Gechter HKPL-DS Operational manual

Gechter GmbH Werkzeug- und Maschinenbau
Translation of the original operating
manual
English
Hand lever press with air assistance
Type:
HKPL-DS standard, MS and MC
4-8-12 kN, 13-20 kN, 33-45-56 kN
Example representation
The operating manual must be read prior to the initial commis-
sioning!
Observe the safety instructions!
Keep for future use!
This documentation is not subject to any change service!
November 2016 - May 2019 Version: 00
June 2019 - December 2020 Version: 01
January 2021 Version: 02

Information
i
This operating manual is part of the technical documentation of the press according to the
EC press guideline.
This operating manual complies with the "Directive 2006/42/EC of the European Parliament
and the Council on the Approximation of the Legal and Administrative Provisions of the Mem-
ber States Relating to Presses" (Press Directive), appendix I, point 1.7.4.
This operating manual is aimed at those responsible in the plant who must hand this over to
the personnel responsible for the installation, connection, use and maintenance of the press.
The responsible persons must ensure that the information contained in the operating manual
and in the accompanying documents has been 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 caused by modifying the press or using
unsuitable spare parts.
The copyright for the operating manual lies exclusively with
Gechter GmbH Werkzeug- und Maschinenbau
Ostring 3
90587 Obermichelbach
GERMANY
or with their legal successor.
This operating manual may only be duplicated or passed on to third parties with written ap-
proval. This is also the case if only excerpts of the operating manual are copied or forwarded.
The same conditions exist for passing on the operating manual in digital form.

Information
i
Archiving

Always store the operating manual on the press!

Always keep the manual handy!
Symbols and Signal Words
The following symbols and signal words are used in this documentation. The
combination of a pictogram and a signal word classifies the respective safety
note. The symbol may vary depending 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-
cal injury.
Safety instructions (or
equivalent) signs indicate
specific safety-related instruc-
tions or procedures.

Content
I
1
1. Identification ...........................................................................................1
1.1 Use in accordance with the intended purpose 1
1.2 Reasonably Foreseeable Misapplication 2
2. General Information ................................................................................3
2.1 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
3.1 Scope and Symbols 5
3.1.1 Safety symbols –pursuant to DIN 4844-2 5
3.2 Obligations 6
3.2.1 Operator responsibilities 6
3.2.2 Obligations of the operating personnel 7
3.2.3 Orientation values for lifting and carrying frequencies 8
3.3 Working, service and protection areae 9
3.4 Safety Devices 10
3.5 Dangers from Energy 10
3.5.1 Dangers from electric power 10
3.5.2 Dangers from mechanical energy 11
3.5.3 Dangers from pneumatic energy 12
3.5.4 Emissions: Airborne noise 12
3.6 Residual dangers 13
3.7 Hazards in specific life cycles 14
3.7.1 Installation 14
3.7.2 Commissioning / Operation 15
3.7.3 Setup 16
3.7.4 Service and maintenance 16
3.8 Additional Information 17
4. Installation ............................................................................................18
4.1 Transport process 19
4.2 Setting up the system 20
4.2.1 Space required 20
4.2.2 General conditions 20
4.2.3 Fastening the press 21
4.2.4 Assembling the hand lever 21

Content
I
2
4.3 Connect the press (power supply 22
4.3.1 Pneumatically connect the press 23
4.4 Operating Conditions 24
4.4.1 Press lighting 24
4.5 Aligning the system 25
4.6 Operating equipment 25
5. Setup and function.................................................................................26
5.1 Description 26
5.2 Standard versions 27
5.3 Technical Data 28
5.3.1 Technical data 4-8-12 kN HKPL-DS 28
5.3.2 Technical data 13-20 kN HKPL-DS 30
5.3.3 Technical data 33-45-56 kN HKPL-DS 32
5.3.4 Nameplate 34
5.4 Overall view –Overview / Work stations 35
5.4.1 Work stations of the operating personnel 36
5.4.2 Tasks of the operating personnel 36
5.5 Components - Pneumatics 37
5.6 Accessories (optional) 38
5.6.1 "maXYmos" press force monitoring system 38
5.6.2 Force displacement measurement system 39
5.6.3 Motion Control (MC) 40
5.6.3.1 General Information 41
5.6.3.2 Functional Description 42
5.6.3.3 Lock of the press in the upper part and lower part 43
5.6.3.4 Damped return of the hand lever 44
5.6.3.5 Emergency unlocking 44
6. Commissioning / Operation ...................................................................45
6.1 Commissioning 45
6.1.1 Functional check before operation 46
6.2 Operation 47
6.2.1 Press process work steps 48
7. Decommissioning ...................................................................................49
7.1 Switching off the press 49
7.2 Shutting down the press (longer period of time) 49
7.3 Relocate the press 50

Content
I
3
7.4 Storing the system 50
7.5 Disposing of the press 51
8. Setup and accessories............................................................................52
8.1 Setup process 52
8.1.1 Tightening torques for screws 54
8.1.2 Bringing the slide into the basic position 55
8.1.3 Remove the clamping piece 55
8.1.4 Clamping the tool 57
8.1.5 Setup 58
8.1.6 Adjust the height 60
8.1.7 Adjust the approach stroke 64
8.1.8 Adjusting the power stroke 64
8.1.9 Adjusting the pressure 65
8.1.10 Adjusting the holding time 66
8.1.11 Trial run 67
8.2 Accessories 69
8.2.1 Precision fine adjustment PFE 69
8.2.2 Precision depth adjustment PTE 75
8.2.3 Sliding table 77
8.2.3.1 Inserting the sliding table and tool 78
8.2.4 Clamping bracket 80
8.2.5 Button control 81
8.2.6 Substructure 82
8.2.7 Centering plate 83
8.3 Recommissioning 84
9. Service and maintenance .......................................................................85
9.1 Maintenance safety 85
9.2 Technical Support 87
9.2.1 Cleaning the press 88
9.2.2 Lubricate the prism guide 89
9.2.3 Maintaining the maintenance unit 91
9.2.4 Check the maintenance unit oil level 92
9.2.5 Checking the pneumatic fittings 93
9.3 Packing system parts 94
9.4 Wear and spare parts lists 94
9.5 Identification Plates 94
9.6 Logging Maintenance Work 94

Content
I
4
10. Faults .....................................................................................................95
10.1 Technical Support 96
10.1.1 Fault table 96
10.1.2 Adjusting the Adjustment Gib 97
10.1.3 Changing the return spring 98
10.1.4 Replacing the sound absorber 107
10.1.5 Adjusting the delay valve 108
11. Spare parts and ordering .....................................................................109
11.1 Spare parts 109
11.2 Order 109
12. Appendix..............................................................................................110
12.1 Register directory 110

Identification
1
HKPL-DS – Translation of the original operating manual
1
1. Identification
Hand lever press with air assistance
Type: 4-8-12 kN HKPL-DS, 13-20 kN HKPL-DS, 33-45-56 kN HKPL-DS
Expected service life: 10 years
Gechter GmbH Werkzeug- und Maschinenbau
Ostring 3
90587 Obermichelbach
GERMANY
Tele-
phone:
0911 / 982873-20
Fax:
0911 / 982873-99
E-mail:
[email protected]
1.1 Use in accordance with the intended purpose
The hand lever press with air assistance HKPL-DS is used for pressing, joining,
assembly, riveting, punching, bending, embossing and cutting work as well as
work with sufficiently insulated heated tools.
The press is 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 for any dam-
ages resulting from this.
Proper use also includes:
▪observing all instructions in the operating manual
▪observing all safety instructions
▪complying with the inspection and maintenance work
Observe the "Technical data" in the chapter "Installation and
Function".
This describes the exact technical specifications for proper use.

Identification
1
HKPL-DS – Translation of the original operating manual
2
1.2 Reasonably Foreseeable Misapplication
Reasonably foreseeable misapplication, which may result in dangers to the us-
er, third party or to the press, for all operating modes is constituted by:
▪using the press and its electrical equipment contrary to the intended
use
▪feeding components whose shape deviates from the shape intended
for the press
▪operating the press outside of the physical application limits described
in the "Commissioning / operation" chapter
▪changing the operating pressure to deviate from the value specified in
the technical data
▪changing the control software without prior consultation with the com-
pany Gechter GmbH Werkzeug- und Maschinenbau
▪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
▪bypassing or decommissioning safety and protective precautions on
the press
▪operating the press in the event of obvious faults
▪repair, cleaning and maintenance work without switching off the press
Risk of injury from unauthorized changes
Dangers result from unauthorized changes to the press or to the
control cabinet and from the use of spare parts from other manu-
facturers.
Only original spare parts and wear parts from the manufacturer
may be used. Do not perform any changes, additions or conver-
sions without approval from the company Gechter GmbH
Werkzeug- und Maschinenbau.

General Information
2
HKPL-DS – Translation of the original operating manual
3
2. General Information
2.1 Warranty and liability
In general, the "General terms and conditions of sale and delivery" of the
company Gechter GmbH Werkzeug- und Maschinenbau shall apply. These are
available to the operator at the latest upon contract conclusion.
Warranty and liability claims in the event of personal injury or property dam-
age are excluded if they are due to one or more of the following reasons:
▪improper use of the press
▪improper 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 personnel with the fol-
lowing areas of expertise:
Work area
Expertise
Installation, transport and storage
Technically trained personnel
Commissioning, operation and decommissioning
Trained personnel
Setup
Technically trained personnel
Service and maintenance
Technically trained personnel
Troubleshooting
Technically trained personnel