Table of Contents - Eaton

1 2 Eaton ET4000 Crimp Machine Set Up and operating manual E-EQCR-TM002-E June 2005 Table of ContentsSECTIONPAGES pecifications and equipment3 Shop/work Table mounting 4 Check-out procedure5 operating instructions (ET4000AR-001)6 operating instructions (ET4000AR-002)7 operating instructions (T-410-25)8 operating Instructions9 Troubleshooting procedures10 Repair and replacement items12 SafetyInstructionsRead and understand theoperator s manual beforeattempting to operate anyequipment. WARNINGA eroquip hose, hosefittings 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, resultingin property damage, seriousinjury or death.

3 Aeroquip and Weatherheadfitting tolerances are engi-neered to match Aeroquipand Weatherhead hose toler-ances. 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 unsafehose assemblies and is nei-ther recommended norauthorized by Eaton . Safety Instructions1. PREVENT UNAUTHO-RIZED OPERATION. Do not permit anyone tooperate this equipmentunless they have read andthoroughly understand 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.

4 Dies used in theET4000 crimp machine arehardened steel, offeringthe best combination ofstrength and wear resist-ance for long dies are gener-ally brittle and care shouldbe taken to avoid anysharp impact. Neverstrike a die with a hard-ened USE ONLY SPECIFIEDAEROQUIP/WEATHER-HEAD PRODUCTS. Make hose assembliesusing only Aeroquip andWeatherhead hose and fit-tings specified for thisassembly VERIFY CORRECT CRIMPDIAMETERS. Check and verify correctcrimp diameters of all fit-tings after crimping. Do notput any hose assembliesinto service if the crimpdiameters do not meetEaton crimp Make sure all dies arecompletely in place, thespacer ring rests againstthe locator bracket, andthe pusher halves areclosed before DO NOT OVER PRESSURIZE.

5 Do notexceed the 5,000 psihydraulic pressure sup-plied to the : All components usedto connect the pump andcrimp cylinder must meetthe criteria 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. Prior to operation, securethe crimp machine to astable work surface to pre-vent the equipment fromtipping. See pages 4-5 formounting . UNPLUG THE POWERSUPPLY WHEN NOT IN KEEP WORK AREACLEAN. Cluttered areas andbenches invite DO NOT OPERATEWITHOUT THE BASEADAPTER RING ET4000 Crimp Machine Set Up and operating manual E-EQCR-TM002-E June 2005 Specifications and EquipmentET4000 Crimp MachineET4000 is ideal for factory high performance machine oper-ations, construction and mine locations.

6 The ET4000 pressoffers the crimping capabilities through 2 six :500 :29 high, 21 deep, 12 wideT-441 Electric PumpThe Eaton T-441 power unit is ideally suited for use with theET4000 press. It features a two-stage pump providing highflow at low pressure for fast ram approach and low flow athigh pressure for actual :7 1/2 high, 10 wide, 22 longWeight:75 :5000 psiReservoir Capacity:6 QuartsOutlet Port Size:3/4-16 straight thread o-ringMotor:1HP, 3450 RPM, 220 volts, 60 cycle, single phaseHydraulic Oil:ISO 32 (SAE 10W) GPM to 900 psi to GPM above 900 psiCaution: The T-441 Electric Pump has the relief valveset at 5000 psi. Damage to the press will result andthe warranty may be voided if higher pressures are 15 amp fused ET4000 Crimp Machine Set Up and operating manual E-EQCR-TM002-E June 2005 Shop/Work Table MountingThe following methods are offered as a guide and may bevaried to suit your particular Prepare mounting surface for ET4000 press and to FIGURE 1 for bolt hole layout and optimumheight.

7 IMPORTANT:Care must be taken to insure that the sur-face to which the press is bolted is capable of support-ing the weight of the press (approximately 500 lbs.) andpump which is 75 Remove shipping carton from ET4000 press. There arefour 5/8-18 tapped hoes in top plate which may be usedfor lifting purposes (see FIGURE 2). If these tappedholes are used, it is recommended that a minimum oftwo be utilized, preferably four. If two holes are used forlifting, use holes directly across from each other on thecenter line and not two on a diagonal. This will preventpress from tilting as it is Using an adequate lifting device, raise the press to themounting surface. Align holes in press support bracketswith holes in mounting surface. Insert four 1/2 boltsfrom top of mounting surface.

8 Washers and nuts areinstalled from underneath. the T-441 pump on the mounting surface to theright and slightly behind the ET4000 press. (ReferenceFIGURE 4, Page 5)5. Mark power unit base plate hole pattern on mountingsurface. Remove power unit and drill Replace pump and align holes on mounting surface withbase plate of pump. Insert bolts from top of mountingsurface. Washers and nuts are installed from under-neath. Remove middle plug from outlet port in pump. (See FIGURE 3.) press/pump connecting hose assembly andremove plugs. Connect unions into outlet port in pumpand press. Remove pipe plug from pump reservoir and replace withbreather cap Before the electric pump (T-441) can be activated, theinterlock cord must be plugged into the switch boxmounted on the ET4000 crimper.

9 After mating thehalves of connection, TIGHTENthe knurled Plug electric cord into a grounded (4-wire connection),220 volt, 60 cycle, single phase outlet. IT IS RECOM-MENDED THAT THE PUMP BE ON AN INDIVIDUAL 15 AMP SERVICE for Shop/Work Table MountingFigure 1 - Bench Layout for ET4000 PressFigure 2 - Lifting Hole Layout on ET4000 Press Top PlateFigure 3 - T-441 Outlet Port 5 Eaton ET4000 Crimp Machine Set Up and operating manual E-EQCR-TM002-E June 2005 Shop/Work Table Mountingand Check-Out Procedure CAUTION:Throughout theCheck-out Procedure, checkhose assembly/adapter con-nections for any necessary. For-Seal Swivel Nut Torque forhose assembly; 32-35 ft. oil lever in powerunit. The oil reservoir wasfilled at the factory, howev-er, if oil is required use ISO32 (SAE 10W).

10 WARNING:Dot notcycle without baseadapter ring in procedure forusing electric pump Plug electric cord into agrounded (4 wire connec-tion), 220 volt, 60 cycle, single phase outlet. IT ISRECOMMENDED THATTHE PUMP BE ON ANINDIVIDUAL 15 AMPSERVICE To completely purge thehydraulic system, the ramreturn stops should be inthe out position to permitthe ram to return to the fullupright position. (See page8, Step 1 for the procedure.)3. Close pusher halves onpress. Due to safety inter-lock switch, power unit willoperate only when pusherhalves are Hold switch ON untilpusher touches the baseadapter SWITCH. Pumpwill stop and pusher REPEAT STEPS 4 & 5 APPROXIMATELY SIXTIMES. This will purge thehy draulic to safety information regarding Eaton hose, hose fittings and assembly equipment compatibility on page 4 - Typical ET4000 Equipment Set-up on Shop/Work Table .