ET1000 Crimp Machine - Eaton Crimper Support

1 ET1000 Crimp Machine Operator s ManualPortableLight DutyPositive StopTable of ContentsSafetyInstructions2 Eaton Hydraulics ET1000 Operator s Manual E-EQCR-TM001-E September 2003 Safety Instructions ..2 Specifications ..3 Accessories ..3 Set-up and Assembly ..3 Operating InstructionsDescription of Components ..4 Crimping Procedures (large collets) ..4 Crimping Procedures (small collets) ..5 MaintenanceMaintenance Intervals ..6 Machine Maintenance Procedures ..6 Crimp Machine Components ..7 Read and understand theoperator s manual beforeattempting to operate anyequipment. WARNINGA eroquip hose, hose fit-tings and assembly equip-ment should be used onlywith other Aeroquip hose,hose fittings and assemblyequipment and Weatherheadhose, hose fittings andassembly equipment shouldbe used only withWeatherhead hose, hose fit-tings and assembly equip-ment.

2 Do not combine or useAeroquip or Weatherheadhose, hose fittings andassembly equipment witheach other, Aeroquip hosewith Weatherhead fittings, orwith hose, hose fittings orassembly equipment suppliedby another hereby disclaims anyobligation or liability (includingincidental and consequentialdamages) arising from breachor contract, warranty, or tort(under negligence or strict lia-bility theories) shouldAeroquip orWeatherheadhose fittings or assemblyequipment be used inter-changeably orwithanyhose, fittings or assemblyequipment supplied by anoth-er manufacturer, or in theevent that product instruc-tions for each specified hoseassembly are not to followprocess and product instruc-tions and limitations couldlead to premature hoseassembly failures, resulting inproperty damage, seriousinjury or death. Aeroquip and Weatherheadfitting tolerances are engi-neered to match Aeroquipand Weatherhead hose toler-ances.

3 The combination oruse of Aeroquip orWeatherhead hose and hosefittings with each other, hose withWeatherhead fittings, or withhose or fittings supplied byanother manufacturer mayresult in the production ofunreliable and/or unsafe hoseassemblies and is neither rec-ommended nor authorized byEaton. Safety Instructions1. PREVENT UNAUTHORIZEDOPERATION. Do not per-mit anyone to operate thisequipment unless theyhave read and thoroughlyunderstand this WEAR SAFETY AVOID PINCH not rest your hand onthe Crimp ring. Keep yourhands clear of all movingparts. Do not allow anyone,other than the operator, close to the equipmentwhile it is in MAINTAIN DIES WITHCARE. Dies used in theET1000 Crimp Machine arehardened steel, offeringthe best combination ofstrength and wear resist-ance for long dies are general-ly brittle and care shouldbe taken to avoid anysharp impact.

4 Never strikea die with a USE ONLY SPECIFIEDAEROQUIP/WEATHER-HEAD PRODUCTS. Makehose assemblies using onlyAeroquip and Weatherheadhose and fittings specifiedfor this assembly VERIFY CORRECT CRIMPDIAMETERS. Check andverify correct Crimp diame-ters of all fittings aftercrimping. Do not put anyhose assemblies into serv-ice if the Crimp diametersdo not meet Eaton Make sure all dies are com-pletely in place, the spacerring rests against the place-ment pins, and the pusheris pulled forward into thedetent position DO NOT OVER PRESUR-IZE. Do not exceed the10,000 psi hydraulic pres-sure supplied to : All components usedto connect the pump andcrimp cylinder must meet thecriteria set forth in theMaterial Handling InstituteSpecification #IJ100 forhydraulic jacking DIE CHANGE. DO NOTINSERT/REMOVE DIESWHILE THE POWER IS ON OR Machine IS SECURE THE EQUIP-MENT TO A STABLEWORK SURFACE.

5 Prior tooperation, secure the crimpmachine to a stable worksurface to prevent theequipment from UNPLUG THE POWERSUPPLY WHEN NOT KEEP WORK AREACLEAN. Cluttered areasand benches invite Hydraulics ET1000 Operator s Manual E-EQCR-TM001-E September 2003 Specificationsand AccessoriesNOTE:Your new Crimp Machine has been calibrated and filledwith hydraulic oil in the factory. Do not remove any plugs or caps until necessary. Excess air in thehydraulic system may causeerratic cylinder movementduring retraction. Refer tothe Setup and Assembly sec-tion for instructions onremoving air from thehydraulic Dimensions: 22 tall x 16 width x 14 deepWeight: 70 lbs. ( Machine &stand only)Pump Requirements: Reservoir Capacity: 36 cu. in (590 cc) Pressure Rating: 10,000 psi (690 bar) The air/hydraulic pumprequires a minimum of100psi to operate at maxi-mum efficiency.

6 Hose Production Capacity:(varies with available tooling)Accessories Die Cage/Collet, spacerring tool box (Part # FT1603) Die Cage/Collet, spacerring wall mount rack (Part # FT1604) High PerformancePTFE Lubricant (Part # 140-06701)1. Your new ET1000 crimpmachine comes disassem-bled for ease of use, the machinemust be assembled to thebase with the supplied fas-teners (ET1000C-0008).2. Remove the plug from thetop cylinder port andinstall the 06 size ORB,90 degree adapter using23-24 ft. lbs. assemblytorque. Orient the adapterso that it points to the rearof the Crimp Machine ,away from the Install the pump connect-ing hose assembly to thecylinder adapter with the 06 size 37 degree swivelnut fittings using 18-20 assembly torque. 4. Do not exceed an 8 mini-mum bend radius of thepump connecting hosewhen attaching the hoseto the pump and cylinder.

7 5. If using your own pump,make sure it has therequirements listed in theSpecifications Place the pump on thework surface to eitherside of the Crimp Machine .(Note: if using theair/hydraulic pump, thepump can be fastened toeither side of the crimpmachine frame as youface the front of the crimpmachine.) Install the 90degree adapter to thepump pressure port (Male NPTF threadsshould be tightened fol-lowing the hex-markingprocedure of 2 to 3 turnspast hand tight).7. Remove excess air fromthe hydraulic system. Thiscan be accomplished byplacing the pump at a high-er level than the cylinderand cycling the machineapproximately five times. 8. Secure the Machine frameto a stable work surfaceusing lag screws or othersuitable andAssembly4 Eaton Hydraulics ET1000 Operator s Manual E-EQCR-TM001-E September 2003 OperatingInstructions Description ofComponentsCrimping Procedures(using larger collets)Step 1:Slide the pusher to the backposition.

8 Using the Collet/Spacer RingSelector Chart, select theproper collet assembly andspacer ring. Lubricate the inside cone ofthe die ring and external sur-faces of the collet assemblywith a high-efficiency PTFE based the collet assemblyinto the base die 2:Insert the hose assemblythrough the bottom of thebase die ring and betweenthe two collet assemblyhalves. Align the fitting withthe top of the collet halvesas referenced on theCollet/Spacer Ring SelectorChart. Step 3:Place the spacer ring in theappropriate position on topof the collet assembly (eitherflat-side up or flat-side downas referenced in theCollet/Spacer Ring SelectorChart).Step 4:Pull the pusher forward intothe detent holding positionwith the pusher 5:Begin crimping by actuatingthe pump. When the spacer ring bottoms outagainst the base die ring,the crimping is complete.

9 (NOTE: Visually inspect thecrimp and verify the correctcrimp diameter and length.)Die RingAdapterSplit ColletAssemblySpacer RingsET1000 Crimp Machine5 Eaton Hydraulics ET1000 Operator s Manual E-EQCR-TM001-E September 2003 OperatingInstructions Crimping Procedures(using smaller collets) Step 5:Pull the pusher forward intothe detent holding positionwith the pusher 6:Begin crimping by actuatingthe pump. When the spacer ring bottoms outagainst the die ringadapter plate,the crimpingis complete. (NOTE:Visually inspect the crimpand verify the correct crimpdiameter and length.)Step 1:Slide the pusher to the backposition. Using the Collet/Spacer RingSelector Chart, select theproper collet assembly andspacer ring. Lubricate the inside cone ofthe base die ring and theoutside cone of the die ringadapter the die ring adapterplate into the base die 2:Lubricate the external surfaces of collet assemblyhalves with a high-efficiencyPTFE- based the collet assemblyinto the die ring 3:Insert the hose assemblythrough the bottom of thebase die ring and upbetween the two colletassembly halves.

10 Align thefitting with the top of the col-let halves as referenced onthe Collet/Spacer RingSelector 4:Place the spacer ring in theappropriate position on topof the collet assembly (eitherflat-side up or flat-side downas referenced in theCollet/Spacer Ring SelectorChart).6 Eaton Hydraulics ET1000 Operator s Manual E-EQCR-TM001-E September 2003 MaintenanceCollet Assembly & DieRing Adapter PlateLubrication:Every 30 crimps = Re-lubricate sliding surfacesof diesEvery 250 crimps = Removeold grease and re-lubricateBase Die Ring & Die RingAdapter PlateMaintenance:Every 250 crimps = Removeold grease and re-lubricateEvery 1,000 crimps =Remove old grease, inspectfor wear or damage and re-lubricate if Sliding surfaces must bekept free of dirt and otherabrasive All exposed black metalsurfaces should be coatedoccasionally with a lightfilm of oil to prevent Some fitting/hose combi-nations require full pumpreservoir capacity to com-plete the Crimp cycle.