Danfoss ET4350 Operator's Manual
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Danfoss ET4350 Operator's Manual

Crimping machine
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  • Page 2 Imprint Manufacturer: UNIFLEX-Hydraulik GmbH Robert-Bosch-Strasse 50-52 D-61184 Karben Germany Phone: +49 (0) 60 39 / 91 71 - 0 Fax: +49 (0) 60 39 / 91 71 - 181 This Operating Manual of the machine is a translation; the origi- nal is in German.
  • Page 4 In accordance with EC Machinery Directive 2006/42/EC and UK-Sup- ply of Machinery (Safety) Regulations 2008. The following machine Danfoss ET4350 was developed, designed and manufactured in compliance with EC Directive 2006/42/EC and UK-Supply of Machinery (Safety) Regulations 2008, in the sole responsibility of...

  • Page 5: Table Of Contents

    Contents About this document ..................8 1.1 Target groups ....................8 1.2 Storage ....................... 10 1.3 Name plate ....................10 1.4 Abbreviations ....................10 Safety instructions .................... 11 2.1 Presentation of warnings ................11 2.2 Intended use ....................11 2.3 Product-specific risks .................. 13 2.3.1 Risks imposed by mechanical equipment ........
  • Page 6 4.3.4 Bleeding the hydraulic system ............31 Operation ......................33 5.1 What you have to observe ................33 5.2 Start ......................33 5.3 Forming the workpiece ................33 5.3.1 Prerequisites ..................33 5.3.2 Operation mode buttons control panel ..........34 5.4 Changing the crimping dies .................
  • Page 7 9.5 Retaining bolt for standard crimping dies (depending on crimping die)..63 9.6 Hydraulic diagram ..................65 9.7 Electric diagram ..................66 9.8 Maintenance log..................67 9.9 Declaration of qualified staff ................ 68...

  • Page 8: About This Document

    About this document In this Operation Manual, the “forming machine Danfoss ET4350” is consistently referred to as machine. This Operation Manual includes important notes on how you operate your machine/unit safely, properly and economically. Use not in compliance with the intended purpose may result in hazard to the operator's health and life and/or in the risk of damage to/the machine/unit.
  • Page 9 • national provisions, occupational safety regulations and applica- ble environmental protection regulations are fully complied with; • persons working on the machine/unit are adequately qualified; • persons working on the machine/unit are suitable for operating the machine/unit; • the Operation Manual has been read and understood. One hard- copy of the Operation Manual must always be kept at a desig- nated place where the machine/unit is used.

  • Page 10: Storage

    Storage The Operation Manual is part of the machine/unit and must be kept near the machine/unit at all times. Upon disposal of the machine/unit, the Operation Manual must also be handed over. Name plate The name plate is fixed near the power cable. Abbreviations Crimp Force Monitoring Manual Flow Divider...

  • Page 11: Safety Instructions

    Safety instructions Presentation of warnings Warning notes in the Operation Manual warn against risks involved with the handling of the machine/unit. Risk levels are identified as fol- lows: The signal word HAZARD identifies an imminent hazard resulting in HAZARD! serious injuries or death. This warning is supplemented by a triangu- lar hazard symbol.
  • Page 12 • use of eight identical original UNIFLEX dies with the same label or seven dies and one associated marking crimping die. • The machine must not be operated by persons not capable of operating the machine without any risk. These may include: ➢...

  • Page 13: Product-Specific Risks

    Product-specific risks The machine/unit is designed in accordance with the latest state of technology. Nevertheless, the machine/unit may impose risks: 2.3.1 Risks imposed by mechanical equipment Risk of squeezing When the die system closes, there is a risk of getting squeezed between the die and the workpiece.

  • Page 14: Risks Imposed By Noise

    • Regularly check lines and bolted connections for leaks and visi- ble damage. Immediately remedy any damage detected. Repair work on the hydraulic system of the machine/unit or on its components may only be performed by UNIFLEX specialist staff. 2.3.4 Risks imposed by noise The noise level meter acc.

  • Page 15: Risks In Case Of Fire

    2.3.7 Risks in case of fire The operating staff has to be familiar with the location as well as with operating the fire alarm and fighting means. Free access to this equipment must be ensured. Never use water to extinguish a fire. For appropriate fire extinguishing action, please read the safety data sheet of the hydraulic oil supplier.

  • Page 16: Protection Equipment

    2.4.2 Protection equipment Due to the variety of customer-specific workpieces, UNIFLEX is not capable of supplying additional standard protection equipment to- gether with the machine for the prevention of potential residual risks imposed by the machine. The necessity of additional, workpiece-specific protection equipment may for instance arise for angled workpiece geometries needing a large opening for being inserted into the forming machine.
  • Page 17 Hand injury on the die system Risk of squeezing on the die system Oiling / greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced by the operator.

  • Page 18: Machine Description

    Machine description Design and function Base machine (1) Crimping tool (2) Micrometer (3) Control console (4) Power unit (5) Manometer connection for pressure test (manometer measuring range: 0 – 400 bar) The crimping tool (1) is closed hydraulically, whereby the work piece is formed.
  • Page 19 Crimping tool The die system comprises base dies, intermediate dies (depending on the application) and crimping dies. All base dies are mounted on slide plates. The crimping dies and the intermediate dies, if present, are attached to the base dies (2). The intermediate dies are required if small work pieces are to be formed on a large machine.

  • Page 20: Operating Elements

    Operating elements (1) Close tool button (2) Open tool button Forming process There is one type of forming: • Forming to a defined diameter Forming to a defined diameter This is the standard process for forming to produce hydraulic hoses. The crimping tool closes until it reaches a pre-set diameter, regar- dless of the required forming force.

  • Page 21: Depth Stop (Accessory)

    ATTENTION! Risk of damage to machinery! The machine lifetime is reduced with a high permanent load, while wear increases disproportionately. Forming machines for servicing are not intended for permanent operation and are not suitable for series production. • Do not perform more than 200 crimping actions per day. Depth stop (accessory) (1) Connection cable with plunger switch (2) Clamp lever...

  • Page 22: Technical Data

    S 3 L Technical data Machine Dimensions of machine 509 x 430 x 485 mm L x W x H Dimensions of power unit L x W 450 x 231 x 296 mm Machine weight approx. 132 kg Power unit weight approx.
  • Page 23 Work piece capacity SAE R12 / 4SP 1-part fittings 2" depending on the fitting SAE R15 / 4SH 2-part fittings 1 1/2", depending on the fitting SAE R12 / 4SP 2-part fittings 2" depending on the fitting Industry 2" 90° bend 1 1/2", depending on the fitting Die type Electrical connection...
  • Page 24 Ambient conditions C – 35 Ambient temperature 45 % – 65 % Air humidity The * data are theoretical/computed values, or values measured on a prototype. Actual values may vary slightly, depending on the ma- chine.

  • Page 25: Transport And Commissioning

    Transport and commissioning Transport The goods should be transported in the original packaging. During transport, the goods must be secured safely within the packaging. All applicable laws and regulations relating to securing loads shall be ob- served during transport. The machine must only be unloaded and transported with a crane. Lifting gear with a sufficient length, width and lifting capacity must be used.

  • Page 26: Intermediate Storage Of Machine/Unit

    WARNING! Danger from falling loads! Risk of injury from falling loads. • Do not stand under suspended loads. WARNING! Danger from tilting machine! The machine may tilt if it is transported improperly. There is a risk of being injured. • Consider the machine's centre of gravity (1).

  • Page 27: Commissioning

    • temperature between 10°C and 35°C, • maximum air humidity 80% (non-condensating). Commissioning The machine is commissioned by the customer's fitter. Place the machine on a stable and level workbench. Bolt the machine onto the workbench. The workbench must be sufficiently solid and stable. Place the machine in a way so that it is easily accessible for main- tenance work from all sides.

  • Page 28: Connecting The Hydraulic Unit

    The rubber-metal buffers will reduce vibration. 1. Mount the rubber-metal buffers (1) on the hydraulic unit legs. 2. Place the hydraulic unit on a solid and level workbench. 3. Bolt the hydraulic unit to the workbench on the rubber-metal buf- fers.

  • Page 29: Filling Hydraulic Oil

    4.3.2 Filling hydraulic oil If the UNIFLEX forming machine was purchased without filled hydrau- lic oil, the suitable, new, clean and pre-filtered hydraulic oil has to be filled before commissioning (for oil type, please refer to "Technical data" in Section 3). CAUTION! Risk of injuries! Contact with hydraulic oil and other consumables imposes a risk...

  • Page 30: Electrical Connection

    2. Add hydraulic oil; for quantity and type, please refer to "Technical data" in Section 3. The oil level can be read on the dipstick of the air ventilation cap. The oil level should be at the centre of the mar- king.

  • Page 31: Bleeding The Hydraulic System

    Fit the supply line of the power cable with a battery disconnection switch. Connect the power cable to the + positive terminal (2) and the - negative terminal (1). Connect the plug (3) of the hydraulic unit to the socket of the machine back.
  • Page 32 Open and close the tool several times. Check oil level, add hydraulic oil if required.

  • Page 33: Operation

    Operation What you have to observe The operator has received the Operation Manual from the owner, has read and understood it and will observe it. Before starting and/or re-starting • Ensure sufficient illumination of the working area of the ma- chine/unit.

  • Page 34: Operation Mode Buttons Control Panel

    • Preferably form the workpiece in the centre of the crimping die length. Eccentric forming will result in a conical forming result and increased lopsided wear on the die system and the bearing plates. 5.3.2 Operation mode buttons control panel WARNING! Risk of squeezing! When the die system closes, there is a risk of getting squeezed...

  • Page 35: Changing The Crimping Dies

    Check the forming dimension after the first forming process. Correct the forming dimension in case of deviations between the actual dimension and the specified dimension (see "Setting the forming dimension" in Section 5). WARNING! Risk of squeezing! When the die system closes, there is a risk of getting squeezed between the die and the workpiece.
  • Page 36 WARNING! Risk of squeezing! When the die system closes, there is a risk of getting squeezed between the dies. • Only replace the crimping dies when the machine is switched off. Use the supplied die wrench (4) to push and hold the locking bolt backward in the basic die (3).

  • Page 37: Adjusting The Depth Stop

    After forming heavy fittings, the locking bolt may be slightly slug- gish. In this case, use a mallet to release the locking bolt by slightly hitting on the die wrench. Adjusting the depth stop The depth stop must be adjusted specifically for the work piece. When inserting the hose, the crimping process is triggered by contact with the stop cone.
  • Page 38 Connect the cable (3) into the socket for the depth stop. WARNING! Risk of squeezing! There is risk of getting squeezed between the depth stop and the machine chassis when positioning the depth stop. • Do not touch the stop cone. •...

  • Page 39: Changing The Crimping Dies With The Quick Die Change System (Only Profile 239)

    5.5.1 Changing the crimping dies with the quick die change system (only profile 239) Set micrometer to 0.0 mm position. Open the crimping tool fully by activating the button. Push the eight pins of the quick die change system (1) into the front holes of the crimping dies (2).
  • Page 40 ATTENTION! Risk of damage to machinery! The retaining bolts and the crimping dies will be destroyed if the retaining bolts do not fit in the mounting hole of the base dies or intermediate dies. • Pay attention to the correct position of the quick die change system with crimping dies.
  • Page 41 ATTENTION! Risk of damage to machinery! If the crimping dies protrude beyond the base and intermediate dies during forming, the crimping dies, the intermediate dies and the machine will be damaged (see (X) in the figure). In the figure, the crimping die (2) is placed incorrectly. •...

  • Page 42: Setting The Forming Dimension

    Setting the forming dimension The forming dimension (X) must be set specifically for the workpiece. Read the forming dimension in the forming dimension table of the system supplier, e.g. Ø 17.4 mm. Select crimping dies with a smaller or the same diameter, e.g. Ø...

  • Page 43: Stop

    Stop Complete the forming process. Deposit the work piece outside the machine. Disconnect the power unit from the power supply. Check the machine for contamination, leaks and external da- mage. Check the crimping tool and retaining bolts for contamination, damage and secure fitting. Check the oil level.

  • Page 44: Cleaning

    5.10 Cleaning ATTENTION! Risk of damage to machinery! If the machine is cleaned with a steam jet or compressed air, dirt and water may ingress in the machine and cause serious da- mage. • Do not use a steam jet to clean the machine. •...

  • Page 45: Maintenance

    Maintenance Regular maintenance will ensure the continuous operation reliability of the device. What you have to observe This Section describes action to be taken by you as the fitter regularly to ensure the troublefree use of the machine/unit. • Maintenance work may only be performed by qualified mainte- nance staff (machine/unit fitters).
  • Page 46 Maintenance item Hydraulic system Hydraulic energy lines – hoses: Check for porosity and leaks. Hydraulic energy lines - bolted connections of hoses and pipes: Check for leaks. Hydraulic oil: Check oil level, add oil if required (see “Replacing hydraulic oil” in Section 6). Hydraulic oil: Replace Hydraulic hoses: Have replaced (DIN 20066) no later than six years after manufacture (see label).

  • Page 47: Hydraulic Oil Change

    Hydraulic oil changes and wear part replacements must be recor- ded in the maintenance log! Hydraulic oil change CAUTION! Risk of injuries! Contact with hydraulic oil and other consumables imposes a risk of injuries for the skin, eyes, respiratory and intestinal tracts! Hyd- raulic liquid spills impose danger of slipping and falling! •...
  • Page 48 Disconnect machine from power supply and secure it against switching on unintentionally. Let the hydraulic oil cool down until the tank enclosure is warm to the touch. Open the air ventilation cap (1). Pump out hydraulic oil using an external pump. Add new hydraulic oil (see “Technical Data”...

  • Page 49: Checking And Replacing Slide Bearing Plates

    Checking and replacing slide bearing plates Checking slide bearing plates Check slide bearing plates for wear, replace defective parts. The slide bearing plate (1) is new, the slide bearing plate (2) is worn. ATTENTION! Risk of damage to machinery! Worn slide bearing plates may cause damage to the machine and lead to inaccuracies of the forming dimension.
  • Page 50 Replacing slide bearing plates Open the crimping tool fully. Deactivate the machine on the main switch and secure it against unintentional restart. Loosen the hexagon socket head screws (1) on the clamping ring (2). Remove clamping ring (2). Pull out old slide bearing plate (3). Insert the new slide bearing plate (3).

  • Page 51: Micrometer Adjustment

    Micrometer adjustment If the measured forming dimensions of the workpiece deviate from the forming dimensions of the crimping die when the micrometer is set to zero, the micrometer must be readjusted. Release the screws on the cover. Remove the cover (see “Annex” in Section 9). Loosen the counter-nut (1) of the contact screw (2).

  • Page 52: Troubleshooting

    Troubleshooting Error Cause Remedy Machine does not close/open Battery disconnection switch Actuate the battery disconnec- set to OFF tion switch Voltage incorrect Check voltage supply Insufficient amount of hydrau- Refill oil lic oil Power unit defective Check power unit Operation buttons defective Check operation buttons and replace, if required Machine forms unevenly/coni-...

  • Page 53: Decommissioning, Disposal

    Decommissioning, disposal WARNING! Risk by electrical voltage! There is a risk of electrocution near the live parts! • Shut down the machine/unit. • Disconnect the machine/unit from the power supply. CAUTION! Risk of injuries! Contact with hydraulic oil and other consumables imposes a risk of injuries for the skin, eyes, respiratory and intestinal tracts! Hy- draulic liquid spills impose danger of slipping and falling! •...

  • Page 54: Dismantling

    CAUTION! Risk of injuries! Parts of the machine/unit may be under pressure and/or tension. Loosening components may impose a risk of injuries! • De-pressurize the machine/unit before performing any work and check for potential sources of hazard. Dismantling This section describes activities to be performed by you as the opera- tor to ensure the safe dismantling of the machine/unit.
  • Page 55 Return consumables, e.g. oils, greases, test media, to supplier - they are hazardous waste. Also observe the information given on the safety data sheet.

  • Page 56: Annex

    Annex Individual machine/unit components may deviate in their features. Please indicate the serial number of the machine for spare part or- ders.

  • Page 57: Accessories (Retrofittable)

    Accessories (retrofittable) Accessories Part code Quick die change system QDC 239.5 Die deposit QDS 239 B QDS 239 C QDS 239 R TU-QDS crimping die deposit system TU-QDS F Basic TU-QDS F Shelf TU-QDS F 239 l Depth stop TA S3.1/4.1 TA S3.1/4.1 A Mirror SHS S3.1...

  • Page 58: Spare Parts List

    Spare parts list 9.2.1 Tool Item Quantity Part code Designation 264.191.0 Pressure plate, back 264.171.0 Pressure plate, front 264.390.3 Hydraulic cylinder 264.2 Set of base dies 264.184.3 Ball nut 264.186.4 Sleeve 264.185.3 Bearing segment 264.196.4 Bearing plate, rear pressure plate 798.320003 T-groove nut...

  • Page 59: Mechanical Equipment

    Item Quantity Part code Designation 798.110088 Cylinder screw with hexagon socket ISO 4762 – M4x8 - galvanised 798.120069 Cylinder screw with hexagon socket DIN 4762 – M5x10 - 12.9 798.110103 Cylinder screw with hexagon socket ISO 4762 – M5x35 - galvanised 798.210035 Washer DIN EN ISO 7089 –...

  • Page 60: Hydraulic Unit Dc

    Item Quantity Part code Designation 263.250.2 Cover 263.251.3 Protective plate, top 263.252.3 Protective plate, right side 263.253.3 Protective plate, left side 263.241.3 Switch attachment angle 263.242.3 Angle for bolted connection 219.400.3 Crimping micrometer 211.502.3 Round closing blank Uniflex 578.4 Oil prohibition sign 715.4 Squeezing risk warning sign 716.4...

  • Page 61: Spare Parts Kit

    Item Quantity Article code Designation 263.350 Hydraulic unit 12 V DC 263.354 Hydraulic unit 24 V DC 263.353 Way-valve 12 V DC 227.001 Way-valve 24 V DC DIN 125-1 - B 8.4 Washer DIN 934 - M8 Hexagon nut 300.001 Rubber buffer VKAM06S Sealing plug...

  • Page 63: Retaining Bolt For Standard Crimping Dies (Depending On Crimping Die)

    Retaining bolt for standard crimping dies (depending on crimping die) Crimping die profile Retaining bolt 262.104.4 262.129.3 239.041.4 239.041.4 (sw) 232.504.4 Ø96 / Ø103 232.505.4 220.502.4...
  • Page 64 Crimping die profile Retaining bolt 245.114.4...

  • Page 65: Hydraulic Diagram

    Hydraulic diagram...

  • Page 66: Electric Diagram

    Electric diagram...

  • Page 67: Maintenance Log

    Maintenance log Remark Date Signature                                    ...

  • Page 68: Declaration Of Qualified Staff

    Declaration of qualified staff I herewith declare that I have attended an internal training for the operation of the UNIFLEX machine and have been informed on all safety-related details. In addition I declare that I have read and under- stood this Operation Manual completely. City Date Name...

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