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Custom Crimp D105-T420 Series Operator's Manual

Hydraulic crimpers
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Innovating SMART Hose Assembly Solutions Since 1979
D105-T420 SERIES HYDRAULIC CRIMPERS
OPERATORS MANUAL
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Summary of Contents for Custom Crimp D105-T420 Series

  • Page 1 Innovating SMART Hose Assembly Solutions Since 1979 D105-T420 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. • D105-T420 SERIES CRIMPERS CAN PRODUCE 35 TONS OF CRIMPING FORCE. • KEEP BOTH HANDS AWAY FROM PINCH POINTS. •...

  • Page 3: Table Of Contents

    STANDARD T420 PRESSURE PLATE---------------------------------------------------------------------------------9 CRIMPING WITH NOTCHED T420 PRESSURE PLATE-----------------------------------------------------------------------------13 CALIBRATION CHECK PROCEDURE---------------------------------------------------------------------------------17 D105 / D165 D-SERIES DRAWER ASSEMBLY / STAND (INSTRUCTIONS)------------------------------------------------------20 INCLUDED ACCESSORIES----------------------------------------------------------------------------------------21 AVAILABLE ACCESSORIES---------------------------------------------------------------------------------------22 TROUBLESHOOTING---------------------------------------------------------------------------------------------------------23 COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------24 CUSTOM CRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------27 ® CUSTOM CRIMP CONTACT INFORMATION--------------------------------------------------------------------------------------28...

  • Page 4: Component Parts & Technical Data

    Innovating SMART Hose Assembly Solutions Since 1979 COMPONENT PARTS & TECHNICAL DATA 1HP/110V/Single Phase 22-½" pump for fast crimps Powerful 35 Ton Power Switch Hydraulic Cylinder Electrical Enclosure Micrometer Style Adjustment Adjustable Retraction Stop Removable Pusher Voltage Tag Adjustment Screw Reservoir T420 Pressure Plate Pneumatic Switch...

  • Page 5: Available D105 / D165 D-Series Drawer Assembly / Stand

    Innovating SMART Hose Assembly Solutions Since 1979 D105/D165 D-SERIES DRAWER ASSEMBLY / STAND D105-T420 Series Crimper The crimper bolts directly on top of the mounting holes of the D-Series Drawer. Base mounting holes allow the drawer to be bench or Die storage drawer to keep truck bed mounted if required.

  • Page 6: Features

    Innovating SMART Hose Assembly Solutions Since 1979 FEATURES T420 Micrometer “Micro-Crimp Open design, two piece rubber Built-in adjustable retraction Adjuster” is fully adjustable to caged die set for heavy duty stop limits ram retraction for make precise and repeatable environments and removable quick repetitive crimps.

  • Page 7: Initial Set

    • Mount the crimper on a sturdy workbench in a well-lit area. Work- bench should be able to support the crimper and components weight. Note: The D105-T420 series crimper can be mounted on the D-Series Drawer/Stand and bolted onto the workbench. (See detailed instruc- tions included with D-Series drawer/stand).

  • Page 8: Lubrication Procedure

    Innovating SMART Hose Assembly Solutions Since 1979 LUBRICATION PROCEDURE Grease Point # 1 Apply a thin layer of CrimpX oil (supplied with the crimper), or a molybdenum disulfide high pressure grease on the surface of the cone base. Photo # 1 (as shown in photo # 1).

  • Page 9: Crimping With Standard T420 Pressure Plate

    Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH STANDARD T420 PRESSURE PLATE Note: Follow the lubrication procedure prior to crimping procedure. CAUTION: Failure to lubricate the die set and T420 pressure plate could result in the die seizing in the cone base. Step 1: Make certain that the Cone Base is clean and lubricated prior to inserting the die set.
  • Page 10 Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH STANDARD T420 PRESSURE PLATE Step 4: Place the Lubricated Die Set squarely in the cone base. Note: Make sure the split of the die cages is facing the operator. (as shown). Step 5: Align the fitting in the die set according to the hose and fitting manufacturer’s recommendation.
  • Page 11 Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH STANDARD T420 PRESSURE PLATE Step 7: Slide the Pusher onto the pusher retaining ring on the hydraulic cylinder. Note: Make sure slot in pusher goes over lip on pusher retaining ring. CAUTION: Damage to pusher and retaining ring can occur if misaligned.
  • Page 12 Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH STANDARD T420 PRESSURE PLATE Step 8: Set the Micro-Crimp Adjuster to the setting recommended by the hose and fitting manufacturer for the combination of hose and fitting being crimped. NOTE: The T420 Micro-Crimp Adjuster is a direct reading micrometer.

  • Page 13: Crimping With Notched T420 Pressure Plate

    Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH NOTCHED T420 PRESSURE PLATE WHEN USING THE NOTCHED T420 PRESSURE PLATE, FOR USE WITH 90 DEGREE FITTING ONLY, FOLLOW THESE PROCEDURES: Note: Follow the lubrication procedure prior to crimping procedure. CAUTION: Failure to lubricate the die set and pressure plate could result in the die seizing in the cone base.
  • Page 14 Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH NOTCHED T420 PRESSURE PLATE Step 2: Place the Lubricated Die Set squarely in the cone base. Note: Make sure the split of the die cages is facing the operator. (as shown). Step 5: Align the 90 degree fitting in the die set according to the hose and fitting manufacturer’s recommendation.
  • Page 15 Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH NOTCHED T420 PRESSURE PLATE CAUTION: DO NOT MISALIGN NOTCHED Step 7: PRESSURE PLATE OR DAMAGE WILL OCCUR. Note: MUST follow these steps when crimping with the notched pressure plate. A. Die split must face operator. B.
  • Page 16 Innovating SMART Hose Assembly Solutions Since 1979 CRIMPING WITH NOTCHED T420 PRESSURE PLATE Step 9: Set the Micro-Crimp Adjuster to the setting recommended by the hose and fitting manufacturer for the combination of hose and fitting being crimped. NOTE: The T420 Micro-Crimp Adjuster is a direct reading micrometer.

  • Page 17: Calibration Check Procedure

    Innovating SMART Hose Assembly Solutions Since 1979 CALIBRATION CHECK PROCEDURE THE CRIMPER IS CALIBRATED PRIOR TO SHIPMENT, BUT A CALIBRATION CHECK IS RECOMMENDED PRIOR TO USING THE CRIMPER FOR THE FIRST TIME. Note: Follow the lubrication procedure prior to calibration check. CAUTION: Failure to lubricate the die set and pressure plate could result in the die seizing in the cone base.
  • Page 18 Innovating SMART Hose Assembly Solutions Since 1979 CALIBRATION CHECK PROCEDURE Step 4: Slide the Pusher onto the pusher retaining ring on the hydraulic cylinder. Note: Make sure slot in pusher goes over lip on pusher retaining ring. Refer to page 12 for details if needed. CAUTION: Damage to pusher and retaining ring can occur if misaligned.
  • Page 19 Innovating SMART Hose Assembly Solutions Since 1979 CALIBRATION CHECK PROCEDURE Step 7: If the above conditions are not met, the crimper requires recalibration, hold the micrometer barrel with a 5/16 inch open end wrench and rotate the stem either in or out with a 5/32 inch hex key wrench. Note: 1/4 turn of the screw will change crimp diameter approximately 0.008”.

  • Page 20: D105 / D165 D-Series Drawer Assembly / Stand (Instructions)

    Innovating SMART Hose Assembly Solutions Since 1979 D105/D165 D-SERIES DRAWER ASSEMBLY / STAND Install (2) 3/8-16 x 1" carriage bolts in front two holes (as shown in picture # 1). Use 3/8" plastic retaining washer to hold bolt into place. Slide the drawer slightly out to access two rear holes (as shown in picture # 2).

  • Page 21: Included Accessories

    Innovating SMART Hose Assembly Solutions Since 1979 INCLUDED ACCESSORIES T420 Micrometer Pusher P/N:100825 Standard T420 Pressure Plate Pneumatic Pendent Switch P/N:103085 P/N:104651 P/N:101349 Coupling Stop CRIMPX Die Lubricant Oil: Die Removal Magnet Vent Plug P/N:100954 4 oz bottle with dauber cap P/N:104679 P/N:9847K13 P/N:103886...

  • Page 22: Available Accessories

    Innovating SMART Hose Assembly Solutions Since 1979 AVAILABLE ACCESSORIES Notched T420 Pressure Plate Flexible 24" Work Lamp Die Storage Shelf D-Series Drawer P/N:104919 P/N:1668-02 P/N:101431-Red Assembly/Stand P/N:104650-Red CRIMPX Die Lubricant: T420 Rubber Die Cages CustomCrimp Notched Digital ® Grease 4 oz can with brush See page 24 for more details Caliper IN/MM P/N:CC-Caliper P/N:104162...

  • Page 23: 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. Use of extension cords or outlets with inadequate power can damage the motor.

  • Page 24: Component Parts Breakdown

    8 PC DIE FINGER SET 102997-XX CUSTOM CRIMP DIE CAGE VARIES WITH THE DIE SIZE 8 PC DIE FINGER SET CUSTOM CRIMP DIE CAGE HALF T420 SERIES PART NUMBER DESCRIPTION 102997-BLACK T420 CUSTOM CRIMP DIE CAGE HALF-BLACK CUSTOM CRIMP DIE CAGE HALF T420 SERIES...
  • Page 25 Innovating SMART Hose Assembly Solutions Since 1979 COMPONENT PARTS BREAKDOWN 35 Ton Cylinder / Flange Assembly (103122) ITEM PART NUMBER DESCRIPTION 102511 Cylinder Body 101515 Cylinder Piston 030D90 030 Disogrin O-Ring 100689 Cylinder Piston Cap 91251A539 1/4-20 X 5/8 SHCS 101282 Cylinder Spring 101516...
  • Page 26 Innovating SMART Hose Assembly Solutions Since 1979 COMPONENT PARTS BREAKDOWN D105 Micrometer Mount Assembly (101788) Item Part Number Description 100898-01 Micrometer Arm 100898-02 Micrometer Base 100898-03 Micrometer Suspension Flange 91253A189 8-32 x 1/4 HSFHS...

  • Page 27: 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 28: 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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