Hohner ORION 4 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
ORION 4
Pad and Folder
Wire Stitching Machine

2 ORION 4 10/2010 Hohner Maschinenbau GmbH

Hohner Maschinenbau GmbH ORION 4 10/2010 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: ORION 4, Volume 1/2
Version: 10/2010
Spare Parts Lists
Document number: ORION 4, Volume 2/2

4 ORION 4 10/2010 Hohner Maschinenbau GmbH

Table of Contents
Hohner Maschinenbau GmbH ORION 4 10/2010 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 Saddle Binder ORION 4 ................................................... 10
2.1 Dimensions.................................................................................................................. 11
2.2 Conformity ................................................................................................................... 11
2.3 Marking and type plate ................................................................................................ 11
2.4 Technical data ............................................................................................................. 11
2.5 Accessories ................................................................................................................. 12
3 Structure and function of the machine........................................................... 13
3.1 Safety-related components.......................................................................................... 14
3.2 Mounting of the finger guard........................................................................................ 14
3.3 Electrical connection and motor protective relay ........................................................ 16
3.4 Installation of the stitching table ................................................................................. 18
3.4.1 Installation of stitching table: flat stitching ............................................................... 18
3.4.2 Installation of the stitching table: for brochure stitching........................................... 18
3.5 Installation of the narrow stitching heads 70/20 .......................................................... 20
3.6 Installation of the clincher box ..................................................................................... 22
3.7 Basic adjustment of clinchers ...................................................................................... 24
3.8 Pressure adjustment for clincher back pressure ......................................................... 26
3.9 Adjustment of the stitching thickness .......................................................................... 28
3.10 Adjustment by hand of the ORION 4 ........................................................................... 30
3.11 Lubrication instructions................................................................................................ 32
4 Flow diagrams .............................................................................................. 33

Table of Contents
6 ORION 4 10/2010 Hohner Maschinenbau GmbH

Basic safety precautions
Hohner Maschinenbau GmbH ORION 4 10/2010 7
1 Basic safety precautions
1.1 Purpose of this document
This document is to inform the operator of the Wire Stitching Machine ORION 4 about the follow-
ing 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 ORION 4 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
8 ORION 4 10/2010 Hohner Maschinenbau GmbH
1.4 Duty and liability
The Wire Stitching Machine ORION 4 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
regulations laid down in our ”General sales and delivery conditions”.
1.5 Correct use of the machine
The Wire Stitching Machine ORION 4 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
environmental 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 ORION 4 10/2010 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
methods 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
cleaning 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
measured 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!
¾Before carrying out maintenance or repairs, take care that the power supply is switched off
and prevented from being switched on again accidentally.
¾Never operate the system without properly mounted finger guard.

Description of the Saddle Binder ORION 4
10 ORION 4 10/2010 Hohner Maschinenbau GmbH
2 Description of the Saddle Binder ORION 4
Fig. 2.1
1
[mm]

Description of the Saddle Binder ORION 4
Hohner Maschinenbau GmbH ORION 4 10/2010 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
This version of the wire stitching machine ORION 4 affords room for four (4) narrow stitching heads
UNIVERSAL 70/20.
The stitching table is placed in a horizontal position for block stitching and in a saddle position for
brochure stitching. Positioning occurs via stops.
Max. stitching thickness - standard stitching
- loop stitching
20 mm
4 mm
Crown width of the staple 14 mm
Staple distance min. 70 mm
max. 550 mm
Stitching wire, round No.20 - 28
(0.90 - 0.40 mm Ø*)
Stitching wire, flat
* Wire sizes corresponding to german standards!
No.I - VI
(0.70 x 0.35 mm -
0.96 x 0.78 mm)*
Stitching capacity per minute and stitching head 192
Size of stitching table 1000 x 330 mm
Max. depth from staple, towards the back up to stand: 230 mm
Stroke length - driver
- bender
- clincher
66 mm
55 mm
5.5 mm
Max. number of usable stitching heads 4
Machine net weight ca. 512 kg
Net weight per narrow stitching head UNIVERSAL 70/20 ca. 8.5 kg
Motor Three-phase-motor (1.10 kW)
230/400 volt, 50 Hz - 3 phases
with clutch-brake combination.
Loudness level not over 81 dB(A)

Description of the Saddle Binder ORION 4
12 ORION 4 10/2010 Hohner Maschinenbau GmbH
2.5 Accessories
Every ORION 4 WIRE STITCHING MACHINE is supplied with:
Art.-No. 31 44 030 setting gauge
Art.-No. 46 00 003 1 screw driver SB 4,5
Art.-No. 46 00 008 1 hexagon socket screw key SW 3
Art.-No. 46 00 004 1 screw driver SB 7,0
Art.-No. 46 00 014 1 diagonal cutting nipper
Art.-No. 46 00 019 1 hexagon socket screw key SW 5
Art.-No. 46 00 038 1 double offset ring wrench
Art.-No. 46 00 044 1 Torx angle screwdriver T10
Art.-No. 46 00 045 1 Torx angle screwdriver T20
Art.-No. 99 67 700 2 centring device, Cpl.

Structure and function of the machine
Hohner Maschinenbau GmbH ORION 4 10/2010 13
3 Structure and function of the machine
Fig. 3.1
1
2
3
Flat stitching Brochures stitching

Structure and function of the machine
14 ORION 4 10/2010 Hohner Maschinenbau GmbH
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
Hohner Maschinenbau GmbH ORION 4 10/2010 15
Fig. 3.2
1

Structure and function of the machine
16 ORION 4 10/2010 Hohner Maschinenbau GmbH
3.3 Electrical connection and motor protective relay
- Employ a specialist to connect the machine to the mains supply. The local connection regulations
must be adhered to. The cable should not lie loosely on the ground after it has been laid.
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
supply of the motor.
- 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 turning the
knob -1- to position I, - 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
Hohner Maschinenbau GmbH ORION 4 10/2010 17
Fig. 3.3
Fig. 3.4
7
1
3
6
2
4
5
8
7
1
3
6
4
5
8

Structure and function of the machine
18 ORION 4 10/2010 Hohner Maschinenbau GmbH
3.4 Installation of the stitching table
3.4.1 Installation of stitching table: flat stitching
- Fig. 3.3 -
- With the lever -1- lift all stitching heads to the highest position. Slide the stitching table -2- with the
small side into the machine. Move it with both handles -3- right and left over the centring
discs -4-.
- Put down the stitching table until it will be supported. Push the triangle-handles -5- upwards and
tighten them.
- Dismantling of the stitching table -2- in reverse order
The "stick-on-level" -8- on the front panel -7- shows, how to fix the safety
guard -6- in the two way position of the stitching table. (see 3.2).
3.4.2 Installation of the stitching table: for brochure stitching
- Fig. 3.4 -
- With the lever -1- lift all stitching heads to the highest position. Slide the stitching table -2- with the
small side into the machine. Tilt the stitching table downwards to 45 degrees.
- Move the stitching table with both fixed angle-supports over the centring discs -4-.
- Put down the stitching table until it will be supported. Push the triangle handles -5- upwards and
tighten them.
- Dismantling of the stitching table -2- in reverse order
The "stick-on-level" -8- on the front panel -7- shows, how to fix the safety
guard -6- in the two way position of the stitching table. (see 3.2).

Structure and function of the machine
Hohner Maschinenbau GmbH ORION 4 10/2010 19
Fig. 3.5
4
2
2
6
16
5
1
3

Structure and function of the machine
20 ORION 4 10/2010 Hohner Maschinenbau GmbH
3.5 Installation of the narrow stitching heads 70/20
- Fig. 3.5 -
- Insert key blocks -1- into the traverses -2- .
Milled part must point downwards!
- Install the stitching head with the boring over the peg of the key blocks -1- , at the same time also
align the driving block -3- , the pusher -4- and adjusting block -5- with the corresponding rails.
- Clamp the stitching head to the machine by turning down the hex sockets -6- of the eccentric until
it is tight.