Introduction
This manual provides comprehensive instructions for the safe and effective operation, maintenance, and troubleshooting of the Mastercool 72485-PRC Universal Hydraulic Flaring Tool Set. This kit is designed for fabricating various types of flares on automotive lines, including brake, fuel, and transmission lines. Please read this manual thoroughly before using the tool set.
Safety Information
Always observe the following safety precautions to prevent injury and damage to the tool:
- Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
- Ensure the work area is clean, well-lit, and free from obstructions.
- Do not operate the tool if it is damaged or malfunctioning.
- Keep hands and fingers clear of moving parts during operation.
- Use only the specified dies and adapters for the intended flare type and tubing size.
- Do not exceed the recommended pressure or force when operating the hydraulic pump.
- Store the tool set in its case in a dry, secure location when not in use.
Proposition 65 Warning: This product may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
Components Overview
Image: The Mastercool 72485-PRC Universal Hydraulic Flaring Tool Set, neatly organized within its durable carrying case. The image displays the hydraulic flaring unit, various dies, adapters, and the included tube cutter.
- Hydraulic Flaring Tool Unit
- Die Sets for various flare types and sizes:
- Push Connect: 1/4", 5/16", 3/8"
- Double Flare: 3/16", 1/4", 5/16", 3/8", 1/2"
- Metric Bubble Flare: 4.75mm, 6mm, 8mm, 10mm
- GM Fuel Line Flares
- GM Transmission Lines (Jiffy-Tight): 3/8", 1/2"
- Tube Cutter
- Custom Molded Case
Setup and Preparation
- Inspect Components: Before each use, inspect all components for any signs of damage, wear, or missing parts. Ensure the hydraulic unit operates smoothly.
- Prepare Tubing:
- Cut the tubing to the desired length using the included tube cutter. Ensure the cut is square and clean.
- Deburr the inside and outside edges of the tubing to remove any sharp edges or burrs that could interfere with flaring or cause leaks.
- Clean the tubing thoroughly to remove any debris or contaminants.
- Select Dies and Adapters: Choose the appropriate die set and adapter for the specific flare type and tubing size you intend to create. Refer to the markings on the dies for size and type identification.
Operating Instructions
General Flaring Procedure
- Insert Tubing: Place the selected die halves into the flaring tool's clamp. Insert the prepared tubing into the die, ensuring it extends beyond the die face by the recommended amount for the specific flare type (refer to specific flare instructions below).
- Secure Tubing: Tighten the clamp securely to hold the tubing firmly in place. The tubing must not slip during the flaring process.
- Position Adapter: Place the correct adapter onto the end of the tubing. The adapter guides the flaring cone and forms the desired flare shape.
- Operate Hydraulic Pump: Engage the hydraulic pump handle. Slowly and steadily pump the handle to advance the flaring cone into the adapter and tubing. Continue pumping until the flare is fully formed. You will feel increased resistance when the flare is complete. Do not over-flare.
- Release Pressure: Open the hydraulic release valve to retract the flaring cone.
- Remove Flare: Loosen the clamp and carefully remove the flared tubing. Inspect the flare for uniformity, cracks, and proper dimensions.
Specific Flare Types
The tool supports various flare types. Always ensure the correct dies and adapters are used for each application.
- Push Connect Flares (1/4", 5/16", 3/8"): Use the designated push connect dies and adapters. Ensure the tubing is inserted to the correct depth as indicated by the adapter.
- Double Flares (3/16", 1/4", 5/16", 3/8", 1/2"): This process typically involves two stages. First, a preliminary flare is created, then it is folded back to form the double flare. Follow the specific instructions for double flare adapters, which usually have a two-step design.
- Metric Bubble Flares (4.75mm, 6mm, 8mm, 10mm): Use the specific bubble flare dies and adapters. These flares are common in European vehicles.
- GM Fuel Line Flares & Transmission Lines (3/8", 1/2"): Utilize the specialized dies and adapters provided for GM applications. These are designed to meet specific OEM requirements.
Using the Tube Cutter
- Open the tube cutter and place the tubing between the cutting wheel and the rollers.
- Tighten the knob until the cutting wheel makes light contact with the tubing.
- Rotate the cutter around the tubing, applying slight pressure with each rotation by tightening the knob.
- Continue rotating and tightening until the tubing is cleanly cut.
Maintenance
- Cleaning: After each use, clean all dies, adapters, and the hydraulic unit with a clean cloth to remove any metal shavings or debris.
- Lubrication: Periodically apply a light coat of machine oil to the moving parts of the hydraulic unit and the threads of the clamp to ensure smooth operation and prevent corrosion.
- Storage: Store the entire tool set in its original custom molded case in a dry, cool environment to protect it from dust, moisture, and physical damage.
- Inspection: Regularly inspect the hydraulic unit for any leaks or signs of wear. Check dies and adapters for damage or deformation. Replace worn or damaged components immediately.
Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Uneven or cracked flare | Tubing not deburred; incorrect tubing extension; tubing not secured; wrong die/adapter; material too hard. | Ensure tubing is deburred; verify correct tubing extension; tighten clamp securely; use correct die/adapter; note that this tool may not be suitable for very hard materials like stainless steel. |
| Tubing slips during flaring | Clamp not tight enough; oily tubing; worn dies. | Tighten clamp firmly; clean tubing to remove oil; inspect and replace worn dies. |
| Hydraulic unit not advancing or retracting | Low hydraulic fluid; air in system; release valve not closed/open. | Check fluid level and refill if necessary (consult manufacturer for fluid type); bleed air from system (consult manufacturer); ensure release valve is fully closed for advancing, fully open for retracting. |
| Flare too large or too small | Incorrect adapter used; tubing extended too far/not far enough. | Verify correct adapter for desired flare type and size; adjust tubing extension according to specific flare instructions. |
Specifications
- Model: Mastercool 72485-PRC
- Flaring Capabilities:
- Push Connect: 1/4", 5/16", 3/8"
- Double Flare: 3/16", 1/4", 5/16", 3/8", 1/2"
- Metric Bubble Flare: 4.75mm, 6mm, 8mm, 10mm
- GM Fuel Line Flares
- GM Transmission Lines (Jiffy-Tight): 3/8", 1/2"
- Tool Type: Hydraulic Flaring Tool Set
- Weight: Approximately 12 pounds (5.44 kg)
- Dimensions (Case): Approximately 14.5 x 10 x 3 inches (36.8 x 25.4 x 7.6 cm)
- Fit Type: Universal Fit (for specified tubing sizes and materials)
- UPC: 700376111187
Warranty and Support
For detailed warranty information, please refer to the official Mastercool website or contact Mastercool customer support directly. Keep your purchase receipt as proof of purchase.
For technical assistance or replacement parts, please contact Mastercool customer service. Contact information can typically be found on the manufacturer's official website or included documentation.
Manufacturer: Mastercool
