07/07/07

HELIOS H-45

BATTERY-POWERED MANUAL TOOL

FOR PLASTIC STRAPPING

OPERATION MANUAL
&
SPARE PARTS LIST IMPOR
K EEP
TANT!
IT W E L
L
 07/07/07

PART I

CONTENTS

1. Safety Instructions…………………………………….1

2. Functional Unit ……………………………………… 3

3. Technical Data………………………………………. 4

4. Operation Elements ……………………………………4

5. Operation ………………………………………………5~8

6. Wiring Diagram ………………………………………9

 07/07/07

1. Safety Instructions
Before using the tool, read the operating instructions carefully.

Operation with Battery

Environment protection：
● Do not dispose of used batteries in the household refuse, water or by burning them.

Danger of Shortcircuit：
● Do not store batteries together with metal objects.
● Do not open batteries and store them only in dry and frostproof rooms. The maximum
ambient temperature is 50℃. Keep dry at all times.
● Never charge a damaged battery. Replace by a new one immediately.

When operating the tool, wear eye, face

and hand protection (cut-proof gloves).

Before starting preventive or corrective maintenance,

remove battery from the tool.

Operation
Tool must not be used by persons not properly trained in their use. Before tensioning strap,
read and understand the tool operating instructions. Failure to follow the operating
instructions or improper load positioning could result in strap breakage.
Become familiar with your tool and keep fingers away from areas that can pinch or cut.

Do not use water or steam to clean the tool.

Do not put your fingers into the tension wheel area.

-1-
 07/07/07

Do not put hands or other parts of the body between

the strap and the package during the strapping process.

Strap Breakage Hazard

Improper operation of the tool, excessive tensioning, using strap not recommended for this tool
or sharp corners on the load can result in a sudden loss of strap tension or in strap breakage
during tensioning, which could result in the following：
● A sudden loss of balance causing you to fall.
● Both tool and strap flying violently towards your face.

Note as follows：
● If the load corners are sharp, use edge protectors.
● Place the strap correctly around a properly positioned load.
● Positioning yourself in-line with the strap, during tensioning and sealing, can result in severe
personal injury from flying strap or tool. When tensioning or sealing, position yourself to one
side of the strap and keep all bystanders away.
● Use the correct strap quality, strap width, strap gauge and strap tensile strength recommended
in this manual for your tool. Using strap not recommended for this tool can result in strap
breakage during tensioning.

When cutting the strap, hold the upper portion

and stand safely away from the strap.
Caution: The lower strap will snap forward.

Do not stand in line with the strap while it is tensioned.

The strap could break!

Tool Hazards
A well maintained tool is a safe tool!
Check tool regularly for broken or worn parts. Do not operate a tool with broken or worn parts.
Never modify any tool. Modification can result in severe bodily injury.

-2-
 07/07/07

2. Functional Unit

6 Battery Unit
H45-60000

3 Linkage Unit
H45-30000

2 Gripper Unit
H45-20000

4 Sealing & Cutting Unit

5 Body Frame Unit H45-40000
H45-50000
1 Tensioning Unit
H45-10000

-3-
 07/07/07

5. Operation
(1) Installation
Putting on the Battery
Please loosen the Battery Fastener (H45-60261) first. Then putting on the battery and you
would see the LED lights on GREEN shortly. That means the battery is installed correctly.
Finally just tighten the Battery Fastener to the battery as (Fig. a) shows.

(Fig. a)
Removing the Empty Battery
If the LED lights on RED while tensioning or welding, that means the battery is exhausted.
Please loosen the Battery Fastener (H45-60261) and push the unlatching buttons on both
sides of the battery to take off the battery.
Warning! The last welding on the package might not have sufficient seal efficiency
and you would need to do it again after recharging the battery.

(2) Adjusting the Welding Pressure

In order to assure optimal welding, the pressure of the welding gripper to the straps to be
welded must be within a certain range. Depending on the thickness of the strap, this pressure
is adjusted by means of the adjusting the quantity of shim(s). Please see the following chart.

When adjusting the welding perssure, the shim must be inserted

into "steel insert".

Disregarding this regulation will cause considerable trouble.

smooth strap emboss strap

quantity for shim(s) quantity for shim(s)
H45-40260 strap thickness H45-40270 H45-40270
Steel Insert 0.4~0.6 mm 2 3

H45-40270 0.7~0.8 mm 1 2
Shim 0.9~1.05 mm 0 1

-5-
 07/07/07

(3) Adjustments

(a) Preselecting of Strap Tension and Tensioning Speed

Do not adjust the tensioning force too high.
If the tensioning force is higher than the
tensioning strength of the strap, the strap
will tear while the tensioning.
Tensioning force can be preselected with
the left adjusting knob. Turning clockwise
increases, turning counterclockwise
Adjusting knob tensioning force
decreases the tensioning force.
Adjusting knob sealing time
When P.P. straps or straps with thinner thickness around 0.55mm to 0.7mm
Protection cover
are still being damaged by H45-10090 (tension wheel) during strapping while
the tension is at the lowest level (make a counterclockwise turn on the tension knob to the end),
simply use an allen key wrench to make a counterclockwise turn on the trimmer of P. C. board.
You need to take off the protection cover first and you will then see the VR underneath the
the protection cover. After making all the adjustments, tension will become lower.
When the tension becomes as low as you desired, just put the protection cover back on.
On the other hand, if tension is not enough while it is at the highest level (make a clockwise
turn on the tension knob to the end), simple make a clockwise turn on the trimmer of P.C.
board for even higher tension.

(b) Adjusting the Sealing Time

Depending on the size and quality of the strap, different welding times are required.
The welding time can be adjusted at the right adjusting knob.
Turning clockwise increases, turning counterclockwise decreases the welding time.
(4) Feeding the Strap Around the Package

The strapping is fed around the package as illustrated.

Warning! The plastic strap which will be welded

must be free from oil, grease and other dirt.
Dirty plastic straps can't be welded correct!

(5) Inserting the Strap

Pull up the handle lever firmly with your right hand.

Insert the two straps well aligned on each other into
the strap guide using your left hand.
Release the handle lever.

-6-
 07/07/07

(6) Tensioning and Sealing the Straps

-Auto
Press down the rocker switch until the desired
strap tension is reached, the tool will do sealing
by itself, at this time, we can release the rocker switch.

-Semi
Press down the rocker switch and then release it,
and press down again and again. Until the
desired tension is reached.

Sealing the Straps

Press the black switch to sealing the straps.

The plastic strap is welded and cut off from the strap coil at the same time.
During welding, the LED lights green.
After expiration of the adjusted welding time, the cooling down time begins
(LED lights yellow).
When the LED lights green again, the sealing procedure is finished.

(7) Removing the Tool

Pull up the handle lever, pull the tool right / backwards

and off the strapping.

(8) Seal - Control

A regular control of the seal is necessary. The seal can

be examined visually.
Make a seal, peel it apart and examine it as follows：

-7-
 07/07/07

Correct Seal
The seal must be completely welded over the whole
width of the strap on a length.
Minot quantities of fused plastic may overflow on
sides.

Welding Time Too Short

The plastic strap is not welded over the whole width of
the strap.
The seal efficiency is insufficient.
Warning! Straps with insufficient seal strength
must be removed from the package!
Adjust the welding time.

Welding Time Too Long

If the welding time is too long the straps are overheated.
The fused plastic overflows on both sides of the straps.
The seal efficiency is affected.
Warning! Straps with insufficient seal strength must
be removed from the package!
Adjust the welding time.

-8-
07/07/07

A B C D E F
4 4
3 3

-9-
2 2
6. Wiring Diagram

1 1
A B C D E F
MACHINE MODEL PAGE
 07/07/07

shape classification shape classification

HBS SR

TMS SP

PMS BR

FMS BK
single cover

HB KT

THS HFL
one way

HSS TAL

CAP MB

HN KYA

WN KYB

FLG KYC

NTE HBW
PWA
PN φ8×φ12~φ16×0.4~0.8t
φ6×φ13~φ4×0.8~1.5t
PWB
PW φ8×φ14~φ16×1.3~1.5t
φ6×φ15~φ16×1.0~1.5t
PWC
SW φ8×φ20~φ23×2.0t
φ6×φ16~φ19×2.0t

TW DS

BWW TTP

ER FTP

RR FHS
 PART II

CONTENTS

1. Tensioning Unit …………………………………………………..

1

2. Gripper Unit ………………………………………………………

4

3. Linkage Unit……………………………………………………..
6

4. Sealing & Cutting Unit ……………………………………………….

8

5. Body Frame Unit ……………………………………………….

11

6. Battery Unit……………………………………………………….
13
1 TENSIONING UNIT H45-10001
H45-10002
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
H45-10001 Tensioning Unit (For 12mm) 1
H45-10002 Tensioning Unit (For 16mm) 1
H45-10003 Tensioning Unit (For 9mm) 1
1 H45-10010 End Cover 1
2 H45-10020 Torsion Spring 1
3 H45-10030 Strap Stop (For 16mm) 1
H45-10031 Strap Stop (For 9mm, 12mm) 1
4 H45-10040 Tensioning Body 1
5 H45-10050 Swivel Shaft 1
6 H45-10060 Holder 1
7 H45-10070 Gripper (For 16mm) 1
H45-10071 Gripper (For 9mm, 12mm) 1
8 H45-10080 Holder (For 16mm) 1
H45-10081 Holder (For 9mm, 12mm) 1
9 H45-10090 Tensioning Wheel 1
10 H45-10100 Dowel 3
11 H45-10110 Parallel Pin 3
12 H45-10120 Idler Gear 3
13 H45-10130 Washer 1
14 H45-10140 Tensioning Wheel Shaft 1
15 H45-10150 Parallel Pin 3
16 H45-10160 Idler Gear 3
17 H45-10170 Cover 1
18 H45-10180 Bearing 1
19 H45-10190 Tension Gear 1
20 H45-10200 Spur Wheel 1
21 H45-10210 M1 Motor Support 1
22 H45-10220 M1 Motor Pinion 1
23 H45-10230 Motor (M1) 1
24 H45-10240 Screw 1
25 H45-10250 Washer 2
26 H45-10260 Tube 1
27 H45-10270 Set Ball 1
28 H45-10280 Strap Stop (For 12mm, 16mm) 1
H45-10281 Strap Stop (For 9mm) 1
29 H45-10290 M1 Motor Ass'y 1

-2-
1 TENSIONING UNIT H45-10001
H45-10002
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
30 H45-10300 Cover 1
31 BK0808Z Needle Bearing, 0808Z 1
32 BR6806 Bearing, 6806 1
33 BR6806Z Bearing, 6806Z 2
34 BR6808Z Bearing, 6808Z 1
35 FHS0410N FHS, M4×10 (N) 3
36 FHS0514N FHS, M5×14 (N) 3
37 FHS0308N FHS, M3×8 (N) 2
38 HBS0410N HBS, M4×10 (N) 2
39 HBS0430HN HBS, M4×30 (H)(N) 2
40 HBS0516N HBS, M5×16 (N) 1
41 HN05 HN, M5 1
42 KT-477N Needle Bearing, 477N 3
43 KT-5810N Needle Bearing, 5810N 3
44 HBS0412N HBS, M4×12 (N) 2
45 SB04 Ball, Ø4 1
46 MB0815 Metal Bush, 0815 2
47 FHS0306N FHS, M3×6 (N) 2
48 SP0306 Spring Pin, 3×6 5
49 SP0432 Spring Pin, 4×32 1

51 SW04 SW, M4 6
52 SW05 SW, M5 2

60 H45-10600 Tensioning Wheel Shaft Ass'y 1

61 H45-10700 Tensioning Body Ass'y (For 16mm) 1
H45-10701 Tensioning Body Ass'y (For 9mm, 12mm) 1

-3-
2 GRIPPER UNIT H45-20000
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.

3 H45-20030 Spring 2
4 H45-20040 Eccentric Shaft 1
5 H45-20050 Inner Raceway 1
6 H45-20060 M2 Motor Gear 1
7 H45-20071 Switch Rocker 1
8 H45-20080 M2 Motor 1

10 H45-20100 Eccentric Shaft Gear 1

11 H45-10250 Washer 1
12 H45-20120 M2 Motor Ass'y 1
13 H45-20110 Spring Slide Ass'y 1

23 HBS0320N HBS, M3×20 (N) 1

24 HN05 HN, M5 1
25 HSS0305 HSS, M3×5 4
26 MB0805 Metal Bush, 0805 1
27 MB1709 Metal Bush, 1709 1
28 PMS0218 PMS, M2×18 2
29 PW05B PW, M5 (B) Ø13 1
30 SP0310 Spring Pin, 3×10 1

32 SW02 SW, M2 2
33 SW03 SW, M3 1

35 SW05 SW, M5 1

-5-
3 LINKAGE UNIT H45-30000
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
1 H45-30010 Pressure Roller 1
2 H45-30020 Front Toggle Link 1
3 H45-30030 Lever 1
4 H45-30040 Torsion Spring 1
5 H45-30050 Stanchion 1
6 H45-30060 Collar 1
7 H45-30070 Spur Wheel 1
8 H45-30080 Collar 1
9 H45-30090 Handle Arm 1
10 H45-30100 Collar 1
11 H45-30110 Arm 1
12 H45-30120 Coupler 1
13 H45-30130 Coupler Shaft 1
14 H45-30140 Handle Lever 1
15 H45-30150 Connector 1
16 H45-30160 Handle Shaft 1
17 H45-30170 Washer 4
18 H45-30180 Shaft 1
19 H45-30190 Spur Wheel Ass'y 1

21 H45-10250 Washer 4
22 HBS0420N HBS, M4×20 (N) 1
23 H45-30230 Collar 2
24 PMS0312 PMS, M3×12 1
25 HFL0615 Bearing, 6×10×15 1
26 NTE04 NTE, M4 2
27 HSS0305 HSS, M3×5 1
28 HSS0508G HSS, M5×8 (G) 2
29 KYA020210 Key, 2×2×10 2
30 MB0810 Metal Bush, 0810 1
31 PW03 PW, M3 2
32 SW03 SW, M3 1
33 MB0812 Metal Bush, 0812 2
34 MB0606 Metal Bush, 0606 2
35 FMS0420 FMS, M4×20 1
36 SW04 SW, M4 2

-7-
4 SEALING & CUTTING UNIT H45-40001
H45-40002
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
H45-40001 Sealing & Cutting Unit (For 12mm) 1
H45-40002 Sealing & Cutting Unit (For 16mm) 1
H45-40003 Sealing & Cutting Unit (For 9mm) 1
1 H45-40011 Bearing Support 1
2 H45-40020 Rocker 1
3 H45-40030 Welding Excentric 1
4 H45-40040 Pinion 1
5 H45-40051 M3 Motor Support 1
6 H45-40060 M3 Motor Pinion 1
7 H45-40070 Thrust Piece 1
8 H45-40080 Coupler 1
9 H45-40090 Cutter 1
10 H45-40100 Pressure Spring 1
11 H45-40110 Driver 2
12 H45-40120 Driver Pin 1
13 H45-40130 Bolt 1
14 H45-40140 Thrust Piece 1
15 H45-40150 Ball Cage 1
16 H45-40160 Welding Gripper 1
17 H45-40170 Seesaw Lever (In Side) 1
18 H45-40180 Guide Case 1
19 H45-40190 Seesaw Lever (Out Side) 1
20 H45-40200 Parallel Pin 1

22 H45-40220 Pressure Spring 2

23 H45-40230 Guide Pin (For 16mm) 1
H45-40231 Guide Pin (For 9mm, 12mm) 1
24 H45-40240 Guide Pin (For 12mm, 16mm) 1
H45-40231 Guide Pin (For 9mm) 1
25 H45-40250 Welding Stop Gripper 1
26 H45-40260 Steel Insert 1
27 H45-40270 Shim
Strap Thickness 0.4~0.6mm 2
Strap Thickness 0.7~0.8mm 1
Strap Thickness 0.9~1.05mm 0
28 H45-40280 Shaft 1

-9-
4 SEALING & CUTTING UNIT H45-40001
H45-40002
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
29 H45-40290 M3 Motor Ass'y 1
30 H45-40300 Welding Excentric Ass'y 1
31 H45-10230 M1/M3 Motor 1
32 T7-5-20210 Grommet 2
33 H44-10710 Lock Pin, 4×8 1
34 H45-40330 Cover 2
35 H45-40340 Cover 1

40 HBS0545HN HBS, M5×45 (H)(N) 1

41 BR627ZZ Bearing, 627ZZ 2
42 TMS0408 TMS, M4×8 1
43 HBS0408N HBS, M4×8 (N) 2
44 HBS0416N HBS, M4×16 (N) 2
45 HBS0420N HBS, M4×20 (N) 1
46 HBS0425N HBS, M4×25 (N) 3
47 SR05 Snap Ring, S-5 7
48 SB04 Ball, Ø4 6
49 SP0318 Spring Pin 3×18 1
50 SW04 SW, M4 8
51 TAL1012 Needle Bearing, 1012 2
52 SW05 SW, M5 1

-10-
5 BODY FRAME UNIT H45-50000
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
1 H45-50010 Body Frame 1
2 H45-50021 Cover Front 1
3 H45-50030 Cover Rear 1
4 H45-50040 Plate 1
5 H45-50050 Battery Lock Pin 1
6 H45-50060 Cover 1
7 H45-50070 Stiff Suspension Bracket (Option) 1
8 H45-50080 Stiff Suspension Bracket Set (Option) 1
9 H45-50090 Bottom Base Wearing Protection Plate 1
(Option)
10 H45-50100 Bottom Base Wearing Protection 1
Plate Set (Option)
11 FHS0310N FHS, M3×10 (N) 2
12 FHS0408N FHS, M4×8 (N) 6

14 FTP0410BN FTP, M4×10 (B)(N) 4

15 HBS0416N HBS, M4×16 (N) 2
16 TTP0420BN TTP, M4×20 (B)(N) 3
17 HBS0440HN HBS, M4×40 (H)(N) 2
18 PW04 PW, M4 2
19 SW04 SW, M4 7
20 H45-50160 Washer(M4×∮8×0.8t) 1
21 HBS0410N HBS, M4×10 (N) 1
22 HBS0410N HBS, M4×10 (N) 1
23 PW05 PW, M5 1
24 HBS0516N HBS, M5×16 (N) (Option) 4
25 SW05 SW,M5 (Option) 4
26 FHS0410N FHS, M4×10 (N) 6
27 H45-50110 Turnable Suspension Bracket (Option) 1
28 H45-50140 Block 1
29 H45-50150 Turnable Suspension Bracket Set 1
(Option)
30 HSS0410GN HSS, M4×10 (G)(N) 1
31 AD-2-20181 Washer 1
32 T7-5-20210 Grommet 1
33 LA-40010 Label 1
34 LA-50008 Label 1

-12-
6 BATTERY UNIT H45-60000
H45-60001
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
H45-60000 Battery Unit (For 230V/220V/240V) 1
H45-60001 Battery Unit (For 110V) 1

10 H45-60100 Connecting Plate 1

11 H45-60110 Battery 1
12 H45-60120 Charger (For 110V) 1
H45-60121 Charger (For 220V/230V/240V) 1
13 H45-60130 Tension Switch (Auto) 1
14 H45-60141 Control Box (PCB) 1
15 H45-60150 Knob 2
16 H45-60160 Sealing Switch (Semi) 1
17 H45-60171 Lock 1
18 H45-60181 Cam 1
19 H45-60190 Spring 1

21 HBS0412N HBS, M4×12 (N) 1

22 HN05 HN, M5 1
23 TTP0305 TTP, M3×5 2
24 PMS0430 PMS, M4×30 2
25 PW03 PW, M3 2
26 PW05 PW, M5 1
27 SW04 SW, M4 3
28 H45-20090 Micro Switch 3
29 H45-60210 Position Wires Ass'y 1
30 H45-60220 Start/Sealing Wires Ass'y 1
31 H45-60230 LED Wire 1
32 H45-60240 Electric Control Group 1
33 H45-60261 Battery Fastener 1
34 SW05 SW, M5 1

06/2009

- 14 -