CRIMPX Die Lubricant

D160-T420 / D165-T420 SERIES HYDRAULIC HOSE CRIMPER OPERATORS MANUAL

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SAFETY PRECAUTIONS

• READ INSTRUCTIONS AND IDENTIFY ALL COMPONENT PARTS BEFORE USING CRIMPER

• CRIMPER CAN PRODUCE 60 TONS OF 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 different variations of the D160-T420 Series and D165-T420 Series Crimpers.

Crimping, calibration and repair procedures are similar for all models.

Rev 12/29/2016

For Parts and Service, Contact:Custom Machining Services, Inc.

Valparaiso, In 46383(219) 462-6128

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COMPONENT PART IDENTIFICATION

Small Footprint for minimum use of space

Powerful 62 Ton Hydraulic Cylinder

Adjustable Retraction Stop

T420 Rubber Caged Die Series

Removable Pusher

Easy Adjustable T420 Micrometer

10-¼"

17"

18-½"

Technical Data62 Ton1-¼" - 1 - 2 Wire1-¼" - 4SPL: 17" x W: 10-¼" x H: 18-½"Weight: 85 lbsMicrometer Style Adjustment: T420Die Series: T420 Rubber Caged Hand Pump Pneumatic Pump Multi-Electric Pump

Available Pumps:

Adjustable Calibration Screw

CustomCrimp® QR Code

High strength frame for better stability and performance

Die Orientation Decal

T420 Pressure Plate

T420 Pressure Plate

Powerful 62 Ton Hydraulic Cylinder

1HP/110V/Single Phase pump for fast crimps

Main Power Switch

Electrical Enclosure

Reservoir

Pneumatic Pendent Switch

Removable Pusher

T420 Rubber Caged Die Series

13"

22-½"

22-½

"

Adjustable Retraction Stop

T420 Micrometer Fully Adjustable

Electronic Shut Off

D165-T42062 Ton1-¼" - 1 - 2 Wire1-¼" - 4SPL: 22-½" x W: 13" x H: 22-½"Weight: 154 lbsPower: 1HP/110V/1Phase (Standard)

2HP/220V/1Phase (Optional)Micrometer Style Adjustment: T420Die series: D160-T420 Rubber CagedReservoir capacity: 1 US GallonOil type: ISO 46 Hydraulic Oil

Small Footprint for minimum use of space

CustomCrimp® QR Code

Die Orientation Decal

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ACCESSORIES

Flexible 24" Work Lamp(Optional) P/N:1668-02For D165-T420 Series

D165 Coupling Stop (Included) P/N:100954

Die Storage Drawer(Optional) P/N:104650Dies sold separately

Crimper shown mounted on the Die Storage Drawer

Pneumatic Pendent Switch (Included) P/N:101349

ValPower® Hand Pump10,000 psi (Optional)

P/N:VHP-10-43

ValPower® Pneumatic Pump 10,000 psi (Optional)

P/N:VAP-10-100

T420 Micrometer (Included)P/N:103085

ValPower® Multi-Electric Pump (Optional)

CRIMPX Die Lubricant: Grease 4 oz can with brush

(Available) P/N:104162

T420/D Series Die Removal Magnet(Included) P/N:104679

Die Storage Shelf(Optional) P/N:101431

CRIMPX Die Lubricant: Oil 4 oz bottle with dauber cap

(Included) P/N:103886

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CALIBRATION CHECK PROCEDURE

T420 MICROMETER

• Plug the D165-T420 crimper directly into a 110 volt wall outlet. CAUTION: DO NOT RUN THE CRIMPER ON AN EXTENSION CORD AS LOW VOLTAGE CAN DAMAGE THE MOTOR.

• Oil level in the D165-T420 pump should be 1-1/2 to 2 inches below the fi ll plug and should be visible in the sight glass window of the pump reservoir

• Check to be certain that the shipping plug in the pump reservoir has been replaced with the Oil Fill and Vent Plug shipped with the crimper.

• Place any Die Set and the Pressure Plate in the crimper bottom fl ange in the order shown. (A hose and fi tting are not required for a calibration check) • Lubricate the die set as shown in Crimping Instructions.

NOTE: FAILURE TO LUBRICATE THE DIE SET AND COMPRESSION CONE COULD RESULT IN THE DIE SET SEIZING IN THE COMPRESSION CONE.

• Slide the Pusher onto the stud on the hydraulic cylinder.

• Set the Micrometer at “0”.

• Depress and hold the Start/Stop switch on the D165-T420 Series or continue to apply pressure to the D160-T420 Series until the Die set is completely closed and oil pressure has built up in the hydrau-lic cylinder.

• For the D165-T420 Series: If the ram extends and shuts off the motor approximately 1 second after the die fi ngers are completely closed and the pump builds pressure (The sound of the pump will change) the crimper is correctly calibrated.

• For the D160-T420 Series: If the micro site indicator (white line) is just visible as shown in the il-lustration after the dies are completely closed and pressure has built up in the hydraulic cylinder the crimper is correctly calibrated.

• If the above conditions are not met, the crimper must be recalibrated. See calibration instructions on P 10.

FOLLOW THESE STEPS BEFORE USING THE CRIMPER FOR THE FIRST TIME

Micro site Indicator

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D165-T420 / D160-T420 LUBRICATION PROCEDURE

Photo # 1

Photo # 2

Grease Point # 1Place a thin layer of CrimpX oil (supplied with crimper) or a high pressure molybdenum high pressure grease on the surface of the bottom fl ange (as shown in photo # 1).

Grease Point # 2 Before sliding the pressure plate or the notched pressure plate over the correct dies, place a thin layer of CrimpX oil (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 fl ange: Continue to lubricate / grease as explained above in addition to lubricating each die fi nger individually (as shown in photo # 3).

Note: The die fi ngers must be lubricated at both positions that come in contact with the pressure plate and the bottom fl ange.

6Photo # 3

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D165-T420 / D160-T420 CRIMPING PROCEDURE

Make certain that the cone base is clean and lubricated prior to inserting the die set.

Select the correct die set for the hose-fi tting combination from the manufacturers specifi cation sheet.

Lubricate the die fi ngers with CrimpX Oil furnished with the crimper.

Place the lubricated die set squarely in the cone base as shown.

Align the fi tting in the die set according to the hose and fi tting manufacturers recommendation.

Place the Compression Plate over the die set and compress the die set by hand to hold the hose and fi tting in place. See micrometer setting example.

Slide the Pusher onto the stud on the ram and press the start stop switch or apply pressure to the D160-T420 series. The crimper will shut off when the crimp cycle is complete.

When the crimp is complete in the D160-T420 series, a white indicator line will be visible.

Check the fi nal crimp diameter to confi rm that it is within manufacturers specifi cations.

Micrometer Setting Example: With a 30mm die and the micrometer set at 3.0mm, the fi nal crimp diameter will be 33mm (30mm + 3mm)

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WHEN USING THE NOTCHED PRESSURE PLATE, FOR USE WITH 90 DEGREE FITTING ONLY, FOLLOW THESE PROCEDURES

Make certain that the cone base is clean and lubricated prior to inserting the die set.

Select the correct die set for the hose-fi tting combination from the manufacturers specifi cation sheet

Lubricate the die fi ngers with CrimpX Oil furnished with the crimper.

Check the fi nal crimp diameter to confi rm that it is within manufacturers specifi cations.

Align the fi tting in the die set according to the hose and fi tting manufacturers recommendation.

Place the Notched Pressure Plate over the dies so that the notched compression plate is covering all 8 die fi ngers (as shown).

Place the pusher onto the retaining ring as shown. Once the correct micrometer setting is set press the start/stop switch. (Apply pressure on D160-T420 series).

Place the lubricated die set squarely in the cone base as shown. Make sure the split of the die cages is facing the operator (as shown).

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DO NOT MISALIGN NOTCHED PRESSURE PLATE OR DAMAGE WILL OCCUR

1. Die split must face operator.

2. Notched Pressure Plate needs to cover all 8 die fi ngers.

3. Damage can occur to die fi ngers if parts aren’t aligned properly.

Wrong Alignment

Broken Die Finger

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CALIBRATION INSTRUCTIONS

• Insert any die set and the Compression Plate in the cone base as shown. Note: There should not be a fi tting in the die set when checking calibration.

• Set the Micro Crimp Adjuster as follows at “0”.

• Slide the Pusher onto the stud of the hydraulic ram.

• Press and hold the start/stop switch until the crimper shuts off for the D165-T420 or apply pressure to the D160-T420 Series until the die set is completely closed and the white indicator on the Micro Sight button is just visible.

• If the D165-T420 motor shuts off in approximately 1 second after the die set is fully closed or the white line on the Micro Sight button is just visible, the crimper is correctly calibrated.

• If the crimper requires recalibration, 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.

• Rotating the stem out of the barrel decrease the time required for the pump to shut off.

• Recheck calibration.

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D105 / D165 SERIES DRAWER ASSEMBLY / STAND (104650)

Install (2) 3/8-16 x 1" carriage bolts in front two holes (as shown in picture # 1). Use 3/8" plastic retaining washer to hold bolt into place.

Slide the drawer slightly out to access two rear holes (as shown in picture # 2). Install (2) 3/8-16 x 1" carriage bolts in rear two holes (as shown in picture # 2). Use 3/8" plastic retaining washer to hold bolt into place.

Place the D105/D165 base plate over the 4 screws as shown in picture # 3. Place 3/8" fl at washer, 3/8" locking washer, and then the 3/8"- 16 nut over the bolt as shown.

Tighten each nut with a 9/16" wrench or socket until the nuts are tight as shown in picture # 4.

Note: Bolt the D105/D165 crimper drawer assembly / stand to work surface before use.

# 1

# 3 # 4

# 2

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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 115 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 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 mo-tor 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 specifi cations. (NOTE: All published machine settings are approximate. To correct for slight variances, the gauge settings may need to be adjusted for the specifi c hose, fi 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 fi ll plug and should be showing in the sight glass window. Fill with ISO 46 weight hydraulic oil if required.• 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 defi nite change in pitch of the pump as it cycles into high pres-sure mode and begins to “work” harder.

PROBLEM: CRIMP DIAMETER TOO SMALL• Incorrect setting of the Micro-Crimp Adjuster. Check crimp specifi cations. ( NOTE: All published machine settings are approximate. To correct for slight variances, the gauge settings may be adjusted for the specifi c hose, fi 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 CONE • Inadequate lubrication of the compression cone and die surfaces. Use only the grease shipped with the machine or equivalent.

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WARRANTY

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 benefi ts of this warranty, fi rst, contact Warranty Repair Department at Custom Machining Services at (219) 462-6128 and then deliver via prepaid transportation the complete hydraulic product to:

ATTN: WARRANTY REPAIR DEPT.Custom Machining Services, Inc.326 North Co. Rd 400 EastValparaiso 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.

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See the complete line of CustomCrimp® Crimpers and Accessories at:(219) 462-6128CustomCrimp® www.customcrimp.com

Custom Crimp®

Custom Machining Services, Inc.326 N. County Rd. 400 East

Valparaiso, IN 46383Ph: (219) 462-6128Fax: (219) 464-2773

www.customcrimp.com