Machines for the production of hose assemblies

Operating Manual
UNIFLEX®-hose crimper S 5

Type: U: V
Serial-No.: I: A
Year of prod: P: kW
Order-no: F: Hz

Uniflex - Hydraulik GmbH Robert -Bosch-Strasse 50-52 D-61184 Karben -1-

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Machines for the production of hose assemblies
CE Declarati on of Conformity

Within the meaning of CE Directive Machines 98/37/EC

The following machine

Make UNIFLEX hose press

Type designation HM 325i/375i/380i

was developed, designed and manufactured in accordance with CE Directive 98/37/EC under
the sole responsibility of

Company UNIFLEX Hydraulik GmbH

Robert-Bosch-Straße 50 -52
D - 61184 Karben

The following harmonized standards were applied:

• CE Directive 98/37/EC
• EMC Directive 89/336/EEC (06/93)

The following national standards, guidelines and specifications were applied:

• EN 292-2: 1991
• EN 60204-1: 1992

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.

- The operating instructions for the machine are available in the original version.

Karben, den 06.04.03 Geschäftsführer

Ort, Datum Unterschrift Funktion des Unterzeichners

Uniflex - Hydraulik GmbH Robert -Bosch-Strasse 50-52 D-61184 Karben -2-

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Machines for the production of hose assemblies

Table of Contents

Please make sure to read the operating manual

Safety notes for hose crimpers

CE Declaration of Conformity .................................................................................... 2

Table of Contents .................................................................................................... 3
Chapter 1 Introduction................................ ................................ .................. 4
Copyright............................................................................................................. 4
General information to operating manuals ................................................................ 4
Security and accident prevention ............................................................................ 4
Transport, unpacking, repair................................................................................... 4
Chapter 2 Description of the system................................ ................................ .. 5
Machine description ................................ ................................ .............................. 5
Unpacking / set up ................................................................................................ 7
Start the machine ................................................................................................. 7
Chapter 3 Crimping ................................ ................................ .................. 8
Exchange of the crimp dies .................................................................................... 8
Setting of the crimp diameter................................ ................................ .................. 9
Crimping of the hose assembly.............................................................................. 10
Crimping of hose lines with elbows......................................................................... 10
Adjustment of the crimp micrometer (1) .................................................................. 10
Overstressing protection of the motor..................................................................... 11
Chapter 4 Maintenance ................................................................................ 12
Maintenance, service ........................................................................................... 12
Spare parts......................................................................................................... 13
Where to obtain spare parts:................................ ................................ ................. 13
Chapter 5 Service ...................................................................................... 14
Spare parts S 5 ................................................................................................... 14
Chapter 6 Anhang ...................................................................................... 15
Hydraulik-Plan / Hydraulic Circuit Diagram.............................................................. 15
Elektro -Plan / Electric Circuit Diagram................................ ................................ .... 16
Declaration of the trained personnel ................................ ................................ ....... 17

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Machines for the production of hose assemblies
Chapter 1 Introduction

Copyright
The copyright of this operating manual rests with UNIFLEX-HYDAULIK GmbH. This manual contains
regulations and hints that may not be copied or distributed as a whole or in part. Offences may bear legal
consequences.
General information to operating manuals
This operating manual is included in the delivery of the UNIFLEX machine and is written for the use of the
operator and the operating personnel. It explains the function of the machine, informs about possible
dangers during the operation, includes detailed information and specifies the required steps for machine
maintenance, as well as actions necessary in the case of an emergency or a default.
Even if you took part in a training seminar to the machine please read the operating manual completely prior
to operating the machine. With your signature on the last page you confirm that you have read and
understood these instructions. The operator of the machine is committed to only allow those persons the
operation and maintenance of the machine who fulfill these preconditions.

Security and accident prevention

This UNIFLEX machine is an up-to -date machine and when operated correctly is working safely. However,
some regulations need to be adhered to which are meant to minimize the risk of injuries for the operating
person and prevent damages to the machine.

Note:
The operator and the operating personnel is committed to read and adhere to the security
information of the UNIFLEX machine.

Transport, unpacking, repair

Transport with a fork lift truck:

Note:
When transporting with a fork lift truck, make sure that it the center of gravity is in the middle
of the forks.

Start -up
The set-up / assembly of the machine may only be performed by trained and authorized personnel.

Repairs / Modifications
Pay attention to the chapter >MAINTENANCE<

Note:
Any warranty works of the operatore during the warranty period may only be performed after
consulting and clearing of UNIFLEX-Hydraulik GmbH! Otherwise any demands on warranty
are forfeited!

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Machines for the production of hose assemblies
Chapter 2 Description of the system

Machine description
The workshop-hose crimper UNIFLEX S5 is easy and safe to operate. The precision-crimp-micrometer
guarantees an equal precision when crimping even if the tool is worn. The UNIMATIControl-E with
illuminated keypad controls the crimping diameter and automatically opens the crimp tool. Due to a
mechanical fast motion using the turning pressure ring the fitting can be held between the crimp dies so
that a fast crimping can be done. Complicated elbows can be crimped easily due to the compact design of
the crimp tool.

Technical Data
Crimp force: 2400kN (240t)
Working range: up to DN 50-4SP
Crimping range: up to 74mm Ø
Allowed crimping path: 8mm Ø
Opening path: 24mm Ø
Opening Ø: 24mm + crimp dies Ø
Crimping speed: 0,5mm Ø/sec
Max. adjustable stroke of the crimp micrometer: 8mm
Design: RAL 5012 blue
Crimp diameter disconnection: automatic
Drive: Hydro power unit
Q = 1,17 L/Min
P = 0,55 kW
Voltage: 380/415V; 50/60 Hz; 3 Ph
(other voltages on demand)
Measures (LxWxH): 650x290x425 mm
Noise level: < 72 dba
Weight: 77 kg
Accessories: Operating manual

Technical details subject to change!

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Machines for the production of hose assemblies
Chapter 2 Description of the system

picture 1

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Machines for the production of hose assemblies
Chapter 3 Inital operation
Note:
The machine may only be initialised and operated by trained personnel!

Unpacking / set up
The UNIFLEX machine was tested prior to delivery and is ready for operation.
How to prevent damage when unpacking:
- Carefully remove all packaging.
- Check the delivery for completeness using the delivery note.

Note:
Pay attention to the correct balance!

Note:
The hose skiving machine needs to be set up so the tool is accessable from all directions.

Note:
Only set up and operate the hose skiving machine in rooms which are weatherproof.

- Lift the machine on the table intended for that purpose.

- Screw the hose skiving machine to the table.
- Exchange the locking screw on the tank for a ventilating filter. The locking screw was only a
transport protection, since the tank is filled with hydraulic oil.

Note:
The table has to be level.

Start the machine

- Turn on main switch (12) (see picture 1); white operating lamp (2.1) lights up.
- open pressure ring (1.3) 1-2 turns, so that the trunk piston does not go under the pressure ring
(Overstressing protection can be triggered).
- operate the green START-key (2.2):
- Key illuminates
- Motor starts;
- Piston goes up until the crimp micrometer is reached
- Machine stops;
- Crimp tool opens automatically.

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Machines for the production of hose assemblies

Chapter 3 Crimping

Exchange of the crimp dies

For the crimping of hose fittings to the prepared hose there are crimp dies (1, see picture 3)
needed. The marking (2) of the crimp dies is corresponding to the smallest crimp diameter. This
diameter is reached when the crimp tool is closed completely. For available crimp dies also see
the crimp die table.

Crimp dies type 239 crimp dies type 265

With intermediate dies Ø 9 – 5 0 without intermediate dies Ø 54 - 7 1

picture 3, crimp dies

Note:
There is only a warranty if original UNIFLEX-crimp dies or by UNIFLEX tested and
authorised crimp dies are used! When using older crimp dies please contact UNIFLEX.

Uniflex - Hydraulik GmbH Robert -Bosch-Strasse 50-52 D-61184 Karben -8-

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Machines for the production of hose assemblies
Chapter 3 Crimping

Pressbacken - Ø Pressbereich Pressfeldlänge Pressbackenserie

Dies - Ø Press range Length of Dies Type
mm Ø mm
9 9 - 12 50
12 12 - 14 50
14 14 - 17 60 239
17 17 - 20 60
20 20 - 24 60
24 24 - 28 60 mit
28 28 - 32 75 Zwischenbacken
32 32 - 36 75
36 36 - 40 75 With
40 40 - 44 75 Intermediate dies
44 44 - 47 75
47 47 - 50 75 265.239
50 50 - 54 75
54 54 - 57 90
57 57 - 62 90
62 62 - 67 90 265
67 67 - 71 90
71 71 - 78 100

Setting of the crimp diameter

The crimp diameter for the individual fitting needs to be taken from the tables of the fitting-
manufacturer.
The scale value or the crimping path is the difference between outer diameter of the fitting prior to
the crimping and after the crimping. One turn of the micrometer leads to 1 mm change of the
crimping diameter.
Example:
Fitting outer diameter = 20,5 mm
Desired crimp diameter = 17,5 mm
Chosen crimp die type = 17 mm
Fitting outer diameter minus desired crimp diamete r
20,5mm - 17,5mm = 3mm
The crimp micrometer needs to be set to 3mm.

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Machines for the production of hose assemblies

Chapter 3 Crimping

Crimping of the hose assembly

1. Insert base dies in the machine.

2. Insert crimp dies in the base dies.
3. Set the crimp diameter on the crimp micrometer (5).
4. Insert the hose with already assembled fitting from underneath in the crimp tool and bring
in crimping position.

Attention:
The o uter fitting lengthens during the crimping. Therefore the crimp dies need to be 3mm
longer than the fitting!

5. Close the pressu re ring (1.3) until the crimp dies hold the fitting.
6. Press the green START -key (2.2), crimping process runs automatically.

Note:
The red STOP-key (2.3) brings the process to a halt at any time! !

7. Open pressure ring (1.3), take out the hose assembly.

8. Check the crimp diameter, if necessary change on the crimp micrometer. For this the
difference between desired and real value needs to be entered.

Crimping of hose lines with elbows

If the opening or the opening path respectively is not sufficient one or more crimp dies (6) can be
taken out before inserting the hose assembly.

Attention :
The allowed crimp path of 8mm may not be exceeded as this may lead to damages on the
crimp tool !

Adjustment of the crimp micrometer (1)

- switch off on main switch (12) and cut off the machine from the electric circuit
- remove front plate (2.5).
- Loosen the counter nut (S) of the contact screw (T).
Increase the crimp diameter =
Turn out contact screw (T)
Decrease the crimp diameter =
Turn inwards the conta ct screw (T).
- Tighten the counter nut (S).
- assemble the front plate (2.5).
- reconnect to the electric circuit.
- Turn on the machine and check the crimp diameter.

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Machines for the production of hose assemblies

Chapter 3 Crimping

Overstressing protection of the motor

To prote ct the motor against overstressing a motor-protection-relay is installed. The motor stops
and the white operating control lamp (2.1) goes out. A re-start of the motor is only possible when
the motor protection relay is loosened.
For this purpose switch off the machine on the main switch (12) and cut it off from the electric
circuit. Remove the black cover in the front plate. After approx. 2 minutes press the blue key ® on
the motor protection relay. Re-connect the machine to the electric circuit. The white control lamp
lights up again. Switch on the machine and start the motor. If the machine switches off
autonomously check the power unit.

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Machines for the production of hose assemblies
Chapter 4 Maintenance

Maintenance, service

− Only use machine oil to lubricate the pressure ring thread.

− Clean all tool surfaces every 6 months.
− Annual oil change of the hydraulic system. For this unscrew the ventilation filter (see Chapter
4) and open the oil-drain-plug. Fill 2,1 l of new oil.
− Only use hydraulic oil "HLPD with a nominal viscosity of 22mm2/s (cSt) at 40°C" choice of oils
according to DIN 51524 (ISO 3448).

NOTE :
We give a warranty of 6 months, valid from the reception of the goods, provided that
the operation was done according to this manual. Otherwise there is no guarantee!
We are not liable if another lubricating agent is being used than was recommended.
Technical details subject to changes!

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Machines for the production of hose assemblies

Chapter 5 Service

Spare parts

Where to obtain spare parts:

You may obtain spare parts from the following address:

UNIFLEX Hydraulik GmbH
Robert-Bosch-Str. 50 - 52
D-61184 Karben
Tel. 0 60 39 / 91 71 - 0
Fax 0 60 39 / 91 71 - 41

Email: sales@uniflex.de

Please state the following information when ordering spare parts:

Machine type
Serial Number
Year of production
Operating voltage

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Machines for the production of hose assemblies

Chapter 5 Service

Spare parts S 5
Pos. Bezeichung Artikel-Nr. Pos. Designation Article No.
1 Presswerkzeug kompl. 213.100.2 1 Press tool comp. 213.100.2
1.1 Gehäuse 213.001.1 1.1 Housing 213.001.1
1.2 Hohlkolben 213.102.2 1.2 Hollow piston 213.102.2
1.3 Druckring kompl. 213.300.1 1.3 Thrust collar comp. 213.300.1

2.1 Betriebskontrolleuchte 213.7 2.1 Working control lamp 213.7

2.2 Taster Start kompl. 213.502.3 2.2 Start Button, comp. 213.502.3

2.3 Taster Stop kompl. 213.505.3 2.3 Stop Button, comp. 213.505.3
2.5 Fronttafel 213.830.2 2.5 Front plate 213.830.2
3.1 Endschalter 213.410.01 3.1 Limit Switch 213.410.01
4 Hydro-Aggregat 4 Hydraulic unit

340V- 460V 50Hz 3Ph 233.050 340V -460V 50Cy3Ph 233.050

220/240V 50Hz 1Ph 233.010 220/240V 50Cy 1Ph 233.010

230V 60Hz 1Ph 233.011 230V 60Cy 1Ph 233.011

230V 50Hz 3Ph 233.009 230V 50Cy3Ph 233.009
230V 60Hz 3Ph 233.013 230V 60Cy3Ph 233.013
500V 50Hz 3Ph 233.014 500V 50Cy 3Ph 233.014

440V 60 Hz 3Ph 233.013 440V 60Cy 3Ph 233.013

4.1 Magnetventil 50/60Hz WH1F-13-G230 4.1 Solenoid valve 50/60Cy WH1F-13- G230

4.2 Luftfilter 6900 025 M18x1,5 4.2 Air filter 6900 025 M18x1,5
5 Pressmikrometer 221.200.3 5 Press microm eter 221.200.3

6 Satz Grundbacken 265.239 6 Set bearing dies 265.239

8 Ersatzteilset 265.1 8 Spare parts set 265.1
Lagerbleche Bearing plates
9 Ersatzteilset 213.2 9 Spare parts set 213.2
Griffe für Druckring Handles for pressure ring
10 Ersatzteilset 213.3 10 Spare parts set 213.3
Dichtungsset Seal kit + springs
+ Rückholfedern
11 Ersatzteilset 213.4 11 Spare parts set 213.4
Motorschutzrelais Motor protection relay
12 Hauptschalter P110- 61199- 12 Main Switch P110- 61199-033M4
033M4
13 Transformator WA- U-75 13 Transformer WA- U-75

Positions- Nr. siehe Bild 1. Position No. see picture 1.

Ersatzteilbestellungen nur mit Angabe von: When ordering spare parts please indicate:
Maschinentyp Machine type
Serien-Nummer Serial number
Baujahr Year of manufacture
Betriebsspannung Operating voltage

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Machines for the production of hose assemblies
Chapter 6 Anhang

Hydraulik-Plan / Hydraulic Circuit Diagram

Zeichnungs-Nr.: 213.810.4
Drawing No.: 213.810.4

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Machines for the production of hose assemblies
Chapter 6 Anhang

Elektro-Plan / Electric Circuit Diagram

HM 10.3, HM 10.5, HM 160, S 5 (Nr. 213.800.3)

Uniflex - Hydraulik GmbH Robert -Bosch-Strasse 50-52 D-61184 Karben - 16 -

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 1 2 3 4 5 6 7 8

L1
L2
L3

21 13
SH1 Taste Stop
Button Stop
-E2
22 14
SH2 Taste Start
Button Start

E2 Endschalter Pressmaß
95 21 End switch press value
-F1/F2/F3 -F5 -F4 -F1.1
3x6,3A 1A 1A -SH1
5x20mm 5x20mm 5x20mm
H2 Start
95 22 Start

H3 Betrieb
Operation

1 3 5 13 13
R6 RC-Glied für H2
RC section for H2
-K1M -SH2 -K1M
5 5 R7 RC Glied für H3
2 4 6 14 14 RC section for H3

K1M Schütz-Motor Ein

Contactor motor on

2 4 6 1 3 5 Y1 Magnetventil-Pressen
-F1.1 Magnetic valve press
-Q1 2-4 A 2 4 6 -R7 -R6
1 3 5 F1-F3 Sicherungen Motor
PE
Fuses Motor

M1 Motor/Hydroaggregat
2
Motor/power-unit
X2 X2 A2 -Y1
V W
F4 Steuersicherung
M -H3 -H2 -K1M 1

L1
L2
L3
N
PE
3 T5,5K/48V T5,5K/48V Klb4S 230V 50/60Hz Control fuses
X1 X1 A1
130902040 PE
F1.1 Motorschutzrelais
HC22L/0,82-B1/550-WH1F-13-WG230 Motorprotection
Hydroaggregat 233.013

Q1 Hauptschalter
PE PE PE
Main switch
220-230V-60Hz-3~
Frontplatte Chassis Trägerwinkel für E2 1 2
frontplate chassis holder for E2 2
3 4
2
5 6
2
13 14
6

17.09.04 Schwarzbach Datum 03.03.98 Anlage HM10/HM160

Uniflex-Hydraulik GmbH Abt.E-Technik HM 10/HM160 213.808.3
Bearb. uniflex Ort 213.808.3
Gepr. F.S D-61184 Karben Tel.06039/9171-37 Schlauchpresse Blatt-Nr. 9
230V-60Hz-3~ HM 10_HM 160
Zustand Änderung Datum Name Norm EN 60204 Urspr. Ers. für Ers. durch Bl von Anz 9/18
 1 2 3 4 5 6 7 8

-F4 SH1 Taste Stop

1A
5x20mm
Button Stop

1 SH2 Taste Start

-F1 Button Start
40A
E2 Endschalter Pressmaß
limit switch press value
H2 Start (LED)
Start
2
2 4 H3 Betrieb (LED)
-Q1 Operation
1 3 21
K1M Halbleiter-Lastrelais
-E2 solid-state relay
22
Y1 Magnetventil-Pressen
Magnetic valve press
21
F1 Sicherungen Motor
-SH1
Fuses Motor
2 3 22
(+) POWER MOSFET (+)
M1 Motor
Motor
-K1M
(-) solid-state-relay (-) F4 Steuersicherung
1 4 13 12 14 Control fuses
-SH2 F1.1 Thermokontakt
14 11 thermo-contact
6 5
-V1
Q1 Hauptschalter
3 Main switch

- + A1
V1 Freilaufdiode (1N5408)
M -M1 -K01 2 transient diode
H2 -Y1 H3
A2 1
V2 Freilaufdiode (1N4007)

-V2
transient diode
+ - 4

12V DC

30.09.02 Schwarzbach Datum 04.03.98 Anlage HM10

Uniflex-Hydraulik GmbH Abt.E-Technik HM 10
Bearb. uniflex Ort 213.812.3
Gepr. F.S D-61184 Karben Tel.06039/9171-37 Schlauchpresse Blatt-Nr. 3
12V DC HM 10.3
Zustand Änderung Datum Name Norm EN 60204 Urspr. Ers. für Ers. durch Bl von Anz 13/14
Machines for the production of hose assemblies

Chapter 6 Anhang

Declaration of the trained personnel

• I hereby declare that I have taken part in an internal training to the

operation of this UNIFLEX machine, and that I am informed about all
security relevant details.
• Additionally I declare that I have read and understood this operating
manual completely.

Place Date Name in Capitals Signature

Place Date Name in Capitals Signature

Place Date Name in Capitals Signature

Place Date Name in Capitals Signatu re

Place Date Name in Capitals Signature

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