Balflex P20, Operation Manual

Page 1: ...OPERATION MANUAL P20 MANUFACTURING YEAR SERIAL NUMBER P32 MANUFACTURING YEAR SERIAL NUMBER ...

Page 2: ...imping 7 TEST RUN 9 SELECTING THE DIE SET P20 9 SELECTING THE DIE SET P32 10 INSTALLING THE DIE SET 11 Quick Change 11 Change of a single die P20 P32 11 SETTING THE CRIMPING DIAMETER MS 12 CRIMPING MS CONTROL 13 PREVENTIVE MAINTENANCE 14 Greasing P20 P32 14 Oil Change 15 Filter Change P20 P32 15 RE CALIBRATION OF CRIMPING DIAMETER DIAL 16 TROUBLESHOOTING 17 GUARANTEE 18 SPARE PARTS LIST 19 ELECTRI...

Page 3: ...lly operated hydraulic crimping machines for hydraulic hose assemblies The crimping machine comprises a crimping head and a hydraulic unit mounted on the oil tank which serves as machine frame BALFLEX crimping machine is normally delivered with a 3 phase electric motor of 4kW on P32 version and 3kW in P20 version On request it can be equipped with a single phase motor TRANSPORT The packed machine ...

Page 4: ...ount the machine on a BALFLEX rack Before mounting the rack must be screwed on the floor with four M12 wedge anchors Boreholes in the floor 12mm depth 55 mm When the machine is mounted on a BALFLEX rack the four shoes under the machine are removed The table with assembly instructions is packed separately The crimper may be installed on some other table as well provided it is sturdy and broad enoug...

Page 5: ...nly by a trained operator who has understood the dangers involved in the operation Openings between the dies exceed 6 mm thus being large enough to let fingers go between the dies and get crimped It is therefore ABSOLUTELY necessary to follow operating instructions and warnings indicated by the stickers on the machine when changing dies and crimping fittings Warning 1 Do not put your hands inside ...

Page 6: ...der Do not remove this housing P20 P32 Warning 6 EMERGENCY STOP Press this button in an emergency or when you for some other reason want to stop the machine quickly Pressing the emergency stop push button stops all machine functions The button is released by turning it clockwise as indicated by the arrow After an emergency stop go on working in manual mode Open the dies to the set retraction posit...

Page 7: ...Bring the supply cable through the hole in the side panel of the electric box Secure the cable with a relief plug 3 phase Connect the phase conductors to the respective L1 L2 and L3 terminals in the supply disconnecting device Connect the earth connection to the ground terminal on the fixing plate Check the connection against the wiring diagram enclosed in the spare parts list Check that the motor...

Page 8: ...e until the button is released or the preset crimping diameter is reached 3 Retraction button When depressed and held down the dies will open until the button is released or the maximum retraction is reached 4 Crimping diameter dial 5 Die chart with crimping diameter range for each die set and corresponding dial adjustment values The main operating area of the machine is in front of the controls S...

Page 9: ...ual mode must be selected RETRACTION DIAMETER REACHED The signal lamp is illuminated when the dies have reached the set retraction diameter i e Retraction position Automatic mode cannot get started unless the retraction position has been reached DELAY SIGNAL LAMP The signal lamp is illuminated when the delay function is active RETRACTION DIAMETER CONTROL The dial is used to adjust the retraction d...

Page 10: ...ING THE DIE SET P20 Use only original BALFLEX die sets in BALFLEX crimping machines Refer to the fitting manufacturer s specifications for proper crimping diameter for the fitting Each die set has its own crimping range Follow it to assure the roundest possible crimping result The minimum crimping diameter D is marked on each die set Example with die set Nº P20 23 the minimum crimping diameter is ...

Page 11: ...on each die set Example with die set Nº P32 10 the minimum crimping diameter is 10 mm Part Number Crimping Range mm D mm L mm Part Number Crimping Range mm D mm L mm P32 10 10 0 12 0 10 55 P32 39 39 0 45 0 39 75 P32 12 12 0 14 0 12 55 P32 45 45 0 51 0 45 90 P32 14 14 0 16 0 14 55 P32 51 51 0 57 0 51 90 P32 16 16 0 19 0 16 55 P32 57 57 0 63 0 57 100 P32 19 19 0 23 0 19 55 P32 63 63 0 69 0 63 110 P3...

Page 12: ... THEIR HOLES Close the master dies completely until the pins are locked in their places Remove the tool The dies are now ready for use Die set is removed from the master dies in reverse order close the dies insert the tool into the die set open the master dies and place the set back in the die table CHANGE OF A SINGLE DIE P20 P32 Start the motor and depress the retraction button until maximum retr...

Page 13: ... Crimping diameters in the grey zone of the chart are not recommended The crimping diameter dial has been calibrated at the factory so that when the dial is set at 0 0 the resulting diameter will be the minimum diameter of the die set installed i e with die set Nº P20 16 the crimping diameter will be 16 mm Nº P20 19 gives a diameter of 19 mm etc Each full turn clockwise of the adjusting knob of th...

Page 14: ...tory with 40 bar pressure This means that when you are crimping a fitting requiring 40 bar pressure the measuring scale of the crimping diameter dial provides an accuracy of 1 0 1 mm possible elastic recovery of the fitting not regarded When fittings requiring higher pressure are crimped the crimping diameter may become larger than the value on the scale due to machine deflections Then the crimpin...

Page 15: ...following maintenance operations can be performed by the operator according to the instructions below However electrical works and repairs like changing seals or the pump must only be carried out by a qualified specialist PRIOR TO ANY SERVICING OPERATION TURN THE SUPPLY DISCONNECTING DEVICE TO POSITION 0 BEFORE CHANGING THE MOTOR CIRCUIT BREAKER OR UNDERVOLTAGE TRIP DISCONNECT THE PLUG OR SUPPLY C...

Page 16: ...hours of operation and every 1000 hours thereafter It is recommended to pump the oil into the tank through a 20 µ filter because new oil in drums is not pure If any oil has run out on the floor wipe it away Filter change P20 P32 Open the tank cover as shown in the figure below Keep the cover open by using e g a block of wood Unscrew the filter insert and remove it Handle the old filter according t...

Page 17: ...ock the dial Crimp the ferrule and measure the real diameter 3 Remove the control dial avoid to turn the dial shaft at the same time 4 Open the dial lock and set the real diameter into it diameter of ferrule relock it and install back 5 Turn the dial to right diameter and crimp another ferrule Now the machine has been calibrated and the real diameter should be the same than the diameter which stat...

Page 18: ... or coupling broken Interchange two phases in the supply disconnecting device Check refill Check replace Check replace Check movability of valve steam Check the solenoids Check replace Insufficient crimping force 1 Insufficient lubrication 2 Low oil level 3 Pressure relief valve stuck Pilot check valve leaking 4 Leaking pump pressure pipe 5 Coupling between motor and pump slipping Lubricate the di...

Page 19: ... guarantee does not compensate for damage due to improper use overload neglect or normal wear Working and travelling costs as well as freight charges caused by guarantee repairs are not covered by the guarantee Guarantee repairs shall be carried out at a BALFLEX distributor In case guarantee repair is demanded the customer has to prove that the machine is under guarantee BALFLEX DO NOT WARRANT FOR...

Page 20: ...P20 P32 OPERATIONS MANUAL Page 19 SPARE PARTS LIST ...

Page 21: ...8 18 LOCKING PIN P 20144 8 P 32144 8 19 ADAPTER SLEEVE M12 6L P 20134 4 P 32134 4 20 CONIC FLANGE P 20120 1 P 32120 1 21 PISTON P 20150 1 P 32150 1 22 CYLINDER P 20110 1 P 32110 1 23 PETURN CYLINDER P 20130 2 P 32130 2 24 PISTON P 20131 2 25 SEAL P 20132 2 P 32132 2 26 SHELL NUT M12X1 5 P 20133 4 P 32133 4 27 SCREW M6X20 P 20113 4 P 32113 4 28 GUIDE RING P20 10XD220X2 P32 20XD250X2 P 20151 1 P 321...

Page 22: ...P20 P32 OPERATIONS MANUAL Page 21 ...

Page 23: ... JOINTS M16X2 G P 202065 P 322065 1 14 PIP INTERFACE M12X6 P 202066 P 322066 1 15 PUMP P20X8L P32X12L P 20302 1 P 32302 1 16 SCREW 7 16 X14 P 20303 2 P 32303 2 17 O RING NBR21x3 3 P 20207 1 P 32207 1 18 HYDRAULIC PIPE P 20304 1 P 32304 1 19 SCREW M6X20 P 20305 4 P 32305 4 20 DIRECTIONAL VALVE 4 3 P 20208 1 P 32208 1 21 FLANGE B5 P 20209 1 P 32209 1 22 RIVET NUT M6 P 20210 20 P 32210 20 23 HYDRAULI...

Page 24: ...P20 P32 OPERATIONS MANUAL Page 23 ELECTRICAL DIAGRAM ...

Page 25: ...under sole responsibility that the following product MACHINE TYPE MACHINE SERIAL NUMBER To which this declaration relates it is in accordance with the following standards STANDARDS ISO 13850 EN 60204 1 EN 693 BASIC CONCEPTS GENERAL PRINCIPLES FOR DESIGN EN ISO 12100 1 EN ISO 12100 2 And it is according to following Directives DIRECTIVES 2006 42 EEC 2006 95 EEC 2004 108 EEC DATE AND PLACE NAME SIGN...