ET1000 Crimp Machine

Operator’s ManualPortable

Light Duty

Positive Stop

Table of Contents

SafetyInstructions

2 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 Instructions

Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Crimping Procedures (large collets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Crimping Procedures (small collets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Maintenance

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Machine Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6

Crimp Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

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

WARNINGAeroquip 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. 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, resulting inproperty 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 unsafe hoseassemblies and is neither rec-ommended nor authorized byEaton.

Safety Instructions

1. PREVENT UNAUTHORIZEDOPERATION. Do not per-mit anyone to operate thisequipment unless theyhave read and thoroughlyunderstand this manual.

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 theET1000 crimp machine arehardened steel, offeringthe best combination ofstrength and wear resist-ance for long life.Hardened dies are general-ly brittle and care shouldbe taken to avoid anysharp impact. Never strikea die with a hardenedinstrument.

5. USE ONLY SPECIFIEDAEROQUIP/WEATHER-HEAD PRODUCTS. Makehose assemblies using onlyAeroquip and Weatherheadhose and fittings specifiedfor this assembly equip-ment.

6. 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 crimpspecifications.

7. 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 beforecrimping.

8. DO NOT OVER PRESUR-IZE. Do not exceed the10,000 psi hydraulic pres-sure supplied to themachine.

NOTE: All components usedto connect the pump andcrimp cylinder must meet thecriteria 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 tooperation, secure the crimpmachine to a stable worksurface to prevent theequipment from tipping.

11. UNPLUG THE POWERSUPPLY WHEN NOT INUSE.

12. KEEP WORK AREACLEAN. Cluttered areasand benches invite acci-dents.

3EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003

Specificationsand Accessories

NOTE:

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 system.

Specifications

Crimper Dimensions: 22” tall x 16” width x 14” deep

Weight: 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.

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 shipment.Before 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 operator.

3. Install the pump connect-ing hose assembly to thecylinder adapter with the–06 size 37 degree swivelnut fittings using 18-20 ft.lbs. assembly torque.

4. Do not exceed an 8” mini-mum bend radius of thepump connecting hosewhen attaching the hoseto the pump and cylinder.

5. If using your own pump,make sure it has therequirements listed in theSpecifications sectionabove.

6. 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 fasteners.

Setup andAssembly

4 EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003

OperatingInstructions

Description ofComponents

Crimping Procedures(using larger collets)

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 die ring and external sur-faces of the collet assemblywith a high-efficiency PTFEbased lubricant.

Insert the collet assemblyinto the base die ring.

Step 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 positioninghandle.

Step 5:

Begin crimping by actuatingthe pump. When the spacer ring bottoms outagainst the base die ring,the crimping is complete.(NOTE: Visually inspect thecrimp and verify the correctcrimp diameter and length.)

Die RingAdapter

Split ColletAssembly Spacer RingsET1000 Crimp Machine

5EATON 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 positioninghandle.

Step 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 plate.

Place the die ring adapterplate into the base die ring.

Step 2:

Lubricate the external surfaces of collet assemblyhalves with a high-efficiencyPTFE- based lubricant.

Insert the collet assemblyinto the die ring adapterplate.

Step 3:

Insert the hose assemblythrough the bottom of thebase die ring and upbetween the two colletassembly halves. Align thefitting with the top of the col-let halves as referenced onthe Collet/Spacer RingSelector Chart.

Step 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

Maintenance

Collet Assembly & DieRing Adapter PlateLubrication:

Every 30 crimps = Re-lubricate sliding surfacesof dies

Every 250 crimps = Removeold grease and re-lubricate

Base Die Ring & Die RingAdapter PlateMaintenance:

Every 250 crimps = Removeold grease and re-lubricate

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

1. Sliding surfaces must bekept free of dirt and otherabrasive materials.

2. All exposed black metalsurfaces should be coatedoccasionally with a lightfilm of oil to prevent corro-sion.

3. Some fitting/hose combi-nations require full pumpreservoir capacity to com-plete the crimp cycle. The oil level in the fluidreservoir of the hydraulicpump should be checkedperiodically and refilled asrequired with the pumpmanufacturer’s hydraulicoil as needed.

NOTE: Completely retractthe cylinder when checkingthe oil level.

Maintenance Intervals

Machine MaintenanceProcedures

7EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003

Crimp MachineComponents

4

3

5

6

7

7

2116

15

15

1

16

11

1718

8

14

15

20

1912

10

13

9 2

1

ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY

1 ET1000C-0001 Base 1 12 140-06602 Detent Screw 12 ET1000C-0002 Die Ring 1 13 140-15984-01 Flat Head Cap Screw 23 ET1000C-0003 Cylinder Cap 1 14 140-15983-01 Flat Head Cap Screw 24 140-05691 T Ring Seal 1 15 120-70188-41 Split Roll Pin 25 ET1000C-0004 Piston 1 16 ET1000C-0008 Hex Head Bolt 46 ET1000C-0005 5 in. Spring 1 17 140-05687 Spring Retainer 17 140-15962 3 1/2 in. Spring 2 18 140-15984 Flat Head Cap Screw 28 140-05688 Slide Plate 1 19 140-05695 Slide Pull Rod 19 140-06924 Flange Slide Plate 1 20 140-05694 Slide Pull Knob 110 140-06925 Bushing Slide Plate 2 21 140-06701 1.5 oz. Grease 111 ET1000C-0006 Pusher 1

© 2003 Eaton CorporationAll Rights ReservedPrinted in USADocument No. E-EQCR-TM001-ESeptember 2003

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