Danfoss FT1360 Crimp Machine Instruction Manual

Danfoss FT1360 Crimp Machine

Warning
Aeroquip fitting tolerances are engineered to match Aeroquip hose tolerances. The use of Aeroquip fittings on hose supplied by other manufacturers and/or the use of Aeroquip hose with fittings supplied by other manufacturers may result in the production of unreliable and unsafe hose assemblies and is neither recommended nor authorized by Aeroquip. Failure to follow the Aeroquip process and product instructions and limitations could lead to premature hose assembly failures resulting in property damage, serious injury, or death. The user must exercise extreme care when operating any Aeroquip assembly equipment with powered moving components. Safety glasses must be worn at all times when using any Aeroquip assembly equipment. Read and understand the owner and operator’s manual before attempting to operate any equipment. 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 hose, fittings, or assembly equipment be used with the hose, fittings, or assembly equipment supplied by another manufacturer or if product instructions for each specified hose assembly are not followed.

FT1360

CAPABILITIES

• ALL SIZES THRU -32 INCLUDING INTERNAL SKIVE

DIE SIZE

• FT1307 CAGE STYLE DIES ARE 1.100” WIDE AND 2.000” LONG
• FT1209 CAGE STYLE DIES ARE 1.237“ WIDE AND 3.250“ LONG

POWER UNIT

• 10 H.P./ 3 PHASE/18 GPM WITH SLOW DOWN CIRCUITRY

CYLINDER SIZE

• 8“ BORE/ 5 3/4“ STROKE/ 4” ROD

MAJOR USE

• PRODUCTION CRIMP MACHINE (LARGE DISTRIBUTORS, OEMS)
• FTl209 REPLACEMENT

COMMENTS

• BACKSTOP LOCATOR SYSTEM STANDARD
• WORK-LAMP STANDARD
• STATIONARY CAGE (CRIMP RING MOVES ONTO DIES FOR CRIMP OPERATION)
• DIGITAL ENCODER/TRANSDUCER POSITION SYSTEM
• 2:1 CALIBRATION RATIO, SAME AS FT1330 AND FT1340

Introduction

The Aeroquip FT1360 crimp machine has been designed to provide production- style crimping capability for all Aeroquip distributors as well as original equipment manufacturers. The user can crimp -2 through -40 size Aeroquip fittings onto all Aeroquip hose styles including four and six-wire spiral hoses requiring internal skive crimp style fittings. Each set of eight crimp dies is contained in a die cage which slides in and out of the machine as one package, thus eliminating time-consuming and messy die insertion and removal. A compact hydraulic power unit supplies pressure to a cylinder which provides the required crimping force through the mechanical advantage of a crimp ring and crimp die cage. The crimp die cage is fixed, and the crimp ring moves over the cage to ease crimping without the fitting moving.

Limited Safety Instructions

1. KEEP THE WORK AREA CLEAN. Cluttered areas and benches invite accidents.
2. AVOID DANGEROUS ENVIRONMENT. Keep the work area well-lit. Do not operate equipment when floors are slippery. Always ensure you have sound footing with both feet on the floor. Do not operate controls if hands or controls are wet.
3. PREVENT UNAUTHORIZED OPERATION. Do not permit anyone to operate this machine unless they have read and thoroughly understand this manual. Unplug the machine when not in use.
4. USE THE RIGHT DIE CAGE. Do not force the dies to do a job they were not designed for. Never mix dies of different sets. Dies are assembled in a cage.
5. WEAR PROPER APPAREL Do not wear loose clothing or jewelry that could get caught in moving parts. Rubber-soled footwear is recommended for best footing.
6. DO NOT OVERREACH. Keep proper footing and balance at all times.
7. MAINTAIN DIES WITH CARE. Most dies used on the FT1360 crimp machine are hardened tool steel affording 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.
8. INSERT CRIMP DIE CAGE. CAUTION: MAKE SURE DIES ARE COMPLETELY IN PLACE, FLAT AGAINST PRESSURE PLATE, OR DAMAGE TO THE DIES OR MACHINE MAY RESULT.
9. CHECK PARTS. Check for alignment of all moving parts, broken parts, and any other conditions that may affect the machine’s operations.
10. STORE DIES PROPERLY. Never place die cages, tools, fittings, or any other material on the machine where it may interfere with or fall into the crimping operation.
11. DO NOT OVER PRESSURE. Do not exceed 3.100 psi hydraulic pressure supplied to the machine. This setting is preset at the factory and should not require adjustment.
12. DIE CAGE TOOLING CHANGE. Do not insert or remove the die cage while the power unit is turned on.
13. AVOID PINCH POINT. Do not rest your hand on the crimp ring. Keep hands well away from all moving parts. Do not operate with any personnel close to moving parts.
14. USE PROPER PROCEDURES. Never rush a hose assembly. Always take the time required to ensure all specified procedures are followed.

Specifications

• Dimensions 32” wide, 42” deep, 50” high
• Weight 2,000 lbs.
• Motor 10 HP
• Electrical Requirements 230/460 volts, 60 Hz, 3 phase
• Pump 15 gpm to preset limit, 2 gpm to 3,000 psi
• Reservoir 10-gallon, SAE 10W hydraulic oil
• Hose -4 through -40 textile and wire reinforced, through -32 six wire spiral

Installation

The FT1360 crimp machine is delivered completely plumbed and wired. The reservoir has been filled with 10-weight hydraulic oil.

1. Uncrate the machine and position it in its work location on a floor capable of supporting a machine weighing 2000 pounds.
2. Position the disconnect switch to the “OFF” position.
3. The transformer in the electrical box is wired for 460 volts.
4. The machine comes wired for 460 volts. Thermal overloads and fuses are provided for conversion to 230 volts. Consult Danfoss with any questions regarding assistance with conversion procedures.

• 5. Install 460-volt power into the disconnect.
• If the FT1360 crimp machine fails to operate properly, 2 of the incoming disconnect 3Ø lines must be switched.

Tooling

Crimp Die Cages: Crimp dies for the FT1360 crimp machine are contained in a die cage which can be inserted as a package into the machine, thus eliminating time-consuming and inaccurate insertion of individual dies. Each set of eight crimp dies is contained in a separate die cage, thus eliminating concern from inter-mixing dies of different sets. Crimp die cage part numbers are similar to crimp die part numbers. In either case, the die suffix number is the same. Use the PowerSource Crimp Spec tool to determine the tooling that should be used. The FT1209 crimp dies are longer than the FT1307 dies. They will accommodate the longer sockets required with these assemblies.

Basic Machine Operation

With the machine installed as outlined in this manual and with the disconnect switch turned on. push the start button. The pump will start running. The crimp ring is pulled over the crimp cage by a hydraulic cylinder. Depressing the footswitch will move the crimp ring forward extending the cylinder. Pressing the jog reverse button will move the crimp ring back to its retracted position.. You will find that being able to jog the crimp ring in either direction will be very helpful when positioning the fitting within the crimp dies during the crimping cycle or when setting up the fitting locator.

Maintenance

1. Sliding surfaces must be kept free of dirt and other abrasive materials.
2. Surfaces of crimp die and the crimp ring where metal-to-metal contact is made should be lubricated with high-efficiency PTFE grease (Danfoss part number FF91455) at the beginning of each production run or as required during production (minimum of once per 25 crimps, and more often with larger hose).
3. All exposed black metal surfaces should be coated occasionally with a light film of oil to prevent corrosion.
4. The oil level in the fluid reservoir of the hydraulic power unit should be checked periodically and maintained at a level one inch below the top. the reservoir. Note: The crimp die cage should be retracted fully when the oil level is checked. Add SAE 10-weight hydraulic oil as necessary.

Using the PowerSource Crimp Spec Tool

• Visit the PowerSource Crimp Spec tool at danfoss.com/crimp for tooling and Crimp Spec details.

Operating Instructions

Hose Preparation

Hose Preparation and Pre-Assembly
Select the proper hose, nipple, and socket combination. Cut the hose to length, assemble, and crimp. Skiving is required for flat factory crimp.

Crimp Machine Setup
Determine the correct crimp die cage to be used to crimp the assembly you have selected. With the cylinder retracted fully, install the crimp die cage by sliding it downward against the pressure plate until the shoulder bolts on the pressure plate are seated in the slots on the back of the crimp die cage and the bolt on the back of the crimp die cage is seated in the slot at the top of the pressure plate.

Positioning The Fitting Locator Straight Fittings
If only one hose assembly is being crimped on this setup, you will probably choose to locate the fittings visually rather than set the locator. Whether the fitting is positioned within the dies visually or with the aid of the locator, the proper position will be the same. The scribe line at the skirt end of the socket must be lined up with the face of the jaw inset. The locator can be moved forward by loosening the locking knob. When the locator touches the end of the fitting tighten the knob. The locator is spring-loaded to accommodate for hose growth during crimping operation.

Setting the digital encoder
The forward travel of the crimp cylinder is limited or controlled by the linear Transducer position system. By setting the encoder to a number between 000 and 999 you can control the last 2 inches of cylinder travel. The larger the encoder number the further the cylinder travels before it stops, therefore the crimp diameter gets smaller as the encoder number increases.

Example: You want to crimp the FC195-16 hose with a 1401 -16 socket. Find that the crimp diameter is 1.529 – 1.539. The goal is to hit the average diameter which is 1.534. Crimp an assembly with the encoder at 000. If you do not make an impression on the socket, increase the setting by 100 and crimp again. Continue this process until you can measure an impression. Let’s say for example that at 300 you’ve made an impression in the socket and measured one of the flats to be 1.793. Because the ratio of the encoder to the cylinder is approximately 2 to 1, the new encoder setting will be (1.793 -1.534) x 2 added to 300. The new setting should be approximately 818. Readjust if necessary, and once you have an established setting, record it in the “Micro Setting” column within your crimp specification bulletin. Remember, always check your first assembly for proper crimp diameter.

Shortening the return stroke
When crimping several identical assemblies, it may be desirable to shorten the machine cycle time by shortening the return stroke of the cylinder. This can be done by jogging the crimp ring forward until just enough clearance remains to insert the uncrimped fitting into position. Now slide the split clamp nearest the proximity switch directly under the front of the cylinder back to check the return stroke. It is infinitely adjustable by sliding the split collar.

Crimping pre crimped -32 assemblies
The crimp dies in the FT1307-200-23 crimp die cage are shorter than the required length of crimp for -32 size Danfoss fittings. To crimp a -32 size fitting with these dies, it is necessary to use a special fitting onto which the socket has been pre-crimped at the factory. The chart below shows the proper position for loading -32 pre-crimped fittings within the FT1307-200-23 crimp die cage. Two-piece -32 fittings (separate nipple and socket) can be crimped with the FT1360 crimp machine using the FT1209-200-17 crimp die cage. Proper location, in this case, will be the same as described in the section “Position the Fitting Locator”.

Crimping field crimp-style assemblies

Field crimp (barrel crimp) style hose assemblies were designed for “on location” repairs with a minimum of equipment. Skiving is not required with field crimp fittings. The socket is pre-crimped to the nipple so the fitting can simply be pushed onto the hose and crimped. When crimping field crimp- style hose assemblies, special procedures must be followed when locating these assemblies in the crimp die cage. The crimp socket has a line scribed near each end. The distance between the scribe lines is equal to the length of the crimp dies. When crimped, the dies must be centered between the scribe lines. This can be done by aligning the face of either end of the crimp die with the scribe line on that end of the socket (See Illustration).

Recalibration procedure

1. Insert an FT1307-200-8 crimp cage into the crimper and then crimp a 1401-16 socket using a setting of 920 on the digital encoder.
2. If a diameter of 1.483 + .003 is obtained, no further adjustments are necessary.
3. If a diameter of less than 1.483 is obtained, the transducer backstop must be moved toward the transducer. Consequently, if the diameter is more than 1.483 the backstop must be moved away from the transducer.
4. The transducer backstop is located at the top left side of the crimper as shown on page 13, detail 19.

FT1360 Crimp Machine

FT1360 Crimp Machine

FT1360 Crimp Machine parts list

Cylinder subassembly

Electrical schematic

Electrical schematic parts list

Hydraulic diagram

Hydraulic diagram parts list

Crimp Die Cage

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
14615 Lone Oak Road 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

Danfoss Power Solutions GmbH & Co.OHG
Krokamp 35 D-2439 Neumünster, Germany Phone: +49 4321 871 0

Danfoss Power Solutions ApS
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.

References

• Crimp Specs | Danfoss PowerSource
• Danfoss' businesses - Engineering since 1933 - Explore innovative solutions for many markets | Danfoss

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