Danfoss T-400-1 Portable Coll O Crimp Installation Guide

CAUTION: It is recommended this booklet be read prior to set-up, then used as a guide during actual assembly. Retain for reference purposes.

System Specifications & Equipment

T-400-1 Coll-0-Crimp® Press Specifications

Crimping Capacity: 3/16” -1-3/8” I.D. 2-wire Hose
Weight: 113 lbs

T-400 Coll-O-Crimp® Press with tooling includes one each of the following:

T-421U Electric Pump

USE ONLY IF OPERATING TEMP. IS BELOW 0°F or above 160°F. NOTE: The electric pump  must be on an individual 15 amp fused circuit.

CAUTION The Coll-O-Crimp power source has the pressure relief valve set at 4000 to 4,200 psi. Damage to the press will result and the warranty may be voided if higher pressures are used.

Crimp Locator T-400-9

The T-400-9 allows you to make large volumes of hose assemblies by automatically aligning hose ends in proper crimp location.

T-400-9 Crimp Locator Installation Instructions:

1. Remove the front allen bolt using an allen wrench or tool provided with kit.
2. Add the washer provided with the kit to existing washer as shown and torque the bolt down to approximately 75ft.-lbs.
3. Attach the locator post of the pre-assembled locator to the bottom of the middle plate and lock it in place with one of the knurled nuts.
4. Align the dimples on the first assembly with the top of the collet to locate the crimp. Drop the locator bracket down to rest on top of the hose end. Lockthe bracket in position with remaining two knurled nuts. The locator now can be used, instead of dimples, to locate crimp accurately and consistently for the remaining hose ends of the same size and type.

Power Unit Specication

T-402-1 Air/Hydraulic Pump

(Some models have air port on right side)

NOTE: It is recommended that a filter, regulator, lubricator and air pressure gauge be installed in the air line as close as possible to the pump. Filter,  Regulator and Lubricator units not included.

T-403-2 Hand Pump

T-412 Mobile Electric Pump

T-421U Electric Pump

 CAUTION All of the above approved Coll-O-Crimr electric power sources have the pressure relief valve set at 4000 to 4,200 psi. Damage to the press will result and the warranty may be voided if higher pressures are used.

Cabinet Mounting Instructions

The FH-135X Stock Cabinet is designed specifically for your Coll-0-Crimp hose service program. The Coll-O-Crimp® press T-400-1 and T-421 U electric pump mount conveniently on top of the cabinet. If T-403-2 hand pump is used, a mounting bracket with hardware (Part No. FH-136) is available. The Coll-0-Crimp unit can also be powered by the air driven hydraulic pump T-402-1 with hand/foot treadle actuator which fits easily under the cabinet for foot operation or mounts to surface for hand use.
The FH-135X cabinet has 50 heavy duty plastic drawers which divide into one, 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, then used as a guide during actual assembly

STEP 1 & 2: Attach legs with bolts, nuts and washers provided. Then label cabinet using the layout guide provided.
STEP 3: Mount T-400-1 Press on top left of cabinet. Predrilled holes align the press. Insert bolts from top of cabinet. Washers and nuts are threaded from   underneath. Tighten.
STEP 4: T-421U Electric Pump. Mount on top right side of cabinet. Predrilled holes align the pump. Insert bolts from top of cabinet. Washers and nuts are installed from underneath. Tighten.
STEP 4a: T-402-2 Air/Hydraulic Pump. Mount on top right side of cabinet (see step 4) or place on the floor for easy foot pedal operation.
STEP 4b: T-403-2 Hand Pump. Mount on top right of cabinet (see step 4) by  installing the FH-136 mounting bracket.
STEP 5: Remove plug from middle port on top of press.
STEP 6: Locate press/pump connecting hose assembly and remove 4315X6X8 For-Seal adapterfrom hose assembly. Thread into port on press (from Step 5) and tighten.
STEP 7: Remove plug from port on pump. (See page 2 for illustration of appropriate pump connecting port).

Electric Pump (T-421U): Remove 4315X6X8 For-Seal adapter from hose assembly (T-400-16) and thread into the top middle port of pump and tighten. Connect hose assembly to pump and press.
Air/Hydraulic Pump (T-402-1): Remove 4315X6X8 For-Seal adapterfrom hose assembly (T-400-18) and thread into middle port of press. Thread 4205X6X6 For-Seal adapter into the female 3/8” NPTF hydraulic swivel connector of the air pump. Connect (T-400-18) assembly to press and pump.
Hand Pump (T-403-2): Remove 4315X6X8 For-Seal adapter from hose assembly (T-400-19) and thread into middle port of press. Thread 4205X6X6 For-Seal adapter into rear port of pump. Connect hose assembly to press and pump

Shop/Work Table Mounting

The following method of mounting your Coll-O-Crimp equipment package is offered as a guide and may be varied to suit your particular needs.

1. Open shipping cartons and remove all equipment and components.
2. Prepare mounting surface for Coll-O-Crimp press and power unit. Refer to Figure 1 for bolt hole layout and optimum working height.
   IMPORTANT – Care must be taken to insure that the surface to which the press is bolted is capable of supporting the weight of the press (approximately 113 lbs.) which extends 8-5/8” over the front edge of the mounting surface.
3. Bolt T-421 U press to the mounting surface.
4. Place power unit on mounting surface adjacent to the T-421 U press within convenient working distance.
5. Remove plug from middle port on top of press.
6. Locate press/pump connecting hose assembly and remove 4315X6X8 For-Seal adapter from hose assembly. Thread into port on press (from Step 5) and tighten.
7. See page 5 (step 7) for appropriate connecting port.
8. ELECTRIC PUMP (T-421U): Remove 4205X6X8 For-Seal adapterfrom hose assembly (T-400-16) and thread into the top middle port of pump. Connect hose assembly to pump and press.

Mobile Set-Up Instructions

INTRODUCTION: T-412 is designed for use with the Coll-O-Crimp I machine. See page 4 for specifications. Due to the mobile equipment application, caution must be taken when installing the DC unit. Adequate wiring is imperative for proper operation. If the battery is grounded to the engine, make sure the engine is grounded to the frame of the vehicle with the same wire gauge used for the power unit cable. Attach the positive cable to the positive battery terminal. Connect the opposite end of the positive cable to the power unit solenoid start switch while the DC unit is in operation. The vehicle’s engine must be running to avoid battery discharge. Remember, the battery ground to the engine only is not sufficient. (See Diagram ‘B’ below). The current draw is several hundred amperes, so adequate wire size and battery capacity is absolutely essential. (See Diagram ‘A’ below). Direct wire ground to battery. Welding cable recommended.

Set Up Instructions:

The following method of setting up your Coll-O-Crimp equipment package is offered as a guide and may be varied to suit your needs.

1. . Before opening any shipping cartons, be sure proper grounding and wiring are used (See Diagram ‘A’ below).
   a. Checkfor a proper ground path. Aground from the battery to only the engine is not sufficient. Be sure the battery is grounded to the frame of the vehicle with the same gauge wire as the cable required for the pump. (See Diagram ‘B’ below).
   b. The pump must be grounded to the vehicle frame and not to the body. There are two 3/8-18 UNC tapped holes in the bottom of the pump housing for mounting the pump to the vehicle frame.
   c. Since current draw can exceed 200 amperes during the crimping cycle, adequate wire size is essential. Number 4 gauge wire is required for a cable length of up to 20 feet from the battery to the pump. Number 2 gauge wire is required for a cable length between 20 and 40 feet from the battery to the pump (see Diagram ‘A’ below).
   d. The 12 volt battery should have an ampere-hours rating of at least 70 and have a minimum of 11 plates per cell. For constant usage, when a large number of hose assemblies are to crimped, it would be appropriate during crimping to run the engine at a fast idle to maintain battery charge.
2. Open the shipping cartons and remove all equipment and components.
3. Prepare the mounting surface or surfaces for the Coll-O-Crimp press and the DC pump. NOTE: Care should be taken to insure that the press mounting surface is capable of supporting 113 pounds. The front edge of the press will extend 8-5/8 inches beyond the edge of the mounting surface. Figure 1, page 6
   
   , shows atypical bench layout forthe crimper. Figure 2, page 6,
   
   shows a typical equipment set up with the DC Pump
4. Bolt the press to the mounting surface using 1/2 inch bolts.
5. Remove the plug from the top of the press and connect the 4205X6X6 adapter from the hose assembly (T-400-21). This adapter can be adjusted easily for the best alignment of the hose assembly after the pump is mounted.
6. Place the T-412 DC pump on a properly grounded mounting surface within convenient working distance of the press. Remove the plug from the pressure port from the top-center of the pump housing and connect the 4315X6X8 adapter from the hose assembly (T-400-21). Loosely connect the T-400-21 hose assembly to the adapters in the press and pump. Locate the pump so that the hose will appear as shown in Figure 2, page 6.
7. Locate and drill mounting holes forthe pump. There are two 3/8-16 UNC tapped holes, 1/2 inch deep and five inches apart in the bottom of the pump housing.
8. Bolt the pump to the mounting surfaces.
9. Tighten the hose connections. Check once again to be sure the pump and battery are properly grounded to the vehicle frame.
   Run a #1, #4 or #2 gauge wire power cable directly from the ‘hot side’ of the battery, or the ‘hot side’ of the engine starter solenoid, to the solenoid start switch on the pump. The solenoid start switch is strap mounted to the outside of the DC motor. The proper connection is the top post on the solenoid which also has a small wire going into the actuator mounting box on the side of the pump housing.

NOTE If battery is grounded to engine, make sure engine is grounded to frame with same gauge   of wire as power unit cable.

Check-out Procedure

Check oil level in power unit. The oil reservoirs in all power units have been filled at the factory; however, if oil is required see pages 2 and 4 for the recommended hydraulic oil

CAUTION Throughout the Check-out Procedure check allhose assembly/adapter connections for any leaks. .Tighten if necessary.

Check-out using electric pump (T-421U)

1. Plug power cord into 220 volt, 60 cycle, single phase outlet. It is recommended that this unit have a 15 amp fused circuit.
2. Remove pipe plug from fluid fill port on top of reservoir and replace with plastic breather cap.
3. The following steps should be conducted without tooling in press.
4. Turn the electric motor switch to the on position and hold during the crimp stroke. Allow piston to travel out of the cylinder until it bottoms (approximately 1”). NOTE: When the electric motor switch is turned on, the hydraulic pump is activated causing the piston on the press to travel downward.
5. Release electric motor switch. Piston will retract.
6. Repeat steps 4 and 5 approximately six times. This will purge the system.
7. With system properly purged, crimp stroke time will be approximately 3-5 seconds.
8. Attach pusher T-432-15 to press. See page 9 for crimping operation.

Check-out using air pump (T-402-1)

1. Connect air line to 1/4” NPT port on air pump. Air pressure available should be from 60 psi to 120 psi. NOTE: To insure that your pump does not become inoperative due to internal corrosion caused by moist air it is recommended that a suitable air line lubricator be installed near the pump air inlet. (Ref. page 4 forWeatherhead lubricator.) If a lubricator is not used, place 3 or 4 drops of a high grade oil directly into the air inlet port weekly.
2. Turn on air pressure to pump.
3. The following steps should be conducted without tooling in press.
4. Push hand/foot treadle. Allow the piston to travel out of the cylinder until it bottoms (approximately 1”).
5. Release hand/foot treadle to return piston.
6. Repeat steps 4 and 5 approximately six times. This will purge the system.
7. With a system pressure of 95 psi, crimp stroke will be approximately 18-30 seconds.
8. Shut-off air supply to pump.
9. Attach Pusher T-432-15 to press. See page 9 for crimping operation.

Check-out using hand pump (T-403-2)

1. Perform the following steps without tooling in press.
2. Open finger tip control valve and pump the handle until piston bottoms (approximately 1”).
3. Release fingertip control valve allowing the piston to return
4. Repeat steps 2 and 3 approximately six times. This will purge the system.
5. Purging completed, attach pusher T-432-15 to press. See page 9 for crimping operation

Check-out Procedure Using 12-Volt DC Pump (T-412)

1. Remove pipe plug from the port on top of the reservoir and replace with plastic breather cap.
2. The following steps should be conducted without tooling in press.
3. Turn the electric motor switch to the on position and hold during the crimp stroke. Allow piston to travel out of the cylinder until it bottoms (approximately 1”). NOTE: When the electric motor switch is turned on, the hydraulic pump is activated causing the piston on the press to  travel downward.
4. Release electric motor switch. Piston will retract.
5. Repeat steps 4 and 5 approximately six times. This will purge the system.
6. With system properly purged, crimp stroke time will be approximately 3-5 seconds.
7. Attach pusher T-432-15 to press. See page 9 for crimping operation.

Operation Instructions

1. Place die ring T-400-8 on base plate against front stops.
   
2. Insert properly sized matched collet halves into the die ring. See chart on press.
3. Place proper size Coll-O-Crimp hose end on hose. Be sure hose is bottomed in hose end. Reference Figure A, page 10.
   
   
4. Insert hose assembly from below between collet halves. Align the dimples on the hose end collar with the top of the collet. When using 757 Series ends, the collar should be flush with the top of the collet.*
   
   NOTE For initial use, lubricate the tapered cone seat with lubriplate grease or equivalent premium grade pressure grease.
5. Reference page 10, Figure B.
   
   Place appropriate side of spacer ring on top of collet with uncrimped hose assembly held in place.
   
6. Slide entire assembly back against rear locating stops.
7. Activate pump to crimp hose end to hose. When spacer ring contacts die ring, crimping is complete. Release the electric switch to retract pusher. Slide entire assembly forward and remove spacer ring.
   
8. Remove factory quality crimped hose assembly and visually inspect the crimped end. The crimp on the collar should be located ± 1/16” from the dimples or ridges.
   
9. To insure a proper crimp has been completed, measure the nominal crimp diameter as shown on page 10, Figure C.
   
   

CAUTION: Always hold the hose assembly in place from below throughout the crimping operation.

Figure A
Insertion Depth
Place hose ends on hose until hose is bottomed in collar.
To insure that hose is bottomed in collar, markthe insertion depth on the hose before inserting it into the hose end. On aluminum hose ends, hose is bottomed when hose is visible in viewing hole in
Figure B
COLL-O-CRIMP® Spacer Ring
Typical spacer ring illustrating both sides of ring

Figure C
Nominal Crimp Diameter Measurement
Measuring crimp diameters should be a part of the normal hose assembly procedure. To insure a proper crimp diameter reading, follow these steps:

1. Measure the diameter in the middle of crimped portion of the hose end.
2. Place the caliper in a postion to allow a measurement across the pressed (flat) portion of the crime.

 NOTE: In the larger sizes, calipers may be used; however, in the smaller sizes, and in the “E” Series thermoplastic hose ends, a point micrometer will provide an accurate reading.

Repair and Replacement Items

Troubleshooting Procedures

Troubleshooting Coll-O-Crimp T-421 U Electric Pump

Troubleshooting Procedures

Troubleshooting Coll-O-Crimp T-421 U Electric Pump
IMPORTANT: Pressure must be relieved from system before disconnecting hose, installing gauge or removing valves from pump   Step 1: Check fuse, loose wire connections, switch malfunctions or for 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.
Step 2: Check oil level – after assembly and system has been purged of air the fluid 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 below 0°F or above 160°F. (See current 411 catalog for oil types.) 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

Step 3: 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 checkvalve and install a 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 final gauge reading before removing gauge and reinstalling pipe plug.
Step 4: Shuttle Valve – If the shuttle valve is in a closed position and Coll-O-Crimp 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 fit. 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 fine crocus cloth. After final 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.

Stock Cabinets

FH-135X Stock Cabinet

The FH-135X stock cabinet is designed specificallyfor your Coll¬0-Crimp® hose service program. It provides an ideal hose service center by combining your hose assembly equipment and stock into one convenient location. The sturdy FH-135X cabinet contains 50 heavy duty plastic drawers that can be divided into one, two, orthree compartments allowing you ample space for a large selection of Coll-O Crimp® hose ends and adapters.

FH-15X Stock Cabinet

Here is the ideal wayto organize your inventory of hose ends and adapters. Stock it any way you want — to fit your particular needs. It can be used for field service or as a jobber display and stock cabinet. The rugged FH-15X cabinet contains 15 plastic drawers for stocking hose ends and adapters.

About Danfoss Power Solutions FC

Danfoss hoses, fittings, and tooling provide the ultimate fluid conveyance solutions for a variety of equipment and applications around the world. We proudly engineer to support a sustainable future for tomorrow.
To learn more please visit: http://www.danfoss.com/en/about-danfoss/our-businesses/ power-solutions

Danfoss Power Solutions
14615 Lone Oak Road
Eden Prairie, MN 55344, USA
Phone: 952-937-9800
Danfoss Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515-239-6000
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Krokamp 35
D-2439 Neumünster, Germany
Phone: +49 4321 871 0
Danfoss Power Solutions ApS
Nordborgveg 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
Danfoss Power Solutions Trade (Shanghai) Co. Ltd.
Building #22, No 1000 Jin Hai Rd Jin Qiao, Pudong New District Shanghai, China 201206
Phone: +86 21 3418 5200w

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 order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed. All trademarks in this material are the property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved 

Documents / Resources

Danfoss T-400-1 Portable Coll O Crimp [pdf] Installation Guide T-400-1 Portable Coll O Crimp, T-400-1, Portable Coll O Crimp, Coll O Crimp, Crimp

References

• User Manual