Hohner UNIVERSAL 48/5 S User manual

hohner Maschinenbau GmbH - 48/5 S
Operating-Instructions
Spare parts list
UNIVERSAL
48/5 S
04/2005
Narrow Stitching Head
hohner Maschinenbau GmbH
Gänsäcker 19, 78532 Tuttlingen, Telephone 07462 / 9468-0, Fax 07462 / 9468-20

hohner Maschinenbau GmbH - 48/5 S
Contents
Chapter Page:
I. General and Services ..................................................................................................4
1. Safety notices ..............................................................................................................4
2. Technical data .............................................................................................................5
3a Foundation plan of the stitching head UNIVERSAL 48/5 s...........................................7
3b Foundation plan of the stitching head and clincher box mounting................................8
4. Accessories .................................................................................................................9
4.1 Equipment: ..................................................................................................................9
4.2 Tools:...........................................................................................................................9
5. Lube specification......................................................................................................10
6. Installation and adjustment of the Universal 48/5 s....................................................11
7. Fine adjustment of the clincher box ...........................................................................13
8. Inserting the wire .......................................................................................................14
9. Straightening of the wire ............................................................................................15
10. Basic setting of wire length ........................................................................................16
11. Setting of leg length...................................................................................................17
12. Alignment of former ...................................................................................................19
13. Alignment of bender...................................................................................................20
14. Exchange of knives....................................................................................................21
15. Exchange of bender...................................................................................................22
16. Exchange of driver.....................................................................................................23
17. Exchange of clincher .................................................................................................24
18. Fitting the holding down device..................................................................................25
II. Conversion of the universal 48/5 s from standard-stitching to loop-stitching..............28
III. Troubleshooting.........................................................................................................30

hohner Maschinenbau GmbH - 48/5 S - 4 -
I. General and Services
1. Safety notices
A T T E N T I O N
1. Before the operation of the stitching head or before working with the machine, do not
forget 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.
2. Do not operate the machine before all safety devices, lock and other security fixtures
function or are set up.
3. Before working, cut off the current supply and set safety switch (main switch) to 0.
4. 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: Gänsäcker 19
Town: D-78532 Tuttlingen
Telephone: 07462 / 94 68 - 0
Fax: 07462 / 94 68 - 20
Email: [e-mail]
Internet: www.hohnerstiching.com
Spare Parts / Customer Service
Fax: 07462 / 9468-20
- modifications reserved -

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I. General and Services
2. 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. ∅
Distance index for standard stitching (in mm):

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Standard loop stitching
Sizes of the staple
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):
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 - 7 -
I. General and Services
3a Foundation plan of the stitching head UNIVERSAL 48/5 s

hohner Maschinenbau GmbH - 48/5 S - 8 -
I. General and Services
3b Foundation plan of the stitching head and clincher box mounting

hohner Maschinenbau GmbH - 48/5 S - 9 -
I. General and Services
4. Accessories
Every new UNIVERSAL 48/5 S is supplied with:
4.1 Equipment:
Art.-No. 1 wire bow cpl.
Art.-No. 1 clincher box cpl. (with clincher and
clincher pusher)
4.2 Tools:
Art.-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 - 10 -
I. General and Services
5. Lube specification
Apply a first-rate oil only, never a viscous mineral
oil, spray lubricants.
We recommend
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 - 11 -
I. 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 in the 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.

hohner Maschinenbau GmbH - 48/5 S - 12 -
IMPORTANT!
The middle of driver 8 and clincher box 9 have
to coincide absolutely. Depending on the 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 - 13 -
I. General and Services
7. Fine adjustment of the clincher box
Loosen clamping nuts 13 . Adjust the clincher box 9 by moving it laterally until it is
centered with the stitching head. 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
until it stops. Tighten the clamping nuts 13 again.

hohner Maschinenbau GmbH - 48/5 S - 14 -
I. General and Services
8. 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 to 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.

hohner Maschinenbau GmbH - 48/5 S - 15 -
I. General and Services
9. 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 - 16 -
I. 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.
Standard stitching
The required length of wire for 2-page
stitching is approx. 26 mm. Set the
stitching aggregate for 2-page stitching.
Turn knurled nut 25 until the upper
edge of the tooth rack 26 indicates
„N“. * After wards fine adjustment.
Standard loop-stitching
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 - 17 -
I. 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 to the scale 29. Turn on the wire transport.

hohner Maschinenbau GmbH - 48/5 S - 18 -

hohner Maschinenbau GmbH - 48/5 S - 19 -
I. General and Services
12. 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 31. This
can be controlled exactly by laying a mirror 32 on the clincher box 9 , by 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.

hohner Maschinenbau GmbH - 48/5 S - 20 -
I. General and Services
13. 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 - 21 -
I. General and Services
14. 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.
a) exchange 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.
b) 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.