iSP 406 User manual

MODEL
406
406-B
OWNERS
MANUAL
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Section 1 INTRODUCTION
1. Model and Serial Number
2. Product Specifications
Section 2 SAFETY PRECAUTIONS
AND PROCEDURES
4. Safety
4. Safety Guards/Cover
Section 3ASSEMBLY,
LUBRICATION,
INSTALLATION
5. Before Unpacking
5. After Unpacking
5. Assembly
6. Threading wire and adjusting wire
straightners
7. Lubrication-Felt Pads
8. Lubrication-Stitcher Head
9. External Lubrication
10. Internal Lubrication
Section 4OPERATION
11. General Stitching
11. Table Stitching Using Work Trip
11. Table Stitching Using Foot Trip
11. Stitch Repeat
11. Hand Jog
12. Master and Secondary
12. Work Guides:
Side Guides
Corner Stitch Guides
12. Changing Work Thickness
Section 5 MAINTENANCE, TROUBLE
SHOOTING AND ADJUSTMENT
13. General
13. Recommended Spare Parts
13. Cleaning and oiling
13. Stitching Adjustments
13. To Equalize Both Legs of Stitch
14. Trouble Shooting-M2000 Head
17. Trouble Shooting-Drive
20. Insufficient or Excessive Compression
20. Table/Clincher Bracket Adjustment
20. Clincher
21. Clincher Point Height Adjustment
21. Reversing or Replacing Clincher Points
22. Head/Clincher Alignment
22. Bender bar
23. Bender bar Friction Plug
23. Driver Bar
24. Bender Bar Latch
24. Grip, Grip Release Slide and Faceplate
25. Wire Cutters
26. Wire cutter Operating Slide
26. Proper Wire
26. Rotator
27. Wire Straighteners
28. Supporter
28. Tension Pawl
28. Work Trip
29. Stitcher Head Disassembly
31. Drive/Frame Disassembly
Section 6PARTS LIST
35. Drive/Frame
40. M2000 Head Stitcher
Section 7ELECTRICAL
42. Electrical Schematic (115 V.A.C.)
CONTENTS
USE REPLACEMENT PARTS
DESIGNED AND
MANUFACTURED ONLY BY
INTERLAKE SPECIFICALLY FOR
YOUR M2000 STITCHER

1
Section 1
INTRODUCTION
MODEL 406
Your stitcher with the M2000 Stitching Head has been engineered and developed to provide you with the
finest equipment available for your stitching needs. With proper care and maintenance it will give you years
of satisfactory efficient service. This manual shows you how to get top performance from your stitcher and
is divided into 7 major sections.
Read the Model 406 Manual throughly. Study it carefully. Best stitching performance will be assured, if all the
adjustments are made as instructed, so that you get the following desired results.
1. Good Cut-Off
2. Uniform wire draw
3. Equal leg length
4. Proper clincher alignment
5. Sufficient compression
When ordering parts or requesting information, please state: Quantity required, part number, part
name, model and serial number of your stitcher.
Model 406 Serial Number____________________
Model 406’s M2000 Head Stitcher Serial Number____________________
Here are the instructions on
how to install
operate, maintain, and make
repairs on your

2
MODEL 406
PRODUCT SPECIFICATIONS
Unit Weight: Overall: 30 Lbs.
Without Wire Spool: 25 Lbs.
Unit Envelope Size: Height Length Width
Overall: 19 3/4" 15" 10"
Without Tables and Wire Guide: 15 1/4" 12 1/2" 4"
Wire (Interlake 417-0025)
Wire Material: 120,000 to 150,000 p.s.i. tensile strength
tinned steel wire
Wire Size: 25 Gauge (.020" Diameter)
Wire Spool Weight: 5 Lb. Spool (Fully Loaded Wire)
Stitching Speed 173 stitches per minute, full load capacity.
199 stitches per minute, minimum load
capacity.
Stitching Capacity (20 Lb. Bond Paper)
Minimum Stitching thickness adjustment .94" Wire Draw, Approx. 57,000 stitches
per 5 Lb. coil.
Maximum Stitching thickness adjustment 1.24" Wire Draw, Approx. 43,000 stitches
per 5 Lb. Coil.
Maximum Stitching thickness: 1/4"
Stitcher: M2000 Head CTTT-2605-T3
(Equipped with faceplate adjustment lever)
Table
Length: 10"
Width: 9"
Optional Equipment:
Side Guides: Pop-Up/Pop Down pins in arms which adjust to 9 5/8" from center of clincher.
Corner Guides: Pop-Up/Pop Down pins in table for 45 degrees corner stitch when flat table stitching.
Foot Switch Assembly: To activate Model 406

3
MODEL 406
PRODUCT SPECIFICATIONS
Throat Depth: 4" Max.
Stitch Modes:
Work Trip (For Table Mode): Plug foot switch into rear of housing.
Foot Trip (For Saddle or Table Mode): Manual Switch Control.
Master-Secondary (For use with Plug master into 2nd-3rd units for
multiple stacked unit): side by side multiple stitch (4 1/2 in.
min. centers).
Quick adjust for 3/16" to 4" throat depth.
Jog: Push in and turn knob, on rear of housing,
for manual forward or reverse operation.
Models:
Solid Clinch Activated Clinch
115 V.A.C. Model 406 Model 406-B
Electrical
Input: 115 V.A.C. 60 HZ
Control Circuit: 12 V.D.C.
Motor: 1/20 HP, 90 V.D.C.
Circuit Breakers: 1 AMP for 115 V.A.C. Input

4
CAUTION
Do not operate stitcher until operating
instructions have been read and understood-
do not operate stitcher at anytime without
work under the head.
CAUTION
FOR YOUR SAFETY, MAKE SURE ALL
COVERS ARE PROPERLY IN PLACE
BEFORE OPERATING MACHINE
DANGER
KEEP HANDS CLEAR OF
STITCHING AREA
CAUTION
THE SUPPLY CIRCUIT FOR ANY
405/406 SERIES UNIT MUST USE A
15 AMP MAXIMUM FUSE OR
CIRCUIT BREAKER. THE SHORT
CIRCUIT CAPACITY OF THE
SUPPLY CIRCUIT MUST NOT
EXCEED 2000 AMPS.
Section 2
SAFETY PRECAUTIONS
AND PROCESURES
SAFETY
1. Make sure electrical power is turned off before
performing any adjustment or maintainence.
2. Keep hand, tools, hair, and clothing clear of
stitching area.
3. Become familiar with the moving components of
your machine. Keep fingers away from areas
that could pinch or cut.
4. Observe your plant safety rules.
5. Exert “good housekeeping” in your work area.
Keep it as clean and uncluttered as possible.
6. A well maintained machine is a safer machine.
Clean and lubricate the machine at regular
intervals. Check machine daily for broken or
worn parts. Replace as necessary. DO NOT
attempt to operate the machine if a part is broken.
7. Route all electrical cables away from pedestrian
transportation lanes.
8. See “Safety Guards/Cover” information. It points
out areas where additional caution should be
exercised. If you are unsure how to safely operate
or maintain your Stitcher, contact your Service
Representative.
SAFETY GUARDS/COVER
A. Grey Plastic Cover: Covers frame, motor,
mechanical, and electrical components.
B. Front, Clear Plastic, Guard Assembly: A three
position guard. In the fully downward position
the guard is spring loaded to: cover the M2000
Head, and work trip adjustment knob; restrict
access to the stitching area; depress a limit
switch to allow the machine to operate. The
guard can be swung up to its first detent position
(about 70 deg.) to allow access to the work trip
adjustment knob and lower portion of the M2000
Head. The guard is swung up to its second
detent position (about 155 deg.) to allow total
access to the M2000 Head for faceplate
adjustment, lubrication, and wire threading.
ATTENTION
LE CIRCUIT D'ALIMENTATION DESTINE
A UNE UNITE DE LA SERIE 405/406 DOIT
COMPORTER UN FUSIBLE OU UNE
PROTECTION THERMIQUE CALIBREE A
15 AMP MAXIMUM. LA CAPACITE DE
COURT CIRCUIT DU RESEAU NE PEUT
PAS DEPASSER 2000 AMPS.

5
Section 3
ASSEMBLY, LUBRICATION
INSTALLATION
Note:
These instructions must be followed to insure
proper installation, efficient operation and the
prevention of serious damage to your stitcher.
Before Unpacking:
Examine the outside of the crate or carton for any
visible damage. If damaged DO NOT UNPACK
THE STITCHER. Notify the carrier who delivered
the stitcher.
After Unpacking:
Examine your stitcher carefully for any damage in
transit. If damaged, DO NOT INSTALL THE
STITCHER. Notify your nearest representative and
the carrier who delivered your stitcher.
Make certain that you get a signed copy of the Carrier
Inspector’s Report of the damage incurred
ASSEMBLY (FIGURES 1,2,3)
1. Place the Model 306 on a table or bench.
Assemble per figure 1.
2. Turn Trip lever Knob (Index D) counter
clockwise and move the work trip (Index E) all
the way toward the clincher (Index F). Install
the Rear Table Plate (Index B) and Table
Assembly (Index A) to the stand using the four
8-32 x .375 flat head cap screws (Index C).
3. Install Wire Guide Spring into wire guide bracket
of M2000 Head.
Wire Spool Washer
Wire Spool Stud
Support Conical Spring
Spool Retainer
Coil of Wire
Hair Pin Cotter
NOTE: Slide coil of wire onto
spool stud so that the wire will
feed upward from the rear
Figure 1
(QF41AF1)
Figure 2
(QF41AF2)
Figure 3
(QF41AF3)
A
E
D
B
C
F

6
Figure 4
(CTTT2605T3 Scene 3, 4)
THREADING WIRE AND
ADJUSTING WIRE
STRAIGHTENERS (See fig. 4)
1. Draw wire by hand, from the the coil (Index A).
2. Thread the wire through the slot (Index B) at the
end of the wire guide spring, through the wire
guides (Index C), between the thin and thick felt
wire wipes (Index D), through the upper wire
straightener (Index E), and through the lower
wire straightener (Index F).
3. Release the rotator operating spring (Index H)
from the rotator and swing it to the left. Remove
Rotator (Index K).
4. Thread the wire between the tension pawl and
tension roll (Index G). Feed the wire through the
wire cutter lead-in hole (Index I) in the bottom
of the face plate.
5. Push grip post to left to open the grip (Index J).
Insert wire and release the post so that the grip
engages the wire for feeding into the rotator.
A
E
B
D
C
J
G
K
I
F
H
L

7
FELT WIPE PADS
LUBRICATION
AND MAINTAINANCE:
(FIGURE 5)
IMPORTANT! In order for the stitchers to operate
properly, the felt wire wipes MUST be rotated and
dampened with SAE 20W oil before each new
spool of wire (50,000 to 70,000 stitches). Replace
felt pads when they become so dirty that they cannot
be rotated to a clean spot.
6. To check adjustment, hold open grip (Index J
and pull about 1 1\2 feet of wire from below
face plate. Cycle machine once by hand to cut
wire. Cycle machine again by hand to observe
wire straightness. The wire (Index L) should
point straight down, prior to being cut, as shown
in Figure 4 .
7. Adjust the upper wire straightener, beginning at
position shown, (Index E, Figure 4) so that the
wire points straight down. Adjust the lower
wire straightener, beginning at the 3:00 o'clock
position, (Index F, Figures 4) so that the wire
(Index L, Figure 4) feeds straight down.
8. Replace the rotator and rotator operating spring.
NOTE:
When changing coils or wire sizes, check straightners
to insure proper wire feed.
Dirty area of pads has been
slightly rotated so that a clean
area of pads can be used for the
next wire spool.
1. After every wire
spool, rotate the dirty
area of the pads
slightly so that a clean
area can be used for
the next wire spool.
2. Dampen both pads
(about 30 to 40 drops)
using an SAE 20W
oil.
Rotate
Figure 5
(CTTT2605T3 Scene 5)

8
Typically, the 1/2 inch crown stitcher will run for
1,000,000 cycles without additional lubrication.
However, the following procedure used after each
spool of wire will assure optimum life and
performance. Use ISP lubricant #CA9640.
A. Inject lube into hole, or remove and lube shafts.
B. Wipe area clean and inject a small amount of
lube into cam area.
C. Remove rotator, wipe rotator clean and lube
rotator body.
D. Apply lube to rotator ramp.
E. Wipe clean inside of rotator holder.
STITCHING HEAD
LUBRICATION:
(FIGURES 6 & 7)
Figure 6
(CTTT2605 Scene 5)
H
B
C
A
D
E
F
G
F. Inject a small amount of lube into cam area of
driver bar.
G. Inject lube into cutter operating slide.
H. Wipe driver clean, and apply a light coating of
lube.
After prolonged use (or storage) accumulations of
wire dust, dirt, or other contaminants can mix with
the stitcher lubricant. This will reduce the lubricant's
effectiveness. The following procedure is
recommended every 1,000,000 cycles.
1. Disassemble the head and clean all parts.
2. Lightly lube all sliding surfaces using ISP
lubricant #CA9640.
3. Double check lube points A through H.
Figure 7
(CTTT2605 Scene 6)

9
Lubricate the following points before each spool of
wire using SAE 20 oil.
L. One drop in top hole of head operating link.
Access through slot at top of cover behind stitcher
head.
M. One drop in lower/side hole of head operating
link. Access through round hole (while viewing
through slot immediately above round hole) in
side of cover.
N. One drop on clincher slide.
EXTERNAL LUBRICATION:
(FIGURES 8, 9, 10)
L
M
Figure 8
(CA44 Layout 2)
Figure 9
(QF41AF4)
L
M
Figure 10
(QF41AF5)
N

10
INTERNAL LUBRICATION
(FIGURES 11, 12)
Frequency of Lubrication: Every 500,000 stitches
or once a year, which ever comes first.
Unplug power cord, remove grey plastic cover and
apply oil as follows:
O. Two drops to pivot point of clincher operating
lever.
P. One drop between cam and clincher operating
lever.
Q. One drop on roll pin.
R. One drop on each clincher rocker lever roll
Figure 11
(QF135B-F6)
Figure 12
(QF41AF7)
P
Q
O
R

11
Section 4
OPERATION
General:
After having properly installed and set up the
machine, it is now ready for stitching. It is
recommended that each operator be instructed as to
correct operating procedure and normal adjustments
necessary for varying work conditions.
WA R N I N G
Prevent accidents by following these
rules:
1. Do not put your hands near area to
be stitched when machine is operating.
2. Turn the power off when the stitcher
is not in use.
Table Stitching Using the Work
Trip:
Switch off power. Swing up front guard assembly.
Turn the trip lever knob counter clockwise and
position the work trip to achieve the desired stitch
location. Swing down the front guard assembly.
Switch power on. Insert work, from the front, into
the stitching area until the work depresses the work
trip, causing stitch.
Table Stitching Using the Foot
Switch (Optional Equipment):
Switch off power. Swing up front guard assembly.
Turn the trip lever knob counter clockwise and
position the work trip to serve as a back gauge or
move work trip completely back out of the way of
the work. Plug the foot switch cord into foot switch
outlet on rear control panel (work trip is then
automatically bypassed). Switch power on. Load
work, from the front, into the stitching area. Once
the work is positioned as desired step on foot switch
to cause a stitch.
Hand Jog:
A hand jog is located at the rear of the machine. To
manually cycle the Model 406: switch off power; push
in and rotate knob counter clockwise to go through a
normal stitch cycle, or clockwise for a reverse cycle.

12
Master Out and SecondaryUnit In:
These outlets are only for use with the "Multiple
Stitch Accessories".
CAUTION
AVOID DAMAGE TO YOUR
STITCHER BY FOLLOWING THESE
RULES:
1. Never operate your stitcher with wire
feeding unless you have work material
between the clinchers and benderbar.
2. Do not drive one stitch on top of
another.
Work Guides (Optional
Equipment):
A. Side Guides: To adjust side guides pop-up the
pins at the end of each guide, loosen the screw
knob beneath the table, position guides as desired,
and retighten the screw knob.
B. Corner Stitch Guides-Table Use Only: Pop Up
the pins located in the table and the pins located
at the end of each side guide. Using your work
as a set up tool, position and secure the side
guides as indicated in figure 13. Switch off
power, swing upfront guard assembly, and move
the work trip all the way forward. Swing front
guard assembly back down and switch on power.
Push work into corner guided area of table until
depression of work trip causes a stitch.
Changing Work Thickness:
Changing work thichness will probably require a
change of the wire draw length used to make a
stitch. This is done by raising or lowering the face
plate. To change face plate position switch off
power; swing front guard assembly up to the second
detente position; loosen the faceplate screw
(Located directly above “M2000” on the face plate),
move the position lever up for more wire or down
for less wire, retighten faceplate screw, and swing
down front guard.
Figure 13
(QF41AF8)

13
Caution
MAKE ALL ADJUSTMENTS WITH
THE POWER OFF AND THE
STITCHING HEAD IN NEUTRAL
POSITION! (Fig. 14)
In neutral position, the wire grip assembly
(Index A) is stopped at the top of the slot
in the face plate.
Stitching Adjustments
Best stitching performance will be assured if all
adjustments are made so that you get the following
results:
1. Good Cut-Off
2. Uniform Wire Draw
3. Equal Leg Length
4. Proper Clincher Alignment
5. Sufficient Compression
To Equalize Both Legs of Stitch
(Fig. 15)
1. Loosen the wire guide locking bolt (Index C).
2. Turn adjusting screw (Index D) clockwise to
shorten left leg of stitch; counter clockwise to
lenghten left leg.
3. Tap bracket (Index E) down before tightening
bolt (Index C).
General
Every Model 406’s M2000 Head Stitcher has a friction-
type head which depends on smooth sliding friction
and proper timing to function correctly. Preventative
maintenance will go far to insure trouble-free operation.
Avoid production down time by keeping your stitcher
in top working condition at all times.
Recommended Spare Parts
Like any equipment that has moving parts, certain
parts of your stitcher will be subjected to more
wear than others and require replacement. The
following listing includes all the parts required for
minimum maintenance and good operation of your
Model 406.
PART NAME PART NO. QTY.
Wire Cutters CA9048 2
Grip CA9015D 1
Grip Spring CA168 1
Tension Roll Clip CA9124 2
Rotator CAA9038E 1
Clincher Points CA9083 2
Section 5
MAINTENANCE, TROUBLE
SHOOTING AND
ADJUSTMENTS
Figure 14
(CTTT2605T3 Scene 8)
Figure 15
(CTTT2605T3 Scene 9, 1)
E
C
D
A

14
2. Wrinkled crown.
M2000 Head Trouble Shooting
HERE'S HOW A PERFECT STITCH LOOKS
Should stitches appear in any form other than illustrated, one or more
kinds of mechanical trouble may have caused the malformation. The
possible causes and remedies are given for each kind of mechanical trouble
and are listed under each section. The remedies are indexed to the
Adjustments Section which gives more detailed information about your
stitcher, the mechanical trouble that may occur and suggested remedies.
Unless you recognize the correct cause, check each possible cause given.
TROUBLE POSSIBLE CAUSE REMEDY
A. Defective Stitches
See "To Equalize Both Legs of
Stitch" Page 13
"K" Page 24
"K" Page 24
Page 40
"P" Page 27
"I" Page 23
"R" Page 28
"K" Page 24
1. One or both legs buckled.
NOTE: Since buckled legs are
often concealed in the work and
may appear the same as a short
leg, always remove two or more
stitches to see which is
occurring.
1. Clincher is worn or improperly
aligned.
2. Insufficient compression.
3. Unequal leg length
1. Leg Lengths not adjusted
properly
2. Gripper is worn or dirty
3. Grip release slide is worn
4. Broken wire guide spring
(index 65H)
5. Excessive tension on wire
straightner
6. Worn Driver bar
7. Worn Tension Pawl or weak
tension pawl spring
8. Weak or broken grip spring
3. Length of one leg varies
"C,F" Page 20,22
"A,B" Page 20
See "To Equalize Both Legs of
Stitch" Page 13
"L" Page 25
"N" Page 26
"G" Page 22
4. Burred stitch leg.
5. Incorrect wire size.
6. Worn bender bar.
FLAT CLINCH
LOOP CLINCH
(QF41AF21)

15
TROUBLE POSSIBLE CAUSE REMEDY
4. Corner of crown distorted or
fractured
1. Excessive compression
2. Broken driver bar end
3. Worn bender bar
4. Clincher improperly aligned
or worn
5. Incorrect wire size
"A,B" Page 20
"I" Page 23
"G" Page 22
"C,F" Page 20,22
"N" Page 26
5. Stitch crown not flat and legs
not bent into work
1. Insufficient compression "A,B" Page 20
6. One or both legs turn out 1. Clincher improperly aligned
2. Dull cutters
7. Flat piece of wire "O" Page 26,27
"P" Page 27
"O" Page 26,27
"O" page 26,27
8. Stitches come out in pieces "O" Page 26,27
"O" Page 26,27
"P" Page 27
"N" Page 26
"G,I" Page 22,23
9. Both stitcher legs are either
too long or too short
See "Changing Work
Thichness" Page 12
"F" Page 22
"L" Page 25
1. Rotator is dirty
2. Improperly adjusted lower wire
straightener
3. Broken or worn rotator
4. Improperly aligned rotator
Face plate not adjusted properly
1. Improperly aligned rotator
2. Weak rotator operating spring
3. Improperly adjusted upper wire
straightener
4. Incorrect wire size
5. Wire jammed in bender bar
grooves
M2000 Head Trouble Shooting

16
M2000 Head Trouble Shooting
REMEDYPOSSIBLE CAUSETROUBLE
B. WIRE BUCKLES
1. Wire buckles above the grip
and below the tension pawl
1. Worn driver bar
2. Worn bender bar latch
3. Worn or broken bender bar
friction plug and/or spring
"I" Page 23
"J" Page 24
"H" Page 22
2. Wire Buckles above the wire
cutters and below the grip
1. Improperly aligned rotator
2. Worn or broken wire cutters
3. Burrs on rotator
4. Improperly adjusted lower
wire straightner
5. Worn or broken wire cutter
operating slide
6. Wire cutter slot in face plate
worn
"O" Page 26,27
"L" Page 25
"O" Page 26,27
"P" Page 27
"M" Page 26
"L" Page 25
C. GRIP
1. Grip does not close with
position lever up.
Face plate is too high Loosen face plate screw, turn
set screw (item 36H, page 40)
downward slightly in face plate
clip (item 35H, page 40),
retighten face plate screw.
Figure 16
(CTTT2605 Scene 10VA)
Figure 17
(CTTT2605 Scene10VB8)

17
Drive Trouble Shooting
POSSIBLE CAUSETROUBLE REMEDY
Power cord unplugged Plug in power cord
Contaminants on electrical
contacts of trip mechanism
Faulty electrical contact of trip
machanism. (Pressing the trip
should break the circuit between
the round trip locating rod, Item
25 page 35, and the hexagonal
paper trip rod, Item 24 page 35)
Faulty safety switch
Faulty motor (test using 90 vdc)
Faulty circuit board Replace circuit board
Replace motor
Faulty electrical connections Use electrical schematic page
42, 43 to check wiring
Remove trip machanism, clean,
repair, or replace contaminated
or damaged items
Turn trip lever knob counter
clockwise and move trip mecha-
nism from front to back a few
times
On/Off switch does not light
when switched on
Replace switch
Press in extended circuit
breaker
NOTE: If recently blown, wait
10 min. before pressing in
Circuit breaker for input power
Use electrical schematic page
42, 43 to check wiring
Faulty electrical connection
Stitcher drive does not operate
with work trip
Safety switch is not being
depressed by front guard
Adjust front guard and/or safety
switch bracket
Foot switch is plugged in Unplug foot switch
Circuit breaker is blown Press in the extended citcuit
breaker. NOTE: If recently
blown, wait 10 min. before
pressing in
Faulty foot switch jack Repair or replace foot switch
jack
See foot switch schematic pages
42 and 43 for reference

18
TROUBLE POSSIBLE CAUSE REMEDY
Stitcher drive does not operate
when foot switch is depressed
Safety Switch is not being
depressed by front guard
Adjust front guard and/or safety
switch bracket
Circuit breaker for drive is
blown
Press in the extended circuit
breaker. NOTE: If recently
blown, wait 10 min. before
pressing in.
Faulty foot switch (pressing foot
switch should break contacts of
switch inside Footswitch
assembly)
Replace footswitch
Faulty electrical connections Use electrical schematic page 42
to check wiring
Faulty safety switch Replace switch
Faulty motor (test using 90 vdc) Replace motor
Faulty circuit board Replace circuit board
Stitcher keeps cycling, without
depressing footswitch or work
trip, until power is shut off
Faulty cam switch
Faulty electrical connections
replace switch
Use electrical schematic page 42
to check wiring
Drive Trouble Shooting