1290 Operators Manual.qxd
Contents
1. ET1295DC M320S ET1295DC M370S ET1295DC M420S ET1295DC M465S ET1295DC M520S ET1295DC M550S ET1295DC M570S ET1295DC M690S Note Insert Sets include 8 dies with insert pins FT1209 DIE CAGES FT1209 200 14 FT1209 200 15 FT1209 200 16 FT1209 200 18 FT1209 200 20 FT1209 200 21 FT1209 200 23 FT1209 200 46 FT1209 200 82 EATON 1290 Crimp Machine Set Up and Operating Manual E EQCR TM005 E November 2006 FT1307 200 M240 FT1307 200 M280 FT1307 200 M320 Bench Top Rack A rack that can hold 12 sets of die inserts This can be mounted to a bench top ET1295C 0029 Hanging Rack A rack that can hold 12 die inserts This can be hung from the FT1209 FT1307 FT1340 FT1360 and FT1390 Crimp Machines ET1295C 0027 Insert Holder An insert holder for one set of die inserts This can be mounted to the front or side of a crimp machine ET1295C 0025 FT1307 200 M370 FT1307 200 M420 FT1307 200 M465 FT1307 200 M520 FT1307 200 M550 FT1307 200 M570 FT1307 200 M690 Lubrication A can of Never seez to lubricate the dies FT1092 Set Up and Operating Instructions Set Up Operating Instructions 110V 220V Power Unit 1 Remove the plug from the hydraulic reservoir vent and replace it with the vent cap supplied with the unit Caution Failure to do so will cause cavitation an2. ETN ET1290 Crimp Machine Set Up and Operating Manual Table of Contents SECTION PAGE Specifications and EQUIPMENT E ETT TES ETE EUER 3 Set Up and Operating INStrUCtONS oci ettet E a aaa A aE REC ease 4 Crimping Procedures 5 6 CL 6 Crimp Machine Components esee nens nsns sss s edens denen seen eee n nsns es ener n nns 7 016 Components OTRO OH IO I Hg on es gode de us dere dated Danae m db quce t 8 Safety Instructions Read and understand the operator s manual before attempting to operate any equipment WARNING Aeroquip hose hose fittings 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 LIA BILITY INCLUD
3. TM005 E November 2006 Backstop Figure 3 Crimping Procedures Establishing Crimp Settings The adjustment knob in the middle of the machine determines the crimp diam eter for each combination of hose fitting and die cage die insert The numbers on the dial and barrel of the machine are for selecting target settings and not crimp diameters Settings between 160 and 550 can be achieved with this crimp machine Consult the target setting chart for the ET1290 crimp machine for the initial setting Crimping Procedures Refer to the current Crimp Specifications Manual on the Eaton website for complete and detailed crimp specifica tion information for each hose and fitting style 1 Select and load the proper die cage die insert according to the current Crimp Specifications Manual on the Eaton website 2 Rotate the adjustment knob barrel indicator to the proper setting see Example Example Position the adjustment knob at a setting of 500 Activate the hydraulic pump and attempt a crimp If the dies crimp the fit ting measure the crimp diame ter and decrease the machine setting rotate the adjustment knob upward by the same amount in thousandths of an There are 25 marks on the dial 0 24 and 15 marks on the barrel 175 525 by 025 increments The top of the barrel corresponds to a 160 setting When the adjust ment knob is rotated to the top most position on the crimper and the 0 m
4. the center ver tical line on the barrel MACHINE MAINTENANCE PROCURES 1 Sliding surfaces must be kept free of dirt and other abrasive materials Then rotate the adjustment knob and dial together until the 0 mark on the dial is once again lined up with the center vertical line on the barrel Repeat the crimp procedure until the 1 000 inch crimp diameter is achieved 2 All exposed black metal surfaces should be coated occasionally with a light film of oil to prevent corrosion 3 Periodically check the oil level in the fluid reservoir of the hydraulic power unit Maintain the oil level of pump manufacturer s hydraulic oil as needed NOTE Completely retract the crimp ring when checking the oil level DIE CAGE MAINTENANCE PROCEDURES 1 Lubricate the die cage For maximum service Die cages require lubrication at 50 crimp intervals with NEVER SEEZ Eaton part number FT1092 FT1092 is an 8 ounce container that will provide sufficient lubricant for approximately 5 000 crimps Periodically remove NEVER SEEZ residue that has built up on the sides of the dies and the crimp ring during the crimping process NEVER SEEZ residue becomes contaminated with metal and plating chips and airborne contaminants which can cause premature wear of the dies and crimp ring It should care fully be removed without mixing it with newly applied NEVER SEEZ 2 Die cage maintenance should be performed at 1000 crimp intervals o
5. the equipment from tipping 11 UNPLUG THE POWER SUPPLY WHEN NOT IN USE KEEP WORK AREA CLEAN Cluttered areas and benches invite accidents Specifications and Equipment ET1290 Crimp Machine Die Cages Machine w 110V Power Unit Crimper Dimensions 30 75 40 125 Dx 41 25 H Weight 1035 Ibs Pump Requirements Reservoir Capacity 50 cubic inches or more 820 cc Pressure Rating 10 000 psi 690 bar Machine w 220V Power Unit Crimper Dimensions 30 75 VV x 40 125 Dx 41 25 H Weight 1035 Ibs Pump Requirements Reservoir Capacity 50 cubic inches or more 820 cc Pressure Rating 10 000 psi 690 bar Table Top Machine Crimper Dimensions 20 W x 41 25 D x 14 5 Weight 910 Ibs Pump Requirements Reservoir Capacity 50 cubic inches or more 820 cc Pressure Rating 10 000 psi 690 bar Accessories MASTER DIE INSERT SETS FT1390 DIE CAGES M SERIES DIE CAGES ET1295DC 14S FT1390 200 14 FT1307 200 M070 ET1295DC 15S FT1390 200 15 FT1307 200 M090 ET1295DC 16S FT1390 200 16 FT1307 200 M120 ET1295DC 18S FT1390 200 20 FT1307 200 M150 ET1295DC 20S FT1390 200 21 FT1307 200 M180 ET1295DC 21S FT1390 200 23 FT1307 200 M210 ET1295DC 23S ET1295DC 46S ET1295DC 82S 12950 0705 12950 0905 12950 1205 ET1295DC M150S ET1295DC M180S ET1295DC M210S ET1295DC M240S ET1295DC M280S
6. 4 1 pc FT1307 2 9 4 Front Plate 5 3 pc FT1307 2 9 5 BHCS 5 16 18x2 56 long 6 4 pc FT1307 2 9 6 Spacer 7 1 pc FT1307 2 9 7 Nut 8 1 pc FT1307 2 9 8 Back Plate 9 1 pc FT1307 2 9 10 BHCS 5 16 18x3 00 long FT1390 Die Cage Breakdown DETAIL OTY PART NUMBER DESCRIPTION 1 1 pc FT1390 2 9 1 Back Plate lower 2 1pc FT1390 2 9 2 Back Plate upper 3 1 pc FT1390 2 9 3 Front Plate lower 4 1 pc FT1390 2 9 4 Front Plate upper 5 4 pc FT1390 2 9 5 Spacer 6 1 pc FT1390 2 9 6 Shoulder Screw long 7 1 pc FT1390 2 9 7 Latch Assembly 8 3 pc FT1209 2 9 1 BHCS 5 16 18 x 3 90 long 9 1 pc FT1209 2 9 5 Shoulder Screw short 10 8 pc FT1209 2 9 7 Spring 11 1 pc FT1209 2 9 8 BHCS 5 16 18 x 3 50 long 12 8 pc 21057 7 Roll Pin 25 dia x 62 long 13 8 pc FT1209 200 size Dies EATON 1290 Crimp Machine Set Up and Operating Manual E EOCR TMOO05 E November 2006 Die Cage Components ET1295 001 2 Piece Assembly 10 DETAIL QTY PART NUMBER DESCRIPTION 1 1 ET1295C 0006 Back Plate Split 2 1 ET1295C 0007 Front Plate Split 3 8 ET1295C 0001 Master Die 4 8 ET1295C 0003 Plunger Pin 5 8 ET1295C 0004 Set Screw 6 16 120 70188 46 Roll Pin 7 8 ET1295C 0005 Spring 8 1 FT1209 2 9 5 Shoulder Screw 9 2 ET1295C 0012 Rotation Pin 10 4 ET1295C 0009 Connecting Block 11 8 FF9339 04 20S Cap Screw 12 16 ET1295C 0017 Dowel Pin 13 2 ET1295C 0011 Fro
7. ING INCI DENTAL AND CONSEQUEN TIAL DAMAGES ARISING FROM BREACH OR CON TRACT WARRANTY OR TORT UNDER NEGLIGENCE OR STRICT LIABILITY THEORIES SHOULD AEROQUIP OR WEATHERHEAD HOSE FIT TINGS OR ASSEMBLY EQUIPMENT BE USED INTERCHANGEABLY OR WITH ANY HOSE FITTINGS OR ASSEMBLY EQUIPMENT SUPPLIED BY ANOTHER MANUFACTURER OR IN THE EVENT THAT PRODUCT INSTRUCTIONS FOR EACH SPECIFIED HOSE ASSEM BLY 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 nei ther recommended nor authorized by Eaton Safety Instructions 1 PREVENT UNAUTHO RIZED OPERATION Do not permit anyone to operate this equipment unless they have read and thoroughly understand this manual WEAR SAFETY GLASSES AVOID PINCH POINTS Do not rest your hand on the crimp ring Keep your hands clear of all moving wW N parts Do not allow anyone other than the operator close to the equipment while it is in opera
8. al Red Indicator Rin ID 9 VE Figure 4 5 When the fitting is fully crimped all movement in the machine will stop and the black guard around the piston pinch point hat will move up and completely cover the red indicator ring see figure 4 and figure 5 located on the adjustment knob 6 Release the hydraulic pressure and remove the crimped hose assembly Scribe Line Ll For a target crimp diameter of 0 990 inches and a machine setting of 250 produces a crimp diameter of 1 004 inches sub tract the target crimp diameter 0 990 inches from the diame ter you measured 1 004 0 990 0 014 Subtract 014 from the machine setting 250 014 236 Adjustment Knob dial would result in a target setting of 275 If the desired target setting is 265 the dial would instead be rotated downward 15 marks on the dial or approximately 2 3 of a turn past the 250 target setting Barrel Figure 5 This is accomplished by pressing and holding the foot switch in the release position until the machine is completely retracted 7 Verify that the correct crimp diameter and crimp length is achieved Figure 6 For proper crimping procedure refer to the Crimp Specification Manual on the Eaton website and change the machine set ting to 236 Crimp the fitting again and measure the crimp diameter If the crimp diameter is too large repeat this process If the crimp diameter is too small
9. ark is located as shown in Figure 4 the machine setting is 160 Each complete down ward rotation of the adjust ment knob increases the target setting by 025 each mark around the dial corre sponds to a 001 change in target setting For example to achieve a target setting of 3 Position the fitting to the proper crimping position within the die cage die insert according to the Crimp Specifications Manual on the Eaton website 4 Press and hold the foot switch in the forward posi tion 5 The foot switch may be toggled back and forth as required to reposition the fit ting Note The use of a 10 000 psi hydraulic power source is required to operate the ET1290 crimp machine If lower rated power units are utilized improper crimping may result inch that you wish to decrease the crimp diameter a smaller target setting number means a smaller crimp diameter If the dies do not crimp the fitting decrease the machine setting by 050 increments until the dies touch the fitting and the result ant crimp diameter can be measured EATON ET1290 Crimp Machine Set Up and Operating Manual E EQCR TM005 E November 2006 WARNING Maintain clear distance from all moving parts 250 the adjustment knob is rotated until the top of it corresponds to the 250 mark on the barrel and the 0 mark on the dial is lined up with the center vertical mark on the barrel see Figure 5 One more full downward rotation of the Di
10. d damage to the pumping mechanism Hand tighten the vent cap Loading and Unloading Die Cages Select proper die cage for style and size of desired hose Refer to the current Crimp Specifications Manual on the Eaton website for complete and detailed crimp specification information for each hose and fitting style To load the die cage press and hold the footswitch until the crimp cylinder reaches the full retract position and stops The die cage may be inserted or removed in this position See figure 1 Caution Figure 2 shows a die cage that is installed improp erly When inserted properly the cage is flush against the pressure plate If the die cage is at an angle to the pressure plate lift it up and realign properly 2 Caution Provide electri cal service with a dedicated circuit per the crimp machine electrical requirements to eliminate the possibility of a low voltage situation 3 Never use an extension cord always plug directly into the power outlet Adjustable Backstop Figure 3 1 Turn off the power to the machine 2 Insert the die cage 3 Loosen the thumbscrew on the backstop 4 Place the fitting against the locator cone Pushing it too hard will compress the spring which will affect the accuracy of the position 5 Slide the backstop to the desired position 6 Tighten the thumbscrew 7 Turn the power on EATON ET1290 Crimp Machine Set Up and Operating Manual E EQCR
11. g Ring 1 12 FT1289 3 15 Pressure Plate 1 13 FT1289 3 13 Push Bars 4 14 FT1303 3 76 Shoulder Bolts 2 15 FF9339 08 245 Cap Screws 4 16 FT1340 3 4 6 Locator Cone 1 17 FT1340 3 4 2 Spring 1 18 FT1340 3 4 4 Bushing 1 19 FT1340 3 4 5 Thumb Screw 1 20 FT1340 3 4 3 Locator Plate 1 21 FT1340 3 4 1 Shoulder Bolt 1 22 222003 6 405 Cap Screws 4 23 ET1290C 0022 Middle Support 1 24 222003 8 325 Cap Screws 4 EATON ET1290 Crimp Machine Set Up and Operating Manual E EQCR TMO005 E November 2006 Die Cage Components FT1209 Die Cage Breakdown 10 DETAIL OTY PART NUMBER DESCRIPTION 1 3 pc FT1209 2 9 1 BHCS 5 16 18x3 90 long 2 1 pc FT1209 2 9 2 Front Plate 3 4 pc FT1209 2 9 3 Spacer 4 1 pc FT1209 2 9 4 Back Plate Assembly Details 5 through 9 5 1 pc FT1209 2 9 4 1 Back Plate 6 2 pc FT1209 2 9 4 2 Roll Pin 09 dia x 50 long 7 2 pc FT1209 2 9 4 3 Rod 8 2 pc FT1209 2 9 4 4 Spring 9 2 pc FT1209 2 9 4 5 Roll Pin 125 dia x 75 long 10 1 pc FT1209 2 9 5 Shoulder Screw 11 8 pc 21057 7 Roll Pin 25 dia x 62 long 12 1 pc FT1209 2 9 7 Spring 13 1pc FT1209 2 9 8 BHCS 5 16 18x3 50 long 8 EATON ET1290 Crimp Machine Set Up and Operating Manual E EQCR TM005 E November 2006 Die Cage Components FT1307 Die Cage Breakdown lt DETAIL PART NUMBER DESCRIPTION 1 8 pc 21057 7 Roll Pin 25 dia x 62 long 2 8 pc FT1209 2 9 7 Spring 3 1 pc FT1307 2 9 3 Spring Plate
12. nt Locating Pin 14 2 ET1295C 0010 Rear Locating Pin 15 16 ET1295C 0013 Spring 16 4 222003 1 6 6S Cap Screw 17 8 FF9339 04 12S Cap Screw 10 EATON 1290 Crimp Machine Set Up and Operating Manual 005 November 2006 Die Cage Components ET1295 011 1 Piece Assembly DETAIL QTY PART NUMBER DESCRIPTION 1 1 ET1295C 0021 Back Plate 2 1 ET1295C 0022 Front Plate 3 8 ET1295C 0001 Master Die 4 8 ET1295C 0003 Plunger Pin 5 8 ET1295C 0004 Set Screw 6 16 120 70188 46 Roll Pin 7 8 ET1295C 0005 Spring 8 1 FT1209 2 9 5 Shoulder Screw 9 2 ET1295C 0012 Rotation Pin 10 4 ET1295C 0009 Connecting Block 11 8 FF9339 04 20S Cap Screw 12 16 ET1295C 0017 Dowel Pin 13 16 ET1295C 0013 Spring 14 8 FF9339 04 12S Cap Screw EATON ET1290 Crimp Machine Set Up and Operating Manual E EOCR TMOO05 E November 2006 11 Eaton 14615 Lone Oak Road Eden Prairie MN 55344 USA Tel 952 937 9800 Fax 952 974 7722 www hydraulics eaton com E T N Eaton 20 Rosamond Road Footscray Victoria 3011 Australia Tel 61 3 9319 8222 Fax 61 3 9318 5714 Eaton Dr Reckeweg Str 1 D 76532 Baden Baden Germany Tel 49 7221 682 0 Fax 49 7221 682 788 2006 Eaton Corporation All Rights Reserved Printed in USA Document 005 November 2006
13. r every six months which ever occurs first Die cages should be clean of grease and debris and inspected for worn or damaged components a The sliding surface of the dies should appear smooth with no apparent galling Galled dies must be replaced Individual dies in a cage can be replaced without replacing all eight dies b Replace springs that show any sign of damage or collapse are shorter than other springs c The spring plate should appear smooth with no apparent galling Galled spring plates must be replaced d Inspect remaining components and replace those that are badly worn 3 Reassemble components and liberally apply NEVER SEEZ to the die surface which slides along the spring plate Torque the die cage bolts to 50in Ibs 4 Ensure that all dies slide in and out freely 6 EATON ET1290 Crimp Machine Set Up and Operating Manual E EQCR TM005 E November 2006 Crimp Machine Components 17 13 shin 15 e 14 A ce PART NUMBER DESCRIPTION QUANTITY 1 ET1290C 0002 Barrel 1 2 ET1290C 0012 Washer 1 3 ET1290C 0003 Adjustable Knob 1 4 ET1290C 0001 Dial Indicator 1 5 ET1290C 0007 Pinch Point Hat 1 6 FF90625 1 4 20 x 3 8 Button Head Cap Screw 4 7 ET1280C 0014 5 16 18 Button Head Cap Screw 1 8 FF90626 Set Screw 2 9 ET1290C 0015 ET1290C 0017 Red Shroud Yellow Shroud 1 10 FT1289 2 2 15 Crimp Ring Insert 1 11 FT1289 2 2 14 Retainin
14. repeat the process but instead add the difference to the machine setting Calibration The ET1290 Crimp Machine is factory calibrated ATTC 8 or WeatherGRIP 8 fitting crimped with an FT1307 200 M240 die cage or the Set Figure 7 Maintenance Intervals DIE CAGE LUBRICATION Every 50 crimps Relube sliding surfaces of dies Every 500 crimps Remove old grease and relube Every 1000 crimps Die cage maintenance CRIMP RING IMAINTENANCE Every 500 crimps Remove old grease and relube Remove old grease Inspect for wear or damage and relube if okay Every 2000 crimps NOTE Use NEVER SEEZ lubricant Eaton part number FT1092 Master Die Cage with the M240 die insert and a machine setting of 260 should result in a socket diameter of 1 000 0 003 inches If excessive wear occurs in the crimp ring or any of the functional components are replaced a minor recalibra tion may be necessary This can be accomplished by first loosening the two 8 32 set screws in the adjustment Procedures WARNING Maintain clear distance from all moving parts knob see Figure 7 and then performing the crimp described above If the actual measured crimp diameter is for example 1 010 inches instead of 1 000 inches the black dial piece can be rotated inside the adjustment knob leaving the adjustment knob exactly where it is positioned until the number 0 on the dial lines up with
15. tion 5 e Oo N MAINTAIN DIES WITH CARE Dies used in the ET1290 crimp machine are hardened steel offering the best combination of strength and wear resist ance for long life Hardened dies are gener ally brittle and care should be taken to avoid any sharp impact Never strike a die with a hard ened instrument USE ONLY SPECIFIED AEROQUIP WEATHER HEAD PRODUCTS Make hose assemblies using only Aeroquip and Weatherhead hose and fit tings specified for this assembly equipment VERIFY CORRECT CRIMP DIAMETERS Check and verify correct crimp diameters of all fit tings after crimping Do not put any hose assemblies into service if the crimp diameters do not meet Eaton crimp specifications Make sure all dies are completely in place and the cage is positioned properly on the pressure plate 2 EATON 1290 Crimp Machine Set Up and Operating Manual E EQCR TM005 E November 2006 8 DO NOT OVER PRESSURIZE Do not exceed the 10 000 psi hydraulic pressure sup plied 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 1J100 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
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