OPERATION MANUAL

MANUFACTURING YEAR

P120
SERIAL NUMBER
 P120 OPERATIONS MANUAL

CONTENTS

CONTENTS 1
GENERAL 2
TRANSPORT 2
MOUNTING 3
DISPOSAL OF THE PACKING MATERIAL 4
WARNINGS 4
COMISSIONING 6
OPERATION 7
OPERATION MODES 7
TEST RUN 8
SELECTING THE DIE SET 9
INSTALLING THE DIE SET 10
SETTING THE CRIMPING DIAMETER 11
CRIMPING 11
PREVENTIVE MAINTENANCE 13
TROUBLESHOOTING 15
GUARANTEE 16
ELECTRICAL DIAGRAM 17
HYDRAULICAL DIAGRAM 18
DECLARATION CE 19

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 P120 OPERATIONS MANUAL

THE MACHINE HAS BEEN DESIGNED FOR CRIMPING HOSE FITTINGS. BALFLEX SHALL NOT BE HELD LIABLE FOR ANY

PRODUCT WHICH HAS BEEN CRIMPED ON THE MACHINE. THE MACHINE HAS BEEN DESIGNED TO OPERATE IN ROOM

TEMPERATURE, IN DRY INDOOR CONDITIONS AND IN SUFFICIENT ILLUMINATION.

GENERAL

BALFLEX crimping machines are electrically 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 P120 crimping machine is normally delivered with a 3-phase electric motor of 5.5kW. On
request it can be delivered different versions.

TRANSPORT

The packed machine is transported on a pallet, which is easy to move and lift by a fork-lift truck. After unpacking,
the machine can be lifted using a hoisting belt.

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 P120 OPERATIONS MANUAL

Size and Weight of package:

Length (X) Width (Y) Height (Z) Net Weight

Specification
mm mm mm Kg

Crimping Unit 940 800 1635 998

P120
Hydraulic Unit 820 640 992 251

MOUNTING

The above picture shows an appropriate way to lift the machine after it has been unpacked. The hydraulic unit is
packed separately. The crimper may be installed on some other table as well, provided it is sturdy and broad enough
or it has been fastened on the floor so that it cannot fall over. Furthermore, there must be a hole in the table to enable
emptying the oil tank through the drain plug.

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 P120 OPERATIONS MANUAL

DISPOSAL OF THE PACKING MATERIAL

The transport and protective packing are mostly manufactured from the recycled or recyclable materials. Please
check local environmental regulations before disposing of packing materials. Rather than throwing these materials
away, please take them to your community recycling center. Handle the waste oil and filters according to law.

WARNINGS

General

The machine is intended for professional use. It is to be operated only 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 the dies while the motor is running!

Warning 2

While crimping a fitting, hold the hose far enough to avoid crimping your hand!

Warning 3

Dies open and close by depressing the hand emergency push-buttons at both ends of the valve. Do not touch these
push-buttons during normal operation!

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 P120 OPERATIONS MANUAL

Warning 4

High voltage. The electric box is to be opened only by a professional electrician!

Warning 5

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 position, after which you can continue in the normal way if the machine is otherwise in
working order.

Warning 6

When changing dies with the quick-change tool, hold the handle as shown in the above figures. Make sure your
hand will not get between the dies!

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 P120 OPERATIONS MANUAL

COMMISSIONING

Oil fill

Fill the oil tank to center line of the indicators in the dipstick, with hydraulic oil like Shell Tellus T46 or equivalent.
Volume of the tank is 135 liters. It is recommended to pump the oil into the tank through a 20 µ filter, because new
oil in drums is not pure.

Electrical connection

CAUTION! Check that the machine voltage (see type plate) is equal to your supply voltage. For proper installation to
local code. Consult a licensed contractor. 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 rotation is parallel with the arrow on the tank
close to the motor. In case the motor rotates in wrong direction, two phase conductors in the supply disconnecting
device must be interchanged.

1-phase: Connect the phase and the neutral to the respective 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.

OPERATION

Starting Up

1. Start the machine by turning the supply disconnecting device.

2. Switch the control by pushing the Power on button.
3. If the control won’t start, make sure the Emergency stop button is not pressed down.

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 P120 OPERATIONS MANUAL

Setting the crimping diameter

Select the crimping mode, and adjust he recommended crimping diameter with an accuracy of 0.1
mm. Make sure that the die recommended by the UC control is installed to the machine.

Tool Change

Select the too change mode. The tool change mode advises the operator step by step to change the die
set.

Correction

If there are differences in scale values between the crimping diameter and the crimped part, perform
the fine adjustment by using the correction function. Can be adjusted with – or +, depending on which direction
the crimping diameter must be corrected.

OPERATION MODES

Manual

Master dies can be opened by pressing retraction button and closed by pressing button. Manual mode
is used when changing dies and adjusting settings.

Automatic

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 P120 OPERATIONS MANUAL

Crimping movement gets started when the crimping button is pressed. The movement can be
interrupted by releasing the button. If need be, dies can be opened by using retraction button. Crimping goes on
when the button is repressed. After reaching the crimping diameter, the dies return to the retraction position
irrespective of whether the button is pressed or not.

Back Stop Device

Crimping stars when the fitting is pressed against the stop device. The movement stops if the stop device
is not adequately pressed by the fitting. It can be also stopped by withdrawing the fitting from the stop device
before it is gripped by dies. If need be, dies can be opened by using retraction button. Crimping goes on when the
fitting is repressed against the stop device. After reaching the crimping diameter, dies return to the retraction
position irrespective of whether the fittings is pressed against the stop device or not.

Foot Pedal

Crimping starts when the foot pedal is pressed. The movement can be interrupted by lifting the foot
from the pedal. If need be, dies can be opened by using retraction button. Crimping goes on when the foot pedal
is repressed. After reaching the crimping diameter, dies return to the retraction position irrespective of the position
of the foot pedal.

Tool Change

The UC control advises the operator to change the die set.

TEST RUN

• To avoid accidents, make sure that there are no foreign objects between the dies.
• Start the machine by turning the supply disconnecting device.
• Switch on the control by pushing the Power on button. NOTE! The motor gets started when the Crimping
button is pressed, or some automatic mode is used.
• Check the correct motor rotation.
• Adjust the crimping diameter to 10.0 and the retraction to the maximum value.
• During the first crimping cycles air in the cylinders may make the piston/dies move irregularly and at high
speed. Open and close the dies a few times till the motion becomes even.

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 P120 OPERATIONS MANUAL

• In case the dies do not move in either direction, the motor rotates in wrong direction. The fault is corrected
by interchanging two phase conductors in the supply disconnecting device. Requires an electrician.
• Test the function of emergency push buttons. Testing has to be done daily.
• Check the possible leaking’s.

SELECTING THE DIE SET

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 P32/10 the minimum crimping diameter is 10 mm.

Crimping Crimping
D L D L
Part Number Range Part Number Range
(mm) (mm) (mm) (mm)
(mm) (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
P32/22** 22.0-26.0 22 70 P32/69** 69.0-75.0 69 110
P32/26** 26.0-30.0 26 70 P32/74 74.0-80.0 74 110
P32/30** 30.0-34.0 30 70 P32/78 78.0-87.0 78 110
P32/34** 34.0-39.0 34 75

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 P120 OPERATIONS MANUAL

INSTALLING THE DIE SET

QUICK CHANGE
Quick Change Tool Base enables storing die sets under the machine. Die sets can be installed into the master dies
with a quick-change tool one set at a time.
• Before installing dies, make sure that the master dies are clean.
• STOP THE MOTOR PRIOR TO CLEANING DIES.
• Open the dies to maximum retraction.
• Insert the pins of the tool into the die set in the die table, turn the tool clockwise and pull the whole set out.
• Hold the handle of the quick-change tool as shown in figures below, and make sure your hand will not get
between the dies.
• Mount the die set between master dies and start closing the dies.
TO AVOID DAMAGING MASTER DIES, MAKE SURE THAT ALL DIE SET PINS HIT IN 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

• Start the motor and depress the retraction button until maximum retraction is reached. Stop the motor.
CAUTION! THE MOTOR SHALL ALWAYS BE STOPPED DURING INSTALLATION OF DIES.
• Prior to installing dies, clean the contact surfaces of both the die set and master dies properly to avoid damaging
the surfaces.
• Pull the pull pin in the master die with the tool delivered together with the machine (see figure).
• Insert the die with the retaining pin into the master die, die number always towards you. Release the pull pin.
• After installing all the dies, make sure they are straight and properly seated in the master dies.

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 P120 OPERATIONS MANUAL

SETTING THE CRIMPING DIAMETER

• While the crimping diameter display is surrounded by the cursor, activate it by pressing.

• Select the desired crimping diameter by turning the selector.

• Check the die set used and change it if need be.
• When required, set the retraction diameter in the same way.
The machine has been calibrated at the factory 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 +/-
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 crimping diameter must be corrected using the correction function.

CRIMPING

WHEN CRIMPING A FITTING, HOLD THE HOSE FAR ENOUGH TO AVOID CRIMPING YOUR HAND!

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 P120 OPERATIONS MANUAL

MANUAL

Manual mode is used during die set change, set-up, test run and when crimping special fittings.

1. Select MANUAL MODE.

2. Adjust the recommended crimping diameter.

3. Adjust the retraction diameter.

4. Make an empty crimp.

5. Insert the fitting between the dies.

6. Press the crimping button until the dies stop.

7. Open the dies and remove the fitting.

8. Check the crimping diameter.

9. If necessary, perform fine adjustment using the correction function.

AUTOMATIC

Automatic mode is used when performing small quantities of crimps.

1. Adjust the crimping and retraction diameters.

2. Select AUTOMATIC MODE.

3. Insert the hose assembly between the dies.

4. Press the crimping button, and dies perform a crimping-retraction cycle. The cycle can be interrupted by releasing
the button. If need be, dies can be opened by using the retraction button.

FOOT PEDAL

As an alternative, a foot pedal can be installed in the stop device plug, e.g. when large fittings are crimped, and more
space is needed behind the machine. The foot pedal enables holding the hose assembly with both hands.

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 P120 OPERATIONS MANUAL

In FOOT PEDAL mode the dies will move if the pedal is pressed or until the set crimping diameter has been reached.
The crimping movement can be interrupted by lifting the foot from the pedal. If need be, dies can be opened by using
the retraction button.

PREVENTIVE MAINTENANCE

The 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
CABLE FROM THE MAINS!

• Open the dies to maximum retraction before servicing.

Greasing

• Lubricate the inner surface of the conical flanges daily with pressure-proof grease like Optimol Viscogen 4.
• Apply the grease to the conical surfaces at the front and back of the die with a small brush.
• Do not grease the piston rod.
• Lubricate the master dies daily with pressure-proof grease like Optimol Viscogen 4.

Oil change

• Empty the tank of oil through the draining plug under the tank.

• Handle the waste oil according to law.

• Fill the tank to center line of the indicators in the dipstick of the filling cap.

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 P120 OPERATIONS MANUAL

• Oil tank volume: 135 litres.

• Recommended oil: Shell Tellus T46 or equivalent.

• Change hydraulic oil after the first 500 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

• Open the tank cover.

• Keep the cover open by using e.g. a block of wood.

• Unscrew the filter insert and remove it.

• Handle the old filter according to law.

• Lubricate the seal of the new filter insert with

hydraulic oil.

• Screw the filter insert on.

• Filter insert must be changed together with oil.

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 P120 OPERATIONS MANUAL

TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE ACTION

Machine will not start. 1. No electric supply Check fuses and supply cable connections.

2. Motor protection tripped Reset. If tripped again, check motor and pump condition.

3. Switch broken Check the voltage up to the motor.

4. Low supply voltage Check the voltage.

Motor runs but no 1. Wrong rotation direction Interchange two phases in the supply disconnecting device.

piston movement. 2. Low oil level Check, refill.

[Link]/rectifier/ transformer out of order Check, replace.

4. Valve out of order Check movability of valve steam. Check the solenoids.

[Link] or coupling broken Check, replace

Insufficient crimping force. 1. Insufficient lubrication Lubricate the dies.

2. Low oil level Check, refill.

3. Pressure relief valve stuck Check, clean.

Pilot check valve leaking Replace if broken.

4. Leaking pump/pressure pipe Check, tighten, replace

5. Coupling between motor and pump Check, replace.

slipping
Crimping diameter varies 1. Insufficient lubrication Lubricate the dies

2. Set value changed Check.

3. Valve sticking Check, clean.

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 P120 OPERATIONS MANUAL

GUARANTEE

The machines produced by BALFLEX are guaranteed against defects in material and manufacture. Within the limits
of the guarantee, the defective part will be replaced with a new one, or when possible, repaired free of charge.

The guarantee is valid for 12 months Invoice date;

The 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 ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, OR FOR ANY OTHER LOSS,
DAMAGE OR EXPENSE OF ANY KIND, INCLUDING LOSS OF PROFITS.

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 P120 OPERATIONS MANUAL

ELECTRICAL DIAGRAM

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 P120 OPERATIONS MANUAL

HYDRAULIC DIAGRAM

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 P120 OPERATIONS MANUAL

DECLARATION CE OF CONFORMITY
We undersigned,

MANUFACTURE’S NAME
BALFLEX PORTUGAL SA
MANUFACTURE’S ADRESS
RUA BOUÇA ESTILHADOUROS 226 – ZI ALTO VILAR – 4445-044 ALFENA - PORTUGAL

Declare 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, SIGNATURE AND TITLE

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