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.

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 11 – www.uniflex.de
Owner
An owner is a natural person or entity using the device himself/herself/
itself, or on whose behalf the device is used. An owner may appoint a
representative to exercise the owner's rights and obligations.
Supervisor
A supervisor is a person acting on behalf of the owner and instructing an
operator to operate the device properly and in compliance with its in-
tended purpose. Unless stipulated otherwise, a supervisor must also ini-
tiate inspection and maintenance work as well as regular checks.
Qualified and competent persons
Qualified and competent persons are individuals with sufficient
knowledge of a special field due to their education, training and experi-
ence, who are familiar with the relevant regulations for occupational
safety and the prevention of accidents, as well as the generally recog-
nized engineering rules.
Instructed persons
Instructed persons are individuals who have been instructed and, if ap-
propriate, trained in the tasks assigned to them and on potential risks re-
sulting from improper conduct by a qualified person, and who have been
informed of required protection equipment and protective measures.
Operator
An operator is a person charged with the proper operation of the device
by the owner or the otherwise contractually obliged person.
Fitter
Fitters of hydraulic presses must be at least 18 years old and have com-
pleted specialist vocational training for the task.
Protection equipment
Protection equipment is personal protection equipment that protects the
body against residual risks resulting from the working process. The re-
sponsibility for the exclusive use of personal protection equipment in
compliance with machinery safety laws rests with the owner.
The situations in which personal protection equipment is required are
defined in the applicable accident prevention regulations for the relevant
activity and/or workplace.

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 12 – www.uniflex.de
2.3 Operational safety instructions
2.3.1 Safety instruction labels on site
Observe all safety instruction labels on site.
2.3.2 Recommendations for working area
Keep the working area clear of trip hazards.
Route wires and cables in shafts, if possible.
Ensure good lighting at the work station.
Keep the access to the hydraulic connection clear.
The device has a working station with a working area as shown below:
Figure 2 - 1 Working area
Manual operation workplace
Front
Back
O
p
erator
Device

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 13 – www.uniflex.de
2.3.3 Noise emission
The operation of the device causes noise emissions of Leq
61.8 dBA at the workplace. Hearing protection is not required.
Higher noise emissions may occur when other machinery is
simultaneously used at the workplace. In such case, the de-
vice owner must provide appropriate information and protec-
tion, e.g.
Instruct staff to wear hearing protectors
Information/instructions on risks
Hazard area identification
Health monitoring
Date Time = 03/12/14 11:41:00
Sampling Time = 1; Record Num = 10
Leq Value = 61.8; SEL Value = 66.4
MAX Leq Value = 70.6; MIN SEL Value = 53.6
Freq Weighting = A Time Weighting=Fast
61.6, 11:41:00,
56.3, 11:41:01,
59.6, 11:41:02,
58.3, 11:41:03,
55.0, 11:41:04,
58.4, 11:41:05,
62.0, 11:41:06,
60.1, 11:41:07,
67.1, 11:41:08,
59.7, 11:41:09,

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 14 – www.uniflex.de
2.4 What to observe
2.4.1 Before starting and/or re-starting the device make sure that:
the working area of the device is well lit.
Operators are familiar with the location and operation of the fire
alarm and fire extinguishers.
Free access to the relevant equipment must be ensured.
The matching die set is mounted on the device.
Start,
stop or
re-start
the device in compliance with this Operation Manual only.
2.4.2 During operation
Production
Observe the safety instructions for the device.
Crimpers can cause serious bodily injury, including
amputation, when not use carefully.
Always keep hands a minimum safe distance of 120
mm from the crimper.

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 15 – www.uniflex.de
Figure 2-2 Minimum safe distance of 120 mm
Safe operation includes visual recognition by the operator as to
the location of their hands.Make sure that no other individuals are
present in the working area.
Do not eat, drink or smoke while operating the device..
After completing the work
Stop the device by turning the main switch to OFF.
Clean your hands thoroughly when finished using the device.

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 16 – www.uniflex.de
2.4.3 For maintenance and repair
Working on the hydraulic system
The device is fitted with a hydraulic power unit including a pump and
motor.
Maintenance and repair work on the hydraulic system may
only be performed by UNIFLEX-HYDRAULIK GmbH specialist staff!
Welding, flame-cutting and grinding work
Welding work
Flame-cutting work and
Grinding work
on and in the device and its vicinity must be approved – there is a fire
risk.
Even if such work has been permitted, the device must be cleaned of
dust and combustible material.
Adequate ventilation must be provided.

Safe operation, protection of the environment
UNIFLEX-Hydraulik - 17 – www.uniflex.de
2.5 Emergency measures
In an emergency, immediately stop the device by turning the main switch
to OFF.
Figure 2-3 Main switch, OFF position
Remove the cause for the emergency stop before re-starting the
device.
2.6 Consumables and waste
All applicable regulations for protection of the environment and
waste disposal applicable to the owner’s business and the location
should be followed.Relevant statutory provisions and any neces-
sary amendments resulting from the device´s function should be
made available to the operating staff.Information on the misuse of
consumables and waste should be provided.Ensure that appropri-
ate steps are taken in case of accidents and/or fire.
The hydraulic oil is hazardous waste – return it to the supplier.

Design and function
UNIFLEX-Hydraulik - 18 – www.uniflex.de
3 Design and function
3.1 Design
Figure 3-1 Device construction
1 Hydraulic cylinder
2 Handle for push ram
3 Micrometer
4 Oil tank
5 Unit (electric motor with hydraulic pump and oil tank)
6 Crimping die set with 2 x 4 dies
7 Main switch with emergency stop function
8 Control panel
9 'Close tool' pushbutton
10 Pressure plate
11 Bearing plates
12 Push ram
13 Eyelet
1 2 3 4 5
6
8 7
10 9
11
12
13

Design and function
UNIFLEX-Hydraulik - 19 – www.uniflex.de
3.2 Technical data UA4
Technical data UA 4
Crimping force 1350 kN / 135 t
Control Micrometer
SAE R 15 / 4SH* 1 part fitting 1 ¼“
SAE R 12 / 4SP* 1 part fitting 1 ½“
SAE R 15 / 4SH* 2 part fitting 1“
SAE R 12 / 4SP* 2 part fitting 1 ¼“
Industry 1 ½“
90° bent 1 ½“
Maximum permissible crimping area (mm)*** ØPB+8 (57 mm****)
Maximum die Ø (mm) 54
Opening distance + 15 mm
Opening size without dies 73 mm
Speed
Closing
Crimping
Opening
3.7 mm/s
1.2 mm/s
--
Die type PB 280 (8-di - set)
Noise level 62 dBA
Drive power 0.75 kW
Operation mode S6-70%
Oil 5 Liters
Oil change Annually
L x W x H (mm) 380 x 390 x 500
Weight approx. 90 kg
* depending on fitting
** without flange
*** max. outside diameter of fitting prior to crimping
**** Only for special applications upon approval by Uniflex
PB = crimping dies

Design and function
UNIFLEX-Hydraulik - 20 – www.uniflex.de
3.3 Function
Figure 3-2 Minimum safe distance of 120 mm
Crimpers can cause serious bodily
injury, invluding amputation, when not used
carefuly.
Always visually check the movements of your
hands when feeding and removing work piec-
es – only then you are able to control your
hand movements.
Always keep hands a minimum
safe distance of 120 mm to the crimper.