CustomCrimp D165M Series User manual

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Innovating SMART Hose Assembly Solutions Since 1979
D165M 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.
• D165 SERIES CRIMPERS CAN PRODUCE 62 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
AVAILABLE D105 / D165 D-SERIES DRAWER ASSEMBLY / STAND--------------------------------------------------------------------5
FEATURES---------------------------------------------------------------------------------------------------------------6
INITIAL SET UP-----------------------------------------------------------------------------------------------------------------------7
LUBRICATION PROCEDURE--------------------------------------------------------------------------------------------9
CRIMPING WITH STANDARD COMPRESSION RING-----------------------------------------------------------------------------10
CRIMPING WITH NOTCHED COMPRESSION RING-----------------------------------------------------------------------------15
CALIBRATION CHECK PROCEDURE---------------------------------------------------------------------------------------------19
D105 / D165 D-SERIES DRAWER ASSEMBLY / STAND (INSTRUCTIONS)------------------------------------------------------22
INCLUDED ACCESSORIES----------------------------------------------------------------------------------------23
AVAILABLE ACCESSORIES----------------------------------------------------------------------------------------24
TROUBLESHOOTING---------------------------------------------------------------------------------------------------------25
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------26
CUSTOM CRIMP®“NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------31
CUSTOM CRIMP®CONTACT INFORMATION--------------------------------------------------------------------------------------32
TABLE OF CONTENT

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Innovating SMART Hose Assembly Solutions Since 1979
Powerful 62 Ton Hydraulic Cylinder
1HP/110V/Single Phase
pump for fast crimps
Removable Pusher
Calibration Adjustment Screw
22-½"
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
22-½"
D160/D165
Pusher w/ Magnets
Standard
D160/D165
Compression Ring
D100 Die Series
D160/D165
Pressure Plate
*Crimper capacity is estimated based on typical 1-piece
tting. Actual results may vary depending
on the tting and hose manufacturer.
D165M Technical Specications
Crimping Force: 62 Ton
Hydraulic Hose Capacity: 2 Wire = 1-¼”
4 Spiral = 1-¼"
6 Spiral = 1"
Crimper Size: L: 22-½" x W: 13" x H:
22-½"
Crimper Weight:140 lbs
Power: 1HP/110V/1Phase (Standard)
2HP/220V/1Phase (Optional)
Micrometer Style Adjustment: Metric
Die series: D100
Reservoir capacity: 1 US Gallon
Oil type: ISO 46 Hydraulic Oil
COMPONENT PARTS & TECHNICAL DATA

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Innovating SMART Hose Assembly Solutions Since 1979
D-Series Drawer Assembly / Stand
The crimper bolts directly on
top of the mounting holes of the
D-Series Drawer
D-Series Drawer Assembly / Stand is available for D105 / D165 Series Crimpers.
D165 Series Crimper
Die storage drawer to keep
frequently used die sets and
your crimping accessories
readily available
Base mounting holes allow
the drawer to be bench or
truck bed mounted if required
D105/D165 D-SERIES DRAWER ASSEMBLY / STAND

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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.
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 D165 series can be mounted on the D-Series Drawer/Stand
and bolted onto the workbench. (See detailed instructions included with
D165 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 D165 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.
INITIAL SET UP

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Innovating SMART Hose Assembly Solutions Since 1979
• Check electrical circuit to be certain that it matches the crimper
requirements shown on the voltage tag attached to the crimper cord.
• Plug the D165 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.
• ValPower® o󰀨ers rugged industrial duty hydraulic power units that will meet the demanding requirements
of industrial users.
INITIAL SET UP

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Innovating SMART Hose Assembly Solutions Since 1979
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 standard compression ring or the notched com-
pression ring over the correct dies, place a thin layer of CrimpX oil
(supplied with crimper) or a high pressure molybdenum high pres-
sure 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 # 3
A
B
Photo # 2
Photo # 1
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.
Note: Make sure the Pressure Plate 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 WITH STANDARD COMPRESSION RING

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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 Fitting in the die set according to the hose and tting
manufacturer’s recommendation.
CRIMPING WITH STANDARD COMPRESSION RING

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Innovating SMART Hose Assembly Solutions Since 1979
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 WITH STANDARD COMPRESSION RING

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Innovating SMART Hose Assembly Solutions Since 1979
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 WITH STANDARD COMPRESSION RING

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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 WITH STANDARD COMPRESSION RING

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Innovating SMART Hose Assembly Solutions Since 1979
WHEN USING THE NOTCHED COMPRESSION RING,
FOR USE WITH 90 DEGREE FITTING ONLY,
FOLLOW THESE PROCEDURES:
Step 2: Place the Lubricated Die Set squarely in the pressure plate
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: Place the Lubricated Notched Compression Ring loosely
but evenly over the die set. Make sure die set is correctly aligned.
Note: Follow the lubrication procedure prior to crimping procedure.
CAUTION: Failure to lubricate the die set and notched compression
ring could result in the die seizing in the base ange.
Step 1: Insert the Pressure Plate into the bottom ange of the crimper,
making sure that it is seated squarely into the bottom ange.
Note: Make sure the Pressure Plate is lubricated prior to inserting the
die set.
CRIMPING WITH NOTCHED COMPRESSION RING

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Innovating SMART Hose Assembly Solutions Since 1979
Step 6: After placing the notched compression ring facing forward,
align the hose assembly with 90 degree tting in the die set according
to the hose and tting manufacturer’s recommendation.
Note: Manually depress the notched compression ring, closing the die
set until the hose and 90 degree tting are held loosely in the die set.
Seat the notched compression ring 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.
Step 7: CAUTION: DO NOT MISALIGN NOTCHED
COMPRESSION RING OR DAMAGE WILL OCCUR.
Note: When crimping with the notched compression ring the “Notched”
MUST face forward or damage can occur to die ngers if parts aren’t
aligned properly.
CRIMPING WITH NOTCHED COMPRESSION RING

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Innovating SMART Hose Assembly Solutions Since 1979
Step 8: 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 13 for details if needed.
CAUTION: Damage to pusher and retaining ring can occur if misaligned.
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.
CRIMPING WITH NOTCHED COMPRESSION RING

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Innovating SMART Hose Assembly Solutions Since 1979
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 WITH NOTCHED COMPRESSION RING

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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.
CALIBRATION CHECK PROCEDURE

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Innovating SMART Hose Assembly Solutions Since 1979
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 13 for details if needed.
CAUTION: Damage to pusher and retaining ring can occur if misaligned.
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.
CALIBRATION CHECK PROCEDURE