Watkiss G8 User manual

G8 Stitch Head
Maintenance Kit
Instruction Manual
Issue 2c, January 2014
969-344
for kits Nov 13 onwards - without the G20199A lower wire tube

© Watkiss Automation Limited 2014
All Rights Reserved.
Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright
laws.
Warranty
The information contained in this document is subject to change without notice. Watkiss Automation Limited makes no war-
ranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fit-
ness for a particular purpose.
Watkiss Automation Limited shall not be liable for errors contained herein or for incidental or consequential damage in con-
nection with the furnishing, performance or use of this material.

G8 Stitch Head Maintenance Kit Instructions
CONTENTS
1. Introduction
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 The 914-880 Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 The 914-881 Supplementary Maintenance Kit . . . . . . . . . . . . . 4
1.4 Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Identify the Lot # of the Stitch Head . . . . . . . . . . . . . . . . . . . . . 5
1.6 Stitch Head Differences by Lot # - as supplied . . . . . . . . . . . . 6
2. Disassemble the Stitch Head
2.1 Remove the Stitch Head from the PSQ . . . . . . . . . . . . . . . . . . 9
2.2 Remove the Upper Wire Tube and the Wire Guide Plate . . . 11
2.3 Remove the Middle Wire Tube . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Clean the Lower Wire Tube . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Remove the Wire-holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Remove the Cutter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Remove the Pivot Block Assembly . . . . . . . . . . . . . . . . . . . . . 18
2.8 Remove the Cutter Operating Lever Assembly . . . . . . . . . . . 19
2.9 Remove the Feed Gear Bracket Assembly . . . . . . . . . . . . . . 20
2.10 Remove the Driving Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.11 Remove the Feed Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.12 Remove the Bender Bar Assembly . . . . . . . . . . . . . . . . . . . . 22
2.13 Remove the Feed Lever Assembly . . . . . . . . . . . . . . . . . . . . 23
2.14 Remove the Cutter Adjustment Bar and Slide Plate . . . . . . . 24
3. Fit the New Parts
3.1 Replace the Wire Cleaning Felts . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Replace the Crank Link Screw - [3000K/8000K Only] . . . . . . 29
3.3 Replace the Cutter Box Components . . . . . . . . . . . . . . . . . . . 31
3.4 Replace the Bender Bar Components . . . . . . . . . . . . . . . . . . 38
3.5 Replace the Clincher Points . . . . . . . . . . . . . . . . . . . . . . . . . . 49
continued . . .

- -
G8 Stitch Head Maintenance Kit Instructions
4. Lubricate and Assemble the Stitch Head
4.1 Lubricate the Bonnet Assembly . . . . . . . . . . . . . . . . . . . . . . . 54
4.2 Lubricate and Fit the Bender Bar Assembly . . . . . . . . . . . . . . 54
4.3 Lubricate and Fit the Feed Rack . . . . . . . . . . . . . . . . . . . . . . 55
4.4 Fit the Driving Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.5 Lubricate and Fit the Feed Lever . . . . . . . . . . . . . . . . . . . . . . 58
4.6 Lubricate the Cutter Adjustment Bar and Slide Plate . . . . . . . 61
4.7 Lubricate and Fit the Cutter Operating Lever . . . . . . . . . . . . . 66
4.8 Lubricate and Fit the Feed Gear Bracket Assembly . . . . . . . . 67
4.9 Fit the Pivot Block and Lubricate and Fit the Wire-holder . . . 70
4.10 Fit the Cutter Box and the Middle Wire Tube . . . . . . . . . . . . . 74
4.11 Fit the Upper Wire Tube and the Wire Guide Plate . . . . . . . . 75
4.12 Fit the Stitch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.13 Clincher to Stitch Head Alignment. Side-to-side. . . . . . . . . . . 82
4.14 Install the Stitch-wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.15 Adjust the Wire Straightener . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.16 Check the Position of the Wire-holder - front-to-back . . . . . . 89
4.17 Adjust the Wire Holder Central to the Bender Bar . . . . . . . . . 92
4.18 Make Test Stitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.19 Reset the Stitch Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5. List of Changes
A Lower Wire Tube Upgrade
A.1 Kit List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A.2 Remove the Old Lower Wire Tube Assembly, G20199A . . . . 98
A.3 Fit the New G20199BAA Lower Wire Tube Assembly . . . . . 101

G8 Stitch Head Maintenance Kit Instructions 1
CHAPTER 1 Introduction
1.1 Overview
1.1.1 G8 Stitch Head Maintenance Kit - 914-880
The G8 Stitch Head Maintenance Kit, part no. 914-880 contains the compo-
nents that you must replace every 1,000K stitches.
Additionally the G20199A lower wire tube (see ‘A’ in FIGURE 1:1. ) that is fitted
to stitch heads prior to Lot 14 must also be replaced with the upgraded lower
wire tube, G20199BAA (see B in FIGURE 1:1. ). This item is available sepa-
rately as the 940-140 kit, PSQ Mod.44, G8 lower wire tube.
The G20199BAA is not a maintenance item and is only fitted once.
FIGURE 1:1. Old and new lower wire tubes
A
B
Prior to Lot 14 Lot 14 onward

1 - Introduction - Overview
2G8 Stitch Head Maintenance Kit Instructions
It is recommended that you keep in stock a 940-140 kit, PSQ Mod.44, G8 lower
wire tube for when you visit a machine to do the 1,000K stitch maintenance.
If you need to fit the G20199BAA lower wire tube, then the correct time to do so
is indicated in the disassembly procedure in the next chapter. Instructions are
supplied in APPENDIX A.
1.1.2 G8 Supplementary Stitch Head Maintenance Kit - 914-881
The G8 Supplementary Stitch Head Maintenance Kit, part no. 914-881 contains
the components that must be inspected and replaced if necessary at 3,000K
stitches and 8,000K stitches in addition to the every 1,000K stitch maintenance
kit. The procedures for these components are labelled ‘[3000K/8000K Only]’.
Also you must lubricate the stitch head. If all of the grease is not used, leave the
grease with the machine for the operator to use.
FIGURE 1:2. G8 stitch head maintenance schedule
Kit Stitches (x,000K)
123456789
G8 Stitch Head Maintenance Kit,
914-880
•••••••••
G8 Supplementary Stitch Head
Maintenance Kit,
914-881 ••
Return to supplier for rebuild •

1 - Introduction - The 914-880 Maintenance Kit
G8 Stitch Head Maintenance Kit Instructions 3
1.2 The 914-880 Maintenance Kit
FIGURE 1:4. Table of parts in the 914-880 Maintenance Kit
801-613801-652
801-612
801-623
801-627
801-704
801-620801-614
801-621
801-628801-622
952-445
801-650
801-651
FIGURE 1:3. The 914-880 Maintenance Kit
Watkiss
Part No.
Description Qty
801-612 G20210 Cutter operating spring 1
801-613 G20214 Moving cutter screw 1
801-614 G20293 Wire cleaner felt 2
801-620 G20151A Driver bar assembly 1
801-621 G20159 Bender bar friction plug 1
801-622 G20263 Feed lever E-clip 2
801-623 G20148W Latch housing 1
801-627 G20346B Supporter pin 1
801-628 G20187 Friction strip 1
801-650 DBSG8W40, G8 Label, No Adjust 1
801-651 071004, G8 lock washer 1
801-652 G20433 G8 torx screw 4
801-704 7257PS, G8 CLINCHER POINT Rev.E 2
952-445 Tool, G20375, G8 torx key 1
*801-610 G20199A Lower wire tube. This item is discontinued. If there
is one in the kit, then discard the item. See Section 1.5
0

1 - Introduction - The 914-881 Supplementary Maintenance Kit
4G8 Stitch Head Maintenance Kit Instructions
1.3 The 914-881 Supplementary Maintenance Kit
FIGURE 1:6. Table of parts in the 914-881 Supplementary Stitch Head
Maintenance Kit
1.4 Tools Needed
• 951-880 Brush - grease application
• 951-095 Klüber Isoflex NBU 15 Grease, 50g
• Wirecutters
•Pencil
• Marker pen
• Allen keys: 1.5, 2, 2.5, 3, 4 and 6 mm
• Screwdrivers: small flat blade, medium flat blade
• Pliers: needle nose, water pump or slip joint
•Punch:4mm
• Spanners: 7, 8, 12, 13 mm
• Feeler gauge: 0.40mm
• 952-437 G-clamp: 100 mm capacity
• Loctite 222 and 242
801-625 801-600801-626 801-604801-608
FIGURE 1:5. The 914-881 Supplementary Maintenance Kit
Watkiss
Part No.
Description Quantity
801-600 G20147WMATL bender bar but
not the latch-housing and screws
1
801-604 18182W G8 clincher slide 1
801-608 G20152 G8 driver 24 wire 1
801-625 G20321W crank link screw 1
801-626 G20559BA wire-holder assembly 1

1 - Introduction - Identify the Lot # of the Stitch Head
G8 Stitch Head Maintenance Kit Instructions 5
1.5 Identify the Lot # of the Stitch Head
Procedure:
1. Open the PSQ main deck. See Section 4.1.3.13. in the PSQ Service Manual,
Issue 4b, 4c or 5b.
2. Inspect the label on the side of the stitch head. See FIGURE 1:7.
FIGURE 1:8. Table of Fitted Stitch Heads
G8 stitch head
Label that shows the Lot #
FIGURE 1:7. G8 stitch head with label for the Lot #
Lot # Fitted as Standard to: Note:
18 Machines from serial number WA/PSQ/764.
17 Machines from serial number WA/PSQ/677 to
WA/PSQ/763.
Later stitch heads can
be fitted as needed.
16 Machines from serial number WA/PSQ/657 to
WA/PSQ/676.
Later stitch heads can
be fitted as needed.
15 Machines from serial number WA/PSQ/0558
to WA/PSQ/0656 and WA/PSQ/0658, 671 and
672.
Later stitch heads can
be fitted as needed.
14 Machines from serial number WA/PSQ/0500
to WA/PSQ/0557.
Later stitch heads can
be fitted as needed.
<13 Machines up to serial number WA/PSQ/0499. Later stitch heads can
be fitted as needed.

1 - Introduction - Stitch Head Differences by Lot # - as supplied
6G8 Stitch Head Maintenance Kit Instructions
1.6 Stitch Head Differences by Lot # - as supplied
Important:
• Unless otherwise documented, the disassembly, assembly and lubrication
procedures are the same for all stitch heads.
• The list below describes the stitch heads as supplied by the manufacturer. All
of the modified components introduced at later Lot # can be a retrofitted to
earlier Lot # stitch heads. For example, it is possible that you can find a Lot
14 stitch head that is modified to Lot 17 specification.
1.6.1 Lot 14 Stitch Head Differences
The Lot 14 stitch head differences are:
• The wire straightener eccentric G20206 - is replaced with wire straightener
eccentric less adj G20206B.
• The wire straightener roller G20208B is replaced with wire straightener roller
- G20208D.
Wire straightener eccentric
less adj - G20206B
Lower wire tube cover -
G20199B-2
Pivot block assembly -
G20139BAA
Lower wire tube base -
G20199B-1
Screw M4x6mm button head -
DW1058
Wire straightener roller -
G20208D
FIGURE 1:9. Lot 14 stitch head

1 - Introduction - Stitch Head Differences by Lot # - as supplied
G8 Stitch Head Maintenance Kit Instructions 7
• The lower wire tube G20199A is replaced with an assembly of: lower wire
tube base G20199B-1, lower wire tube cover G20199B-2 and screw
M4x6mm button head - DW1058.
• The pivot block assembly G20139A is replaced with pivot block assembly
G20139BAA.
• The cutter wire shield G20211 is discarded.
1.6.2 Lot 15 Stitch Head Differences
• The only difference between Lot 15 heads and Lot 14 heads is that Lot 15
heads use the later 801-704 clincher points as standard. The 801-704
clincher points are included in the G8 Stitch Head Maintenance Kit, part no.
914-880 and are retrofittable to all stitch heads.
1.6.3 Lot 16 Stitch Head Differences
• At Lot 16, the upper wire tube is machined with a groove and an e-clip is fit-
ted. The e-clip prevents the upper wire tube from being inserted too far into
the stitch head and making contact with the feed gears. See FIGURE 1:10.
The G20181WA upper wire tube and e-clip, 801-721 is retrofittable to all
stitch heads. You must carefully follow the fitting instructions.
FIGURE 1:10. Position of the e-clip on the new upper wire tube

1 - Introduction - Stitch Head Differences by Lot # - as supplied
8G8 Stitch Head Maintenance Kit Instructions
1.6.4 Lot 17 Stitch Head Differences
• The cutter block adjustment stud and disc spring washers are replaced by a
re-designed cutter block adjustment stud and compression spring. The new
components remove the need to make an adjustment and are retrofittable to
all stitch heads. An update kit, 940-154 is available.
See FIGURE 1:11. and FIGURE 1:12.
1.6.5 Lot 18 Stitch Head Differences
• Reduced tolerance on the pivot block mounting holes
• Improved quality of the wire-hook spring.
1.6.6 Retro Fit of Upgrades
Important:
• All of the above modifications can be retrofitted to earlier stitch heads.
M5 nut
Washers
Cutter block adjustment
stud
FIGURE 1:11. The old cutter block adjustment stud with washers.
FIGURE 1:12. New cutter block adjustment stud with compression spring.

G8 Stitch Head Maintenance Kit Instructions 9
CHAPTER 2 Disassemble the Stitch Head
IMPORTANT:
• Unless otherwise documented, the disassembly, assembly and lubrication
procedures are the same for all stitch heads.
2.1 Remove the Stitch Head from the PSQ
Stitch head fixing nut
Crank link screw
Crank drive link
Drive plate
Cutter box adjustment bar
Wire drive coupling
Wire-feed cam-shaft
Mounting bolt
FIGURE 2:1. Remove the stitch head
Stitcher mounting plate
Mounting block and spacer

2 - Disassemble the Stitch Head - Remove the Stitch Head from the PSQ
10 G8 Stitch Head Maintenance Kit Instructions
Tools:
• Wire cutters.
• Spanner: 13mm
• Pencil or pen.
Step Action Information
1Turn off the PSQ.
2Prepare a clean, flat surface to
receive the components when
you disassemble the stitch head.
3 Open the PSQ main deck. • Open the connecting bridge
cover.
• Open the folder cover.
• Lift the clincher frame assembly.
• Open the gathering area cover.
• Lift the PSQ main deck.
4 Cut the stitch-wire between the
wire cleaning felts and the stitch-
wire cabinet.
The exact location is not important.
5 Mark the position of the stitch head
with a pencil or pen.
This mark is a reference to help fit
the stitch head in the original posi-
tion.
6 Remove the fixing nut behind the
stitch head.
See FIGURE 2:1.
7 Remove the spacer and mounting
block.
See FIGURE 2:1.
8 Pull the stitch head towards you. This action disengages the
• mounting bolt
• crank link screw
• cutter box adjustment bar
• wire-feed cam-shaft
9 Remove the stitch head from the
PSQ.
10 Remove the stitch-wire from the
stitch head.
Pull the stitch-wire from the upper
wire tube.

2 - Disassemble the Stitch Head - Remove the Upper Wire Tube and the Wire Guide Plate
G8 Stitch Head Maintenance Kit Instructions 11
2.2 Remove the Upper Wire Tube and the Wire Guide Plate
Tools:
• Allen key: 3mm
•Pencil
Wire guide plate
Grub screw
Upper wire tube
FIGURE 2:2. Remove the upper wire tube and the wire guide plate
Feed gear bracket
Upper wire tube
FIGURE 2:3. Mark the position of the upper wire tube
Step Action Information
1 Make a pencil mark on the upper
wire tube to show how far the
upper wire tube enters into the
feed gear bracket.
Note: This step is not needed for
Lot 16 and later stitch heads or
stitch heads fitted with the modi-
fied upper wire tube.
See Section 1.6.3
This mark is to make sure that you do
not insert the upper wire tube too far
into the feed gear bracket on assem-
bly.
There must be a clearance of 0.5mm
between the end of the upper wire
tube and the feed gears when the
feed gears are engaged.

2 - Disassemble the Stitch Head - Remove the Middle Wire Tube
12 G8 Stitch Head Maintenance Kit Instructions
2.3 Remove the Middle Wire Tube
2 Loosen the grub screw. See FIGURE 2:2.
3 Remove the upper wire tube and
the wire guide plate.
Step Action Information
FIGURE 2:4. The middle wire tube
Metal spring clip
Middle wire tube
FIGURE 2:5. Old and new lower wire tubes
A
B
Prior to Lot 14 Lot 14 onward or upgrade fitted

2 - Disassemble the Stitch Head - Remove the Middle Wire Tube
G8 Stitch Head Maintenance Kit Instructions 13
Step Action Information
1 Press the metal spring clip to
release the middle wire tube.
See FIGURE 2:4.
2 Remove the middle wire tube.
3 Identify the type of lower wire tube
fitted to the stitch head.
See FIGURE 2:4.
IMPORTANT
• If the old type of lower wire tube
(A) is fitted, then you must fit
the new type of lower wire tube.
Follow the instructions in
APPENDIX A, then return to
Section 2.5.
• If the new type of lower wire
tube (B) is fitted, then go to the
next section, Section 2.4.

2 - Disassemble the Stitch Head - Clean the Lower Wire Tube
14 G8 Stitch Head Maintenance Kit Instructions
2.4 Clean the Lower Wire Tube
Button head screw
Cutter box fixing screw
Cutter box fixing screw
Lower wire tube
Cutter box (shown transparent)
FIGURE 2:6. Cutter box.
Grub screws
Step Action Information
1 Loosen but do not remove the 2 x
grub screws that hold the lower
wire tube in place.
See FIGURE 2:6.
2 Remove the button head screw. See FIGURE 2:6.

2 - Disassemble the Stitch Head - Clean the Lower Wire Tube
G8 Stitch Head Maintenance Kit Instructions 15
3 Rotate the lower wire tube cover to
the right and disengage from the
cutter box.
Important: When you remove or
fit the G20199B-2 lower wire tube
cover, be careful. You must not
damage the end of the G20199B-2
lower wire tube cover.
4 Clean the inside of the lower wire
tube.
• Make sure the wire groove in
the rear half of the lower wire
tube is free from debris
• Remove any dust, grease or
metal particles from inside the
lower wire tube.
5 Fit the lower wire tube cover and
rotate to the left.
6 Fit the button head screw. See FIGURE 2:6.
7 Push the lower wire tube to the left
and hold in position against the
cutter box fixing screws.
See FIGURE 2:6.
8 Tighten the grub screws to fasten
the lower wire tube in position.
9GotoSection 2.5.
Step Action Information

2 - Disassemble the Stitch Head - Remove the Wire-holder
16 G8 Stitch Head Maintenance Kit Instructions
2.5 Remove the Wire-holder
Wire-holder
Wire-holder retaining-spring
FIGURE 2:7. The wire-holder
Step Action Information
1 Move the wire-holder retaining-
spring away from the wire-holder.
See FIGURE 2:7.
2 Remove the wire-holder.