DAYCO D105DC Manuale utente
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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
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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
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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
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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.
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