OPERATING INSTRUCTIONS FOR HYDRAULIC DRIVE SYSTEMS
Contents
1. Pedal switch N OO N gt II 310701B04eng 0306 gn ge schw bk br gr ye 5 Ma stab Gewicht kg ES Werkstoff Halbzeug Stromlaufplan HA2 D SEN 319714 i Blatt Neuss CAD Nr 313753197101 zust Datum Ursprung Ersetzt_durch Tolerierung ISO 8015 zust aw Datum gt Allg Toleranzen Oberfizcherg Reihe 2 Werkstoff Halbzeug DIN 3141 CN Stromlaufplan epr en HA2 Norm D Sach Nr 319714 Blatt Neuss CAD Nr 313753197101 Ursprung Ersetzt_durch Se 93 96700 561041 _bDunzueb 3 PH 86102 20P 90X0LOLE EI HOA 022 1 1 Seen A u 1u3e q ot NIG YILU AJIWIIAZINYIS 4 8912 OSI QV Jaqn u bunJ puy SNY LON N Y34IMS 4004 Bunsaipo 4992915 neq af 2040 UNZ UIZ OQSPULISQY PUN Jaqn Jd 494 1 JOLOW uf t a puey EN A EA T tia EN LI lM V Y Tolerierung ISO 8015 Allg Toleranzen Oberfl chen nderungen nur nber CAD ISO 2768 Reihe 2 Werkstoff Halbzeug DIN 3141 Hydraulikplan HA1 ES HA1 Bau lt lt 31505 4 Neuss CAD Nr 31072. Carefully maintain the electric device The best and most secure work is guaranteed if you e keep the electric device clean observe the instructions for greasing changing the tools and ancillary equipment regularly check the connection cable and the extension cable have damaged cables repaired by a specialist keep hand grips dry clean and free form oil and fat have the electric device examined and cleaned by a specialist after 900 operating hours 009 005 10 Keep electric devices in a safe place Store electric tools and accessories out of the reach of children in dry high lying places or in locked rooms 11 Electric devices are often used by more than one person Therefore before beginning to work you should check the socket to ensure it is securely fixed and is not damaged in such a way as can be seen from the outside the connection cable for outward damage to the insulation and for sharp kinks that the cable is securely fixed to the device and whether the insulating plastic tube is damaged that the switch is secure and shows no outward signs of damage whether protective appliances or damaged parts function properly whether movable parts jam or are damaged do not use the device in the event of finding defects only allow the device to be repaired by a specialist or in an authorised NOVOPRESS specialist work shop only use original and identical NOVOPRESS spare parts 009 005 Technical data Elect
3. ES 3 5 litres HA 2 6 5 litres Hydraulic oil See Technical Data Oil filter The oil filter is the suction strainer with a mesh width of 0 06 mm e Unscrew the oil filling screw with the air relief valve 3 on the oil tank cover e Draw off the old oil by means of suction e Fill with new oil Note The gauge stick of the oil level oil gauge 4 must be between the two markings Cleaning Remove the oil film from the hydraulic unit every month Hydraulic hose The hydraulic hose is to be checked for damage every month Replace hydraulic hose If any cracks crush points or kinks are visible on the outer layer If blister formation is visible If pressurised fluid is escaping If the hose armature is damaged If any discolouration of the outer layer is visible e g due to the effect of solvents Hydraulic hoses must be replaced after 5 years even if no damage is visible 31070 B04eng 0306 Visual and electrical inspection Regularly Every 6 months Check mains cable including plug and extension cord with plug connectors for visible damage and have repaired if necessary Have an inspection complying with DIN VDE 0701 1 and DIN VDE 0702 for electric devices of the protection class 1 carried out by a qualified technician an authorized workshop or Novopress Neuss Hydraulic drive unitHA1ES Legend Control line Hydraulic hose Air relief valve Oil gauge Plug in connector Pushbutton
4. The hydraulic unit may only be used with Novopress system tools which have been approved for this unit see operating manual for the system tool Construction An oil filling screw with breather valve 3 and an oil gauge 4 are mounted on the oil tank cover Oil gauge 4 The gauge stick of the oil gauge must be between the two markings If the gauge stick is at the lowest marking oil needs to be added Bleeding valve 3 The air relief valve closes if the tank is on the slant no oil can emerge In the vertical position operating position a slight amount of oil vapour may be carried over with the escaping air The oil film which this causes on hydraulic equipment should be removed from time to time Note The equipment must not be switched on while horizontal There is a risk that the pump will not draw in oil and is damaged as a result 31070 B04eng 0306 Connecting system tools The system tools are connected to the hydraulic control unit by means of the control line 1 and the hydraulic hose 2 using the quick action coupling Connecting the hydraulic line Quick action coupling Coupling up Hold the coupling socket KM up to the sliding sleeve SH and slide it onto the coupling plug KS Uncoupling Hold the coupling socket KM at the sliding sleeve SH and pull it of the coupling plug KS KS Note When changing the system tools a small amount of oil will remain between the back press
5. d sign e ci apr s 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 Normes harmonis es utilis es en particulier voir point 1 Normes nationales utilis es en particulier voir point 2 Datum Herstellerunterschrift 01 04 04 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 Applied harmonized standards in particular see Item 1 above Applied national standards in particular see Item 2 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 overeenkomstig haar bestemming gebruikt of worden hieraan niet met ons overeengekomen wijzigingen aangebracht dan verliest deze verklaring h
6. 01 31505J01 DWG ac Datum Nome ursprung Ersetzt_durch N E 150bar Ma stab Gewicht kg Werkstoff Halbzeug H ydraulikplan HA2 arpas 31507 4 Neuss CAD Nr 313751 31507J01 DWG zust an Datum _ Nome ursprung Ersetzt durch Repairs Service novo Fess 1 101163 D 41460 Neuss D 41411 Neuss Tel 02131 2880 Federal Republic of Germany Telefax 02131 28855
7. MERGENCY OFF function of the pedal switch is active The equipment must not be switched on while horizontal There is a risk that the pump will not draw in oil and is damagedas a result e Actuate the manual key or pedal switch and hold it down Note When the manual or pedal switch is released the piston of the system tool will return immediately e The piston of the conected system tool will travel forwards The system tool is working e Once the work process has been completed or the safety valve has responded release the manual key or the pedal switch immediately Otherwise the oil will heat up unnecessarily Note Care should be taken to ensure that the oil temperature does not exceed 70 C during operation Pressure can only be built up again once the key has been released and actuated again 31070 B04eng 0306 Maintenance We recommend that our authorized NOVOPRESS specialist workshops be used for repair and maintenance work Only have the equipment maintained by a specialist Caution Check oil level BEFORE ANY MAINTENANCE OR REPAIR WORK ALWAYS PULL OUT THE MAINS PLUG The gauge stick of the oil level indicator 4 must be between the two markings If it is at the lowest marking oil must be added Top up the oil if necessary Oil change First oil change After about 1 000 starts or after 3 months Other oil changes After every 15 000 starts but at least once annually Oil volume for HA1
8. OPERATING INSTRUCTIONS FOR novo Fess HYDRAULIC DRIVE SYSTEMS HA1ES HA2 4879 31070 B04eng 0306 Table of contents CE Conformity Declaration Safety regulations Technical data Intended use Construction Connecting system tools Three phase safety pedal switch Operation Maintenance Appendix Circuit diagram Hydraulics diagram 31070 B04eng 0306 Page O OI 5 gt DIN EN ISO 9001 CE KONFORMITATSERKLARUNG entsprechend EG Maschinenrichtlinie 98 37 EG Anhang Novopress GmbH amp Co KG Scharnhorststr 1 D 41460 Neuss Hydr Antriebsaggregat HA1ES HA2 Sern aia A 1 EN 292 EN 294 EN 349 EN ISO 9001 EN 60947 1 EN 60947 4 1 2 UVV VBG1 UVV VBG4 UVV VBG5 VDE 0100 VDE 0106 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 Angewandte harmonisierte Normen insbesondere siehe Punkt 1 Angewandte nationale Normen insbesondere siehe Punkt 2 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 march la machine
9. aar geldigheid Toegepaste geharmoniseerde normen in het bijzonder zie punt 1 Toegepaste nationale normen in het bijzonder zie punt 2 EE Geschaftsfuhrer s 31070 ce 31070c04 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 Normas armonizadas aplicadas en particular v ase bajo el punto 1 Normas nacionales aplicadas en particular v ase bajo el punto 2 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 Till mpade harmoniserade normer i synnerhet se punkt 1 Till mpade nationella normer i synnerhet se punkt 2 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 grunnle
10. d when discolouration is established on the outer layer e g due to the influence of solvents 8 hydraulic fluid used 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 open fire DANGER OF EXPLOSION 009NP006 DOC SAFETY TIPS FOR ELECTRIC TOOLS ATTENTION In order to avoid electric shock danger of injury and burning the following basic safety measures are always to be taken when using electric tools Read and observe the notes before using the device Keep the safety tips in a safe place 1 Take influences of the surroundings into account Do not expose electric devices to rain Do not use electric devices in damp or wet surroundings Do not use electric devices in the vicinity of flammable liquids or gases 2 Protect yo
11. e 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 009 004 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 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 e when cracks squashed or bent points are to be seen when blistering is established when hydraulic fluid escapes when pipe fittings are damage
12. 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 Normas harmonizadas aplicadas especialmente vide par grafo 1 Normas nacionais aplicadas especialmente vide par grafo 2 s 31070 ce 31070c04 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 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 maintenanc
13. ggende 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 Benyttede harmoniserte standarder s rlig se punkt 1 Benyttede nasjonale standarder s rlig se punkt 2 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 Norme armonizzate applicate in particolare vedi punto 1 Norme nazionali applicate in particolare vedi punto 2 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 yksi 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 K ytetyt harmonisoidut standardit varsinkin katso Kohta 1 K ytetyt kansalliset standardit varsinkin katso Kohta 2 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
14. ric motor Connection voltage Power consumption Rotational speed Mode of operation Protection class Mode of protection Radio interference Power connection Hydraulics Hydraulic connection Operating pressure Delivery capacity Dimensions Weight incl oil Hydraulic oil See identification plate 800 W max 10000 min 1 3 25 100s 1 IP 44 As per VDE 0875 Cable 5 m long with a three phase safety pedal switch and earthing contact type plug Quick action coupling plug with back pressure valve 150 bars max at n 1000 min HA 1 0 45 l min HA 2 0 9 l min HA 1 ES H 470mm 250 mm lt 280 mm 2 470 280 mm 460 mm HA 1 ES 18 kg HA 2 34 kg Oil filled in at works ISO VG 10 DIN 51519 suitable for external temperatures from 5 to 35 C Oil usable Oil in viscosity class ISO VG DIN 51519 from 10 to 46 viscosity in CSt 7 4 30 at 50 C Oil for temperatures lt 5 C ISO VG 5 DIN 51519 31070 B04eng 0306 Hydraulic control units basic equipment With respect to the hydraulic control units there are the following versions 1 1 ES Order No 31070 Hydraulic control unit with 1 electric motor 2 HA 2 Order No 31375 Hydraulic control unit with 2 electric motors Intended use NOVOPRESS hydraulic control units operate in the low pressure range up to 150 bars and they are used as drive units for our hydraulic system tools
15. ure valves of the coupling Handle the hydraulic hose with care Bends at the connection points will lead to premature breakdown When coupling up make sure that dirt does not penetrates the coupling Before coupling up another system tool wipe out the coupling socket with a clean cloth that is free of fluff The system tools should as far as possible remain coupled up at all times Connecting electrical leads 1 ES e Connect the control line 1 of the hydraulic control unit HA 1 ES to the system tool with the aid of the plug connector 5 HA 1 ES HA 2 e Connect the mains cable to the power suply line Note Observe the mains voltage see identification plate 31070 B04eng 0306 Three phase safety pedal switch 2 3 1 Pedal not actuated System tool OFF 2 Pedal actuated as far as detectable stop of pressure point System tool ON 3 Pedal actuated beyond pressure point EMERGENCY OFF Pedal switch locked Note When EMERGENCY OFF is actuated The hydraulic control unit is switched off and cannot be restarted by pressing the pedal again To release the system press the blue pushbutton 6 31070 B04eng 0306 Operation Note The hydraulic unit can only be actuated with the manual button located on the system tool or by the pedal switch The system tool which is connected will determine how the hydraulic device has to be operated When the manual key is actuated the E
16. urself from electric shock Do not fix additional rating plates or symbols with rivets or screws Use adhesive signs When working with electric devices avoid body contact with earthed objects such as pipes heating appliances refrigerators etc 3 Use the correct tools Only use the tools and accessories outlined in the operating instructions Do not use the electric device to do work for which it is not intended 4 Secure the work piece Use gripping devices or vice grips to hold the work piece steady It is more securely held than by hand and you can operate the device with two hands 5 Do not overload your electric device You can work better and more securely in the indicated power range 6 Do not use the cable for purposes for which it is not intended Do not carry the electric device by the cable Do not use the cable in order to pull the plug out of the socket Protect the cable from heat oil acids and sharp edges For working in wet rooms or in the open only use the authorised extension cables with the corresponding marking 7 Avoid unintentional starting Ensure that the electric device is switched off before connecting the mains plug Do not carry the electric device in such a way as that your finger is on the switch Do not use the electric device H the ON OFF switch does not work perfectly 8 Disconnect the mains plug e if the device is not in use e before maintenance of the electric device e when changing tools 9
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