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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.

Date of revision: 2022-10-05
Version:

1.0

© Copyright by UNIFLEX-Hydraulik GmbH

Technical modifications reserved.

The reproduction, distribution and utilization of this document as well
as the communication of its contents to others without explicit authori-
zation are prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, util-
ity model or design.

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Содержание ET4200

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Страница 2: ...erman Date of revision 2022 10 05 Version 1 0 Copyright by UNIFLEX Hydraulik GmbH Technical modifications reserved The reproduction distribution and utilization of this document as well as the communi...

Страница 3: ......

Страница 4: ...h Strasse 50 52 D 61184 Karben The following standards codes and specifications have been applied EC Directive 2006 42 EC EMC Directive 2014 30 EC EN ISO 12100 2010 EN 60204 1 2018 UK Supply of Machin...

Страница 5: ...nt 13 2 3 4 Risks imposed by noise 14 2 3 5 Risks imposed by substances 14 2 3 6 Risk by hot surfaces 14 2 3 7 Risks in case of fire 14 2 4 Safety 15 2 4 1 Working area 15 2 4 2 Emergency Stop 16 2 4...

Страница 6: ...orming dimension 41 5 6 Forming travel limitation 41 5 7 Stop 42 5 8 Emergency stop 43 5 9 Cleaning 43 6 Maintenance 45 6 1 What you have to observe 45 6 2 Maintenance schedule 45 6 3 Hydraulic oil ch...

Страница 7: ...s kit 64 9 5 Service tool 64 9 6 Retaining bolt for standard crimping dies depending on crimping die 65 9 7 Hydraulic diagram 67 9 8 Electric diagram 68 9 9 Maintenance log 72 9 10 Declaration of qual...

Страница 8: ...ss of risks and haz ards in compliance with all notes included in this Operation Manual The machine unit may only be operated by staff who has read the Operation Manual has understood it has been inst...

Страница 9: ...m and fighting means Free access to this equipment must be ensured personal protection equipment is worn safety footwear protec tion gloves and safety glasses Machine unit fitters Machine unit fitters...

Страница 10: ...ate is fixed near the power cable 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 Monit...

Страница 11: ...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...

Страница 12: ...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...

Страница 13: ...is a risk of electrocution near the live parts Work on electric systems may only be performed by qualified electricians or instructed and trained persons under the supervi sion of a qualified electri...

Страница 14: ...e machine unit owner must pro vide for appropriate protection e g instruct staff to wear ear protection provide information instructions on risks identify hazardous areas provide health monitoring 2 3...

Страница 15: ...safety data sheet of the hydraulic oil supplier 2 4 Safety 2 4 1 Working area The working area is defined as the area 1 metre all around the ma chine shaded Keep the working area free from trip hazard...

Страница 16: ...omer 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 T...

Страница 17: ...efore commissioning of the ma chine UNIFLEX will provide you with customized solutions for protection equipment upon request Please do not hesitate to address your per sonal contact for consultation M...

Страница 18: ...Oiling greasing prohibited on the die system Illegible or missing warning signs must immediately be replaced by the operator...

Страница 19: ...gency stop button 4 Control panel 5 Micrometer 6 Crimping tool The crimping tool 6 is closed hydraulically whereby the work piece is formed The pressure needed for this purpose is generated in the cyl...

Страница 20: ...es are to be formed on a large machine After the forming process the base dies are pressed apart by the pressure springs 3 when the tool opens The bearing segments 1 on the front guide the base dies a...

Страница 21: ...es may by overstressed by the forming process so that this may result in a sudden failure Chips or seriously accelerated workpiece parts impose a high risk po tential for operators individuals and obj...

Страница 22: ...3 4 Operation and display elements 1 Close tool button 2 Main switch emergency stop button 3 Open tool button 3 5 Depth stop accessory 1 Connection cable with plunger switch...

Страница 23: ...2 Clamp lever 3 Compression spring 4 Compression spring 5 Stop cone 6 Clamp 7 Bushing 8 Plunger sleeve...

Страница 24: ...level 70 dB A Protection class IP 40 Function Forming force 1200 kN 120 t Max forming range crimping dies 12 mm max outside diameter of the fittings before the forming process Maximum crimping dies 6...

Страница 25: ...ll load current of circuit 13 7 A Full load current of control circuit primary 0 48 A Hydraulic system Oil volume approx 35 l Oil type HM 46 or HLP 46 ISO 11158 ISO 6743 4 10 filtered The oil type can...

Страница 26: ...tions 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 chine Work pie...

Страница 27: ...aws 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 liftin...

Страница 28: ...that it supports with its full width 4 Use the crane to lift the machine with the lifting gear and trans port it to the installation site 4 2 Intermediate storage of machine unit If the machine unit c...

Страница 29: ...taff Section 9 WARNING Risk of injuries Machine components might loosen during transport Such com ponents might be flung out during to the forming process There is a risk of being injured Open and clo...

Страница 30: ...e supplier s protection and safety instructions see data sheet Wear personal protection equipment Do not eat drink or smoke in the working area and when handling consumables Ensure good ventilation Av...

Страница 31: ...power cable of the machine connected to the local mains by a electrically qualified person according to the regu lations of the Electricity Board Do not operate the machine without a sufficiently rate...

Страница 32: ...y the hyd raulic pump Make sure that the amount of hydraulic oil in the machine is sufficient before starting the machine 4 3 3 Bleeding the hydraulic system 1 Switch on the machine 2 Operate the mach...

Страница 33: ...operation Observe the safety instructions on the machine unit Make sure that no other persons stay in the working area Use appropriate aids to handle heavy workpiece Each movement of the hand must be...

Страница 34: ...ectly mounted in the tool The forming dimension is set correctly please also refer to Set ting the forming dimension Section 5 Preferably form the workpiece in the centre of the crimping die length Ec...

Страница 35: ...ing pro cess starts and ends when the pre set diameter pressure is reached 4 Press the button upon completion of the forming process to open the tool 5 Remove the workpiece from the tool 6 Check the f...

Страница 36: ...es of the crimping dies 2 4 Rotate anti clockwise and remove the crimping dies 2 from the deposit 5 Check the retaining bolts 3 of the crimping dies for damage 6 Hold the quick die change system with...

Страница 37: ...mediate dies and the spring mounted pressure pieces must engage into the retaining bolts 8 Remove the quick die change system 1 and check that the crimping dies fit tightly 9 Proceed in reverse order...

Страница 38: ...ce the crimping die 2 in the intermediate die 3 so that it does not protrude In the figure the crimping die 1 is placed correctly 5 4 Adjusting the depth stop The depth stop must be adjusted specifica...

Страница 39: ...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 t...

Страница 40: ...4 5 Push the sleeve 2 towards the fitting 6 Tighten the clamping lever 4 securely 7 Switch on the machine 8 Activate the illuminated foot pedal The machine is closed automatically when the workpiece i...

Страница 41: ...g dimension less crimping die di ameter 5 Form the workpiece 6 Check the workpiece 7 If the dimension is reached manufacture other identical workpie ces 8 If the dimension is not reached Adjust differ...

Страница 42: ...ain switch 1 4 Check the machine for contamination leaks and external da mage 5 Check the crimping tool and retaining bolts for contamination damage and secure fitting 6 Check the oil level 7 Remove c...

Страница 43: ...hazardous situation A restart of the machine may cause injuries if the hazardous situation has not yet been remedied Remedy the hazardous situation before a restart 1 Remedy the cause of the emergency...

Страница 44: ...1 Vacuum the machine from metal abrasion crimping scale in the opened crimping tool or use a soft cloth to clean it For this pur pose remove the crimping dies and the intermediate dies...

Страница 45: ...n in Section 5 Use the lock to prevent the main switch from being switched on and also attach a sign Example text Machine unit out of service for maintenance work Do not switch on Welding flame cuttin...

Страница 46: ...Crimping tool Crimping tool Check for damage and wear X Retaining bolt Check for damage X Slide bearing plates Check for wear see Checking and replacing slide bearing plates in Sec tion 6 X Pressure...

Страница 47: ...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...

Страница 48: ...ion cap 1 7 Do not operate the machine for a minimum of four hours so that the dirt particles in the system can settle 8 Switch on the machine 9 Operate the machine in the idle mode for two minutes 10...

Страница 49: ...lates 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 machin...

Страница 50: ...ring 2 4 Remove clamping ring 2 5 Pull out old slide bearing plate 3 6 Insert the new slide bearing plate 3 Replace all eight slide bearing plates in this manner 7 Mount clamping ring 2 8 Tighten the...

Страница 51: ...the micrometer must be readjusted 1 Release the screws on the cover 2 Remove the cover see Annex in Section 9 3 Loosen the counter nut 1 of the contact screw 2 4 Adjust the contact screw 2 2 5 revolut...

Страница 52: ...achine forms unevenly coni cally Bearing plates 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...

Страница 53: ...in eyes respiratory and intestinal tracts Hy draulic liquid spills impose danger of slipping and falling Observe supplier s protection and safety instructions see data sheet Wear personal protection e...

Страница 54: ...e the machine unit before dismantling it deactivate the hydraulic pump and secure it against restart operate valve manually if any open bolted hydraulic connections slowly and carefully Check the mach...

Страница 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...

Страница 56: ...9 Annex Individual machine unit components may deviate in their features Please indicate the serial number of the machine for spare part or ders...

Страница 57: ...9 1 Machine overview...

Страница 58: ...9 C QDS 239 R TU QDS crimping die deposit system TU QDS F Basic TU QDS F Shelf TU QDS F 239 l End stop TA S3 1 4 1 Mirror SHS S3 1 Camera set OCS 10 3 retro Lamp with magnetic base LUS Die wrench 239...

Страница 59: ...64 191 0 Pressure plate back 2 1 264 171 0 Pressure plate front 3 4 263 390 3 Hydraulic cylinder 4 1 264 2 Base dies set 5 4 264 194 3 Ball nut 6 4 264 186 4 Sleeve 7 2 264 185 3 Bearing segment 8 8 2...

Страница 60: ...ocket ISO 4762 M5x35 galvanised 504 4 798 210035 Washer DIN EN ISO 7089 36 galvanised 505 8 798 110127 Cylinder screw with hexagon socket ISO 4762 M8x80 galvanised 506 8 798 750004 Spring washer DIN12...

Страница 61: ...side 6 1 777 943 Designation sign 7 1 219 400 3 Crimping micrometer 8 1 211 502 3 Round closing blank Uniflex 9 1 578 4 Oil prohibition sign 10 1 715 4 Squeezing risk warning sign 11 1 716 4 Hand inj...

Страница 62: ...ydraulic block complete 6 1 235 326 Hydraulic block pressure limitation valve 7 2 239 516 Suction filter 8 1 227 001 NG 6 directional valve 24 V DC 9 1 264 321 3 Air ventilation cap with oil dipstick...

Страница 63: ...mer 2 2 2 8 06 077 8 06 078 Pushbutton frame Contact block 1 make 1 break with retainer 3 1 800 053 Main switch 4 1 8 06 001 8 06 002 8 06 145 8 06 147 Motor protection switch 6 3 10 A Motor protectio...

Страница 64: ...ts set S3 1 4 1 front bearing segments 8 per set 239 041 4 sw Retaining bolt plastic profile 239 239L 8 per set 239 041 4 Retaining bolt steel profile 239 239L 8 per set 239 151 Pressure piece 1 263 1...

Страница 65: ...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...

Страница 66: ...Retaining bolt Crimping die profile 262 263 239 266 232 237 554 245 246 247 245 114 4 x x x...

Страница 67: ...9 7 Hydraulic diagram...

Страница 68: ...9 8 Electric diagram...

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Страница 72: ...9 9 Maintenance log Hydraulic oil Hose assembly Retaining bolt Slide bearing plate Pressure springs Guiding plate Relay Remark Date Signature...

Страница 73: ...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 Signature City Date...

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