CSI CS205 User manual

Page
1Page
CS205-CS206 HYDRAULIC HOSE CRIMPER
OPERATORS MANUAL

2
Models Covered:
CS205 (2 HP - 220V SINGLE PHASE)
CS206 (1 HP - 110V)
SAFETY PRECAUTIONS
READ AND IDENTIFY ALL COMPONENT PARTS BEFORE USING
CRIMPER
CRIMPER CAN PRODUCE 80 TONS OF FORCE. KEEP BOTH HANDS
AWAY FROM PINCH POINTS
CONSULT HOSE AND FITTING MANUFACTURERS SPECIFICATIONS
FOR CORRECT MACHINE SETTINGS AND CRIMP MEASUREMENTS.
ALWAYS WEAR EYE PROTECTION
REVISED 6/22/2005
For Parts and Service, Contact:
Couplamatic Systems, Inc.
Scottsbluff, NE 69361
[phone]

Page
3Page
Die Stack with
CC020 Series Dies Die Stack with
CC032 Series Dies
Work Light
Oil Fill &
Vent Cap
Power Switch
&Circuit Breaker
Micro-Crimp
Adjuster
Start/Stop Switch
Bent Tube
Pusher Plate Standard
Pusher Plate
Cone Insert
CC020 Die
Series
(Not included)
Large Pusher Plate
CC032 Die
Series
(Not included)
Pusher
CS205-206 COMPONENT IDENTIFICATION

4
CS205-206 SPECIFICATIONS
Die Series (1)-------------------------------------------------------CC020/CC032
Maximum Cylinder Force--------------------------------------------------80 Ton
Maximum Hose Diameter (2 Wire)---------------------------------------------2”
Maximum Hose Diameter (4 Wire)---------------------------------------------2”
Maximum Hose Diameter (6 Wire)---------------------------------------------2”
Crimper Depth---------------------------------------------------------------------32”
Crimper Width-------------------------------------------------------------------16.5”
Crimper Height------------------------------------------------------------------28.5”
Weight--------------------------------------------------------------------------420 Lb
Pump---------------------------------------------------------------------------Electric
Maximum Pump Pressure---------------------------------------------10,000psi
Pump HP (D205WB)-------------------------------------------------2 HP (220V)
Pump HP (D206WB)-------------------------------------------------1 HP (110V)
Reservoir Capacity------------------------------------------------------------1 Gal
Oil Type--------------------------------------------------ISO Viscosity Grade 46
Electric Power Requirement (D205WB)-------------------------220V 1 Ph
Electric Power Requirement (D206WB)--------------------------------110V
(1) Dies Interchange with Dayco NP and WB Series

Page
5Page
QUICK START GUIDE - CALIBRATION CHECK
FOLLOW THESE STEPS BEFORE USING THE CRIMPER FOR THE FIRST TIME
 Remove reservoir plug and replace with Oil Fill and Vent Cap. The Oil Fill and Vent cap and the work light bulb
are found in the accessories box. (Note that the CS205 work light is furnished with a special 220 volt bulb. Do not replace
with a standard 110 volt bulb)
 Place the crimper on a sturdy bench in a well lit area, and plug the crimper directly into a 220V Single
Phase outlet (CS205) or a 115 V 15 Amp wall outlet (CS206). Do not run the crimper on an extension cord
as low voltage can damage the motor.
 The oil level in the pump should be approximately 1-1/2 inches below the fill plug. If necessary, re-
plenish with ISO Viscosity Grade 46 hydraulic oil.
Note: The crimper is calibrated prior to shipment, but a calibration check is recommended prior to using the
crimper for the first time.
 Lubricate all contact surfaces and place the Cone Insert, any CC020
Series die set and the Standard Pusher in the crimper in the order shown.
Note that a hose and fitting are not required for an initial calibration check.
Note: failure to lubricate all contact surfaces can cause the
Cone Insert and/or the dies to seize in the cone base.
 Slide the Pusher onto the stud on the hydraulic
ram.
 Set the Micro-Crimp adjuster at “95”
 Press and hold the start switch bulb.
 If the ram extends and the crimper shuts off approx-
imately 1 second after the dies are completely closed and
the pump starts to build pressure, the crimper is correctly
calibrated.
 If the time to shut off is not approximately 1 second,
the crimper must be recalibrated. Recalibrate as follows:
CALIBRATION INSTRUCTIONS
 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.
 If the motor shuts off too quickly or before the dies are com-
pletely closed, rotate the stem in.
 If the motor does not shut off or shuts off in substantially more
than 1 second, rotate the stem out.
 Recheck calibration.

6
Lubricate all contact surfaces
of the cone insert and place
it squarely in the base of the
crimper.
Place the die set and hose and
fitting loosely in the cone insert.
Use care to be certain that the
die halves do not overlap. Place the Pusher Plate on top of the die set.
Slide the Pusher onto the stud
on the hydraulic ram. Check the finished crimp diameter to be certain that it is within the hose
and fitting manufacturers crimp speci-
fication limits.
Lubricate die fingers, all contact
surfaces and die cones.
WARNING: Failure to lubricate
will cause damage to die sets and
crimper.
Alignment of the hose and fitting
in the die set is shown. Refer-
ence hose and fitting manufac-
turers specifications for correct
locations
Press and hold the start switch until
the motor shuts off.
CRIMPING WITH CC020 SERIES DIES

Page
7Page
Crimping with CC032 series dies is essentially identical to crimping with the CC020 series dies except that the
Cone Insert is removed from the crimper base
Insert the die set and Pusher
Plate in the order illustrated.
Remove the Cone Insert from the
crimper base and lubricate all con-
tact surfaces of the die set.
WARNING: Failure to lubricate
will cause damage to die sets and
crimper
Align the hose and coupling as
recommended. Load the Pusher
Plate and Pusher and press and
hold the start/stop switch until the
crimper shuts off. Check the final
crimp diameter to be certain that it is
within specifications.
ADDITIONAL CS205/CS206 FEATURES
Retraction Stop
The easily removable Coupling Stop makes
repetitive crimps faster by not having to visu-
ally align the fitting before each crimp.
The adjustable retraction stop limits the retraction
of the ram to only the amount required to easily
remove the hose and fitting. This feature saves
time when doing multiple crimps.
CRIMPING WITH CC032 SERIES DIES

8
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 220 volt single phase (D205WB)
or a 115 volt single phase circuit. (D206WB) Use of extension cords or outlets with inadequate power can
damage the motor . Do not run the crimper from a portable power source.
Check the stop switch mounted to the switch bracket under the Micro-CrimpAdjuster. This is a normally
closed switch and if it does not close the crimper will not operate.
CAUTION: Do not operate the crimper with this switch jumpered as the pump will not shut off and the
brackets can be damaged.
Checkthepneumatically actuatedswitchin theelectricalboxmounted on themotor. Thisswitch controls
power to the motor and is actuated with air pressure from the pendant switch bulb.
PROBLEM: CRIMP DIAMETER TOO LARGE
Incorrect setting of the Micro-Crimp Adjuster. Check crimp specifications.
(NOTE:All published machine settings are approximate. To correct for slight variances, the gauge settings
may be adjusted for the specific hose, fitting and size combination.)
Incorrect die being used. Each die has a range of approximately 3mm (.120 in) above the closed diam-
eter of the die. The closed diameter is the die size stamped on the die ring.
Check crimper calibration and re-calibrate if required.
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. Use only the grease shipped with the machine or equivalent.
Inadequatepressurebeing generated bythe pump. This ismostlikely if thecrimpercan crimp thesmaller
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

Incorrect setting of the Micro-Crimp Adjuster. Check crimp specifications.
( NOTE:All published machine settings are approximate. To correct for slight variances, the gauge settings
may be adjusted for the specific hose, fitting and size combination.)
Incorrect die being used (See die range under Crimp Diameter too Large)
Check crimp diameter and re-calibrate if necessary
PROBLEM: DIES STICKING IN COMPRESSION CONE

Inadequate lubrication of the compression cone and die surfaces. Use only the grease shipped with
the machine or equivalent.
TROUBLESHOOTING

Page
9Page
COMPONENT IDENTIFICATION

10
COMPONENT IDENTIFICATION

Page
11Page
CRIMP SPECIFICATIONS

12
CRIMP SPECIFICATIONS

Page
13Page
CRIMP SPECIFICATIONS

14
CRIMP SPECIFICATIONS

Page
15Page
CRIMP SPECIFICATIONS

16
CRIMP SPECIFICATIONS