Prebena KTVH-B19D User manual

PREBENA Wilfried Bornemann GmbH & Co. KG
Seestraße 20 –26, 63679 Schotten, Germany
Tel.: [phone] / 96 01 –0, Fax: [phone]
eMail: [e-mail]
www.prebena.de, www.kartuschen-tausch.de
Original instructions for carton sealing
staplers
PREBENA KTVH-B19D
PREBENA KTVH-B19H
PREBENA KTVH-B22D
PREBENA KTVH-R19D
PREBENA KTVH-R19H
97510601

Foreword
This manual helps you to
properly,
safely and
economically
use the following air-powered carton sealing staplers:
KTVH-B19D
KTVH-B22D
KTVH-R19D
And use the following manually operated carton sealing staplers:
KTVH-B19H
KTVH-R19H
In this manual, these carton sealing staplers are abbreviated to
"stapler unit".
We assume that each user of the stapling device has knowledge of
air-powered equipment and the materials used. People without these
skills must be trained by an experienced user in the operation of the
stapler unit.
This manual addresses to the following people:
People using this stapler unit,
People cleaning this stapler unit or
People who dispose of this stapler unit.
Each of these people must have taken not of and understood the
contents of this manual.
This manual is part of the product. Always keep it close to the stapler
unit. Pass on the manual, if you sell the stapler unit or make it
available in any other way.

Table of Contents
3
Table of Contents
Foreword ..........................................................................................2
Table of Contents ............................................................................3
Design characteristics ....................................................................6
General design characteristics..........................................................6
Characteristics of hazard warnings ...................................................6
Characteristics of warnings to property or environmental damages.7
Safety................................................................................................8
Intended use......................................................................................8
Improper use .....................................................................................8
Avoid risk of fatal injury......................................................................9
Avoid explosion hazards in air-powered stapler units......................9
Avoid risks of injury............................................................................9
Avoid damage to the stapler unit.....................................................10
Description.....................................................................................11
Unit overview and delivery KTVH-B19D, KTVH-B22D, KTVH-R19D
.........................................................................................................11
Unit overview and delivery KTVH-B19H, KTVH-R19H ...................12
Mode of operation............................................................................13
Product features ..............................................................................13
Indicating labels on the stapler unit.................................................13
Details on the nameplate.................................................................13
Accessories.........................................................................................14
Prepare stapler ..............................................................................15
Unpack stapler.................................................................................15
Check the condition.........................................................................16
Connect the stapler unit to the compressed air supply ...................17
Use with a gravity balancer .............................................................20

Table of Contents
4
Operate stapler ..............................................................................21
Open the magazine .........................................................................21
Insert fasteners................................................................................21
Close the magazine.........................................................................23
Check function.................................................................................24
Setting driving depths......................................................................25
Staple adjustment for pressure-operated staplers ..........................27
Staple adjustment for manually-operated staplers..........................29
Check driving depths.......................................................................30
Drive in the fasteners.......................................................................30
Triggering air-powered stapler units................................................31
Triggering manually-operated stapler units.....................................32
After operation...............................................................................33
Disconnect compressed air supply..................................................33
Remove compressed air hose (only for air-powered stapler
units)..........................................................................................33
Emptying the magazine...................................................................33
Transport and store stapler.........................................................35
Packaging........................................................................................35
Transport .........................................................................................35
Transport over short distances..................................................35
Transport over long distances...................................................37
Storage ............................................................................................37
Service stapler ...............................................................................38
Clean the housing and outer surfaces.............................................38
Slight soiling ..............................................................................38
Heavy soiling.............................................................................39
Oil stapler unit..................................................................................39
Faults ..............................................................................................40
Remove jammed fasteners..............................................................40
Other faults ......................................................................................41
Fault overview..................................................................................41
Order accessories .........................................................................44
Reorder fasteners............................................................................44
Explanation of type designation ................................................44

Table of Contents
5
Dispose stapler..............................................................................46
Technical Data ...............................................................................47
Stapler unit KTVH-B19D, KTVH-B22D, KTVH-R19D .....................47
Stapler unit KTVH-B19H, KTVH-R19H ...........................................47
Manufacturer address...................................................................48
Warranty.........................................................................................49
Index ...............................................................................................50

Design characteristics
6
Design characteristics
General design characteristics
Various elements of the manual are provided with set design
characteristics. This way you can easily distinguish whether it is
normal text,
enumerations or
action steps.

Tips contain additional information, such as specific
information on the economic use of the stapler unit.
Characteristics of hazard warnings
All hazard warnings in this manual are based on the same pattern.
There is a symbol on the left representing the type of hazard. To the
right you can see another symbol and a signal word indicating the
severity of hazard. Below is a description of safety hazard and
information on how you can avoid this hazard.
HAZARD
Warnings containing the word HAZARD warn
of hazards that directly cause serious injury or
death.
WARNING
Warnings containing the word WARNING warn
of hazards that could possibly cause serious
injury or death.

Design characteristics
7
CAUTION
Warnings containing the word CAUTION warn
of hazards that could possibly cause minor or
moderate injury.
Characteristics of warnings to property or
environmental damages
ATTENTION
These warnings warn of hazards that cause property or
environmental damages.

Safety
8
Safety
Observe and follow all warnings and instructions in this manual and
on the stapler unit, when dealing with the stapler unit. The enclosed
spare parts list is part of this manual.
Intended use
The stapler unit is used for sealing filled folding boxes made of
cardboard materials. The use of the stapler unit to other materials is
permitted only after consultation with the manufacturer. Intended use
also includes compliance with accident prevention regulations and
legal regulations and standards applicable at the site. Any other use
is considered improper and may lead to damage or even personal
injury.
Improper use
Improper use includes in particular operation
by people without knowledge about the use of stapler units and
materials used,
of unauthorised altered stapler units,
with accessories other than those specified in this
manual
to compressed air sources not listed in this manual
PREBENA WILFRIED BORNEMANN GMBH & CO. KG assumes no
liability for any damage caused by improper use.

Safety
9
Avoid risk of fatal injury
Make sure that there are no body parts in the vicinity of the mouth
opening during the triggering process and in every moment that
the stapler unit is connected to the air supply.
You may only trigger the stapler unit when the tool nose is
pressed onto the material to be stapled.
Do not let children play with packaging foils; there is risk of
suffocation.
Avoid explosion hazards in air-powered stapler units
Do not use the stapler unit in a potentially explosive atmosphere.
Never operate the stapler unit with oxygen or other flammable
gases or gas mixtures.
Do not expose the compressor to temperatures above 100°C.
Avoid risks of injury
Keep the stapler unit out of the reach of children and other
unauthorized people.
Disconnect the stapler unit from the compressed air supply before
transporting.
Wear safety glasses, hearing protection and sturdy work clothes,
when operating the stapler unit.
Hold the stapler unit so that you cannot get hurt by a possible
rebound.
Use the stapler unit only if you have a secure footing.

Safety
10
Avoid damage to the stapler unit
Never open the stapler unit. Always leave repair work to qualified
personnel.
Do not use the stapler unit, when it has been dropped or
damaged. Have it checked by qualified personnel before
operating it again.
Do not connect the stapler unit to a compressed air supply, where
the maximum operating pressure of 8 bar is exceeded.
Assemble fixed mount stapler units only in securely anchored
holders. The stapler unit should not be rotated or moved. The
holder must not damage the stapler unit and its accessories.

Description
11
Description
Unit overview and delivery KTVH-B19D, KTVH-B22D,
KTVH-R19D
No.
Explanation
1
Pusher
2
Magazine
3
Adjustment knob (depth adjustment)
4
Adjustment values (staple length adjustment)
5
Setscrew (fixing the staple length)
6
Adjusting disc (setting the bending form)
8
Handle
9
Release lever
11
Sound absorber
12
Compressed air connection

Description
12
Unit overview and delivery KTVH-B19H, KTVH-R19H
No.
Explanation
1
Pusher
2
Magazine
3
Adjustment knob (depth adjustment
4
Adjustment values (staple length adjustment)
5
Setscrew (fixing the staple length)
7
Adjusting disc (setting the bending form)
8
Handle
10
Handle lever

Description
13
Mode of operation
The stapler unit is placed and triggered on the box to be closed. The
staple is thereby driven into the box and bent there and anchored in
the box. This way cardboard lid can be closed quickly and cleanly.
Excess pressure is derived by pressure relief valves.
You can adjust the stapler unit to be processed cardboard thickness
and staple length.
Product features
The stapler unit has the following features:
Magazine with top loader system,
Adjustable driving depth of the staples,
Adjustable bending images of the staples,
Setting the staple lengths.
Indicating labels on the stapler unit
The nameplate
Details on the nameplate
The nameplate is pasted on the inside front of the magazine holder.
It contains the following details:
the company name and full address of the manufacturer
the name of the machine (DN - Type = Air-operated stapler unit or
manually-operated stapler unit)
the types name of the stapler unit
the type name of usable fasteners
the maximum allowable operating pressure (only for air-powered
stapler units)
the CE mark (The product conforms to the standards listed in the
attached declaration.)
the year of manufacture

Description
14
Accessories
The following accessories are available for the stapler unit:
Compressors for compressed air supply (not included),
Spiral tube with 8 mm inner diameter and 4 m working length (not
included),
Compressed air hose set (not included),
Hose reel (not included),
Suspension eyelet for steady-state operation,
Staples of Type B & Type R (see section "Order accessories" on
page 44).
PREBENA special nailer oil (not included).
The order numbers can be found in section "Order accessories" on
page 44

Prepare stapler
15
Prepare stapler
Unpack stapler
Remove the stapler unit from its packaging
Remove all packaging material, such as foils, packing material
and the packing carton.
WARNING
Choking hazard for children playing with
packaging foils.
Do not let children play with packaging
foils.
Keep packaging material out of the reach
of children.
Keep packing materials for future use.
Store the carrying case for transporting the stapler.

The transport of the stapler unit is only permitted in the
cardboard box.

Prepare stapler
16
Check the condition
WARNING
Risk of injury when operating a damaged
stapler unit or not properly attached
accessories.
Check the condition of the stapler unit
before use.
Make sure that the stapler unit is in perfect
condition.
Check particularly the following points:
-All parts of the stapler unit and all accessories must be
securely fastened.
-No parts of the stapler unit or accessory may have superficial
damage such as scratches or dents.
-The hose line must be undamaged.

Scratches in the paint of the housing or the magazine are not
considered damages.
Do not connect a damaged stapler unit to a compressed air
supply.
Have a damaged stapler unit repaired by qualified personnel
before operating it.

Prepare stapler
17
Connect the stapler unit to the compressed air
supply
You can connect the stapler unit to a compressor or a compressed
air system. (only valid for air-powered stapler units)
Operation with a compressor or a compressed air system is
permitted only under the following conditions:
The operating pressure of the compressor or compressed air
system must be no more than 10% above the maximum operating
pressure of the stapler unit. You can find information on the
operating pressure of the stapler unit in this chapter on page 19.
In compressed air systems with a higher pressure, a pressure-
regulating valve (pressure reducing valve) with a downstream
pressure-limiting valve must be installed in the compressed air
supply.
Compressed air must be filtered to be dry and lubricated with
special PREBENA nailer oil.
A compressed air maintenance unit must be mounted on the
clutch side at the suspension of the compressed air line to the
stapler. This should contain
-a filter,
-a water separator and
-an oiler.
When using hose lengths over 10 m, it is not guaranteed that the
drive-in device will be supplied with oil. We therefore recommend
to add on working days two to five drops of the recommended oil
into the air inlet of the device or to install a lubricator directly on
the drive-in device.
The compressed air system must also be able to maintain the
operating pressure at the desired air extraction.
The inner diameter of the air duct should be at least 8 mm.
The connector for the stapler must be equipped with a quick
coupling with NW 7.2 and with at least 6.5 mm inner diameter

Prepare stapler
18
CAUTION
The operation on compressed air systems that do
not meet the aforementioned requirements may
result in damage to the stapler unit.
Operate the stapler unit only in suitable compressed air
systems.
Use the stapler unit only in perfect condition.
Check the condition of the stapler unit (see page 16).
Check the connection of the compressed air hose for debris and
dirt, and clean it, if necessary.
Set the operating pressure at the compressor pressure regulator
at 5 - 8.3 bar.
WARNING
Accidentally triggering when connected to the
compressed air supply can cause serious injury
or death.
Do not point the stapler unit at people or animals.
Empty the magazine before connecting.
CAUTION
Damaged hoses can burst and cause injury.
Check the compressed air system and the stapler unit for
damages before connecting.
Connect the stapler unit only to a functioning compressed air
system.

Prepare stapler
19
ATTENTION
Damaged hoses can burst and cause property damage due to
escaping air.
Check the compressed air system and the stapler unit for
damages before connecting.
Connect the stapler unit only to a functioning compressed air
system.
Push the quick-release (1) of the compressed air hose to the
connector (2) until it clicks into place.
Check the operating pressure at the pressure gauge of the
compressor.
The maximum allowable operating pressure of the stapler unit is 8.3
bar.
WARNING
Danger of explosion if maximum operating
pressure is exceeded.
In this case, disconnect the air hose from the stapler unit
immediately.

Prepare stapler
20
Use with a gravity balancer
You can use the air-powered stapler units with a gravity balancer. To
attach the rope of the gravity balancer at the stapler unit, you must
attach a suspension eyelet on the casing head. Proceed as follows:
Remove the compressed air hose from the unit (see page 33).
Empty the magazine (see page 33).
Loosen and remove the two rear cylinder screws (15) on the
housing head.
Position the suspension eyelet (17) as shown below.
Fasten the suspension eyelet (17) with the cylinder screws (15).
The suspension eyelet is now ready for use.
Check the condition of the driving tool (see page 16)
The suspension eyelet (item number: Z85608001) is available as an
accessory from PREBENA (see page 44)