Wireteknik Swagers

Manual
model A270
1. Manufacturer’s EU declaration of conformity and address........ 3

2. About the manual................................................................................................ 3

3. Tools for the A270 model................................................................................ 4

4. Safety instructions.............................................................................................. 5
4.1. General things to observe.................................................................... 5
4.2 Intended use and function................................................................... 5
4.3 Clothing and protective equipment................................................ 5

5. General description of the machine......................................................... 6

5.1 Technical data............................................................................................. 7
5.2 Installing the machine in the work area........................................ 7
5.3 Connecting a hydraulic pump............................................................ 7
5.4 Connecting electric power................................................................... 7
5.5 Work area for the operator when swaging................................. 8

6. Operating instructions...................................................................................... 9
6.1 Step 1 – Choosing and mounting roller dies............................. 9
6.2 Step 2 – Choosing and mounting pulling tools...................... 10
6.3 Step 3 – Preparing wire and terminal.......................................... 11
6.4 Step 4 – Swaging.................................................................................... 12
6.5 Swage dimensions................................................................................. 13

7. General description of swaging................................................................ 14

8. Service and maintenance............................................................................. 15

8.1 Planned service intervals.................................................................... 15

9. Storing the machine......................................................................................... 15

Model A270 – 2
1. Manufacturer’s EU declaration
of conformity and address
Wireteknik AB, P.O Box 4053, SE-102 61 Stockhol­m, plate) correspond to the regulations in the council
Sweden, phone +46 8 643 67 33, hereby declares­ directive of 17 May 2006 concerning machinery
at its own risk that the machines for swaging A100, 2006/42/EC.
A200, A270, A350, A400, A400rs and A500 with
serial numbers from 2020 onwards (the year followed Standards applied are SS-EN ISO 12100:2010 and
by the serial number is clearly stated on the type SIS-ISO/TR14121-2:2112.

Stockholm 2021-12-08

Jesper Ott
CEO and responsible for technical documentation

Wireteknik AB
P.O Box 4053
SE-102 61 Stockholm
Sweden

2. About the manual

It is of utmost importance
that the safety and operating
instructions are read and under-
stood by all users before installing
and operating the machine.

Model A270 – 3
3. Tools for the A270 model
Roller dies

Required equipment, sold separately.

One pair of roller dies for each wire size.

Pulling tools supplied as standard equipment

Straight and bended links Fork Puller Small Fork Puller Medium
Art. No: CHL-6 / CHL-10 Art. No: PP6.2 Art. No: PP10

Fork Puller Large Fork Small, pin Ø 6 mm Fork Medium, pin Ø 10 mm Fork Medium, pin Ø 12 mm
Art. No: PP20 Art. No: F2 Art. No: F3 Art. No: F35

Fork Large, pin Ø 16 mm Ball Puller 4–8 mm Stem Ball Puller 10–12 mm Stem Multipurpose Pulling Tool
Art. No: F4 Balls. Art. No: BP4-8 Balls. Art. No: BP10-12 Art. No: MP-1

Nuts ”Olives”. Metric and UNF, right hand thread.

Adapter UNF Nuts, right hand Left hand thread optional.
Art. No: M12/M20 thread. Art. No: Olives, M10-M5 / M12-M6 / M14-M8 / M16 /
Art. No: 3/4” / 7/8” / 1” 1/4”-7/16” / 3/8”-9/16” / 1/2”-5/16” / 5/8”

Model A270 – 4
4. Safety instructions
Special safety measures are required when operating­ Read and understand all the operating instructions
the machine as there is a risk of crushing and cutting before using the machine for the first time and keep
injuries and leakage. the manual safe for future reference.

4.1 General things to observe

Follow current safety regulations from the Work operating instructions. The person operating the
Environment authorities in your country. machine must have full ability in arms and hands
and satisfactory vision. The person must also be
Minors are not allowed to operate the machine rested, healthy and in good shape.
– excepting­those who are 16 years of age and
over and have been trained under supervision. Never operate the machine after the intake of
alcohol, drugs or medications that impair the ability
Keep children, animals and onlookers away. to react.

The machine is intended for use in a specified work The machine may only be handed over or lent
area by a person with knowledge and experience of to people who know it and how to use it. Always
using this type of machine in accordance with the include the manual.

4.2 Intended use and function

The machine is intended for swaging terminals (e.g The machine must not be used for other purposes
eye-terminals, forks, threaded studs) onto full-steel than those intended as it can be a risk of accident.
wire. This is done by pressing (cold forming) the
metallic terminal around the wire. Changes or modifications to the machine are
not allowed.
There are a number of different dimensions of
wires and terminals to choose from. Choosing Wireteknik AB is not responsible for the injury of
the appropriate machine model is based on these persons or damage of equipment that occurs with
dimensions. incorrect use or lack of protective equipment.

4.3 Clothing and protective equipment

Wear appropriate, tight-fitting Use tight-fitting protective glasses
clothing that won’t obstruct the to minimize the risk of eye injuries.
work or get caught in the moving Make sure the glasses fit properly.
parts of the machine. Remove all
scarves, ties and jewellery. Put long
hair up and tuck it away safely with a hat, cap etc.

Use appropriate shoes med slip- Use sturdy work gloves made of a
free soles and steel caps. This is durable material (e.g. leather) when
especially important when installing handling wire and teminals.
and moving the machine and when
changing roller dies.

Model A270 – 5
5. General description of the machine
The machine is intended for swaging terminals A hydraulic pump and hydraulic cylinders [2] are used
(e.g eye-terminals, forks, threaded studs) onto the to achieve the mechanical power needed to perform
end of a wire by the use of hydraulics. The material­ the swaging. The hydraulic pump is con­nected to
to be worked with (wire and terminal) is placed the machine [3] to obtain hydraulic pressure (up to
manually­in the machine. The terminal that encloses 700 bar) in the cylinder. The hydraulic pump can be a
the wire is pulled through pressing tools (roller dies) hand pump, an electric pump, a pump powered by an
under pressure which presses the terminal onto the electric screwdriver or a pump powered by fossil fuel.
wire (cold formed). The roller dies [1] in the machine
are specially designed for this type of machine. For how to use different types of hydraulic pumps
please refer to the manual of your selected pump.
The machine comes with different sized roller dies to
fit several different dimensions of wires and terminals. The machine is intended to be used by a trained
Installing and adjusting the roller dies is done manually. operator only.

1. Pressing tools
(roller dies) 4. Protective shield

8. Pulling tool

6. Drawbar

7. Knob for
adjusting length

5. Synchronization
cogwheel 2. Hydraulic
cylinders
3. Connection to
hydraulic oil pump

Hydraulic pumps suitable for model A270 and available from Wireteknik AB

Hand pump Electric pump (single-phase) Electric pump (three-phase)

Existing hydraulic oil systems can also not exceed 700 bar. The flow of hydraulic oil
be used with the machine. It is very affects the speed of swaging and should conform
important that the pressure does to the specifications in the table below (section 5.1).

Model A270 – 6
5.1 Technical data

Diameter of wire to be worked Ø 2.5–12 mm (3/32”–1/2”)

Length of the machine 750 mm (29 1/2”)
Width of the machine 420 mm (16 1/2”)
Height of the machine 177 mm (7”)
Weight of the machine 51 kg (113 lbs)
Dimensions of hydraulic hoses and connections 1/4”, 3/8” and 1/2”
Hydraulic oil pressure ≤700 bar
Hydraulic oil flow 0.8 –2.5 litres/minute
Operating temperature 0–30°C

5.2 Installing the machine in the work area

Remove the machine from the packaging and place Remember to wear appropriate shoes
it where it will be operated. For ergonomic and with anti-slip soles and steel caps when
safety reasons the machine should be placed on a lifting the machine.
sturdy bench or table at a comfortable height. It is
important to have a stable surface and ample free
space (over 2 metres) around the machine.

5.3 Connecting a hydraulic pump

Connect the hydraulic pump to the coupling on the Check the hydraulic system to make
machine and place the pump where it is not in the sure that they are intact and undamaged
way of the work or risk falling over in the case of and that there is no leakage around the
electric and motor driven pumps. Use the foot pedal connectors. If there is a damage or leakage,
to start and stop the pump. the hydraulic hoses, connections, cylinders
must be replaced before use. Pressure in the
If a hand pump is used, it is important that it is hydraulic pump unit, hoses and cylinders can be
placed on a stable surface at a suitable height. up to 700 bar.

Check that external hydraulic units or other pres-

surized hydraulic systems are connected corrrectly.
If that is not the case, they must be adjusted
or replaced before use.

5.4 Connecting electric power

If using an electric hydraulic pump, make sure that Position the power cord in such a way as
it is connected to the same voltage as stated on the to avoid the risk of tripping over it.
pump (one-phase or three-phase).

Model A270 – 7
5.5 Work area for the operator when swaging
The operator must be within the work or incorrectly chosen terminal. Work areas are
area along the side of the machine to shown in the figure below.
avoid potential splintering from a faulty

RISK AREAS – alternative 1

Work area for the operator during swaging.

Pump

Machine

Work area where no one, including the

operator, is allowed during swaging.

RISK AREAS – alternative 2

Work area where no one, including the

operator, is allowed during swaging.

Machine

Pump

Work area for the operator during swaging.

Model A270 – 8
6. Operating instructions
6.1 Step 1 – Choosing and mounting roller dies
NB! It is important to choose the roller dies It is of utmost importance that terminals
corresponding to the dimensions of the are not made of other materials than
wire and terminal. The roller dies are marked intended. Otherwise they may crack and/
with the wire dimensions they are to be used for. or not comply with the standard, and will not have
sufficient performance.
Use protective gloves to avoid cutting and
crushing injuries.

1. Pressing tools
(roller dies) 4. Protective shield

8. Pulling tool

6. Drawbar

7. Knob for
adjusting length

5. Synchronization
cogwheel 2. Hydraulic
cylinders
3. Connection to
hydraulic oil pump

1. Choose the roller dies [1] that correspond to 4. Place the chosen roller dies onto the cogwheel
the diameter of your wire. synchronizing pins [5].

2. Move the protective shield [4] aside. 5. The arrows on the roller dies should always point
in the swaging direction.
3. If roller dies that do not correspond to the
diameter of your wire are already mounted on
the machine, remove them.

Model A270 – 9
6.2 Step 2 – Choosing and mounting pulling tools
1. Use the guide below to choose a pulling tool to NB! In some cases the terminal is attached directly
mount on the drawbar [6]. to the pulling tool mounted on the drawbar. [6]

2. Choose the corresponding pulling tool to be

attached to the terminal.

Guide to choosing pulling tools

Terminal Pulling tool to be mounted Pulling tool to be mounted

on the drawbar [6]* on the terminal*

T-terminal

Art. No: F2, F3 or F35 Art. No: CHL-6 or CHL-10

Fork

Art. No: F3 or F4 Art. No: PP6.2 or PP10 or PP20

Eye-
terminal
Mount the terminal directly
on Art. No. F2 or F3 or F4

Art. No: F2 or F3 or F4

Ball

Mount the terminal directly

on Art. No: BP4-8 or BP10-12

Art. No: BP4-8 or BP10-12

Threaded
studs

Art. No: Olives, M10-M5 / M12-M6 / M14-M8 /

M16 / 1/4”-7/16” / 3/8”-9/16” / 1/2”-5/16” / 5/8”
Art. No: BP4-8 or BP10-12 Right hand thread. Left hand thread optional

Threaded
studs

Art. No: MP-1 Art. No: 3/4” / 7/8” / 1”. Right hand thread.

* Choose tool depending on dimension of terminal

Model A270 – 10
How to mount pulling tools, depending on the terminal

Ändstycke
Drawbar
Terminal

Pulling tool B
Dragverktyg B Pulling
Dragverktyg
tool A A
Dragstång [6]

Roller dies
Formverktyg
(vals) [1]

Ändstycke
Drawbar
Terminal Ändstycke

Dragverktyg B Pulling
Dragverktyg
tool A A
DragstångA[6]
Dragverktyg
Dragstång [6]
Roller dies
Formverktyg
(vals) [1]

6.3 Step 3 – Preparing wire and terminal

Ändstycke

NB! It is of utmost importance that the 3. Apply just enough hydraulic pressure (from the
terminal is made of the right kind of pump) to make the roller dies hold the terminal
material. Dragverktyg A firmly in place. NB! Watch your fingers. Risk of
crushing injuries.
Dragstång [6]
1. Choose a terminal and attach it to the pulling tool
on the drawbar [6]. 4. Insert the wire to the bottom of the terminal throat
and put a mark on the wire at the opening of the
2. Adjust the length so that the roller dies meet the terminal. After swaging the mark will tell if the
terminal shank at desired position. wire is still inserted to the bottom of the shank.

Model A270 – 11
6.4 Step 4 – Swaging
It is important to use safety NB! If there is a power cut an electric
glasses as splintering may occur hydraulic pump will stop and so will the
if the terminal is faulty or made roller dies. Remove your foot from the
of the wrong material. foot pedal or manually turn off the switch to stop
the machine from starting up automatically when
It is important to make sure that there is power is restored. When power is restored, start
no leakage around the connections in the the machine in the usual, controlled way.
hydraulic oil system (hoses, connectors etc).

When swaging the operator must stand

in the work area shown in section 5.5.

1. Move the protective shield [4] to safety position. NB! The machine is designed to reduce the terminal
NB! Remove fingers from the roller dies [1]. shank to the required diameter in one step (one
passage through the machine). However, dimensional
2. Close the hydraulic valve in the hydraulic oil variations in terminals and wires or material hard-
system. ness might make it necessary to pass the terminal
through twice in the same tracks. If this too fails to
3. Apply hydraulic pressure (from the pump) until reach the correct dimension, discard the swaged
the whole terminal has been pulled through the material.
roller dies [1]. When the roller dies rotate the
terminal shank is pressed onto the wire. If the marking is not at the opening of the terminal
or partly/totally covered by the terminal elongation,
4. Move the protective shield [4] to the side. discard the swaged terminal.

5. Lift out the wire with the swaged terminal. When swaging solid rods a special swaging com-
ponent must be used. After swaging, wipe off the
6. Check that the wire is inserted to the bottom roller dies and the machine and apply a corrosion
of the terminal by looking at the mark made on preventative.
the wire before swaging. It should still be at the
opening of the terminal or partly/totally covered NB! The machine is designed to swage complete
by the terminal elongation. wire ropes and solid rods. For swaging solid rods,
silicon carbide grit size 80-120 must be used.
7. Measure the diameter of the terminal and
compare it to the dimensions listed in the table
of swage dimensions (section 6.5). If the correct
dimension has not been obtained see further
below.

8. Repeat Step 3 (1–4) and Step 4 (3–7) until all

terminals of the same type and dimension have
been swaged.

Model A270 – 12
6.5 Swage dimensions

Diameter Diameter of Diameter of Diameter of Diameter of Diameter of

of wire terminal before terminal after wire (inch) terminal before terminal after
(mm) swaging (mm) swaging (mm) swaging (inch) swaging (inch)
1.6 4.06/3.94 3.50/3.40 1/16 .160/.155 .138/.133
2.5 5.53/5.41 4.82/4.70 3/32 .218/.213 .190/.185
3 6.35/6.22 5.56/5.44 1/8 .250/.245 .219/.214
4 7.54/7.42 6.35/6.23 5/32 .297/.292 .250/.245
5 9.12/9.00 7.95/7.83 3/16 .359/.354 .313/.308
5.5 10.84/10.72 9.50/9.35 7/32 .427/.422 .375/.368
6 12.54/12.42 11.12/10.95 1/4 .494/.489 .438/.431
7 14.30/14.18 12.70/12.50 9/32 .563/.558 .500/.492
8 16.13/16.01 14.30/14.07 5/16 .635/.630 .563/.554
9–10 17.85/17.73 15.90/15.70 3/8 .703/.698 .625/.618
11 19.83/19.63 17.47/17.27 7/16 .781/.773 .688/.680
12 21.44/21.32 19.05/18.82 1/2 .844/.839 .750/.741
12E 20.08/20.00 17.80/17.60 9/16 .984/.979 .875/.866
14 25.00/24.88 22.23/22.00 5/8 1.109/1.104 1.000/.990
16 28.17/28.05 25.40/25.15 3/4 1.359/1.354 1.250/1.238
19 34.52/34.40 31.75/31.44 7/8 1.593/1.583 1.437/1.425
22 40.46/40.21 36.50/36.20 1 1.812/1.802 1.625/1.613
25 46.02/45.77 41.28/40.97 1 1/8 1.968 1.732/1.751
28 50.0 44/44.5 1 1/4 2.284 2.007/2.028
32 58 51.0/51.5 1 3/8 2.559 2.244/2.275
36 65.0 57.0/57.8 1 1/2 2.835 2.488/2.519
38 ~ 40 72 63.2/64.0 1 3/4 2.952 2.598/2.640

Model A270 – 13
7. General description of swaging
The basic principles of swaging a terminal on a wire. NB! Follow the detailed instructions in section 6.

1. Choose the roller dies that correspond to the 2. Mount the pulling tool on the drawbar and attach
wire diameter, and slip them onto the cogwheel the terminal to it. Adjust the length so the roller dies
synchronizing pins. meet the terminal shank at desired postion.

3. Apply hydraulic power to fasten the terminal 4. Move the transparent protective shield into
between the roller dies. Insert the wire to the bottom position. Apply hydraulic pressure to pull the
of the terminal throat and mark the wire. terminal through the roller dies.

5. When the roller dies rotate, they will press the 6. Measure the diameter of the terminal after
terminal shank onto the wire. swaging and compare it to the swage dimensions
table (section 6.5).

Model A270 – 14
8. Service and maintenance
Changes or modifications to the machine are Use only original replacement parts from the
not allowed. manufacturer.

8.1 Planned service intervals

Work cycles Service

<2 000 cycles/year Machine service interval 5 years
2 000–35 000 cycles/year Machine service interval 1 year

The hydraulic hoses must be replaced every five

years or less depending on local regulations.

9. Storing the machine

Store the machine in a cool, dry space without corrosion preventative oil to both machine and tools.
direct sunlight. When transporting the machine place it securely to
prevent it from receiving knocks and blows. Remove
When the machine is not in use remove the roller the roller dies and pulling tools from the machine
dies and pulling tools and apply a suitable light and place them next to it.

Model A270 – 15
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