Hohner M 45/6 Guide

Hohner Maschinenbau GmbH
Gänsäcker 19, 78532 Tuttlingen, Telefon [phone], Telefax 07462/9468-20
Operating-Instructions Page: 1
Spare parts list E1
M 45/6
Edition 06/2008
Stitching Head

M 45/6 Hohner Maschinenbau GmbH
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Hohner Maschinenbau GmbH M 45/6 3
Customer Entries
Stitching head no: ...........................
Machine manufacturer: ...........................
Type of manufacturer: ...........................
Manufacturer' s Address
Company name: Hohner Maschinenbau GmbH
Street: Gänsäcker 19
Town: D-78532 Tuttlingen
Telephone: [phone] / 94 68-0
Fax: [phone] / 94 68-20
Email: [email protected]
Internet: http://www.hohner-postpress.com
Spare Parts / Customer Service
Service telephone no: +49 (0) 74 62 / 94 68-23

List of Contents
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List of Contents
1 SAFETY INFORMATION 6
1.1 Purpose of this document ...............................................................................................6
1.2 The operator....................................................................................................................6
1.3 Safety symbols and the displays that have been used...................................................6
1.4 Obligation and liability.....................................................................................................7
1.5 Correct use......................................................................................................................7
1.6 Organisational measures................................................................................................7
1.7 Safety and protective devices.........................................................................................7
1.8 Non-formal safety measures...........................................................................................7
1.9 Staff training....................................................................................................................7
1.10 Parts of the equipment which are particularly dangerous...............................................8
1.11 Maintenance and repair work, elimination of faults.........................................................8
1.12 Structural modifications to the stitching head.................................................................8
1.13 Cleaning the machine and the disposal of waste products.............................................8
2 DESCRIPTION OF THE STITCHING HEAD 9
2.1 General overview..........................................................................................................10
2.2 Conformity.....................................................................................................................10
2.3 Marking and type plate..................................................................................................10
2.4 Technical data...............................................................................................................10
2.4.1 Normal stitch ...............................................................................................................11
2.5 Dimensional sheet.........................................................................................................13
2.6 Outfitting of the stitching head ......................................................................................13
2.6.1 Basic features..............................................................................................................13
2.6.2 Additional equipment...................................................................................................13
3 OPERATION 14
3.1 Installation of the stitching head....................................................................................15
3.1.1 Clamping the stitching head........................................................................................15
3.1.1.1 Lateral adjustment of the stitching head.........................................................15
3.1.2 Fitting the wire guide...................................................................................................17
3.1.3 Fitting the clincher box ................................................................................................19
3.1.4 Adjusting the clincher box ...........................................................................................21
3.2 Feeding the stitching wire .............................................................................................23
3.3 Removing the stitching wire..........................................................................................23
3.4 Removing the wire guide parts in the event of a stitching wire jam..............................23
3.5 Straighten the stitching wire..........................................................................................25
3.6 Setting the stitch length.................................................................................................27
3.6.1 Basic setting of the stitch length..................................................................................27
3.6.2 Fine adjustment of the stitch length ............................................................................27
3.6.3 Setting the leg length of the stitch...............................................................................29
3.7 Setting the former..........................................................................................................31
3.8 Spine centering parts....................................................................................................33
3.8.1 Installing the holding down device (standard version)................................................33
3.8.2 Adjusting the holding down device (standard version)................................................33
3.8.3 Installing the holding down device (optional narrow version)......................................33
3.8.4 Adjusting the holding down device (optional narrow version).....................................33
4 SERVICING 34
4.1 Lubrication.....................................................................................................................35
4.1.1 Lubricants....................................................................................................................35
4.1.2 Lubrication plan...........................................................................................................35
4.2 Installation and replacement of parts............................................................................36
4.2.1 Replacing the former...................................................................................................37
4.2.2 Replacing the driver ....................................................................................................39
4.2.3 Replacing the bender..................................................................................................39
4.2.4 Replacing the knife......................................................................................................41
4.2.4.1 Rotating/Changing the flat knife .....................................................................41

List of Contents
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4.2.4.2 Replacing the circular knife............................................................................ 41
4.2.4.3 Adjusting the circular knife ............................................................................. 41
4.2.5 Replacing the clincher.................................................................................................43
5 FAULTS 44
5.1 Causes and elimination of faults...................................................................................44
SPARE PARTS LIST E1

Safety Information
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1Safety Information
1.1 Purpose of this document
This document will inform the operator of the Stitching Head M 45/6 of the following:
•The safety symbols and signs
•The packing of the machine and its transportation
•The function and operation of the machine
•Commissioning the machine
•The elimination of faults which arise
•Servicing
Familiarity with this Operating Manual is thus a prerequisite for the safe and correct operation of
the stitching head. It must be read carefully by the operator before the machine is commissioned.
Keep the manual safely in a place where it is readily available and which is close to hand for
persons working on the machine.
1.2 The operator
The Stitching Head M 45/6 must only be operated by trained personnel.
Training will be undertaken by the manufacturer or by persons who have been authorised by the
manufacturer to undertake such training.
1.3 Safety symbols and the displays that have been used
This symbol indicates immediate danger to the life or health of
persons in the immediate vicinity of the machine.
Non-observance of dangers which are so indicated can have grave
consequences and can cause serious damage to health, or may even to
lead to deaths.
This symbol indicates that a potentially dangerous situation has
arisen.
Non-observance of dangers which are so indicated can lead to slight injuries
to persons or damage to equipment.
This symbol indicates that tips on how to use the machine or
particularly useful information are available.
These will help you to use all of the functions of the machine in an optimal
manner.
-This symbol requires you to take action.
•This sign serves as a symbol for listing items.

Safety Information
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1.4 Obligation and liability
The Stitching Head M 45/6 has been built according to state-of-the art technology under
observance of all the recognised safety regulations. However, dangers to life and limb of the user
or third parties and damage to the system or other material assets can still occur during use.
The stitching head should only be used,
• for the purpose for which it was designed
• when it is in a perfect technical condition.
Faults which could reduce levels of safety when using the machine must be eliminated
immediately.
Warranties and liability on the part of the manufacturer are fundamentally covered by the
regulations laid down in our ”General sales and delivery conditions”.
Warranty claims will only be valid if the number label is affixed
(number label on stitching head housing).
1.5 Correct use
The Stitching Head M 45/6 is designed exclusively for binding brochures and leaflets or similar
items.
Any use of the machine contrary to that described above is forbidden, since incorrect use of the
machine can present a danger.
1.6 Organisational measures
The user of machine is required to provide the required personal safety equipment. All existing
safety devices should be checked regularly.
1.7 Safety and protective devices
All safety and protective devices must be correctly attached to the machine and should be in full
working order before every start-up of the machine and Stitching Head M 45/6.
Safety and protective devices may only be removed:
• After the machine has come to a standstill and
• As security against the machine starting up again.
1.8 Non-formal safety measures
The Operating Manual must be kept so that it is permanently at hand at the machine with
Stitching Head M 45/6. There are also generally valid local regulations concerning accident
prevention and environmental protection measures which should be made available and observed
in addition to those described in the Operating Instructions.
All safety and danger signs on the machine should be maintained in a legible condition and should
be renewed where necessary.
1.9 Staff training
Only trained and instructed personnel may install, operate, set and maintain the stitching head.

Safety Information
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1.10 Parts of the equipment which are particularly dangerous
There is a risk of injury in the area of moving parts of the stitching head.
1.11 Maintenance and repair work, elimination of faults
Undertake the required setting, servicing and inspection work on schedule.
The machine may only be operated in cycle mode during all servicing, inspection and repair work
on the Stitching Head M 45/6.
Always make absolutely sure that the machine is only being operated by one person in order
to avoid any influence to the machine by any other persons.
1.12 Structural modifications to the stitching head
Changes to the stitching head, additions or modifications may only be undertaken with the
manufacturer's permission.
1.13 Cleaning the machine and the disposal of waste products
The functionality of the stitching head and perfect processing of the product can only be
guaranteed over a prolonged period of time if the stitching head is regularly cleaned and
maintained in accordance with the standard methods of mechanical engineering.
In this regard, particular attention should be paid to the regular removal of trimmed paper
residue and paper dust, as these can result in jamming of the stitching head or increased
wear.
Substances and materials used (e.g. solvents and lubricants) must be handled correctly and
disposed of in an environmentally friendly manner.

Description of the Stitching Head
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2Description of the Stitching Head
Fig. 1

Description of the Stitching Head
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2.1 General overview
- Fig. 1 -
2.2 Conformity
The Stitching Head M 45/6 conforms to the following guidelines and standards:
- Machine Guideline (98/37/EEC)
- EN 1010-1:1998 (final draft version) and
EN 1010-4:1997 ”Machine safety – safety requirements in connection with the design and
manufacture of printing and paper processing machines”, ”Part 1: General requirements” and
”Part 4: Bookbinding, paper processing and paper finishing machines”.
- This Operating Manual takes account of DIN EN 292, machine safety, basic terminology, general
principles of design.
2.3 Marking and type plate
The type plate is located at the front of the stitching head.
The stitching head serial number is located on an adhesive plate on the right side of the housing.
2.4 Technical data
Net weight of the stitching head 1.8 kg / 3.97 lbs
Quality of the stitching wire Only use perfect quality classes, in normal or
steel strength as required. Pay attention to
abrasion resistance, as heavy abrasion will clog
the wire-guidance parts.

Description of the Stitching Head
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2.4.1 Normal stitch
- N 12 - - N 14 -
Wire stitch dimensions
Max. stitch thickness
Round stitching wire
No. 24 - 26
Ø 0.60 - 0.50 mm
(Ø 0.024 - 0.020 in.)
or:
Round stitching wire
No. 26 - 28
Ø 0.50 - 0.40 mm
(Ø 0.020 - 0.016 in.)
or:
Round stitching wire
No. 23
Ø 0.70 mm
(Ø 0.027 in.)
Possible distances
between wire stitches and
stitch thicknesses in mm
With holding down device
- standard -
Optional:
with holding down device,
left

Description of the Stitching Head
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Fig. 2

Description of the Stitching Head
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Fig. 3
2.5 Dimensional sheet
- Fig. 2 , Fig. 3-
2.6 Outfitting of the stitching head
2.6.1 Basic features
The stitching head is delivered with the following accessories:
DESCRIPTION ORDER NUMBER
Clincher box adjustment gauge 31 64 448
Hexagon key SW 3 46 00 008
Allen key with T-handle SW4 x 150 46 00 033
Torx screwdriver T7 46 00 036
Torx screwdriver T10 46 00 044
Torx screwdriver T20 46 00 045
Adjusting handle 94 55 096
Holding down set, complete 99 55 090
Wire clamp, complete 99 55 150
Clincher box, complete Depending on machine type
2.6.2 Additional equipment
The following optional accessories are available:
DESCRIPTION ORDER NUMBER
Holding down set, left - narrow version 99 55 075
Pan area 99 55 515
Kit of interchange parts - gripper version "N12” stitch 99 55 712
Kit of interchange parts - gripper version "N14” stitch 99 55 714
Centre of wire stitch
Stroke

Operation
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3Operation
Fig. 4
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Operation
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3.1 Installation of the stitching head
3.1.1 Clamping the stitching head
- Fig. 4 -
The stitching head is held by a tenon block which is inserted into the stitching head mounting on
the machine.
- Loosen tenon block with Allen key SW4 .
- Fit the stitching head by inserting the tenon block in the stitching head holder . The two driver
lugs on the stitching head must be located in the guides of the lifting bar.
- Fix stitching head in stitching head mounting by tightening the tenon block with the Allen key.
3.1.1.1 Lateral adjustment of the stitching head
- Fig. 4 -
The center of the wire formed parts within the stitching head must be set to the desired stitching
position for the wire stitch by lateral adjustment.
- Loosen the tenon block with the Allen key .
- Move the stitching head sideways, until the desired position is reached.
- Fix the tenon block in the stitching head mounting with the Allen key.

Operation
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Fig. 5
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Operation
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3.1.2 Fitting the wire guide
- Fig. 5 -
- Loosen screw and place wire clamp on wire guidance tube .
- Align wire clamp with wire roller and wire feed tube , in order to ensure perfect wire
guidance.
- Fix wire clamp by tightening screw .

Operation
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Fig. 6

Operation
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3.1.3 Fitting the clincher box
- Fig. 6 -
The procedure for fitting the clincher box is described in the stitching unit instruction manual.

Operation
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Fig. 7
Fig. 8
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