DAYCO D206DC User manual

1Page
REPLACES DAYCO DE60 MODELS
D206DC-DAYCO OPERATORS MANUAL

2Page
WARNING - SAFETY NOTE
IMPORTANT-DONOTOPERATETHISEQUIPMENTUNTILYOUREADANDFULLY
UNDERSTANDTHISMANUALANDITSASSEMBLYINSTRUCTIONS
ALWAYSWEAREYEPROTECTION
WARNING!!
!!
!USE ONLYTHOSE HOSEAND COUPLING COMBINATIONSAND
CRIMPING EQUIPMENT SPECIFIED IN DAYCO HYDRAULIC PUBLISHED
LITERATURE. DAYCO RECOMMENDATIONS ARE BASED ON TESTING,
AND USE OF HOSEAND COUPLING COMBINATIONS OTHER THAN
THOSE RECOMMENDED BY DAYCO CAN RESULT IN SERIOUS INJURY,
DEATH OR SUBSTANTIALPROPERTY DAMAGE. DAYCO DISCLAIMSALL
LIABILITY FORANY HOSEAND COUPLING ASSEMBLY THAT IS NOT MADE
ACCORDING TO DAYCO RECOMMENDATIONS. CONSULTYOUR LOCAL
DAYCO REPRESENTATIVE OR DAYCO DISTRIBUTOR IF YOU HAVEANY
QUESTIONS.
file: D205DC MarkIV Manual(Rev 4-20-2005).pmd

3Page
TABLE OFCONTENTS
PartsIdentification------------------------------------------------------------------4
QuickStartGuide-------------------------------------------------------------------5
HosePreparation--------------------------------------------------------------------6
HoseCrimping-Standard Dies---------------------------------------------------7
Hose Crimping-DoubleAngle Dies--------------------------------------------10
Calibration---------------------------------------------------------------------------11
Troubleshooting-------------------------------------------------------------------12
Kwikrimp®Concept--------------------------------------------------------------13
PartsBreakdown------------------------------------------------------------------14
LimitedWarranty------------------------------------------------------------------21

4Page
D206DC-MARKIVPARTSIDENTIFICATION
10,000PSI PUMP
1HP, 110V-15AMPMOTOR
80TONHYDRAULIC
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
D206DC QUICK START GUIDE
RETAINING
SCREW(1/8HEXKEY)


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 SETAND 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 D206DC


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

6Page
HOSE PREPARATION


Daycorecommendsthatall users familiarize themselveswithDayco’s warning
statements,SAEJ1273,and the Kwikrimp®concept,foundinthisoperator’smanual.


Select the Dayco hose and coupling to be assembled.


Determinethecorrectcrimp
settingfromthecrimp specifications
sheet.


Determinehose cutlength
bysubtractingthecutofffactorfor
eachcouplingfromthe overall
length of the assembly. For these
cutoff factors, see Dayco’s
publishedcatalogdata.


Cutthe hosesquareandtothe properlength withasuitable saw.


Coatthe couplingstem withDayco hoseassembly lubricant(HAL16) toease hose
insertion. Insertthe hose untilit“bottoms” inthecoupling shell.
To insure thatthehose isbottomed inthecollar,mark the insertiondepth onthehose
beforeinserting it intothecoupling (seefigurebelow).
Usinga clockwise twistingmotionor fixingthehex on thecouplingin avisemay helpwhen
tolerancesare tight.

7Page
D206DC HOSE CRIMPING
CRIMPING WITH STANDARD DIES


InserttheStandardPressurePlateinthebottomflangemaking
certainthatthePressurePlate is seatedsquarelyinthebottomflange.
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


Selectthecorrectdiesetforthecombinationofhoseandfitting
beingcrimped.
Thenumber etchedon the diering representsthe fully closeddiameter
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 andfittinginthe dieset. Ifthefitting has knurl
marks, align as shown. If there are no knurl marks on the fitting,
obtainthecorrectcrimplengthfromthecrimpspecificationchartand
markthefittingattheproper point.
CAUTION: The notches on the die set must be
completelycoveredbytheCompression Ringprior
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

8Page
D206DC HOSE CRIMPING


Positionthedies inthecrimperasshown makingcertainthat
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 untilthefitting isheld loosely inthe dieset.


Selectthe propercrimp setting fromthe CrimpSpecification
chartandset theMicroCrimpadjuster at thesettingrecommended.
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.

9Page
D206DC HOSE CRIMPING


SlidethePusherintoposition on thehydraulicram


Recheck the fitting for correct alignment and depress the
pneumaticStart/Stopswitchbulb. Keepitdepresseduntilthecrimper
shutsoffautomatically.


Measure the finished fitting diameter to be certain that it is
withinthecrimpspecificationtolerances.


If multiple fittings are being crimped set the coupling stop to
automatically position the fitting and set the retraction stop to limit
the ram retraction to the position where the hose and fitting can just
be easily removed.


Checkthediameterofthefinishedcrimp to becertainthatitis
withinthehoseandfittingmanufacturer’sspecifications.

10Page
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,thefittingmustbe approximatelycentered
axially along the crimping face to avoid taper in the final crimp.


Remove the standard flat Pressure Plate and replace it with
theDBLBASEbottom compression ring.
The bottom Pressure Plate is 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
compressionringsandtheoutersurfacesofthedoubleangledieswith
thedielubricantfurnishedwiththecrimper.


Seattheappropriatesize doubleangledieintheconical recess
of the DBL BASE lower compression ring and align the fitting as
specifiedby the hosemanufacturer.


Placethe DBLTOP compressionringon topof
the die set and manually compress the die set until it
contactsthefitting.


Slide the Pusher onto the cylinder stud and set
theMicro-CrimpAdjusterattheappropriatesetting.


Press and hold the Start/Stop switch until the
crimpershutsoff.


When the crimp cycle is complete, check the
fittingdiametertomakecertainthatitiswithinthehosemanufacturer’s
specifications.

11Page
CALIBRATION PROCEDURE
Whenthecrimperiscorrectlycalibrated,theram willextendandfully
closethe dieset. Afterthedie set is fullyclosed, the timefromwhich
the pump starts to build pressure and the point at which the motor
shutsofautomatically will beapproximately1second.
Many problems associated with incorrect crimp diameters are caused
by incorrect calibration.
CALIBRATION


Insertthe StandardPressurePlate,anydieset,
andthecompressionringin theorderillustrated.


SettheMicro-Crimp adjusterat“95”


Pressandhold thestartSwitch


Iftheramextendsclosing thediestotheirfully
closedposition andthemotor shutsoffapproximately 1second after
thepumpstartstobuildpressure(thesoundofthepumpwill change),
thenthecrimperiscorrectly calibrated.


Ifthecrimperrequiresre-calibration,holdthe
micrometerbarrelwitha 5/16inchopenendwrench
androtatethestemeither in oroutwitha5/32inhex
keywrench.
If the time from which the pump starts to build
pressure is greater than approximately 1 second,
rotatethestem outslightly.
Ifthetimeislessthanapproximately1second,rotate
the stem in slightly.


RecheckCalibration

12Page
TROUBLESHOOTING
PROBLEM: CRIMPERWILLNOTRUNATALL


The white rockerswitch is also a circuit breaker. Check to see that the circuit breaker has
notbeentripped


Checkthewall outlet. Thecrimpercomesfrom thefactorywiredfora110voltsingle phase
circuit. .Use of extension cords or outlets with inadequate power can damage the motor . Do
not runthecrimperfromaportable power source.


CheckthestopswitchmountedtotheswitchbracketundertheMicro-CrimpAdjuster. This
isa normallyclosed switch andif it doesnot close the crimper willnot operate.
CAUTION: Do not operate the crimper with this switch jumpered as the pump will not shut off
and the brackets can be damaged.


Checkthe pneumaticallyactuatedswitch intheelectrical boxmounted on themotor. This
switchcontrolspowertothe motor andisactuatedwithairpressurefromthebulb on theendof
the hose going into the box
PROBLEM: CRIMPDIAMETER TOO LARGE


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.


Incorrect settingof theMicro-CrimpAdjuster. Checkhosemanufacturer’sspecifications.


Inadequatepumppressure. Checkoillevelinthe pump. It shouldbe1-1/2to2inchesbelow
thefillplug. Replenish withISOViscosity Grade46hydraulicoil.


Inadequatelubrication ofthedies andcompressionring causingthepump toworkharder
thannormaltoreachtherequireddiameter.


Inadequate pressure being generated by the pump. This is most likely if the crimper can
crimpthesmallersizehosesandnotthelargerhoses. Whencorrectlyadjusted,thepumpshould
generateapproximately 10,000 psi.
Do Not adjust pump to produce in excess of 10,000 psi as damage to components or personal
injury may result


Nopressurebeing generated bythepump. Thereshould be adefinitechangein pitch ofthe
pumpas it cyclesintohigh pressuremode andbeginsto “work” harder.
PROBLEM:CRIMP DIAMETER TOOSMALL


Checkcrimpdiameter andre-calibrateifnecessary


Incorrectdie being used(Seedie rangeunderCrimp DiametertooLarge)


Incorrect settingof theMicro-CrimpAdjuster. Checkhosemanufacturer’sspecifications.
PROBLEM: DIES STICKING IN COMPRESSION RING


Inadequatelubricationof the compressionringanddiesurfaces.

13Page
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.

14Page
1
2
43
4
31
2
COMPONENT PARTS BREAKDOWN
D200 Standard Series Dies
1) Die Ring 100753-COLOR
2) Die Finger Varies with die set
3) Die Spring LC 026 06 M
4) Die Screw EN82-004
ColorOptions
Red
Orange
Yellow
Purple
Green
Blue
Black
Silver
Brown
D200 DA (Double Angle Dies
1) Die Ring 100873-COLOR
2) Die Finger Varies with Die Set
3) Die Spring LC 022D 05 M
4) Die Screw EN83-034
NotShown:
DA Cone Base
Insert 100870
DATopComp. Cone 100871

15Page
18
12
13
19
2
14
16
6
3
8
7
5
4
3
9
17
1
6
3
10
15
11
1101585 D205 Base 1
2101624 D205 Support Rod 2
390126A031 3/8 Flat Washer 10
492865A622 3/8-16 X 3/4 Hex Bolt 4
5101621 D205 Support Rod Brace 1
692865A624 3/8-16 X 1 Hex Bolt 4
791102A031 3/8 Lock Washer 4
895462A031 3/8-16 Nut 4
9101634 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 45T
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 101349 Pendant Switch & Plug 1
19 101625 D205 Die Shelf Assembly (Optional) 1
D205/D206 Crimper Assembly (101626)
Item Part Number Description Qty
3
7
8
COMPONENT PARTS BREAKDOWN
D206DC 1 HP110V CRIMPER

16Page
1100679 80 Ton Cone Base 1
2100642 Strain Rod 4
390500A040 Heavy Hex Nut 1 1/4-12 Gd.8 8
4100661 Limit Switch Bracket 1
56_32X375SHCS 6-32 X 3/8 SHCS 2
6903 Switch Limit Switch 1
7100692 Limit Switch Guard 1
891255A190 8-32 X 1/4 BHCS 2
9100641 Micrometer Mount Assembly 1
10 100628 Standard Micrometer Assembly 1
10 101489 DC Micrometer Assembly 1
10 101587 Metric Micrometer Assembly 1
11 100727 Micrometer Nut 1
12 100640 80 Ton Top Flange 1
13 100663 80-Ton Cylinder Assembly 1
14 100648 Pusher Suspension Pin 1
15 100711 Stop Rod 1
16 100710 Stop Rod Locking Handle 1
17 100818 Pusher 1
18 100712 Compression Cone 1
19 100843 Retaining Clip 2
20 91251A540 1/4-20 X 3/4 SHCS 2
21 100713 Pressure Plate 1
22 100680 Mounting Bracket 2
23 90126A031 3/8 Flat Washer 4
24 91102A031 3/8 Lock Washer 2
25 92865A622 3/8-16 X 3/4 Hex Bolt 4
D205 Head Assembly (101634)
Item Part Number Description Qty
13
15
25
23
22
16
3
6
8
7
4
17
14
19
20
18
21
2
1
22
25 24
23
12
5
9
10
11
3
COMPONENT PARTS BREAKDOWN

17Page
1 100636 Top Cap 1
2 100653 Retaining Plug 1
3 90962A357 1/4 X 2 Roll Pin 1
4100760 Spring (21 Coils) 1
5 100637 Cylinder Ram - 80 Ton 1
6 450 Polypak 4-1/2 X 4 X 3/8 Polypak 1
7 227 O-Ring 227 O-Ring - Disogrin 1
8 100635 End Cap 1
9 91251A424 3/8-24 X 1 SHCS (Gd. 8) 6
10 157 O-Ring 157 O-Ring - Disogrin 1
11 GP2C04500-T47 Ram Wear Ring 1
12 100639 Cylinder Body - 80 Ton 1
13 GR2B03750-T47 Ram Guide Wear Ring 1
14 375 Wiper Wiper (SH940-35) 1
15 100663-REPAIR Seal Repair Kit (Not Shown) 1
Item Part Number Description Qty
80 Ton Cylinder Assy (100663)
31
2
10
11
6
5
7
8
9
14
13
12
COMPONENT PARTS BREAKDOWN

18Page
1101435 1 Gallon Reservoir 1
1101336 2 Gallon Reservoir 1
2 101358 015 Buna 70 O-Ring Seal 4
3 101432 Reservoir Standoff 4
495462A525 1/2-20 Hex Nut 4
5 101395 1HP/2HP Pump Sub-Assembly 1
6 101470 Square Shaft Key 1
7 116259 1HP Electric Motor 1
7 116260 2HP Electric Motor 1
8 101338 3/8-16 x 7/8 SHCS 4
9 101339 1/4-20 x 1/2 SHFCS 10
10 101377 3/8-18 NPTF Pipe Plug 1
11 101378 3/8-18 NPT Shipping Plug 1
12 101341 3/8-18 NPT Vented Filler Cap (Shipped Loose) 1
13 101438-110 110V Electrical Enclosure 1
13 101438-220 220V Electrical Enclosure 1
14 91251A540 1/4-20 x 3/4 SHCS 2
15 90126A029 1/4 Flat Washer 4
16 90675A029 1/4-20 KEPS Nut 2
Pump Assembly (101633)
Item Part Number Description Qty
7
16
13
611 9
10
5
12
8
4
2
3
1
14
15
COMPONENT PARTS BREAKDOWN
110V1 HPPUMP

19Page
Motor Gasket 1 121300
5 101329 Reservoir Gasket 1 121305
6 101400 Upper Plate 1 151300
7 101375 1/16-27 NPTF Pipe Plug 5
8 9528K15 Ø1/4" Precision Ball 2 350301
9 101340 1/4-20 X 2 1/4 Serrated Hex FLHCS 4 345307
10 101477 Lower Plate & Gear Pump Ass'y. 1 200467
11 101406 Wear Washer 2 364300
12 101425 Eccentric - 5/8" Shaft 1 190300
13 101473 Bearing Sleeve Assembly 1 349200
14 101382 1/8 X 3/8 Dowel Pin 4 342301
15 101478 Piston Block Assembly 2 200215
16 101352 010 O-Ring 4354313
17 101476 Unloading Block Assembly 1 200346
18 101355 014 Disogrin O-Ring 3 354302
19 101443 Dump Block Assembly 1 200203
20 92323A525 1/4-20 X 2" Serrated Hex FLHCS 8 345306
21 101385 1/4-20 X 2 1/2 Serrated Hex FLHCS 4345308
22 101328 CR-6247 Shaft Seal 1 355303
Item Part Number Description Qty Ref. Part No.
1 HP/2 HP Pump Sub-Assembly (101395)
414 122
5
6
11 15
16
12
13
11 10
21
20
20
19
2
9
8
17
18
7
7
3
1 101335 Reservoir Cover 1 132301
2 101337 Port Block Gasket 1 121304
3 101584 Port Block Assembly 1
4 101330
COMPONENT PARTS BREAKDOWN

20Page
Driver Shaft - 5/8 1
10 101379 Retaining Ring 4
11 98381A470 1/8 X 3/8 Dowel Pin 2
12 101361 Gear - 5/8 2
13 101410 Center Gear Plate - 5/8 1
14 101409 Lower Gear Plate 1
15 BA88ZOHX Needle Roller Bearing 2
16 4534K42 1/4-18 NPTF Pipe Plug 1
17 92316A552 1/4-20 X 2 1/2 Hex Flg. Hd. Screw 4
18 101419 Screen 1
19 90272A827 10-32 X 3/8 Phillips Pan Hd. Mach. Screw 2
Item Part Number Description Qty
Lower Plate & Gear Pump Assembly (101477)
1
2
3
4
5
6
7
8
10 11
12
9
10
10
11
12
10
13
15 14
16
17 18
19
1 101401 Lower Plate - 2 Piston 1
2 101466 Intake Seat Assembly 2
3 9528K11 Ø 1/8 Precision Ball 2
4 101447 Ball Retainer 2
5R10 - Open 5/8 Ball Bearing 1
6 4534K39 1/16-27 NPTF Pipe Plug 1
7 98381A510 3/16 X 1 Dowel Pin 2
8 101446 Idler Shaft - 5/8 1
9 101426
COMPONENT PARTS BREAKDOWN