Danfoss T-420 User manual

2Danfoss T-420 Crimp machine operator´s manual December 2022
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 T-420 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
T-420 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
T-420 Crimp machine 3
Power source options 3
Mounting instructions 4 - 5
Check-out procedure 6
Operating instructions 7-8
Adapter rings 8
Spacer ring and nominal crimp diameter measurement 8
Troubleshooting procedures 9-10
Repair and replacement items 11

3Danfoss T-420 Crimp machine operator´s manual December 2022
CAUTION: The above pumps have the pressure relief valve
set at 4,000 - 4,200 PSI, Damage to the press may result and
warranty may be voided if higher pressures are used.
Specifications and equipment
T-420 Crimp machine and accessories
T-420 Crimp machine
The T-420 is a versatile machine ideal for your shop,
factory, construction, and mine locations. Large
capacity combined with lever-activated crimping gives
you wide coverage and a quick and simple way to
make factory-quality hose assemblies. The T-420 press
offers crimping capabilities through 1-1/4”. I.D. four
spiral hose.
Weight 210 lbs.
Size 22”high, 20-1/2”deep, 10”wide
T-421U Electric pump (220 volt)
T-421UCSA CSA approved
Dimensions 7½” high, 10” wide, 22” long
Weight 75 lbs.
Pressure 4000-4200 psi
Reservoir capacity 6 Quarts
Outlet port size ¾-16 Straight thread
Motor 1HP, 3450 RPM, 220 volts, 60 cycle,
Single Phase
Hydraulic oil ISO 32 (SAE 10W)
Flow 2.5 GPM to 750 psi. 0.5 GPM above
4000 psi
*For low temperature applications automatic transmission fluid
can be substituted.
Note: It is recommended that the electric pump be used on a
15 amp. fused circuit. Pump wired for 220 volts, single phase.
T-421U-110 Electric pump (110 volt)
For dimensional data other than voltage information,
refer to T-421U see above.
T-421U-110CSA CSA approved
Note: It is recommended that the electric pump be used on an
individual 30 amp. fused circuit. Pump wired for 100 volts, single phase
Pump kit part numbers
ET420-007 110 volt electric pump kit with hose assembly
ET420-007CSA 110 volt electric pump kit with hose assembly,
CSA approved
ET420-008 220 volt electric pump kit with hose assembly
ET420-008CSA 220 volt electric pump kit with hose assembly,
CSA approved
Crimp machine part numbers
T-420-1 Base T-420 machine
T-420-1CSA Base T-420 machine, CSA approved
Crimp machine and tooling package part numbers
T-420-001 Contains T-420 crimper, 220v pump kit,
T420TP-1001 tooling package
T-420-002 Contains T-420 crimper, 110v pump kit,
T420TP-1001 tooling package
T-420-001CSA Contains T-420 crimper, 220v pump kit,
T420TP-1001 tooling package, CSA approved
T-420-002CSA Contains T-420 crimper, 110v pump kit,
T420TP-1001 tooling package, CSA approved
Crimp machine and tooling package part numbers
T420TP-1001 New placement tooling package
Capabilities: Braided -4 thru -20, Spiral -8 thru -20
T420TP-1002 Winner tooling package
Capabilities: Braided -4 thru -20, Spiral -6 thru -20
*both packages exclude -5 and -10 sizes

4Danfoss T-420 Crimp machine operator´s manual December 2022
Mounting Instructions
C-40X Cabinet
The C-40X Stock Cabinet is designed specically for the T-420-1
press and T-421U electric pump. Holes are pre-drilled so that the
press and pump can be mounted conveniently on top of the
cabinet. The C-40X cabinet has 40 heavy duty plastic drawers
which divide into two, three or four compartments providing
ample space for a large selection of hose ends and adapters.
CAUTION: It is recommended these instructions be read
thoroughly prior to set-up, and then used as a guide during
actual assembly.
STEP 1: Remove packaging from C-40X cabinet.
STEP 2: Remove shipping carton from T-420-1 press. There are
two 1/2”-13 tapped holes in top of plate which may be used for
lifting purposes (gure 1 ).
STEP 3: Using an adequate lifting device, raise the press to the
left side of cabinet. Align holes in press support brackets with
predrilled holes in cabinet. Insert bolts (found in cabinet) through
top of cabinet. Washers and nuts are installed from underneath.
Tighten.
STEP 4: The T-421U Electric Pump mounts on the right side of
the cabinet. Predrilled holes align the pump. Insert bolts through
top of cabinet. Washers and nuts are installed from underneath.
Tighten.
STEP 5: Remove plug from outlet port in pump.
STEP 6: Locate press/pump connecting hose assembly (T-410-
22) and remove 4315X8 For-Seal adapter. Thread adapter into
outlet port in pump (step 5).
STEP 7: Connect Hose assembly (T-410-22) to For-Seal adapter
on press and pump. Tighten.
STEP 8: Before the electric pump (T-421U) can be activated,
the male and female electrical disconnects must be mated. The
female half and wire harness is shipped with the T-421U pump.
Both male and female halves are keyed so that they can be con-
nected in only the correct position. After the connection is made,
tighten the knurled nut.
STEP 9: Plug electric cord into a grounded 220 volt, 60 cycle,
single phase outlet. THE PUMP MUST BE ON A 15 AMP FUSED
ELECTRICAL CIRCUIT. If using T-421U-110 110v pump, plug elec-
tric cord into a grounded 110 volt, 60 cycle, single phase outlet.
The pump must be on a 30 amp fused electrical circuit.
FF91420 Cart
Holes are pre-drilled for the T-420 and ET4001 crimp machines.
FF91420 Cart
½ -13UNC-2Bx ¾DP.
TAPPED HOLES
(2 PLACES)
8½ DIA.
Figure 1 - Lifting hole
Layout on Top Plate

5Danfoss T-420 Crimp machine operator´s manual December 2022
Mounting Instructions
Bench/Work Table
The following method of mounting your T-420 equipment
package is oered as a guide and may be varied to suit your
particular needs.
1. Prepare mounting surface for T-420 press and pump.
IMPORTANT: Care should be taken to ensure the
mounting surface is capable of supporting the weight
of the press (210 lbs.) and power source (75 lbs.)
2. Remove shipping carton from T-420-1 press. There are
two 1/2-13 tapped holes in top of plate which may be
used for lifting purposes (see Figure 1, Page 4).
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 bolts
through top of mounting surface. Washers and nuts are
installed from underneath. Tighten.
4. Place the T-421U power unit on mounting surface to
the right and slightly behind the T-420-1 press
5. Mark mounting hole location for power unit and drill
holes in mounting surface.
6. Replace power unit and align holes on mounting
surface with base plate on power unit. Insert bolts
through top of mounting surface. Washers and nuts
are installed from underneath. Tighten.
7. Remove plug from outlet port in pump.
8. Locate the T-421U power unit on mounting surface to
the right and slightly behind the T-420-1 press.
9. Connect Hose assembly (T-410-22) to 4315X8 For-Seal
adapter on press and pump. Tighten.
10. Before the electric pump (T-421U) can be activated,
the male and female electrical disconnects must
be mated.
11. Plug electric cord into a grounded, 220 volt, 60 cycle,
single phase outlet. THE PUMP MUST BE ON
AN INDIVIDUAL 15 AMP FUSED ELECTRICAL
CIRCUIT.
If using T-421U-110 pump, plug electric cord inot a grounded
110 volt, 60 cycle, single phase outlet. The pump must be on
a 30 amp fused electrical circuit.
Figure 2 -Typical T-420 Equipment Set Up on Shop/Work Table

6Danfoss T-420 Crimp machine operator´s manual December 2022
Check out procedures
CAUTION: Throughout the Check-out Procedure check hose
assembly/adapter connections for any leaks. TIGHTEN if necessary.
CHECK oil level in power unit. The oil reservoir was lled at the factory; however,
if oil is required use ISO 32 (SAE 10W) hydraulic oil or equivalent.
1. Remove pipe plug from uid ll port on top of
reservoir and replace with plastic breather cap.
2. Plug power cord into 220 volt, 60 cycle, single phase
outlet. It is recommended that the pump be on an
individual 15 amp fused electrical circuit. If using
T-421U-110 pump, plug power cord into 110 volt,
60 cycle, single phase outlet. It is recommended that
the pump be on an individual 30 amp fused electrical
circuit.
3. Pull activating lever down. Pusher halves will close.
Continue to pull activating lever down until pump is
activated. Hold down until pump bypasses.
4. Release activating lever. Pump will stop and pusher
will retract.
5. Repeat Steps 3 and 4 approximately six times.
This will purge the hydraulic system.
Check-out using electric pump
(T-421U or T-421U-110)

7Danfoss T-420 Crimp machine operator´s manual December 2022
Operating instructions
1. Measure the appropriate insertion depth and scribe a
T-marking on the hose. Insert the hose into the tting.
The socket should cover a portion of the depth marking
or be fully bottomed out into the tting.
3. Insert hose assembly from bottom between collet
halves. Our optimized tooling provides built in tting
locators, ensuring correct alignment for optimal crimp
position.
5. Release activating lever. Pusher will automatically retract
and pusher halves will open. Remove factory quality
crimped hose assembly and visually inspect.
6. To ensure a proper crimp has been completed, measure
the nominal crimp diameter as shown in gure on page 8
2. To establish the crimp settings and tooling needed,
access the PowerSource Crimp Spec Tool from the Tools
Menu on PowerSource.
Select proper size collet for hose type and size being
crimped. Apply grease to outside of each collet segment.
Insert collet in cavity of base plate. Place spacer ring on
top of collet if called for in the crimp spec.
4. Pull activating lever down. Pusher halves will close.
Continue to pull activating lever down (pump will activate)
until pusher contacts the base plate. The crimp is complete.

8Danfoss T-420 Crimp machine operator´s manual December 2022 8
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 reading, follow these
steps:
1. Measure the diameter in
the middle of the crimped
portion of the hose end.
2. Place the caliper in a
position to allow for a
measurement across the
pressed (flat) portion of the
crimp.
3. See crimp diameters in
crimp specifications.
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,
hose fittings, and assembly compatibility on page 2.

9Danfoss T-420 Crimp machine operator´s manual December 20229
Troubleshooting procedures
T-421U and T-421U-110 Electric pump
Troubleshooting T-421U and T-421U-110 electric pump
IMPORTANT: Pressure must be relieved from system before disconnecting
hose, installing gauge or removing valves from pump.
Check fuse, loose wire connections, switch malfunctions or damaged cord. Pump electric cord must be
plugged into a grounded 220 volt, 60 cycle, single phase outlet on a 15 amp fused electrical circuit. If using
T-421U-110, pump electric cord must be plugged into a grounded 110 volt, 60 cycle, single phase outlet on a
30 amp fused electrical circuit.
Check oil level - after assembly and system has been purged of air the uid level should be 1/2”from top of
reservoir. Clean, anti-wear type, hydraulic oil having a (ISO 32) 300 SSU/100 F is recommended. Use only if
operating temperature is above 0°F or below 160°F. Oil is needed to:
1) Transmit power easily through system
2) Lubricate moving parts
3) Provide seal clearances between parts
4) To cool or dissipate heat
Clean or Reset Relief Valve - A 6000 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 3/8” NPTF plug from
port above check valve and install 6000 PSI pressure gauge. With 6000 PSI pressure gauge in place operate
unit to full crimping position. Gauge should read 4000-4200 PSI. To raise setting, turn screw in (clockwise);
to lower turn screw out (counterclockwise) in 1/4 turn increments. After each adjustment recycle and read
gauge for proper setting. Run a cycle of the crimping system for nal gauge reading before removing gauge
and reinstalling pipe plug.
Shuttle Valve - If the shuttle valve is in a closed position and pusher will not retract it may be helpful to tap
the shuttle valve cap several times to dislodge any silt that may be causing stem to bind. If this does not free
valve and allow 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 0-Ring Seals. If cartridge disassembly is required, use care in removing stem as it has a .0005
metal seal t. 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 ne
crocus cloth. After nal cleaning reassemble 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.
Step 1:
Step 2:
Step 3:
Step 4:

10 Danfoss T-420 Crimp machine operator´s manual December 2022
Troubleshooting procedures
T-421U and T-421U-110 Electric pump
PROBLEM CAUSE SOLUTION
Pump/motor does not start
Blown fuse; Improper electrical hookup
(cut cord, loose wire, switch malfunc-
tions)
Step #1
Motor starts but blows fuses High Amps; Pusher doesn’t advance;
Pump binding or scored; Cold oil
Step #1
Replace pump
Motor runs - Pusher does not advance Shuttle stuck open; Pump coupling
sheared; Pump unload valve stuck open
Step #4
Replace pump
Motor runs - Pusher advances but
doesn’t develop nal crimp pressure,
blows fuse
Pump unload valve stuck shut
Replace pump
Motor runs - Pusher advances but
doesn’t develop nal crimp pressure
Relief valve leaking;
Shuttle valve leaking;
Relief valve set low
Step #3
Step #4
Step #5
Pusher won’t retract Shuttle valve stuck closed Step #4
Erratic Pusher movement Low oil level
Worn Seal
Step #2
Replace pump
Noisy Pump: On start up only
(continuous)
Low room temp - oil too thick
Air leaking - low oil level
Use lighter weight oil
Step #2
Oil temperature hot
Having unit operate at crimping
PSI too long
Low oil level;
Pump worn (longer cycle time)
Leaking RV, shuttle valve
Operate for 3 seconds at crimp pressure
Step #2
Replace Pump
Step #3, #4
Troubleshooting T-421U and T-421U-110 Electric Pumps
(For steps please refer to page 9)

11Danfoss T-420 Crimp machine operator´s manual December 2022
T-420 Repair and replacement items
Catalog
number Description
T-420-1M Micro-switch for T-420-1 press
T-420-28 Tool locator bracket
T-420-B Pusher bolt and washers
W-EQCR-TE006-E Shroud decal
T-420-H Handle
T-420-L Light bulb
T-420-LA Light assembly
T-420-LS Light switch
T-420-P Pusher set (2) with wear plates and screws
T-420-S Press shroud with decals
T-420-26 Insert – base plate
T-420-G Linkage assembly
T-420-2R Rack
T-420-2K Pinion shaft assembly
(incl’d T-420-2G, T-420-2R and T-420-2S)
T-420-2S Replacement pinion gear shaft
140-06745 Pusher wear plates includes (1) left and (1) right
140-06748 Pusher wear plates screws (1)
FF91042 Cart for ET4001 or T-420
Assembly Equipment
T-420 Repair and replacement items

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 orderprovided that such alterations can be made without subsequent changes being necessary in specications already agreed. All trademarks in this material are
property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
AN436777624684en-000101 © Danfoss | Danfoss T-420 Crimp machine operator´s manual | Machines, Tools & Accessories | JC | December 2022