NovoPress HP 95 Einrichtungshandbuch

01000\R06eng

0704

Repair Instructions

and

Spare Parts Lists

for

PRESSING CYLINDERS

16566

TABLE OF CONTENTS

Page

Safety Regulations

General Notes ................................................................................................. 1

Pressing Cylinder HP 95

Dismantling .....................................................................................................2

Assembly.........................................................................................................4

Parts list and exploded view ...........................................................................6

31830 Hand switch HP 95 and HP 300 ........................................................10

Pressing Cylinder HP 300

Dismantling ...................................................................................................14

Assembly.......................................................................................................16

Parts list and exploded view .........................................................................18

Pressing Cylinder HPM 400

Dismantling ...................................................................................................22

Assembly.......................................................................................................24

Parts list and exploded view .........................................................................27

Pressing Cylinder HP 450

Dismantling ...................................................................................................30

Assembly.......................................................................................................32

Parts list and exploded view .........................................................................34

31831 Hand switch HP 450 ..........................................................................38

7375 Valve ....................................................................................................40

30645 Punch stop .........................................................................................41

30655 Die stop ..............................................................................................41

009NP004.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 recommended 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. Do not 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. Hand 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.

009NP006.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,

•when the equipment is not in use

•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 in a manner in contravention of the instructions.

Never 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

•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. The hydraulic fluid used in the system is kerosene-based.

This requires particular care and attention.

•Avoid continuous contact with the skin

•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

•must not be operated in closed rooms, due to the

DANGER OF INTOXICATION!

•do not pour in petrol while the motor is running or in the vicinity of open fire.

DANGER OF EXPLOSION!

General Notes

The Instructions for assembling and dismantling the pressing cylinder refer in all cases to the

individual drawing of the corresponding part of the tool.

(23) refers to item 23 of corresponding pressing cylinder.

(3/31830) refers to item 3 of the parts list 31830.

NOTE! (3/31830) refers to

item 3 of Spare Parts List 31830

Item 3 in this case lock nut

Spare Parts List 31830 in this case hand switch HP 95 and HP 300

Pressing Cylinder HP 95

For spare parts list and drawing of the part, see pages 6 and 7

1 DISMANTLING

1.1 Cut open the shrink-on sleeve (23) and remove it.

1.2 For devices as of serial no.: 2350:

Undo the grub screw (10)

1.3 Grip the HP 95 by its head (1) in a vice.

1.4 Undo the screw connector (21).

1.5 For HP’s with hand switch only:

•Undo the screw (17/31830).

•Unscrew the lock nut (3/31830).

•Pull off the cup washer (6/31830), hand switch (27) and shims

(5/31830).

•Unscrew the adapter (4/31830)

1.6 Draw the control bar (9) out of the threaded hole for the screw connector and pour out the oil.

1.7 Using a screwdriver inserted through the threaded hole, apply pressure to the hole of the

valve (6). This releases the remaining oil.

NOTE! Collect the oil with due regard to the environment and dispose of it in a

suitable container.

1.8 Grip the HP 95 by the piston (3) in a vice.

NOTE! Grip the piston (3) at the inlet pressure valve (V)

(See drawing)

1.9 Strike the head (1) with a hammer to undo the thread.

1.10 Unscrew the head (1)

WARNING! The head (1) is under pressure from the

spring.

With one hand, push the head (1) against the

spring pressure as you unscrew it.

Pressing Cylinder HP 95

1.11 Remove the head (1) with the piston (2) and the valve (6) from

the piston (3).

1.12 Up to serial no.: 2349:

Remove the piston (4) with the locating washer (14), the

springs (11) and (12) and the supporting washer (5) from the

cylinder (3).

As of serial no.: 2350:

•Remove the piston (4) with the Glyd ring (14), the springs (11)

and (12) and the supporting washer (5) from the cylinder (3).

•Detach the supporting washer from the piston (4).

•Remove the O-ring (22) from the supporting washer (5).

•Detach the Turcon stepseal (16) from the supporting washer

(5).

1.13 As of serial no.: 2350:

Detach the Glyd ring (14) from the piston (4).

1.14 Grip the head (1) in a vice as shown.

1.15 Using a tube, press the piston (2) down about 3 mm and

hold it.

1.16 Unscrew the grub screw (20).

Then slowly release the pressure on the tube until the

spring (11) is released.

1.17 Up to serial no.: 2349:

Remove the piston (2) with the control valve (6) and the parts (11), (15) and (16) from the

crimping head (1).

As of serial no.: 2350:

•Remove the piston (2) with the control valve (6) and the parts (11) and (15) from the crimping

head (1).

•Detach the Turcon stepseal (15) from the piston (2).

WARNING! Any scoring of the contact faces of the cylinder

or of the head (1) must be polished or ground out.

If scoring is very severe, replace the cylinder.

Pressing Cylinder HP 95

1.18 Undo the cap screw (8) and push the locating washer

(17) out with a piece of wire.

1.19 Remove the washer (18), spring (13) and conical pin (7).

2ASSEMBLY

WARNING! Please note the position of all locating washers.

2.1 The faces of the cylinder must be perfectly clean.

Before assembly, carefully rinse with a cleaning medium (e.g. white spirit).

2.2 Grip the head (1) in a vice. (See drawing under 1.12)

2.3 Up to serial no.: 2349:

Place the new locating washer (15) onto the piston (2).

As of serial no.: 2350:

Correctly fit the new Turcon stepseal (15) onto the piston (2).

2.4 Fit the spring (11) and the piston (2) with locating washer (15) into the head (1).

2.5 Rotate the piston (2) so that the grub screw

(20) and the groove on the piston are in line.

2.6 Press the piston down using a tube until the

groove at the bottom is visible.

2.7 Advance the grub screw (20) fully home and

then retire it by one full turn. The grub screw

must not make contact with the bottom of the groove.

2.8 Arrest the grub screw (20) with a centre punch mark.

2.9 Grip the head (1) horizontally in a vice.

2.10 Up to serial no.: 2349:

Insert the locating washer (16) into the crimping head (1).

As of serial no.: 2350:

Correctly fit the Turcon stepseal (16) into the slot in the supporting washer (16).

2.11 Fit the supporting washer (5) into the head.

2.12 As of serial no.: 2350:

Fit the O-ring (22) onto the supporting washer (5).

2.13 Up to serial no.: 2349:

Insert the locating washer (14) into the cylinder (3).

As of serial no.: 2350:

Correctly fit the Glyd ring (14) onto the piston (4).

2.14 Insert the piston (4) into the cylinder (3) fully home.

2.15 Fit the springs (11) and (12) into the cylinder (3).

2.16 Fit the supporting washer (5) onto the piston (4)

2.17 Fit the cylinder (3) with the piston and springs on to the head (1), press it down and screw it

into place.

2.18 Use a monkey wrench when tightening the cylinder (3).

Pressing Cylinder HP 95

2.19 Insert and fully seat the locating washer (17) into the cap screw (8).

2.20 Place the washer (18) and the spring (13) on to the cap screw (8).

2.21 Insert the cone of the pin (7) into the locating washer.

2.22 Screw the assembled inlet pressure valve into the cylinder (3).

2.23 Fit the thrust pin (9).

2.24 Only for HP’s with hand switch:

•Screw the adapter (4/31830) into the cylinder (2) and place the shims (5/31830) on to the

adapter (4/31830).

•Fit hand switch (27) on adapter (4/31830).

•Fit cup washer (6/31830) on adapter (4/31830).

•Tighten hand switch with lock nut (3/31830). The groove in the nut (see enlargement)

must point towards the hollow side of the cup washer.

•Arrest the lock nut (3/31830) by tightening grub screw (17/31830).

2.25 Insert plug connector and tighten it.

3000 Pressing Cylinder HP 95 up to serial no.: 2349

Item Description Order

No.

Qty.

1 Head 3001 1

2 Piston 3002 1

3 Low-pressure cylinder 3003 1

4 Low-pressure piston 2352 1

5 Supporting washer 3005 1

6 Valve 3007 1

7 Conical pin 1497 1

8 Cap screw 1498 1

9 Thrust pin 1499 1

11 Spring 1215 2

12 Spring 1216 1

13 Spring 1613 1

14 Locating washer 50x35x10 11061 1

15 Locating washer 37x30x8/4 11059 1

16 Locating washer 38x26x8/5 11060 1

17 Locating washer 3x7x3 11056 1

18 Washer 4241 1

19 Bushing 11062 1

20 Grub screw AM 8x16 11052 1

21 Plug connector R3/8" 3718 1

23 Shrink sleeve 16728 1

24 Tool label 5693 1

25 Dust cap for plug end 1514 1

26 Ribbed nail 11120 2

27 Hand switch 31830 1

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