CustomCrimp D100 SERIES User manual

Page 1
D100 SERIES HYDRAULIC HOSE
CRIMPER OPERATORS MANUAL

2Page
Revised 11-13-2015
D100P SERIES CRIMPER D100H SERIES CRIMPER
MODELS COVERED
This manual is applicable to diff erent versions of the D100 Series Crimpers. A
“Standard”, “Metric” and “DC” micrometer is available on diff erent models.
Crimping, calibration and repair procedures are similar for all models. See
specifi c instructions and parts breakdown for the model in question
D100S SERIES
CRIMPER
D101S SERIES
CRIMPER VALPOWER PUMP
(OPTIONAL)
For Parts and Service, Contact:
Custom Machining Services, Inc.
Valparaiso, IN 46383
[phone]

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COMPONENT PART IDENTIFICATION
MICRO-CRIMP
ADJUSTER
POWER SOURCE
MANUAL UNIT
SHOWN
CALIBRATION
ADJUSTMENT
SCREW
REMOVABLE
PUSHER
COMPRESSION
RING
AVAILABLE MICRO-CRIMP MICROMETERS
STANDARD
DIE SET
STANDARD
“DC” METRIC
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.
SAFETY PRECAUTIONS

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D100 SERIES QUICK START GUIDE
TO ASSURE ACCURATE CRIMP DIAMETERS FOLLOW THESE STEPS
BEFORE YOU USE THE CRIMPER FOR THE FIRST TIME
CALIBRATION CHECK PROCEDURE
• Position the crimper on a sturdy surface in a will lighted area
• Check crimper calibration prior to initial operation
• Seat the Pressure Plate (fl at plate) in the base of the crimper
• Place any D100 series die set on top of the Pressure Plate making certain
that the die set is fi rmly seated against the Pressure Plate.
• Place the Compression Ring on top of the die
set in the order shown and slide the pusher onto
the ram.
• Set the Micro-crimp adjuster
as follows:
Standard Micrometer: “100”
“DC” Micrometer: “95”
Metric Micrometer: “0”
• Bring the Pusher into contact
with the Compression Ring and
continue to apply force until the
die set is fully closed and the
white line is fl ush with the surface
of the micro crimp adjuster as
shown.
• Note that for the D101S series, the electric switch
will shut off the power source at the point at which
the die set is fully closed and the pump starts to
build pressure.
• If the white line is not just visible as shown or the
pump does not shut off at the point where the die
set is fully closed, the crimper must be recalibrated.
See calibration instructions.

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CALIBRATION INSTRUCTIONS
• Place the Pressure Plate, any D100 Series Standard Die Set and the Compression
Ring in the crimper in the order shown.
• Set the Micro-Crimp Adjuster as follows:

Standard Micrometer: “100”
“DC” Micrometer: “95”
Metric Micrometer: “0”
• Bring the ram and pusher down on top
of the compression cone and increase the
pump pressure until the die set is completely
closed and the pump starts to build pressure.
All D100 Series Crimpers
• Continue increasing the pressure on the
compression Cone until the circumferential
white line on the Micro-Crimp Sight Button just becomes
visible above the Micro-Crimp Adjuster as shown in the
illustration.
D101S Series Crimpers (with electric pump)
• The Electric pump should completely close the die set
before the pump shuts off .
• If the white line is not visible or the electric pump does not
shut off when the dies are completely closed, adjust
the calibration adjustment screw under the Micro-Crimp
Adjuster contact button as illustrated. Repeat the calibration
procedure until the above conditions are satisfi ed.
• When the above conditions are met, the crimper is
calibrated and ready for use.

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• Place the fl at pressure plate in the bottom fl ange and select
the correct die set for the combination of hose and fi tting to be
crimped. Refer to the hose and fi tting manufacturer’s recommen-
dation for the correct die set to use.
• Lubricate the contact surfaces of the die fi ngers and compres-
sion cone thoroughly with the die lubricant furnished with the
crimper (EZCRIMP M).
Failure to lubricate the contact surfaces with the proper lubri-
cant will cause the dies to seize in the compression cone.
• Set the Micro-Crimp Adjuster to the setting recommended by the
hose and fi tting manufacturer for the combination of hose and fi t-
ting being crimped.
NOTE: The Metric Micro-Crimp Adjuster is a direct reading
micrometer. Add the setting on the micrometer to the closed
diameterofthediesettoobtainthefinishedcrimpdiameter. For
example: With a 39mm die and the Micro-Crimp Adjuster set at
3 the finished crimp diameter would be 42mm
• Place the Compression Ring over the die set and align the fi tting
to the correct position.
• Slowly bring the Pusher in contact with the Compression Ring
until the hose and fi tting are held in position with a very light pres-
sure. Recheck the fi tting for correct alignment.
• Continue to apply pressure until the white circumferential line on
the Micro-Crimp Sight Button just appears above the Micro-Crimp
Adjuster (See illustration on P 5) or the electric power unit shuts
off for the 101S crimper.
• Check the diameter of the fi nished crimp to be certain that it is
within the specifi cations of the hose and fi tting manufacturer.
NOTE: Each die set has a limited range of diameters for which
it can be used. A “Rule of Thumb” is that if you can see the
notches on the die fingers under the Compression Ring prior to
crimping, you must select a larger die size.
CRIMPING WITH STANDARD DIES

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COMPONENT IDENTIFICATION
D100H Assembly (100935)
QTYDESCRIPTIONPART NUMBERITEM
1Base Assembly1009301
1
Cover Assembly
1009312
1D100 Head Assembly1009293
23/8 Plain Washer90126A0314
2
3/8 Lock Washer
91102A0315
23/8-16 x 1 1/4 Hex Bolt92865A6266
1Hand Pump Assembly100934
7
2
Hand Pump Clamp
1003388
25/16 Plain Washer91090A1119
25/16-18 x 1/2 SHCS91251A57810
1Hand Pump Tube100935-0111
1Straight Comp Fitting52215K62412
1Elbow Comp Fitting52215K63413
6
5
4
7
12
11
3
2
1
13
8
9
10

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COMPONENT IDENTIFICATION
D100P Assembly (100937)
QTYDESCRIPTION
PART NUMBERITEM
1Base Assembly1009301
1Head Assembly1009292
2
3/8 Plain Washer
90126A0313
23/8 Lock Washer91102A0314
23/8-16 x 1 1/4 Hex Bolt92865A6265
1Pneumatic Pump1006206
1Straight Comp Fitting52215K624
7
1Pneumatic Pump Tube100620-018
1
Elbow Comp Fitting
52215K6349
21/4 Plain Washer90108A02910
21/4-20 x 1/2 SHCS91251A53711
1
Cover Assembly
10093112
5
4
31
11
10
6
2
12
7
9
8

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COMPONENT IDENTIFICATION

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COMPONENT IDENTIFICATION
1
2
3
4
5
35-Ton Head Sub-Assembly (101209)
QTYDESCRIPTIONPART NUMBERITEM
1
35-Ton Cylinder/Flange
1031221
4Strain Rod - 8 1/2"1003292
1Bottom Flange1003253
4
3/4 Flat Washer - Special750SPCL
4
43/4-10 Hex Nut95462A538
5

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COMPONENT IDENTIFICATION
35 Ton Cylinder / Flange Assembly (103122)
QTYDESCRIPTION
PART NUMBERITEM
1
Cylinder Body
1025111
1Cylinder Piston1015152
1
030 Disogrin O-Ring
030D903
1Cylinder Piston Cap100689
4
8
1/4-20 X 5/8 SHCS
91251A539
5
1Cylinder Spring1012826
1
Spring Plug
1015167
1210 Disogrin O-Ring210D908
1
T-Seal
TP0329
1Ram WiperSH959-2610
1
Cylinder Retaining Ring
10151411
15/16 Flat Washer90108A41512
1
5/16-18 x 1.50 HHCS
92865A58713
13
12
1
9
2
6
3
4
10
11
7
8
5

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D100 SERIES WARRANTY
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 benefi ts of this warranty, fi rst, contact Warranty
Repair Department at Custom Machining Services at [phone] 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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See the complete line of CustomCrimp®Crimpers and Accessories at: [phone]CustomCrimp® www.customcrimp.com
Custom Crimp®
Custom Machining Services, Inc.
326 N. County Rd. 400 East
Valparaiso, IN 46383
Ph: [phone]
Fax: [phone]
www.customcrimp.com