Signode BHC Use and care manual

BHC
COMBINATION STRAPPING TOOL

2
BHC Automatic Strapping Tool
Part No. 423750
1
Technical data
2
2
General information
3
2.1
Information on environmental
3
protection
3
Safety instructions
4
3.1
Safety instructions for battery
5
charger and battery
4
Description
5
4.1
Design
5
4.2
Battery charger indicators
5
5
Initial operation
6
5.1
Battery charger
6
5.2
Charging the battery
6
6
Operating instructions
7
6.1
Operating the tool
7
7
Preventative & corrective maint
10
7.1
Changing the battery
10
7.2
Adjusting the weld time
10
7.3
Initial setting of strap tension
11
7.4
Adjusting the strap width
11
7.5
Tension wheel Maintenance
12
7.6
Changing the tension shoe
12
7.7
Changing tooth plate
12
8
Parts list
14
Exploded drawing
15
9
Recommended spare parts
14
Weight
4.3 kg (8.9 lbs.)
Dimensions
Length 400 mm (1 5.75")
Width 130 mm (5")
Height 200 mm (7.90")
Strap tension
up to 1200 N
Preset at factory
800 N up to 13mm (1/2")
Strap width
1200 N from 15mm (5/8")
strap width
Sealing
Friction welded
Voltage
Battery charger 230V (115V)
Battery 12V
PLASTIC STRAP
Strap quality
Polypropylene (PP)
Polyester (PET)
Strap width
9-10, 12-13, 15-16 or 19mm
(3/8", 1/2", 5/8" or 3/4")
Strap thickness
Polypropylene
0.5-0.9mm
(.019-.035")
Polyester
0.4-0.9mm
(.016-.035")
TABLE OF CONTENTS
1
TECHNICAL DATA

3
These operating instructions are intended to
simplify familiarization with the strapping tool and
the possibilities of application for the intended
purpose. The operating instructions contain
important information concerning the safe,
proper and efficient use of the strapping tool.
Observation of the information will help to avoid
danger, reduce repairs and stoppages and
increase the reliability and service life of the
strapping tool.
The operating instructions must always be
available at the place of operation of the
strapping tool. They must be read and observed
by all persons concerned with work on the
strapping tool. This work specificity includes
operation, refilling of operating material, fault
elimination and maintenance
In addition to the operating instructions and the
regulations for accident prevention effective in
the country of use and place of application, the
recognized technical regulations for safety and
proper working must also be observed.
CAUTION!
Used where there is
danger to life and health.
WARNING!
Used for danger which
can cause material
damage.
NOTE!
Used for general
information and
information which if not
followed can cause faults
in the operating
sequence.
This tool is manufactured without any physical or
chemical substances which could be dangerous
to health. For disposal of all the parts, the
governmental instructions must be observed.
Dealers offer an
environmentally
friendly battery
disposal service
Do not open the battery.
Do not throw the used
battery into household
waste, fire or water.
Defective or used
batteries undergo a
complete recycling
process.
2
GENERAL INFORMATION
2.1 INFORMATION ON
ENVIRONMENTAL PROTECTION

4
Inform yourself!
Read the operating
instructions carefully
Protect yourself[
When operating the tool,
wear eye, face and hand
protection (cut-proof
gloves).
Power resource!
Before starting preventive
or corrective
maintenance, remove
battery from the tool.
Warning:
Strap will snap forward!
When cutting the strap,
hold the upper portion
and stand safely away
from the strap.
Caution:
The lower strap will snap
forward.
Warning:
Strap could break!
Do not stand in line with
the strap while it is
tensioned. The strap
could break!
Do not use water!
Do not use water or
steam to clean the
tool.
Caution:
Danger of squeezing!
Do not put your fingers
into the tension wheel
area.
Caution:
Only strap packed
goods!
Do not put hands or other
parts of the body
between the strap and
the package during the
strapping process.
Original spare parts
must be used
exclusively!
Not using original spare
parts will dissolve the
warranty and the liability.
Use for the intended purpose
The tool is intended for strapping packages,
pallet loads etc.
This tool was designed and manufactured for
safe handling during the strapping operation.
The tool processes plastic straps (polypropylene
and polyester).
Possible misuse
The use of steel straps is not possible.
Always inspect the electrical plug and cable
before use. If damaged, they must be replaced
by a qualified professional.
•
Do not charge other types of batteries and
use original accessories only.
•
Keep the battery charger slot free of foreign
objects and protect against dirt.
•
Protect battery charger against humidity and
operate in dry areas only.
•
Do not open the battery. Protect the battery
against impact, heat and fire. Danger of
explosion!
•
When the battery is outside the battery
charger, cover battery terminals to avoid
short circuits from metal objects. Danger of
fire and explosion!
•
Keep battery dry and away from frost. Do not
store in temperatures over 500C.
•
Damaged batteries should not be used
anymore.
3
SAFETY INSTRUCTIONS
3.1 SAFETY INSTRUCTIONS FOR
BATTERY CHARGER & BATTERY

5
Fig 1
Fig 2
Continous green light
Continuos green light
Flashing green light
Continuos red light
Flashing red light
1.
Rotary knob "Strap tension"
2.
Sealing lever
3.
Battery
4.
Push button 'Strap tensioning"
5.
Cutting device
6.
Tension shoe
7.
Tension wheel
8.
Potentiometer 'Initial setting, strap tension"
9.
Potentiometer "Welding time"
10.
Indicator "Battery"
11.
Battery charger
Battery not inserted,
main voltage is on.
Rapid charging
operates until the
battery is fully
recharged. The battery
charger then
automatically switches
to trickle charging.
Battery inserted, the
battery charger is only
delivering a trickle
charge because the
battery is already fully
charged.
Warning: The battery is
too hot (or too cold).
Trickle charging is
possible only, The
battery charger
automatically switches
to rapid charging when
a suitable temperature
is reached.
Warning: The battery is
defective or the
charging contacts are
dirty. Charging is no
longer possible.
4
DESCRIPTION
4.1 DESIGN
4.2 BATTERY CHARGER INDICATORS

6
Fig 3
Fig 4
The main voltage must comply with the
specifications on the rating plate, 230 V (115 V)
battery chargers can be operated at 220 V or
240 V (I10 V).
The battery charger is suitable only for charging
NTC batteries from the Bosch range of tools.
The battery charger can be wall mounted.
The charging process begins as soon as the
main plug is inserted into the power supply
socket and the battery is placed into battery
charger slot (4/2).
The surfaces (4/1) marked by color
must coincide.
The charging process and error
functions are indicated by a green light (4/4) and
a red light (4/3) (see chapter 4.2).
The intelligent charger with fuzzy control charges
the battery with the optimum rapid charging
current, depending on temperature and voltage.
This results in a shorter charging time and a long
battery service life.
The maximum charging current flows when the
temperature of the battery is between 15-45°C.
The charging time is approx. 12 min.
Trickle charging compensates for the natural self
discharge of the battery. The battery always
remains fully charged and will not suffer any
damage if left in the connected battery charger.
A new battery or one which has not been used
for an extended period achieves full
performance only after five charging and
discharging cycles.
If the tool is not being used for a longer period,
the battery should be taken out
and be charged in the battery
charger.
5
INITIAL OPERATION
5.1 BATTERY CHARGER
5.2 CHARGING THE BATTERY

7
Fig 5
Fig 6
Insert charged battery and close the bow spring
Place the strap around the package and hold it
with the left hand so that the lower strap lead is
approx. 20 cm (8") away from the hand.
Take the tool with the right hand and press the
lever towards the handle.
Slide the strap lead under the tension shoe (6/2)
and under the cutting device (6/1) into the tool
until the stop is reached.
The lower strap is new approx. 5
cm (2") beyond the tool.
Release the lever.
6
OPERATING INSTRUCTIONS
6.1 OPERATING THE TOOL

8
Fig 7
Fig 8
Insert the strap from coil holder between the
tension wheel (7/3) and the tension shoe (712).
Then insert the strap into the slot of the cutting
device (711) until stop is reached.
Press the yellow button with the right thumb, until
the required strap tension is reached.
If the tool is used in a dusty
environment, it is recommended to
clean the tool regularly. The
tension wheel in particular should be kept clean
(see chapter 7.5).
With the rotary knob (8/1) the strap tension can
be set to the following values:
&
= approx. 140 N
5 = approx. 800 N up to 13mm (1/2") width
5 = approx. 1200 N from 15mm (5/8") width
(dependent on initial setting, see chapter 7.3)

9
Fig 9
Fig 11
Flashing green light
Continuous green light
Continuous red light
This tool is provided with a safety
logic device to prevent accidental
starting of the welding process
(e. g. when carrying the tool with the sealing
lever). For this reason the strap must first be
tensioned to a minimum tension to start the
welding process (press yellow button).
Push lever to stop (sealing position). The left
hand remains on the handle of the tool to bear
the counterforce.
The straps are welded together and
the upper strap is cut off. The
signal lamp (10/1) indicates the
following functions
After finishing the
friction welding, the
green light flashes for
approx. 2 sec. The
sealing lever must stay
in the sealing position,
during this time.
When the green light is
on continuously, the
sealing cycle is finished.
When the red light is on
continuously, the battery
must be charged (see
chapter 5.2).
When the red signal lamp lights up,
the unit is blocked, since the
remaining charge in the battery is
insufficient to ensure proper welding of the
straps.
Press lever against the handle. Then swing the
tool away from the strapping to the right at the
rear.
If the straps are poorly welded,
check the setting of the welding
time (see chapter 7.2).

10
Fig 13
Continuous red light
Fig 12
Fig 14
If the red signal lamp
(12/1) is lit continuously,
the battery must be
charged (see chapter
5.2).
Open bow spring and remove discharged
battery. Insert charged battery and lock with bow
spring.
When changing the battery, the
new battery must only be inserted
after approx. five seconds to
ensure that the electronic system can reset to
the initial position. If the battery change
is too
rapid, the red signal lamp lights up and the unit
remains blocked.
The welding time can be infinitely adjusted with a
screwdriver (no 1), depending on strap quality
and dimension.
By turning the screw carefully clockwise, the
welding time will be longer, by turning
counterclockwise it will be shorter.
If straps are poorly welded, there is the risk that
the seal will tear. We advise you to
regularly check the strap seals.
1.
Poorly welded seal (not welded over
the complete surface), welding time too short.
2.
Good seal
(the complete surface is cleanly
welded without excess material being forced
out sideways)
3.
Poorly welded seal (excess material is
forced out sideways), welding time too long.
The welding time for PET straps is
longer than for PP straps.
7
PREVENTATIVE & CORRECTIVE MAINTENANCE
7.1 CHANGING THE BATTERY
7.2 ADJUSTING WELDING TIME

11
Fig 16
Fig 17
Fig 15
Remove plastic cover (15/1).
The initial setting of the strap tension can be set
fully variably with a screwdriver (no 1) depending
on the quality and size of the strap.
The strap tension is increased by gradually
turning the screw clockwise ( 200 N) or
decreased by turning counter-clockwise (800 N).
When the initial setting of strap tension has been
made, fine setting can then be performed with
the rotary knob (see Fig. 8/1).
To change the strap width, the strap stop (16/2)
must be removed with the screw (16/1) from the
tool and refitted with washers (1.5 mm thick)
according to the width of the strap.
Strap width
19mm (3/4") without washer
Strap width
15-16mm (5/8") one washer
Strap width 12-13mm (1/2") two washers
Strap width 9-10mm (3/8") three washers
Loosen screw (17/4) and remove knife bushing
(17/1).
Withdraw roll pin (17/2) and move the pawl
(17/3) to desired position according to strap
width. Replace roll pin (17/2).
Insert washers between base plate and knife
bushing according to strap width.
Tighten screw (17/4).
Strap width
19mm (3/4") without washer
Strap width
15-16mm (5/8") one washer
Strap width 12-13mm (1/2") two washers
Strap width 9-10mm (3/8") three washers
7.3 INITIAL SETTING OF STRAP TENSION
7.4 ADJUSTING STRAP WIDTH

12
Fig 18
Fig 19
Fig 20
Removal
•
Open bow spring (1811) and remove battery
(18/6).
•
Release three countersunk screws (18/2)
and remove protective lid (1 8/3).
•
Press lever (1 8/5) against the handle and
carefully withdraw tension wheel (18/4).
•
Clean the tension wheel with compressed air
or replace it.
•
If the tension wheel toothing is covered with
heavy dirt, it must be carefully cleaned with a
screwdriver or a marking tool.
Installation
•
Install the parts in reverse order.
Grease gear teeth of tension wheel
lightly with grease (Microlube).
Removal
•
Open bow spring (1 9/1) and remove battery
(19/2).
•
Remove the brace (19/3) with small
screwdriver from tension shoe support
(19/5).
•
Slide the tension shoe (1 9/4) with a small
screwdriver out of the tension shoe support
(19/5) and replace it.
Installation
•
Install the parts in reverse order.
Removal
•
Open bow spring (20/1) and remove battery
(20/2).
•
Remove set screw (20/9) with compression
spring (20/10) and bolt (20/11).
•
Release set screw (20/8).
•
Push out shaft (20/12) with a small
screwdriver.
•
Raise rocker drive unit (20/13) slightly (1cm,
3/8") and remove tension shoe support
(20/7).
•
Remove brace (20/4) with a small
screwdriver from tension shoe support and
slide the tension shoe (20/5) with a small
screwdriver out of the tension shoe support
(20/7).
•
Remove counter sunk screw (20/3), remove
tooth plate (20/6) and replace it.
Installation
•
Install the parts in reverse order.
Screw in set screw (2019) until it
projects out 2mm from the case.
7.5 CHANGING & CLEANING THE
TENSION WHEEL
7.6 CHANGING THE TENSION SHOE
7.7 CHANGING THE TOOTH PLATE

13
KEY
QTY
PART#
DESCRIPTION
1
1
423714
Base plate
5
1
423602
Needle bushing
7
1
423603
Set screw, M 4 x 8
8
1
423715
Housing part right
9
1
423605
Cover, ø 10
10
1
423716
Cover, ø 7,2
11
1
423606
Cover
12
1
423607
Bow spring
14
1
423717
Housing part left
15
6
423609
PT-Screw,
KA 35 x 16
16
2
423610
PT-Screw,
KA 35 x 30
17
4
423611
Head screw,
M 4 x 12
18
1
423612
Bolt
19
1
423718
Bushing
20
1
423719
Housing
21
1
423720
Push button
22
1
423721
Set screw screw
23
1
423722
Compression spring
24
1
423723
Potentiometer
27
1
423724
Nut
28
1
423725
Washer
32
1
423726
Micro switch
38
1
423727
PT-Screw,
KA 35 x 35
40
1
423728
Rocker left
45
1
423729
Compression spring
48
1
423731
Rocker shaft
49
1
423732
Tension shoe
support
50
1
423733
Tooth plate
51
1
423734
Counter sunk
screw, M 2,5 x 4
53
1
423735
Tension shoe
54
1
423736
Brace
55
1
423737
Pawl
51
1
423738
Torsion spring
57
1
423739
Bolt
58
1
423631
Welding shoe
59
1
423632
Bolt
60
1
423740
Cotter pin
61
4
423741
Tooth plate
62
1
423742
Counter sunk
screw, M 5 x 10
65
1
423743
Needle bushing
66
1
423637
Eccentric shaft
67
4
423638
Washer
68
4
423639
Flange
69
3
423640
Cylinder screw,
M 4 x 12
70
2
423641
Cylinder screw,
M 4 x 8
71
1
423642
Precision shaft
coupling
72
4
423643
Set screw,
M 3 x 6
75
1
423644
Needle bushing
KEY
QTY
PART#
DESCRIPTION
76
1
423645
Motor
77
1
423646
Connecting rod
78
1
423647
Link
79
1
423648
Bolt
80
4
423649
Retaining ring
82
1
423650
Pressure lever
85
1
423651
Stroke plate
86
1
423652
Pressure roll
87
1
423653
Bolt
88
1
423654
Set screw
89
1
423655
Tension spring
90
10
423656
Saucer spring,
ø 8,2/18 x 1
91
1
423657
Bolt
92
6
423658
Retaining ring
98
1
423744
Cover
99
1
423745
Planetary gear
100
1
423746
Motor complete
108
1
423747
Motor flange
109
1
423748
Stop bolt
111
3
423749
Cylinder screw,
M 3 x 25
112
3
423751
Planetary wheel
113
6
423752
Washer
114
1
423753
Planetary support
117
1
423754
Internal ring
118
1
423755
Flange complete
120
3
423756
Planetary wheel
121
3
423757
Bearing
122
1
423758
Tension wheel
123
1
423759
Bushing
124
1
423760
Needle bushing
125
1
423761
Protection lid
126
6
423762
Counter sunk
screw, M 3 x 12
127
3
423763
Counter sunk
screw, M 2,5 x 8
128
3
423764
Counter sunk
screw, M 3 x 12
130
1
423765
Lever
131
1
423766
Ejector
132
1
423767
Rollpin, ø 4 x 16
133
1
423768
Special screw
134
1
423769
Pressure roll
135
2
423770
Ball, ø 5,5
136
1
423771
Compression spring
138
1
423772
Rocker right
142
1
423615
Cylinder screw,
M 6 x 20
143
1
423616
Lock washer, M 6
146
1
423773
Tooth plate
147
1
423685
Strap guide
148
1
423686
Washer
151
2
423687
Counter sunk
screw, M 4 x 12
153
1
423688
Knife sleeve
154
1
423689
Pawl
155
1
423690
Rollpin, ø 2,5 x 12
156
1
423691
Compression spring
8
BHC PARTS LIST

14
KEY
QTY
PART#
DESCRIPTION
157
1
423692
Knife complete
159
1
423693
Torsion spring
162
1
423774
Stroke lever
163
1
423694
Bushing
164
1
423695
Bolt
165
1
423696
Bolt
171
1
423775
Printed circuit board
182
4
423699
PT-Screw,
KA 35 x 12
184
1
423706
Battery, 12 V
186
1
423707
Charger, 230 VEU
188
1
423708
Charger, 115 VUSA
204
1
423712
Suspension bow
205
1
423713
Cylinder screw,
M 4 x 35
RECOMMENDED SPARE PARTS
1
1
423714
Base plate
50
1
423733
Tooth plate
53
1
423735
Tension shoe
58
1
423631
Welding shoe
59
1
423632
Bolt
122
1
423758
Tension wheel
146
1
423773
Tooth plate
148
1
423686
Washer
151
2
423687
Counter sunk
screw, M 4 x 12
154
1
423689
Pawl
155
1
423690
Rollpin, ø 2,5 x 12
156
1
423691
Compression spring
157
1
423692
Knife complete
159
1
423693
Torsion spring
162
1
423774
Stroke lever
171
1
423775
Printed circuit board
184
1
423706
Battery, 12 V
186
1
423707
Charger, 230 VEU
188
1
423708
Charger, 115 VUSA
204
1
423712
Suspension bow
205
1
423713
Cylinder screw,
M 4 x 35
8
BHC PARTS LIST, CONTINUED
9
RECOMMENDED SPARE PARTS

15

16