DeLuxe Stitcher G5 User manual

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.
DELUXESTITCHER
COMPANY INC.
G5 Stitcher Head
OPERATION AND MAINTENANCE MANUAL
Wire Size: 25 Ga. Round (0.52 mm)
Crown Sizes: 1/2” (12mm) and 13/64” (5 mm) Loop
Capacity: 2 sheets to 13/64” (5 mm)
Head Serial Number :
Date Purchased :
Where Installed:
(make/model of machine)

This manual is produced by DeLuxe Stitcher Company Inc. for Deluxe G5 stitching heads as fitted to
Watkiss Automatic Stitch-Fold units.
Watkiss part number 960-681, Deluxe G5 Stitch Head Operator Manual, March 2003.

Specifications
2
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 Type . . . . . . . . . . . . . . . . . . 25 round (0.52 mm max)
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

13
8[34.9m m]
1
17
32 [39.0m m]
45
64 [18.0mm]
11
59
64 [302.8m m]
123
32 [43.6mm]MIN
1
29
32 [48.4m m]MAX
349
64 [95.6mm]
217
64 [57.4mm]
319
64 [83.7mm]
325
64 [86.0mm]MAX
2
13
16 [71.4mm]
3
55
64 [98.0m m]
77
64 [180.5mm]
13
64 [5.0mm]
DRIVE
ADJUSTMENT
1
59
64 [49.0m m]
STROKE
13
32 [27.9m m]
127
64 [36.0m m]
103
4[273.0mm]
3
8[9.5m m]
13
16 [30.3mm]
24 5
8 [625.6mm]
2131
64 [545.7m m]
17
7
64 [434. 4mm]
Dimensions
3

Installation
4
• G5 Manual
• Bag of tools; 2.0mm, 3.0mm and Double Open End Wrench (5.5mm and 7mm)
• T-Handle Hex Head Wrench; 4mm
• Clamp Block and Cap Screw (for mounting)
• Wire Guide Spring and Wire Anti-Backup Unit
• Clincher Plate, Points, Slide, Nuts and Studs
• Stitch Samples
Contents
Figure 1 - Inspection
A9086DA
G50286WA
G20374
(2 mm)
G20360
(3 mm)
G50707
(5.5 and 7 mm)
G50708
(4 mm)
G50800A

5
Always disconnect the power supply before
making any adjustments or servicing the head.
rWARNING
!
Figure 2 - Assembly
G50181
G50286WA
Assembly (Figures 2 & 4)
G20522
G50181
Align the Clincher
Slide and Driver
G50286WAA G20241 (2)
G50804
G50800A
Do not Jam Tube
into Feed Gears.
Leave a distance
of 1/32” (.5mm)
before tightening
the Set Screw
Insert Tube while
the Feed Gears
are engaged

6
Figure 3 - Mounting the Head
Mounting (Figure 3)
G50716
Turn to adjust
for position
G50102
G50394 (4)
G50162A
Position in rail on
Stitcher Machine
Engage the
Feed Gears
to assist
in mounting
G50367

Figure 4 - Threading the Head
7
Wire Threading (Figures 4 & 5)
Figure 5 - Threading the Head
G50144A
G50110A
G50112
G20293
G50245
Turn to disengage
Small and Large
Feed Gears
G50286WA
G50181
G20293B
G50800A
Insert wire into
Anti-Backup Unit
Pass wire
between
Oiler Felts
G50245
Turn to engage
Small and Large
Feed Gears
Guide Wire between
the Small and
Large Feed Gears
G50804
Loosen to allow
thread to pass

Make sure all guards are in place before
operating the stitcher head
rWARNING
!
Adjusting the Length of the Stitch Leg (Figure 6)
Figure 6 - Adjusting the Stitch Leg
G50197A
G20573
8
G50245
G50181
Longer
Right Leg
Shorter
Right Leg
Move wire
center right
Move wire
center left
G50245
Disengage the
Feed Gears when
making adjustments
See also the addendum at the back of this manual.

Aligning the Clincher Plate (Figure 7)
9
Figure 7 -Clincher Plate Alignment
0030.0030 (2)
Adjust upper or
lower Cap Screws
to correct alignment
G20191 (2)
Locks adjustment
Screws in position
Front View Side View Back View
9083A
G50710 (2)
Always disconnect the power supply before
making any adjustments or servicing the head.
rWARNING
!
Align Driver with gap
in Clincher Plate

10
Lubrication (Figure 8)
Recommended Oil
- SAE #10
- Household 3-in-1
Figure 8 -Lubrication
G20293 and
G20293B
One drop of
oil on each
G50131
One drop of oil
on both sides
G50262A
One drop of oil
in the oil cup

11
Figure 10 - Rotating the Driver
Rotating Replacement Parts (Figures 9 & 10)
G50152
Slide out from
Bender Bar,
Rotate and
Replace
G50183
Swing out
of the way
Figure 9 - Rotating the Cutters
G50383
Loosen to
rotate Cutter
G50206
Remove
G50197A
Remove
completely
from Head
G20589
Loosen
G50200
Rotate to
new surface
G50559A
Remove
G50153 (2)
Remove

PROBLEM:Gap Out of Center
SOLUTION:Lengthen or shorten the left leg by adjusting the Cutter Box.
(See page 9)
PROBLEM:Gap Too Big
SOLUTION:Increase wire draw with the Feed Rack Adjustment Knob, then
center stitch gap as described above. (See page 9)
PROBLEM:Corner Buckled
SOLUTION:Check the Driver (G50152) for a chipped corner and
rotate or replace it if needed.
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.
12
Troubleshooting (Figure 11)
Figure 11 - Troubleshooting
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

13
PROBLEM:Staple Legs Too Long or Too Short
SOLUTION:Correct the overall wire draw by turning the
Feed Rack Adjustment Knob (G20573) (See page 8)
PROBLEM:Legs are Spread or Contracted
SOLUTION:Check wire cut-off.
PROBLEM:Legs Stray Forward or Backward Consistently
SOLUTION:The Stitcher Head is not aligned properly front
to back with respect to the Clincher Plate. (See page 9)
PROBLEM:Stitch Stray Randomly In and Out and Front to Back
SOLUTION:Make sure the Cutters are aligned properly. Check
the tensile strength of the wire or use thicker wire.
PROBLEM:Loose Clinch
SOLUTION:The Clincher Points are too low and need adjusting.
The compression of the stitcher machine is insufficient and needs to be
increased. The eccentric on the Driving Slide Assembly needs to be adjusted.
PROBLEM:Multiple Pieces of Wire Loaded
SOLUTION:Make sure the Wire Holder is clean and free from debris. It
should pass freely within the Bender Bar; straighten the Pivot Block if not.
PROBLEM:Wire Jam
SOLUTION:One or both of the Cutters could be worn or damaged; rotate to a
new cutting surface. (See page 11)
PROBLEM:No wire being drawn
SOLUTION:Make sure the Cutter Box Adjustment Knob is turned
counter-clockwise and the Feed Gears engaged. (See page 8)
Figure 11 - Troubleshooting

14
The G5 Stitcher Head

15

16
Bonnet Sub-Assembly 1
G50117
G50264 (2)
G50132A
G50138
G20140 (2)
G50262A
G50112
G50266
G20233
G50232
G20515
G50235
G50126
G20191 (2)
G50101
G50268
G50703
G50142 (2)
G50182
G50245
0030.0030 (2)
G50714
G50713
G50120
G20579 (2)
0031.5103 (2)
G20223 (3)
G50230A
G50100A

Bonnet Sub-Assembly
ITEM No. DESCRIPTION QUANTITY
G20140 Follower Ball Bearing 1
G20191 Screw M4x.7x8 2
G20515 Dowel Pin M6x14 1
G50100A Bonnet Assembly 1
G50120 Feed Release Handle Bushing 1
G50101 Clamp Block 1
G50112 Small Feed Gear 1
G50117 Forming Pin Cam 1
G50223 Dowel Pin- M3 X 6 LG 3
G50126 Screw M5x.8x25 1
G50132A Feed Lever Assembly 1
G50138 Feed Pinion Bearing 1
G50142 Screw M3x0.5x5 2
G50182 Feed Gear Plate 1
G50230A Cutter Operating Lever Assembly 1
G20140 Follower Ball Bearing 1
G20233 Cutter Operating Lever Roller 1
G50232 Dowel Pin 1
G50235 Dowel Pin M5x12 1
G50245 Cutter Box Adjustment Knob 1
G50262A Small Feed Gear Shaft Assembly 1
G50264 E-Ring 6mm 2
G50266 Dowel M5x10 1
G50268 Feed Lever Spring 1
G20579 Screw M4x0.7x6 2
G50703 Feed Lever Spring Screw 1
G50713 Hex Jam Nut M5 1
G50714 Feed Lever Spacer 1
0030.0030 Screw M5x.8x8 2
0031.5103 Lock Washer Ribbed 2
17

18
Bonnet Sub-Assembly 2
G50141
G50181 or
G50181W
G50111A
G50129
G50137
G50143
G50183
G20191
G50114
G20121
G20274
G50136
G50244
G50646 (2)
G50256
G50144A
G50128B
G20298
G20615
G50397
G50383 (2)
G50695
G50617 (2)
G20191
G50142
G50186
G50187
0031.5103
0031.5103 (2)
0030.3434 (2)
G20522
G20236
0030.3434 (3)
0031.5103 (6)
G50142 (3)
G50711
G50705
G50110A