DAYCO D105DC User manual

1Page
REPLACES DAYCO DE30 MODELS
D105DC/D100S-DC DAYCO
OPERATORS MANUAL

2Page
WARNING - SAFETY NOTE
IMPORTANT-DONOTOPERATETHISEQUIPMENTUNTILYOUREADANDFULLY
UNDERSTANDTHISMANUAL ANDITSASSEMBLYINSTRUCTIONS
ALWAYSWEAREYEPROTECTION
WARNING!!
!!
!USE ONLY THOSE HOSE AND COUPLING COMBINATIONS AND
CRIMPING EQUIPMENT SPECIFIED IN DAYCO HYDRAULIC PUBLISHED
LITERATURE. DAYCO RECOMMENDATIONSARE BASED ON TESTING,
AND USE OF HOSEAND COUPLING COMBINATIONS OTHER THAN
THOSE RECOMMENDED BY DAYCO CAN RESULT IN SERIOUS INJURY,
DEATH OR SUBSTANTIAL PROPERTY DAMAGE. DAYCO DISCLAIMSALL
LIABILITY FORANY HOSEAND COUPLINGASSEMBLY THAT IS NOT MADE
ACCORDING TO DAYCO RECOMMENDATIONS. CONSULT YOUR LOCAL
DAYCO REPRESENTATIVE OR DAYCO DISTRIBUTOR IF YOU HAVEANY
QUESTIONS.
file: D105DC/D100D-DC MarkIV Manual(Rev 4/23/2008).pmd

3Page
TABLE OFCONTENTS
PartsIdentification-----------------------------------------------------------------4
D105DC Quick Start Guide------------------------------------------------------5
D105s-DC Quick Start Guide---------------------------------------------------6
HosePreparation-------------------------------------------------------------------7
HoseCrimping-StandardDies---------------------------------------------------8
Hose Crimping-DoubleAngle Dies-------------------------------------------11
Calibration--------------------------------------------------------------------------12
Troubleshooting -------------------------------------------------------------------13
Kwikrimp®Concept--------------------------------------------------------------14
PartsBreakdown------------------------------------------------------------------15

4Page
D105DC/D100S-DCPARTSIDENTIFICATION
10,000PSI PUMP
1HP, 110V-15AMPMOTOR
35TONHYDRAULIC
CYLINDER OILFILLAND
VENTPLUG
ADJUSTABLERAM
RETRACTIONSTOP
MICRO-CRIMP
ADJUSTER
CALIBRATION
ADJUSTMENT
SCREW
MANUALPNEUMATIC
START-STOPSWITCH
AUTOMATICSTOP
SWITCH
DOUBLEANGLETOP
COMPRESSION
RING
DOUBLE
ANGLEDIESET
DOUBLEANGLE
BASE RING
STANDARD DIE
SET
STANDARD
PRESSUREPLATE
POWERON/OFF
CIRCUITBREAKER
SWITCH
STANDARD
COMPPRESSION
RING

5Page
D105DC QUICK STARTGUIDE
CALIBRATION CHECK FOR THE D105DC
(See the following page for D100S-DC Calibration)


PLUG THE CRIMPER DIRECTLY INTO A 110 VOLT 20
AMP SINGLE PHASE WALL OUTLET.
DO NOT USE AN EXTENSION CORD OR RUN FROM
PORTABLE POWER SOURCES AS LOW VOLTAGE CAN
DAMAGE THE MOTOR.


THE OIL LEVEL IN THE PUMP SHOULD BE APPROX.
1 1/2 INCHES BELOW THE FILLER/VENT PLUG.


PLACE THE STANDARD PRESSURE
PLATE, ANY STANDARD DIE SET AND THE
STANDARD COMPRESSION RING 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 “95” FOR THE D105DC


PRESS AND HOLD THE START SWITCH.


IF THE RAM EXTENDS AND SHUTS OFF 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 OFF IS NOT APPROXIMATELY
1 SECOND, THE CRIMPER MUST BE RECALIBRATED. SEE
INSTRUCTIONS.
FOLLOW THESE STEPS BEFORE YOU USE YOUR
CRIMPER FOR THE FIRST TIME
CALIBRATION CHECK PROCEEDURE

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D100S-DC QUICK START GUIDE
CALIBRATION CHECK PROCEEDURE
FOLLOW THESE STEPS BEFORE YOU USE YOUR
D100S-DC CRIMPER FOR THE FIRST TIME
CALIBRATION CHECK FOR THE D100S-DC


A HYDRAULIC POWER SOURCE CAPABLE OF
GENERATING 10,000 PSI MUST BE ATTACHED TO THE D100S-
DC CRIMPER.


PLACE THE STANDARD PRESSURE PLATE, ANY
STANDARD DIE SET AND THE STANDARD COMPRESSION
RING 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 “95” FOR THE D100S-DC


APPLY ENOUGH PRESSURE TO
THE RAM TO BRING THE DIE SET TO
THE FULLY CLOSED POSITION AND
FULLY SEAT ALL COMPONENTS.


WHEN THE DIE SET IS FULLY CLOSED AND ALL OF
THE COMPONENTS FIRMLY SEATED, THE WHITE LINE OF
THE MICRO-SITE ADJUSTER SHOULD BE JUST VISIBLE AS
SHOWN.


IF THE WHITE LINE DOES NOT APPEAR AS SHOWN
AT THE RIGHT, LENGTHEN OR SHORTEN THEADJUSTMENT
SCREW AS REQUIRED.

7Page
HOSE PREPARATION


Daycorecommendsthatall users familiarizethemselveswith Dayco’swarning
statements,SAEJ1273,and theKwikrimp®concept,foundin thisoperator’smanual.


Select the Dayco hose and coupling to be assembled.


Determinethecorrectcrimp
settingfromthecrimp specifications
sheet.


Determinehose cutlength
bysubtractingthecutofffactor for
eachcouplingfromthe overall
length of the assembly. For these
cutoff factors, see Dayco’s
publishedcatalogdata.


Cutthe hosesquareand to theproperlengthwith asuitable saw.


Coatthe coupling stemwith Dayco hoseassembly lubricant(HAL16) to easehose
insertion. Insertthe hoseuntilit “bottoms”in thecoupling shell.
To insurethatthe hoseis bottomedin thecollar,mark theinsertiondepth onthe hose
beforeinserting itintothe coupling(see figure below).
Usinga clockwisetwistingmotion orfixing thehexon thecoupling ina vise mayhelp when
tolerancesare tight.

8Page
D100 SERIES HOSE CRIMPING
CRIMPING WITH STANDARD DIES


InserttheStandardPressurePlateinthebottomflangemaking
certainthatthePressure Plate isseatedsquarelyinthe bottomflange.
Make certain that the seating area of the bottom flange is clean and
allows the Pressure Plate to seat squarely in the bottom flange


Selectthecorrectdiesetforthecombinationofhoseandfitting
beingcrimped.
Thenumber etchedon the die ring representsthe fullyclosed diameter
of the die set in either inches or millimeters depending upon the die
set.


Lubricate the contact surfaces of the die fingers and the
CompressionRing withthedielubricantfurnishedwiththecrimper.
Failure to lubricate the contact surfaces with the correct lubricant
can cause the dies to seize in the compression ring.


Alignthehose andfittingin thedie set. If thefitting has knurl
marks, align as shown. If there are no knurl marks on the fitting,
obtainthecorrectcrimplengthfromthecrimpspecificationchartand
markthefittingatthe properpoint.
CAUTION: The notches on the die set must be
completelycoveredbythe CompressionRingprior
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 personal
injury

9Page
D100 SERIES HOSE CRIMPING


Positionthedies inthecrimper asshownmaking certainthat
the die rings set squarely on the pressure plate and that the die ring
halves do not overlap each other.


Align the hose and fitting in the die set and place the
Compression Ring loosely over the die set. Manually depress the
compressionring untilthe fittingis heldloosely inthe dieset.


Selectthe propercrimp setting from the CrimpSpecification
chartandset theMicroCrimp adjusteratthe settingrecommended.
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 fitting manufacturer’s
recommendation for the correct die set to use.

10Page
D100 SERIES HOSE CRIMPING
COUPLINGSTOP RAMRETRACTIONSTOP


SlidethePusherinto position onthehydraulicram


Recheck the fitting for correct alignment and depress the
pneumaticStart/Stopswitchbulb. Keepitdepresseduntilthecrimper
shutsoffautomatically.


FortheD100S-DC,bringthePusherdownuntilthewhiteMicro-
Site line just appears on the micrometer and release the pressure
sourceallowingthe Pushertoretract.


Measure the finished fitting diameter to
becertainthatit iswithinthecrimpspecification
tolerances.


Checkthe diameterofthe finishedcrimp
to be certain that it is within the hose and fitting
manufacturer’sspecifications.


Ifmultiple fittingsarebeingcrimped setthe CouplingStopto
automaticallyposition thefitting andset theRam RetractionStop to
limitthe ram retractionto thepositionwhere thehoseand fittingcan
just be easily removed.
Magnetsembedded inthePusher willretractthe CompressionCone
withthe Pusherwhile still permittingthe CompressionCone toalign
correctlyforthenextcrimpingoperation.

11Page
CRIMPINGWITH DOUBLEANGLE DIES
CRIMPING WITH DOUBLE ANGLE DIES
Double Angle dies double the radial crimping force of the die set
allowing heavier fittings to be crimped. Due to the doubling of the
radial crimp force, they are effective for a smaller range of diameters
thanastandarddieset. Also,the fittingmustbeapproximately centered
axially along the crimping face to avoid taper in the final crimp.


Remove the standard flat Pressure Plate and replace it with
theDBLBASEbottom compressionring.
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
compressionringsandtheoutersurfacesofthe double angledieswith
thedielubricantfurnishedwiththecrimper.


Seattheappropriate size doubleanglediein theconicalrecess
of the DBL BASE lower compression ring and align the fitting as
specifiedby the hosemanufacturer.


PlacetheDBL TOPcompressionring on topofthe diesetand
manuallycompress thedieset untilit contactsthefitting.


SlidethePusherontothecylinderstudandsettheMicro-Crimp
Adjusterattheappropriate setting.


PressandholdtheStart/Stopswitchuntilthecrimpershutsoff.
For the D100S-DC, bring the Pusher down until the Micro-Site ring
justappearson the micrometer.


When the crimp cycle is complete, check the fitting diameter
tomakecertainthatitiswithinthehosemanufacturer’sspecifications.

12Page
CALIBRATION PROCEDURE
Whenthecrimperiscorrectlycalibrated,theramwillextendandfully
closethe dieset. Afterthe dieset isfully closed, the time fromwhich
the pump starts to build pressure and the point at which the motor
shutsofautomatically willbeapproximately1 second.
Many problems associated with incorrect crimp diameters are caused
by incorrect calibration.
CALIBRATION


Insertthe StandardPressurePlate, anydie
set, and the compression ring in the order
illustrated.


SettheMicro-Crimp adjusterat“95”


Pressandhold thestartSwitch


Iftheram extends closingthedies totheirfullyclosed position
andthemotor shutsoffapproximately1 secondafterthepump starts
tobuildpressure(thesoundofthepumpwillchange),thenthecrimper
iscorrectlycalibrated.
Note:forD105S-DC calibration,see QuickStart Guide


If the crimper requires re-calibration, hold the
micrometer barrel with a 5/16 inch open end wrench and
rotate the stem eitherin or out with a 5/32 inch hex key.
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
stemin slightly.


Recheckcalibration.

13Page
TROUBLESHOOTING
PROBLEM: CRIMPERWILLNOTRUNATALL


The white rockerswitch is also a circuit breaker. Check to see that the circuit breaker has
notbeentripped


Checkthewall outlet. Thecrimpercomesfromthefactory wired fora110 voltsinglephase
circuit. .Use of extension cords or outlets with inadequate power can damage the motor . Do
not runthecrimperfroma portable powersource.


Checkthestopswitchmountedtotheswitch bracket underthe Micro-CrimpAdjuster. This
isa normallyclosed switch and if it doesnot close the crimperwill notoperate.
CAUTION: Do not operate the crimper with this switch jumpered as the pump will not shut off
and the brackets can be damaged.


Checkthe pneumaticallyactuated switchin theelectrical boxmounted onthe motor. This
switchcontrolspowerto the motorandisactuatedwith air pressurefromthebulbon theendof
the hose going into the box
PROBLEM: CRIMPDIAMETER TOOLARGE


Checkcrimpercalibrationandre-calibrateifrequired.


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.


Incorrectsettingof theMicro-CrimpAdjuster. Checkhosemanufacturer’s specifications.


Inadequatepumppressure. Checkoillevelin thepump. Itshouldbe1-1/2to2 inchesbelow
thefill plug. Replenish withISOViscosityGrade 46hydraulicoil.


Inadequatelubrication ofthe diesand compressionring causing thepump towork harder
thannormaltoreachtherequired diameter.


Inadequate pressure being generated by the pump. This is most likely if the crimper can
crimpthesmallersizehosesandnotthelargerhoses. Whencorrectlyadjusted,thepumpshould
generateapproximately 10,000psi.
Do Not adjust pump to produce in excess of 10,000 psi as damage to components or personal
injury may result


Nopressurebeing generatedbythe pump. There shouldbea definitechangein pitch ofthe
pumpas itcyclesinto highpressure modeand beginsto“work” harder.
PROBLEM:CRIMP DIAMETERTOOSMALL


Checkcrimpdiameter andre-calibrateif necessary


Incorrectdie beingused(See dierange underCrimp Diameter tooLarge)


Incorrectsettingof theMicro-CrimpAdjuster. Checkhosemanufacturer’s specifications.
PROBLEM: DIES STICKING IN COMPRESSION RING


Inadequatelubricationof the compressionringand diesurfaces.

14Page
KWIKRIMP® CONCEPT
THE KWIKRIMP® CONCEPT IS AN ENGINEERED PROGRAM, DESIGNED TO
INCORPORATE DAYCO HOSE, FITTINGS AND CRIMPERS INTO ONE EFFECTIVE AND
RELIABLE HOSE ASSEMBLY SYSTEM.
The Kwikrimp® Concept is an affirmation to all Dayco Distributors, OEMs and users of the
Kwikrimp® system that Dayco will support only those who use Dayco hose and couplings in the
Kwikrimp® assembly system. However, the Kwikrimp® Concept is also a statement that serves to
warn that Dayco will not be responsible when interchanging a Dayco hose and/or couplings with
hose and/or couplings of any other manufacturer. Dayco products are part of an engineered
system, which must be assembled and used in accordance with Dayco instructions and limitations.
Dayco hose, couplings and crimping machines are designed into an effective and reliable assembly
system and the use of other than Dayco products may produce hose assemblies that will not meet
rated performance. Failure to follow Dayco instructions and limitations could lead to premature
hose failures resulting in property damage, serious injury or death.
Dayco’s limited warranty shall apply only if the customer uses hose, fittings, hose fitting
components and crimp equipment specifically engineered, designed and produced to Dayco
process specifications.
DAYCO DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY CRIMPED HOSE
ASSEMBLIES NOT PRODUCED FROM GENUINE DAYCO HOSE FITTINGS, HOSE AND
EQUIPMENT, IN CONFORMANCE WITH DAYCO PROCESS SPECIFICATIONS FOR EACH
SPECIFIC HOSE ASSEMBLY.
The argument that hoses branded with identical SAE numbers are the same and can be
interchanged with Dayco couplings is not true! Hose with identical brand can be expected to
perform only to the requirements of SAE when assembled with compatible couplings. SAE
recognizes this fact as shown by the following statement taken from the 1998 SAE Handbook,
J1273, Volume 2, and page 22.198.
3.10 Proper End Fitting – Care must be taken to insure proper compatibility exists between
the hose and coupling selected based on the manufacturer’s recommendations substantiated by
testing to industry standards such as SAE J517.
All Dayco distributors, OEMs and Kwikrimp® users must recognize that the following points are
critical when considering any and all aspects of the Kwikrimp® program.
1. The data supplied with each Crimper was developed after extensive impulse testing with
Dayco hose and couplings. All Dayco hose styles are tested with the proper Kwikrimp® couplings
before they are added to the Dayco Approved List. Dayco is constantly checking and upgrading
hose quality.
2. Dayco Kwikrimp® data does not apply to all hose and couplings, only those products
bearing the Dayco identification with the proper Dayco catalog number.
Dayco couplings used with other than Dayco branded hose will not necessarily produce a good
assembly. Identical hose styles, made by different suppliers, are not the same when it comes to
performance with Dayco couplings.

15Page
1
2
43
4
31
2
COMPONENT PARTS BREAKDOWN
D100 Standard Series Dies
1) Die Ring 101065-COLOR
2) Die Finger Varies with die set
3) Die Spring LC 022D 01 M NF
4) Die Screw EN84-115
D100 DA(Double Angle Dies
1) Die Ring 101072-COLOR
2) Die Finger Varies with Die Set
3) Die Spring LC 022D 05 M MD
4) Die Screw EN84-115
NotShown:
DA Cone Insert 100880
DATop Cone 100881
ColorOptions
Red
Orange
Yellow
Purple
Green
Blue
Black
Silver
Brown

16Page
COMPONENT PARTS BREAKDOWN

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COMPONENT PARTS BREAKDOWN

18Page
6
5
4
3
2
1
1100325 (Yellow) Bottom Flange 1
2100329 Strain Rod - 8 1/2" 4
3100326 (Yellow) Top Flange 1
43/4 Special 3/4 Flat Washer - Special 4
595462A538 3/4-10 Hex. Nut 4
6100685 35-Ton Cylinder Assembly 1
Item Part Number Description Qty
35-Ton Head Sub-Assembly (101209)
COMPONENT PARTS BREAKDOWN

19Page
COMPONENT PARTS BREAKDOWN

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COMPONENT PARTS BREAKDOWN