Danfoss ET4100 User manual

Imprint
Manufacturer:
UNIFLEX-Hydraulik GmbH
Robert-Bosch-Strasse 50-52
D-61184 Karben
Germany
Phone: [phone] / 91 71 - 0
Fax: [phone] / 91 71 - 181
This Operating Manual of the machine is a translation; the origi-
nal is in German.
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 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.

EC Declaration of Conformity
In accordance with EC Machinery Directive 2006/42/EC.
The following machine
Danfoss ET4100
was developed, designed and manufactured in compliance with EC
Directive 2006/42/EC, in the sole responsibility of
UNIFLEX-Hydraulik 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 machine is modified or if un-
authorized and unapproved third-party components are used without
our prior approval.
Entity authorised for documentation: Uniflex-Hydraulik GmbH, Tech-
nical Documentation Dept.
Karben, 02.11.2021
Managing Director Harald von Waitz

Contents
1About this document........................................................................................... 7
1.1 Target groups................................................................................................7
1.2 Storage.........................................................................................................8
1.3 Name plate ...................................................................................................9
1.4Abbreviations................................................................................................9
2Safety instructions............................................................................................ 10
2.1 Presentation of warnings ............................................................................10
2.2 Intended use...............................................................................................10
2.3 Product-specific risks..................................................................................12
2.3.1 Risks imposed by mechanical equipment........................................ 12
2.3.2 Risks imposed by hydraulic equipment............................................ 12
2.3.3 Risks imposed by substances .........................................................13
2.3.4 Risks imposed 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
3Machine description.......................................................................................... 17
3.1 Design and function.................................................................................... 17
3.2 Forming process.........................................................................................18
3.3 Technical data............................................................................................. 20
4Transport and commissioning......................................................................... 23
4.1 Transport ....................................................................................................23
4.2 Intermediate storage of machine/unit.......................................................... 24
4.3 Commissioning ...........................................................................................24
4.4 Mounting the telescopic handle ..................................................................25
4.4.1 Filling hydraulic oil ...........................................................................26
5Operation ........................................................................................................... 28
5.1 What you have to observe..........................................................................28
5.2 Forming the workpiece................................................................................28
5.2.1 Prerequisites....................................................................................28
5.2.2 Hand pump operation mode............................................................29

5.3 Changing the crimping dies.........................................................................31
5.4 Setting the forming dimension.....................................................................32
5.5 Completing the forming process..................................................................33
5.6 Emergency stop...........................................................................................34
5.7 Cleaning ......................................................................................................34
6Maintenance.......................................................................................................35
6.1 What you have to observe...........................................................................35
6.2 Maintenance schedule.................................................................................35
6.3 Hydraulic oil change....................................................................................37
6.4 Checking and replacing slide bearing plates ...............................................39
6.5 Micrometer adjustment................................................................................40
6.6 Replacing the battery...................................................................................41
7Troubleshooting.................................................................................................42
8Decommissioning, disposal..............................................................................43
8.1 Dismantling..................................................................................................43
8.2 Recycling.....................................................................................................44
8.3 Consumables and waste .............................................................................44
9Annex..................................................................................................................45
9.1 Machine overview........................................................................................46
9.2 Accessories (retrofittable)............................................................................47
9.3 Spare parts list.............................................................................................48
9.3.1 Tool..................................................................................................48
9.3.2 Mechanics and Pneumatics .............................................................50
9.4 Spare parts kit .............................................................................................51
9.5 Retaining bolt for standard crimping dies (depending on crimping die).......52
9.6 Hydraulic diagram........................................................................................54
9.7 Maintenance log..........................................................................................55
9.8 Declaration of qualified staff ........................................................................57

1 About this document
In this Operation Manual, the “forming machine Danfoss ET4100” 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. Consequently, please only use the machine/unit
•in good order and condition,
•in accordance with its intended purpose,
•in a safety-conscious manner, with awareness 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 instructed in the operation of the machine/unit, and
•has signed in the Annex.
Figures may include accessories/options. Customer-specific
equipment may vary.
The product images shown are for reference only and may differ
from the product delivered.
1.1 Target groups
The target groups of this Operation Manual are:
Owner
An owner is a natural person or entity using the device himself/her-
self/itself, or on whose behalf the device is used. An owner may ap-
point a representative to exercise the owner's rights and obligations.
The owner has to make sure that
•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.
•persons working on the machine/unit are aware of potential
risks;
•the operating staff is familiar with the location as well as with op-
erating the fire alarm 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 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 instructions in the Operation Manual;
•must inform the owner on failures and damage.
Operator
An operator is a person charged with and instructed in the proper op-
eration of the machine/unit by the owner or the otherwise contractu-
ally obliged person.
The operator
•must observe the instructions in the Operation Manual;
•must inform the owner on failures and damage.
•must not perform and maintenance or repair work on the ma-
chine/unit.
1.2 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.

1.3 Name plate
The name plate is fixed on the 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 crimping die change system
ZWB Intermediate dies

2 Safety instructions
2.1 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
serious injuries or death. This warning is supplemented by a triangu-
lar hazard symbol.
The signal word WARNING identifies a potentially hazardous situa-
tion, which might result in serious injuries or death. This warning is
supplemented by a triangular hazard symbol.
The signal word CAUTION identifies a potentially hazardous situa-
tion, which might result 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 environment may be dam-
ages. This warning is supplemented by a hazard symbol or a excla-
mation mark.
2.2 Intended use
This machine is a forming machine for industrial use, only suitable for
the manufacture of hose connections with a permissible diameter de-
pending on the fitting and the hose thickness, see “Technical Data” in
Section 3.
Intended purposes include:
•single workplace for one person only,
•single stroke with manual feed and withdrawal,
•for maximum hydraulic operating pressure, see “Technical Data”
in Section 3.
•operating temperature between 10 °C and 35 °C,
•operation in a closed room,
HAZARD!
WARNING!
CAUTION!
ATTENTION!

•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:
➢persons with physical or mental disabilities;
➢children and persons under age;
➢persons with a restricted capability for the operation of ma-
chines (e.g. under the influence of drugs, alcohol or narcot-
ics)
Use of the control in compliance with the intended purpose also inclu-
des compliance with the instructions in this Operation Manual.
Use for other than the intended purpose
Any other use is considered 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 ap-
proved by UNIFLEX;
•misuse of consumables and waste materials.
In particular non-metal workpieces may by overstressed by the for-
ming process so that this may result in a sudden failure. Chips or se-
riously accelerated workpiece parts impose a high risk potential for
operators, individuals and objects, even outside the working area.
WARNING!
Risk for life and health!
Use not in compliance with the intended purpose imposes risks
for life and health. Consequences resulting from use for other
than the intended purpose shall be under the sole responsibility
of the owner.
•Always use the machine in compliance with its intended pur-
pose.

2.3 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.
•Keep the feed opening for the workpiece as small as possible.
•Keep sufficient distance to the die system.
Tilting hazard
The risk of tilting mainly exists while the machine is being trans-
ported.
•Observe the machine's centre of gravity during transport.
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 only be performed by persons with expert knowledge
of and experience with hydraulic equipment.
•After the machine is deactivated, the given and potentially ha-
zardous residual energy has to be considered.
•Relieve the residual pressure in the system before performing
repair or maintenance work on hydraulic systems.
•Regularly check lines and bolted connections for leaks and vi-
sible damage. Immediately remedy any damage detected.
Repair work on the hydraulic system of the machine or on its compo-
nents may only be performed by the manufacturer’s specialist staff.

2.3.3 Risks imposed by substances
Oils, greases and emulsions may penetrate the skin. When handling
hazardous substances, oils and greases, the manufacturers' safety
instructions have to be observed. Apply skin protection appropriate
for the hazardous substances used.
2.3.4 Risks imposed by noise
The noise level meter acc. to IEC 804, Class 2, was calibrated before
measuring.
The operation of the machine/unit causes noise emissions of < 70
dB(A) at the workplace. Noise 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.
•instruct staff to wear ear protection,
•provide information/instructions on risks,
•identify hazardous areas,
•provide health monitoring.
2.3.5 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.

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 hazards
•Use ducts for lines and cables
•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 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. The pres-
sure joining of insulators, structural steel and steel ropes, too, may re-
quire special safeguards.
The owner has to consider 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 protection equipment can be delivered upon
request. Please do not hesitate to address your personal contact for
consultation.
Mounted safety equipment must not be removed, bypassed or
avoided.

2.4.3 Warning signs 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 by
the operator.

3 Machine description
3.1 Design and function
Base machine
(1) Crimping tool
(2) Micrometer
(3) Signal lamp
(4) Drainage valve hand wheel
(5) Oil filling and drainage screw
(6) Hydraulic hand pump
(7) Pump handle
The 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-
nal lamp (3) lights up when the crimping diameter is reached. The
crimping tool (1) is opened by slowly opening the drainage valve
hand wheel (4).
The actual forming process is controlled via the pump handle.

The micrometer (2) is used to change the final diameter of the die
system.
Crimping tool
The die system comprises base dies and crimping dies.
All base dies are mounted on sliding plates (1). The crimping dies are
plugged onto the base dies (3).
After the forming process, the base dies are pressed apart 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 ac-
cessories is included in the Annex, Section "Accessories".
3.2 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,

regardless of the required forming force. The required forming force
may be up to the machine's maximum capacity.
WARNING!
Risk of injuries!
In particular non-metal workpieces 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 objects, even outside the
working area!
•Relevant workpieces should only be formed using specific
safeguards.
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.

3.3 Technical data
Machine
Dimensions L x W x H
500 x 420 x 440 mm
Machine weight
approx. 30 kg
Operation mode
Short-time duty S2
Function
Forming force
900 kN / 90 t
Max. forming range
Ø crimping dies + 8 mm
(max. outside diameter of the fittings
before the forming process)
Maximum Ø crimping dies
47 mm
Opening size without dies
77 mm
Opening distance
+22 mm