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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
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)
Watkiss Edition
G8WAHD241/2
TITCHER
C O M P A N Y
I N C .

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Summary of Contents for DeLuxe Stitcher G8

  • Page 1 OPERATION AND MAINTENANCE MANUAL 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 2 W A R N I N G ! G8 Stitcher Head Watkiss Edition The intended application of this stitcher head is limited to installation within an enclosed Watkiss book finishing system. Any other installation of this stitcher head compromises the operator safety.

  • Page 3: Table Of Contents

    Table of Contents Specifications .....................4 Installation .......................4 Pre-Inspection .................4 Inspection ..................4 Assembly Parts ................5 Mounting ..................6 Operation ......................7 Wire Threading ................7 Wire Straightening .................9 Aligning the Wire Holder ...............10 Adjusting the Stitch ................11 Maintenance ......................14 Lubrication & Maintenance ............14 Appendices ......................15 Sub-Assembly Exploded Drawings ..........15 Part Number / Description Cross Reference ........22...

  • Page 4: Specifications

    Installation Pre-Inspection Carefully inspect the condition of the shipping container before unpacking your G8 Stitcher Head . If the container is broken or damaged and there is evidence that the stitcher head may be damaged, immediately notify the carrier who delivered the head and the DeLuxe Stitcher...

  • Page 5: Assembly Parts

    • Complete Wire Guide Spring Plate Assembly (G50808WA) • Upper Wire Tube (G20181W) with C-Clip (G20207) • Rear Clamp Pin (G20366) • Rear Clamp Nut (G20367) • Adjustment Knob Assembly (G20228A) • Mounting Block (G50102) • Crank Drive Link (G20340WA) • Clincher Plate Assembly - Thick (7650WA) • Stitch Samples Assembly Parts (Figure 1) Please take a few moments to fill out the registration card located on page 25-26 prior to beginning installation . Clincher Plate Assembly (See page 21 for G20228A more detail on full G20340WA...

  • Page 6: Mounting

    Mounting (Figure 2) Upper Cutter Block Adjustment Bar G20245 Figure 2 - Mounting the Head...

  • Page 7: Operation

    Operation Wire Threading (Figures 3-8) 1 . Remove the wire holder by first sliding the Figure 3 - Threading the Head retaining leaf spring to the side (Figure 3) . 2 . Thread the wire from the supply spool Wire Holder through the center of the wire felt cleaning pads Retaining Spring...
  • Page 8 Figure 5 - Threading the Head Figure 8 Cut-out View of Wire Straightener Wire Threading Eccentric Lower Wire Tube Large Feed Gear Wire Figure 6 - Threading the Head Small Feed Gear Middle Wire Tube Upper Wire Tube Adjustment Handle Feed Release Shaft Cutter Block Wire Guides...

  • Page 9: Wire Straightening

    Adjusting Wire Straightness (Fig. 9-12) NOT APPLICABLE TO LOT14 ONWARD .010 [.25mm] GAP SKIP UNLESS WIRE TUBE HAS BEEN MOVED OR Figure 11a - Straight Wire SHIFTED FROM FACTORY SETTINGS. Figure 9 - Adjust the Wire Feed Gap Note: Using a metal shim to set this gap will simplify this step. LOWER WIRE RAISE WIRE Wire Straightener...

  • Page 10: Aligning The Wire Holder

    G8 Head from the side past both the Right and Left Wire Guide Bars (Figure 12). Make sure there is a clear view of the opening Fixed Wire in the Fixed Wire Cutter from the side of the G8 Head . If there Cutter is not, loosen the Flat Head Machine Screws securing the Wire Guide Bars to the Pivot Block and move them out of the path of the wire .

  • Page 11: Adjusting The Stitch

    Load a piece of wire into the Wire Holder . Check to make sure the wire in the Wire Holder is lined up with the grooves in the Bender Bar (Figure 13b) . If it is not, loosen the Socket Head Set Screw in the front of the Wire Holder and the Hex Nut (seen in Figure 10) securing the Wire Holder Adjustment Screw (Figure 13a). Turn the Adjustment Screw until the wire is aligned with the grooves in the Bender Bar.
  • Page 12 For G8 Heads mounted to a machine with an Cutter Box adjuster rail, loosen the two (2) Hex Head Screws securing the Lower Cutter Block Adjustment Lower Bar and Cutter Block Adjustment Connector to Cutter Block the Upper Cutter Block Adjustment Bar. For Adjustment all G8 style Heads, place the Adjustment Knob...
  • Page 13 CORRECT SETTING. CENTER LINE OF BOTH STITCH Figure D & DRIVER ARE ALIGHED Correct Stitch The ideal stitch has the center of gap aligned to the center of the finished stitch . Figure 18 - Adjusting the Stitch  WARNING Always disconnect the power supply before making any adjustments or servicing the head.

  • Page 14: Maintenance

    Maintenance Lubrication & Maintenance (Figure 19) Your new Deluxe Stitcher head was designed to minimize both the maintenance and lubrication require- ments that are normally associated with standard stitcher heads . This was accomplished by incorporat- ing a high tech bonded coating that helps reduce friction and wear to many of the critical wear parts .

  • Page 15: Appendices

    Bonnet Sub-Assembly G20000A (INCLUDES G20191 (2), G20229 (2) & G20120 (2)) G20273 (2) G20122A (2) G20120 (2) G20170 G20378W G20367 G20191 (2) G50102W G20229 (2) G20190 (2) G20366 G20115 G20264 (2) G20275...
  • Page 16 Bonnet Sub-Assembly G20119W G20263 G50431 (USE BLUE LOCKTITE) G20118W G20167 (2) G20133 G20133A G20249 (2) (INCLUDES G20133 & G20250 (2) G20245 G20269) G20269 (Use Blue Loctite) G20182 G20246 G20196 (2) G20289 (2) G20244 G20264 G20214 (2) G20220 (Use Blue Loctite) G20126 G20240 (4) G20236...
  • Page 17 Feed Lever and Feed Gear Assemblies G20262A (2) G20268 G20263 (2) G20132 DBSG8W40 G20140 G20181WA G20264 G20112 INCLUDES G20181W AND G20207 G20181W G20267 G20207 1. - MUST BE INSTALLED USED ON 5mm BELOW G20132 SURFACE LOT16 AND UP 2. - APPLY BLUE LOCTITE G20266 G20129 G20111...
  • Page 18 Driving and Feed Slide Assemblies G20264 G20173 G20340WA G20179 G20131W G20177 USE KLUBER ISOFLEX G20130 NBU15 ON BEARINGS (REF. G20824) G20176 (2) G20174 G20320WA G20127 Complete G20171 Assembly G20321W G20320 G20170 G20165W G20167 (2) G20323A G20164B...
  • Page 19 Bender Bar and Wire Holder Assemblies G20147WAA Complete Assembly G20160B G20161 (USE BLUE LOC-TITE TO ASSEMBLE) G20159 G20342 G20147WMATL G20224 G20149W G20150 G20344W G20148W G20154A G20346B G20156 G20433 (4) G20155 G20559WA G20665 Complete G20147WA G20135 Assembly G20151 (INCLUDES G20147WMATL, G20148W & G20431 (4) G20255 G20253...
  • Page 20 Cutter Block Assembly G20197WAA LOT14 ONWARD Complete Assembly (All parts on this page) G20145CW (CARBIDE) G20218 G20210 APPLY BLUE LOCTITE APPLY GREASE G20198 G20197A G20200C (CARBIDE) G20226 (2) G20216 (2) G20219 (4) G20191 (2) LOWER WIRE TUBE PARTS THRU LOT13 G20196B APPLY BLUE LOCTITE G20199B-1...
  • Page 21 Wire Guide and Clincher Plate Assemblies G50808WA Wire Guide Spring G20264 G20298 Mount Assembly G20287 G20810 G20292 G20293 (2) G20288 (2) G50808W G20297 7650BW 7257PS 18183W 7650WA 18182W G50125 (2) 18184W...

  • Page 22: Part Number / Description Cross Reference

    DBSG8W40 Label, "NO ADJUST" G20149W Bender Bar Latch DW1058 Screw M4 x 6mm Button Head G20150 Bender Bar Latch Spring G20000A Bonnet Assembly - G8 G20151 Driver Bar G20110 Large Feed Gear G20152 Driver, 24W G20110A Large Feed Gear Assembly...
  • Page 23 (1) - APPLIES TO LOT13 AND LOWER Part Number / Description Cross-Reference (2) - APPLIES TO LOT14 AND HIGHER G20195 Screw M6x1.0x8 SHS G20240 Cutter Block Adjustment Washer G20196 Screw M3x0.5x6 SHC G20241 Screw M4x0.7x6 SHC G20196B Screw M3x0.5x6 SHC G20242 Cutter Adjustment Bar - Lower G20197A...
  • Page 24 801-614 Wire Cleaning Felt G20346B 801-627 Supporter Guide Pin, Composite G20375 952-445 Torx Key Wrench, T8 G20433 801-652 Screw, M2.5 x 0.45 x 12, Torx-w/Nylon Patch 914-875 - G8 Supplementary Head Maintenance Kit DeLuxe Part No. Watkiss Part No. Description Qty. 18182W 801-604 Clincher Slide - Watkiss G20147WMATL 801-600 Bender Bar Material - Watkiss...
  • Page 28 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.

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