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Date Purchased : Where Installed: ( m a k e / m o d e l o f m a c h i n e ) G5 Stitcher Head OPERATION AND MAINTENANCE MANUAL Wire Size: 25 Ga. Round (0.52 mm) Crown Sizes: 1/2”...
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Before using this Stitcher Head, all operators must study this manual and follow the safety warnings and instructions. Keep these instructions with the G5 Stitcher Head for future reference. If you have any questions, contact your local DeLuxe Stitcher Company Graphic Arts Representative or Distributor.
W A R N I N G ! G5 Stitcher Heads 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 the stitcher machine.
Mounting (Figure 2) Disengage the Feed Gears to assist in mounting G50162CA Position in rail on Stitcher Machine G50708 Turn to adjust for position G50101 G50126 Figure 2 - Mounting the Head...
Assembly (Figure 3) G50286A G50666 G50279A G20241 (2) Align the Clincher Slide and Driver G50181 G50800CA Do not Jam Tube into Feed Gears. G50181 Leave a distance of 1/32” (.5 mm.) G50264 before tightening the Set Screw G20522 Insert Tube while the Feed Gears are engaged Figure 3 - Assembly...
Operation Wire Threading (Figures 4 & 5) Pass wire G50279A between the Wire Guide Spring Studs Pass wire G50800CA between Oiler Felts G50119A Turn to disengage Small and Large Feed Gears G50181 Figure 4 - Threading the Head G50119A Turn to engage Small and Large Feed Gears G50112...
Adjusting Wire Straightness (Figures 6-9) ROTATED VIEW OF FIXED WIRE CUTTER, MOVING WIRE CUTTER, AND WIRE STRAIGHTENER. G50200 FIXED WIRE CUTTER G50200 WIRE STRAIGHTENER G50183 PULL WIRE HOLDER OUT WIRE HOLDER TO MAKE ADJUSTEMENTS TO THE WIRE SPRING STRAIGHTENER ROTATE WIRE HOLDER SPRING TO REMOVE WIRE HOLDER AND GAIN ACCESS TO WIRE STRAIGHTENER.
Horizontal Adjustment (Figures 6-7) To begin horizontal wire adjustment; (A) Swing open the Wire Holder Spring (G50183)by rotating it away from center. (B) Pull out the Wire Holder (G50559A) to gain access to the Wire Straigtener. (C) Observe the direction the wire is moving as it emerges out of the Fixed Wire Cutter (G50200). Use an M3 wrench to loosen the Wire Straightener Screw (G50189) and allow adjustment to the Wire Straightener (G50200). Adjustment is accomplished by simply sliding the Wire Straightener up or down to counter the effects of wire curl shown in Figs. 7a-7c. If the wire is curved upwards, slide the Wire Straightener down.
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Figure 8b - Wire Holder Alignment WIRE BETWEEN BENDER INSERT GROOVES In order to form a quality stitch, the Wire Holder has to be in alignment with the Bender Bar. Specifically, the cut piece of wire held in the Wire Holder has to line up with the grooves in the Bender Bar. Poor adjustment 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 8b). Turn the Adjustment Screw (G50665) until the wire is aligned with the grooves in the Bender Bar. Tighten the Hex Nut to secure this setting. Remove the wire in the Wire Holder and load another piece in the Stitcher Head. Verify that the setting established is accurate by again checking the piece of wire with the mirror.
Aligning the Clincher Plate (Figure 9) Front View Side View Back View Align Driver with gap in Clincher Plate G20191 (2) Locks adjustment Screws in position G50710 (2) 042001 (2) 9093A Adjust upper or lower Cap Screws to correct alignment Figure 9 -Clincher Plate Alignment ...
Adjusting the Length of the Stitch Leg (Figure 10) Longer Right Leg G20573 Shorter Right Leg G50181 G50119A Disengage the Feed Gears when making adjustments G50245 G50197A Move wire center right Move wire center left Figure 10 - Adjusting the Stitch Leg ...
Maintenance Lubrication (Figure 11) G20293 and G20293B Moisten completely every spool change or G50131 once a month, One drop of oil whichever occurs first on both sides Recommended Oil - SAE #10 - Household 3-in-1 G50262A One drop of oil in the oil cup Figure 11 - Lubrication...
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Rotating Replacement Parts (Figures 12 & 13) G50206 Remove G20589 Loosen G50383B Loosen to G50197A rotate Cutter Remove G50200 completely Rotate to from Head new surface Figure 12 - Rotating the Cutters G50183 Swing out of the way G50152 Slide out from Bender Bar, Rotate and Replace...
Wire Holder and blow clean with pressurized air. Ordering Spare Parts In time, you will need to replace some parts in your G5 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 part number, 800-634-0810.
Troubleshooting (Figure 14) The quality and quantity of work that can be produced with the G5 Stitching 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. In the event of trouble of this nature occurring, the operator can,...
: Gap Out of Center problem : Lengthen or shorten the left leg by adjusting the Cutter Box. solution (See page 9) : Gap Too Big problem : Increase wire draw with the Feed Rack Adjustment Knob, then solution center stitch gap as described above. (See page 9) : Corner Buckled problem : Check the Driver (G50152) for a chipped corner and solution rotate or replace it if needed. : Leg(s) Buckled problem : If the ends of an unformed piece of wire are not smooth, solution the Wire Cutters (G50145B or G50200) are worn. Check for wear and rotate or replace if needed. Figure 14 - Troubleshooting...
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: Staple Legs Too Long or Too Short problem : Correct the overall wire draw by turning the solution Feed Rack Adjustment Knob (G20573) (See page 8) : Legs are Spread or Contracted problem : Check wire cut-off. solution : Legs Stray Forward or Backward Consistently problem : The Stitcher Head is not aligned properly front solution to back with respect to the Clincher Plate. (See page 9) : Stitch Stray Randomly In and Out and Front to Back problem : Make sure the Cutters are aligned properly.
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G5KL-Loop Stitch Conversion Kit The standard G5 Head with 25 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. Contact your DeLuxe Stitcher Graphic Arts Representative or the DeLuxe Stitcher Customer Service Department for ordering information or for additional technical information on other wire sizes available in Loop Stitch. G50252 G50135 G50160B G50301 G50342 G50253L G50159B G20311 G50344 G20310 G50189 G20226 G20641 G50313 G50161B G50331BA G50147BAA G20255 (3) G50309 G50665B G50151 G50305 G50712 G50198B-1 G50314 G50153 (2) G50301A Complete G50391B-1 G50210...
CEE104 - G5 Work Alignment Gauge Assembly The standard G5 Head can be fitted with a work alignment gauge to properly hold and align the booklet being stitched. Contact your DeLuxe Stitcher Graphic Arts Representative or the DeLuxe Stitcher Customer Service Department for ordering information or for additional technical information on other accessories available..
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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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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 DBSG5_0415...
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