DELUXE STITCHER C O M P A N Y I N C . Head Serial Number : Date Purchased : Where Installed: (make/model of machine) G8 Stitcher Head OPERATION AND MAINTENANCE MANUAL Wire Sizes: 23-28 Ga. Round and 21x25 Flat Crown Size: 1/2” (13.5 mm) Capacity: 2 sheets to 5/16” (8 mm) Standard and Loop Stitch 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.
WARNING! 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. 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 G8 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.
* These are just examples and should be used as reference only.
Specifications Weight Shipping Weight . . . . . . . . . . . . . 11 lbs (5 kg) Physical Dimensions Height . . . . . . . . . . . . . . . . . . 13-9/16” (34.5 cm) Width . . . . . . . . . . . . . . . . . . 2-3/4” (7 cm) Stitching Capacity . . . . . . . . . . . . . . . . . Two Sheets to 5/16” (8 mm) (stitching capacities are highly dependent on wire type, tensile strength and machine capacity) Wire Types . . . . . . . . . . . . . . . . . .
Dimensions 8
Installation Pre-Inspection 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 Representative from whom the G8 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.
G20362 G20286A G20279A G20361 G20360 G20367 or G20341 G20278AA G20366 G20374 G20364 G20124 G20228A 9002 9083A or 9083C G20181 9086A Figure 2 - Assembly Pre-Installation Please take a few moments to fill out the registration card located on page 52 prior to beginning installation. Always disconnect the power supply before making any adjustments or servicing the head.
Assembly Each new G8 Stitcher Head comes fully assembled with the exception of the Complete Wire Guide Spring Plate Assembly (G20278AA), the Wire Guide Spring (G20279 or G20286) and the Clincher Plate Assembly (9086A). Slip the Wire Guide Spring Bracket onto the Upper Wire Tube (G20181) 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.
G8HD24C (Bolt Mount/Crank Drive) This G8 Head comes with a Rear Mounting Bolt (G20341), a Rear Clamp Pin (G20366) and a Bonnet Stud Nut (HN1213) for mounting. The G8HD24C also comes with a Crank Drive Link (G20340) and Driving Slide Assembly (G20320A) for driving the Head. Refer to Figure 4. NOTE: Instructions may vary with other types of Bolt Mount / Crank Drive machines.
Operation Wire Threading (Figures 5 & 6) 1. Slide the Wire Holder Retaining Spring (G20183) over to the side and remove the Wire Holder Assembly (G20559BA or G20301A) from the Stitcher Head. 2. Pass the wire from the Spool over the Wire Guide Spring Assembly (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 (G20181). 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 G8 style heads, it is important that the wire leaves the Cutter Block Assembly (G20197A) in 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 G8 Stitcher Head ensuring its continuous operation, it is important that the wire leaves the Lower Wire Tube Assembly (G20199A) in 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 G8 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 (G20127) 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* (round or flat, thick or thin) must be exactly in line with the Driver* (depending on the wire gauge being used) both left-to-right and front-to-back. The following are instructions for both types of adjustment. Upper Screw G20229 Front-to-Back Manually activate the G8 until the Stitcher Head 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* (round or flat) should be flush, or slightly above flush, with the Clincher Plate* (round or flat) 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* (depending on the wire gauge being used) is at the lowest position of its stroke, the Clincher Points are at their highest position.
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. FLAT CLINCH SOLID CLINCH Adjusting the Bender Bar Stop Like other G8 Stitcher Head settings, the Bender Bar Stop is set at the factory. The Stop controls the position of the Bender Bar Latch (G20149) at the top Figure 13 - Solid Clincher Plate of the stitcher head’s stroke.
Maintenance Your G8 Stitcher Head has been fully lubricated at the factory, but to insure continuous superior operation and a longer life of the head, the operator should be sure that the G8 is lubricated regularly and carefully maintained. The operator should periodically inspect all moving parts for signs of wear and when required, replace the worn parts.
• the top of the Bonnet (G20000A) on either G20131 side of the Feed Slide (G20131). • the fittings on the Feed Lever Pivot Pin and the Small Feed Gear Pin (G20262A). • the Cutter Operating Lever Pivot Pin (G20231) and Roller Pin (G20232). G20000A • the Wire Straightening Rollers (G20208B) in the Cutter Block Assembly (G20197A). • on the Wire Holder Assembly under the G20262A Wire Holder Retaining Spring Foot (G20184).
Ordering Spare Parts 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. Always power down the stitcher machine before any maintenance or adjustments are made to the stitcher head.
poor stitch quality. To change or reverse the Moving Wire Cutter, first remove the complete Cutter Block Assembly (G20197A) from the stitcher head. Loosen and remove the two (2) Socket Flat Head Screws (G20216) on the front of the assembly and pull the Cutter Block away from the G8 Head. Be careful, the Cutter Operating Slide may spring out from the Cutter Block Assembly.
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 (G20183) off of the Wire Holder Assembly (G20559BA) and out of the way. Remove the two (2) Driver Retaining Screws (G20153) securing the Driver* to the Driver Bar (G20151) and slide the Driver out of the Bender Bar.
Housing and compress it against the Spring. Insert the Driver Bar from the bottom of the Assembly until the Latch drops into the profile slot in the Driver Bar. Assembly the Supporter to the Bender Bar with the Supporter Pivot Pin inserted from the left 9083B or side. Secure the Pivot Pin with the Set Screw, mak9083C (2) ing sure there is free movement between the Supporter and Bender Bar.
G20131 G20127 G20171 G20162A or G20320A G20124 G20000A G20136A G20164 G20132 G20268 G20189 (2) G20262A G20267 G20264 G20244 G20190 (2) 9002 G20202 G20183 G20199A HN1213 or G20170 G20144A G20216 (2) Bender Bar Asy G20197AA G20559BA Figure 21 - Disassembling the Head out from the bottom of the Bonnet at this time. Remove the Feed Lever Spring Bushing (G20267) and Feed Lever Spring (G20268) from the Feed Lever (G20132).
the Head. Always turn the machine over manually anytime repairs or adjustments are made for the safety of both the operator and the Stitcher Head. Re-assembling the Stitcher Head (Figure 21) 1. Slide the Feed Slide Assembly into the Bonnet from the top. Make sure the Slide moves freely within the Bonnet but has minimal side-to-side play.
Troubleshooting (Figure 22) The quality and quantity of work that can be produced with the G8 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 16) PROBLEM : Staple Legs Too Long or Too Short SOLUTION: Correct the overall wire draw by repositioning the Feed Slide within the G8 Head. (See Page 17) PROBLEM : Left Leg Missing SOLUTION: Straighten the wire. (See page 14) The Wire Holder Assembly is not aligned properly with the groove in the Bender Bar.
The G8 Stitcher Head 31
Bonnet Sub-Assembly G20264 Bolt-mount Heads G20170 G20368 G20274 G20367 G20118 G20273 (2) G20121 G20341 G20119 HN1213 G20167 (2) G20133A 9002 G20366 G20122A (2) Clamp-mount Heads G20269 G20251 G20275 G20182 G20245 G20196 (2) G20250 (2) G20264 G20246 G20244 G20191 (2) G20214 (2) G20126 G20289 (2) G20240 (2) G20249 (2) G20236 G20239 (2) G20220 Discs should be cupped G20229 (2) G20124 G20242 G20115 G20235 G20191 G20140 G20204 G20241 (4) G20237 G20190 (2) G20243 G20231 G20202
Bonnet Sub-Assembly ITEM No.
Feed Lever and Feed Gear Assemblies G20262A (2) G20268 G20132 G20263 (2) G20112 G20267 G20264 G20181 G20266 G20140 G20110A G20262A G20138 (2) G20129 G20189 (2) G20215 (2) G20111A G20128 G20195 G20142 G20273 G20187 G20114 G20186 G20180 G20241 G20261 G20190 (2) G20229 G20215 (2) G20214 (2) G20143 G20316 G20184 G20256 G20175 G20196 (2) G20141 G20183 35
Feed Lever and Feed Gear Assemblies ITEM No.
Driving and Feed Slide Assemblies G20264 G20173 G20179 G20131 G20340 G20177 G20176 (2) G20174 G20127 G20171 G20171 G20170 G20321 G20162 G20320 G20170 G20169 G20165 G20165 G20167 (2) G20167 (2) G20163A For rail-driven Heads G20323A G20164 For crank-driven Heads 37 G20164
Driving and Feed Slide Assemblies ITEM No. DESCRIPTION G20127 G20131 G20162 G20163A G20164 G20165 G20167 G20169 G20170 G20171 G20173 G20174 G20176 G20177 G20179 G20264 G20320 G20321 G20323A G20340 Feed Rack Feed Slide Driving Slide Cutter Operating Ramp Assembly Driving Slide Plunger Driving Slide Spring Screw, M4x.7x10 FHCS Driving Slide Plunger Screw Hex Jam Nut M8x1.25 Screw M8x1.25x12 Feed Rack Knob - Knurled Feed Rack Adjustment Stud Screw M4x.
Bender Bar and Wire Holder Assemblies G20161 G20160 G20159 G20342 G20224 G20149 G20150 G20344B G20148B G20154A G20346 G20156 G20431 (4) G20155 G20135 G20252 G20255 G20151 G20253 G20147BA (24-28 rd) G20347BA (21X25 flat) G20357BA (23 rd) G20265 G20152 (24-28 rd) G20352 (21X25 flat) G20358 (23 rd) G20254 G20226 G20273 G20559BA 39 G20153 (2)
Bender Bar and Wire Holder Assemblies ITEM No.
Cutter Block Assembly G20210 G20198 G20214 G20145 or G20145C G20197A G20200 or G20600C G20219 (4) G20223 G20226 (2) G20191 (2) G20217 G20196 G20206 G20211 G20212 G20199A G20213 (2) G20196 G20208B (2) 41
Cutter Block Assembly ITEM No. DESCRIPTION G20145 G20145C G20191 G20196 G20197A G20198 G20199A G20200 G20206 G20208B G20210 G20211 G20212 G20213 G20214 G20217 G20219 G20223 G20226 G20600C Moving Wire Cutter Moving Cutter - Carbide Screw, M4x.7x8 SHSS Screw M3x.
Wire Guide Bracket, Spring and Clincher Plate Assemblies G20286A G20279A G20278A G20288 (2) G20297 G20285 G20290 (2) G20283 G20284 G20288 G20234 (2) G20298 G20293 (2) G20292 G20287 43
Wire Guide Bracket, Spring and Clincher Plate Assemblies ITEM No. DESCRIPTION G20234 G20278A G20279A G20283 G20284 G20285 G20286A G20287 G20288 G20290 G20292 G20293 G20297 G20298 E-Ring- 3/16" Wire Guide Spring Plate Assembly Wire Guide Spring Assembly - Short Tension Pawl Tension Pawl Spring Tension Pawl Roller Wire Guide Spring Assembly - Long Wire Oiler Felt Spring Screw, M4x.
Loop Stitch Assemblies G20210 G20198 G20214 G20161 G20145 or G20145C G20219 (4) G20160 G20300A G20200 or G20600C G20226 (2) G20159 G20216 (2) G20191 (2) G20342 G20224 G20147BA G20212 G20149 G20206 G20199A G20211 G20150 G20196 G20344B G20213 (2) G20208B (2) G20154A G20196 G20313A G20431 (4) G20346 G20135 G20156 G20155 G20304A G20151 G20226 G20310 G20306 G20314 (24-25 rd) G20311 G20309A G20273 (2) G20312 G20305 G20301A G20265 G20255 45 G20153 (2)
Loop Stitch Assemblies ITEM No.
Part Number / Description Cross-Reference G20000A Bonnet Assembly - G8 1 G20150 Bender Bar Latch Spring 1 G20110A Large Feed Gear Assembly 1 G20151 Driver Bar 1 G20111A Feed Pinion Assembly 1 G20152 Driver, 24W 1 G20112 Small Feed Gear 1 G20153 Driver Retaining Screw 2 G20113 Supporter Guide Plate 2 G20154A Supporter Assembly 1 G20114 Feed Pinion Shaft 1 G20155 Supporter Pivot Pin 1 G20115 Latch Release Cam 1 G20156 Supporter Pivot Pin Screw 1 G20118 Feed Release
Part Number / Description Cross-Reference G20190 Screw M3x.5x10- FHMS- Slotted 4 G20236 Tube Pivot Screw 1 G20191 Screw, M4x.7x8 SHSS 5 G20237 Cutter Block Adjustment Stud 1 G20195 Set Screw M6x1x8 2 G20239 Disc Washer Spring 2 G20196 Screw M3x.5x6 SHCS 6 G20240 Cutter Block Adjustment Washer 2 G20197A Cutter Block Assembly 1 G20241 Screw M4x0.
Part Number / Description Cross-Reference G20283 Tension Pawl 1 G20346 Supporter Guide Pin 1 G20284 Tension Pawl Spring 1 G20347BA Bender Bar Assembly,21x25 1 G20285 Tension Pawl Roller 1 G20352 Driver, 21x25W 1 G20286A Wire Guide Spring Assembly - Long 1 G20357BA Bender Bar Assembly, 23W 1 G20287 Wire Oiler Felt Spring 1 G20358 Driver, 23W 1 G20288 Screw, M4x.7x8 SHCS 3 G20360 Hex Key Wrench 3.0mm 1 G20289 Screw M4x.7x16 2 G20361 Hex Key Wrench 2.
Optional Equipment In addition to the standard features offered with the G8 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. G8KC The G8 Crank Drive Kit is available to owners of all styles of rail-driven G8 Heads who need to convert, for whatever reason, their existing G8 head to a crank-driven model.
G8KS The G8 Stop Stitch Kit is another optional purchase for the G8 Stitcher Head owner. It is designed for use with the DeLuxe Stitcher G8 series Heads. The G8KS mounts on the Adjustment Rail of many Saddle Stitchers like, McCain. This kit stops the feeding of wire through the Stitcher Heads by pushing open the Feed Release Handles (thereby stopping the stitch) when it receives a signal from the calipers of the Stitcher.
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.
DBSG80401
