Hohner ECONOMY 25/40 User manual

Hohner Maschinenbau GmbH
Gänsäcker 19, D-78532 Tuttlingen, Telefon [phone] / 94 68-0, Telefax +49 (0) 74 62 / 94 68-20
Operating Instruction Page 1
Spare Parts List E1
ECONOMY
25/40
Pad and Folder
Wire Stitching Machine

2 ECONOMY 25/40 02/2016 Hohner Maschinenbau GmbH

Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 3
Customer Details
Inventory no.: ...........................
Location ...........................
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 home page: www.hohner-postpress.com
Obtaining Spare Parts / Customer Service
Telephone: [phone] / 94 68-0
Fax: [phone] / 94 68-20
Operating Manual
Document: Translation of the german original Operating
Instructions
Document number: ECONOMY 25/40, Volume 1/2
Version: 02/2016
Spare Parts Lists
Document number: ECONOMY 25/40, Volume 2/2

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Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 5
Table of Contents
1 Basic safety precautions.................................................................................. 7
1.1 Purpose of this document.............................................................................................. 7
1.2 The operator .................................................................................................................. 7
1.3 Safety symbols and the displays in use......................................................................... 7
1.4 Duty and liability ............................................................................................................ 8
1.5 Correct use of the machine ........................................................................................... 8
1.6 User requirements ......................................................................................................... 8
1.7 Safety and protective systems....................................................................................... 8
1.8 Informal safety measures .............................................................................................. 8
1.9 Personnel training.......................................................................................................... 8
1.10 Parts of the machine that are particularly dangerous .................................................... 9
1.11 Servicing and repair work, elimination of faults ............................................................. 9
1.12 Structural modifications to the machine......................................................................... 9
1.13 Cleaning the machine and the removal of waste products............................................ 9
1.14 Noise levels produced by the machine.......................................................................... 9
2 Description of the ECONOMY 25/40 ............................................................. 10
2.1 Dimensions.................................................................................................................. 11
2.2 Conformity ................................................................................................................... 11
2.3 Marking and type plate ................................................................................................ 11
2.4 Technical data ............................................................................................................. 11
2.5 Accessories ................................................................................................................. 13
3 Installation and commissioning of the machine ............................................. 14
3.1 Safety-related components.......................................................................................... 15
3.2 Mounting of the finger guard........................................................................................ 15
3.3 Motor drive................................................................................................................... 15
3.4 Electrical connection................................................................................................... 17
3.5 Motor protective relay .................................................................................................. 17
3.6 Turning the machine by hand ...................................................................................... 17
4 Operation....................................................................................................... 19
4.1 Stitching wire ............................................................................................................... 19
4.2 Inserting the stitching wire ........................................................................................... 21
4.3 Wire coil and straightening the wire............................................................................. 23
4.4 Adjusting the stitching thickness and wire length ........................................................ 27
4.4.1 Setting the stitching thickness ................................................................................. 27
4.4.2 Setting the length of the stitching wire..................................................................... 27
4.5 Exchanging the upper and lower knife ........................................................................ 29
4.6 Exchanging the driver and bender............................................................................... 31
4.6.1 Exchanging the two KITS ........................................................................................ 31
4.7 Aligning the former ...................................................................................................... 33
4.8 Stitching very thick stitching material........................................................................... 35
4.9 Pad stitching 25/40 mm ............................................................................................... 35
4.10 Table adjustment for pads and folders ........................................................................ 37
4.10.1 Pad stitching............................................................................................................ 37
4.10.2 Folder stitching ........................................................................................................ 37
4.11 Loop stitching with economy 25/40 ............................................................................. 39
4.12 Adjustment for loop-stitching, wire length stitching thickness - stitching table ............ 41
4.12.1 Adjusting the wire length ......................................................................................... 41
4.12.2 Adjustment of the stitching thickness ...................................................................... 41
4.12.3 Adjustment of the stitching table and limit stops...................................................... 41
4.13 lubrication specification ............................................................................................... 42

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5 Trouble shooting ............................................................................................ 43
5.1 Causes and elimination of faults.................................................................................. 43
6 Flow diagrams .............................................................................................. 47

Basic safety precautions
Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 7
1 Basic safety precautions
1.1 Purpose of this document
This document is to inform the operator of the Wire Stitching Machine ECONOMY 25/40 about
the following matters:
• the safety symbols and signs
• the installation and commissioning
• the adjustment and operation
Familiarity with this Operating Manual is a prerequisite for the safe and correct running of the
machine. 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 per-
sons working on the machine.
1.2 The operator
The Wire Stitching Machine ECONOMY 25/40 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 in use
This symbol displays immediate danger to the life or health of persons
in the immediate vicinity of the machine.
Non-observance of the warnings indicated can have immediate, grave con-
sequences and can cause extensive damage to health or may even lead to
death.
This symbol displays possible danger to the life or health of persons
in the immediate vicinity of the machine.
Non-observance of the warnings indicated can have grave consequences,
and can cause extensive damage to health, or may even lead to death.
This symbol displays the existence of a potentially dangerous
situation.
Non-observance of the warnings indicated can lead to minor injuries to per-
sons.
This symbol displays the existence of the risk of damage to
equipment.
Non-observance of the warnings indicated can lead to slight damage to
equipment.
This symbol indicates the availability of tips on how to use the
machine or particularly useful information.
These tips will help you to use all of the functions of the machine to best
advantage.
-This sign requires you to take action.
•This sign serves as a symbol for listing items.
TIP

Basic safety precautions
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1.4 Duty and liability
The Wire Stitching Machine ECONOMY 25/40 has been built according to state-of-the-art tech-
nology under the observance of all the recognised safety regulations. It is, nevertheless, still possi-
ble when using this machine to cause danger to life and limb of the user or a third party or to cause
damage to the machine or other property.
The machine should only be used,
• for the purpose for which it was designed
• when it is in a perfect technical condition
Faults that could reduce the levels of safety in using the machine must be removed immediately.
Warranties and liability on the part of the manufacturer are fundamentally covered by the regula-
tions laid down in our ”General sales and delivery conditions”.
1.5 Correct use of the machine
The Wire Stitching Machine ECONOMY 25/40 is designed exclusively stitching of 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 User requirements
The user of the machine is required to provide the required personal safety equipment. All existing
safety systems should be checked regularly.
1.7 Safety and protective systems
All safety and protective systems must be attached to the machine and should be in full working
order before every start-up of the machine.
Safety and protective systems may only be removed:
• when the machine is stationary and
• after it has been secured against being started up again.
1.8 Informal safety measures
The Operating Manual should be stored in such a way as to be permanently to hand at the
machine. There are also generally valid local regulations concerning accident prevention and envi-
ronmental protection measures that 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 Personnel training
Only skilled and trained personnel are allowed to work on the machine.
The responsibility of the various parties involved is laid out in the following table:
Trained persons Specialists
Transportation A haulage company
Installation and commis-
sioning
The Hohner company,
Customer Service
Operation x
Locating faults x
Removing the fault The Hohner company,
Customer Service
Setting up, equipping x
Servicing x

Basic safety precautions
Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 9
1.10 Parts of the machine that are particularly dangerous
1.11 Servicing and repair work, elimination of faults
Mount the finger guard again after adjustment-, maintenance- and inspection work.
1.12 Structural modifications to the machine
Changes to the machine, additions or modifications may only be undertaken with the permission of
the manufacturer.
1.13 Cleaning the machine and the removal of waste products
The functionality of the machine and clean processing of the products can only be guaranteed over
a prolonged period of time, if the machine is regularly cleaned in accordance with the normal meth-
ods used in mechanical engineering.
Clean with mild, non-abrasive and non-scratch cleaners. Never use aggressive cleaning agents
such as e.g. solvents.
While doing this, it is particularly important to remove trimmed paper remnants
and paper dust regularly, as these can result in jamming of the machine and in
increased wear of its parts.
The machine contains bare metal parts. These should be cleaned regularly with a protective clean-
ing agent, especially when using the machine in rooms of high air humidity.
All substances and materials used (e.g. solvents and lubricants) must be handled appropriately and
removed in an environmentally friendly way.
1.14 Noise levels produced by the machine
The noise emitted by the machine when it is running does not exceed a value of 81 dB(A) as meas-
ured in accordance with DIN 45635, Part 27.
Quick stroke movements of the stitching heads!
Danger of crushing!
 Never operate the system without properly mounted finger guard.
Quick stroke movements of the stitching heads!
Danger of crushing!
Before carrying out maintenance or repairs, take care that the power supply is switched off
and prevented from being switched on again accidentally.
Never operate the system without properly mounted finger guard.

Description of the ECONOMY 25/40
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2 Description of the ECONOMY 25/40
Fig. 2.1
1
[mm]

Description of the ECONOMY 25/40
Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 11
2.1 Dimensions
- Fig. 2.1 -
2.2 Conformity
Please observe the document attached:
„EC Declaration of Conformity according to the EC Machinery Directive 2006 / 42 / EC“
2.3 Marking and type plate
The type plate and the CE labelling are fitted below the main switch- Fig. 2.1 -, Pos. 1.
2.4 Technical data
Max. stitching thickness - clenched
- stubbed
25 mm / 1.000 in.
40 mm / 1.575 in.
Crown width 14 mm / 0.550 in.
Stitching wire, round No. 21 - 30
(0.80 - 0.35 mm Ø / diametric)
Stitching wire, flat No. I - VI
(0.70 x 0.35 mm / 0.028 x 0.014 in.
up to
0.96 x 0.78 mm / 0.038 x 0.031 in.)
Exchange parts for loop stitching up to 3 mm / 0.12 in.
Stitching per minute 206 stitches
Size of stitching table 700 x 240 cm / 27.5 x 9.4 in.
Working height 880 mm / 34.64 in.
Area of the machine 840 x 570 mm / 33.0 x 22.45 in.
Total height of the machine 1540 mm / 60.60 in.
Space required without the operator 920 x 620 mm / 36.20 x 24.40 in.
Insertion depth from clincher box
Pad stitching
Saddle stitching
approx. 95 mm / 3.75 in.
approx. 290 mm / 11.02 in.
Packing dimensions approx. 1030 x 800 x 1540 mm
approx. 40.6 x 31.5 x 60.6 in.
Net weight approx. 200 kg / 440 lbs
Gross weight approx. 240 kg / 530 lbs
Motor Geared motor
0.55 kW 230/400 Volt
50 Hz (3-phase)
Noise emission, not exceeding 81 dB(A)

Description of the ECONOMY 25/40
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Description of the ECONOMY 25/40
Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 13
2.5 Accessories
Every new ECONOMY 25/40 is supplied with:
Art. no. 43 00 068 1 pedal switch
1 KIT coarse consisting of already mounted on the machine
Art. no. 31 35 536 1 driver
Art. no. 31 35 538 1 bender, left
Art. no. 31 35 539 1 bender, right
for round wire No. 21 - 25
and flat wire No. I - VI
1 KIT fine consisting of
Art. no. 31 35 547 1 driver
Art. no. 31 35 548 1 bender, left
Art. no. 31 35 549 1 bender, right
for round wire No. 24 - 30
Art. no. 94 03 650 2 clinchers, coarse
from round wire No..
23
and flat wire No. VI
Art. no. 37 34 323 1 inserting block
SPARE PARTS
Art. no. 31 03 412 1 clincher pusher
Art. no. 39 34 556 1 compression spring / gripper
Art. no. 39 35 620 1 compression spring / wire feed
TOOLS
Art. no. 46 00 009 1 hexagon socket screw key, size 5
Art. no. 46 00 014 1 diagonal cutting nipper
Art. no. 46 00 044 1 Torx angle screwdriver T 10
Art. no. 46 00 045 1 Torx angle screwdriver T 20

Installation and commissioning of the machine
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3 Installation and commissioning of the machine
Fig. 3.1
1
3
2

Installation and commissioning of the machine
Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 15
3.1 Safety-related components
- Fig. 3.1 -
The combined ON/EMERGENCY-STOP button -1-, the door safety switch -2- and the
finger guard -3- are essential for the safe function of the machine.
3.2 Mounting of the finger guard
- Fig. 3.1 -
The finger guard must be mounted and adapted to the block- and brochure stitching. Mounting is
simplified by corresponding symbols which are sticked on the finger guard.
Fit the finger guard -2- for block- and brochure stitching as shown below.
Block stitching
Brochure stitching
3.3 Motor drive
- Fig. 3.1 -
The machine is switched on by means of the main switch -1- on the right of
the machine stand. When the pedal switch -3- is depressed, the motor is started; the stitching head
is activated and completes one cycle.
Quick stroke movements of the stitching heads!
Danger of crushing!
Before carrying out maintenance or repairs, take care that the power supply is switched off
and prevented from being switched on again accidentally.
Never operate the system without properly mounted finger guard.
2
2

Installation and commissioning of the machine
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Fig. 3.2
Fig. 3.3
1
2
5
3
6
4

Installation and commissioning of the machine
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3.4 Electrical connection
Unless a different motor is ordered, the ECONOMY 25/40 is supplied with a threephase gear motor
for connection to 230/400 volt, 3 phase, 50 Hz. Motors for other current types, voltages, frequencies
and motors with tropical protection are available on request (at an extra charge).
The type plate specifies for which mains voltage and mains frequency the machine has been
designed.
- When installing the machine, the local connection regulations must be observed. The supply line
to the machine must be appropriately protected. In accordance with the valid VDE regulations, the
protective conductor is yellow-green.
- Fig. 3.3 -
Special attention must be paid to the direction of rotation of the motor shaft (visi-
ble on the fan blade), marked by a arrow -3-. The direction of rotation is changed
by swapping 2 phases of the mains supply line.
3.5 Motor protective relay
- Fig. 3.2 -
The motor protective relay is triggered upon overload of the motor and switches off the power sup-
ply of the motor. This is indicated on the trigger display window -2-.
• Yellow display, invisible: relay not triggered
• Yellow display, visible: relay triggered
- Should the motor protective relay have triggered, the machine must first be switched off with the
ON/EMERGENCY-STOP button. Then determine and eliminate the cause.
- Once the cause has been eliminated, the motor protective relay can be reset by pressing the
reset key -1-, - Fig. 3.2 -.
While doing so, ensure that all protective systems are installed on the machine and all tools
have been removed from the machine.
3.6 Turning the machine by hand
- Fig. 3.3 -
In the event of faults, for setting and functional testing, the machine can be turned by hand. Use
hexagon key SW 5 -4- from the tool set for this purpose.
Insert hexagon key -4- into the hexagon mounting (on the back of the drive motor -5- in the fan
shaft) like a crank, move fan lever -7- for brake in the direction of the arrow and turn fan shaft in the
direction of the arrow -3-.
Before switching on the machine, make sure that all protective devices are fit-
ted to the machine and all tools have been removed from the machine!
Voltage
Danger of electrical shock!
 Only qualified skilled workers may carry out work in the vicinity of the mains
power supply.
Quick stroke movements of the stitching heads!
Danger of crushing!
Before carrying out maintenance or repairs, take care that the power supply is switched off
and prevented from being switched on again accidentally.
Never operate the system without properly mounted finger guard.

Installation and commissioning of the machine
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Operation
Hohner Maschinenbau GmbH ECONOMY 25/40 02/2016 19
4 Operation
4.1 Stitching wire
The ECONOMY 25/40 processes stitching wire of standard quality
Round wire No. 21 - 30 (diameter 0.80 - 0.35 mm)
Flat wire No. I - VI (0.70 x 0.35 to 0.96 x 0.78 mm)
Thumb rule
The thicker the material to be stitched, the thicker the wire, but it should be not thicker than neces-
sary. A wire that is too thick is not aesthetically pleasing, but a wire that is too thin will result in mis-
takes!
Stitching wire - round or flat?
Very thin folders of just a few sheets are usually stitched with round wire no. 30 or 28. The selection
of round or flat wire is dictated by experience and economy (round wire is cheaper). Blocks of 18
mm thickness can be stitched with either round or flat wire. For thicknesses over 18 mm, we recom-
mend flat wire in principle.
Stitching wire index
Stitching
thickness
from approx. to approx.
Round wire
no.
Flat wire no.
Occasionally you might
need a stronger type of
wire, e.g. when working with
very hard paper or in case
of blunt cutters, which
weaken the driving power of
the staples.
2 sheets 1 mm 30 -
2 sheets 2 mm 28 -
2 sheets 4 mm 26 -
2 mm 6 mm 25 -
6 mm 10 mm 23 III
10 mm 14 mm 22 IV
14 mm 18 mm 21 V
18 mm 25 mm - VI

Operation
20 ECONOMY 25/40 02/2016 Hohner Maschinenbau GmbH
Fig. 4.1
9
16
10
45
11
12
13
11
14
15
8
On
Off