KW Hydraulik SSBZ User manual

Stand: 19.03.12 Seite 1
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
Operating manual for
contact rail machining centre
SSBZ
The contact rail machining centre SSBZ is used for bending, punching, cutting and
offsetting of aluminium or copper rails to a max. cross-cut of
120 x 12 mm.

Stand: 19.03.12 Seite 2
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
Index
1 Introduction................................................................................................................................................. 2
2 Directions of safety..................................................................................................................................... 3
3 Technical data for SSBZ ............................................................................................................................ 5
4 Starting of the basic device........................................................................................................................ 6
4.1 hydraulical connection......................................................................................................................... 6
4.2 electrical connection............................................................................................................................ 7
4.3 settings of the height........................................................................................................................... 8
4.4 operating of the survey-bar................................................................................................................. 8
4.5 operating of the pump ......................................................................................................................... 9
5 Insertion of the tools................................................................................................................................... 9
5.1 bending tool....................................................................................................................................... 10
5.2 punching tool..................................................................................................................................... 14
5.3 cutting tool......................................................................................................................................... 17
5.4 offsetting tool..................................................................................................................................... 20
6 Searching for an error .............................................................................................................................. 22
7 Servicing, maintenance, storage and transportation................................................................................ 22
8 Guarantee-service.................................................................................................................................... 23
9 Drawings for assembling.......................................................................................................................... 24
10 Spare-part lists...................................................................................................................................... 33
11 Declaration of conformity...................................................................................................................... 36
1 Introduction
The contact rail machining centre SSBZ consists of a basic device and different tools. It is
responsible for its easy handling and universal employability. The appliance can be
equipped by an easy changing of the tools at the basic device within a few seconds. Tools
for bending, punching, cutting and offsetting are available.
The basic device is used for working with aluminium or copper contact-rails to a maximum
cross-cut of 120 x 12 mm. Therefor it has to be connected by a high-pressure-hose at a
hydraulic-pump with a max. pressure of 700 bar and an output-work up to 1.5 l/min. The
required volume of the oil is around 0.15 l.
For the work we propose the electrical-hydraulic-pump NP-230 or ANP-24/230. There is a
selection of pumps with system-connection and also a combination of system-/battery-
pumps. All electronic-hydraulic-pumps are equipped with a control-electronic. This
electronic makes an automatically stop at a bending-angle which was chosen before. You
do not have the chance for using this function through an insertion of foreign-parts.

Stand: 19.03.12 Seite 3
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
2 Directions of safety
danger area / handling
 It has to be that the hydraulic-pump can be activated only from the user of the
machining centre.
 It is only allowed that one person is in the danger zone of the machine.
 Especially pay your attention to the contact rails. They swing in the direction of the
piston during the bending process. In this area there must not be neither persons
nor items.
 Do not touch into the danger zone of the tools during the working-process.
 During the placing of the punch on the piston there must not be fingers between the
punch and the die during the forward-moving of the punch (see in capture 5).
 Never bow over the tool between a working-process.
insertion
 It is only allowed to use the contact rail machining centre and its tools for its
working-aims.
 It is only allowed to work with the tools from KW at the SSBZ.
 The pressure-hose has to be for a working pressure of 700 bar and it must not be
damaged or wear out.
 It is not allowed to install pumps with a pressure of more than 700 bar.
 It is only allowed to install pumps with a maximum output-work of 1.5 l/min.
 Hydraulic pumps have to be equipped with a coupling and an SSBZ-adjustment for
optoelectronic sensor.
 It is only allowed to connect the hydraulic system under a pressure-free condition.
 Please take care of a perfect condition of the tools.
 The appliance has to stand on a firm and straight ground.
 Put the dust protecting caps into each other during the working-process.
 Protect and store the contact rail machining centre that it is protected against
misuse.
 Do never cut steel. The blade does not take this load.

Stand: 19.03.12 Seite 4
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
protection-equipment
 You have to operate the tool with gloves and safety goggles.
demands for training
 The owner has the duty that the user read and understood the operating manual –
the directions of safety especially.
 The owner has the duty that only persons who are familiar with the appliance, the
instructions and the working-process are allowed to work with this appliance.
 The operating manual has to be at the appliance at every time.
servicing / maintenance
 The appliance has to be checked for its perfect condition (indication: biannual) in
regular intervals (the user has to lay it down according to the working conditions).
 Servicing-work is only allowed by professional skilled and trained staff.
 The hydraulic oil must filled up with original oil.
 It is only allowed to install original spare parts.
 Do not remove screws or other components.
 Pay attention to a clear pick up of the die during the install of the die.
 Protect the tools against humidity to avoid a corrosion.
 Do not make a manipulation at the appliance, remove parts or replace them with
foreign-parts.
 Before every work, the user has to check the equipment for a perfect condition.
Especially the pressure-hose, the coupling and the tool which is connected.

Stand: 19.03.12 Seite 5
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
3 Technical data for SSBZ
basic device SSBZ
maximum working-pressure 700 bar
pressing-force 185 kN at 700 bar
required oil-volume 0.15 l
max. permissible output-work of the pump 1.5 l/min.
working tension (optoelectronic sensor) 10...30 VDC
sizes (l x w x h) 480 x 500 x 360 mm
weight 51 kg
hydraulic oil Shell Naturelle HF-E 15
permissible working temperature -20 °C to + 40 °C
relative air-humidity 0 to 100 %
bending tools
Maximum bending-angle 100°
working material Al/Cu 120 x 12 mm
bending-radius 5. 8, 10 or 20 mm
Weight 7.1 kg (at radius r=8mm)
punching tools I
punching diameter 6.5 to 21.0 mm
working material Al/Cu-massive-rails to max. 12 mm
weight 4.5 kg
punching tools II
punching diameter 6.5 to 21.0 mm
working material Al/Cu-massive- and lamina-
rails
to max. 12 mm
weight 4.5 kg
cutting tools
working material Al/Cu to max. 120 x 12 mm
weight 5.3 kg
offsetting tools
maximum tool-pawning 12 mm (Al, Cu)
working material 175 x 90 x 135 mm
weight 10.0 kg

Stand: 19.03.12 Seite 6
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
picture 1: operating elements of the contact rail machining centre SSBZ
4 Starting of the basic device
4.1 hydraulical connection
The contact rail machining centre SSBZ is delivered ready for operating from the KW
Hydraulik GmbH. Connect it with the fast-coupling and a high-pressure hose to a suitable
hydraulic pump.
Attention! Only connect them in a pressure-free condition.
fast
-
coupling
clamping
-
screw
clamping device
opto electronic sensor
piston
leading rail
remote control
clamping lever
height
-
scale
length-stroke
reading label at
the clamping bow
leadership in the
die
-
holder
hand-wheel for the
setting of the height

Stand: 19.03.12 Seite 7
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
By putting together the dust protecting caps (picture 2) you can avoid that dirt gets into the
caps or the coupling. Dirt in the hydraulic system can cause operating-errors.
picture 2: put together the dust protecting caps
4.2 electrical connection
By using a hydraulic pump the common plug for remote control and optoelectronic sensor
has to be plugged in the remote control-socket of the pump (see also in the operating
manual of the pump). The optoelectronic sensor has to be fastened with the fix on the
basic device (picture 1).
Indication! The optoelectronic sensor is only used for bending-jobs. In all other jobs the,
in the direction of the tool pointing, front side of the holder has to end in a bundle with the
fix (see picture 1) because otherwise the pump does not start.

Stand: 19.03.12 Seite 8
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
4.3 settings of the height
The SSBZ is equipped with a hydraulic height-setting. By turning of the hand-wheel the
distance can be adjusted from the working-plate to the piston-axle. Adjust the height
during the cutting and bending always that the middle-axe of the piston is in agreement
with the tool (picture 3). You can read the adjusted worth (worth at the height-scale = ½ x
height of the rail) at the height-scale (picture 1).
picture 3: adjusting the height of the working-device
Indication! Adjust the wanted height always by turning the hand-wheel in the clock’s
direction. Otherwise the showed worth could change during the operation by itself.
4.4 operating of the survey-bar
The survey-bar (picture 4) is used for punching with priority. You can adjust it by opening
of the two fixes. The adjusted measure refers always to the piston-axle. This means,
during the punching it refers to the centre of the punch. You can read the worth at the
outside of the fix-handle. (see arrow in picture 4).
Should the survey-bar-angle for a special using be in a difficult position you can adjust it
after untie the front sided hexagon-screw easily.
material
cutting tool
piston middle-axle
moving direction of the working device

Stand: 19.03.12 Seite 9
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
picture 4: survey-bar
4.5 operating of the pump
The KW hydraulic-pumps are equipped with a touch-control. In the touch-control working-
process the piston of the hydraulic cylinder moves as long to the front direction as you
press the button of the remote control. The piston stays in its position by releasing the
button. The piston moves to its starting position by a short touch of the button.
The piston moves back to its starting position automatically after reaching the maximum
pressure of 700 bar.
5 Insertion of the tools
We offers tools for bending, punching, cutting and offsetting. Therefor there is also a tool-
case in which all these tools can be stored
(picture 5).
picture 5: tool-case
offsetting tool bending tool
cutting tool
punching tool
reading-label at
the fix-handle

Stand: 19.03.12 Seite 10
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
On principle all tools consist of two groups. One of these groups has to be put on the
piston. The other one has to be put on from above on the guide rail. For further details
please read the paragraphs of the tools.
5.1 bending tool
The bending tool (picture 6) is used to bend contact rails of aluminium and copper up to
120 x 12 mm. The maximum bending-angle is 100º at a bending-radius of 8 mm. You can
also get special tools with a bending-radius of 5 mm, 10 mm and 20 mm.
picture 6: bending-tool
At first make the contact rail machining centre according to capture 4 clear for working. For
bending, operate the SSBZ according to the following points:
 You have to remove the plate (picture 7) of the basic-device before installing the
tool you.
die
not
stopping-bolt
punch

Stand: 19.03.12 Seite 11
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
picture 7: plate
 Put the bending-punch with the below not on the guide rail and push the punch in
direction of the piston-bar until the latch stops and held it. Attention! Pull the latch!
 Put the bending-die in the guiding-way from above.
 After that put the contact rail in and adjust the height of the working-group with the
hand-wheel on a half height of the contact rail (see in picture 3). The height-scale at
the basic-device (picture 1) shows the distance between working-plate and piston-
axle.
Now the appliance is ready for working (picture 8).
picture 8: ready bending tool in the SSBZ-basic device
plate
Auflage

Stand: 19.03.12 Seite 12
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
Either you can read the bending-angle at the scale of the working-table or adjust it at the
optoelectronic sensor (picture 9). You have to use an electronic hydraulic pump with a
stop-electronic (SSBZ-adjustment) for using the optoelectronic sensor as an angle-
disconnect.
You have to adjust the wanted bending-angle at the optoelectronic sensor (picture 9). But
you have to take care that the angle-mark (white scale: 0º, 30º, 45º, 60º, 90º) is adjusted to
the right strength of the material (red scale: 5, 8, 10, 12 mm).
picture 9: optoelectronic sensor
Indication! The different worthies of the materials could cause a small deviation of the
adjusted and the reached bending-angle. In these cases you have to find out the best
setting of the button by testing. For preventing an over-bending of the rail we advise that
you go slow to the wanted angle.
By bending without optoelectronic sensor you have to take the suitable angle-settings from
the working-table. For this you can take all hydraulic pumps with a maximum pressure of
700 bar.

Stand: 19.03.12 Seite 13
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
re-bending tool
If you bend a contact rail over you can re-bend it with the re-bending tool (picture 10).
picture 10: re-bending tool
Therefor you have to replace the bending-punch with the re-bending punch. The bending-
die stays is the SSBZ. As well the put in as the put out of the re-bending punch is the
same like the bending-punch. Lay the over-bend rail
with the bending-place in direction to the re-bending punch into the SSBZ
(picture 11). You can re-bend the contact rail by using the pump.
picture 11: re-bending tool and contact rail in the SSBZ
re-bending punch stopping-bolt
bending-die

Stand: 19.03.12 Seite 14
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
Attention! The contact rail waves in the direction to the bending-punch during all bending-
processes. There must not be any person or item in the distance of the wave.
5.2 punching tool
punching tool 1
The punching tool 1 is used for punches and long-punches in contact rails of aluminium
and copper. The maximum strength of the material is 12 mm.
The punching tool 1 consist of hole-punch and die-reception. The punch-insert consist of a
die and a hole-punch (picture 12). The hole-punch (picture 13) is equipped with a centring-
spike which allows a faster and exact positioning.
picture 12: punching tool 1
* belongs to the punch-insertion
For insertion the hole-punch the latch (rubber feather) has to be taken away from the hole-
punch reception. For the re-latching, the female-screw has to be turned with the milled
side in direction to the cylinder. You can take the latch away; you can install the punch and
tie it up with the hexagon-screw. After that you have to pull the latch over the hole-punch
reception and to tie it up with the female-screw.
die*
hole
-
punch reception
female-screw
stopping-bolt
not
latch
hexagon-
screw
die-reception

Stand: 19.03.12 Seite 15
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
picture 13: sketch of the punching tool without latch
At first make the basic device SSBZ, according to capture 4, ready for the work. For
punching please adjust the SSBZ as followed:
 Put the hole-punch reception of the punching tool with the not below on the guide
rail of the basic device (picture 1) and move the piston-bar out until the latching-bolt
is latched. Attention! Pull the latching-bolt!
 After that, move the piston-bar with the complete hole-punch reception to its starting
position by pressing the button.
 The die has to be put in the reception and tied up with the side screw. Take care
that the die is in the right position. The not has to be behind (see picture 13). The
height-data of the punch and the die have to agree. In each case they are at the
back of the tools.
Indication! Take care that the punch and the die are in the right position for long-
punch insertions. You have to take care that the locking-screw and the centre-
sinking are at the same side by the insertion of the long-punch die into the
reception. The die is fixed in the right position automatically by tying up the screw.
 After that please push the die-reception into the guiding-way from above.
 For using the electronic hydraulic pump the optoelectronic sensor has to be in the
0-position, i. e. that the to the tool showing front side of the button is flush with the
fix-appliance (picture 1).
die
-
reception
hole-punch reception
die
p
unch

Stand: 19.03.12 Seite 16
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
Now the appliance is ready (picture 14).
picture 14: punching tool 1 in the SSBZ
The dismantling of the tools are in a reversed turn. For the removing of the hole-punch
reception you have to move the die-reception by the touch-control a little bit forward, to
untie the latching-bolt.
You should use cutting-spray for the increase of the lifetime of the punching-insertion.
punching tool 2
You can make all sorts of working with the punching tool 2 (picture 15) like the punching
tool 1. In addition it is good for punching lamina-rails.
The punching tool 2 is a little bit different to the punching tool 1. At the front side of the
latch it has a latch-plate which locks the punch very exactly. The latch is hold from
permanent magnets. By changing the punch you have to remove the latch and the latch-
plate. There is not a female-screw which you have to untie before.
The shaft of the punches for the punching tool 2 has two centring. After a insertion of a
punch you have to fix it with both worm-bolts of the hole-punch reception on this centring.
Afterwards put the latch on the latch-plate.
The change of a die and the insertion of die-holders as well as a hole-punch reception in
the SSBZ is the same as at the punching tool 1.

Stand: 19.03.12 Seite 17
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
picture 15: punching tool 2
* belongs to the punch-insertion
punching tool for 15 mm strength of the material
We offers you also a punching tool for punching aluminium and copper up to 15 mm. It
looks nearly like the punching tool 1. The using is almost the same as the using of the
punching tool 1. An extra operating manual is present.
5.3 cutting tool
The cutting tool (picture 16) is used for cutting contact rails of aluminium and copper up to
120 x 12 mm.
die
-
reception
latch
latch-plate*
die*
not
latch-bolt
hole
-
punch reception

Stand: 19.03.12 Seite 18
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
picture 16: cutting tool
At first make the contact rail machining centre SSBZ, according to capture 4, ready for the
work.
For cutting please adjust the SSBZ as followed:
 Before the insertion of the tool you have to remove the plate at the basic device
(small way between the plates, see picture 7).
 For montage of the tool at first you have to insert the blade (picture 16) into the
counter blade. The labels of the two parts “above” have to agree.
 Then put both blades together from above into the guide (picture 1).
 After that please push the blade on the piston-bar until the latch-bolt is locked.
Attention! Pull the latch-bolt!
 Lay the contact rail in and adjust the working-group with the hand-wheel that the
counter blade cuts in a middling position to the contact rail (worth at the height-
scale = ½ x height of rail, like in picture 3). The height-scale shows the distance
between working-plate and piston-middle-axle (picture 1).
 For using the our electronic hydraulic pump with a stop-electronic you have to take
care that the optoelectronic sensor (picture 9) is in the 0-position, i. e. that the to the
tool showing front side of the button is flush with the fix-appliance (picture 17).
counter
blade
not
latch-bolt
cutting
blade

Stand: 19.03.12 Seite 19
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
Now the appliance is ready!
The dismantling of the tool is in a reversed turn.
You should use cutting-spray for the increase of the lifetime of the punching-insertion.
WARNING! Do never cut steel! Never bow yourself above the basic-device during a
cutting process.
picture 17: cutting tool in the SSBZ

Stand: 19.03.12 Seite 20
KW Hydraulik GmbH Tel.: [phone]
Köppelsdorfer Str. 132 Fax: [phone]
D-96515 Sonneberg e-mail: [e-mail]
Germany Internet: www.kw-hydraulik.de
SSBZ
SSBZSSBZ
SSBZ
5.4 offsetting tool
The offsetting tool is used for offset contact rails of aluminium and copper up to 120 x 12
mm (picture 18).
picture 18: offsetting tool
At first make the contact rail machining centre SSBZ, according to capture 4, ready for the
work.
For offsetting please adjust the SSBZ as followed:
 Before you put the tool in you have to remove the lay on of the basic-device.
 For the wanted pawning you have to look in the schedule for the right copulation of
the plates.
Copulation of plates / pawning 10.0 mm 8.0 mm 6.0 mm 5.0 mm
12.00
10.00 x
8.00 x x
6.00 x x
5.00 x x
 At the insertion of the plates to the offsetting-cheeks you have to take care that for a
montage of more than one plate at each offsetting-cheek the plate has to be at the
outside with the label 10.0. This means it has to show in the direction of the rail.
 Put the movable cheek of the offsetting tool with the below not on the guide rail of
the basic device and move the piston-bar out until the latch-bolt is locked.
Attention! Pull the latch-bolt!
fixed offsetting
-
cheek
latch-bolt
support-plates
movable
offsetting-cheek