Gechter 2,5 HKPE, Translation Of The Original Operating Manual

Page 1: ...V and HKP Type 2 5 HKPE 2 5 HKPV 5 HKPE 5 HKPV 8 12 HKPV 8 16 HKPV 50 HKP The operating manual must be read prior to the initial commissioning Observe the safety instructions Keep for future use This documentation is not subject to any change service January 2016 Version 00 December 2020 Version 01 Representation of HKPV ...

Page 2: ...n read and understood The operating manual must be stored in a known and easy to access location and must also be consulted even in cases of minor doubt The manufacturer assumes no liability for damage to people animals or objects as well as the press itself which is caused from improper use neglect or insufficient observance of the safety criteria contained in this operating manual or that is cau...

Page 3: ...ng on the type of hazard ANSI Z535 6 DANGER indicates a hazard ous situation which if not avoided will result in death or serious injury WARNING indicates a hazard ous situation which if not avoided could relust in death or serious injury CAUTION indicates a hazard ous situation which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to physi c...

Page 4: ...tallation 10 4 1 Transport process 11 4 2 Setting up the system 12 4 2 1 Space required 12 4 2 2 Fastening the press 13 4 3 Operating Conditions 13 4 3 1 Press lighting 13 4 4 Aligning the system 14 4 5 Operating equipment 14 5 Setup and function 15 5 1 Description 15 5 2 Standard versions 15 5 3 Technical Data 16 5 3 1 Technical data 2 5 HKPE 2 5 HKPV 16 5 3 2 Technical data 5 HKPE 5 HKPV 17 5 3 ...

Page 5: ... 3 Clamping the tool 35 8 1 4 Setup 36 8 1 5 Adjust the height 38 8 1 6 Adjusting the stroke length and pressing force only for type 8 12 and 8 16 39 8 1 7 Changing the hand lever from right to left 40 9 Service and maintenance 42 9 1 Maintenance safety 42 9 2 Technical Support 44 9 2 1 Cleaning the press 45 9 2 2 Lubricate the prism guide 46 9 3 Packing system parts 47 9 4 Wear and spare parts li...

Page 6: ... embossing and cutting work as well as work with suffi ciently insulated heated tools The device is only suitable for processing metal cardboard plastic rubber leather and metal powder Any other or extended use of the press is considered as unintended and is thus incorrect This may impair the safety and its protection The company Gechter GmbH Gechter GmbH Werkzeug und Maschinenbau is not liable fo...

Page 7: ...ning operation chapter changes to the press as well as additions and conversions without pri or consultation with the company Gechter GmbH Werkzeug und Mas chinenbau operating the press contrary to the provisions of the operating manual with respect to safety instructions installation operation mainte nance and repair setup and faults Risk of injury from unauthorized changes Dangers result from un...

Page 8: ... assembly commissioning operation and maintenance operating the press with defective safety devices disregarding instructions in the operating manual unauthorized structural changes deficient maintenance repair and service measures cases of disaster caused by foreign bodies or force majeure 2 2 Target group of the operating manual Target Group The operating manual is intended for the operator and ...

Page 9: ...Gechter GmbH Werkzeug und Maschinenbau and who are therefore familiar with the technology are physically and mentally capable to do so Outside of the Federal Republic of Germany the applicable accident prevention regulations safety provisions and youth employment protection laws of the re spective country shall apply 2 3 Objectives of the operating manual This operating manual is intended as an ai...

Page 10: ...ng to the recognized technical safety rules In order to exclude dangers to the life and limb of the user third parties or other damage during its use only use the press for the intended use and in the clearly technically safe and perfect condition Property damage and physical injuries that are due to the instructions in the operating manual being ignored are the responsibility of the press operato...

Page 11: ...se of the press is the prerequisite for safe operation That is why the press operator is obligated to ensure that the fol lowing points are observed Ensure that the press is only operated by trained and authorize person nel Prohibit safety impairing and dangerous working methods If necessary review the personnel s actions Have personnel confirm they have understood the operating manual with their ...

Page 12: ... shift Risk of injury when used by unauthorized personnel There are hazards if unauthorized personnel intervene in the press The press may only be operated after briefing or training The operating personnel are required to personally behave so as to contribute to preventing work accidents and their consequenc es 3 2 3 Setup Risk of crushing from the intervention of unauthorized persons There are h...

Page 13: ...b ited Only parts approved by the manufacturer may be used 3 2 5 Residual dangers There can be residual risks that are not apparent despite all precautions taken Residual risks can be reduced if the safety instructions and the intended use as well as the operating manual are observed in their entirety Risk of crushing and hand injury There is a risk of injury from the movement of press compo nents...

Page 14: ...g regulations at the site of use the recognized technical rules for safety and professional work existing regulations for environmental protection other applicable regulations Employee training with respect to hazards and the required pro tective measures must be repeated regularly but at least once a year Operating instructions are required in the interest of occupational safety which the operato...

Page 15: ...ly inspect that all sling gear is undamaged and in good condition Screw in the full length of hooks and eye bolts Check the delivered parts for completeness damage or other abnormali ties During transport observe the valid safety and accident prevention regu lations BGV D8 D6 If you have questions about transport setup and installation of the press contact the company Gechter GmbH tool making and ...

Page 16: ...sport equipment lift truck forklift Wear appropriate protective clothing during transport work For transport only use technically flawless and functional hoisting gear with sufficient load bearing capacities Lift the press at the marked attachment points 3 Ensure that the load bearing capacity of the hoisting gear as well as the load receiving and transport equipment correspond to the loads specif...

Page 17: ...lways raise the other presses at the stand never at the guide part or hand lever damage to the guide possible When raising the press balance the forward tilt by holding on to the press table Unpack and grease the press Example Eye bolt for transport 4 2 1 Space required Observe the exact specifications of the installation dimensions in the fol lowing schematic diagrams of the press specifications ...

Page 18: ...ion max 2000 m above sea level Contamination No high contamination from dust acids corrosive gases Special conditions No direct sunlight The operators must install additional lighting equipment if the working area is insufficiently lit Sufficient ventilation of the working area load on the operator The press does not have any explosion protection 4 3 1 Press lighting The press does not have its ow...

Page 19: ...ached press elements Spirit level Check the horizontal position with the spirit level Spirit level 4 5 Operating equipment Please refer to the documentation for supplier components in the appen dix When using cleaning agents follow the operator s current work instruc tions Refer to the Lubrication chapter for specifications about lubricating the press ...

Page 20: ... fastened to an existing workbench or a sturdy base frame The hand toggle press may only be used for pressing joining assembly rivet ing punching bending embossing and cutting work as well as work with suffi ciently insulated heated tools The device is only suitable for processing metal cardboard plastic rubber leather and metal powder 5 2 Standard versions A modified stand version may be required...

Page 21: ... data 2 5 HKPE 2 5 HKPV Dimensions and weights 2 5 HKPE 2 5 HKPV 1 1 Force in the lower part with permissi ble max 5 kN max 190 N max 8 kN max 280 N A 188 202 A2 200 220 C 320 320 D 150 150 E 70 90 F 55 60 G 39 40 U 25 25 V ø 10H7 ø 10H7 X 75 190 75 190 X1 0 32 0 42 413 510 413 510 480 600 Weight kg 7 11 5 1 Standard press ...

Page 22: ...HKPV 1 2 3 Force in the lower part with permissi ble max 14kN max 320N A 227 380 234 A2 243 396 243 C 344 360 444 D 180 200 180 E 90 200 90 F 60 120 60 G 50 70 50 U 21 21 21 V ø 10H7 ø 10H7 ø 10H7 X 70 195 70 195 115 300 X1 0 40 0 40 0 40 Y 595 715 610 758 695 815 Weight kg 20 30 27 1 Standard press 2 Enlarged overhang 3 Enlarged installation height ...

Page 23: ...t stroke long stroke max 420N max 420N A 310 548 315 420 603 443 A2 328 566 328 445 628 468 C 415 507 515 590 670 690 D 200 200 200 300 300 300 E 120 300 120 160 300 160 F 92 120 92 130 130 130 G 76 85 75 100 100 100 U 21 21 21 29 29 29 V ø 10H7 ø 10H7 ø 10H7 ø 15H7 ø 15H7 ø 15H7 X 75 240 180 235 110 335 100 320 220 320 150 420 X1 0 23 45 0 23 45 0 23 45 0 25 58 0 25 58 0 25 58 Y 655 820 755 910 7...

Page 24: ...orce in the lower part with permissible lever tensile max 55kN max 330N A 520 670 522 A2 565 715 567 C 715 769 815 D 340 340 350 E 200 300 200 F 150 150 150 G 120 120 120 U 49 49 49 V Ø 25H7 Ø 25H7 Ø 25H7 X 110 370 230 370 110 470 X1 0 15 0 15 0 15 Y 1250 1250 1350 Weight kg 242 306 254 1 Standard press 2 Enlarged overhang 3 Enlarged installation height ...

Page 25: ...Setup and function 5 Hand toggle presses Translation of the original operating manual 20 5 3 5 Nameplate Nameplate example ...

Page 26: ...rating manual 21 5 4 Overall representation 1 Adjusting lever 6 Press stand 2 Eye bolt 7 Press table 3 Spindle clamping screw 8 Press sled 4 Clamping screws 9 Lever clamping 5 Guide part 10 Hand lever Not all components are available for all press types 10 1 2 3 4 9 8 7 6 5 ...

Page 27: ...are not available for all press types Installation manuals are available for the accessories 5 5 1 Fine adjustment PFE Release both threaded pins to adjust the PFE Releasing the threaded pins Adjust the PFE according to the scale Tighten both threaded pins Scale A dash on the scale corresponds to 0 025 mm Travel distance max 3 mm ...

Page 28: ...y unlocking Pull out Disabling Pull out and turn 90 Mechanical return stroke lock 5 5 3 Precision depth adjustment PTE Loosen the threaded pin to adjust Adjust the depth according to the scale Tighten the threaded pin Adjusting the PTE The precision depth adjustment PTE can be adjusted by 3 mm A dash on the scale corresponds to 0 025 mm ...

Page 29: ...er tightly during the entire work cycle Release the hand lever once this has reached the uppermost po sition Carry out the following activities Unscrew the Allen screw Remove the clamped piece Align the ergonomic handle Screw on the clamped piece Ergonomic handle 1 Ergonomic handle 3 Fastening screw 2 Clamping piece An installation manual is available for the ergonomic handle 1 2 3 ...

Page 30: ...llowing activities Slide the T shaped sliding blocks into the T groove guide Place the centering plate on the press table Affix the centering plate with the centering pin Tighten the centering plate onto the press table with the fastening screws Centering plate 1 Fastening screw 3 T shaped sliding blocks 2 Centering plate 1 2 3 ...

Page 31: ...Setup and function 5 Hand toggle presses Translation of the original operating manual 26 5 5 6 Mechanical stroke counter An installation manual is available for the mechanical stroke counter ...

Page 32: ... sliding table Sliding table with the spring pressure piece in the press position Heavy duty mechanical sliding table with locking pin The sliding table with locking pin is used to absorb non vertical forces Sliding table with locking pin in the loading and removal position Separate instructions are available for the sliding tables ...

Page 33: ...re commissioning check the press to ensure it has the cor rect setting and ensure the presence of the required protective and safety devices If defects are identified stop the press until these defects are rectified Immediately replace defective press components Use the addi tional documents in the appendix of this operating manual to en sure an undoubted identification of the component 6 1 1 Func...

Page 34: ...spirator mask during powder processing Never work without a protective goggles during powder pro cessing 6 2 1 Press process work steps Due to the number of application possibilities of the hand toggle press detailed work steps cannot be described The respective work steps must be specified by the operator The following work steps describe a simplified pressing process in order to il lustrate the ...

Page 35: ... to decommis sion the press for longer than 4 weeks Empty Remove parts Storage Cover the press to protect it from contaminants Slightly oil the bare metal parts to protect them from corrosion Store the press on transport pallets Fasten moving parts 7 2 Relocate the press Carry out the following work steps if the press is to be relocated Empty Remove parts Relocate Cover the press to protect it fro...

Page 36: ...bility 7 4 Disposing of the press Dispose of the packaging material according to the local regulations Dispose of cardboard protective packaging made of plastic and preservatives separately and properly The disposal of the press also press parts operating materials depends on the local disposal regulations as well as the environmental protection laws in the country of application If the press has ...

Page 37: ...tructions in the Safety Instructions chapter In addition observe all safety instructions in the manufacturer documentation found in the appendix 8 1 Setup process Risk of crushing and hand injury Have setup work only carried out by professionals Before operating the hand lever ensure that the tool area is clear Do not hold your hand in the tool area during a test stroke ...

Page 38: ...ques for screws The screw connections are to be tightened with the corresponding tightening torque to ensure a secure hold of the assemblies Tightening torques HKPE HKPV 2 5 HKPE HKPV 5 HKPV 8 12 1 2 3 1 2 3 1 2 3 Torque Nm 70 6 5 11 70 6 5 11 90 6 5 11 HKPV 8 16 HKP 50 1 2 3 1 2 3 Torque Nm 120 6 5 25 170 6 5 25 ...

Page 39: ... the pin retaining screw in the clamping piece with an Allen key Unscrew the tensioning screws with an Allen key Remove the clamping piece forward Remove the clamping piece 1 Clamping piece 3 Pin retaining screw 2 Clamping screw Observe the installation position marking so that the clamping piece can be reinstalled without contorting it 1 2 3 ...

Page 40: ...rved for the tool Measured variable Dimensions mm 2 5 HKPE 2 5 HKPV 5 HKPE 5 HKPV 8 12 HKPV 8 16 HKPV 50 HKP Length of the clamping pin max 21 25 21 21 21 29 45 Clamping bore ø 10H7 10H7 10H7 10H7 10H7 15H7 25H7 The dimensions of the tool may not be greater than those of the press table If the tool protrudes beyond the press table particu lar care should be taken ...

Page 41: ...oth tensioning screws Screw the pin retaining screw all the way into the clamping piece with an Allen key The pin retaining screw now presses on the cone and pulls the upper die all the way up against the half shell of the clamping bore Clamp the tool 1 Clamping piece 3 Pin retaining screw 2 Clamping screw The upper die must be clamped first and then the lower die in order to avoid the tool from b...

Page 42: ...erating manual 37 T shaped sliding blocks are available to clamp the lower die For 2 5 8 12 HKPV 1x DIN 650 M8x10 middle symmetrical For 8 16 HKPV 2x DIN 650 M8x10 middle symmetrical For 50 HKP 2x DIN 650 M8x12 middle symmetrical Fasten the tool to the press table Press table ...

Page 43: ...the guide unit clamp with a ring wrench but do not unscrew it all the way Loosen the clamping screw at the threaded spindle from 5 HKPV with a 4 mm hex wrench but do not unscrew it all the way Depending on the press type adjust the guide unit up or down to the de sired height by hand via the hand crank or via the hand wheel or the ratchet Tighten the clamping screws of the guide unit to the specif...

Page 44: ...n pin 2 to the side Unfold the fork piece 3 forward together with the hand lever Unscrew the threaded pin 4 Reinsert the adjusting pin 5 with the strap 7 into the bore 6 Screw the threaded pin 4 into the threaded bore 8 and secure the ad justing screw 6 Reinstall the fork piece in the reverse order 1 Threaded pin 5 Adjusting pin and pin bore for the long stroke 2 Main pin 6 Short stroke pin bore 3...

Page 45: ...cessories 8 Hand toggle presses Translation of the original operating manual 40 8 1 7 Changing the hand lever from right to left Carry out the following activities Loosen the cylinder head screws Pull the lever out ...

Page 46: ...Setup and accessories 8 Hand toggle presses Translation of the original operating manual 41 Pivot the lever to the left side Push in the lever flush and tighten the cylinder head screws ...

Page 47: ...xecuted maintenance work Maintenance work may only be performed by technically trained personnel Risk of crushing your hand and fingers Ensure the tool area is clear before actuating the hand lever Do not hold your hand in the tool area during a test stroke Observe the general accident prevention regulations and VDE guidelines Carry out the prescribe adjustment maintenance and repair work on sched...

Page 48: ...ions the press opera tor may perform and for which interventions the press operator must inform the appointed specialist Only use tools in perfect condition Keep suitable containers available for any small parts to be removed Only use original spare parts approved by the manufacturer ALT ÖL US ED OIL IMPORTANT Ensure that greases and other pollutants do not make their way into the drainage system ...

Page 49: ...ed wear is identified during regular checks the required maintenance intervals are to be shortened according to the actual signs of wear Please contact the company GECHTER Werkzeug und Maschinenbau GmbH for questions about maintenance work and intervals Please refer to the Identification chapter for how to contact the custom er service of Gechter GmbH Observe the following specified time intervals...

Page 50: ...jury from ignoring the manufacturer s specifi cations The press function may be impaired if the manufacturer s clean ing instructions are ignored Comply with all environmental protection regulations during cleaning Dust and heat leave residues on the press components an can cause functional disruptions Do not use any sharp tools for cleaning as they can damage the paint and thus cause corrosion Pr...

Page 51: ... 9 2 2 Lubricate the prism guide Do not use grease as this cannot spread through the channels inside the sled The lubrication nipple for the prism guide is located on the front of the press sled Lubricate the lubrication point with an oil press e g sliding guide oil Shell T 68 Lubrication point ...

Page 52: ...he press parts if necessary so that they are not damaged from external influences during transport Secure press parts from unintentional tipping and instability during transport 9 4 Wear and spare parts lists When replacing parts only original parts or equivalent parts may be used i e parts that have the same safety standard The list of wear and spare parts for the individual press components is f...

Page 53: ... immediately in the event of faults The system must be electrically and pneumatically disconnected be fore repair work Switch off the press if necessary Turn the main switch to the 0 position Secure the main switch with a padlock Set the main start up valve of the pneumatic system to OFF and se cure with a U lock Attach the following notice sign to the system Es wird gearbeitet It s being worked o...

Page 54: ...ror description Cause Remedial measure Personnel The press sled moves laterally or jams The press sled has too much or too little play Adjust the adjust ment gib Technically trained per sonnel The hand lever only moves upwards with dif ficulty Return spring broken Install a new return spring Technically trained per sonnel The press sled does not have enough play Adjust the adjust ment gib Technica...

Page 55: ...en lock nuts on the right side of the guide unit with an open end wrench Align the adjustment gib evenly and in parallel by turning the threaded pins with an Allen key so that it has the same play up and down Tighten lock nuts on the right side of the guide unit with an open end wrench The adjustment gib may not be set too tightly since the press will not reach its specified press force and increa...

Page 56: ... presses Translation of the original operating manual 51 10 1 3 Changing the return spring If the return spring breaks it must be replaced The following activities are to be carried out according to the figures 1 2 3 4 5 6 ...

Page 57: ...Faults 10 Hand toggle presses Translation of the original operating manual 52 7 8 9 10 Note The recommended change for the return spring is max 18 000 20 000 work processes ...

Page 58: ...www gechter com in the download area Note In general the General terms and conditions of sale and deliv ery of Gechter GmbH shall apply These are available to the op erator at the latest upon contract conclusion You confirm the order with your signature 11 2 Order Contact the following address when ordering spare parts Gechter GmbH Werkzeug und Maschinenbau Ostring 3 90587 Obermichelbach GERMANY T...

Page 59: ...ister directory Supplementary documents to this operating manual are attached in the follow ing The individual elements are separated from each other with index sheets DECLARATION OF COMPLIANCE PARTS LISTS SPARE PARTS DRAWINGS SEE WWW GECHTER COM DOWNLOAD DOCUMENTATION FOR SUPPLIER COMPONENTS OPTIONAL ...

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