Danfoss ET1187 Crimp Machine

Product Information

The ET1187 Crimp Machine is a hydraulic crimping machine designed for creating hose assemblies. It is manufactured by Danfoss and is compatible with Aeroquip and Weather head hoses and fittings. The machine is equipped with hardened steel dies for long-lasting performance.

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)
• Hose Production Capacity: (-4 through -16 4S)

Accessories
The ET1187 Crimp Machine comes with the following accessories:

• None specified in the provided text. Please refer to the complete user manual for a detailed list of accessories.

Product Usage Instructions

1. Read and thoroughly understand the operator’s manual before operating the ET1187 Crimp Machine.
2. Prevent unauthorized operation by only allowing individuals who have read and understood the manual to operate the equipment.
3. Wear safety glasses during operation to protect your eyes.
4. Avoid pinch points by keeping your hands clear of all moving parts and not resting your hand on the crimp ring.
5. Ensure proper maintenance of the hardened steel dies. Avoid sharp impacts and never strike a die with a hardened instrument.
6. After crimping, check and verify the correct crimp diameters of all fittings. Do not use hose assemblies that do not meet Danfoss crimp specifications.
7. Make sure all dies are correctly in place, the spacer ring rests against the placement pins, and the pusher is pulled forward into the detent position before crimping.
8. Do not exceed the 10,000 psi hydraulic pressure supplied to the machine. Ensure all components used to connect the pump and crimp cylinder meet the specified criteria for hydraulic jacking applications.
9. Do not insert or remove dies while the power is on or the machine is in operation.
10. Prior to operation, secure the crimp machine to a stable work surface to prevent tipping.
11. Use only specified Aeroquip and Weather head hoses and fittings for creating hose assemblies with this machine.
12. Unplug the power supply when the machine is not in use.
13. Keep the work area clean to avoid accidents.

Safety instructions

Read and understand the operator’s manual before attempting to operate any equipment.

WARNING
Aeroquip hose, hose fittings and assembly equipment should be used only with other Aeroquip hose, hose fittings and assembly equipment and Weather-head hose, hose fittings and assembly equipment should be used only with Weather head hose, hose fittings and assembly equipment. Do not combine or use Aeroquip or Weather head hose, hose fittings and assembly equipment with each other, i.e. Aeroquip hose with Weather head fittings, or with hose, hose fittings or assembly equipment supplied by an-other manufacturer.
Danfoss hereby disclaims any obligation or liability (including incidental and consequential damages) arising from breach of contract, warranty, or tort (under negligence or strict liability theories) should Aeroquip or Weather head hose fittings or assembly equipment be used interchangeably or with any hose, fittings or assembly equipment supplied by another manufacturer, or in the event that product instructions for each specified hose assembly are not followed.

WARNING
Failure to follow process and product instructions and limitations could lead to premature hose assembly failures, resulting in property damage, serious injury or death. Aeroquip and Weather head fitting tolerances are engineered to match Aeroquip and Weather head hose tolerances. The combination or use of Aeroquip or Weatherhead hose and hose fittings with each other, i.e. Aeroquip hose with Weather-head fittings, or with hose or fittings supplied by another manufacturer may result in the production of unreliable and/or unsafe hose assemblies and is neither recommended or authorized by Danfoss.

Safety Instructions

1. PREVENT UNAUTHORIZED OPERATION. Do not permit anyone to operate this equipment unless they have read and thoroughly understand this manual.

2. WEAR SAFETY GLASSES.

3. AVOID PINCH POINTS. Do not rest your hand on the crimp ring. Keep your hands clear of all moving parts. Do not allow any-one, other than the operator, close to the equipment while it is in operation.

4. MAINTAIN DIES WITH CARE. Dies used in the ET1187 crimp machine are hardened steel, offering the best combination of strength and wear resistance for long life. Hardened dies are generally brittle and care should be taken to avoid any sharp impact. Never strike a die with a hardened instrument.

5. USE ONLY SPECIFIED AEROQUIP/ WEATHERHEAD PRODUCTS. Make hose assemblies using only Aeroquip and Weather head hose and fittings specified for this assembly equipment.

6. VERIFY CORRECT CRIMP DIAMETERS. Check and verify correct crimp diameters of all fittings after crimping. Do not put any hose assemblies into service if the crimp diameters do not meet Danfoss crimp specifications.

7. Make sure all dies are completely in place, the spacer ring rests against the placement pins, and the pusher is pulled forward into the detent position before crimping.

8. DO NOT OVER PRESSURIZE. Do not exceed the 10,000 psi hydraulic pressure supplied to the machine.
   NOTE: All components used to connect the pump and crimp cylinder must meet the criteria set forth in the Material Handling Institute Specification

   IJ100 for hydraulic jacking applications.

9. DIE CHANGE. DO NOT INSERT/REMOVE DIES WHILE THE POWER IS ON OR MACHINE IS IN OPERATION.

10. SECURE THE EQUIPMENT TO A STABLE WORK SURFACE. Prior to operation, secure the crimp machine to a stable work surface to prevent the equipment from tipping.

11. UNPLUG THE POWER SUPPLY WHEN NOT IN USE.

12. KEEP WORK AREACLEAN. Cluttered areas and benches invite accidents.

Specifications and Accessories

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)
• Hose Production Capacity: (-4 through -16 4S)

ET1187 Crimp Machine shown with base frame.
(Part number: ET1187-001 Kit, includes ET1187C-0017 bench top stand).

ET1187 Crimp Machine shown with wall mount frame.
(Part number: ET1187-002 Kit, includes wall mount bracket ET1187-0019).

NOTE
Your new crimp machine has been calibrated and filled with hydraulic oil in the factory. Do not remove any plugs or caps until necessary. Excess air in the hydraulic system may cause erratic cylinder movement during retraction.

Accessories

• Bench Mount Stand.
  (Part number: ET1187C-0017).

• Wall Mount Bracket.
  (Part number: ET1187C-0019).

• High Performance PTFE Lubricant (Part # T-400-G)

Setup and Assembly

1. Your new ET1187 crimp machine comes assembled for ease of shipment. Before use, the machine must be assembled to the base with the supplied quick release pins.

2. Remove the cap from the top cylinder port and install the –06 size ORS, 90 degree adapter using 23-24 ft. lbs. assembly torque. Orient the adapter so that it points to the rear of the crimp machine, away from the operator.

3. Install the pump connecting hose assembly to the cylinder adapter with the –06 size 37 degree swivel nut fittings using 18- 20 ft. lbs. assembly torque.

4. Do not exceed an 8” minimum bend ra-dius of the pump connecting hose when attaching the hose to the pump
   and cylinder.

5. If using your own pump, make sure it has the requirements listed in the specifications section above.

6. Place the pump on the work surface to either side of the crimp machine. Install the 90 degree adapter to the pump pressure port (Male NPTF threads should be tightened following the hex-marking procedure of 2 to 3 turns past hand tight).

7. Remove excess air from the hydraulic system. This can be accomplished by placing the pump at a higher level than the cylinder and cycling the machine approximately five times.

8. Secure the machine frame to a stable work surface using lag screws or other suitable fasteners.

Operating Instructions

Establishing Crimp Settings
The color coded collar and crimp adjustment knob above the pusher is designed to easily adjust to the Aeroquip and Weatherhead core products to determine the crimp diameter for each combination of hose, fitting, and die cage (See below). Simply turn the collar to the correct color to match the lay line on the hose, adjust the ring so that the correct size dot aligns with the correct size line on the collar and the machine is set for the correct crimp. Load the correct crimp die based on the crimp die chart attached to the machine, and the machine is ready to crimp.
The micrometer section can be used to crimp other products not captured on the 3 primary collar settings, based on crimp target settings available in PowerSource.

GH681 / H180
Standard machine comes with GH681/H180 settings built in for use with TTC/Z fittings in sizes -4 through -16. -12 size setting shown

GH781 / H280
Standard machine comes with GH781/H280 settings built in for use with TTC/Z fittings in sizes

GH493 / H430
Standard machine comes with GH493/H430 set-tings built in for use with TTC12/4S fittings in sizes – 6 through -10, and 4S fittings in sizes -12 and -16. – 16 size setting shown

Micrometer Dial
The micrometer section can be used to crimp other products not captured on the 3 primary collar settings, based on crimp target settings available in Power- Source.

Crimp Procedures (using FT1380-200-MXXX Series Die Cages)

• Step 1
  Figure 1
  Reference the crimp specification chart on the front of the crimp machine to determine proper crimp dies for hose and fitting.

• Step 2
  Figure 2
  Install FT1380-200-XXX Die Cage per crimp die chart on the front of the machine.

• Step 3
  Figure 3
  Rotate hose product selection collar until desired product group is facing operator. NOTE: Collar has detents at each position to help ensure proper alignment with corresponding product groups.
  

• Step 4
  Figure 4
  Rotate crimp adjustment ring until desired dash size is lined up with corresponding dash size on product selection collar.

• Step 5
  Figure 5
  Insert the hose assembly up through the bottom of the base ring and die cage. Begin crimping by actuating the pump.

• Step 6
  Figure 6
  Crimp cycle is complete when cylinder travel stops and the green indicator ring on the piston shows beneath the top plate. After completion, visually inspect the crimp and verify the correct crimp diameter and length.

Correct Crimp Settings Example

Figure 7
Crimp adjustment ring is in correct position for crimping -16, when vertical lines on the crimp adjustment ring and product selection collar are aligned, and -16 horizontal line on the collar is even with the top of the crimp adjustment ring.

Figure 8
Crimp adjustment ring rotated one turn past correct position for -16 hose on the product selection collar.

Figure 9
Crimp adjustment ring rotated one turn short of correct position for -16 hose on the product selection collar.

Establishing Crimp Settings – Micrometer Dial

The micrometer section on the color coded collar can be used to crimp other products not captured on the 3 primary color coded collar settings, based on crimp target settings available in Power Source.
The crimp adjustment knob above the pusher determines the target crimp diameter for each combination of hose, fitting, and die cage. The numbers on the color coded collar and crimp adjustment knob are for selecting target settings and not crimp diameters.
Settings between 000 and 400 can be achieved with this crimp machine.
Consult the target setting chart in Power-Source for the ET1187 crimp machine for the initial setting.

There are 25 marks on the crimp adjustment knob (0-24), and 16 marks on the barrel (025-400 by 025 increments)
When the crimp adjustment knob is rotated to where the knob is lined up with the 000 line on the collar, and the “0” mark on the knob is lined up as shown in figure 10. The crimper target setting is set at 000.
When the crimp adjustment knob is rotated to the top most position on the crimper, and the “0” mark is located as shown in Figure 11, the machine setting is 400.
Each complete upward rotation of the adjustment knob increases the target setting by 025; each mark around the dial corresponds to a 001 change in target setting.

For example, to achieve a target setting of 050, the adjustment knob is rotated until the top of it corresponds to the 050 mark on the collar, and the 0 mark on the dial is lined up with the center, vertical mark on the collar.
One more full upward rotation of the crimp adjustment knob would result in a target setting of 075. If the desired target setting is 065, the dial would instead be rotated upward 15 “marks” on the dial as shown in figure 12, or approximately 2/3 of a turn, past the 050 target setting.

Maintenance

Intervals
DIE CAGE LUBRICATION

• Every 50 crimps Relube sliding surfaces of dies
• Every 500 crimps Remove old grease and relube
• Every 1000 crimps Die cage maintenance

Crimp Ring Maintenance

• Every 500 crimps Remove old grease and relube
• Every 2000 crimps Remove old grease, inspect

NOTE: Use Accrolube lubricant (Danfoss part number T-400-G).

Procedures
MACHINE MAINTENANCE PROCURES

1. Sliding surfaces must be kept free of dirt and other abrasive materials.
2. All exposed zinc coated 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 PROCEDURES1

1. Lubricate the die cage.
   For maximum service. FT1380 die cages require lubrication at
   50-crimp intervals with Accrolube (Danfoss part number T-400-G). Periodically remove Accrolube residue that has built-up on the sides of the dies and the crimp ring during the crimping process. Accrolube residue becomes contaminated with metal and plating chips and airborne contaminants, which can cause premature wear of the dies and crimp ring. It should carefully be removed without mixing it with newly applied Accrolube.

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

3. 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.

4. Replace springs that show any sign of damage or collapse (are shorter than other springs).

5. The spring plate should appear smooth with no apparent galling. Galled spring plates must be replaced.

6. Inspect remaining components and replace those that are badly worn.

7. Reassemble components and liberally apply Accrolube to the die surface which slides along the spring plate. Torque the die cage bolts to 50in.-lbs .

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

Description of Components

About Danfoss Power Solutions FC
Danfoss hoses, fittings, and tooling provide the ultimate fluid conveyance solutions for a variety of equipment and applications around the world. We proudly engineer to support a sustainable future for tomorrow.
To learn more please visit: http://www.danfoss.com/en/about-danfoss/our- businesses/power-solutions
Danfoss Power Solutions
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Eden Prairie, MN 55344, USA
Phone: 952-937-9800
Danfoss Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515-239-6000
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Krokamp 35
D-2439 Neumünster, Germany
Phone: +49 4321 871 0
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Nordborgveg 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
Danfoss Power Solutions Trade (Shanghai) Co. Ltd.
Building #22, No 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: +86 21 3418 5200w

Danfoss can accept no responsibility for possible errors in catalogs, brochures, and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed. All trademarks in this material are the property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
©Danfoss ET1187 Crimp Machine Operator’s Manual | 2023.02.

References

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