Danfoss ET1187 User manual

Operator’s Manual
ET1187
Crimp Machine

ET1187 Crimp Machine Operator’s Manual
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Table of contents
Section Page
Safety Instructions 2
Specifications 3
Accessories 3
Set-up and Assembly 3
Operating Instructions 4
Maintenance 7
Description of Components 8
Contact Information 10
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 Weatherhead hose, hose
fittings and assembly equipment. Do not
combine or use Aeroquip or Weatherhead
hose, hose fittings and assembly equipment
with each other, i.e. Aeroquip hose with
Weatherhead fittings, or with hose, hose
fittings or assembly equipment supplied by
an-other manufacturer.
Danfoss hereby disclaims any obligation or
liability (including incidental and consequen-
tial damages) arising from breach of contract,
warranty, or tort (under negligence or strict
liability theories) should Aeroquip or Weath-
erhead 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 instruc-
tions and limitations could lead to premature
hose assembly failures, resulting in property
damage, serious injury or death. Aeroquip and
Weatherhead fitting tolerances are engineered
to match Aeroquip and Weatherhead hose tol-
erances. 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 hard-
ened instrument.
5. USE ONLY SPECIFIED AEROQUIP/
WEATHERHEAD PRODUCTS. Make hose
assemblies using only Aeroquip and
Weatherhead 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 Han-
dling 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.
Safety instructions

ET1187 Crimp Machine Operator’s Manual
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Specifications and Accessories
Setup and Assembly
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)
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).
Wall Mount Bracket.
(Part number: ET1187C-0019).
Bench Mount Stand.
(Part number: ET1187C-0017).
ET1187 Crimp Machine shown
with wall mount frame.
(Part number: ET1187-002 Kit,
includes wall mount bracket
E T1187- 0 019 ).
High Performance PTFE Lubricant
(Part # T-400-G)
!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
retrac-tion.
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 de-
gree adapter using 23-24 ft. lbs. assem-bly
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 assem-
bly 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 specifica-
tions 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.
Accessories

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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
Figure 1
Reference the crimp specification chart on
the front of the crimp machine to determine
proper crimp dies for hose and fitting.
Figure 2
Install FT1380-200-XXX Die Cage per crimp die
chart on the front of the machine.
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 corre-
sponding product groups.
GH781 / H280
Standard machine comes with
GH781/H280 settings built in for
use with TTC/Z fittings in sizes
-4 through -16.
-8 size setting shown
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 Step 2 Step 3

ET1187 Crimp Machine Operator’s Manual
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Crimp Procedures - Continued
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.
Figure 4
Rotate crimp adjustment ring until desired
dash size is lined up with corresponding dash
size on product selection collar.
Figure 5
Insert the hose assembly up through the
bottom of the base ring and die cage.
Begin crimping by actuating the pump.
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
Step 4 Step 5 Step 6

ET1187 Crimp Machine Operator’s Manual
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Establishing Crimp Settings - Micrometer Dial
Figure 10 Figure 11 Figure 22
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 PowerSource.
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 incre-ments)
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 adjust-
ment 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.

ET1187 Crimp Machine Operator’s Manual
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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
for wear or damage and relube if okay
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 materi-
als.
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 PROCEDURES
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.
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 Accrolube 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.

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Description of Components
15
15
11
18
1
13
12
13
12
16
17
2
3
5
6
7
4
Detail Part Number Description Qty
1ET1187C-0007 CRIMP RING WELDMENT 1
2ET1187C-0001 CYLINDER 1
3ET1187C-0002 PISTON 1
4ET1187C-0006 PUSHER CASTING 1
5ET1187C-0008 BARREL 1
6ET1187C-0009 ADJUSTABLE KNOB 1
7E T1187C- 0 010 PINCH POINT HAT 1
8140-05691 SEAL KIT - PISTON 1
9E T118 7C- 0 011 SPRING (Not Shown) 1
10 T-400-G LUBRICANT (Not Shown) 1
11 E T1187C- 0 012 QUICK RELEASE PIN 2
12 E T1187C- 0 013 QUICK RELEASE PIN 2
13 ET1187C-0014 SHOULDER SCREW 2
14 E T1187C- 0 015 SPRING PLUNGER 2
15 E T1187C- 0 016 ROLL PIN 2
16 E T1187C- 0 017 BENCH MOUNT STAND 1
17 ET1187C-0018 WALL MOUNT BRACKET 1
18 E T1187C- 0 019 SHROUD 1

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/
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Phone: [phone]
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2800 East 13th Street
Ames, IA 50010, USA
Phone: [phone]
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Krokamp 35
D-2439 Neumünster, Germany
Phone: [phone]
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DK-6430 Nordborg, Denmark
Phone: [phone]
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Building #22, No 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: [phone]w
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