ENDEAVOUR Int. Ltd. Tel +44 (0) 1225 446770 Fax +44 (0) 1225 446775 USER MANUAL Swaging Machine Type H50-46ECO Website: www.hydralok.net
CONTENTS WARRANTY CONDITIONS... 3 EC DECLARATION OF CONFORMITY... 4 SAFETY REGULATIONS... 5 HANDLING/TRANSPORT... 6 ELECTRICAL INSTALLATION... 6 PRELIMINARY CHECKS... 6 LIGHTING... 6 ROUTINE MAINTENANCE... 6 MACHINE DESCRIPTION & OPERATING INSTRUCTIONS... 7 DIE FITTING INSTRUCTIONS... 10 CALIBRATOR... 11 DIE CHART... 12 MAINTENANCE AND SERVICE.... 12 CALIBRATION INSTRUCTIONS... 13 ELECTRICAL DIAGRAM... 14 Page.2
WARRANTY CONDITIONS 1. Please note that all machines undergo strict testing before shipment. 2. All machines are warranted against any defects for a period of twelve (12) months starting from the date of delivery to the customer. 3. Defective items/machines must be returned to our address with shipping charges prepaid. We will return items/machines with carriage forward. We are unable to accept items/machines returned to us unless carriage charges have been paid. 4. This warranty covers the replacement and or repair of any component found to be defective during the warranty period. 5. Replacements and repairs completed under this warranty do not extend the original twelve (12) month warranty period. 6. This warranty does not cover normal wear under normal operating conditions 7. This warranty is not valid for damage resulting from incorrect operation, or use not in compliance with the machine instructions. 8. This warranty is not valid in case of unauthorised machine modification. Page. 3
EC DECLARATION OF CONFORMITY H50-46ECO Page.4
SAFETY REGULATIONS Always work in safe conditions and with the necessary space around the machine. Ensure that the machine is placed on a stable and appropriate working surface. 1. DO NOT USE the equipment before reading the user manual. 2. CAUTION! If improperly used, the equipment may be dangerous and may cause injury. Do not touch any moving parts. 3. CAUTION! It is absolutely essential that all working operations are carried out by one operator only 4. This manual must be provided for the machine operator. Ensure that the operator is aware of his/her responsibilities. 5. Guards must never be removed or tampered with. 6. (Where applicable) A fully trained and competent electrician must connect the machine to the appropriate electricity supply. 7. Always wear protective gloves, safety glasses and appropriate clothing. 8. (Where applicable) Disconnect the power supply before removing any covers, or attempting any maintenance of the machine 9. Only original spare parts can be used in the maintenance of the machine. Page. 5
HANDLING/TRANSPORT The machine will normally be shipped bolted to a wooden pallet. The bolts should be removed and the machine lifted onto the work place using suitable lifting equipment. ELECTRICAL INSTALLATION All electrical installation must be carried out by a qualified electrician. Check that your electrical installation is compatible with the motor requirements and specification supplied with the swaging machine such as: 380 V / 3ph or 220 V / 3ph supply 230 V 1 ph or 110 V 1ph supply IMPORTANT: 220/240V Single phase machines require a minimum 16 Amp C type motor rated MCB / Fuse. It is not recommended to connect the machine to a domestic supply. Install the machine as close to the socket as possible, without using long extension leads as this increases the current demand from the machine. PRELIMINARY CHECKS Place the machine on a stable surface. Where applicable, ensure that the power supply line is fitted with a differential safety breaker and overload cut-out. LIGHTING The equipment does not have its own lighting and so it must be used in a suitably illuminated area. ROUTINE MAINTENANCE Ensure that moving parts are always lightly greased. Where applicable check periodically that the limit switches and emergency controls are in good working order. At the rear of the machine remove the oil filler cap and check that the oil level is between 20-25mm from the top of the tank. Where necessary add oil (ISO 32 Hydraulic oil) Page.6
MACHINE DESCRIPTION & OPERATING INSTRUCTIONS MACHINE DESCRIPTION. A bench mounted annular eight-segment hose assembly swaging machine with interchangeable dies. OPERATING INSTRUCTIONS When operating the machine for the first time check that the motor rotation direction is correct. (Three phase machines only) If the jaws of the swaging head do not begin to close when the green button is pressed the phase rotation of the motor will have to be reversed. To reverse the rotation of the motor change over any two of the phase cables in the plug from the machine (supplied with the machine). A competent electrician should carry out the rewiring of the electric plug. Switch the selector to MANUAL. Select the appropriate die set using the die chart and the manufacturers recommended finished swage size. Fit the dies into the swaging head as illustrated in Fig.2. Set the calibration unit to the required setting. To determine setting, subtract the die size in millimeters from the finished swage size in millimeters. This final figure is the calibrator setting. (example - For a finished swage size of 25.40mm using die size 22, (range 22.00mm to 28.00mm) 25.4 22.0 = 3.40, Calibrator setting 3.40. WARNING. To avoid damage to the calibrator unit, adjustments must be made with the swaging head fully open. The calibrator must not be set below zero. Position the assembly to be swaged within the dies of the swaging head. Ensure machine is switched on and the emergency stop button is unlatched, and the power indicator light is on. Operate the swaging head by depressing the green button. The dies will close onto the assembly and the swage is complete when the indicator light is illuminated. To open the swaging head press the red opening button NB. The swaging head does not need to be fully open to release the assembly. The finished swage size should be checked and calibration settings adjusted where necessary as spring back (energy trapped and released by the rubber and metal after swaging) make occur especially with very large hose and fitting assemblies. Page. 7
Switch off machine when not in use, using the latching emergency stop button To unlatch the stop button twist the red knob clockwise and release. To stop the machine in an emergency press the RED emergency STOP BUTTON. DO NOT START THE MACHINE UNDER LOAD. ALWAYS RELEASE PRESSURE BEFORE RESTARTING. ISOLATE THE MACHINE FROM THE ELECTRICAL SUPPLY WHEN NOT IN USE. Page.8
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DIE FITTING INSTRUCTIONS Page.10
CALIBRATOR Page. 11
DIE CHART H50-46ECO SWAGING MACHINE DIE SWAGE SETTING RANGE FERRULE SET DIAMETER LENGTH MAX M06* 6.0 7.9 40.0 18.0 M08* 8.0 9.9 40.0 20.0 M10* 10.0 12.9 40.0 22.0 M13* 13.0 15.9 40.0 25.0 M16 16.0 18.9 55.0 28.0 M19 19.0 20.9 40.0 31.0 M22 22.0-25.9 50.00 34.00 M28* 28.0-33.9 50.00 40.00 M30 30.0-33.9 60.00 42.00 M34 34.0-39.9 70.00 46.00 M40 40.0-45.9 85.00 52.00 M46 46.0-51.9 90.00 58.00 M52 52.0-57.9 100.00 64.00 M58 58.0-63.9 105.00 70.00 M64 64.0-69.9 110.00 76.00 M70 70.0-76.0 110.00 82.00 * Non Standard Dies WARNING: Do not try swaging ferrules larger than Max MAINTENANCE AND SERVICE. A monthly check on the oil level should be carried out, more often for machines in regular use. The sliding surfaces of the head must be regularly lubricated with a molybdenum disulphide based spray. A light spray of the surfaces each day should be sufficient but for machines operating continuously or in hot climates it may require more frequent applications. At yearly intervals it is recommended to re-calibrate the swaging head. Calibration instructions enclosed. A full service and calibration service is available from the manufacturer or authorized distributor. Page.12
CALIBRATION INSTRUCTIONS 1. Complete a swaging assembly within the range of an appropriate die set. 2. Measure the finished assembly and from that size subtract the die size. 3. Using the figure arrived at from (2), check the calibrator reading. 4. If the calibrator requires adjustment loosen the retaining screw (item 3, fig 3) 5. Retain the knob (item1, fig 3) and rotate the adjusting ring (item 4, fig 3) using the retaining screw key as a lever. 6. When the correct figure is reached re-tighten the retaining screw. 7. Set the calibrator to a new setting and produce a swaged assembly. 8. Check the finished swage size. (If incorrect repeat the calibration operation) Page. 13
ELECTRICAL DIAGRAM Page.14