48/5-S Operating Manual
Contents
1. hohner Maschinenbau GmbH 48 5 5 5 Standard loop stitching Sizes of the staple ge Max stitching thickness Round stitching wire No 24 26 0 60 0 50 mm 0 024 0 020 in Distance index for loop stitching in mm 54 net weight approx 2 7 kg 5 9 lbs IMPORTANT Please only use name brand steel in normal or extra high tension steel versions depending on usage By heavy scuffing of wire scuff resistibility causes wire guides to clog hohner Maschinenbau GmbH 48 5 S 6 General and Services Foundation plan of the stitching head UNIVERSAL 48 5 5 680 max 340 LIFTING 181 oe UPPER EDGE OF CLINCHER BOX 310 Gy f 49 ha el Y MIDDLE OF STAPLE hohner Maschinenbau GmbH 48 5 S 7 General and Services 3b Foundation plan of the stitching head and clincher box mountin 51 JUNIVERSAL 2 JJ 8 48 55 Qui Ki SiM 20 STITCHING HEAD MOUNTING MIDDLE OF STAPLE 714 1966 1034 CLINCHER BOX MOUNTING 102 101 hohner Maschinenbau GmbH 48 5 S 8 4 1 4 2 General and Services Accessories Every new UNIVERSAL 48 5 S is supplied with Equipment Art No 1 wire bow cpl Art No 1 clincher box cpl with clincher and clincher pusher Tools Ar2. groove the bender is clogged by wire pieces WEY knives worn out see chapter 14 ES Wire groove in the driver its dirty worn out or broken out remove driver see chapter 16 clean wire groove resp exchange driver shoe tongue spring too weak remove blocking wire pieces or replace compression spring in the shoe tongue clincher box not aligned properly see chapter 7 hohner Maschinenbau GmbH 48 5 S 30 Staples legs break off latch not adjusted see chapter 13 wire its brittle use other wire quality former is blocked by wire pieces remove wire pieces eventually remove former tension spring or gripper in former defective hook spring in bender defective wire sizes does not coincide with the wire bender parts bender and driver adjust the former to the groove of the bender Bulge at one staple edge wire weak or soft driver is broken out see chapter 16 knives worn out see chapter 14 Staple legs run together or apart wire not straightened see chapter 9 knives worn out see chapter 14 One leg is formed wrong wire not straightened see chapter 9 clincher box must be aligned see chapter 7 Za One or both legs are formed diagonally wire weak or soft wire not straightened see chapter 9 75 knives worn out see chapter 14 AZ clinchers broken out see chapter 17 adjustment of the cutting box receiver to the stit hea
3. A knives worn out see chapter 14 pressure of the shoe tongue weak or blocked remove blocking wire pieces or replace compression spring in the shoe tongue wire groove in the driver is dirty worn out or broken out remove driver see chapter 16 clean wire groove resp exchange driver Staple back does not lay tight pressure of the stitching too weak adjust stitching aggregate to stitching thickness Staple legs are not bent enough pressure of the stitching too weak adjust stitching aggregate to stitching thickness clincher do not go upwards enough adjust pression for the clincher lifting at the stitching aggregate timing from clincher actuation to lifting actuation not correct stitching aggregate must be adjusted again at the manufacturer Staple back does not lay tight is saddle shaped pressure of the stitching too weak adjust stitching aggregate to stitching thickness wire weak or soft pressure of the shoe tongue too weak or blocked remove blocking wire pieces or replace compression spring in the shoe tongue Staple legs rammed and are not correctly bent wire weak or soft wire not straightened see chapter 9 clincher box must be aligned see chapter 7 staple legs not equal length see chapter 11 overall wire length too short see chapter 10 knives worn out see chapter 14 gt Wire does not pierce through and builds sling GQ wire weak or soft
4. 1 This can be controlled exactly by laying a mirror 32 on the clincher box 9 that means the position of the former respecting the wire can be seen cleary A correction eventually necessary can be obtained by the hexagon socket set screw 33 Important After adjustment tighten hexagon nut 34 again carefully SN S NS III 22227727 Sw hohner Maschinenbau GmbH 48 5 5 19 13 General and Services Alignment of bender To maintain a proper function the stitching head must be adjusted to the stroke of your stitching aggregate which is roughly done at our factory A correction is only necessary if the latch 35 in the bender 31 does not come out laterally approx 2 5 mm when the stitching head is at its highest position If an adjustment is necessary place the stitching aggregate to the lowest position and remove the former 14 Loosen hexagon socket set screw 36 and unscrew hexagon socket set screw 37 about 1 2 turns After adjustment tighten hexagon socket set screw 36 again Now switch on the stitching aggregate and examine if the latch comes out enough Repeat this procedure until the function is correct hohner Maschinenbau GmbH 48 5 S 20 14 b General and Services Exchange of knives The quality of the stitching mainly depends on the condition of the knives The knives can be used several times by turning them some degrees e
5. LI Standard loop stitching with centering device hohner Maschinenbau GmbH 48 5 S 27 ll Conversion of the universal 48 5 s from standard stitching to loop stitchin p Es Q For standard loop stitching a change part set prs 6 Art No 05 48 051 consisting of the following parts is needed Art No 38 63 418 L leaf spring short Art No 99 61 355L bender complete Art No 99 63 4101 former complete see page 26 Pivot the leaf spring 23 sideways and remove the former 14 Remove hexagon Socket head cap screw 45 and the corresponding carrier 46 out the bender 31 downwards Now install the bender 31 for standard loop stitching and make sure that the latch see chapter 12 position 35 is pressed a bit into the bender Install carrier 46 and tighten hexagon socket head cap screw 45 again Install former 14 and put the leaf spring short 23X on the leaf spring 23 with the prevailing torque type hexagon nut 57 pivot back leaf spring 23 hohner Maschinenbau GmbH 48 5 S 28 hohner Maschinenbau GmbH 48 5 5 29 lll Troubleshooting Here are some examples of faults with specifications of the possible causes There are often different reasons which have to be investigated step by step Do not apply all suggestions simultaneously but one after the other making tests in between Worn out parts should be exchanged nN Staple back arched wire weak or soft wire not straightened see chapter 9
6. Operating Instructions Spare parts list Lc nm car 48 5 S 6x 04 2005 Ley ei 3 Narrow Stitching Head hohner Maschinenbau GmbH G ns cker 19 78532 Tuttlingen Telephone 07462 9468 0 Fax 07462 9468 20 hohner Maschinenbau GmbH 48 5 S hohner Maschinenbau GmbH 48 5 5 Contents Chapter Page General and RE e A T Safty le 4 ENK lee RE EE 5 Foundation plan of the stitching head UNIVERSAL 48 5 7 3b Foundation plan of the stitching head and clincher box mounting nenn 8 Ge EE 9 4 7 oci ee ES 9 9 5 Lube specification WEE 10 6 Installation and adjustment of the Universal A9 be nennen 11 7 Fine adjustment of the clincher born ee 13 8 Inserting TNE Wire rerai i 14 9 Straightening of the wire EEN 15 10 Basic setting of wire length EE 16 UR Setting f leg lengths EE 17 Eet ue r TEE 19 13 Alignment of bender Ae 20 s ce Eat TEE 21 T5 Exchahge ot Le EE 22 16 Exchange Of driver au He 23 17 en Eu RT 24 18 Fitting the Ree Re 25 Il Conversion of the universal 48 5 s from standard stitching to loop stitching 28 Troubleshooting EE 30 hohner Maschinenbau GmbH 48 5 S General and Services Safety notices ATTENTION Before the operation of the stitching head or before working with the machine do not f
7. d rec sch 3b N 2 Staple legs are formed diagonally to the same side wire not straightened see chapter 8 adjustment of the cutting box receiver to the stit head rec sch 3b N NN 2 Slightly formed wire pieces trop out Beet E wire not straightened see chapter 9 v adjust bender see chapter 13 hook spring in the bender is defective or bender worn out A Snarled wire between transport wheels and wire tube eg wire not straightened see chapter 9 fa Vo cutting pusher is jamming round knife is SCH x pressed against flat knife see chapter 14b 92 6 cutting rocker is blocked compression spring in the cutting block is So defective lower wire tube misplaced or wrongly adjusted move slightly upwards or downwards former wrongly adjusted see chapter 12 Troubleshooting loop stitching Most faults and specifications of the eventual reasons are indicated in the section before Do Only straight wire pieces appear adjust the short leaf spring for the former on the cover s chapter 11 wire not straightened see chapter 9 former wrongly adjusted see chapter 12 hohner Maschinenbau GmbH 48 5 S 31
8. nsure that the rod assembly runs smoothly Fitting the slide Insert slotted screw 10 laterally into the clinching box mounting Fix slide 9 with slot on slotted screw and tighten lightly using the locking nut 11 Push the complete slide 9 against the clinching box Align the V block of the slide to the center of the clinching box with the help of the M5 setscrew 12 Set the height of the V block to approx 0 5 mm above the clinching box Tighten the locking nut 11 Setting the holding down device The centering V block 17 on the lower part of the rod linkage should lie approx 3 5 mm beneath the edge of the bender This can be adjusted by moving the plate 15 in the slot Install stitching head in the stitching unit You must ensure that the locating key 13 of the plate is positioned on the lifting bar and is not as is the case with the stitching head locating key inserted into the locating groove Loosen the 2 countersunk screws 14 Drive rod linkage into plate 15 until the lower part of the rod linkage is positioned approx 3 5 mm beneath the edge of the bender Tighten the 2 countersunk screws 14 The centring V block 17 can be moved backwards or forwards by turning the adjusting screw 16 Move centring V block 17 far enough backwards or forwards so that it is precisely aligned with the V block of the slide 9 hohner Maschinenbau GmbH 48 5 S 26 Standard stitching with centering device
9. o the knives with the delivered adjusting handle 28 rotate clockwise adjusting handle 28 To take back the wire in case of change over wire type or stitching head disassembly push down the adjusting washer 19 in that way the wire return stop 17 is not pressed GET E m St N E IMS iini hohner Maschinenbau GmbH 48 5 S 14 9 General and Services Straightening of the wire The wire must be straight for stitching If the wire is not straight or if any difficulties appear try to change the course of the wire by slightly turning the wire straightener 22 by using a screw driver If this is unsuccessful the former 14 must be removed Pivot the leaf spring 23 sideways and remove the former 14 Now put the adjusting handle 28 on the adjusting nut 24 turn to the right and you will see whether the stitching wire 30 is transported bent or straight If the wire is not exactly horizontal it must be corrected by the wire straightener 22 until getting a straight wire Put in again the former 14 and turn back the leaf spring 23 hohner Maschinenbau GmbH 48 5 S 15 General and Services 10 Basic setting of wire length The adjustment is necessary only once and that is when the stitching head is installed and compression is set A slight correction is only necessary if you change the stitching wire thickness al Standard stitching The required length of wire for 2 page sti
10. orget to read carefully the hohner instructions for use and observe all warning on the machine The non observance of this prescription may lead to severe injuries Do not operate the machine before all safety devices lock and other security fixtures function or are set up Before working cut off the current supply and set safety switch main switch to 0 Your right to claim under guarantee can only be followed if the label with the serial number is stuck on the body of the head The user is responsible for the safe function of the machine at any time as well as for the observance of all prescriptions of these instructions for use by the operating person For all questions regarding the safe operation of this machine please contact your senior officer or hohner sales representative or directly to hohner Maschinenbau GmbH Street G ns cker 19 Town D 78532 Tuttlingen Telephone 07462 94 68 0 Fax 07462 94 68 20 Email info hohner gmbh de Internet www hohnerstiching com Spare Parts Customer Service Fax 07462 9468 20 modifications reserved hohner Maschinenbau GmbH 48 5 S 4 General and Services Technical data Crown width Max stitching thickness clenched Round stitching wire No 24 28 0 60 0 40 mm 0 024 0 016 in or alternatively No 26 30 0 50 0 35 mm 0 020 0 014 in 2 Distance index for standard stitching in mm 54 52 V
11. r see chapter 12 pos 35 hohner Maschinenbau GmbH 48 5 S 22 16 General and Services Exchange of driver Pivot the leaf spring 23 sideways and remove the former 14 Turn out both threaded bolts 47 in the driver 8 and pull out the driver downwards Assemble in reversed order If the lower edge of the driver is worn out the driver can be turned round and used again hohner Maschinenbau GmbH 48 5 S 23 17 General and Services Exchange of clincher Draw out clincher pusher 48 downwards Turn clinchers 49 in the clincher box 9 upwards and extract them out of the locking bolt 50 Push in new clinchers into the locking bolt 50 turn them around to the middle of the clincher box Insert the clincher pusher 48 again hohner Maschinenbau GmbH 48 5 S 24 General and Services 18 Fitting the holding down device incorrect incorrect correct I E Cas DI 7 SE WE 25 hohner Maschinenbau GmbH 48 5 S Spine centering parts The spine centering parts are only for saddle stitching They help to precisely position the stitch 1 in the center of the sheet fold 2 see page 22 Fitting the holding down device Attach tension spring 3 to the two spring bolts 4 Mount distance plate 5 on stitching head Place complete rod assembly 6 with the guide plate 7 on the distance plate and fix to the housing with the help of the two countersunk screws 8 E
12. t No 46 00 006 1 hexagon socket screw key no 2 Art No 46 00 007 1 hexagon socket screw key no 2 5 Art No 46 00 033 1 hexagon key with T handle no 4 x 150 Art No 94 61 230 1 adjusting handle hohner Maschinenbau GmbH 48 5 S 9 General and Services Lube specification Apply a first rate oil only never a viscous mineral oil spray lubricants We recommend oO Sliding oil with viscosity grade 65 70 ISO viscosity grade according to DIN 51 519 Oiling how often In case of need approx every 16 working hours From time to time slightly oil the felt discs on the wire bow Please observe all these regulations carefully to guarantee a faultless operation Former for loop stitching hohner Maschinenbau GmbH 48 5 S 10 General and Services 6 Installation and adjustment of the Universal 48 5 s Insert mounting block 1 into stitching head receiver 2 laterally Insert stitching head over the protruding journal of the mounting block 1 taking caution that the carrier nose 3 inthe main drive bar 4 is properly seated Tighten the hexagon socket head cap screw 5 with the delivered hexagon key no 4 54 By loosing both hexagon socket set screws 6 the stitching head can be adjusted to the clincher box EL IL gest IS Ld CZ 5 hohner Maschinenbau GmbH 48 5 5 11 IMPORTANT The middle of driver 8 and clincher box 9 have to coincide absolutely Depending on the
13. tching is approx 26 mm Set the 15 Ce stitching aggregate for 2 page stitching 0 55 Turn knurled nut 25 until the upper edge of the tooth rack 26 indicates N After wards fine adjustment Standard loop stitching 6 19023 The required length of wire for 2 page stitching is approx 32 mm Set the stitching aggregate for 2 page stitching Turn knurled nut 25 until the upper edge of the tooth rack 26 indicates L After wards fine adjustment Fine Adjustment knurled nut 25 turned to the right longer wire knurled nut 25 turned to the left shorter wire hohner Maschinenbau GmbH 48 5 S 16 General and Services 11 Setting of leg length The thickness of the folder or pad determines the required length of the stitching wire for a complete staple but first the stitching aggregate must be adjusted to the required stitching thickness see corresponding machine operating instructions Turn off the wire transport with the three square handle 15 Put the delivered adjusting handle 28 on the stand up bolt 55 Adjust the needed stitching thickness from the marking stitch on the cutting pusher 42 tothe scale 29 Turn on the wire transport hohner Maschinenbau GmbH 48 5 S 17 12 General and Services Alignment of former The stitching will be correctly only when the former 14 swings in so far that the stitching wire 30 comes exactly under the middle of the groove of the bender 3
14. type of machine an adjustment may be necessary By removing the hexagon socket set screws 10 or 11 the stitching head can be aligned with the clincher box 9 First loosen both hexagon socket set screws 12 and retighten them after adjustment hohner Maschinenbau GmbH 48 5 S 12 General and Services Fine adjustment of the clincher box Loosen clamping nuts 13 Adjust the clincher box 9 by moving it laterally until it is The middle of the former 14 must be exactly in alignment with the middle of the clincher box 9 It is helpful to use a straight flat material i e a ruler The flat material 53 is put against the right side of the stitching head Then move the clincher box 9 to the right side against the flat material 53 centered with the stitching head until it stops Tighten the clamping hohner Maschinenbau GmbH 48 5 S nuts 13 again SE SSS SI I SPSS II E 13 8 General and Services Inserting the wire Turn off the wire transport turn the three square handle 15 to the right Push the stitching wire 30 from the topside through eyelets 16 between both felt discs 18 into the wire return stop 17 through the upper wire tube between both transporting wheels 20 so that some stitching wire is inserted the center wire tube 21 Turn on the transport turn the three square handle 15 to the left Now the stitching wire can be transported t
15. xchange of flat knife 41 Loosen hexagon socket set screw 56 Remove stand up bolt 55 and take out the cutting block 39 Loosen the slotted countersunk head cap screw 40 at the flat knife 41 and exchange the flat knife Assemble in reversed order exchange of round knife 44 Loosen hexagon socket set screw 56 Remove stand up bolt 55 and take out the cutting block 39 Carefully remove the cutting pusher 42 the installed compression spring is under pressure Loosen hexagon socket head cap screw 43 and squeeze out the round knife 44 from the left Exchange round knife Assemble in reversed order When assembling the new round knife you must pay attention that the round knife projects so far that an absolute cutting effect with the counter cutting edge results For the best results push in the round knife and adjust it at the flat knife pressed down Tighten the hexagon socket head cap screw 43 again Make sure that the stand up bolt 55 is tightened so strongly that the cutting block 39 can only be slightly adjusted when using the adjusting handle 28 hohner Maschinenbau GmbH 48 5 S 21 15 General and Services Exchange of bender Pivot the leaf spring 23 sideways and remove the former 14 Remove hexagon socket head cap screw 45 and the corresponding carrier 46 Pull out the bender 31 downwards Assemble in reversed order When inserting the bender 31 into the stitching head the latch must be pressed a bit into the bende
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