Manual - CustomCrimp

Manual - CustomCrimp
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D105 SERIES HYDRAULIC HOSE
CRIMPER OPERATORS MANUAL
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MODELS COVERED
This manual is applicable to different variations of the D 105 Series Crimpers.
A “Standard”, “Metric” and “DC” micrometer is available on different models.
Crimping, calibration and repair procedures are similar for all models.
See specific instructions and parts breakdown for the model in question.
SAFETY PRECAUTIONS
READ INSTRUCTIONS AND IDENTIFY ALL
COMPONENT PARTS BEFORE USING CRIMPER

CRIMPER CAN PRODUCE 35 TONS OF
FORCE. KEEP BOTH HANDS AWAY FROM
PINCH POINTS

CONSULT HOSE AND FITTING MANUFACTURER FOR CORRECT MACHINE SETTINGS
AND CRIMP MEASUREMENTS


ALWAYS WEAR EYE PROTECTION
For Parts and Service, Contact:
Custom Machining Services, Inc.
Valparaiso, In 46383
(219) 462-6128
Rev 06/22/2016
COMPONENT IDENTIFICATION
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WORK LIGHT
(OPTIONAL)
35 TON HYDRAULIC
CYLINDER
REMOVABLE
PUSHER
OIL FILL AND
VENT PLUG
110 VOLT VALPOWER
HYDRAULIC PUMP
POWER
SWITCH
ADJUSTABLE RAM
RETRACTION STOP
MICRO-CRIMP
ADJUSTER
CALIBRATION
ADJUSTMENT
SCREW
AUTOMATIC
STOP SWITCH
PNEUMATIC
START/STOP
SWITCH
DIE STORAGE SHELF
(OPTIONAL WITH SOME CRIMPERS
DIES NOT INCLUDED)
DOUBLE ANGLE
TOP COMPRESSION
RING
STANDARD
COMPRESSION
RING
DOUBLE ANGLE
DIE SET
STANDARD DIE SET
DOUBLE ANGLE
BASE RING
STANDARD
PRESSURE
PLATE
CRIMPER QUICK START GUIDE
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FOLLOW THESE STEPS BEFORE YOU USE YOUR
CRIMPER FOR THE FIRST TIME.

Plug the crimper directly into a 110 volt wall
outlet. CAUTION: DO NOT RUN THE CRIMPER ON AN
EXTENSION CORD AS LOW VOLTAGE CAN DAMAGE
THE MOTOR.
PUSHER
COMPRESSION RING

Oil level in the pump should be
1 1/2 to 2 inches below the fill plug.
CALIBRATION CHECK PROCEDURE

Place the pressure plate, any
die set and the Compression Ring in
the crimper bottom flange in the order
shown. DO NOT USE DOUBLE ANGLE
COMPONENTS.
PRESSURE PLATE
Slide the pusher onto the hydraulic cylinder plug.

Set the micro-crimp micrometer at
“100” for the Standard Micrometer
“0” for the Metric Micrometer
“95” for the DC micrometer

Depress and hold the start/stop switch.

If the ram extends and shuts off the motor
approximately 1 second after the pump starts to build
pressure (the sound of the pump will change), the crimper
is correctly calibrated.
METRIC
DC

If the time is not approximately 1 second, the unit
must be recalibrated. See instructions in the manual.
STANDARD
CRIMPING GUIDE
 Insert the Pressure Plate in the bottom flange making sure
that the pressure plate is seated squarely in the bottom flange.
 Select the correct die set for the combination of hose and
fitting being crimped. This information is available from the hose
and fitting manufacturer.
The number etched on the die ring represents the fully closed diameter of the die set in either inches or millimeters depending upon
the die set.
 Lubricate the contact surfaces of the die fingers, the
Compression Ring and the Pressure Plate with the die lubricant
furnished with the crimper and place the Compression Ring loosely
over the Die Set.
Failure to lubricate the contact surfaces with the correct lubricant
will cause the dies to seize in the compression ring.
 Insert the hose and fitting and align the fitting with the die
set according to the hose and fitting manufacturer’s recommendations. Manually depress the Compression Ring closing the die set
until the hose and fitting is held loosely in the Die Set.
CAUTION: The notches
on the die set must be
completely covered by the
Compression Ring prior to
starting the crimp. If the
notches are showing, you
must go to a larger die set.
Crimping with an incorrect die size could result in
personal injury
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CRIMPING GUIDE

Page
Slide the Pusher in place above the hose assembly.
 Set the Micro-Crimp Adjuster to the setting recommended
by the hose and fitting manufacturer for the combination of hose
and fitting being crimped. The Standard Micro-Crimp Adjuster is
shown set at “100” or die set fully closed, in the illustration.
STANDARD
METRIC
DC
Note: Each die set has a limited range of diameters for which a satisfactory crimp can be obtained. As a “rule of thumb” a standard die set
can crimp 3mm (.120 inches) above the closed diameter etched on the
die ring. Always consult the hose and fitting manufacturer’s recommendations for the correct die set to use.
Micrometer setting Example: With a 39mm die and the metric
micrometer set at 3.0, the finished crimp diameter would be
42mm. (39.0mm + 3.0mm)
 Recheck the fitting for correct alignment in the die set and
depress the Start/Stop switch. Hold the Start/Stop switch depressed
until the Automatic Stop Switch shuts the pump off. Release the
Start/Stop switch and allow the pusher to return to the retracted
position. Powerful magnets in the Pusher will retract the Compression Ring with the Pusher.
 Check the diameter of the finished assembly to be certain that
it is within the manufacturer’s specifications.
6
CRIMPING WITH DOUBLE ANGLE DIES
Double Angle Dies doubles the radial crimping force allowing heavier
fittings to be crimped. Due to the doubling of the radial crimping force,
the dies are effective for a smaller range of diameters than a standard
die set. Also, the fitting must be approximately centered axially along
the crimping face to avoid taper in the final crimp.
  Remove the flat Standard Pressure Plate from the bottom
Cone Base and insert the tapered Double Angle Base Ring with the
tapered surface up.
Note: The angles are not the same on standard dies and Double Angle
Dies and the Double Angle Top Compression Ring and the Standard
Compression Rings are NOT interchangeable.
 Insert the appropriate Double Angle Die in the Double Angle
Base Ring as shown.
 Place the Double Angle Top Compression Ring on top of the
Double Angle Die Set.
 Insert the hose assembly to be crimped and manually depress
the Double Top Compression ring to snug the fitting in Place.

Slide the Pusher on the stud of the hydraulic cylinder.
 Set the Micro-Crimp Adjuster to the appropriate setting as
recommended by the hose and fitting manufacturer.
 Bring the Pusher into light contact with the Double Angle Top
and check for correct position of the fitting.
 Press the Start/Stop switch and proceed with standard crimping procedure.
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ADDED FEATURES
The Crimper comes with standard features which increase
accuracy and improve productivity for jobs which require
repeat crimps of similar or identical assemblies.
 The easily removable Coupling Stop provides an
automatic stop for straight fittings without the need to
sight the alignment of the fitting on every crimp.
 The adjustable Retraction Stop allows the operator
to limit the retraction of the hydraulic ram at the point
where the die set is open only enough to remove the hose
and fitting. This feature can greatly speed up crimping
on production jobs since the ram does not have to fully
advance and retract on every cycle.
 Powerful magnets in the Pusher retract the Compression Ring with the ram on each cycle. This permits
the operator to operate the crimper essentially “hands
free”.

Note: An optional work light is available.
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CALIBRATION PROCEDURE
 When the crimper is correctly calibrated, the hydraulic pump
will be at approximately 10,000 psi, and the die set will be fully closed
at the diameter etched on the O.D. of the die ring.
Many problems associated with incorrect crimp diameters are caused
by incorrect calibration.
 Insert the Pressure Plate, any die set,
and the Compression Ring in the order illustrated. Set the Micro-Crimp Adjuster at:
“100” for the Standard Micrometer
“0” for the Metric Micrometer
“95” for the DC Micrometer
Follow the instructions in the Quick Start
Guide at the front of this manual.
 If the crimper requires re-calibration, 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.
 Rotating the stem out of the barrel will decrease the time required for the pump to shut off after
the stem contacts the automatic stop switch. Rotating
the stem knob into the barrel will increase the time
for the pump to shut off.

Recheck calibration.
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TROUBLESHOOTING
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PROBLEM: CRIMPER WILL NOT RUN AT ALL
The power switch (white rocker switch) is also a circuit breaker. Make certain that this
circuit breaker has not tripped.
Check the wall outlet. The crimper comes from the factory wired for a 110 volt circuit.
Use of extension cords or outlets with inadequate power can damage the motor or crimper
controls. Do not run the crimper from a portable power source.
Check the stop switch mounted to the switch bracket under the Micro-Crimp Adjuster.
This is a normally closed switch and it must close to complete the circuit and allow the crimper
to operate.
CAUTION: Do not operate the crimper with this switch jumpered as the pump will not shut off
and the brackets can be damaged.
Check the pneumatically actuated switch in the electrical box mounted on the motor. This
switch controls power to the motor and is actuated with air pressure from the bulb on the end
of the hose going into the box.
PROBLEM: CRIMP DIAMETER TOO LARGE
Check crimper calibration and recalibrate if required.
Incorrect die being used. Each die has a range of approximately 3mm (.120 in) above the
closed diameter of the die. The closed diameter is the die size stamped on the die ring.
Incorrect setting of the Micro-Crimp Adjuster. Check hose manufacturer’s specifications.
Inadequate pump pressure. Check oil level in the pump. It should be 1-1/2 to 2 inches
below the fill plug. Replenish with ISO Viscosity Grade 46 hydraulic oil.
Inadequate lubrication of the dies and compression ring causing the pump to work harder
than normal to reach the required diameter.
Inadequate pressure being generated by the pump. This is most likely if the crimper can
crimp the smaller size hoses and not the larger hoses. When correctly adjusted, the pump
should generate approximately 10,000 psi.
Do Not adjust pump to produce in excess of 10,000 psi as damage to components or personal
injury may result.
No pressure being generated by the pump. There should be a definite change in pitch of
the pump as it cycles into high pressure mode and begins to “work” harder.
PROBLEM: CRIMP DIAMETER TOO SMALL
Check crimp diameter and recalibrate if necessary.
Incorrect die being used (See die range under Crimp Diameter Too Large).
Incorrect setting of the Micro-Crimp Adjuster. Check hose manufacturer’s specifications.
PROBLEM: DIES STICKING IN COMPRESSION RING
Inadequate lubrication of the compression ring and die surfaces.
DIE COMPONENTS
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3
4
1
2
D100 Standard Series Dies
1) Die Ring
101065-COLOR
2) Die Finger
Varies with die set
3) Die Spring
D100-SPRING
4) Die Screw
D100-SCREW
D100 DA (Double Angle Dies)
1) Die Ring
101072-COLOR
2) Die Finger
Varies with Die Set
3) Die Spring
D100-SPRING
4) Die Screw
D100-SCREW
Not Shown:
DA Cone Insert
100880
DA Top Cone
100881
4
3
1
2
Color Options
Red
Orange
Yellow
Purple
Green
Blue
Black
Silver
Brown
EXPLODED PARTS VIEW
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12
EXPLODED PARTS VIEW
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13
EXPLODED PARTS VIEW
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1
2
3
4
5
35-Ton Head Sub-Assembly (101209)
ITEM PART NUMBER
DESCRIPTION
1
103122
35-Ton Cylinder/Flange
2
100329
Strain Rod - 8 1/2"
3
100325
Bottom Flange
4
750SPCL
3/4 Flat Washer - Special
5
95462A538
3/4-10 Hex Nut
QTY
1
4
1
4
4
14
EXPLODED PARTS VIEW
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15
4
3
1
4
11
6
5
2
10
7
3
Item
1
2
3
4
D105 Micrometer Mount Assembly (101788)
Description
Part Number
100898-01
100898-02
100898-03
91253A189
Micrometer Arm
Micrometer Base
Micrometer Suspension Flange
8-32 x 1/4 HSFHS
1
1
1
4
8
9
Qty
1
4
2
Coupling Stop Assy (100954)
Item
Part No.
Description
1
100950
Coupling Stop Block
1
2
98381A544
Stop Block Pin
2
Qty
3
100951
Stop Block Rod
1
4
91251A540
1/4-20 X 3/4 SHCS
2
5
9489T47
Eye Bolt
1
6
100952
Adjustable Stop Arm
1
7
DK-655
Knob
1
8
100953
Fixed Stop Arm
1
9
94750A588
T-Nut (1/4-20)
1
10
90126A029
1/4 Flat Washer
1
11
94052A133
Push-On Cap
1
EXPLODED PARTS VIEW
Page
1
12
7
9
2
4
3
8
5
6
10
11
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
35 Ton Cylinder / Flange Assembly (103122)
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
Spring Plug
210D90
210 Disogrin O-Ring
TP032
T-Seal
SH959-26
Ram Wiper
101514
Cylinder Retaining Ring
90108A415
5/16 Flat Washer
92865A587
5/16-18 x 1.50 HHCS
QTY
1
1
1
1
8
1
1
1
1
1
1
1
1
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13
D105 Series Warranty
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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.
326 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. Custom Crimp 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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