CustomCrimp CC150 Manuel utilisateur

CC150 General Production Hose Crimper

Updated 08/2017

CC150 CRIMPER OPERATORS MANUAL

WITH DIAL MICROMETER STYLE ADJUSTMENT

The CC150 Series hose crimper with the Micrometer Style Adjustment and 240

tons of crimping force has the capability to crimp up to 2" 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 ttings.

Max Head Opening

W/O Dies

120mm

4.72"

Micrometer Style Adjustment:

Provides speed, precision

and repeatability.

CC150 General Production Hose Crimper

SAFETY PRECAUTIONS

• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER.

• CRIMPER CC150 CAN PRODUCE 240 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

! !

CC150 General Production Hose Crimper

SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2

COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4

INITIAL SET UP & MAINTENANCE--------------------------------------------------------------------------------------------------------5

HYDRAULIC DIE INSTALLATION------------------------------------------------------------------------------------------------6

AccuStopTM COUPLING STOP------------------------------------------------------------------------------------------------7

CRIMPING--------------------------------------------------------------------------------------------------8

CALIBRATION------------------------------------------------------------------------------------------------9

TROUBLESHOOTING--------------------------------------------------------------------------------------------------10

CC150 CRIMPER REPLACEMENT ACCESSORIES--------------------------------------------------------------------------------11

COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------12

CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------16

CUSTOMCRIMP® CONTACT INFORMATION--------------------------------------------------------------------------------------17

TABLE OF CONTENT

CC150 General Production Hose Crimper

COMPONENT PARTS & TECHNICAL DATA

20"

28"

29"

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: 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

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

Small Footprint for

minimum use of space

Built-in die storage panel

keeps frequently used die

sets readily available

Power Switch

Metric Micrometer

Style Adjustment

Oil Filler Cap

Reservoir

CC150 General Production Hose Crimper

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)

220 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

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 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

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 only a high quality moly-disulde grease. Failure to do so may

result in damage to the wearing surfaces.

CC150 General Production Hose Crimper

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 tting 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.

CC150 General Production Hose Crimper

AccuStopTM 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.

CC150 General Production Hose Crimper

CRIMPING

CRIMPING/CALIBRATION

CRIMPING

Select the correct die for the combination of hose and tting being

crimped. Consult the hose and tting manufacturer’s specications

for the correct die to use and the nal crimp diameter required.

The nal 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 nal crimp diameter would be 59.4 mm ( 57mm

+ 2.4mm)

Insert the hose and tting in the crimper head to the correct depth

and press and hold the foot switch until the crimper shuts o󰀨. If the

AccuStopTM coupling stop is being used make settings according to

instructions.

Check the nished crimp diameter with calipers to be certain that it is

within the hose manufacturer’s specications.

CC150 General Production Hose Crimper

CALIBRATION

Step 1. Use a 0.050" allen wrench to

loosen the set screw on the black knob

to remove the micrometer dial.

Step 2. Rotate the micrometer shaft

counter clockwise until the shaft stops

spinning.

Step 3. Align the numbers on the dial so

that 20 is shown in the black and 75 is

shown in the silver.

Step 4. Align the post on the bottom of the dial to the bottom hole on the micrometer

face as shown.

Step 5. Make sure the dial is sitting at

against the micrometer then retighten

the set screw on the black knob.

Step 6. Load correct die set into crimper for your test crimp. Put the proper setting into the micrometer then perform test crimp.

If crimp is still tight or loose follow steps 7 thru 10.

Step 7. If the crimp diameter is too tight by 0.004” spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw on

the black knob, spin the dial to 1 at the top and 90 at the bottom and then retighten the set screw. Return the dial to your setting

and crimp another tting.

Step 8. If the crimp diameter is too tight by 0.008" spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw on

the black knob, spin the dial to 1 at the top and 80 at the bottom and then retighten the set screw. Return the dial to your setting

and crimp another tting.

Step 9. If the crimp diameter is too loose by 0.004" spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw on

the black knob, spin the dial to 2 at the top and 10 at the bottom and then retighten the set screw. Return the dial to your setting

and crimp another tting.

Step 10. If the crimp diameter is too loosen by 0.008" spin the dial to 2 at the top and 00 at the bottom. Loosen the set screw

on the black knob, spin the dial to 2 at the top and 20 at the bottom and then retighten the set screw. Return the dial to your

setting and crimp another tting.

Step 11. If your crimp it outside of these numbers, or you need additional assistance please call technical service at

219.462.6128.

CC150 General Production Hose Crimper

TROUBLESHOOTING

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.

• 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 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.

If problem(s) persist contact Customer Service for additional troubleshooting assistance

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