Danfoss ET1000 User manual

Operator’s manual
Danfoss ET1000
Crimp machine

Danfoss ET1000 Crimp machine operator’s manual
2 | © Danfoss ET1000 Crimp machine operator’s manual | 2022.06. AQ418954799548en-000101
Table of contents
Safety instructions
ET1000 Crimp machine
Section Page
Safety instructions 2
Specifications and accessories 3
Specifications, accessories & pumps 3
Setup and assembly 3
Crimping procedures 4
Maintenance 5
Crimp machine components 6
Read and understand the
operator’s manual before
attempting to operate any
equipment.
!WARNING
Danfoss’s hose and Danfoss hose
fittings should only be assembled
using Danfoss approved assem-
bly equipment. Do not use any
combinations of Danfoss’s hose,
Danfoss hose fittings, or Dan-
foss assembly equipment with
hose, hose fittings, or assembly
equipment supplied by another
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 Danfoss hose,
Danfoss hose fittings, or Danfoss
assembly equipment be used
with any hose, hose fittings, or
assembly equipment supplied by
another manufacturer, or in the
event that product instructions
for each specified hose assembly
are not followed. (Reference SAE
J1273 – Recommended practice
for hydraulic hose assemblies).
!WARNING
Failure to follow Danfoss pro-
cesses and product instructions
and limitations could lead to
premature hose assembly failures,
resulting in property damage,
serious injury, or death.
Danfoss fitting tolerances are
engineering to match Danfoss’s
hose tolerances. The combina-
tion or use of Danfoss’s hose and
hose fittings supplier by another
manufacturer may result in the
production of unreliable and/
or unsafe hose assemblies and is
neither recommended nor autho-
rized by Danfoss.
Safety Instructions
1. PREVENT UNAUTHORIZED
OPERATION. Do not permit
anyone to operate this equip-
ment 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
anyone, other than the oper-
ator, close to the equipment
while it is in operation.
4. MAINTAIN DIES WITH CARE.
Dies used in the ET1000 crimp
machine are sintered pow-
dered metal, offering the best
combination of strength and
wear resistance for long life.
Sintered powdered metal dies
are generally brittle and care
should be taken to avoid any
sharp impact. Never strike a
die with a hardened instru-
ment.
5. USE ONLY SPECIFIED Danfoss
PRODUCTS. Make hose assem-
blies using only Danfoss 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 com-
pletely in place, the spacer
ring rests against the place-
ment 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 applica-
tions.
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 sur-
face to prevent the equipment
from tipping.
11. UNPLUG THE POWER SUPPLY
WHEN NOT IN USE.
12. KEEP WORK AREA CLEAN.
Cluttered areas and benches
invite accidents

Danfoss ET1000 Crimp machine operator’s manual
AQ418954799548en-000101 © Danfoss ET1000 Crimp machine operator’s manual | 2022.06. | 3
Specifications and accessories
ET1000 Crimp machine and accessories
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. Refer
to the Setup and Assembly section
for instructions on removing air
from the hydraulic system.
Specications
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 pump
requires a minimum of
100psi to operate at maxi-
mum efficiency.
Hose Production Capacity:
Crimps up to -16 in braided and spi-
ral hydraulic hose with core tooling
and up to -20 in braided hose using
non-core, specialty tooling.
Accessories
• Bench mount bracket
(Part # ET1000C-0001)
• Truck/wall mount bracket
(Part # ET1000C-0021)
• 1.5 oz. tube high efficiency
PTFE grease (
Part # T-400-G)
• 16 oz. can high efficiency
PTFE grease
(Part # FF91455)
• Handle kit includes 2 easy
grip handles with mounting
hardware
(Part # ET1187C-0028)
• Portability kit includes
2 easy grip handles with
mounting hardware, longer
hose assembly, and FF
series quick disconnect
couplings
(Part # ET1187C-0029)
Available pump options:
• Hand pump kit
(Part #ET1000PK-001)
• Air/hydraulic pump kit
(Part #ET1000PK-002)
• 110v electric pump kit
(Part #ET1000PK-003)
• 12v DC electric pump kit
(Part #ET1000PK-004)
Note: These pump kits include the pump,
connecting hose assembly, and all of the
adapters necessary to connect the pump to
the ET1000 crimp machine.
1. Your new ET1000 crimp
machine comes disassembled
for ease of shipment. Before
use, the machine must be
assembled to the base with the
supplied quick release pins. Pins
should be installed from the
inside of the machine to avoid
any contact between the pins
and tooling during the crimping
process (See Figure A).
2.
Remove the plug from the top
cylinder port and install the
–06 size ORB,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 radius of the pump con-
necting hose when attaching the
hose to the pump and cylinder.
5.
If using your own pump, make
sure it has the requirements list-
ed 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 fasten-
ers.
Setup and Assembly
Hand pump Air/hydraulic
pump
110v electric
pump
12v DC electric
pump
Figure A

Danfoss ET1000 Crimp machine operator’s manual
4 | © Danfoss ET1000 Crimp machine operator’s manual | 2022.06. AQ418954799548en-000101
Operating instructions
ET1000
Crimping procedures
Description of components
ET1000 Die Ring AdapterSplit Collet Assembly Spacer Rings
Step 1:
Slide the pusher to the
back position.
Using the PowerSource crimp
spec tool, select the proper collet
assembly and spacer ring.
Lubricate the inside cone of the
die ring and external surfaces of
the collet assembly with a high-ef-
ficiency PTFE based lubricant.
Insert the collet assembly into
the base die ring.
Step 3:
Place the spacer ring in the appro-
priate position on top of the collet
assembly (either flat-side up or
flat-side down as referenced in the
PowerSource crimp spec tool).
Step 1A:
If using smaller collets, which
require an additional adapter
ring, lubricate the inside cone of
the base die ring and the outside
cone of the die ring adapter plate.
Place the die ring adapter plate
into the base die ring.
Step 4:
Pull the pusher forward into the
detent holding position with the
pusher positioning handle
Step 2:
Insert the hose assembly through
the bottom of the base die ring
and between the two
collet assembly halves. Align
the fitting with the top of the
collet halves.
Step 5:
Begin crimping by actuating
the pump. When the spacer ring
bottoms out against the base die
ring, the crimping
is complete.

Danfoss ET1000 Crimp machine operator’s manual
AQ418954799548en-000101 © Danfoss ET1000 Crimp machine operator’s manual | 2022.06. | 5
Maintenance
Maintenance
Intervals
Machine
maintenance
procedures
Collet Assembly & Die
Ring Adapter Plate
Lubrication:
Every 30 crimps =
Re-lubricate sliding
surfaces of dies
Every 250 crimps =
Remove old grease
and re-lubricate
Base Die Ring & Die Ring
Adapter Plate
Maintenance:
Every 250 crimps = Remove old
grease and re-lubricate
Every 1,000 crimps =
Remove old grease,
inspect for wear or damage and
relubricate if okay.
1. Sliding surfaces must be kept
free of dirt and other abrasive
materials.
2. All exposed black metal surfac-
es should be coated occasion-
ally with a light film of oil to
prevent corrosion.
3. Some fitting/hose combina-
tions require full pump reser-
voir capacity to complete the
crimp cycle. The oil level in the
fluid reservoir of the hydraulic
pump should be checked peri-
odically and refilled as required
with the pump manufacturer’s
hydraulic oil as needed.
NOTE: Completely retract
the cylinder when checking the
oil level.
Nominal crimp diameter
Crimping procedures (cont.)
Measuring crimp diameters
should be a part of the
normal hose assembly
procedure. To ensure a
proper crimp diameter,
follow these steps:
1. Measure the diameter in
the middle of the crimped
portion of the hose end. Place
the caliper in a position to al-
low for a measurement across
the pressed (flat) portion of
the crimp.
2. Repeat step 1 for each of the
remaining sides for a total of
four measurements.
3. Average the four measure-
ments and compare this
average to the target crimp
diameter shown in the Power
Source crimp spec tool and
ensure it falls within tolerance.

Danfoss ET1000 Crimp machine operator’s manual
6 | © Danfoss ET1000 Crimp machine operator’s manual | 2022.06. AQ418954799548en-000101
Crimp machine components
Item Part No. Description Qty
1ET1000C-0001 Base 1 1
2ET1000C-0002 Die Ring 1
3ET1000C-0003 Cylinder Cap 1
4140-05691 T Ring Seal 1
5ET1000C-0004 Piston 1
6ET1000C-0005 5 in. Spring 1
7140-15962 3 1/2 in. Spring 2
8T-460-SP Slide Plate 1
9140-06924 Flange Slide Plate 1
10 140-06925 Bushing Slide Plate 2
11 ET1000C-0006 Pusher 1
12 140-06602 Detent Screw 1
13 140-15984-01 Flat Head Cap Screw 2
14 140-15984-03 Flat Head Cap Screw 2
Item Part No. Description Qty
15 120-70188-41 Split Roll Pin 2
17 140-05687 Spring Retainer 1
18 140-15984 Flat Head Cap Screw 2
19 140-05695 Slide Pull Rod 1
20 140-05694 Slide Pull Knob 1
21 T-400-G Lubricant 1
27 E-EQCR-TE006-E Lubricator Decal 1
28 FF2138-06S Plug Assembly 1
29 ET1187C-0014 Shoulder Screw 2
30 ET1000C-0020 Shroud 1
31 FF91569 Cap Screw 4
32 ET1187C- 0 012 Quick Release Pin 2
33 1000DANFOSSDECAL ET1000 Name Decal 1

Danfoss ET1000 Crimp machine operator’s manual
AQ418954799548en-000101 © Danfoss ET1000 Crimp machine operator’s manual | 2022.06. | 7

8 | © Danfoss ET1000 Crimp machine operator’s manual | 2022.06. AQ418954799548en-000101
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.
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: [phone]
Danfoss Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: [phone]
Danfoss Power Solutions GmbH & Co.OHG
Krokamp 35
D-2439 Neumünster, Germany
Phone: [phone]
Danfoss Power Solutions ApS
Nordborgveg 81
DK-6430 Nordborg, Denmark
Phone: [phone]
Danfoss Power Solutions Trade (Shanghai) Co. Ltd.
Building #22, No 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: [phone]w