Hohner EXACT User manual

Hohner Maschinenbau GmbH
Gänsäcker 19, D-78532 Tuttlingen, Telefon [phone] / 94 68-0, Telefax +49 (0) 74 62 / 94 68-20
Operating Instructions Page 1
Spare parts list E1
EXACT
Pad and Folder
Wire Stitching Machine

2EXACT06/2010 Hohner Maschinenbau GmbH

Hohner Maschinenbau GmbH EXACT 06/2010 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: EXACT, Volume 1/2
Version: 06/2010
Spare Parts Lists
Document number: EXACT, Volume 2/2

Table of Contents
4EXACT06/2010 Hohner Maschinenbau GmbH
Table of Contents
1 Basic safety precautions.................................................................................. 5
1.1 Purpose of this document .............................................................................................. 5
1.2 The operator .................................................................................................................. 5
1.3 Safety symbols and the displays in use......................................................................... 5
1.4 Duty and liability............................................................................................................. 5
1.5 Correct use of the machine............................................................................................ 6
1.6 User requirements ......................................................................................................... 6
1.7 Safety and protective systems....................................................................................... 6
1.8 Informal safety measures .............................................................................................. 6
1.9 Personnel training.......................................................................................................... 6
1.10 Parts of the machine that are particularly dangerous .................................................... 7
1.11 Servicing and repair work, elimination of faults ............................................................. 7
1.12 Structural modifications to the machine......................................................................... 7
1.13 Cleaning the machine and the removal of waste products ............................................ 7
1.14 Noise levels produced by the machine .......................................................................... 7
2 Description of the Saddle Binder EXACT ........................................................ 8
2.1 Dimensions .................................................................................................................... 9
2.2 Conformity ..................................................................................................................... 9
2.3 Marking and type plate .................................................................................................. 9
2.4 Technical data ............................................................................................................... 9
3 Structure and function of the machine ........................................................... 10
3.1 Safety-related components.......................................................................................... 11
3.2 Mounting of the finger guard........................................................................................ 11
3.3 Electrical connection and motor protective relay ........................................................ 13
3.4 Installation of the stitching table.................................................................................. 15
3.4.1 Installation of stitching table: flat stitching................................................................ 15
3.4.2 Installation of stitching table for brochures stitching ................................................ 15
3.5 Installation - Stitching head......................................................................................... 17
3.6 Installation of the clincher box ..................................................................................... 17
3.7 Fine adjustment of the clincher box ............................................................................. 17
3.8 Pressure adjustment for clincher back press............................................................... 19
3.9 Installation of centering device and rider for stitching brochures................................. 19
3.10 Adjustment for stitching thickness ............................................................................... 21
4 Flow diagrams ............................................................................................... 22

Basic safety precautions
Hohner Maschinenbau GmbH EXACT 06/2010 5
1 Basic safety precautions
1.1 Purpose of this document
This document is to inform the operator of the Wire Stitching Machine EXACT 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 EXACT 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.
1.4 Duty and liability
TIP

Basic safety precautions
6EXACT06/2010 Hohner Maschinenbau GmbH
The Wire Stitching Machine EXACT has been built according to state-of-the-art technology under
the observance of all the recognised safety regulations. It is, nevertheless, still possible 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 EXACT 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 EXACT 06/2010 7
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!
¾Never operate the system without properly mounted finger guard.
Quick stroke movements of the stitching heads!
Danger of crushing!
¾Never operate the system without properly mounted finger guard.

Description of the Saddle Binder EXACT
8EXACT06/2010 Hohner Maschinenbau GmbH
2 Description of the Saddle Binder EXACT
Fig. 2.1
1

Description of the Saddle Binder EXACT
Hohner Maschinenbau GmbH EXACT 06/2010 9
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
Stroke - narrow stitching head 50 mm
Stroke - clincher 5.5 mm
Table size 550 x 280 mm
Max. breadth for brochures 320 mm
Max. distance from staple to machine stand (throat) 170 mm
Max. setting dimension for narrow stitching heads 330 mm
Max. sheets thickness for flat stitching ca. 8 mm
Max. sheets thickness for loop stitching ca. 3 mm
Stitching wire for flat stitching
* Wire sizes corresponding to german standards!
Standard for round wire
Nr. 24-28*
(0.60-0.40 mm)
or, optional for round wire
Nr. 26-30*
(0.50-0.35 mm)
or, optional for flat wire
Nr. I-III*
(0.70 x 0.35-0.75 x 0.55 mm)
Stitching wire for loop stitching only for round wire
Nr. 24-26 (0.60-0.50 mm)
Net weight of the machine with stitching heads ca. 150 kg
Motor-Standard execution 0.37 kW
for 230/400 Volts
3-phase A.C., 50 cycles
Loudness level not over 81 dB(A)

Structure and function of the machine
10 EXACT 06/2010 Hohner Maschinenbau GmbH
3 Structure and function of the machine
Fig. 3.1
1
2
3
Flat stitching Brochures stitching

Structure and function of the machine
Hohner Maschinenbau GmbH EXACT 06/2010 11
3.1 Safety-related components
- Fig. 2.1 -
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
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 -1- for block- and brochure stitching as shown below.
Flat stitching
Brochures stitching
Quick stroke movements of the stitching heads!
Danger of crushing!
¾Never operate the system without properly mounted finger guard.
1
1

Structure and function of the machine
12 EXACT 06/2010 Hohner Maschinenbau GmbH
Fig. 3.2
1
2

Structure and function of the machine
Hohner Maschinenbau GmbH EXACT 06/2010 13
3.3 Electrical connection and motor protective relay
Specifically observe the direction of rotation of the motor shaft (visible at the vane
marked by the red arrow). Direction can be reversed by exchanging 2 phases in
the mains supply cable.
Motor protective relay
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.
Voltage
Danger of electrical shock!
¾Only qualified skilled workers may carry out work in the vicinity of the mains
power supply.

Structure and function of the machine
14 EXACT 06/2010 Hohner Maschinenbau GmbH
Fig. 3.3
Fig. 3.4
2
1
3
4
4
1
3
2

Structure and function of the machine
Hohner Maschinenbau GmbH EXACT 06/2010 15
3.4 Installation of the stitching table
3.4.1 Installation of stitching table: flat stitching
- Fig. 3.3 -
- Remove the finger guard.
- Open the front plate.
- Carefully insert the stitching table -1- with broad table part into the machine, then with
flat mount -4-, bring into position via the centring plates -2- on the left and right side.
- Lower the stitching table -1- until it rests. Successively push the three-cornered grips -3- on the
left and right side slightly upwards and screw them firmly.
- Mount the finger guard in the "block stitching" position and note the markings (see 3.2).
- Close the front door.
- Dismantling of the stitching table -1- in reverse order
3.4.2 Installation of stitching table for brochures stitching
- Fig. 3.4 -
- Remove the finger guard.
- Open the front panel.
- Slide the stitching table -1- with the small side into the machine. Tilt the small side of the stitching
table downwards in 45°. Move the stitching table -1- with both fixed angle-supports -5- over the
centering disks -2-.
- Put down the stitching table -1- until it will be supported. Push the triangle-handles -3- upwards
and tighten it.
- Mount the finger guard in the "saddle stitching" position and note the markings (see 3.2).
- Close the front door.
- Dismantling of the stitching table -1- in reverse order

Structure and function of the machine
16 EXACT 06/2010 Hohner Maschinenbau GmbH
Fig. 3.5
Fig. 3.6
2
1
34
5
7
6
1

Structure and function of the machine
Hohner Maschinenbau GmbH EXACT 06/2010 17
3.5 Installation - Stitching head
- See stitching head operating instructions.
3.6 Installation of the clincher box
- Fig. 3.5 -
- Remove the finger guard.
- Open the front plate.
- Hang clincher box -1- into the groove of clincher box carrier -2- , place hexagon head screw -3-
into groove of the track -4- and position under the corresponding narrow stitching head
- Mount the finger guard in the correct position and note the markings (see 3.2).
- Close the front door.
3.7 Fine adjustment of the clincher box
- Fig. 3.6 -
- Remove the finger guard.
- Open the front plate.
- The middle of the driver -5- and bender -6- must be exactly in the middle of the clincher box -1-!
- Now, rotate the unit by hand until the driver -5- and bender -6- will be just over the
clincher box -1-.
- Adjust the middle of the clincher box -1- to the middle of the driver -5-, tighten the clamp-nuts -7-.
- Mount the finger guard in the correct position and note the markings (see 3.2).
- Close the front door.

Structure and function of the machine
18 EXACT 06/2010 Hohner Maschinenbau GmbH
Fig. 3.7
1
2
3
4

Structure and function of the machine
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3.8 Pressure adjustment for clincher back press
- Fig. 3.7 -
- Remove the finger guard.
- Open the front plate.
- Loosen the slotted set screw -3-, turn the hexagon head bolt -4-, counter clockwise to increase
pressure or clockwise to decrease pressure.
- Now re-secure slotted set screw -3-.
It is very important that the groove-middle of the driver -1- and the middle of the
clincher box -2- coincide absolutely.
- Mount the finger guard in the correct position and note the markings (see 3.2).
- Close the front door.
3.9 Installation of centering device and rider for stitching brochures
See stitching head operating instructions.

Structure and function of the machine
20 EXACT 06/2010 Hohner Maschinenbau GmbH
Fig. 3.8
3
2
1
2
1