Operating Instructions for the SYSTEM TOOLS HSBL
Contents
1. Order No 4121 Maintenance ATTENTION UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING OUT MAINTENANCE WORK In case of wear or damage Replace or regrind cutting edge Regrinding The cutting edge can be reground up to a max of 4 mm When the edge is reground should be taken that the edge remains parallel the edge s back The cutting edge and the pressure piece of the cable cutters are subject to wear and tear When changing the cutting edge the pressure piece should also be changed HSBL 120 Cutting Tool Order No 2350 Operative range You can cut the following with this tool copper and aluminium rails of up to 120 x 10 mm 4 3 4 x 3 8 with a max strength of 250 N mm 36 250 psi steel rails of up to 120 x 6 mm 4 3 4 x 1 4 with a max strength of 370 N mm 53 650 psi Waste consists of a piece as wide as the cutting edge Technical specifications Width without vice 210 mm 8 3 with vice 340 mm 13 4 Depth without vice 200 mm 8 with vice 225 mm 8 8 Height with working cylinder 785 mm 31 Weight without vice 12 0 kg 26 4 lb vice 3 0 kg 6 6 lb Operation There are four holes in the bases of the HSBL cutting tool 120 Use these holes to fasten the tool to a work bench The working cylinder 1 Order No 2420 should be attached to the cutting tool as follows 1 Place the protective device with the cutter blade 102. into the stand 13 Pull out the fixing bolts 2 on the cylinder 1 as far as possible Slide the cylinder 1 with the spars 4 on to the cutting tool s spars Align the holes on the cutting tool with the fixing bolts 2 on the working cylinder 1 4 Slide the fixing bolts 2 in as far as possible Push the base plate 11 with the knurled screws 12 onto the piston rod 3 Fix the base plate 11 to the piston rod 3 using the knurled screws 12 The points of the knurled screws 12 must enter the groove in the piston rod 3 7 Connect the working cylinder 1 and the HA hydraulic unit using the rapid action coupling and the plug see page 2 To deaerate the cylinder carry out a few idle strokes The hydraulic unit should be on a higher level than the working cylinder when deaerating Cutting 1 Lift the protective device 10 2 Place the rail into the cutting tool and align Note The distance between the outer edge of the cutting strip 14 and that of the cutting edge 15 is 25 mm 3 Release the protective device 10 4 Press the foot switch on the hydraulic unit and keep pressed until cutting is completed ATTENTION BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS Accessories Vice 100 Order No 6950 The vice is fastened to the cutting tool with 2 screws It is used fo
3. of max 250 N mm 36 250 psi steel rails of up to 160 x 6 mm 6 x 1 4 with a strength of max 370 N mm 53 650 psi Waste consists of a piece the width of the cutting edge Technical specifications Width without vice 255 mm 10 with vice 375 mm 14 8 Depth without length stop 310 mm 12 2 with length stop 1440 mm 56 7 Height with working cylinder 940 mm 37 Weight without vice and length stop 21 5 kg 47 3 lb vice 3 0 kg 6 6 Ib length stop 6 0 kg 13 2 Ib Operation There are four holes in the bases of the HSBL cutting tool 160 Use these holes to fasten the tool to a work bench The working cylinder 1 Order No 2420 should be attached to the cutting tool 10 as follows 1 Pull out the fixing bolts 2 on the work ing cylinder 1 as far as possible 2 Slide the working cylinder 1 with the spars 4 onto the cutting tool 10 Align the holes on the cutting tool 10 with the fixing bolts 2 at the working cylinder 1 3 Slide the fixing bolts 2 in as far as possible 4 Slide the base plate 11 onto the piston rod 5 of the working cylinder 1 The tip of the holding screw 12 must be able to fit into the groove on the piston rod 5 5 Tighten the holding screw 12 Connect the working cylinder 1 and the HA hydraulic unit using the rapid action coupling and the plug see page 2 To deaerate the cylinder carry out a few idle strokes The hydraulic unit should
4. rs kran g ller endast om maskinen drivs med hydraulikaggregat HA1ES eller HA3 Till mpade harmoniserade normer i synnerhet se punkt 1 Herved erkl rer vi at den i det f lgende betegnede maskinen p grunn av dens konsipering og konstruksjon samt utf relsen som vi har brakt p markedet tilsvarer de respektive grunnleggende krav til sikkerhet og helse Ved en bruk av maskinen som ikke er form lstjenlig eller ved en endring av maskinen som ikke er avstemt med oss mister denne erkl ringen sin gyldighet Konformitetserkl ringen er bare gyldig hvis maskinen drives med hydraulikkaggregatet HA1ES eller Benyttede harmoniserte standarder s rlig se punkt 1 Formular Nr Norm 001NP037 doc Si dichiara che la macchina appresso descritta soddisfa per concetto tipo e modello messo in commercio le esigenze di base di sicurezza e sanita relative a tali apparecchiature In caso di uso non appropriato della macchina o in caso di una sua modifica eseguita senza il nostro accordo questa dichiarazione non ha pi effetto La dichiarazione di conformit valida solo se la macchina messa in funzione con il gruppo idraulico HA1ES o HA3 Norme armonizzate applicate in particolare vedi punto 1 T ten vakuutamme ett seuraavassa nimetty kone vastaa suunnittelunsa rakenteensa sek meid n taholtamme liikenteeseen p stetyn mallinsa puolesta asiaankuuluvia perustavaa laatua olevia turvallisuus ja terveysm r yks
5. 0 mm 10 2 Depth 200 mm 7 8 Working cylinder height 860 mm 33 8 Weight 15 kg 3310 Clear width of the stand 200 mm 7 8 Operation There are four holes in the bases of the HSBL punching tool 120 Use these holes to fasten the tool to a work bench Slide the working cylinder 1 Order No 2420 with the cylinder spars 4 onto the punch s press plate 10 and fasten with the fixing bolts 2 Connect the cylinder to the hydraulic unit using the rapid action coupling and the plug see page 2 To deaerate carry out a few idle runs The hydraulic unit should be on a higher level than the working cylinder when deaerating ATTENTION BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DISCON NECT IT FROM THE MAINS 18 Application rules for tools The diameter of the hole to be punched must not be less than the thickness of the material If this rule is not followed the tool will be damaged It is not permitted to increase the size of a hole by consequential punching since this results in damage of the tool Furthermore the minimum distance from one hole to the next and the distan ce from a hole to the edge of the bar must be at least the diameter of the tool Exchange the tools at due time Excessive wear of the tool might result in the upper tool getting stuck in the rail Sepration of the tools from the rail by excessive force can lea
6. 20 x 10 4 3 4 3 8 placed in it 1 Turn back the nuts 16 on the threaded pins 15 and 17 by about 3 revolutions 2 Unsrew the threaded pins 15 and 17 so that there is at least 2 mm of play be tween the cylinder spars 4 and the threaded pins 3 Place a piece of conductor rail 21 e g 120 x 10 200 4 3 4 3 8 8 into the plying iron 4 Bend until the safety valve in the basic unit shuts the machine off Keep the foot switch pressed down and tighten the screws 12 Now switch off and let the piston 3 return 5 Tighten the threaded pins 15 and 17 so that they slide along the whole length of the cylinder spars 4 without any play To test this let the piston 3 run its whole length forwards and backwards Then counter the threaded pins 15 and 17 with the nuts 16 Bending without the hydraulic stop 1 Place the conductor rail on the angle indicator and hold straight 2 Activate the foot switch and keep pressed until the required angle has been reached Red scale for 8 mm 5 16 radius Black scale for 16 mm g radius Release the foot switch and let the piston return Check the angle on the angle indicator If the angle 1 not sufficient then bend further by tapping the switch lightly Note The top tool can be tilted out by removing one of the fixing bolts on the cylinder spar This makes removing long pieces of rail easier ATTENTION BEFORE ATTACHING AND REMOVIN
7. Bottom tool see HSBL 120 Punch Punching 1 WITHOUT STOP DEVICE 1 1 Place the center marked conductor rail in the working area of the punching tool 1 2 Pull down the top tool with the hand lever and align the center mark with the punching tool s back center 1 3 the HA 1 hydraulic unit s foot switch Keep pressed until the punching process has been completed 23 2 WITH STOP DEVICE 2 1 Slide the rail in onto the stop device and hold it there until punching is completed Setting the stop device see section STOP DEVICE ATTENTION BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS Accessories Punching with a template Stop device Order No 7190 The stop device can be adjusted by 150 mm in the X and Y axses The distance between the holes can be set by using the scale or by using the fixed distances on the templates The arrangement of the holes in the completed template conforms to DIN 43673 The respective width of the intended bar is inscribed on the template 1 Setting the stop device with the scale 1 1 Turn the thumb screws 56 anti clock wise as far as they will go 1 2 X axis Loosen the locking lever 55 Set the stop rail 30 and tighten 1 3 Y axis Loosen the thumb screw 57 Set the slide 31 and tighten Setting the stop device with a template 2 1 X axis Loosen the lockin
8. G THE SYSTEM TOOLS OR CARRYIN OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DIS CONNECT IT FROM THE MAINS 15 Accessories HAV 2 Hydraulic Stop Order No 1627 Operative range A hydraulic stop HAV 2 can be supplied as an accessory to the HSBL plying iron The HAV 2 hydraulic stop limits the forward and backward movements of the HSBL cylinder The HAV 2 is of great use in mass production Once the angle has been set it can be used over and over again Mounting the hydraulic stop 1 The cylinder must be upright with the coupling plug facing upwards Screw the coupling plug out of the HSBL cylinder 2 see page 1 Fix the valve s body 20 to the cylinder with the banjo bolt 21 Screw the coupling plug 22 into the valve s body 20 Remove nut 16 from the threaded pin 17 of the bottom tool Place the fastening square 24 onto the threaded pin 17 and replace the nut 16 and tighten 5 Loosen the banjo bolt 21 a little Then align the valve s body 20 so that the holes for the sliding selector rod 25 in the fastening square 24 are in a line with those of the valve s body 20 Then tighten the banjo bolt 21 again Setting the forward movement limit 1 Place the conductor rail on the angle indicator and hold straight 2 Screw the adjusting nut 23 to a distance of approximately 20 mm 3 4 from the shut off valve Press the foot switch and keep pressed until the HAV 2 shuts off 3 Tur
9. ING OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DI SCONNECT IT FROM THE MAINS Maintenance ATTENTION UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING OUT MAINTENANCE WORK Every week Clean and grease piston rod Clean and grease fixing bolts Every month Check cylinder for leakage If necessary send in for repair HSBL CABLE CUTTERS Order No 1081 Operative range Copper and aluminium cables of up to a diameter of 120 mm 4 9 4 can be cut with these cutters Technical specifications Width 140 mm 5 5 Length with working cylinder 650 mm 25 6 Height 350 13 8 Weight 3 kg 6 6 lb ATTENTION BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS Attaching the Tools Place the HSBL cylinder 1 on the stand 5 Slide the pressure plate Order No 1098 11 on to the piston rod 3 and tighten the fastening screw Slide the cutting edge Order No 1097 13 between the cylinder spars 4 and fasten using the bolts 2 Operation The mouth can be opened by pulling out a fixing bolt 2 and by tilting out the edge 13 This makes it easier to put in longer cable pieces _ The HA hydraulic unit is switched on and off by using the foot switch on the unit Accessories A specially ground edge is available for cutting reinforced cables
10. Operating Instructions for the 5 SYSTEM TOOLS HSBL 99991 02420 B05eng 0696 Contents Page CE Conformity Attestation Safety regulations Working cylinder 1 HSBL Cable cutters Order No 1081 3 HSBL Cutting tool 120 Order No 2350 4 HSBL Cutting tool 160 Order No 7020 7 HSBL Plying iron with angle indicator Order No 1179 10 HSBL Punching tool 120 Order No 1118 14 HSBL Punching tool 160 Order No 7050 19 5 DIN EN ISO 9001 CE KONFORMIT TSERKL RUNG entsprechend EG Richtlinie 98 37 EG Novopress GmbH 8 Co KG Scharnhorststr 1 D 41460 Neuss Systemwerkzeuge HSBL OS 1 EN 294 EN 349 EN ISO 12100 1 EN ISO 12100 2 Hiermit erkl ren wir da die nachfolgend bezeichnete Maschine aufgrund Ihrer Konzipierung und Bauart sowie der von uns in Verkehr gebrachten Ausf hrung den einschl gigen grundlegenden Sicherheits und Gesundheitsanforderungen entspricht Bei einer nicht bestimmungsgem en Anwendung der Maschine oder bei einer nicht mit uns abgestimmten nderung der Maschine verliert diese Erkl rung ihre G ltigkeit Die Konformit tserkl rung ist nur g ltig wenn die Maschine mit dem Hydraulikaggregat HA1ES oder betrieben wird Angewandte harmonisierte Normen insbesondere siehe Punkt 1 Nous d clarons par la pr sente que par sa conception et son type ainsi que par l ex cution que nous avons mise sur le
11. and cutting strips 3 Every week Clean complete cutting tool Any worn or damaged cutting edges or strips must be replaced immediately Changing the cutting edges 1 Remove the working cylinder 2 Take out the guard plate 14 3 Pull up the cutting edge holder with the edge 29 and 2 and tilt out 4 Unscrew the bolt 24 and change the edge 2 Changing the cutting rails 1 Unscrew the four bolts 21 2 Remove parts Nos 5 and 6 also the complete protective device 3 Remove the cutting edge guides 8 4 Unscrew the bolts 23 and change the cutting strips 3 Changing the protective window 1 Unscrew the No 21 bolts Remove Nos 5 and 6 and the complete protective device Pull the guard plates 14 out of the protective device Loosen the No 25 bolts on one side Change the window 11 12 HSBL Plying Iron and Angle Indicator Order No 1179 Operative range This plying iron can bend copper and aluminium conductor rails of up to 120 x 10 mm 4 9 4 x 3 8 with a strength of up to 250 N mm 36 250 psi The maximum bending angle is 100 degrees Technical specifications Width 210 8 3 Depth 200 mm 7 8 Working cylinder length 625 mm 24 6 Weight 4 4 kg 9 7 lb Smallest flange length inside size at a rail thickness of 10 mm 3 8 At a 90 angle 40 mm 1 6 At U flange height 80 mm 3 1 At Z at 90 flange height 80 mm 3 1 Operation 1 Conne
12. be on a higher level than the working cylinder when deaerating Cutting 1 Place the rail into the cutting tool and align 2 Press the foot switch on the hydraulic unit and keep pressed until cutting is completed Return Stroke Limitation The return stroke can be adjusted continuously Before setting the return stroke the cutting edge must have been lowered 1 1 Lower the cutting edge and keep the foot switch depressed 1 2 in the handwheel 14 of the return stroke screw 15 against the stop in the direction of the arrow 13 Release the foot switch 1 4 out the handwheel 14 until the cutting edge is in the desired position Attention The cutting edge must not be forced down with the return stroke screw 15 ATTENTION BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DIS CONNECT IT FROM THE MAINS Accessories 1 Vice 16 Order No 7030 Description on page 5 2 Length stop 17 Order No 6990 The length stop 17 is fastened to the cutting tool by two screws Any sizes between 20 and 1600 mm can be set with the slide 18 Maintenance ATTENTION BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTENANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DI SCONNECT IT FROM THE MAINS After every 10 cutting operations Remove any shreds chips etc from the cutting edge 2
13. c unit punching 4 Release the foot switch immediately after the hole has been punched This will prevent an unnecessary heating of the hydraulic oil Holding down appliance stripper The punch is equipped with a holding down appliance The holding down appliance pad also functions as a stripper when flat bars of over 40 mm 15 8 width are being worked For flat bars with a width of less than 40 mm 15 8 and for lamellar copper we offer auxiliary strippers in addition to round tools Each upper tool has an auxiliary stripper of its own in a diameter range from 5 to 7 9 mm In a diameter range of 8 to 14 mm 5 16 to 9 16 one auxiliary stripper is sufficient for all upper tools Auxiliary stripper Upper tool Soe Ge Order No Order No Order No 8478 5 0mm 21990018 8481 8479 6 0mm 21990019 8482 8399 6 6 21990013 7861 9 0 21990014 7862 11 0 21990015 7665 12 5 21990016 7863 8401 14 0 21990017 Ca ATTENTION When subsequently ordering upper tools it is absolutely necessary to state that the upper tool is used in conjunction with the auxiliary stripper Intermediate sizes e g D 5 2 mm 16 on request Long upper tool bare Key 25 holding down appliance 26 auxiliary stripper 27 cutting plate 28 position of the workpiece after stripping correct wrong The metallically bare upper tools may only be used in conjunction with the auxiliary strip
14. commended that you wear rubber gloves and non slip footwear Wear a hair net if you have long hair 4 Always be alert Only use a device after having been instructed in its operation Concentrate on your work Proceed sensibly Do not use the device when you are distracted 5 lean too far forward Avoid abnormal stance Make sure that you have a secure standing position and maintain balance at all times 6 Leave safety devices where they belong 7 tools may not be installed as fixtures 8 Repair and maintenance Have repairs and maintenance work carried out in an authorised NOVOPRESS specialist workshop Only use original and identical NOVOPRESS spare parts We reject all responsibility and liability for work carried out by third party personnel 009NP004 DOC SAFETY INSTRUCTIONS FOR HYDRAULIC EQUIPMENT 1 Please read the operating instructions Acquaint yourself with the hydraulic equipment 2 Provide the equipment with the necessary care Always keep the equipment in operational condition Cleanness is an essential requirement for good and safe working 3 Switch off the electric power supply to the hydraulic equipment e when the equipment is not in use e when maintenance work is to be carried out 4 Avoid unintentional switching on Keep hands and feet away from the switch when the equipment is not being used 5 Do not use the equipment a manner in contravention of the instructions Ne
15. ct the HSBL cylinder 1 to the hydraulic unit using the rapid action coupling and the plug see page 2 2 Carry out a few idle strokes to deaerate it The hydraulic unit should be on a higher level than the working cylinder when deaerating Installing the tool 1 Place the HSBL cylinder 1 on the stand 5 Put the U shaped bottom tool 11 on to the piston rod 3 and screw in the 2 holding screws 12 by hand 2 Place the angle indicator 13 with the fitting piece between the two cylinder spars 4 and slide in as far as possible 3 Slide the top tool 14 between the cylinder spars 4 so that the chosen bending radius 8 or 16 mm faces towards the bottom tool 4 Fasten the top tool 14 with the fixing bolts 11 Push the angle indicator 13 back onto the top tool 14 as far as possible and tighten with the screw 3 3 6 13 Aligning the bottom tool A At right angles to the angle indicator Align the U shaped bottom tool 11 at right angles to the angle indicator 13 with the help of a back square 20 Screw the threaded pins 15 and 17 onto the cylinder spars 4 so that they slide along the whole length of the cylinder spars 4 without any play To test this let the piston 3 run its whole length backwards and forwards Counter the threaded pins 15 and 17 with the nut 16 Tighten the screws 12 14 B By running the machine with a piece of con ductor rail sized 1
16. d to tools damage When not in use clean and oil the tools The tools life is increased if they are lightly oiled from time to time Tool storage Do not place the upper tool into the lower tool The cutting edges can be damaged Top tool 1 Place the top tool 15 with the shaft into the hole in the column The counter sunk hole in the tools shaft should be facing the locking screw 16 2 Screw in the locking screw 16 by hand and test whether the point of the locking screw 16 is in the counter sunk hole of the shaft by turning the top cool 15 3 Tighten the locking screw 16 The top tool has a fixed back center and cannot be eground Bottom tool 1 Mounting Note The receptacle for the lower tool must be free from dirt chips etc Place the bottom tool 17 into the hole on the press plate 10 and fasten with the locking screw 18 2 Dismantling a Unscrew the screw 18 from the bottom tool b Push out the bottom tool 17 with the ejector The bottom tool can be reground by approximately 2 mm Warning When mounting tools with a profile the top 15 and bottom tools 17 are not to be staggered 15 19 Punching without a template 1 Place the center marked rail in the punch s working area Lift the rail and align the center mark with the back center of the top tool and hold Straighten the rail so that it is parallel to the bottom tool s surface Activate the foot switch on the hydrauli
17. g haar bestemming gebruikt of worden hieraan niet met ons overeengekomen wijzigingen aangebracht dan verliest deze verklaring haar geldigheid De conformiteitsverklaring is slechts geldig indien de machine met het hydraulische aggregaat HA1ES of HA3 wordt aangedreven Toegepaste geharmoniseerde normen in het bijzonder zie punt 1 Gesch ftsf hrer s 02420 ce 02420c06 doc Con la presente declaramos que la m quina denominada a continuaci n por su concepto y por su construcci n cumple con los requisitos fundamentales de seguridad y sanidad en vigor Lo dicho aplica exclusivamente a la m quina en su versi n original tal y cual ha sido fabricada por nosotros El empleo inapropiado de la misma as como cualquier modificaci n ejecutada sin nuestra intervenci n hace que esta declaraci n pierda su validez Para que esta declaraci n de conformidad tenga validez la m quina se habr de operar categ ricamente con un grupo hidr ulico tipo HA1ES o tipo HA3 Normas armonizadas aplicadas en particular v ase bajo el punto 1 H rmed f rs krar vi att nedan n mnd maskin motsvarar de till mpliga och principiella s kerhets och h lsof reskrifterna b de g llande koncipieringen och konstruktionen samt g llande den av oss s lda modellen Anv nds denna maskin inte enligt anvisningarna eller f r ndras maskinen p ett s tt som vi inte har godk nt g ller denna f rs kran ej Konformitetsf
18. g lever 55 Turn the thumb screw 56 clockwise as far as it will go and hold Set the stop rail 80 so that the stop bolt is positioned between the holes on the template 32 Release the thumb screw 56 and slide the stop rail 30 until the stop bolt clicks into the next hole on the template 2 2 Y axis Loosen the thumb screw 57 Turn the thumb screw 56 clockwise as far as it will go and hold Set the slide 31 so that it is positioned between the holes on the template 32 Release the thumb screw 56 Continue moving the slide 31 until it clicks into place in the next hole 24 Changing the templates 1 The templates are flat irons with holes fo the corresponding hole arrangement 2 Move the slide 31 or the stop rail 30 until it comes to rest against the stop 3 the template 33 34 and pull out 4 care when inserting the template that the centering bolt clicks into the last hole on the template Mounting the stop device 1 Move the slide 31 off the stop rail 30 2 Place the stop device onto the punch and fasten with the two supplied screws 3 Move the slide 31 onto the stop rail 30 Maintenance siehe HSBL Lochwerkzeug 120 25 For the manufacture of templates which comply with your requirements we will supply unmarked guiding plates Ref Nos Unmarked guiding plate for X axis 60 is 7681 Unmarked guiding plate for the Y axis 61 is 7682 The distance e for the bori
19. i Jos konetta ei k ytet m r ysten mukaisesti tai jos koneeseen tehd n muutos ilman meid n suostumustamme ei t m selvitys en p de Standardinmukaisuusselvitys on vain silloin voimassa kun konetta k ytet n hydraulisen yksik n HA1ES tai HA3 kanssa K ytetyt harmonisoidut standardit varsinkin katso Kohta 1 Declaramos pelo presente que a m quina a seguir designada na sua planifica o e constru o assim como no modelo por n s comercializado obedece s respectivas exig ncias fundamentais de seguran a e de sa de A presente declara o perde a validade em caso de uso impr prio da m quina ou em caso de modifica es na m quina que n o tenham sido acordadas antecipadamente connosco A declara o de conformidade v lida somente quando a m quina accionada com o agregado hidr ulico HA1ES ou HA3 Normas harmonizadas aplicadas especialmente vide par grafo 1 s 02420 ce 02420c06 doc GENERAL SAFETY REGULATIONS Read all safety regulations and instructions 1 Keep the place of work clean Disorderly work places and work benches invite accidents Ensure that lighting is good 2 Keep children away Do not allow unauthorised persons to touch the device or the cable Keep unauthorised persons away from your place of work 3 Wear suitable working clothing Do not wear any wide clothes nor jewellery they may get caught up in moving parts When working in the open it is re
20. march la machine d sign e ci apres r pond aux exigences de s curit et de pr vention de la sant applicables La pr sente d claration perd sa validit si la machine n est pas utilis e conform ment aux instructions ou dans le cas d une modification de la machine laquelle nous n avons pas donn notre accord La d claration de conformit n est valable que si la machine est utilis e avec le groupe hydraulique HA1ES ou HA3 Normes harmonis es utilis es en particulier voir point 1 Datum Herstellerunterschrift 01 08 05 Angaben zum Unterzeichner Formular Nr Norm 001NP037 doc We hereby declare that with respect to its design and construction the machine stated below and the model thereof which we have brought into circulation conform with the applicable basic requirements on health and safety Any use of the machine other than that for which it is intended and any modification made thereto without our consent shall render this declaration null and void This declaration of conformity shall only be valid if the machine is operated with hydraulic unit HA1ES or HA3 Applied harmonized standards in particular see ltem 1 above Hiermede verklaren wij dat de hierna genoemde machine op grond van haar constructie en type alsmede de door ons in de handel gebrachte uitvoering aan de desbetreffende fundamentele eisen ten aanzien van de veiligheid en de gezondheid voldoet Wordt de machine niet overeenkomsti
21. n fire DANGER OF EXPLOSION 009NP006 DOC HSBL SERIES HYDRAULIC SYSTEM TOOLS HSBL Hydraulic Cylinder Order No 2420 Operative Range This cylinder has been designed to work with a pressure of max 150 bar 2200 psi and is used with HSBL Series tools The cylinder 1 is fastened with a bolt 2 to the tool being used The bolts 2 are situated at the end of the cylinder spars The cylinder can be driven by the NOVOPRESS hydraulic unit we recommend the HA 1 hydraulic system with an electric motor Technical specifications Length 620 mm 24 4 Width 140 mm 5 5 Height 365 14 4 Stroke length 120 mm 4 7 Weight 21 kg 46 Ib Max working pressure 150 bar 2200 psi Power 150 kN 15 tonf Operation Connect the control conduit 1 ofthe hydraulic unit to the plug on the device HSBL cylinder Note The hydraulic unit can only be operated if the plug is connected The cylinder is attached to the HA hydraulic system with a rapid action coupling S Rapid action coupling Coupling Hold the coupling sleeve KM at the sliding sleeve SH and slide onto the coupling plug KS Uncoupling Hold the coupling sleeve KM at the sliding KS sleeve SH and pull off of the coupling plug KS To deaerate the cylinder carry out a few idle strokes The hydraulic unit must be on a higher level than the cylinder during this procedure ATTENTION WHEN ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRY
22. n the adjusting nut 23 back a little and then activate the foot switch again Keep pressed until the HAV 2 shuts off Then measure the angle on the bent rail Repeat this procedure until the re quired angle has been achieved After this counter the adjusting nut 23 with the star grip 26 Setting the backward movement limit The backward movement is set by moving and tightening the control cam 27 The movement should be set so that it is easy to remove the angled piece of material 16 Maintenance ATTENTION UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING OUT MAINTENANCE WORK After each use Remove any dirt chips etc from the HSBL plying iron and the HA2 V Every week Clean HSBL plying iron HA2 V After every 3 months Grease thread of the HA2 V 17 HSBL 120 Punch Order No 1118 Operative range Holes can be punched into the following with this puncher copper and aluminium rails of up to 120 x 13 mm 43 4 x 1 2 with a strength of up to 250 N mm 36 250 psi The largest hole diameter is 18 mm at a 10 mm rail thickness 21 mm steel rails of up to 120 6 mm 4 3 4 x 1 4 with a strength of up to 370 N mm 53 650 psi The largest hole size is 21 mm diameter The punch can be operated with all NOVOPRESS hydraulic units except with the HA 2 We recom mend that the HA 1 hydraulic unit equipped with an electric motor be used Technical specifications Width 26
23. ng D 216 are to be determined in accordance with the attached drawing For the measures 1 ez and please refer to the applicable standards Bar width B ez Measure e4 De EXAMPLE FOR TEMPLATE MANUFACTURE Bar width B 4 the X axis The distance X 196 es 4 2 196 4 1 x 3 196 After having determined the distance X mark the measures on the guiding plate 62 For the Y axis The distance Y 5 51 e Y 5 51 1 Y 4 51 After having determined the distance Y mark the measures e2 on the guiding plate 62 Drawing Bmax 6 Bmin 1 25 62 DIA 236 001 tolerance DIA 216 61 DIA 216 62 DIA 236 x 196 B e4 003 tolerance 60 ATTENTION Holes in square configuration s drawing as follows ei e4 and e2 Service 65 Scharnhorststra e 1 Postfach 101163 D 41460 Neuss D 41411 Neuss Tel 02131 288 0 Federal Republic of Germany Telefax 02131 28855
24. ngement ei ei e3 4026 40 80 20 40 40 4068 50 100 20 40 50 4070 60 120 20 40 60 Special templates on inquiry 21 Mounting 1 Attach the holder 20 Order No 4109 with two cap screws M10 x 16 21 to the press plate 10 in such a way that the top edges of the holder 20 and press plate 10 are level 2 While pressing down the catch button 22 slide the template 23 into the holder 20 until it reaches the bottom tooling 17 and let it snap into place 3 Let go of the catch button 22 Dismantling x 1 Press down the catch button 22 2 Slide out the template 23 24 The width of the rails and hole arrangement are stated on every template The rail 24 is to be centered in the template as shown in pictures 1 to 4 To get a certain hole arrangement the rail must always be centered with the same Y side on the template Maintenance ATTENTION UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING OUT MAINTENANCE WORK Punch Before each tool installation Clean the hole for the lower tool The receptacle must be free from dirt shreds etc If dirty Clean the seat for the rails Clean the templates Every week Clean and grease the HSBL punch Tools See application rules 22 HSBL 160 Punch Order No 7050 Operative range The following can be punched with this punching tool copper and aluminium
25. pers 26 These upper tools are longer than the black standard upper tools When using the bare upper tools without auxiliary strippers the workpiece will stick to the upper tool will not be stripped off RISK OF DIEBREAKAGE Prior to punching it is absolutely necessary to strip the material The material thickness without insulation may amount to max 10 mm 20 Standard upper tool black correct wrong The black standard upper tools must not be used in conjuction with the auxiliary strippers because the center is not visible the collar of the upper tool may collide with the auxiliary stripper 7 Assembly Place the auxiliary stripper 26 in the holding down appliance 25 and push it firmly into position manually beware of the center 26 The auxiliary stripper 26 must be in plane contact with the lower side of the holding down appliance 25 correct wrong Disassembly Pull the auxiliary stripper 26 out of the holding down appliance 25 Accessories Punching with a template No marking no center marking Templates for punching with the HSBL punch are available These are attached to a holder Order No 4109 that can be screwed onto the punch The width of the rails b and the hole arrangement are listed in the table below The holes are arranged according to DIN 43 673 Order No of b mm Hole b mm Hole Sizes in LS Template arrangement arra
26. r holding and aligning the rail at right angles to the cutting edge Maintenance ATTENTION BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTE NANCE WORK UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS After every 10 cutting operations Remove any shreds chips etc from the cutting edge 6 and cutting strips 4 Every week Clean complete cutting tool Any worn or damaged cutting edges or strips must be replaced immediately Changing the cutting edge 1 Pull the cutting edge 6 together with the base plate 7 and the protection device 8 out of the stand 1 see fig 2 2 Unscrew the screws 8 9 from the protective device 8 and remove items 8 2 and 8 3 3 Pull the base plate out of the protection device 8 together with the cutting edge 4 Knock out the clamping sleeve 12 with a mandrel with a diameter of 5 mm Change the cutting edge Assemble the base plate and the new cutting edge Slip the protective device 8 over the base plate 7 and onto the cutting edge 6 8 Use the screws 8 9 to attach items 8 2 and 8 3 to the protective device Changing the cutting strips 1 Dismantle the cutting edge 14 guides 2 Unscrew the bolts 10 change the cutting strips 4 HSBL 160 Cutting Tool Order No 7020 Operative range You can cut the following with this tool copper and aluminium rails of up to 160 x 12 mm 6 1 2 with a strength
27. rails of up to 160 x 13 mm 63 8 1 2 with a strength of up to 250 N mm 36 250 psi The largest hole diameter is 18 mm at a 10 mm rail thickness 21 mm steel rails of up to 160 x 6 mm with a strength of up to 370 N mm 53 650 psi The maximum hole diameter is 21 mm The punch can be used with NOVOPRESS hydraulic units except with the HA2 We recommend that the HA 1 with an electric motor be used Technical specifications Width without stop device 440 mm 17 3 with stop device 600 mm 23 6 Depth without stop device 300 mm 11 8 with stop device 460 mm 18 Height of the working cylinder 900 mm 35 4 Weight without stop device 27 8 kg 61 2 lb with stop devic e 38 2kg 84 Ib working cylinder Operation Order No 2420 There are four holes in the bases of the HSBL punching tool 120 Use these holes to fasten the tool to a work bench cylinder spar fixing bolts Slide the 2420 working cylinder with the cylinder spars on to the punch s pressure plate and fasten with the fixing bolts hand lever Connect the working cylinder to the hydraulic unit using the rapid action coupling and the plug see page 2 deaerate the cylinder carry out few idle accessory runs de j The hydraulic unit should be on a higher level than the working cylinder when deaerating punching tool Order No 7050 ua Application rules for tools see HSBL 120 Punch Top tool see HSBL 120 Punch
28. ver carry the equipment by the pipe or pull on the pipe Protect the piping from heat oil sharp edges and high levels of weight strain 6 Use only piping fittings and accessories wich have been designed for the operating pressure of the hydraulic unit BURSTING PRESSURE OR TEST PRESSURE IS NOT OPERATING PRESSURE Avoid squashing or bending of the piping Piping must not be painted over 7 Replace the hydraulic piping e when cracks squashed or bent points are to be seen when blistering is established when hydraulic fluid escapes when pipe fittings are damaged when discolouration is established on the outer layer e g due to the influence of solvents 8 hydraulic fluid used in the system is kerosene based This requires particular care and attention e Avoid continuous contact with the skin e ensure that the hydraulic fluid does not get into the eyes or mouth Hydraulic pipes have to be replaced after 5 years of usage despite of the circumstance that no damages should be remarkable 9 The equipment must not be operated if it has leaks and there is a danger of hydraulic fluid coming into contact with persons open fire heating equipment electric cabling ground water foods and other substances which are intended for human consumption 10 Hydraulic units with petrol engines e must not be operated in closed rooms due to the DANGER OF INTOXICATION e donot pour in petrol while the motor is running or in the vicinity of ope
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