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G5 Stitcher Head
OPERATION AND MAINTENANCE MANUAL
Wire Size: 25 Ga. Round (0.52 mm)
Crown Sizes: 1/2" (12mm) and 13/64" (5 mm) Loop
Capacity: 2 sheets to 13/64" (5 mm)
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.
S
TITCHER
C O M P A N Y
(make/model of machine)
I N C .
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Summary of Contents for DeLuxe Stitcher G5
- Page 1 Capacity: 2 sheets to 13/64” (5 mm) 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...
- Page 3 This manual is produced by DeLuxe Stitcher Company Inc. for Deluxe G5 stitching heads as fitted to Watkiss Automatic Stitch-Fold units. Watkiss part number 960-681, Deluxe G5 Stitch Head Operator Manual, March 2003.
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Page 4: 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 5 Dimensions [30.3mm] [9.5mm] 24 5 [625.6mm] [95.6mm] 1 17 21 31 [39.0mm] [545.7mm] [27.9mm] 17 7 [434. 4mm] [5.0mm] DRIVE ADJUSTMENT 11 59 [302.8mm] [36.0mm] 64 [49.0mm] STROKE 4 [273.0mm] [180.5mm] 64 [98.0mm] 2 13 [7 1.4mm] 1 23 [43.6mm] MIN [48.4mm] MAX [18.0mm] 8 [34.9mm]...
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Page 6: Installation
Installation Contents • G5 Manual • Bag of tools; 2.0mm, 3.0mm and Double Open End Wrench (5.5mm and 7mm) • T-Handle Hex Head Wrench; 4mm • Clamp Block and Cap Screw (for mounting) • Wire Guide Spring and Wire Anti-Backup Unit •... - Page 7 Assembly (Figures 2 & 4) G50286WA G20241 (2) G50286WAA G50804 Align the Clincher G50800A Slide and Driver G50181 G50181 Do not Jam Tube into Feed Gears. Leave a distance Insert Tube while of 1/32” (.5mm) G20522 the Feed Gears before tightening are engaged the Set Screw Figure 2 - Assembly...
- Page 8 Mounting (Figure 3) Engage the Feed Gears to assist in mounting G50162A Position in rail on Stitcher Machine G50102 G50716 Turn to adjust G50394 (4) for position G50367 Figure 3 - Mounting the Head...
- Page 9 Wire Threading (Figures 4 & 5) G50286WA Pass wire between Oiler Felts Insert wire into G20293 Anti-Backup Unit G20293B G50804 Loosen to allow thread to pass G50800A G50245 Turn to disengage Small and Large Feed Gears G50181 Figure 4 - Threading the Head G50245 Turn to engage Small and Large...
- Page 10 Adjusting the Length of the Stitch Leg (Figure 6) Longer Right Leg G20573 Shorter Right Leg G50181 G50245 Disengage the Feed Gears when making adjustments G50245 G50197A Move wire center right Move wire center left Figure 6 - Adjusting the Stitch Leg WARNING Make sure all guards are in place before operating the stitcher head...
- Page 11 Aligning the Clincher Plate (Figure 7) Front View Side View Back View Align Driver with gap in Clincher Plate G20191 (2) Locks adjustment Screws in position 0030.0030 (2) G50710 (2) 9083A Adjust upper or lower Cap Screws to correct alignment Figure 7 -Clincher Plate Alignment WARNING Always disconnect the power supply before...
- Page 12 Lubrication (Figure 8) G20293 and G20293B One drop of oil on each G50131 One drop of oil on both sides Recommended Oil - SAE #10 - Household 3-in-1 G50262A One drop of oil in the oil cup Figure 8 -Lubrication...
- Page 13 Rotating Replacement Parts (Figures 9 & 10) G50206 Remove G20589 Loosen G50383 Loosen to rotate Cutter G50197A G50200 Remove Rotate to completely new surface from Head Figure 9 - Rotating the Cutters G50183 Swing out of the way G50152 Slide out from Bender Bar, Rotate and Replace...
- Page 14 Cleaning Routine cleaning is important for the maintenance of your G5 Head. Blow off dust, dirt and build-up with compressed air at least during Spool changes. The Head should be refurbished every one million stitches: • Large Feed Gear Assembly (G50110A): Remove and wash in a petroleum-based, oil-dissolving solvent, dry and repack the Feed Gear with any general Lithium-based light weight Grease.
- Page 15 : 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...
- Page 16 The G5 Stitcher Head...
- Page 18 Bonnet Sub-Assembly 1 G50100A G50245 G50713 G50264 (2) G50132A G50268 G50703 G50120 G50138 G50142 (2) G50714 G20223 (3) G50182 G50266 G50101 G20140 (2) 0031.5103 (2) G50235 G20515 G50262A G50232 0030.0030 (2) G50112 G20233 G50230A G20191 (2) G20579 (2) G50126 G50117...
- Page 19 Bonnet Sub-Assembly ITEM No. DESCRIPTION QUANTITY G20140 Follower Ball Bearing G20191 Screw M4x.7x8 G20515 Dowel Pin M6x14 G50100A Bonnet Assembly G50120 Feed Release Handle Bushing G50101 Clamp Block G50112 Small Feed Gear G50117 Forming Pin Cam G50223 Dowel Pin- M3 X 6 LG G50126 Screw M5x.8x25 G50132A...
- Page 20 Bonnet Sub-Assembly 2 G50111A G50110A G50181 or G50181W G50129 G20121 G50397 G20274 G50136 G50128B G50137 G50244 G50705 G50646 (2) 0031.5103 (2) G20522 G50711 G20236 0030.3434 (3) G20191 0031.5103 (6) 0030.3434 (2) G50187 G50142 G50114 G50186 G50144A G50256 0031.5103 G20298 G50143 G50383 (2) G20615 G50695...
- Page 21 Bonnet Sub-Assembly ITEM No. DESCRIPTION QUANTITY G20121 Feed Release Plunger G20191 Screw M4x.7x8 G20236 Tube Pivot Screw G20274 Hex Jam Nut, M6x1 G20298 Nylock Lock Nut, M6x1 G20522 Screw M6x1.0x5 G20615 Screw M5x0.8x8 G50110A Large Feed Gear Assembly G50110 Large Feed Gear G50137 Feed Gear Clutch G50111A...
- Page 22 Alternate Head Mounting G50394 (4) G50102 G20275 G50367 or G50367B G50716 G50366...
- Page 23 Alternate Head Mounting ITEM No. DESCRIPTION QUANTITY G20275 Ball Spring Plunger G50102 Mounting Block - Keyed G50366 Bonnet Clamp Pin G50367 Head Mounting Bolt, M8 G50367B Head Mounting Bolt, M10 G50394 Flat Washer M8 G50716 Mounting Block Handle...
- Page 24 Driver and Feed Slide Assemblies G20272 G20573 G50320A G20578 G50174 0031.5103 G50130 G20179 0031.5103 (2) G20196 (2) G50171 G50131 G20520 G50162A G50163 G50127 G20190 (2) G20170 G20165 G20169B G50164...
- Page 25 Driver and Feed Slide Assemblies ITEM No. DESCRIPTION QUANTITY G20165 Driving Slide Spring G20169B Driving Slide Plunger Screw Eccentric 1 G20170 Hex Jam Nut M8x1.25 G20179 Screw M3x.5x4 G20190 Screw M3x.5x10 G20196 Screw M3x.5x6 G20272 Screw M5x0.8x12 G20520 Ribbed Lock Washer M6 G20573 Feed Rack Adjustment Knob G20578...
- Page 26 Driver and Bender Bars G50161B G50147BAA G50160B G50159B G50148 G50383 (4) G50331BA G50153 (2) G50147BA G50151 G50152...
- Page 27 Driver and Bender Bars ITEM No. DESCRIPTION QUANTITY G50147BAA Bender Bar Assembly G50147BA Bender Bar G50148 Bender Bar Friction Plate G50383 Screw M3x.5x6 G50151 Driver Bar G50152 Driver - 25 Gauge Wire G50153 Driver Retaining Screw G50159 Friction Plug G50160B Bender Bar Friction Spring G50161B Friction Plug Bushing...
- Page 28 Wire Guide Bracket and Spring G50286A G50279A G50286WA G20293B G20297 G20293 G20292 G20241 (2) G20298 G20287 G50800A G50804...
- Page 29 Wire Guide Bracket, Spring and Clincher Plate ITEM No. DESCRIPTION QUANTITY G20241 Screw M4x0.7x6 G20287 Wire Oiler Felt Spring G20292 Wire Oil Felt Washer G20293 Wire Oiler Felt G20293B Wire Oiler Felt, Thin G20297 Screw M6x1.0x40 G20298 Nylock Lock Nut, M6x1 G50279A Wire Guide Spring Assembly - 90°...
- Page 30 Cutter Box Assembly...
- Page 31 Cutter Box Assembly ITEM No. DESCRIPTION QUANTITY G20579 Screw M4x0.7x6 G20589 Screw M4x0.7x10 G50145 Moving Cutter G50196 Screw M3x.5x6 G50197A Cutter Box Assembly G50223 Dowel Pin M3x6 G50198 Cutter Slide G50199 Lower Wire Tube G50200 Fixed Wire Cutter G50206 Wire Straightener G50210 Cutter Operating Spring G50383...
- Page 32 Wire Holder Assembly G50135 G50255 G50559A G20226 G50254 G50252 G50253 G50665...
- Page 33 Wire Holder Assembly ITEM No. DESCRIPTION QUANTITY G20226 Hex Nut M4x.7 G50135 Wire Holder Pivot Pin G50252 Wire Hook G50253 Wire Hook Spring G50254 Wire Holder Spring Screw G50255 Dowel Pin M3x10 G50559A Wire Holder Assembly G50665 Wire Holder Adjustment Screw...
- Page 34 Clincher Plate Assembly 9088 9083A 9086DA G50710 UA4808.7 9093A 9084B 9087...
- Page 35 Clincher Plate Assembly ITEM No. DESCRIPTION QUANTITY 9083A Clincher Point - Thick, Round 9084B Adjustable Clincher Slide 9086DA Clincher Plate - Thick 9087 Clincher Slide Adjustment Screw 9088 Clincher Plate Binder Bolt 9093A Clincher Slide - Thick G50710 Clincher Plate Nut UA4808.7 Screw 1/4-28 x 1/4...
- Page 36 Part Number / Description Cross-Reference 0030.0030 Screw M5x.8x8 G20292 Wire Oil Felt Washer 0030.3434 Screw M3x.5x10 G20293 Wire Oiler Felt 0031.5103 Lock Washer Ribbed G20293B Wire Oiler Felt, Thin 0031.5104 Lock Washer Ribbed, M4 G20296 Wire Guide Spring Guide Stud 9083A Clincher Pint - Thick, Round G20297...
- Page 37 Part Number / Description Cross-Reference G50132A Feed Lever Assembly G50196 Screw M3x.5x6 G50135 Wire Holder Pivot Pin G50197A Cutter Box Assembly G50136 Feed Gear Bracket G50198 Cutter Slide G50137 Feed Gear Clutch G50199 Lower Wire Tube G50138 Feed Pinion Bearing G50200 Fixed Wire Cutter G50138...
- Page 38 Part Number / Description Cross-Reference G50333 Bushing G50804 Thumb Screw M5 G50335 Spring, Internal UA4808.7 Screw 1/4-28x1/4 G50337 Spring Pin, M2.5 x 6 G50366 Bonnet Clamp Pin G50367 Head Mounting Bolt, M8 G50367B Head Mounting Bolt, M10 G50368 Feed Release Handle Cap G50383 Screw M3x.5x6 G50391...
- Page 39 Addendum (to Deluxe G5 Stitcher Head Manual, ref DBSG5W1103) Initial set-up of the G5 stitch head Before you begin 1. Align the stitch head and the clincher. This procedure is explained in your Watkiss Stitch-Fold Operating Man- ual. 2. Unplug and disconnect the Automatic Stitch-Fold from the mains electricity supply.
- Page 40 DBSG5W0103 Watkiss part number 960-681...
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