CustomCrimp D205M Series User manual
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Innovating SMART Hose Assembly Solutions Since 1979
D205M SERIES HYDRAULIC CRIMPERS
OPERATORS MANUAL
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Innovating SMART Hose Assembly Solutions Since 1979
• 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.
• CONSULT HOSE AND FITTING MANUFACTURER FOR CORRECT MACHINE SETTINGS
AND CRIMP MEASUREMENTS.
• ALWAYS WEAR EYE PROTECTION.
SAFETY PRECAUTIONS
! !
Rev: 05/2023
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Innovating SMART Hose Assembly Solutions Since 1979
SAFETY PRECAUTIONS-------------------------------------------------------------------------------------------------------------2
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
TABLE OF CONTENT
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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS & TECHNICAL DATA
D205M Technical Specications
80 Ton with
D200 Dies
160 Ton with
DA Dies
Hydraulic Hose Capability:
2 Wire = 1 ¼"
4 SP = 1 ¼"
6 SP = 1 ¼"
2 Wire = 2"
4 SP = 2"
6 SP = 2"
Control System: Metric Micrometer
Crimper Size: L: 32" x W: 17" x H: 29"
Crimper Weight: 305 Lbs.
Power: 2HP / 220V / 1Phase (Standard)
1HP / 110V / 1Phase ( Optional)
Die Series: D200 / D200DA
Reservoir capacity: 1 US Gallon
Oil Type: ISO 46 Hydraulic Oil
17"
32"
29"
Powerful 80 Ton
Hydraulic Cylinder
Built-in Work Lamp
Removable Pusher
Coupling Stop
Double Angle
Die Series with
the optional
conversion kit.
D200 Die Series
2HP/220V/1Phase
pump for fast crimps
Power Switch
Adjustable Micrometer
Automatic Shut O
Voltage Tag
Pneumatic Switch
Small Footprint for
minimum use of space
D200 DOUBLE ANGLE TOOLING
D200 Double Angle
Top Compressing Ring
D200 Double Angle
Die Set
D200 TOOLING
D200 Standard
Compression Ring
D200 Standard
Die Set
D200 Standard
Pressure Plate
D200 Double Angle
Base Ring
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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 shuto
switch makes crimping process fast.
• 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 tting. This feature can greatly
speed up crimping on production jobs since the ram does not have
to fully advance and retract on every cycle.
• The easily removable Coupling Stop provides an automatic stop
for straight ttings without the need to sight the alignment of the tting
on every crimp. A short and a long Coupling Stop are furnished with
each crimper to accommodate a wide range of tting congurations.
• Easily removable pusher and split dies accommodate dicult
crimps (Bent Tube & Special Fittings). “Feature” Show with Optional
Spacer Kit for more clearance. Adds exactly 1 inch between the pusher
and DBL Top Compressing Ring to allow extra tting clearance.
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Innovating SMART Hose Assembly Solutions Since 1979
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.
• The crimper should be mounted close enough to the edge of the work surface
so that hose will not contact the bench or work surface while crimping. There
must be enough clearance for the hose to align perpendicular with the cone
base, or the dies will not seat properly and the crimps will not be accurate.
Check electrical circuit to be certain that it matches the crimper
requirements shown on the voltage tag attached to the crimper cord.
• Plug the D20M crimper directly into a 110 volt, 15 amp wall outlet.
Note: The optional 220 volts / 2HP unit must be connected to a 220 volts 20
amp wall outlet.
• Always check oil level in the D205M pump, should be 1-1/2 to 2 inches below
the vent plug when the cylinder is in the retracted position and should be visible
in the sight glass window of the pump reservoir.
• If oil needs to be added use ISO 46 weight hydraulic oil.
• Oil can be drained from the rear oil port of the reservoir.
• Check to be certain that the shipping plug in the pump reservoir
has been replaced with the vent plug shipped with the D205 crimper.
INITIAL SET UP
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Innovating SMART Hose Assembly Solutions Since 1979
CRIMPING WITH STANDARD DIES
• Insert the Standard Pressure Plate in the bottom ange making certain that
the Pressure Plate is seated squarely in the bottom ange.
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” decal.
• Select the correct die set for the combination of hose and tting being crimped.
Note: This information is available from the hose and tting 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 ngers and the Compression Ring
with the die lubricant furnished with the crimper.
Failure to lubricate the contact surfaces with the correct lubricant will
cause the dies to seize in the compression ring.
• Align the hose and tting in the die set and place the Compression Ring
loosely over the die set. Manually depress the compression ring until the tting
is held loosely in the die set.
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Innovating SMART Hose Assembly Solutions Since 1979
CRIMPING WITH STANDARD DIES
• Set the Micro-Crimp Adjuster to the setting recommended by the hose and
tting manufacturer for the hose and tting being crimped. Both the standard
and the metric micrometers are shown.
• The standard micrometer (Readings of 0 to 100) and the “DC” micrometer
(Readings of 20 to 100) are adjusted to the position recommended by the hose
and tting manufacturer. The metric micrometer (Readings of 0 to 10) is a direct
reading micrometer. The setting on the micrometer is added to the number in
mm etched on the die ring to obtain the nal crimp diameter.
For example: With a 39mm die and the METRIC micrometer set at 3.0 the
nished crimp diameter would be 42.0 mm (39mm + 3.0mm).
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 3 mm (.120 inches) above the closed diameter etched on the die
ring. Always consult the hose and tting manufacturer’s recommendation
for the correct die set to use.
CAUTION: THE FINISHED CRIMP DIAMETER SHOULD NOT BE MORE
THAN 4 MM (0.16 INCHES) ABOVE THE CLOSED DIAMETER OF THE DIE
SET.
DO NOT ATTEMPT TO CRIMP A FITTING IF THE COMPRESSION CONE
DOES NOT COMPLETELY COVER THE NOTCHES ON THE DIE FINGERS.
FAILURE TO HEED THESE WARNINGS COULD RESULT IN DAMAGE TO
THE DIE SET AND/OR PERSONAL INJURY.
• Recheck the tting for correct alignment and depress the pneumatic Start/
Stop switch bulb and keep it depressed until the crimper shuts o automatically.
• Check the diameter of the nished crimp to be certain that it is within the
hose and tting manufacturer’s specications.
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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 ttings to be crimped. Due to the doubling of the radial crimp
force, they are eective for a smaller range of diameters than a standard
die set. Also, the tting must be approximately centered axially along the
crimping face to avoid taper in the nal crimp.
• Remove the standard at Pressure Plate and replace it with the DBL BASE
bottom compression ring.
The bottom Pressure Plate may be held in place with a set screw. Access
to this set screw is through the hole in the hand hazard decal.
Note: The angles are not the same on standard and double angle dies
and the standard compression rings are not interchangeable with double
angle compression rings.
• Lubricate the contact surfaces of both the upper and lower compression
rings and the outer surfaces of the double angle dies with the CRIMPX Die
Lubricant Grease furnished with the crimper.
• Seat the appropriate size double angle die in the conical recess of the DBL
BASE lower compression ring.
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Innovating SMART Hose Assembly Solutions Since 1979
CRIMPING WITH DOUBLE ANGLE DIES
• Insert the tting as specied 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 tting.
• Slide the Pusher onto the cylinder stud and set the Micro-Crimp
Adjuster at the appropriate setting.
• Press and hold the Start/Stop switch until the crimper shuts o.
• When the crimp cycle is complete, check the tting diameter to make
certain that it is within the hose manufacturer’s specications.
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