KTVHB22D - Pneumatic stapler Prebena - Free user manual and instructions

USER MANUAL KTVHB22D Prebena

• Zubehör p. 14
• Zubehör bestellen 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 p. 44

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

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

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

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

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

Description Unit overview and delivery KTVH-B19D, KTVH-B22D, KTVH-R19D No. Explanation

Adjustment knob (depth adjustment)

Adjustment values (staple length adjustment)

Setscrew (fixing the staple length)

Adjusting disc (setting the bending form)

Unit overview and delivery KTVH-B19H, KTVH-R19H No. Explanation

Adjustment knob (depth adjustment

Adjustment values (staple length adjustment)

Setscrew (fixing the staple length)

Adjusting disc (setting the bending form)

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 manufactureDescription

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 44Prepare stapler

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

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

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 diameterPrepare stapler

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

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

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)Operate stapler

Operate stapler Open the magazine To open the magazine, pull the pusher (1) according to the direction of the arrow to the back and place it at the magazine end around the pivot point on the bottom of the magazine. Insert fasteners

WARNING Accidentally triggering when filling the magazine can cause serious injury or death. Do not point the stapler unit at yourself, other people or animals.Operate stapler

CAUTION Wrong fasteners can lead to injuries that affect the proper function of the stapler unit or damage the stapler unit. Use only the PREBENA fasteners mentioned in the chapter "Order accessories" (see page 44).

Slide one or two stapler rods (13) from behind in the open magazine (2). Slide the fasteners (13) as far as possible according to the direction of the arrows pointing forward into the inlet.Operate stapler

Close the magazine To close the magazine (2), loosen the fixing of the pusher (1) and insert it slowly with the spring force against the fastener (13).Operate stapler

Check function To ensure proper operation of the stapler unit, proceed as follows: ATTENTION Observe the safety instructions in the chapter "Safety" on page

Place the mouth opening on a sample cardboard material with the thickness of the material to be processed. Trigger the stapler device (see chapter "Drive in fasteners" on page 31). To do this, check the following properties: - At each triggering a fastener must be driven in the cardboard material. In order to obtain the desired bending image, change the staple setting (6/7) (see page 31), the depth setting (3) (see page 25) or the setting of staple length (9) (see page 26) W If necessary, repeat these steps. The stapler unit is now ready for use.Operate stapler

Setting driving depths You can adjust the driving depth of the fastener into the cardboard materials by adjusting the depth setting of the adjusting knob (3). ► To reduce the driving depth, push the adjustment knob against the case and turn it to the right mark (/) ► To increase the driving depth, push the adjustment knob against the case and turn it to the left mark (///)Operate stapler

Setting the staple length In order to achieve an optimal bending image you can adjust the stapler length of the stapler unit. Selection should be made between the S & L position. ► Loosen the setscrew (5). ► DTurn the adjusting shaft (4) to the respective position. Staple length 16 mm 19 mm Position of adjusting shaft

► Lock the adjusting shaft (4) again with the setscrew (5)Operate stapler

Staple adjustment for pressure-operated staplers With the adjusting disc (6) the pressing of the stapler can be set. It is possible to bend the staple from very loose to very tight. ► Disconnect the stapler unit from the compressed air supply. ► Use a rod with a 3mm diameter of a 2.5mm Allen key. ► Turn the adjustment wheel (6) to the right to bend the staple very loosely. ► Turn the adjustment wheel (6) to the left to bend the staple very tightly. Position of the adjusting disc

Bending image of the staple Tight Standard LooseOperate stapler 28Operate stapler

Staple adjustment for manually-operated staplers With the adjusting screw (7) the pressing of the stapler can be set. It is possible to bend the staple from very loose to very tight. ► Loosen the lock nut (14). ► Turn the adjustment screw (7) clockwise to bend the staple very loosely. ► Turn the adjustment screw (7) anti-clockwise to bend the staple very tightly. ► Then lock the adjusting screw (7) again with the lock nut (14) Position of the adjusting screw

Bending image of the staple Tight Standard LooseOperate stapler

Check driving depths Replace the stapler with the mouth of a cardboard material. Press the trigger button or the hand lever. A fastener is driven through the box and formed by both benders. Check the setting by a simple triggering on the sample material (see page 31). Repeat these steps until you have set the desired driving depth and staple bending. Drive in the fasteners

WARNING During operation, eye damage or other injury may occur from flying splinters. Wear safety goggles during operation and suitable protective clothing. Comply with the applicable health and safety regulations.

WARNING Hearing damage is possible due to loud noise operation. Wear suitable hearing protection. Comply with the applicable noise regulations. Select the lowest possible operating pressure.Operate stapler

WARNING Risk of injury due to sliding and too deeply driven nails or due to rebound. Use the stapler unit only for cardboard materials. Hold the stapler during the stapling process with a firm grip. Triggering air-powered stapler units Replace the stapler with the mouth of a cardboard material. Press the trigger button. A fastener is driven through the box and formed by both benders. Check the setting by a simple triggering on the sample material (see page 30). Release the trigger (1). To drive in further fasteners, repeat these steps.Operate stapler

Triggering manually-operated stapler units Replace the stapler with the mouth of a cardboard material. Hold the handle (8) firmly. Press the hand lever (10) with the other hand and apply even pressure downwards until it stops. A fastener is driven through the box and formed by both benders. Check the setting by a simple triggering on the sample material (see page 30). Move the hand lever (10) back into its original position. To drive in further fasteners, repeat these steps.After operation

After operation Carry out the steps described below after operation or during extended interruption of operation. Disconnect compressed air supply Remove compressed air hose (only for air-powered stapler units) Pull the quick release of the compressed air hose from the push- in nipples. Quick release is now unlocked. Disconnect the compressed air hose from the connection from the stapler unit The compressed air contained in the stapler unit escapes audibly. Emptying the magazine Remove the fasteners not used in the magazine, if you no longer use the stapler. To do this, proceed as follows:

WARNING Accidentally triggering when emptying the magazine can cause serious injury or death. Disconnect the stapler unit from the compressed air supply (see page 33).

Open the magazine (2) (see page 21). Slide the fasteners (13) remaining in the magazine to the back of the inlet. Remove the fasteners (13) remaining in the magazine (2).After operation

Close the magazine (2) (see page 23).Transport and store stapler

Transport and store stapler Packaging Pack the stapler unit prior to storage or transport over the following distances: Distances longer than 10 m. Routes passing through unstable surface. Routes that are travelled in an unusual posture. To do this, carry out the following preparatory steps: Disconnect the stapler unit from the compressed air feed (see page 33). Let the pressure escape completely from the stapler unit. Empty the magazine (see page 33). If necessary, clean the compressed air connections of foreign substances and impurities. Place the stapler unit in the carrying case. S Close the transport case and the latches for the lid. Transport The method of transport differs depending on whether you move the stapler unit over short or long distances. Transport over short distances Short distances are distances of up to 10 meters in length.

WARNING Accidentally triggering can cause serious injury or death. Disconnect the stapler unit from the compressed air supply during each transportation (see page 33). Carry the stapler unit by the handle. Do not touch the trigger button during transport.Transport and store stapler

Disconnect the stapler unit from the pressure supply (see page 33). ATTENTION Shock or impact can cause damage to the stapler unit. Do not drop the stapler unit. Protect the stapler unit from bumping on obstacles.

Carry the stapler unit by the handle with the mouth opening facing down. Connect the compressed air supply again only at the new site.Transport and store stapler

Transport over long distances The following distances are considered as "long distances" transporting the stapler device: Distances longer than 10 m, Routes passing through unstable surface and routes that are travelled in an unusual posture. To transport the stapler over long distances, proceed as follows: Pack the stapler unit in the supplied carrying case (see page 35). Carry the carrying case by the handle to the desired location. Place the carrying case only horizontally only, with the cover side facing up. Storage Oil all metal parts of the stapler unit thinly with PREBENA special nailer oil. Pack the stapler unit in the carrying case (see page 35). Store the stapler unit at room temperature in a dry and dust- protected place.Service stapler

Service stapler The stapling device should be serviced only by persons who have the knowledge, skills and experience to do so. All work described herein may only be carried out by the customer service of the manufacturer or the manufacturer.

WARNING Accidentally triggering when servicing the stapler unit can cause serious injury or death. Disconnect the compressed air supply before servicing the stapler device (see page 33). Empty the magazine prior to maintenance work (see page 33).

Clean the housing and outer surfaces ATTENTION The stapler unit or the accessories may be damaged due to unsuitable cleaning agents. To clean, use only a dry, slightly damp or a cloth moistened with mild soapy water.

Slight soiling Wipe the outside of the stapler unit with a dry cloth. Oil all metal parts of the stapler unit thinly with PREBENA special nailer oil.Service stapler

Heavy soiling Wipe the outside of the stapler unit with a cloth slightly moistened with mild soapy water. Then wipe the outside with a cloth slightly moistened with tap water. Rub with a dry, soft cloth. Oil all metal parts of the stapler unit thinly with PREBENA special nailer oil. Oil stapler unit ATTENTION Insufficient lubrication or using incorrect lubricants can damage the stapler unit. Use only PREBENA special nailer oil.

If no lubricator is mounted and the length of the air line to the stapler unit exceeds 10 m, sufficient lubrication is not guaranteed. In these two cases, fill two to five drops PREBENA special nailer oil, one day prior to start of operation, directly into the connection for compressed air source. ATTENTION In case of spillage of lubrication oil, there is a risk of environmental damage. Bind any spillage of oil with a binding agent. Gather bound oil with a cloth. Dispose of the rag in accordance with the legal regulations applicable at the site.Faults

WARNING When operating a damaged or faulty stapler unit serious or fatal injuries may occur. Disconnect the stapler unit immediately from the compressed air supply in case of fault (see page 33). Empty the magazine (see page 33). Use the stapler unit only when the problem is resolved.

ATTENTION The stapler unit can be damaged by unauthorized people during repairs. Make sure that repairs to the stapler unit are only performed by the manufacturer.

Remove jammed fasteners To remove a jammed fastener, proceed as follows: Disconnect the stapler unit from the compressed air supply (see page 33). Empty the magazine (see page 33). Pull back the pusher and snap it on. Loosen the jam in the device with a thin pair of pliers or a screwdriver Move the pusher again carefully into position. Remove the jammed or deformed fasteners. Connect the compressed air supply (see page 17). Fill the magazine as described on page 20. Check the functioning of the stapler unit (see page 24). If you cannot eliminate the fault, contact your dealer or the manufacturer (see page 48).Faults

Other faults If a fault occurs on the stapler unit that you cannot resolve by oiling and cleaning, you must notify PREBENA service. Do not make any repairs to the stapler unit. Make sure that all faults of the stapler unit are remedied by PREBENA service. Fault overview In the following overview, possible faults and the necessary measures are listed. Symptom Possible cause Corrective actions The stapler unit loses air. The mounting screws are loosened. Tighten the mounting screws. A seal is broken. Contact customer service (see page 48). Fasteners are not fully driven. The operating pressure is too low. Increase operating pressure (see page 17). The driver tip on the stapler unit is worn. Contact customer service (see page 48).Faults

Symptom Possible cause Corrective actions Triggering is not possible. The operating pressure is too low. Increase operating pressure of the compressed air system to the maximum allowable operating pressure. Then trigger several times. When triggered, set the desired operating pressure (see page 17). The moving parts are glued together by lubricants after long storage. Clean and re-oil the stapler unit (see page 39). Setting the maximum operating pressure. Then trigger several times. When triggered, set the desired operating pressure (see page 17). Otherwise, contact customer service (see page 48).Faults

Symptom Possible cause Corrective actions Triggering without a fastener being driven in (blank firing). The spring of the pusher is defective. Contact customer service (see page 48). The magazine is dirty. Clean the magazine. Wrong fasteners are loaded in the magazine. Empty the magazine. Fill the magazine with PREBENA fasteners (from page 20). The stapler unit is not sufficiently lubricated. Fill PREBENA special nailer oil into used compressed air supply. Trigger a few times. The operating pressure is too low. Increase operating pressure (see page 17). The piston with the driver is not returned to the initial position after the stapling operation. Contact customer service (see page 48). The triggering process is not completed. Contact customer service (see page 48). The driver is bent. Contact customer service (see page 48). A fastener is jammed. Remove jammed fasteners (see page 40). Otherwise, contact customer service (see page 48). If despite all that you cannot eliminate the fault, contact your dealer or the manufacturer (see page 48).Order accessories

Order accessories Zubehör You can order some more accessories from the manufacturer (see page 44). Use only original accessories PREBENA or accessories approved by PREBENA for the operation of the stapler unit. Reorder fasteners The stapler unit may only be operated with the PREBENA fasteners stated on the respective nameplate. Explanation of type designation Example: B19 C LF Abbreviation Explanation B19 PREBENA type and side length

Cutting tip; default is C = chisel cutting edge

Quality of the wire; default is LF = bronzed steel

Other resin treatment or quality of the fastener wire on request. For more information on the type designation, contact PREBENA.Order accessories

Order more accessories Types Order number PREBENA special nailer oil Z200.10 Spiral hose with 9 mm inner diameter, 12 mm outer diameter, 4 m working length, 7.5 m stretched length Z160.12 Compressed air hose set with 9 mm inner diameter, 15 mm outer diameter, 10.0 m stretched length Z200.20 Compressed air hose reel with 8 mm inner diameter, 12 mm outer diameter, for a hose length of 30 m Z180.00 Suspension eyelet Z85608001Dispose stapler

ATTENTION Environmental damage resulting from environmentally incompatible disposal. Clean the stapler unit prior to disposal (see page 38). Follow local regulations for disposal of oil.

Do not throw the stapler unit or parts thereof in any way in your normal household waste. If you wish to dispose of the stapler unit, send it to PREBENA. The stapler unit is properly disposed by PREBENA. You can find contact details on page 48.Technical Data

Warranty For the designated unit, PREBENA provides a 1-year warranty from date of purchase in accordance with the following guarantee conditions. PREBENA guarantees free of charge repair of defects caused by material or manufacturing faults. Malfunction or damage caused by improper use will not be considered to fall under free of charge warranty. In addition, original PREBENA fasteners may only be used; in case of non-compliance product liability and thus the warranty becomes null and void. The warranty does not cover wearing parts such as O- rings, etc. It is at the discretion of PREBENA to effect the warranty by replacing the defective part or replacement delivery. Further claims are excluded. To qualify for warranty, the completely filled out warranty card with dealer stamp and date of purchase must be enclosed or an invoice stating the data and information to be carried out in accordance with the warranty card. Shipping: The faulty unit must be sent to PREBENA carefully and break-proof packed and sufficiently stamped.

Warranty Model Name: Date of purchase: Dealer: (Stamp)Index

Avoid explosion hazards ........... 9 Avoid risks of injury .................. 9

General design characteristics .. 6

KTVH-B19H, KTVH-R19H