Uniflex UA 4 Operation Manual Download Page 50

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Anhang / Annex

UNIFLEX-Hydraulik -

51 – www.uniflex.de

8.3

Wartungsbuch / Maintenance book / Carnet d’entretien / Libro de mantenimiento / Libretto die manutenzione / Onderhoud boek

Summary of Contents for UA 4

Page 1: ...istribution 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 in the event of the grant of a patent utility model or design ...

Page 2: ...lowing standards directives and specifications have been applied EG Richtlinie 2006 42 EG CE Directive 2006 42 EEC EG Richtlinie 2014 35 EG CE Directive 2014 35 EEC EMV Richtlinie 2004 108 EG EMC Directive 2004 108 EEC EN ISO 12100 2010 EN 60204 2006 Any modification of the machine not agreed with us or the use of any parts other than those tested and approved will render this Declaration of Compl...

Page 3: ... 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 UA4_MVC UA4_08_11 Date of revision September 2014 Version 1 1 Revision 0 0 Copyright 2014 by Uniflex Hydraulik GmbH Subject to changes without prior notice ...

Page 4: ...starting the device make sure that 14 2 4 2 During operation 14 2 4 3 For maintenance and repair 16 2 5 Emergency measures 17 2 6 Consumables and waste 17 3 Design and function 18 3 1 Design 18 3 2 Technical data UA4 19 3 3 Function 20 3 4 Crimping dimension setting Crimping die table PB 280 23 4 Transport assembly intermediate storage 24 4 1 Transport 24 4 1 1 Weights 24 4 2 Dimensions 24 4 3 Ass...

Page 5: ...pare 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 8 3 Wartungsbuch Maintenance book Carnet d entretien Libro de mantenimiento Libretto die manutenzione Onderhoud boek 51 8 4 Erklärung des geschulten Personals Declaration of Trained Personnel 52 ...

Page 6: ...quently please only use the device in good working order and condition in compliance with its intended purpose in a safety conscious manner with awareness of risks and dan gers as well as in compliance with all instructions included in this Operation Manu al This Operation Manual contains the instructions and provisions for the intended use of your device Strictly following these instructions and ...

Page 7: ...hose and or fitting manu facturer Processing is effected by single stroke manual feed and manual removal The maximum hydraulic operating pressure is 350 bar Do not make any structural modifications to the device The operation temperature is from 10 C to 40 C The device must be operated indoor Operation in rooms with an explosion hazard is not permissible Any other use is considered as not in compl...

Page 8: ...Any person performing maintenance or other work on the device must have read and understood the relevant parts of this Operation Manual in particular Section 2 Safe operation protection of the environment Owners of the device must inform their staff of potential risks National regulations shall be applicable without limitation The owner must ensure that the Operation Manual has been under stood Pl...

Page 9: ...tional protection equipment be required these shall be mounted before commissioning in order to ensure the operator s safety at all times The device must only be used in compliance with its intended pur pose In particular non metal workpieces may by overstressed by the crimping process and may result in a sudden failure Chips or flying workpiece parts are potential hazards for operators individ ua...

Page 10: ...ions to avoid damaging or destroying the device CRUSHING RISK This symbol appears when there is a crushing risk for hands SHEARING RISK This symbol appears when there is a shearing risk for hands NOTE Note in the Operation Manual referring to the optimum use of the device Working and operating steps to be per formed in the given sequence General listing Table 3 1 Symbols and their meanings 2 2 Def...

Page 11: ...enerally recog nized engineering rules Instructed persons Instructed persons are individuals who have been instructed and if ap propriate trained in the tasks assigned to them and on potential risks re sulting from improper conduct by a qualified person and who have been informed of required protection equipment and protective measures Operator An operator is a person charged with the proper opera...

Page 12: ...tion labels on site 2 3 2 Recommendations for working area Keep the working area clear of trip hazards Route wires and cables in shafts if possible Ensure good lighting at the work station Keep the access to the hydraulic connection clear The device has a working station with a working area as shown below Figure 2 1 Working area Manual operation workplace Front Back Operator Device ...

Page 13: ...ce In such case the de vice owner must provide appropriate information and protec tion e g Instruct staff to wear hearing protectors Information instructions on risks Hazard area identification Health monitoring Date Time 03 12 14 11 41 00 Sampling Time 1 Record Num 10 Leq Value 61 8 SEL Value 66 4 MAX Leq Value 70 6 MIN SEL Value 53 6 Freq Weighting A Time Weighting Fast 61 6 11 41 00 56 3 11 41 ...

Page 14: ...ation of the fire alarm and fire extinguishers Free access to the relevant equipment must be ensured The matching die set is mounted on the device Start stop or re start the device in compliance with this Operation Manual only 2 4 2 During operation Production Observe the safety instructions for the device Crimpers can cause serious bodily injury including amputation when not use carefully Always ...

Page 15: ...ion includes visual recognition by the operator as to the location of their hands Make sure that no other individuals are present in the working area 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 ...

Page 16: ...or 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 Grinding work on and in the device and its vicinity must be approved there is a fire risk Even if such work has been permitted the device must be cleaned of dust and combustible material Adequate ventilat...

Page 17: ... waste All applicable regulations for protection of the environment and waste disposal applicable to the owner s business and the location should be followed Relevant statutory provisions and any neces sary amendments resulting from the device s function should be made available to the operating staff Information on the misuse of consumables and waste should be provided Ensure that appropri ate st...

Page 18: ...ydraulic cylinder 2 Handle for push ram 3 Micrometer 4 Oil tank 5 Unit electric motor with hydraulic pump and oil tank 6 Crimping die set with 2 x 4 dies 7 Main switch with emergency stop function 8 Control panel 9 Close tool pushbutton 10 Pressure plate 11 Bearing plates 12 Push ram 13 Eyelet 1 2 3 4 5 6 8 7 10 9 11 12 13 ...

Page 19: ...mum permissible crimping area mm ØPB 8 57 mm Maximum die Ø mm 54 Opening distance 15 mm Opening size without dies 73 mm Speed Closing Crimping Opening 3 7 mm s 1 2 mm s Die type PB 280 8 di set Noise level 62 dBA Drive power 0 75 kW Operation mode S6 70 Oil 5 Liters Oil change Annually L x W x H mm 380 x 390 x 500 Weight approx 90 kg depending on fitting without flange max outside diameter of fitt...

Page 20: ...of 120 mm Crimpers can cause serious bodily injury invluding amputation when not used carefuly Always visually check the movements of your hands when feeding and removing work piec es only then you are able to control your hand movements Always keep hands a minimum safe distance of 120 mm to the crimper ...

Page 21: ...the appropriate die set Push the compression die backward to the stop this provides a large clearing in the device Place the first die half into the 4 grooves at the back Place the second die half into the 4 grooves at the front Check whether all dies are fully inserted in the grooves Mark the fitting s plug in depth on the hose Mount the fitting on the hose in accordance with the plug in mark Man...

Page 22: ...time cannot be set Remove the workpiece from the device Minimum safe distance of 120 mm Check the correct positioning of the fitting and the crimp ing diameter You can use any Uniflex die set to crimp 0 4 to 0 6 mm smaller than the nominal diameter Figure 3 7 Micrometer Use the micrometer to set the crimping diameter The scale has a setting range of 0 6 to 8 mm Each full 360 revolution of the micr...

Page 23: ... table PB 280 XX XX mm 17 00 mm XX XX mm 17 40 mm XX XX mm Ø mm ZZ ZZ mm 17 40 mm 17 00 mm 0 40 mm Die type 280 Ø mm mm 6 8 70 9 70 12 70 14 70 17 70 19 70 20 70 22 70 24 70 25 70 28 70 32 70 36 70 38 70 40 70 44 70 47 70 50 70 54 70 57 Only for special ap plications upon ap proval by Uniflex CHANGE ...

Page 24: ...ng a forklift truck a lifting carriage or a crane Use the transport lugs if transporting by crane Please observe the device s center of mass when unloading and transporting it The area beneath the suspended load must be kept clear of persons at all times Make sure that the transport routes from the un loading place to the installation site are suffi ciently wide Mark parking spaces and transport r...

Page 25: ...3 Device installation Mount the device on a solid workbench and properly fix it using four machine screws M 10 using the hole pattern 115 x 140 mm The machine screws M 10 are not included with the device Select screws that match the base ma terial Adjust the working height to the operators body heights 115 115 140 ...

Page 26: ...140 x 140 mm The machine screws M 8 are not included with the device 4 3 1 Required utilities Make sure that the following utilities are provided upon delivery of the device Voltage Frequenz Mot Nennstrom A Volllast 350 bar Ohne Last Einstellung Type UA4_ MVC 220V 240V 230V 50Hz 7 8 9 6 3 9 10 0 230V 60Hz 5 4 11 2 3 7 12 0 Type UA4_08_11 220V 240V 115V 50Hz 15 5 20 8 7 4 15 5 115V 60Hz 10 7 24 3 7...

Page 27: ...device cannot be mounted immediately upon deliv ery protect the device against the following conditions Contamination Weather Mechanical damage Store device components indoors The temperature must be be tween 10oC and 45oC 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 ingres...

Page 28: ... expert staff Mount the device on a solid workbench Mount the power unit in the immediate vicinity of the device Connect the power unit to the device using the supplied hydraulic hose Connect the power unit to the device on the electrical sheet using the supplied 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...

Page 29: ... Hydraulik 30 www uniflex de 5 Operation 5 1 First commissioning Initial startup Figure 5 1 Site gage for checking the oil level Check the oil level on the sight gage Connect the plug to an appropriate electrical outlet ...

Page 30: ...the operator is in the working area Any emergency stop sit uations have been remedied The operator has been provided with the Operation Manual by the owner has read and understood it and will follow its instructions The operator is familiar with the relevant safety regulations Figure 5 2 Main switch ON Start the device by turning the main switch to ON The device is activated 5 3 Stoping the device...

Page 31: ...5 2 5 5 Operation mode The device has one operation mode Manual Figure 5 4 Operating panel 1 Close tool pushbutton In the manual operation mode lower the push ram by pressing the button 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 1 ...

Page 32: ...ulik 33 www uniflex de 5 6 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 ...

Page 33: ...away from the device Stop the device by operating the main switch The device is deactivated Smooth operation of the device requires regular checks of specific components This section describes activities to be performed by the operator at regular intervals to ensure smooth operation of the device If you work in 2 shifts the check frequency should be doubled If you work in 3 shifts proceed as with ...

Page 34: ...ng plate To replace the bearing plates Loosen the screws fixing the bearing plates on the compression place using a 3 mm Allen wrench 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 ...

Page 35: ... device visually for Contamination Leaks External damage Figure 6 5 Crimping tool Check the crimping tool and the dies visually for Contamination Integrity Figure 6 6 Site gage for checking the oil level 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 ...

Page 36: ...on as a large area of the bronze layer becomes visi ble Section 3 4 Figure 6 9 Safety function Check the safety function Activate and hold the Close tool button dur ing the entire procedure Turn the main switch to OFF as soon as the push ram moves downward The push ram should now move upward Release the Close tool button If the push ram does not move upward automatically the device is not working ...

Page 37: ...aulic lines Check hoses for porosity and leakage screw connections and clamps for leakage Hydraulic oil Check the hydraulic oil filling level on the level indicator see Figure 5 1 Only use clean and filtered hydraulic oil type HLP 46 DIN 51524 10 for an oil change The filling quantity is 5 litres Bleed the device after a hydraulic oil change Open and close the tools several times Crimping tool Che...

Page 38: ... it using the brass screw of the micrometer as required Loosen the counter nut Turn the brass screw counter clockwise to reduce the crimp ing diameter Turn the brass screw clockwise to increase the crimping di ameter Tighten the counter nut Figure 6 12 Die pins Lubricate the 8 die pins in the compression rings with some graphited grease Table 6 2 Monthly inspection 1 2 ...

Page 39: ...Anhang Annex UNIFLEX Hydraulik 40 www uniflex de 7 Anhang Annex 7 1 Ersatzteileliste Spare Parts List 48 21 23 24 26 27 29 30 31 32 33 40 41 43 44 45 46 47 49 ...

Page 40: ...Anhang Annex UNIFLEX Hydraulik 41 www uniflex de Ersatzteil Set 280 5 28 19 20 36 37 ...

Page 41: ...Anhang Annex UNIFLEX Hydraulik 42 www uniflex de 6 14 16 17 10 1 5 3 4 11 7 2 8 9 35 39 ...

Page 42: ...Anhang Annex UNIFLEX Hydraulik 43 www uniflex de ...

Page 43: ...15 Leuchtkontaktgeber Illuminated contactor 13 1 XA Anschlussstecker Terminal plug 14 1 8 06 027 Bezeichnungsschild Halbautomat BSOK 1138 Signboard Halbautomat BSOK 1138 15 1 8 06 030 Leuchtdioden Illuminating diode 16 1 8 06 012 Drücker 25x25 Button 25x25 17 1 8 06 021 Tasterkappe flach Push button cap low 18 1 8 12 037 Anbaugehäuse gerade Mounting housing 19 1 8 00 43 Buchseneinsatz Typ CKF 04 0...

Page 44: ...rundblech RAL 7021 Electric base plate RAL 7021 40 1 280 029 3 Elektroabdeckblech RAL 9007 Electric cover plate RAL 9007 41 1 SK 575 4 Uniflex Aufkleber Sticker Uniflex 42 ohne Bild without picture 1 211 502 3 Verschlussronde Uniflex Cover blank Uniflex 43 1 798 000005 Ringschraube DIN 580 M8 Eye bolt DIN 580 M8 44 1 798 320002 Mutter M 24x2 DIN EN 24032 Hexagon nut M 24x2 DIN EN 24032 45 1 798 22...

Page 45: ...280 125 3 Thread pin 280 127 Druckfeder 5x18 mm 280 127 Pressure spring 5x18 mm 798 400009 Zylinderstift DIN EN ISO 8734 3x24 798 400009 Parallel pin hardened DIN EN ISO 8734 3x24 280 3 1 Satz 1 Set Zylinder Dichttungsset UA4 Cylinder Sealing kit UA4 280 4 1 Satz 1 Set Rückhubplatte Set Return plate kit UA4 280 105 2 Rückhubplatte 280 105 2 Return plate 280 106 Rückhubplatte 280 106 Return spring ...

Page 46: ...1 Set Pressbacken Verschleißteil Set UA4 Dies wear parts kit UA4 280 125 3 Gewindestift 280 125 3 Thread pin 280 127 Druckfeder 5x18 mm 280 127 Pressure spring 5x8 mm 798 400009 Zylinderstift gehärtet DIN EN ISO 8734 3x24 798 400009 Parallel pin hardened DIN EN ISO 8734 3x24 ...

Page 47: ...Anhang Annex UNIFLEX Hydraulik 48 www uniflex de 8 Pläne 8 1 Hydraullikplan UA 4 ...

Page 48: ...Anhang Annex UNIFLEX Hydraulik 49 www uniflex de 8 2 Elektropläne UA 4 8 2 1 Elektroplan 230V 50 60 Hz ...

Page 49: ...Anhang Annex UNIFLEX Hydraulik 50 www uniflex de 8 2 2 Elektroplan 115V 50 60 Hz ...

Page 50: ...Anhang Annex UNIFLEX Hydraulik 51 www uniflex de 8 3 Wartungsbuch Maintenance book Carnet d entretien Libro de mantenimiento Libretto die manutenzione Onderhoud boek ...

Page 51: ...eitung vollständig gelesen und verstanden habe I herewith declare that I have attended an internal training course for the operation of this machine and have been informed about all details regard ing safety I also declare that I have read and understood this Operation Manual in full Ort Place Datum Date Name Name Unterschrift Signature Ort Place Datum Date Name Name Unterschrift Signature Ort Pla...

Page 52: ...UNIFLEX Hydraulik 53 www uniflex de Note ...

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