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DeLuxe Stitcher G8 Series Operation And Maintenance Manual

Stitcher head
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D
L
E
UXE
Head Serial Number :
Date Purchased :
Where Installed:
G8 Stitcher Head
OPERATION AND MAINTENANCE MANUAL
Wire Sizes: 23-28 Ga. Round, 20x24 and 21x25 Flat
Capacity: 2 sheets to 5/16" (8 mm) Standard
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
(make/model of machine)
Crown Size: 1/2" (13.5 mm)
2 sheets to 5/32" (4 mm) Loop
TITCHER
C O M P A N Y
I N C .

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Summary of Contents for DeLuxe Stitcher G8 Series

  • Page 1 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.
  • Page 3 Thank you for choosing the G8 STITCHER HEAD for your binding needs.
  • Page 4 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. Do not operate this stitcher head without all stitcher machine guards in place.

  • Page 5: Table Of Contents

    Table of Contents Introduction ......................5 Part Number Definition ..................5 Specifications .....................7 Installation .......................9 Pre-Inspection .................9 Inspection ..................9 Assembly Parts ................10 Mounting ..................11 Operation .......................13 Wire Threading ................13 Wire Straightening ................15 Adjustments and Settings .............17 Maintenance ......................23 Lubrication ..................23 Cleaning ..................25 How to Order Spare Parts .............25 Troubleshooting ....................25...

  • Page 6: Introduction

    Introduction Typical Style Uses: G8BHD ............. No. 2 and M2 Wire Stitchers G8MHD ............No. 17 and M17 Wire Stitchers G8HD ..............Automatic Saddle-Stitchers, ..............Gang-Stitchers, Multibinders and Others Examples of Replacement Heads for OEM Users*: AM Graphics / Harris / Heidelberg / Sheridan 455, 562, 690 .... G8HD24A AM Graphics / Harris / Heidelberg / Sheridan 705 ......
  • Page 7 Some Head Style Examples Figure 1 - Style Comparisons...

  • Page 8: Specifications

    Specifications Weight Shipping Weight ....11 lbs (5 kg) Box Size ....21 x 10 x 7 Physical Dimensions Height .
  • Page 9 Dimensions 2 1/4 [57.2] 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 1/8 [689] 25 13/32 [645.5] 1 1/2 [38.5] 23 23/32 [602.6] 1 1/32 [26] 2 3/64 [52] 5/16 [8] THICKNESS ADJUSTMENT...

  • Page 10: Installation

    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 Graphic Arts...

  • 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. G20362 5mm Hex Key G20360 G20286A 3mm Hex Key G20679A G20361 2.5mm Hex Key G20286AA G50716 G20279A G20679AA OPTIONAL G20279AA 9002 G20124...

  • 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 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 Front-to-Back Adjustment Screw G20215 (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 For G8 Heads mounted to a machine Upper Cutter Block Cutter Block Adjustment Bar with an adjuster rail, loosen the two (2) Hex Adjustment G20245 or Rack Head Screws securing the Lower Cutter Block G20251 G20143 Adjustment Bar and Cutter Block Adjustment Connector to the Upper Cutter Block Adjustment Bar (both versions shown in Fig.
  • Page 20 Figure 23 - Adjusting the Stitch Figure D Correct Stitch The ideal stitch has the center of gap CORRECT SETTING. aligned to the center of the finished stitch. CENTER LINE OF BOTH STITCH & DRIVER ARE ALIGHED Aligning the Clincher Plate (Figures 24-27) In order to produce properly clinched staples, the center of the Clincher Plate (round or flat, thick or thin) must be exactly in line with the Driver both left-to-right and front-to-back.
  • 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 Note: Ensure that the stitcher machine's compres- Clincher Points sion setting is correct before making Clincher 9083A or 9083C Point adjustments. To adjust the Clincher Points, loosen the Set Screw on the top of the Clincher Slide (9084B). Turn the Clincher Slide Adjustment Screw clockwise to lower the Clincher Points and counter-clockwise to raise them.
  • Page 23 Adjusting the Bender Bar Stop (Figures 29-31) The Bender Bar Stop is set at the factory. The Stop controls the position of the Bender Bar Latch at the top of the stitcher head’s stroke. If the Latch does not fall within the proper area of the Driver Bar, partially 3/32"...

  • 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: Troubleshooting

    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 27 : Crown Not Straight PROBLEM : Straighten the wire. (See page 14) Align the Clincher SOLUTION Points. (See page 19) Reverse or replace the worn or broken Driver. (See page 26) Make sure the Cutters are aligned and not dull. (See page 24) Check for correct wire size and strength being used.
  • Page 28 : Staple Legs Too Long or Too Short PROBLEM : Correct the overall wire draw by repositioning the Feed Rack SOLUTION within the G8 Head. (See Page 18) : Left Leg Missing PROBLEM : Straighten the wire. (See page 14) The Wire Holder Assembly SOLUTION is not aligned properly with the groove in the Bender Bar.

  • Page 29: Appendices

    Bonnet Sub-Assembly G50716 G50394 (4) Bolt-mount Heads G20367 [8MM THREAD] G20170 [OPTIONAL METRIC] HN1213 G20000A G20341 G20122A (2) G20273 (2) [1/2-13 THREAD] G20366 G20275 Clamp-mount Heads 9002 G20191 (2) G20229 (2) G20190 (2) G20124 G20115 G20264 (2)
  • Page 30 The G8 Stitcher Head...
  • Page 32 Bonnet Sub-Assembly G20264 G20274 G20118 G20368 G20121 G20119 G20167 (2) G20251 G20133A G20245 G20269 G20250 (2) G20182 G20246 G20196 (2) G20244 G20289 (2) G22144A G20214 (2) G20220 G20126 G20249 (2) G20236 G20240 (2) G20243 G20242 G20239 (2) Discs should be cupped G20237 G20231 G20191...
  • Page 33 Feed Lever and Feed Gear Assemblies G20262A (2) G20268 G20132 G20263 (2) G20112 G20267 G20264 G20181 G20266 G20181B G20140 G20137 (BEARING) G20110A G20136BA G20138 (2) (BEARINGS) G20129 G20189 (5) G20111A G20195 G20128 G20195 G20188 (3) G20187 G20114 G20186 G20180 G20261 072001 G20139 G20273...
  • Page 34 Driving and Feed Slide Assemblies G20264 G20173 G20340 G20179 G20131 (OLD STYLE) G20177 G20130 G20176 (2) G20174 G20340 G20127 G20320A G20162BA G20171 Complete Complete G20171 Assembly Assembly G20321 G20170 G20162A G20320 G20170 G20169B G20165 G20165 G20167 (2) G20323A G20163A G20164B G20167 (2) G20164B For rail-driven Heads...
  • Page 35 Bender Bar and Wire Holder Assemblies G20161 G20160B G20159 G20342 G20224 G20149 G20150 G20344 G20148B G20154A G20431 (4) G20346 G20156 G20155 G20147BA (24-28 rd) G20559BA G20135 G20252 G20347BA (21x25 flat) Complete G20357BA (23 rd) Assembly G20151 G20377B (20x24 flat) [INCLUDES G20148B & (4) G20431] G20253 G20255 G20665...
  • Page 36 Cutter Block Assembly G20198 G20210 G20214 G20145 (ROUND WIRE) G20145C (CARBIDE) G20145F (FLAT WIRE) G20197A G20200 or G20600C (CARBIDE) G20219 (4) G20223 G20226 (2) G20191 (2) G20217 G20196 G20206 G20211 G20212 G20199A G20213 (2) G20196 G20208B (2)
  • Page 37 Wire Guide Bracket, Spring and Clincher Plate Assemblies G50286SA (FOR USE ON STITCHMASTER) G20287 G20286A G20279A G20298 G20288 (2) G50808 G20679A G20292 18184 G20297 G20293 18182 G50800BA UA3216.2 (2) 7257B (FOR M2 ONLY.) 18183 9083A (FOR STANDARD ROUND WIRE.) 9083C (FOR FLAT WIRE.) 18186 G20241 (2)
  • Page 38 Loop Stitch Kit G8KL Loop Conversion Kit includes all parts shown below. G20210 G20300AA G20198 Complete G20214 Assembly G20161 G20145 G20219 (4) G20300A G20160B G20200 G20226 (2) G20191 (2) G20159 G20196 G20342 G20317AA Complete Assembly G20224 G20149 G20147BA G20212 G20150 G20206 G20344 G20211...

  • Page 39: Part Number / Description Cross Reference

    Part Number / Description Cross-Reference G20000A Bonnet Assembly - G8 G20152 Driver, 24W G20110A Large Feed Gear Assembly G20153 Driver Retaining Screw G20111A Feed Pinion Assembly G20154A Supporter Assembly G20112 Small Feed Gear G20155 Supporter Pivot Pin G20113 Supporter Guide Plate G20156 Supporter Pivot Pin Screw G20114...
  • Page 40 Part Number / Description Cross-Reference G20197A Cutter Block Assembly G20245 Cutter Adjustment Bar - Upper G20198 Cutter Operating Slide G20246 Cutter Block Adjustment Connect G20199A Lower Wire Tube Assembly G20249 Cutter Block Washer G20200 Fixed Wire Cutter G20250 Screw M4x.7x14 G20202 Cutter Block Slide Plate G20251...
  • Page 41 Part Number / Description Cross-Reference G20310 Wire Holder Roller Lever Spring G20559BA Wire Holder Assembly 1/2 G20311 Spring Anchor Screw G20579 Screw, M4x0.7x6-FHM-Slotted G20312 Spirol Pin M3x12 G20600C Fixed Cutter - Carbide G20313A Supporter Assembly - Loop G20665 Wire Holder Eccentric Adj Screw G20314 Driver - Loop G20679A...
  • Page 42 Bender Bar Assembly. Refer back to pages 23 through 28 for complete disassembly and reassembly instructions. 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.
  • Page 43 G8KS-Stop Stitch Kit The G8KS mounts on the Adjustment Rail of McCain Saddle Stitchers. It stops the feeding of wire through the Stitcher Heads by pushing open the Feed Release Handles (stopping the stitch) when it receives a signal from the calipers of the Stitcher. The G8KS Stop Stitch Kit comes complete with all the components necessary for converting your existing stitcher machine, along with fully illustrated instructions.

  • Page 44: 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 48 DBSG8-0308...

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