Eaton ET1000 User manual

ET1000 Crimp Machine
Operator’s Manual Portable
Light Duty
Positive Stop

Table of Contents
Safety
Instructions
2EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Set-up and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operating Instructions
Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Crimping Procedures (large collets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Crimping Procedures (small collets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Maintenance
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Machine Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6
Crimp Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Read and understand the
operator’s manual before
attempting to operate any
equipment.
WARNING
Aeroquip hose, hose fit-
tings and assembly equip-
ment 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 fit-
tings and assembly equip-
ment. 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.
Eaton hereby disclaims any
obligation or liability (including
incidental and consequential
damages) arising from breach
or contract, warranty, or tort
(under negligence or strict lia-
bility theories) should
Aeroquip or Weatherhead
hose fittings or assembly
equipment be used inter-
changeably or with any
hose, fittings or assembly
equipment supplied by anoth-
er manufacturer, or in the
event that product instruc-
tions 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 engi-
neered to match Aeroquip
and Weatherhead hose toler-
ances. 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 rec-
ommended nor authorized by
Eaton.
Safety Instructions
1. PREVENT UNAUTHORIZED
OPERATION. Do not per-
mit 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
ET1000 crimp machine are
hardened steel, offering
the best combination of
strength and wear resist-
ance for long life.
Hardened dies are general-
ly brittle and care should
be taken to avoid any
sharp impact. Never strike
a die with a hardened
instrument.
5. USE ONLY SPECIFIED
AEROQUIP/WEATHER-
HEAD PRODUCTS. Make
hose assemblies using only
Aeroquip and Weatherhead
hose and fittings specified
for this assembly equip-
ment.
6. VERIFY CORRECT CRIMP
DIAMETERS. Check and
verify correct crimp diame-
ters of all fittings after
crimping. Do not put any
hose assemblies into serv-
ice if the crimp diameters
do not meet Eaton crimp
specifications.
7. Make sure all dies are com-
pletely in place, the spacer
ring rests against the place-
ment pins, and the pusher
is pulled forward into the
detent position before
crimping.
8. DO NOT OVER PRESUR-
IZE. Do not exceed the
10,000 psi hydraulic pres-
sure 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 EQUIP-
MENT 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 AREA
CLEAN. Cluttered areas
and benches invite acci-
dents.

3
EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003
Specifications
and Accessories
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 retraction. Refer to
the Setup and Assembly sec-
tion for instructions on
removing air from the
hydraulic system.
Specifications
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)
•The air/hydraulic pump
requires a minimum of
100psi to operate at maxi-
mum efficiency.
Hose Production Capacity:
(varies with available tooling)
Accessories
• Die Cage/Collet, spacer
ring tool box
(Part # FT1603)
•Die Cage/Collet, spacer
ring wall mount rack
(Part # FT1604)
•High Performance
PTFE Lubricant
(Part # 140-06701)
1. Your new ET1000 crimp
machine comes disassem-
bled for ease of shipment.
Before use, the machine
must be assembled to the
base with the supplied fas-
teners (ET1000C-0008).
2. Remove the plug from the
top cylinder port and
install the –06 size ORB,
90 degree adapter using
23-24 ft. lbs. assembly
torque. Orient the adapter
so that it points to the rear
of the crimp machine,
away from the operator.
3. Install the pump connect-
ing hose assembly 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”mini-
mum bend radius 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
Specifications section
above.
6. Place the pump on the
work surface to either
side of the crimp machine.
(Note: if using the
air/hydraulic pump, the
pump can be fastened to
either side of the crimp
machine frame as you
face the front of the crimp
machine.) Install the 90
degree adapter to the
pump pressure port
(Male NPTF threads
should be tightened fol-
lowing 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 high-
er 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.
Setup and
Assembly

4EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003
Operating
Instructions
Description of
Components
Crimping Procedures
(using larger collets)
Step 1:
Slide the pusher to the back
position.
Using the Collet/Spacer Ring
Selector Chart, select the
proper collet assembly and
spacer ring.
Lubricate the inside cone of
the die ring and external sur-
faces of the collet assembly
with a high-efficiency PTFE
based lubricant.
Insert the collet assembly
into the base die ring.
Step 2:
Insert the hose assembly
through the bottom of the
base die ring and between
the two collet assembly
halves. Align the fitting with
the top of the collet halves
as referenced on the
Collet/Spacer Ring Selector
Chart.
Step 3:
Place the spacer ring in the
appropriate position on top
of the collet assembly (either
flat-side up or flat-side down
as referenced in the
Collet/Spacer Ring Selector
Chart).
Step 4:
Pull the pusher forward into
the detent holding position
with the pusher positioning
handle.
Step 5:
Begin crimping by actuating
the pump. When the
spacer ring bottoms out
against the base die ring,
the crimping is complete.
(NOTE: Visually inspect the
crimp and verify the correct
crimp diameter and length.)
Die Ring
Adapter
Split Collet
Assembly Spacer Rings
ET1000 Crimp Machine

5
EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003
Operating
Instructions
Crimping Procedures
(using smaller collets)
Step 5:
Pull the pusher forward into
the detent holding position
with the pusher positioning
handle.
Step 6:
Begin crimping by actuating
the pump. When the
spacer ring bottoms out
against the die ring
adapter plate, the crimping
is complete. (NOTE:
Visually inspect the crimp
and verify the correct crimp
diameter and length.)
Step 1:
Slide the pusher to the back
position.
Using the Collet/Spacer Ring
Selector Chart, select the
proper collet assembly and
spacer ring.
Lubricate the inside cone of
the base die ring and the
outside cone of the die ring
adapter plate.
Place the die ring adapter
plate into the base die ring.
Step 2:
Lubricate the external
surfaces of collet assembly
halves with a high-efficiency
PTFE- based lubricant.
Insert the collet assembly
into the die ring adapter
plate.
Step 3:
Insert the hose assembly
through the bottom of the
base die ring and up
between the two collet
assembly halves. Align the
fitting with the top of the col-
let halves as referenced on
the Collet/Spacer Ring
Selector Chart.
Step 4:
Place the spacer ring in the
appropriate position on top
of the collet assembly (either
flat-side up or flat-side down
as referenced in the
Collet/Spacer Ring Selector
Chart).

6EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003
Maintenance
Collet Assembly & Die
Ring Adapter Plate
Lubrication:
Every 30 crimps =
Re-lubricate sliding surfaces
of dies
Every 250 crimps = Remove
old grease and re-lubricate
Base Die Ring & Die Ring
Adapter Plate
Maintenance:
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.
1. Sliding surfaces must be
kept free of dirt and other
abrasive materials.
2. All exposed black metal
surfaces should be coated
occasionally with a light
film of oil to prevent corro-
sion.
3. Some fitting/hose combi-
nations require full pump
reservoir capacity to com-
plete the crimp cycle.
The oil level in the fluid
reservoir of the hydraulic
pump should be checked
periodically and refilled as
required with the pump
manufacturer’s hydraulic
oil as needed.
NOTE: Completely retract
the cylinder when checking
the oil level.
Maintenance Intervals
Machine Maintenance
Procedures

7
EATON Hydraulics ET1000 Operator’s Manual E-EQCR-TM001-E September 2003
Crimp Machine
Components
4
3
5
6
7
7
21
16
15
15
1
16
11
17
18
8
14
15
20
19
12
10
13
92
1
ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY
1ET1000C-0001 Base 1 12 140-06602 Detent Screw 1
2 ET1000C-0002 Die Ring 1 13 140-15984-01 Flat Head Cap Screw 2
3 ET1000C-0003 Cylinder Cap 1 14 140-15983-01 Flat Head Cap Screw 2
4 140-05691 T Ring Seal 1 15 120-70188-41 Split Roll Pin 2
5 ET1000C-0004 Piston 1 16 ET1000C-0008 Hex Head Bolt 4
6 ET1000C-0005 5 in. Spring 1 17 140-05687 Spring Retainer 1
7 140-15962 3 1/2 in. Spring 2 18 140-15984 Flat Head Cap Screw 2
8 140-05688 Slide Plate 1 19 140-05695 Slide Pull Rod 1
9 140-06924 Flange Slide Plate 1 20 140-05694 Slide Pull Knob 1
10 140-06925 Bushing Slide Plate 2 21 140-06701 1.5 oz. Grease 1
11 ET1000C-0006 Pusher 1

© 2003 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. E-EQCR-TM001-E
September 2003
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