Gomax QUADRA RXA006 User manual

AIR-HYDRAULIC
CRIMPING UNITS
RXA006 - RXA008
Instruction Sheet
Manuale Istruzioni

CONTENTS
1 STRUCTURE AND USE OF THE MANUAL 1
2 WARNING SYMBOLS 2
2.1 PICTOGRAMS 2
2.2 ADHESIVE LABELS 4
3 GENERAL NOTES 4
3.1 MANUFACTURER - DISTRIBUTOR IDENTIFICATION 4
3.2 MARKING 5
3.3 MANUFACTURER'S LABEL 5
4 SAFETY 6
4.1 DEFINITIONS 6
4.2 DUTIES OF EMPLOYERS
4.3 DUTIES OF OPERATORS
4.4 PERSONAL PROTECTIVE EQUIPMENT
4.5 WORK STATION 9
4.6 PERSONNEL QUALIFICATION 9
4. RESIDUAL RISKS 10
5 PRECAUTIONS FOR OPERATOR SAFETY 10
5.1 WARNINGS 10
5.2 SAFETY DEVICES 12
5.3 ENVISAGED USE 13
5.4 IMPROPER USE 13
6 INFORMATION ON THE TOOL 13
6.1 INTRODUCTION 13
6.2 PACKAGE 15
6.3 TECHNICAL DATA 16
6.4 MEASUREMENT CONVERSION TABLE 1
6.5 TOOL DESCRIPTION 1
7 BASIC OPERATION 20
.1 LATCH OPENING/CLOSING 20
.2 UNIT CONFIGURATIONS - OPERATION 21
.3 FITTING THE DIES 25
8 CRIMPING OPERATION 27
8.1 PRELIMINARY OPERATIONS 2
8.2 CRIMPING 2
9 MAINTENANCE 28
9.1 CLEANING 28
9.2 VISUAL INSPECTION 29
9.3 OIL CHECK AND CHANGE 29
9.4 OIL BLEEDING 29
9.5 STORAGE 30
9.6 DEMOLITION AND DISPOSAL 30
10 SPARE PARTS 31
10.1 CRIMPER 31
10.2 AIR-HYDRAULIC UNIT 32
10.3 PEDAL CONTROL KIT 32
11 TROUBLE SHOOTING GUIDE 33
12 CE DECLARATION OF CONFORMITY 35

RXA006
RXA008
1 STRUCTURE AND USE
Please read this manual carefully before putting the tool into operation In case of any doubts about
the correct interpretation of the instructions, contact our office for the necessary clarifications
The purpose of this manual is to give the user all the information on the tool necessary for using it correctly and managing it in
the most autonomous and safest way possible.
The manual includes information aimed at both employers and operators, the safety rules, technical aspects, information
regarding operation, storage, maintenance, spare parts, trouble shooting, and disposal of the tool.
Before carrying out any operation on the tool, the operators and qualified technicians must carefully read the instructions
contained in this manual.
The manual constitutes an integral part of the tool and must therefore be kept in perfect condition in
the immediate vicinity of the tool, in its original packaging and protected from liquids or any other
substances that could make it illegible
The manual must always accompany the tool in the event that it is transferred to a new user.
The contents of the manual comply with European Directive 2006/42/EC and it has been written following the guidelines of the
UNI 10893 2000 standard.
The manual is composed of 35 pages, excluding the contents page and cover.
It is strictly prohibited for anyone to divulge, copy in whole or in part, or use the manual for his own purposes
without prior written authorization from the author
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The manual is identified on this page to allow its traceability or for future reference.
Identification of the tool: RXA006 - RXA008
Crimper serial code: (810XXX) →
Pump serial code: (XXXXXX) →
File name of the manual: NMBG10
2 WARNING SYMBOLS
2 1 PICTOGRAMS
The manual contains a few evident warning pictograms for the purpose of making consultation simpler and more immediate.
The operations that represent a situation of potential danger to the operators are highlighted by this
symbol
These operations may cause serious physical dangers.
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Prohibited operations are highlighted by this symbol
These operations may compromise the result of the work, make the use of the tool unsafe, or make its traceability
difficult.
The operations that require special attention are highlighted by this symbol
These operations must be followed correctly in order not to damage objects or the surrounding environment.
The operations that require careful reading of the instructions provided in the manual are highlighted
by this symbol
The operations that require the operator to wear protective gloves are highlighted by this symbol
The operations that require the operator to wear protective goggles are highlighted by this symbol
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2 2 ADHESIVE LABELS
On one of the plastic side plates on the crimping tool you will find the following notice:
3 GENERAL NOTES
3 1 MANUFACTURER – DISTRIBUTOR IDENTIFICATION
manufacturer distributor
PUNZ TEC srl
Via Cremona 62/E
46041 Asola (MN) Italy
Tel. [phone]
Fax [phone]
[email protected]
TRANSFER OIL S p A
Via Sacca, 64
43052 Colorno (PR) – Italy
Tel. [phone]
Fax [phone]
[email protected]
www.transferoil.com
4
IT IS PROHIBITED TO ALTER
OR REMOVE THE ADHESIVE
LABEL!
IT IS MANDATORY TO
READ BEFORE USE!

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3 2 MARKING
The tool is manufactured in compliance with the European Directives pertinent and applicable at the moment of its release on
the market. As this is a machine not included in Enclosure IV of the European Directive 2006/42/EC, a special self declaration of
CE conformity is issued (see Ch 12 CE DELCARATION OF CONFORMITY). The tool is not subject to the Directive 97/23/EC
(PED).
3 3 MANUFACTURER'S LABEL
La targhetta del costruttore è stampata su di un adesivo posto su una delle piastrine laterali in plastica della pressa.
PUNZ TEC srl
Via Cremona 62/E
46041 Asola (MN) Italy
3 4 SERIAL CODES OF THE TOOL
The serial numbers on page 2 are reported directly to the base of the crimper and on the cover of the air hydraulic pump.
IT IS STRICTLY PROHIBITED FOR THE DISTRIBUTOR, THE USER, OR THE OPERATOR TO ALTER,
REMOVE, OR DAMAGE THE SERIAL CODES
5
IT IS STRICTLY PROHIBITED FOR THE
DISTRIBUTOR, THE USER, OR THE
OPERATOR TO ALTER, REMOVE, OR
DAMAGE THE MANUFACTURER'S LABEL

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4 SAFETY
4 1 DEFINITIONS
- DANGER ZONE
Any zone inside or in the vicinity of the tool in which there is a risk to the safety and health of an exposed person.
- EXPOSED PERSON
Any person who is situated entirely or partially in a danger zone.
- OPERATOR
The person or persons assigned to install, operate, adjust, service, clean, and transport the tool.
Classification of the operators
The operator can be distinguished as two main figures, which in certain cases may be identified as the same person:
A. Operator for the use of the tool, whose job is to:
•activate and control the operation of the tool;
•perform simple adjustment operations;
•eliminate causes of tool stoppage that do not involve broken parts but simple operating anomalies;
•clean the tool.
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B. Operator for tool maintenance, who is a qualified technician able to:
•work on the tool in conditions where the guards are not engaged;
•work on the mechanical parts to perform adjustments, maintenance, and repairs.
- USER
The entity or person legally responsible for the tool.
4 2 DUTIES OF EMPLOYERS
The employer is responsible for providing a copy of this manual to all personnel who interact with the tool.
4 3 DUTIES OF OPERATORS
In addition to the duty to follow the instructions given in this manual scrupulously, the operators are obligated to notify their
direct supervisors of any deficiency or potentially dangerous situation that may arise.
4 4 PERSONAL PROTECTIVE EQUIPMENT
As is necessary or required by the related internal rules, personalized protective equipment must be used.
All the necessary personal protective equipment be furnished to each individual worker.
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Personal protective equipment (PPE) comprises articles to be used or worn by workers to protect them from the specific risks of
the activity being performed.
The employer furnishes the PPE, chosen in agreement with the workers and their representatives.
The PPE must be:
•entirely individual;
•used or worn obligatorily;
•schosen in such a way that they are suitable for preventing the specific risks of the activity the worker is asked to
perform;
•comfortable and easy to manage;
•kept in efficient condition and replaced when worn out or damaged.
The following articles of PPE must be used during operation of the tool as well as when maintenance is being
performed on it:
safety goggles;
protective gloves
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4 5 WORK STATION
The tool must be operated under pressure by a single operator.
The actual crimping operation, with the consequent use of the tool under pressure, is reserved to only one operator.
4 6 PERSONNEL QUALIFICATION
Before starting work, the personnel assigned to operate the tool must have studied this Chapter 4 Safety. This is true in
particular for personnel who may only use the tool sporadically.
Periodically check that the personnel, during their work, are following the safety and accident
prevention rules indicated in the instruction manual
Define the responsibilities of the tool operator and authorize him to refuse any instructions given by other persons that are
contrary to the safety rules. Personnel in training may operate the tool only if constantly supervised by an experienced operator.
9
Before working with the tool, the operators must have read and understood the
instructions given in this manual, paying particular attention to the safety rules Do
not use the tool if there are any other persons in the work station!

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4 7 RESIDUAL RISKS
It is possible that, despite the warnings provided, certain risks exist for any persons who, going against the rules, are situated in
the work area during the crimping operation.
ALWAYS REMEMBER THAT THE OPERATOR MUST OPERATE THE TOOL ONLY WHEN THE WORK ZONE IS EMPTY OF
ALL OTHER PERSONS
5 PRECAUTIONS FOR OPERATOR SAFETY
5 1 WARNINGS
BEFORE STARTING WORK, THE OPERATOR MUST HAVE A THOROUGH KNOWLEDGE AND
UNDERSTANDING OF THE ALL THE CONTROLS AND OPERATIONS DESCRIBED IN THE INSTRUCTION
MANUAL
THE OPERATOR MUST NEVER BE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL WHILE PERFORMING
HIS DUTIES
ALWAYS PAY THE MAXIMUM ATTENTION TO THE WARNINGS AFFIXED ON THE TOOL
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BEFORE OPERATING THE TOOL, MAKE SURE THERE ARE NO OTHER PERSONS IN THE VICINITY
DO NOT ELIMINATE, REMOVE, OR MODIFY THE SAFETY SYSTEMS ON THE TOOL
ALL REPAIRS OR MAINTENANCE ON THE HYDRAULIC PARTS OF THE TOOL MUST ONLY BE CARRIED
OUT BY SPECIALIZED TECHNICIANS WHO ARE AUTHORIZED BY THE MANUFACTURER
NEVER BRING YOUR FACE CLOSE TO THE TOOL AND NEVER POINT THE TOOL TOWARDS OTHERS
WHEN IT IS UNDER HYDRAULIC PRESSURE
ALWAYS FIT THE DIES BEFORE PUTTING THE TOOL UNDER HYDRAULIC PRESSURE
ALWAYS WEAR PROTECTIVE GOGGLES AND GLOVES, IN PARTICULAR WHEN WORKING WITH THE
TOOL UNDER HYDRAULIC PRESSURE
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5 2 SAFETY DEVICES
The tool is equipped with the following safety devices:
CRIMPER
•Protective guards and side plates
These guards protect the operator's hand from the danger of crushing by coming into contact with moving parts.
PUMP
•Pressure relief valve (by-pass)
This device, calibrated by the manufacturer, prevents the accumulation during pumping of an internal pressure
greater than the limits of resistance of the tool, automatically discharging the pumped oil in the pump reservoir.
CONTROLS
•Pressure release control with hand lever or pedal at single pulse operation
Just press once on the release controls to get the immediate and full relief of the hydraulic pressure from the crimper
and pump thereby avoiding the danger caused by residual pressure remained into the tool.
IT IS STRICTLY PROHIBITED TO ELIMINATE, TAMPER WITH, OR CIRCUMVENT THE SAFETY SYSTEMS
PROVIDED BY THE MANUFACTURER
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5 3 ENVISAGED USE
The tool and its dies are designed solely for the repair and construction of flexible capillary hoses connected
GOMAX ® Quadra and used in refrigeration systems
The tool may also be used for the production of small lots of fitted hoses, after having consulted with the manufacturer.
5 4 IMPROPER USE
Any use not expressly indicated in section 5 3 above is considered an IMPROPER USE
THE MANUFACTURER MAY NOT BE HELD RESPONSIBLE FOR DAMAGE TO THINGS, PERSONS, OR TO THE
TOOL ITSELF DUE TO ACCIDENTS CAUSED BY THE IMPROPER USE OF THE TOOL
6 INFORMATION ON THE TOOL
6 1 INTRODUCTION
The two cylinder crimping tool powered by the air hydraulic pump with pneumatic controls is a compact and lightweight tool
designed to repair the flexible hoses connected GOMAX ® Quadra and used in refrigeration systems.
The crimper and pump bodies are made of high strength chrome-titanium aluminium alloy; the pistons are made of high
quality steel alloy; the closing latch and the surface of the dies have undergone special hardening treatments The crimping
dies are made of hardened and tempered AISI 420 steel.
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The upper part of the crimper can be easily removed to allow crimping of assemblies of particular shapes as well as on site
crimping of hose splicers.
The snap opening/closing system by means of a butterfly latch is simple and safe: just a small lateral rotation of the plastic
cover will release or lock the upper body; the closing cover has an ergonomic form that facilitates the grip and protects the
sliding mechanism from soiling.
The considerable force of the tool, combined with the radial 8-die crimping system, makes it possible to carry out crimping
with adjustable diameter, safe and uniform on the circumference of the fitting equal to the original one.
Die fitting and changeover is quick and easy and does not require the use of specific tools. The crimper is factory fitted with a
threaded hole for attaching a device (not supplied) for aligning the fitting to ensure the correct crimping position.
The hydraulic inlet of the crimper is composed of a fitting with 360° rotation to give the tool easy handling in all kinds of
working conditions.
The air-hydraulic pump is a device that allows to draw out from pneumatic source an hydraulic flow in pressure. The unit is
complete with silencer in order to reach an acceptable level of noise pollution.
The pedal control allows the operator to work hands-free by reducing the working times and margins of error associated with
positioning of the connector to be crimped between dies performed with one hand the other being undertaken to control the
operation of the tool.
The inlet source can be an air compressor or a nitrogen bottle, even a small capacity, equipped with a pressure reducer.
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6 2 PACKAGE
The tool is supplied in a package that includes:
1. Hhydraulic crimper
2. Carter ABS w/internal air hydraulic pump
3. Adapter (1/4” female) for quick pneumatic coupler
4. 3 series of dies (Q2 Q4 Q6)
5. Control pedal kit (optional, code RXB008)
6. Instruction Manual
15
Check to make sure that the product has not
been damaged during transport and that the
content correspond to the description above

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6 3 TECHNICAL DATA
dies for thermo-plastic capillaries, QUADRA® series:
•DN2 (Q2) ............................................................................................................... Ø nominal 7 mm ± 0,15
•DN4 (Q4) .............................................................................................................. Ø nominal 10 mm ± 0,15
•DN6 (Q6) ........................................................................................................... Ø nominal 12,4 mm ± 0,20
crimper:
•height (w/o quick fitting): ............................................................................................................... 180 mm
•length: ......................................................................................................................................... 146 mm
•width: .................................................................................................................................... 30 ÷ 46 mm
•die opening with crimper at rest: ............................................................................. nominal Ø dies + 10 mm
•force: ................................................................................................................................ 62 kN a 48 MPa
•weight: ........................................................................................................................................... 3,4 kg
air-h draulic unit:
•height (w/o control lever): .............................................................................................................. 230 mm
•length: …....................................................................................................................................... 365 mm
•width (w/o drawer valve): ............................................................................................................... 160 mm
•weight: ........................................................................................................................................... 9,6 kg
•source pressure: ................................................................................................................... 500 ÷ 800 kPa
•noise (at 1 meter): .................................................................................................................. 70 ÷ 80 dbA
•air/nitrogen flow rate supply: ........................................................................................................... 250 l/m
•pneumatic inlet: ........................................................................................ hose Ø 6/hose adapter x 1/4” BSP
•oil reservoir capacity (max): ................................................................................................................. 1,4 l
•min oil level under cover plate: ......................................................................................................... 20 mm
•max working pressure: .................................................................................................................... 50 MPa
•pressure relief valve calibration: ........................................................................................................ 48 MPa
•oil grade: ....................................................................................................................................... ISO 15
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6 4 MEASUREMENT CONVERSION TABLE
CONVERSION CHART
1 mm (millimeter) → 0.03937 (inch) 1 kN (kilonewton) → 0.10036 (ton)
1 m (meter) → 3.28083 (foot) 1 kPa (kilopascal) → 0.01 (bar)
1 l (liter) → 0.26417 (gallon) 1 kPa (kilopascal) → 0.14504 (PSI)
1 kg (kilogram) → 2.20462 (pound) 1 MPa (megapascal) → 10 (bar)
1 cc (cubic centimeter) → 0.06102 (cubic inch) 1 MPa (megapascal) → 145.0377 (PSI)
6 5 TOOL DESCRIPTION
1. Upper body
2. Lower body
3. Latch cover
4. Closing latch
5. Side flanges
6. Die position symbols
7. Crimping dies
8. Warning label
9. Distributor label
10. Piston heads
11. Side guards
12. Manufacturer label (back)
13. Threaded hole for device
14. Crimping notches
15. Ram vent caps
16. Quick coupler
17. ABS carter
18. Adapter air supply inlet
19. Service space
20. Hydraulic outlet
21. Pneumatic inlets
22. Pedal control inlets
23. Lever pedal drawer valve
24. Hand lever control
25. Oil check/fill cap
26. Carring slots
27. Air supply inlet
28. Carter fixing bolts
29. Rubber feet
30. Foot pedal control
31. Pneumatic hoses
32. Quick couplers
33. Auxiliary inlets
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