Danfoss ET4001 User manual

Operator’s Manual
Danfoss ET4001
Crimp machine

Danfoss ET4001 Crimp machine operator’s manual
2 | © Danfoss ET4001 Crimp machine operator’s manual | 2022.06. AQ418954741547en-000101
Table of contents
1. PREVENT UNAUTHORIZED
OPERATION.
Do not permit
anyone to operate this
equipment unless they
have read and thoroughly
understood 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
ET4001 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
DANFOSS PRODUCTS.
Make
hose assemblies using only
Danfoss's hose and Danfoss
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 locator bracket, and the
pusher halves are closed
before crimping.
8.
DO NOT OVER PRESSURIZE.
Do not exceed the 5,000 psi
hydraulic pressure supplied
to the machine
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 4-5 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
ET4001 Crimp machine
!WARNING
Danfoss's hose and Danfoss hose fittings should only be assembled using
Danfoss approved assembly equipment. Do not use any combinations
of Danfoss's hose, Danfoss hose fittings, or Danfoss 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 processes 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 combination 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 authorized
by Danfoss.
Read and understand the operator’s manual before attempting to
operate any equipment.
Section Page
Safety instructions 2
Specifications and equipment 3
ET4001 Crimp machine 3
ET4001P-002 Electric pump 3
Shop/Work table mounting instructions 4 - 5
Check-out procedure 5
Operating instructions 6 - 9
ET4000AR-001: Using ET4000AR-001 Base adapter rings 6
ET4000AR-002: Using ET4000AR-002 Base adapter rings for heavy 4-wire and 6-wire fittings (-24 thru -32 collets) 7
T-410-25 Adapter ring 8
Spacer ring and nominal crimp diameter measurement 9
Troubleshooting procedures 11
Repair and replacement items 11

Danfoss ET4001 Crimp machine operator’s manual
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Specifications and equipment
ET4001 Crimp machine and accessories
ET4001 Crimp machine
ET4001 is ideal for factory high performance machine operations,
construction and mine locations. The ET4001 press offers crimping
capabilities through 2” I.D. six spiral hose.
Weight 500 lbs.
Size 30”high, 22”deep, 12”wide
ET4001P-002 Electric pump
The Danfoss ET4001P-002 power unit is ideally suited for use with
the ET4001 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 7½”high, 10”wide, 22”long
Weight 75 lbs.
Pressure 5000 psi
Reservoir capacity 6 Quarts
Outlet port size ¾-16 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. 0.6 GPM above 900 psi
!CAUTION
The ET4001P-002 Electric pump has the relief valve set
at 5,000 psi. Damage to the press will result and the warranty may
be voided if higher pressures are used. Requires individual 20 amp
service breaker (220 v).
Components needed: T-410-22 hose assembly (1)
included in ET4001-004 package

Danfoss ET4001 Crimp machine operator’s manual
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Figure 3
ET4001P-002 Outlet port
Shop/Work table mounting
ET4001 Press and pump
The following methods are offered
as a guide and may be varied to
suit your particular needs.
1. Prepare mounting surface for
ET4001 press and pump. Refer
(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 (approximately 75 lbs).
2. Remove shipping carton from
ET4001 press. There are four
5/8-18 tapped holes in the top
plate which may be used for
lifting purposes (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 ½” bolts from top
of mounting surface. Washers
and nuts are installed from
underneath. TIGHTEN.
4. Place the ET4001P-002 pump
on the mounting surface to
the right and slightly behind
the ET4001 press. (Reference
figure 8, Page 5)
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.
Figure 1
Bench layout for
ET4001 press
Figure 4
Connection at top plate
Figure 5
Gauge installation
Figure 6
Hose connection
Figure 2
Lifting hole layout on ET4001
press top plate
Shop/Work table
mounting instructions*
IT IS RECOMMENDED
THAT THE PUMP BE ON
AN INDIVIDUAL 20 AMP
SERVICE OUTLET.
7. Standing behind the press,
install the # 8ORB x ORFS
fitting into the top port of the
crimper (Figure 4).
8. Screw the 90º end of the
T-410-22 hose loosely onto the
adapter installed in the top
port (Figure 4).
9. Remove the 08ORB plug
from the D05 valve manifold
mounted on the pump. Install
the 90º ORB x ORFS adapter.
Loosely install the straight end
of the T-410-22 hose assembly.
Note, you will need to orient
the elbow fitting in a slight
angle so the hose assembly
clears the D05 valve (Figure 6).
10. Standing at the back of the
machine, remove the #4
pipe plug from the center
of valve manifold. Install the
straight pipe nipple into the
pump. Then install the #4 size,
90º elbow onto the straight
adapter and the gauge into the
female port of the 90º elbow
fitting (Figure 5).
11. Tighten all fitting connections.
12. Remove the tank plug and
screw in reservoir vent cap.
Screw black cord into switch
on shroud (Figure 3). Plug
electrical plug into 220 volt 20
amp circuit.
*NOTE: When using
Cart (part number FF 91042)
holes are pre-drilled. See page
5 for photo.
Instructions

Danfoss ET4001 Crimp machine operator’s manual
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Shop/Work table
mounting and
check-out procedure
ET4001P-002 Electric pump
Figure 8
Typical ET4001 equipment set-
up on shop/work table
ET4001 on FF91042 cart
!Refer to safety information regarding Danfoss hose, hose
fittings and assembly equipment compatibility on page 2.
!WARNING
Do not attempt to disconnect the hose sssemblies when the
pusher is not fully retracted.
Cart, FF91042, holes are pre-
drilled for ET4000, ET4001 or
T-420 crimp machines
Note: Machine to be mounted on sturdy surface to
accommodate the machine and components (500+lbs.).
!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 level in power unit. The oil reservoir was filled
at the factory; however, if oil is required, use ISO 32
(SAE 10W).
!WARNING
Do not cycle without base adapter ring in place.
Check out procedure
Check-out procedure for using electric pump ET4001P-002.
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 20 AMP SERVICE OUTLET.
2. Close pusher halves on press. Due to safety interlock switch,
power unit will operate only when pusher halves are closed.
3. Hold switch until pusher touches the base adapter ring.
4. RELEASE SWITCH. Pump and pusher will stop.
5. Move switch to the RETRACT position. The pusher will retract
fully in approx. 12 to 14 seconds.
6. REPEAT STEPS 3 & 5 APPROXIMATELY SIX TIMES. This will purge
the hydraulic system.

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Operating instructions
Using ET4000AR-001
1. OPEN the pusher halves.
Select the proper tooling for
hose type being crimped as
referenced in the Danfoss
crimp specifications manual
or chart 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 (T-400-G).
2. 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
Danfoss crimp specifications.
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 Danfoss crimp
specifications).
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) contact the base
adapter ring, the crimp is
complete.
5.
RELEASE the switch and
the pusher will stop. Move
the switch to the RETRACT
position to return the pusher.
OPEN the pusher halves and
remove the crimped hose
fittings.
6. Visually inspect the crimp
and verify the
correct crimp
diameter and crimp length.
!Refer to safety information regarding Danfoss hose,
hose fittings, and assembly compatibility on page 2.
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 ET4001 Crimp machine operator’s manual
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Operating instructions
Using ET4000AR-002 for
heavy 4-wire and 6-wire ttings
(-24 thru -32 collets)
1. OPEN the pusher halves.
NOTE: Lubricate the inside cone
of the base adapter ring and
external surfaces of the collet
assembly with a high-efficiency
PTFE based lubricant (T-400-G).
2. PULL the pusher tab upward.
The pusher tab is located
behind the top of the
pushers at the back of the
machine.
3. SLIDE pushers to side while
holding the pusher tab 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.
6. TURN locator bracket 90˚
until aligned properly.
7. SELECT the proper collet
assembly for hose type being
crimped as referenced in the
crimp specifications manual
or chart 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 (T-400-G).
8. INSERT the hose assembly
through the bottom of
the base adapter ring and
between the two collet
assembly halves. To achieve
a full flat crimp for 4SP/6SP
fittings, locate the bottom
of the socket approximately
1/8" (3mm) from the bottom
edge of the collet halves as
referenced in Danfoss crimp
specifications.
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 stop. Move
the switch to the RETRACT
position to return the pusher.
OPEN the pusher halves and
remove the crimped hose
assembly.
11 . Visually inspect the crimp
and verify the
correct crimp
diameter and crimp length.
!Refer to safety information regarding Danfoss hose,
hose fittings, and assembly compatibility on page 2.
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 ET4001 Crimp machine operator’s manual
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Operating instructions
Using T-410-25 adapter ring
1. 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 (T-400-G).
2. SELECT proper size collet
(referenced in the crimp
specifications manual) 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.
3. SELECT PROPER spacer ring
referenced in the crimp
specifications manual. 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.
RELEASE the switch and
the pusher will stop. Move
the switch to the RETRACT
position to return the pusher.
OPEN the pusher halves and
remove the crimped hose
fittings.
6. Visually inspect the crimp
and verify the
correct crimp
diameter and crimp length.
4. CLOSE pusher halves. HOLD
SWITCH ON. When spacer
ring (shown in step 3 in
black) bottoms on adapter
ring below it, the crimp is
complete.
!Refer to safety information regarding Danfoss hose,
hose fittings, and assembly compatibility on page 2.
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 ET4001 Crimp machine operator’s manual
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Operating instructions
Spacer ring and nominal crimp
diameter measurement
Spacer ring
Typical spacer ring illustrating
both sides of ring
Nominal crimp diameter
measurement
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 allow 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
measurements and compare
this average to the target
crimp diameter shown in the
Power Source crimp spec
tool and ensure it falls within
tolerance.
Maintenance
Collet assembly lubrication Every 30 crimps = Re-lubricate sliding surfaces of dies
Every 250 crimps = Remove old grease and re-lubricate
Base adapter ring lubrication Every 250 crimps = Remove old grease and re-lubricate
Every 1,000 crimps = Remove old grease, inspect for wear or damage and re-lubricate if okay.
Flat side Counterbore side
!Refer to safety information regarding Danfoss hose,

Danfoss ET4001 Crimp machine operator’s manual
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Troubleshooting procedures
ET4001P-002 electric pump
Problem Cause Solutions (page 11)
Pump/motor does not start Blown fuse; Improper electrical hookup Step #1
(cut cord, loose wire, switch malfunctions)
Motor starts but blows fuses High amps; Pusher doesn’t advance; Step #1
Pump binding or scored; cold oil Replace pump
Motor runs - pusher does not advance Shuttle stuck open; Pump coupling sheared; Step #4
Pump unload valve stuck open Replace pump
Check valve stuck shut Step #5
Motor runs - Pusher does not advance Solenoid malfunction Step #5
Motor runs - Pusher advances Pump unload valve stuck shut Replace pump
but doesn’t develop final crimp pressure,
blows fuse
Motor runs - Pusher advances Relief valve leaking; Step #3
but doesn’t develop final crimp pressure Shuttle valve leaking; Step #4
Relief valve set low Step #3
Pusher won’t retract Shuttle valve stuck closed Step #4
Erratic pusher movement Low oil level; Step #2,
Worn seal Replace pump
Noisy pump; On start up only Low room temp. - Oil too thick; Use lighter weight oil
(continuous) Air leaking - Low oil Level Step #2
Oil temperature hot Having unit operate at crimping psi too long; Operate for 3 seconds
at crimp pressure;
Low oil level: Step #2,
Pump worn (longer cycle time); Replace pump,
Leaking relief valve and /or shuttle valve Step #3, #4
Back view
Front view

Danfoss ET4001 Crimp machine operator’s manual
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Step 1: Check –Look for fuse,
loose wire connections, switch
malfunctions or damaged cord.
Check for proper installation of
a 220 volt circuit.
Step 2: Check oil level –after
assembly and system has
been purged of air, the fluid
level should be½” from top of
reservoir. Clean, anti-wear type,
having a 300 SSU/100˚ hydraulic
oil is recommended (ISO 32 or
SAE 10W). Oil is needed to:
1. Transmit power easily
through system
2. Lubricate moving parts
3. Provide seal clearances
between parts
4. Cool or dissipate heat
Step 3: Clean or reset relief
valve –a 6,000 psi pressure
gauge, a 5/16” Allen wrench,
a 1” socket and a screwdriver
are required. Remove cap from
relief valve. Remove adjustment
screw, spring and ball. Ball
should be attached to spring.
Check ball and seat for possible
scoring. Replace spring and ball
in cavity. Insert a small punch
through spring against ball. Give
punch a moderate tap to seat
ball. Return adjustment screw
to original position making sure
adjustment screw is at least one
turn from bottoming. Remove
1/4” NPTF plug from port above
check valve and install a 6,000
psi pressure gage. With 6,000
psi pressure gauge in place,
operate unit to full crimping
position. Gauge should read
approximately 5,000 psi. To
raise setting, turn screw inward
(clockwise); to lower, turn screw
outward (counterclockwise) in
¼ turn increments. After each
adjustment, recycle and read
gauge for proper setting. Run
a cycle of the crimping system
for final gauge reading before
removing gauge and reinstalling
pipe plug.
Step 4: Shuttle valve –
If the shuttle valve is in a closed
position and the ET4001 pusher
will not retract, it may be helpful
to tap the shuttle valve cap
several times to dislodge any silt
that may be causing the stem
to bind. If this does not free the
valve and allow the pusher to
retract, use extreme caution
prior to proceeding with shuttle
valve removal as the system is
still under pressure. It may be
advisable to relieve pressure at a
hose connection to avoid an oil
bath. After pressure is removed
from system, remove cap and
valve cartridge. Soak cartridge
in a PETROLEUM BASED
SOLVENT ONLY (clean Stoddard
solvent). Do not use Triethene,
gasoline or paint thinner as
they will damage the O-ring
seals. If cartridge disassembly is
required use care in removing
stem as it has a .0005 metal seal
fit. Rotate stem in solvent and
push from seat end to remove
from cartridge. Do not lose the
loose ball. Wash parts in clean
solvent and examine for any
surface markings. If necessary,
polish with a fine crocus cloth.
After final cleaning, reassembly
cartridge. Shake cartridge and
check for free movement of ball
and stem. Replace cartridge
if not functional at this point.
Reassemble shuttle valve into its
cavity and check crimping cycle
prior to using system.
!IMPORTANT: Pressure
must be relieved from system
before disconnecting hose,
installing gauge or removing
valves from pump.
Troubleshooting procedures
ET4001P-002 electric pump
5
6
1
9
8
7
2
3
4
* must be ordered as a pair
Repair and replacement items
ET4001 Crimp machine
Item
Number Qty. Part number Description
11 T-410-1M Micro switch
21 ET4000AR-001 Base adapter ring
31 ET4000AR-002 Base adapter ring
41 ET4000TP-0001 Locator bracket kit
51 ET4000TP-0002 Wear plate kit
61 ET4001C-0015 Blue shroud
78 120-00429 Screw, hex head
81 ET4001C-0006* Left hand pusher assembly
91 ET4001C-0005* Right hand pusher assembly

12 | © Danfoss ET4001 Crimp machine operator’s manual | 2022.06. AQ418954741547en-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
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Eden Prairie, MN 55344, USA
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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Nordborgveg 81
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