CustomCrimp CC200 User manual

CC200 / CC400 General Production Hose Crimper
Updated 01/2017
CC200 / CC400 CRIMPERS OPERATORS MANUAL
WITH DIAL MICROMETER STYLE ADJUSTMENT
The CC200 Series hose crimper with the Micrometer StyleAdjustment and 340
tons of crimping force has the capability to crimp up to 3" industrial hose.
The CC400 with 265 tons of crimping force has the capability to crimp up to 4"
industrial hose.
UNIQUE USER FRIENDLY MICROMETER STYLE ADJUSTMENT
• Easy to use and read.
• Ideal for repetitive crimps.
• Fully adjustable micrometer for a precise crimp.
• Simple to calibrate and minimum maintenance.
• Micrometer style adjustment permits crimping a wide variety of hose and fittings.
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Max Head Opening
W/O Dies
160mm
6.30"
Q
• Eas
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to use and read.
• Ideal
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Max Head Opening
W/O Dies
182mm
7.17"
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18
2
7
Micrometer Style Adjustment:
Provides speed, precision
and repeatability.

CC200 / CC400 General Production Hose Crimper
2
SAFETY PRECAUTIONS
• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER.
• CRIMPER CC200 CAN PRODUCE 340 TONS OF CRIMPING FORCE.
• CRIMPER CC400 CAN PRODUCE 265 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
! !

CC200 / CC400 General Production Hose Crimper
3
SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2
COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4
INITIAL SET UP & MAINTENANCE--------------------------------------------------------------------------------------------------------5
DIESETUP&INSTALLATION---------------------------------------------------------------------------------------------------------------------6
HYDRAULIC DIE INSTALLATION------------------------------------------------------------------------------------------------7
AccuStopTM COUPLING STOP------------------------------------------------------------------------------------------------8
CRIMPING/CALIBRATION-----------------------------------------------------------------------------------------9
TROUBLESHOOTING----------------------------------------------------------------------------------------10
CC200 / CC400 CRIMPERS REPLACEMENTACCESSORIES------------------------------------------------------------------------11
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------12
CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------16
CUSTOMCRIMP® CONTACT INFORMATION--------------------------------------------------------------------------------------17
TABLE OF CONTENT

CC200 / CC400 General Production Hose Crimper
4
COMPONENT PARTS & TECHNICAL DATA
Notch for clearance
of 90° fittings Metric Micrometer Style Adjustment
Manual Back Stop
The Foot Switch permits dies
to be “jogged” into position
and keeps both hands free
The 5 HP motor delivers the
power needed to get the job
done quickly
29"
20"
Small Footprint for
minimum use of space
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: 5HP / 230V / 3Phase (Standard)
5HP / 440V / 3Phase (Optional)
5HP / 230 / 1Phase (Optional)
1HP / 12VDC (Optional)
1HP / 24VDC (Optional)
Die series: 99S / 130S
Adjustability: 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
Built-in die storage panel
keeps frequently used die
sets readily available
Power Switch
Metric Micrometer
Style Adjustment
Manual Back Stop
CC200 Hydraulic Hose Crimper
CC400 Hydraulic Hose Crimper
The Foot Switch permits dies
to be “jogged” into position
and keeps both hands free
The 5 HP motor delivers the
power needed to get the job
done quickly
29"
20"
Small Footprint for
minimum use of space
32"
Built-in die storage panel
keeps frequently used die
sets readily available
Power Switch
Technical Data
265 Ton
Max 2SP: 2", 4SP: 2", 6SP: 1-½"
Max Industrial: 4"
L: 20" x W: 29" x H: 32"
Weight: 660 lbs
Power: 5HP / 230V / 3Phase (Standard)
5HP / 440V / 3Phase (Optional)
5HP / 230 / 1Phase (Optional)
1HP / 12VDC (Optional)
1HP / 24VDC (Optional)
Die series: 99S / 145S
Adjustability: Metric
Opening w/o dies: 182mm / 7.17"
Master die inside diameter: 145mm / 5.71"
Master die travel: 60mm / 2.4"
Reservoir capacity: 8 US Gallons
Oil type: ISO 46 Hydraulic Oil
Oil Filler Cap
Reservoir
Oil Filler Cap
Reservoir

CC200 / CC400 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:
230 Volt 3 Phase Current (Standard)
440 Volt 3 Phase Current (Optional)
230 Volt single phase (Optional)
DO NOT RUN CRIMPER ON AN EXTENSION CORD.
Check to be certain that the motor rotates in the direction of the arrow
shownon themotorhousing. If motorrotationis oppositeof thedirection
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,thefront flangebolttorqueshould bechecked.Thecorrect 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
fingers through the 8 lubrication fittings in the front flange face.
• Bringthe diestothe fullyopen positionandlubricate all8 fittingsagain.
UseCRIMPXDie LubricantGreaseor highqualitymoly-disulfidegrease.
Failure to do so may result in damage to the wearing surfaces.

CC200 / CC400 General Production Hose Crimper
6
DIE SET UP AND INSTALLATION
• Dies are available for the CC200 crimper in 84S, 99S and 130S Series
• Dies are available for the CC400 crimper in 84S, 99S and 145S Series
• A set of 130mm O.D - 99mm I.D. Intermediate Dies is furnished with the
CC200 crimper.
• A set of 145mm O.D - 99mm I.D. Intermediate Dies is furnished with the
CC400 crimper.
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.
Bring the master dies to the full open position as shown in photoA, 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.
Mount all 8 dies in a similar manner as shown in photo D.
If 130mm O.D. Dies are being used, proceed to crimping
Operating instructions and set up the crimper for the correct
crimp diameter.
If Hydraulic Dies are being used, see Hydraulic Die Installation
instructions.
A
B
C
D

CC200 / CC400 General Production Hose Crimper
7
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 theAdapter Dies
andSLOWLYclose thecrimper headonthe diesetas shownin photoC.
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 fitting 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.
A
B
C
D
E

CC200 / CC400 General Production Hose Crimper
8
AccuStopTM COUPLING STOP
Coupling Stop
Coupling Stop
Clamp
Coupling
Stop Guide
The AccuStopTM coupling stop eliminates guesswork
allowingtheoperator to visuallyobserveexactlywhere
the crimp will be positioned on the fitting without the
need for trial and error and product scrap due to poor
crimp positioning.
Withthe CouplingStopretracted, loadtheappropriate
set of dies and set crimp diameters as required.
Withthe crimperin the MANUAL mode,bring thedies
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 StopArmwithdraw the CouplingStop
Rod such that the Guide is aligned
with the 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.

CC200 / CC400 General Production Hose Crimper
9
CRIMPING / CALIBRATION
Set Screw (.050 hex wrench)
CRIMPING
Select the correct die for the combination of hose and fitting being
crimped. Consult the hose and fitting manufacturer’s specifications
for the correct die to use and the final crimp diameter required.
The final crimp diameter will be the closed diameter stamped on the
face of the die plus the number shown on the micrometer gage. See
the micrometer setting example below:
Micrometer Setting Example
Each 100 on the micrometer dial represents 1 mm above the
closed diameter of the die set. For example, with a 57mm
die set installed and the micrometer set at 240 as shown in
the photo, the final crimp diameter would be 59.4 mm ( 57mm
+ 2.4mm)
Insert the hose and fitting in the crimper head to the correct depth
and press and hold the foot switch until the crimper shuts off. If the
AccuStopTM coupling stop is being used make settings according to
instructions.
Check the finished crimp diameter with calipers to be certain that it is
within the hose manufacturer’s specifications.
CALIBRATION
Due to physical variations in hose and fitting combinations, it may be
necessary to offset the crimper in either the plus or minus direction by
afew mmto getthemeasured crimpdiameter tomatch themicrometer
setting. Ifthe finalcrimpdimension isconsistently offineither direction
the micrometer dial can be adjusted to compensate.
Make a crimp with the hose and fitting combination most commonly
used, and measure the finished crimp diameter.
If necessary, loosen the set screw on the adjustment knob with a .050’
hex key wrench.
Rotate the adjustment knob so that the number on the dial matches
the actual diameter of the finished crimp.
Tighten the set screw and make another crimp to confirm that the
crimper is set correctly.

CC200 / CC400 General Production Hose Crimper
10
TROUBLESHOOTING
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.
• If the crimper is connected to a three phase circuit, check all three legs of the circuit to be certain that all legs are hot.
• Measure the voltage to the crimper when the crimper is under load. Voltage should be a minimum of 90% of line voltage
when the crimper is under load.
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.
• The circuit in the crimper is protected by a thermal overload relay. If the relay trips after resetting it from the master pow-
er switch, call for technical service.
PROBLEM: MOTOR RUNS BUT FOOT SWITCH WILL NOT OPERATE
• Power to the secondary circuit is supplied from a 24 volt step down transformer. If the motor runs normally but the foot
switch will not function check the 2 amp slo blow fuse located in the control box as shown in the photo below.
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.
If problem(s) persist contact Customer Service for additional troubleshooting assistance

CC200 / CC400 General Production Hose Crimper
11
CC200 / CC400 REPLACEMENT ACCESSORIES
Dial Micrometer Assembly
CC200 Crimper P/N:102941-450
CC400 Crimper P/N:102941-60
Die Lock Pin For 84S/99S
Die Series P/N:101582
CustomCrimp®Notched Digital
Caliper IN/MM P/N:CC-Caliper
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
Foot Pedal Assembly
P/N:104118 99mm Quick Change Tool P/N:102571
Crimper Stand 16 Station
Die Holders P/N:101247-99
Die Rack 9 Station Die Holders
P/N:102616-99mm
Intermediate Die Removal Tool
P/N:5691A13
Protective Master Die Foam Pad
CC200 Crimper P/N:102529
CC400 Crimper P/N:102530
Adapter Die Set 130mm OD to
99mm ID P/N:101575 Die Lock Pin For 130S/145S Die Series P/N:101403
Adapter Die Set 145mm OD to
99mm ID P/N:103726
Manual Back Stop
P/N:MBS-60

CC200 / CC400 General Production Hose Crimper
12
COMPONENT PARTS BREAKDOWN
CC150/200/400 Assembly (103052) QTYDESCRIPTION
PART NUMBERITEM 1
CC Crimper Reservoir
102618-WELD11
CC-60 Head Assembly
10280021
CC-450 Head Assembly
10251331CC-38 Head Assembly102594
41Front Die Panel102946
55
99MM Die Holder10124265 84MM Die Holder1012436201/4-20 x 3/8" SHCS91251A535
74
1/4-20 x 1/2 BHCS
91255A53781Electrical Box Assembly10305394
1/4-20 x 1/2 SHFCS
92323A51210 1
Dial Micrometer Assembly
10294111 14 Pin Plug/12 Foot Cord10306112 1Foot Switch10305813 1Full Guard for Foot Switch10305414 15 HP/3 Ph/8cc Motor and Pump101714-5-8-315 1
5 HP/1 Ph/8cc Motor and Pump
101714-5-8-116
14
13
12
65
8
7
11
9
234
1
10 15 16

CC200 / CC400 General Production Hose Crimper
13
COMPONENT PARTS BREAKDOWN
CC-150/200/400 Electrical Box (103053)
ITEM PART NUMBER DESCRIPTION STOCK NUMBER QTY
1 102945 Electrical Box Metal Assembly 102945 1 2 69915K65 Cable Strain Relief 69915K65 1 3 69915K56 3/4 NPT Cord Grip 69915K56 1 4 7807K64 Multi-Wire Cord Grip 7807K64 1 569915K51 3/8 NPT Cord Grip 69915K51 1 6 103060 4 Pin Receptical 1R4004A20A120 1 7 91251A537 1/4-20 x 1/2 SHCS 91251A537 2 8 3.125LDIN 3.125 Length DIN Rail 3.125LDIN 1 9 90675A029 1/4-20 Nut with Tooth Washer 90675A029 3
10 103057-2303 Manual Starter with Overload - 230V 3Ph BM3RHB-016 1 11 103057-2301 Manual Starter with Overload - 230V 1Ph BM3RHB-032 1
CC-150/200/400 Electrical Box (103053)
ITEM PART NUMBER DESCRIPTION STOCK NUMBER QTY
12 103057-4603 Manual Starter with Overload - 460V 3Ph BM3RHB-004 1 13 103059-LINK1.355L Starter Switch Linkage BZ0VYRL 1 14 103059 External Starter Handle and Linkage BZ0VYRL 1 15 90273A197 #8-32 x 3/4 CS Screw 90273A197 2 16 103055 230/460-24VAC Transformer PT50QG 1 17 90480A009 #8-32 Nut 90480A009 2 18 MEN2 Time-Delay 2 Amp Fuse MEN2 1 19 103056 Bridge Rectifier MP1505 1 20 91251A541 1/4-20 X 7/8" SHCS 91251A541 1 21 91255A190 #8-32 x 1/4 BHCS 91255A190 5
7
9
5
420
3
2
10 11 12
13
8
1
6
14
21
15
17
18
19
16

CC200 / CC400 General Production Hose Crimper
14
COMPONENT PARTS BREAKDOWN
CC Motor and Pump Assembly (101714) QTYDESCRIPTIONPART NUMBERITEM 15 HP 1800 RPM Motor101541117.5 HP 1800 RPM Motor1015402110 HP 1800 RPM Motor10299431Motor Mounting Flange10153944
1/2 Lock Washer
91101A03354
1/2-13 x 1 1/4" Bolt92865A71461Motor Coupling101543-01
71
Coupling Spider Insert
101543-0381
8cc Gear Pump
10171391
11cc Gear Pump
10154210 1
14cc Gear Pump
10299211 23/8 Washer98023A3112 23/8 Lock Washer91102A03113 23/8-16 x 1 1/4" Bolt92865A62614 1
3/4" Shaft Coupling
101543-0215 1
Flange Gasket
101539-0116 1
8 JIC 37 M to 12 SAE Adapter
6400-8-1217 18 JIC 37 M to 10 SAE Adapter6400-8-1018
123
15
8
7
4
16
5
6
17
91011
18
12
13
14
FINAL ASSEMBLY PART NUMBER CREATION:
101714-"MOTOR HP"-"PUMP SIZE"-"PHASE (IF REQ'D)"
EX. 7.5 HP MOTOR WITH 11cc PUMP: 101714-7.5-11
EX. 5 HP MOTOR WITH 8cc PUMP, SINGLE PHASE:101714-5-8-1

CC200 / CC400 General Production Hose Crimper
15
COMPONENT PARTS BREAKDOWN
CC Crimper Table Assembly (101755) Qty
DescriptionPart NumberItem 1Die Panel10124412End Panel1012462165/16 Flat Washer90108A03038
5/16 Lock Washer
91102A03048
5/16-18 X 1 Hex Bolt
92865A58158
5/16-18 Hex Nut
95462A03061CC Crimper Table Top101754
71699MM Die Holder10124281684MM Die Holder1012438641/4-20 X 3/8 BHCS91255A5359
3
4
6
9
8
5
3
72
3
5
2
1
3
4
6

CC200 / CC400 General Production Hose Crimper
16
CustomCrimp® “No-Nonsense” Warranty Statement
All CustomCrimp® Products are warranted to be free of defects in workmanship and materials for one
year from the date of installation. This warranty ends when the product becomes unusable for reasons
other than defects in workmanship or material.
AnyCustomCrimp®Productproven to be defective in workmanship or material will be repaired or replaced
at no charge. To obtain benefits of this warranty, first, contact Warranty Repair Department at Custom
Machining Services at [phone] and then deliver via prepaid transportation the complete hydraulic
product to:
ATTN: WARRANTY REPAIR DEPT.
Custom Machining Services, Inc.
318 North Co. Rd 400 East
Valparaiso IN 46383
If any product or part manufactured by CustomCrimp® is found to be defective by CustomCrimp®, at its
option, CustomCrimp® will either repair or replace the defective part or product and return via ground
transportation, freight prepaid.
CustomCrimp® will not cover any incoming or outgoing freight charges for machines sold outside
The United States.
This warranty does not cover any product or part which is worn out, abused, altered, used for a purpose
other than for which it was intended, or used in a manner which was inconsistent with any instructions
regarding its use.
Electricmotorsareseparatelywarrantedbytheirmanufacturerundertheconditionsstatedintheirseparate
warranty.
CUSTOMCRIMP®“NO-NONSENSE” WARRANTY STATEMENT

CC200 / CC400 General Production Hose Crimper
17
CONTACT US
CustomCrimp®
Custom Machining Services, Inc.
326 N. County Rd. 400 East
Valparaiso, IN 46383
Ph: [phone]
Fax: [phone]
www.customcrimp.com
See the complete line of CustomCrimp®Crimpers and Accessories at: [phone]CustomCrimp® www.customcrimp.com
CUSTOMCRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS.
Products and services to support industry wide hose assembly needs.