Hydralok H25ECO-QC User manual
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page.2
CONTENTS
WARRANTY CONDITIONS.....................................................................................................3
EC DECLARATION OF CONFORMITY..................................................................................4
SAFETY REGULATIONS........................................................................................................5
TECHNICAL / DIMENSIONAL DATA ......................................................................................6
HANDLING/TRANSPORT.......................................................................................................6
ELECTRICAL INSTALLATION................................................................................................6
PRELIMINARY CHECKS.........................................................................................................6
LIGHTING................................................................................................................................6
ROUTINE MAINTENANCE......................................................................................................7
MACHINE DESCRIPTION & OPERATING INSTRUCTIONS..................................................8
QUICK CHANGE...................................................................................................................10
DIE FITTING INSTRUCTIONS..............................................................................................11
CALIBRATOR........................................................................................................................11
DIE CHART ...........................................................................................................................12
MAINTENANCE AND SERVICE. ..........................................................................................12
CALIBRATION INSTRUCTIONS...........................................................................................12
SPARE PARTS......................................................................................................................13
ELECTRICAL DIAGRAM.......................................................................................................14
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page. 3
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 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.
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.
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page. 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.
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page.6
TECHNICAL / DIMENSIONAL DATA
TECHNICAL/DIMENSIONAL DATA
H25ECO-QC
Capacity
3/16”- 11/4” (4 wire)
R9R/4SP
Motor
2.2KW
Gross weight in Kgs
108
Voltage
220/240-1-50HZ or
220/240 - 380/440-3-50 Hz
225/280 –440/480 60 Hz
Standard dies
16 22 28 34 40
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.
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page. 7
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).
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page.8
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.
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 H22, (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.
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page. 9
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.
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.
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page.10
QUICK CHANGE
Inserting dies into the machine
1. Set calibrator to quick change setting
2. With the machine set on manual press the green, swage, button and close dies until
they reach the required setting. The green swage light will come on when this
setting has been reached.
3. Select required die set
4. 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.
5. Switch on quick change tool
6. Dies will now be attached to the tool
7. Pull dies out of their insert on the rack.
8. 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.
9. Replace die tool back into its holder.
10.You are now ready to complete a swage.
Note: Quick change tool must be removed from dies BEFORE dies are opened.
Removing dies from the machine
1. Set calibrator to quick change setting
2. With the machine set on manual press the green, swage, button and close dies until
they reach the required setting. The green swage light will come on when this setting
has been reached.
3. 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.
4. Switch on quick-change tool; you should hear a firm click when the dies attach
themselves to the tool.
5. Remove the dies from machine in a parallel motion (not at an angle) with a firm pull
movement. The dies must slide back over the ball bearing in a parallel movement,
sometimes it is useful to give them a wiggle before removing to loosen them from their
position.
6. The dies will now be attached to the quick change tool
7. Replace the dies into the correct insert in the rack, and turn off the tool.
8. Replace tool into the tool holder for safekeeping.
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page. 11
DIE FITTING INSTRUCTIONS
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 dies. Ensure that the die is fully inserted in the T slot
and that the longest portion of the die from the pin is facing the back of the head as shown in
Figure 1 below.
CALIBRATOR
Figure 1
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page.12
DIE CHART
Die No
Range (mm)
Length
Ferrule Dia Max
Die No
Range (mm)
Length
Ferrule dia Max
*06
06.0 - 07.9
40.00
18.00
*26
26.0 - 29.9
50.00
38.00
*08
08.0 - 09.9
40.00
20.00
28
28.0 - 33.9
50.00
40.00
*10
10.0 - 12.9
40.00
22.00
*30
30.0 - 33.9
60.00
42.00
*13
13.0 - 15.9
40.00
25.00
34
34.0 - 39.9
70.00
46.00
16
16.0 - 18.9
40.00
28.00
40
40.0 - 45.9
70.00
52.00
*19
19.0 - 21.9
40.00
31.00
*46
46.0 - 51.9
75.00
58.00
22
22.0 - 25.9
50.00
34.00
*52
52.0 - 57.9
75.00
64.00
*These dies not supplied as standard
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.
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)
Machines manufactured at Hydralok, Bristol, UK
Machine enquiries, sales, after sales service :
Interpump Hydraulics (UK) Ltd t/a IMM Hydraulics (UK) : Kidderminster
Page. 13
SPARE PARTS
Item Part Number Description
9, 10,11,12,13,14 300-078 seal kit
5, 7,17,18,19,20 300-079 spring kit
25 YA1001 calibrator assembly
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