DeLuxe Stitcher G8 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 G8 Stitcher Head
for future reference. If you have any questions, contact your local DeLuxe Stitcher
Company Graphic Arts Representative or Distributor.
G8 Stitcher Head
OPERATION AND MAINTENANCE MANUAL
Head Serial Number :
Date Purchased :
Where Installed:
(make/model of machine)
Watkiss Edition
G8WAHD241/2
DELUXE STITCHER
COMPANY INC.
®
solving your wire stitching needs for 125 years...

WARNING!
G8 Stitcher Head
Watkiss Edition
The intended application of this stitcher head is limited to installation
within an enclosed Watkiss book finishing system. Any other installation
of this stitcher head compromises the operator safety.
No untrained operator should attempt to make any adjustments or
service to the stitcher head.
Please make sure you read and understand all of the safety and
interlock features built into the Watkiss book finishing system before
attempting to service or make adjustments to the stitcher head.
Serious damage to the stitcher head can occur if the stitcher head is
cycled with wire feed in the absence of paper stock.
Always disconnect power before attempting to service or make
adjustments to the stitcher head.

3
Specifications.....................................................................................................4
Installation .......................................................................................................4
Pre-Inspection.................................................................................4
Inspection .......................................................................................4
Assembly Parts ..............................................................................5
Mounting ........................................................................................6
Operation ........................................................................................................7
Wire Threading ..............................................................................7
Wire Straightening .........................................................................9
Aligning the Wire Holder ...............................................................10
Adjusting the Stitch........................................................................11
Maintenance......................................................................................................14
Lubrication & Maintenance ...........................................................14
Appendices ......................................................................................................15
Sub-Assembly Exploded Drawings ...............................................15
Part Number/Description Cross Reference ..................................22
Registration Card.............................................................................................25
Replacement/Wear Parts Kit........................................................................26
Warranty .......................................................................................................27
Table of Contents

4
Specifications
Weight
Shipping Weight ..............12.6 lbs (5.7 kg)
Box Size ...................22 x 11 x 3 1/2
Physical Dimensions
Height ...................13-9/16” (345 mm)
Width ...................2-3/4” (70 mm)
Stitching Capacity ..................Two Sheets to 5/16” (8 mm)
(Stitching capacities are highly dependent on wire and paper type, tensile strength and machine capacity.)
Installation
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.
Pre-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:
 •G8Manual
 •2.0mmHexKeyWrench(G20374)
 •2.5mmHexKeyWrench(G20361)
 •3.0mmHexKeyWrench(G20360)
 •7.0mmOpenEndWrench(G20364)
 •T8TorxWrench(G20375)
Inspection

5
Please take a few moments to fill out the registration card located on page 25-26 prior to beginning installation.
Assembly Parts (Figure 1)
 •CompleteWireGuideSpringPlateAssembly(G50808WA)
 •UpperWireTube(G20181W)withC-Clip(G20207)
 •RearClampPin(G20366)
 •RearClampNut(G20367)
 •AdjustmentKnobAssembly(G20228A)
 •MountingBlock(G50102)
 •CrankDriveLink(G20340WA)
 •ClincherPlateAssembly-Thick(7650WA)
 •StitchSamples
Figure 1 - Assembly Parts
G20228A
G20364
7mm Wrench
G50808WA
G20366
G20367
(8mm thread)
G20181WA
Clincher Plate
Assembly
(See page 21 for
more detail on full
assemblies.)
G20170
(8mm thread)
G50102W
G20340WA
G20378W
G20361
2.5mm Hex Key
G20374
2mm Hex Key
G20375
T8 Torx Key
G20360
3mm Hex Key

6
Mounting (Figure 2)
Upper Cutter Block
Adjustment Bar
G20245
Figure 2 - Mounting the Head

7
1. Remove the wire holder by first sliding the
retaining leaf spring to the side (Figure 3).
2. Thread the wire from the supply spool
through the center of the wire felt cleaning pads
and into the stitch-wire guide block (Figure 8).
3. Continue to feed the wire until it gets
through the feed gears and into the lower wire
tube (Figures 4-8).
4. Run a single book with six stitches through
the machine to load the wire.
Operation
Wire Threading (Figures 3-8)
Figure 3 - Threading the Head
Wire Holder
Retaining
Spring
Wire Holder
Feed Gears
Middle Wire Tube
Figure 4 - Threading
the Head

8
Figure 6 - Threading the Head
Figure 8
Cut-out View of
Wire Threading
Figure 5 - Threading the Head
Small Feed Gear
Large Feed Gear
Lower Wire Tube
Figure 7 - Threading the Head
Middle Wire Tube
Cutter Block
Wire Straightener
Eccentric
Adjustment Handle
Wire Guides
Wire
Feed Release Shaft
Upper Wire Tube

9
Horizontal Adjustment (Figures 10-11)
Turn the wire feed on and manually cycle the stitcher head.
Observe the direction the wire is moving as it emerges. Use a
slotted head screwdriver on the Wire Straightener Eccentric in the
CutterBlocktoadjustthewire.Ifthewireiscurvedupwards,turn
the Wire Straightener Eccentric counter-clockwise. If the wire is
.010 [.25mm] GAP
Figure 11c - Wire Curls Down
Figure 11b - Wire Curls Up
Figure 11a - Straight Wire
Figure 9 - Adjust the Wire Feed Gap
Adjusting Wire Straightness (Fig. 9-12)
Figure 10 - Adjusting Wire Straightness
LOWER WIRE
RAISE WIRE
Note:Usingametalshimtosetthisgapwillsimplifythisstep.
Wire
Straightener
Eccentric
Hex Nut
Set Screw
SKIP
UNLESS
WIRE TUBE
HAS BEEN
MOVED OR
SHIFTED
FROM
FACTORY
SETTINGS.
NOT APPLICABLE
TO LOT14
ONWARD

10
feeding downward, turn the Eccentric clockwise.
Front-to-Back Adjustment (APPLY ONLY UP TO LOT13)
If the Wire Guide Bars are not properly positioned, the wire
will rub against them as it exits the Cutter Block. Look at the
G8 Head from the side past both the Right and Left Wire Guide
Bars(Figure12).Makesurethereisaclearviewoftheopening
in the Fixed Wire Cutter from the side of the G8 Head. If there
isnot,loosentheFlatHeadMachineScrewssecuringtheWire
Guide Bars to the Pivot Block and move them out of the path of
the wire. Tighten the Screws after making sure the Wire Guide
Bars are even with each other. Replace the Wire Holder and re-
engage the Wire Holder Retaining Spring.
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.
Aligning the Wire Holder (Figure 13a & b)
Figure 12 - Wire Guide Alignment
Fixed Wire
Cutter
Screw
(1 per side)
WIRE IN
WIRE
HOLDER
ALIGN TO
BENDER
BAR
GROOVE
Wire Holder
Adjustment Screw
Figure 13a - Wire Holder Alignment
WIRE
BETWEEN
BENDER
INSERT
GROOVES
Figure 13b - Wire Holder Alignment

11
Load a piece of wire into the Wire Holder. Check to make sure the wire in the Wire Holder is lined up
with the grooves in the Bender Bar (Figure 13b). If it is not, loosen the Socket Head Set Screw in the
frontoftheWireHolderandtheHexNut(seeninFigure10)securingtheWireHolderAdjustmentScrew
(Figure13a).TurntheAdjustmentScrewuntilthe wireis alignedwiththe groovesin theBenderBar.
Tighten the Hex Nut and Set Screw 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.
Beforemakinganyadjustments,makesure
your stitching machine compression setting
issettotheproperthicknessofwork.Makeafewsamplestitchesandlookattheresults.
Setting the Stitch Gap (Or Adjusting the Wire Draw)
 Toadjusttheoveralllength(wiredraw)ofthestitch,disengage the Small Feed Gear by turning the Feed
ReleaseHandle1/4ofaturntotherightasshown.AdjusttheFeedRackAdjustmentKnobuntilthegap
betweenthestaplelegsallowsonlytheedgeofangernailtopassbetweenthem.
• Toextendthelengthofthestitchordecreasethegap,turntheFeedRackAdjustmentKnobclockwise.
(See upper view of Figure A)
• To shorten the length of the stitch or increase the gap, turn the knob counter-clockwise. (See lower view
of Figure A)
Centering the Stitch Gap (Or Setting Equal Length Legs)
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 Block. As thicker work is stitched, the Cutter Block must be moved further from
the Wire Holder to keep the legs of the stitch even and the gap centered.
Adjusting the Stitch (Figures 14-18)
RIGHT LEG TOO SHORT
RIGHT LEG TOO LONG
Figure A
Adjust Length
Figure 14 - Adjusting the Wire Draw
LESS WIRE DRAW
MORE WIRE DRAW
Feed Rack
Adjustment Knob

12
For G8 Heads mounted to a machine with an
adjusterrail,loosen thetwo (2)HexHead Screws
securing the Lower Cutter Block Adjustment
BarandCutterBlockAdjustmentConnectorto
the Upper Cutter BlockAdjustment Bar.  For
all G8 style Heads,placetheAdjustmentKnob
over the Cutter Adjustment Stud as shown in
Figure 15 and engage the teeth of the Cutter
Block Adjustment Rack and adjust as shown
in the following illustrations. Be sure to run a
coupleofstitchesaftereachadjustment.
1/16"[1.6mm]
TOO FAR LEFT OF
CENTER OF STITCH
WIRE LENGTH
1/16"[1.6mm]
TOO FAR RIGHT OF
CENTER OF STITCH
WIRE LENGTH
Gap of stitch is
1/16" off center to
the right. To correct.
turn the Adjustment
Knob clockwise. to
shift the Cutter Box
1/16" to the left.
Gap of stitch is 1/16"
off center to the left.
To correct. turn the
Adjustment Knob
counter-clockwise
to shift the Cutter
1/16" to the right.
Figure B
Adjust Left
Figure C
Adjust Right
Figure 16 - Adjusting the Stitch Figure 17 - Adjusting the Stitch
Figure 15 - Adjusting the Stitch
Socket
Head
Screw
Cutter Box
Lower
Cutter Block
Adjustment
Bar
Cutter Block
Adjustment
Connector
Upper Cutter Block
Adjustment Bar
Adjustment
Knob
Cutter Block
Adjustment
Rack
Always disconnect the power supply
before making any adjustments or
servicing the head.
WARNING
!

13
CORRECT SETTING.
CENTER LINE OF BOTH STITCH
& DRIVER ARE ALIGHED
The ideal stitch has the center of gap
aligned to the center of the finished stitch.
Figure D
Correct Stitch
Figure 18 - Adjusting the Stitch
Always disconnect the power supply before
making any adjustments or servicing the head.
WARNING
!

14
Lubrication & Maintenance (Figure 19)
Your new Deluxe Stitcher head was designed to minimize both the maintenance and lubrication require-
ments that are normally associated with standard stitcher heads. This was accomplished by incorporat-
ing a high tech bonded coating that helps reduce friction and wear to many of the critical wear parts.
The lubrication and maintenance schedule is as follows:
Maintenance
Time or Cycle Interval Required Maintenance
Monthly 9Checkforandremoveanypaperberordustaccumulation
onstitcherhead.Useahighpressuredustertoblowout
dust and debris.
9Lubricate driver bar (G20151) visible surface as shown
inFigure19withsmallamountKluberIsoexNBU15
grease.
Every wire reel change 9Checkforandremoveanypaperberordustaccumulation
onstitcherhead.Useahighpressuredustertoblowout
dust and debris.
9Lubricate driver bar (G20151) visible surface as shown
inFigure19withsmallamountKluberIsoexNBU15
grease.
Every 3 reels of wire consumption
(approximately 1,000,000 cycles)
9Remove and disassemble stitcher head per replacement
part instructions.
8Clean off any residual lubrication
8Replace all wear parts (included in
ServiceKit#914-874)
8Re-LubricatestitcherheadwithKluberIsoexNBU
15greaseinspecicareasshownininstructions.
Every 15 reels of wire consumption
(approximately 5,000,000 cycles)
9Remove Head and send in to Watkiss for a complete
factory rebuild.
Figure 19 - Lubrication Points

15
Bonnet Sub-Assembly
G20170
G20367
G20366
G20229 (2)
G20273 (2)
G20275
G20264 (2) G20115
G20122A (2)
G20191 (2)
G20190 (2)
G20000A
(INCLUDES
G20191 (2),
G20229 (2) &
G20120 (2))
G50102W
G20378W
G20120 (2)

16
Bonnet Sub-Assembly
G20264
G20118W
G20119W
G20245
G20250 (2)
(Use Blue Loctite)
G20289 (2)
G20246
G20191
G20243
G20242
G20220
(Use Blue
Loctite)
G20241 (4)
G20113W (2)
G20202
G20204
G20175 (2)
G20234 (2)
G20140
G20231
G20230A
G20233
G20232
G20235
G20167 (2)
G20237B
G20240 (4)
G50268
G20214 (2)
G20244
G20126
G20236
G20196 (2)
G20182
G20269
G20133A
(INCLUDES
G20133 &
G20269)
G20263
G50431
(USE BLUE LOCKTITE)
G20249 (2)
G20133
G20144A
G20240 (2)
G20237 THRU
LOT 16
G20239 (2)
DISCS SHOULD BE CUPPED

17
Feed Lever and Feed Gear Assemblies
G20268
G20112
G20262A (2)
G20263 (2)
G20132
G20264
G20266
G20140
G20267
DBSG8W40
1. - MUST BE INSTALLED
5mm BELOW G20132 SURFACE
2. - APPLY BLUE LOCTITE
G20110
G20110A
INCLUDES
G20110 & G20137 G20137
(BEARING)
G20181W
G20189 (3)
G20136BA
G20111A
INCLUDES
G20111,
G20138 (2)
G20139BA
INCLUDES
G20139B,
G20229,
G20273
G20139BAA
INCLUDES
G20139BA,
G20196, G20541B
G20128
G20129
G20138 (2)
(BEARINGS)
G20111
G20195
G20541 (2)
G20579 (2)
*
*
*
*
*
*
*
*
G20214 (2)
G20143
G20541B (2) G20229
G20229
G20273
G20196 (2)
G20256
072001
G20195
G20207
USED ON
LOT16 AND UP
G50394
G20114
G20261B
G20175
G20184
G20183
PIVOT BLOCK ASSEMBLY
THRU LOT13 G20187
G20186
G20273
G20196 (2)
G20196 (2)
G20298
G50617
G20139A
INCLUDES
G20139,
G20229,
G20273
INDICATED PARTS NOT USED ON LOT14 ONWARD
G20181WA
INCLUDES
G20181W AND
G20207

18
Driving and Feed Slide Assemblies
G20131W
G20127
G20174
G20264
G20176 (2)
G20173
G20179
G20177
G20164B
G20171
G20165W
G20320
G20321W
G20170
G20323A
G20167 (2)
G20130
G20340WA
G20320WA
Complete
Assembly
USE KLUBER ISOFLEX
NBU15 ON BEARINGS
(REF. G20824)

19
Bender Bar and Wire Holder Assemblies
G20160B
G20161
(USE BLUE
LOC-TITE TO
ASSEMBLE)
G20159
G20344W
G20342
G20154A
G20152 (24-28 rd)
G20153 (2)
G20151
G20149W
G20155
G20150
G20224
G20433 (4)
G20156
G20148W
G20147WA
(INCLUDES
G20147WMATL,
G20148W &
G20431 (4)
G20346B
G20147WAA
Complete
Assembly
G20147WMATL
G20252
G20253
G20255
G20135
G20559WA
Complete
Assembly
G20254
G20273
071004
G20226
G20559W
(WITHOUT COMPONENTS)
G20665
USE BLUE LOCTITE
TO ASSEMBLE

APPLY BLUE LOCTITE
APPLY GREASE
20
Cutter Block Assembly
LOWER WIRE TUBE UPGRADE KIT
FROM LOT13 TO LOT14
---------------------------------------------------
ORDER KIT NUMBER: G20199WAA
KIT INCLUDES:
• G20199B-1,
• G20199B-2,
• G20206B,
• G20208D,
• G20213,
• DW1058
LOWER WIRE TUBE PARTS
THRU LOT13
G20196B
APPLY BLUE LOCTITE
APPLY BLUE LOCTITE G20206B
G20210
G20200C
(CARBIDE)
G20191 (2)
G20197A
G20198
G20145CW
(CARBIDE)
G20218
G20219 (4)
G20226 (2)
G20197WAA
LOT14 ONWARD
Complete Assembly
(All parts on this page)
G20216 (2)
G20208B (2)
G20213 (2)
G20212
G20199A
G20196
G20199B-1
G20208D
DW1058
G20206
G20208B
G20213 (2)
G20199B-2
G20211
071004
*
*
*
*
*
*
INDICATE PARTS NOT USED ON LOT14 ONWARD