Granit G20 User manual

Operating Instructions for Hydraulic hose swage machine G20/G32
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Operating Instructions for
Hydraulic hose swage machine G20/G32
These operating instructions must be read thoroughly before use and followed.
These operating instructions must be retained for future reference.
Hydraulic hose swage machine G20
Hydraulic hose swage machine G32

Operating Instructions for Hydraulic hose swage machine G20/G32
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Table of Contents
1. ABOUT THESE INSTRUCTIONS AND SYMBOL DESCRIPTIONS 3
2. SAFETY AND ACCIDENT PREVENTION RULES 3
2.1 GENERAL SAFETY INSTRUCTIONS 3
2.2 PRECAUTIONARY MEASURES 4
2.3TRANSPORT AND ASSEMBLY 4
3. INTENDED USE 4
4. WARNINGS ON THE MACHINE 5
5. FIRST USE 7
5.1 FILLING WITH HYDRAULIC OIL 7
5.2 ELECTRICAL CONNECTION 7
6. OPERATING THE EQUIPMENT 8
6.1 CONTROL ELEMENTS 8
6.2 CRIMPING CONTROLS 8
6.3 TEST RUN 9
6.4 DIE SELECTION 10
6.5 CHANGING A MATRIX 10
6.6 DIE SETS 11
6.7 CRIMPING CONNECTIONS 12
7. CARE AND MAINTENANCE 12
8. CALIBRATION OF THE CRIMP DIAMETER 13
9. DISPOSAL 13
10.FAULT RECTIFICATION 14
11.EC DECLARATION OF CONFORMITY 15
12.GUARANTEE 16
13.ADDRESSES 16
14.LEGAL NOTICE 16
15.CIRCUIT DIAGRAMS 17
15.1 ELECTRICAL CONTROL: 17
15.2 HYDRAULIC CIRCUIT DIAGRAM 17

Operating Instructions for Hydraulic hose swage machine G20/G32
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1. About these Instructions and symbol descriptions
The information in these Operating Instructions is labelled as follows:
DANGER
Warning of personal injury or environmental damage.
IMPORTANT
Warning of property damage.
NOTE
Additional information.
Numbers in illustrations (1, 2, 3 ...) refer to the corresponding numbers in brackets (1), (2), (3) ...
in the text next to the item numbers in the tables.
Instructions for which the order must be followed are numbered (1, 2, 3, ...)
Lists are marked with a dot (●, ●, ...)
2. Safety and accident prevention rules
2.1 General safety instructions
These operating instructions were prepared so that you can work safely with the equipment.
People who are not familiar with these instructions should not perform these actions.
Read these Operating Instructions thoroughly before use. Pay particular attention to the safety
instructions.
These Operating Instructions are intended for people with basic technical knowledge in using
equipment such as that described here.
If you have no experience with such equipment, you should first get assistance from experienced
persons.
Keep all supplied documents with the equipment for future reference if required. Keep the
purchase receipt for any warranty claims.
If you lend or sell the equipment, supply all documentation with it.
Observe the operating and maintenance instructions found in this manual.
Children should be supervised to ensure that they do not play with the equipment.
Mechanical maintenance should be performed at the prescribed intervals and in the prescribed
scope.
Following maintenance work, all dismantled protective devices must be properly reinstalled. The
protective devices and their protective functions should be inspected by a competent person
before using the machine.
Defective equipment must be repaired promptly in order to minimize the extent of damage and
avoid endangering the safety of the equipment.
The presses should only be used and operated under the conditions laid down in these operating
instructions.
Retrofits, changes or modifications to the equipment are strictly prohibited. They require
consultation with and written approval by the manufacturer.
If during operation (residual) hazards and risks become apparent which are not described in this
manual, the operator is obliged to report this to the manufacturer.
Never work or reach between or on moving pressing tools.
Do not change the settings of the safety components. Before each use check for proper
functioning, especially the hydraulic oil level, and check for possible leaks.
Liquid under high pressure can cause severe or fatal injury! In case of injury contact a physician
immediately!
Before working on the hydraulic system de-pressurize the system!

Operating Instructions for Hydraulic hose swage machine G20/G32
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Regularly check hydraulic lines and replace if worn or aged! Replacement hoses must meet the
manufacturer’s technical specifications! If not otherwise specified by the manufacturer, replace
hydraulic hose lines at least after 6 years (due to aging)!
2.2 Precautionary measures
Always wear protective gloves when performing setup, maintenance and cleaning work
on the equipment, to prevent injury from sharp parts.
While working with and on the equipment wear protective work gloves that fit snugly,
safety goggles and work shoes.
Wear body-covering, snug-fitting clothing.
Before each use always perform a visual and then a function check of the equipment to
identify damage and worn parts and arrange for their repair by trained personnel before
use.
Ensure that the equipment is always on a solid and stable base.
Observe care and maintenance instructions.
The press may be operated only by persons 16 years or older. As an exception, use by a teenager
is permitted in the course of training to attain skill under the supervision of an instructor.
2.3 Transport and assembly
The press is delivered on a pallet. The palette can be
moved with a pallet jack or forklift. (Fig. 3)
After unpacking, lift the machine off the pallet with lifting
belts and place it in the desired location.
The dimensions are X = 76cm / Y = 56cm / Z = 80cm. The
total weight of the G20 is 138 kg and 208 kg for the G32.
F
igure 1
3. Intended use
The machine was developed to make hydraulic hose connections.
It is designed for use in dry, non-freezing interior spaces.
The press consists of a 3-phase (or 1-phase) electric motor that drives a hydraulic pump. The crimp
die is powered by the hydraulics.
The manufacturer shall not be liable for damages caused by failure to comply with generally
accepted rules as well as the instructions in this manual, including insufficient maintenance.
The manufacturer is not liable for any damages resulting from these causes.

Operating Instructions for Hydraulic hose swage machine G20/G32
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4. Warnings on the machine
Figure 2
The machine is intended only for professional use. It should be operated only by trained personnel.
The openings between the matrices exceed 6 mm for technical reasons, and so are large enough
that they can crush a finger!
It is therefore absolutely necessary to observe the Operating Instructions and warnings in all
operating cycles of the machine.
Warnings are given as stickers on the machine and in these Instructions.
Do not remove or cover the warning stickers. Immediately replace damaged warning signs with
new ones.
Warning 1:
Keep body parts out of the
press as long as the drive
motor is running.
Warning 2:
Keep hands far enough away
from moving parts during
pressing.
Warning 3:
The crimping dies will open as soon as the
emergency off switch is operated. Use two-
hand control for normal operation.
Warning 4:
High voltage!
The electrics may be opened
only by a qualified electrician.

Operating Instructions for Hydraulic hose swage machine G20/G32
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Warning 5: (G32)
The back of the “crimping head” is
covered by a housing that protects the
operator from the crush hazard behind it
between the rear flange and the cylinder.
This housing must not be removed!
Warning 6:
When changing the dies with the quick-
change device, hold the handle as shown
in the illustrations.
Make sure that your hand does not get
between the crimp elements.
For technical reasons, some die parts are not covered. Their travel is short and they move very
slowly. This limits the danger of crush injury, since the movement is small and the speed is low.
However, never let body parts get between these or any moving parts.
Additional warnings:
Warning of rotating machine
parts
Warning of hand injury
General warning
The noise developed by the equipment in operation has been measured as no higher than 70dB(A).

Operating Instructions for Hydraulic hose swage machine G20/G32
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5. First use
5.1 Filling with hydraulic oil
Fill the oil tank to the middle of the two markings on the dipstick. Use a hydraulic oil like Shell Sagen
T46 or equivalent. The tank volume is 32 litres. We recommend filling the oil tank through a 20-y
filter in order to keep possible contamination out of the system.
5.2 Electrical connection
DANGER: Before connecting the machine make sure that the supply voltage is identical to the
required machine voltage (see type plate). For more information, consult your power
supplier. Insert the supply cable through the hole in the side panel of the electrics cabinet and secure
it with a strain relief plug.
3-phase motor: Connect phase conductor with terminals L1, L2 and L3 in the electrics cabinet.
Connect the ground wire to the ground terminal on the mounting plate. Check the connection
against the circuit diagram in the spare parts list. Make sure that the motor’s direction of rotation is
the same as the arrows on the motor illustration. If the motor is running in the wrong direction, the
two-phase conductors need to be switched on their terminals.
1-phase motor: Connect the phase and the neutral conductor to the respective terminals in the
electrics cabinet. Connect the ground wire to the ground terminal on the mounting plate. Check the
connection against the supplied circuit diagram.
DANGER: This work may only be done by a qualified electrician. Fatal shock hazard!

Operating Instructions for Hydraulic hose swage machine G20/G32
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6. Operating the equipment
6.1 Control elements
1. Motor on and off switch. This separates the machine from the power supply. But the
undervoltage release can only be disconnected by pulling the plug or disconnecting the power
cable.
2. Pressing the crimp button moves the matrices until the button is released or the set crimp
diameter is reached.
3. Pressing the opening button opens the matrices until the button is released or the maximum
return travel is reached.
4. Crimping diameter display
5. The crimp diameter chart for each die set and the associated setting display.
NOTE: For good results, the parameters should always be set specifically for the individual
hose connection.
6.2 Crimping controls
The main controls are on the front of the machine.
(A) Close the die: (B) Open the die:
1. Semiautomatic machine control
This button starts the crimping motion, if the matrices have reached the set return position. (A)
2. Crimp button
The matrices move when this button is pushed. The matrices continue moving until the button is
released or the set crimp diameter is reached. This button can only be used if the machine is in
manual mode. If the machine is started in manual mode, the crimp button cannot be used to start
crimping until the 0 position or the opening dies have been set with return button 7. The matrices
will not open if they have reached the set return position. (B)
3. Reaching the set crimp diameter
The signal light comes on when the matrices have reached the set crimp diameter. (A)
4. Return button
The matrices open when this button is pushed. The matrices continue to open until the button is
released or the set return diameter is reached. This button can only be used if the machine is in
manual mode. (B)
5. Return diameter reached
The signal light comes on when the matrices have reached the set return diameter. Automatic
operation cannot start until the return position has been reached.

Operating Instructions for Hydraulic hose swage machine G20/G32
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6. Delay indicator light
The delay indicator light comes on when the delay function is active.
7. Return diameter check
The return diameter of the matrices after crimping is set with the dial face. Set the return large
enough that the connector to be crimped fits easily between the matrices but has minimal play.
Turning the dial face clockwise increases the return.
8. Crimp diameter check
The crimp diameter is adjusted by means of the dial face and the die set used. The dial face covers 0
to 10 mm. It is graduated in 0.01 mm or 0.1 mm increments. Turning the dial face clockwise increases
the return. On the IS models, one turn equals a 1 mm change in the crimp diameter. On the AS
models the crimp diameter changes by 1 mm between two numbers.
6.3 Test run
1. Start the motor.
2. Set the crimp diameter to 10.0 and the return to the maximum amount.
NOTE: During the first crimp cycles the air in the cylinders can cause the matrices to move
irregularly.
3. Repeat the crimp cycle a few times until the movement is regular.
To prevent accidents, make sure that there are no foreign objects between the matrices.
NOTE: If the matrices do not move in both directions, the motor is running in the wrong
direction. Correct this by switching the two-phase conductors in the switchgear cabinet.
4. Test the operation of each button and each setting in the table per Chapter 6.1.
Observe also the information in the VS Operating Instructions.

Operating Instructions for Hydraulic hose swage machine G20/G32
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6.4 Die selection
G20, see Figure 5
Figure 5
G32, see Figure 6
Figure 6
Use only intact die sets approved for the device.
Observe the manufacturer’s specifications for the right crimp diameter. The smallest crimp diameter
is marked on the die with a “D.”
Example: On die set NO 18013/10 the minimum crimp diameter is 10 mm.
6.5 Changing a matrix
1. Start the motor and press the return button until the matrices have reached their maximum
return.
2. Stop the motor.
3. Matrices may be installed only with the motor off.
DANGER: The motor must be switched off and secured against starting before doing any
repair and maintenance work. If this is not done, there is a danger of uncontrolled starting,
resulting in severe injury.
4. Using the tool supplied, pull on the pin of the matrix to be
switched out.
5. Before installing matrices, clean the contact surfaces of the
two joining components.
IMPORTANT: Avoid damaging the dies themselves and
their contact surfaces.
6. Place the replacement matrix in the space holding it by the
pin with the tool. The number on the matrix must face you.
7. Remove the tool.
Figure 3
NOTE: To get a clean connection, after replacement check the seating and movement of the
matrices as described in Chapter 6.2.
Diameter
Diameter