Danfoss ET4000 User manual

Operator’s Manual
Danfoss ET4000
Crimp Machine

Danfoss ET4000 Crimp Machine Operator’s Manual
2 | © Danfoss ET4000 Crimp Machine Operator’s Manual | 2023.02. AQ439269047772en-000101
Table of Contents
Safety Instructions ...............................................................................................................................3
Specifications and equipment ..........................................................................................................4
Shop/work table mounting ...............................................................................................................5
Check-out procedure ..........................................................................................................................6
Operating instructions (ET4000AR-001) .........................................................................................7
Operating instructions (ET4000AR-002) ......................................................................................8-9
Operating instructions (T-410-25) ..................................................................................................10
Operating Instructions .....................................................................................................................11
Troubleshooting procedures .....................................................................................................12-13
Repair and replacement items ..................................................................................................14-15

Danfoss ET4000 Crimp Machine Operator’s Manual
AQ439269047772en-000101 © Danfoss ET4000 Crimp Machine Operator’s Manual | 2023.02. | 3
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 Weatherhead
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 another
manufacturer.
Danfoss hereby disclaims any
obligation or liability (including
incidental and consequential
damages) arising from breach
or contract, warranty, or tort
(under negligence or strict liability
theories) should Aeroquip or
Weatherhead 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 Weatherhead fitting
tolerances are engineered to match
Aeroquip and Weatherhead hose
tolerances. The combination or
use of Aeroquip or Weatherhead
hose and hose fittings with each
other, i.e. Aeroquip hose with
Weatherhead 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 nor
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 anyone,
other than the operator, close to the
equipment while it is in operation.
4. MAINTAIN DIES WITH CARE.
Dies used in the ET4000 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 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
and the cage is positioned
properly on the pressure plate.
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. See pages 5-6 for mounting
instructions.
11. UNPLUG THE POWER
SUPPLY WHEN NOT IN USE.
12. KEEP WORK AREA CLEAN.
Cluttered areas and benches invite
accidents.
13. DO NOT OPERATE WITHOUT
THE BASE ADAPTER RING IN
PLACE.
!
Safety Instructions
!

Danfoss ET4000 Crimp Machine Operator’s Manual
4 | © Danfoss ET4000 Crimp Machine Operator’s Manual | 2023.02. AQ439269047772en-000101
Specications and Equipment
ET4000 Crimp Machine
ET4000 is ideal for factory high performance machine operations,
construction and mine locations. The ET4000 press offers the crimping
capabilities through 2” I.D. six spiral hose.
Weight: 500 lbs.
Size: 29”high, 21”deep, 12”wide
.
T-441 Electric Pump
The Danfoss T-441 power unit is ideally suited for use with the ET4000 press.
It features a two-stage pump providing high flow at low pressure for fast
ram approach and low flow at high pressure for actual crimping.
Dimensions: 7 1/2” high, 10” wide, 22” long
Weight: 75 lbs.
Pressure: 5000 psi
Reservoir
Capacity: 6 Quarts
Outlet Port Size: 3/4-16 straight thread o-ring
Motor: 1HP, 3450 RPM, 220 volts, 60 cycle,
single phase
Hydraulic Oil: ISO 32 (SAE 10W)
Flow: 2.6 GPM to 900 psi to
0.6 GPM above 900 psi
Caution: The T-441 Electric Pump has the relief valve set at 5000 psi.
Damage to the press will result and the warranty may be voided if higher
pressures are used. Requires 15 amp fused breaker.
!

Danfoss ET4000 Crimp Machine Operator’s Manual
AQ439269047772en-000101 © Danfoss ET4000 Crimp Machine Operator’s Manual | 2023.02. | 5
Shop/Work Table Mounting
Instructions for Shop/Work Table Mounting
Figure 1 - Bench Layout for ET4000 Press
Figure 2 - Lifting Hole Layout on ET4000 Press Top Plate
Figure 3 - T-441 Outlet Port
The following methods are offered as a guide and may be varied to suit
your particular needs.
1. Prepare mounting surface for ET4000 press and pump. Refer to FIGURE
1 for bolt hole layout and optimum height.
IMPORTANT: Care must be taken to insure that the surface to which
the press is bolted is capable of supporting the weight of the press
(approximately 500 lbs.) and pump which is 75 lbs.
2. Remove shipping carton from ET4000 press. There are four 5/8-18
tapped hoes in top plate which may be used for lifting purposes (see
FIGURE 2). If these tapped holes are used, it is recommended that a
minimum of two be utilized, preferably four. If two holes are used for
lifting, use holes directly across from each other on the center line and
not two on a diagonal. This will prevent press from tilting as it is raised.
3. Using an adequate lifting device, raise the press to the mounting
surface. Align holes in press support brackets with holes in mounting
surface. Insert four 1/2” bolts from top of mounting surface. Washers
and nuts are installed from underneath. TIGHTEN.
4. Place the T-441 pump on the mounting surface to the right and
slightly behind the ET4000 press. (Reference FIGURE 4, Page 6)
5. Mark power unit base plate hole pattern on mounting surface.
Remove power unit and drill holes.
6. Replace pump and align holes on mounting surface with base plate of
pump. Insert bolts from top of mounting surface. Washers and nuts are
installed from underneath. TIGHTEN.
7. Remove middle plug from outlet port in pump. (See FIGURE 3.)
8. Locate press/pump connecting hose assembly and remove plugs.
Connect unions into outlet port in pump and press. TIGHTEN.
9. Remove pipe plug from pump reservoir and replace with breather cap
provided.
10. Before the electric pump (T-441) can be activated, the interlock cord
must be plugged into the switch box mounted on the ET4000 crimper.
After mating the halves of connection, TIGHTEN the knurled nut.
11. Plug electric cord into a grounded (4-wire connection), 220 volt, 60
cycle, single phase outlet. IT IS RECOMMENDED THAT THE PUMP BE ON
AN INDIVIDUAL 15 AMP SERVICE OUTLET.

Danfoss ET4000 Crimp Machine Operator’s Manual
6 | © Danfoss ET4000 Crimp Machine Operator’s Manual | 2023.02. AQ439269047772en-000101
Shop/Work Table Mounting
and Check-Out Procedure
Refer to safety information regarding Danfoss hose, hose
fittings and assembly equipment compatibility on page 3
!
Figure 4 - Typical ET4000 Equipment Set-up on Shop/Work
CAUTION: Throughout the
Check-out Procedure, check hose
assembly/adapter connections for
any leaks. TIGHTEN if necessary.
For- Seal Swivel Nut Torque for hose
assembly; 32-35 ft. lbs. Check oil
lever in power unit. The oil reservoir
was filled at the factory, however, if
oil is required use ISO 32 (SAE 10W).
WARNING: Dot not cycle
without base adapter ring in place.
Check-out procedure for using
electric pump T-441.
1. Plug electric cord into a
grounded (4 wire connection),
220 volt, 60 cycle, single phase
outlet. IT IS RECOMMENDED
THAT THE PUMP BE ON AN
INDIVIDUAL 15 AMP SERVICE
OUTLET.
2. To completely purge the
hydraulic system, the ram
return stops should be in
the “out” position to permit
the ram to return to the full
upright position. (See page 10,
Step 1 for the procedure.)
3. Close pusher halves on press.
Due to safety interlock switch,
power unit will operate only
when pusher halves are
closed.
4. Hold switch “ON” until pusher
touches the base adapter ring.
5. RELEASE SWITCH. Pump will
stop and pusher will retract.
6. REPEAT STEPS 4 & 5
APPROXIMATELY SIX TIMES.
This will purge the hydraulic
system.
!

Danfoss ET4000 Crimp Machine Operator’s Manual
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Operating Instructions
Using ET4000AR-001
Refer to safety information regarding Danfoss hose,
hose fittings, and assembly compatibility on page 3.
Eye protection required when press and pump are in use.
NOTE: Based on the fitting style, correctly
align the fitting with the top of the collet
!
1. OPEN the pusher halves. Select
the proper collet assembly for
hose type being crimped as
referenced in the PowerSource
Crimp Spec tool at danfoss.
com/crimp and insert the
collet assembly into the base
adapter ring.
NOTE: Lubricate the inside
cone of the base adapter
ring and external surfaces of
the collet assembly with a
high-efficiency PTFE based
lubricant.
2. INSERT the hose assem-
bly through the bottom of
the base adapter ring and
between the two collet
assembly halves. Align the
fitting with the top of the
collet halves as referenced in
the PowerSource Crimp Spec
tool at danfoss.com/crimp.
3. PLACE the spacer ring (if
applicable) in the appropriate
position on top of the collet
assembly (either flat-side up or
flat-side down as referenced in
the PowerSource Crimp Spec
tool at danfoss.com/crimp).
4. CLOSE the pusher halves and
begin crimping by activating
the pump with turning on
the switch. When the pusher
halves or spacer ring (if
applicable) contacts the base
adapter ring, the crimp is
complete.
5. RELEASE the switch and the
pusher will automatically
return. OPEN the pusher halves
and remove the crimped hose
assembly.
6. Visually inspect the crimp
and verify the correct crimp
diameter and length.

Danfoss ET4000 Crimp Machine Operator’s Manual
8 | © Danfoss ET4000 Crimp Machine Operator’s Manual | 2023.02. AQ439269047772en-000101
Operating Instructions (-20 thru -32 Collets) for
Heavy 4-Wire and 6-Wire Fittings
Using ET4000AR-002
1. OPEN the pusher halves. 2. PULL the pusher knob upward.
The pusher knob is located
behind the top of the pushers
near the back of the machine.
3. SLIDE pushers to side while
holding the pusher knob up.
4. PULL spacer ring locator
bracket upward. TURN the
locator bracket 90˚.
5. REMOVE the base adapter ring
from base plate and PLACE the
ET4000AR- 002 base adapter
ring inside the base plate.
NOTE: Lubricate the outside
diameter of base adapter ring
before placing into the base
plate.

Danfoss ET4000 Crimp Machine Operator’s Manual
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6. TURN locator bracket 90˚ until
aligned properly.
7. SELECT the proper collet
assembly for hose type being
crimped as referenced in the
PowerSource Crimp Spec tool
at danfoss.com/crimp and
insert the collet assembly into
the base adapter ring.
NOTE: Lubricate the inside
cone of the base adapter
ring and external surfaces of
the collet assembly with a
high-efficiency PTFE-based
lubricant.
8. INSERT the hose assembly
through the bottom of
the base adapter ring and
between the two collet
assembly halves. Align the
fitting with the top of the
collet halves as referenced in
the PowerSource Crimp Spec
tool at danfoss.com/crimp.
9. CLOSE the pusher halves and
begin crimping by activating
the pump with turning on
the switch. When the pusher
halves or spacer ring (if
applicable) contacts the base
adapter ring, the crimp is
complete.
10. RELEASE the switch and the
pusher will automatically
return. OPEN the pusher halves
and remove the crimped hose
assembly.
11. Visually inspect the crimp
and verify the correct crimp
diameter and length.
Refer to safety information regarding Danfoss hose,
hose fittings, and assembly compatibility on page 3.
Eye protection required when press and pump are in use.
NOTE: Based on the fitting style, correctly
align the fitting with the top of the collet
!

Danfoss ET4000 Crimp Machine Operator’s Manual
10 | © Danfoss ET4000 Crimp Machine Operator’s Manual | 2023.02. AQ439269047772en-000101
Operating Instructions
Using T-410-25 Adapter Ring
Refer to safety information regarding Danfoss hose,
hose fittings, and assembly compatibility on page 3.
Eye protection required when press and pump are in use.
NOTE: Based on the fitting style, correctly
align the fitting with the top of the collet
!
1. HOLD SWITCH “ON”. As ram
starts downward, rotate the
ram return stops outward from
their inward position. RELEASE
SWITCH. Ram will return to the
full upright position allowing
enough clearance for insertion
of required tooling.
2. OPEN pusher halves and
place T-410-25 adapter ring
in the base adapter ring
(ET4000AR-001).
NOTE: Lubricate the inside
cone of the base adapter
ring and external surfaces of
the collet assembly with a
high-efficiency PTFE-based
lubricant.
3. SELECT proper size
collet (referenced in the
PowerSource Crimp Spec tool
at danfoss.com/crimp) for hose
type and size being crimped.
INSERT collet halves into
adapter ring. PLACE proper
size hose end on hose. Be sure
to bottom the hose.
4. SELECT PROPER spacer ring
referenced in the PowerSource
Crimp Spec tool at danfoss.
com/crimp.
INSERT hose assembly from
below, between collet halves.
Place appropriate side of
spacer ring on top of collet
with uncrimped hose
assembly held in place.
5. CLOSE pusher halves. HOLD
SWITCH ON. When spacer ring
(shown here in black) bottoms
on adapter ring below it, the
crimp is complete.
6. RELEASE SWITCH to shut off
pump and retract pusher
halves. OPEN pusher halves.
Remove factory crimped hose
assembly and inspect the
crimp.
Visually inspect the crimp
and verify the correct crimp
diameter and length.