et1280 crimper manual - eaton aeroquip

ET1280 Crimp MachineSet Up and Operating Manual

2 EATON ET1280 Crimp Machine Set Up and Operating Manual E-EQCR-TM003-E September 2005

Table of Contents

SECTION PAGE

Specifications and Equipment ..................................................................................................................................................3

Set-Up and Operating Instructions............................................................................................................................................4

Crimping Procedures ................................................................................................................................................................5

Calibration ................................................................................................................................................................................6

Maintenance ............................................................................................................................................................................6

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

Die Cage Components..............................................................................................................................................................8

SafetyInstructions

Read 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 theET1280 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 andthe cage is positionedproperly on the pressureplate.

8. DO NOT OVER PRESSURIZE. Do notexceed the 10,000 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 AREA CLEAN. Cluttered areas andbenches invite accidents.

3EATON ET1280 Crimp Machine Set Up and Operating Manual E-EQCR-TM003-E September 2005

Specifications and Equipment

Machine Only:

Crimper Dimensions: 13”W x 25.75”D x 13”H

Weight: 141 lbs.

Pump Requirements

Reservoir Capacity: 50 cubic inches or more (820 cc)

Pressure Rating: 10,000 psi (690 bar)

Machine w/110V Power Unit:

Crimper Dimensions: 13”W x 25.75”D x 29”H

Weight: 253 lbs.

Pump Requirements

Reservoir Capacity: 50 cubic inches or more (820 cc)

Pressure Rating: 10,000 psi (690 bar)

Die Cages

Note: Can order FT1380-275-size for tool steel dies vs. powdered metal dies.

FT1380-200-M070 FT1380-200-M180† FT1380-200-M320*†FT1380-200-M090 FT1380-200-M210*† FT1380-200-M370*†FT1380-200-M120 FT1380-200-M240*† FT1380-200-M420FT1380-200-M150*† FT1380-200-M280† FT1380-200-M465†

* Included in the 5 die cage package. † Included in the 8 die cage package.

Die Holder KitFT1380P-2-4

A plate and mounting hardware that can hold two cages. This kit attaches to the back of the Eaton ET1280 crimp machine.

Fitting LocatorsFT1330-XL

For easy positioning of fittings into FT1380 “M” series die cages.

Accessories

ET1280 Crimp Machine

4 2 5 3


Set-Up and OperatingInstructions

Set-Up 110V Power Unit:

1. Mount the crimper onto aworkbench that will supporta minimum of 300 lbs.

2. Remove the plug fromthe hydraulic reservoir ventand replace it with the ventcap supplied with the unit.

Caution: Failure to do so willcause cavitation and damageto the pumping mechanism.Hand tighten the vent cap.

3. Caution: Provide electri-cal service with a dedicatedcircuit (per the crimp machineelectrical requirements) toeliminate the possibility of alow voltage situation.

4. Never use an extensioncord, always plug directlyinto the power outlet.

Hand Pump, Air/HydraulicPump, 12V DC Pump:

1. Mount the crimper to astable workbench using (4)1/2” lag screws or othersuitable fasteners.

2. Place the pump on thebench near the crimper, andinstall a 2021-6-4S adapter inthe pressure port.

3. Install a 2021-6-4Sadapter in the crimper cylin-der port.

4. Connect the hose assem-bly provided to both adapters.(Hose length will vary withpump option.)

OperatingInstructions

Loading and UnloadingDie Cages

Select proper die cage forstyle and size of desiredhose. Refer to the currentCrimp Specifications Manualon the Eaton website forcomplete and detailed crimpspecification information foreach hose and fitting style. Toload the die cage, extend thecrimp ring to its fullest lengthby releasing the hydraulicpressure from the powersource (Figure 1). The diecage may be inserted orremoved in this position.

Figure 1


Establishing CrimpSettings

The adjustment knob at thetop of the machine deter-mines the crimp diameterfor each combination ofhose, fitting, and die cage.The numbers on the dial andbarrel of the machine are forselecting target settings andnot crimp diameters.Settings between 000 and400 can be achieved withthis crimp machine. Consultthe target setting chart forthe ET1280 crimp machinefor the initial setting.

There are 25 marks on thedial (0-24), and 16 marks onthe barrel (025-400 by 025increments). The top of thebarrel corresponds to a 000setting. When the adjust-ment knob is rotated to thetop most position on thecrimper, and the “0” mark islocated as shown in Figure2, the machine setting is000. Each complete down-ward rotation of the adjust-ment knob increases thetarget setting by 025; eachmark around the dial corre-sponds to a 001 change intarget setting. For example,

to achieve a target setting of050, the adjustment knob isrotated until the top of itcorresponds to the 050mark on the barrel, and the0 mark on the dial is linedup with the center, verticalmark on the barrel (seeFigure 3). One more full

downward rotation of thedial would result in a targetsetting of 075. If thedesired target setting is 065,the dial would instead berotated downward 15“marks” on the dial, orapproximately 2/3 of a turn,past the 050 target setting.

Crimping Procedures

Refer to the current CrimpSpecifications Manual on theEaton website for completeand detailed crimp specifica-tion information for eachhose and fitting style.

1. Select and load the properdie cage according to the cur-rent Crimp SpecificationsManual on the Eaton website.

2. Rotate the adjustmentknob/barrel indicator to theproper setting (see Example).

3. Position the fitting to the proper crimping positionwithin the die cage according to the CrimpSpecifications Manual on the Eaton website.

4. To crimp the fitting in an 110V Power Unit model,press and hold the crimpswitch in the upward position.

5. The crimp switch may betoggled up and down asrequired to reposition the fit-ting. To crimp the fitting in aHand Pump, Air/HydraulicPump or 12V DC Pumpmodel, activate the hydraulicpower source according tothe respective pump manual.

Note: The use of a 10,000psi hydraulic power sourceis required to operate theET1280 crimp machine. Iflower rated power units areutilized, improper crimpingmay result.

5. When the fitting is fullycrimped, all movement in themachine will stop, and theblack guard around the piston(pinch point hat) will move upand completely cover the redindicator ring located on theadjustment knob.

6. Release the hydraulicpressure and remove thecrimped hose assembly.

For the 110V Power Unitmodel, this is accomplishedby pressing and holding thecrimp switch in the down-ward position until themachine is completelyretracted. For the HandPump, Air/Hydraulic Pump or12V DC Pump model, referto the manual provided withthe respected pump forpressure release.

7. Verify that the correctcrimp diameter and crimplength is achieved.

Crimping Procedures WARNING:Maintain clear distance from all moving parts.

Figure 4

For proper crimping procedure, refer to the Crimp SpecificationManual on the Eaton website.

Example:

Position the adjustment knob ata setting of 300. Activate thehydraulic pump and attempt acrimp. If the dies crimp the fit-ting, measure the crimp diame-ter and decrease the machinesetting (rotate the adjustmentknob upward) by the sameamount in thousandths of an

inch that you wish to decreasethe crimp diameter (a smallertarget setting number means asmaller crimp diameter. If thedies do not crimp the fitting,decrease the machine settingby 050 increments until the diesdo touch the fitting and theresultant crimp diameter canbe measured.

For a target crimp diameter of0.990 inches and a machinesetting of 250 produces a crimpdiameter of 1.124 inches, sub-tract the target crimp diameter(0.990 inches) from the diame-ter you measured (1.124 - 0.990= 0.134). Subtract 134 from themachine setting (250-134=116)

and change the machine set-ting to 116. Crimp the fittingagain and measure the crimpdiameter. If the crimp diameteris too large, repeat thisprocess. If the crimp diameteris too small, repeat the processbut instead add the differenceto the machine setting.

Figure 2 Figure 3


Calibration

The ET1280 Crimp Machineis factory calibrated. A TTC-8 or WeatherGRIP –8 fittingcrimped with an FT1380-200-M240 die cage and amachine setting of 100

should result in a socketdiameter of 1.000 +/- 0.003inches.

If excessive wear occurs inthe crimp ring, or any of thefunctional components arereplaced, a minor recalibra-tion may be necessary. Thiscan be accomplished by firstloosening the two #8-32 setscrews in the adjustmentknob (see Figure 5) and thenperforming the crimpdescribed above.

If the actual measured crimpdiameter is, for example,1.010 inches instead of 1.000inches, the black dial piececan be rotated inside theadjustment knob (leavingthe adjustment knob exactlywhere it is positioned) untilthe number “10” on the diallines up with the center ver-tical line on the barrel.

Then rotate the adjustmentknob and dial together untilthe “0” mark on the dial isonce again lined up with thecenter vertical line on thebarrel. Repeat the crimpprocedure until the 1.000inch crimp diameter isachieved.

WARNING:Maintain clear distance from all moving parts.

Maintenance

IntervalsDIE CAGE LUBRICATION

Every 50 crimps Relube slidingsurfaces of dies

Every 500 crimps Remove oldgrease andrelube

Every 1000 crimps Die cage maintenance

CRIMP RING MAINTENANCE

Every 500 crimps Remove oldgrease andrelube

Every 2000 crimps Remove oldgrease;.Inspect forwear or damage andrelube if okay.

NOTE: Use NEVER-SEEZ lubricant (Eaton part number FT1092).

Procedures

MACHINE MAINTENANCE PROCURES

1. Sliding surfaces must be kept free of dirt and other abrasive materials 2. All exposed black metal surfaces should be coated occasionally with a light film of oil

to prevent corrosion.3. Periodically check the oil level in the fluid reservoir of the hydraulic power unit.

Maintain the oil level of pump manufacturer’s hydraulic oil as needed.

NOTE: Completely retract the crimp ring when checking the oil level.

DIE CAGE MAINTENANCE PROCEDURES

1. Lubricate the die cage. For maximum service. FT1380 die cages require lubrication at 50-crimp intervals with NEVER-SEEZ (Eatonpart number FT1092). FT1092 is an 8-ounce container that will provide sufficient lubricant for approximately 5,000 crimps.Periodically remove NEVER-SEEZ residue that has built-up on the sides of the dies and the crimp ringduring the crimping process. NEVER-SEEZ residue becomes contaminated with metal and plating chipsand airborne contaminants, which can cause premature wear of the dies and crimp ring. It should care-fully be removed without mixing it with newly applied NEVER-SEEZ.

2. Die cage maintenance should be performed at 1000-crimp intervals or every six months, which ever occursfirst. Die cages should be clean of grease and debris and inspected for worn or damaged components.

a. The sliding surface of the dies should appear smooth with no apparent galling. Galled dies must be replaced. Individual dies in a cage can be replaced without replacing all eight dies.

b. Replace springs that show any sign of damage or collapse (are shorter than other springs).c. The spring plate should appear smooth with no apparent galling.

Galled spring plates must be replaced.d. Inspect remaining components and replace those that are badly worn.

3. Reassemble components and liberally apply NEVER-SEEZ to the die surface which slides along the spring plate. Torque the die cage bolts to 50in.-lbs.

4. Ensure that all dies slide in and out freely.

Figure 5


Crimp Machine Components

5

1

6

3

98

42

7

10

ITEM PART NUMBER DESCRIPTION MATERIAL QUANTITY

1 ET1280C-0002 Barrel Aluminum 12 ET1280C-0012 Washer Steel 13 ET1280C-0003 Adjustable Knob Steel 14 ET1280C-0001 Dial Indicator Aluminum 15 ET1280C-0007 Pinch Point Hat Plastic 16 FF90625 1/4-20 x 3/8" Button Head Cap Screw Steel 47 ET1280C-0014 5/16-18 Button Head Cap Screw Steel 18 FF90626 Set Screw Steel 29 FF90627 229 O-Ring Neoprene 110 ET1280C-0015/ET1280C-0017 Red Shroud/Yellow Shroud Steel 1


Die Cage Components

4 2 5 3 1 6

DETAIL FT1380-2-9 FT1380-2-9A QUANTITYNUMBER BILL OF MATERIAL BILL OF MATERIAL DESCRIPTION REQUIRED

1 FT1330-2-9-21 FT1330-2-9-2 Die spring 8 or 16*2 FT1380-2-9-3 FT1380-2-9-2 Front plate 13 FT1330-2-9-13 FT1330-2-9-3 Spring Plate 14 FT1330-2-9-55 FT1330-2-9-5 Button head Cap Screw 45 FT1330-2-9-66 FT1330-2-9-6 Spacers 46 FT1380-2-9-1 FT1380-2-9-1 Back Plate 1

*The FT1380-200-NO. (FT1380-2-9) requires 16 springs and the FT1380-201-NO. (FT-1380-2-9A) requires 8 springs.

© 2005 Eaton CorporationAll Rights ReservedPrinted in USADocument No. E-EQCR-TM003-ESeptember 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

et1280 crimper manual - eaton aeroquip

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