D

E

L

UXE

S

TITCHER

C O M P A N Y I N C .

Head Serial Number :

Date Purchased :

Where Installed:

(make/model of machine)

G5 Stitcher Head

OPERATION AND MAINTENANCE MANUAL

Wire Sizes: 25-28 Ga. Round

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.

W A R N I N G !

G5 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.

Never operate the machine with wire feeding through the head unless there is stock above the clinchers, otherwise serious damage may result.

Always turn power off when making adjustments. Always disconnect the power cord before any disassembly work.

2

Table of Contents

Introduction ........................................................................................................4

Specifications ....................................................................................................5

Installation ......................................................................................................7

Pre-Inspection ................................................................................7

Inspection ......................................................................................7

Mounting ........................................................................................9

Operation ......................................................................................................10

Wire Threading ............................................................................10

Wire Straightening ........................................................................11

Adjustments and Settings ............................................................12

Maintenance ......................................................................................................17

Lubrication ....................................................................................17

Cleaning ........................................................................................18

How to Order Spare Parts..............................................................19

Replacing Spare Parts ..................................................................19

Troubleshooting ................................................................................................25

Formed Staple Chart......................................................................25

Appendices ......................................................................................................27

Exploded Drawings......................................................................27

Part Number/Description Cross Reference ..............................47

Registration Card ............................................................................................50

Wear/Replacement Parts ..............................................................................51

Warranty ......................................................................................................52

3

Introduction

The DeLuxe Stitcher G5 Stitcher Head is the latest addition to the Company’s side-feed stitcher head product line. This head along with a complete line of replacement parts are now available for current users of the DeLuxe 26/26D Heads.

The G5 Head can also be used anywhere Hohner 48/5, 52/8 and 43/6, 55/7, Acme,

Champion, Interlake, Magnatek, ISP and M2000 Stitcher Heads are used.

The G5HD251/2 has a stitching capacity from 2 sheets up to 5mm (13/64”) and will accommodate wire sizes from 25-28 gauge round. The minimum center to center distance between heads is only 1-1/2” (39mm) at a 3/64” (1.0mm) capacity setting. This specification lends itself well to unique jobs requiring little space between stitches, such as CD and coupon booklets and all types of “two-up” work.

The G5 has a minimum distance of 3-7/16” (86mm) from its mounting surface to the face of the Head and so is ideal for low-profile collators. The smaller dimensioning of this Head make it perfect for special bindery applications. Watkiss

Collators, which up until now, have not been able to use Side-Feed Heads, can accommodate the new G5.

Each of these heads weighs 5.4 lbs (2.5 kgs.) independently. The packaged shipping weight including the Wire Guide Spring, Clincher Plate assembly, tools for maintenance and the user manual is 7.4 lbs. (3.4 kgs.).

Always use a high quality Galvanized Wire so the plating does not peel during operation. Excessive peeling will cause clogging and the premature wear of many components.

4

Specifications

Weight

Shipping Weight . . . . . . . . . . . . . 7.4 lbs (3.4 kg)

Physical Dimensions

Height . . . . . . . . . . . . . . . . . . 10-3/4” (26.3 cm)

Width . . . . . . . . . . . . . . . . . . 2” (5.1 cm)

Stitching Capacity

. . . . . . . . . . . . . . . . . Two Sheets to 5mm (13/64”)

Wire Types

. . . . . . . . . . . . . . . . . . 25 through 28 round

Crown Sizes

. . . . . . . . . . . . . . . . . . 1/2” (12mm), 13/64” (5mm) Loop

Minimum Head Center

. . . . . . . . . . . . . . . . . 1-1/2” (39mm)

Stitches Per Hour

. . . . . . . . . . . . . . . . . . 10,000

Replacement for:

. . . . . . . . . . . . . . . . . . DeLuxe Stitcher 26/26D heads as well as Hohner 43/6, 48/5, 52/8 and 55/7 heads and Acme, Champion, Interlake, ISP and

Magnatek heads

5

Dimensions

6

Installation

Pre-Inspection

Carefully inspect the condition of the shipping container before unpacking your G5 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 G5 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. Refer to Figure 1 in this manual for reference to the following pieces:

• G5 Manual

• Bag of tools; 2.0mm, 3.0mm, Double Open End Wrench (5.5mm and 7mm) and a

Clincher Alignment Tool

• T-Handle Hex Head Wrench; 4mm

• Clamp Block and Cap Screw (for mounting)

• Wire Guide Spring and Spring Bracket Assemblies

• Clincher Plate, Points, Slide, Nuts and Studs

• Stitch Samples

G20279A

A9086A

G20278AA

G50707

(5.5 and 7 mm)

G20360

(3 mm)

G20374

(2 mm)

G50708

(4 mm)

G50666

(alignment)

Figure 1 - Inspection

7

G20279

G50181

Align the Clincher

Slide and Driver

G20278AA

(assembly)

G50708

G50101

G20278A

Figure 2 - Assembly

Pre-Installation

Please take a few moments to fill out the registration card located on page 50 prior to beginning installation.

Always disconnect the power supply before making any adjustments or servicing the head.

r

WARNING

8

Assembly (Figure 2)

Each new G5 Stitcher Head comes assembled with the exception of the Complete Wire Guide Spring

Plate Assembly (G20278AA), the Upper Wire Tube (G50181), the Wire Guide Spring Assembly

(G20279A) and the Clincher Plate Assembly. Install the Upper Wire Tube (G50181) in the Bonnet while the Wire Feed is on and secure the Tube with a Set Screw (G20522). Be careful not to jam the

Tube into the Feed Gears, instead back the Tube out 1/32” (.5mm) before tightening the set screw. Slip the Wire Guide Spring Bracket onto the Wire Tube and rotate it until the wire is feeding into the Head in the most direct line possible. Tighten the Socket Head Cap Screw (G20288) to hold the Wire Guide

Spring Bracket Assembly in place.

Attach the Clincher Plate Assembly to the clincher mounting rail of the stitcher machine using the

Clincher Plate Nuts (G50710) and two (2) Clincher Plate Binder Bolts (9088) provided. Center the

Clincher Slide (9093A) under the Driver Bar (G50151) and the Driver (G50152) of the G5. Tighten the Nuts once the correct position has been established. See Figure 2.

Mounting (Figure 3)

The quality and quantity of work that can be produced by the DeLuxe Stitcher Heads is dependent upon the operator making the various operating adjustments as accurately as possible. The following illustrated instructions are provided so that the operator will clearly understand how to make the various required operating adjustments.

*Note: The 4mm T-Handle Wrench will be required for mounting and removing the

Stitcher Head

The G5 Head Models come with a Clamp

Block (G50101) and a long Socket Head Cap

Screw (G50126) for use on stitchers with a

T-Slot mounting rail. Refer to Figures 2 & 3.

Loosen the Cap Screw until the Clamp Block can be removed from the Head. Slide the

Clamp Block into the T-slot on the stitcher, as shown. Next, mount the Head onto the Clamp

Block and against the stitcher machine.

Visually, make sure the Head is as vertical as possible. Begin to tighten the Cap Screw

(G50126) even before lining up the Driving

Slide with the rail on the Stitcher Machine.

Next, make sure the Driving Slide (G50162A) is positioned in its slot on the stitcher machine.

Use a 4mm T-Handle Wrench, in the Cap Screw, to secure the G5 Head to the stitcher machine.

G50162A

G50101 G50708

G50126

Figure 3 - Mounting the Head

9

Operation

Wire Threading (Figures 4 & 5)

1. Pass the wire from the Spool over the Wire

Guide Spring Assembly (G20279A), 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

(G50181).

2. Make sure the Feed Release Handle (G50119A) is turned horizontally so that the Small Feed Gear

(G50112) on the Feed Lever Assembly (G50132A) is disengaged from the Large Feed Gear Assembly

(G50110A). Use a pair of pliers to gently pull the wire off the Wire Spool and guide it through the

Upper Wire Tube, between the Small and Large

Feed Gears, into the Middle Wire Tube Assembly

(G50144A). Turn the Feed Release Handle counter-clockwise so that the Small and Large Feed

Gears are engaged.

3. Turn the stitcher machine on and trip it until the wire emerges from the Fixed Wire Cutter (G50200) in the Cutter Box Assembly (G50197A).

G20293 (2)

G20279A

G20285

G50181

G20283

G20293 (2)

Figure 4 - Threading the Head

G50119A Note: Never operate the Stitcher Head with the

Wire Holder Assembly (G50559A) in place unless there is stock above the Clincher Points.

G50132A

G50112

G50144A

G50110A

Figure 5 - Threading the Head

10

Wire Straightening (Figure 6)

In order to ensure the stitches are loaded, driven and clinched properly in addition to ensuring continuous operation of the G5 style heads, it is important that the wire exits the Wire Holder

Assembly (G50559A) in a reasonably straight vertical line. Wire straightness is preset at the

Factory and generally does not have to be changed. If it does, the Wire Straightener (G50206) may not be set properly. Use the following steps for making the adjustments necessary to achieve relative wire straightness.

G50183

Horizontal Adjustment

G50245

G50196

Slide the Wire Holder Retaining Spring

(G50183) over to the side and remove the

Wire Holder Assembly (G50559A) from the Stitcher Head. Make sure the Small and Large Feed Gears are engaged by turning the Cutter Box Adjustment Knob

G20579

G50197A

G50206

GOOD

G50200

(G50245) to a vertical position. Activate the stitcher and observe the wire exiting from the Fixed Wire Cutter (G50200) in

G50431 the Cutter Box Assembly (G50197A). If the wire curves upward severely, loosen the Hex Head Cap Screw (G50196) which Figure 6 - Straightening the Wire secures the Wire Straightener (G50206) and move the Straightener down. Be sure to tighten the Screw again and continue to watch the wire exiting the Wire Cutter.

Note: Moving the Straightener too low may cause a kink to appear in the wire that will cause poor stitch quality.

If the wire curves downward, loosen the Cap Screw and move the Straightener up. Tighten the

Cap Screw again and resume feeding wire through the Head. Adjust the Wire Straightener until the wire exits the Fixed Wire Cutter with a slight upward curve. Replace the Wire Holder and re-engage the Wire Holder Retaining Spring. Test the wire’s straightness by activating the stitcher and loading a piece of wire into the Wire Holder.

Side-to-Side Adjustment

If the wire fails to feed past the Bender Bar or Wire Straightener, a slight side-to-side adjustment can be made. First loosen the Flat Head Machine Screw (G20579) securing the Lower Wire Tube

(G50199) to the Cutter Box. Then turn the Socket Head Set Screw (G50431) counter-clockwise to move the Wire Tube toward the front of the Head or clockwise to move the Tube toward the back of the Head.

11

Adjusting the Length of the Stitch Leg (Figure 7)

The following instructions illustrate how to calibrate the G5 Stitcher Head the first time it is used after mounting it to the stitcher machine. It also illustrates how to adjust the Cutter Box when a different stitching capacity is required.

Adjust the compression setting on the stitcher machine for the capacity of work to be stitched if applicable. Make a few sample stitches and turn the stock away from you to look at the results.

LONGER

LEG

Q

SHORTER

LEG

G20573

G50119

The length of each staple leg should equal the other, meaning, the amount of wire on either side of the stitch gap should be the same. The gap position is controlled by the position of the Cutter Box

Assembly (G50197A). As thicker work is stitched, the Cutter Box must be moved further from the Wire

Holder Assembly in order to keep the legs of the stitch even and the gap centered.

MOVE GAP

LEFT

Q

MOVE GAP

RIGHT

G50246

G50197A

Machines With Compression Adjustment Figure 7 - Adjusting the Stitch Leg

First, make sure the wire feeding is off by turing the Feed Release Handle (G50119A) clockwise so that the Small Feed Gear (G50112A) on the Feed

Lever (G50132A) is disengaged from the Large Feed Gear Assembly (G50110A). Refer to Figure 8.

To shorten the length of the left staple leg, lengthen the length of the right staple leg or move the gap between the legs to the left, adjust the compression of the machine to match the work being bound and turn the Cutter Box Adjustment Knob (G50245) clockwise. Return the Feed Release Handle to its original position and run a couple of stitches to test this setting.

Once the gap is centered, make sure that it is the desired width. As the thickness of work being stitched increases, the length of wire required must also increase. The longer the length of wire required, the further up the Feed Rack has to be in comparison to the Feed Slide. The overall length of wire is correct when the gap between the staple legs allows only the edge of a fingernail to pass between them. If the gap is too large, increase the wire draw by turning the Feed Rack Adjustment

Knob (G20573) clockwise. Alternatively, if the gap is too small, decrease the wire draw by turning the Feed Rack Adjustment Knob counter-clockwise.

To lengthen the length of the left staple leg, shorten the length of the right staple leg or move the gap between the legs to the right on these same machines: turn the Cutter Box Adjustment Handle counter-clockwise. If both legs are equal in length or if the gap between the legs is centered, no more adjustment is necessary. At thicker compression settings, fine adjustment of the Feed Rack

Adjustment Knob may be necessary.

12

Machines Without Compression Adjustment

Similarly, when the G5 is mounted on a machine without a compression setting, turn the wire feeding off. Adjust the Cutter Box

Adjustment Knob until the gap between the staple legs is centered. Next, turn the Feed Rack

Adjustment Knob until the wire draw is correct and the length of the staple legs is satisfactory.

Return the Feed Release Handle to its original position and run a couple of stitches to test this setting.

But unlike machines with compression adjustments, when there is a change in the material to be bound, both the Cutter Box

Adjustment Knob and the Feed Rack Adjustment

Knob have to be adjusted each time. Run a couple of stitches to test this setting.

MORE

WIRE

DRAW

Q

LESS

WIRE

DRAW

G50132A

G20573

G50119A

G50112A

Figure 8 - Adjusting the Wire Draw

Aligning the Wire Holder

The wire held in the Wire Holder (G50559A) must be positioned exactly under the grooves in the

Bender Bar (G50147A) to properly form a stitch. This is set at the Factory but may need to be adjusted when installing replacement parts. To check this alignment use a mirror to see the Head from below. Checking alignment is easiest if a piece of wire is in place in the Wire Holder and the Bender

Bar is just about to bend the wire. This test can also be performed on heads that are not currently mounted to a machine.

The Wire Holder is adjusted by loosening the Hex Nut (G20226) located on the side of the assembly using the Open End Wrench (G50707). Use the 3mm Hex Key Wrench (G20360) to turn the Eccentric Screw (G50665) clockwise until it is all the way in and then to turn it counter-clockwise until the proper position is reached. To lock in place, keep the Eccentric

Screw in place using the Hex Key Wrench and tighten the Nut using the Open End Wrench.

13

Make sure all guards are in place before operating the stitcher head r

WARNING

Aligning the Clincher Plate (Figure 9)

In order to produce properly clinched staples, the center of the Clincher Plate 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 G5 until the Stitcher Head is at the bottom of its stroke and the Driver is touching the top of the Clincher Plate. Looking from the side of the Stitcher Head, make sure the rib of the Driver is aligned with the center of the gap between the front and back plates of the Clincher

Plate Assembly. All adjustments to this setting are made by adjusting the screws in the back of the

G5 while the Head is removed from the Stitcher Machine. First, loosen the Set Screws (G20191) securing these Screws. If the Driver is positioned in back of the Clincher Plate then the lower Socket

Head Cap Screw (0030.030) must be turned counter-clockwise until the Screw sticks out slightly from the back of the Head, while the upper Screw remains under flush. If the Driver is positioned in front of the Clincher Plate then the upper Socket Head Cap

Screw must be turned

FRONT VIEW SIDE VIEW BACK VIEW counter-clockwise until it sticks out slightly from the back of the Head, while the lower Screw remains under flush. Slight adjustments to the Set Screws make significant differences in position. Once the position is set, tighten the two (2)

Socket Head Set Screws

(G20191) in the side of the

Stitcher Head.

G50710 (2)

Alignment

Tool

G20191 (2)

0030.0030 (2)

9083A

*Note: In most cases, front-to-back adjustment will not be necessary.

Figure 9 -Clincher Plate Alignment

14

Adjusting the Clincher Points

Left-to-Right

Looking from the front of the Stitcher Head, make sure the Driver is centered directly above the

Clincher Slide (9084B) while using the Clincher

Plate Alignment Tool (G50702). If it is not, loosen the two (2) Clincher Plate Nuts (G50710) and move the entire Clincher Plate Assembly to the right or to the left. Secure this position while tightening the

Screws.

The final position of the Clincher Points should be flush, or slightly above flush, with the Clincher Plate 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 that do not pivot high enough will produce a weak clinch, where Clincher Points that pivot too high will cause poor stitch quality or cut the stock being stitched.

If the clinch on the staple is not tight enough, the

Clincher Points 9083A have to be raised, assuming the Stitcher machine’s compression setting is correct. If the legs of the staple are being pushed back through the stock, the Clincher Points are set too high and have to be lowered. These adjustments are specific to each stitcher machine and cannot be fully explained in this manual, since many Machines have Clincher Lever adjustments built in. Consult the stitcher machine’s operating manual for complete Clincher Point adjustment instructions.

The G5 Head comes with an optional Adjustable

Clincher Plate, as illustrated in Figure 10 and so some adjustment can be made to the Clincher Points as follows. Loosen the Set Screw (UA4808.7) on

9083A

UA4808.7

9084B

9087

Figure 10 - Adjusting Clincher Points

Figure 11 - Solid Clincher Plate

15

the top of the Clincher Slide (9084B). Turn the Clincher Slide Adjustment Screw (9087) clockwise to lower the Clincher Points and turn the Clincher Slide Adjustment Screw counter-clockwise to raise the Clincher Points. Once the Clincher Point height is set, tighten the Set Screw on the front of the

Clincher Slide.

Some style stitcher heads do not utilize moving Clincher Points, but rather a solid Clincher Plate as shown in Figure 11. The legs of each stitch are bent when the wire is pushed through the stock and hits the Clincher Plate, as opposed to the 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 though. 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 following, are examples of a flat clinch, made with moveable Clincher Points and of a solid clinch, made with a solid Clincher Plate. The only difference between the resulting staples is aesthetic.

FLAT CLINCH SOLID CLINCH

16

Maintenance

Your G5 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 G5 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. Parts such as the Wire Cutters, the

Clincher Points and the Driver are subject to wear and have been so designed to be reversible to provide multiple cutting and driving surfaces. If after continuous usage, the original cutting or gripping surfaces of any of these parts show signs of wear, their position in the head can be reversed, thereby providing a new surface and lengthening the life of the part. For a complete list of wear and replacement parts for your G5 style Stitcher Head, refer to page 50 in the back of this manual.

The following instructions are provided so that the operator will clearly understand how to lubricate the Stitcher Heads and how to identify and remove any of the parts which may need to be replaced.

Always disconnect the power supply before making any adjustments or servicing the head.

r

WARNING

Lubrication (Figure 12)

Use any standard S.A.E. #10 oil for lubricating the heads. Heads that are in constant operation (at speeds exceeding 6,000 stitches per hour) should be lubricated weekly or once every 250,000 stitches. Heads that are operated periodically should be lubricated every 120,000 stitches or every third five pound wire spool change, which ever comes first. Usually, only a drop of oil is required at each lubrication point. Care must be taken that those parts of the head that contact the work to be stitched are free of oil. Lubricate regularly instead of excessively. Excessive oiling will result in work becoming spotted with oil. Use one drop of oil in the following lubrication points:

17

• the top of the Bonnet (G50100) on either side of the Feed Slide (G50131).

• where the Wire Holder Assembly (G50559A) pivots in the Pivot Block (G50143).

• on the Cutter Slide (G50198)

• on the Wire Oiler Felts (G20293).

• under the Wire Holder Retaining Spring

(G50183).

• in the oil cup of the Small Feed Gear Shaft

Assembly (G50262A) securing the Small Feed

Gear to the Feed Lever.

G20293

G50131

Cleaning ( Figure 12)

In addition to proper lubrication, routine cleaning is important for the maintenance of your G5 Head. Blow off dust, dirt and build-up with compressed air at least once a month. The entire Head should be torn down and the following areas thoroughly cleaned every one million stitches:

• Large Feed Gear Assembly (G50110A): remove and wash in an petroleum-based, oil-dissolving solvent, dry and repack the

Feed Gear with any general Lithium-based

Grease.

G50198

G50559A

G50183

• Anywhere that dust, oil or pieces of wire

and paper have built up - for example: around the Clincher Points and by the Left and Right Forming Pin Cams (G50115L &

G50115R). Remove the Wire Holder and blow clean with pressurized air

Figure 12 - Lubrication and Cleaning

Contact the DeLuxe Stitcher Graphic Arts Representative from whom your Stitcher Head was purchased and inquire about having a complete diagnostic evaluation performed on your G5.

18

Ordering Spare Parts

In time, you will need to replace some parts in your G5 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.

r

CAUTION

Replacing Spare Parts (Figure 13)

The following are some of the more common wear parts which will need to be removed and replaced in your G5 style Stitcher

Head. Some common replacement parts do not require the Stitcher Head to be removed from the stitcher machine. These parts will be addressed first, then a more specific explanation for disassembling and replacing wear parts for the

G5 Head will follow.

Removing and Replacing the Clincher Points

(Figure 14)

The Clincher Point

(9083A) is double-sided so that when one side is worn, it can be reversed to provide a new clinching surface and increase the life of the part. A worn

Clincher Point may cause poorly formed staple legs.

G50705

G50244

G50101

G50711

G50144A

G50604

0031.5103 (2)

G50237

G50199

G50183

0030.3434 (2)

Figure 13 - Replacing Spare Parts

G50559A

G50665

G50126

G50197A

G50196

0031.5103

G50206

19

Loosen, but do not remove, the two (2) Clincher

Plate Nuts (G50710) until the Clincher Slide

(9084B) can be disengaged from the stitcher machine and slid out of the Clincher Plate Assembly

(9086A) or down within it. Rotate the Clincher

Points upwards until they can be pulled out. Reverse the Points when one of their sides is worn or chipped or replace them. Rotate the Clincher Points downward before replacing the Clincher Slide. Make sure the Points are engaged by the Slide before tightening the Clincher Plate Nuts.

Removing and Replacing the Driver Figure 15

Swing the Wire Holder Retaining Spring (G50183) out of the way and remove the Wire Holder

Assembly (G50559A). Remove the Driver

Retaining Screws (G50153) and slide the Driver

(G50152) down and out of the Bender Bar Assembly

(G50147A). Since the Driver is reverseable, it can be rotated and replaced or a new Driver can be inserted into the grooves in the Bender Bar until it stops against the edge of the Driver Bar (G50151).

Replace the Driver Retaining Screws after applying a light duty locking compound to them, then replace the Wire Holder Assembly and Wire Holder

Retaining Spring.

Disassembling the Stitcher Head (Figure 13)

Remove the G5 style Stitcher Head from the stitcher machine by loosening and removing the long

Socket Head Cap Screw (G50126) securing it to the

Clamp Block (G50101). Remove the Head from the stitcher machine and place it on a clean work area.

Swing the Wire Holder Retaining Spring (G50183) away from the G5 and remove the Wire Holder

Assembly (G50559A). Snap the Middle Wire Tube

(G50144A) out of the Middle Wire Tube Clip

(G50244) and remove it from the Lower Wire Tube

(G50199A) in the Cutter Box Assembly (G50197A).

Move the Cutter Box Assembly (G50197A) away from the Bonnet by turning the Cutter Box

G50710 (2)

Figure 14 - Replacing Clincher Points

G50183

9083A (2)

9086A

G50151

G50559A

G50153 (2)

G50152

Figure 15 - Replacing the Driver

20

Adjustment Knob (G50245) counter-clockwise.

Loosen and remove the two (2) Flat Head Cap

Screws (G50399), securing the Cutter Box to the

Cutter Box Mounting Plate (G50391). Turn the Hex

Jam Nut (G50713), behind the Cutter Box

Adjustment Knob, slightly clockwise to unlock the

Knob. Continue to turn the Knob counter-clockwise to remove it from the Cutter Box Adjusting Eccentric

(G50237). Remove the Hex Jam Nut as well. Pull the Cutter Box away from the Head. Loosen and remove the Hex Head Cap Screw (G50196) securing the Wire Straightener (G50206) to the Cutter Box.

G50198

G50210

G50245

G50383

G50399 (2)

G50145

G50197A

Removing and Replacing the Wire Cutters

Figures 16 and 17

G50391

G50237

The Moving Wire Cutter (G50145) has several cutting surfaces, each of which may be used by rotating the Cutter’s position on the Cutter Operating

Slide (G50198). Dull Cutters can cause poor stitch

G50206

Figure 16 - Replacing the Moving Cutter quality. To change or reverse the Moving Wire

Cutter, first remove the complete Cutter Box Assembly (G50197A) from the stitcher head (see pre-

vious instruction) and the Wire Straightener (G50206) from the Cutter Box. Remove the Cutter Slide and the Cutter Operating Spring (G50210) from the Cutter Box. Loosen the Flat Head Machine Screw

(G50383) securing the Cutter to the Slide and rotate the Cutter until a new cutting surface is exposed.

If there are no more sharp edges available, remove the Screw completely and install a new Moving Cutter. Replace the Machine Screw and be sure to tighten it completely so that the Cutter does not rotate on the Slide.

G50183

Like the Moving Cutter, the Fixed Wire Cutter

(G50200) can be rotated when the cutting surface is dull or replaced when no sharp surfaces are left.

Loosen, but do not remove, the Socket Head Cap

Screw (G20589) on the front of the Cutter Box which secures the Cutter. Rotate the Cutter until a new surface is exposed or replace it when completely worn. The Cutter can be rotated three or four times on each end before needing to be replaced. Once the

Cutter has been rotated and before tightening the Cap

Screw to secure the new position, make sure the

Fixed Wire Cutter is aligned correctly within the

Cutter Block.

Insert the Cutter Operating Spring (G50210) into

G50197A

G50243

G50237

G20589 G50200

Figure 17 - Replacing the Fixed Cutter

21

G50171

G50131

G50264

G20520

G50162A

G50132

G50268

G20697

G50136A

G50199

G50190 (2)

G50397

G50100A

G50115R

G50115L

G50151

Figure 18 - Disassembling the Head the slot in the top of the Cutter Block Assembly. Align the Cutter Slide along the groove in the Cutter

Box. Compress the Cutter Operating Spring and return the Slide to its position in the Cutter Box

Assembly. Slide the Cutter Box over the Cutter Box Adjusting Eccentric (G50237) and secure the

Cutter Box to the Mounting Plate with the two (2) Machine Screws. Return the Hex Jam Nut and

Adjustment Knob (G50245) to the end of the Adjusting Eccentric. Tighten the Hex Jam Nut

(G50713) against the Knob to secure it in position.

In order to obtain a clean edge on the cut wire, there can be no gap between the Moving and Fixed

Cutters. Compress the Cutter Operating Slide against the Cutter Operating Spring until the Moving

22

Cutter just passes the hole in the Fixed Cutter. While holding this position, push the Fixed Cutter against the Moving Cutter, using a small screwdriver as a lever. Tighten the Cap Screw to secure the position of the Fixed Cutter, but be sure to test it once before re-assembling the Cutter Block to the

G5 by compressing the Cutter Operating Slide. The Moving Cutter must pass the Fixed Cutter freely and with no visible gap. Take special care not to put too much pressure between the Moving and

Fixed Cutters as Cutter Slides may stick in the down position, causing wire jams.

Replace the Wire Straightener to the Cutter Box with the Hex Head Cap Screw through a Ribbed

Lock Washer. Typically, the Wire Straighteners can be butted against the stop on the Cutter Box.

Continue to disassemble the G5, by loosening and removing the Socket Head Cap Screw (G20697) securing the Feed Lever Spring (G50268) to the Bonnet Assembly, as well as the Spring itself. Refer

to Figure 18. Loosen and remove the Socket Head Cap Screw (G50171) securing the Driving Slide

Assembly (G50162A) to the Feed Slide (G50131) while paying special attention to the Lock Washer

(G20520). Disengage the Driving Slide from the Driver Bar (G50151) and remove the Slide from the back of the Bonnet. Slide the Feed Slide Assembly out the top of the Bonnet and the Bender Bar

Assembly out the bottom. Move the Cutter Box all the way to the left to make room for the Bender

Bar removal.

Loosen and remove the two (2) Cheese Head Machine Screws (0030.3434) and the Shoulder Bolt

(G50397) securing the Feed Gear Bracket (G50136) to the Bonnet Assembly (G50100A). Once the

E-Ring (G50264) is removed from the back of the Feed Release Handle (G50199A), the entire Feed

Gear Bracket can be removed from the Head. Once the Bracket is removed, the Feed Lever Assembly

(G50132A) will no longer be secured to the Bonnet and should be removed as well, along with the

Washer (G50714).

Removing and Replacing the Bender Bar, the Friction Plate and the Forming Pin (Figure 19)

After removing the Bender Bar Assembly from the G5 Stitcher Head, remove the Forming Pin

Assembly (G50331A) and inspect for wear or damage. Replace the Pin if necessary. Remove the

Friction Plug Bushing (G50161), the Bender Bar Friction Spring (G50160) and the Friction Plug

(G50159). The Driver Bar (G50151) and Driver (G50152) can be removed from the bottom of the

Bender Bar now. Next, remove the four (4) Flat Head Machine Screws (G50383) that secure the

Bender Bar Friction Plate (G50148) to the Bender Bar. Replace the existing Friction Plate with a new one and secure it with the four (4) existing Flat Head Machine Screws. Lastly, inspect the Bender Bar for signs of wear or damage. If the Bender Bar itself is worn or broken, replace it with a new one.

Slide the Driver Bar and Driver in through the bottom of the Bender Bar and secure it by replacing the Friction Plug, Friction Plug Spring and Friction Bushing in the back of the Assembly.

Re-assembling the Stitcher Head (Figure 18)

Any of these assemblies can now be taken apart for cleaning or repair. The Bonnet itself can also be cleaned or checked for damage. Reassembling the Head is as simple as reversing the method used to disassemble the Head. Always turn the machine over manually anytime repairs or adjustments are

23

made for the safety of both the operator and the

Stitcher Head.

1. Position the Feed Lever Assembly over the hole in the Bonnet so the Shoulder Bolt in the Feed Gear

Bracket can secure both assemblies to the G5.

2. Assemble the Feed Gear Bracket Assembly to the

Bonnet by fitting the Feed Gear Bracket over the

Dowel Pin located on the Bonnet, lining up the hole in the Feed lever with the hole in the top left corner of the Bracket. Also line up the Feed Gear Shaft

(G50114) with the hole in the Feed Gear Plate

(G50182). Secure the Feed Gear Bracket with two

(2) Machine Screws and one (1) Shoulder Bolt. The teeth of the Feed Pinion Assembly (G50111A) may have to be lined up manually with the teeth of the

Feed Rack (G50127).

G50161

3. 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.

Slide the Bender Bar Assembly into the Bonnet from the bottom.

G50160

G50159

G50148

G50383 (4)

4. Turn the Bonnet over and position the Driving

Slide Assembly so that the Driving Slide Plunger

(G50164) rests in the notch of the Driver Bar and secure this position with the Cap Screw tightened completely.

G50331A G50151

G50152

G50147

5. Slide the Cutter Box over the Cutter Box

Adjusting Eccentric and secure the Cutter Box to the

Figure 19 - Replacing the Bender Bar Assembly

Mounting Plate with the two Machine Screws.

Return the Hex Jam Nut and Adjustment Knob to the end of the Adjusting Eccentric and tighten the

Hex Jam Nut against the Knob to secure it in position. Make sure the Cutter Box moves freely under the Cutter Box Guide Plate by turning the Adjustment Knob clockwise and counter-clockwise. If it does not, loosen the screws securing the Plate to the Bonnet and readjust them.

6. Return the Wire Holder Assembly to its position under the Wire Holder Retaining Spring and the

Middle Wire Tube to its position by inserting it into the Lower Wire Tube and snapping it into place in the Middle Wire Tube Clip.

24

Troubleshooting (Figure 20)

The quality and quantity of work that can be produced with the G5 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. In the event of trouble of this nature occurring, the operator can, by referring to the following troubleshooting chart, quickly locate and remedy the cause or causes of the trouble.

The following is a brief list of problems and solutions which should cover the majority of situations encountered when stitching with the G5 Stitching Head. The cause of staple imperfections usually can be traced to inaccurate settings or normal wear of moving parts. In the event of problems of this nature occurring, the operator can, by referring to the following troubleshooting chart, quickly locate the solutions.

PROBLEM : Gap Out of Center

SOLUTION : Lengthen the left leg by adjusting the Cutter Box. (See page 12)

PROBLEM : Gap Too Big

SOLUTION : Increase wire draw with the Feed Rack Adjustment Knob, then center stitch gap as described above.. (See page 12)

PROBLEM : Corner Buckled

SOLUTION : Check the Driver (G50152) for a chipped corner and rotate or replace it if needed. (See page 20) Check the tensile strength of the wire or use thicker wire.

Figure 20 - Troubleshooting

PROBLEM : Leg(s) Buckled

SOLUTION : If the ends of an unformed piece of wire are not smooth, the Wire Cutters (G50145 or G50200) are worn. Check for wear and rotate or replace if needed. (See page 21) Make sure the correct wire size is being used and that the wire is reasonably straight. Wire that is too weak or thin may cause this problem.

25

Figure 20 - Troubleshooting

PROBLEM

SOLUTION

: Partially Formed Stitches

: Replace the worn Forming Pin (G50331A). (See page 23)

PROBLEM

SOLUTION

: Staple Legs Too Long or Too Short

: Correct the overall wire draw by repositioning the Feed Rack within the G5 Head. (See page 12)

PROBLEM

SOLUTION

: Left Leg Missing

: Straighten the wire. (See page 11) The Wire Holder Assembly is not aligned properly. Align it with the groove in the Bender Bar. (See page 13)

PROBLEM

SOLUTION

: Legs are Spread or Contracted

: Straighten the wire. (See page 11) Check wire cut-off.

PROBLEM

SOLUTION

: Legs Stray Forward or Backward Consistently

: The Stitcher Head is not aligned properly front to back.

(See page 14) Straighten the wire. (See page 11)

PROBLEM

SOLUTION

: Stitch Stray Randomly In and Out and Front to Back

: Straighten the wire. (See page 11) Make sure the Cutters are aligned properly. (See page 21) Check the tensile strength of the wire or use thicker wire.

PROBLEM

SOLUTION

: Loose Clinch

: The Clincher Points are too low and need adjusting.

(See page 15) The compression of the stitcher machine is insufficient and needs to be increased.

PROBLEM

SOLUTION

: No wire being drawn

: Make sure the Feed Release Handle is turned to the “on” position and the Feed Gears engaged. (See page 10)

26

The G5 Stitcher Head

27

28

Bonnet Sub-Assembly

G50368

G50119A

G50132A

G50138

G50266

G50262A

G50112

G50714

G20140 (2)

G50120

G50235

G20515

G50232

G20233

G50230

G50264 (2)

G50268

G50703

G50142 (2)

G50182

G50101

G50126

G50115L

29

0031.5103 (2)

0030.0030 (2)

G20191 (2)

G20579 (4)

G50115R

Bonnet Sub-Assembly

ITEM No.

G50119A

G50120

G50126

G50132A

G50138

G50142

G50182

G50223

G50230

G50232

G50235

G50262A

0030.0030

0031.5103

G20140

G20191

G20233

G20515

G20579

G50101

G50112

G50115L

G50115R

G50264

G50266

G50268

G50368

G50703

G50714

DESCRIPTION

Screw, M5x.8x8 SHCS

Lock Washer Ribbed

Follower Ball Bearing

Screw, M4x.7x8, SHSS

Cutter Operating Lever Roller

Dowel Pin M6x14

Screw M4x0.7x6 FHMS

Clamp Block

Small Feed Gear

Forming Pin Cam, Left

Forming Pin Cam, Right

Feed Release Handle Assembly

Feed Release Handle Bushing

Screw, M5x.8x25

Feed Lever Assembly

Feed Pinion Bearing

Screw, M3x0.5x5, CHMS

Feed Gear Plate

Dowel Pin, M3x6

Cutter Operating Lever

Dowel Pin

Dowel Pin M5 x 12

Small Feed Gear Shaft Assembly

E-Ring 6mm

Dowel, M5x10

Feed Lever Spring

Feed Release Handle Cap

Feed Lever Spring Screw

Feed Lever Spacer

QUANTITY

1

1

1

1

3

1

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

4

1

2

2

1

2

2

30

Bonnet Sub-Assembly

G50397

G50181

G20121

G50136

G20274

G50244

0031.5103 (2)

G20236

G20522

0030.3434 (2)

G20191

G50187

0031.5103

G50142

G50114

G50186

G50144A

G50237

G50245

G50713

G50604

G20298

G50695

G50617 (2)

G50256

31

G50142 (3)

G20191

G50183

G50128B

G50110

G50129

G50138 (2)

G50100

G50646 (2)

G50137

G50705

G50711

0030.3434 (3)

0031.5103 (6)

G50111

G50143

G20615

G50383 (2)

G50141

Bonnet Sub-Assembly

ITEM No.

G50137

G50138

G50141

G50142

G50143

G50144A

G50181

G50183

G50186

G50187

G50215

G50237

G50244

G50245

G50256

G50383

0030.3434

0031.5103

G20121

G20191

G20236

G20274

G20298

G20522

G20615

G50100

G50110

G50111

G50114

G50128B

G50129

G50136

G50397

G50604

G50617

G50646

G50695

G50705

G50711

G50713

DESCRIPTION QUANTITY

Screw M3x.5x10, CHMS

Lock Washer Ribbed

Feed Release Plunger

Screw, M4x.7x8, SHSS

Tube Pivot Screw

Hex Jam Nut, M6x1

Nylock Lock Nut, M6x1

Screw M6x1.0x5

Screw M5x0.8x8

Bonnet

Large Feed Gear

Feed Pinion

Feed Gear Pin

Rear Feed Gear Spacer

Large Feed Gear Washer

Feed Gear Bracket

Feed Gear Clutch

Feed Pinion Bearing

Wire Guide Bar

Screw, M3x0.5x5, CHMS

Pivot Block

Middle Wire Tube Assembly

Upper Wire Tube

Wire Holder Retaining Spring

Feed Gear Friction Spring

Feed Gear Friction Pad

Screw, M3x.7x4, FHMS

Cutter Box Adjusting Eccentric

Tube Clip

Cutter Box Adjustment Knob

Scale

Screw M3x.5x6, FHMS

Shoulder Bolt, M8x20

Cutter Box Guide Plate

Wire Holder Retaining Spring Washer 2

Cutter Box Eccentric Bearing 2

1

1

Screw, M6x1.0x20

Shoulder Screw, M6x8 Long

Cutter Box Eccentric Screw Spring

Hex Jam Nut, M5

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

5

9

1

2

1

1

1

1

1

1

1

1

1

1

1

4

1

2

32

Alternate Head Mounting

G50394

G50102

G20275

G50716

G50367

G50366

33

Alternate Head Mounting

ITEM No.

G20275

G50102

G50366

G50367

G50394

G50716

DESCRIPTION

Ball Spring Plunger

Mounting Block

Bonnet Clamp Pin

Rear Head Mounting Bolt

Flat Washer, M8

Mounting Block Handle

QUANTITY

1

1

1

1

1

1

34

Driver and Feed Slide Assemblies

G20573

G50130

G50174

G50171

G20520

G50163

G20190 (2)

G50162A

G50131

G20170

G20169B

G20165

35

G50164

G20272

G20578

0031.5103

G20179

0031.5103 (2)

G20196 (2)

G50127

Driver and Feed Slide Assemblies

ITEM No.

G20165

G20169B

G20170

G20179

G20190

G20196

G20272

G20520

G20573

G20578

G50127

G50130

G50131

G50162A

G50163

G50164

G50171

G50174

0031.5103

DESCRIPTION

Driving Slide Spring

Driving Slide Plunger Screw Ecc

Hex Jam Nut M8x1.25

Screw M3x.5x4, SHCS

Screw M3x.5x10

Screw M3x.5x6 SHCS

Screw M4x.7x12 SHSS

Lock Washer M6x10

Feed Rack Adjustment Knob

Rack Adjustment Knob Detent

Feed Rack

Feed Adjustment Block

Feed Slide

Driving Slide Assembly

Cutter Operating Cam

Plunger

Screw, M6X1.0X6 SHCS Low-Head

Feed Rack Adjustment Stud

Lock Washer, Ribbed- M3

QUANTITY

1

1

1

2

1

1

1

1

2

1

1

1

1

1

1

3

1

1

1

36

Driver and Bender Bars

G50161

G50160

G50159

G50147AA

G50148

G50383 (4)

G50331A

G50147A

G50151

37

G50152

G50153 (2)

Driver and Bender Bars

ITEM No.

G50147A

G50147AA

G50148

G50151

G50152

G50153

G50159

G50160

G50161

G50331A

G50383

DESCRIPTION

Bender Bar - 25 Gauge Wire

Bender Bar Assembly

Bender Bar Friction Plate

Driver Bar

Driver - 25 Gauge Wire

Driver Retaining Screw

Friction Plug

Bender Bar Friction Spring

Friction Plug Bushing

Forming Pin

Screw M3x.5x5 FHMS

QUANTITY

1

1

4

2

1

1

1

1

1

1

1

38

Wire Guide Bracket and Spring

G20286A

G20279A

G20297

G20278A

G20288 (2)

G20285

G20283

G20290 (2)

G20284

G20288

G20293 (2)

39

G20292

G20234 (2)

G20298

G20287

Wire Guide Bracket, Spring and Clincher Plate

ITEM No.

G20234

G20278A

G20279A

G20283

G20284

G20285

G20286A

G20287

G20288

G20290

G20292

G20293

G20297

G20298

DESCRIPTION QUANTITY

E-Ring 3/16" 2

Wire Guide Spring Plate Assembly 1

Wire Guide Spring Assembly - Short 1

Tension Pawl 1

Tension Pawl Spring

Tension Pawl Roller

Wire Guide Spring Assembly - Long

Wire Oiler Felt Spring

Screw, M4x0.7x8, SHCS

Flat Washer, M5

1

3

2

1

1

1

Wire Oil Felt Washer

Wire Oiler Felt

Screw, M6x1x40

Nylock Lock Nut, M6x1

1

2

1

1

40

Cutter Box Assembly

G20579

G50198

G50145

G50383

G50391

G50399 (2)

G50210

G50199

G50431

G20589

G50197A

G50200

41

G50223 (2)

G50206

0031.5103

G50196

Cutter Box Assembly

ITEM No.

0031.5103

G20579

G20589

G50145

G50196

G50197A

G50198

G50199

G50200

G50206

G50210

G50223

G50383

G50391

G50399

G50431

DESCRIPTION

Lock Washer, Ribbed- M3

Screw M4x0.7x6

Screw, M4x0.7x10 SHCS

Moving Cutter

Screw M3x.5x6 HHCS - Long

Cutter Box Assembly

Cutter Slide

Lower Wire Tube

Fixed Wire Cutter

Wire Straightener Eccentric

Cutter Operating Spring

Dowel Pin, M3x6

Screw M3x.5x5

Cutter Box Mounting Plate

Screw, M3x.5x8 FHCS

Screw, M3x0.5x6 Long SHSS

QUANTITY

1

1

1

1

1

1

1

1

1

1

1

2

1

1

2

1

42

Wire Holder Assembly

G50559A

G50254

G50255

G50135

G20226

G50252

G50665

G50253

43

Wire Holder Assembly

ITEM No.

G20226

G50135

G50252

G50253

G50254

G50255

G50559A

G50665

DESCRIPTION

Hex Nut M4x.7

Wire Holder Pivot Pin

Wire Holder Hook

Wire Hook Spring, G5

Wire Holder Spring Screw

Dowel Pin M3x10

Wire Holder Assembly

Wire Holder Adjustment Screw

QUANTITY

1

1

1

1

1

1

1

1

44

9084B

G50710

UA4808.7

Clincher Plate Assembly

9083B

9093A

9086A

9088

9087

45

Clincher Plate Assembly

ITEM No.

9083A

9084B

9086A

9087

9088

9093A

G50710

UA4808.7

DESCRIPTION

Clincher Point - Thick, Round

Adjustable Clincher Slide

Clincher Plate - Thick

Clincher Slide Adjustment Screw

Clincher Plate Binder Bolt

Clincher Slide - Thick

Clincher Plate Nut

Screw, 1/4-28 x 1/4, SHSS

QUANTITY

2

1

2

1

1

1

2

1

46

Part Number / Description Cross-Reference

G20170

G20179

G20190

G20191

G20226

G20233

G20234

G20236

G20272

G20274

G20278

G20278A

G20278AA

G20279

G20279A

G20282

G20283

G20284

9086A

9086BA

9093A

G20121

G20140

G20140

G20165

G20169B

0030.0030

0030.3434

0031.5103

0031.5104

9088

9091

87922

9083A

Screw, M5x.8x8 SHCS

Screw M3x.5x10, CHMS

Lock Washer Ribbed

Lock Washer Ribbed, M4

Clincher Plate Binder Bolt

Clincher Slide Strap Rivet

Oil Hole Cover

Clincher Point - Thick, Round

Clincher Plate - Thick

Clincher Back Plate - Thick

Clincher Slide - Thick

Feed Release Plunger

Follower Ball Bearing

Follower Ball Bearing

Driving Slide Spring 1

Driving Slide Plunger Screw Eccentric 1

1

1

1

1

1

1

1

2

2

2

15

4

2

7

Hex Jam Nut M8x1.25

Screw M3x.5x4, SHCS

Screw M3x.5x10, FHMS

Screw, M4x.7x8, SHSS

Hex Nut M4x.7

Cutter Operating Lever Roller

E-Ring 3/16"

Tube Pivot Screw

Screw M5x0.8x12

Hex Jam Nut, M6x1

Wire Guide Spring Plate

Wire Guide Spring Plate Assembly

W/G Spring Plate Asy - Complete

Wire Guide Spring - Short

Wire Guide Spring Assembly - Short 1

Tension Pawl Pivot Pin 2

1

1

Tension Pawl

Tension Pawl Spring

1

1

1

1

1

1

2

1

1

1

2

4

1

1

Tension Pawl Roller

Wire Oiler Felt Spring

Screw, M4x0.7x8, SHCS

Flat Washer, M5

Wire Oil Felt Washer

Wire Oiler Felt

Wire Guide Spring Guide Stud

Screw, M6x1.0x40

Nylock Lock Nut, M6x1

Nylock Lock Nut, M6x1

Hex Key Wrench 3.0mm

Dowel Pin M6x14

Ribbed Lock Washer-M6

Screw M6x1.0x5

Feed Rack Adjustment Knob

Rack Adjustment Knob Detent

Screw M4x0.7x6

Screw, M4x0.7x10, SHCS

Screw M5x0.8x8

Bonnet Assembly

Clamp Block

Large Feed Gear

Large Feed Gear Assembly

Feed Pinion

Feed Pinion Assembly

Small Feed Gear

Feed Gear Pin

Forming Pin Cam, Left

Forming Pin Cam, Right

Feed Release Cam

Feed Release Handle

Feed Release Handle Bushing

Screw, M5x.8x25

Feed Rack

G50111A

G50112

G50114

G50115L

G50115R

G50118

G50119

G50120

G50126

G50127

G20579

G20589

G20615

G50100A

G50101

G50110

G50110A

G50111

G20298

G20298

G20360

G20515

G20520

G20522

G20573

G20578

G20285

G20287

G20288

G20290

G20292

G20293

G20296

G20297

47

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5

1

1

2

3

2

1

1

Pinion Washer

Large Feed Gear Washer

Feed Adjustment Block

Feed Slide

Feed Lever

Feed Lever Assembly

Wire Holder Pivot Pin

Feed Gear Bracket

Feed Gear Clutch

Feed Pinion Bearing

Feed Pinion Bearing

Wire Guide Bar

Screw, M3x0.5x5, CHMS

Pivot Block

Middle Wire Tube

Middle Wire Tube Assembly

Moving Cutter

Bender Bar Assembly

Bender Bar Friction Plate

Dowel Pin M4 x 16

Driver Bar

Driver - 25 Gauge Wire

Driver Retaining Screw

Friction Plug

Bender Bar Friction Spring

Friction Plug Bushing

Driving Slide

Driving Slide Assembly

Cutter Operating Cam

Plunger

Screw, M6x1.0x6, SHCS- Low

Feed Rack Adjustment Stud

Upper Wire Tube

Feed Gear Plate

G50160

G50161

G50162

G50162A

G50163

G50164

G50171

G50174

G50181

G50182

G50145

G50147AA

G50148

G50149

G50151

G50152

G50153

G50159

G50137

G50138

G50138

G50141

G50142

G50143

G50144

G50144A

G50128

G50129

G50130

G50131

G50132

G50132A

G50135

G50136

Part Number / Description Cross-Reference

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

6

1

1

1

1

2

1

1

1

1

1

1

1

1

G50258

G50262

G50262A

G50264

G50266

G50268

G50331

G50332

G50333

G50335

G50237

G50244

G50245

G50252

G50253

G50254

G50255

G50256

G50206

G50210

G50223

G50223

G50230

G50230A

G50232

G50235

G50183

G50186

G50187

G50196

G50197A

G50198

G50199

G50200

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5

2

1

1

1

1

1

1

1

1

1

1

Wire Holder Retaining Spring

Feed Gear Friction Spring

Feed Gear Friction Pad

Screw M3x.5x6, HHCS

Cutter Box Assembly

Cutter Slide

Lower Wire Tube

Fixed Wire Cutter

Wire Straightener

Cutter Operating Spring

Dowel Pin, M3x6

Dowel Pin, M3x6

Cutter Operating Lever

Cutter Operating Lever Assembly

Dowel Pin

Dowel Pin M5 x 12

Cutter Box Adjusting Eccentric

Tube Clip

Cutter Box Adjustment Knob

G5 Wire Hook

Wire Hook Spring, G5

Wire Holder Spring Screw

Dowel Pin, M3 x 10

Scale

Wire Tube Sleeve

Small Feed Gear Shaft

Small Feed Gear Shaft Assembly

E-Ring 6mm

Dowel, M5x10

Feed Lever Spring

Forming Pin

Forming Pin Insert

Bushing

Spring, Internal

48

Part Number / Description Cross-Reference

G50559A

G50604

G50617

G50646

G50665

G50695

G50703

G50705

G50337

G50368

G50383

G50383

G50391

G50397

G50431

G50559

G50707

G50708

G50711

G50712

G50713

G50714

G50715

G5HD251/2

Spring Pin, M2.5 x 6

Feed Release Handle Cap

Screw M3x.5x6, FHMS

Screw M3x.5x6, FHMS

Cutter Box Mounting Plate

Shoulder Bolt, M8x20

Screw, M3x0.5x6

Wire Holder

Wire Holder Assembly

Cutter Box Guide Plate

Wire Holder Retaining Spring Washer 2

Cutter Box Eccentric Bearing 2

1

1

Wire Holder Adjustment Screw

Screw, M6x1.0x20

Feed Lever Spring Screw

Shoulder Screw, M6x8 Long

1

1

1

1

1

1

1

1

4

5

1

1

Double Open End Wrench - 5.5 & 7mm 1

T-Handle Hex Key Wrench - 4mm 1

Cutter Box Eccentric Screw Spring

Dowel Pin, M3 x 18 Lg

1

2

Hex Jam Nut, M5

Feed Lever Spacer

Screw, M4x.7x6, CHMS

Stitcher Head Assembly

4

1

1

1

49

51

L I M I T E D W A R R A N T Y

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.

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.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

To obtain warranty service you must return the product, at your expense, together with proof of purchase to an authorized

DeLuxe Stitcher Company Graphic Arts Dealer.

Always use genuine DeLuxe Stitcher parts. When ordering parts, please identify the part number, the part name, the wire size and crown size of your Stitcher.

DeLuxe Stitcher Company Inc.

6635 West Irving Park Road

Chicago, Illinois 60634-2410

Phone: 773-777-6500 800-634-0810

Fax: 773-777-0156 800 -417-9251

E-mail: [email protected]

Web Site: http://www.deluxestitcher.com

52

DBSG50501