Gechter HKPE Series Operational manual

Gechter GmbH Werkzeug- und Maschinenbau
Translation of the original operating manual
English
Hand toggle presses HKPE, HKPV and HKP
Type:
2,5 HKPE; 2,5 HKPV
5 HKPE; 5 HKPV
8/ 2 HKPV; 8/ 6 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
– 20 6 Version: 00
December- 2020 Version: 0
Representation
of HKPV

Information
i
This operating manua is part of the technica documentation of the press according to the
EC press guide ine.
This operating manua comp ies with the "Directive 2006/42/EC of the European Par iament
and the Counci on the Approximation of the Lega and Administrative Provisions of the Mem-
ber States Re ating to Presses" (Press Directive), appendix I, point 1.7.4.
This operating manua is aimed at those responsib e in the p ant who must hand this over to
the personne responsib e for the insta ation, connection, use and maintenance of the press.
The responsib e persons must ensure that the information contained in the operating manua
and in the accompanying documents has been read and understood.
The operating manua must be stored in a known and easy-to-access ocation and must a so be
consu ted even in cases of minor doubt.
The manufacturer assumes no iabi ity for damage to peop e, anima s or objects as we as the
press itse f, which is caused from improper use, neg ect or insufficient observance of the safety
criteria contained in this operating manua or that is caused by modifying the press or using
unsuitab e spare parts.
The copyright for the operating manua ies exc usive y with
Gechter GmbH Werkzeug- und Maschinenbau
Ostring 3
90587 Obermiche bach
GERMANY
or with their ega successor.
This operating manua may on y be dup icated or passed on to third parties with written ap-
prova . This is a so the case if on y excerpts of the operating manua are copied or forwarded.
The same conditions exist for passing on the operating manua in digita form.

Information
i
Archiving

A ways store the operating manua on the press!

A ways keep the manua handy!
Symbols and Signal Words
The fo owing symbo s and signa words are used in this documentation. The
combination of a pictogram and a signa word c assifies the respective safety
note. The symbo may vary depending on the type of hazard.
ANSI Z535.6
DANGER indicates a hazard-
ous situation which, if not
avoided, wi resu t in death
or serious injury.
WARNING indicates a hazard-
ous situation which, if not
avoided, cou d re ust in death
or serious injury.
CAUTION indicates a hazard-
ous situation which, if not
avoided, cou d resu t in minor
or moderate injury.
NOTICE is used to address
practices not re ated to physi-
ca injury.
Safety instructions (or
equiva ent) signs indicate
specific safety-re ated instruc-
tions or procedures.

Content
I
1
. Identification ...........................................................................................
. Use in accordance with the intended purpose
.2 Reasonably Foreseeable Misapplication 2
2. General Information ................................................................................ 3
2. Warranty and liability 3
2.2 Target group of the operating manual 3
2.3 Objectives of the operating manual 4
3. General Safety Instructions ..................................................................... 5
3. Scope and Symbols 5
3.1.1 Safety symbo s – pursuant to DIN 4844-2 5
3.2 Obligations 6
3.2.1 Operator responsibi ities 6
3.2.2 Ob igations of the operating personne 7
3.2.3 Setup 7
3.2.4 Service and maintenance 8
3.2.5 Residua dangers 8
3.3 Additional Information 9
4. Installation ............................................................................................ 0
4. Transport process
4.2 Setting up the system 2
4.2.1 Space required 12
4.2.2 Fastening the press 13
4.3 Operating Conditions 3
4.3.1 Press ighting 13
4.4 Aligning the system 4
4.5 Operating equipment 4
5. Setup and function ................................................................................. 5
5. Description 5
5.2 Standard versions 5
5.3 Technical Data 6
5.3.1 Technica data 2.5 HKPE; 2.5 HKPV 16
5.3.2 Technica data 5 HKPE; 5 HKPV 17
5.3.3 Technica data 8/12 HKPV; 8/16 HKPV 18
5.3.4 Technica data 50 HKP 19
5.3.5 Namep ate 20
5.4 Overall representation 2
5.5 Accessories (optional) 22
5.5.1 Fine adjustment PFE 22
5.5.2 Mechanica return stroke ock RHS 23
5.5.3 Precision depth adjustment PTE 23
5.5.4 Ergonomic hand e 24
5.5.5 Centering p ate 25
5.5.6 Mechanica stroke counter 26
5.5.7 S iding tab es 27

Content
I
2
6. Commissioning / Operation ................................................................... 28
6. Commissioning 28
6.1.1 Functiona check before operation 28
6.2 Operation 29
6.2.1 Press process work steps 29
7. Decommissioning ................................................................................... 30
7. Shutting down the press (longer period of time) 30
7.2 Relocate the press 30
7.3 Storing the system 3
7.4 Disposing of the press 3
8. Setup and accessories ............................................................................ 32
8. Setup process 32
8.1.1 Tightening torques for screws 33
8.1.2 Remove the c amped piece (from 5 HKPV) 34
8.1.3 C amping the too 35
8.1.4 Setup 36
8.1.5 Adjust the height 38
8.1.6 Adjusting the stroke ength and pressing force (on y for type 8/12 and
8/16) 39
8.1.7 Changing the hand ever from right to eft 40
9. Service and maintenance ....................................................................... 42
9. Maintenance safety 42
9.2 Technical Support 44
9.2.1 C eaning the press 45
9.2.2 Lubricate the prism guide 46
9.3 Packing system parts 47
9.4 Wear and spare parts lists 47
0. Faults ..................................................................................................... 48
0. Technical Support 49
10.1.1 Fau t tab e 49
10.1.2 Adjusting the Adjustment Gib 50
10.1.3 Changing the return spring 51
. Spare parts and ordering ....................................................................... 53
. Spare parts 53
.2 Order 53
2. Appendix ................................................................................................ 54
2. Register directory 54

Identification
1
Hand togg e presses – Trans ation of the origina operating manua
1
. Identification
Hand togg e presses HKPE, HKPV and HKP
Type: 2.5 HKPE; 2,5 HKPV; 5 HKPE; 5 HKPV; 8/12 HKPV; 8/16 HKPV; 50HKP
Expected service ife: 10 years
Gechter GmbH Werkzeug- und Maschinenbau
Ostring 3
90587 Obermiche bach
GERMANY
Te e-
phone:
0911 / 982873-20
Fax: 0911 / 982873-99
E-mai : [e-mail]
. Use in accordance with the intended purpose
The hand togg e press may on y be used for pressing, joining, assemb y, rivet-
ing, punching, bending, embossing and cutting work as we as work with suffi-
cient y insu ated heated too s.
The device is on y suitab e for processing meta , cardboard, p astic, rubber,
eather and meta 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 iab e for any dam-
ages resu ting from this.
Proper use a so inc udes:
 observing a instructions in the operating manua
 observing a safety instructions
 comp ying with the inspection and maintenance work
Observe the "Technica data" in the chapter "Insta ation and
Function".
This describes the exact technica specifications for proper use.

Identification
1
Hand togg e presses – Trans ation of the origina operating manua
2
.2 Reasonably Foreseeable Misapplication
Reasonab y foreseeab e misapp ication, which may resu t in dangers to the us-
er, third party or to the press, for a operating modes is constituted by:
 using the press contrary to the intended use
 feeding components whose shape deviates from the shape intended
for the press
 operating the press outside of the physica app ication imits described
in the "Commissioning / operation" chapter
 changes to the press as we as additions and conversions without pri-
or consu tation with the company Gechter GmbH Werkzeug- und Mas-
chinenbau
 operating the press contrary to the provisions of the operating manua
with respect to safety instructions, insta ation, operation, mainte-
nance and repair, setup and fau ts
Risk of injury from unauthorized changes
Dangers resu t from unauthorized changes to the press and from
the use of spare parts from other manufacturers.
On y origina spare parts and wear parts from the manufacturer
may be used. Do not perform any changes, additions or conver-
sions without approva from the company Gechter GmbH
Werkzeug- und Maschinenbau.

General Information
2
Hand togg e presses – Trans ation of the origina operating manua
3
2. General Information
2. Warranty and liability
In genera , the "Genera terms and conditions of sa e and de ivery" of the
company Gechter GmbH Werkzeug- und Maschinenbau sha app y. These are
avai ab e to the operator at the atest upon contract conc usion.
Warranty and iabi ity c aims in the event of persona injury or property dam-
age are exc uded if they are due to one or more of the fo owing reasons:
 improper use of the press
 improper assemb y, commissioning, operation and maintenance
 operating the press with defective safety devices
 disregarding instructions in the operating manua
 unauthorized structura 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 manua is intended for the operator and personne with the fo -
owing areas of expertise:
Work area Expertise
Insta ation, transport and storage Technica y trained personne
Commissioning, operation and decommissioning Trained personne
Setup Technica y trained personne
Service and maintenance Technica y trained personne
Troub eshooting Technica y trained personne

General Information
2
Hand togg e presses – Trans ation of the origina operating manua
4
Definition according to DIN EN 60204-1:
Trained personnel:
A person who has been instructed and trained where necessary by an expert
regarding the tasks to be transfered as we as the possib e dangers in the
event of improper behavior and who has been instructed on the necessary pro-
tective equipment and protective measures.
Technically trained personnel:
A person whose professiona training, know edge and experience as we as
know edge of re evant standards a ows him/her to assess the assigned work
and detect possib e dangers.
Qualification of the operating personnel:
Work may on y be carried out on the machine independent y by peop e who
 have been instructed and trained on the system by expert or service
personne of Gechter GmbH Werkzeug- und Maschinenbau and who
are therefore fami iar with the techno ogy
 are physica y and menta y capab e to do so
Outside of the Federa Repub ic of Germany, the app icab e accident prevention
regu ations, safety provisions and youth emp oyment protection aws of the re-
spective country sha app y.
2.3 Objectives of the operating manual
This operating manua is intended as an aid and contains a necessary infor-
mation that must be taken into consideration for the genera safety, transport,
insta ation, operation, maintenance and setup.
This operating manua with a of the safety instructions (as we as a addi-
tiona documents of the modu es from third party supp iers) must:
 be observed, read and understood by a peop e who work on the
press (especia y know edge of the safety instructions)
 be free y accessib e to everyone
 be consu ted in cases of even the s ightest doubt (safety)
Goa s:
 Avoid accidents
 Increase the service ife and re iabi ity of the press
 Reduce production downtime costs

General Safety Instructions
3
Hand togg e presses – Trans ation of the origina operating manua
5
3. General Safety Instructions
3. Scope and Symbols
Danger to life, risk of injury and cause of physical damage
Fai ure to observe the operating manua and a of the safety in-
structions contained therein may resu t in dangers.
Carefu y read the operating manua prior to the initia commis-
sioning. Meet the required safety conditions prior to the initia
commissioning.
Genera safety instructions and a so the specia safety instruc-
tions inserted in other chapters are to be observed.
The machine is bui t in keeping with the atest techno ogica deve opments and
according to the recognized technica safety ru es. In order to exc ude dangers
to the ife and imb of the user, third parties or other damage during its use,
on y use the press for the intended use and in the c ear y technica y safe and
perfect condition.
Property damage and physica injuries that are due to the instructions in the
operating manua being ignored are the responsibi ity of the press operator of
the persons commissioned by said operator.
Fau ts that may impair the safety must be rectified immediate y.
A safety and hazard information about the press is to be observed and con-
stant y kept in a good egib e condition.
3.1.1 Safety symbo s – pursuant to DIN 4844-2
Risk of injury from ignoring the safety symbols
Dangers arise from ignoring the warning information about the
press and in the operating manua .
Observe the warning information in the "Appendix" chapter.

General Safety Instructions
3
Hand togg e presses – Trans ation of the origina operating manua
6
3.2 Obligations
Risk of death from negligence
Despite numerous protection and safety devices, there are sti
hazards in the event of neg igent behavior when using the press.
A ways work on the press with great care and caution. Fai ure to
observe the safety instructions wi ead to the oss of any c aims
for compensation.
The fo owing conditions may increase the hazard potentia of the press:
 Fai ure of important functions of the press
 Fai ure of prescribed methods for maintenance and repair
 Hazard of personne from mechanica or therma effects
3.2.1 Operator responsibi ities
A safe technica condition and safe use of the press is the prerequisite for safe
operation. That is why the press operator is ob igated to ensure that the fo -
owing points are observed:

Ensure that the press is on y operated by trained and authorize person-
ne !

Prohibit safety-impairing and dangerous working methods! If necessary,
review the personne 's actions!

Have personne confirm they have understood the operating manua
with their signature!

Ensure that a copy of the entire operating manua is a ways handy and
avai ab e at the press!

Regu ar y check the comp ete and egib e condition of the operating
manua !

Prescribe the wearing of appropriate persona protective equipment
(PPE) for work with an increased risk of injury!

Determine the responsibi ities according to the different task areas (op-
eration, maintenance)!

Require the operating and maintenance personne to report any occur-
ring and recognizab e safety defects to their superiors immediate y!

General Safety Instructions
3
Hand togg e presses – Trans ation of the origina operating manua
7
3.2.2 Ob igations of the operating personne
Risk of injury from an improper condition of the press
There are risks when working on the press that are caused by
fau ts or ma functions, inc uding of the safety equipment during
operation.
Check the proper overa condition of the press once per shift.
Risk of injury when used by unauthorized personnel
There are hazards if unauthorized personne intervene in the
press.
The press may on y be operated after briefing or training.
The operating personne are required to persona y 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 hazards if retrofitting work is carried out by unauthor-
ized personne .
Unauthorized modifications and changes to the press are prohib-
ited!
On y parts approved by the manufacturer may be used!

General Safety Instructions
3
Hand togg e presses – Trans ation of the origina operating manua
8
3.2.4 Service and maintenance
Risk of injury from mechanical energy
There are risks from mechanica energy as we as specific resid-
ua risks on the press.
On y have maintenance and repair work carried out by unauthor-
ized instructed personne .
Unauthorized modifications and changes to the press are prohib-
ited!
On y parts approved by the manufacturer may be used!
3.2.5 Residua dangers
There can be residua risks that are not apparent despite a precautions taken!
Residua risks can be reduced if the safety instructions and the intended use as
we as the operating manua are observed in their entirety!
Risk of crushing and hand injury
There is a risk of injury from the movement of press compo-
nents.
During the pressing operation, it is strict y forbidden to reach into
the working areas of the press. Observe the risk of crushing and
hand injury during c eaning, setup, maintenance and fau t rectifi-
cation.

General Safety Instructions
3
Hand togg e presses – Trans ation of the origina operating manua
9
3.3 Additional Information
For a work on the press, the accident prevention provisions of professiona
associations a so app y.
A so to be noted:
 app icab e binding regu ations for accident prevention
 app icab e binding regu ations at the site of use
 the recognized technica ru es for safety and professiona work
 existing regu ations for environmenta protection
 other app icab e regu ations
Emp oyee training with respect to hazards and the required pro-
tective measures must be repeated regu ar y, but at east once a
year.
Operating instructions are required in the interest of occupationa
safety, which the operator must create!
In addition to the operating manua , these instructions are to be
fu y observed by the press operator!

Installation
4
Hand togg e presses – Trans ation of the origina operating manua
10
4. Installation
Observe the basic safety instructions in the "Safety Instructions"
chapter.
In addition, observe a safety instructions in the manufacturer
documentation found in the appendix.

Visua y inspect that a s ing gear is undamaged and in good condition!

Screw in the fu ength of hooks and eye bo ts!

Check the de ivered parts for comp eteness, damage or other abnorma i-
ties!

During transport, observe the va id safety and accident prevention regu-
ations (BGV D8, D6)!

If you have questions about transport, setup and insta ation of the
press, contact the company Gechter GmbH too making and mechanica
engineering!

Refer to the "Identification" chapter for contact options!

Installation
4
Hand togg e presses – Trans ation of the origina operating manua
11
Examp e representation
4. Transport process
The press is de ivered on a pa et. This must remain under
the press during transport to the site of insta ation in order to avoid any
tipping or bumping during transport.

Bring the transport crate to the fina site of insta ation with suitab e
transport equipment ( ift truck / fork ift).

Wear appropriate protective c othing during transport work!

For transport, on y use technica y f aw ess and functiona hoisting gear
with sufficient oad-bearing capacities!

Lift the press at the marked attachment points (3)!

Ensure that the oad-bearing capacity of the hoisting gear as we as the
oad receiving and transport equipment correspond to the oads specified
for the press!

For arger presses, have trained transport personne carry out the
transport!

Remove the transport straps (1).

Remove the pa et packaging (2).

Remove the safety screws.

Installation
4
Hand togg e presses – Trans ation of the origina operating manua
12
4.2 Setting up the system
The press is de ivered assemb ed and ready for operation. An as-
semb y of accessories may be necessary in certain cases (ob-
serve the separate instructions for accessories).

On y ift the presses 8/16 and 50 HKP at the eye bo ts provided!

A ways raise the other presses at the stand, never at the guide part or
hand ever (damage to the guide possib e)!

When raising the press, ba ance the forward ti t by ho ding on to the
press tab e.

Unpack and grease the press
Example: Eye bolt for transport
4.2.1 Space required

Observe the exact specifications of the insta ation dimensions in the fo -
owing schematic diagrams of the press (specifications in mi imeters)!

Observe the required oad-bearing capacity of the workbench (see
"Technica Data" chapter)!
The provided ocation must be firm and eve !

Installation
4
Hand togg e presses – Trans ation of the origina operating manua
13
4.2.2 Fastening the press
A stab e workbench or the press underframe avai ab e as an accessory are
suitab e for the insta ation.
Fasten the press with hexagon bo ts, washers and nuts through the bores on
the press base feet.
Fastening the press
4.3 Operating Conditions
Physical operating conditions
Ambient temperature: ± 0°C to +55°C
Air humidity: 30% to 60%
E evation: max. 2000 m above sea eve
Contamination: No high contamination from dust, acids, corrosive gases
Specia conditions:  No direct sun ight
 The operators must insta additiona ighting equipment if the working area is
insufficient y it
 Sufficient venti ation of the working area ( oad on the operator)
 The press does not have any exp osion protection
4.3.1 Press ighting
The press does not have its own ighting equipment and is there-
fore to be integrated into to the ha ighting avai ab e at the site
of insta ation!
The operators are to insta additiona ighting equipment if the
ighting of the working area at the press is insufficient!

Installation
4
Hand togg e presses – Trans ation of the origina operating manua
14
4.4 Aligning the system
You need the fo owing too s to a ign the attached press e ements:
 Spirit eve

Check the horizonta position with the spirit eve !
Spirit level
4.5 Operating equipment

P ease refer to the documentation for supp ier components in the appen-
dix!

When using c eaning agents, fo ow the operator's current work instruc-
tions!

Refer to the "Lubrication" chapter for specifications about ubricating the
press!

Setup and function
5
Hand togg e presses – Trans ation of the origina operating manua
15
5. Setup and function
5. Description
The hand togg e press is used for riveting, punching, bending, embossing, cut-
ting, pressing and joining work. A constant work performance of the operator
can be assumed due to the ow physica force input.
The press is suitab e as a work station both in a sitting and standing position.
It is primari y fastened to an existing workbench or a sturdy base frame.
The hand togg e press may on y be used for pressing, joining, assemb y, rivet-
ing, punching, bending, embossing and cutting work as we as work with suffi-
cient y insu ated heated too s. The device is on y suitab e for processing meta ,
cardboard, p astic, rubber, eather and meta powder.
5.2 Standard versions
A modified stand version may be required in certain circumstances for the re-
spective app ication case. The fo owing other versions are avai ab e for the
hand ever press with air assistance.
Stands with a greater overhang Stands with a larger installation
height