Gates UNIPRESS 4, Operation Manual

Page 1: ...OPERATION MANUAL UNIPRESS 4 UP4 GATES TUBE FITTINGS GMBH...

Page 2: ...lations 13 1 2 8 Guarantee and Legal Liability 13 1 2 9 Disposal 14 1 2 10 Specification Plate 14 1 2 11 Declaration of incorporation 15 2 Technical Data 16 3 Transport Erection of the Machine 17 3 1...

Page 3: ...36 7 Spare Parts 37 7 1 Housing 37 7 2 Error Codes Housing 38 7 3 Cylinder 39 7 4 Hydraulic Drive 40 7 5 Electric System 42 7 6 Accessory Kit 44 7 7 Accessories 46 7 7 1 Presetting Attachment 46 7 7 2...

Page 4: ...ator s reference material this Operation Manual is of special importance Heeding the instructions data and regulations of the OM will help you to operate the machine safely and efficiently In referenc...

Page 5: ...prevention and environmental protection regulations must be observed The Operation Manual has to be permanently available and in legible condition at the working site of the machine Any persons worki...

Page 6: ...right remains the property of GATES TUBE FITTINGS GmbH Kolumbusstr 54 D 53881 Euskirchen Tel 49 0 2251 1256 0 Fax 49 0 2251 1256 400 This OM is intended for the owner of the machine and his staff Neit...

Page 7: ...nt a risk for your safety Preserve all safety precaution and warning signs attached to the machine completely and in legible condition Keep this Operation Manual permanently handy on any working site...

Page 8: ...he operator should not come too close or reach in ONE MAN WORKING PLACE The Tuboform must be treated as a working place for a single operator If the machine is operated by two persons they run the ris...

Page 9: ...ies All existing protective caps and facilities must be assembled correctly Do not remove protective caps or facilities during machine operation SUSPENDED LOADS Do not stand beneath suspended loads Yo...

Page 10: ...d and instructed their area of responsibility for operation setting up maintenance and repair should be framed clearly and precisely In addition to this Operation Manual please heed the legal rules in...

Page 11: ...are obliged to acknowledge the basic regulations concerning safety at work and accident prevention read the safety precautions and warning directions in this Operation Manual and confirm their compre...

Page 12: ...gency off facilities are available and in working order Any safety related failures shall be corrected immediately 1 2 6 USE AS INTENDED The basic unit of the TUBOFORM C is a universal basic adaptor f...

Page 13: ...neral sales terms and delivery conditions apply These are available to the user from the date of the contract on Guarantee and claims on liability for damage to persons or property shall be precluded...

Page 14: ...nd oily cloths shall be disposed at collecting points according to the local legislation Further information concerning POL products i e quantity and type can be found in the technical data and safety...

Page 15: ...f the European Communities EN ISO 12100 2010 EN ISO 14120 2015 EN 349 1993 A1 2008 EN ISO 13849 1 2015 EN ISO 4413 2010 EN ISO 13849 2 2012 EN ISO 13857 2008 The special technical documents according...

Page 16: ...s 5 10 kg Height 265 mm Width 660 mm Depth 515 mm ELECTRICS Driving mechanism Elektroantrieb 1 2 KW Voltage 400V 50Hz 3phases special voltage see identification plate Power input 2 8 A special voltage...

Page 17: ...QUIREMENTS The UNIPRESS 4 requires a footprint of app 700 mm width and 550 mm depth on top of a stable rest for instance a work bench The height of the working place should be laid out according to er...

Page 18: ...re if the rotational direction is wrong Correction Use a screwdriver to twist the interpoles of the mains plug by 180 comp fig 3 2 Attention Pull out the plug before beginning to work Check direction...

Page 19: ...machine with the power supply Activate the machine control with the 0 1 switch The digital display lights up to indicate that the machine is ready If nothing happens the emergency off switch might be...

Page 20: ...the machine If a dangerous situation for man or equipment arises take the necessary steps to prevent injury or damage immediately Heed all safety precaution and warning signs attached to the machine...

Page 21: ...o operational safety Unauthorized modifications are not permitted Only open the protective covers after unplugging the power plug 4 1 3 EMERGENCY OFF SWITCH Sudden imminent danger for man or equipment...

Page 22: ...ny operation may be started This is the basic prerequisite for faultless machine operation The machine shall be ready for operation and in functional order any risk for persons and the machine itself...

Page 23: ...ent for presetting with tool identification for metallic fittings with 24 cone Presetting attachment for presetting for metallic fittings with 24 cone Flaring attachment for flares according to DIN EN...

Page 24: ...PERATION 4 3 1 DESCRIPTION OF THE CONTROLS Emergency off STOP and return stroke control lamp pressure goes out when the pressure has been reached START forming stroke Display Adjusting button USB conn...

Page 25: ...s stopped by pressing the button If no further values are changed it stops automatically after 6 seconds From the parameters F back stroke and A absolute counter the indicator leaps back to pressure i...

Page 26: ...size 0 999 Return stroke of the cylinder The way can be set from 1 to 10 100 List selection Depends on programming up to 7 lists Absolute counter cylinder strokes in thousands 034 000 Continuous coun...

Page 27: ...justing button activates the display again If automatic pressure adjustment is deactivated e g after pulling the plug only the key position manual mode is active The assembly process can only be carri...

Page 28: ...28 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL 4 4 1 CUTTING RING PRESETTING Presetting connection Cutting ring Spigot nut Counter support plate Holding clasp...

Page 29: ...diameter first onto the pipe which is cut at right angles and deburred Place the pipe with the spigot nut and cutting ring between the counter support plate and presetting connection Mind the correct...

Page 30: ...step sequence for flaring The attachment for pipe flaring is suspended in the universal basic adaptor When hanging in the head please make sure that the carrier tappet of the piston rod extends into t...

Page 31: ...e flaring dies pointing upward Release the flaring dies by placing them into the milled in groove of the flaring head and canting the pipe sideways Check the flare The flared collar must be in a recta...

Page 32: ...contained in this manual Have maintenance work carried out only by personnel authorized to do so Only carry out the maintenance and adjustment work listed in these instructions yourself If you need t...

Page 33: ...to DIN 20 066 for assessing functional capability the period of use of a hose assembly including any storage period must not exceed six years The storage period should not exceed two years The hoses...

Page 34: ...7 You should correct any operational faults the moment they occur in order to avoid greater damage Look into the operation manuals of the various unit parts for information on how to detect the source...

Page 35: ...ued in the operation manual and in the directions for maintenance works All security facilities have to be replaced and their functions checked after carrying out any of the works mentioned above Wipe...

Page 36: ...SIBLE CAUSE CLEARANCE The engine is not running supply lines are not connected check and connect properly if necessary the socket is dead call an electrician emergency off switch is activated de activ...

Page 37: ...37 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL 7 SPARE PARTS 7 1 HOUSING...

Page 38: ...ED M 4X30 170 8 PCS 180128012040 SPRING LOCK WASHER DIN 128 SHAPE A ST GALVANISED M 4 175 4 PCS 180912512006 CHEESE HEAD SCREW DIN 912 8 8 GALVANISED M 4X10 205 4 PCS 180084212009 CHEESE HEAD SCREW DI...

Page 39: ...10 X 2 MM 35 1 PC 21160095 GROOVE RING AUN 90106 92 SHORE SERIES 100 105X90X12MM 40 2 PCS 21254667 O RING NBR 70 SHORE A 100X2 MM 45 1 PC 1401125001 PRESSURE SPRING D12 5MM DM 63 5 LO 193 MM IF 7 0 IG...

Page 40: ...40 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL 7 4 HYDRAULIC DRIVE...

Page 41: ...8G001012019 THREAD INSERT ENSAT M6X10 SELFCUTTING GALV STEEL 200 1 PC 2014925020 STRAIGHT MALE STUD COUPLING GE 10 LR 1 2 ED OMD CF 205 1 PC 2056025015 ADJUSTABLE ELBOW CONNECTION FITTING M D EW 10 L...

Page 42: ...TACT MAKER PTF00 SGL 65 2 PCS 2303805300 CONTACTOR 9 AMP 1S TEL LP 1 K 0910 BD3 70 1 PC 2301906200 ENGINE PROTECTION RELAY LR2 K0312 3 7 5 5 A 3 POLES TEL 75 6 PCS 2308608500 2 CONDUCTOR THROUGH TERMI...

Page 43: ...M2 HYSLY OZ HOE 175 1 M 2330251000 CABLE OILFLEX J 5X1 0 MM2 HYSLY IZ DRA 180 1 M 2330291000 CABLE OILFLEX J 9X1 0 MM2 HYSLY DRA 200 4 PCS 180912512051 CHEESE HEAD SCREW DIN 912 8 8 GALVANISED M 5X18...

Page 44: ...44 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL 7 6 ACCESSORY KIT 15 25 30 5 20 40 35 10 25 45 421560...

Page 45: ...NGLISH 15 1 PC 362000005 STICKER BEWARE OF HAND INJURY SL 30 MM 20 1 PC 362000006 STICKER REACHING IN IS PROHIBITED D 30 MM 25 2 PCS 362000007 STICKER 66 KG T SHAPE C GERMAN 30 1 PC 369900544 PROHIBIT...

Page 46: ...OR CUTTING RING PRESETTING EOMAT II 10 1 PC EO 2 0312400 PLATE FOR CUTTING RING ATTACHMENT 15 6 PCS 180912512178 CHEESE HEAD SCREW DIN 912 8 8 GALVANISED M 10X30 20 2 PCS 180912512181 CHEESE HEAD SCRE...

Page 47: ...4 40 1 PC TUB 072028 PROTECTIVE CAP 45 1 PC TUB 072030 HOLDER FOR SPRING FLARING UNIT 105 50 1 PC 180915011148 SET SCREW DIN 915 45 H BLACK M 10X70 55 1 PC 180934412010 HEXAGON NUT DIN 934 8 GALVANIS...

Page 48: ...48 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL YY 401169 7 7 3 FLARING ATTACHMENT WITH TOOL IDENTIFICATION 24 YY 401169 YY 401169...

Page 49: ...49 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL 8 APPENDIX 8 1 ELECTRIC CIRCUIT DIAGRAM...

Page 50: ...50 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL ELECTRIC CIRCUIT DIAGRAM...

Page 51: ...51 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL ELECTRIC CIRCUIT DIAGRAM...

Page 52: ...52 GATES COM UNIPRESS 4 UP4 OPERATION MANUAL 8 2 HYDRAULIC CIRCUIT DIAGRAM...

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Page 54: ...GATES 2024 GATES COM E2 50240 02 2024...