Page 1

D165DC DAYCO
OPERATORS MANUAL
 Page 2

WARNING - SAFETY NOTE

IMPORTANT - DO NOT OPERATE THIS EQUIPMENT UNTIL YOU READ AND FULLY
UNDERSTAND THIS MANUAL AND ITS ASSEMBLY INSTRUCTIONS

ALWAYS WEAR EYE PROTECTION

WARNING!! USE ONLY THOSE HOSE AND COUPLING COMBINATIONS AND

CRIMPING EQUIPMENT SPECIFIED IN DAYCO HYDRAULIC 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 PROPERTY DAMAGE. DAYCO DISCLAIMS ALL
LIABILITY FOR ANY HOSE AND COUPLING ASSEMBLY THAT IS NOT MADE
ACCORDING TO DAYCO RECOMMENDATIONS. CONSULT YOUR LOCAL
DAYCO REPRESENTATIVE OR DAYCO DISTRIBUTOR IF YOU HAVE ANY
QUESTIONS.

file: D165DC/D160D-DC MarkIV Manual(Rev 10/27/2005).pmd

TABLE OF CONTENTS Page 3

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 Warranty-----------------------------------------------------------------18

D165DC
 D165DC PARTS IDENTIFICATION Page 4

60 TON HYDRAULIC ADJUSTABLE RAM

CYLINDER RETRACTION STOP
10,000 PSI PUMP
1HP, 110V-15 AMP MOTOR

POWER ON/OFF
CIRCUIT BREAKER
SWITCH
MICRO-CRIMP
ADJUSTER

CALIBRATION
ADJUSTMENT
SCREW

AUTOMATIC STOP
SWITCH
MANUAL PNEUMATIC
START-STOP SWITCH
OIL FILL AND COMPPRESSION
VENT PLUG RING

STANDARD DIE
SET

PRESSURE PLATE
D165DC QUICK START GUIDE Page 5

FOLLOW THESE STEPS BEFORE YOU USE YOUR

CRIMPER FOR THE FIRST TIME
CALIBRATION CHECK FOR THE D165DC
(See the following page for D160S-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.
CALIBRATION CHECK PROCEEDURE

„ 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”.

„ 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.
HOSE PREPARATION Page 6

„ Dayco recommends that all users familiarize themselves with Dayco’s warning
statements, SAE J1273, and the Kwikrimp® concept, found in this operator’s manual.

„ Select the Dayco hose and coupling to be assembled.

„ Determine the correct crimp

setting from the crimp specifications
sheet.

„ Determine hose cut length

by subtracting the cutoff factor for
each coupling 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 Dayco hose assembly lubricant (HAL16) to ease hose
insertion. Insert the hose until it “bottoms” in the coupling shell.

To insure that the hose is bottomed in the collar, mark the insertion depth on the hose
before inserting it into the coupling (see figure below).

Using a clockwise twisting motion or fixing the hex on the coupling in a vise may help when
tolerances are tight.
 D165 SERIES HOSE CRIMPING Page 7

CRIMPING PROCEDURE

„ Insert the Standard Pressure Plate in the bottom flange making

certain that the Pressure Plate is seated squarely in the bottom flange.
Make certain that the seating area of the bottom flange is clean and
allows the Pressure Plate to seat squarely in the bottom flange

„ Select the correct die set for the combination of hose and fitting
being crimped.

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 and the

Compression Ring with the die lubricant furnished with the crimper.

Failure to lubricate the contact surfaces with the correct lubricant

can cause the dies to seize in the compression ring.

„ Align the hose and fitting in the die set. If the fitting has knurl
marks, align as shown. If there are no knurl marks on the fitting,
obtain the correct crimp length from the crimp specification chart and
mark the fitting at the proper point.

CAUTION: The notches on the die set must be

completely covered by the Compression Ring prior
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
D165 SERIES HOSE CRIMPING Page 8

„ Position the dies in the crimper as shown making certain that

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
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 recommended.

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.
D165 SERIES HOSE CRIMPING Page 9

„ Slide the Pusher into position on the hydraulic ram

„ Recheck the fitting for correct alignment and depress the

pneumatic Start/Stop switch bulb. Keep it depressed until the crimper
shuts off automatically.

„ Measure the finished 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 Retraction Stop to
limit the ram retraction to the position where the hose and fitting can
just be easily removed.

Magnets embedded in the Pusher will retract the Compression Cone

with the Pusher while still permitting the Compression Cone to align
correctly for the next crimping operation.

COUPLING STOP RAM RETRACTION STOP

 CALIBRATION PROCEDURE Page 10

When the crimper is correctly calibrated, the ram will extend and fully
close the die set. After the die set is fully closed, the time from which
the pump starts to build pressure and the point at which the motor
shuts of automatically will be approximately 1 second.

Many problems associated with incorrect crimp diameters are caused

by incorrect calibration.

CALIBRATION

„ Insert the Standard Pressure Plate, any die

set, and the compression ring in the order
illustrated.

„ 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 pump starts
to build pressure (the sound of the pump will change), then the crimper
is correctly calibrated.

„ If the crimper requires re-calibration, 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.

If the time from which the pump starts to build pressure is

greater than approximately 1 second, rotate the stem out
slightly.

If the time is less than approximately 1 second, rotate the

stem in slightly.

„ Recheck calibration.
TROUBLESHOOTING Page 11

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 110 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 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 re-calibrate 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 re-calibrate 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.
KWIKRIMP® CONCEPT Page 12

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.
COMPONENT PARTS BREAKDOWN Page 13

3
4

1
2

D100 Standard Series Dies Color Options

1) Die Ring 101065-COLOR Red
2) Die Finger Varies with die set Orange
3) Die Spring LC 022D 01 M NF Yellow
4) Die Screw EN84-115 Purple
Green
Blue
Black
Silver
Brown
 COMPONENT PARTS BREAKDOWN Page 14

24 23

15
22

13
21 20 19

14

18
25
16

17

10 9 11
1
7
8

9 12
3 4 5 26
10 10
D165 Crimper Assembly (102221)
Item Part Number Description Qty
1 101430 D165 Base Plate 1
2 101633 Pump Assembly 1
3 92865A540 1/4-20 x 3/4 HHCS 4
4 91102A029 1/4 Lock Washer 4
5 90126A029 1/4 Flat Washer 4
6 102161 D165 Crimper Head Assembly 1
7 101429 Crimper Head Mounting Bracket 1
8 92865A626 3/8-16 x 1 1/4 HHCS 2
9 91102A031 3/8 Lock Washer 4
10 90126A031 3/8 Flat Washer 6
11 92865A623 3/8-16 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 x 1/2 BHCS 2
18 91255A585 5/16-18 x 1 1/4 BHCS 2
19 95462A030 5/16-18 Hex Nut 2
20 91102A030 5/16 Lock Washer 2
21 90126A030 5/16 Flat Washer 2
22 60TA-06X08 45 Deg Swivel Fitting 1
23 102225 D165 High Pressure 1/2" Hose 1
24 60TA-08X08 45 Deg Swivel Fitting 1
25 100954 Coupling Stop Assembly 1
26 101349 Pneumatic Pendant Switch 1
COMPONENT PARTS BREAKDOWN Page 15

2
13
7

6
9

10 11

15 8

12

17

14 16
23
18

20 22

21
4
19
D165 Crimper Head Assembly (102161)
Item Part Number Description Qty
5 3
1 102219 60 Ton Cylinder / Top Flange 1
2 102212 Strain Rod 4
3 102159 Bottom Flange 1
4 7/8 Special 7/8 Narrow Rim Washer 4
5 90499A845 7/8 - 14 Hex Nut 4
6 102224 Retraction Stop Rod 1
7 KHA-126 Stop Rod Locking Handle 1
8 102220 Micrometer Mount Assembly 1
9 100812 Pusher Retaining Disc 1
10 91253A624 3/8-16 x 1 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 Pressure Plate 1
15 102213 Compression Cone 1
16 101092 Limit Switch Bracket 1
17 903 Switch Limit Switch 1
18 91255A537 1/4-20 x 1/2 BHCS 2
19 100692 Limit Switch Guard 1
20 91255A190 8-32 x 1/4 BHCS 2
21 95630A237 #6 Teflon Washer 2
22 102218 Die Retaining Clip 2
23 91251A146 6-32 x 3/8 SHCS 2
COMPONENT PARTS BREAKDOWN Page 16

60 Ton Cylinder / Top Flange Assembly (102219)

Item Part Number Description Qty
1 102158 60 Ton Body / Top Flange 1
2 100651 60 Ton Piston 1 1 10
11
3 227-9250 227 Disogrin O-Ring 1
4 101106 Piston End Cap 1
5 91251A424 3/8-24 x 1 SHCS 6
6 100760_12 60 Ton Spring 1
7 100653 Spring Plug 1
8 F1-POM-3.75X4.00X0.375 3.75 x 4.00 x 0.375 Wear Ring 2
9 3500-4000-0375 POLYPAK 3.50 x 4.00 x 0.375 Polypak 1
10 93744A160 3/8 Copper Flat Washer 1
9
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 8

8 6
13

12
2

D165 Micrometer Mount Assembly (102220)

Item Part Number Description Qty
1 102214 Micrometer Suspension Flange 1
2 102217 Micrometer Brace 1
3 102215 Micrometer Base Bracket 1
4 91253A194 8-32 x 1/2 HSFHCS 4
5 98296A245 3/16 Dia. x 1/2 Spring Pin 1
3
COMPONENT PARTS BREAKDOWN Page 17

4 11

6
5

7 10

9 8

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
LIMITED WARRANTY Page 18

D165 SERIES is warranted to be free from defects in material and workmanship under normal
operating conditions and recommended usage for a period of ninety (90) days from date of
delivery. Any product which is shown to be defective shall be replaced or repaired free of charge
or extended a credited refund of the original acquisition cost to purchaser. This limited warranty
is contingent upon the conditions that prompt receipt of notice of any defect, that purchaser
establish the product has been property installed, maintained, and operated within the limits of
related and normal usage as specified, and that upon request purchaser will return the defective
product.

The terms of this limited warranty do not in any way extend to any product or part which have a
life, under normal usage, inherently shorter than ninety (90) days.

THESE LIMITED WARRANTIES TO REPAIR OR REPLACE DEFECTIVE PRODUCTS AS

SET FORTH ABOVE AND ANY ADDITIONAL WARRANTY EXPRESSLY STATED TO BE A
WARRANTY AND SET FORTH IN WRITING ARE IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR
PURPOSE.

PURCHASER’S SOLE AND EXCLUSIVE REMEDY PURSUANT TO ANY CLAIM OF ANY

KIND, INCLUDING BUT NOT LIMITED TO, A CLAIM IN CONTRACT, WARRANTY,
NEGLIGENCE OR STRICT LIABILITY, SHALL BE (a) THE REPAIR OR REPLACEMENT
AT THE OPTION OF THE MANUFACTURER OF DEFECTIVE PRODUCTS OR (b) A
CREDITED REFUND OF THE PRICE OF THE DEFECTIVE PRODUCT OR PART IF THE
PRODUCT OR PART IS UNABLE TO BE EFFECTIVELY REPAIRED, REPLACED OR
CORRECTED IN A REASONABLE TIME AFTER USING BEST EFFORTS. CLAIMS OF
ANY KIND INCLUDE BUT ARE NOT LIMITED TO THOSE FOR ANY LOSS OR DAMAGE
ARISING OUT OF, CONNECTING WITH, OR RESULTING FROM THE DESIGN,
MANUFACTURE, SALE, DELIVERY, RESALE, INSTALLATION, TECHNICAL DIRECTION
OF INSTALLATION, INSPECTION, REPAIR, OPERATION OR USE OF ANY PRODUCT OR
PART. IF, HOWEVER, ANY WARRANTIES ARE EXPRESSLY SET FORTH IN WRITING IN
ADDITION TO THOSE SET FORTH HEREIN, THE LIABILITY UNDER SUCH
ADDITIONAL WARRANTY SHALL TERMINATE NINETY (90) DAYS FROM THE DATE OF
SHIPMENT TO PURCHASER.

UNDER NO CIRCUMSTANCES SHALL ANY LIABILITY WHATSOEVER BE IMPOSED

FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT
LIMITED TO, LOSS OF PROFIT OR REVENUE, LOSS OF USE OF THE PRODUCT, COST
OF CAPITAL, COST OF REPLACEMENT EQUIPMENT, OR CLAIMS RESULTING FROM
CONTRACTS WITH THIRD PARTIES, UNLESS EXPRESSLY PROVIDED IN WRITING, IN
NO EVENT SHALL ANY LIABILITY OR RESPONSIBILITY BE ASSUMED FOR
PENALTIES, PENALTY CLAUSES OR LIQUIDATED DAMAGES OF ANY DESCRIPTION,
CERTIFICATIONS OR INDEMNIFICATIONS OF PURCHASERS OR OTHERS OR COSTS,
DAMAGES OR EXPENSES ARISING OUT OF OR RELATED TO THE PRODUCTS.
NOTES Page 19