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DeLuxe Stitcher G5 Operation And Maintenance Manual

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D
L
S
E
UXE
TITCHER
®
C O M P A N Y
I N C .
solving your wire stitching needs for 125 years...
Head Serial Number :
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" (12 mm) and 13/64" (5 mm) Loop
Capacity: 2 sheets to 13/64" (5 mm)

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Summary of Contents for DeLuxe Stitcher G5

  • Page 1 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”...
  • Page 3 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.

  • Page 4: Safety Warning

    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.

  • Page 5: Table Of Contents

    Table of Contents Safety Warning ....................4 Specifications .....................6 Installation .......................8 Pre-Inspection ................8 Inspection ..................8 Mounting ..................9 Assembly ..................10 Operation ....................... 11 Wire Threading ................11 Wire Straightening ................12 Aligning the Wire Holder ...............13 Aligning the Clincher Plate ............15 Adjusting the Wire Length (Draw) ..........16 Adjusting the Length of the Stitch Leg ..........16 Maintenance ......................17...

  • Page 6: Specifications

    ....10,000 Replacement for: ....DeLuxe Stitcher 26/26D heads as well as Hohner 43/6, 48/5, 52/8 and 55/7 heads...
  • Page 7 Dimensions 2 1/4” [57.2mm] 5/32” [3.9mm] CENTER OF STITCH 1 3/16" [30.3mm] 3/8" [9.5mm] DETAIL A SCALE 1.5 : 1 27" [685mm] 1 17/32" [39.0mm] 25 1/4" [641mm] 3 9/16" [90.7mm] 13/64" [5.0mm] DRIVE ADJUSTMENT 11 59/64" [302.8mm] 1 27/64" [36.0mm] 10 3/4"...

  • Page 8: Installation

    Installation Contents • G5 Manual • Bag of tools; 2.0 mm., 3.0 mm. and Open End Wrench (7 mm.) • T-Handle Hex Head Wrench; 4 mm. • Head Mounting Accessories • Front Mount: Clamp Block (G50101), Screw M5x0.8x25 (G50126) • Bolt Mount: Head Mounting Bolt, M8 (G50367), Mounting Block - Keyed (G50102), Bonnet Clamp Pin (G50366), Mounting Block Handle (G50716) and Flat Washer M8 (G50394) • Clincher Plate, Points, Slide, Nuts and Studs • Clincher Alignment Gauge • Wire Guide Spring and Wire Anti-Backup Unit • Manual Feed Gear Tool • Stitch Samples G20364 G50279A (7 mm) G20360 (3 mm) A9086JA G50228A G20374 (2 mm) G50666 G50800CA G50708 (4 mm) Figure 1 - Parts Package Contents...

  • Page 9: Mounting

    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...

  • Page 10: Assembly

    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...

  • Page 11: Operation

    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...

  • Page 12: Wire Straightening

    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.

  • Page 13: Aligning The Wire Holder

    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.
  • Page 14 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.

  • Page 15: Aligning The Clincher Plate

    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 ...

  • Page 16: Adjusting The Wire Length (Draw)

    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 ...

  • Page 17: Maintenance

    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...
  • Page 18 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...

  • Page 19: Ordering Spare Parts

    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.

  • Page 20: Troubleshooting

    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,...

  • Page 21: Formed Staple Chart

    : 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...
  • Page 22 : 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.

  • Page 23: Appendices

    Head Mounting - Front - STANDARD Head Mounting Hardware see Figure3 (page5) G20275 Ball Spring Plunger for more details G50101 Clamp Block G50102 Mounting Block - Keyed G50126 Screw M5x0.8x25 G50366 Bonnet Clamp Pin G50367 Head Mounting Bolt, M8 G50394 Flat Washer M8 (watkiss) G50716 Mounting Block Handle G50101 G50126 Alternate-Style Head Mounting - Rear CPBOURG/HORIZON/WATKISS G20275 G50102 G50367...
  • Page 24 071004 Bonnet Sub-Assembly 1 G50100A G50100BA G50264 G50119A G50368 G50720 G50132A G50722 (includes G50132, G50132 G50268 G50138 G50397B G50703 G50120 G50720 G50714 G50223) G50182 G50266 G20140 G20515 G50235 G50232 G20140 G50262A G20233 G50112 042001 G50230 G20191 G50230A G20579 - Supplied with LOT 025 and above. G50117...
  • Page 25 Bonnet Assembly - G5 G50100BA Bonnet Assembly - G5 G50112 Small Feed Gear G50117 Forming Pin Cam G50119A Feed Release Handle Assem. G50132A Feed Lever Assembly G50182 Feed Gear Plate G50230A Cutter operating Lever Assem. G50262A Sm Feed Gear Shaft Assembly G50264 E-Ring 6mm G50266 Dowel M5x10 G50268 Feed Lever Spring G50368 Handle Cap - Grey G50397B Stud, G5 Feed Lever G50703 Feed Lever Spring Screw G50714 Feed Lever Spacer G50720 Screw M3x0.5x6 G50722 Feed Release Handle Stop...
  • Page 26 Bonnet Sub-Assembly 2 G50111A G50110A G50181 G50128 G50129 G20121 G20274 G50136 G50718 G50244 G50137 G20236 G50705 G50646 G20522 G50711 G20191 G50711L (for LOOP) G50721 071004 071004 G50187 G50114 G50721 G50144A G50186 G50143 G50256 G20298 G50717 G50144AL G50399 (for LOOP) G50695 G50720 G20191 G50617...
  • Page 27 Bonnet Sub-Assembly 2 071004 Lock Washer Ribbed G20121 Feed Release Plunger G20191 Screw M4x0.7x8 G20236 Tube Pivot Screw G20274 Hex Jam Nut, M6x1 G20298 Nylock Lock Nut, M6x1 G20522 Screw M6x1.0x5, Nylon G20615 Screw M5x0.8x8 G50110A Large Feed Gear Assembly G50111A Feed Pinion Assembly G50114 Feed Gear Pin G50128 Pinion Washer G50129 Large Feed Gear Washer G50136 Feed Gear Bracket G50141 Wire Guide Bar G50143 Pivot Block G50144A Middle Wire Tube Assembly G50144AL...
  • Page 28 Driver and Feed Slide Assemblies G20272 2215 G20573 G20578 G50320B 071004 G20179 G50174 G50130 G50131 G50131B G50321 G50170 G20190(2) 071004 G50171 G20520 G50163B G20165 G50720 G50164B G50127 G50162B G50163B G50320BA G20190 G50162CA G50170 G20165L G20165 (for LOOP) G50169 G50164C - supplied with LOT 025 and above...
  • Page 29 Screw M3x0.5x6 G50320BA Driving Slide Assembly, Crank Drive G20165 Driving Slide Spring G20190 Screw M3x0.5x10 G50163B Cutter Operating Cam G50164B Driving Slide Plunger G50170 Custom Hex Nut M10x1.25 G50320B Driving Slide, G5 Crank G50321 Crank Link Screw G50162CA Driving Slide Assembly, STANDARD G20165 Driving Slide Spring G20190 Screw M3x0.5x10 G50162B Driving Slide G50163B Cutter Operating Cam G50164C...
  • Page 30 (ALL COMPONENTS) G50135 G50559 G20255 G50331BA G50153 G50254 G20226 G50252 G50147BAA G50151 G50152 G50665 G50253 AG50147BAA Bender Bar Assembly, G5, G50559A Wire Holder Assembly Complete G20226 Hex Nut M4x.7 G20255 Dowel Pin M3x10 G50147BAA Bender Bar Assembly G50135 Wire Holder Pivot Pin G50151 Driver Bar G50252 Wire Hook G50152...
  • Page 31 Wire Guide Bracket and Spring G50286SA (FOR USE ON STITCHMASTER) Clincher Plate Assembly G20293B G20293 G20292 CA9083A (2) G50710 G20297 G50279A CT9088 (2) 9086JA G20293B G20293 UA4808.7 G20292 CT9093A G20298 G20287 G50800CA (includes G20241 screws) 9084B 9087 G20264 G20297 G20241 (2) Wire Guide Bracket and Spring Assemblies. Clincher Plate Assembly G20241 Screw M4x0.7x6...
  • Page 32 Cutter Box Assembly G50711L G50711 G50705 (For Loop) G50198 G50383B G50145B G50383B G50237 G50199 G50210 G50719 G50713 G50197A G50391 G50223 071004 G50604 G50720 G50245 G50721 071004 G50431 G50189 G50200 071004 G20589 G50206...
  • Page 33 Cutter Box Assembly 071004 Lock Washer Ribbed G20589 Screw M4x0.7x10 G50145B Moving Cutter G50189 Screw M3x0.5x10 G50197A Cutter Box Assembly G50198 Cutter Operating Slide G50199 Lower Wire Tube G50200 Fixed Wire Cutter G50206 Wire Straightener G50210 Cutter Operating Spring G50223 Dowel Pin M3x6 G50237 Adjusting Eccentric G50245 Cutter Box Adjustment Knob G50383B Screw M3x0.5x6 G50391 Cutter Box Mounting Plate G50431...
  • Page 34 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...
  • Page 35 G50198B-1 Cutter Slide Block - G5 Loop G50665B Eccentric Screw, G5 Loop G50198B-2 Cutter Slide Shaft - G5 Loop G50305 Anvil G5 - Loop G50199B-1A Lower Tube Assembly G50199B-2 Lower Tube Cover - G5 Loop G50206B Eccentric. Shaft G50208 Roller, G5 loop G50317A Bender Bar Assembly - G5 LOOP G50210 Cutter Operating Spring G20641 Dowel Pin M3x12 G50300A Cutter Box Assembly, G5 Loop G50147BAA Bender Bar Assembly G50337 Spring Pin M2.5x6, Hardened G50151 Driver Bar G50383B Screw M3X0.5X6, Hardened...

  • Page 36: Parts Index

    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..
  • Page 37 NOTES...

  • Page 38: Warranty Information

    Clincher Point - Thick, Round G50100A Bonnet Assembly - G5 9084B Adjustable Clincher Slide G50100BA Bonnet Assembly - G5 9086JA Clincher Plate - Thick, G5 G50101 Clamp Block 9087 Clincher Slide Adjustment Screw G50102 Mounting Block - Keyed CT9088 Clincher Plate Binder Bolt...
  • Page 39 Bender Bar Assy-Loop G50170 Custom Hex Nut M10 x 1.25 G50320A Driving Slide Assembly - Crank Drive G50171 Screw M6x1.0x6 G50320B Driving Slide, G5 Crank G50174 Feed Rack Adjustment Stud G50320BA Driving Slide Assembly - Crank Drive G50181 Upper Wire Tube G50321...
  • Page 40 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 44 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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