Custom Crimp D205M Series Operator's Manual
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Custom Crimp D205M Series Operator's Manual

Hydraulic crimpers
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Innovating SMART Hose Assembly Solutions Since 1979
D205M SERIES HYDRAULIC CRIMPERS
OPERATORS MANUAL
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Summary of Contents for Custom Crimp D205M Series

  • Page 1 Innovating SMART Hose Assembly Solutions Since 1979 D205M SERIES HYDRAULIC CRIMPERS OPERATORS MANUAL...

  • Page 2: Safety Precautions

    Innovating SMART Hose Assembly Solutions Since 1979 SAFETY PRECAUTIONS • READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER. • D205M SERIES CRIMPERS CAN PRODUCE 80 TONS OF CRIMPING FORCE. • KEEP BOTH HANDS AWAY FROM PINCH POINTS. •...

  • Page 3: Table Of Contents

    COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4 D205M FEATURES-----------------------------------------------------------------------------------------------------------5 INITIAL SET UP---------------------------------------------------------------------------------------------------------------------------------------6 CRIMPING WITH STANDARD DIES------------------------------------------------------------------------------------------------------7 CRIMPING WITH DOUBLE ANGLE DIES-------------------------------------------------------------------------------------------9 CALIBRATION CHECK PROCEDURE---------------------------------------------------------------------------------------------11 D200 SERIES DIE OPTION------------------------------------------------------------------------------------------------------------12 D205M REPLACEMENT ACCESSORIES----------------------------------------------------------------------------------------13 TROUBLESHOOTING---------------------------------------------------------------------------------------------------------14 COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------15 ® CUSTOM CRIMP “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------24 ® CUSTOM CRIMP CONTACT INFORMATION--------------------------------------------------------------------------------------25...

  • Page 4: Component Parts & Technical Data

    Innovating SMART Hose Assembly Solutions Since 1979 COMPONENT PARTS & TECHNICAL DATA Powerful 80 Ton D205M Technical Specifications Hydraulic Cylinder Built-in Work Lamp 80 Ton with 160 Ton with 2HP/220V/1Phase D200 Dies DA Dies pump for fast crimps 29" Hydraulic Hose Capability: Power Switch Removable Pusher 2 Wire = 1 ¼"...

  • Page 5: D205M Features

    Innovating SMART Hose Assembly Solutions Since 1979 FEATURES • The D205M Series Crimper comes with standard features which increase accuracy and improve productivity for jobs which require repeat crimps of similar or identical assemblies. • Fully adjustable micrometer for a precise crimp and electric shutoff switch makes crimping process fast.

  • Page 6: Initial Set

    Innovating SMART Hose Assembly Solutions Since 1979 INITIAL SET UP FOLLOW THESE STEPS BEFORE YOU USE THE CRIMPER FOR THE FIRST TIME. • Mount the crimper on a sturdy workbench in a well-lit area. Workbench should be able to support the crimper and components weight. •...

  • Page 7: Crimping With Standard Dies

    Innovating SMART Hose Assembly Solutions Since 1979 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. This screw can be loosened through the access hole in the front of the machine through the “Hand Hazard”...
  • Page 8 Innovating SMART Hose Assembly Solutions Since 1979 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 9: Crimping With Double Angle Dies

    Innovating SMART Hose Assembly Solutions Since 1979 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 10 Innovating SMART Hose Assembly Solutions Since 1979 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 11: Calibration Check Procedure

    Innovating SMART Hose Assembly Solutions Since 1979 CALIBRATION CHECK PROCEDURE When the crimper is correctly calibrated, the ram will extend and fully close the die set. After the die set is fully closed, the time from which the pump starts to build pressure and the point at which the motor shuts of automatically will be approximately 1 second.

  • Page 12: D200 Series Die Option

    Innovating SMART Hose Assembly Solutions Since 1979 D200 SERIES DIE OPTIONS DIE RING COLOR (1) CRIMP FACE LENGTH (MM/IN) DIE CLOSED DIAMETER (MM/IN) DIE SERIES (D200/D200 DOUBLE ANGLE (DA)) D200 STANADARD SERIES DIE D200 DOUBLE ANGLE (DA) SERIES DIE (1) DIE RING COLOR OPTIONS: ORANGE YELLOW PURPLE...

  • Page 13: D205M Replacement Accessories

    Innovating SMART Hose Assembly Solutions Since 1979 REPLACEMENT ACCESSORIES D205/D206 Coupling Stop Metric Micrometer DC Micrometer Standard Micrometer P/N:101631 P/N:101587 P/N:101489 P/N:100628 CRIMPX Lubricant Grease CRIMPX Lubricant Grease Pneumatic Pendent Switch Vent Plug 4 oz can with brush P/N:104162 16 oz can with brush P/N:104111 P/N:101349 P/N:9847K13 D200 Spacer Kit...

  • Page 14: Troubleshooting

    Innovating SMART Hose Assembly Solutions Since 1979 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 115 volt single phase circuit. (Available in a 220 volt single phase circuit) Use of extension cords or outlets with inadequate power can damage the motor.

  • Page 15: Component Parts Breakdown

    Innovating SMART Hose Assembly Solutions Since 1979 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 DIE RING HALF D200 SERIES PART NUMBER DESCRIPTION...
  • Page 16 Innovating SMART Hose Assembly Solutions Since 1979 COMPONENT PARTS BREAKDOWN D200 DOUBLE ANGLE SERIES DIE PARTS (AI-100872) ITEM PART NUMBER DESCRIPTION 100873-XX DOUBLE ANGLE DIE RING SET VARIES WITH THE DIE SIZE 8 PC DIE FINGER SET LC 022D 05 M DOUBLE ANGLE DIE SPRING EN83-034 DOUBLE ANGLE DIE SCREW...
  • Page 17 Innovating SMART Hose Assembly Solutions Since 1979 COMPONENT PARTS BREAKDOWN D205/D206 Crimper Assembly (101626) Item Part Number Description 101585 D205 Base 101624 D205 Support Rod 90126A031 3/8 Flat Washer 92865A622 3/8-16 X 3/4 Hex Bolt 101621 D205 Support Rod Brace 92865A624 3/8-16 X 1 Hex Bolt 91102A031...
  • Page 18 Innovating SMART Hose Assembly Solutions Since 1979 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 98296A249 3/16 x 3/4 Slotted Spring Pin...
  • Page 19 Innovating SMART Hose Assembly Solutions Since 1979 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 101525 Fixed Stop Arm 9489T47...
  • Page 20 Innovating SMART Hose Assembly Solutions Since 1979 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 Limit Switch 100692 Limit Switch Guard...
  • Page 21 Innovating SMART Hose Assembly Solutions Since 1979 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 100760 Spring (21 Coils) 100637...
  • Page 22 Innovating SMART Hose Assembly Solutions Since 1979 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 101470 Square Shaft Key 116259...
  • Page 23 Innovating SMART Hose Assembly Solutions Since 1979 COMPONENT PARTS BREAKDOWN...

  • Page 24: Customcrimp® "No-Nonsense" Warranty Statement

    318 North Co. Rd 400 East Valparaiso IN 46383 If any product or part manufactured by Custom Crimp® is found to be defective by Custom Crimp®, at its option, Custom Crimp® will either repair or replace the defective part or product and return via ground transportation, freight prepaid.

  • Page 25: Custom Crimp ® Contact Information

    Innovating SMART Hose Assembly Solutions Since 1979 CUSTOM CRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS. CUSTOM CRIMP® | Custom Machining Services, Inc. 326 North 400 East Valparaiso, IN 46383 Visit us at: www.customcrimp.com For sales: ccsales@customcrimp.us For support: ccsupport@customcrimp.us...

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