Table of Contents - Eatonpub/@eaton/@hyd/documents/content/...2 EATON ET4000 Crimp Machine Set Up...

2 EATON ET4000 Crimp Machine Set Up and Operating Manual E-EQCR-TM002-E June 2005

Table of Contents

SECTION PAGE

Specifications and equipment 3

Shop/work table mounting 4

Check-out procedure 5

Operating instructions (ET4000AR-001) 6

Operating instructions (ET4000AR-002) 7

Operating instructions (T-410-25) 8

Operating Instructions 9

Troubleshooting procedures 10

Repair and replacement items 12

SafetyInstructionsRead and understand theoperator’s manual beforeattempting to operate anyequipment.

WARNINGAeroquip hose, hose

fittings 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. Do not combine or useAeroquip or Weatherheadhose, hose fittings andassembly equipment witheach other, i.e. Aeroquip hosewith Weatherhead fittings, orwith hose, hose fittings orassembly equipment suppliedby another manufacturer.

Eaton hereby disclaims anyobligation or liability (includingincidental and consequentialdamages) arising from breachor contract, warranty, or tort(under negligence or strict lia-bility theories) shouldAeroquip or Weatherheadhose fittings or assemblyequipment be used inter-changeably or with anyhose, fittings or assemblyequipment supplied by anoth-er manufacturer, or in theevent that product instruc-tions for each specified hoseassembly are not followed.

WARNINGFailure to follow

process and product instruc-tions and limitations couldlead to premature hoseassembly failures, resultingin property damage, seriousinjury or death.

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, i.e.Aeroquip 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 thismanual.

2. WEAR SAFETY GLASSES.

3. AVOID PINCH POINTS.Do 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 operation.

4. MAINTAIN DIES WITHCARE. Dies used in theET4000 crimp machine arehardened steel, offeringthe best combination ofstrength and wear resist-ance for long life.Hardened dies are gener-ally brittle and care shouldbe taken to avoid anysharp impact. Neverstrike a die with a hard-ened instrument.

5. USE ONLY SPECIFIEDAEROQUIP/WEATHER-HEAD PRODUCTS. Make hose assembliesusing only Aeroquip andWeatherhead hose and fit-tings specified for thisassembly equipment.

6. 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 specifications.

7. Make sure all dies arecompletely in place, thespacer ring rests againstthe locator bracket, andthe pusher halves areclosed before crimping.

8. DO NOT OVER PRESSURIZE. Do notexceed the 5,000 psihydraulic pressure sup-plied to the machine.

NOTE: All components usedto connect the pump andcrimp cylinder must meetthe criteria set forth in theMaterial Handling InstituteSpecification #IJ100 forhydraulic jacking applications.

9. DIE CHANGE. DO NOTINSERT/REMOVE DIESWHILE THE POWER IS ON OR MACHINE IS INOPERATION.

10. 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 instructions.

11. UNPLUG THE POWERSUPPLY WHEN NOT IN USE.

12. KEEP WORK AREACLEAN. Cluttered areas andbenches invite accidents.

13. DO NOT OPERATEWITHOUT THE BASEADAPTER RING INPLACE.

3EATON ET4000 Crimp Machine Set Up and Operating Manual E-EQCR-TM002-E June 2005

Specifications and Equipment

ET4000 Crimp Machine

ET4000 is ideal for factory high performance machine oper-ations, construction and mine locations. The ET4000 pressoffers the crimping capabilities through 2” I.D. six spiralhose.

Weight: 500 lbs.

Size: 29”high, 21”deep, 12”wide

T-441 Electric Pump

The 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 crimping.

Dimensions: 7 1/2” high, 10” wide, 22” long

Weight: 75 lbs.

Pressure: 5000 psi

Reservoir Capacity: 6 Quarts

Outlet Port Size: 3/4-16 straight thread o-ring

Motor: 1HP, 3450 RPM, 220 volts, 60 cycle, single phase

Hydraulic Oil: ISO 32 (SAE 10W)

Flow: 2.6 GPM to 900 psi to 0.6 GPM above 900 psi

Caution: The T-441 Electric Pump has the relief valveset at 5000 psi. Damage to the press will result and

the warranty may be voided if higher pressures are used.Requires 15 amp fused breaker.


Shop/Work Table Mounting

The following methods are offered as a guide and may bevaried to suit your particular needs.

1. Prepare mounting surface for ET4000 press and pump.Refer to FIGURE 1 for bolt hole layout and optimumheight.

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 lbs.

2. 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 raised.

3. 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. Washers and nuts areinstalled from underneath. TIGHTEN.

4. Place 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 holes.

6. 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. TIGHTEN.

7. Remove middle plug from outlet port in pump. (See FIGURE 3.)

8. Locate press/pump connecting hose assembly andremove plugs. Connect unions into outlet port in pumpand press. TIGHTEN.

9. Remove pipe plug from pump reservoir and replace withbreather cap provided.

10. Before the electric pump (T-441) can be activated, theinterlock cord must be plugged into the switch boxmounted on the ET4000 crimper. After mating thehalves of connection, TIGHTEN the knurled nut.

11. 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 15AMP SERVICE OUTLET.

Instructions for Shop/Work Table Mounting

Figure 1 - Bench Layout for ET4000 Press

Figure 2 - Lifting Hole Layout on ET4000 Press Top Plate

Figure 3 - T-441 Outlet Port


Shop/Work Table Mountingand Check-Out Procedure

CAUTION: Throughout theCheck-out Procedure, checkhose assembly/adapter con-nections for any leaks.TIGHTEN if necessary. For-Seal Swivel Nut Torque forhose assembly; 32-35 ft. lbs.

Check oil lever in powerunit. The oil reservoir wasfilled at the factory, howev-er, if oil is required use ISO32 (SAE 10W).

WARNING: Dot notcycle without base

adapter ring in place.

Check-out procedure forusing electric pump T-441.

1. 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 OUTLET.

2. 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 closed.

4. Hold switch “ON” untilpusher touches the baseadapter ring.

5.RELEASE SWITCH. Pumpwill stop and pusher willretract.

6. REPEAT STEPS 4 & 5APPROXIMATELY SIXTIMES. This will purge thehydraulic system.

Refer to safety information regarding Eaton hose, hose fittings and assembly equipment compatibility on page 2.

Figure 4 - Typical ET4000 Equipment Set-up on Shop/Work Table.


Operating Instructions Using ET4000AR-001

1. OPEN the pusher halves.Select the proper colletassembly for hose typebeing crimped as referencedin the Crimp SpecificationsManual and insert the colletassembly into the baseadapter ring.

NOTE: Lubricate the insidecone of the base adapterring and external surfaces ofthe collet assembly with ahigh-efficiency PTFE basedlubricant.

2. INSERT the hose assem-bly through the bottom ofthe base adapter ring andbetween the two colletassembly halves. Align thefitting with the top of thecollet halves as referencedin the Crimp SpecificationsManual.

3. PLACE the spacer ring (ifapplicable) in the appropriateposition on top of the colletassembly (either flat-side upor flat-side down as refer-enced in the CrimpSpecifications Manual).

4. CLOSE the pusher halvesand begin crimping by acti-vating the pump with turn-ing on the switch. When thepusher halves or spacer ring(if applicable) contacts thebase adapter ring, the crimpis complete.

5. RELEASE the switch andthe pusher will automaticallyreturn. OPEN the pusherhalves and remove thecrimped hose assembly.

6. Visually inspect the crimpand verify the correct crimpdiameter and length.

Refer to safety information regarding Eaton hose, hose fittings, and assembly compatibility on page 2.

Eye protection required when press and pump are in use.

NOTE: Based on the fitting style, correctly align the fittingwith the top of the collet.


Operating Instructions (-20 thru -32 Collets) for Heavy 4-Wire and 6-Wire FittingsUsing ET4000AR-002

1. OPEN the pusher halves. 2. PULL the pusher knobupward. The pusher knob islocated behind the top ofthe pushers near the back ofthe machine.

3. SLIDE pushers to sidewhile holding the pusherknob up.

4. PULL spacer ring locatorbracket upward. TURN thelocator bracket 90˚.

5. REMOVE the baseadapter ring from base plateand PLACE the ET4000AR-002 base adapter ring insidethe base plate.

NOTE: Lubricate the outsidediameter of base adapterring before placing into thebase plate.

6. TURN locator bracket 90˚until aligned properly.

7. SELECT the proper colletassembly for hose typebeing crimped as referencedin the Crimp SpecificationsManual and insert the colletassembly into the baseadapter ring.

NOTE: Lubricate the insidecone of the base adapterring and external surfaces ofthe collet assembly with ahigh-efficiency PTFE-basedlubricant.

8. INSERT the hose assem-bly through the bottom ofthe base adapter ring andbetween the two colletassembly halves. Align thefitting with the top of thecollet halves as referencedin the Crimp SpecificationsManual.

9. CLOSE the pusher halvesand begin crimping by acti-vating the pump with turn-ing on the switch. When thepusher halves or spacer ring(if applicable) contacts thebase adapter ring, the crimpis complete.

10. RELEASE the switch andthe pusher will automaticallyreturn. OPEN the pusherhalves and remove thecrimped hose assembly.

11. Visually inspect the crimpand verify the correct crimpdiameter and length.





Operating Instructions Using T-410-25 Adapter Ring




1. HOLD SWITCH “ON”. Asram starts downward, rotatethe ram return stops out-ward from their inward posi-tion. RELEASE SWITCH.Ram will return to the fullupright position allowingenough clearance for inser-tion of required tooling.

2. OPEN pusher halves andplace T-410-25 adapter ringin the base adapter ring(ET4000AR-001).

NOTE: Lubricate the insidecone of the base adapterring and external surfaces ofthe collet assembly with ahigh-efficiency PTFE-basedlubricant.

3. SELECT proper size collet(referenced in the CrimpSpecifications Manual) forhose type and size beingcrimped. INSERT collethalves into adapter ring.PLACE proper size hose endon hose. Be sure to bottomthe hose.

4. SELECT PROPER spacerring referenced in the CrimpSpecifications Manual.INSERT hose assembly frombelow, between collethalves.

Place appropriate side ofspacer ring on top of colletwith uncrimped hoseassembly held in place.

5. CLOSE pusher halves.HOLD SWITCH ON. Whenspacer ring (shown here inblack) bottoms on adapterring below it, the crimp iscomplete.

6. RELEASE SWITCH toshut off pump and retractpusher halves. OPEN push-er halves. Remove factorycrimped hose assembly andinspect the crimp.

Visually inspect the crimpand verify the correct crimpdiameter and length.


Operating Instructions

FIGURE 8 (BELOW)

Coll-O-Crimp Spacer Ring

Typical spacer ring illustrat-ing both sides of ring

FIGURE C (ABOVE)

Nominal Crimp DiameterMeasurement

Measuring crimp diametersshould be a part of the nor-mal hose assembly proce-dure. To insure a propercrimp diameter reading, fol-low these steps:

1. Measure the diameter inthe middle of the crimpedportion of the hose end.

2. Place the caliper in a position to allow for a measurement across thepressed (flat) portion of the crimp.

3. See crimp diameters in Crimp SpecificationsManual.

Maintenance

Collet AssemblyLubrication:

Every 30 crimps = Re-lubricate sliding surfacesof dies

Every 250 crimps = Removeold grease and re-lubricate

Base Adapter RingLubrication:

Every 250 crimps = Removeold grease and re-lubricate

Every 1,000 crimps =Remove old grease, inspectfor wear or damage and re-lubricate if okay.

Refer to safety information regarding Eaton hose, hose fittings and assembly equipment compatibility on page 2.


Troubleshooting Procedures

Troubleshooting the Eaton T-441 Electric Pump

PROBLEM CAUSE SOLUTIONS (PAGE 11)

Pump/motor does not start Blown fuse; Improper electrical hookup Step #1(cut cord, loose wire, switch malfunctions)

Motor starts but blows fuses High Amps; Pusher doesn’t advance; Step #1Pump binding or scored; Cold oil Replace Pump

Motor runs - Pusher does not advance Shuttle stuck open; Pump coupling sheared; Step #4 Pump unload valve stuck open Replace pump

Motor runs - Pusher advances Pump unload valve stuck shut Replace Pumpbut doesn’t develop final crimp pressure, blows fuseMotor runs - Pusher advances Relief valve leaking; Step #3 but doesn’t develop final crimp pressure. Shuttle valve leaking; Step #4

Relief valve set low Step #3Pusher won’t retract Shuttle valve stuck closed Step #4Erratic Pusher movement Low oil level; Step #2,

Worn Seal Replace PumpNoisy pump; On start up only Low room temp. - Oil too thick; Use lighter weight oil (continuous) Air leaking - Low oil Level Step #2Oil temperature hot Having unit operate at crimping PSI too long; Operate for 3 seconds

at crimp pressure;Low oil level: Step #2,Pump worn (longer cycle time); Replace Pump, Leaking relief valve and /or shuttle valve Step #3, #4

FRONT VIEW BACK VIEW


Troubleshooting Procedures

Troubleshooting EatonT-441 Electric Pump

IMPORTANT: Pressuremust be relieved from

system before disconnect-ing hose, installing gauge orremoving valves from pump.

Step 1: Look for fuse, loosewire connections, switchmalfunctions or damagedcord. Check for properinstallation of a 220 volt cir-cuit.

Step 2: Check oil level -after assembly and systemhas been purged of air, thefluid level should be 1/2”from top of reservoir. Clean,anti-wear type, having a 300SSU/100˚ hydraulic oil is rec-ommended (ISO 32 or SAE10W). Oil is needed to:

1. Transmit power easilythrough system

2. Lubricate moving parts

3. Provide seal clearancesbetween parts

4. To cool or dissipate heat

Step 3: Clean or reset reliefvalve - a 6000 PSI pressuregauge, a 5/16” Allenwrench, a 1” socket and ascrewdriver are required.Remove cap from reliefvalve. Remove adjustmentscrew, spring and ball. Ballshould be attached tospring. Check ball and seatfor possible scoring.Replace spring and ball incavity. Insert a small punchthrough spring against ball.Give punch a moderate tapto seat ball. Return adjust-ment screw to original posi-tion making sure adjustmentscrew is at least one turnfrom bottoming. Remove1/4” NPTF plug from portabove check valve and installa 6000 PSI pressure gage.With 6000 PSI pressuregauge in place, operate unitto full crimping position.Gauge should read approxi-mately 5000 PSI. To raisesetting, turn screw inward(clockwise); to lower, turnscrew outward (counter-clockwise) in 1/4 turn incre-ments. After each adjust-ment, recycle and readgauge for proper setting.Run a cycle of the crimpingsystem for final gauge read-ing before removing gaugeand reinstalling pipe plug.

Step 4: Shuttle Valve - If theshuttle valve is in a closedposition and the ET4000pusher will not retract, itmay be helpful to tap theshuttle valve cap severaltimes to dislodge any siltthat may be causing thestem to bind. If this doesnot free the valve and allowthe pusher to retract, useextreme caution prior to pro-ceeding with shuttle valveremoval as the system isstill under pressure. It maybe advisable to relieve pres-sure at a hose connection toavoid an oil bath. After pres-sure is removed from sys-tem, remove cap and valvecartridge. Soak cartridge in aPETROLEUM BASED SOL-VENT ONLY (clean Stoddardsolvent). Do not useTriethene, Gasoline or PaintThinner as they will damagethe O-Ring Seals. If car-tridge disassembly isrequired use care in remov-ing stem as it has a .0005metal seal fit. Rotate stemin solvent and push fromseat end to remove fromcartridge. Do not lose theloose ball. Wash parts inclean solvent and examinefor any surface markings. Ifnecessary, polish with a finecrocus cloth. After finalcleaning, reassembly car-tridge. Shake cartridge andcheck for free movement ofball and stem. Replace car-tridge if not functional atthis point. Reassemble shut-tle valve into it’s cavity andcheck crimping cycle prior tousing system.

© 2005 Eaton CorporationAll Rights ReservedPrinted in USADocument No. E-EQCR-TM002-EJune 2005

Eaton14615 Lone Oak RoadEden Prairie, MN 55344USATel: 952 937-9800Fax: 952 974-7722www.hydraulics.eaton.com

EatonDr.-Reckeweg-Str. 1D-76532 Baden-BadenGermanyTel: (49) 7221 682-0Fax: (49) 7221 682-788

Eaton20 Rosamond RoadFootscrayVictoria 3011AustraliaTel: (61) 3 9319 8222Fax: (61) 3 9318 5714

Repair and Replacement Items

ITEM NUMBER QTY. PART NUMBER DESCRIPTION

1 1 T-410-1M Micro Switch2 1 ET4000AR-001 Base Adapter Ring3 1 ET4000AR-002 Base Adapter Ring4 1 ET4000TP-001 Locator Bracket Kit5 1 ET4000TP-002 Wear Plate Kit6 1 ET4000C-0018/ET4000C-0017 Yellow Shroud / Red Shroud7 8 120-00429 Screw, Hex Head

5

6

1

7

2

3

4

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