CustomCrimp D205M Series User manual

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Innovating SMART Hose Assembly Solutions Since 1979
D205M 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.
• D205M SERIES CRIMPERS CAN PRODUCE 80 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
D205M FEATURES-----------------------------------------------------------------------------------------------------------5
INITIAL SET UP---------------------------------------------------------------------------------------------------------------------------------------6
CRIMPING WITH STANDARD DIES------------------------------------------------------------------------------------------------------7
CRIMPING WITH DOUBLE ANGLE DIES-------------------------------------------------------------------------------------------9
CALIBRATION CHECK PROCEDURE---------------------------------------------------------------------------------------------11
D200 SERIES DIE OPTION------------------------------------------------------------------------------------------------------------12
D205M REPLACEMENT ACCESSORIES----------------------------------------------------------------------------------------13
TROUBLESHOOTING---------------------------------------------------------------------------------------------------------14
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------15
CUSTOM CRIMP®“NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------24
CUSTOM CRIMP®CONTACT INFORMATION--------------------------------------------------------------------------------------25
TABLE OF CONTENT

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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS & TECHNICAL DATA
D205M Technical Specications
80 Ton with
D200 Dies
160 Ton with
DA Dies
Hydraulic Hose Capability:
2 Wire = 1 ¼"
4 SP = 1 ¼"
6 SP = 1 ¼"
2 Wire = 2"
4 SP = 2"
6 SP = 2"
Control System: Metric Micrometer
Crimper Size: L: 32" x W: 17" x H: 29"
Crimper Weight: 305 Lbs.
Power: 2HP / 220V / 1Phase (Standard)
1HP / 110V / 1Phase ( Optional)
Die Series: D200 / D200DA
Reservoir capacity: 1 US Gallon
Oil Type: ISO 46 Hydraulic Oil
17"
32"
29"
Powerful 80 Ton
Hydraulic Cylinder
Built-in Work Lamp
Removable Pusher
Coupling Stop
Double Angle
Die Series with
the optional
conversion kit.
D200 Die Series
2HP/220V/1Phase
pump for fast crimps
Power Switch
Adjustable Micrometer
Automatic Shut O
Voltage Tag
Pneumatic Switch
Small Footprint for
minimum use of space
D200 DOUBLE ANGLE TOOLING
D200 Double Angle
Top Compressing Ring
D200 Double Angle
Die Set
D200 TOOLING
D200 Standard
Compression Ring
D200 Standard
Die Set
D200 Standard
Pressure Plate
D200 Double Angle
Base Ring

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Innovating SMART Hose Assembly Solutions Since 1979
FEATURES
• The D205M Series Crimper comes with standard features
which increase accuracy and improve productivity for jobs which
require repeat crimps of similar or identical assemblies.
• 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). “Feature” Show with Optional
Spacer Kit for more clearance. Adds exactly 1 inch between the pusher
and DBL Top Compressing Ring to allow extra tting clearance.

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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.
• 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.
Check electrical circuit to be certain that it matches the crimper
requirements shown on the voltage tag attached to the crimper cord.
• Plug the D20M 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.
• Always check oil level in the D205M 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 D205 crimper.
INITIAL SET UP

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Innovating SMART Hose Assembly Solutions Since 1979
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.
Note: 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.

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Innovating SMART Hose Assembly Solutions Since 1979
CRIMPING WITH STANDARD DIES
• 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 satisfactory
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.

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Innovating SMART Hose Assembly Solutions Since 1979
CRIMPING WITH DOUBLE ANGLE DIES
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.

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Innovating SMART Hose Assembly Solutions Since 1979
CRIMPING WITH DOUBLE ANGLE DIES
• 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.

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Innovating SMART Hose Assembly Solutions Since 1979
CALIBRATION CHECK PROCEDURE
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
Compression 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 approximately
1 second, rotate the stem out slightly.
If the time is less than approximately 1 second, rotate the stem in slightly.
• Recheck calibration.

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Innovating SMART Hose Assembly Solutions Since 1979
D200 SERIES DIE OPTIONS
DIE RING COLOR (1)
CRIMP FACE LENGTH (MM/IN)
DIE CLOSED DIAMETER (MM/IN)
DIE SERIES (D200/D200 DOUBLE ANGLE (DA))
D200 STANADARD SERIES DIE
D200 DOUBLE ANGLE (DA) SERIES DIE
(1) DIE RING COLOR OPTIONS:
RED
ORANGE
YELLOW
PURPLE
GREEN
BLUE
BLACK
SILVER
BROWN

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Innovating SMART Hose Assembly Solutions Since 1979
Metric Micrometer
P/N:101587
Pusher w/ Magnets
P/N:100825-01
Pneumatic Pendent Switch
P/N:101349
Vent Plug
P/N:9847K13
REPLACEMENT ACCESSORIES
Standard Micrometer
P/N:100628
DC Micrometer
P/N:101489
Flexible 24" Work Lamp
P/N:1668-02
D200 Spacer Kit
P/N:D200-1-SPACER-KIT
CustomCrimp® Notched Digital
Caliper IN/MM P/N:CC-Caliper
Die Removal Magnet
P/N:104679
D205/D206 Coupling Stop
P/N:101631
CRIMPX Lubricant Grease
4 oz can with brush P/N:104162
CRIMPX Lubricant Grease
16 oz can with brush P/N:104111
D200 STD Compression Ring P/N: 1007123
D200 STD Pressure Plate P/N: 100713
D200 Double Angle Top P/N: 100871
D200 Double Angle Base P/N: 100870

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Innovating SMART Hose Assembly Solutions Since 1979
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 115 volt single phase circuit. (Available in a 220
volt single phase circuit) 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-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 pendant switch bulb.
PROBLEM: CRIMP DIAMETER TOO LARGE
• Incorrect setting of the Micro-Crimp Adjuster. Check crimp specications.
(NOTE: All published machine settings are approximate. To correct for slight variances, the gauge settings may need
to be adjusted for the specic hose, tting and size combination).
• Incorrect die being used. Each die has a useable 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.
• 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 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. Use only the crimpx oil / grease shipped with the machine or a high pressure molybdenum high pressure
grease (equivalent).
• 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
• Incorrect setting of the Micro-Crimp Adjuster. Check crimp specications.
( NOTE: All published machine settings are approximate. To correct for slight variances, the gauge settings may be
adjusted for the specic hose, tting 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 RING
• Inadequate lubrication of the compression ring and die surfaces. Use only the crimpx oil / grease shipped with the machine
or a high pressure molybdenum high pressure grease (equivalent).
TROUBLESHOOTING

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Innovating SMART Hose Assembly Solutions Since 1979
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

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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS BREAKDOWN
SECTION E-E
SCALE 1 : 1
D200 DOUBLE ANGLE SERIES DIE PARTS (AI-100872)
QTYDESCRIPTIONPART NUMBERITEM
2DOUBLE ANGLE DIE RING SET100873-XX
1
88 PC DIE FINGER SETVARIES WITH THE DIE SIZE2
8DOUBLE ANGLE DIE SPRINGLC 022D 05 M3
8DOUBLE ANGLE DIE SCREWEN83-034
4
E
E
2
1
3
4
DOUBLE ANGLE DIE RING D200 SERIES
PART NUMBER DESCRIPTION
100873-BLACK D200 DOUBLE ANGLE DIE RING SET-BLACK
100873-BROWN D200 DOUBLE ANGLE DIE RING SET-BROWN
100873-CLEAR D200 DOUBLE ANGLE DIE RING SET-SILVER
100873-BLUE D200 DOUBLE ANGLE DIE RING SET-BLUE
100873-GREEN D200 DOUBLE ANGLE DIE RING SET-GREEN
100873-ORANGE D200 DOUBLE ANGLE DIE RING SET-ORANGE
100873-PURPLE D200 DOUBLE ANGLE DIE RING SET-PURPLE
100873-RED D200 DOUBLE ANGLE DIE RING SET-RED
100873-YELLOW D200 DOUBLE ANGLE DIE RING SET-YELLOW
"Length"
"Bore"

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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS BREAKDOWN
1 101585 D205 Base 1
2 101624 D205 Support Rod 2
3 90126A031 3/8 FlatWasher10
4 92865A622 3/8-16 X3/4 HexBolt4
5 101621 D205 Support Rod Brace 1
6 92865A624 3/8-16 X1 HexBolt4
7 91102A031 3/8 LockWasher4
8 95462A031 3/8-16 Nut 4
9 101634 D205 HeadAssembly1
10 101633 Pump Assembly1
11 90126A029 1/4 FlatWasher4
12 91102A029 1/4 LockWasher4
13 92865A540 1/4-20 X3/4 HexBolt4
14 60TA06X08 45Hydraulic Fitting1
15 101645 D205 Hydraulic Hose 1
16 101631 D205 CouplingStop Assembly1
17 91251A544 1/4-20 X1 1/4 SHCS 1
18 100628 Standard Micr ometerAssembly1
18 101489 DC MicrometerAssembly1
18 101587 M etric MicrometerAssembly1
19 100727 MicrometerNut 1
20 101349 PendantSwitch & Plug 1
21 101625 D205 Die ShelfAssembly (Optional)1
D205/D206 CrimperAssembly (101626)
ItemPart NumberDescription 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
1 101585 D205 Base 1
2 101624 D205 Support Rod 2
3 90126A031 3/8 FlatWasher10
4 92865A622 3/8-16 X3/4 HexBolt4
5 101621 D205 Support Rod Brace 1
6 92865A624 3/8-16 X1 HexBolt4
7 91102A031 3/8 LockWasher4
8 95462A031 3/8-16 Nut 4
9 101634 D205 HeadAssembly1
10 101633 Pump Assembly1
11 90126A029 1/4 FlatWasher4
12 91102A029 1/4 LockWasher4
13 92865A540 1/4-20 X3/4 HexBolt4
14 60TA06X08 45Hydraulic Fitting1
15 101645 D205 Hydraulic Hose 1
16 101631 D205 CouplingStop Assembly1
17 91251A544 1/4-20 X1 1/4 SHCS 1
18 100628 Standard MicrometerAssembly1
18 101489 DC MicrometerAssembly1
18 101587 Metric MicrometerAssembly1
19 100727 MicrometerNut 1
20 101349 PendantSwitch & Plug 1
21 101625 D205 Die ShelfAssembly (Optional)1
D205/D206 CrimperAssembly (101626)
ItemPart NumberDescription 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

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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS BREAKDOWN
1 100641-01 Micro Plate 1
2 100641-02 Micro Brace 1
3 100672 MicrometerBracket1
4 91253A194 8-32 x1/2 HSFHS 2
5 91251A240 10-24 x3/8 SHCS 2
6 91253A197 8-32 x3/4 HSFHS 2
7 98296A249 3/16 x3/4 SlottedSpringPin 1
Micro MountAssy (100641)
ItemPart NumberDescriptionQty
4
1
2
3
6
5
7

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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS BREAKDOWN
1 100952 Adjustable Stop Arm 1
2 94052A133 Push-on Cap 1
3 91251A540 1/4-20 x3/4 S HCS 1
4 90126A029 1/4 FlatWasher1
5 DK-655 10-24 Knob 1
6 94750A588 1/4-20 T-Nut 1
7 101525 FixedStop Arm 1
8 9489T47 10-24 Eye Bolt1
9 101632 D205 CouplingStop Rod 1
10 92383A256 1/8 x3/4 LongSpringPin 1
D205 CouplingStop Assembly (101631)
ItemPart NumberDescription Qty
9
1
5
6
7
4
3
2
8
10

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Innovating SMART Hose Assembly Solutions Since 1979
COMPONENT PARTS BREAKDOWN
D205 Head Assembly (101634)
Qty
DescriptionPart NumberItem
1
80 Ton Cone Base
1006791
4
Strain Rod
1006422
81 1/4-12 Grade 8 Hex Nut90500A0403
1Limit Switch Bracket1006614
26-32 x 3/8 SHCS91251A146
5
1Limit Switch9036
1Limit Switch Guard1006927
2
8-32 x 1/4 BHCS
91255A1908
1Micrometer Mount Assembly1006419
1Metric Micrometer Assembly10158710
1DC Micrometer Assembly10148910
1Standard Micrometer Assembly10062810
1Micrometer Nut10072711
180 Ton Top Flange10064012
1
80-Ton Cylinder Assembly
10066313
1
Pusher Suspension Pin
10064814
1
Stop Rod
10071115
1Stop Rod Locking Handle10071016
1Pusher, 100 Ton10081817
1Compression Ring10071218
1Pressure Plate10071319
280 Ton Angle Bracket10068020
4
3/8 Flat Washer
90126A03121
2
3/8 Lock Washer
91102A03122
4
3/8-16 x 3/4 Hex Bolt92865A62223
13
15
23
21
20
16
3
6
8
7
4
14
19
2
1
20
23 22
21
12
5
9
10
11
3
17
18
D205 Head Assembly (101634)
Qty
DescriptionPart NumberItem
1
80 Ton Cone Base
1006791
4
Strain Rod
1006422
81 1/4-12 Grade 8 Hex Nut90500A0403
1Limit Switch Bracket1006614
26-32 x 3/8 SHCS91251A146
5
1Limit Switch9036
1Limit Switch Guard1006927
2
8-32 x 1/4 BHCS
91255A1908
1Micrometer Mount Assembly1006419
1Metric Micrometer Assembly10158710
1DC Micrometer Assembly10148910
1Standard Micrometer Assembly10062810
1Micrometer Nut10072711
180 Ton Top Flange10064012
1
80-Ton Cylinder Assembly
10066313
1
Pusher Suspension Pin
10064814
1
Stop Rod
10071115
1Stop Rod Locking Handle10071016
1Pusher, 100 Ton10081817
1Compression Ring10071218
1Pressure Plate10071319
280 Ton Angle Bracket10068020
4
3/8 Flat Washer
90126A03121
2
3/8 Lock Washer
91102A03122
4
3/8-16 x 3/4 Hex Bolt92865A62223
13
15
23
21
20
16
3
6
8
7
4
14
19
2
1
20
23 22
21
12
5
9
10
11
3
17
18