D E L UXE S TITCHER

COMPANYINC . solving your wire stitching needs for 125 years...

Machine Serial Number : Head Serial Number : Date Purchased :

Model M2 Stitchers

OPERATION AND MAINTENANCE MANUAL

M2-AST Stitcher...with 26D Head....115V and 60HZ M2-BST Stitcher...with 26D Head....230V and 50HZ M2G8-AST Stitcher..with G8 Head...115V and 60HZ M2G8-BST Stitcher..with G8 Head...230V and 50HZ

Before using this Stitcher, all operators must study this manual and follow the safety warnings and instructions. Keep these instructions with the M2 Stitcher for future reference. If you have any questions, contact your local DeLuxe Stitcher Graphic Arts Representative or Distributor.

WARNING!

Model M2 Stitchers

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 this machine.

Do not operate this stitcher without all guards in place. The stitcher will not operate without the front guard closed properly. 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 supply before any disassembly work.

INTRODUCTION.....................................................................................................4

INSTALLATION.......................................................................................................6

Belt Guard Removal and Assembly................................................6

OPERATING ADJUSTMENTS................................................................................7

Adjusting the Machine for Thickness of Work................................7

Raising or Lowering the Clinchers..................................................9

MAINTENANCE.....................................................................................................10

M2 DIAGRAM & PARTS LIST................................................................................11

CLUTCH-BRAKE MAINTENANCE........................................................................16

Clutch and Brake Springs..............................................................17

ITEM / INDEX NUMBER CROSS-REFERENCE...................................................21

NOTES

WARRANTY AND SERVICE INFORMATION........................................................23

The DeLuxe Stitcher M2 Book Stitcher is a combination light & heavy duty stitcher designed to staple both flat and saddle work ranging in thickness from a few sheets to 1/4" for 2601 heads, 5/16" (8mm) for G8 heads.

The recommended wire sizes to be used on the M2 are as follows: 25 to 30 round wire for 2601 heads, 24 to 28 for G8 heads.

The M2 is easily adjusted from saddle work to flat work by means of tilting the 5-1/2" (14cm) x 26" (66cm) work table. An adjustable work guide and adjustable work stops are easily attached to the work table and provide for accurate registering of flat work for uniform spacing of staples.

The M2 is footswitch operated and is belt driven by a 1/2 HP motor, making possible operating speeds up to 215 stitches per minute. The motor is mounted on an adjustable bracket which can be raised or lowered for adjusting the driving belt tension. The machine driving mechanism is thoroughly shielded thus preventing the possibility of personal injury.

The M2 has a 14" (35.6cm) throat depth for both flat and saddle stitching. The work table is approximately 34" (86.4cm) above the floor, and there is approximately 17/32" (24mm) clearance between the top of the work table and the stitching head.

The M2 weighs approximately 325 lb (145 kgs) net, shipping weight is approximately 3 80 lb (I 72 kgs). With the table installed, the M2 requires about 28" (71.1 cm) x 30" (76.2cm) of floor space.

Because of the length of the work table, the M2 must be secured to the floor to meet CE stability requirements. Sound level readings at the normal operator position are approximately 84 dBC.

Shipping Weight . . . . . . . . . . . . . . . 396 lbs (180 kg) 26D Stitcher Head . . . . . . . . . . . . 6 lbs. (3 kg) G8 Stitcher Head. . . . . . . . . . . . . . 9 lbs. (4 kg) Wire Spool . . . . . . . . . . . . . . . . . . 5 lbs. (2.3 kg) or 10lbs. (4.6 kg) optional Foot Switch . . . . . . . . . . . . . . . . . 4.5 lbs. (2.0 kg) Table . . . . . . . . . . . . . . . . . . . . 8 lbs. (3.5 kg)

Height Width

. . . . . . . . . . . . . . . . . . . . 65.0 ” (165 cm)

With Tables . . . . . . . . . . 33” (84 cm) Without Tables . . . . . . . 16” (41 cm) . . . . . . . . . . . . . . . . . . . . 29” (74 cm)

Stitching Capacity . . . . . . . . . . . . . . . . . . . Two Sheets to 3/4” (19 mm) (with G8 Heads)

. . . . . . . . . . . . . . . . . . . . at 20# paper stock (75 g/m 2 ) . . . . . . . . . . . . . . . . . . . . Two Sheets to 1/4” (6.5 mm) (with 26D Heads) . . . . . . . . . . . . . . . . . . . . at 20# paper stock (75 g/m 2 )

. . . . . . . . . . . . . . . . . . . . 24-26 Round, (STANDARD) . . . . . . . . . . . . . . . . . . . . 23 Round, 20x25 and 21x25 Flat (OPTIONAL)

Flat or Saddle . . . . . . . . . . . . . . . . . 14” (36 cm)

. . . . . . . . . . . . . . . . . . . . 6-1/4 - 23-3/4” (16 cm-60 cm)

M2-AST, M2G8-AST. . . . . . . . . . . 115VAC 60 Hz M2-BST, M2G8-BST. . . . . . . . . . . 230VAC 50 Hz

Minimum Recommended Circuit Capacity

M2-AST . . . . . . . . . . . . . . . . . . . . 8.1 A M2-BST . . . . . . . . . . . . . . . . . . . . 5.8 A

The M2 is a free standing, floor mounted, wire stitcher. The following parts must be assembled after shipment: work table, spool bracket, spool stud, wire spool, adjuster handwheel handle, and wire guide springs. The M2 can be lagged to the floor, if desired, after leveling.

Thread the wire onto the head and make adjustments to wire length & straightness as described in the head Operation Manual.

Electrical power is provided through the attached line cord to be connected to an appropriate supply outlet rated as shown:

SUPPLY POWER

115V / 60HZ

230V / 50HZ

M2 Interrupt Current, Internal Breaker

Do not operate the M2 under power until the machine has been turned over manually (see below) to verify that the stitching heads are operating freely.

! WARNING



Belt Guard Removal and Assembly

Always disconnect the power supply before making any adjustments or servicing the stitcher.

! WARNING



The plastic belt guard must first be removed before the M2 can be turned over manually. To remove the belt guard, remove the retaining screw from the top of guard. Press on one side tab while prying out the locking face. This will release the first tab. Next, pull down slightly on the top of the guard to release the bottom tab. Guard will now be free to lift off remaining tabs on mounting plate.

To reassemble, interlock the top tab and one side tab. Pull down slightly on top of guard to interlock bottom tab, then squeeze mounting plate and guard together to lock remaining tab, completing assembly. Reassemble the retaining screw at the top of the guard.

To turn the machine manually, it is necessary to first disconnect the power and remove the belt guard

Always disconnect the power supply before making any adjustments or servicing the stitcher.

! WARNING



(see above). Locate the actuator assembly on the wrap spring clutch and push the actuator to pivot it away from the control collar cam, releasing the brake. The machine will rotate one revolution when the large drive pulley is turned manually in the direction of the arrow on the pulley (top of pulley toward front of machine).

The quality and quantity of work that can be stitched on the M2 is dependent upon the operator making the various operating adjustments as accurately as possible. The following information and instructions are provided so that the operator will clearly understand how to make the required operating adjustments.

Adjusting the Machine for Thickness of Work (See Figure 2)

Turn the thickness adjustment handwheel (1) clockwise until the gage spool (2) is raised sufficiently to allow a sample of work to be inserted between the gage spool and its lower stop.

With the work held in this position, turn the handwheel (1) counter-clockwise until the work is firmly clamped between the gage spool (2) and the stop.

Turn the handwheel back clockwise just enough to allow the work to be withdrawn from the gage, then return the handwheel to the setting at which the work was firmly clamped.

Figure 2 - Work Thickness Adjustment

If the Machine is operated on work thicker than is set to handle, damage will result and the Stitcher will not operate properly.

! CAUTION



Raising or Lowering the Clinchers (See Figure 3)

Always disconnect the power supply before making any adjustments or servicing the stitcher.

! WARNING



If staples are being loosely clinched, requiring that the clinchers be raised or lowered, proceed as follows:

Remove the clincher guard (1) . Loosen the clincher adjustment binder screw (2). Rotate the clincher adjustment screw (3) to raise or lower the clincher points as needed.

Retighten the binder screw (2) and attach the clincher guard (1). Turn the machine over manually a few revolutions and ensure that the machine if operating freely before running under power.

Figure 6 - Wire Straightening

To insure continuous operation of the M2 Stitcher, the operator should be sure that the machine is regularly lubricated and carefully maintained. The operator should periodically inspect all moving parts for signs of wear and, when required, replace the worn parts.

The following instructions are provided so that the operator will understand how to lubricate the machine, and how to adjust the clutch.

Lubrication (See Figure 4)

If the machine is operated on work thicker than it is set to handle, damage will result.

! WARNING



Use an S.A.E. No. 10 oil for lubricating the M2 Stitcher. Machines that are in constant use should be lubricated daily. Machines that are operated periodically should be lubricated just prior to use. Usually only a drop of oil is required at each lubrication point in the Stitcher. After lubricating the machine, wipe off any excessive oil.

Refer to the stitcher head Operation Manual for additional lubrication points on each stitching head.

Figure 4 - Lubrication Points

M2 Diagrams & Part List

The following diagrams show exploded views of the M2 Stitcher. The DeLuxe Stitcher Item Number and description can be found by using the Item number table that follows.

Figure A - Face Plate and Guard Assemblies

Part Number / Description Cross-Reference

ITEM NO.

DESCRIPTION

QUANTITY

INDEX

ITEM NO.

DESCRIPTION

QTY

Side Cover Plate - Left

Adjuster Crank Shaft Insert

CB837E

Hex Jam Nut 1/2-13

Clincher Upright Link Asy

Clincher Slide Link Spring

Cl. Op. Lever Spring Screw

INDEX

ITEM NO.

DESCRIPTION

QTY

ITEM NO.

HN51618.2 Hex Jam Nut 5/16-18

Table Support Brkt Asy - RH

Set Screw - Cup Point

Hex Jam Nut 1/4-20

Work Table Swivel Pin

Clincher Point 1/2 - Flat

Clincher Point 1/2 - Round

Clincher Plate Assembly 1/2

W/G Spring Holder Screw

Clincher Slide Adjust Screw

Clincher Slide Block Screw

Clincher Slide Adjust Screw

UA3810.10 Shoulder Screw 1/4x5/8

Clincher Slide Adjust Block

Clincher Slide Block Clamp

Terminal Strip - Holes

Clincher Slide Adjust Screw

Set Collar - Reamed

Power Cord - 115V

Power Cord - 230V

UV Trip - 115V

Electric Clutch - 115V

UV Trip - 230V

Electric Clutch - 230V

DESCRIPTION

QUANTITY

Always disconnect the power supply before making any adjustments or servicing the stitcher.

! WARNING



This stitcher is equipped with a solenoid actuated, continuous trip, wrap spring clutch-brake unit. It is a dependable device and seldom needs service. But should a malfunction occur, the following information is a service and troubleshooting guide for maintenance of this unit.

The actuator is a simple, straight-forward mechanical linkage. When the actuator does not trip, the following checks should be made:

PROBLEM

CAUSE AND REMEDY

No Power to the Coil

Check all wiring and switching in the Clutch Actuation System Replace the Coil

Lack of continuity in the Coil windings

The Coil may have shifted, or the Plunger end may have mushroomed due to striking the backstop. In the latter, the plunger may be filed or turned to its true diameter Adjust the linkage as needed

Mechanical binding of the Plunger

Insufficient clearance of the Actuator over the Stop Collar Actuator loaded by the Stop Collar so hard that the Actuator cannot be pulled by the Coil

Breaking force is exceeding the limits of the Brake, or the differential setting of the unit is too close (see Assembly/Disassembly instructions)

Clutch and Brake Springs

With the brake engaged (full limit of output), the input hub should be free to rotate by hand. With the clutch engaged, the input and output hubs should rotate together. If the unit does not rotate in either of these modes, the clearance between the hubs of the unit on the shaft may have been disturbed or damaged. See Assembly/Disassembly instructions for re-adjusting.

Listed below are additional checks to be made if the clutch does not function correctly:

PROBLEM

Clutch Brake does not drive but Input turns

Clutch-Brake jams and stalls Input Motor

Output does not repeat stopping point

CAUSE AND REMEDY

A. Drive Spring may be broken at crossover point from an overload caused by a jam. Replace Spring and check Hubs for damage.

B. Collar may not snap forward because of foreign matter restricting movement. Clean unit.

C. Actuator does not pull in. See Actuator section.

A. Spring tang broken off Drive Spring, not allowing Clutch to disengage while Brake is engaged. Replace Drive Spring.

B. Clutch output bound up. Check clearance between Output Hub and Brake Hub.

C. Completely out of adjustment caused by losing an internal Spring Tang. Replace Spring.

A. Not enough inertia to actuate brake.

B. Tang broken off Brake Spring, replace SPring.

C. Adjust Collar Locking Screw, may be loose allowing Adjusting Screw to rotate.

Disassembly (See Figure 5)

Always disconnect the power supply before making any adjustments or servicing the stitcher

! WARNING



To disassemble the clutch-brake unit (124) it will first be necessary to remove the drive pulley (125) from the stitcher by removing the V-belt (30), retaining ring (51), and clutch anchor screw (27). Disconnect the ground and solenoid wires, and swing the anchor strap (24) clear of the drive pulley assembly and slide it off of the drive shaft. Remove the three screws (126) connecting the drive pulley to the clutch-brake unit.

When disassembling the clutch-brake unit, always mark the spring tang locations with reference to which slots they go in if the same springs are to be used for reassembly. To disassemble the clutchbrake unit, proceed as follows:

Release Actuator Lever so that clutch is engaged and brake released. Remove Retaining Ring and Shim Washer, if any, from the input Hub end. Remove input Hub by rotating opposite to the drive direction. Remove Retaining Ring and Shim Washer, if any, from the Mounting Plate end.

Remove Output Shaft Springs and Control Collar assembly by rotating Output Shaft in the drive direction (DO NOT DISASSEMBLE BRAKE HUB FROM MOUNTING PLATE). Remove Control Collar from the Output Shaft and Spring assembly by extracting toward the Brake Spring end.

Assembly (See Figure 5)

Replace Clutch, Brake and Anti-Backup Springs as required. Assemble Springs concentric and square to the Output Shaft. Assemble Control Collar over the Output Shaft and Spring assembly by inserting from the Brake Spring end (it will be necessary to extend Brake Spring using long nose pliers). Place the Brake Spring tang in any one (1) of the nine (9) Control Collar slots at random.

Assemble Output Shaft, Springs, and Control Collar assembly to the Mounting Plate assembly by rotating Output Shaft in the drive direction. Assemble Retaining Ring to Output Shaft at the Mounting Plate end (smooth surface facing Brake Hub). Check end play between Hub and Retaining Ring with feeler gauge. There should be 0.004" to 0.010" end play. Use Shim Washer to adjust.

Rotate Output Shaft in the drive direction until it reaches a full brake position. With the Clutch Spring Tang not in slot, insert the Input Hub by rotating opposite to the drive direction. Select the one (1) of ten (10) Control Collar slots for the Clutch Spring Tang that will provide a 0.38" to 0.50" circumferential overtravel of the Control Collar when released.

Note: At this point it may be necessary to reselect one (1) of the nine (9) Control Collar slots for the Brake Spring Tang (release Actuator Lever, remove Clutch Spring Tang from slot, then move Control Collar axially toward the Input Hub end and rotate it opposite to the drive direction to pick up the next slot). Continue to select Control Collar slots until the 0.38" to 0.50" specification is achieved.

Assemble Retaining Ring to Output Shaft at the Input Hub end (smooth surface facing Input Hub). Check end play between Input Hub and Retaining Ring with feeler gauge. There should be 0.002" to 0.003" end play on the Input Hub.

Reassemble unit to machine.

IMPORTANT: After Clutch is assembled to machine, the Clutch Plate should be free to float on bearing - the anchor strap is only there to prevent rotation of the plate.

Retaining Ring

Drive Sleeve

Stop Cam

Coupling Sleeve

For assembly and disassembly see page 95.

Brake Sleeve

COMPONENT PARTS

COMPONENT PARTS

Item Description Cam Design 3 Split Retaining Ring

Actuator Assembly (includes plunger)

Control Collar (Specify No. of Stops) Stop Sleeve Retaining Standard

• 1.8° Adjustable Cam Ring

Button Head Cap Screw (3)

Coil Assembly “D” Frame 230 AC 115 AC

Output Assembly 0.750 Bore

Figure 5 - Clutch-Brake

Skt. Head Cap Screw (2)

Headless Socket Set Screw (2) (.75 Bore only)

Shim .005 .010

Shims used as required

The clutch-brake unit is designed with the bearing parts made from sintered metal that has been impregnated with oil and normally do not need to be re-lubricated. In cases where there is severe duty, the unit may be re-oiled or flushed out with minimal or no disassembly by using a light bearing oil as used in manufacture (Shell Bearing Infusion Oil #33). If disassembly of the unit for cleaning and oiling is necessary, follow the detailed disassembly instructions to the point needed, flush and wipe parts in the oil to be used for re-lubrication. DO NOT USE SOLVENT to clean the parts. To get more cleaning action for the oil, it may be heated while cleaning the components, but bring the parts back to ambient temperature submerged in cool oil.

Place the Spring onto the Plunger with the narrow end towards the Actuator. Slide the Solenoid onto the Actuator and Plate Assembly. Assemble the Solenoid to the Plate Assembly with the cap screws and washers. DO NOT tighten more than finger tight.

Energize the Coil and adjust the gap between the Actuator and the top of the Collar Stop to 0.015" to 0.030" by sliding the Solenoid assembly. Note: push the Collar toward the Actuator to allow for Collar movement. Tighten the cap screws.

The stopping position of the head can be changed if necessary by adjusting the position of the stop cam on the control collar sleeve. Turn the machine manually until the driver is in the desired stopping position, the proceed as follows:

Work Retaining Ring "A" out of its groove and slide it forward on Sleeve "C". Slide Cain "B" off Splines, rotate to align Collar Stop with Actuator and slide the Cam back on the Splines. The Actuator Prawl will have to be held clear during this operation. Slide the Retaining Ring back into its groove.

Note: Make sure brake is locked up before proceeding to insure getting the proper stop point.

Figure 6 - Clutch-Brake

Item No. Index No. Cross-Reference

Item No.

Index No.

Item No.

Index No.

Item No.

Index No.

18182 18183 18184 18186 203B 2245

7024B 7056 7253A 7423 7645A 7648 7656A 7675 7676 7678 7681 7690 7691 7693 850300 850301 850302 850303 850304 850305 850306 850307 850308 850314 850315 850673 850674 850696 850730 850738 851005 86243 9081 B554 FC9632 FC9656 G30001A G30002 G30005A G30006A G30007B

G30011A G30013A G30014 G30016 G30017A G30020A G30027 G30028 G30029 G30030 G30031 G30032 G30034 G30037A G30041A G30043 G30044A G30048 G30049 G30061 G30063 G30064 G30065 G30067 G30097 G30099 G30100 G30101 G30102 G30103 G30113 G30117 G30118 G30124 G30127 G30128 G30130 G30142 G30143 G30145 G30152 G30155 HN1024 HN1032 HN1213.2 HN1420 HN1420.2 HN1420.5 HN3816 HN51618 HN51618.2 LW10 LW14 M11009 M7201 P7507

P7863 P8054 PG 10271 PG 10512 PW10 PW10.3 PW12 PW14 PW14.6 PW38 PW516 SU-0308853 SW14 SW14.1 SW516.2 UA3216.2 UA3410.4 UA3806.16 UA3806.3 UA3806.9 UA3808.1 UA3810.10 UA3812.2 UA4808.3 UA4810.1 UA4810.5 UA4812.1 UA4812.7 UA4816.1 UA4828.3 UA5112.1 UA5120.2 UA6112.1 UA8164

Item No.

Index No.

LIMITED WARRANTY

DeLuxe Stitcher Company warrants to the original retail purchaser that this product is free from defects in material and workmanship and agrees to repair or replace, at DeLuxe Stitcher’s option, any defective product within 90 days from the date of purchase. This warranty is not transferable. It covers damage resulting only from defects in material or workmanship and does not cover conditions or malfunctions resulting from normal wear, neglect, abuse or accident.

This warranty is in lieu of all other express warranties. Any warranty of merchantability or fitness for a particular purpose is limited to the duration of this warranty. DeLuxe Stitcher shall not be liable for any incidental or consequential damages.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

To obtain warranty service you must return the product, at your expense, together with proof of purchase to an authorized DeLuxe Stitcher Company Graphic Arts Dealer.

D E L UXE S TITCHER

ISP Stitching & Bindery Products

COMPANY

3747 Acorn Lane • Franklin Park • Illinois 60131 Phone: 847-455-4400 • 800-634-0810 Fax: 847-455-4900 • 800-417-9251 http://www.deluxestitcher.com

DBSM2 - 0723