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Watkiss G8 Instruction Manual

Stitch head maintenance kit
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G8 Stitch Head
Maintenance Kit
Instruction Manual
Issue 2c, January 2014
969-344
for kits Nov 13 onwards - without the G20199A lower wire tube

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Summary of Contents for Watkiss G8

  • Page 1 G8 Stitch Head Maintenance Kit Instruction Manual Issue 2c, January 2014 969-344 for kits Nov 13 onwards - without the G20199A lower wire tube...
  • Page 2 Watkiss Automation Limited shall not be liable for errors contained herein or for incidental or consequential damage in con- nection with the furnishing, performance or use of this material.

  • Page 3: Table Of Contents

    Replace the Clincher Points ......49 continued . . . G8 Stitch Head Maintenance Kit Instructions...
  • Page 4 Kit List ......... . . 97 Remove the Old Lower Wire Tube Assembly, G20199A ..98 Fit the New G20199BAA Lower Wire Tube Assembly ..101 G8 Stitch Head Maintenance Kit Instructions...

  • Page 5: Introduction

    Overview 1.1.1 G8 Stitch Head Maintenance Kit - 914-880 The G8 Stitch Head Maintenance Kit, part no. 914-880 contains the compo- nents that you must replace every 1,000K stitches. Additionally the G20199A lower wire tube (see ‘A’ in FIGURE 1:1.
  • Page 6 1 - Introduction - Overview It is recommended that you keep in stock a 940-140 kit, PSQ Mod.44, G8 lower wire tube for when you visit a machine to do the 1,000K stitch maintenance. If you need to fit the G20199BAA lower wire tube, then the correct time to do so is indicated in the disassembly procedure in the next chapter.

  • Page 7: The 914-880 Maintenance Kit

    Tool, G20375, G8 torx key *801-610 G20199A Lower wire tube. This item is discontinued. If there is one in the kit, then discard the item. See Section 1.5 914-880 FIGURE 1:4. Table of parts in the Maintenance Kit G8 Stitch Head Maintenance Kit Instructions...

  • Page 8: The 914-881 Supplementary Maintenance Kit

    • Pliers: needle nose, water pump or slip joint • Punch: 4mm • Spanners: 7, 8, 12, 13 mm • Feeler gauge: 0.40mm • 952-437 G-clamp: 100 mm capacity • Loctite 222 and 242 G8 Stitch Head Maintenance Kit Instructions...

  • Page 9: Identify The Lot # Of The Stitch Head

    Procedure: G8 stitch head Label that shows the Lot # FIGURE 1:7. G8 stitch head with label for the Lot # 1. Open the PSQ main deck. See Section 4.1.3.13. in the PSQ Service Manual, Issue 4b, 4c or 5b.

  • Page 10: Stitch Head Differences By Lot # - As Supplied

    The Lot 14 stitch head differences are: • The wire straightener eccentric G20206 - is replaced with wire straightener eccentric less adj G20206B. • The wire straightener roller G20208B is replaced with wire straightener roller - G20208D. G8 Stitch Head Maintenance Kit Instructions...
  • Page 11 • The only difference between Lot 15 heads and Lot 14 heads is that Lot 15 heads use the later 801-704 clincher points as standard. The 801-704 clincher points are included in the G8 Stitch Head Maintenance Kit, part no. 914-880 and are retrofittable to all stitch heads.
  • Page 12 • Reduced tolerance on the pivot block mounting holes • Improved quality of the wire-hook spring. 1.6.6 Retro Fit of Upgrades Important: • All of the above modifications can be retrofitted to earlier stitch heads. G8 Stitch Head Maintenance Kit Instructions...

  • Page 13: Disassemble The Stitch Head

    Mounting block and spacer Stitch head fixing nut Crank link screw Crank drive link Stitcher mounting plate Drive plate Cutter box adjustment bar Wire drive coupling Wire-feed cam-shaft FIGURE 2:1. Remove the stitch head G8 Stitch Head Maintenance Kit Instructions...
  • Page 14 • crank link screw • cutter box adjustment bar • wire-feed cam-shaft Remove the stitch head from the PSQ. Remove the stitch-wire from the Pull the stitch-wire from the upper stitch head. wire tube. G8 Stitch Head Maintenance Kit Instructions...

  • Page 15: Remove The Upper Wire Tube And The Wire Guide Plate

    Lot 16 and later stitch heads or between the end of the upper wire stitch heads fitted with the modi- tube and the feed gears when the fied upper wire tube. feed gears are engaged. Section 1.6.3 G8 Stitch Head Maintenance Kit Instructions...

  • Page 16: Remove The Middle Wire Tube

    Remove the Middle Wire Tube Metal spring clip Middle wire tube FIGURE 2:4. The middle wire tube Prior to Lot 14 Lot 14 onward or upgrade fitted FIGURE 2:5. Old and new lower wire tubes G8 Stitch Head Maintenance Kit Instructions...
  • Page 17 Follow the instructions in APPENDIX A , then return to Section 2.5. • If the new type of lower wire tube (B) is fitted, then go to the next section, Section 2.4. G8 Stitch Head Maintenance Kit Instructions...

  • Page 18: Clean The Lower Wire Tube

    FIGURE 2:6. Cutter box. Step Action Information Loosen but do not remove the 2 x FIGURE 2:6. grub screws that hold the lower wire tube in place. Remove the button head screw. FIGURE 2:6. G8 Stitch Head Maintenance Kit Instructions...
  • Page 19 Push the lower wire tube to the left FIGURE 2:6. and hold in position against the cutter box fixing screws. Tighten the grub screws to fasten the lower wire tube in position. Go to Section 2.5. G8 Stitch Head Maintenance Kit Instructions...

  • Page 20: Remove The Wire-Holder

    2 - Disassemble the Stitch Head - Remove the Wire-holder Remove the Wire-holder Wire-holder retaining-spring Wire-holder FIGURE 2:7. The wire-holder Step Action Information Move the wire-holder retaining- FIGURE 2:7. spring away from the wire-holder. Remove the wire-holder. G8 Stitch Head Maintenance Kit Instructions...

  • Page 21: Remove The Cutter Box

    Action Information Loosen and remove the 2 FIGURE 2:8. and see FIGURE 2:9. cutter box fixing screws. Remove the cutter box. Make sure the cutter operating slide remains in position in the cutter box. G8 Stitch Head Maintenance Kit Instructions...

  • Page 22: Remove The Pivot Block Assembly

    Lot 14 or for stitch heads fitted with the upgraded pivot block. Section 1.6.1. for refer- ence. Note: The fixing screws are not the same length. Remove the pivot block assembly. G8 Stitch Head Maintenance Kit Instructions...

  • Page 23: Remove The Cutter Operating Lever Assembly

    FIGURE 2:12. The cutter operating lever assembly Tools: • Screwdriver: small flat blade Step Action Information Remove the ‘E’ clip from the pivot FIGURE 2:12. pin. Remove the cutter operating lever assembly from the pivot pin. G8 Stitch Head Maintenance Kit Instructions...

  • Page 24: Remove The Feed Gear Bracket Assembly

    FIGURE 2:13. The feed gear bracket assembly Tools: • Allen key: 2.5mm Step Action Information Loosen and remove the 3 fixing FIGURE 2:13. screws. Note: The fixing screws are not the same length. Remove the feed gear bracket assembly. G8 Stitch Head Maintenance Kit Instructions...

  • Page 25: Remove The Driving Slide

    Remove the Driving Slide Crank link screw Part No. 801-625 Lock nut Driving slide assembly Retaining screw FIGURE 2:14. Rear of the G8 stitch head Retaining screw Driving slide FIGURE 2:15. Remove the driving slide Tools: • Allen key: 6mm...

  • Page 26: Remove The Feed Rack

    Remove the Bender Bar Assembly Bonnet Bender bar assembly FIGURE 2:17. Remove the bender bar assembly Step Action Information Hold the bonnet in one hand. Push the bender bar assembly FIGURE 2:17. from the bonnet. G8 Stitch Head Maintenance Kit Instructions...

  • Page 27: Remove The Feed Lever Assembly

    If a label is fitted over the feed FIGURE 2:19. lever bushing, then remove and discard the label. Remove the feed lever bushing (a) and the feed lever spring (b). Remove the feed lever assembly. G8 Stitch Head Maintenance Kit Instructions...

  • Page 28: Remove The Cutter Adjustment Bar And Slide Plate

    Loosen the grub screw that holds FIGURE 2:20. the dowel pin in position. Remove the dowel pin and the cut- ter box slide plate. Remove the M5 lock nut from the end of the cutter box adjustment stud. G8 Stitch Head Maintenance Kit Instructions...
  • Page 29 1.6.4. for reference. Lot 17 and later or upgrade fit- ted: The design of the cutter box adjustment stud is different and has plain washers with a compres- sion spring. Remove the cutter adjustment bar. G8 Stitch Head Maintenance Kit Instructions...
  • Page 30 2 - Disassemble the Stitch Head - Remove the Cutter Adjustment Bar and Slide Plate G8 Stitch Head Maintenance Kit Instructions...

  • Page 31: Fit The New Parts

    Fit the New Parts CHAPTER 3 IMPORTANT: • Unless otherwise documented, the disassembly, assembly and lubrication procedures are the same for all stitch heads. G8 Stitch Head Maintenance Kit Instructions...

  • Page 32: Replace The Wire Cleaning Felts

    FIGURE 3:1. washer. Remove and discard the old wire cleaning felts. Fit the new 801-614 wire cleaning 2 wire cleaning felts are supplied felts. 914-880 in the Maintenance Kit. Fit the washer, spring and nut. G8 Stitch Head Maintenance Kit Instructions...

  • Page 33: Replace The Crank Link Screw - [3000K/8000K Only]

    Crank link screw Part No. 801-625 Lock nut Driving slide assembly Retaining screw FIGURE 3:2. Rear of the G8 stitch head Tools: • Screwdriver: Flat blade • Spanner: 13mm or water pump pliers; slip joint pliers • G-clamp: 100 mm capacity...
  • Page 34 • Loosen the crank link screw by one quarter of a turn. Lock the crank link screw in posi- tion with the lock nut. Remove the G-clamp from the driving slide assembly. G8 Stitch Head Maintenance Kit Instructions...

  • Page 35: Replace The Cutter Box Components

    FIGURE 3:3. slide assembly from the cutter The cutter operating slide holds in posi- box. tion a spring under tension. Be careful when you remove the cutter operating slide because the spring can be ejected. G8 Stitch Head Maintenance Kit Instructions...
  • Page 36 • Screwdriver: Flat blade • Permanent marker pen Step Action Information Mark the current position of the FIGURE 3:5. moving cutter with a permanent marker pen. Remove and discard the moving FIGURE 3:3. cutter screw. G8 Stitch Head Maintenance Kit Instructions...
  • Page 37 Stitches Service Position Factory Set  1,000K  2,000K  3,000K  4,000K  5,000K Factory rebuild  6,000K  7,000K  8,000K  9,000K  Fit and tighten the new moving cutter screw. G8 Stitch Head Maintenance Kit Instructions...
  • Page 38 Cutter operating spring FIGURE 3:6. Location of the cutter operating spring Fixed cutter Fixed cutter clamp-screw Moving cutter Cutter block FIGURE 3:7. Fixed cutter adjustment - 01 0.0mm FIGURE 3:8. Fixed cutter adjustment - 02 G8 Stitch Head Maintenance Kit Instructions...
  • Page 39 Action Information Loosen but do not remove the fixed-cutter clamp-screw (A) that holds the fixed cutter in position. Lubricate the cutter box. Fit the cutter operating slide into the cutter box without the spring. G8 Stitch Head Maintenance Kit Instructions...
  • Page 40 Apply Loctite 222 to the threads of the fixed-cutter clamp-screw. Tighten the fixed-cutter clamp- Use a normal length Allen key to screw. tighten the fixed cutter clamp screw as much as possible by hand. Remove the cutter operating slide. G8 Stitch Head Maintenance Kit Instructions...
  • Page 41 You must be able to feel resistance between the cutters. The moving cutter must return under spring pressure. • Adjust the position of the fixed cutter if necessary. G8 Stitch Head Maintenance Kit Instructions...

  • Page 42: Replace The Bender Bar Components

    Bender bar. Part No. 801-600 Does not include the latch housing or the latch housing screws. Driver bar assembly. Part No. 801-620 Driver. Part No. 801-608 FIGURE 3:10. Wear components of the bender bar assembly G8 Stitch Head Maintenance Kit Instructions...
  • Page 43 When the supporter pivot pin is removed, the supporter spring plunger can eject. • Push the supporter pivot pin through the bender bar assembly. • Remove the supporter. • Remove the supporter pivot pin. G8 Stitch Head Maintenance Kit Instructions...
  • Page 44 The supporter pin is a tight fit in the supporter. • Push the supporter pin from the supporter using a 4mm punch. • Push the new supporter pin into the supporter. The supporter pin must be central. G8 Stitch Head Maintenance Kit Instructions...
  • Page 45 FIGURE 3:10. Two versions of the G20161 bender bar friction bushing are used in the G8 stitch head. One version has a slotted-head and needs a 12mm spanner for removal as shown above. The other version does not have the slotted-head and needs an 8mm spanner for removal.
  • Page 46 Remove the bender bar latch spring. Remove the driver bar assembly and the bender bar latch. Remove the driver from the driver FIGURE 3:10. bar assembly and discard the driver bar assembly. G8 Stitch Head Maintenance Kit Instructions...
  • Page 47 From machine PSQ/0300, the latch housing is fastened with Torx screws. Torx screws are supplied in the Maintenance Kit and are fully ret- rofittable to all stitch heads. A Torx key is supplied in the kit. G8 Stitch Head Maintenance Kit Instructions...
  • Page 48 Driver. Part No. 801-608 FIGURE 3:11. Wear components of the bender bar assembly Do not apply grease to this face. Driver bar - rear Driver bar - front FIGURE 3:12. Lubrication of the driver bar G8 Stitch Head Maintenance Kit Instructions...
  • Page 49 [3000K/8000K only] Inspect the bender bar for wear. A typical failure of this component is stitch-wire fusing into the bender bar grooves. Replace the bender 914-881 bar with one from the Supplementary Kit as necessary. G8 Stitch Head Maintenance Kit Instructions...
  • Page 50 Fit the driver to the new driver bar. FIGURE 3:11. [3000K/8000K only] If both ends of the driver are worn, replace the driver with the one from the 914-881 Supplementary Kit. G8 Stitch Head Maintenance Kit Instructions...
  • Page 51 Push the driver bar assembly to the end of the bender bar. Fit the bender bar latch spring and FIGURE 3:13. the bender bar latch spring screw. G8 Stitch Head Maintenance Kit Instructions...
  • Page 52 Fit the supporter and the supporter pivot pin. Tighten the grub screw to hold the supporter pivot pin in position. Make sure the cone-point of the grub screw engages with the groove on the supporter pivot pin. G8 Stitch Head Maintenance Kit Instructions...

  • Page 53: Replace The Clincher Points

    • Allen key: 4mm. • Loctite 242 3.5.1 Remove the Old Clincher Points Step Action Information Remove the clincher slide-block FIGURE 3:14. clamp. • Remove the clincher slide-block fixing screws to release the clincher slide-block clamp. G8 Stitch Head Maintenance Kit Instructions...
  • Page 54 • If wear can be seen, then reverse the clincher slide. • If both ends of the clincher slide are worn, then replace the clincher slide with one from the 914-881 Supplementary Kit. G8 Stitch Head Maintenance Kit Instructions...
  • Page 55 Clincher fixing screws Clincher plate FIGURE 3:17. Clincher assembly components Step Action Information Fit the new clincher points. Make sure the clincher slide FIGURE 3:16. engages with the clincher points. Fit the clincher back plate. G8 Stitch Head Maintenance Kit Instructions...
  • Page 56 • Fit the clincher slide-block clamp. Make sure the clincher slide engages with the clincher-slide adjustment block. FIGURE 3:17. • Fit the clincher slide-block clamp fixing screws. G8 Stitch Head Maintenance Kit Instructions...

  • Page 57: Lubricate And Assemble The Stitch Head

    Lubricate and Assemble the CHAPTER 4 Stitch Head IMPORTANT: Unless otherwise documented, the disassembly, assembly and lubrication pro- cedures are the same for all stitch heads. G8 Stitch Head Maintenance Kit Instructions...

  • Page 58: Lubricate The Bonnet Assembly

    Lubricate and Fit the Bender Bar Assembly Bender bar assembly Bender bar latch Bonnet FIGURE 4:2. Fit the bender bar assembly Tools: • Allen key: 6mm • Feeler gauge: 0.40mm • Klüber Isoflex NBU 15 grease. G8 Stitch Head Maintenance Kit Instructions...

  • Page 59: Lubricate And Fit The Feed Rack

    FIGURE 4:3. Fit the feed rack Tools: • Allen key: 6mm • Feeler gauge: 0.40mm • Klüber Isoflex NBU 15 grease. Step Action Information Lubricate the feed rack. Insert the feed rack into the bonnet. FIGURE 4:3. G8 Stitch Head Maintenance Kit Instructions...

  • Page 60: Fit The Driving Slide

    • Klüber Isoflex NBU 15 grease. Step Action Information Put the driving slide into position in FIGURE 4:4. the bonnet. Engage the plunger of the driving slide with the end of the driver bar. G8 Stitch Head Maintenance Kit Instructions...
  • Page 61 FIGURE 4:5. clearance of 0.40 mm between each side of the driving slide and the bonnet. Tighten the retaining screw. Push the assembly backward and forward to make sure the assem- bly moves freely. G8 Stitch Head Maintenance Kit Instructions...

  • Page 62: Lubricate And Fit The Feed Lever

    Feed lever spring Feed lever ‘E’ clip. Part No. 801-622 FIGURE 4:6. Fit the feed lever FIGURE 4:7. Feed lever bushing label. Wire feed cam bearing surface FIGURE 4:8. Wire feed cam bearing surface G8 Stitch Head Maintenance Kit Instructions...
  • Page 63 FIGURE 4:6. Fit a new ‘E’ clip to the pivot pin. Apply Loctite 242 to the threads in the feed lever. Fit the feed lever bushing to the feed lever. G8 Stitch Head Maintenance Kit Instructions...
  • Page 64 Fit the 801-650 ‘DO NOT ADJUST’ FIGURE 4:7. label over the feed lever bushing. Lubricate the bearing surface of FIGURE 4:8. the wire feed cam. Apply grease to where the wire FIGURE 4:9. feed cam touches the feed lever. G8 Stitch Head Maintenance Kit Instructions...

  • Page 65: Lubricate The Cutter Adjustment Bar And Slide Plate

    For Lot 16 stitch heads and earlier without the upgraded cutter box adjustment stud, see Section 4.6.1. • For Lot 17 stitch heads and later or stitch heads fitted with the upgraded cutter box adjustment stud, see Section 4.6.2. G8 Stitch Head Maintenance Kit Instructions...
  • Page 66 The bottom of the dowel pin must not touch the bottom of the seating slot for the cutter box adjust- ment bar. Go to Section 4.7. G8 Stitch Head Maintenance Kit Instructions...
  • Page 67 When assembled, the disc spring washers must fit face-to-face: |()|. FIGURE 4:10. Fit and fully tighten the cutter box adjustment stud. • One turn is 360°. Loosen by one turn maximum the cutter box adjustment stud. G8 Stitch Head Maintenance Kit Instructions...
  • Page 68 1/8 to 1/4 of a turn as needed. When the adjustment is correct, use a screwdriver to hold the cut- ter box adjustment stud in position and tighten the M5 nut. G8 Stitch Head Maintenance Kit Instructions...
  • Page 69 Fit the spring (B) then the remaining 2 x cutter block adjustment washers (A). Fit the cutter block adjustment stud • Completely tighten the cutter assembly to the stitch head. block adjustment stud. Fit and tighten the M5 nut. G8 Stitch Head Maintenance Kit Instructions...

  • Page 70: Lubricate And Fit The Cutter Operating Lever

    Lubricate the pivot pin and the FIGURE 4:11. areas of the stitch head against which the cutter operating lever moves. Fit the cutter operating lever over the pivot pin. Fit the ‘E’ clip to the pivot pin. G8 Stitch Head Maintenance Kit Instructions...

  • Page 71: Lubricate And Fit The Feed Gear Bracket Assembly

    Caution: Do not get grease on the wire feed roller and the friction surface of the large feed gear assembly. See FIGURE 4:13. Tools: • Allen keys: 2.5mm, 3mm • Klüber Isoflex NBU 15 grease G8 Stitch Head Maintenance Kit Instructions...
  • Page 72 Lubricate the large feed gear assem- bly. Fit the feed pinion assembly to the large feed gear. Fit the large feed gear assembly onto the feed pinion shaft. Lubricate the feed pinion. G8 Stitch Head Maintenance Kit Instructions...
  • Page 73 See FIGURE 4:14. • Make sure the feed gear bracket is in the correct position before you fit and tighten the fixing screws. G8 Stitch Head Maintenance Kit Instructions...

  • Page 74: Fit The Pivot Block And Lubricate And Fit The Wire-Holder

    FIGURE 4:16. Fit the pivot block. Lot 14 stitch heads and later. FIGURE 4:17. Wire holder. Lock washer not fitted. FIGURE 4:18. Wire holder. Lock washer fitted. Tools: • Allen key: 2.5mm • Screwdriver: flat-blade • Loctite 242 • Klüber Isoflex NBU 15 grease G8 Stitch Head Maintenance Kit Instructions...
  • Page 75 If the wire-holder is worn, replace wire-holder after you fit the stitch the wire-holder with one from the head to the PSQ. G8 Supplementary Stitch Head Section 4.16. Maintenance Kit. Go to the next step. G8 Stitch Head Maintenance Kit Instructions...
  • Page 76 • Remove and discard the stitch- wire hook. • Go to the next step, Step 6. Lubricate the dowel pin on which the wire-holder pivots. Fit the wire-holder to the pivot block. G8 Stitch Head Maintenance Kit Instructions...
  • Page 77 4 - Lubricate and Assemble the Stitch Head - Fit the Pivot Block and Lubricate and Fit the Wire-holder Step Action Information Apply grease to the contact patch for the wire-holder retaining-spring foot. Move the wire-holder retaining- spring into position. G8 Stitch Head Maintenance Kit Instructions...

  • Page 78: Fit The Cutter Box And The Middle Wire Tube

    Engage the pin on the under slide plate. side of the cutter box with the hole in the cutter box slide plate. Fit and tighten the cutter box fixing FIGURE 4:19. screws. Fit the middle wire tube. G8 Stitch Head Maintenance Kit Instructions...

  • Page 79: Fit The Upper Wire Tube And The Wire Guide Plate

    Hold the crank link screw in the other hand. FIGURE 4:30. • Push and pull the crank link screw to operate the mechanism. Remove excess grease from the top of the stitch head. Go to Section 4.12. G8 Stitch Head Maintenance Kit Instructions...
  • Page 80 Upper wire tube FIGURE 4:22. Depth setting for the upper wire tube (1) Large feed gear Small feed gear 2.5mm Allen key Upper wire tube FIGURE 4:23. Depth setting for the upper wire tube (2) G8 Stitch Head Maintenance Kit Instructions...
  • Page 81 Use a 2mm Allen key to set the FIGURE 4:24. clearance between the upper FIGURE 4:25. wire tube and the feed slide The upper wire tube must not touch the feed slide. G8 Stitch Head Maintenance Kit Instructions...
  • Page 82 Fit the Upper Wire Tube. Lot 16 and Later. FIGURE 4:26. Position of the e-clip on the upper wire tube Feed gear bracket Upper wire tube E-clip Bonnet assembly FIGURE 4:27. Fit the upper wire tube to the feed gear bracket G8 Stitch Head Maintenance Kit Instructions...
  • Page 83 Attach the upper wire tube to the stitch FIGURE 4:20. head. • Insert the upper wire tube in the feed gear bracket until the e-clip is against the bottom of the feed gear bracket. G8 Stitch Head Maintenance Kit Instructions...
  • Page 84 The upper wire tube must not touch the feed slide. Use a 3mm Allen key to tighten the FIGURE 4:20. grub screw to lock the upper wire tube in position. Remove the Allen keys. G8 Stitch Head Maintenance Kit Instructions...

  • Page 85: Fit The Stitch Head

    The wire-feed cam-shaft to the wire drive coupling. Fit the mounting block and the spacer. Fit and tighten the stitch head fix- ing nut. Check the side to side alignment Section 4.13. of the stitch head to clincher. G8 Stitch Head Maintenance Kit Instructions...

  • Page 86: Clincher To Stitch Head Alignment. Side-To-Side

    FIGURE 4:31. Clincher to stitch head side-to-side alignment 4.13.1 Remove the Wire-holder from the Stitch Head Wire-holder Wire-holder retaining-spring FIGURE 4:32. Stitch Head Wire-holder Step Action Information Move the wire-holder retaining- spring to the right. G8 Stitch Head Maintenance Kit Instructions...
  • Page 87 Access Level options. Put a piece of paper on top of the The stitch clutch will not operate optical sensor next to the stitch unless the sensor is covered. head. Touch TEST > STITCH WIRE OFF. G8 Stitch Head Maintenance Kit Instructions...
  • Page 88 Adjust the alignment as necessary. Section 4.13.3. Manually operate the stitch head to complete the cycle. Remove the piece of paper on the optical sensor and fit the wire-holder to the stitch head. G8 Stitch Head Maintenance Kit Instructions...

  • Page 89: Install The Stitch-Wire

    Lower and lock the clincher frame. Check the stitch head to clincher alignment and adjust as neces- sary. 4.14 Install the Stitch-wire See Chapter 4 of the PSQ Service manual or Chapter 6 of the PSQ User Man- ual. G8 Stitch Head Maintenance Kit Instructions...

  • Page 90: Adjust The Wire Straightener

    FIGURE 4:35. Stitch-wire cabinet Large feed gear Small feed gear Stitch head crank tool FIGURE 4:36. Manual operation of the wire feed Wire straightener eccentric Screw driver Lower wire tube FIGURE 4:37. Adjust the stitch-wire straightness G8 Stitch Head Maintenance Kit Instructions...
  • Page 91 Rotate the stitch head crank tool to the right Identify the direction of the Compare with Table 4:1. and do stitch-wire when the stitch-wire the recommended action. appears from the end of the lower wire tube. G8 Stitch Head Maintenance Kit Instructions...
  • Page 92 Check the wire straightness and adjust until correct. • Remove and store the stitch head crank tool. • Fit the wire holder. • Close the PSQ. • Make some test stitches. Table 4:1. Wire straightness G8 Stitch Head Maintenance Kit Instructions...

  • Page 93: Check The Position Of The Wire-Holder - Front-To-Back

    • Select the access level Service on the touch screen. • Touch MOTOR SLOW>WIRE FEED ON>MOTOR SLOW Lift the PSQ main deck. Also remove the piece of paper over the paper position optical sensor. G8 Stitch Head Maintenance Kit Instructions...
  • Page 94 Fit the wire-holder. 4.16.1 Adjust the Position of the Wire-holder Lock nut Grub screw Eccentric adjuster screw Wire-holder FIGURE 4:40. Wire-holder eccentric adjuster screw Tools: • Allen key: 3mm • Spanner: 7mm G8 Stitch Head Maintenance Kit Instructions...
  • Page 95 Repeat the check and adjustment Section 4.16. procedure until the wire-holder is in the correct position. Make sure there is no stitch-wire loaded in the wire-holder. G8 Stitch Head Maintenance Kit Instructions...

  • Page 96: Adjust The Wire Holder Central To The Bender Bar

    Adjust the Wire Holder Central to the Bender Bar Locating dowel 2 cap-head screws Pivot block Locating dowel FIGURE 4:41. The pivot block of the G8 stitch head Bender bar Wire holder (out) FIGURE 4:42. The wire holder in the outward position G8 Stitch Head Maintenance Kit Instructions...

  • Page 97: Make Test Stitches

    Excess grease on the stitch head will transfer to the books and mark the covers. • Make more test books and repeat the cleaning procedure if necessary. G8 Stitch Head Maintenance Kit Instructions...

  • Page 98: Reset The Stitch Counter

    • Select the ‘Service’ access level. The code is 1973. • Touch and hold 'Maintenance Reset'. A red line appears. The red line fills from left to right. • Hold 'Maintenance Reset' until the red line reaches the right-hand side. G8 Stitch Head Maintenance Kit Instructions...

  • Page 99: List Of Changes

    Section 4.10 - Fit the Cutter Box and the Middle Wire Tube • Amended Section 4.11 - Fit the Upper Wire Tube and the Wire Guide Plate • Amended Section 4.15 - Adjust the Wire Straightener G8 Stitch Head Maintenance Kit Instructions...
  • Page 100 5 - List of Changes - Appendix A: • New chapter. G8 Stitch Head Maintenance Kit Instructions...

  • Page 101: Lower Wire Tube Upgrade

    Lower Wire Tube Upgrade APPENDIX A Kit List 940-140 KIT, PSQ MOD 44, G8 LOWER WIRE TUBE • G20199B-1 lower wire tube base • G20199B-2 lower wire tube cover • DW1058 screw M4x6mm button head • G20208D wire straightener roller •...

  • Page 102: Remove The Old Lower Wire Tube Assembly, G20199A

    G20206B wire straightener eccentric Wire straightener roll stud Cutter wire shield Cap-head screw for the cutter wire shield 2 x grub-screws G20199A lower wire tube Cutter box FIGURE A:2. The G8 stitch head. Pre Lot 14. G8 Stitch Head Maintenance Kit Instructions...
  • Page 103 Remove and discard the FIGURE A:2. cutter wire shield. • Remove and discard the cap-head screw that holds the cutter wire shield to the cut- ter box. • Remove and discard the cutter wire shield. G8 Stitch Head Maintenance Kit Instructions...
  • Page 104 Remove and keep the 2 x M4 nuts from from the cutter box. the G20206 wire straightener eccentric. • Remove and keep the 4 x wire straight- ener disk springs. • Remove and discard the G20206 wire straightener eccentric. G8 Stitch Head Maintenance Kit Instructions...

  • Page 105: Fit The New G20199Baa Lower Wire Tube Assembly

    FIGURE A:4. The new G20199BAA lower wire tube G20213 wire straightener roll clip G20208D wire straightener roller Wire straightener roll stud G20199B-1 lower wire tube base FIGURE A:5. Fit the G20208D wire straightener roller G8 Stitch Head Maintenance Kit Instructions...
  • Page 106 FIGURE A:7. Alignment of the G20199BAA lower wire tube to the cutter box Step Action Information If the G20199BAA is supplied FIGURE A:4. assembled, then remove the DW1058 button-head screw to separate the two halves. G20199B-1 G20199B-2 G8 Stitch Head Maintenance Kit Instructions...
  • Page 107 Fit the G20208B wire straight- FIGURE A:6. ener roller to the G20206B wire • Fit a new G20213 wire straightener straightener eccentric. roll clip to hold the G20208B wire straightener roller to the G20206B wire straightener eccentric. G8 Stitch Head Maintenance Kit Instructions...
  • Page 108 Hold the assembled G20199BAA lower wire tube in position in the cutter box and tighten the 2 x grub screws to hold in posi- tion. G8 Stitch Head Maintenance Kit Instructions...
  • Page 109 Action Information Update the Modification List • Open the stitch-wire cabinet. Label. • Mark an ‘X’ over the number ‘44’ on the Modification List Label. • Close the stitch-wire cabinet. Return to Section 2.5. G8 Stitch Head Maintenance Kit Instructions...
  • Page 110 APPENDIX A - Lower Wire Tube Upgrade - Fit the New G20199BAA Lower Wire Tube Assembly G8 Stitch Head Maintenance Kit Instructions...
  • Page 112 Watkiss Automation Limited Blaydon Road Middlefield Industrial Estate Sandy, Bedfordshire SG19 1RZ United Kingdom Tel: +44 (0)1767 685700 Fax: +44 (0)1767 689900 Email: info@watkiss.com Web: www.watkiss.com...

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