CustomCrimp D105M Series User manual

Innovating SMART Hose Assembly Solutions Since 1979
D105M 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.
• D105 SERIES CRIMPERS CAN PRODUCE 35 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
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
CUSTOM CRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------25
CUSTOM CRIMP® CONTACT INFORMATION--------------------------------------------------------------------------------------26
TABLE OF CONTENT

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Innovating SMART Hose Assembly Solutions Since 1979
D100/D105
Pusher
D100/D105
Compression Ring
D100/D105
Die Series
D100/D105
Pressure Plate
Powerful 35 Ton Hydraulic Cylinder
1HP/110V/Single Phase
pump for fast crimps
Removable Pusher
Calibration Adjustment Screw
22"
13"
Optional Flexible 24"
Work Lamp
Electronic Shut O󰀨
Compression Ring
D100 Die Series
Micrometer Style Adjustment
Small Footprint for
minimum use of space
Main Power Switch
Adjustable Retraction Stop
Electrical Enclosure
1 Gallon Reservoir
Pneumatic Switch
CustomCrimp® QR Code
22-½"
D105M Technical Specifications
Crimping Force: 35 Ton
Hydraulic Hose Capacity: 2 Wire = 1"
4 Spiral = 3/4"
Crimper Size: L: 22" x W: 13" x H: 22-½"
Crimper Weight: 114 lbs
Power: 1HP/110V/1Phase (Standard)
2HP/220V/1Phase (Optional)
Die series: D100
Micrometer style adjustment: Metric
Reservoir capacity: 1 US Gallon
Oil type: ISO 46 Hydraulic Oil
D105M COMPONENT PARTS & TECHNICAL DATA

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Innovating SMART Hose Assembly Solutions Since 1979
Automatic stop
switch shuts the
pump o󰀨 when
the crimp cycle
is complete.
Built-in adjustable retraction
stop limits ram retraction for
quick repetitive crimps.
An easily removable Coupling
Stop makes repetitive crimps
faster by not having to visually
align the tting before each
crimp.
Easy calibration adjustment to
increase or decrease crimp OD.
Metric Micrometer “Micro-Crimp
Adjuster” is fully adjustable to
make precise and repeatable
crimps.
Open design, two piece “slide
in” die set and removable
pusher allows the operator to
accurately position the tting
prior to crimping.
D105M FEATURES

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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.
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).
• 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.
• Always check oil level in the D105 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 D165 crimper.
• Check electrical circuit to be certain that it matches the crimper
requirements shown on the voltage tag attached to the crimper cord.
• Plug the D105 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.
Note: Use of extension cords or outlets with inadequate power can damage
the motor or crimper controls.
INITIAL SET UP

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Innovating SMART Hose Assembly Solutions Since 1979
Photo # 1
Place a thin layer of CrimpX oil (supplied with crimper) or a high
pressure molybdenum high pressure grease on the surface the dies
sit on (as shown in photo # 1).
Grease Point # 2
Before sliding the compression ring over the correct die set, place
a thin layer of CrimpX oil (supplied with crimper) or a high pres-
sure molybdenum high pressure grease on the entire area that dies
come in contact with on the inner diameter (as shown in photo # 2).
If Breaking Die Screws Often: Continue to lubricate / grease as
explained above in addition to lubricating each die nger individually
(as shown in photo # 3A).
If Compression Ring Sticks: The die ngers must be lubricated on
each segment that comes in contact with the compression ring (as
shown in photo # 3B).
Note: Lubrication is not required before each crimp.
Typical lubrication is after 100 crimps.
Grease Point # 1
Insert the pressure plate into the bottom ange of the crimper, making
sure that it is seated squarely into the bottom ange.
Photo # 2
Photo # 3
A
B
LUBRICATION PROCEDURE

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Innovating SMART Hose Assembly Solutions Since 1979
Step 2: Select the correct die set for the combination of hose and tting
being crimped.
Note: Consult your hose and tting manufacturer for the correct die size
for the combination of hose and tting being crimped.
Note: The number etched on the OD of the die ring represents the fully
closed diameter of the die set in millimeters. In addition, die sets are
color-coded for easier identication.
Step 3: Lubricate the contact surfaces, both bottom and outside edges
of the die ngers, with CrimpX oil (supplied with crimper) or a high
pressure molybdenum high pressure grease.
Failure to lubricate the contact surfaces with the correct lubricant
will cause the dies to seize in the compression ring, causing
damage to the die set as well as possibly damaging the crimper.
Note: Follow the lubrication procedure prior to crimping procedure.
Step 1: Insert the pressure plate into the bottom ange of the crimper,
making sure that it is seated squarely into the bottom ange.
Make sure is lubricated prior to inserting the die set.
NOTE: FAILURE TO LUBRICATE THE DIE SET AND COMPRESSION
RING COULD RESULT IN THE DIE SET SEIZING IN THE BASE FLANGE.
CRIMPING PROCEDURE

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Innovating SMART Hose Assembly Solutions Since 1979
Step 4: Place the lubricated die set squarely in the pressure plate.
Step 6: Place the lubricated compression ring over the die set and
compress the die set by hand to hold the hose and tting in place.
Step 5: Align the tting in the die set according to the hose and tting
manufacturer’s recommendation.
CRIMPING PROCEDURE

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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.
• Crimping with an incorrect die size could result in personal injury.
CRIMPING PROCEDURE

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Note: Make sure the pusher is positioned correctly as shown.
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.
Rear View
SlotSlot
Front View
Lip Lip
Pusher
Retaining Ring
CRIMPING PROCEDURE

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Innovating SMART Hose Assembly Solutions Since 1979
Step 8: Set the Micro-Crimp Adjuster to the setting recommended by
the hose and tting manufacturer for the combination of hose and tting
being crimped.
NOTE: The Metric Micro-Crimp Adjuster is a direct reading
micrometer. Add the setting on the micrometer to the closed
diameter of the die set to obtain the nished crimp diameter.
For example: With a 23mm die set and the Micro-Crimp Adjuster set at
3.0, the nished crimp diameter would be 26.0 mm (23mm + 3.0mm).
Note: Each die set has a limited range of diameters for which a satisfactory
crimp can be obtained. Always consult your hose and tting manufacturer
for the correct die set for the hose and tting being crimped.
Step 9: Recheck the tting for the correct alignment in the die set and
depress the start/stop switch.
Depress and hold the Start/Stop switch, until the micrometer touched the
electronic red button as shown, “count one mississippi” the automatic
stop switch will shut the pump o󰀨, and the ram will return to the retracted
position. Allow the pusher to return to the retracted position as well.
Step 10: Check the nal crimp diameter with calipers to conrm that
it is within manufacturer’s specications.
Note: Always consult with your hose and tting manufacturer to obtain
the must current crimp specications.
CRIMPING PROCEDURE

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Innovating SMART Hose Assembly Solutions Since 1979
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.
Step 1: Place the Lubricated Pressure Plate, into the bottom ange of
the crimper, making sure that it is seated squarely into the bottom ange.
Step 2: Place Any Lubricated Die Set squarely in the pressure plate.
Step 3: Place the Lubricated Compression Ring over the die set.
Note: Make sure the compression ring is seated evenly on the die set.
Note: A hose and tting are not required for a calibration check.
NOTE: FAILURE TO LUBRICATE THE DIE SET AND
COMPRESSION RING COULD RESULT IN THE DIE SET
SEIZING IN THE BASE FLANGE.
Step 4: 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.
Refer to page 11 for details if needed.
CAUTION: Damage to pusher and retaining ring can occur if misaligned.
CALIBRATION CHECK PROCEDURE

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Innovating SMART Hose Assembly Solutions Since 1979
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.
If the ram extends, the dies are completely closed, the pump builds
pressure (The sound of the pump will change) when the micrometer
touched the electronic red button as shown, “count one mississippi” the
automatic stop switch will shut the pump o󰀨, and the ram will return to
the retracted position the crimper is correctly calibrated.
Step 7: If the above conditions are not met, the crimper requires
recalibration, 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.
Note: 1/4 turn of screw will change crimp diameter approximately
0.008".
• Rotating the stem out of the barrel decreases the time required for
the pump to shut o󰀨.
• Recheck calibration.
CALIBRATION CHECK PROCEDURE

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Innovating SMART Hose Assembly Solutions Since 1979
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.
Slide the drawer slightly out to access two rear holes
(as shown in picture # 2). Install (2) 3/8-16 x 1" carriage
bolts in rear two holes (as shown in picture # 2). Use
3/8" plastic retaining washer to hold bolt into place.
Place the D105/D165 base plate over the 4
screws as shown in picture # 3.
Place 3/8" at washer, 3/8" locking washer, and
then the 3/8"- 16 nut over the bolt as shown.
Tighten each nut with a 9/16" wrench or socket until the
nuts are tight as shown in picture # 4.
Note: Bolt the D105/D165 crimper drawer assembly /
stand to work surface before use.
# 1
# 3 # 4
# 2
Note: This instructions can be used for D105/D165/D165-T420 series crimpers.
D105/D165 D-SERIES DRAWER ASSEMBLY / STAND

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Innovating SMART Hose Assembly Solutions Since 1979
Metric Micrometer
P/N:101587
D100/D105 Pressure Plate
P/N:100869
D100/D105 Compression Ring
P/N:100849
D100/D105 Pusher w/
Magnets P/N:100813-01
CRIMPX Die Lubricant Oil:
4 oz bottle with dauber cap
P/N:103886
D165 Coupling Stop
P/N:100954
Pneumatic Pendent Switch
(Included) P/N:101349
Vent Plug
P/N:9847K13
(5) D100 Screws
P/N:EN84-115 (Sold individually)
(5) D100 Spring
P/N:LC 022D 01 (Sold individually)
INCLUDED ACCESSORIES

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Innovating SMART Hose Assembly Solutions Since 1979
Die Storage Shelf
P/N:101431
Die Removal Magnet
P/N:104679
Standard Micrometer
P/N:100628
DC Micrometer
P/N:101489
Flexible 24" Work Lamp
P/N:1668-02
D-Series Drawer Assembly/Stand
P/N:104650
D100/D105 Notched
Compression Ring
P/N:101190
D100 Series Die Rings
Refer to page 19 for more details
CRIMPX Die Lubricant:
Grease 4 oz can with brush
P/N:104162
CustomCrimp®Notched Digital
Caliper IN/MM P/N:CC-Caliper
AVAILABLE ACCESSORIES

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Innovating SMART Hose Assembly Solutions Since 1979
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. 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 o󰀨 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 specications.
• Inadequate pump pressure. Check oil level in the pump. It should be 1-1/2 to 2 inches below the ll
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 denite 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 specications.
PROBLEM: DIES STICKING IN COMPRESSION RING
• Inadequate lubrication of the compression ring and die surfaces.
TROUBLESHOOTING

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Innovating SMART Hose Assembly Solutions Since 1979
D100 SERIES DIE PARTS (AI-100724)
QTYDESCRIPTION
PART NUMBERITEM
2DIE RING HALF D100 SERIES101065-COLOR1
88 PC DIE FINGER SETVARIES WITH THE DIE SIZE2
8D100 SCREWEN84-1153
8D100 SPRINGLC 022D 014
3
4
1
2
DIE RING HALF D100 SERIES
PART NUMBER DESCRIPTION
101065-BLACK DIE RING HALF BLACK
101065-BLUE DIE RING HALF BLUE
101065-BROWN DIE RING HALF BROWN
101065-GREEN DIE RING HALF GREEN
101065-ORANGE DIE RING HALF ORANGE
101065-PURPLE DIE RING HALF PURPLE
101065-RED DIE RING HALF RED
101035-SILVER DIE RING HALF SILVER
101065-YELLOW DIE RING HALF YELLOW
D100 SERIES DIE PARTS (AI-100724)
QTYDESCRIPTION
PART NUMBERITEM
2DIE RING HALF D100 SERIES101065-COLOR1
88 PC DIE FINGER SETVARIES WITH THE DIE SIZE2
8D100 SCREWEN84-1153
8D100 SPRINGLC 022D 014
3
4
1
2
DIE RING HALF D100 SERIES
PART NUMBER DESCRIPTION
101065-BLACK DIE RING HALF BLACK
101065-BLUE DIE RING HALF BLUE
101065-BROWN DIE RING HALF BROWN
101065-GREEN DIE RING HALF GREEN
101065-ORANGE DIE RING HALF ORANGE
101065-PURPLE DIE RING HALF PURPLE
101065-RED DIE RING HALF RED
101035-SILVER DIE RING HALF SILVER
101065-YELLOW DIE RING HALF YELLOW
COMPONENT PARTS BREAKDOWN

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Innovating SMART Hose Assembly Solutions Since 1979
D105 Crimper Assembly (101428)
ITEM PART NUMBER DESCRIPTION QTY
1 101430 D-105 Base Plate 1
2 101633 Pump Assembly 1
3 90126A029 1/4 Flat Washer 4
4 91102A029 1/4 Lock Washer 4
5 92865A540 1/4-20 x 3/4 Hex Bolt 4
6 101433 D105 Handle 1
7 101433-Slotted D105 Slotted Handle 1
8 92323A516 1/4-20 x 3/4 SHFCS 4
9 101429 Mounting Bracket 1
10 90126A031 3/8 Flat Washer 6
11 91102A031 3/8 Lock Washer 4
12 92865A623 3/8-16 x 7/8 Hex Bolt 2
13 95462A031 3/8-16 Hex Nut 2
14 101480 D105 Head Assembly 1
15 92865A626 3/8-16 x 1 1/4 Hex Holt 2
16 101434 Handle Brace 2
17 91255A578 5/16-18 x 1/2 BHCS 2
18 91255A585 5/16-18 x 1 1/4 BHCS 2
19 90126A030 5/16 USS Flat Washer 2
20 91102A030 5/16 Lock Washer 2
21 95462A030 5/16-18 Hex Nut 2
22 3/8 NPT Comp. Ftg 3/8 NPT Straight Compression Ftg. 2
23 101436-01 D105 Hydraulic Tube 1
24 100954 Coupling Stop Assembly 1
25 101349 Pneumatic Pendant Switch 1
26 101431 D105 Shelf Unit (Optional) 1
7
2
19
20
21
18
16
17
14
24
15
11
13
10
25
26
1
23
6
12
11
10
9
3
4
5
22
8
D105 Crimper Assembly (101428)
ITEM PART NUMBER DESCRIPTION QTY
1101430 D-105 Base Plate 1
2101633 Pump Assembly 1
3 90126A029 1/4 Flat Washer 4
4 91102A029 1/4 Lock Washer 4
5 92865A540 1/4-20 x 3/4 Hex Bolt 4
6 101433 D105 Handle 1
7 101433-Slotted D105 Slotted Handle 1
8 92323A516 1/4-20 x 3/4 SHFCS 4
9 101429 Mounting Bracket 1
10 90126A031 3/8 Flat Washer 6
11 91102A031 3/8 Lock Washer 4
12 92865A623 3/8-16 x 7/8 Hex Bolt 2
13 95462A031 3/8-16 Hex Nut 2
14 101480 D105 Head Assembly 1
15 92865A626 3/8-16 x 1 1/4 Hex Holt 2
16 101434 Handle Brace 2
17 91255A578 5/16-18 x 1/2 BHCS 2
18 91255A585 5/16-18 x 1 1/4 BHCS 2
19 90126A030 5/16 USS Flat Washer 2
20 91102A030 5/16 Lock Washer 2
21 95462A030 5/16-18 Hex Nut 2
22 3/8 NPT Comp. Ftg 3/8 NPT Straight Compression Ftg. 2
23 101436-01 D105 Hydraulic Tube 1
24 100954 Coupling Stop Assembly 1
25 101349 Pneumatic Pendant Switch 1
26 101431 D105 Shelf Unit (Optional) 1
7
2
19
20
21
18
16
17
14
24
15
11
13
10
25
26
1
23
6
12
11
10
9
3
4
5
22
8
COMPONENT PARTS BREAKDOWN