25
CC4-50 PREVENTATIVE MAINTENANCE PACKAGE------------------------------------------------------------------26
CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------28
CUSTOMCRIMP® CONTACT INFORMATION--------------------------------------------------------------------------------------29
TABLE OF CONTENT

CC4-50 General Production Hose Crimper
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COMPONENT PARTS & TECHNICAL DATA
Notch for clearance
of 90° ttings
Manual Back Stop
Patented ACTTM Controller
Easy to use push buttons
Power Switch
Foot Pedal for use in Semi
and Full automatic mode
The 7.5 HP motor delivers
the power needed to get the
job done quickly
29"
20"
Small Footprint for
minimum use of space
Pressure
Compensation
32"
Technical Data
340 Ton
Max 2SP: 2-½", 4SP: 2-½", 6SP: 2-½"
Max Industrial: 3"
L: 20" x W: 29" x H: 32"
Weight: 635 lbs
Power: 7.5HP / 230V / 3Phase (Standard)
7.5HP / 440V / 3Phase (Optional)
5HP / 230 / 1Phase (Optional)
1HP / 12V (Optional)
1HP / 24V (Optional)
Die series: 99S / 130S
Adjustability: Inch / 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
Oil Filler Cap
Reservoir

CC4-50 General Production Hose Crimper
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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
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 a high quality moly-disulde
grease. Failure to do so may result in damage to the wearing surfaces.

CC4-50 General Production Hose Crimper
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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

CC4-50 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 nished 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 nished crimp diameter and press ENTER.
• From the ENTER CRIMP screen, press the MANUAL button
to put the crimper in manual mode.
• Conrm that the die and nished crimp diameters are correct
and that MANUAL MODE is displayed.
• Press and hold the green CLOSE button until the crimper
stops closing.
• Check the nal 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.

CC4-50 General Production Hose Crimper
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HOW TO MAKE MINOR CORRECTIONS
• Due to variations in hose and tting tolerances a minor crimp
adjustment may be required if the measured diameter of the final
crimp is not within the hose and tting manufacturer’s specications.
ACTTM technology makes minor corrections a simple process which
requires no addition or subtraction.
If the nished crimp diameter is not within the required specications:
• Press the ADJUST CRIMP button.
• Enter the measured diameter of the tting in either inches
or mm (Do not enter the amount of correction)and press
ENTER.
• Press OK.
• Make another crimp and verify that the tting is within
specications.
EXAMPLE: If the hose and tting manufacturer species that the
nished 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 nished 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 tting into
specications, 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 tting combinations. This
unique feature means that the operator can enter the nished crimp
diameter and will seldom, if ever, have to enter an offset to achieve
the correct nished crimp diameter.
AccuCrimp ACTTM CONTROL PANEL QUICK START

CC4-50 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
• Select CRIMP 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 START

CC4-50 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

CC4-50 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
nished 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
or the CLOSE button will close the crimper head and releasing it will cause
the head to stop closing. This mode allows the crimper to be jogged into
position allowing more precise positioning of a tting in the dies.
Pressing the SEMI AUTO button will toggle the crimper back to FULL
AUTO mode
In FULL AUTO mode pressing the foot switch will start the crimp cycle and
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.

CC4-50 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
be accessed by pressing the MORE button on the MACHINE
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.

CC4-50 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.

CC4-50 General Production Hose Crimper
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DIE SET UP AND INSTALLATION
84S, 99S, and 130S series dies are available for the CC4-50 Crimper.
(84S series dies have an 84mm O.D. etc).
A set of 130mm O.D. to 99mm I.D. Intermediate Dies is furnished with the
CC4-50 crimper. The Master Dies in the CC4-50 Crimper have an I.D. of
130mm.
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. Tap the START button on
the ACT™ controller then CHANGE DIES button in the lower left corner of
the screen; it will start to ash. This button allows you to “jog” the crimper
head in and out during die installation using the green CLOSE and OPEN
button below the screen on the front of the ACT™ controller.
Bring the master dies to the fully 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.
Install the remaining 7 adapter die ngers in the similar manner as shown
in photo C.
Once the 130mm to 99mm adapter die set is installed. Proceed to install
the hydraulic die set.
A
B
C
D

CC4-50 General Production Hose Crimper
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HYDRAULIC DIE INSTALLATION
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.
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

CC4-50 General Production Hose Crimper
16
AccuStopTM COUPLING STOP
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.
An electronic Coupling Stop is avail-
able. Set up is identical, but when the
tting touches 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.

CC4-50 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

CC4-50 General Production Hose Crimper
18
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 specied 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 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.
PROBLEM: CRIMPER WILL NOT OPEN TO RETRACT POSITION IN AUTO MODE
• Retract position must be at least 3 mm larger than the nal crimp diameter.
If problem(s) persist contact Customer Service for additional troubleshooting
assistance

CC4-50 General Production Hose Crimper
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CC4-50 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:101247-99
Protective Master Die Foam Pad
P/N:102529
Intermediate Die Removal Tool
P/N:5691A13
Adapter Die Set 130mm OD to
99mm ID P/N:101575
Die Lock Pin For 84S/99S Die
Series P/N:101582
Die Lock Pin For 130S/145S
Die Series P/N:101403
CustomCrimp®Notched Digital
Caliper IN/MM P/N:CC-Caliper
Manual Back Stop
P/N:MBS-60
99mm Quick Change Tool
P/N:102571
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:102616-99mm

CC4-50 General Production Hose Crimper
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Touch Panel Housing Assembly (102633)
QTYDESCRIPTION
PART NUMBERITEM
13/4" NPT Straight Flex Cord Grip69915K651
2Grommet - 1/4"9600K242
1
Grommet - 1/8"
9600K113
1Foot Pedal Jack W/Nut103874
4
11/2" NPT Cord Grip69915K57
5
10
#10 Sheet Metal Screw
90935A2406
1USB Connector103792
7
1USB Cable4974T78
1Receptacle6897K389
1
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