CC200 / CC400 General Production Hose Crimper

The CC200 Series hose crimper with the Micrometer Style Adjustment 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.

6.30"

160mm

Max Head Opening

W/O Dies

Micrometer Style Adjustment:

Provides speed, precision
and repeatability.

7.17"

182mm

Max Head Opening

W/O Dies

CC200 / CC400 CRIMPERS OPERATORS MANUAL

WITH DIAL MICROMETER STYLE ADJUSTMENT

Updated 01/2017
CC200 / CC400 General Production Hose Crimper

SAFETY PRECAUTIONS

! 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 HANDS AWAY FROM PINCH POINTS.

• CONSULT HOSE AND FITTING MANUFACTURER FOR CORRECT MACHINE SETTINGS

AND CRIMP MEASUREMENTS.

• ALWAYS WEAR EYE PROTECTION.

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CC200 / CC400 General Production Hose Crimper

TABLE OF CONTENT

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

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

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

DIE SET UP & INSTALLATION---------------------------------------------------------------------------------------------------------------------6

HYDRAULIC DIE INSTALLATION------------------------------------------------------------------------------------------------7

AccuStop TM COUPLING STOP------------------------------------------------------------------------------------------------8

CRIMPING----------------------------------------------------------------------------------------------------9

C A L I B R AT I O N - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 0

T R O U B L E S H O O T I N G - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

CC200 / CC400 CRIMPERS REPLACEMENT ACCESSORIES------------------------------------------------------------------------12

COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------13

CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------17

CUSTOMCRIMP® CONTACT INFORMATION--------------------------------------------------------------------------------------18

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CC200 / CC400 General Production Hose Crimper

COMPONENT PARTS & TECHNICAL DATA

Technical Data
340 Ton
Notch for clearance Metric Micrometer
Max 2SP: 2-½", 4SP: 2-½", 6SP: 2-½"
of 90° fittings Style Adjustment The 5 HP motor delivers the
power needed to get the job Max Industrial: 3"
done quickly L: 20" x W: 29" x H: 32"
Manual Back Stop
Built-in die storage panel Weight: 635 lbs
keeps frequently used die Power: 5HP / 230V / 3Phase (Standard)
sets readily available 5HP / 440V / 3Phase (Optional)
Oil Filler Cap 5HP / 230 / 1Phase (Optional)
1HP / 12VDC (Optional)
Power Switch 1HP / 24VDC (Optional)
32" Die series: 99S / 130S
The Foot Switch permits dies
Reservoir to be “jogged” into position Adjustability: Metric
and keeps both hands free Opening w/o dies: 160mm / 6.30"
Master die inside diameter: 130mm / 5.12"
Master die travel: 38mm / 1.5"
Small Footprint for
Reservoir capacity: 8 US Gallons
20

29" minimum use of space

"

Oil type: ISO 46 Hydraulic Oil

CC200 Hydraulic Hose Crimper

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

29" minimum use of space

"

Oil type: ISO 46 Hydraulic Oil

CC400 Hydraulic Hose Crimper

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CC200 / CC400 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)
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
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 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, the front flange 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
fingers through the 8 lubrication fittings in the front flange face.

• Bring the dies to the fully open position and lubricate all 8 fittings again.

Use CRIMPX Die Lubricant Grease or high quality moly-disulfide grease.

Failure to do so may result in damage to the wearing surfaces.

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CC200 / CC400 General Production Hose Crimper

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 A
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 photo A, or to the B
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. C
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.

D
If Hydraulic Dies are being used, see Hydraulic Die Installation
instructions.

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CC200 / CC400 General Production Hose Crimper

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.

A
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.
B
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.

C
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. D

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.

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CC200 / CC400 General Production Hose Crimper

AccuStopTM COUPLING STOP

Coupling Stop
The AccuStop coupling stop eliminates guesswork
TM

allowing the operator to visually observe exactly where Coupling Stop

the crimp will be positioned on the fitting without the Clamp
need for trial and error and product scrap due to poor
crimp positioning.

With the Coupling Stop retracted, load the appropriate Coupling

set of dies and set crimp diameters as required. Stop Guide

With the crimper in the MANUAL mode, bring the dies

to a fully closed position.

Loosen the Coupling Stop Clamp Slide the Coupling Stop Guide Hold the fitting against the Coupling
and position the Coupling Stop against the Coupling Stop Arm. Stop Arm withdraw the Coupling Stop
against the back face of the dies. Rod such that the Guide is aligned
with the desired crimp position. Lock
the Coupling Stop Clamp.

Position the fitting against the Cou- The dimension from the face of the
pling Stop and actuate the crimper fitting to the crimp position will now
in the normal manner. be the dimension established in the
previous step.

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CC200 / CC400 General Production Hose Crimper

CRIMPING / CALIBRATION

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.

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CC200 / CC400 General Production Hose Crimper

CALIBRATION

20

75

Step 1. Use a 0.050" allen wrench to Step 2. Rotate the micrometer shaft Step 3. Align the numbers on the dial so
loosen the set screw on the black knob counter clockwise until the shaft stops that 20 is shown in the black and 75 is
to remove the micrometer dial. spinning. shown in the silver.

Step 4. Align the post on the bottom of the dial to the bottom hole on the micrometer Step 5. Make sure the dial is sitting flat
face as shown. 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 fitting.
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 fitting.
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 fitting.
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 fitting.
Step 11. If your crimp it outside of these numbers, or you need additional assistance please call technical service at
219.462.6128.

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CC200 / CC400 General Production Hose Crimper

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

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CC200 / CC400 General Production Hose Crimper

CC200 / CC400 REPLACEMENT ACCESSORIES

Dial Micrometer Assembly Foot Pedal Assembly 99mm Quick Change Tool Intermediate Die Removal Tool
CC200 Crimper P/N:102941-450 P/N:104118 P/N:102571 P/N:5691A13
CC400 Crimper P/N:102941-60

Manual Back Stop Die Rack 9 Station Die Holders Crimper Stand 16 Station Protective Master Die Foam Pad
P/N:MBS-60 P/N:102616-99mm Die Holders P/N:101247-99 CC200 Crimper P/N:102529
CC400 Crimper P/N:102530

Mini Grease Gun w/ CRIMPX Die CRIMPX Die Lubricant 3 oz mini CRIMPX Die Lubricant 14 oz CustomCrimp® Notched Digital
Lubricant 3 oz mini grease tube grease tube P/N:103887 large grease tube P/N:103888 Caliper IN/MM P/N:CC-Caliper
P/N:103889

Adapter Die Set 130mm OD to Adapter Die Set 145mm OD to Die Lock Pin For 84S/99S Die Lock Pin For 130S/145S
99mm ID P/N:101575 99mm ID P/N:103726 Die Series P/N:101582 Die Series P/N:101403

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CC200 / CC400 General Production Hose Crimper

COMPONENT PARTS BREAKDOWN

CC150/200/400 Assembly (103052)

ITEM PART NUMBER DESCRIPTION QTY
1 102618-WELD CC Crimper Reservoir 1
2 102800 CC-60 Head Assembly 1
3 102513 CC-450 Head Assembly 1
4 102594 CC-38 Head Assembly 1
5 102946 Front Die Panel 1
6 101242 99MM Die Holder 5
6 101243 84MM Die Holder 5
7 91251A535 1/4-20 x 3/8" SHCS 20
2 3 4 8 91255A537 1/4-20 x 1/2 BHCS 4
9 103053 Electrical Box Assembly 1
10 92323A512 1/4-20 x 1/2 SHFCS 4
11 102941 Dial Micrometer Assembly 1
12 103061 4 Pin Plug/12 Foot Cord 1
13 103058 Foot Switch 1
14 103054 Full Guard for Foot Switch 1
15 101714-5-8-3 5 HP/3 Ph/8cc Motor and Pump 1
16 101714-5-8-1 5 HP/1 Ph/8cc Motor and Pump 1
10 15 16
11
1
8
9
14
13
7
6 5
12
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CC-150/200/400 Electrical Box (103053) CC-150/200/400 Electrical Box (103053)
ITEM PART NUMBER DESCRIPTION STOCK NUMBER QTY ITEM PART NUMBER DESCRIPTION STOCK NUMBER QTY
CC200 / CC400 General Production Hose Crimper

1 102945 Electrical Box Metal Assembly 102945 1 12 103057-4603 Manual Starter with Overload - 460V 3Ph BM3RHB-004 1
2 69915K65 Cable Strain Relief 69915K65 1 13 103059-LINK1.355L Starter Switch Linkage BZ0VYRL 1
3 69915K56 3/4 NPT Cord Grip 69915K56 1 14 103059 External Starter Handle and Linkage BZ0VYRL 1
COMPONENT PARTS BREAKDOWN

4 7807K64 Multi-Wire Cord Grip 7807K64 1 15 90273A197 #8-32 x 3/4 CS Screw 90273A197 2
5 69915K51 3/8 NPT Cord Grip 69915K51 1 16 103055 230/460-24VAC Transformer PT50QG 1
6 103060 4 Pin Receptical 1R4004A20A120 1 17 90480A009 #8-32 Nut 90480A009 2
7 91251A537 1/4-20 x 1/2 SHCS 91251A537 2 18 MEN2 Time-Delay 2 Amp Fuse MEN2 1
8 3.125LDIN 3.125 Length DIN Rail 3.125LDIN 1 19 103056 Bridge Rectifier MP1505 1
9 90675A029 1/4-20 Nut with Tooth Washer 90675A029 3 20 91251A541 1/4-20 X 7/8" SHCS 91251A541 1
10 103057-2303 Manual Starter with Overload - 230V 3Ph BM3RHB-016 1 21 91255A190 #8-32 x 1/4 BHCS 91255A190 5
11 103057-2301 Manual Starter with Overload - 230V 1Ph BM3RHB-032 1
19
16
18
5
4
20
17
7
3
9
2
15
21
8
10 11 12
1 13
14
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CC200 / CC400 General Production Hose Crimper

COMPONENT PARTS BREAKDOWN

CC Motor and Pump Assembly (101714)

ITEM PART NUMBER DESCRIPTION QTY
1 101541 5 HP 1800 RPM Motor 1
2 101540 7.5 HP 1800 RPM Motor 1
3 102994 10 HP 1800 RPM Motor 1
4 101539 Motor Mounting Flange 1
5 91101A033 1/2 Lock Washer 4
6 92865A714 1/2-13 x 1 1/4" Bolt 4
7 101543-01 Motor Coupling 1
8 101543-03 Coupling Spider Insert 1
9 101713 8cc Gear Pump 1
3 2 1
10 101542 11cc Gear Pump 1
11 102992 14cc Gear Pump 1
12 98023A31 3/8 Washer 2
13 91102A031 3/8 Lock Washer 2
14 92865A626 3/8-16 x 1 1/4" Bolt 2
15 101543-02 3/4" Shaft Coupling 1
16 101539-01 Flange Gasket 1
17 6400-8-12 8 JIC 37 M to 12 SAE Adapter 1
18 6400-8-10 8 JIC 37 M to 10 SAE Adapter 1

FINAL ASSEMBLY PART NUMBER CREATION:

15 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

16

18
6

12

11 10 9
17

14
13

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CC200 / CC400 General Production Hose Crimper

COMPONENT PARTS BREAKDOWN

2
7

3
4

CC Crimper Table Assembly (101755)

Item Part Number Description Qty
1 101244 Die Panel 1
2 101246 End Panel 2
3 90108A030 5/16 Flat Washer 16
4 91102A030 5/16 Lock Washer 8
5 92865A581 5/16-18 X 1 Hex Bolt 8
6 95462A030 5/16-18 Hex Nut 8
7 101754 CC Crimper Table Top 1
8 101242 99MM Die Holder 16
8 101243 84MM Die Holder 16
9 91255A535 1/4-20 X 3/8 BHCS 64

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CC200 / CC400 General Production Hose Crimper

CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT

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.

Any CustomCrimp® Product proven 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 (219) 462-6128 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.

Electric motors are separately warranted by their manufacturer under the conditions stated in their separate
warranty.

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CC200 / CC400 General Production Hose Crimper

CONTACT US

CUSTOMCRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS.

Products and services to support industry wide hose assembly needs.

CustomCrimp®
Custom Machining Services, Inc.
326 N. County Rd. 400 East
Valparaiso, IN 46383
Ph: (219) 462-6128
Fax: (219) 464-2773
www.customcrimp.com

See the complete line of CustomCrimp® Crimpers and Accessories at:

CustomCrimp® www.customcrimp.com (219) 462-6128

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