D E L UXE S TITCHER

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solving your wire stitching needs for 125 years...

ISP Stitching & Bindery Products

Machine Serial Number : Head Serial Number : Date Purchased :

Model M30 Stitchers

OPERATION AND MAINTENANCE MANUAL

M30-AST Stitcher...............115V and 60HZ M30-BST Stitcher...............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 M30 Stitcher for future reference. If you have any questions, contact your local DeLuxe Stitcher Graphic Arts Representative or Distributor.

WARNING!

Model M30 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.

Specifications ........................................................................................................4 Recommended Wire Sizes .....................................................................................6

Operating Adjustments Wire Threading..............................................................................13 Wire Straightening ........................................................................14 Adjusting the Machine for Thickness of Work ..............................15

Adjustments and Settings Adjusting the Left Leg ...................................................................15 Adjusting the Clincher Points .......................................................16 Adjusting the Machine for Stab Stitching .....................................18

Lubrication.....................................................................................19 Troubleshooting.............................................................................20 Cycling Machine Manually.............................................................21 Adjusting the V-Belt.......................................................................22 Cleaning.........................................................................................23 Disassembling the Head ..............................................................23 Ordering & Replacing Spare Parts ...............................................25 Clutch-Brake Maintenance ...........................................................33

Part Number / Description Cross-Reference ........................................................58

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

! WARNING



Shipping Weight . . . . . . . . . . . . . . . 670 lbs [304 kg]

Wire Spool . . . . . . . . . . . . . . . . . . 5 lbs. [2.3 kgs] or 10lbs. [2.6 kgs] optional

Foot Switch . . . . . . . . . . . . . . . . . 4.5 lbs. [2.0 kgs]

. . . . . . . . . . . . . . . . . . . . 27 lbs. [12.3 kgs]

Skid Size . . . . . . . . . . . . . . . . . . . 30” x 40” x 70” [76.2cm x 101.6cm x 177.8cm]

. . . . . . . . . . . . . . . . . . . . 66.5 ” [168.9 cm]

With Table . . . . . . . . . . 30” [76.2 cm]

Without Table . . . . . . . . 21 3/4” [55.2 cm]

. . . . . . . . . . . . . . . . . . . . 30” [76.2 cm]

Stitching Capacity . . . . . . . . . . . . . . . . . . . Two Sheets to 1-1/4” [30 mm] (Using 18x20 Wire)

. . . . . . . . . . . . . . . . . . . . at 20# paper stock [75 grams/meter2] . . . . . . . . . . . . . . . . . . . . Stab Stitch to 2” [50mm] (Using 18x20 Wire)

. . . . . . . . . . . . . . . . . . . . 20-25 Round (24Rd STANDARD, 25Rd SPECIAL)

. . . . . . . . . . . . . . . . . . . . 18x20, 19x21½ (STANDARD)

. . . . . . . . . . . . . . . . . . . . 20x24, 20x25 and 21x25 ( SPECIAL)

Flat or Saddle . . . . . . . . . . . . . . . . . 20” [50.8 cm]

. . . . . . . . . . . . . . . . . . . 9-30” [22.9 cm-76.2 cm]

M30-AST . . . . . . . . . . . . . . . . . . . . 115VAC 60 Hz

M30-BST . . . . . . . . . . . . . . . . . . . . 230VAC 50 Hz

Motor Size. . . . . . . . . . . . . . . . . . . . 3/4 HP

Minimum Recommended Circuit Capacity

M30-AST . . . . . . . . . . . . . . . . . . . . 10.7 A

M30-BST . . . . . . . . . . . . . . . . . . . . 7.1 A

. . . . . . . . . . . . . . . . . . . . 125 Cycles/Minute (when running continuously)

Recommended Wire Sizes (Figure 1)

The wire sizes that can be used on the M30 as well as recommended uses are listed below. Note that when size changes, several parts on the Head will have to be changed to accommodate the wire size change. Instructions for changing these parts are detailed later in this manual. Wire gauges smaller than the specific size for which the head is set can still be used, but the maximum capacity for the machine will not be reached. For example, if the Head is set for 19x21-1/2 gauge wire, it will still function properly with 20x24 gauge wire, but the stitching capacity will drop. Please refer to Figure 6 stitching capacities of different wire gauges.

Two types of Clincher Points are available for the M30. When running round wire, use the Clincher Points with part number G40955R. For flat wire, use the Clincher Points with part number G40955F.

When stitching stock over 20# it is possible that high tensile wire will be required, which is available in 21x25, 20x24, 19x21-1/2, and 18x20 flat wire sizes. Note that high tensile wire may cause increased wear on certain parts. For any stock over 33# or coated, it is recommended that 19x20-1/2 or 18x20 flat wire be used. Refer to Figure 6 for a general overview of suggested wire sizes to use for specific stitch capacities.

Install G40955R Clincher Points for:

25 Round 24 Round 23 Round 21 Round 20 Round

Light Flat or Saddle Light Flat or Saddle Light Flat or Saddle Medium Flat or Saddle Medium Flat or Saddle

2 -20 Sheets 2 -30 Sheets 2-60 Sheets 2- 80 Sheets 20-100 Sheets

Install G40955F Clincher Points for:

21 x 25 Flat 20 x 25 Flat 20 x 24 Flat 19 x 21 1/2 Flat 18 x 20 Flat

Medium Flat Only Heavy Flat Only Heavy Flat Only Heavy Flat Only Heavy Flat Only

Over 50 Sheets 1/4”- 3/8” Over 50 Sheets 1/4”- 1/2” Over 50 Sheets 1/4”- 3/4” 1/2”- 7/8” and Heavy Paper 7/8”- 1-1/4” and Heavy Paper

Figure 1 - Recommended Wire Sizes

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

! WARNING



The DeLuxe Stitcher M30 Stitcher Machine is a single-head stitcher designed to accommodate both light and heavy-duty work, stitch both flat and saddle work and can reliably stitch any thickness of stock from 2 sheets to 1-1/4” (30mm). It even stab stitches up to 2” (50mm) of material. The recommended wire sizes to be used on the M30 are: 20 to 25 gauge round wire and 20x24, 20x25, 21x25, 19x21-1/2 and 18x20 flat wire.

The M30 is easily adjusted from saddle work to flat work by tilting the 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 uniformly spacing the staples. In addition a work table extension is available to accommodate larger sizes of work to be stitched. The M30 is the most versatile of all single-head machines.

Because of the length of the work table, the M30 must be secured to the floor to meet CE stability requirements. Sound level readings at the normal operator position are approximately 70 dB.

Table Set for Saddle Work

Table Set for Flat Work

Carefully inspect the condition of the shipping container before unpacking your M30 Stitcher. If the container is broken, damaged or has been tipped over and there is evidence that the machine may be damaged, immediately notify the carrier who delivered the machine and the DeLuxe Stitcher Graphic Arts Representative from whom the M30 was purchased.

As you carefully unpack the machine, check to make sure all components were delivered and are in good working order. Refer to Figures 1 to 3 in this manual for reference to the following pieces:

• Complete Work Table Assembly (G40964A), the Work Guide (G40973), and two of each of the following: Large Work Stop (7423C) with Thumb Screw (63), Work Guide Screws (63), Flat Washers (PW14)
• Table Pivot Shaft (G40962)
• Upper Wire Straightening Bracket (G40767AA) and Wire Guide Spring (G40286A)
• Assembled Wire Spool Mounting Bracket (G40520) with Spool Stud (7693), Plastic

Washer (M11009), Tension Spring (7690), Set Collar (7691) with Thumb Screw (P2731),

9/16" Washer (PG10271), Spool Washer (2245), 3/8" Washer (PW38), and Hex Nut

• Lower Wire Tube (G40599A)
• Bag of tools: 3mm Hex Key Wrench (G20360), 7mm Open End Wrench (G20364)

Please take a few moments to fill out the registration card prior to beginning installation.

IMPORTANT: Make sure that the Shipping Tab (G40978) is removed and replaced with the Clincher Plate (G40954) before proceding to the next step. See Instruction Sheet (DBSM30UINST) in your included packet.

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

! WARNING



Tools required:

4mm & 6mm Hex Wrenches

1. Remove Face Guard by lifting to disconnect it from Safety Switch and then pulling it away.
2. Remove screws & washers from shown locations.

M6 Socket Screw G40809 (2)

M6 Lock Washer G20520 (2)

Safety Switch 850319B

M8 Lock Washer G40851 (2)

M8 Socket Screw G20171 (2)

Figure 2 - Assembling

3. Attach the Upper Wire Straightening Bracket and the Wire Spool Mounting Bracket.
4. Attach the Spool Stud to the Bracket.
5. Install Wire Spool. Secure with the Set Collar and Thumb Screw.
6. Re-attach the Face Guard.

FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

Wire Straightener G40767AA

Wire Guide Spring G40286A

3/8-16 Hex Nut HN3816

3/8” Lock Washer LW38

9/16” Washer PG10271

Spool Stud 7693

Plastic Washer M11009

Set Collar 7691

Tension Spring 7690

Thumb Screw P2731

Figure 3 - Assembling

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

! WARNING



Table Pivot Shaft G40962

7. Prepare Work Table for install by disassembling the Work Guides.
8. Remove Table Pivot Shaft.

Figure 4 - Assembling

Figure 5 - Assembling

Work Table Assy. G40964A

9. Install Work Table.

Set Screw UA1428.1

Table Pivot Shaft G40962

Work Stop 7423C

Work Guide G40973B

(2) Table Support Brackets & (2) Stop Studs

10. Tighten the Set Screws.

11. Attach the Work Guide and Work Stops as seen in Fig. 6. (NOTE: Back Guide can only be used when stitching flat work.)

Figure 6 - Assembling

Figure 6 - Assembling

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

! WARNING



FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

Wire Threading (Figures 8 - 10)

Figure 8 - Wire Threading

Figure 9 - Wire Threading

1. Pull wire off the spool and thread through the studs in the Wire Guide Spring Assy. (Fig. 8)
2. Continue between the Tension Pawl and its roller and through two sets of wire straightener rollers (Fig. 8). It may be necessary to turn the Adjustable Straightener Rollers to the full open position to make threading easier. (Figs.

12 & 13)

3. Now tuck the wire between the two

Figure 10 - Wire Threading

Oiler Felts and on into the Upper Wire Tube Fig. 8).

4. With the Feed Release Handle in the off position, use a pair of plier to pull the wire past the Feed Gears and through the Lower Wire Tube (Fig. 9).

5. Now through the Tension Pawl, Straightener Rollers and finally into the Cutter Box.

FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

Wire Straightening (Figure 11-14)

1. Once through, turn each of the four Adjustable Straightener Rollers until they’re just touching the wire.
2. Cycle the machine several times and notice which direction the wire is curving out of the Cutter Box (Fig.

11). STRAIGHT

3. If curving up, adjust the Lower Straightener turning the Roller (#4) counterclockwise until wire is emerging straight (Fig 12).
4. If not fully straight, likewise adjust the upper Roller (#3) closest

OUT

DOWN

Figure 11 - Wire Direction

Adjustable Roller #4

Figure 12 - Lower Adjustable Rollers

Note that it will take several cycles for adjustments made to the Upper Straightener Rollers to become evident at the Cutter Box.

to the Oiler felts (Fig 13).

5. If the wire is curving towards the machine, adjust the first upper Roller (#1) towards the wire and/or turn the second Roller (#2) away from the

Adjustable Roller #3

Figure 14 - Adjusting Rollers

Adjustable Roller #2

Adjustable Roller #1

Figure 13 - Upper Adjustable Rollers

wire (Fig. 13).

6. If the wire is turning away from the machine, turn the second Roller (#2) towards the wire and/or the first Roller (#1) away from the wire.

Adjusting for Thickness of Work & Legs (Figure 15-17)

Figure 14 - Adjusting for Thickness of Work

M6 Screws G40818 (2)

Cutter Box Adjustment Slide G40642

LOOSEN

SHORTER

LEFT LEG

LONGER

LEFT LEG

Adjuster Lock Lever G40772

Hand Wheel G30128

Adjustment Gauge G30119B

Cutter Box Assy. G40597A

UNLOCK

Figure 15 - Adjusting the Left Leg

Feed Rack Adjustment Knob G20573

WORK THICKNESS

Feed Rack G40527B

Adjuster Stop G30103

 WARNING

FAILURE TO UNLOCK lever prior to compression adjustment may result in internal damage to stitcher that will not be covered by warranty. Be sure to lock when adjustment is completed.

MORE WIRE

& LONGER RIGHT LEG

LESS WIRE

& SHORTER RIGHT LEG

Feed Release Handle G40119

Figure 16 - Adjusting the Right Leg

1. Unlock Adjuster Lock Lever by turning it counter-clockwise.
2. Using a sample of thickness, turn Hand Wheel clockwise until the Adjustment Gauge firmly clamps it in the work thickness area as shown in Fig. 15.
3. Back off with the Hand Wheel to release sample and then return to to it pre-release position.

4 Tighten Adjuster Lock Lever and test setting. Unlock and adjust with Hand Wheel to fine tune if stitch is too loose or tight and lock again.

5. To adjust left leg length (Fig. 16), loosen Cutter Box Adjustment Slide and move Cutter Box left or right. NOTE: Adjustment should be minor. Tighten, test and repeat if necessary.
6. To adjust the right leg length, disengage the Feed Gears by turning the Feed Release Hande and adjust with the Feed Rack Adjustment Knob (Fig. 17).
7. Engage, test and repeat as necessary.

Adjusting The Clincher Point Height (Figures 17)

Figure 17 - Clincher Point Height

1/16” [1.5mm] Max. out of plate.

Clincher Slide G40976

Set Screw UA1428.1

1. With the Work Table in the flat work position, check the clinch by manually cycling the machine to the point of clincher activation.
2. Loosen the Set Screw and rotate the Clincher Slide Adjustment Screw to raise or lower the Clincher Points. Once set, tighten Set Screw.
3. Complete the cycle and test.

Repeat if necessary.

Clincher Slide Adjustment Screw 18186

Adjusting The Clincher Mount (Figures 18 & 19)

1. With the Work Table in the flat work position, check the clinch by manually cycling the machine to the point of clincher activation.
2. Loosen the Set Screw and rotate the Clincher Slide Adjustment Screw to raise or lower the Clincher Points.

Once set, tighten Set Screw.

3. Complete the cycle and test.

Repeat if necessary. If clinching properly, but legs are misaligned:(See warning below)

4. Align the Driver & Clinchers by loosening the (2) Hex Head Cap Screws.
5. Manualy cycle until until the Formers are near the top of the Clincher Plate. It is helpful to form a piece of wire so that it protrudes out past the Formers. (Best done when thickness is set to 1/4” [6mm])

M6 Cheese Head Screws 072012 (2)

Clincher Slide G40976

Set Screw UA1428.1

Clincher Slide Adjustment Screw 18186

Figure 18 - Adjusting the Clincher

Warning! This adjustment, if factory preset, should not be required unless Clincher Mounting is severely moved.

6. Move the Clincher Base Assy. until the front of Clincher Plate & Driver are centered and from the side the Former grooves and Driver are likewise. Tighten down when complete.
7. Very small additional adjustments are made by loosening the M6 Cheese head Screws and moving Clincher Plate to either side.

This is method is employed primarily when Clincher Points have been changed to realign them with the Formers. (For left to right adjustment only.)

Work Table G40964A

Hex Head Cap Screws G30159 (2)

Washers PW12.4 (2)

Figure 19 - Adjusting the Clincher

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

! WARNING



Adjusting for Stab Stitching (Figures 20-21)

Clincher Upright Extension G40975

Clincher Slide Adjustment Screw 18186

Clincher Pad G40950AA

Flat or Saddle Stitch

Stab Stitch

Indicator 9070

M6 Shoulder Screws G40820 (2)

Clincher Base G40956A

Clincher Height Adjustment Wheel G40959

Figure 20 - Adjusting for Stab Stitching

1. With the Work Table in the flat work position, remove the (2) M6 Shoulder Screw that attach the Clincher Upright Extension to the Clincher Upright Link Assy.
2. Disengage from the Clincher Slide Adjustment Screw and remove the Clincher Upright Extension.
3. Rotate it 180° (left-right, not top-over) and reattach.

Paper Thickness Gauge G30119B

M6 Screw G20576

4. Now lower the Work Table to the Stab Stitch position by turning the Clincher Height Adjustment Wheel counter-clockwise until the Clincher Pad Indicator moves to the Stab Stitch position.
5. Lastly, loosen the M6 Screw of the Paper Thickness Gauge and rotate 180°, then retighten.
6. Work thickness must now be set without the benefit of the Paper Thickness Gauge and as described previously.

Cutter Box Adjustment Link G40711

Figure 21 - Adjusting for Stab Stitching

! WARNING



FAILURE TO REMOVE Clincher Slide & Upright Extension will cause serious damage to stitcher not covered by the warranty.

FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

Figure 22 - Lubrication Points

Mounting Block (Cam Plate grooves) G40213

NOTE: Lubricate regularly instead of excessively.

Thoroughly oil the Felt Washer and for all else, use only one or two drop of any standard S.A.E. #10 oil in the areas shown. Excessive oiling produces oil spotting in the work. Wipe any excess oil. Lubricate as follows:

Tension Pawl Roller G20285

Tension Pawl Pivot Stud G20282

Oiler Felt Washers G20293

Bonnet Plates (grooves) G40500BA [R] G40501BA [L]

4. The outside of Figure 23 - Lubrication Points both Cutter Operating Lever Bearings.

5. Each side of the Driver grooves.

6. Both the upper and lower Pivot Studs for the Tension Pawl Cutter Operating Rollers. Lever

7. The front face of G40630BA (at Pivot the Cutter Operating Cutter Pin) Slide. Operating Slide

8. The pivot slots in G40598A the Pivot Block for Tension Pawl the Wire Holder. Pivot Stud

9. The outside of G20282 the Feed Release Tension Bearing. Pawl Roller G20285 10. The Cutter Operating Lever pivot area.

11. The Oiler Felts thoroughly.

1. In the the Mounting Block, the grooves for the Cam Plates and

2. the grooves for the Crank Housing Slide Plate Assy.

3. In the Bonnet, the grooves for the Driving and Bending Slides.

Feed Release Bearing &

2. Cutter Operating Lever Bearings G40904

Pivot Block Insert (slots) G40680 [5/8”] G40681 [1/2”]

Driver (Various P/Ns)

The following is a brief list of problems and solutions which should cover the majority of situations encountered when stitching with the M30. The quality and quantity of work that can be produced with the M30 Stitcher is dependent upon the operator making all adjustments as accurately as possible and carefully maintaining the machine. The cause of staple imperfections usually can be traced to inaccurate settings or normal wear of moving parts. In the event of problems of this nature occurring, the operator can, be referring to the troubleshooting chart, quickly locate the solution.

problem: The machine will not complete a cycle, under power or manually.

solution :

1. Make sure the compression setting is correct. If not turn the Hand Wheel (G30128) counterclockwise to raise the Stitcher Head.
2. If the V-Belt is too loose, it must be tightened.
3. Make sure none of the Clutch Springs are broken and that the Clutch has not failed. If either is the case, the entire assembly.

4.Make sure the Safety Interlock Key (850343) on the plastic Head Guard (G40135) is in complete contact with the switch on the right side of the head.

problem: The stitch quality is poor.

solution:

1. Make sure the wire is feeding straight from the Wire Spool and through the Stitcher Head.
2. Make sure the compression setting is correct.
3. Make sure the Clincher Plate (G40952A) is lined up with the Driver, both side-to-side and front-to-back.
4. Make sure the Clincher Points (G40955R or G40955F) are not set too low or too high.
5. Make sure the left leg of the stitch is the same length as the right leg.
6. Check the following Head parts for wear: the Cutters (G40145 & G40600), Driver, Formers, Supporter (G40653A), and Wire Holder (G20659BA). Reverse or replace worn parts as necessary.
7. Make sure the Clincher Points are clear of debris and paper build-up.
8. Make sure the Clincher Roller Bearing (G40905), located inside the frame, is not worn or broken.

problem: Wire is dropped before it can be formed, is drawn in inconsistent lengths, or is jamming.

solution:

1. Make sure the wire is feeding straight from the Wire Spool and through the Stitcher Head.
2. Make sure the Clincher Points are clear of debris and paper build-up.
3. Check the following Head parts for wear: the Cutters (G40145 & G40600), Driver, Formers, Supporter (G40653A), and Wire Holder (G20659BA). Reverse or replace worn parts as necessary.
4. Verify that the Wire Holder is properly aligned with the grooves in the Formers.
5. Make sure the Tension Spring on the Wire Spool is not set too tightly.
6. Make sure the Feed Gear Friction Plug is exerting enough pressure on the Large Feed Gear. (Between 3 & 4 turns after contact is made).
7. Make sure there is enough tension on the Feed Lever Spring.

problem: Left Leg Short solution: Lengthen the left leg by loosening the two screws on the Cutter Box Adjustment Slide, and moving the Cutter Box to the left.

problem: Left Leg Long solution: Shorten the left leg by loosening the two screws on the Cutter Box Adjustment Slide, and moving the Cutter Box to the right.

problem: Corner Buckled solution: Check the Driver for a chipped corner and rotate or replace if necessary.

problem: Leg(s) Buckled solution: Check the Wire Cutters for wear and rotate or replace if needed.

problem: Crown Buckled solution: Check Supporter Spring tension. Check for correct wire size being used. Check for correct work thickness setting.

problem: Stitch in Pieces solution: Clean the Wire Holder. If problem persists, file the forming corner of the Wire Holder slightly with a honing stone. Or replace the Wire Holder.

problem: Corners of the Crown are Rounded solution: Replace the worn Wire Holder.

problem: Loose Clinch solution: 1. Check for correct work thickness setting. Check and reset the Clincher Points height if necessary. Check Clincher Points and replace if worn. Check Clincher Slide and replace if worn.

problem: Legs are Spread or Contracted solution: Readjust the Wire Straightener Eccentrics to improve straightness. Check the Wire Cutters for wear and rotate or replace if necessary. Check the Former grooves and replace if necessary.

Figure 25 - Troubleshooting

Belt Guard Removal & Cycling Machine Manually / Adjusting the V-Belt (Figures 26-28)

1. To remove the Belt Figure 27 - Locating the Actuator Lever Guard cover, push down Control Collar Cam on the (4) rounded tabs 850888 while pulling away the cover. Alternately, use a screw driver and pry away cover at or near the tab locations (Figs. 8 Actuator Lever

(4) Locking Tabs 850992 & 10). (For BST models, (Opposite each other.) remove a securing screw Figure 26 - Belt Guard Removal first.)

Push here to start cycle.

Wrap Spring Clutch 850677 or 850678

To adjust belt, loosen hex nuts and pry or push here to tighten. (20 lbs.[9 kgs] Max.)

Drive Pulley 7678B

Belt Guard 7676

Small Pulley 11399A or 850732

4. Hex Nuts HN3816

Motor Mounting Plate G30048

Figure 28 - Manual Cycling & Adjusting V-Belt

2. To manually cycle the machine, first locate the Actuator Lever on the Wrap Spring Clutch and push it where shown (in Fig 9) to pivot it away from the Control Collar Cam. Rotate Drive Pulley (as shown by the arrows on it, see Fig. 10) for one cycle. Repeat as necessary.
3. To tighten the V-Belt, loosen (do not remove) the (4) Hex Nuts on the Motor Mounting Plate. Use a screwdriver as a lever between the frame and the Mounting Plate to move it down slightly. Be careful not to shift the Small Pulley out of position.
4. Once taut, tighten the Hex Nuts.

In addition to proper lubrication, routine cleaning is important for the maintenance of the M30 Stitcher Machine. The entire head should be torn down and rebuilt every 250,000 to 500,000 cycles. The following areas should be cleaned once a month:

• Large Feed Gear (G40510A) remove and wash in an oil-dissolving solvent; dry and relubricate the clutch and bearings. Use Isoflex NBU 15 Bearing Grease
• Anywhere that dust, oil or pieces of wire and paper have built up - for example: around the Clincher Points and the Wire Straightener Rollers.
• Blow Head and Clinchers off daily with compressed air.

Head Disassembly (Figures 29 & 30)

1. Remove the Head Guard by lifting to disengage Safety Interlock Key.
2. Clear away all remaining wire and perform a full manual cycle.
3. Swing Wire Holder Retaining Spring clear and remove the Wire Holder.
4. Loosen Thumb Screw and remove Lower Wire Tube.
5. Remove the screws holding the Pivot Block and Feed Gear Bracket and pull away. The Feed Gear Bracket may require a slight pivot downward to remove.
6. Remove the Safety Interlock Switch followed by the Right Bonnet Plate Assy.
7. The Driving Slide and Bender Bar Assemblies can now be removed by sliding out to the right.
8. Remove the Cutter Operating Lever Assy., the Cutter Box Adjustment Slide and then the Left Bonnet Assy.
9. If mounted, remove the Wire Spool and then detach the Wire Spool Mounting Bracket.
10. Disconnect the Upper Wire Straightening Bracket Assy. and then remove the Left and Right Mounting Bars.
11. The Bender and Driver Cam Plate Assemblies can now be removed by pulling them forward and off the Crank Bushings.
12. Now remove the Cutter Operating Connecting Link, sliding it out the side of the machine.
13. Loosen the Set Screw securing the Crank Arm and pull it and the Key off the Head Drive Shaft.

FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

Feed Gear Bracket G40536

Screw M6x1.0x50 G40802 (3)

Lower Wire Tube Assy G40599A

Upper Wire Straightener Bracket G40767AA

Wire Spool Mounting Bracket G40520

Head Guard G40135

Wire Holder Retaining Spring G20583

Socket Head Screw G20697 (3)

Knurled Thumbscrew G40773

Wire Holder Pivot Block G40643BA

Upper Wire Straightener Bracket G40716AA

Shoulder Screw M12X20 G40817 (2)

Wire Holder G20659BA

Bonnet Plate Assy. - Right G40501BA

M6 Ribbed Lock Washer G20520 (6)

Figure 29 - Disassembling the Head

CAUTION: The Supporter is under tension and will spring out towards the front of the Head as these parts are removed. Keep fingers away from the Supporter to avoid injury.

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

! WARNING



Crank Arm G40238B

Mounting Bar Assy.-Left G40200A

Mounting Bar-Right G40201

Bender Cam Plate Assy. G40235A

Driver Bar Assy.

Shoulder Screw M12x20 G40817 (2)

Cutter Operating Lever Assy. G40630BA

Bonnet Plate Assy.-Left G40500BA

Shoulder Screw M10x25 G40800

Driver Cam Plate Assy. G40236A

Figure 30 - Disassembling the Head

In time, you will need to replace some parts in the M30 Stitcher Machine. To do this locate the DeLuxe Stitcher part number in one of the following diagrams and contact your Graphic Arts Representative to order the replacement by part number, description and quantity.

The operator should periodically inspect all moving parts for signs of wear and when required, replace the worn parts. The following are some of the more common wear parts which will need to be removed and replaced in your M30 as well as step-by-step instructions to replace them.

Clincher Front Plate G40954

Clincher Point G40955R (Round) G40955F (Flat)

Clincher Back Plate Assy. G40952A

Removing and Replacing the Clincher Points and Clincher Slide

The Clincher Points are not reversible as with other styles, but are easy to replace.

Screw M6x1.0x20 072012 (2)

Clincher Pad G40950AA

1. Free the entire Clincher Plate Assy. with the Clincher Slide by removing the screws securing it to the Clincher Pad.

Figure 31 - Changing the Clincher Points

2. Lift off the Clincher Front Plate to reveal the Clincher Points.

3. Remove the worn Clincher Points.

4. To replace the Clincher Slide, loosen the two Clincher Slide Block Screws that connect the Clincher Slide Block Clamp to the Clincher Slide Adjustment Block.

6. Remove the old Clincher Slide Clincher Slide and Block Clamp Clincher Slide replace with a new 18184 G40976 one. Clincher Slide Adjustment Block

7. Retighten the 18183 Clincher Slide Block Screws.

8. To replace the Clincher Points, slide the new ones over the pins in the Clincher Back Plate Assy. mak- Clincher Slide ing sure the large Clincher Slide Adjustment Screw Block Screw radius on the Points 18186 UA3216.2 (2) rests on the top of the Clincher Slide. Figure 32 - Changing the Clincher Slide

9. Replace the Clincher Front Plate.

10. While holding the entire assembly, move the Clincher Slide up and down a few times to ensure everything is moving freely and does not lock up.

11. Reattach the Clincher Plate Assy. to the Clincher Pad making sure the bottom of the Adjustment Screw rests in the cutout of the Clincher Upright Extension.

12. Insert the screws and lock washers and tighten.

13. Check the alignment of Clincher Plate Assy. with the Formers and adjust if necessary.

14. Cycle the machine manually to ensure the Clincher Point height prior to beginning work.

Adjusting and Replacing the Cutters

Cutters become worn or chipped and must be adjusted or replaced. The Fixed Cutter must be replaced when worn. The Moving Cutter can be adjusted 3 or 4 times before needing replacement. To adjust or replace Cutters:

Cutter Box Assembly G40597A

1. Remove the Cutter Box Assy as shown in Fig. 33.

Moving Cutter

2. To adjust the Moving Cutter, first remove the Cutter Operating Slide. Note: The Cutter Operating CUTTING EDGE Spring is compressed, take Flat Head Screw care when removing the Cutter G40219 (2) Operating Slide.
3. Loosen the screw holding the Figure 33 - Removing the Cutter Box Moving Cutter, rotate the Cutter so that a new cutting edge will cut the wire and then tighten the screw. (To prevent the Cutter from spinning as you tighten, rest the side of the Cutter on a flat surface and while holding the Cutter Moving Cutter Operating Slide, tighten the screw. Cutter

Flat Head Screw G20167

Fixed Cutter

4. To replace the Fixed Cutter, loosen the Set Screw below it and be wary of the Cutter Operating Spring, pull it out along with the Cutter Operating Slide.
5. Separate and retain all the other parts, replacing only the worn Fixed Cutter with a new one.
6. Reassemble all the parts and place them back into the Cutter Box. The spring will have to be compressed while doing this. Also ensure that the Wire Hold Down settles in the groove of the Fixed Cutter.
7. Adjust the Fixed Cutter by holding down the Cutter Operating Slide in the cutting position and lightly push the Fixed Cutter against the Moving Cutter. Tighten the Set Screw and release the Slide and then push the Slide down a few times to ensure free movement.
8. Replace the Cutter Box Assy.

Operating Slide G40598A

Wire Hold Down G40701

Cutter Operating Spring G20210

Fixed Cutter Cover G40601

Fixed Cutter G40600

M6 Set Screw G40811

Figure 34 - Changing the Cutters

Driver Bar G40551B

M6 Cap Screw G40809 (4)

Driver Retaining Screw G40809

Bender Bar walls

Figure 36 - Changing the Formers

Figure 35 - Changing the Driver

Replacing the Formers & Driver

The Driver and Formers must be replaced when worn or when changing wire size. Replace them as follows:

1. Unlock the Hand Wheel by turning the Adjuster Lock Lever counter-clockwise and raise the Head to its highest position by turning it counter-clockwise..
2. Swing aside the Wire Holder Retaining Spring and remove the Wire Holder Assy.

Driver Only

3. Remove the Driver Retaining Screw and the Lock Washer. It will now slide out of the Head.
4. Slide the new Driver up the Former grooves until it stops against the Driver Bar and fasten.

Formers

5. After removing the Driver, remove the four Screws and Lock Washers and to separate the Formers from the Bender Bar.
6. Replace with new Formers by pushing them up and to the side against the walls of the Bender Bar as pointed out in Fig. 36. Reattach with Formers and Driver with aforesaid screws and washers, keeping the Driver just short of fully tightened..
7. Manually cycle the Machine two or three times to set the Formers, then fully tighten the Driver.

Manually cycle again to ensure free movement of everything.

8. Return the Head to its appropriate position amd lock by turning both the Hand Wheel and Lock Lever clockwise.

Large Feed Gear Set Screw G20691

Feed Gear Friction Bushing G20694

Feed Gear Friction Spring G20586

Upper Wire Tube G40581

Friction Plug G20587

Large Feed Gear Washer G40129 (2)

Feed Gear Shaft G40114

Large Feed Gear G40510A

Feed Gear Clutch G40537

Rear Feed Gear Spacer G40128

Feed Pinion G40511A

Feed Pinion Bearings G40538

Feed Release Handle G40119

Small Feed Gear G40512

Feed Lever Bushing GG20267

Pivot Shaft G40114

Small Feed Gear Shaft G40262

Cam Set Screw G20264

Feed Release Plunger G20121

M6 Dowel G40751

Feed Release Cam G20118

Feed Lever G40532A

Figure 37 - Feed Gear and Pinion Replacement

Feed Release Bearing G40904

Feed Gears and Feed Pinion Replacement

1. Remove Feed Gear Bracket Assy. as previously instructed and turn the Feed Release Handle so that the Set Screw in the Feed Release Cam is accessible.Loosen and remove the Cam from the Feed Release Handle.
2. Loosen the Feed Release Plunger and remove the Feed Release Handle.
3. Unscrew the Feed Lever Bushing from the Feed Lever and remove the Feed Lever Spring. (If necessary, the Upper Wire Tube can be removed after loosening the M6 Set Screw (G20522) securing it.)
4. Lay the Feed Gear Bracket flat on its front. The Feed Lever Assembly can be removed by pulling it up off its Pivot Shaft.
5. To remove the Small Feed Gear, unscrew and remove the Small Feed Gear Shaft from the Feed Lever.
6. Remove the Feed Release Bearing by pressing the Bearing and M6 Dowel out of the Feed Lever.

Press the Bearing off the Dowel and press a new Bearing on the Dowel. Press the new Bearing and Dowel back into the Feed Lever.

7. Replace the Small Feed Gear and screw in the Small Feed Gear Shaft using a thread locking compound, being careful not to get any compound on the surface upon which the Gear rides.
8. To remove the Large Feed Gear loosen and remove the Set Screw in the Feed Gear Friction Bushing to relieve the pressure the Feed Gear Friction Plug is placing on the Feed Gear. Remove the Friction Plug and the Feed Gear Friction Spring from the Bushing. Check them wear and replace if necessary.

9. Lift the top Large Feed Gear Washers, the Large Feed Gear and the Feed Pinion off the Feed Gear Shaft and away from the Feed Gear Bracket.
10. Remove the Feed Pinion and Rear Feed Gear Spacer from the Large Feed Gear. If necessary, liberally apply Kluber ISOFLEX NBU 15 grease to the Feed Pinion Bearings and/or the Feed Gear Clutch and rub into the rollers using your finger and reassemble.

11.Replace the Feed Lever Assembly and if necesary the Upper Wire Tube. Insert the Feed Gear Friction Plug in the Feed Gear Friction Bushing. Apply any Lithium-based grease to the Feed Gear Friction Spring and insert it into the Bushing. Tighten the Set Screw, over the Spring, 3 to 4 turns after contact is made. The Feed Release Handle and Cam can be installed after the Feed Gear Bracket is re-attached to the Machine.

To begin disassembly of the Bender Bar Assembly (G40547BA):

1. First, if the Driver Bar and Formers are still attached, remove them now (Figs. 35 & 36)
2. Remove the Supporter Assy. by pushing the top of it forward and pushing the M5 Dowel Pin out towards the right.

CAUTION: Be very careful separating Supporter Assy. from the Bender Bar. The Supporter and Supporter Plunger are under pressure from the Supporter Spring and can shoot out of the Supporter.

Figure 38- Bender Bar Assembly

Supporter Plunger G20742

Bender Slide Block G40562

Heavy Duty E-Ring G40752

Supporter Spring G20744

Bender Slide Pin Block Assy. G40564A

Bender Slide Pin G40569

M5 Dowel Pin G20567

Bender Slide Spring 15025L

M6 Dowel G40751

M6 Cap Screw G20576

Supporter Cam Pin G40557

Supporter Assy. G40653BA

Bender Slide Pin Block G40564

3. Push the M6 Dowel out the right side of the Supporter.
4. Remove the Bender Slide Pin Block Assy. from the the Bender Bar.
5. To disassemble the Bender Slide Pin Block Assy., place it in a vise. Clamp the bottom of the Bender Slide Pin Block and the top of the Bender Slide Block. With clearance left for it, pry off the E-ring with a screwdriver, and carefully unclamp the Bender Slide Pin Block Assy.

CAUTION: The Bender Slide Pin Block Assembly is under tension from the Bender Slide Spring.

6. Lift the Bender Slide Block off the Bender Slide Pin and remove the Bender Slide Spring. The Bender Slide Pin can be removed from the Bender Slide Pin Block by pressing the M6 Dowel out of the Block.

Begin disassembly of the Driving Slide Assembly (G40531BA) by:

1. Removing the M6 Cap Screw and Lock Washer (G20520) securing the Feed Slide Block.
2. Remove the Cutter Operating Cam from the Driving Slide and then the Rack Assembly by removing the Feed Rack Guide and M4 Cap Screws

Feed Rack Adjustment Knob G20573

Feed Rack Block G40530

M4 Cap Screw 072003

M6 Cap Screw G20576

Feed Rack Adjustment Stud G40574

Feed Slide Block G40672

Rack Assembly

Feed Release Cam G40638

Feed Rack G40527B

M5 Cap Screw 042001

Feed Rack Guide Screw G20625

Cutter Operating Cam G40563

M6 Cap Screws G40803

Figure 39 - Driving Slide Assembly

3. Remove the Feed Rack by holding the Feed Rack Block and turning the Feed Rack Adjustment Knob counter-clockwise until the Rack comes off the Feed Rack Adjustment Stud.
4. Remove the Feed Release Cam (G40638).

 WARNING

! Do not operate the M30 under power until the machine has been turned over manually to verify that the stitching head is operating freely.

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 the 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. Refer to Figure 40 for more details.

No power to the Coil.

Check all wiring and switching in the Clutch actuat-

Lack of continuity in the Coil Replace the Coil. (850998 - 230 VAC or 850999

• 115 VAC)

Mechanical binding of the Plunger. 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 to its true

the Adjust the Linkage as needed.

Actuator over the Stop Collar.

Actuator loaded by the Stop Collar Braking force is exceeding the limits of the Brake

so hard that the Actuator cannot be or the Differential setting of the unit is too close.

pulled by the Coil.

(see Figure 30 for instructions)

Figure 40 - Actuator Checklist

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. Refer to Figure 41 for details.

Clutch Brake does not drive but Input 1. Drive Spring (850889) may be broken at thecross-

over point from an overload caused by a jam. Replace

the Spring and check the Hubs (851321 or 850892)

2. The Control Collar (850888) may not snap forward

because of foreign matter restricting movement.Clean

3. Actuator Assembly does not pull in. (Figure 28)

Clutch Brake jams and stalls the Input 1. Spring tang broken off Drive Spring not allowing-

the Clutch to disengage while the Brake is engaged.

Replace the Drive Spring.

2. Clutch output is bound up. Check the clearance

between the Output Hub and the Brake Hub.

3. Completely out of adjustment caused by losing an

internal Spring tang. Replace Spring. Output does not repeat stopping point 1. Not enough inertia to actuate Brake.

2. Tang broken off the Brake Spring. Replace the
3. Adjustable Collar Locking Screw may be loose

allowing Adjusting Screw to rotate.

Figure 41 - Clutch and Brake Spring Checklist

Disassembly (See figure 42)

To disassembly the Clutch-Brake unit (850673 or 850674) it will be necessary to remove the Drive Pulley (7678) from the stitcher by removing the V-Belt (850730), Retaining Ring (P7863), and Clutch Anchor Screw (7681). Disconnect the Ground and Solenoid wires, and swing the anchor strap (FC9656) clear of the Drive Pulley Assembly and slide it off of the Drive Shaft. Remove the three

3. Screws (UA4812.7) 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 Clutch-Brake unit, proceed as follows:

Release the Actuator Lever so that the Clutch is engaged and the Brake is released. Remove the Retaining Ring and the Shim Washer, if any, from the Input Hub (851321) end. Remove the Input Hub by rotating opposite to the drive direction. Remove the Retaining Ring and the Shim Washer, if any, from the Mounting Plate end.

Remove the Output Shaft Springs and the Control Collar (850888) Assembly by rotating the Output Shaft (850891) in the drive direction. (Do not disassemble the brake Hub (850892) from the Mounting Plate. (850890)) Remove the Control Collar from the Output Shaft and the Spring Assembly by extracting toward the Brake Spring end.

Assembly (See figure 42)

Replace the Clutch (850888), Brake (850889) and Anti-Back (850962) Springs as required. Assemble the Springs concentric and square to the Output Shaft.(850891) Assemble the Control Collar over the Output Shaft and Spring Assembly by inserting it from the Brake Spring End (it will be necessary to extend the Brake Springs using long nose pliers.) Place the Brake Spring Tang in any one (1) of the nine (9) Control Collar slots at random.

Assemble the Output Shaft, Springs and Control Collar assembly to the Mounting Plate Assembly by rotating the Output Shaft in the drive direction. Assemble the Retaining Ring (850886) to the Output Shaft at the Mounting Plate end (the smooth surface facing the Brake Hub.) Check the end play between the Hub and the Retaining Ring with a feeler gauge. There should be 0.004” to 0.010” end play. Use a Shim Washer to adjust if necessary.

Rotate the 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 (851321) by rotating opposite to the drive direction. Select 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 the Clutch Spring tang from the 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 the Retaining Ring to the Output Shaft at the Input Hub end (the smooth surface facing the Input Hub). Check the end play between the Input Hub and the Retaining Ring with feeler gauge. There should be 0.002" to 0.003" end play on the Input Hub.

Reassemble the unit to the machine.

Note: After the Clutch is assembled to the machine, the Clutch Plate should be free to float on bearing

• the Anchor Strap is only there to prevent rotation of the plate.

SPLIT CAM DESIGN CONTROL COLLAR

Retaining Ring

Drive Sleeve

Stop Cam

Coupling Sleeve

Brake Sleeve

Thrust Washer (Input) Input Hub Assembly w/Roller Bearing Control Collar Assembly Drive Spring Anti-Overrun Spring

• **NOT USED*** Output Assembly SPCL Anti-Back Spring Brake Spring Brake Hub w/Roller Bearing Plate Assembly Thrust Washer (Plate Hub)

Actuator Assembly w/Plunger Button Head Cap Screw Coil Assembly - 230V-50Hz Coil Assembly - 115V-60Hz Headless Socket Set Screw Retaining Ring Shims Shims (Clutch Shim .005") Shims (Clutch Shim .010") Spacer

Figure 42 - Clutch - Brake

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 solvents 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.

Control Collar Adjustment (Figure 43)

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 the Retaining Ring (850886) out of its groove and slide it forward on the Input Hub (851321). Slide the cam of the Control Collar Assembly (850888) off of the splines, rotate to align the collar stop with the actuator and slide the cam back on the splines. The actuator pawl will have to be held clear during this operation. Slide the retaining ring back into its groove.

Make sure brake is locked up before proceeding, to insure the proper stop point.

Figure 43 - Control Collar Adjustment

Internal Assemblies - Compression Adjustment Linkage

G40768 (LONG)

G40769 (2) (SHORT)

REMOVABLE

PANEL THIS SIDE

G40238B (See page 48)

Bearing Collar

on G40902

Shaft Rotation

UA5812.7

SW516.3

G20195 or G40824

Internal Assemblies - Lower Drive Gear & Bearing Mounts

Table and Clincher Assemblies - Clincher Mount & Work Table

G40977A (2) (OPTIONAL)

DBS1099

G40950AA

G40955R or G40955F (2)

This Shipping Tab must be removed [G40978] before attempting to operate this machine .

A Shipping tab is supplied to ensure proper alignment of stitching head during transport

Table and Clincher Assemblies - Clincher Pad

PW14.6 (4)

850344A (110V) or 850344B (220V)

850731-AST or 850732-BST

220VAC/50HZ

850316 (BST ONLY)

UA3304.2 (2)

851005 (AST) 850314 (3) (AST)

LW38 (8)

850314 (BST) 851005 (BST)

PW38 (8)

HN3816 (4)

UA6116.1 (4)

850306 - UV TRIP 850301 - STARTER

850323B - (BST)

850305 - UV TRIP 850311 - STARTER

850322B - (AST)

85982 (2) (AST) 850315 (2) (BST)

Motor Assemblies

PW14

CB606

CB145

FC9632

PW14

HN51618

PW14

CB860

(220VAC/50HZ)

or 850661

(110VAC/60HZ)

UA8164

UA5114.1

UA5114.1

3x UA3806.9

3x PW10

Guard Assembly

External and Head Assemblies - Head Crank & Driving and Bending Cam

Note: Chamfers should face each other

G40239BA

COMPRESSION STICKER

DBS1120

G40500BA

SU-0308853 (2)

G40501BA

External and Head Assemblies - Bonnet Plates

External and Head Assemblies - Feed Slide and Bender Bar

G40531BA

G40652 (24Ga WIRE) G40654 (23Ga WIRE) G40656 (20x24Ga WIRE) G40657 (19x21.5Ga WIRE) G40658 (20Ga WIRE) G40659 (18x20Ga WIRE)

G40547BA

G40653BA

• NEW PIN DESIGN AVAILABLE ON MODELS BUILT 2017 AND LATER WITH SERIAL NUMBERS 17XXXM30 AND UP.

G40648 (2) (20x24 - 23Ga WIRE) G40649 (2) (19x21.5 - 24Ga WIRE) G40650 (2) (18x20 - 20Ga WIRE)

• * MODELS WITH SERIAL NUMBERS 16999M30 AND LOWER COME WITH PIN AND SNAP RING.

NEW PIN CAN BE INSTALLED IN

OLDER MACHINES.

External and Head Assemblies - Large Feed Gear & Lower Wire Straightener

FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

External and Head Assemblies - NEW Lower Wire Straightener

TURNING THIS KNOB

ADJUST LEFT OR RIGHT WIRE DIRECTION

G40716BA

TURNING THIS KNOB

ADJUST UP OR DOWN WIRE DIRECTION

WIRE IS GOING DOWN

IF TURNING KNOB IN UP DIRECTION

External and Head Assemblies - Wire Guide Spring

FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

FOR M30 MACHINES WITH SN STARTING FROM XXXXXX

LOOK AT NEW WIRE STRAIGTENER WITH NEW WIREGUIDE SPRING SEE PAGE 55 AND PAGE 57

External and Head Assemblies - Head Guard

HN3816

LW38

PG10271 (2)

UA3806.9

KN1032 (2)

PW14 (2)

UA3410.4 (2)

Part Number / Description Cross-Reference

PART NO.

DESCRIPTION

Screw M5x.8x8 Lock Washer Ribbed M3 Lock Washer Ribbed M4 Lock Washer Ribbed M5 Screw M4x0.7x12 Screw M6x1.0x12 Screw M6X1.0X25 Screw M6x1.0x30 Screw M6x1.0x20 Screw M6x1.0x22 Bender Slide Spring - Light Duty Clincher Slide Adjustment Block Clincher Slide Block Clamp Clincher Slide Adjustment Screw Drive Pulley, CB-7 Clutch

19211/2G5 Wire Spool - Galvanized Clincher Slide Link Spring 36 Pin Clincher Oper. Lever Spring Screw Work Guide Screw 7423C Work Stop - Large 7645A Table Support Bracket Asy - RH 7645LA Table Support Bracket Asy - LH 7648 Table Support 7675 Belt Guard Base 7676 Belt Guard Cover 7678B Drive Pulley - 4L 7679 Drive Pulley Washer 7690 Tension Spring 7691 Set Collar - Reamed 7693 Spool Stud 850303B Terminal Strip - Holes 850307 Power Cord - 230V 850313 Footswitch Guard 850314 Strain Relief 850315 Strain Relief Nut 850316 RFI Filter 850317 Clutch, Wire Harness 850318 Footswitch, Wired 850319B Safety Switch, Wired-Side Mount 850322B Starter Assembly 3/4 - 115V 850323B Starter Assembly 3/4 - 230V 850337 Wire Terminal Ring 850344A Motor 3/4 HP - 115V 850344B Motor 3/4 HP - 230V 850660 CB-7 Clutch - 115V 850661 CB-7 Clutch - 230V 850677 Electric Clutch, Heavy Duty - 115V 850678 Electric Clutch - 230V

QUANTITY

PART NO.

DESCRIPTION

850730C 850731 850732 851005 85128 85982 86243 88038 9070 AF203 AF207 AF223 B554 FC9633 FC9656A

V-Belt Pulley Pulley Strain Relief Connector 3/8 Lock Nut 1/2 Power Cord - 115V Nylon Cable Clamp Wire Straightener Eccentric Pointer Lock Washer 5/16 Hel Lock Washer 1/2 Helical Spring Flat Washer 5/16 Torsion Spring Shaft Key Clutch Anchor Assembly

Feed Release Handle Cam Feed Release Plunger Dowel Pin M5x24 Follower Ball Bearing Driver Retaining Screw Screw M4x.7x10 Screw M8x1.25x12 Screw M4x.7x6, with Nylon Patch Screw M3x.5x4 Wire Holder Retaining Spring Foot Screw M3x.5x10 Screw M6x1.0x8 Cutter Operating Spring Wire Straightener Disc Spring Hex Nut M4x.7 E-Ring 3/16 Tube Pivot Screw Tube Pivot Clip Screw M4x.7x14 Wire Hook Wire Hook Spring Wire Hook Spring Screw Screw, M5 x 0.8 x 5, Nylon Feed Lever Bushing Screw M4x.7x4, with Nylon Patch Hex Jam Nut, M6x1 Tension Pawl Pivot Pin Tension Pawl Tension Pawl Spring Tension Pawl Roller Wire Guide Spring Assembly - Long Wire Oiler Felt Spring

Screw M4x0.7x8 Flat Washer, M5 Wire Oil Felt Washer

QUANTITY

Part Number / Description Cross-Reference

QUANTITY

PART NO.

DESCRIPTION

Wire Oiler Felt Screw M6x1.0x40 Nylock Lock Nut, M6x1 Spring Anchor Screw Hex Key Wrench 3.0mm Open End Wrench Feed Release Handle Cap Dowel Pin M6x14 Ribbed Lock Washer M6 Screw M6x1.0x5 Feed Rack Block Wire Guide Bar - Left Wire Guide Bar - Right Screw M4x0.7x20 Dowel Pin M5x40

Belt Guard Bracket Paper Thickness Gauge, M30 Actuator Key Bracket Starter Mounting Flange Hand Wheel Screw 1/2-20x1-1/4 Self Tapping Screw Screw M4x.7x25 Self Tapping Screw Adapter, CB-7 Clutch End Cap, CB-7 Clutch Key-Rectangular, CB-7 Clutch Crank Shaft, CB-7 Clutch Clutch Anchor, CB-7 Clutch Tool Kit Hanger

G20570 G20573 G20574 G20576 G20578 G20579 G20583 G20586 G20587 G20588 G20589 G20615 G20617 G20625 G20626 G20659BA G20661 G20665 G20668 G20691 G20694 G20697 G20742 G20744 G30006A G30007B G30048 G30053 G30054 G30063 G30064 G30067

Spirol Pin M5x20 Feed Rack Adjustment Knob Feed Rack Adjustment Stud Screw M6x1.0x20 Rack Adjustment Knob Detent Screw M4x0.7x6 Wire Holder Retaining Spring Feed Gear Friction Spring Feed Gear Friction Plug Dowel Pin M4x12 Screw M4x0.7x10 Screw M5x0.8x8 Washer M6x18x1.6 Feed Rack Guide Screw, Nylon Screw M4x0.7x16 Wire Holder Assembly 5/8 Cr. Wire Holder Retaining Spring Screw Wire Holder Eccentric Screw Feed Lever Spring Screw M12x1.75x12 Feed Gear Friction Bushing Screw M6x1.0x30 Supporter Plunger Supporter Spring Bearing Housing Assembly Crank Shaft Motor Mounting Plate Bearing 1/2x1/2 Bearing 5/8x3/4 Shoulder Screw 5/8x1 Shoulder Screw 3/4x1-1/4 Bolt 3/8-16x1

Adjustment Crank Housing Adjuster Stop Motor Cover

G40001A G40002 G40013A G40017A G40037A G40043A G40044 G40100 G40101 G40102 G40114 G40119 G40128 G40129 G40135 G40145 G40153 G40174 G40200A G40201 G40202 G40203A G40207A G40208A G40211 G40212 G40213 G40219 G40220 G40231 G40235A G40236A G40237 G40238B G40239BA

Frame Weldmnet, M30 Side Cover Plate-Left, M30 Pivot Arm Assembly Crank Housing Connecting Link Assy Clincher Upright Link Assembly Clincher Lever Assembly Clincher Mounting Plate Adjuster Crank Shaft Insert Compression Adjustment Yoke Adjustment Shaft Feed Gear Shaft Feed Release Handle Rear Feed Gear Spacer Large Feed Gear Washer Head Guard Moving Wire Cutter Driver Retaining Screw Small Clincher Arm Spacer Mounting Bar Assembly - Left Mounting Bar - Right Upper Bearing Block - Horizontal Upper Bearing Block Assy - Vertical Adjustment Shaft Block Assembly Adjustment Shaft Support Brkt Assy Bender Rail Driving Rail Head Mounting Block Screw M6x1.0x30 Spring Clip Block Upper Gear Shaft Bender Cam Plate Assembly Driver Cam Plate Assembly Crank Pin Crank Arm Crank Housing Slide Plate Assembly

PART NO.

DESCRIPTION

QUANTITY

Part Number / Description Cross-Reference

PART NO.

DESCRIPTION

QUANTITY

G40240A G40242 G40262 G40284 G40286A G40301 G40302 G40402 G40500BA G40501BA G40510A G40511A G40512 G40513B G40515 G40520 G40527B G40530 G40531BA G40532A G40536 G40537 G40547BA G40551B G40557 G40562 G40563 G40564A G40569 G40571 G40574 G40581 G40597A G40598A G40599A G40600 G40601 G40603 G40604 G40605 G40630BA G40638 G40642 G40643BA G40648 G40649 G40650 G40652 G40653BA G40654

Crank Housing Assembly Head Drive Shaft Small Feed Gear Shaft Lower Tension Pawl Spring Wire Guide Spring Drive Cam Gear Drive Gear Screw M5x0.8x16 Bonnet Plate Assembly - Left Bonnet Plate Assembly - Right Large Feed Gear Assembly Wire Feed Pinion Assembly Small Feed Gear Supporter Guide Plate Dowel Pin M6x18 Wire Spool Mounting Bracket Feed Rack Feed Rack Block Feed Slide Assembly Feed Lever Assembly Feed Gear Bracket Feed Gear Clutch Bender Bar Assembly Driver Bar, M30 Dowel Pin M6x50 Bender Slide Block Cutter Operating Cam Bender Slide Pin Block Assembly Bender Slide Pin Dowel Pin M6x12 Feed Rack Adjustment Stud Upper Wire Tube Cutter Block Assembly Cutter Operating Slide Assembly Lower Wire Tube Assembly Fixed Wire Cutter Fixed Cutter Cover Cutter Box Guide Plate Upper Cutter Box Guide Plate Lower Cutter Box Guide Plate Cutter Operating Lever Assembly Feed Rack Cam Cutter Box Adjustment Slide Wire Holder Pivot Block 5/8 Cr. Bender Insert 5/8 - 20x24 & 23 Wire Bender Insert 5/8 - 19x21-1/2 & 24 Wire 2 Bender Insert 5/8 - 18x20 & 20 Wire Driver 5/8 - 24 Wire Supporter Assembly 5/8 Driver 5/8 - 23 Wire

PART NO.

DESCRIPTION

QUANTITY

G40656 G40657 G40658 G40659 G40672 G40680 G40701 G40702 G40703 G40704 G40705A G40708 G40709 G40710A G40711B G40716A G40716AA G40750 G40751 G40752 G40753 G40754 G40755 G40756 G40757 G40758 G40759 G40760 G40761 G40763 G40764 G40765 G40766 G40767A G40767AA G40768

Driver 5/8 - 20x24 Wire Driver 5/8 - 19x21-1/2 Wire Driver 5/8 - 20 Wire Driver 5/8 - 18x20 Wire Feed Slide Block Pivot Block Insert-5/8” Cr. Wire Hold Large Clincher Arm Spacer Cam Follower Stud Lower Bearing Block Vertical Drive Shaft Assembly Bearing Mounting Plate Wire Holder Spring Block Feed Lever Spring Bracket Assembly Cutter Box Adjustment Link Lower Wire Straightener Bracket Lower Wire Straight Brkt, Complete Wire Hold Spring Dowel Pin M6x20 E-Ring - Heavy Duty Lock Collar Dowel Pin M8x20 Clincher Pad Guide Shaft Spring Pin M4x24 Dowel Pin M10x28 E-Ring 12mm Keyway - 8mm x 1/2 Keyway - 6mm x 3/4 Keyway - 6mm x 1-1/2 Keyway - 8mm x 3/4 E-Ring 1/2 Wire Straightener Roll Stud Straightener Eccentric Upper Wire Straightener Brkt Asy Upper Wire Straight Brkt - Complete Clevis Pin 1/2x2-1/4

Clevis Pin 1/2x2 Hitch Pin Dowel Pin M4X10 Adjuster Lock Lever Thumbscrew - Knurled Shoulder Screw M10x25 Screw M6x1.0x50 Screw M6x1.0x16 Screw M8x1.25x16 Screw M6x1.0x12 - Dog Point Screw M6x1.0x12 - Low Head Shoulder Screw Screw M6x1.0x8 - Dog Point Screw M8x1.25x16 - Low Head

Part Number / Description Cross-Reference

PART NO.

DESCRIPTION

QUANTITY

PART NO.

DESCRIPTION

G40813 G40814 G40815 G40816 G40817 G40818 G40820 G40821 G40823 G40824 G40851 G40852 G40901 G40902 G40903 G40905 G40906 G40907 G40908 G40909 G40911A G40912 G40950AA G40952A G40954 G40955F G40955R G40956A G40957 G40958 G40959 G40960 G40961 G40962 G40964A G40973B

G40975 G40976 G50125 G50234 G50266 G50396 HN1024 HN1213.2 HN1420.2 HN3816 HN51618 HN51618.2

Shoulder Screw Shoulder Screw Screw M8x1.25x12 Screw M8x1.25x25 Shoulder Screw M12x20 Screw M6x1.0x25 Shoulder Screw M6x10 Screw 1/2-13x1 Screw M6x1.0x16 Screw, NM8 x 1.25 x 8, Nylon Lock Washer Ribbed M8 Spring Pin, M5 x 30 Feed Lever Pivot Bearing Upper Drive Shaft Bearing Worm Shaft Bearing Clincher Cam Follower Ball Bearing Drive Shaft Coupling Crank Bushing Head Drive Shaft Bearing U-Joint & Splined Shaft Assembly Grooved Straightener Roller Clincher Pad Assembly Clincher Back Plate Assembly Clincher Front Plate Clincher Point - Flat Clincher Point - Round Clincher Base Assembly Clincher Adjustment Shaft Clincher Adjustment Worm Gear Clincher Height Adjust Handle Worm Shaft Clincher Adjusting Worm Table Pivot Shaft Work Table Assembly Work Guide Backtop

KN1032 KN1420 LW14 LW38 M-TOOL KIT M11009 P2582 P2731 P7507 P7863 PG10219 PG10255 PG10271 PW10 PW10.3 PW12.1 PW12.4 PW14 PW14.2 PW14.6 PW38 SU-0308853 SW14.1 SW516.3 UA1428.1 UA3216.2 UA3410.4 UA3806.2 UA3806.9 UA3808.2 UA3810.10 UA4810.1 UA4812.7 UA4828.3 UA5112.1 UA5116.1

Kep Nut 10-32 Kep Nut 1/4 Lock Washer Lock Washer Kit - M-Series Tool Plastic Washer Connector 3/8x90 Degrees Thumb Screw 1/4-20x3/4 Screw 1/4-20x3/4 Retaining Ring Terminal 1/4x90 5/8 Screw, 1/4-20 x 3/4”, FHM Washer 9/16 Washer Flat Washer 3/16 Washer Black 1/2 Washer Black 1/2 Flat Washer Washer Zinc Washer 1/4 Washer Screw 3/8X3/8 Lock Washer C'Sunk Lock Washer Set Screw 1/4-28X1/4 Clincher Slide Block Screw Screw, 10-32 x 5/8” Screw 10-32x3/8 Screw 10-32x3/8 Screw 10-32x1/2 Shoulder Screw 1/4x5/8 Screw 1/4-20x5/8 Screw 1/4-20x3/4 Set Screw - Cup Point Screw 5/16-18x3/4 Screw 5/16-18x1

Clincher Upright Extension Clincher Slide Screw M5x0.8x20 E-Ring 4mm Dowel M5x10 Screw M5x.8x12 Nut 10-24 Hex Jam Nut 1/2-13 Hex Jam Nut 1/4-20 Hex Nut 3/8-16 Hex Nut 5/16-18 Hex Jam Nut 5/16-18

UA5120.2 UA51618.1 UA5812.7 UA6112.1 UA6116.1 UA8164

Screw 5/16-18x1-1/4 Screw, 5/16-18 x 7/8 Screw 5/16-18x3/4 Screw 3/8-16x3/4 Screw 3/8-16x1 Screw 1/2-13x4

QUANTITY

Wiring Diagram

Black

Black

Black (To Bottom Center)

Blue *Green To Ground Black

• GREEN TO GROUND BLUE DETAIL BLACK BROWN BROWN BLACK

7.8AMPS

Set T0 11.8 Amps Bst

• 115V SET TO -230V

See Detail

In Foot Switch Body

Leads As Shown. Switch Wiring Diagram

To The Conductors Ootswtch To Screw Provided

Swtch Approved Termin Terminals

Fasten Ground

Wire Using Onl

Black 1On

Fasten

Ttach

Complete Wiring with Detail

Wiring Diagram

Switch (Top) Switch (Bottom) Safety Switch

Brown

Brown Black Bro

Clutch

Black

Ground

Green

Power Power Foot Switch

Cord Cord Motor

AST-115V Models

Switch (Bottom)

Switch (Top) Safety Switch

Brown

Filter

Black

Brown Black

Blue Brown

Reen

Clutch

Green

Ground

Green

Power Foot Switch

Cord Motor

BST -230V Models

( Type/Quantity Purchased )

Country :

City :

Dealer Street Address :

Dealer Name :

Date Received :

Dealer Phone :

State/Province :

Zip :

DE LUXE STITCHER GRAPHIC ARTS REPRESENTATIVE

Serial Number(s) :

Head(s) Purchased :

Serial Number(s) :

With Head(s) :

Serial Number(s) :

Machine(s) Purchased :

PRODUCT

State/Province :

Zip :

E-mail :

Zip :

Would you like information sent to you about new products that would benefit your company?  Yes  No

Other Bindery Products Used :

Dealer Phone :

Country :

City :

Fax :

( Type/Quantity Purchased )

Dealer Street Address :

Dealer Name :

Date Received :

Serial Number(s) :

Head(s) Purchased :

Serial Number(s) :

With Head(s) :

Serial Number(s) :

( Middle Initial )

State/Province :

Machine(s) Purchased :

Phone :

Country :

City :

Street Address :

Company :

Name :

To better service your wire stitching needs, please take a moment to fill out and return this registration card.

REGISTRATION

CUSTOMER

P RO DUCT

DEALER

Please take a moment to fill out the attached card and

mail it to DeLuxe Stitcher Company, Inc.

In addition, duplicate the information for your records

to assist when making further inquiries.

Clincher Point - Flat

Clincher Point - Round

Below is a list of the most common wear/replacement parts for the M30 Stitcher. This guide should help you when ordering replacement parts. If the part you need is not listed below, please refer to the more detailed parts list in this manual.

C O M PA N Y, I N C .

3747 N Acorn Ln Franklin Park, Illinois 60131 U.S.A. Attn: Customer Service

D e L uxe S titcher

HERE

STAMP

PLACE

LIMITED WARRANTY

DeLuxe Stitcher Company, Inc. 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.

Always use genuine DeLuxe Stitcher parts. When ordering parts, please identify the part number, the part name, the wire size and crown size of your Stitcher.

Declaration of Conformity

We, DeLuxe Stitcher Company

3747 Acorn Lane Franklin Park, Illinois 60131 U.S.A Telephone 847-455-4400 Facsimile 847-455-4900

hereby declare under our sole responsibility that the

M30-BST Stitching /Stapling Machines

to which this declaration relates is in conformity with the following European product safety directives:

(89/392/EEC and amendments 91/368/EEC, 93/44/EEC, 93/68/EEC)

(89/336/EEC and amendments 91/C162/08, 92/31/EEC, 93/68/EEC)

as is verified by compliance with the following standards:

EN 60204 -1:1992 EN 294:1992 prEN 614 -1:1991

prEN 894 -1:1992 prEN 894 -3 :1992 prEN 1050:1993

prEN 953 :1992 EN 55014 :1193 EN 55104 :1995

Executed for DeLuxe Stitcher Company this first day of January in the year 2009

By Frank P. Cangelosi Signature Title President

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

DBSM30 10-23