STAUFF SPR-PRC-H User manual

Translation of the original
Operating Manual
Cutting Ring Pre-Assembly Machine
SPR-PRC-H
To avoid injuries and damage read through this operating manual thoroughly
and attentively. Keep it for further reference purposes.
6010016757 R0.2_en

2 www.stauffconnect.com

This document can be found in additional languages online at www.stauffconnect.com
Walter Stauffenberg GmbH & Co. KG
Im Ehrenfeld 4
58791 Werdohl
Telephone: [phone]
Fax: [phone]
[email protected]
www.stauffconnect.com

SPR-PRC-H www.stauffconnect.com 3
Table of Contents


Table of Contents
1Information on the Manual........................................................................5
1.1.Targeted group of the operating manual...............................................5
1.2.Warnings structure................................................................................5
1.3.Instructions structure.............................................................................6
1.4.Additional information structure.............................................................6
1.5.References structure.............................................................................6
2For Your Safety...........................................................................................7
2.1.General safety instructions....................................................................7
2.2.Intended use..........................................................................................8
2.3.Tasks and obligations of the company operator...................................8
2.4.Personnel eligibility................................................................................9
2.5.Personnel protective gear.....................................................................9
3Machine Description................................................................................10
3.1.Overview of machine...........................................................................10
3.2.Technical data.....................................................................................11
3.3.Function...............................................................................................12
3.4.Tools and manufactured item..............................................................12
3.5.Type plate............................................................................................13
3.6.Spares and wear parts........................................................................13
4Operation..................................................................................................14
4.1.Safety..................................................................................................14
4.1.1 Work area safety.......................................................................15
4.1.2 Electrical safety.........................................................................15
4.1.3Personalsafety..........................................................................15
 4.1.4Power tool use and care...........................................................16
4.2. Choose the right parts ........................................................................ 17
4.3. Turning on machine............................................................................ 17
4.4. Setting the working pressure .............................................................. 17
4.5. Socket change.................................................................................... 17
4.6. Tube installation ................................................................................. 18
4.7. Pre-assembly...................................................................................... 18
4.8. Checking the Pre-assembly ............................................................... 19
4.9. Service................................................................................................ 19


4 www.stauffconnect.com
Table of Contents


5 Shut-down ................................................................................................. 20
5.1 Safety.................................................................................................. 20
5.2 Dismantling......................................................................................... 21
5.3 Disposal.............................................................................................. 21
6 Battery........................................................................................................ 22
6.1 Labels on Charger and Battery Pack ................................................. 22
7 Battery Charger and Battery Pack .......................................................... 23
8 Battery Pack .............................................................................................. 33
9 Annex ........................................................................................................ 36






























SPR-PRC-H www.stauffconnect.com 5
1 Information on the Manual


1 Information on the Manual
This manual includes important instructions and information on the
intended use. Keep the operating manual where it can be accessed by
the operating personnel.
1.1 Targeted group of the operating manual
The operating personnel charged with the following work must read and take
notice of this operating manual:
• Installation
• Operation
• Fault
• Servicing
See personnel qualifications ►Section 2.4, Page 9.
1.2 Warnings structure
Coloured signal word boxes emphasise the warnings. Always read the full
warning text for effective protection from hazards!
The various colours and signal words of the following boxes designate
various danger levels:
Ignoring this warning results in serious or lethal injuries.
Ignoring this warning can result in serious or lethal injuries.
Ignoring this warning can result in minor or moderately severe
injuries.
Ignoring this warning can result in damage.
DANGER
WARNING
CAUTION
IMPORTANT

6 www.stauffconnect.com
1 Information on the Manual


Warnings are always structured in the same manner. They include the
signal word, hazard type and source, consequences of ignoring them and
steps to ward off / avoid hazards.
Example:
Risks from fingers shearing off and being injured
►Ensure before start-up that all safety equipment is properly installed and
in working order!
►Make sure your fingers are not in the assembly area when carrying out
the machine functions!
1.3 Instructions structure
Instructions request you to undertake an immediate operation. They are
structured in line with the operation involved. Always carry out the operating
steps in the prescribed sequence.
The instructions are structured as follows and marked with the appropriate
symbols:
►
Aim of the instruction
1. Operating step
✓
Effect of the operating step in checking if the step has been
properly executed.
2. Additional operating step
 Outcome of the overall instruction
1.4 Additional information structure
1.5 References structure
References are shown in this manual as follows:
Example:
“… only operate the machine as intended ►Chapter 2.2, Page 8.
WARNING
Texts with an info symbol provide you with additional
information and tips.

SPR-PRC-H www.stauffconnect.com 7
2 For your Safety


2 For Your Safety
To avoid accidents and injuries …
• Pay attention to all the general and specific safety instructions and the
warnings in this manual.
• Pay attention to danger and prohibitory signs.
• Follow the accident prevention regulations and directives applying to
where the operation is taking place.
• Keep to all the inspection and maintenance intervals.
• Only operate the machine as intended.
2.1 General safety instructions
Safety instructions help you in avoiding injuries and in avoiding damage.
Ensure that you have read and understood all the safety instructions in this
operating manual.
Safe working entails doing more that just reading the general safety
instructions in this chapter. Also read and follow the specific safety
instructions in every chapter affecting your work. Follow as well the
information in the associated product documents in force.
The following general safety instructions hold good for all work
undertaken on the machine:
• Keep to the valid national and international job safety provisions.
• Only operate the machine …
– In a technically satisfactory condition
– In a safety and danger-conscious manner
– As intended
– With attention paid to this operating manual and
– With a complete number of unchanged, properly installed
and functional protective appliances.
• Wear the appropriate personal protective gear for all work
undertake on the machine ►Chapter 2.5, Page 9.
• Pay attention to all the safety labels attached to the machine
• Only Walter Stauffenberg GmbH & Co.KG is to carry out work on
the electrical equipment.
• Immediately rectify faults which affect your safety and a reliable
operation of the machine. Place the machine out of service until the fault
is rectified.
• Except for tools, only Walter Stauffenberg GmbH & Co.KG is to replace
components.

8 www.stauffconnect.com
2 For your Safety


• Keep away from moving component parts. Wear close fitting clothes.
Bundle long hair to prevent it from being drawn into the machine. Take
off rings and necklaces before the work.
• Be aware of the presence of residual energies in mechanical,
hydraulic and electrical components.
2.2 Intended use
The cutting ring machine is solely for mechanical pre-assembly of cutting
rings on light and heavy series tube ends for 6 mm to 42 mm tube external
diameters.
The machine is used together with assembly studs specially designed for
mechanical mounting.
The assembling parameters saved in the machine apply solely to the use
of an original STAUFF cutting ring FI-DS-.. in combination with the
selected tube material and the original STAUFF union nut FI-M-.. .
The machine may only be used within the specifications prescribed in the
Technical Data chapter ►Chapter 3.2, Page 10 and with due consideration
given to the maintenance requirements and instructions in this manual and in
the associated documents in force.
No changes, attachments or conversions are to be carried out without
consultations had with the manufacturer. These kinds of modifications could
limit the fail-safeness of the machine and are deemed to be at variance to
the intended use.
Any use other than that indicated in the use as intended is not allowed.
2.3 Tasks and obligations of the company operator
Not only the instructions and information in this operating manual are to be
followed but also the general, statutory and other mandatory regulations on
accident prevention and environmental protection.
To ensure fail-safe machine operation, the company operator must at least
…
• Ensure that the machine is only run as intended, is in a proper state,
has the full complement of safety appliances and reveals no signs of
damage.
• Establish the operative range and prepare the corresponding operating
instructions.
• Always keep the safety labels attached to the machine complete and
legible.
• Always have available the operating manual in a complete and
legible form where the machine is deployed.
• Instruct those operating the machine as to the work involved with it.

SPR-PRC-H www.stauffconnect.com 9
2 For your Safety


• Acquire the specifications applicable to the machine in their most
recent version and to familiarize personnel working on the machine
with them.
• Provide the personnel operating the machine with the required
personal protective gear.
• Carry out a safety briefing at the machine itself.
• Ensure that ventilation and lighting of the working area is adequate.
2.4 Personnel eligibility
Whatever the work on the machine, it is only to be carried out by personnel
qualified and authorised to do just that. Personnel instructed, trained or
briefed in the work involved is judged to be qualified. This is to be backed up
by appropriate certificates and supporting records.
A distinction is made in this manual between:
• Operating personnel - those who have been demonstrably briefed in
both operating the machine and in its mode of operation. They put in the
data required for the operation and carry out the requisite operating
steps to operate the machine. They are also responsible for simple
servicing work and fault rectification as specified in the inspection and
maintenance plan and in fault rectification.
• Personnel learning on the job may only work on the machine under
the constant supervision of personnel eligible to perform this work.
2.5 Personal protective gear
The following personal protective gear is prescribed for those working on the
machine:
Wear close-fitting working clothes!
Wear safety boots!

10 www.stauffconnect.com
3 Machine Description


3 Machine Description
3.1 Overview of machine
3: Operating elements overview
Pos. Designation Description
1Device Ergonomically, light-weight and robust design
2Assembling area Processing workpiece
3 Release button Releasing the machine
4 Press button For operation the machine
5Rechargeable
battery
Lithium-ion (18V / 5.0 Ah)
6 Mode dial To manually adjust the pressure;
on the bottom of the machine
7 Status lights On the back of the machine
3.2 Technical Data
General data
Dimensions (L x H x W) 440 mm x 330 mm x 80 mm
17.32 in x 12.99 in x 3.15 in
Weight: 6,8 kg / 15 lbs
Rechargeable Battery (Battery operated)
Battery type: Lithium-ion (18V / 5.0 Ah)
7
6

SPR-PRC-H www.stauffconnect.com 11
3 Machine Description


3.3 Function
The machine mechanically mounts cutting rings onto tube ends. Use can be
made of light and heavy series tubes for tube diameters between 6 mm and
42 mm.
The machine is used together with assembly studs specially designed for
mechanical mounting.
3.4 Tools and Product
The cutting ring pre-assembly machine mounts cutting rings onto tube ends.
4: Product
1 Assembly stud
2 Cutting ring
3 Union nut
5: Parts
The construction size is labelled on the assembly stud:
• The number corresponds to the tube external diameter
• L stands for the Light Series
• S stands for the Heavy Series
Please refer to the STAUFF Connect Product Catalogue for additional
information on selection of the construction size.

12 www.stauffconnect.com
3 Machine Description


3.5 Type plate
The type plate is on top of the machine.
6: Type plate
3.6 Spares and wear parts
Replacing components
Machine damage, malfunctions, faults
►Only Walter Stauffenberg GmbH&Co.KG is to carry out work involving
opening up the machine!
►Only authorized rigging and maintenance personnel are to carry out
servicing work!
►Only use appropriate tools which are in a good condition!
►Only replace components with genuine spares or those authorized by
the manufacturer!
IMPORTANT

SPR-PRC-H www.stauffconnect.com 13
6 Operation


4 Operation
To ensure fail-safe operations, the machine is only to be operated as
intended.
4.1 Safety
Risks from fingers shearing off and being injured
►Ensure before start-up that all safety equipment is properly installed and
in working order!
►Make sure your fingers are not in the assembly area when carrying out
the machine functions!
Danger from incorrect operating and behaviour of the operator of the
machine
►Those operating the machine must have read and understood the
operating manual!
►Those operating the machine must be trained and instructed in handling
it!
Danger from the operator meddling with the safety equipment
►Ensure before start-up of the machine that all safety equipment is
properly installed and operable! ►Those operating the machine must
be trained and instructed in handling it!
Read all safety warnings and all instructions.
►Do not use the machine for anything else than pre-assembling of
cutting rings as instructed. Any other use of machine is forbidden.
►The machine weights approximately 7 kg, so please always use the
shoulderstrap to prevent dropping the machine and causing injury
►Before using the machineholder accessory, please remove the
shoulderstrap and battery from machine. Do the same when
removing machine from machineholder
►Always keep the machine clean and inspect the machine of any
irregularities. A broken or damaged machine should never be used
►If machine suddenly stops mid-cycle and is stuck on tube, it is easily
removable by decreasing the pressure setting from machine body
WARNING
CAUTION
CAUTION
WARNING

14 www.stauffconnect.com
4 Operation


4.1.1 Work area safety
Keep work area clean and well-lit. Cluttered or dark areas invite
accidents. Do not operate power tools in explosive atmospheres, such
as in the presence of flammable liquids, gases or dust.
Power tools create sparks which may ignite the dust or fumes.
Keep bystanders away while operating a power tool.
Distractions can cause you to lose control.
4.1.2 Electrical safety
Do not expose power tools to rain or wet conditions. Water entering a
power tool will increase the risk of electric shock.
Use power tools only with specifically designated battery packs. Use of
any other battery packs may create a risk of injury and fire.
If battery contents come into contact with the skin, immediately wash
the area with mild soap and water. If the battery liquid gets into the eye,
rinse water over the open eye for 15 minutes or until irritation ceases.
If medical attention is needed, the battery electrolyte is composed of a
mixture of liquid organic carbonates and lithium salts.
4.1.3 Personal safety
Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use a power tool while you are tired or
under the influence of drugs, alcohol or medication. A moment of
inattention while operating power tools may result in serious personal
injury.
Use personal protective equipment. Always wear eye protection.
Protective equipment such as dust mask, non-skid safety shoes, hard
hat, or hearing protection used for appropriate conditions will reduce
personal injuries.
Prevent unintentional starting. Carrying power tools with your finger on
the switch or energising power tools that have the switch on invites
accidents.
Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
WARNING
WARNING
WARNING

SPR-PRC-H www.stauffconnect.com 15
4 Operation


4.1.4 Power tool use and care
Do not use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and
must be repaired.
Disconnect the power source and/or the battery pack from the power
tool before making any adjustments, changing accessories, or
storing power tools. Such preventive safety measures reduce the risk
of starting the power tool accidentally.
Store idle power tools out of the reach of children and do not allow
persons unfamiliar with the power tool or these instructions to operate
the power tool. Power tools are dangerous in the hands of untrained
users.
Maintain power tools. Check for misalignment or binding of moving
parts, breakage of parts and any other condition that may affect the
power tool's operation. If damaged, have the power tool repaired before
use. Many accidents are caused by poorly maintained power tools.
Use the power tool, accessories and tool bits etc. in accordance
with these instructions, taking into account the working conditions
and the work to be performed. Use of the power tool for operations
different from those intended could result in a hazardous situation.
WARNING

16 www.stauffconnect.com
4 Operation


4.2 Choose the right parts
 Choose the nut, cutting ring and socket to match the tube.
Notice differences between L- and S-types.
4.3 Turning on machine
 Turn on the machine from the power button found on the back of the machine body.
The battery light found on the same panel indicates your battery power level by color.
If the maintenance light is on, please contact your dealer. The machine turns off
automatically when inactive.
4.4 Setting the working pressure
 Pressure can be adjusted underneath the body of the machine. Pressure settings are
listed on the side panel of the machine. As different couplings and materials require
different working pressure, please check the function of the cutting ring after every
installation and make sure it is installed correctly.
4.5 Socket change
 Adjust pressure to minimum. Push the press button until the groove on the
piston or socket is visible. Detach the battery from the machine as measure of
precaution. Detach the socket pin and the socket from the machine. Place new
socket on the end of the piston and fasten it with the socket pin. Make sure that the
socket is properly attached. Attach the battery to the machine and by pressing the
release button return the piston back to starting position. Apply oil on the
inner surface of the socket. Oil is content of the set.

SPR-PRC-H www.stauffconnect.com 17
4 Operation


4.6 Tube installation
Tube preparation: The tubes are prepared in keeping with tube and assembling
preparation of the assembling instructions of the STAUFF Connect Product Catalogue.
Refer on this to Chapter Assembly instructions in the STAUFF Connect Product
Catalogue.
 Place the nut and the cutting ring on the tube. Place the tube firmly against the socket
so that the nut and the cutting ring are between the socket and the clamps. Make sure
that the tube is straight in the middle of the clamps and in the right angle. Make sure that
no fingers or anything irrelevant is between clamps and socket.
4.7 Pre-assembly
 Make sure that nothing irrelevant is between brackets and socket. Pre-assembly is
done by holding the machine firmly with other hand and holding the tube from
outside the clamps with the other hand and pushing it against the socket. Push the
press button until the automatic release happens. Release the press button. Push
the release button and return the piston back to starting position. Open brackets
and take the tube away.










Fit support sleeves for thin-walled tubes in keeping
with the STAUFF Connect Product Catalogue!

18 www.stauffconnect.com
4 Operation




4.8 Checking the pre-assembly
 Check that pre-assembly is done correctly, right amount of pressure was applied and
that the cutting ring is attached to the tube in the right way.
The cutting ring might be too loose or the tube can be deformed from too much
pressure. If the pre-assembly is not good enough, tube must be cut and a new pre-
assembly has to be made. Adjust the working pressure again if needed.
Remember to turn the pressure adjustment to minimum every time you stop working.
Never use the machine if you notice any functional or mechanical problems. The
manufacturer is not responsible of any damage caused by faulty machine. In problem
situations contact your dealer.
 Final assembly: For final assembly in the fitting body, do follow the detailed
instructions in the assembly instructions in the STAUFF Connect Product Catalogue.
4.9 Service
 Have your power tool serviced by a qualified repair person using only identical
replacement parts. This will ensure that the safety of the power tool is maintained.
Check the machine for breakage or other flaws. Brackets that are bent, bracket springs that
are broken or tooling that are damaged will cause unwanted results.

SPR-PRC-H www.stauffconnect.com 19
4 Operation


5 Shut-down
5.1 Safety
Carrying out dismantling
Serious or lethal injuries
►Only authorized specialist personnel is to carry out dismantling work!
►Only use appropriate tools which are in a good condition!
►Wear your personal protective gear for all work!
Work on the hydraulic system
Eye injuries possible from hydraulic oil being squirted out
►Depressurize the machine!
►Only Walter Stauffenberg GmbH &Co.KG is to carry out work
involving opening up the machine!
►Wear your personal protective gear incl. goggles for all work undertaken
on the hydraulic system!
WARNING
CAUTION

20 www.stauffconnect.com
6 Battery


5.2 Dismantling
Don’t dismantle the machine, because the internal hydraulic pressure can reach
700 bar during normal use. This should only be done by authorized technicians.
5.3 Disposal
Do not dispose of electric tools together with household waste material! In
observance of European Directive 2002/96/EC on waste electrical and electronic
equipment and its implementation in accordance with national law, electric tools that
have reached the end of their life must be collected separately and returned to and
environmentally compatible recycling facility.
WARNING