ENDEAVOUR Hydralok H25BE4 User manual

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USER MANUAL
Swaging Machine
Types H25BE4,H32BE4,H32CE4
H50BE4, H50CE4, H50CE6

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Table Of Contents
Table Of Contents .........................................................................................................................2
WARRANTY CONDITIONS.......................................................................................................3
WARRANTY CONDITIONS.......................................................................................................4
EC DECLARATION OF CONFORMITY ....................................................................................5
SAFETY REGULATIONS ...........................................................................................................6
TECHNICAL / DIMENSIONAL DATA ......................................................................................7
HANDLING/TRANSPORT..........................................................................................................7
PRELIMINARY CHECKS ...........................................................................................................7
LIGHTING ...................................................................................................................................7
ROUTINE MAINTENANCE........................................................................................................8
INSTALLATION..........................................................................................................................8
Three Phase Machines:..............................................................................................................8
Single Phase Machines: .............................................................................................................8
Starting the machine for the first time:.......................................................................................8
SAFETY PRECAUTIONS............................................................................................................8
MANUAL SWAGING PROCEDURE (Machines without Quick Change)..................................10
MANUAL SWAGING PROCEDURE (Machines with Quick Change) ......................................11
QUICK CHANGE TOOL OPERATING INSTRUCTIONS *.....................................................12
Inserting dies into the machine ................................................................................................12
AUTO MODE *..........................................................................................................................13
Dwell*: ...................................................................................................................................13
Opening Time .........................................................................................................................13
Hose Counter*.........................................................................................................................14
Swage Offset...........................................................................................................................14
ADVANCED OPTIONS.............................................................................................................15
Preset Menu *..........................................................................................................................15
Save a Preset .......................................................................................................................15
Use a preset .........................................................................................................................16
Edit a preset.........................................................................................................................17
Delete a preset .....................................................................................................................17
SETUP MENU............................................................................................................................19
Die Table.................................................................................................................................19
Custom Die Sets ..................................................................................................................19
Lubrication..............................................................................................................................21
Quick Change (QC) Position Adjustment †..............................................................................23
Calibration Instructions ...........................................................................................................24
Display....................................................................................................................................26
Language.................................................................................................................................26
Reset to Factory Settings .........................................................................................................27
TECHNICAL INFORMATION ..................................................................................................28
Maintenance And Service........................................................................................................28
Spare Parts ..............................................................................................................................28
Swaging Head Drawing (Fig 1) ...............................................................................................29
Die Chart.................................................................................................................................30
Die Fitting Instructions............................................................................................................31
Electrical Diagram: 3 Phase.....................................................................................................33

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Electrical Diagram: 1 Phase.....................................................................................................34

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WARRANTY CONDITIONS
Please note that all machines undergo strict testing before shipment.
1. All machines are warranted against any defects for a period of twelve (12) months starting
from the date of delivery to the customer.
2. Defective items/machines must be returned to our address with shipping charges pre-paid. We
will return items/machines with “carriage forward”. We are unable to accept items/machines
returned to us unless carriage charges have been paid.
3. This warranty covers the replacement and or repair of any component found to be defective
during the warranty period.
4. Replacements and repairs completed under this warranty do not extend the original twelve (12)
month warranty period.
5. This warranty does not cover normal wear under normal operating conditions
6. This warranty is not valid for damage resulting from incorrect operation, or use not in
compliance with the machine instructions.
7. This warranty is not valid in case of unauthorized machine modification.

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EC DECLARATION OF CONFORMITY

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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.

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TECHNICAL / DIMENSIONAL DATA
TECHNICAL/DIMENSIONAL
DATA
H25BE4 H32BE4/
H32CE4
H50BE4/
H50CE4
H50C6
Capacity 3/16”- 1” (4 wire)
R9R/4SP
3/16”- 11/4”
(4 wire)
R9R/4SP
3/16”- 2” (4
wire)
R9R/4SP
3/16”- 2” (6
wire)
Motor 2.2KW 2.2KW 2.2KW 2.2KW
Packed Dimensions in mm 900x600x900 940x640x10
30
940x640x1030 800x1200x930
Gross weight in Kg 130 130 175 300 Kg
Voltage (Current) 1 Phase
220/240-1-
50HZ (15) or
380/440-3-50HZ (5)
220/240-1-
50HZ
220/240 -
380/440-3-
50 Hz
225/280 –
440/480 60
Hz
220/240-1-50HZ
or
220/240 -
380/440-3-50
Hz 225/280 –
440/480 60 Hz
220/240-1-50HZ
or
220/240 -
380/440-3-50
Hz 225/280 –
440/480 60 Hz
Swaging force 24 AC & DC 1750 Kn 2509 KN 4500 KN
Swaging range 6 mm – 45.9
mm
0.6 mm – 76
mm
0.6 mm – 82
mm
Standard dies Not exceeding
73dB(A)
16 19 22 26
30 34 40 46
16 19 22 26 30
34
40 46 52 58 64
70
16 19 22 26 30
34 40 46 52 58
64 70 76
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.
PRELIMINARY CHECKS
Place the machine on a flat and stable base.
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.

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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 top of the machine base, remove the oil filler cap and check that the oil level correct. Where
necessary add oil (ISO 32 Hydraulic oil).
INSTALLATION
The machine must be bolted to a firm workbench in a horizontal position. If a quick change rack is
supplied, the machine must be bolted to it with the bolts supplied. The machine is top heavy,
therefore ensure that it is stable and does not pose a danger for the user or other people.
Three Phase Machines:
When operating the machine for the first time check that the motor rotation direction is correct.
(Three phase machines only) If the motor starts but jaws of the swaging head do not begin to close
when the green button is pressed to swage, 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
machine’s plug. A competent electrician should carry out the rewiring of the electric plug.
Single Phase Machines:
Ensure that the power loop is for industrial use, rated for at least 20Amps. Install the machine as
close to the socket as possible. Do not use long extension leads as this increases the current
demand from the machine. Do not connect to residential rated 13Amps loops.
Starting the machine for the first time:
After the machine is connected to the power supply, if the Emergency Stop is pressed, rotate it to
disengage. The LCD screen will still show the E-Stop message. This is a safety measure to avoid
starting the machine by accident. Press the jog wheel once to acknowledge the message and start
the machine..
SAFETY PRECAUTIONS
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.
Emergency Stop
Restart ()

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MANUAL SWAGING PROCEDURE (Machines without Quick Change)
From the main menu, press the jog wheel once to access the diameter selection option.
Rotate the jog wheel to select the swage size. Clockwise to increase / anticlockwise to decrease
size. Once the size is selected, press jog wheel to confirm.
Manually fit the dies as shown on screen and press Jog wheel to confirm.
Place the hose in position and press green button to swage to selected size
Buzzer will sound and machine will stop when size is reached. Press Red Button to open.
L16
Swage to 17.90mm
Menu() 17.90mm
Swage to 17.90mm
Menu() --.--mm
Fit Die L16
Manual OK(↓)
Push to Confirm
 17.90mm 
Main Menu
Set Diameter 
BUZZ

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MANUAL SWAGING PROCEDURE (Machines with Quick Change)
From the main menu, press the jog wheel to access the diameter selection option.
Rotate the jog wheel to select the swage size. Clockwise to increase / anticlockwise to decrease
size. Once the size is selected, press jog wheel to confirm.
Press and hold green button to go to Quick Change Position
Fit the dies using quick change tool, remove tool and press red button to open machine.
Place the hose in position and press green button to swage to selected size
Buzzer will sound and machine will stop when size is reached. Press Red Button to open.
Push to Confirm
 17.90mm 
L16
Swage to 17.90mm
Menu() --.--mm
Fit Die L16
Red When Fitted
Fit Die L16
Hold Green Btn
Swage to 17.90mm
Menu() 17.90mm
Fit Die L16
Q/C(Grn) OK(↓)
Main Menu
Set Diameter 
BUZZ

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QUICK CHANGE TOOL OPERATING INSTRUCTIONS *
* Optional Extra
Inserting dies into the machine
1. The electronic controller will automatically position the piston ready for replacement using
the quick change tool.
2. Holding the quick-change tool with both hands, line up the tool with the required die set.
Line up the tool so that the pins on the tool sit in the holes positioning holes of the die set.
3. Switch on quick change tool
4. Dies will now be attached to the tool
5.
6. Pull dies out of their insert on the rack.
7. Insert dies into machine in a parallel motion (not at an angle), with a firm push movement
so that they click into place over the ball bearings, and then switch the die tool off.
8.
9.
10. Replace die tool back into its holder.
11. You are now ready to complete a swage.
Note: Quick change tool must be removed from dies BEFORE dies are opened.

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AUTO MODE *
* Only available on the “C” Range.
The auto mode allows the operation of the machine by means of a foot switch ( ), freeing both
hands for better control of the hose. In Auto Mode, it is possible to adjust the Dwell and the
Opening Time:
After adjusting the swage size, pressing the foot pedal initializes the auto sequence as follows.
Dwell*:
In order to allow a more controlled and precise swage finish, it is sometimes advisable to maintain
pressure on the ferrule for an extended period of time at the swage diameter. This helps to
minimise the “spring back effect” that a ferrule experiences after swaging, especially on hoses of
larger size.
To set up the dwell time:
From the main menu, scroll to the Dwell option
Spin the jog wheel to adjust the Dwell time in seconds and press to confirm..
Opening Time
In certain circumstances, it may not be necessary to fully open the machine after each swaging
operation, it may save time to open the machine just enough to take the fitting out.
To set up the opening time:
From the main menu, scroll to the Opening Time option
Dwell Time
 0.50s 
Main Menu
Set Diameter 
Main Menu
 Dwell 
FOOT SWITCH M/C CLOSES TO
SWAGE SIZE
DWELL TIME OPENING TIME

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Spin the jog wheel to adjust the Opening Time in seconds and press to confirm..
Hose Counter*
The hose counter counts the number of completed swaging operations. By default, it is turned off,
in order to turn it on follow the next steps: From the Main Menu, select the Hose Counter option:
by default, it is turned off, spin and press the jog wheel to activate it. If the hose counter is already
on, this operation will reset the counter to zero:
The number of hoses counted is displayed after every swaging operation is completed.
Swage Offset
This function allows you to adjust the swage size to compensate for “spring back effect” or any
other factors that may alter the final swage dimensions. To use this function, follow the next steps:
From the main menu, scroll to the Swage Offset option
Main Menu
Set Diameter 
Hose Counter
 On / Zero
Hose Counter
Off 
Main Menu
Set Diameter 
Main Menu
 Hose Counter 
Opening Time
 5.00s 
Main Menu
Set Diameter 
Main Menu
 Opening Time 

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Spin the jog wheel to adjust the adjust the value of the offset; it can be a positive (rotate
clockwise) or a negative value (rotate anticlockwise). i.e. if a swage size of 22.50mm is selected
with an Offset of -.-0.15mm, the hose will be swaged to 22.35mm.
The Offset value is cancelled when a new swage size is selected.
ADVANCED OPTIONS
Preset Menu *
The preset menu allows the user to save machine settings with a name to be used when required.
By saving a preset stores the following information:
Swage size
Swage Offset
Dwell Time *
Opening Time *
*If foot switch available
Save a Preset
To store a configuration, set up the machine parameters as required, including Swage Size, Swage
Offset, Dwell Time and Opening time. After this, follow the next steps to save the configuration:
From the main menu, scroll to the Preset Menu option and press the jog wheel
On the Preset Menu, scroll to the “Save to preset” option and press the jog wheel
Adjust Swage
 -0.15mm 
Main Menu
 Swage Offset 
Preset Menu
Use Preset 
Main Menu
Set Diameter 
Main Menu
 Preset Menu 

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Use the jog wheel to name the preset by rotating the jog wheel to select the characters and
pressing the jog wheel to accept it. i.e 1/4 R2
Note that the blank space is found after the letter “Z”
When the name is complete, scroll to “DONE” and press the jog wheel to memorize.
Use a preset
To use a preset, from the main menu go to the PRESET MENU and then select USE PRESET:
Preset Name?
1/2 R2 DONE
Preset Name?
1/2 R2  2 
Preset Name?
1/2 R  1 
Preset Name?
1/2  R 
Preset Name?
1/2  
Preset Name?
1/  2 
Preset Name?
1  / 
Preset Name?
 1 
Preset Menu
Save to Preset

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Rotate the Jog wheel to select the Preset to use and press to load it.
The machine parameters are now changed to those stored previously with this name.
Edit a preset
The values saved as preset can be modified if necessary. To do this, from the preset menu select
the “Edit Preset” option and select the parameter to be changed.
Select the preset to be edited
Select the feature to be edited from:
Swage size
Swage Offset
Dwell Time
Opening Time
Delete a preset
A preset can be easily deleted from the memory by selecting the “Delete Preset” option, selecting
the preset to be deleted and confirming by pressing the jog wheel:
Preset Menu
Use Preset 
Preset to Edit
 1/2 R2 
Preset Menu
 Edit Preset 
Preset Menu
Use Preset 
Preset to Use?
 1/2 R2 
Preset Menu
Use Preset 
Main Menu
Set Diameter 
Main Menu
 Preset Menu 

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Select the name of the preset and press jog wheel to delete it
Preset to Delete
 1/2 R2 
Preset Menu
 Delete Preset 

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SETUP MENU
Die Table
Die sets that are supplied with a new machine are readily available to be used by the controller.
When additional die sets are purchased afterwards, they need to be added to the controller and
mark as “Present”; on the other hand, if a die set is not longer available, it need to be marked as
“Absent”. Follow the next steps.
From the main menu go to the SETUP MENU and then select DIE TABLE:
Select the Die Set to be added or deleted from the controller by scrolling and pushing on the jog
wheel:
To add the selected die set as available
Or to delete the die set from the list of available dies scroll to “Mark absent” and press the jog
wheel.
Custom Die Sets
When special or customised die sets are purchased, it is necessary to define the following
parameters:
Die set name
H13
 Mark Absent
H13
Mark Present 
Select Die Set
 H13 
Setup Menu
Die Table 
Main Menu
Set Diameter 
Main Menu
 Setup Menu 