widos 4400 User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0) 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40
website: www.widos.de email: [email protected]
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Working Instructions
Translation
Heating Element Butt Welding Machine
WIDOS 4400
Keep for further use!

Kunststoffschweißtechnik
Product Identification
23.06.15 Working Instructions WIDOS 4400 Page 2 of 44
Model: Heating element butt welding machine
Type: WIDOS 4400
Serial number / year of construction: see type lable
Customer entries
Inventory-No.:
Place of working:
Order of spare parts and after sales service:
Address of manufacturer WIDOS
W. Dommer Söhne GmbH
Einsteinstrasse 5
D-71254 Ditzingen-Heimerdingen
Phone: ++49 7152 / 99 39 - 0
Telefax: ++49 7152 / 99 39 - 40
Address of the subsidiary companies:
WIDOS
WIDOS GmbH W. Dommer Söhne AG
An der Wiesenmühle 15 St. Gallerstr. 93
D-09224 Grüna / Sachsen CH-9201 Gossau
Phone: ++49 371 / 8 15 73 - 0 Phone: [phone]
Fax: ++49 371 / 8 15 73 - 20

Kunststoffschweißtechnik
Introduction
23.06.15 Working Instructions WIDOS 4600 Page 3 of 44
Purpose of the document
These working instructions give you information about all important questions which refer to
the construction and the safe working of your machine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our service teams in the factory or in our subsidiary
companies.
We will help you with pleasure.
According to our interest to continuously improve our products and working instructions,
we kindly ask you to inform us about problems and defects which occur during exercise.
Thank you.
Structure of the working instructions
This manual is arranged in chapters, which belong to the different using phases of the
machine.
Due to this structure, the searched information can be easily found.
¤WIDOS 23.06.2015
W. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
All rights reserved.
Reprinting only allowed with permission of the corporation.
Any changes prior to technical innovations.

Kunststoffschweißtechnik
Contents
23.06.15 Working Instructions WIDOS 4400 Page 4 of 44
1. DESCRIPTION OF THE PRODUCT................................................................................ 6
1.1. Usage and purpose oriented use ............................................................................................6
1.2. Safety measures........................................................................................................................6
1.3. Conformity .................................................................................................................................6
1.4. Machine overview......................................................................................................................7
1.5. Designation of the product ......................................................................................................7
1.5.1. Technical data ....................................................................................................................7
1.5.1.1. WIDOS 4400 General data......................................................................................7
1.5.1.2. Heating element.........................................................................................................8
1.5.1.3. Planer.........................................................................................................................8
1.5.1.4. Hydraulic aggregate...................................................................................................9
1.5.1.5. Basic frame ................................................................................................................9
1.5.1.6. Reception box ............................................................................................................9
1.6. Equipment and accessories: ...................................................................................................9
2. SAFETY RULES............................................................................................................ 10
2.1. Explanation of the symbols and indications........................................................................10
2.2. Obligations of the owner ........................................................................................................11
2.3. Obligations of the worker.......................................................................................................11
2.4. Measures of organisation.......................................................................................................11
2.5. Information about safety precautions...................................................................................11
2.6. Instructions for the staff.........................................................................................................11
2.7. Dangers while handling the machine....................................................................................12
2.8. Danger caused by electric energy.........................................................................................12
2.9. Dangers caused by the hydraulic aggregate .......................................................................12
2.10. Specific dangers......................................................................................................................13
2.10.1. Danger of catching clothes by the planer.........................................................................13
2.10.2. Risk of injury by noises.....................................................................................................13
2.10.3. Danger of being burnt by heating element, reception box and welding area..................13
2.10.4. Danger of stumbling over hydraulic and electric wires.....................................................13
2.10.5. Danger of squeezing by clamping devices and guideways .............................................13
2.11. Structural modifications on the machine .............................................................................14
2.12. Cleaning the machine .............................................................................................................14
2.13. Warranty and liability ..............................................................................................................14
3. FUNCTIONAL DESCRIPTION ...................................................................................... 15
4. OPERATING AND INDICATING ELEMENTS .............................................................. 16
4.1. Elements on the aggregate ....................................................................................................16
4.1.1. Hydraulic aggregat with manometer analog.....................................................................17
4.2. Elements on the side of the aggregate .................................................................................17
4.3. Elements at planer and heating element ..............................................................................18
5. STARTING AND OPERATING...................................................................................... 19

Kunststoffschweißtechnik
Contents
23.06.15 Working Instructions WIDOS 4400 Page 5 of 44
5.1. Starting.....................................................................................................................................19
5.1.1. Replacing the reduction inserts ........................................................................................20
5.1.2. Using small and large reduction inserts ...........................................................................20
5.2. Welding process......................................................................................................................21
6. WELDING LOG AND TABLES ..................................................................................... 23
7. MAINTENANCE AND REPAIR ..................................................................................... 28
7.1. Maintenance and inspection, repair ......................................................................................28
7.2. Clamping elements .................................................................................................................28
7.3. Planer........................................................................................................................................28
7.4. Storage .....................................................................................................................................28
7.5. Used hydraulic oil ...................................................................................................................28
7.6. Checking the hydraulic oil-level ............................................................................................29
7.7. Venting the hydraulic cylinders.............................................................................................29
8. TRANSPORT................................................................................................................. 30
9. HYDRAULIC AND ELECTRIC DIAGRAMS.................................................................. 31
10. SPARE PARTS LIST ................................................................................................. 33
10.1. Basic machine .........................................................................................................................33
10.2. Planer........................................................................................................................................35
10.3. Hydraulic aggregate................................................................................................................37
10.4. Heating element.......................................................................................................................40
10.5. Protection box .........................................................................................................................42
11. DECLARATION OF CONFORMITY .......................................................................... 44

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0) 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40
website: www.widos.de email: [email protected]
23.06.15 Working Instructions WIDOS 4400 Page 6 of 44
1. Description of the product
This chapter gives important basic information about the product and its prescribed use.
All technical details of the machine are put together as a general arrangement.
1.1. Usage and purpose oriented use
The WIDOS 4400 has been designed only for heating element butt welding of pipes and
fittings with a diameter range of Ø = 50 - 160 mm (standard diameters: 50 / 63 / 75 / 90 / 110 /
125 / 140 / 160 mm).
It is a building site machine and is designed especially for the use on site as well as in the
workshop. For this reason, the frame is kept small such that it can be used also in constrained
positions (e.g. building ditches).
All use going beyond is not purpose oriented.
The manufacturer is not responsible for any damages caused by inexpert handling or
operation.
For personal injuries, material and immaterial damages resulting herefrom, only the user is
responsible!
Also part of the purpose oriented use is
xrespecting all the indications of the working instructions and
xperforming the inspection and maintenance works.
1.2. Safety measures
In case of wrong use, wrong operation or wrong maintenance, the machine itself or products
standing nearby can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thoroughly read and the corresponding safety
regulations must be necessarily adhered to.
1.3. Conformity
The machine corresponds in its construction to the valid recommendations of the European
Community as well as to the according European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.

Kunststoffschweißtechnik
Description of Product Chapter 1
23.06.15 Working Instructions WIDOS 4400 Page 7 of 44
1.4. Machine overview
No. Description
1 Hydraulic aggregate
2 Basic machine with clamping devices
3Heating element
4Reception box
5Planer
1.5. Designation of the product
The product is designated by two type labels.
The type labels are attached at the aggregate and at the basic machine.
They contain the type, the serial number and the year of construction of the machine.
1.5.1. Technical data
1.5.1.1. WIDOS 4400 General data
Material: PE, PP, PVDF,
Pipe diameter range:: outside-= 50 – 160 mm
Packing box (l x w x h):
Weight:
appr. 820 x 680 x 750 mm
appr. 14 kg
Weight (without boxes): appr. 60 kg
Protection: 10 A
Wire cross section: 1,5 mm²
Emissions - Noises exceeding 80 dB (A) may occur; during
planing it is obligatory to wear ear protection!
- When using the named pipe materials and when
welding below 260 °C / 500 °F no toxicant damp
arises.
12
3
5
4

Kunststoffschweißtechnik
Description of Product Chapter 1
23.06.15 Working Instructions WIDOS 4400 Page 8 of 44
Environmental conditions at the
welding area:
- Keep the workshop clean (no dust at the welding
area)
- If secured by an appropriate measurement that
allowed conditions for welding are indicated, it is
possible to work in any outside temperature
condition as far as the welder is not constrained in its
manual skill.
- Avoid humidity, if necessary use a welding tent
- Avoid strong sun rays influence
- Protect from wind, shut the pipe ends.
1.5.1.2. Heating element
Power: 800 Watt
Voltage: 230 V (r10 %)
Current: 3,5 A (r10 %)
Frequency: 50 Hz
Outside-: 200 mm
Surface: Nonstick-coated
Attached elements: - Electronic temperature control
- On / off switch red illuminated
- Control lamp green
- Connecting cable and plug
Weight: appr. 3,5 kg
1.5.1.3. Planer
Motor: Monophase-alternating current-motor
Power: 950 Watt
Voltage: 230 V (r10 %)
Current: 4,1 A
Frequency: 50 Hz (r10 %)
RPM n of planer: 100 rpm
Attached elements: - Switch on/off with fixing device
- Connecting cable and plug
Weight: appr. 7,5 kg

Kunststoffschweißtechnik
Description of Product Chapter 1
23.06.15 Working Instructions WIDOS 4400 Page 9 of 44
1.5.1.4. Hydraulic aggregate
Power: 0,315 kW
Voltage: 230 V (r10 %)
Current: 1,5 A
Frequency: 50 Hz
Phase shift: appr. 18°
Hydraulic fluid tank: appr. 1 L
System of protection: IP 54
Electro motor and pump:
Rotation speed: 1380 rpm
Max. working pressure of pump: appr. 120 bar
Working pressure: 100 bar
Volume velocity: 1,0 L/min
Weight: 23 kg
1.5.1.5. Basic frame
Dimension (l x w x h): 600 x 320 x 300 (mm)
Reductions insert: Dimension upon request
Material of frame: Construction steel
Material of reduction inserts: Aluminium
Weight: 25 kg
of cylinder: 28 mm
of piston rod: 25 mm
Length of stroke of cylinder: 100 mm
max. force (F=P*A): 2500 N (at 100 bar)
Velocity of piston rod: 6,7 cm/s
1.5.1.6. Reception box
Weight: appr. 4,0 kg
For article numbers and component parts see spare parts list
1.6. Equipment and accessories:
The following accessories are part of the first delivery:
1 Tool bag for 10 parts
1 Socket spanner size 24
1 Torx srew driver T10
1 each Allen key angulate size 3 / 5 / 6
1 each Allen key with T grip size 3 / 4
option Reduction inserts (large, extra large), roller brackets for the pipes, transformer

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0) 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40
website: www.widos.de email: [email protected]
23.06.15 Working Instructions WIDOS 4400 Page 10 of 44
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of
the basic safety indications and rules.
The security notices of this chapter represent the general part.
Particular indications are listed directly at the description of the corresponding actions.
xThese working instructions provide you with the most important information to run the
machine safely.
xThe safety indications must be read by all persons working on the machine.
2.1. Explanation of the symbols and indications
In the working instructions, following denominations and signs are used for dangers:
This symbol means a possibly danger for the life and the health of persons.
xThe disrespect of these indications may have heavy consequences for the
health.
This symbol means a possible dangerous situation.
xThe disrespect of these indications may cause slight injuries or damages on
goods.
This symbol means a possible dangerous situation by moving parts of the
machine
xThe disrespect of these indications may cause heavy crushings of parts of
the body resp. damages of parts of the machine.
This symbol means a possible dangerous situation due to hot surfaces.
xThe disrespect of these indications may conduct to heavy burns,
respectively to self-ignition or even fire.
This symbol means a possible risk of injury by noises exceeding 80 dB (A).
xEar protection is obligatory
This symbol gives important indications for the proper use of the machine.
xThe disrespect of these indications may conduct to malfunctions and
damages on the machine or on goods in the surrounding.
Under this symbol you get user tips and particularly useful information.
xIt is a help for using all the functions on your machine in an optimal way and
helps you to make the job easier.
T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) .

Kunststoffschweißtechnik
Safety Rules Chapter 2
23.06.15 Working Instructions WIDOS 4400 Page 11 of 44
2.2. Obligations of the owner
The owner is obliged only to let persons work at the machine, who
xknow about basic safety and accident prevention rules and are instructed in the handling of
the machine, as well as who
xhave read and understood the safety chapter of this manual and certify this with their
signature.
The safety-conscious working of the staff has to be checked in regular intervals.
2.3. Obligations of the worker
All persons who are to work at the machine are obliged before working:
xto follow the basic safety and accident protection rules.
xto have read and understood the safety chapter and the warnings in this manual and to
confirm by their signature that they have well understood them.
xto inform themselves about the functions of the machine before using it.
2.4. Measures of organisation
xAll equipment required for personal safety is to be provided by the owner.
xAll available safety equipment is to be inspected regularly.
2.5. Information about safety precautions
xThe working instructions have to be permanently kept at the place of use of the machine.
They are to be at the operator‘s disposal at any time and without effort.
xIn addition to the manual, the common valid and the local accident protection rules and
regulations for the environmental protection must be available and followed.
xAll safety and danger indications on the machine have to be in a clear readable condition.
xEvery time the machine changes hands or is being rented to third persons, the working
instructions are to be sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
xOnly skilled and trained persons are allowed to work at the machine.
xIt must be clearly defined who is responsible for transport, mounting and dismounting,
starting the operation, setting and tooling, operation, maintenance and inspection,
repair and dismounting.
xA person who is being trained may only work at the machine under supervision of an
experienced person.

Kunststoffschweißtechnik
Safety Rules Chapter 2
23.06.15 Working Instructions WIDOS 4400 Page 12 of 44
2.7. Dangers while handling the machine
The machine WIDOS 4400 is constructed according to the latest technical standard and the
acknowledged technical safety rules. However, dangers for the operator or other persons
standing nearby may occur. Also damages to the machine itself or to other things are possible.
The machine may only be used:
xaccording to the purpose-oriented usage
xin safety technical impeccable status
Disturbances, which may affect the safety of the machine must be eliminated immediately.
2.8. Danger caused by electric energy
Only skilled persons are allowed to work at electrical appliances !
xThe electrical equipment of the machine has to be checked regularly.
xLoose connections and damaged cables have to be replaced immediately.
xIf works at alive parts are necessary, a second person has to assist who can disconnect the
machine from the mains if necessary.
xAll electric tools (heating element, planer and aggregate) have to be protected from rain
and dropping water (if need be use a welding tent).
xAccording to VDE 0100, the use on construction sites is only allowed with a power
distributor with a FI-safety switch.
2.9. Dangers caused by the hydraulic aggregate
System parts and pressure hoses should be made pressureless before beginning
of any repair works. Even if the machine is switched off, pressure may be in the
hydraulic accumulator!
There is a danger of injuring the eyes by hydraulic oil squirting out.
xDamaged hydraulic hoses have to be immediately replaced.
xMake a visual inspection of the hydraulic hoses before each work beginning.
xThe hydraulic oil is inedible !

Kunststoffschweißtechnik
Safety Rules Chapter 2
23.06.15 Working Instructions WIDOS 4400 Page 13 of 44
2.10. Specific dangers
2.10.1. Danger of catching clothes by the planer
You can cut yourself or even get bones broken!
xOnly wear clothes tight to the body.
xDo not wear rings or jewellery during the work.
xIf necessary, wear a hair-net.
xAlways put the planer back into the reception box after and before each use.
xTransport the planer at the handle only.
xDo not touch the planer surfaces.
xSwitch the planer on only for usage. Otherwise the planer will start every time when the
security microswitch is pressed.
2.10.2. Risk of injury by noises
Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!
2.10.3. Danger of being burnt by heating element, reception box and
welding area
You can burn yourself, inflammable materials can be ignited!
The heating element temperature gets over 200 °C / 392 °F!
xDo not touch the surface of the heating element.
xDo not leave the heating element unsupervised.
xTake enough safety distance to inflammable materials.
xDo wear safety gloves.
xAlways put the heating element back into the reception box after and before each use.
xTransport the heating element at the holder only.
2.10.4. Danger of stumbling over hydraulic and electric wires
xMake sure that no person has to step over the wires.
xLay the wires in such a way that the danger is kept to a minimum.
2.10.5. Danger of squeezing by clamping devices and guideways
There is a danger of serious injuries:
on the one hand between the inner clamping devices and on the other hand
between the outside clamping device and the end of the guideway.
xDo not stand or put hands between clamped pipe ends.
xDo not stand or put hands between the inner clamping tools with not yet clamped pipes.
xDo not block opening and closing of the machine slides.

Kunststoffschweißtechnik
Safety Rules Chapter 2
23.06.15 Working Instructions WIDOS 4400 Page 14 of 44
2.11. Structural modifications on the machine
xNo modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer.
xMachine parts which are not in a perfect condition are to be replaced immediately.
xOnly use original WIDOS spare and wear parts.
xIn case of purchase orders please always state the machine number.
2.12. Cleaning the machine
The used materials and tissues are to be handled disposed of properly, especially
xwhen cleaning with solvents
xwhen lubricating with oil and grease
2.13. Warranty and liability
Our „General Sales and Delivery Conditions“ are principally valid.
They are at the owner's disposal at the latest when signing the contract.
Warranty and liability demands referring to damages of persons or objects are suspended if
they are caused by one or several of the following reasons:
xnot using the machine according to the prescriptions
ximproper transport, building-up, starting and operating the machine and maintenance
xoperating the machine with defective or improperly installed security measures
xignoring the information given in this manual
xstructural changes at the machine without permission
xunsatisfactory checking of machine parts which are worn out
xrepairs performed in an inexpert way
xcatastrophes by external influence and Acts of God.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0) 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40
website: www.widos.de email: [email protected]
23.06.15 Working Instructions WIDOS 4400 Page 15 of 44
3. Functional description
B a s i c a l l y t h e i n t e r n a t i o n a l a n d n a t i o n a l s t a n d a r d s p e c i f i c a t i o n s a r e
t o b e f o l l o w e d .
The plastic pipes are clamped in the clamping devices. Then the front sides of the pipes are
cut plane and parallel by means of the planer and the misalignment of the pipes is checked.
The cleaned and heated heating element is inserted and the pipes are pressed against the
heating element under defined adjusting pressure. This process is called "adjusting".
After the prescribed bead height being reached, pressure is reduced, the heating time begins.
The function of this time is to heat up the pipe ends.
After expiration of the heating time, the slides are opened, the heating element is removed
quickly and the pipes are driven together again. The time gap from the removal of the heating
element to joining the pipes is called change over time.
The pipes are joined under prescribed welding pressure and then cool down under pressure
(cooling time).
The welded joint can be unclamped, the welding process is finished.
Heating element heats the pipes
u
p
to weldin
g
tem
p
erature
Finished welding with
internal and external bead

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0) 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40
website: www.widos.de email: [email protected]
23.06.15 Working Instructions WIDOS 4400 Page 16 of 44
4. Operating and indicating elements
4.1. Elements on the aggregate
No. Denomination Function
6 Manometer, digital Display of the hydraulic pressure
7 Valve lever Opening the slides. There are 4 different positions:
- to the left side: slides close.
- in the middle (usual position): the pressure which is
currently achieved is kept (also by means of the built-in
hydraulic accumulator)
- slightly to the right side (position pressureless): a
possibly existing pressure is released without moving the
slides. Due to the hydraulic accumulator, it takes about
10 s until the pressure is completely released.
- to the right side: slides open
8 Setting screw for
pressure relief valve
- Limitation of the pressure to the desired value
9 Hydraulic connection for
closing the slides
- Non-dropping quick-acting coupling
10 Hydraulic connection for
opening the slides
- Non-dropping quick-acting coupling
11 Screw with oil dipstick - checking the oil level
- oil filler neck
6
7
9
10
8
11
Label „opening/
closing“
Indicating label
„Setting the pressure
relief valve“

Kunststoffschweißtechnik
Operating and Indicating Elements Chapter 4
23.06.15 Working Instructions WIDOS 4400 Page 17 of 44
4.1.1. Hydraulic aggregat with pressure gauge analog
4.2. Elements on the side of the aggregate
No. Denomination Function
12 Socket 230V/50 Hz Possibility for connecting the planer / heating element
13 Socket 230V/50 Hz Possibility for connecting the planer / heating element
14 Mains cable 230V/50Hz Power supply
12
13
14
(11)
(8)
(10)
(9)
(7)
Pressure gauge
analog (version)

Kunststoffschweißtechnik
Operating and Indicating Elements Chapter 4
23.06.15 Working Instructions WIDOS 4400 Page 18 of 44
4.3. Elements at planer and heating element
No. Denomination Function
15 On/off switch - For switching on/off the planer.
- Planing is only possible if the security micro
switch is pressed
16 Security micro switch - Protection against unintended running of
the planer
17 Locking lever - Protection of the planer against jumping out of the
machine.
18 On/off switch with lamp - As soon as the heating element is switched on,
the red control lamp lightens
19 Setting screw - For regulating the temperature of the heating
element
18 Control lamp green - There are three different states:
xoff: signalizes that the heating element is not
heated up at the moment or that it cools down
xblinking: the heating element temperature is
maintained by a certain pulse-position ratio
xon: signalizes that the heating element is heated
up at the moment. It has not yet reached the desired
temperature
15
16
20
18
19
17

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0) 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40
website: www.widos.de email: [e-mail]
23.06.15 Working Instructions WIDOS 4400 Page 19 of 44
5. Starting and operating
The instructions of this chapter are supposed to initiate in the operation of the machine and to
lead during the approppriate starting of the machine.
This includes:
xthe safe operation of the machine
xusing all the possibilities
xrunning the machine economically
5.1. Starting
The machine may only be operated by initiated and authorized persons.
For the qualification, a plastic welding exam can be taken according to DVS and
DVGW.
In situations of danger for persons and the machine, the mains plug has to be
unplugged immediately.
In case of power failure, there may still be pressure in the hydraulic system. For
this reason, release pressure if need be.
After completion of the welding work and during breaks the machine has to be
switched off. Further take care that no unauthorized person has access.
Protect the machine from wetness and humidity !
According to VDE 0100, the use on construction sites is only allowed with a
power distributor with a FI-security protective switch.
Check the oil level of the hydraulic system before each starting of the control unit
in order to avoid damages on the pump. The oil-level must be between the two
marks at the oil dipstick.
xConnect the hydraulic aggregate to the mains (230 V / 50 Hz).
xConnect heating element and planer to the corresponding socket at the aggregate.
xPush the hydraulic hoses of the basic machine into the quick-acting couplings of the
hydraulic aggregate.
Lay hydraulic and electric lines carefully (danger of stumbling) !
xTake into account the surrounding conditions:
xThe welding may not be performed under direct sun rays influence,
xIf necessary use a welding umbrella.
xIf the surrounding temperature is under 5 °C / 41 °F, measures have to be taken:
xUse a welding tent or preheat the pipe ends if necessary.
xIn addition, take measures against rain, wind and dust.

Kunststoffschweißtechnik
Starting and Operating Chapter 5
23.06.15 Working Instructions WIDOS 4400 Page 20 of 44
5.1.1. Replacing the reduction inserts
xUnscrew the mounted reduction inserts by means of the provided Allan key.
xScrew the reduction inserts with the corresponding diameter into the clamping devices.
xIf necessary (e.g. for T-pieces) the outer fixed clamping device can be dismantled by
unscrewing the three hexagon socket screws.
Dismantling of the outer fixed clamping device
5.1.2. Using small and large reduction inserts
Small reduction inserts:
xPipe fittings often have only a short straight surface area on which they can be clamped.
xFittings mostly need to be clamped in the inner clamping devices with the small reduction
inserts.
xWhen fittings are to be welded (bends, T-pieces etc.), the inner small reduction insert can
also be used flush to the inside or to the outside.
Small reduction insert,
centered (for pipes)
Shown here:
Small reduction insert,
flush to the inside
(for bends, T-pieces)