NovoPress HPM 400 User manual

Operating Instructions
for
CRIMPING TOOL
with manual hydraulics
HPM 400
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TABLE OF CONTENTS
Safety Regulations
Operative Range.............................................................................................................1
Technical Specifications .................................................................................................1
Crimping .........................................................................................................................2
Description of Functions .................................................................................................3
Return stroke..................................................................................................................3
Changing Tools...............................................................................................................4
Maintenance...................................................................................................................4
Minimum Quantity of Pressing Operations to be carried out per Cable Termination......5
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CRIMPING TOOL WITH MANUAL HYDRAULICS HPM 400, Order No.: 5200
Operative range:
Cable lugs and pressing connectors for copper and aluminium conductors can be pressed with the HPM 400.
Pressing Range for V-pressings:
Copper conductors from 16 to 400 mm2
Aluminium conductors from 50 to 400 mm2
For the minimum quantity of the V-pressings to be carried out per cable termination, see table on page 5.
NOTE:
The largest outer diameter of the connectors/connector sleeves is 38.5 mm (1.5"). Optimum crimpings of all
connectors with cross-sections in the above range is quaranteed by the automatic indentation depth control
which is built into the crimping tool.
Pressing Range for Hexagon Pressings:
Copper conductors from 16 to 240 mm2
Aluminium conductors from 25 to 185 mm2
For the minimum quantity of the hexagon pressings to be carried out per cable termination, see table on
page 5.
Technical data :
Length approx. 550 mm (21,6")
Width approx. 180 mm (7")
Force 110 kN (11 ton f)
Weight 5,9 kg without case (13 lb)
Max. work-piece dia. 38,5 mm
1
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Crimping
Insert the connector/connector sleeve with cable into the crimping head.
Operate the pump levers (1) until a clear recoil is felt. The crimping process is then completed.
Depending on the cross-section to be crimped, up to 50 strokes may be necessary.
NOTE:
Only for V-pressings:
When crimping aluminium conductors, the sleeve may be bent. To avoid this, perform every other crimping
with an offset of 180°.
NOTE: - Only for V-pressings:
Crimping in the same place more than once results in
over-crimping and reduces the cross-section.
- In order to check the indentation depth we supply test
rods with test instructions (Order No.6468) on request.
Pressing of AL conductor
- Roughen oxidized cable ends with abrasive paper before crimping.
- Use cable lugs/pressing connectors filled with a quartz containing
heat-conductive grease or lubricate the cable terminations
with a suitable grease.
- Select the distance to the next pressing operations such
that the tool is fully contacting a nondeformed area.
Selected distance all right: identical pressing depth
5
6
Key:
5 = Lower tool
6 = Cable lug
1
2
15
2
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Too close a distance: pressed too deep
Description of functions
While the pump levers (1) are being operated the following functions are performed
automatically:
- Accelerated pre-stroke of the piston with the lower die until contact is made with the connector/
connector sleeve at the point to be crimped. This pre-stroke occurs when the pump levers are
moved apart.
- Determination of the cross-section of the connector/connector sleeve to be crimping and the
indentation depth correct for this cross-section.
- Changeover to the crimping process. Crimping occurs when the pumping levers are moved
together.
- Completion of the crimping process on reaching the required indentation depth. At this point
a clear recoil can be felt in the pump levers, which spring apart slightly.
If the crimping cylinder reaches its maximum force during crimping, the recoil effect pulls the pump levers
together.
Return stroke
1. Rotate the turn button (2) by a maximum of 45 degrees and hold it there; the piston (15) returns.
Release the turn button (2); the piston (15) stops.
The return stroke of the piston (15) may be halted in any position.
The idle stroke can thus be restricted to a minimum.
2. Rotate the turn button (2) by 90 degress. The piston (15) will retract fully.
Return the turn button (2) to its original position before crimping again.
5
6
3
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Changing tools
1. Loosen the retaining screws (10)+(11) until the upper tool (12) can be removed from the crimping
head or the lower tool (13) can be removed from the piston rod (15).
2. Insert the new tools and tighten the screws firmly.
NOTE:
When mounting a lower tool for hex. press moulding operations (13a), care is to be taken that the side with
the centering bore (14) will ALWAYS point to the
retaining screw (11).
F A U L T Y P R E S S M O U L D I N G IN CASE OF ANY NON-COMPLIANCE
Maintenance
If dirty: Clean upper and lower tool.
Clean entire crimping cylinder.
Every week: Check upper and lower tool for any damage.
Replace, if necessary.
Every month: Check marked areas for possible leakage and send in
HPM 400 for repair, if necessary.
13a
13
2
11
12
1
14
15
4
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* Crimp DIN 46234 cable lugs only once.
Pressing Cylinder HPM 400
Minimum Quantity of the Pressing Operations to be carried out per
Cable Termination
Cross
section mm2
V-pressings Hexagon Pressings as per
DIN 48083, Part 4
Cu
Al Tool
Ident No. Cu Al
<80 N/mm2>80 N/mm2Cu Al
Cable Lug
DIN 46235
Connector
DIN 46267
Part 1
Cable Lug
DIN 46329
Connector
DIN 46267
Part 2
16 1  810 1 
25 1  10 12 1 2
35 1  12 14 1 3
50 1 2 2 14 16 2 3
70 1 3 2 16 18 2 3
95 1 3 2 18 22 24
120 2 4 3 20 2 4
150 2* 4 3 22 25 2 5
185 2* 4 3 25 28 3 5
240 2 4 3 28 32 3 
300 2 4 3   
400 2 4 3   
5
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Service
Scharnhorststraße 1 Postfach 101163
D-41460 Neuss D-41411 Neuss
Telex 8 518 015
Tel. 02131 / 288-0
Telefax 02131 / 28855

Pump levers Lower die Turn button Retaining screw Upper die
Retaining screw
Lower tool
Cable lug
Lower tool
Cable lug
Unterwerkzeug = bottom tooling
Oberwerkzeug = top tooling
Gewindestift Retaing screw
Halteschraube= holding screw
Unterwerkzeug 6-kant Hexagon lower tool
Zentrierbohrung Centering bore
7
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