Page 1

KD105 SERIES HYDRAULIC HOSE

CRIMPER OPERATORS MANUAL
 Page 2

MODELS COVERED
This manual is applicable to different variations of the D_105_ Series
Crimpers.
A “Standard”, “Metric” and “DC” micrometer is available on different
models.
Crimping, calibration and repair procedures are similar for all models.
See specific instructions and parts breakdown for the model in question.

SAFETY PRECAUTIONS
„ READ INSTRUCTIONS AND IDENTIFY ALL
COMPONENT PARTS BEFORE USING CRIMPER

„ CRIMPER CAN PRODUCE 35 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

Rev 02/04
 COMPONENT IDENTIFICATION Page 3

WORK LIGHT
(OPTIONAL)

35 TON HYDRAULIC OIL FILL AND

CYLINDER VENT PLUG

REMOVABLE 110 VOLT VALPOWER

PUSHER HYDRAULIC PUMP
POWER
SWITCH

ADJUSTABLE RAM
RETRACTION
STOP

MICRO-CRIMP
ADJUSTER

CALIBRATION
ADJUSTMENT
SCREW

DIE STORAGE SHELF

PNEUMATIC AUTOMATIC (OPTIONAL WITH SOME CRIMPERS
START/STOP STOP SWITCH DIES NOT INCLUDED)
SWITCH

DOUBLE ANGLE STANDARD

TOP COMPRESSION COMPRESSION
RING RING

DOUBLE ANGLE STANDARD DIE SET

DIE SET

DOUBLE ANGLE STANDARD

BASE RING PRESSURE
PLATE
CRIMPER QUICK START GUIDE Page 4

FOLLOW THESE STEPS BEFORE YOU USE YOUR

CRIMPER FOR THE FIRST TIME
„ PLUG THE CRIMPER DIRECTLY INTO A 110 PUSHER
VOLT WALL OUTLET. CAUTION: DO NOT RUN THE
CRIMPER ON AN EXTENSION CORD AS LOW VOLTAGE
CAN DAMAGE THE MOTOR
COMPRESSION RING
„ OIL LEVEL IN THE PUMP
SHOULD BE 1-1/2 TO 2 INCHES
BELOW THE FILL PLUG.

„ PLACE THE PRESSURE

PLATE, ANY DIE SET AND THE
CALIBRATION CHECK PROCEDURE

COMPRESSION RING IN THE

CRIMPER BOTTOM FLANGE IN
THE ORDER SHOWN. DO NOT USE
DOUBLE ANGLE COMPONENTS.

PRESSURE PLATE
„ SLIDE THE PUSHER ONTO THE HYDRAULIC
CYLINDER STUD.

„ SET THE MICRO-CRIMP MICROMETER AT

“100” FOR THE STANDARD MICROMETER
“0” FOR THE METRIC MICROMETER
“95” FOR THE DC MICROMETER

„ DEPRESS AND HOLD THE START/STOP

SWITCH.

„ IF THE RAM EXTENDS AND SHUTS OFF THE METRIC DC

MOTOR APPROXIMATELY 1 SECOND AFTER THE
PUMP STARTS TO BUILD PRESSURE (THE SOUND OF
THE PUMP WILL CHANGE), THE CRIMPER IS
CORRECTLY CALIBRATED.

„ IF THE TIME IS NOT APPROXIMATELY 1

SECOND, THE UNIT MUST BE RECALIBRATED. SEE
INSTRUCTIONS IN THE MANUAL.

STANDARD
CRIMPING GUIDE Page 5

„ Insert the Pressure Plate in the bottom flange making sure

that the pressure plate is seated squarely in the bottom flange.

„ Select the correct die set for the combination of hose and
fitting being crimped. This information is available from the hose
and fitting manufacturer.

The number etched on the die ring represents the fully closed diameter
of the die set in either inches or millimeters depending upon the die
set.

„ Lubricate the contact surfaces of the die fingers, the

Compression Ring and the Pressure Plate with the die lubricant
furnished with the crimper and place the Compression Ring loosely
over the Die Set.

Failure to lubricate the contact surfaces with the correct lubricant

will cause the dies to seize in the compression ring.

„ Insert the hose and fitting and align the fitting with the die
set according to the hose and fitting manufacturer’s
recommendations. Manually depress the Compression Ring closing
the die set until the hose and fitting is held loosely in the die set.

CAUTION: The notches

on the die set must be
completely covered by the
Compression Ring prior to
starting the crimp. If the
notches are showing, you
must go to a larger die set.
Crimping with an
incorrect die size could
result in personal injury
 CRIMPING GUIDE Page 6

„ Slide the Pusher in place above the hose assembly.

„ Set the Micro-Crimp Adjuster to the setting recommended

by the hose and fitting manufacturer for the combination of hose
and fitting being crimped. The Standard Micro-Crimp Adjuster is
shown set at “100” or die set fully closed, in the illustration.

STANDARD METRIC DC

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 3mm (.120 inches) above the closed diameter etched
on the die ring. Always consult the hose and fitting manufacturer’s
recommendations for the correct die set to use.

„ Recheck the fitting for correct alignment in the die set and
depress the Start/Stop switch. Hold the Start/Stop switch depressed
until the Automatic Stop Switch shuts the pump off. Release the
Start/Stop switch and allow the pusher to return to the retracted
position. Powerful magnets in the Pusher will retract the
Compression Ring with the Pusher.

„ Check the diameter of the finished assembly to be certain

that it is within the manufacturer’s specifications.
 CRIMPING WITH DOUBLE ANGLE DIES Page 7

Double Angle Dies doubles the radial crimping force allowing heavier
fittings to be crimped. Due to the doubling of the radial crimping
force, the dies are effective for a smaller range of diameters than a
standard die set. Also, the fitting must be approximately centered axially
along the crimping face to avoid taper in the final crimp.

„ Remove the flat Standard Pressure Plate from the bottom

Cone Base and insert the tapered Double Angle Base Ring with the
tapered surface up.

Note: The angles are not the same on standard dies and Double Angle
Dies and the Double Angle Top Compression Ring and the Standard
Compression Rings are NOT interchangeable.

„ Insert the appropriate Double Angle Die in the Double Angle

Base Ring as shown.

„ Place the Double Angle Top Compression Ring on Top of the

Double Angle Die Set.

„ Insert the hose assembly to be crimped and manually depress

the Double Top Compression ring to snug the fitting in Place.

„ Slide the Pusher on the stud of the hydraulic cylinder.

„ Set the Micro-Crimp Adjuster to the appropriate setting as

recommended by the hose and fitting manufacturer.

„ Bring the Pusher into light contact with the Double Angle
Top and check for correct position of the fitting.

„ Press the Start/Stop switch and proceed with standard

crimping procedure.
 ADDED FEATURES Page 8

The Crimper comes with standard features which increase

accuracy and improve productivity for jobs which require
repeat crimps of similar or identical assemblies

„ The easily removable Coupling Stop provides an

automatic stop for straight fittings without the need to
sight the alignment of the fitting on every crimp.

„ The adjustable Retraction Stop allows the operator

to limit the retraction of the hydraulic ram at the point
where the die set is open only enough to remove the hose
and fitting. This feature can greatly speed up crimping
on production jobs since the ram does not have to fully
advance and retract on every cycle.

„ Powerful magnets in the Pusher retract the

Compression Ring with the ram on each cycle. This
permits the operator to operate the crimper essentially
“hands free”.

„ Note: An optional work light is available.

 CALIBRATION PROCEEDURE Page 9

„ When the crimper is correctly calibrated, the hydraulic pump

will be at approximately 10,000 psi, and the die set will be fully closed
at the diameter etched on the O.D. of the die ring.

Many problems associated with incorrect crimp diameters are caused

by incorrect calibration.

„ Insert the Pressure Plate, any die set,

and the compression ring in the order
illustrated. Set the Micro-Crimp Adjuster at:

“100” for the Standard Micrometer

“0” for the Metric Micrometer
“95” for the DC Micrometer

Follow the instructions in the Quick Start

Guide at the front of this manual.

„ If the crimper requires re-calibration, loosen the jam nut

under the barrel of the Micro-Crimp Adjuster and rotate the black
knob slightly in or out. Hold the stem by the flats while rotating the
black knob and tightening the jam nut.
STEM
JAM NUT

„ Rotating the black knob out of the barrel will

decrease the time required for the pump to shut off after
the knob contacts the automatic stop switch. Rotating the
black knob into the barrel will increase the time for the
pump to shut off.

„ Retighten the jam nut and recheck calibration.

 TROUBLESHOOTING Page 10

PROBLEM: CRIMPER WILL NOT RUN AT ALL

„ The power switch (white rocker switch) is also a circuit breaker. Make certain that this
circuit breaker has not tripped.

„ Check the wall outlet. The crimper comes from the factory wired for a 110 volt circuit.
Use of extension cords or outlets with inadequate power can damage the motor or crimper
controls. 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 it must close to complete the circuit and allow the crimper
to 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 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

„ Check crimper calibration and recalibrate if required.
„ 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 setting of the Micro-Crimp Adjuster. Check hose manufacturer’s specifications.
„ 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.
„ Inadequate lubrication of the dies and compression ring causing the pump to work harder
than normal to reach the required diameter.
„ 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 definite change in pitch of
the pump as it cycles into high pressure mode and begins to “work” harder.

PROBLEM: CRIMP DIAMETER TOO SMALL

„ Check crimp diameter and recalibrate if necessary
„ Incorrect die being used (See die range under Crimp Diameter too Large)
„ Incorrect setting of the Micro-Crimp Adjuster. Check hose manufacturer’s specifications.

PROBLEM: DIES STICKING IN COMPRESSION RING

„ Inadequate lubrication of the compression ring and die surfaces.
DIE COMPONENTS Page 11

3
4

1
2
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 4) Die Screw EN84-115
Not Shown:
DA Cone Insert 100880
3 1 DA Top Cone 100881

Color Options
2 Red
Orange
Yellow
Purple
Green
Blue
Black
Silver
Brown
EXPLODED PARTS VIEW Page 12

20
19 6
21
18 16

17 23
22
8

14

24

26

12

11
10

10 3

11
4
15 1
5

10

13 25

D105 Crimper Assembly (101428)

Item Part Number Description Qty
1 101430 D105 Base Plate 1
2 101633 Pump Assembly 1
3 90126A029 1/4 Flat Washer 4
4 91102A029 1/4 Lock Washer 4
5 92865A540 1/4-20 x 3/4 Hex Bolt 4
6 101433 D105 Handle 1
7 101433-Slotted D105 Slotted Handle 1
8 92323A516 1/4-20 x 3/4 SHFCS 4
9 101429 Mounting Bracket 1
10 90126A031 3/8 Flat Washer 6
11 91102A031 3/8 Lock Washer 4
12 92865A623 3/8-16 x 7/8 Hex Bolt 2
13 95462A031 3/8-16 Hex Nut 2
14 101480 D105 Head Assembly 1
15 92865A626 3/8-16 x 1 1/4 Hex Bolt 2
16 101434 Handle Brace 2
17 91255A578 5/16-18 x 1/2 BHCS 2
18 91255A585 5/16-18 x 1 1/4 BHCS 2
19 90126A030 5/16 USS Flat Washer 2
20 91102A030 5/16 Lock Washer 2
21 95462A030 5/16-18 Hex Nut 2
22 3/8 NPT Comp. Ftg. 3/8 NPT Straight Compression Ftg. 2
23 101436-01 D105 Hydraulic Tube 1
24 100954 Coupling Stop Assembly 1
25 101349 Pneumatic Pendant Switch 1
26 101431 D105 Shelf Unit (Optional) 1
EXPLODED PARTS VIEW Page 13

15

16

10
12

4 11
6
14
7

8
13

9
5

D105 Head Assembly (101480)

Item Part Number Description Qty
1 101209 Head Sub-Assembly 1
2 101788 Micrometer Mount Assembly 1
3 100812 Pusher Retaining Pin 1
4 91253A624 3/8-16 x 1 HSFHS 1
5 101092 Limit Switch Bracket 1
6 91255A537 1/4-20 x 1/2 BHCS 2
7 903 Switch Limit Switch 1
8 100692 Limit Switch Guard 1
9 91255A190 8-32 x 1/4 BHCS 2
10 100628 Standard Micrometer Assembly 1
10 101489 DC Micrometer Assembly 1
10 101587 Metric Micrometer Assembly 1
11 100727 Micrometer Nut 1
12 100813_01 Pusher With Magnets 1
13 100869 Pressure Plate 1
14 100849 Compression Cone 1
15 101499 D105 Stop Rod 1
16 KHA-122 Stop Rod Locking Lever 1
EXPLODED PARTS VIEW Page 14

35-Ton Head Sub-Assembly (101209)

Item Part Number Description Qty
1 100325 (Yellow) Bottom Flange 1
2 100329 Strain Rod - 8 1/2" 4
3 100326 (Yellow) Top Flange 1
4 3/4 Special 3/4 Flat Washer - Special 4
5 95462A538 3/4-10 Hex. Nut 4
6 100685 35-Ton Cylinder Assembly 1
EXPLODED PARTS VIEW Page 15

4 11

6
2 5

7 10

3
D105 Micrometer Mount Assembly (101788)
9 8
Item Part Number Description Qty
1 100898-01 Micrometer Arm 1
1
2 100898-02 Micrometer Base 1
3 100898-03 Micrometer Suspension Flange 1
4 91253A189 8-32 x 1/4 HSFHS 4

Coupling Stop Assy (100954)

Item Part No. Description Qty
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 100953 Fixed Stop Arm 1
9 94750A588 T-Nut (1/4-20) 1
10 90126A029 1/4 Flat Washer 1
11 94052A133 Push-On Cap 1
EXPLODED PARTS VIEW Page 16

10

4
3

11

12

35 Ton Cylinder Assembly (100685)

Item Part Number Description Qty
1 100689 Ram End Cap 1
2 030D90 030 Disogrin O-Ring 1
3 101282 Retraction Spring 1
4 101516 Spring Retainer 1
5 101515 Ram 1
6 102-33400-173-0450 Ram Guide Ring/Seal 1
7 72096 1/4-20 X 3/4 SHCS Gd 8 8
8 101517 Cylinder Body 1
9 93744A030 5/16 Washer - Copper 1
10 92865A585 5/16-18 X 1 1/4 HHCS Gd.5 1
11 101514 Ram Guide 1
12 SH959-26 Wiper 1
EXPLODED PARTS VIEW Page 17

15
13

16

7 14

6 9
11
5

10

12
8

4 1

Pump Assembly (101633)

Item Part Number Description Qty
1 101435 1 Gallon Reservoir 1
1 101336 2 Gallon Reservoir 1
2 101358 015 Buna 70 O-Ring Seal 4
3 101432 Reservoir Standoff 4
4 95462A525 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
EXPLODED PARTS VIEW Page 18

18 19
20
7

20
8

21

10
11
13

16

9 12
17
11 15

6 7

4 14
1 22

1 HP/2 HP Pump Sub-Assembly (101395)

Item Part Number Description Qty Ref. Part No.
1 101335 Reservoir Cover 1 132301
2 101337 Port Block Gasket 1 121304
3 101584 Port Block Assembly 1
4 101330 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 4 354313
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 4 345308
22 101328 CR-6247 Shaft Seal 1 355303
EXPLODED PARTS VIEW Page 19

9 10
16
12 11

10

6
2

4 3

18
17
19
15
14

7 13
5

10
8

11
10 12

Lower Plate & Gear Pump Assembly (101477)

Item Part Number Description Qty
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
5 R10 - 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 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
EXPLODED PARTS VIEW Page 20

4
3 5

5
4

6
1 7

5 2 8

Piston Block Assembly (101478)

Item Part Number Description Qty
1 101408 Piston Block 1
2 101381 Port Plug - 7/16-20 1
3 101372 Piston Spring 1
4 101445 Piston 1
5 101355 014 Disogrin O-Ring 2
1

Dump Block Assembly (101443)

Item Part Number Description Qty
1 101412 Dump Block 1
2 101374 Dump Valve Spring 1
3 101417 Dump Valve Plunger 1
4 101353 Plunger Piston O-Ring 1
5 101427 Plunger Piston 1
6 101444 Block Cap O-Ring 1
7 101407 Dump Block Cap 1
8 101391 10-24 X 1/2 Pan Hd Mach Screw 4
EXPLODED PARTS VIEW Page 21

11
10

9
8

12

14
13

16
15

3 2

5 4

6
7

Unloading Block Assembly (101476)

Item Part Number Description Qty
1 101399 Unloading Block 1
2 101467 High PSI Seat Assembly 1
3 9528K13 3/16 Dia. Precision Ball 1
4 91301A180 1/4-20 x 1/4 Hollow Set Screw 1
5 101462 Relief Ball Retainer 1
6 101373 High Pressure Spring 1
7 101471 High Pressure Adjust. Screw 1
8 101474 Stick Valve Assembly 1
9 9528K15 1/4 Dia. Precision Ball 1
10 101371 Stick Valve Spring 1
11 50925K435 9/16-18 Port Plug 1
12 101464 Pin 1
13 9528K19 3/8 Dia. Precision Ball 1
14 101423 Ball Retainer 1
15 101370 Low Pressure Spring 1
16 101472 Low Pressure Adjust. Screw 1
NOTES Page 22