Danfoss ET4100 User Manual Download

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Summary of Contents for ET4100

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Page 2: ...erman Date of revision 2022 09 27 Version 1 0 Copyright by UNIFLEX Hydraulik GmbH Technical modifications reserved The reproduction distribution and utilization of this document as well as the communi...

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Page 4: ...GmbH Robert Bosch Strasse 50 52 D 61184 Karben The following standards codes and specifications have been applied EC Directive 2006 42 EC EN ISO 12100 2010 This declaration are invalid when the machin...

Page 5: ...by noise 13 2 3 5 Risks in case of fire 13 2 4 Safety 14 2 4 1 Working area 14 2 4 2 Protection equipment 14 2 4 3 Warning signs on the machine 16 3 Machine description 17 3 1 Design and function 17 3...

Page 6: ...39 6 5 Micrometer adjustment 40 6 6 Replacing the battery 41 7 Troubleshooting 42 8 Decommissioning disposal 43 8 1 Dismantling 43 8 2 Recycling 44 8 3 Consumables and waste 44 9 Annex 45 9 1 Machine...

Page 7: ...this Operation Manual The machine unit may only be operated by staff who has read the Operation Manual has understood it has been instructed in the operation of the machine unit and has signed in the...

Page 8: ...chine unit fitters Machine unit fitters must be at least 18 years old and have completed training for the task i e they must have attended a specialist voca tional training A fitter must observe the i...

Page 9: ...machine back 1 4 Abbreviations CFM Crimp Force Monitoring FD Manual Flow Divider PB Crimping dies PBK Calibration crimping dies PFC Pressure Force Control PFM Pressure Force Monitoring QDC Quick crim...

Page 10: ...lt in light injuries This warning is supplemented by a triangular hazard symbol The signal word ATTENTION identifies a potentially hazardous situa tion in which the product or property in the environm...

Page 11: ...dered as being not in compliance with the in tended purpose in particular design modification of the machine use in explosive environments forming of non metal workpieces without specific safeguards a...

Page 12: ...sport 2 3 2 Risks imposed by hydraulic equipment Risks are imposed by all hydraulic lines and connections Hydraulic systems are subject to special safety provisions Work on hydraulic equipment may onl...

Page 13: ...protection is not required Higher noise emissions may occur when other machine unitry is sim ultaneously used at the workplace The machine unit owner must pro vide for appropriate protection e g instr...

Page 14: ...es Provide good illumination 2 4 2 Protection equipment Due to the variety of customer specific workpieces no additional standard protection equipment can be supplied with the machine that can prevent...

Page 15: ...the need for adapted protection equip ment before commissioning If such need exists the relevant protec tion equipment has to be mounted before commissioning of the ma chine Customized solutions for...

Page 16: ...igns on the machine Risk of crushing on the die system Risk of shearing on the die system Oiling greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced b...

Page 17: ...he crimping tool 1 is closed hydraulically whereby the work piece is formed The pressure needed for this purpose is generated by the hydraulic hand pump 6 and transferred to the hollow piston The sig...

Page 18: ...by the pressure springs 2 when the tool opens The bearing segments on the front guide the base dies axially in the tool Accessories The machine can be fitted with accessories A list of the available a...

Page 19: ...workpiece parts impose a high risk po tential for operators individuals and objects even outside the working area Relevant workpieces should only be formed using specific safeguards ATTENTION Risk of...

Page 20: ...weight approx 30 kg Operation mode Short time duty S2 Function Forming force 900 kN 90 t Max forming range crimping dies 8 mm max outside diameter of the fittings before the forming process Maximum c...

Page 21: ...m Oil volume approx 0 65 l Oil type HLP 22 DIN 51524 10 filtered System pressure max 700 bar Workbench Stable level workbench with a carrying capacity of approx 500 kg We recommend industrial flooring...

Page 22: ...bient conditions Ambient temperature 10 o C 35 o C Air humidity 45 65 The data are theoretical computed values or values measured on a prototype Actual values may vary slightly depending on the ma chi...

Page 23: ...red safely within the packaging All applicable laws and regulations relating to securing loads shall be ob served during transport The machine can only be transported manually For machine weight pleas...

Page 24: ...st Contamination Weather influences Mechanical damage The machine unit components may only be stored in closed rooms and under the following conditions temperature between 10 C and 35 C maximum air hu...

Page 25: ...ransport Such com ponents might be flung out during to the forming process There is a risk of being injured Open and close the machine several times without any work piece Check the machine for atypic...

Page 26: ...AUTION 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 a danger of slip...

Page 27: ...dering work near the hydraulic oil filling 1 Open the oil filling screw bleed screw 1 2 Add hydraulic oil for quantity and type please refer to Technical data in Section 3 3 Close the oil filling scre...

Page 28: ...the hand must be observed Eating drinking and smoking at the workplace is prohibited Wear close fitting clothes Do not wear watches or jewellery 5 2 Forming the workpiece 5 2 1 Prerequisites Prerequis...

Page 29: ...provide for a two stage flow Without load the pump op erates in the first stage with a high flow for rapid extension As soon as there is load contact the pump automatically changes to the sec ond sta...

Page 30: ...ignal lamp lights up The crimping dimension is reached 5 Adjust pumps Keep the drainage valve hand wheel closed longer for large fittings manual holding time Holding time time interval in which the pl...

Page 31: ...ng dies Positioning the crimping dies 1 Completely open the crimping tool Slowly open the drainage valve hand wheel WARNING Risk of squeezing When the die system closes there is a risk of getting sque...

Page 32: ...ng dies when the machine is switched off 2 Manually turn the crimping die to be moved 2 by 30 This loosens the retaining bolt in the mounting hole 3 Remove the crimping die concerned A flat head screw...

Page 33: ...reached Adjust difference on control and or in the micrometer repeat the forming process and check the workpiece 5 5 Completing the forming process 1 Complete the forming process 2 Deposit the work pi...

Page 34: ...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 Do not use co...

Page 35: ...ment must be approved in advance There is a risk of fire The machine must be cleaned from dust and inflam mable substances Adequate ventilation must be ensured 6 2 Maintenance schedule If not specifie...

Page 36: ...g and replacing slide bearing plates in Section 6 Replace the slide bearing plates below the basic dies after 5 years or 100 000 crimping operations respectively at the latest Replace the slide bearin...

Page 37: ...cts Hyd raulic liquid spills impose danger of slipping and falling Observe supplier s protection and safety instructions see data sheet Wear personal protection equipment Do not eat drink or smoke in...

Page 38: ...e Technical Data in Section 3 5 Close the oil filling screw 1 6 Do not operate the machine for a minimum of four hours so that the dirt particles in the system can settle 7 Operate the machine in the...

Page 39: ...earing 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 result in forming dimension inaccuracies Rep...

Page 40: ...bearing plate replace ment and readjust the micrometre if necessary The bearing plate on the front plate can only be replaced by the UNIFLEX Service 6 5 Micrometer adjustment If the measured forming...

Page 41: ...correspond to 1 mm change in the forming dimension V 5 Remount the enclosure front panel 6 Test the crimping process and readjust if necessary 6 6 Replacing the battery 1 Loosen the two bolts on the l...

Page 42: ...tes worn Check bearing plates for wear and replace if necessary Base dies damaged Check base dies for damage and replace if necessary Crimping dies damaged Check crimping dies for da mage and replace...

Page 43: ...tion Avoid floor contamination ATTENTION Risk of fire Hydraulic liquid spray or spills impose a risk of fire Avoid ignition sources welding cutting and soldering work near the hydraulic oil filling CA...

Page 44: ...y the machine unit of all consumables see Maintenance Section 6 8 2 Recycling The machine unit contains metal hydraulic hoses electric cables and electronic components depending on the type As regards...

Page 45: ...9 Annex Individual machine unit components may deviate in their features Please indicate the serial number of the machine for spare part or ders...

Page 46: ...9 1 Machine overview...

Page 47: ...etrofittable Accessories Part code Camera set OCS 10 3 retro Lamp with magnetic base LUS Universal table TU QDS 26x B Crimping die case PB 263 Crimping dies Please contact our Sales department for ord...

Page 48: ...9 3 Spare parts list 9 3 1 Tool Item Quantity Part code Designation 1 1 262 010 1 Piston 2 1 262 212 2 Cylinder case 3 1 262 2 Gasket set S2 4 1 262 8 Base jaw set...

Page 49: ...Pressure spring screw 7 16 262 034 Pressure spring 8 1 262 015 2 Front plate 9 1 262 1015 Hollow piston tool 10 2 262 023 4 Guide pin 11 1 262 021 3 Bearing plate front plate 12 1 262 371 4 Rotation...

Page 50: ...s and Pneumatics Item Quantity Part code Designation 1 1 262 063 2 RAL 7035 Base plate 2 1 262 264 4 Mounting bracket 3 1 262 226 4 Bracket 4 1 262 232 3 RAL 7047 Protective cover 5 1 262 221 4 Limit...

Page 51: ...1 8 12 022 Battery clip 15 1 266 400 3 Crimping micrometer 16 1 211 502 3 Uniflex round closing blank 17 1 578 4 Oil prohibition sign 18 1 715 4 Squeezing risk warning sign 19 1 716 4 Warning of hand...

Page 52: ...standard crimping dies depending on crimping die Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 262 104 4 x 262 129 3 x 239 041 4 x 239 041 4 sw x 232 504 4 x x x 232 505...

Page 53: ...Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 245 114 4 x x x...

Page 54: ...9 6 Hydraulic diagram...

Page 55: ...9 7 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature...

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Page 57: ...ion of the machine and have been informed on all safety rela ted details In addition I declare that I have read and understood this Operation Manual completely City Date Name Signature City Date Name...

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