CustomCrimp D205 User manual

D205 / D206 Service Hose Crimper
Updated 02/2017
The D205 / D206 Series crimper with the Micrometer Style Adjustment and 80
ton cylinder has the capacity to crimp hoses up to: 1-¼" 6SP (with standard dies) and
up to 2" 6SP (with optional double angle dies).
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 ttings.
D205 / D206 SERIES HYDRAULIC CRIMPER OPERATORS MANUAL
Double Angle Tooling: Using double
angle dies e󰀨ectively double the
crimping force to 160 ton.

D205 / D206 Service Hose Crimper
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SAFETY PRECAUTIONS
• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER.
• CRIMPER D205 / D206 SERIES CAN PRODUCE 80 TONS OF CRIMPING FORCE WITH
STANDARD DIES AND 160 TONS OF CRIMPING FORCE WITH DOUBLE ANGLE DIES.
• 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
! !
MODELS COVERED:
This manual is applicable to a number of variations of the D205 Series Crimpers.
A “Standard”, “Metric” and “DC” Micrometer is available on di󰀨erent models.
A 1HP-110Volt and a 2 HP-220 Volt ValPower pump are used on di󰀨erent models.
Crimping, calibration and repair procedures are similar.
See detailed parts breakdown at the back of the manual for parts applicable to specic models

D205 / D206 Service Hose Crimper
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SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2
COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4
D205 / D206 FEATURES--------------------------------------------------------------------------------------------------------------------------5
INITIAL SET UP & MAINTENANCE------------------------------------------------------------------------------------------------------------6
D205 / D206 SERIES QUICK START GUIDE-------------------------------------------------------------------------------------------------7
CRIMPING WITH STANDARD DIES---------------------------------------------------------------------------------------------------------8
CRIMPING WITH DOUBLE ANGLE DIES-----------------------------------------------------------------------------------------------10
CALIBRATION PROCEDURE-----------------------------------------------------------------------------------------------12
D205 / D206 SERIES DIE OPTION-------------------------------------------------------------------------------------------------------------13
D205 / D206 SERIES CRIMPER REPLACEMENT ACCESSORIES-----------------------------------------------------------------14
TROUBLESHOOTING----------------------------------------------------------------------------------------15
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------16
CUSTOMCRIMP® “NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------29
TABLE OF CONTENT

D205 / D206 Service Hose Crimper
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COMPONENT PARTS & TECHNICAL DATA
Technical Data
80 Ton
Single angle dies
160 Ton
DA dies
1-¼" - 1 - 2 Wire 2" - 1 - 2 Wire
1-¼" - 4SP 2" - 4SP
1-¼" - 6SP 2" - 6SP
L: 32" x W: 17" x H: 29"
Weight: 305 lbs
Power: 2HP / 220V / 1Phase (Standard)
1HP / 110V / 1Phase (Optional)
Die series: D200 / D200DA
Micrometer Style Adjustment: Metric
Reservoir capacity: 1 US Gallon
Oil type: ISO 46 Hydraulic Oil
Double Angle
Die Series with
the optional
conversion kit.
&
Built-in
Work Lamp
Removable Pusher
2HP/220V/1PH
pump for fast crimps
Power Switch
Pneumatic Switch can be
used with hands or feet
Powerful 80 Ton
Hydraulic Cylinder
Small Footprint for
minimum use of space
D200 Die Series Easy adjustable micrometer
Automatic Shut O󰀨
32"
17"
29"
CustomCrimp®QR Code
Oil Drain Port
Oil Sight Glass
Oil Fill & Vent Plug
Extension Cord Plug
Voltage Tag
Double Angle
Top Compression Ring
Standard
Compression Ring
D200 Double
Angle Die Set
Standard
D200 Die Set
Double Angle
Base Ring
Standard
Pressure Plate

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• The D205 / D206 Series Crimper comes with standard features
which increase accuracy and improve productivity for jobs which
require repeat crimps of similar or identical assemblies.
(Optional accessories available).
• Fully adjustable micrometer for a precise crimp and electric shuto󰀨
switch makes crimping process fast.
• The Adjustable Retraction Stop allows the operator to limit the
retraction of the hydraulic ram at the point where the die set is open
only enough to remove the hose and tting. This feature can greatly
speed up crimping on production jobs since the ram does not have
to fully advance and retract on every cycle.
• The easily removable Coupling Stop provides an automatic stop
for straight ttings without the need to sight the alignment of the tting
on every crimp. A short and a long Coupling Stop are furnished with
each crimper to accommodate a wide range of tting congurations.
• Easily removable pusher and split dies accommodate di󰀩cult
crimps (Bent Tube & Special Fittings). Show with Optional Spacer
Kit for more clearance.
D205 / D206 FEATURES

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INITIAL SET UP & MAINTENANCE
FOLLOW THESE STEPS BEFORE YOU USE YOUR CRIMPER FOR
THE FIRST TIME.
Mount the crimper on a sturdy surface.
Check electrical circuit to be certain that it matches the crimper
requirements shown on the tag attached to the crimper cord.
Plug the crimper directly into a 220 volt 15 amp single phase wall outlet.
(NOTE: The optional 110 volt 1 Hp unit must be connected to a 110V-15
amp circuit.)
DO NOT USE AN EXTENSION CORD OR RUN FROM PORTABLE
POWER SOURCES AS LOW VOLTAGE CAN DAMAGE THE MOTOR.
Check the oil level in the sight glass on rear end of the reservoir
The oil level should be approx. 1-1/2 inches below the ller/vent plug.
If additional oil is required ll with ISO Grade 46 hydraulic oil.
Oil can be drained from the rear end port on the reservoir.
LUBRICATION:
• Use CRIMPX Grease (supplied with crimper) or a high pressure
molybdenum high pressure grease to lubricate tooling and dies.
• Lubricate the inner wall of the standard compression ring, and each
die nger of the standard dies.

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D205 / D206 SERIES QUICK START GUIDE
• Select the correct die set for the combination of hose and tting being
crimped. Consult the hose and tting manufacturer’s specications
for the correct die to use and nal crimp diameter required..
• Place the standard Compression Ring, any standard Die Set, and
the standard Pressure Plate in the base of the crimper in the order
shown.
• Slide the pusher onto the stud of the hydraulic ram.
• Set the micro-crimp adjuster at:
“100” for the Standard D205
“95” for the D205-DC
“0” for metric units.
• Press and hold the start switch.
• If the ram extends and shuts o󰀨 the motor in approximately one
second after the pump starts to build pressure, (the sound of the pump
will change) and the Die Set is fully closed, the crimper is correctly
calibrated.
• If the time to shut o󰀨 is not approximately 1 second, the crimper
must be re-calibrated. See Instructions.
METRIC
DCSTANDARD

D205 / D206 Service Hose Crimper
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CRIMPING WITH STANDARD DIES
• Insert the Standard Pressure Plate in the bottom ange making certain that
the Pressure Plate is seated squarely in the bottom ange.
Note that the bottom Pressure Plate is held in place by a set screw.
This screw can be loosened through the access hole in the front of the
machine through the “Hand Hazard” decal.
• Select the correct die set for the combination of hose and tting being crimped.
This information is available from the hose and tting manufacturer.
The number etched on the die ring represents the fully closed diameter
of the die set in either inches or millimeters depending upon the die set.
• Lubricate the contact surfaces of the die ngers and the Compression Ring
with the die lubricant furnished with the crimper.
Failure to lubricate the contact surfaces with the correct lubricant will
cause the dies to seize in the compression ring.
• Align the hose and tting in the die set and place the Compression Ring
loosely over the die set. Manually depress the compression ring until the tting
is held loosely in 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 visible, you must go to a larger
die set. Crimping with an incorrect
die size could result in damage to
the die set and/or personal injury.

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• Set the Micro-Crimp Adjuster to the setting recommended by the hose and
tting manufacturer for the hose and tting being crimped. Both the standard
and the metric micrometers are shown.
• The standard micrometer (Readings of 0 to 100) and the “DC” micrometer
(Readings of 20 to 100) are adjusted to the position recommended by the hose
and tting manufacturer. The metric micrometer (Readings of 0 to 10) is a direct
reading micrometer. The setting on the micrometer is added to the number in
mm etched on the die ring to obtain the nal crimp diameter.
For example: With a 39mm die and the METRIC micrometer set at 3.0 the
nished crimp diameter would be 42.0 mm (39mm + 3.0mm).
Note: Each die set has a limited range of diameters for which a satisfac-
tory crimp can be obtained. As a “rule of thumb” a standard die set can
crimp 3 mm (.120 inches) above the closed diameter etched on the die
ring. Always consult the hose and tting manufacturer’s recommendation
for the correct die set to use.
CAUTION: THE FINISHED CRIMP DIAMETER SHOULD NOT BE MORE
THAN 4 MM (0.16 INCHES) ABOVE THE CLOSED DIAMETER OF THE DIE
SET.
DO NOT ATTEMPT TO CRIMP A FITTING IF THE COMPRESSION CONE
DOES NOT COMPLETELY COVER THE NOTCHES ON THE DIE FINGERS.
FAILURE TO HEED THESE WARNINGS COULD RESULT IN DAMAGE TO
THE DIE SET AND/OR PERSONAL INJURY.
• Recheck the tting for correct alignment and depress the pneumatic Start/
Stop switch bulb and keep it depressed until the crimper shuts o󰀨 automatically.
• Check the diameter of the nished crimp to be certain that it is within the
hose and tting manufacturer’s specications.
CRIMPING WITH STANDARD DIES
METRIC
DCSTANDARD

D205 / D206 Service Hose Crimper
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Double Angle dies double the radial crimping force of the die set allowing
heavier ttings to be crimped. Due to the doubling of the radial crimp
force, they are eective for a smaller range of diameters than a standard
die set. Also, the tting must be approximately centered axially along the
crimping face to avoid taper in the nal crimp.
• Remove the standard at Pressure Plate and replace it with the DBL BASE
bottom compression ring.
The bottom Pressure Plate may be held in place with a set screw. Access
to this set screw is through the hole in the hand hazard decal.
Note: The angles are not the same on standard and double angle dies
and the standard compression rings are not interchangeable with double
angle compression rings.
• Lubricate the contact surfaces of both the upper and lower compression
rings and the outer surfaces of the double angle dies with the CRIMPX Die
Lubricant Grease furnished with the crimper.
• Seat the appropriate size double angle die in the conical recess of the DBL
BASE lower compression ring.
CRIMPING WITH DOUBLE ANGLE DIES

D205 / D206 Service Hose Crimper
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• Insert the tting as specied by the hose manufacturer.
• Place the DBL TOP compression ring on top of the die set and
manually compress the die set until it contacts the tting.
• Slide the Pusher onto the cylinder stud and set the Micro-Crimp
Adjuster at the appropriate setting.
• Press and hold the Start/Stop switch until the crimper shuts o󰀨.
• When the crimp cycle is complete, check the tting diameter to make
certain that it is within the hose manufacturer’s specications.
CRIMPING WITH DOUBLE ANGLE DIES

D205 / D206 Service Hose Crimper
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When the crimper is correctly calibrated, the ram will extend and
fully close the die set. After the die set is fully closed, the time
from which the pump starts to build pressure and the point at which
the motor shuts of automatically will be approximately 1 second.
Many problems associated with incorrect crimp
diameters are caused by incorrect calibration.
CALIBRATION
• Insert the Standard Pressure Plate, any die set, and the Compres-
sion Ring in the order illustrated.
• Set the Micro-Crimp adjuster at:
“100’ For the Standard D205 (0-100)
“95” For the D205-DC (20-100)
“0” for metric units(0-10)
• Press and hold the start Switch.
• If the ram extends closing the dies to their fully closed position and the
motor shuts o󰀨 approximately 1 second after the pump starts to build pressure
(the sound of the pump will change), then the crimper is correctly calibrated.
• If the crimper requires re-calibration, 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 time from which the pump starts to build pressure is greater than approx-
imately 1 second, rotate the stem out slightly.
If the time is less than approximately 1 second, rotate the stem in slightly.
• Recheck calibration.
CALIBRATION PROCEDURE

D205 / D206 Service Hose Crimper
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D200 STANDARD
SERIES DIE
D200 DOUBLE ANGLE (DA)
SERIES DIE
D200 STANDARD. SERIES DIES
D200 DOUBLE ANGLE DIES
INCH SERIES DIES
METRIC SERIES DIES
D200-0.520-2.000-RED
D200-0.670-2.000-YELLOW
BORE SIZE RANGE:
D200-0.830-2.000-BLUE
50 MM-78 MM
D200-1.100-2.500-GREEN
D200-1.320-2.500-BLACK
STANDARD CRIMP LENGTHS:
D200-1.500-2.500-BROWN
65 MM
D200-1.730-3.000-SILVER
75 MM
D200-1.920-3.000-PURPLE
85 MM
METRIC SERIES DIES
95 MM
D200-07-51-BLUE
105 MM
D200-09-51-RED
115 MM
D200-10-51-PURPLE
125 MM
D200-11-51-GREEN
D200-12-51-BLACK
STANDARD RING COLOR
D200-14-51-YELLOW
BLACK
D200-16-51-ORANGE
OPTIONAL COLORS AVAILABLE
D200-17-51-RED
D200-18-51-BLACK
D200-19-51-GREEN
D200-20-51-GREEN
D200-22-51-BLUE
D200-24-51-BLUE
D200-26-64-BROWN
D200-27-64-BROWN
D200-28-64-PURPLE
D200-30-64-RED
D200-31-64-YELLOW
D200-34-64-RED
D200-35-64-ORANGE
D200-39-76-RED
D200-41-76-YELLOW
D200-43-76-YELLOW
D200-48-76-SILVER
D200-51-76-GREEN
D200-52-76-BLACK
D200-56-76-SILVER
D200-60-76-PURPLE
DIE SIZE CODES: D200-XX-XX-COLOR
DIE RING COLOR (1)
CRIMP FACE LENGTH (MM/IN)
DIE CLOSED DIAMETER (MM/IN)
DIE SERIES (D200/D200DA)
(1) DIE RING COLOR
OPTIONS
RED
ORANGE
YELLOW
PURPLE
GREEN
BLUE
BLACK
SILVER
BROWN
D205 / D206 SERIES DIE OPTIONS

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D205 / D206 REPLACEMENT ACCESSORIES
CRIMPX Lubricant Grease
4 oz can with brush
P/N:104162
CRIMPX Lubricant Grease
16 oz can with brush
P/N:104111
Pneumatic Pendent Switch
P/N:101349
Metric Micrometer
P/N:101587
D205/D206 Coupling Stop
P/N:101631
D205/D206 Die Storage Shelf
P/N:101625
D205 Pusher
P/N:100818
Double Angle Top P/N:100871
Double Angel Base P/N:100870
STD Compression Ring P/N:100712
STD Pressure Plate P/N:100713
D205 Screws P/N:EN82-004
D205 Spring P/N:LC 022D 05
For D200 Die Series
Double Angle Screws P/N:EN83-034
Double Angle Springs P/N:LC 022D 05
For D200 Double Angle Die Series
Mobile Cart
P/N:101956
Spacer Kit for more clearance
P/N:D200-1-SPACER-KIT
Flexible 24" Work Lamp
P/N:1668-02
Standard Micrometer
P/N:100628
DC Micrometer
P/N:101489

D205 / D206 Service Hose Crimper
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TROUBLESHOOTING
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 circuit.
An optional 110 volt 1 HP unit is available, and this unit must be run on a 15 amp circuit. Use of ex-
tension 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-Crimp Adjuster. 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 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 re-calibrate 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 re-calibrate 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.

D205 / D206 Service Hose Crimper
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COMPONENT PARTS BREAKDOWN
D200 SERIES DIE PARTS (AI-100717)
QTYDESCRIPTIONPART NUMBERITEM
2D200 Die Ring (Half)100753-XX
1
88 PC Die Finger Set
Varies With Die Size
2
8D200 ScrewEN82-0043
8D200 SpringLC 022D 05
4
3
4
1
2
DIE RING HALF D200 SERIES
PART NUMBER DESCRIPTION
100753-00 DIE RING HALF SILVER
100753-01 DIE RING HALF ORANGE
100753-02 DIE RING HALF GREEN
100753-03 DIE RING HALF BLUE
100753-04 DIE RING HALF BROWN
100753-05 DIE RING HALF YELLOW
100753-06 DIE RING HALF RED
100753-07 DIE RING HALF BLACK
100753-08 DIE RING HALF PURPLE

D205 / D206 Service Hose Crimper
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D200 SERIES DIE PARTS (AI-100717)
QTYDESCRIPTIONPART NUMBERITEM
2D200 Die Ring (Half)100753-XX
1
88 PC Die Finger Set
Varies With Die Size
2
8D200 ScrewEN82-0043
8D200 SpringLC 022D 05
4
3
4
1
2
DIE RING HALF D200 SERIES
PART NUMBER DESCRIPTION
100753-00 DIE RING HALF SILVER
100753-01 DIE RING HALF ORANGE
100753-02 DIE RING HALF GREEN
100753-03 DIE RING HALF BLUE
100753-04 DIE RING HALF BROWN
100753-05 DIE RING HALF YELLOW
100753-06 DIE RING HALF RED
100753-07 DIE RING HALF BLACK
100753-08 DIE RING HALF PURPLE
COMPONENT PARTS BREAKDOWN

D205 / D206 Service Hose Crimper
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COMPONENT PARTS BREAKDOWN
1 101585 D205 Base 1
2 101624 D205 Support Rod 2
3 90126A031 3/8 Flat Washer 10
4 92865A622 3/8-16 X 3/4 Hex Bolt 4
5 101621 D205 Support Rod Brace 1
6 92865A624 3/8-16 X 1 Hex Bolt 4
7 91102A031 3/8 Lock Washer 4
8 95462A031 3/8-16 Nut 4
9 101634 D205 Head Assembly 1
10 101633 Pump Assembly 1
11 90126A029 1/4 Flat Washer 4
12 91102A029 1/4 Lock Washer 4
13 92865A540 1/4-20 X 3/4 Hex Bolt 4
14 60TA06X08 45Hydraulic Fitting 1
15 101645 D205 Hydraulic Hose 1
16 101631 D205 Coupling Stop Assembly 1
17 91251A544 1/4-20 X 1 1/4 SHCS 1
18 100628 Standard Micrometer Assembly 1
18 101489 DC Micrometer Assembly 1
18 101587 Metric Micrometer Assembly 1
19 100727 Micrometer Nut 1
20 101349 Pendant Switch & Plug 1
21 101625 D205 Die Shelf Assembly (Optional) 1
D205/D206 Crimper Assembly (101626)
Item Part Number Description Qty
3
7
8
20
12
13
21
2
14
16
6
3
8
7
5
4
3
9
17
18
1
6
3
10
15
19
11

D205 / D206 Service Hose Crimper
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COMPONENT PARTS BREAKDOWN
1 100641-01 Micro Plate 1
2 100641-02 Micro Brace 1
3 100672 Micrometer Bracket 1
4 91253A194 8-32 x 1/2 HSFHS 2
5 91251A240 10-24 x 3/8 SHCS 2
6 91253A197 8-32 x 3/4 HSFHS 2
7 98296A249 3/16 x 3/4 Slotted Spring Pin 1
Micro Mount Assy (100641)
Item Part Number Description Qty
4
1
2
3
6
5
7

D205 / D206 Service Hose Crimper
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COMPONENT PARTS BREAKDOWN
1 100952 Adjustable Stop Arm 1
2 94052A133 Push-on Cap 1
3 91251A540 1/4-20 x 3/4 SHCS 1
4 90126A029 1/4 Flat Washer 1
5 DK-655 10-24 Knob 1
6 94750A588 1/4-20 T-Nut 1
7 101525 Fixed Stop Arm 1
8 9489T47 10-24 Eye Bolt 1
9 101632 D205 Coupling Stop Rod 1
10 92383A256 1/8 x 3/4 Long Spring Pin 1
D205 Coupling Stop Assembly (101631)
Item Part Number Description Qty
9
1
5
6
7
4
3
2
8
10