DeLuxe Stitcher G5 User manual

solving your wire stitching needs for 125 years...
G5 Stitcher Head
OPERATION AND MAINTENANCE MANUAL
Wire Size: 25 Ga. Round (0.52 mm)
Crown Sizes: 1/2” (12 mm) and 13/64” (5 mm) Loop
Capacity: 2 sheets to 13/64” (5 mm)
Head Serial Number :
Date Purchased :
Where Installed:
DELUXE STITCHER
COMPANY INC.
®
(make/model of machine)

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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.

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WARNING!
G5 Stitcher Heads
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 the stitcher 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.
EYEWEAR
REQUIRED

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Table of Contents
Safety Warning .................................................................................................4
Specifications.....................................................................................................6
Installation .......................................................................................................8
Pre-Inspection ................................................................................8
Inspection ......................................................................................8
Mounting ........................................................................................9
Assembly ......................................................................................10
Operation .......................................................................................................11
Wire Threading .............................................................................11
Wire Straightening ........................................................................12
Aligning the Wire Holder ...............................................................13
Aligning the Clincher Plate ...........................................................15
Adjusting the Wire Length (Draw) ................................................16
Adjusting the Length of the Stitch Leg ..........................................16
Maintenance......................................................................................................17
Lubrication ....................................................................................17
Ordering Spare Parts.....................................................................19
Troubleshooting................................................................................................20
Formed Staple Chart .................................................................. 21-22
Appendices ......................................................................................................23
Assembly Drawings with
Part Number/Description Cross Reference/Qty......................... 23-35
Parts Index .................................................................................36-37
Warranty Information ......................................................................................38

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Specifications
Weight
Shipping Weight ..............7.0 lbs... (3.2 kg)
Physical Dimensions
Height ...................12" Max.” (30.5 cm)
Width ...................2” (5.1 cm)
Stitching Capacity ..................Two Sheets to 5 mm. (3/16”)
Wire Type ...................25 round (0.52 mm max)
...................21x25 flat
Crown Sizes ...................1/2” (12 mm.), 13/64” (5 mm.) Loop
Minimum Head Center
..................1-1/2” (39 mm.)
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

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1 3/16" [30.3mm]
3/8" [9.5mm]
10 3/4" [273mm]
13/64" [5.0mm]
DRIVE
ADJUSTMENT
1 59/64" [49.0mm]
STROKE
7 1/8" [181.0mm]
3 55/64" [98.0mm]
2 13/16" [71.3mm]
3 9/16" [90.7mm]
1 27/64" [36.0mm]
2 1/4" [57.0mm]
3 19/64" [83.7mm]
3 25/64" [86.0mm] MAX
1 29/32" [48.6mm] MAX
1 23/32" [43.8mm] MIN
1 3/8" [34.9mm]
45/64" [18.0mm]
11 59/64" [302.8mm]
1 17/32" [39.0mm] 25 1/4" [641mm]
27" [685mm]
DETAIL A
SCALE 1.5 : 1
A
2 1/4” [57.2mm]
5/32” [3.9mm]
CENTER OF
STITCH
Dimensions

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 •G5Manual
 •Bagoftools;2.0mm.,3.0mm.andOpenEndWrench(7mm.)
 •T-HandleHexHeadWrench;4mm.
 •HeadMountingAccessories
  •FrontMount:ClampBlock(G50101),ScrewM5x0.8x25(G50126)
  •BoltMount:HeadMountingBolt,M8(G50367),MountingBlock-Keyed
  (G50102),BonnetClampPin(G50366),MountingBlockHandle(G50716)
  andFlatWasherM8(G50394)
 •ClincherPlate,Points,Slide,NutsandStuds
 •ClincherAlignmentGauge
 •WireGuideSpringandWireAnti-BackupUnit
 •ManualFeedGearTool
 •StitchSamples
Contents
Figure 1 - Parts Package Contents
A9086JA
G50279A
G20374
(2 mm)
G20360
(3 mm)
G20364
(7 mm)
G50708
(4 mm)
G50666
G50800CA
G50228A
Installation

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Figure 2 - Mounting the Head
Mounting (Figure 2)
G50708
Turn to adjust
for position
G50162CA
Position in rail on
Stitcher Machine
Disengage the
Feed Gears
to assist
in mounting
G50101
G50126

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Always disconnect the power supply before
making any adjustments or servicing the head.
WARNING
!
Figure 3 - Assembly
G50181
G50279A
Assembly (Figure 3)
G20522
G50181
Align the Clincher
Slide and Driver
G50286A
G20241 (2)
Do not Jam Tube
into Feed Gears.
Leave a distance
of 1/32” (.5 mm.)
before tightening
the Set Screw
Insert Tube while
the Feed Gears
are engaged
G50666
G50800CA
G50264

Figure 4 - Threading the Head
Wire Threading (Figures 4 & 5)
Figure 5 - Threading the Head
G50144A
G50110A
G50112
G50119A
Turn to disengage
Small and Large
Feed Gears
G50181
G50800CA
Pass wire
between the Wire
Guide Spring
Studs
Pass wire
between
Oiler Felts
G50119A
Turn to engage
Small and Large
Feed Gears
Guide Wire between
the Small and
Large Feed Gears
G50279A
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Operation

TO ADJUST WIRE STRAIGHTNESS, LOOSEN SCREW
AND MOVE WIRE STRAIGHTENER UP OR DOWN TO
PRODUCE DESIRED RESULT .
ROTATE WIRE HOLDER SPRING
TO REMOVE WIRE HOLDER AND GAIN
ACCESS TO WIRE STRAIGHTENER.
PULL WIRE HOLDER OUT
TO MAKE ADJUSTEMENTS
TO THE WIRE
STRAIGHTENER
WIRE STRAIGHTENER
SCREW
ROTATED VIEW OF
FIXED WIRE CUTTER,
MOVING WIRE CUTTER,
AND WIRE STRAIGHTENER.
G50183
(A)
(B)
(C)
G50559A
G50189
G50200
WIRE HOLDER
WIRE HOLDER
SPRING
FIXED WIRE CUTTER
G50200
WIRE STRAIGHTENER
Figure 6 - Adjusting Wire Straightness
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Adjusting Wire Straightness (Figures 6-9)

Horizontal Adjustment (Figures 6-7)
Tobeginhorizontalwireadjustment;
(A) Swing open the Wire Holder Spring (G50183)by rotating it away from center.
 (B)PullouttheWireHolder(G50559A)togainaccesstotheWireStraigtener.
 (C)ObservethedirectionthewireismovingasitemergesoutoftheFixedWire
Cutter(G50200).UseanM3wrenchtoloosentheWireStraightenerScrew(G50189)and
allow adjustment to the Wire Straightener (G50200).
Adjustment is accomplished by simply sliding the Wire Straightener up or down
to counter the effects of wire curl  shown in Figs. 7a-7c.  If the wire is curved upwards,
slide the Wire Straightener down. Likewise If the wire is feeding downward, slide the Wire
Straightener up.
Figure 7a - Wire Curls Up
Figure 7c - Optimal Setting with
Wire Pointing at 2 o'clock.
Figure 7b - Wire Curls Down
Aligning the Wire Holder (Figures 8a & 8b)
WIRE IN
WIRE
HOLDER
ALIGN TO
BENDER
BAR
GROOVE
Wire Holder
Adjustment Screw
G50665
Figure 8a - Wire Holder Alignment
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  Inordertoformaqualitystitch,theWireHolderhastobeinalignmentwiththeBenderBar.
Specifically,thecutpieceofwireheldintheWireHolderhastolineupwiththegroovesintheBender
Bar.Pooradjustmentmaycausebrokencrownsorotherpoorstitching.Loadapieceofwireintothe
Wire Holder.
  Usingamirror,checktomakesurethewireintheWireHolderislinedupwiththegrooves
intheBenderBar(Figure8b).TurntheAdjustmentScrew(G50665)untilthewireisalignedwiththe
groovesintheBenderBar.TightentheHexNuttosecurethissetting.
  RemovethewireintheWireHolderandloadanotherpieceintheStitcherHead.Verifythat
the setting established is accurate by again checking the piece of wire with the mirror.
WIRE
BETWEEN
BENDER
INSERT
GROOVES
Figure 8b - Wire Holder Alignment
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Aligning the Clincher Plate (Figure 9)
Figure 9 -Clincher Plate Alignment
042001 (2)
Adjust upper or
lower Cap Screws
to correct alignment
G20191 (2)
Locks adjustment
Screws in position
Front View Side View Back View
9093A
G50710 (2)
Always disconnect the power supply before
making any adjustments or servicing the head.
WARNING
!
Align Driver
with gap in
Clincher Plate

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Make sure all guards are in place before
operating the stitcher head
WARNING
!
Adjusting the Length of the Stitch Leg (Figure 10)
Figure 10 - Adjusting the Stitch Leg
G50197A
G20573
G50245
G50181
Longer
Right Leg
Shorter
Right Leg
Move wire
center right
Move wire
center left
G50119A
Disengage the
Feed Gears when
making adjustments

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Lubrication (Figure 11)
Recommended Oil
- SAE #10
- Household 3-in-1
Figure 11 - Lubrication
G20293 and G20293B
Moisten completely
every spool change or
once a month,
whichever occurs first
G50131
One drop of oil
on both sides
G50262A
One drop of oil
in the oil cup
Maintenance

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Figure 13 - Rotating the Driver
Rotating Replacement Parts (Figures 12 & 13)
G50152
Slide out from
Bender Bar,
Rotate and
Replace
G50183
Swing out
of the way
Figure 12 - Rotating the Cutters
G50383B
Loosen to
rotate Cutter
G50206
Remove
G50197A
Remove
completely
from Head
G20589
Loosen
G50200
Rotate to
new surface
G50559A
Remove
G50153 (2)
Remove

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RoutinecleaningisimportantforthemaintenanceofyourG5Head.Blowoffdust,dirtand
build-upwithcompressedairatleastduringSpoolchanges.TheHeadshouldberefurbishedevery
one million stitches:
•Large Feed Gear Assembly (G50110A):
Removeandwashinapetroleum-based,oil-dissolvingsolvent,dryandrepacktheFeedGear
with any general Lithium-based light weight Grease.
•Anywhere that dust, oil, pieces of wire and/or paper have built up:
Forexample,aroundtheClincherPointsandbytheFormingPinCam(G50117).Remove
the Wire Holder and blow clean with pressurized air.
Cleaning
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partnumber,
description and quantity at 800-634-0810.
Ordering Spare Parts

Troubleshooting (Figure 14)
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The quality and quantity of work that can be produced with the G5 Stitching 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possiblesolutionswhichshouldcoverthemajorityof
situations encountered when stitching with the G5 style Stitching Heads.