Flexco XP Safety, Operation And Maintenance Manual
Hydraulic Flexco® XP™ Staple Fastener
Installation System
Safety, Operation, and Maintenance Manual
h I Mb
WARNING
Improper use of this tool can result in serious bodily injury! is manual contains important information about
product function and safety. Please read and understand this manual BEFORE operating the tool. Please keep this
manual available for other users and owners before they use the tool. is manual should be stored in a safe place.
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Hydraulic Flexco® XP™ Staple Fastener System
Table of Contents
Introduction .................................................................................................................................... 3
Tool Specications ..........................................................................................................................3
System Components .................................................................................................................. 4-6
General Safety Rules ................................................................................................................... 7-9
Operational Instructions .............................................................................................................10
Belt Preparation ............................................................................................................................11
Installation Instructions ........................................................................................................11-17
Troubleshooting Guide ................................................................................................................ 18
Power Diagram .............................................................................................................................19
CE Declaration ..............................................................................................................................20
Limited Warranty
Flexco warrants to the original purchaser that this product is free from defects in material and workmanship, and
agrees to repair or replace, at Flexco’s option, any defective product within 1 year from the date of purchase. is
warranty is not transferable. It only covers damage resulting from defects in material or workmanship, and it does not
cover conditions or malfunctions resulting from normal wear, neglect, abuse, accident or repairs attempted or made by
other than our regional repair center or authorized warranty service center.
To obtain warranty service, return the product at your expense together with proof of purchase to Flexco or a Flexco
authorized distributor.
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Hydraulic Flexco® XP™ Staple Fastener System
Introduction
Role of Applicator
e Hydraulic Staple Applicator is designed to be used with Flexco® XP Staple Fasteners.
Precision Built
Flexco tools are precision-built tools designed for precise, high volume installation. ese tools will deliver ecient, dependable
service when used correctly and with care. As with any ne power tool, for best performance, the manufacturer’s instructions must
be followed. Please study this manual before operating the tool and understand the safety warnings and cautions. e instructions
on installation, operation, and maintenance should be read carefully, and the manual kept for reference.
Flexco® XP™ Hydraulic Staple Applicator
Specifications
Overall weight 26 kg
Overall dimensions 559 mm x 482 mm
Operating pressure 110 bar, 11 Mpa, 1600 psi
Min. pressure 103 bar, 10.3 Mpa, 1500 psi
Max. pressure 117 bar, 11.7 Mpa, 1700 psi
Flow rate 7-9 L/m, 1.5-2 GPM
Hydraulic fluid MSHA approved fire resistant hydraulic fluid, MA approved #46 or equivalent (not included)
Coupling ISO 16028 compliant couplings, flat face quick release coupling
High pressure in: Female 3⁄8” body size
Low pressure return: Male ½” body size
Max. hose length
(hoses included with
Flexco power source
purchase)
10 meters, 32.8 feet
High pressure hose (smaller hose OD), each end has factory installed male and female 3/8” body size
couplings
Low pressure return hose (larger hose OD), each end has factory installed male and female 1/2” body size
couplings
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Hydraulic Flexco® XP™ Staple Fastener System
System Components
Flexco® XP™ Hydraulic Staple Applicator
1. Advance/actuation handle 6. Advance mechanism lever
2. Carrying handle 7. Hydraulic cylinder
3. Fastener compression adjustment knob and lock 8. High pressure in: 3/8” Female quick release coupling
4. Integrated belt thickness gauge 9. Low pressure return: 1/2” Male quick release coupling
5. Mounting bracket 10. Standalone belt thickness gauge
1
3
2
7
9
4
5
6
8
10
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Hydraulic Flexco® XP™ Staple Fastener System
System Components
Flexco® XP™ Staple Tool Frame
1. Frame 4. Clamp bar
2. Belt guide plate 5. Bed
3. Clamp bar handle 6. Hydraulic staple applicator
6
4
3
5
2
1
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Hydraulic Flexco® XP™ Staple Fastener System
System Components
Flexco® XP™ Staple Fasteners
1. Fastener Strips
2. Hinge Pin
2
1
Protective Equipment
1. Safety Glasses
2. Gloves
3. Hearing Protection
4. Safety Shoes
Power Source
Immediate Need Power Pack
– For mobility throughout the mine
– OR –
1 2
3 4
Power Take-off Unit (PTO)
– For diverting hydraulic power from your conveyor at the mine
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Hydraulic Flexco® XP™ Staple Fastener System
General Safety Rules – Save These Instructions
Signal words
“DANGER” indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury. e signal word is
limited to the most extreme situations.
“WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
“CAUTION” indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used to
alert against unsafe practices.
International Safety Symbol
!
is international safety symbol is used
to identify and call attention to specic
safetymatters.
Safety Information
To Avoid Severe Personal Injury or Property
Damage, read carefully and understand the
following Safety Precautions.
2. PERSONAL PROTECTIVE EQUIPMENT
!
WARNING
EYE PROTECTION which conforms to ANSI specications and provides protection against ying particles
both from the FRONT and SIDE should ALWAYS be
worn by the operator and others in the work area. Eye
protection is required to guard against ying debris,
which could cause severe eye injury.
e employer and/or user must ensure that proper
eye protection is worn. Eye protection equipment
must conform to the requirements of the Ameri- can
National Standards Institute, ANSI Z87.1 and provide
both frontal and side protection. NOTE: Non-side
shielded spectacles and face shields alone do not provide
adequate protection.
!
CAUTION
HEARING PROTECTION will be required in some
environments. For example, the working area may
include exposure to noise level which can lead to
hearing damage. e employer and user must ensure
that any necessary hearing protection is provided and
used by the operator and others in the work area.
!
CAUTION
HEAD PROTECTION – Some environments will
require the use of head protection equipment. When
required, the employer and user must ensure that
head protection conforming to ANSI Z89.1 is issued.
FOOT PROTECTION – Safety footwear should
always be worn. Operators must be protected against
falling tools and slippery conditions.
HAND PROTECTION – Safety gloves should always
be worn against hot surfaces and other sharp objects.
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Hydraulic Flexco® XP™ Staple Fastener System
General Safety Rules
3. PERSONAL SAFETY
!
WARNING
Do not use in explosive environments as this may result in serious personal injury.
Always handle the tool with care: 1.) Never engage in horseplay; 2.) Never pull the advance/actuation handle unless the
applicator is loaded onto the bed/frame base; 3.) Keep others a safe distance from the tool while tool is in operation as
accidental actuation may occur, possibly causing injury; 4.) Never place a hand or any part of body in the downward path of
the head applicator.
Potential Pinch Points
1. Adjustment Knob & Tool Cover
2. Tool Head & Clamp Bar
Potential Hot Surfaces
Do not operate the equipment if you are:
1.) Taking medication, feeling drowsy, feeling unwell or feeling tired; 2.) Under the inuence of drugs or alcohol; 3.) Experiencing
pain in hands, feet, lower back, or other parts of your body hurt or are injured. Failure to observe this precaution can result
serious injury or even death.
3. Tool Head & Bed (Fastener)
4. Hydraulic Tool & Frame
1
2
3
4
5
5. Clamp Bar & Bed (Belting)
6. Tool Advance & Cover Plate
6
!
CAUTION
Do not touch the machine with your bare hands: 1.) e oil tank may become hot under continuous running; 2.) Tools may
become hot under continuous use, make sure to wear safety gloves before any contact with the tools. Failure to observe this
precaution can result in burn injuries.
When lending someone the equipment, make sure the safety instructions have been thoroughly read and fully understood by
the person who is going to use the equipment.
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