Uniflex HM 200, HM 200 Ecoline, HM 200 Ecoline DC, HM 260, HM 250 Operating Manual

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OPERATING MANUAL

- HM 200

- HM 200 Ecoline

- HM 200 Ecoline DC

- HM 250

- HM 260

Technical Details subject to change EN

Copying and distributing this document and the use or communication of the contents thereof are forbidden without expressed authority. Offenders are liable to the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design.

CE-Declaration of Conformity

within the meaning of Directive Machines 2006/42/EC. The following machine

HM 200 / HM 200 Ecoline / HM 200 Ecoline DC HM 250 HM 260

was developed, designed and manufactured in accordance with Directive 2006/42/EC under the sole responsibility of

Company

UNIFLEX - Hydraulik GmbH Robert-Bosch-Straße 50 - 52 D - 61184 Karben

Documentation officer Carsten Baumgartner

The following standards, directives and specifications were applied:

• EG-Richtlinie 2006/42/EG - Directive 2006/42/EEC

• EG-Richtlinie 2014/35/EU - Directive 2014/35/EEC

• EMV Richtlinie 2014/30/EU - EMC Directive 2014/30/EEC

• EN ISO 12100: 2010

• EN 60204: 2006 If the machine is changed in any way without consulting us beforehand or if any non-tested and non-accepted

outside parts are used, this declaration shall lose its validity. Complete technical documentation is available. This Operating Manual of the machine is a translation; the original version is in German.

Karben

---------------------------------- -------------------------------------- ---------------------- ----------------

21. Juni 2016

Place, Date Signature Function of the signee

Geschäftsführer / /

Gérant /

UNIFLEX-Hydraulik - 2 - www.uniflex.de

CE-Declaration of Conformity ................................................................................................................................................ 2

Chapter 1 Introduction ............................................................................................................................................. 5

General information regarding the operating instructions .............................................................................................. 5

Safety and accident prevention ...................................................................................................................................... 5

Pictograms ..................................................................................................................................................................... 5

Chapter 2 Security .................................................................................................................................................. 6

Safety ................................................................................................................................................................................. 6

Safety information provided in the Operating manual .................................................................................................... 6

Obligations of the owner ................................................................................................................................................ 6

Obligations of the personnel .......................................................................................................................................... 6

Hazards when operating the machine ............................................................................................................................ 6

Usage to the intended purpose ...................................................................................................................................... 7

Warranty and liability ...................................................................................................................................................... 7

Informal Security Measures ........................................................................................................................................... 7

Training of the personnel ............................................................................................................................................... 7

Control of the hose crimper ............................................................................................................................................ 7

Safety measures for normal operation ........................................................................................................................... 7

Hazards caused by electrical energy ............................................................................................................................. 7

Dangers of hydraulic oil .................................................................................................................................................. 7

Maintenance and servicing, trouble-shooting ................................................................................................................. 7

Constructional modifications of the machine .................................................................................................................. 8

Cleaning the machine and waste disposal ..................................................................................................................... 8

Safety installations ......................................................................................................................................................... 9

Emergency switch (if applicable) ................................................................................................................................ 9

Security installations ...................................................................................................................................................... 9

Safety-switch back stop (if applicable) ........................................................................................................................... 9

Path limitation ................................................................................................................................................................. 9

Hazards and safety measures ....................................................................................................................................... 9

Personal safety .............................................................................................................................................................. 9

Chapter 3 Description of the system ........................................................................................................................ 10

Design .............................................................................................................................................................................. 10

Technical Details HM 200 Ecoline, HM 200 Ecoline DC, HM 200, HM 250, HM 260 .................................................. 11

Chapter 4 Commissioning ..................................................................................................................................... 12

Unpacking / set up ....................................................................................................................................................... 12

Hydraulic Power Unit – Only ECOLINE DC: ................................................................................................................ 13

Filling with hydraulic oil ................................................................................................................................................ 13

Ventilate the Hydraulic System .................................................................................................................................... 13

Connecting the electric supply ..................................................................................................................................... 14

HM200Ecoline Connecting the electric supply ............................................................................................................. 15

Connecting the electric supply (Ecoline DC only) ........................................................................................................ 16

Chapter 5 Crimping .............................................................................................................................................. 17

Quick die change QDC 239.5 .......................................................................................................................................... 17

Insert the crimp dies 239 / 239L in the machine .......................................................................................................... 17

Take the crimp dies 239 / 239L out of the machine ..................................................................................................... 17

Set the crimp diameter / Crimp die table PB 239 ......................................................................................................... 18

General Notes for Crimping ......................................................................................................................................... 19

Control of the hose crimper .......................................................................................................................................... 19

Chapter 6 Maintenance ......................................................................................................................................... 20

Daily Maintenance works ............................................................................................................................................. 20

Monthly maintenance ................................................................................................................................................... 20

Six-month maintenance ............................................................................................................................................... 20

Annual maintenance .................................................................................................................................................... 20

Calibrate the crimp micrometer .................................................................................................................................... 21

Exchange Slide Bearings ............................................................................................................................................. 22

UNIFLEX-Hydraulik - 3 - www.uniflex.de

_ Anhang / Appendix / Apéndice / Appendice ....................................................................................................... 23

Ersatzteilliste / Spare Parts List / Pièces détachées / Lista de piezas de recambio ........................................................ 23

Haltebolzen für Standard Pressbacken / Pins for standard dies / Tourillon de mors standard / Gorrón de mordza

estándar ........................................................................................................................................................................... 30

Wo Sie Ersatzteile bestellen können / Where to obtain spare parts / .............................................................................. 31

Adresse pour nous contacter / La dirección para encargar piezas de recambio: ............................................................ 31

HM 200 Ecoline ............................................................................................................................................................ 32

Elektro- & Hydraulikplan / Electric & Hydraulic Circult Diagram ................................................................................... 32

HM 200 Ecoline ............................................................................................................................................................ 33

Elektroplan für Unteröl-Aggregat PUU 45L 3.0_04/ Electric Circuit Diagram for Aggregate under oil PUU 45L 3.0_04

(440V-60Hz-3~) ........................................................................................................................................................... 33

HM 200 ......................................................................................................................................................................... 34

Elektroplan (Steuerteil) / Electric Circuit Diagram (Control Part) ................................................................................. 34

HM 200 ......................................................................................................................................................................... 35

Elektroplan (Leistungsteil) / Electric Circuit Diagram (Power Section) ......................................................................... 35

HM 250 / HM 260 ......................................................................................................................................................... 36

Elektroplan / Electronic Circuit Diagram (480V 50/60Hz 3P) ....................................................................................... 36

HM 250 / HM 260 ......................................................................................................................................................... 37

Elektroplan / Electric Circuit Diagram (220/239V 50/60Hz 3Ph) ................................................................................. 37

HM 200 / HM 250 / HM 260 ......................................................................................................................................... 38

Hydraulikplan / Hydraulic Diagram ............................................................................................................................... 38

HM 200 / HM 250 / HM 260 ......................................................................................................................................... 39

Wartungsbuch / Maintenance book / Carnet d’entretien / Libro de mantenimiento / Libretto die manutenzione /

Onderhoud boek .......................................................................................................................................................... 40

Erklärung des geschulten Personals / Declaration of Trained Personnel .................................................................... 41

Gültig seit: 21.06.16 Änderungszustand: t Erstellt: Jarrasch Genehmigt



UNIFLEX-Hydraulik - 4 - www.uniflex.de

Chapter 1 Introduction

General information regarding the operating instructions

This operating manual forms part of the scope of delivery of your UNIFLEX machine and it is intended for the user and maintenance / service staff.

The manual describes how the hose crimper works, provides information on hazards that may arise during its operation, contains detailed information on how to operate the machine, and describes the steps necessary for servicing and checking the accuracy of the hose crimper. Even if you have attended a training course for op erating this machine, please read these operating instructions completely before starting up the machine.

By signing your name on the last page >Appendix<, you confirm that you have read completely and understood this Operating Manual. The owner of the machine shall be obliged to only let such persons operate and ca rry out maintenance work on the hose crimper, who satisfy the above-mentioned prerequisite.

Safety and accident prevention

This hose crimper is a state-of-the-art machine and it is safe to use. Nonethel ess, certain rules have to be observed to minimize the risk of injuries and protect the machine. Please pay particular attention to Chapter 2 >Safety< in these operating instructions.

Pictograms

This pictogram indicates texts providing useful information on the application of the machine and how it can be handled and used op timally.

This symbol points out cri tical poin ts, which can lead to damage of the machine , incorrect functioning, or faulty produc tion.

This symbol points out hazards to life and health as well as risks of injuries.

This symbol refers to haza rds aris ing during the crimping process.

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Chapter 2 Security

Safety

Attention: Serious accidents may occur if the mac hine is handled inco rrectly.

Safety information provided in the Operating manual

All rules and regulations regarding the prevention of accidents, which are applicable at the place of use, h ave to be observed.

Obligations of the owner

The owner undertakes to only let such persons work on the machine who are familiar with the basic regulations on work safety and accident prevention, have been instructed in the operation of the hose press, and have read and understood the operating manual. The owner shall check at regular intervals whether the personnel is ope rating the machine according to the safety regulations.

Obligations of the personnel

All persons authorized to work with this Uniflex machine are obliged to observe the basic regulations on work safety and accident prevention and read the operating manual.

Hazards when operating the machine

This machine has been constructed according to state-of-the-art engineering and acknowledged safety regulations. Nonetheless, dangers can arise for the operator and third persons. Additionally the machine and/or other property can be damaged during incorrect operation. The machine may therefore only be used:

 for its proper purpose and intended use,  when it is in perfect and safe working order.  Any faults have to be remedied immediately.

Compliance with all existing safety guidelines is mandatory for the safe operating of the hydraulic press. Necessary slits for inserting the workpiece must be minimized by limiting the opening strok e.

Due to the diversity of changing, customized workpieces it is not possible for Uniflex Hydraulik to include additional safety devices in the machine’s delivery that could avert any remaining dangers resulting from the machine.

The operator must check the necessity for additional safety devices, tailored to the workpiece, before putting the machine into operation. This may for example, become necessary for angled workpiece geometries that require a large opening of the press for insertion.

If additional safety devices become necessary, they must be installed prior to commissioning to ensure the continuous safety of the operator.

We particularly point out that the machine may only be used for its intended purpose. Especially non-metal workpieces can, by the pressing procedure, be stressed in such a manner that this may lead to a sudden failure of the material. Chips or strongly accelerated workpiece parts also present a high potential risk of danger for the operator and persons and objects even beyond the work area.

On request Uniflex Hydraulik can provide individual solutions for safety devices. For a consultati on please contact your personal contact partner.

UNIFLEX-Hydraulik - 6 - www.uniflex.de

Usage to the intended purpo se

This UNIFLEX machine is designed only for crimping hose assemblies. Any other usage or any usage exceeding the tasks described above shall not be considered usage to the intended purpose. Operating the machine in a potentially explosive atmosphere is prohibited. The object to be pressure-joined must be positioned in the tool centre in order to achieve good conicity and a long machine lifetime.

Usage to the intended purpose also includes the observance of all information and instructions provided in the operating manual and the timely execution of the inspection and maintenance work.

Note: Other types of application are only permissible fol lowing prior co nsultation wi th the manufactu rer!

Warranty and liability

As a rule our "General Terms and Conditions of Sale and Delivery" shall apply. These are available to the buyer on demand. Warranty and liability claims for injuries to persons and/or damage to property shall be excluded if such claims can be attributed to one or several of the causes listed below:

 Use of the machine not to the intended purpose.  Improper assembly, start up, operation and/or maintenance/repair of the machine.  Operation of the machine without the protective coverings being mounted correctly.  Non-observance of the information concerning the transport, storage, assembly, start up, operation and

maintenance of the machine provided in the operating manual.

 Unauthorized constructional changes on the machine.  Unauthorized modification of programs that affect the control of the machine.  Inadequate inspection of wearing parts.  Incorrectly performed repair work.  Emergencies due to external causes and/or force majeure.  Improper work on automatic-program P3 with the pedal switch or back stop (if applicable)

Informal Security Measures

The operating manual needs to be at the location of the machine at all times. Additionally to the operating manual the local regulations for accident prevention and environmental protection need to be available and they need to be observed. All safety notes and danger indication need to be kept in legible condition.

Training of the personnel

Only adequately trained and instructed personnel should be authorized to work on the machine. The responsibilities of the personnel as to the assembly, start up, operation, maintenance and repair of the machine should be clearly defined. Personnel undergoing training should only work at the machine und er the supervision of an experienced person.

Control of the hose crimp er

Warning: Under no circumstances may the control system be modified in any way!

Safety measures for normal operation

The machine must only be operated when all protective coverings have been mounted correctly. Prior to switching on the machine it must be certain that no one can be injured or endangered by the working machine. Inspect the outside of the machine at least once during every shift to check for any damages.

Hazards caused by electrical energy

Only qualified electricians should carry out work on the electric power supply. The electrical components of the machine need to be checked at regular intervals. Any loose connections and damaged cables should b e repaired immediately. The housing must always be kept closed and access should only be permitted to authorized personnel.

If works are needed on any electrical components of the machine, a second person must take part to activate the main switch in case of an emergency.

Dangers of hydraulic oil

Be sure to prevent any hydraulic oil from seeping into the ground, water and/or sewage system. Hydraulic oil is not water soluble and hardly biologically degradable. Therefore hydraulic oil is water polluting according to the German Water Resources Management Law (WHG, WHG 1). Avoid long and intensive skin contact.

Maintenance and servicing, trouble-shooting

Carry out prescribed maintenance work in time. Inform the operating personnel before you begin with the maintenance and servicing work. Always make sure that the machine is off circuit when any maintenance,

UNIFLEX-Hydraulik - 7 - www.uniflex.de

inspection or repair work is to be carried out and that the main switch cannot be switched on unexpectedly (i.e. by securing it accordingly). Put up a warning sign prohibiting any third persons from starting up the machine. Mount all protective and safety guards again as soon as the maintenance work has been completed and check that all screwed connections are fastened.

Constructional modifications of the mach ine

The machine may not be modified and no parts may be built on or modified without the manufacturer’s approval. Any modifications need to be confirmed in writing by UNIFLEX-Hydraulik GmbH. Any parts that are not in perfect working order should be replaced immediately. Only original spare parts and wearing parts should be used. It cannot be guaranteed that other parts are designed and manufactured in such a way that they will meet the load and safety requirements.

Cleaning the machine and waste disposal

All substances and materials used have to be handled and disposed of properly, in particular when work with lubricants was carried out. The national regulations on waste disposal have to be observed.

UNIFLEX-Hydraulik - 8 - www.uniflex.de

Safety installations Emergency switch (if applicable)

Note: the emergency switch must be activate d in all situa tions where injuries of people or damage on the machine can arise:

The emergency switch is located on the control board.

Security installations

Before each use of the crimping machine or the system, all safety installations must be fitted and working correctly. Authorized personnel may only remove safety installations:

 After the complete stop of the machine.  After safeguarding against accidental switching on.

In the case of partial delivery of components the provided safety instructions and notes need to be displayed correctly by the user.

Safety-switch back stop (if applicable)

For safety reasons the back stop stops whenever during the crimping process the hose no longer touches the back stop.

Path limitation

Adjust the opening diameter of the crimping tool so that it exceeds the diameter of the hose fitting only fractional. This setting protects the operator from reaching into the crimping area with his or her hand.

Hazards and safety measures Personal safety

Irrespective of the local accident prevention regulations, the following instructions should be observed as a mean s of protecting the health and safety of the maintenance and operating personnel:

 Never reach into the machine with your hands during operation.  Always keep a copy of the operating manual at the place of use of the machine.  Make sure that all safety and danger notices on the machine (if applicable) are always legible.  Only operate the machine when all safety devices are in working order.  Before starting up the hydraulic unit, make sure that the running machine can endanger no one.  Do not place any objects on the floor near the workplace.  Wear working gloves, especially when heavy work pieces have to be loaded.  Do not bring work materials to the machine with a fork lift truck.  Wear safety shoes.

Danger: Never reach into the crimp tool with yo ur hands while the elec tric motor is running ! Always mak e sure that there is an adeq uate safe ty distance of at least 12 0 mm to the crimp tool when you are inserting a hose fitting.

Warning: Switch off the machine using the main switch during all main tenance and setting works!

Danger: When the machine is handled improperly, there is the danger of hands getting caught and crushed!

UNIFLEX-Hydraulik - 9 - www.uniflex.de

Chapter 3 Description of the system

Design

HM 200 Ecoline / HM 200 Ecoline DC

1 Crimp tool 3 Hydraulic-oil tank 2 Control 4 Main Switch

HM 2..

HM 2.. E

Warning: Always keep a safety distance of at least 120 mm to the crimp tool if the machine is switched on.

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Technical Details HM 200 Ecoline, HM 200 Ecoline DC, HM 200, HM 250, HM 260

Technical Details

Crimp Force (kN / Ton)

HM 200 Ecoline /

HM 200 Ecoline DC

1300/130 1300/130 1300/130 650/65

HM 200

HM 250 HM 260

Control Ecoline A-Control Control B plus Control B plus SAE R13 1 piece Fittings* 1 1/2" 1 1/2" 1 1/2" 1" SAE R12 2 piece Fittings * 1 1/4" 1 1/4" 1 1/4" 3/4" SAE R13 2 piece Fittings * 1" 1" 1" 3/4" SAE R15 2 piece Fittings * 1" 1" 1" 3/4" Industrial 2" 2" 2" 2" 90° Elbow* 1 1/2" 1 1/2" 1 1/2" 1 1/2" Maximally permissible Crimp Area (mm)****

Ø Dies (PB)+8 Ø Dies (PB)+8 Ø Dies (PB)+8 Ø Dies (PB)+8

Maximally Ø Dies (mm) 62 62 62 62 Opening Path + 30 mm + 30 mm + 30 mm + 30 mm Opening without dies 100 mm 100 mm 100 mm 100 mm Speed (mm/sec) Close Crimp Open

3,5** 3,5** 5,9**

3,5 3,5 5,9

6 6

10,5 Noise Level (dBA) 62** 69 53 53 Drive 2,2 - 3 kW, 3~** 3 kW 5,5 kW 5,5 kW Duty type S6-40% / S3-30% S6-70% S6-70% S6-70% L x W x H (mm) 420 x 535 x 520 *** 800x530x630 800x530x630 800x530x630 Oil 40 l (4 l DC) 40 l 40 l 40 l Change of oil Annually Annually Annually Annually Weight (kg) ca. 88 ca. 140 ca. 160 ca. 160 QDS 239.3 YES YES YES YES Die System 239 239 239 239 Special Accessories

12/24 Volt

12 Volt = 1,6 kW

24 Volt = 2 kW

- -

1 ~ 2,2 kW YES YES YES * according to the fitting ** according to the power unit *** Measures Tool (Power Unit Ecoline: L:300mm, B: 450mm, H: 560mm, Power Unit Ecoline DC: L:450mm x B:270mm x H:230mm) **** max. Outer diameter of the fitting prior to pressing.

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Chapter 4 Commissioning

Note: The machine may only be commissioned and operated by trained and authorised personnel!

Note: For optimal operation of th e machine th e surrounding temperature has to be between 10°C and 35°C.

Unpacking / set up

The UNIFLEX machine was tested prior to delivery and is delivered ready for operation.

How to prevent damage when unpa cking:

 Carefully remove all packaging.  Check the delivery for completeness using the delivery note.  Remove the four screws in the corners of the fastening.  Use a fork lift truck to lift the hose crimping machine off the palette.

Note: Pay attention to the correct balance! Set the hose crimping machine on a stable and level work bench.

Note: The hose crimper needs to be placed so that it is accessible from all sides for maintenance works. The work bench needs to be able to support the weight.

 Fasten the machine feet to the work bench.

P T P

HM 200 Ecoline Rear view Connections

P Pump Connection

T Connection to oil tank

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Hydraulic Power Unit – Only ECOLINE DC:

For commissioning the HM 200 Ecoline DC an external Hydraulic Power Unit is needed Hydraulik – Power Unit z.B. UNIFLEX Art. Nr. PUF 4L 2.0_90 (12V) Or z.B. UNIFLEX Art. Nr. PUU 45 L 3,0_00 As well as 1 set of hoses z.B. UNIFLEX Art. Nr. SA Ecoline 2xx / 1200

When using other power units the following technical data must be adhered to: Motor power max. 3 KW, Pump delivery rate 9 l /min 280 bar max. pressure.

Warning: For security reasons the HM 200 Ecoline DC is restricted to 280 bar pressure internally.

Connect the plug of the hydraulic power unit as shown on the pictures to the socket in the rear of the machine.

Filling with hydraulic oil

Caution: If the UNIFLEX- crimping machine was ordered without hydraulic oil, it must be filled with the appropriate new, clean and filtered (10µ) hydraulik oil be fore commissioning .

The following oil must be used: HM 200, HM 250, HM 260, HM 200 Ecoline : HM or HV 46 ISO6743 /4 (HLP 46 DIN51524) HM 200 Ecoline DE: HM or HV 68 ISO6743/4 (HLP 68 DIN51524)

Close the oil filler on the tank plate when the correct oil level has been reached.

Ventilate the Hydraulic System

 Switch on the hose crimper.  Open and Close the tool a few times.  The Hydraulic system is ventilated. The machine is now ready for operation.

Attention: Always ventilate when the hydraulic oil is changed.

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Connecting the electric supply

Caution: This work should only be performed by a qualified electrician! Note the marked voltage on the type plate and select the appropriate electric circuit diagra m! Works on live wires are h azardous!

 Switch the main connection of the hose crimper off-circuit and make sure that it cannot be switched on

again.

 Connect the electric connecting cable to the connection of the power supply. For the correct voltage refer

to the type plate

Note: The rotating direction of the electric motor is indicated by an arrow on the motor!

Note: The connecting plug must comply to current loc al electrical regulations !

Checking the rotating direction of the electric motor (only with 3-Phases)

If the motor does not rotate in the direction indicated by the arrow, two phases must be switched as shown:

Attention: The motor will be damaged if it rotates in the wrong direction for some time.

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HM200Ecoline Connecting the e lectric sup ply

 Switch the main connection of the hose crimper off-circuit and make sure that it cannot be switched on

again.

 Connect the electric connecting cable to the connection of the power supply. For the correct voltage

refer to the type plate.

Note: The rotating direction of the electric motor is indicated by an arrow on the motor!

Note: The connecting plug must comply to current loc al electrical regulations !

 Check the rotating direction of the electric motor (only with 3-Phases)

If crimping tool doesn’t drive or drives very slowly, direction of motor is wrong.

 Switch the main connection of the hose crimper off-circuit and make sure that it cannot be switched on

again.

 If the motor does not rotate in the right direction, two phases must be switched as shown:

Attention: The motor will be damaged if it rotates in the wrong direction for some time.

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Connecting the electric supply (Ecoline DC onl y)

+ Positive Pole Connection to the crimp tool (refer to page 9, Pos. 9)

The Hydraulic power unit has to be connected according to the local electric regulations by a professional. The power cable needs to be fitted with a lug on both ends. Corresponding cables are deliverable as Art.No. GK 205A. Square millimeter of connecting cable = 25mm Make sure that the cable is fitted and fastened correctly. A very strong heat development on the connectors may occur otherwise.

 Battery power of the vehicle needs to be at least 88Ah.  The Hydraulic power unit may only be started while the vehicle motor is running.  To disrupt the battery there needs to be a main switch in the working area of the hose crimper!

Warning: The hydraulic power unit is not fit for permanent operation. The maximum on-time is 30 crimp processes per hour.

- Negative Pole

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Chapter 5 Crimping

Quick die change QDC 239.5

Insert the crimp dies 239 / 239L in the machine

If applicable set the crimp micrometer to 0,0 mm. Put the UNIMATIControl B / E in the die changing position.

Hold the QDC 239.5 in the centre of the crimp tool.

Take the crimp dies 239 / 239L out of the machine

Open the crimp tool completely.

Close the crimp tool and make sure that the holding pins slide smoothly in the bore hole in base or intermediate dies and make sure that they lock in.

Insert the eight pins in the front of the crimp dies and turn towards the left. Take the tool and the dies out of the Quick Die Storage.

Take out the QDC 239.5 and check the tight fit of the crimp dies.

To take out the crimp dies do the above in reverse order.

Attention: Holding pins or crimp dies will be damaged if they do not slide in the bore holes of th e base or intermediate dies.

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Set the crimp diameter / Crimp die table PB 239

XX,XX mm

Type of dies 239 Ø mm

6,8 40

9 50 12 50 14 60 16 60 17 60 19 60 20 60 22 60 24 60 26 75 28 75 32 75 36 75 40 75 44 75 47 75 50 75 54 75 57 75 62 75

19,20 mm < XX,XX mm

19,00 mm

XX,XX mm - mm = ZZ,ZZ mm 19,20 mm – 19,00 mm = 0,20 mm

Attention:

Always insert 8 equal crimp dies with equal marking !

And respectively 7 crimp dies and one correspond ing embossing crimp dies!

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General Notes for Crimping

It is important to always crimp centrically, otherwise the result may be conical crimping or increased abrasion. The crimp tool should only be opened far enough to insert or take out the hose easily. Too large opening paths may lead to crushing injuries and time loss.

Check the crimp diameter after the first crimping, if there are differences between real and nominal value, the crimp diameter needs to be adjusted.

Picture 4, Check the crimp diameter

Differences may occur due to springing open of the fitting after the crimping and as a result of hose or fitting tolerances or differing material hardness of the fittings.

Attention: Always insert a full set of equal crimp dies with equal marking and diameter!

Control of the hose crimp er

For operating the UNIMATIControl B-Plus please refer to Operating Manual Control.

HM 200

HM 200 Ecoline

UNIFLEX-Hydraulik - 19 - www.uniflex.de

Chapter 6 Maintenance

Warning: Always switch the machine off on the main switch during any maintenance works!

Note: During the first 4 weeks after the initial o peration check a ll screws and h ydraulic connec tions and fasten if necessary!

Daily Maintenance works

 Open the crimp tool completely.  Switch off the motor and switch off the machine on the main switch.  Clean the crimp tool of crimping scales with some pressurized air.  Check the emergency-off-switch by operating it.  Check the level of oil through the glass.  Check visually for oil leakage.  Check the machine for outer damages or dismounting of parts (e.g. covers)  Check the holding bolts of the crimping dies for damages.

Monthly maintenance

 Check the hydraulic hose assemblies for porosity and leaks.  Check the screwed joints and clamps of the hose assemblies for leaks.

Six-month maintenance

 Check the bearing plates for wear.

Note: Worn bearing plates can lea d to dama ges on the machine or imprec ise crimp values.

 Worn bearing plates need to be exchanged.

Annual maintenance

Note: You need to change the oil after a year.

 Open the crimp tool completely.  Switch off the motor and turn off the machine on the main switch.  Pump the oil out and fill in new, clean and filtered (10 µ) hydraulic oil.

Attention: The user has to ensure that the hose ass emblies are replaced at appropr iate intervals even if there are no obvious safety- related defects in the hose ass emblies. The hyd raulic hoses are high-pressure hoses. When a hose is replaced, care must be taken that the new one is of the same quality. The hose assembly must be replaced a t least within s ix years of the production da te (see marking).

UNIFLEX-Hydraulik - 20 - www.uniflex.de

Calibrate the crimp micrometer

 If you notice a difference of the set crimp diameter on the work piece to the crimp diameter marked on the

crimp die, while the crimp micrometer is in zero-position, it needs to be recalibrated.

Note: Make sure that there are no measuring mistakes, e.g. due to springing open of the work piece.

Requirements

 Remove the screws on the cover or front plate and take it off.  Loosen the counternut of the contact screw.  2,5 rotations of the contact screw are equal to 1 mm change in the crimp value.

Counternut

Contactscrew

UNIFLEX-Hydraulik - 21 - www.uniflex.de

Exchange Slide Bearings

Open the crimp tool completely.

Important: If there are balancing plates underneath th e slide bearings, they must be replaced to their original position.

Push the base dies towards the centre of the tool. Take out the slide bearings with a screw driver.

Take out and renew all eight slide bearing plates one after another. The insertion happens the other wa

around.

UNIFLEX-Hydraulik - 22 - www.uniflex.de

_ Anhang / Appendix / Apéndice / Appendice

Ersatzteilliste / Spare Parts List / Pièces détachées / Lista de piezas de recambio

Ecoline,HM 200, HM 250, HM 260

Ecoline, HM 200, HM 250, HM 260

7_7.1

HM 200, HM 250, HM 260

17 18 19

HM 200, HM 250, HM 260

20 21

UNIFLEX-Hydraulik - 23 - www.uniflex.de

23 24 25

HM 200, HM 250, HM 260

30a - e

HM 200, HM 250, HM 260

HM 200 Ecoline

39 46

ECOLINE: 38 a-d

UNIFLEX-Hydraulik - 24 - www.uniflex.de

HM 200 / HM 200 Ecoline HM 200

43 44

HM 2.. B HM 2.. E

42 41

UNIFLEX-Hydraulik - 25 - www.uniflex.de

Pos. Anzahl

Artikel / Article Name Nom Denominación Name / Amount

1 1 226.101.1 Druckplatte vorn Plaque faciale Placa de presión, delante Front Pressure Plate 2 1 226.1 Gleitlager – Set Kit plaque de glissement Cojinete deslizante – juego Slide Bearings Set 3 16 D – 311 Federn Ressorts Resortes Springs 4 4 DIN 912 M 20x 2 x 60 Schrauben 4 x vis 4 x Tornillos Screws 5 1 TH 10LR KDS OMD A3C Hydroverschraubung Connection hydraulique Empalme hidráulico Hydraulic connection 6 1 226.102.1 Druckplatte hinten Plaque arrière et rondelle de

glissement

Placa de presión, atrás con casquillo del cojinete

Rear Pressure Plate

7 8 219.206 Grundbacken Mors base Mordazas básicas Base Dies

7.1 8 239.151 Druckstück federnd Pièce de maintien montée sur ressort

8 4 226.303.3 Hydraulikzylinder Vérin hydraulique Cilindro hidráulico 9 1 WH 10LR KDS OMD

Hydroverschraubung Connection hydraulique Empalme hidráulico Hydraulic connection

Pieza de presión resiliente Spring mounted pressure

piece

Hydraulic cylinder

A3C 10 4 3550.DU Lagerbuchse Cylindre de glissement Casquillo del cojinete Bearing Bush 11 1 235.021 Steuerblock Bloc de contrôle hydraulique Bloque de control Control Block 12 1 Siehe Tabelle / see table Elektromotor Moteur électrique

400 – 50 – 3 230 – 50 – 1 230 – 50 – 3

Motor eléctrico 400 – 50 – 3 230 – 50 – 1 230 – 50 – 3

Electric Motor

13 1 227.001 Wegeventil Valves hydraulique Válvula distribuidora Solenoid Valve 14 1 235.321 Druckbegrenzungsventil Vavles contrôle pression Válvula limitadora de presión Pressure Control Valve 15 1 235.320 Druckbegrenzungventil Valves contrôle pression Válvula limitadora de presión Pressure Control Valve 16 1 226.10 Taste Öffnen ( Control A) Touche OPEN ( Control A) Tecla para abrir (control A) Open Key ( Control A) 17 1 226.9 Taste Schließen ( Control A) Touche CLOSE ( Control A) Tecla para cerrar (control A) Clo se Key ( Control A) 18 1 8.06.003 Hilfsschalterblock Block auxiliaire Bloque de conmut. auxiliar Auxiliary Switch Block 19 1 8.06.005 Hauptschalter Interrupteur principal Interruptor principal Main switch 20 1 235.011.3 E-Blech Plaque de support électrique Placa E con piezas eléctr. E-plate 21 1 227.011 Transformator Transformateur Transformador Transformer 22 1 04 41 02 5 Schutzleiterklemme Pièce de connection Borne conductor protector Grounded Conductor

Clamp

23 1 30 01 035 Reihenklemme Terminal Borne en fila Terminal

UNIFLEX-Hydraulik - 26 - www.uniflex.de

24 1 8.06.004 Motorenschutzschalter Contacteur protection moteur Interruptor protector del

Motor Protection Switch

motor 25 1 8.06.006 Achsverlängerung Rallongement axe Prolongación axial Axial Enhancement 26 1 PL 250 – 1 – 8 Pumpenträger Lanterne Soporte de bomba Bell Housing 27 1 GN 552-R3/4-A1 Entlüftungsschraube Vis de ventilation Tornillo de escape de aire Ventilating Screw 28 1 235.201.2 Tankplatte Plaque réservoir Placa depósito Tank Plate 29 1 VSTI 33x2-ED A3C Hydroverschraubung Hydraulic connection Empalme hidráulico Hydraulic connection 30a 1 239.350 HM 250 Hydraulikpumpe

(9L) Xxx – 50 – 3

30b 1 1D 04 RO HM 200 Hydraulikpumpe

(4L) Xxx – 50 – 1 / xxx – 60 – 1

30c 1 1 D 7 RO HM 200 Hydraulikpumpe

(7L) Xxx – 60 – 3

30d 1 239.351 H Version 5,5 KW

Hydraulikpumpe (12L) Xxx – 60 – 3

30e 1 239.352 H Version 5,5 KW

Hydraulikpumpe (15L) Xxx – 50 – 3

HM 200 / HM 250 Pompe hydraulique (9L) Xxx – 50 – 3

HM 200 / HM 250 Pompe hydraulique (4L) Xxx – 50 – 1 / xxx – 60 – 1

HM 200 / HM 250 Pompe hydraulique (7L) Xxx – 60 – 3

H Version 5,5 KW Pompe hydraulique (12L) Xxx – 60 – 3

H Version 5,5 KW Pompe hydraulique (15L) Xxx – 50 – 3

HM 250 Bomba hidr. (9L)

Xxx – 50 – 3

HM 200 Bomba hidr. (4L)

Xxx – 50 – 1 / xxx – 60 – 1

HM 200 Bomba hidr. (7 L)

Xxx – 60 – 3

H Versión 5,5 KW

Bomba hidráulica (12L)

Xxx – 60 – 3

H Versión 5,5 KW

Bomba hidráulica (15L)

Xxx – 50 – 3

HM 250 Hydraulic Pump (9L) Xxx – 50 – 3

HM 200 Hydraulic Pump (4L) Xxx – 50 – 1 / xxx – 60 – 1

HM 200 Hydraulic Pump (7L) Xxx – 60 – 3

H Version 5,5 KW Hydraulic pump (12L) Xxx – 60 – 3

H Version 5,5 KW Hydraulic pump (15L)

Xxx – 50 – 3 31 1 239.515 Rohrdoppelnippel Tube 2 nipple Boquilla doble de tubo Pipe Double Nipple 32 1 239.516 Saugfilter ST 12 Nirosta Filtre d´aspiration Filtro de succión ST 12

Suction Filter ST 12 Nirosta

Nirosta 33 1 226.092 Hydraulikrohr Tube hydraulique Tubo hidráulico Hydraulic Pipe 34 1 FL 3/8 x 30 St 4 – Lochkreis Öl-Flansch Bride Círc. de 4 aguj. brida aceite 4-Bolt-Circle Oil Flange

35 1 Fl ½ x 30 St 4 – Lochkreis Öl-Flansch Bride Círc. de 4 aguj. brida aceite 4-Bolt-Circle Oil Flange

36 1 226.093 Hydraulikrohr Tube hydraulique Tubo hidráulico

Hydraulic Pipe

37 1 M 28 Hydraulikkupplung Accouplement hydraulique Acoplamiento hidráulico

Hydraulic coupling

38 a 1 PUU 45L 3.0 _00 Ecoline –

Hydraulikaggregat 400 V – 50 Hz – 3~

Ecoline – Groupe hydraulique 400 V – 50 Hz – 3~

Ecoline – grupo hidráulico

400 V – 50 Hz – 3~

Ecoline – Power Unit 400 V – 50 Hz – 3~

38 b 1 PUU 45L 2.2 _23 Ecoline – Ecoline – Groupe hydraulique Ecoline – grupo hidráulico Ecoline – Power Unit

UNIFLEX-Hydraulik - 27 - www.uniflex.de

Hydraulikaggregat 230 V – 50 Hz – 1~

38 c 1 PUF 4L 2.0_90 Ecoline –

Hydraulikaggregat 12V DC

38 d 1 PUF 4L 2.0_91 Ecoline –

Hydraulikaggregat 24V DC

230 V – 50 Hz – 1~ 400 V – 50 Hz – 3~

Ecoline – Groupe hydraulique 12V DC

Ecoline – grupo hidráulico

12V DC

Ecoline – Groupe hydraulique 24V DC

Ecoline – grupo hidráulico

24V DC

230 V – 50 Hz – 1~

Ecoline – Power Unit 12V DC

Ecoline – Power Unit 24V DC

39 1 226.052 Handventil Bloc hydraulique manuel Válvula manual Hand Valve 40 1 219.400.3 Mikrometer Micromètre Micrómetro Micrometer

41 1 226.051.4 Endschalterbefestigung Fixation interrupteur de fin de

course

Sujeción del interruptor de fin

de carrera

End Switch Holder

42 1 Z-15-GQ3 Endschalter Interrupteur de fin de course Interruptor fin de carrera End Switch 43 1 238.055 Wegaufnehmer Capteur de course Registrador de recor rido Position Encoder 44 1 227.014.3 Weggeberabdeckung Capot transmetteur de course Tapa del transmisor de

Position Encoder Cover

recorrido 45 1 227.013.3 Werkzeughalter Porte-outil Portaherramientas Tool Holder

46 1 226.114 Druckbegrenzungsventil Clapet de décharge Válvula límitadora de presión Pressure control v alv e 47 1 235.325 Druckbegrenzungsventil P2 Clapet de décharge P2 Válvula límitadora de presión

Pressure control valve P2

P2 48 1 235.326 Druckbegrenzungsventil P1 Clapet de décharge P1 Válvula límitadora de presión

Pressure control valve P1

UNIFLEX-Hydraulik - 28 - www.uniflex.de

Pos.12 E-Motor

226.011 230V-400V -50Hz-3~

226.011 415V-50Hz-3~

226.011 440V-60Hz-3~

226.025 230V-60Hz-1~

Spannung / Voltage

226.025 230V-50Hz-1~

226.013 200V-60Hz-3~

226.011 380V-60Hz-3~

226.011 230V-60Hz-3~

226.011 480V-60Hz-3~

226.011 400V-60Hz-3~

UNIFLEX-Hydraulik - 29 - www.uniflex.de

Haltebolzen für Standard Pressbacken / Pins for standard dies / Tourillon de mors standard / Gorrón de mordza estándar

262.104.4 262.129.3 239.041.4 239.041.4 (sw) 232.504.4 232.505.4 220.502.4 245.114.4

Profil 262 Profil 263 Profil 239 Profil 266 Profil 232 Profil 237 Profil 554 Profil 245 Profil 246 Profil 247

x x Ø96 / Ø103 x

x x x

UNIFLEX-Hydraulik - 30 - www.uniflex.de

Wo Sie Ersatzteile bestellen können / Where to obtain spare parts / Adresse pour nous contacter / La dirección para encargar piezas de recambio:

Uniflex Hydraulik GmbH Robert-Bosch-Straße 50 - 52 D-61184 Karben

Tel.: 06039 / 91 71 – 0 Fax: 06039 / 9171 - 181

E-Mail: sales@uniflex.de http://www.uniflex.de

Bei der Bestellung eines Ersatzteiles bitte unbedingt folgende Angaben machen! When ordering spare parts please have the following information ready! Veuillez indiquer impérativement les données suivantes dans votre commande !

¡En el pedido de una pieza de recambio es imprescindible de hacer los siguie ntes indicaciones!

 Maschinentyp / Machine type / Le type de la machine / Tipo de máquina  Seriennummer / Serial-Number / Le numéro de série / Número de serie  Baujahr / Year of production / L’année de construction / Año de construcción  Spannung / Voltage / La tension de service / Voltaje

UNIFLEX-Hydraulik - 31 - www.uniflex.de

HM 200 Ecoline Elektro- & Hydraulikplan / Electric & Hydraulic Circult Diagram

UNIFLEX-Hydraulik - 32 - www.uniflex.de

HM 200 Ecoline Elektroplan für Unteröl-Aggreg at PUU 45L 3.0_04/ Electric Circuit Diagr am for Aggregate under oil PUU 45L 3.0_04 (440V-60Hz-3~)

UNIFLEX-Hydraulik - 33 - www.uniflex.de

HM 200 Elektroplan (Steuerteil) / Electric Circu it Diagram (C ontrol Part)

UNIFLEX-Hydraulik - 34 - www.uniflex.de

HM 200 Elektroplan (Leistungsteil) / Electric Circuit Diagram (Power Section)

UNIFLEX-Hydraulik - 35 - www.uniflex.de

HM 250 / HM 260 Elektroplan / Electronic Circuit Diagram (480V 50/60Hz 3P)

UNIFLEX-Hydraulik - 36 - www.uniflex.de

HM 250 / HM 260 Elektroplan / Electric Circuit D iagram (220 /239V 50/60Hz 3Ph)

UNIFLEX-Hydraulik - 37 - www.uniflex.de

HM 200 / HM 250 / HM 260 Hydraulikplan / Hydraulic Diagram

UNIFLEX-Hydraulik - 38 - www.uniflex.de

HM 200 / HM 250 / HM 260

UNIFLEX-Hydraulik - 39 - www.uniflex.de

Wartungsbuch / Maintenance book / Car net d’entretien / Libr o de mantenimiento / Li bretto die manutenzio ne / Onderhoud boek

UNIFLEX-Hydraulik - 40 - www.uniflex.de

Erklärung des geschulten Personals / Declaration of Trained Personnel

Ich erkläre hiermit, dass ich an einer innerbetrieblichen Schulung zur Bedienung der UNIFLEX Maschine teilgenommen habe und über alle sicherheitsrelevanten Details informiert wurde. Des Weiteren erkläre ich, dass ich diese Betriebsanleitung vollständig gelesen und verstanden habe.

I herewith declare that I have attended an internal training course for the operation of this machine and have been informed about all details regarding safety. I also declare that I have read and understood this operating manual in full.

Par la présente, je déclare avoir suivi une formation dans l’entreprise pour m’initier à l’utilisation de la machine UNIFLEX et avoir été informé de tous les détails liés à la sécurité. De plus, je déclare avoir lu et compris entièrement la présente notice d’instructions

Confirmo con esto de haber participado en un entrenamiento interno para la operación de la máquina UNIFLEX, y que fue informado sobre todos l os detalles relevantes a la seguridad técnica. Además, confirmo de haber leido y comprendido el presente manual de instrucciones por completo.

Ort / Place Datum / Date Name / Name Unterschrift / Signature Lieu / Lugar Date / Fecha Nom / Nombre Signature / Firma

UNIFLEX-Hydraulik - 41 - www.uniflex.de

Note :

UNIFLEX-Hydraulik - 42 - www.uniflex.de

Note :

UNIFLEX-Hydraulik - 43 - www.uniflex.de

Note :

UNIFLEX-Hydraulik - 44 - www.uniflex.de

Uniflex HM 200, HM 200 Ecoline, HM 200 Ecoline DC, HM 260, HM 250 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual