Eaton ET5040 User manual

2EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
ET5040 operator's manual
Table of contents Page No.
Safety instructions 3
Safety decal explanations 4
Specifications 5
Machine setup and installation 5
Environment 5
Height adjustment 5
Filling hydraulic fluid reservoir 6
Connecting the electric supply 6
Hydraulic system preparation 6
Control symbols overview 7
Tooling - installation (QDC) 8
Tooling - removal (QDC) 9
Tooling - installation/removal (die-key) 10
Tooling installation with die key 10
Tooling removal with die key 10
General notes for crimping 10
Operating instructions crimp selections – auto mode 11
Operating instructions crimp selections – manual operation 16
Adjusting the switching point of the crimp machine 17
Settings menus 20
Controller log-in 20
Language 20
Display units of measurement 21
Software version 21
User administration 22
Tooling editor 23
Product/operational updates 24
User input crimp database 25
Machine settings 26
Calibration procedure 27
Maintenance 28
ET5040 dies and kits 29
Standard die part numbers 29
Large bore die part numbers 30
430 “U” series die part numbers 31
Accessories 32

3EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Safety instructions
1. Prevent unauthorized
operation
Do not permit anyone
to operate this machine
unless they have read and
thoroughly understand
this manual. Failure
to follow operating
instructions could result
in injury or damage to the
equipment
2. This machine should
be operated by only 1
trained operator at any
time
3. Wear safety glasses
Risk of eye injury! Eye
protection required at
all times during the
installation, operation
and maintenance of this
machine.
4. Avoid pinch points
Stay clear of the crimp
ring, keep your hands
clear of all moving parts.
Do not allow anyone,
other than the operator,
to stand close to the
machine
5. Maintain dies with care
Dies used in the 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
6. Use only specified Eaton
products
Use only Eaton or Eaton
approved products.
7. 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 Eaton crimp
specifications
8. Die change
Follow prescribed
directions regarding
tooling change in the
manual
9. Keep work area clean
Cluttered areas and
benches invite accidents
10. Emergency stop button
The controller is provided
with an emergency stop
button. In case of an
emergency, actuate the
emergency button on the
front of the controller.
After the emergency
stop button has been
activated, the production
area is without function,
but all assemblies are still
energized. De-energize
the equipment via the
main switch
11. Never reach into crimp
tooling when power is on
Always make sure there is
adequate safety distance
of at least 4.75" (120mm)
to the crimp tooling during
the crimping process
12.Crimping with base dies
When crimping with base
dies only, the uncrimped
coupling diameter cannot
exceed crimp range
(6"/160m)
Read and understand the operator’s manual before attempting to operate this machine. Failure to follow operating instructions
could result in injury or damage to the equipment.
Failure to follow Eaton process and product instructions and
limitations could lead to premature hose assembly failures,
resulting in property damage, serious injury or death.
Eaton fitting tolerances are engineered to match Eaton
hose tolerances. The use of Eaton fittings on hose supplied
by other manufacturers and/or the use of Eaton hose with
fittings supplied by other manufacturers may result in the
production of unreliable and unsafe hose assemblies and
is neither recommended nor authorized by Eaton. Read
and understand the operator’s manual before attempting to
operate any equipment.
Eaton 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 Eaton hose, fittings or assembly
equipment be used with the hose, fittings or assembly
equipment supplied by another manufacturer, or in the event
that product instructions for each specified hose assembly
are not followed.
Please note that ET5040 is not a field serviceable machine.
For issues beyond the preventive maintenance described
below, customers are instructed to contact Eaton. Any
additions or modifications to the machine may affect the
operation of the machine, could result in injury or damage to
the machine, and will void Eaton warranty.
Warning
!

4EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Safety decal explanations
Do Not Lift
From This Side
Caution
Pinch and crush hazard.
Keep hands clear of moving
parts. Never reach into
the crimp tool with your
hands while the electric
motor is running. Always
make sure that there is an
adequate safety distance of
at least 4.75" (120mm) to
the crimping tool during the
crimping process.
Risk of eye injury
Eye protection required.
Caution
Crush Hazard. Keep hands
clear of moving parts. Never
reach into the crimp tool
with your hands while the
electric motor is running.
Always make sure that
there is an adequate safety
distance of at least 4.75"
(120mm) to the crimping
tool when you are inserting
a hose fitting.
Electrical hazard
Only qualified electricians
should carry out work on the
electric power supply.
Caution
Lift points are to help ensure
load is evenly distributed
on fork lift when moving.
Position the heaviest part
(front) of the machine
nearest the front wheels of
the fork lift.
Always position the heaviest
part (front) of the machine
nearest the front wheels of
the fork lift. Ensure load is
evenly distributed on fork lift
when moving.
Greaseless bearing slides
Do not lubricate bearing
slides.
Read and understand
operator's manual before
using this machine.
Failure to follow operating
instructions could result
injury or damage to
equipment.
Legs fully extended: 52" (1321 mm) high
Legs fully retracted: 36" (914 mm) high (center line of crimp head)
Note: Minimum of 36" of perimeter clearance is recommended for safety and
maintenance.
*Adjustable height:
*
36”
25”

5EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Specifications
Electrical service options
Weight: 1,050 lbs. (Dry)
Noise Level: 63 dBA
Overall machine dimensions:
• Width: 34”
• Depth: 25”
• Height: 52”- 70” (Adjustable)
• Center line of Crimp Head: 36" - 52"
(Adjustable)
Crimp force: 280 Ton (2800 KN)
Amps
50Hz 60Hz
ET5040-001-230 Crimp Machine, 230V, 3 Phase (50/60 Hz) 16.8 20.6
ET5040-001-380 Crimp Machine, 380V, 3 phase (50/60 Hz) 10.2 12.4
ET5040-001-400 Crimp Machine, 400V, 3 Phase (50/60 Hz) 9.7 11.8
ET5040-001-420 Crimp Machine, 420V, 3 Phase (50/60 Hz) 9.7 11.2
ET5040-001-460 Crimp Machine, 460V, 3 Phase (50/60 Hz) 8.4 10.2
ET5040-001-480 Crimp Machine, 480V, 3 Phase (50/60 Hz) 8.0 9.8
Note: Machine was shipped without Hydraulic Oil: Customer will need
to supply 13.2 gallons or 50 liters of AW46 (ISO46) hydraulic oil, after
filling use reservoir cap dip stick to check level. (Note: Do not attempt
to run machine prior to fill- ing with hydraulic fluid)
!
Machine setup and installation
Read and understand the operator’s manual before
attempting to operate this machine. Failure to follow
operating instructions could result in injury or damage
to the equipment.
Environment
1. The machine should be installed indoors on a level
surface and operated in a clean dry environment, under
normal atmospheric pressure. Avoid high humidity, dusty
environments. Optimal operating temperature: 50°F to 95°F).
2. Cover machine when not in use.
Height adjustment
1. Machine was shipped with adjustable legs fully retracted.
2. Use a forklift with a rated weight capacity that exceeds the
combined weight of the machine and shipping crate.
3. Position the forks beneath the hydraulic tank. Distribute the
heaviest part (front) of the machine nearest the front wheels
of the forklift.
4. Remove machine from shipping crate and set in desired
production location.
5. Use a fork lift to lift the machine to the desired working
height. (See figure 1).
6. Remove the (4) ball detent pins from each leg and extend the
legs to the desired position and re-insert the ball detent pins.
7. Confirm all legs are evenly extended and the ball detent pins
are secured before lowering the machine with the forklift.
Figure 1
Never get underneath the machine and keep the load low
during transport.
Caution
!
Caution
!

6EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Machine setup and installation
Filling hydraulic fluid reservoir
1. Machine is shipped without hydraulic fluid.
2. Remove the oil cap on the top rear of machine.
3. Fill the reservoir with 13.2 gallons or 50 liters of new, clean
AW46 (ISO46) hydraulic fluid. (See figure 2).
4. Filter oil through a 10 micron filter to remove any
contaminates before filling machine.
5. The oil level can be checked with the oil level dipstick
attached to the vented cap. (See figure 3).
6. Review instructions below for preparing the hydraulic system
prior to operating.
Hydraulic system preparation
1. After filling or changing the hydraulic oil, the hydraulic
system needs be manually cycled under a no load condition
to remove air from hydraulic lines before production use.
Reference page 16 for manual operation.
2. Cycle the machine several times by advancing and retracting
the crimp head. Upon completion, the advance and retract
travel will be smooth.
3. Ventilate the hydraulic system by loosening (2) screws on top
of the crimp head using a 5 mm Allen wrench. (See figure 5).
4. Upon completion, leave the crimp head in the fully retracted
position.
Connecting the electric supply
1. Note: The machine has six voltage options. If your electrical
supply changes, factory voltage settings and amperage
settings have to be changed. Contact customer service for
assistance.
2. The machine is supplied with a 12’ electrical pigtail that
will require wiring to customer supplied plug/service by a
qualified electrician.
3. The connecting plug must rated for the service connection
and comply with local electrical regulations.
4. After connection to a power source, if the head does not
actuate, the rotation of the electrical motor is incorrect
and two phases must be switched in the electrical plug or
service.
Note: Over filling hydraulic reservoir may result in blown seals and
machine leakage.
!
Note: Always cycle the hydraulic system under a no load condition
after filling or changing the hydraulic oil before use.
!
Note: The machine is factory set to customer electrical supply
requirements as noted on tag attached to the electri- cal disconnect.
(See figure 4).
!
Figure 2
Figure 3
Figure 4
Figure 5

7EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Control symbols overview
The following symbols and buttons are utilized in the operation of the crimp machine:
Emergency Stop Button – In
the event of an emergency,
press the red emergency
stop button on the front of
the control panel. To restart,
pull and twist the emergency
stop button.
Closes the crimp tooling.
Takes you to the machine
settings.
Displays the next screen.
Motor on – to switch on the
hydraulic motor.
Crimp tooling opens
automatically after crimping
Password entry.
Activates foot switch control.
Motor off – to switch off the
hydraulic motor.
Takes you back to the Home
screen.
User name.
Exits existing screen, and
returns to menu screen.
Opens the crimp tooling.
Crimp tooling does not open
automatically after crimping.
Manual retract required.
Takes you back to the
previous screen.
Crimp Nominal Diameter.
Crimp tooling diameter. (Size) Offset to crimp target.Displays current tooling
position.
Select the number of pieces
to be produced. (Manual
operation only)
Target is the die change position.

8EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Tooling – installation using
Quick Die Change (QDC) tool
After fitting and hose selections are made on menu screens,
screen will display correct tooling for application.
Position the QDC tool with crimp dies in the center of the
crimp head. Make sure the holding pins are aligned with
the bore holes in the base or intermediate dies and
gradually jog - close the crimp head while confirming all
eight pins are aligned.
Remove the QDC tool and retract the crimp head. Confirm
the crimp dies are loaded correctly and secured to the base
dies. No space should be visible between the dies and base
dies. Then press the check button to acknowledge installation
of correct tooling for application.
Figure 6
Figure 8 Figure 9
Step 1
Step 3 Step 4
Align and insert the eight pins of the QDC tool
(ET5040C-0004) with the holes in the front of desired crimp
dies in the optional storage rack (ET5040C-0014) Rotate the
handle to the right (clockwise) to remove the crimp dies from
the storage rack.
Figure 7
Step 2

9EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Tooling – installation using
Quick Die Change (QDC) tool
When prompted to make a tooling change, close the head
to the QDC position. Head will stop and light will no longer
illuminate when in QDC position.
Gradually retract the crimp head completely until the crimp
die holding pins have completely disengaged from the
intermediate dies.
Place the crimp dies into the storage rack, rotate the QDC to
the left, (counter clockwise) this locks the die segments into
the storage rack.
Figure 10
Figure 12 Figure 13
Step 5
Step 7 Step 8
Align the eight pins on the QDC tool with the holes on the
crimp dies, insert the pins fully into the crimp dies until
magnets are fully seated.
Figure 11
Step 6

10 EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Tooling – installation/removal
adapter and large bore dies (die-key)
General notes for crimping
Tooling installation with die key
1. Retract the crimp dies completely.
2. The site holes, figure (A) should be exposed and accessible.
3. Turn off the machine on the main switch.
4. Insert and hold (depress) the die key in hole (A).
5. Insert the crimp die segment as shown with the holding pin
in the bore hole B.
6. Release the pressure on holding pin A by pulling out the
die key.
7. This die should now be securely connected.
8. Repeat same procedure for each die.
9. Upon completion, restart machine.
Tooling removal with die key
1. Partially open the crimp head leaving site holes (A)
exposed.
2. Turn off the machine on the main switch.
3. To remove the crimp dies hold the crimp die to be changed
in one hand. With the other hand push and hold the die
key in the bore hole A in the base die C.
4. Remove the die and release the pressure on holding pin A
by pulling out the die key.
5. Remove the remaining die segments using the same
procedure.
6. Restart the machine.
BAC Die Key
Note: Failing to turn off machine prior to inserting die key may result
in injury or damage to machine.
!
Attention: Always insert a full set of matching dies.
!
Attention: When crimping with base dies only, the uncrimped coupling
diameter cannot exceed crimp range (6"/160mm).
!
Check the achieved crimp diameter after the first crimp.
If there are discrepancies between actual size, ovality and
specification value an offset adjustment must be entered.
(See pages 14 and 17 for instructions). Differences may occur
due to spring back of the fitting socket after the crimping,
as a result of hose or fitting tolerances, or differing material
hardness of the fittings.

11EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Follow the settings and calibration steps prior to initial
production use of the machine (Page 21).
Operating instructions
Crimp selections – auto mode
Rotate the main power switch (see figure 14) on the right
side of the machine to the “On” position. Wait for the
machine to boot up.
Select desired product line. (See figure 16).
• Aeroquip
• Everflex
• Industrial
• Weatherhead
• Synflex
Select Hose Series (Use either method A or method B):
A. Use scroll bar on right side of screen to scroll through the
available hose series. Make selection by touching hose
series, then press check mark. (See figure 17).
B. Touch filter box on the left, key pad will pop up, type in
desired hose series and press check mark.
Figure 14
Figure 16 Figure 17
Step 1
Step 3 Step 4
Select “Crimp Selections” for Eaton Factory Pre-populated
Specifications. (See figure 15).
Figure 15
Step 2
Note: Favorites icon provides direct selection of commonly
used crimp selections.
!

12 EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Operating instructions
Crimp selections – auto mode continued
Screen will prompt you to select “Hose Dash” size, press
down arrow to view options. Make selection by pressing
desired dash size. (See figure 18).
Install the defined dies per the load/ unload procedure.
(Page 8) Select the check mark when the correct dies are
securely installed. (See figure 20).
Press Check prompt on bottom of screen to finish selection
process and to display tooling requirements for hose series
selection. (See figure 20).
Once the selection process is complete, the screen will
change to display to current selection menu with relevant
crimping specification displayed.
Figure 18
Figure 20 Figure 21
Step 5
Step 7 Step 8
Next select “Fitting Type” by pressing down arrow to view
options and pressing desired “Fitting Type”. (See figure 19).
Figure 19
Step 6
Note: If hose series or hose dash size is not available in the
selection, please review Eaton PowerSource for compatibility. If crimp
specifications and die part number information is available for hose
series and hose dash size on PowerSource for ET5040, please use
manual mode (page 16) to perform the crimping operation.
!
Note: “Current Selection” screen displays selected product, assembly
instructions and appropriate specifications. (See figure 21).
!

13EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Operating instructions
Crimp selections – auto mode continued
1. Load hose & fitting into machine.
2. Position the scribe line on the fitting to the edge of the
tooling. (See figure 22).
Figure 22 Figure 23
Step 9
Note: Optional back stop aids in positioning the hose and fitting
assembly before crimping. (See figure 22).
!
Never reach into the crimp tooling with your hands while
the electric motor is running! Always make sure there is
adequate safety distance of at least 4.75" (120 mm)
between the crimp tooling and your hands during the
crimping process.
Caution
!
With the Auto Retraction activated (Green Icon, figure 24),
turn the crimper hydraulic motor on by depressing the green
"Motor On" button on the controller. Then press and hold
the "Crimp Advance" button on the controller or depress the
foot pedal if activated. Once the machine has crimped the
fitting, the crimp tooling will automatically retract and you can
release the cycle start button or foot pedal. (See figure 24).
Figure 24
Step 10.a. - Auto Retraction Mode
With the Manual Retraction activated (Red Icon, figure 25),
turn the crimper hydraulic motor on by depressing the green
"Motor On" button on the controller. Then press and hold the
"Crimp Advance" button on the controller or depress the foot
pedal if activated. Once the machine has crimped the fitting,
depress the crimp tooling retract button to manually retract
the crimp tooling or you can press the retract foot pedal.
(See figure 25).
Figure 25
Step 10.b - Manual Retraction Mode

14 EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Operating instructions
Crimp selections – auto mode continued
After first crimp, compare achieved crimp dimensions against
crimp specifications. (See figure 26).
Figure 26
Figure 27
Step 12
Step 13
Figure 28
If achieved crimp is larger or smaller than
specification, enter the appropriate offset to
correct. Offset will automatically be saved for
specific hose configuration.
Note: Product assembly information is displayed in box on
right side of screen. Additional information (Such as photos,
See figure 28 & 29) are available by pressing the question
mark icon. (See figure 27).

15EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Operating instructions
Crimp selections – auto mode continued
Crimp tooling diameter.
Crimp Position Specification.
Add current selection to
Favorites Menu.
Opening Diameter. The tool
automatically retracts to
set opening diameter after
crimp when green icon is
displayed. (Touch to set).
Current Tooling Position
Crimp diameter tolerance.
Correction/offset to diameter.
Crimp tooling does not open
automatically after crimping.
Manual retract required.
(Touch to change)
Returns you to Home
screen.
Crimp diameter specification.
(Target)
Crimp Position Tolerance.
Open Favorites Menu.
Displays product
information.
Crimp Ovality tolerance.
Takes you back to the
previous screen.
Crimp tooling opens
automatically after crimping.
Displays the next screen.

16 EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Operating instructions
Crimp selections – manual mode
Rotate the main power switch located on the right side of the
machine to the “On” position. Wait for the machine to boot
up. (See figure 29).
Manual Operation Screen is shown in figure 31.
See explanation of all icon on page 18.
To save manually entered crimp specification, press the save
data to user input database icon. (See figure 32).
Figure 29
Figure 31 Figure 32
Step 1
Step 3 Step 4
Select “Manual Operation”. (See figure 30).
Note: “Manual Operation” allows operator to enter and save their own
desired crimp specifications.
Figure 30
Step 2
Note: Manual Operation is for crimping hose & fittings not in the
pre-populated Eaton database.
!
Follow the settings and calibration steps prior to initial
production use of the machine (Page 21).

17EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Operating instructions
Crimp selections – manual mode continued
Enter name of manually entered crimp specification and then
press the check to save. (See figure 33).
Figure 33
Figure 34 Figure 35
Step 5
Step 6
1. Load hose & fitting into machine
2. Position the scribe line on the fitting to the edge of the
tooling. (See figure 34).
Note: Optional back stop aids in positioning the hose and fitting
assembly before crimping. (See figure 35).
!
Never reach into the crimp tooling with your hands while
the electric motor is running! Always make sure there is
adequate safety distance of at least 4.75" (120 mm)
between the crimp tooling and your hands during the
crimping process.
Caution
!
If achieved crimp is larger or smaller than
specification, enter the appropriate offset to
correct. Offset will automatically be saved for
specific hose configuration.
Note: Product assembly information is displayed in box on
right side of screen. Additional information (Such as photos,
See figure 28 & 29) are available by pressing the question
mark icon. (See figure 27).

18 EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Operating instructions
Crimp selections – manual mode continued
Data entry field for naming
custom crimp specification.
Note: Entry not required for
operation. Save required to
retain for future use.
Offset for achieved diameter
correction. Click icon to
enter value.
Crimp diameter target (User
defined via pop up numerical
keypad)
Tooling diameter. Tooling
auto populates, displaying
suggested tooling for target
crimp diameter. Note: User
may input an alternate
tooling selection.
Clears data entered from
data entry field.
Set dwell time. (Time at fully
closed position prior to auto
open)
Set desired automatic retract
opening diameter/position.
Note: The crimp tooling
automatically retracts to this
opening diameter only when
green icon is displayed.
Auto Open
Red - Off
Green - On
(Touch icon to change)
Quick die change: Initiates
the die change, install
sequence. (Touch to change)
Additional inputs (to switch
parameters) (Page 17)
Save data to user input
database.
Return to “Home” screen.
Select number of pieces to
crimp.
Note: Not required to crimp. “0”
selection will allow unlimited
crimps.
Displays total number of
pieces crimped so far.
Displays current position of
crimp tooling/pressure of
crimp.

19EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Adjusting the switching point of
the crimp machine
Adjust the switching point
of the machine from closing
speed to (slow) crimping
speed in the “Switching
Point” fields, either based
on the displacement or the
pressure.
The value first reached by the
machine triggers switching
from closing to crimping
speed.
Takes you back to the
previous screen.
Operational steps
1. Define crimp specification in the appropriate field.
2. Reference the controller specified die required.
3. Load the appropriate dies utilizing the QDC button and
instructions listed in this manual for safe die installation.
4. Verify uncrimped fitting diameter is smaller than the
‘switching point’ dimension (see pg 17) Adjust to adhere
as needed.
5. Set any desired dwell time to hold the crimp in the closed
position before auto opening (if desired).
6. Set the auto opening diameter (if desired).
7. Safely locate the fitting properly within the crimp tooling.
8. Activate crimper by depressing the cycle start button on
the controller or the foot pedal if activated, completing
the crimp.
9. Measure the crimped fitting to proper specification.
10. If achieved crimp is larger or smaller than acceptable
range, enter the needed numerical correction in the
offset field (+/-).
11. Save the crimp setting under a user specified name
(if desired).

20 EATON ET5040 Operator´s Manual E-EQCR-TT002-E1 July 2015
Settings menu
#1 Controller log-in
Note: Walk through all machine settings during initial machine set-up.
Language
Select desired language by selecting “Flag” icon. (See figure 38).
Enter your password.
Note: Factory default is “user”.
(See figure 35).
Select the settings icon to
access the settings menu’s.
(See figure 36).
Press the “Check” icon
to log-in to the “Settings”
Menu. (See figure 35).
Enter your user name.
Note: Factory default is “user”.
(See figure 35).
Press forward arrows to display
the next “Settings Menu”.
Displays the language
selected. (See figure 36)
Figure 36
Figure 38
Figure 37