Hydralok H19MM User manual

USER MANUAL
Swaging Machine Manually Operated
H19MM

2
CONTENTS
WARRANTY CONDITIONS.................................................................................................3
DECLARATION OF CONFORMITY ....................................................................................4
SAFETY REGULATIONS....................................................................................................5
TECHNICAL / DIMENSIONAL DATA ..................................................................................6
HANDLING / TRANSPORT.................................................................................................6
PRELIMINARY CHECKS.....................................................................................................6
LIGHTING............................................................................................................................6
ROUTINE MAINTENANCE..................................................................................................6
DESCRIPTION OF THE MACHINE.....................................................................................7
OPERATING INSTRUCTIONS............................................................................................7
MICROMETER SETTING....................................................................................................8
CALIBRATION PROCEDURE.............................................................................................9
SWAGE CHART................................................................................................................11
DIE FITTING INSTRUCTIONS..........................................................................................12
MAINTENANCE AND SERVICE .......................................................................................12
LUBRICATON....................................................................................................................13
SPARE PARTS..................................................................................................................14
OPTIONAL AIR/HYDRAULIC FOOT PUMP (700 BAR.)...................................................15

3
WARRANTY CONDITIONS
1. Note that all machines undergo strict testing before shipment.
2. All machines are warranted against any defects for a period of 12 MONTHS starting
from the date of delivery to the customer. The company reserves the right to require
a copy of the sales invoice.
3. We must verify defects. Therefore, each defective item must be returned to our
address with SHIPPING CHARGES PREPAID. We will return the item with
CARRIAGE FORWARD. ANY DELIVERIES TO OUR COMPANY WITH
CARRIAGE FORWARD WILL BE SENT BACK TO THE SENDER.
4. This warranty covers replacement and repair of any component found to be
defective.
5. Replacements and repairs completed under this warranty cannot extend its 12
months validity.
6. This warranty does not cover any damages caused by deterioration from use.
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.
9. This Instruction Manual is also to be considered as a warranty certificate, with
validity commencing from the date indicated on the freight bill.
GENERAL SALES TERMS AND CONDITIONS
For general sales terms and conditions, always refer to the catalogue Technical data -
General sales terms and conditions, page 59.

4
DECLARATION OF CONFORMITY
(according to current EC legislation)
the subscribed: I.M.M. Hydraulics S.p.A.
registered office in: Via Italia 49, 51
66041 ATESSA
VAT and fiscal Code 01427010697
in the person of Marcello Di Campli
declares:
Model: H19MM-M-1
Construction Year:
Serial Number:
Description: Swaging machine, manual pump operated
The machine is not included in the list of the Annex IV of Machinery Directive 2006/42/CE.
The machine complies with the requirements of Machinery Directive 2006/42/CE and to
the following modifications.
Atessa, 26/10/2018 Signed

5
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
H19MM
Capacity
3/16” –3/4” (2 wire)
R1AT, R2AT, 1SN, 2SN
Pressure requirements for optional
air/hydraulic power pack
7.0 bar (100 psi)
Packed Dimensions [mm]
600x400x460
Net weight [kg]
20
Type of operation
Twin speed hand pump
(10.000 psi)
Noise level
< 70 dB
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 stable surface.
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.

7
DESCRIPTION OF THE MACHINE
Machine for connecting hoses with eight interchangeable segments of clamps.
OPERATING INSTRUCTIONS
Fig.1
The machine is operated by a hand operated hydraulic pump. (Item 1 - Fig.1). When the
release valve (Item 2 - Fig.1) is closed and the pump operated, the swaging head will
close and a hose assembly can be swaged.
To release the finished assembly unscrew the release valve two turns.
To operate the machine, set the micrometer (Item 3 - Fig 1) to the swage size
recommended by the fitting manufacturers. (See Micrometer setting instructions below.)
Close the release valve and operate the pump to close the dies onto the assembly to be
swaged. Ensure the ferrule is within the die length before proceeding.

8
Operate the pump until the indicator rod (Item 4 - Fig.1)is level with the end of the
micrometer adjusting thimble (Item 5 - Fig.1).Swage is now complete. Initial swages
should be checked for swage size.
To remove completed assembly, unscrew the release valve and allow the machine to
open. The machine opening can be stopped by closing the release valve and need not be
fully opened each time, unless the complete opening of the pressing head is necessary to
remove the assembly.
MICROMETER SETTING
To set the machine to swage a fitting whose final swage size 24,10 mm, select the die
set S22 as indicated on the swage chart in page 11. The micrometer must be set to the
difference between the dieset size and the final swage size. In this case:
(24,10) - (22) = 2,10
To set the micrometer to the desired value (2.10), rotate the thimble (Num.1 - Fig.2) until
the line below the value "1", on the thimble, scale is aligned with the center line present on
the scale of the micrometer and the horizontal line corresponding to the value "2" indicated
on the micrometer scale indicator is flush with the thimble ring nut (Num.2 - Fig.2). The
machine is now ready to press to a diameter of 24,10 mm.
Micrometer set at 2.00 mm Micrometer set at 2.10 mm
Fig. 2

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CALIBRATION PROCEDURE
1. Fit the S28 die set into the machine.
2. Use a mandrel of known size of 30mm.
3. With mandrel in the machine pump until the maximum pressure has been achieved.
4. Set the calibrator to 2.00 on the dial.
5. Turn adjusting screw (Item 4 - Fig.4) at the end of the calibrator rod, until it is level
with the top of the calibrator (Item 1 - Fig.4).
6. To check calibration, release pressure and repeat step 3. At maximum pump
pressure the calibrator rod should be level with the top of the calibrator.
+
=
24,10
Die size: 22
Micrometer = 2,10
Swage size
Fig 3
S22

10
Fig. 4

11
SWAGE CHART
Use this chart to select the correct die set for the swaging required. The diameters indicate
the FINAL SWAGE SIZE.
DIE set
Crimping Range
(mm)
Length
(mm)
Ferrule Max
diameter (mm)
S06*
6.0 –7.9
40.0
18.0
S08*
8.0 –9.9
40.0
20.0
S10*
10.0 –12.9
40.0
22.0
S13*
13.0 –15.9
40.0
25.0
S16
16.0 –18.9
40.0
28.0
S19
19.0 –21.9
40.0
31.0
S22
22.0 –25.9
50.0
34.0
S26
26.0 –27.9
50.0
38.0
S28
28.0 –33.9
50.0
40.0
Max opening without dies: 55.0 / with die S28: 41.00
*These dies are not supplied as standard

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DIE FITTING INSTRUCTIONS
To Insert or remove the dies, the head must be closed. The dies are inserted from the front
of the swaging head. The die holders have a T slot with a spring loaded ball bearing to
retain the die in place. Ensure that the die is fully inserted in the T slot and that the longest
portion of the die from the pin is to the back of the head as shown in the next figure:
Fig.5
MAINTENANCE AND SERVICE
For machines in regular use it is recommended that a monthly check on the oil level in the
pump is carried out. To check oil level, first ensure the machine is fully open and then
remove the oil filler (Item 6 - Fig.1). The oil should be level with the top of the tie rod that
passes through the centre of the pump. If required top up with ISO 32 hydraulic oil. DO
NOT OVER FILL.
At regular annual intervals it is recommended that the calibration of the press is checked in
accordance with the calibration instructions.

13
LUBRICATON
The swaging head must be lubricated at least every 350 swage cycles. To apply the
grease, ensure that the machine is fully open. Lubrication is easily done with a small clean
brush ensuring that the inside of the swaging ring (chromed moving piston) and flat face of
the die holders are evenly coated with grease (see below).
Fig. 6
PROCEDURE TO BLEED THE SYSTEM
Close the pump operating knob and operate the pump until the piston in the swaging
machine moves 15-20mm. Position the machine in the vertical plane and loosen the bleed
screw (item 12) located in the center of the top face of the piston. (DO NOT REMOVE). Air
trapped in the system will escape through the bleed screw. When oil appears from the
bleed screw and no more air is expelled, retighten the bleed screw. This operation may
need to be repeated should there be excessive air in the system. It is advisable to check
the oil level in the pump after the bleeding operation.
Lubrificare qui
!
VERY IMPORTANT!
Lubrication is the most important factor that affects the performance of
your Hydralok swaging machine. It is vital that the machine is regularly
lubricated using a high-performance grease based on molybdenum
disulphide. Lack of lubrication or the use of other types of lubricants
could cause irreparable damage to the machine.

14
SPARE PARTS
PART No.
DESCRIPTION
300-117
Seal kit
300-136
Spring kit
500-022
Hand pump hose kit
500-010
Pneumo hydraulic pump Kit
300-121
Calibrator kit
105-031
Hand pump
105-082
Pneumo hydraulic pump
Additional dies are available for this machine, as indicated above in the swaging table. In
addition, special clamps are available for the assembly of one-piece fittings, PTFE,
FREON and other special applications.
Air conditioning die set:
DIE PART No.
DIAMETER [mm]
DA10193R6
Air conditioning die set rid.ø6mm
DA10193N6R8
Air conditioning die set nor.ø6mm/rid.ø8mm
DA10193N8R10
Air conditioning die set nor.ø8mm/rid.ø10mm
DA10193N10R12
Air conditioning die set nor.ø10mm/rid.ø12mm
DA10193N12R14
Air conditioning die set nor.ø12mm/rid.ø14mm

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OPTIONAL AIR/HYDRAULIC FOOT PUMP (700 BAR.)
SETTING INSTRUCTIONS
Connect the hose from the Swaging Head to the outlet connection of the pump (Fig.7).
Ensure pressure rating of the hose is suitable for 700 Bar operation.
AIR SUPPLY
Connect a suitable air supply to the air inlet connection of the foot pump as indicated.
N.B. The air must be supplied using a filtered and lubricated supply, regulated to a
MAXIMUM operating pressure of 7 Bar (100psig).
OPERATING THE FOOT PUMP
•Press down the Foot Pedal to close the head and perform the swage.
•Release the Foot Pedal when the Calibration Indicator reaches its set position.
•To open the Head press down on the release part of the Foot Pedal.
The head doesn’t need to be fully opened after each operation and can be stopped at any
position by releasing the Foot Pedal.
Fig. 7