Custom Crimp D105 Series Operator's Manual
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Custom Crimp D105 Series Operator's Manual

Service hydraulic hose crimper
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D105
D105
Service Hose Crimper
Service Hose Crimper
Updated 06/2017
The D105 Series hose crimper with the Micrometer Style Adjustment and 35 tons
of crimping force has the capability to crimp hoses up to 1" 2 wire* and up to ¾" 4SP*.
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.
D105 SERIES HYDRAULIC CRIMPERS
OPERATORS MANUAL

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Summary of Contents for Custom Crimp D105 Series

  • Page 1 Service Hose Crimper Service Hose Crimper The D105 Series hose crimper with the Micrometer Style Adjustment and 35 tons of crimping force has the capability to crimp hoses up to 1" 2 wire* and up to ¾" 4SP*. UNIQUE USER FRIENDLY MICROMETER STYLE ADJUSTMENT •...

  • Page 2: Safety Precautions

    ALWAYS WEAR EYE PROTECTION. MODELS COVERED • This manual is applicable for the D105 series crimpers. • A “Standard”, “Metric” and “DC” Micrometer Style Adjustment is available on this model. • Crimping, Calibration and Repair procedures are similar for all models.

  • Page 3: Table Of Contents

    D105 Service Hose Crimper TABLE OF CONTENT SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2 COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4 FEATURES------------------------------------------------------------------------------------------------------------------------5 INITIAL SET UP-------------------------------------------------------------------------------------------------------------------------------6 LUBRICATION PROCEDURE-------------------------------------------------------------------------------------------------------7 CRIMPING PROCEDURE---------------------------------------------------------------------------------------------------8 CALIBRATION CHECK PROCEDURE---------------------------------------------------------------------------------------------13 D105 / D165 D-SERIES DRAWER ASSEMBLY / STAND (INSTRUCTIONS)------------------------------------------------------15 INCLUDED ACCESSORIES----------------------------------------------------------------------------------------16 AVAILABLE ACCESSORIES----------------------------------------------------------------------------------------17 TROUBLESHOOTING---------------------------------------------------------------------------------------------------------18 COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------19 CUSTOMCRIMP®...

  • Page 4: Component Parts & Technical Data

    D105 Service Hose Crimper COMPONENT PARTS & TECHNICAL DATA 1HP/110V/Single Phase pump for fast crimps Powerful 35 Ton Hydraulic Cylinder Adjustable Retraction Stop Optional Flexible 24" Work Lamp Main Power Switch Electrical Enclosure Removable Pusher CustomCrimp QR Code ® Micrometer Style Adjustment 1 Gallon Reservoir Calibration Adjustment Screw Pneumatic Switch...

  • Page 5: Features

    D105 Service Hose Crimper FEATURES Metric Micrometer “Micro-Crimp Open design, two piece “slide Built-in adjustable retraction Adjuster” is fully adjustable to in” die set and removable stop limits ram retraction for make precise and repeatable pusher allows the operator to quick repetitive crimps.

  • Page 6: Initial Set

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

  • Page 7: Lubrication Procedure

    D105 Service Hose Crimper LUBRICATION PROCEDURE Grease Point # 1 Insert the pressure plate into the bottom flange of the crimper, making sure that it is seated squarely into the bottom flange. Place a thin layer of CrimpX oil (supplied with crimper) or a high Photo # 1 pressure molybdenum high pressure grease on the surface the dies sit on (as shown in photo # 1).

  • Page 8: Crimping Procedure

    D105 Service Hose Crimper CRIMPING PROCEDURE Note: Follow the lubrication procedure prior to crimping procedure. NOTE: FAILURE TO LUBRICATE THE DIE SET AND COMPRESSION RING COULD RESULT IN THE DIE SET SEIZING IN THE BASE FLANGE. Step 1: Insert the pressure plate into the bottom flange of the crimper, making sure that it is seated squarely into the bottom flange.
  • Page 9 D105 Service Hose Crimper CRIMPING PROCEDURE Step 4: Place the lubricated die set squarely in the pressure plate. Step 5: Align the fitting in the die set according to the hose and fitting manufacturer’s recommendation. Step 6: Place the lubricated compression ring over the die set and compress the die set by hand to hold the hose and fitting in place.
  • Page 10 D105 Service Hose Crimper CRIMPING PROCEDURE Note: Make sure the compression ring is seated evenly on 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. •...
  • Page 11 D105 Service Hose Crimper CRIMPING PROCEDURE 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. Front View Pusher Rear View...
  • Page 12 D105 Service Hose Crimper CRIMPING PROCEDURE 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 Metric Micro-Crimp Adjuster is a direct reading micrometer.

  • Page 13: Calibration Check Procedure

    D105 Service Hose Crimper 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. NOTE: FAILURE TO LUBRICATE THE DIE SET AND COMPRESSION RING COULD RESULT IN THE DIE SET SEIZING IN THE BASE FLANGE.
  • Page 14 D105 Service Hose Crimper CALIBRATION CHECK PROCEDURE Step 5: Set the Metric Micro-Crimp Adjuster at “0”. Note: Set the Micro-Crimp Adjuster at “100” for the Standard Micrometer. Set the Micro-Crimp Adjuster at “95” for the DC Micrometer. Step 6: Depress and hold the Start/Stop switch, until the Die set is completely closed and oil pressure has built up in the hydraulic cylinder.

  • Page 15: D105 / D165 D-Series Drawer Assembly / Stand (Instructions)

    D105 Service Hose Crimper D105/D165 D-SERIES DRAWER ASSEMBLY / STAND Note: This instructions can be used for D105/D165/D165-T420 series crimpers. 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.

  • Page 16: Included Accessories

    D105 Service Hose Crimper INCLUDED ACCESSORIES Metric Micrometer D100/D105 Pusher w/ D100/D105 Compression Ring D100/D105 Pressure Plate P/N:101587 Magnets P/N:100813-01 P/N:100849 P/N:100869 Pneumatic Pendent Switch D165 Coupling Stop CRIMPX Die Lubricant Oil: Vent Plug (Included) P/N:101349 P/N:100954 4 oz bottle with dauber cap P/N:9847K13 P/N:103886 (5) D100 Screws...

  • Page 17: Available Accessories

    D105 Service Hose Crimper AVAILABLE ACCESSORIES Standard Micrometer DC Micrometer D100/D105 Notched Flexible 24" Work Lamp P/N:100628 P/N:101489 Compression Ring P/N:1668-02 P/N:101190 Die Storage Shelf D-Series Drawer Assembly/Stand Die Removal Magnet CRIMPX Die Lubricant: P/N:101431 P/N:104650 P/N:104679 Grease 4 oz can with brush P/N:104162 D100 Series Die Rings CustomCrimp...

  • Page 18: Troubleshooting

    D105 Service Hose Crimper TROUBLESHOOTING 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 exten- sion cords or outlets with inadequate power can damage the motor or crimper controls.

  • Page 19: Component Parts Breakdown

    D105 Service Hose Crimper COMPONENT PARTS BREAKDOWN D100 SERIES DIE PARTS (AI-100724) ITEM PART NUMBER DESCRIPTION 101065-COLOR DIE RING HALF D100 SERIES D100 SERIES DIE PARTS (AI-100724) VARIES WITH THE DIE SIZE 8 PC DIE FINGER SET ITEM PART NUMBER DESCRIPTION EN84-115 D100 SCREW...
  • Page 20 D105 Service Hose Crimper COMPONENT PARTS BREAKDOWN D105 Crimper Assembly (101428) ITEM PART NUMBER DESCRIPTION 101430 D-105 Base Plate 101633 Pump Assembly 90126A029 1/4 Flat Washer 91102A029 1/4 Lock Washer 92865A540 1/4-20 x 3/4 Hex Bolt 101433 D105 Handle 101433-Slotted D105 Slotted Handle 92323A516 1/4-20 x 3/4 SHFCS...
  • Page 21 D105 Service Hose Crimper COMPONENT PARTS BREAKDOWN D105 Head Assembly (101480) ITEM PART NUMBER DESCRIPTION 101209 Head Sub-Assembly 101788 Micrometer Mount Assembly 100812 Pusher Retaining Pin 91253A624 3/8-16 x 1 FHCS 101092 Limit Switch Bracket 903 Switch Limit Switch 100692 Limit Switch Guard 91255A190 #8-32 x 1/4 BHCS...
  • Page 22 D105 Service Hose Crimper COMPONENT PARTS BREAKDOWN 35-Ton Head Sub-Assembly (101209) ITEM PART NUMBER DESCRIPTION 103122 35-Ton Cylinder/Flange 100329 Strain Rod - 8 1/2" 100325 Bottom Flange 750SPCL 3/4 Flat Washer - Special 95462A538 3/4-10 Hex Nut...
  • Page 23 D105 Service Hose Crimper 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 24 D105 Service Hose Crimper 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 Spring Plug 210D90...

  • Page 25: Customcrimp® "No-Nonsense" Warranty Statement

    D105 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 26: Customcrimp® Contact Information

    D105 D105 Service Hose Crimper Service Hose Crimper CONTACT US CUSTOMCRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS. Products and services to support industry wide hose assembly needs. CustomCrimp ® Custom Machining Services, Inc. 326 N. County Rd. 400 East Valparaiso, IN 46383 Ph: (219) 462-6128 Fax: (219) 464-2773...

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