Astor A 53 User manual

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Operating manual (2006/42/EG)
A 53 Manual toggle press

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Table of Contents
1 User instructions ......................................................................................................... 3
1.1 Purpose of the document .............................................................................................. 3
1.2 Explanation of symbols and indications ....................................................................... 3
1.3 Sample - Declaration of conformity ............................................................................. 4
1.4 Machine identification .................................................................................................. 5
1.5 Intended use ................................................................................................................. 6
1.6 Misuse of the machine .................................................................................................. 6
1.7 Remaining residual hazards.......................................................................................... 7
1.8 Reasonable foreseeable misuse .................................................................................... 8
1.9 Conversions or modifications ....................................................................................... 8
1.10 Liability ........................................................................................................................ 8
1.11 Risks of handling the machine ..................................................................................... 9
1.12 Obligation of the owner/operator ............................................................................... 10
1.13 Obligation of the staff................................................................................................. 11
1.14 Staff qualification ....................................................................................................... 12
1.15 Safety .......................................................................................................................... 13
2 Machine description ................................................................................................. 14
2.1 Technical specifications ............................................................................................. 14
2.2 Maintenance and care ................................................................................................. 14
2.3 Setting up the machine / commissioning .................................................................... 15
2.4 Button manufacture .................................................................................................... 16
3 Documentation of accessory components ............................................................... 17
3.1 Exploded view with component list 4 pages .............................................................. 17

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1 User instructions
1.1 Purpose of the document
This operating manual
 describes the intended use of the device
 describes the function, operation and maintenance of the machine,
 provides important information for safe and efficient handling of the
machine.
Lists
1.2 Explanation of symbols and indications
In this chapter you will find the safety instructions that must be observed when using
the machine. The instructions are valid for all persons working with and on the
machine, including the operating and maintenance personnel. All safety-relevant
points are marked with a warning.
When describing the dangers, the severity of the imminent damage is differentiated.
DANGER Immediately imminent risk to the life and health of persons
(serious injury or death).
WARNING Potential imminent risk to the life and health of persons (serious
injury or death).
CAUTION Potentially hazardous situation
(minor injuries or property damage)

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1.3 Sample - Declaration of conformity

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1.4 Machine identification

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1.5 Intended use
The machine is designed and built according to the applicable requirements of the
EC directives, the state of the art and technical safety regulations.
The applicable documentation is intended for use in Germany. Use in another
European Member State is not foreseen. However, if the machine is to be used within
the company Group in another Member State, the applicable documentation for the
language version of the country concerned must be adapted.
The purpose of the machine is to produce buttons and buckles. For this purpose, the
generally three-part button/buckle consisting of the upper lower part and a material
cutout is pressed together. A corresponding tool depending on the button/buckle size
must be used. The machine is loaded exclusively by the machine operator.
Intended use also includes:
 complying with all instructions in this manual.
1.6 Misuse of the machine
Any other use, in particular by private consumers or for other work, is expressly
prohibited. Only tools and blanks from ASTOR may be used. The pressing of
buttons/buckles may only be carried out using suitable tools; only ORIGINAL parts
may be used.
HAND INJURY
Operation without a fitted original tool is
prohibited. Make sure that no parts of the
body encroach in the tool area during
operation. The tool area is the main
hazard area of the press

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1.7 Remaining residual hazards
The machine is built according to the state of the art and recognised technical safety
regulations.
WARNING Operating the machine is intended for one
person. This is an essential safety factor in the
risk assessment of the machine. Operation by
another (second) person is not permitted!
WARNING The hand lever of the press must be held firmly
during the entire work sequence so that it
cannot cause injuries from a possible repelling
of the spring loaded lever
CAUTION Operation without a fitted original tool is
prohibited.
General hazards
 Installation, disassembly and cleaning work must be carried out in such a
way that they cannot cause injury or damage.
 Do not clean the machine with pressurised water (spraying with water hose
or high pressure cleaner).

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1.8 Reasonable foreseeable misuse
The operator of the machine is specially trained in handling the machine. The
operator must ensure that the machine operators are adequately trained. Previous
experience with similar machine types has been taken into account.
The machine can only be put into operation and controlled by means of the operating
stations.
WARNING Any use other than the one specified under
"Intended use" or beyond this is considered to
be not intended!
1.9 Conversions or modifications
 The manufacturer must be informed of
any modifications or alterations.
 Unauthorised modifications or alterations
are not permitted for safety reasons.
 Only ORIGINAL PARTS may be used. .
1.10 Liability
The information, data and instructions given in this operating manual were up to date
at the time of going to press. We reserve the right to make technical changes within
the framework of the further development of the machine.
No liability shall be assumed for damages and malfunctions caused by:
 failure to observe the operating instructions,
 operating errors,
 improper work on and with the machine,
 use of non-original spare parts and accessories,
 unauthorised conversion and alteration of the machine by the
owner/operator or his personnel.

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1.11 Risks of handling the machine
Risks and impairments may occur when using the machine
 to the machine itself,
 to other material assets,
 to one´s self.
NOTE The safety and user instructions in this manual
are the basis for safe handling and trouble-
free operation of this machine.
IMPORTANT lways keep the operating instructions at the
place where the machine is operated! The
operating instructions must be freely
accessible to operators and maintenance
personnel.
Furthermore:
 general and local regulations on accident
prevention and environmental protection
must be complied with.
NOTE The local safety and accident prevention
regulations apply in all cases for connection,
operation and repair of the machine.

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1.12 Obligation of the owner/operator
The owner/operator has, in particular, a number of obligations which must be
taken into account. The owner/operator undertakes to have only persons working
on the machine that:
 are familiar with the fundamental regulations on work safety and
accident prevention
 are trained to work on/with the machine,
 have read and understood this manual.
The owner/operator is obliged
to:
 supplement the operating manual with instructions that include
national regulations on accident prevention and environmental
protection. The usual regulations apply to detergents and other
lubricants and auxiliaries.
 ensure that all relevant regulations, instructions and laws are
observed,
 define the responsibilities of the personnel for operation,
maintenance and repair,
 check whether the defined responsibilities are also complied with,
 determine a machine operator who will refuse to comply with any
illegal instructions from third parties,
 regularly check whether his/her personnel are operating the
machine safely and risk-consciously according to the operating
manual,
 ensure that personnel have read and understood the operating
instructions for all system components, especially the chapter
"Safety instructions",
 have damaged or missing parts replaced immediately,
 ensure that the machine is properly earthed. The
ownwer/operator is responsible for this.
 perform a noise level measurement for the installation location of
the machine (the local value may be different).
NOTE The requirements of the EC Directive on the
use of work equipment 2009/104 /EC are to be
complied with.

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1.13 Obligation of the staff
This machine is built according to the state of the art and is operationally safe.
However, this machine may pose a risk if it is improperly connected and
commissioned by untrained personnel or put to improper use.
 Any person who is involved in the connection, operation and
repairs must have read and understood this manual,
especially the "Safety" section.
 The machine may only be connected, commissioned and
repaired by persons who are familiar with the manual and
are aware of the dangers.
 The relevant regulations and laws as well as other generally
accepted regulations must be complied with.
 Should you still be unclear, ask your supervisor.
 All repairs must only be carried out when the machine is at a
standstill.
 Have the machine inspected for its proper condition once a
year by an expert.
 Never reach into the running machine.

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1.14 Staff qualification
Persons
Activity
Expert
Employee
Trained person
Transport X -- --
Commissioning X -- --
Troubleshooting and
repair
X -- X
Operation X X --
Maintenance X -- X
Destruction/recycling X -- X
Legend: X..permitted --..not permitted
NOTE It is to be ensured, in accordance with the
qualification matrix, that only appropriate
persons with the respective level of training
assume the assigned activities.
Definitions according to company safety regulations
Employees are persons who are designated as such in accordance with § 2,
paragraph 2 of the Occupational Health and Safety Act. The following persons are
equal to the employees if they use work equipment:
1. Students,
2. homeworkers according to § 1 Paragraph 1 of the Homeworkers Act and
3. other persons, in particular persons working in scientific institutions.
An expert is someone who has the necessary expertise to carry out a task defined in
this regulation. The requirements for the expert/specialist are dependent on the
respective type of task. Requirements include appropriate vocational training,
professional experience or a corresponding recently practiced professional activity.
The knowledge must be kept up to date by attending training courses.
A person qualified to examine is a person who, through his/her professional
training, his/her professional experience and his/her current professional activity, has
the necessary knowledge to examine work equipment

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1.15 Safety
IMPORTANT Only appropriately trained and initiated
personnel may work on the machine
DANGER Make sure that no parts of the body encroach
in the tool area during operation. The tool area
is the main hazard area of the press
NOTE This manual must be carefully read before
installation/commissioning and use of the
product
WARNING The hand lever of the press must be held
firmly during the entire work sequence so that
it cannot cause injuries from a possible
repelling of the spring loaded lever

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2 Machine description
This chapter provides a comprehensive overview of the structure and function of
the machine. Read it as far as possible at the machine. This will allow you to
become familiar with the machine.
2.1 Technical specifications
Pressing force 500 kg
Plunger stroke 45 mm
Height with lever 580 mm
Width 170 mm
Depth 238 mm
Empty weight 9 kg
2.2 Maintenance and care
In the case of continuous use, the movable machine parts are to be thoroughly cleaned
once a week with a brush and cleaning cloth to remove dust, lint and fabric residue.
The plunger projecting beyond the plunger guide is to be lubricated.
To avoid malfunctions, the original tool must be cleaned once a week (brush and
cleaning cloth).
Do not use hard objects such as scissors, screwdrivers, abrasive paper.

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2.3 Setting up the machine / commissioning
Place the machine on level ground. A stable workbench, for example, is appropriate. Before
using the press, it is essential to secure the machine using the 2 holes. Always lift the
press on the casting and base, never on the hand lever or between the hand lever and the
cast body.
Swing the machine swivel plate to the left until it stops. Raise both locking bolts of the swivel
plate and turn the two holders 90° to the left or right.
Place the mounting plate with the tool A and B lower parts bolted on over both studs on the
machine swivel plate. Unscrew the two holders until the locking bolts engage audibly.
Pull out the index pin of the catch clockwise by its knob as far as it will go and hold it in this
position. Push in the tool upper part bolt head (pointing forward) with the holding pin into the
receiving hole of the machine until it stops. Release the knob and move the tool upper part
back and forth briefly until the index pin engages in the lateral hole of the holding pin. Ensure
that the index pin is locked by pulling the upper part downwards.

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2.4 Button manufacture
Place the button parts and material cutouts on the workbench in front of the machine.
First, set the button-top-open side underneath, then the material cutout (later visible side) on
top into the fabric holder (tool A). The cover material must not protrude beyond the edge of the
fabric intake!
Swing the machine swivel plate to the right until it stops. Move the machine lever downwards.
The material cutout and the button top are fed into the tool top part. Simultaneously, insert the
button bottom into tool B. Return the machine lever. Swivel the swivel plate to the left until it
stops. Pull the machine lever down to close the button tool and then return the machine lever
to its original position. The first button is ready.
Further button manufacturing is performed as described above.
Before starting serial production, the first buttons must be checked that they are tightly closed.
Correct pressure adjustment ensures that the buttons are evenly and tightly closed during
serial production, preventing damage to the button edges when processing sensitive covering
materials.

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3 Documentation of accessory components
3.1 Exploded view with component list 4 pages

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A 53 swivel plate

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A 53 plunger plate

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A 53 Assembly catch
Accessories
Art.: 03919000 A 53 Assembly COUNTING DEVICE