DELUXE STITCHER C O M P A N Y I N C . Head Serial Number : Date Purchased : Where Installed: (make/model of machine) G20 Stitcher Head OPERATION AND MAINTENANCE MANUAL Wire Sizes: 23-28 Ga. Round and 21x25 and 20x24 Flat Crown Sizes: 1/2” (13.5 mm) and 5/8” (15.9 mm) Capacity: 2 sheets to 3/4” (20 mm) Standard 2 sheets to 5/32” (4 mm) Loop Before using this Stitcher Head, all operators must study this manual and follow the safety warnings and instructions.
WARNING! G20 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. Do not modify the guards in any way. Always disconnect the power supply before removing any guards for servicing.
Table of Contents Introduction ........................................................................................................4 Part Number Definition ....................................................................................5 Specifications ....................................................................................................7 Installation ......................................................................................................9 Pre-Inspection ...............
Introduction Each Head in the G20 Stitcher Head Series is basically identical with respect to operation. The style variations in the Heads mentioned below, occur in some of the component parts used for adaptation to single stitch or gang stitch machines. As model design changes are made, part numbers also change. These Heads were designed with a side-feed element to eliminate the need for a Swivel and to increase their reliability.
Part Number Definition The part number for each Stitcher Head can be used to define the stitcher head itself, in most cases. The Head’s model type, mounting style, nominal wire size and crown size can all be determined from the part number.
Specifications Weight Shipping Weight . . . . . . . . . . . . . 22 lbs (10 kg) Physical Dimensions Height . . . . . . . . . . . . . . . . . . 17-1/2” (44.4 cm) Width . . . . . . . . . . . . . . . . . . 2-3/4” (7 cm) Stitching Capacity . . . . . . . . . . . . . . . . . Two Sheets to 3/4” (20 mm) . . . . . . . . . . . . . . . . . . Two Sheets to 5/32” (4 mm) Loop (stitching capacities are highly dependent on wire type, tensile strength and machine capacity) Wire Types . . . . . . . . . . . . . . . . .
Dimensions 4.583 [116.4mm] MAX. 4.395 [111.6mm] MIN. 2.756 [70.0mm] 30" [762mm] 28" [713mm] 26 3/16" [665mm] .624 [15.8mm] .787 ADJUSTMENT [20.0mm] .787 ADJUSTMENT [20.0mm] .624 [15.8mm] 2.625 [66.7mm] 16.601 [442mm] .875 [22.2mm] 11.313 [287.3mm] 7.939 [201.7mm] .787 ADJUSTMENT [20.0mm] 9.185 [233.3mm] 2.156 [54.8mm] 4.312 [109.5mm] .250 [6.4mm] 2.656 [67.5mm] 1.250 [31.8mm] .686 [17.4mm] .250 [6.4mm] .438 [11.1mm] 2.632 [66.9mm] .968 [26.4mm] CENTER OF STITCH .563 [14.3mm] 5.135 [130.
Installation Pre-Inspection Carefully inspect the condition of the shipping container before unpacking your G20 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 Representative from whom the G20 Stitcher Head was purchased. Inspection As you carefully unpack the head, check to make sure all components were delivered and are in good working order.
G20286A G20362 G20279A G20360 G20679A G20278AA G20361 G20341 (2) G20376 (2) G20374 G20524 or G20503 (2) G20501 or G20502 (2) G20364 7024B or 7257B (2) G20628A G20581 Figure 2 - Assembly 7253A or 7650A Pre-Installation Please take a few moments to fill out the registration card located on page 54 prior to beginning installation. Always disconnect the power supply before making any adjustments or servicing the head.
Assembly Each new G20 Stitcher Head comes fully assembled with the exception of the Complete Wire Guide Spring Plate Assembly (G20278AA), the Wire Guide Spring (G20679A, G20279A or G20286A) and the Clincher Plate Assembly. Slip the Wire Guide Spring Bracket onto the Upper Wire Tube (G20581) and rotate until the Bracket accommodates the wire payoff of the stitcher machine. Tighten the Socket Head Cap Screw (G20288) to hold the Wire Guide Spring Bracket Assembly in place.
Block (G20672) and Bender Slide (G20562) are in their respective slots on the stitcher machine. Rotate the 5mm Hex Key Wrench (G20362), in the Eccentric as shown, to secure the G20 Head to the stitcher machine. G20BHD (Bolt Mount/Rail Drive) This G20 Head comes with two (2) Rear Mounting Bolts (G20341), Rear Clamp Pins (G20376) and Bonnet Stud Nuts (HN1213) for mounting. Refer to Figure 4. G20592 NOTE: Instructions may vary with other types of Bolt Mount / Rail Drive machines.
Operation Wire Threading (Figures 5 & 6) 1. Slide the Wire Holder Retaining Spring (G20583) over to the side and remove the Wire Holder Assembly (G20559BA or G20659A) from the Stitcher Head. G20279A, G20286A or G20679A 2. Pass the wire from the Spool over the Wire Guide Spring Assembly (G20679A, G20279A or G20286A), between the Tension Pawl (G20283) and the Tension Pawl Roller (G20285), between the two (2) Wire Oiler Felts (G20293) and into the Upper Wire Tube (G20581). G20285 G20283 G20293 3.
Wire Straightening (Figure 7) In order to ensure the stitches are loaded, driven and clinched properly in addition to ensuring continuous operation of the G20 style heads, it is important that the wire leaves the Cutter Block Assembly (G20597BA) in a straight horizontal line. Wire straightness is the single biggest factor for ensuring good stitches and stitcher head reliability.
Adjusting the Lower Wire Tube (Figure 8) In order to ensure the proper feeding of wire through the G20 Stitcher Head ensuring its continuous operation, it is important that the wire leaves the Lower Wire Tube Assembly (G20599A) in a straight horizontal line and enters the Cutter Block Assembly without assistance. Wire straightness is the single biggest factor for ensuring good stitches and stitcher head reliability.
Adjusting the Length of the Stitch Leg (Figure 9) The following instructions illustrate how to calibrate the G20 Stitcher Head the first time it is used after mounting it to the stitcher machine. It also illustrates how to manually adjust the Cutter Block each time a different stitching capacity is required. Adjust the compression setting on the stitcher machine for the capacity of work to be stitched. Make a few sample stitches and turn the stock away from you to look at the results.
Adjusting the Wire Draw The overall length of the stitch is controlled by the amount of wire that is drawn from the spool after each stroke of the stitcher machine. To change the overall length of the stitch, the position of the Feed Rack (G20527) has to be changed within the Stitcher Head. (Figure 10).
Aligning the Clincher Plate (Figure 11) In order to produce properly clinched staples, the center of the Clincher Plate (standard or Solid) must be exactly in line with the Driver* both left-to-right and front-to-back. The following are instructions for both types of adjustment. Front-to-Back Manually activate the G20 until the Stitcher Head G20229 (2) is at the bottom of its stroke and the Driver is touching the top of the Clincher Plate.
Adjusting the Clincher Points The final position of the Clincher Points (7024B or 7257B) should be flush, or slightly above flush, with the Clincher Plate (7253A or 7650A) in order to achieve a quality stitch. The best way to see the position of the Clincher Points is to manually turn the stitcher machine over. When the Driver* is at the lowest position of its stroke, the Clincher Points are at their highest position. Turn the stitcher machine just past this point to reveal the Clincher Points’ position.
Clincher Points in moveable Clincher Plates, coming up to meet the wire. The resulting stitch will not lay as flat as one clinched with moving Clincher Points. The only adjustment that can be made to a Solid Clincher Plate is to make sure it is centered below the Head’s Driver and even that adjustment can only be made on multi-head stitcher machines.
• the top of the Bonnet (G20500A) on either side of the Feed Slide (G20531). G20519 G20531 • in the oil hole in the Feed Release Cam (G20519). • the fittings on the two (2) Feed Lever Pin G20500A Assemblies (G20262BA and G20262A). • the Cutter Operating Lever Pivot Pin (G20631) and Cutter Lever Bearing Pin (G20571). • the Wire Rollers (G20608) in the Cutter G20262A & G20262BA G20184 Block Assembly (G20597BA).
Ordering Spare Parts In time, you will need to replace some parts in your G20 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. Always power down the stitcher machine before any maintenance or adjustments are made to the stitcher head.
complete Cutter Block Assembly (G20597BA) from the stitcher head. Loosen and remove the two (2) Socket Flat Head Screws (G20616) on the front of the assembly and pull the Cutter Block away from the G20 Head. Be careful, the Cutter Operating Slide may spring out from the Cutter Block Assembly. Loosen the Flat Head Machine Screw (G20214) securing the Cutter to the Slide and rotate the Cutter until a new cutting surface is exposed.
Removing and Replacing the Driver (Figure 18) If the staples produced have crowns that are buckled or corners that stick up, or if wire is jamming between the Driver and Driver Bar, the Driver may have to be reversed or replaced. Swing the Wire Holder Retaining Spring (G20583) off of the Wire Holder Assembly (G20559BA) and out of the way. Remove the two (2) Socket Head Cap Screws (G20175) securing the Driver* to the Driver Bar (G20551) and slide the Driver out from between the two (2) Bender Inserts.
Removing and Replacing the Clincher Points (Figure 20) The Clincher Point (7024B or 7257B), when worn, may cause poorly formed staple legs. Loosen, but do not remove, the two (2) Round Head Machine Screws (UA3310.3) until the Clincher Slide (18182) can be disengaged from the stitcher machine and slid out of the Clincher Plate Assembly (7253A or 7650A) or down within it. Rotate the Clincher Points upwards until they could be pulled out. Replace the Points when they are worn or chipped.
G20531 G20537 HN1213 (2) G20536 G20596 (2) G20267 G20583 G20668 G20544A G20501 or G20502 G20589 G20524 (2) G20597BA G20547 G20616 (2) G20543 or G20643 G20589 and G20596 G20559BA Figure 21 - Disassembling the Head Any of the other G20 Head assemblies can now be taken apart for cleaning or repair. The Bonnet itself can also be cleaned or checked for damage. Most common wear parts can be exchanged while the Head is still assembled though.
Re-assembling the Stitcher Head (Figure 21) 1. Compress the Supporter Plunger (G20742) with the Bender Slide Plunger (G20564) until the Bender Slide Pin (G20569) can be hooked in the back of the Bender Bar. Slide these two assemblies into the G20 Bonnet, from the top. 2. Hook the Driver Bar (G20551) on the Feed Slide (G20531) and slide both assemblies in from the top of the Bonnet. Make sure the Driver slides freely between the two (2) Bender Inserts on the Bender Bar.
Troubleshooting (Figure 22) The quality and quantity of work that can be produced with the G20 Stitcher 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.
PROBLEM : Left Leg Too Long / Right Leg Too Short SOLUTION: Adjust the position of the Cutter Block Assembly by moving it away toward the Head. (See page 15) PROBLEM : Staple Legs Too Long or Too Short SOLUTION: Correct the overall wire draw by repositioning the Feed Slide within the G20 Head. (See Page 16) PROBLEM : Left Leg Missing SOLUTION: Straighten the wire. (See page 13) The Wire Holder Assembly is not aligned properly with the groove in the Bender Bar.
The G20 Stitcher Head 29
Bonnet Sub-Assembly G20273 (2) G20503 G20275 G20522 (2) G20502 (2) G20229 (2) G20523 (2) HN1213 (2) G20341 (2) G20522 G20524 (2) G20273 (2) G20681 G20501 (2) G20588 (4) G20229 (2) G20312 G20229 G20619 (2) G20589 (2) G20376 (2) G20524 G20589 (2) G20513 (2) 31
Bonnet Sub-Assembly PART No.
Bonnet Sub-Assembly G20768 G20263 (2) G20526 G20521 G20275 G20592 G20519 G20533 G20264 G20555 (2) G20646 G20596 (2) G20567 G20500 G20596 G20272 (2) G20645 G20582 G20589 (2) G20520 G20244 G20544A G20236 G20571 (2) G20697 G20515 G20640 G20642 G20263 G20167 (2) G20575 (2) G20604 G20247 G20647 (2) G20639 G20605 G20641 G20603 G20634 33 G20631
Bonnet Sub-Assembly PART No.
Feed Lever and Feed Gear Assemblies G20581 G20267 G20539 G20568 G20534B G20668 G20567 G20533 G20KFL2 G20697 G20264 G20262BA G20666 G20264 G20555 (2) G20580 G20263 (2) G20540 G20262A G20511 G20596 G20272 (2) G20512A G20536 G20298 G20584 G20528 G20537 G20596 (2) G20617 (2) G20510 G20529 G20695 G20583 G20617 G20587 G20586 G20589 G20694 G20661 G20691 G20175 G20184 35
Feed Lever and Feed Gear Assemblies PART No. DESCRIPTION G20KFL2 G20175 G20184 G20262A G20262BA G20263 G20264 G20267 G20272 G20298 G20510 G20511 G20512A G20528 G20529 G20533 G20534B G20536 G20537 G20539 G20540 G20555 G20567 G20568 G20580 G20581 G20583 G20584 G20586 G20587 G20589 G20596 G20617 G20661 G20666 G20668 G20691 G20694 G20695 G20697 Kit - Feed Lever Screw M4x0.7x6, Nylon Wire Holder Retaining Spring Foot Feed Lever Pin Assembly Feed Lever Pin Asy ( With V-Groove ) Feed Lever E-Ring Screw M5x0.
Driving and Feed Slide Assemblies G20646 G20592 G20615 G20520 G20531 G20173 or G20573 G20530 G20645 G20576 G20626 (2) G20697 G20639 (2) G20179 G20345 (2) G20177 or G20578 G20672 G20190 (2) G20551 G20638 G20562 G20563 G20579 (2) G20552 G20556 G20558 G20652 G20656 G20658 15025 G20625 G20527 G20175 (2) G20569 G20564 37
Driving and Feed Slide Assemblies PART No. DESCRIPTION G20173 G20175 G20177 G20179 G20190 G20345 G20520 G20527 G20530 G20531 G20551 G20552 G20556 G20558 G20562 G20563 G20564 G20569 G20573 G20576 G20578 G20579 G20592 G20615 G20625 G20626 G20638 G20639 G20645 G20646 G20652 G20656 G20658 G20672 G20697 15025 Feed Rack Knob - Knurled Screw M4x0.7x6, Nylon Feed Rack Adj Knob Pointer Screw M3x0.5x4 Screw M3x0.
Bender Bar and Wire Holder Assemblies G20543 or G20643 G20596 G20579 G20589 G20614 (2) G20559BA G20253 G20226 G20541 G20542B G20252 G20273 G20255 G20742 G20254 G20665 G20744 or G20744B G20555 G20554A or G20654A G20829 G20557 G20548 G20549 G20550 G20648 G20649 G20650 (2) (2) (2) (2) (2) (2) G20547 G20589 (4) or G20618 (4) 39
Bender Bar and Wire Holder Assemblies PART No. DESCRIPTION G20226 G20252 G20253 G20254 G20255 G20273 G20541 G20542B G20543 G20547 G20548 G20549 G20554A G20555 G20557 G20559BA G20579 G20589 G20596 G20614 G20618 G20643 G20648 G20649 G20650 G20654A G20665 G20742 G20744 G20744B G20829 Hex Nut M4x.7 Wire Hook Wire Hook Spring Wire Hook Spring Screw, Nylon Hook Pivot Pin Screw M4x.
Cutter Block Assembly G20607A G20598 G20606A G20210 G20611 G20621 G20145 or G20145C G20599A G20613 G20214 G20597BA G20219 (5) G20589 G20602 G20623 (2) G20624 G20588 G20591 (2) G20622 G20616 (2) G20600 or G20600C G20217 G20612 (2) G20615 (3) G20608 (2) 41
Cutter Block Assembly PART No. DESCRIPTION G20145 G20145C G20210 G20214 G20217 G20219 G20588 G20589 G20591 G20597BA G20598 G20599A G20600 G20600C G20602 G20606A G20607A G20608 G20611 G20612 G20613 G20615 G20616 G20621 G20622 G20623 G20624 Moving Wire Cutter Moving Cutter - Carbide Cutter Operating Spring Screw M4x0.7x8 Spirol Pin M5x12 Wire Straightener Disc Spring Dowel Pin M4x12 Screw M4x0.7x10 Screw M3x0.
Wire Guide Bracket, Spring and Clincher Plate Assemblies G20679A G20279A G20286A G20288 (2) G20278A G20283 7024B or 7257B (2) G20297 G20234 (2) G20290 (2) G20285 18179 7256B 7650A or 7253A G20293 (2) 18183 G20298 UA3310.3 or 9081 (2) G20284 G20292 UA3216.4 (2) G20287 18184 18182 18186 UA1428.
Wire Guide Bracket, Spring and Clincher Plate Assemblies PART No. DESCRIPTION G20234 G20278A G20278AA G20279A G20283 G20284 G20285 G20286A G20287 G20288 G20290 G20292 G20293 G20297 G20298 G20679A UA1428.1 UA3216.4 UA3310.
Loop Stitch Assemblies G20304A G20301A G20145 G20598 G20135 G20191 G20214 G20226 G20306 G20311 G20210 G20615 (3) G20665 G20310 G20600 G20700A G20273 G20309A G20307 G20312 G20305 G20599A G20616 (2) G20742 G20612 (2) G20551 G20714 G20638 G20753 G20744 or G20744B G20190 (2) G20527B G20555 G20829 G20589 (4) G20618 (4) G20557 G20713A G20547 G20639 (2) 45 G20548 (2) G20549 (2) G20550 (2) G20648 (2) G20649 (2) G20650 (2)
Loop Stitch Assemblies PART No. DESCRIPTION G20135 G20145 G20190 G20191 G20210 G20214 G20226 G20273 G20301A G20304A G20305 G20306 G20307 G20309A G20310 G20311 G20312 G20527B G20527BA G20547 G20548 G20549 G20550 G20551 G20555 G20557 G20589 G20598 G20599A G20600 G20612 G20615 G20616 G20618 G20638 G20639 G20648 G20649 G20650 G20665 G20700A G20713A G20714 G20742 G20744 G20744B G20753 G20829 Dowel Pin M5x24 Moving Wire Cutter Screw M3x.5x10 Screw M4x.7x8 Cutter Operating Spring Screw, M4x0.
Part Number / Description Cross-Reference G20110A Large Feed Gear Assembly 1 G20169 Driving Slide Plunger Screw 1 G20111A Feed Pinion Assembly 1 G20170 Hex Jam Nut M8x1.25 1 G20112 Small Feed Gear 1 G20171 Screw M8x1.25x12 1 G20113 Supporter Guide Plate 2 G20173 Feed Rack Knob - Knurled 1 G20114 Feed Pinion Shaft 1 G20174 Feed Rack Adjustment Stud 1 G20115 Latch Release Cam 1 G20175 Screw M4x.7x6 SHCS 3 G20118 Feed Release Handle Cam 1 G20176 Screw M4x.
Part Number / Description Cross-Reference G20230A Cutter Operating Lever Assembly 1 G20283 Tension Pawl 1 G20231 Cutter Operating Lever Pivot Pin 1 G20284 Tension Pawl Spring 1 G20232 Cutter Operating Lever Roll Pin 1 G20285 Tension Pawl Roller 1 G20233 Cutter Operating Lever Roller 1 G20286A Wire Guide Spring Assembly - Long 1 G20234 E-Ring- 3/16" 1 G20287 Wire Oiler Felt Spring 1 G20235 Follower Bearing Shaft 1 G20288 Screw, M4x.
Part Number / Description Cross-Reference G20374 Hex Key Wrench 2.0mm 1 G20599A Lower Wire Tube Assembly 1 G20376 Rear Clamp Pin 2 G20600 Fixed Wire Cutter 1 G20431 Screw, M2.5x.
Part Number / Description Cross-Reference G20700AA Cutter Block Asy Complete - Loop 1 G20713A Supporter Assembly - Loop 1 G20714 Driver - Loop 1 G20742 Supporter Plunger 1 G20744 Supporter Spring 1 G20744B Supporter Spring - Light 1 G20742 Supporter Plunger 1 G20744 Supporter Spring 1 G20744B Supporter Spring - Light 1 G20753 Driver Retaining Screw 1 G20780 Bender Insert 1/2 - 19x21-1/2 Wire 2 G20781 Driver 1/2 - 19x21-1/2 Wire 1 G20806A Saddle Paper Guide, Right 1 G2
Optional Equipment In addition to the standard features offered with the G20 Stitcher Head, optional equipment items can be purchased to better accommodate your stitching needs. The following kits can be purchased from your Graphic Arts Representative. G20FLC (Figure 23) The G20 Feed Lever Conversion Kit converts the Transport/Feed Lever Assembly on your existing Hohner 70/20 Heads to the DeLuxe Stitcher Feed Lever Assembly.
G20K1921 (Figure 25) G20780 (2) The G20 19x21 Conversion Kit allows existing G20 Stitcher Heads to accommodate 19x21 gauge flat wire. 19x21 gauge flat wire allows your M19G20, M27G20 and other collating systems to consistently stitch at a higher capacity through thicker stock. The parts included in this Kit have to only replace their counterparts on the existing head. Complete instructions are included with each Conversion Kit.
G20KL (Figure 27) The standard G20 Head can be converted into a 24 or 25 gauge wire loop stitching head by exchanging four complete sub-assemblies and adding a new Driver and Right Wire Guide Bar included in the G20 Loop Stitch Kit. For further instructions and parts diagrams on Loop Stitching, refer to page 46 in this manual. G20547 G20700AA G20542B G20527BA G20301A G20714 Figure 27 - Loop Stitch Kit G20KSH & G20KSH230 The G20KSH Stop Stitch Kit is designed for use with the G20 Series Stitching Heads.
LIMITED WARRANTY DeLuxe Stitcher Company warrants to the original retail purchaser that this product is free from defects in material and workmanship and agrees to repair or replace, at DeLuxe Stitcher’s option, any defective product within 90 days from the date of purchase. This warranty is not transferable. It covers damage resulting only from defects in material or workmanship and does not cover conditions or malfunctions resulting from normal wear, neglect, abuse or accident.
DBSG201103
