Custom Crimp D205 Operator's Manual
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Custom Crimp D205 Operator's Manual

Service hose crimper
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D205 / D206
Service Hose Crimper
The D205 / D206 Series crimper with the Micrometer Style Adjustment and 80
ton cylinder has the capacity to crimp hoses up to: 1-¼" 6SP (with standard dies) and
up to 2" 6SP (with optional double angle dies).
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.
Double Angle Tooling: Using double
angle dies effectively double the
crimping force to 160 ton.
D205 / D206 SERIES HYDRAULIC CRIMPER OPERATORS MANUAL
Updated 02/2017

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Summary of Contents for Custom Crimp D205

  • Page 1 D205 / D206 Service Hose Crimper The D205 / D206 Series crimper with the Micrometer Style Adjustment and 80 ton cylinder has the capacity to crimp hoses up to: 1-¼" 6SP (with standard dies) and up to 2" 6SP (with optional double angle dies).

  • Page 2: Safety Precautions

    SAFETY PRECAUTIONS MODELS COVERED: This manual is applicable to a number of variations of the D205 Series Crimpers. A “Standard”, “Metric” and “DC” Micrometer is available on different models. A 1HP-110Volt and a 2 HP-220 Volt ValPower pump are used on different models.

  • Page 3: Table Of Contents

    SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2 COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4 D205 / D206 FEATURES--------------------------------------------------------------------------------------------------------------------------5 INITIAL SET UP & MAINTENANCE------------------------------------------------------------------------------------------------------------6 D205 / D206 SERIES QUICK START GUIDE-------------------------------------------------------------------------------------------------7 CRIMPING WITH STANDARD DIES---------------------------------------------------------------------------------------------------------8 CRIMPING WITH DOUBLE ANGLE DIES-----------------------------------------------------------------------------------------------10 CALIBRATION PROCEDURE-----------------------------------------------------------------------------------------------12 D205 / D206 SERIES DIE OPTION-------------------------------------------------------------------------------------------------------------13...

  • Page 4: Component Parts & Technical Data

    D205 / D206 Service Hose Crimper COMPONENT PARTS & TECHNICAL DATA Technical Data Powerful 80 Ton Hydraulic Cylinder Built-in 80 Ton 160 Ton Work Lamp Single angle dies DA dies 2HP/220V/1PH 1-¼" - 1 - 2 Wire 2" - 1 - 2 Wire...

  • Page 5: D205 / D206 Features

    D205 / D206 Service Hose Crimper D205 / D206 FEATURES • The D205 / D206 Series Crimper comes with standard features which increase accuracy and improve productivity for jobs which require repeat crimps of similar or identical assemblies. (Optional accessories available).

  • Page 6: Initial Set Up & Maintenance

    D205 / D206 Service Hose Crimper INITIAL SET UP & MAINTENANCE FOLLOW THESE STEPS BEFORE YOU USE YOUR CRIMPER FOR THE FIRST TIME. 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.

  • Page 7: D205 / D206 Series Quick Start Guide

    D205 / D206 Service Hose Crimper D205 / D206 SERIES QUICK START GUIDE • Select the correct die set for the combination of hose and fitting being crimped. Consult the hose and fitting manufacturer’s specifications for the correct die to use and final crimp diameter required..

  • Page 8: Crimping With Standard Dies

    D205 / D206 Service Hose Crimper CRIMPING WITH STANDARD DIES • Insert the Standard Pressure Plate in the bottom flange making certain that the Pressure Plate is seated squarely in the bottom flange. Note that the bottom Pressure Plate is held in place by a set screw.
  • Page 9 D205 / D206 Service Hose Crimper CRIMPING WITH STANDARD DIES • Set the Micro-Crimp Adjuster to the setting recommended by the hose and fitting manufacturer for the hose and fitting being crimped. Both the standard and the metric micrometers are shown.

  • Page 10: Crimping With Double Angle Dies

    D205 / D206 Service Hose Crimper CRIMPING WITH DOUBLE ANGLE DIES Double Angle dies double the radial crimping force of the die set allowing heavier fittings to be crimped. Due to the doubling of the radial crimp force, they are effective for a smaller range of diameters than a standard die set.
  • Page 11 D205 / D206 Service Hose Crimper CRIMPING WITH DOUBLE ANGLE DIES • Insert the fitting as specified by the hose manufacturer. • Place the DBL TOP compression ring on top of the die set and manually compress the die set until it contacts the fitting.

  • Page 12: Calibration Procedure

    Insert the Standard Pressure Plate, any die set, and the Compres- sion Ring in the order illustrated. • Set the Micro-Crimp adjuster at: “100’ For the Standard D205 (0-100) “95” For the D205-DC (20-100) “0” for metric units(0-10) • Press and hold the start Switch.

  • Page 13: D205 / D206 Series Die Option

    D205 / D206 Service Hose Crimper D205 / D206 SERIES DIE OPTIONS DIE SIZE CODES: D200-XX-XX-COLOR DIE RING COLOR (1) CRIMP FACE LENGTH (MM/IN) D200 STANDARD. SERIES DIES DIE CLOSED DIAMETER (MM/IN) INCH SERIES DIES D200-0.520-2.000-RED DIE SERIES (D200/D200DA) D200-0.670-2.000-YELLOW D200 DOUBLE ANGLE DIES D200-0.830-2.000-BLUE...

  • Page 14: D205 / D206 Series Crimper Replacement Accessories

    D205 / D206 Service Hose Crimper D205 / D206 REPLACEMENT ACCESSORIES Metric Micrometer Standard Micrometer DC Micrometer D205/D206 Coupling Stop P/N:101587 P/N:100628 P/N:101489 P/N:101631 Pneumatic Pendent Switch Flexible 24" Work Lamp D205/D206 Die Storage Shelf Mobile Cart P/N:101349 P/N:1668-02 P/N:101625...

  • Page 15: T R O U B L E S H O O T I N

    D205 / D206 Service Hose Crimper TROUBLESHOOTING PROBLEM: CRIMPER WILL NOT RUN AT ALL  The white rocker switch is also a circuit breaker. Check to see that the circuit breaker has not been tripped.  Check the wall outlet. The crimper comes from the factory wired for a 220 volt single phase circuit.

  • Page 16: Component Parts Breakdown

    D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN D200 SERIES DIE PARTS (AI-100717) ITEM PART NUMBER DESCRIPTION 100753-XX D200 Die Ring (Half) Varies With Die Size 8 PC Die Finger Set EN82-004 D200 Screw LC 022D 05 D200 Spring...
  • Page 17 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN D200 SERIES DIE PARTS (AI-100717) ITEM PART NUMBER DESCRIPTION 100753-XX D200 Die Ring (Half) Varies With Die Size 8 PC Die Finger Set EN82-004 D200 Screw LC 022D 05 D200 Spring...
  • Page 18 D205 Hydraulic Hose 101631 D205 Coupling Stop Assembly 91251A544 1/4-20 X 1 1/4 SHCS 100628 Standard Micrometer Assembly 101489 DC Micrometer Assembly 101587 Metric Micrometer Assembly 100727 Micrometer Nut 101349 Pendant Switch & Plug 101625 D205 Die Shelf Assembly (Optional)
  • Page 19 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN Micro Mount Assy (100641) Item Part Number Description 100641-01 Micro Plate 100641-02 Micro Brace 100672 Micrometer Bracket 91253A194 8-32 x 1/2 HSFHS 91251A240 10-24 x 3/8 SHCS 91253A197 8-32 x 3/4 HSFHS...
  • Page 20 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN D205 Coupling Stop Assembly (101631) Item Part Number Description 100952 Adjustable Stop Arm 94052A133 Push-on Cap 91251A540 1/4-20 x 3/4 SHCS 90126A029 1/4 Flat Washer DK-655 10-24 Knob 94750A588 1/4-20 T-Nut...
  • Page 21 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN D205 Head Assembly (101634) Item Part Number Description 100679 80 Ton Cone Base 100642 Strain Rod 90500A040 1 1/4-12 Grade 8 Hex Nut 100661 Limit Switch Bracket 91251A146 6-32 x 3/8 SHCS...
  • Page 22 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN 80 Ton Cylinder A ITEM PART NUMBER 100636 100653 90962A357 100760 100637 80 Ton Cylinder Assy (100663) ITEM PART NUMBER DESCRIPTION 100636 Top Cap 100653 Retaining Plug 90962A357 1/4 X 2 Roll Pin...
  • Page 23 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN Pump Assembly (101633) Item Part Number Description 101435 1 Gallon Reservoir 101336 2 Gallon Reservoir 101358 015 Buna 70 O-Ring Seal 101432 Reservoir Standoff 95462A525 1/2-20 Hex Nut 101395 1HP/2HP Pump Sub-Assembly...
  • Page 24 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN...
  • Page 25 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN...
  • Page 26 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN Unloading Block Assembly (101476) ITEM PART NUMBER DESCRIPTION 101399 Unloading Block 011D90 011 Disogrin O-Ring High PSI Seat 101463 91301A180 1/4-20 x 1/4 Hollow Set Screw 9528K13 3/16 Dia. Precision Ball...
  • Page 27 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN Dump Block Assembly (101443) ITEM PART NUMBER DESCRIPTION 102094 Dump Block W/Cavity 102093 Dump Block Cartridge Insert 114D90 114 Disogrin O-Ring 91255A194 8-32 x 1/2 BHCS 101374 Dump Valve Spring 102097...
  • Page 28 D205 / D206 Service Hose Crimper COMPONENT PARTS BREAKDOWN Piston Block Assembly (101478) Piston Block Assembly ITEM PART NUMBER DESCRIPTION Per Build Sheet Piston Block 101478 101381 Port Plug - 7/16-20 904D90 904D Disogrin O-Ring 101386 1/8 Dia. Ball 101355...

  • Page 29: Customcrimp® "No-Nonsense" Warranty Statement

    D205 / D206 Service 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.
  • Page 30 Service Hose Crimper 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 Custom Crimp Crimpers and Accessories at: ® www.customcrimp.com (219) 462-6128...

This manual is also suitable for:

D206

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