Uniflex UA 4 Operation Manual

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OPERATION MANUAL

- UA 4

Subject to changes without prior notice

The reproduction, distribution and utilization of this document as well as the communication of its contents to others

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Summary of Contents for Uniflex UA 4

Page 1 OPERATION MANUAL - UA 4 Subject to changes without prior notice The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved...
Page 2 EC Machinery Directive 2006/42/EEC. The following machine has been developed, designed and manufactured in accordance with EC Directive 2006/42/EEC under the sole responsibility of Company name UNIFLEX - Hydraulik GmbH Robert-Bosch-Straße 50 - 52 D - 61184 Karben Documentation officer Carsten Baumgartner The following standards, directives and specifications have been applied: •...
Page 3 Imprint Original Operation Manual - English Vertical hose crimper UA 4 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 Item no.:...
Page 4: Table Of Contents
5.1 First commissioning Initial startup ..................30 5.2 Starting the device ......................31 5.3 Stoping the device ......................31 5.4 Re-starting the device ....................... 32 5.5 Operation mode ......................... 32 5.6 Emergency stop ........................ 33 4 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 5 Ersatzteileliste / Spare Parts List ..................40 7.2 Ersatzteilset / Spare Part Set .................... 46 8 Pläne ..........................48 8.1 Hydraullikplan UA 4 ......................48 8.2 Elektropläne UA 4 ......................49 8.2.1 Elektroplan 230V 50/60 Hz ....................49 8.2.2 Elektroplan 115V 50/60 Hz ....................50 ...
Page 6: Introduction, Use In Compliance With Intended Purpose
Introduction, use in compliance with intended purpose Introduction, use in compliance with intended purpose Basic Principles In this Operation Manual, the "Vertical hose crimper UA 4" is referred to as 'device'. This Operation Manual contains important about how to operate your device ...
Page 7: Target Audience
The maximum crimping area is 65 mm (57 mm + 8 mm crimping distance).  Only Uniflex die sets with 2 x 4 dies may be used.  Matching hydraulic hoses, fittings and die sets must be used to meet the specifications provided by the hose and/or fitting manu- facturer.
Page 8 National regulations shall be applicable without limitation. The owner must ensure that the Operation Manual has been under- stood. Please always keep a copy of the Operation Manual at a desig- nated place near the device. 8 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 9: Safe Operation, Protection Of The Environment
Gaps required for inserting the workpiece should always be minimized by limiting the opening distance. Due to the variety of customer-specific workpieces, UNIFLEX- Hydraulik GmbH is not capable of supplying additional standard protection equipment together with the device to prevent any po- tential residual risks imposed by the device.
Page 10: Definition Of Terms
Although the device has been developed, designed and constructed in compliance with the latest technology and generally recognized safety regulations, residual risks cannot be fully excluded – not even if the de- vice is used as intended. 10 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 11 The situations in which personal protection equipment is required are defined in the applicable accident prevention regulations for the relevant activity and/or workplace. 11 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 12: Operational Safety Instructions
 Keep the access to the hydraulic connection clear. The device has a working station with a working area as shown below: Back Device Operator Front Figure 2 - 1 Working area Manual operation workplace 12 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 13: Noise Emission
MAX Leq Value = 70.6; MIN SEL Value = 53.6 Freq Weighting = A Time Weighting=Fast 58.4, 11:41:05, 61.6, 11:41:00, 56.3, 11:41:01, 62.0, 11:41:06, 59.6, 11:41:02, 60.1, 11:41:07, 58.3, 11:41:03, 67.1, 11:41:08, 55.0, 11:41:04, 59.7, 11:41:09, 13 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 14: What To Observe
 Observe the safety instructions for the device.  Crimpers can cause serious bodily injury, including amputation, when not use carefully.  Always keep hands a minimum safe distance of 120 mm from the crimper. 14 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 15 Do not eat, drink or smoke while operating the device.. After completing the work  Stop the device by turning the main switch to OFF.  Clean your hands thoroughly when finished using the device. 15 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 16: For Maintenance And Repair
The device is fitted with a hydraulic power unit including a pump and motor. Maintenance and repair work on the hydraulic system may only be performed by UNIFLEX-HYDRAULIK GmbH specialist staff! Welding, flame-cutting and grinding work  Welding work  Flame-cutting work and ...
Page 17: Emergency Measures
The hydraulic oil is hazardous waste – return it to the supplier. 17 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 18: Design And Function
Unit (electric motor with hydraulic pump and oil tank) Crimping die set with 2 x 4 dies Main switch with emergency stop function Control panel 'Close tool' pushbutton Pressure plate Bearing plates Push ram Eyelet 18 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 19: Technical Data Ua4
380 x 390 x 500 Weight approx. 90 kg * depending on fitting ** without flange *** max. outside diameter of fitting prior to crimping **** Only for special applications upon approval by Uniflex PB = crimping dies 19 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 20: Function
– only then you are able to control your hand movements. Always keep hands a minimum safe distance of 120 mm to the crimper. Figure 3-2 Minimum safe distance of 120 mm 20 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 21 3 mm, otherwise there may be increased crimping conicity. Die sets may be ordered from UNIFLEX-Hydraulik.  Mount the appropriate die set.  Push the compression die backward to the stop – this Figure 3-3 Hit push ram to the back provides a large clearing in the device.
Page 22  Check the correct positioning of the fitting and the crimp- ing diameter. Figure 3-6 Operating panel 'Close tool' pushbutton You can use any Uniflex die set to crimp 0.4 to 0.6 mm smaller than the nominal diameter. Use the micrometer to set the crimping diameter. ...
Page 23: Crimping Dimension Setting / Crimping Die Table Pb 280
< XX.XX mm 17.00 mm XX.XX mm Only for special ap- 17.40 mm plications upon ap- CHANGE proval by Uniflex XX.XX mm - Ø mm = ZZ.ZZ mm 17.40 mm - 17.00 mm = 0.40 mm 23 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 24: Transport, Assembly, Intermediate Storage
Figure 4-2 Transport lugs ciently wide.  Mark parking spaces and transport routes.  Avoid unnecessary risks by pre-arranging the method of transport and transport routes. Dimensions Length (mm) Width (mm) Height (mm) Table 4-1 Device dimensions 24 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 25: Assembly
 115 x 140 mm. The machine screws M 10 are not included with the device. Figure 4-3 Device installation Select screws that match the base ma- terial. Adjust the working height to the operators' body heights. 25 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 26: Required Utilities
(220V – 240V) 230V 60Hz 11,2 12,0 Type UA4_08_11 115V 50Hz 15,5 20,8 15,5 (220V – 240V) 115V 60Hz 10,7 24,3 16,0 Capacity 1 kW Back-up fuse 1 x 16 A Table 4-2 Electric power supply 26 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 27: Ambient Conditions
The maximum permissible relative humidity is 80% (non- condensing).  Never clean the device or device components by steam blasting or spraying water. Contamination and water may ingress in the device and cause serious damage. 27 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 28: Installation
 Fill the oil tank with 5 litres of 10 filtered hy- draulic oil HLP 46 DIN 51524.  Mount a plug connector on the power line. The installation is completed. Figure 4-6 Filtered hydraulic oil 28 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 29: Operation
Operation Operation First commissioning Initial startup  Check the oil level on the sight gage.  Connect the plug to an appropriate electrical outlet. Figure 5-1 Site gage for checking the oil level 30 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 30: Starting The Device
Figure 5-2 Main switch ON Stoping the device  Fully complete the crimping process.  Place the workpiece away from the device.  Stop the device by operating the main switch. The device is deactivated. Figure 5-3 Main switch 31 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 31: Re-Starting The Device
'Close tool’ pushbutton ' (1) When the crimping dimension has been achieved or the button is release, the comprssion die will automatically return to the top (automatic return stroke). Figure 5-4 Operating panel 1 ‘Close tool’ pushbutton 32 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 32: Emergency Stop
Operation Emergency stop In an emergency, immediately stop the device by turning the main switch to OFF. Figure 5-5 Main switch, OFF position Remove the cause for the emergency stop before re-starting the device. 33 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 33: Maintenance
Figure 6-1 Main switch Main switch, OFF position If you work in 2 shifts, the check frequency should be doubled. If you work in 3 shifts, proceed as with 2-shift operation. 34 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 34: Replace Bearing Plate
Slide the bearing plates up to remove them.Insert new bearing plates.  Tighten all of the screws fixing the bearing plates finger tight.Check the zero point setting in a test crimping process. Figure 6-2 Loosen screw Figure 6-3 Remove bearing plate 35 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 35: Daily Inspection
Check the hydraulic oil level on the sight gage.  The level indicated should be MIN and MAX. Use a shop vacuum to remove oil, contamina- tion, dust and chips. Figure 6-6 Site gage for checking the oil level 36 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 36  Release the 'Close tool' button. If the push ram does not move upward automatically, the device is not working properly and must not be used. Please contact your local UNIFLEX service representative. Figure 6-9 Safety function Table 6-1 Daily inspection 37 – www.uniflex.de...
Page 37: Monthly Inspection
Check the crimping tool for integrity and wear.  Check the return stroke springs in the return stroke plate.  Check whether the 8 nuts on the drawbars are tightened to 800 Nm. Figure 6-10 Nuts on drawbars 38 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 38  Tighten the counter nut. Figure 6-11 Micrometer brass screw 1 Counter nut 2 Brass screw  Lubricate the 8 die pins in the compression rings with some graphited grease. Figure 6-12 Die pins Table 6-2 Monthly inspection 39 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 39: Anhang / Annex
Anhang / Annex Anhang / Annex Ersatzteileliste / Spare Parts List 40 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 40 Anhang / Annex Ersatzteil Set 280.5 41 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 41 Anhang / Annex 14,16,17 42 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 42 Anhang / Annex 43 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 43 Mounting housing 8.00.43 Buchseneinsatz Typ CKF 04 04, 4-polig + PE Bush insert Typ CKF 04 04, 4-polig + PE 800.043 Motorkabel für Hydraulikaggregat UA 4 mit Motor cable for Power Unit UA4 with connector Steckvorrichtung 280.021.0 Druckplatte Pressure plate 280.002.2...
Page 44 Elektroabdeckblech RAL 9007 Electric cover plate RAL 9007 SK 575.4 Uniflex Aufkleber Sticker Uniflex 42 ohne Bild 211.502.3 Verschlussronde, Uniflex Cover blank Uniflex / without picture 798.000005 Ringschraube, DIN 580-M8 Eye bolt, DIN 580-M8 798.320002 Mutter, M 24x2, DIN EN 24032 Hexagon nut, M 24x2, DIN EN 24032 798.220017...
Page 45: Ersatzteilset / Spare Part Set
Splint pin ISO 8752 – – 6x26 6x26 280.5 1 Satz / 1 Set T-Führung-Set T-Guide-kit UA4 280.118.3 Nutenstein 280.118.3 T-nut 777.108 Federndes Druck- 777.108 Pressure spring screw stück M10 798.310022 Sicherungsmutter 798.310022 Hex nut DIN 985 – M10 46 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 46 Dies wear parts-kit Verschleißteil-Set 280.125.3 Gewindestift 280.125.3 Thread pin 280.127 Druckfeder 5x18 mm 280.127 Pressure spring 5x8 mm 798.400009 Zylinderstift gehärtet 798.400009 Parallel pin hardened DIN EN ISO 8734 – DIN EN ISO 8734 – 3x24 3x24 47 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 47: Pläne
Anhang / Annex Pläne Hydraullikplan UA 4 48 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 48: Elektropläne Ua 4
Anhang / Annex Elektropläne UA 4 8.2.1 Elektroplan 230V 50/60 Hz 49 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 49: Elektroplan 115V 50/60 Hz
Anhang / Annex 8.2.2 Elektroplan 115V 50/60 Hz 50 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 50: Wartungsbuch / Maintenance Book / Carnet D'entretien / Libro De Mantenimiento / Libretto Die Manutenzione / Onderhoud Boek
Anhang / Annex Wartungsbuch / Maintenance book / Carnet d’entretien / Libro de mantenimiento / Libretto die manutenzione / Onderhoud boek 51 – www.uniflex.de UNIFLEX-Hydraulik -...
Page 51: Erklärung Des Geschulten Personals / Declaration Of Trained Personnel
Erklärung des geschulten Personals / Declaration of Trained Personnel Ich erkläre hiermit, dass ich an einer innerbetrieblichen Schulung zur Bedienung der UNIFLEX Maschine teilgenommen habe und über alle sicher- heitsrelevanten Details informiert wurde. Des Weiteren erkläre ich, dass ich diese Betriebsanleitung vollständig gelesen und verstanden habe.
Page 52 Note: 53 – www.uniflex.de UNIFLEX-Hydraulik -...