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 TROUBLESHOOTING

PROBLEM:  CRIMPER WILL NOT RUN AT ALL

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The white rocker switch is also a circuit breaker.  Check to see that the circuit breaker has

not been tripped

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Check the wall outlet.  The crimper comes from the factory wired for a 110 volt single phase

circuit.  

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  Use of extension cords or outlets with inadequate power can damage the motor .  Do

not  run the crimper from a portable power source.

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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.

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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 bulb on the end of
the hose going into the box

PROBLEM:  CRIMP DIAMETER TOO LARGE

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Check crimper calibration and re-calibrate if required.

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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.

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Incorrect setting of  the Micro-Crimp Adjuster.  Check hose manufacturer’s specifications.

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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.

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Inadequate lubrication of the dies and compression ring causing the pump to work harder

than normal to reach the required diameter.

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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

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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

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Check crimp diameter and re-calibrate if necessary

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Incorrect die being used (See die range under Crimp Diameter too Large)

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Incorrect setting of  the Micro-Crimp Adjuster.  Check hose manufacturer’s specifications.

PROBLEM:  DIES STICKING IN COMPRESSION RING

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Inadequate lubrication of the compression ring and die surfaces.

Summary of Contents for D165DC

Page 1: ...1 Page D165DC DAYCO OPERATORS MANUAL...

Page 2: ...PUBLISHED LITERATURE DAYCO RECOMMENDATIONS ARE BASED ON TESTING AND USE OF HOSE AND COUPLING COMBINATIONS OTHER THAN THOSE RECOMMENDED BY DAYCO CAN RESULT IN SERIOUS INJURY DEATH OR SUBSTANTIAL PROPE...

Page 3: ...OF CONTENTS D165DC Parts Identification 4 D165DC Quick Start Guide 5 Hose Preparation 6 Hose Crimping Standard Dies 7 Calibration 10 Troubleshooting 11 Kwikrimp Concept 12 Parts Breakdown 13 Limited...

Page 4: ...OR 60 TON HYDRAULIC CYLINDER OILFILLAND VENTPLUG ADJUSTABLE RAM RETRACTION STOP MICRO CRIMP ADJUSTER CALIBRATION ADJUSTMENT SCREW MANUALPNEUMATIC START STOPSWITCH AUTOMATICSTOP SWITCH STANDARD DIE SET...

Page 5: ...IE 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 PRESS AND HOLD THE START S...

Page 6: ...oupling from the overall length of the assembly For these cutoff factors see Dayco s published catalog data Cut the hose square and to the proper length with a suitable saw Coat the coupling stem with...

Page 7: ...e die set Lubricate the contact surfaces of the die fingers and the Compression Ring with the die lubricant furnished with the crimper Failure to lubricate the contact surfaces with the correct lubric...

Page 8: ...ress the compression ring until the fitting is held loosely in the die set Select the proper crimp setting from the Crimp Specification chart and set the Micro Crimp adjuster at the setting recommende...

Page 9: ...fitting diameter to be certain that it is within the crimp specification tolerances If multiple fittings are being crimped set the Coupling Stop to automatically position the fitting and set the Ram...

Page 10: ...ustrated Set the Micro Crimp adjuster at 95 Press and hold the start Switch If the ram extends closing the dies to their fully closed position and the motor shuts off approximately 1 second after the...

Page 11: ...iameter of the die The closed diameter is the die size stamped on the die ring Incorrect setting of the Micro CrimpAdjuster Check hose manufacturer s specifications Inadequate pump pressure Check oil...

Page 12: ...UCED 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...

Page 13: ...ENT 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 Color Options Red Orange Yellow Purple Green Bl...

Page 14: ...16 x 7 8 HHCS 2 12 95462A031 3 8 16 Hex Nut 2 13 102160 Front Handle Assembly 1 14 92323A516 1 4 20 x 3 4 HHFCS 4 15 102222 Rear Handle Assembly 1 16 102052 Crimper Head Brace 2 17 91255A578 5 16 18...

Page 15: ...HSFHCS 1 11 100628 Standard Micrometer Assembly 1 11 101489 DC Micrometer Assembly 1 11 101587 Metric Micrometer Assembly 1 12 100727 Micrometer Nut 1 13 100825 Pusher With Magnets 1 14 102211 Pressur...

Page 16: ...93744A160 3 8 Copper Flat Washer 1 11 91251A633 3 8 16 x 2 1 4 SHCS 1 12 SH940 35 375 Ram Wiper 1 13 102169 60 Ton Retaining Ring 1 60 Ton Cylinder Top Flange Assembly 102219 Item Part Number Descript...

Page 17: ...8 9 2 4 1 3 1 100950 Coupling Stop Block 1 2 98381A544 Stop Block Pin 2 3 100951 Stop Block Rod 1 4 91251A540 1 4 20 X 3 4 SHCS 2 5 9489T47 Eye Bolt 1 6 100952 Adjustable Stop Arm 1 7 DK 655 Knob 1 8...

Page 18: ...OFANY KIND INCLUDINGBUT NOT LIMITED TO ACLAIM IN CONTRACT WARRANTY NEGLIGENCE OR STRICT LIABILITY SHALLBE a THE REPAIR OR REPLACEMENT ATTHE OPTION OFTHE MANUFACTURER OFDEFECTIVE PRODUCTS OR b A CREDI...

Page 19: ...19 Page NOTES...

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