Danfoss FT1244 User manual

Operator’s Manual
Danfoss FT1244
Crimp Machine

Danfoss FT1244 Crimp Machine Operator’s Manual
2 | © Danfoss FT1244 Crimp Machine Operator’s Manual | 2023.05. AQ439269330776en-000101
Table of Contents
Introduction ........................................................................................................................................ 3
Safety Instructions ............................................................................................................................. 3
Specifications ...................................................................................................................................... 3
Preoperation Procedures .................................................................................................................. 4
Installation ........................................................................................................................................... 4
Tooling .................................................................................................................................................. 4
Operating Instructions ...................................................................................................................5-9
Maintenance ........................................................................................................................................9
Machine Breakdown ...................................................................................................................10-11
Hydraulic Breakdown ..................................................................................................................12-13
Electrical Schematic ....................................................................................................................14-15
The calibration method for some early model crimp machines used fittings that are no longer supplied by Danfoss
Corporation.
Therefore, some of the data on the following pages may be considered obsolete, such as machine settings (i.e. 1401
socket data).
Calibration can still be performed using current (global) fittings. Please contact Danfoss for specific information.
Obsolate Data Notice

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The Danfoss FT1244 Crimp Machine is designed for the distributor or O.E.M. who needs production style crimping capacity. The FT1244 is a
hydraulically operated machine that will crimp Danfoss standard crimp fittings; -3 through -32*, including four spiral hose. The FT1244 will crimp
both straight and standard elbow fitting assemblies.
A compact hydraulic unit supplies pressure to a cylinder which provides the required crimping forces through the mechanical advantage of a
crimp ring and dies.
*Special fittings are required for -32 sizes. Refer to section “Procedure For Crimping -32 Hose Assemblies.”
Introduction
1. KEEP 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. Dies used in the
FT1244 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..
Safety Instructions
Specications
Dimensions 31 1/2” wide x 30” long x 42” high
Weight 425 lbs. without tooling
Electrical 115 volt, 1 phase, 60 Hz
Crimp Dies Eight per set
Max. Operating Pressure 4000 psi
Pump 2 3/4 gpm to 1000 psi
3/4 gpm to 4000 psi

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Preoperation Procedures
CAUTION: THIS MACHINE IS TOP HEAVY!
Uncrate the FT1244 crimp machine and inspect the machine for possible shipping damage. The following components are in the tool box.
1 can of high efficiency PTFE grease (Danfoss part number FF91455)
1 Cone Locator Assembly
1 Hydraulic Unit Breather Cap
This machine is shipped completely plumbed and wired. The hydraulic unit reservoir has been filled with hydraulic oil.
Remove the pipe plug from the top of the reservoir and install the breather cap. Install the cone locator in the holder.
Installation
Install the machine on a solid floor capable of holding 425 pounds. Secure the machine to the floor with four 5/16” diameter fasteners
through the slots provided in the base. Position the motor switch (located on the front panel) in the stop position and plug in the cord.
The FT1244 crimp machine is wired for 115V, 60 Hz service and requires a 30 amp circuit breaker or fuse.
Tooling
Atooling set up consists of eight crimp dies and a fitting locator. The locator is used to locate the fitting in the machine. A cone shaped
locator is used when crimping straight fittings and a series of optional yoke locators is available for locating elbow fittings.
Do not attempt to operate the machine with less than eight (8) dies or intermix dies of different sets.
A die storage area is provided within the machine. Dies should be put away after use to avoid abrasive dust and dirt from sticking to the
friction surfaces and causing premature wear on dies or other machine components.
!

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Operating Instructions
HOSE PREPARATION
Select the proper hose and fitting style for the desired application. Some hose styles require the removal of a length of hose cover prior to
crimping. This is referred to as “Skiving.”
PROPER CRIMP DIE INSTALLATION
Remove the clear plastic guard.
Select the crimp dies specified in the PowerSource Crimp Spec Tool at danfoss.com/crimp for the selected hose style and size.
Liberally lubricate all sliding surfaces of the crimp dies with high efficiency PTFE grease (Danfoss part number T-400-G). Do not lubricate
the crimping surface of the dies. Also lubricate the crimp ring where the crimp dies slide.
Install the crimp dies by pulling the die release pins (Det. 18) and inserting the dies into the die slots from the outside as shown in
illustration 1. Make certain the angled surface on the dies is positioned as illustrated. Inserting crimp dies in any other position may result
in damage to the machine. Remove crimp dies in the opposite manner.
SETTING THE LOCATOR
STRAIGHT FITTINGS
The purpose of the locator is to properly position the fitting within the crimp dies area and to provide a positive back stop so no visual
alignment is required after initial set up. The cone shaped locator is used for locating all sizes of straight fittings.
Refer to illustration 1 for proper fitting location using the cone locator. Position the fitting and socket as shown (the 1/32” will move flush
with the end of the crimp die during the crimp cycle). Slide Det. 3 until Det. 1 seats into the fitting. Run nut (Det. 4) against Det. 3. It may
be necessary to adjust Det. 1 into Det. 3 for more clearance. Lock with Det. 2.
Illustration 1

Danfoss FT1244 Crimp Machine Operator’s Manual
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ELBOW FITTINGS
(Optional tooling not supplied with the machine)
Elbow fittings may be crimped without a locator, but for quantity production, an elbow fitting locator kit (FT1204-150) is available. This kit
will accommodate elbow fittings through -20 size. (Visual alignment is necessary when crimping -24 and -32 sizes.)
The FT1204-150 kit consists of a yoke holder and yokes for tube sizes -4 through -16 (no yoke is required when crimping -20 size fittings). A
spacer is also included to provide the additional clearance required on some elbows.
Remove the cone locator and attach the yoke holder by tightening the set screw on the shoulder of Det. 3 (See illustration 2). Position the
fitting within the crimp dies as illustrated. Set up the assembly with the spacer inserted as shown. Slide Det. 3 forward as was instructed for
the cone locator and run nut (Det. 4) against the spacer. Crimp the fitting, pull out the spacer, push Det. 3 back against Det. 4 and remove
elbow..
Illustration 2

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SETTING THE MICROMETER FOR THE PROPER CRIMP DIAMETER
The micrometer is mounted to a tie rod of the crimp machine. With the correct micrometer setting, the machine will produce the desired
crimp diameter.
The crimp diameter specifications are listed in the PowerSource Crimp Spec Tool at danfoss.com/crimp for crimp spec details.
The exact micrometer settings may vary from one machine to another due to manufacturing tolerances. Furnished in the back of this
manual is a sheet of approximate micrometer settings for the first crimp. A calculation and a micrometer adjustment should establish
correct crimp diameter.
Example: Aeroquip 2681-12 hose requires a crimp diameter of 1.90-1.96. The recommended micrometer setting for set
up is .739. The micrometer was set to .739 and a sample fitting crimped. The crimp diameter obtained was
1.216. The nominal crimp diameter desired is 1.193. Subtracting 1.193 from 1.216, we conclude that our socket
is crimped .023 oversize. Each .001 change in crimp diameter requires a .004 change in micrometer setting.
Therefore, .023 x 4 = .092 change in micrometer setting. Add .092 to .739 to obtain a new setting of .831.
Crimp the same fitting again using the newly calculated micrometer setting. A crimp diameter between 1.190 and 1.196 should be
obtained. If further adjustment is necessary, the same procedure should be followed until the proper crimp diameter is obtained.
NOTE: Large size crimps will probably require more adjustment than smaller sizes.
When the correct micrometer setting is found, record it. The next time that style and size of hose is crimped, dial your recorded micrometer
setting and the first crimp should be good.

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PROCEDURE FOR CRIMPING -32 HOSE ASSEMBLIES
Crimping -32 fittings requires special procedure to properly attach the fitting. The fitting used for this application is of one piece
construction (the socket is precrimped to the nipple to establish the required crimp length). Refer to the PowerSource Crimp Spec Tool at
danfoss.com/crimp for crimp spec details which outlines the required crimping information. Scribe a mark on the socket at the nipple end
at the desired dimension as indicated in the PowerSource Crimp Spec Tool at danfoss.com/crimp for crimp spec details. Locate the fitting
within the crimp die area (See illustration 3). Crimp the fitting as previously described.
HOSE
1509-32 .41
1529-32 .41
1546-32 .41
2661-32 .40
2665-32 .41
2681-32 .41
2766-32 .41
2777-32 .41
2781-32 .41
2791-.32 .35
FC194-32 .41
FC241-32 .41
FC299-32 .41
Illustration 3

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CRIMPING FIELD CRIMP STYLE HOSE ASSEMBLIES
Crimping field crimp style fittings requires special locating procedure. The fittings are located using the scribe lines on the socket of the
fitting (See illustration 4).
Maintenance
Normal maintenance of the FT1244 crimp machine requires a light film of oil coating over all the exposed black surfaces, crimp ring die,
contact surface lubricated with high efficiency PTFE grease (Danfoss part number T-400-G), and a maintained oil level within the hydraulic
power unit oil reservoir (one inch below the top of the reservoir).
Illustration 4

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Machine Breakdown