Uniflex UA 4 User manual

OPERATION MANUAL
- UA 4
Subject to changes without prior notice EN
The reproduction, distribution 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.

Imprint
UNIFLEX-Hydraulik - 2 – www.uniflex.de
EC Declaration of Conformity
pursuant to EC Machinery Directive 2006/42/EEC.
The following machine
UA4
has been developed, designed and manufactured in accordance with EC Directive 2006/42/EEC under the
sole responsibility of
Company name UNIFLEX - Hydraulik GmbH
Robert-Bosch-Straße 50 - 52
D - 61184 Karben
Documentation officer Carsten Baumgartner
The following 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 Compliance invalid.
A complete technical documentation is available.
This Operating Manual of the machine is a translation; the original version is in German.
---------------------------------- ---------------------------------- -------------------------------------
Karben, 29 June 2015
Geschäftsführer – President

Imprint
UNIFLEX-Hydraulik - 3 – www.uniflex.de
Original Operation Manual - English
Vertical hose crimper UA 4
Manufacturer:
Uniflex-Hydraulik GmbH
Robert-Bosch-Strasse 50-52
D-61184 Karben
Germany
Phone: [phone] / 91 71 - 0
Fax: [phone] / 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

Contents
UNIFLEX-Hydraulik - 4 – www.uniflex.de
Section Page
1Introduction, use in compliance with intended purpose.............................................6
1.1Basic Principles...................................................................................................................6
1.2Target audience ..................................................................................................................7
1.3Use in compliance with intended purpose...........................................................................7
2Safe operation, protection of the environment.............................................................9
2.1General notes......................................................................................................................9
2.2Definition of terms .............................................................................................................10
2.3Operational safety instructions..........................................................................................12
2.3.1Safety instruction labels on site..........................................................................................12
2.3.2Recommendations for working area...................................................................................12
2.3.3Noise emission...................................................................................................................13
2.4What to observe ................................................................................................................14
2.4.1Before starting and/or re-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Assembly...........................................................................................................................25
4.3.1Required utilities.................................................................................................................26
4.4Ambient conditions............................................................................................................27
4.5Intermediate storage of device..........................................................................................27
4.6Installation.........................................................................................................................28
5Operation........................................................................................................................30
5.1First commissioning Initial startup.....................................................................................30
5.2Starting the device.............................................................................................................31
5.3Stoping the device.............................................................................................................31
5.4Re-starting the device .......................................................................................................32
5.5Operation mode.................................................................................................................32
5.6Emergency stop ................................................................................................................33

Contents
UNIFLEX-Hydraulik - 5 – www.uniflex.de
6Maintenance...................................................................................................................34
6.1Replace bearing plate .......................................................................................................35
6.2Daily inspection.................................................................................................................36
6.3Monthly inspection.............................................................................................................38
7Anhang / Annex .............................................................................................................40
7.1Ersatzteileliste / Spare 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


Introduction, use in compliance with intended purpose
UNIFLEX-Hydraulik - 6 – www.uniflex.de
1 Introduction, use in compliance with intended purpose
1.1 Basic Principles In this Operation Manual, the "Vertical hose crimper UA 4" is referred to
as 'device'.
This Operation Manual contains important about how to operate your
device
safely,
properly and
economically.
Compliance on your part will
reduce risks
minimize repair costs and downtimes, and
increase the device's reliability and lifetime.
The device is designed in accordance with the latest technology.
Use of this device for other than the intended purpose may sesult in se-
vere injury or death and/or may damage the device.
Consequently, 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 pro-
visions is deemed as use in accordance with theintended purpose. Op-
erator’s/owner’s take sole responsibility for injuries or damage resulting
from methods of use not I compliance with the intended purpose.
Please read this Operation Manual thoroughly before
starting
stopping
maintaining and
repairing the device.
Only staff that have
read and
understood the always available Operation Manual, and
who have received thorough instructions are permitted to operate the
device.

Introduction, use in compliance with intended purpose
UNIFLEX-Hydraulik - 7 – www.uniflex.de
1.2 Target audience This Pperation Manual is intended for:
Owners
Operators
1.3 Use in compliance with intended purpose
This device is intended for industrial use. It is only suitable for
crimping hydraulic hoses in batch production - continuous opera-
tion is not permissible.
Smallest die diameter: 6.8 mm, largest: 57 mm.
The maximum crimping area is 65 mm (57 mm + 8 mm crimping
distance).
Only Uniflex die sets with 2 x 4 dies may be used.
Matching hydraulic hoses, fittings and die sets must be used to
meet the specifications provided by the 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 compliance with the intended pur-
pose.
Operator’s/owner’s take sole responsibility for injuries or damage result-
ing from methods of use not in compliance with the intended purpose.
Please also note:
Use of the device in compliance with the intended purpose also includes
compliance with the specified
Starting instructions
Stopping instructions
Operating instructions
Inspection and maintenance procedures and
Disposal procedures.

Introduction, use in compliance with intended purpose
UNIFLEX-Hydraulik - 8 – www.uniflex.de
Only staff that have read and understood the always available Operation
Manual, who have signed this Manual in the Annex and who have re-
ceived thorough instructions are permittedoperate the device.
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. Please always keep a copy of the Operation Manual at a desig-
nated place near the device.

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 9 – www.uniflex.de
2 Safe operation, protection of the environment
2.1 General notes
The device is designed in accordance with the latest technology. Inju-
ries or damage may result from improper use or use not in compliance
with the intended purpose.
Compliance with all given safety instructions is compulsory for the
safe operation of the hydraulic crimper. Gaps required for inserting
the workpiece should always be minimized by limiting the opening
distance.
Due to the variety of customer-specific workpieces, UNIFLEX-
Hydraulik GmbH is not capable of supplying additional standard
protection equipment together with the device to prevent any po-
tential residual risks imposed by the device.
The necessity of additional protection equipment adapted to the
relevant workpiece shall be verified by the operator before com-
missioning the device. Such equipment may for instance be re-
quired for angled workpiece geometries needing a large opening
for being inserted into the crimper.
Should additional 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-
uals and objects, even outside the working area.
UNIFLEX-Hydraulik GmbH will provide you with individual solu-
tions for protection equipment upon request. Please do not hesi-
tate to contact your local UNIFLEX representative.
This Operation Manual contains the instructions and provisions for the
safe and intended use of your device.Any person working on the device
must have read and understood the Operation Manual, in particular the
present section, "Safe operation, protection of the environment".
All safety instructions must be strictly followed.For this reason, please
always keep this Operation Manual readily available at a designated
place near the device.For the purpose of protecting you and your col-
leagues against injuries and harm, your cooperation is required.
Please work carefully and be always aware of safety aspects –
risks are frequently hidden.

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 10 – www.uniflex.de
The symbols below point out passages in the Operation Manual that are
particularly important:
DANGER This symbol indicates important safety in-
formation for preventing injury or death.
Carefully follow these instructions and in-
form all users of the device of these and
any other applicable safety regulations re-
garding operation of the device.
ATTENTION This symbol indicates important operating
or maintenance instructions. Carefully fol-
low these instructions 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 Definition of terms
Residual risks
Residual risks are non-evident risks resulting from the use of the device.
Although the device has been developed, designed and constructed in
compliance with the latest technology and generally recognized safety
regulations, residual risks cannot be fully excluded – not even if the de-
vice is used as intended.