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DeLuxe Stitcher G8 Operation And Maintenance Manual

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D
L
E
®
Head Serial Number :
Date Purchased :
Where Installed:
G8 Stitcher Head
OPERATION AND MAINTENANCE MANUAL
Wire Sizes: 23-28 Ga. Round, 20x24 and 21x25 Flat
Crown Size: 1/2" (13.5 mm)
Capacity: 2 sheets to 5/16" (8 mm) Standard
2 sheets to 5/32" (4 mm) Loop
Before using this Stitcher Head, all operators must study this manual and follow the
safety warnings and instructions. Keep these instructions with the G8 Stitcher Head
for future reference. If you have any questions, contact your local DeLuxe Stitcher
Company Graphic Arts Representative or Distributor.
S
UXE
solving your wire stitching needs for 125 years...
(make/model of machine)
TITCHER
C O M P A N Y
I N C .

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Summary of Contents for DeLuxe Stitcher G8

  • Page 1 2 sheets to 5/32” (4 mm) Loop Before using this Stitcher Head, all operators must study this manual and follow the safety warnings and instructions. Keep these instructions with the G8 Stitcher Head for future reference. If you have any questions, contact your local DeLuxe Stitcher...

  • Page 4: Safety Warning

    W A R N I N G ! G8 Stitcher Head Machine operators and others in the work area should always wear safety glasses to prevent serious eye injury from fasteners and flying debris when loading, operating, or unloading this machine.

  • Page 5: Table Of Contents

    Table of Contents Safety Warning ................. Introduction ......................7 Part Number Definition ..................7 Specifications .....................9 Installation ......................11 Pre-Inspection ................11 Inspection ..................11 Assembly Parts ................12 Mounting ..................13-14 Operation .......................15 Wire Threading ................15-16 Wire Straightening ..............17-18 Adjustments and Settings ............19-24 Maintenance ......................25 Lubrication .................

  • Page 6: Introduction

    The Head’s model type, mounting style, nominal wire size and crown size can all be determined from the part number. 1/2 = Crown size in inches = Mount and Wire Guide Spring Type 24 = Wire Size HD = Head = Original Equipment Manufacturer G8 = Model type...
  • Page 7 Some Head Style Examples A9086A A9086A A9086A 9193A 9193A Figure 1 - Style Comparisons...

  • Page 8: Specifications

    Specifications Weight Shipping Weight ....13 lbs (5.9 kg) Box Size ....21 x 10 x 6 Physical Dimensions Height .
  • Page 9 Dimensions 2.256 [57.30] 5/32 [3.9] CENTER OF STITCH 1 3/16 [30.3] 3/8 [9.5] DETAIL A SCALE 1.5 : 1 4 1/2 [114] 27 5/8 [702] 25 11/16 [653] 1 1/2 [38.5] 21 1/32 [611] 1 1/32 [26] 2 3/64 [52] 5/16 [8] THICKNESS ADJUSTMENT...

  • Page 10: Installation

    Clincher Plate Binder Nut (2091), Bolt (9088), Adjustable Clincher Slide (9084B), Clincher Slide Adjusting Screw (9087) and Clincher Slide Adjusting Lock Screw (UA4808.7). • Stitch Samples * Note: the accessories included with the G8 will vary with the style of Head purchased...

  • Page 11: Assembly Parts

    Assembly Parts Please take a few moments to fill out the registration card located on page 44 prior to beginning installation. G20279A G20679A G20380 5mm T-Handle Hex Key OPTIONAL G20286A G20362 5mm Hex Key G20279AA G50286SA (Spring not shown here, see pg. 44) G20360 3mm Hex Key G20181 or...

  • Page 12: Mounting

    Mounting Figure 4 - Alternate Mount Methods Upper Cutter Block Adjustment Bar G20245 G20251 Figure 3 - Attaching the Wire Guide Figure 5 - Attaching & Removing the Clincher Plate...
  • Page 13 Figure 5 - Attaching & removing Stitcher Heads...

  • Page 14: Operation

    Operation Wire Threading (Figures 7 - 13) 1. Slide the Wire Holder Retaining Spring over to the side Figure 7 - Threading the Head and remove the Wire Holder (Figure 7) from the Stitcher Wire Holder Head. Retaining Spring G20183 2.

  • Page 15: Wire Threading

    Figure 10 - Threading the Head Small Feed Gear G20112 Large Feed Gear G20110A Wire Middle Wire Tube G20144A Figure 11 - Threading the Head Feed Release Lever G20119 (Turn to engage position as shown) Adjustment Handle G20228A Lower Wire Tube G20199A Cutter Block G20197A...

  • Page 16: Wire Straightening

    Adjusting Wire Straightness (Fig. 14-17) Figure 14 - Adjust the Wire Feed Gap SKIP UNLESS WIRE TUBE HAS BEEN MOVED OR SHIFTED FROM FACTORY SETTINGS. .010 [.25mm] GAP Figure 16a - Wire Curls Up Note: Use a metal shim to set gap will simplify this step. Set Screw G20273 Hex Nut...
  • Page 17 (1 per side) If the Wire Guide Bars are not properly positioned, the wire will rub against them as it exits the Cutter Block. Look at the G8 Head from the side past both the Right and Left Wire Guide Bars (Figure 17).

  • Page 18: Adjustments And Settings

    may cause broken crowns or other poor stitching. Load a piece of wire into the Wire Holder. Using a mirror, check to make sure the wire in the Wire Holder is lined up with the grooves in the Bender Bar (Figure 18b). If it is not, loosen the Socket Head Set Screw in the front of the Wire Holder and the Hex Nut (seen in Figure 15) securing the Wire Holder Adjustment Screw (Figure 18a).
  • Page 19 G20251 G20143 Adjustment Bar and Cutter Block Adjustment Connector to the Upper Cutter Block Adjustment Bar (both versions shown in Fig. 4). For all G8 style Heads, place the Adjustment Knob over Hex Head Screw the Cutter Adjustment Stud as shown in Figure...
  • Page 20 Driver both left-to-right and front-to-back. Front-to-Back Adjustment Manually activate the G8 until the Stitcher Head is at the bottom of its stroke and the Driver is touch- ing the top of the Clincher Plate. Looking from...
  • Page 21 DRIVER TOO FAR DRIVER TOO FAR FORWARD, ADJUST BACK, ADJUST CENTERED STITCH UPPER SET SCREW LOWER SET SCREW Figure 26 - Front To Back Alignment Figure 25 - Properly Aligned Slight adjustments to the Set Screws make significant differences in position. Once the position is set, tighten the two (2) Socket Head Set Screws in the side of the Stitcher Head.
  • Page 22 Once set, reighten the Set Screw. Set Screw UA4804.7 Refer to the complete list of wear parts for the G8 style Stitcher Head, found in the back of this manual on page Clincher Slide 47. The Clincher Points and Clincher Plates necessary...
  • Page 23 G20149 out from the Bender Bar at least 3/32” [2.5mm] (Figure 30) when the G8 reaches the top of its stroke. If the Latch does not protrude this far then the Bender Bar Stop Screw is set too high. If the Stop Screw is set too low then the wire will hit the Bender Bar rather than feeding below it for forming.

  • Page 24: Maintenance

    Screw clockwise to raise the Bender Bar’s Figure 32 - Adjusting the Bender Bar Stop position and counter-clockwise to lower it’s position. The normal position is about 1/8” or 3mm out from the Feed Gear Bracket. Replace the Pivot Block using its Locating Pins with the holes in the Bonnet.
  • Page 25 Figure 33 - Lubrication Points...

  • Page 26: Cleaning

    In addition to proper lubrication, routine cleaning is important for the maintenance of your G8 Head. The entire Head should be torn down and rebuilt every three to six months and the following areas should be cleaned once every three months: • Large Feed Gear (G20110A): remove and wash in an oil-dissolving...

  • Page 27: How To Order Spare Parts

    Ordering Spare Parts In time, you will need to replace some parts in your G8 style Stitcher Head. When this happens, first locate the needed part in one of the following diagrams. Then locate the DeLuxe Stitcher part number and contact your Graphic Arts Representative to order the part by the part number, description and quantity.

  • Page 28: Troubleshooting

    Troubleshooting (Figure 35) The quality and quantity of work that can be produced with the G8 Stitcher Head is dependent upon the operator making all adjustments as accurately as possible and carefully maintaining the head. The cause of staple imperfections usually can be traced to inaccurate settings or normal wear of moving parts.

  • Page 29: Formed Staple Chart

    problem: Crown Not Straight solution: Straighten the wire. (See page 17) Align the Clincher Points. (See page 22) Reverse or replace the worn or broken Driver. (See page 28) Make sure the Cutters are aligned and not dull. (See page 18) Check for correct wire size and strength being used.
  • Page 30 Staple Legs Too Long or Too Short solution: Correct the overall wire draw by repositioning the Feed Rack within the G8 Head. (See Page 21) problem: Left Leg Missing solution: Straighten the wire. (See page 17) The Wire Holder Assembly is not aligned properly with the groove in the Bender Bar.

  • Page 31: Appendices

    Bonnet Sub-Assembly BOLT MOUNT G50716 G50394 (4) HEADS G20367 (Panduro type collators) [8MM THREAD] M8 (HORIZON TYPE COLLATORS), CP BOURG G20170 [OPTIONAL METRIC] HN1213 G20341 G20122A (2) G20273 (2) [1/2-13 THREAD] (M2 DELUXE) G20366 G20120 (2) CLAMP MOUNT HEADS 9002 G20229 (2) G20191 (2) FRONT MOUNT...
  • Page 32 REAR MOUNTING BOLT, 8MM G50394 FLAT WASHER - M8 G50716 MOUNTING BLOCK HANDLE, M8 HN1213 BONNET STUD NUT, 1/2”-13 Front Mount Heads G20101 FRONT MOUNT BLOCK - G8 G20102 SCREW M6X1.0X12, NYLON G20103 SCREW M6X1.0X30 Clamp Mount Heads 9002 BONNET CLAMP BLOCK G20124...
  • Page 33 Bonnet Sub-Assembly G20264 G20274 G20118 Optional Feed Release Handle (STAHL) ST-90 G20368 G20371 G20121 G20119 G20167 (2 G20264 G20133A G20251 G20372 G20245 G20250 (2) G20269 G20182 G20246 G20196 (2) G20244 G20289 (2) G20144A G20214 (2) G20126 G20249 (2) G20220 G20236 G20240 G20243 G20242...
  • Page 34 Bonnet Sub-Assembly G20118 FEED RELEASE HANDLE CAM G20234 E-RING- 3/16" G20119 FEED RELEASE HANDLE G20235 FOLLOWER BEARING SHAFT G20121 FEED RELEASE PLUNGER G20236 TUBE PIVOT SCREW G20126 TUBE PIVOT PLATE G20237B ADJUSTMENT STUD G20133A FEED RELEASE BLOCK ASSY G20240 ADJUSTMENT WASHER G20140 FOLLOWER BALL BEARING G20242...
  • Page 35 Feed Lever and Feed Gear Assemblies G20262A (2) G20268 G20132 G20263 (2) G20112 G20267 G20181 G20181B G20264 G20140 G20266 G20137 G20136BA G20138 (2) (BEARING) (BEARINGS) G20110A G20129 G20189 (4) G20111A G20128 G20195 (2) G20195 G20261B G20187 G20114 G50394 G20186 G20273 G50617 G20139A INCLUDES...
  • Page 36 SMALL FEED GEAR WASHER G20136BA FEED GEAR BRACKET ASSEMBLY G20137 ROLLER CLUTCH BEARING G20138 FEED PINION BEARING G20139BAA PIVOT BLOCK ASSEMBLY COMPLETE - G8 G20175 SCREW M4X0.7X6 SHCS G20180 FLAT WASHER M6 G20181 UPPER WIRE TUBE G20181B UPPER WIRE TUBE, G8 STITCHEMASTER...
  • Page 37 Driving and Feed Slide Assemblies G20173 G20264 G20340 G20179 G20131 (OLD STYLE) G20177 G20130 G20176 (2) G20174 G20340 G20127 G20320A G20162BA G20171 G20171 Complete Complete Assembly Assembly G20321 G20170 G20162 G20320 G20170 G20169B G20165 G20165 G20167 G20163A G20163A G20164B G20167 G20164B For rail-driven Heads For crank-driven Heads...
  • Page 38 Driving Slide Assembly G20127 FEED RACK G20130 FEED ADJUSTMENT BLOCK G20131 FEED SLIDE G20173 FEED RACK KNOB - KNURLED G20174 FEED RACK ADJUSTMENT STUD G20176 SCREW M4X.7X12 SHCS LOW HEAD G20177 FEED RACK ADJ KNOB POINTER G20179 SCREW M3X.5X4, SHCS G20264 SCREW M5X.8X5 SHCS G20340...
  • Page 39 Bender Bar and Wire Holder Assemblies G20147BAA (24/25 rd) STANDARD G20347BAA (21x25 flat) G20161 G20160B G20159 G20224 G20342 G20149 G20150 G20344 G20148B G20147B G20154A G20346B (PLASTIC) G20433 G20156 G20155 G20147BA (24/25 RD) G20559BA G20252 STANDARD Complete G20347BA (21x25 FLAT) Assembly G20151 G20357BA (23 RD) G20253...
  • Page 40 G20147BAA Bender Bar/Driver Assembly (24/25 RD) STANDARD G20147BA BENDER BAR ASSEMBLY, 24W G20149 BENDER BAR LATCH G20150 BENDER BAR LATCH SPRING G20151 DRIVER BAR G20152 DRIVER, 24W G20153 DRIVER RETAINING SCREW G20154A SUPPORTER ASSEMBLY G20155 SUPPORTER PIVOT PIN G20156 SUPPORTER PIVOT PIN SCREW G20159 BENDER BAR FRICTION PLUG G20160B...
  • Page 41 Cutter Block Assembly G20197BAA (round wire) G20197FAA (flat wire) G20145 (STANDARD) Complete Assembly (ROUND WIRE) (All parts on this page) G20145C (CARBIDE) G20145F (FLAT WIRE) G20210 APPLY GREASE G20214 APPLY BLUE LOCTITE G20197A TO THREADS G20198 G20200 (STANDARD) G20200C(CARBIDE) G20226 (2) Available for use with 25 or 24 gauge wire only.
  • Page 42 G20226 HEX NUT M4X.7 G20211 CUTTER WIRE SHIELD (OLD STYLE) G20212 WIRE STRAIGHTENER ROLL STUD Lower Wire Tube Assembly, G8 Round Wire, Upgrade Kits G20199BAA (ROUND WIRE) G20199FAA (FLAT WIRE) 071004 LOCK WASHER, M3 (OLD STYLE) G20199B-1 LOWER WIRE TUBE BASE, G8...
  • Page 43 G50286SA (FOR USE ON Wire Guide Bracket, Spring and Clincher Plate STITCHMASTER) NOTE: G20293B GUIDE SPRING REVERSED. G20293 G20279A G20292 G20679A G20286A G50808 G20241 (2) G20298 G20287 G20292 7257B ROUND WIRE G20297 (STANDARD G20293 (2) 7024B FLAT WIRE G50800CA USED ON M MACHINE G50806 G20288 (2)
  • Page 44 Wire Guide Bracket, Spring and Clincher Plate Assemblies CLINCHER SLIDE ADJUSTMENT SCREW 9087 CLINCHER SLIDE ADJUSTING SCREW 18182 CLINCHER SLIDE 18183 CLINCHER SLIDE ADJUSTMENT BLOCK 18184 CLINCHER SLIDE BLOCK CLAMP 18186 CLINCHER SLIDE ADJUSTMENT SCREW 7024B CLINCHER POINT - FLAT 7253A CLINCHER PLATE ASSEMBLY - 1/2 7257B...
  • Page 45 Loop Stitch Kit G8KL Loop Conversion Kit includes all parts shown below. G20300BAA G20210 Complete Assembly G20214 G20198 G20145 G20300A G20219 G20200 G20226 G20191 G20196B G20216 G20212 G20199B-1 G20206 G20208D G20213 G20199B-2 G20208B DW1058...
  • Page 46 G20300BAA Cutter Box Complete, Loop Round - 2 pc Wire Tube (24/25 rd) STANDARD DW1058 SCREW, M4 X 6, BUTTON HEAD G20145 MOVING CUTTER - ROUND WIRE G20191 SCREW, M4X.7X8 SHSS, NYLON G20196B SCREW, M3X0.5X6 G20198 CUTTER OPERATING SLIDE G20199B-1 LOWER WIRE TUBE BASE G20199B-2 LOWER WIRE TUBE COVER...
  • Page 47 G20161 G20317AA Complete Assembly G20160B G20159 G20342 G20224 G20344W G20149 G20147BA G20150 G20313A G20346B G20156 G20155 G20151 G20314 (25 Round) G20153 (2)
  • Page 48 G20317AA Bender/Driver Assembly, Loop G20147BA BENDER BAR ASSEMBLY, 24W G20149 BENDER BAR LATCH G20150 BENDER BAR LATCH SPRING G20151 DRIVER BAR G20153 DRIVER RETAINING SCREW G20155 SUPPORTER PIVOT PIN G20156 SUPPORTER PIVOT PIN SCREW G20159 BENDER BAR FRICTION PLUG G20160B BENDER BAR FRICTION SPRING G20161 BENDER BAR FRICTION BUSHING...
  • Page 49 G20301A G20135 Complete Assembly G20304A G20307B G20226 G20306 G20310 G20311 G20309A G20273 G20301 G20305 G20312 G20309 G20665 G20301A Wire Holder Assembly, Loop G20135 DOWEL PIN M5X24 G20226 HEX NUT M4X0.7 G20273 SCREW M4X.7X4 SHSS G20310 WIRE HOLDER ROLLER LEVER SPRING G20311 SPRING ANCHOR SCREW G20312...

  • Page 50: Optional Equipment

    G8KL-Loop Stitch Conversion Kit The standard G8 Head with 24 gauge wire can be converted to a Loop style by exchanging the following three sub-assemblies: the Wire Holder Assembly, the Cutter Block Assembly and the Bender Bar Assembly.
  • Page 51 G8KT-Stop Stitch Toggle Kit The G8KT is a Stop Stitch Toggle Kit specifically designed for users of McCain Stitchers using both 26/26D and G8 Stitcher Heads. The Electrical Box, Box Cover and Toggle Switch replace your machine’s existing equipment to make switching between the two styles of Stitcher Heads easier. This Kit comes complete with a wir- ing diagram and replacement electrical box. For more information or technical support, contact your...

  • Page 52: Parts Index

    G20138 Feed Pinion Bearing 7024B Clincher Point - Flat G20139 Pivot Block Insert 7253A Clincher Plate Assembly - 1/2 G20139LA Pivot Block Assembly, G8 Loop Optional 7257B Clincher Point - Round G20140 Follower Ball Bearing 9002 Bonnet Clamp Block G20143...
  • Page 53 G20171 Screw M8x1.25x12 G20216 Screw M4x.7x25 SFHS G20173 Feed Rack Knob - Knurled G20217 Spirol Pin M5x12 G20174 Feed Rack Adjustment Stud G20219 Wire Straightener Disc Spring G20175 Screw M4x.7x6 SHCS G20220 Hex Nut M5x.8 G20176 Screw M4x.7x12 SHCS Low Head G20223 Dowel Pin 1/8x1/4 G20177...
  • Page 54 G20267 Feed Lever Bushing G20344B Supporter Spring - Heavy G20268 Feed Lever Spring G20346 Supporter Guide Pin G20269 Spirol Pin 3/16x5/8 G20347BA Bender Bar Assembly,21x25 G20273 Screw M4x.7x4 SHSS G20352 Driver, 21x25W G20274 Hex Jam Nut, M6x1 G20353 Driver, 20x24W G20275 Ball Spring Plunger G20357BA...

  • Page 55: Warranty

    This warranty is in lieu of all other express warranties. Any warranty of merchantability or fitness for a particular purpose is limited to the duration of this warranty. DeLuxe Stitcher shall not be liable for any incidental or consequential damages.
  • Page 60 TITCHER ® C O M P A N Y I N C . Stitching & Bindery Products 3747 Acorn Lane • Franklin Park • Illinois 60131 Phone: 847-455-4400 • 800-634-0810 Fax: 847-455-4900 • 800-417-9251 http://www.deluxestitcher.com DBSG8_0115...

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