CustomCrimp D205WB Series User manual

D205WB / D206WB Service Hose Crimper
Updated 01/2018
The D206-WB hose crimper with the Micrometer Style Adjustment and 80 ton
cylinder has the capacity to crimp hoses up to: 1-¼" 4SP (with standard EN98-020
dies) and up to 2" 4SP (with optional EN98-032 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 fittings.
• Utilizes existing NP60 and DE60 die sets.
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D205WB / D206WB SERIES HYDRAULIC CRIMPER
OPERATORS MANUAL
Large
Pusher Plate
EN98-032
Die Series
Adapter cone insert enables
you quickly to change to
EN98-020 die series

D205WB / D206WB Service Hose Crimper
2
SAFETY PRECAUTIONS
• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER.
• CRIMPER D205WB / D206WB SERIES 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
! !
MODELS COVERED:
This manual is applicable to a number of variations of the D205WB Series Crimpers.
A “Standard”, “Metric” and “DC” Micrometer is available on different models.
A 1HP-110Volt and a 2 HP-220 Volt ValPower pump are used on different models.
Crimping, calibration and repair procedures are similar.
See detailed parts breakdown at the back of the manual for parts applicable to specific models

D205WB / D206WB Service Hose Crimper
3
SAFETY PRECAUTIONS-----------------------------------------------------------------------------------------------------2
COMPONENT PARTS & TECHNICAL DATA--------------------------------------------------------------------------------------------------4
D205WB / D206WB FEATURES------------------------------------------------------------------------------------------------------------------5
INITIAL SET UP & MAINTENANCE------------------------------------------------------------------------------------------------------------6
EN98-032 DIE SERIES LUBRICATION PROCEDURE----------------------------------------------------------------------------7
EN98-020 DIE SERIES LUBRICATION PROCEDURE--------------------------------------------------------------------------8
CRIMPING WITH EN98-020 DIE SERIES-----------------------------------------------------------------------------------------------9
CRIMPING WITH EN98-030 DIE SERIES--------------------------------------------------------------------------------------------10
INCLUDED ACCESSORIES--------------------------------------------------------------------------------------------11
AVAILABLE ACCESSORIES--------------------------------------------------------------------------------------------12
TROUBLESHOOTING----------------------------------------------------------------------------------------13
COMPONENT PARTS BREAKDOWN--------------------------------------------------------------------------------------------14
CUSTOMCRIMP®“NO-NONSENSE” WARRANTY STATEMENT---------------------------------------------------------------16
CUSTOMCRIMP®CONTACT INFORMATION--------------------------------------------------------------------------------------17
TABLE OF CONTENT

D205WB / D206WB Service Hose Crimper
4
COMPONENT PARTS & TECHNICAL DATA
1HP/110V/Single
Phase pump for
fast crimps
Main Power Switch
Electrical Enclosure
CustomCrimp®
QR Code
1 Gallon Reservoir
Voltage Tag
Removable Pusher
Micrometer
Style Adjustment
Pneumatic Switch
Electronic Shut Off
17"
32"
29"
Built-in Work Lamp
Powerful 80 Ton
Hydraulic Cylinder
*Crimper capacity is estimated based on typical
1-piece fitting. Actual results may vary depending
on the fitting and hose manufacturer.
Technical Data
80 Ton
EN98-020 Dies
80 Ton
EN98-032 Dies
1-¼" - 1 - 2 Wire 2" - 1 - 2 Wire
1-¼" - 4SP 2" - 4SP
L: 32" x W: 17" x H: 29"
Weight: 305 lbs
Power: 2HP / 220V / 1Phase (Standard)
1HP / 110V / 1Phase (Optional)
Die series: EN98-020 / EN98-032
Micrometer Style Adjustment: Standard
Reservoir capacity: 1 US Gallon
Oil type: ISO 46 Hydraulic Oil
Large
Pusher Plate
1
H
P
h
fa
M
E
l
C
Q
1
V
o
P
nic
S
hut
Of
f
17"
32
"
2
9"
EN98-032 Die Series
(Not included with
the crimper unit)
Small Footprint for
minimum use of space
Die Stack with
EN98-032 Series Dies
Die Stack with
EN98-032 Series Dies
Bent Tube
Pusher Plate
Standard
Pusher Plate
Cone Insert
EN98-020 Die Series
(Not included)
Large Pusher Plate
EN98-032 Die Series
(Not included)

D205WB / D206WB Service Hose Crimper
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• The D205WB / D206WBVVV 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 shutoff 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
fitting. This feature can greatly speed up crimping on
production jobs since the ram does not have to fully
advance and retract on every cycle.
• With the EN98-032 series dies can crimp up to 1-¼"
4 spiral hose.
• With the EN98-032 series dies can crimp up to 2" 4
spiral hose.
D205WB / D206WB FEATURES

D205WB / D206WB Service Hose Crimper
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INITIAL SET UP & MAINTENANCE
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.
• Always check oil level in the D205WB 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 D205WB 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 D206WB 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.

D205WB / D206WB Service Hose Crimper
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EN98-032 LUBRICATION PROCEDURE
Photo # 3
Photo # 1
Grease Point # 1
Place a thin layer of CrimpX grease (supplied with crimper)
or a high pressure molybdenum high pressure grease
on the surface of the bottom flange.
(as shown in photo # 1).
Grease Point # 2
Before sliding the large pressure plate over the correct dies,
place a thin layer of CrimpX grease (supplied with crimper)
or a high pressure
molybdenum high pressure grease on the entire area that
dies come in contact with (as shown in photo # 2).
If Dies are sticking in the surface of the bottom flange:
Continue to lubricate / grease as explained above in addition
to lubricating each die finger individually.
(as shown in photo # 3).
Note: The die fingers must be lubricated at the positions
that come in contact with the pressure plate and the
bottom flange.
Note: Lubrication is not required before each crimp.
Typical lubrication is after 100 crimps.
Photo # 2

D205WB / D206WB Service Hose Crimper
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EN98-020 LUBRICATION PROCEDURE
Photo # 4
Photo # 1
Photo # 2
Photo # 3
Grease Point # 1
Place a thin layer of CrimpX grease (supplied with crimper)
or a high pressure molybdenum high pressure grease
on the surface of the adapter cone inert.
(as shown in photo # 1).
Grease Point # 2
Before sliding the standard pusher plate or the bent tube push-
er plate (as shown in photo # 2 and # 3) over the correct dies,
place a thin layer of CrimpX grease (supplied with crimper) or a
high pressure molybdenum high pressure grease on the entire
area that dies come in contact with
If Dies are sticking in the surface of the bottom flange:
Continue to lubricate / grease as explained above in addition
to lubricating each die finger individually.
(as shown in photo # 4).
Note: The die fingers must be lubricated at the positions
that come in contact with the pressure plate and the
bottom flange.
Note: Lubrication is not required before each crimp.
Typical lubrication is after 100 crimps.

D205WB / D206WB Service Hose Crimper
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CRIMPING WITH EN98-020 DIE SERIES
Lubricate all contact surfaces
of the cone insert and place
it squarely in the base of the
crimper.
Place the die set and
hose and fitting loosely in
the cone insert.
Use care to be certain
that the die halves do not
overlap.
Place the Pusher Plate on
top of the die set.
Slide the Pusher onto the
stud on the hydraulic ram.
Check the finished crimp diame-
ter to be certain that it is within the
hose and fitting manufacturers crimp
specification limits.
Lubricate die fingers, all contact
surfaces and die cones.
WARNING: Failure to lubricate
will cause damage to die sets
and crimper.
Alignment of the hose and
fitting in the die set is shown.
Reference hose and fitting
manufacturers specifications
for correct locations
Press and hold the start switch
until the motor shuts off.

D205WB / D206WB Service Hose Crimper
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CRIMPING WITH EN98-030 DIE SERIES
Crimping with CC032 series dies is essentially identical to crimping with the CC020 series dies except
that the Cone Insert is removed from the crimper base
Insert the die set and Pusher
Plate in the order illustrated.
Remove the Cone Insert from
the crimper base and lubricate
all contact surfaces of the die
set.
WARNING: Failure to lubricate
will cause damage to die sets
and crimper
Align the hose and coupling
as recommended. Load the
Pusher Plate and Pusher and
press and hold the start/stop
switch until the crimper shuts
off. Check the final crimp
diameter to be certain that it
is within specifications.

D205WB / D206WB Service Hose Crimper
11
Adapter cone
P/N:EN94-027-C
Bent Tube Pusher Plate
P/N:EN96-027
Standard Pusher Plate
P/N:EN97-058
Work Lamp Installed
P/N:668-02
Vent Plug
P/N:104007
(5) Screws for die series EN98-020
P/N:EN84-115
(5) Springs for die series EN98-020
№:LC 022D 01
Removable Pusher
(Included) P/N:100818
D205WB/D206WB Coupling
Stop P/N:101631
CRIMPX Lubricant Grease
4 oz can with brush (Included)
P/N:104162
Large Pusher Plate (Included)
P/N:EN94-030
Pneumatic Pendent Switch
(Included) P/N:101349
INCLUDED ACCESSORIES

D205WB / D206WB Service Hose Crimper
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D205/D206 Die Storage Shelf
(Optional) P/N:101625
Mobile Cart
(Optional) P/N:101956
AVAILABLE ACCESSORIES
Screws for die series EN98-032
P/N:EN00-061
Springs for die series EN98-032
P/N:LC 032E 04 M
CustomCrimp®Notched Digital
Caliper IN/MM P/N:CC-Caliper
Die Removal Magnet
P/N:104679

D205WB / D206WB 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 (D205WB) or a 115 volt
single phase circuit. (D206WB) 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 off 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 specifications.
(NOTE: All published machine settings are approximate. To correct for slight variances, the gauge settings may be
adjusted for the specific hose, fitting and size combination.)
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.
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 fill 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 grease shipped with the machine or 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 definite 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 specifications.
( NOTE: All published machine settings are approximate. To correct for slight variances, the gauge settings may be
adjusted for the specific hose, fitting 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 CONE
Inadequate lubrication of the compression cone and die surfaces. Use only the grease shipped with the machine
or equivalent.

D205WB / D206WB Service Hose Crimper
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COMPONENT PARTS BREAKDOWN
D205WB/D206WB Crimper Head Assembly (102263)
ITEM PART NUMBER DESCRIPTION QTY
1 100679 80-Ton Cone Base 1
2 100642 Strain Rod 4
3 90500A040 Heavy Hex Nut 1 1/4-12 Gd.8 8
4 100661 Limit Switch Bracket 1
5 91251A146 6-32 X 3/8 SHCS 2
6903 Switch Limit Switch 1
7100692 Limit Switch Guard 1
8 91255A190 8-32 X 1/4 BHCS 2
9 101995 3/8 Dia. X 5 1/2 Pin 2
10 100643 Compression Cone 1
11 100641 Micrometer Mount Assembly 1
12 100628 Standard Micrometer Assembly 1
13 100727 Micrometer Nut 1
14 100640 80-Ton Top Flange 1
15 100663 80-Ton Cylinder Assembly 1
16 100648 Pusher Suspension Pin 1
17 100711 Stop Rod 1
18 100710 Stop Rod Locking Handle 1
19 100818 Pusher 1
20 100964 Cone Reducer 1
21 100915 NP Pusher Plate 1
22 100961 WB Pusher Plate 1
23 100960 NP Bent Tube Pusher Plate 1
24 100954 Coupling Stop Assembly 1
25 100680 Mounting Bracket 2
26 90126A031 3/8 Flat Washer 4
27 91102A031 3/8 Lock Washer 2
28 92865A622 3/8-16 X 3/4 Hex Bolt 4
6
7
8
4
5
9
1
3
26
27
28
10
20
21
22
23
24
19
16
13
11
12
18
15
14
17
25
28
26
2

D205WB / D206WB Service Hose Crimper
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COMPONENT PARTS BREAKDOWN

D205WB / D206WB Service Hose Crimper
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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 benefits of this warranty, first, 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.
CustomCrimp® 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.
CUSTOMCRIMP®“NO-NONSENSE” WARRANTY STATEMENT

D205WB / D206WB Service Hose Crimper
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See the complete line of CustomCrimp®Crimpers and Accessories at:
[phone]CustomCrimp® www.customcrimp.com
CONTACT US
CustomCrimp®
Custom Machining Services, Inc.
326 N. County Rd. 400 East
Valparaiso, IN 46383
Ph: [phone]
Fax: [phone]
www.customcrimp.com
CUSTOMCRIMP®, YOUR SINGLE SOURCE FOR HOSE ASSEMBLY PRODUCTS.
Products and services to support industry wide hose assembly needs.
D205WB / D206WB Service Hose Crimper