OWNERS MANUAL CTTT2606R3
Contents
1. CTT 9086 CTT9086 A CTTT 9086 CTTT9086 A CTTT9086 M CTT9086 M CTTT9086 V CTT9086 V CTT 9086 B CTT9086 F CAA 2089 CAA 2089 A B SK852G2 SK852H2 Clincher Guide Plate CA9085A Layout 2 CA 2090 Stud 5 85212 Includes CA 9083 CTT 9086 CT 9093 CA 2091 CT 9088 Includes CA 9083 A CTT 9086 A CT 9093 A CA 2091 CT 9088 Includes CA 9083 A CTT 9086 M CT 9093 A CA 2091 CT 9088 Includes CA 9083 A CTT 9086 V CT 9093 A CT 9088 Binderbolt SK852K2 CA 2091 Nut SK852L2 CLINCHER POINT 1 16 Nominal CA 9083 A Thick 1 2 Crown 1 32 Nominal CA 9083 Thin 1 2 Crown CLINCHER SLIDES i E E SK85202 SK852P2 G SK852Q2 i il J SK852R2 TYPE L CLINCHER CLINCHER SLIDE POINT 3 17 32 3 37 64 5 9 16 5 9 16 3 3 1 64 12 25 32 12 25 32 3 17 32 Adjustable CT 9093 CT 9093 A CT 9093 R CT 9093 S CA 2095 G CA 2095 A CA 2095 CTT 9093 Y Thin Thick Thin Thick Thick Thick Thin Thin Thick lt T Omm mog WIRE GUIDE SPRING COMPONENTS Figure 22 SK883 Scene 5 ITEM PART DESCRIPTION QTY See Figures 20 WIRE GUIDE SPRING ASSEMBLY CAAA2133W CAAA2133L4 CAAA2133B2 CAAA2133L5 CAAA2133R2 CTTT2133A2 CTTT2133C2 CTTT2133D2 mo e NOTE Most of the above Wire Guide Spring2. STITCHING HEAD LUBRICATION FIGURES 3 amp 4 Typically the 1 2 inch crown stitcher will run for 1 000 000 cycles without additional lubrication However the following procedure used after each spool of wire will assure optimum life and performance Use ISP lubricant CA9640 A Inject lube into hole or remove and lube shafts B Wipe area clean and inject a small amount of lube into cam area C Remove rotator wipe rotator clean and lube rotator body D Apply lube to rotator ramp Figure 4 CTTT2605 Scene 6 E Wipe clean inside of rotator holder F Inject a small amount of lube into cam area of driver bar G Inject lube into cutter operating slide H Wipe driver clean and apply a light coating of lube After prolonged use or storage accumulations of wire dust dirt or other contaminants can mix with the stitcher lubricant This will reduce the lubricant s effectiveness The following procedure is recommended every 1 000 000 cycles 1 Disassemble the head and clean all parts 2 Lightly lube all sliding surfaces using ISP lubricant CA9640 3 Double check lube points A through H Section 4 OPERATION General After having properly installed and set up the ma chine it is now ready for stitching It is recom mended that each operator be instructed as to cor rect operating procedure and normal adjustments necessary for varying work conditions WARNING
3. Assemblies include the following parts through 12 WIRE GUIDE SPRING SUB ASSY CAA2133W f CTT2133A2 CAA2133B2 g CTT2133C2 CAA2133R2 h CTT2133D2 fo 1 essen D 1 T g 1 T CAAA2133W L4 L5 CAAA2133R2 CTTT2133A2 CAAA2133W View A CAAA2133W View A CTTT2133A2 Layout 2 PART NO CB651E CA9651 CA9652 CA9653 CA9032C CB860B CA9065A CA172 CA9103C CA9124 CA9066A D T CTTT2133D2 CTTT2133D2 Layout 2 DESCRIPTION SCREW 10 32 x 2 000 WASHER FELT WASHER THICK FELT WASHER THIN SPRING COMPRESSION NUT 10 32 ELASTIC STOP ROLLER ECCENTRIC SCREW NYLON TIP ROLLER WIRE STRAIGHTENER CLIP ROLLER ECCENTRIC eB be 2133 2 CAAA2133B2 CTTT2133C2 Layout 2 CAAA2133B2 Layout 2 27 CONTENTS Section 1 INTRODUCTION Section 5 MAINTENANCE TROUBLE 1 Model and Serial Number SHOOTING AND 2 Product Specifications ADJUSTMENT 8 General Section 2 SAFETY PRECAUTIONS 8 Recommended Spare Parts AND PROCEDURES 8 Cleaning and oiling 3 Safety 8 Stitching Adjustments 8 To Equalize Both Legs of Stitch 3 Safety Guards Cover 9 Trouble Shooting M2000 Head 12 Insufficient or Excessive Compression Section 3 ASSEMBLIES 12 Clincher LUBRICATION 13
4. BLOCK d CAAA9013K3 1 2 Cr 20 21 x 25 wire CA9075 WIRE GUIDE BRACKET SCREW e CAAA9013M3 1 2 Cr 24 rd wire McCain CA9127 ROTATOR OPERATING CAM STUD f 9 CAAA9013R3 1 2 Cr 22 Rd wire CA9058 ROTATOR OPERATING CAM STUD SCREW 901325 1 2 Cr CTTT2606R3 CA9056C FACE PLATE RETAINING CLIP OTE The above Bender Bar Assembly includes the following items CA2081 FACE PLATE RETAINING CLIP SCREW through item 23 CA9056A FACE PLATE RETAINING CLIP TABLE 1 For use in determining customer s Driving Slide Assembly ITEM PARTNO DESCRIPTION DRIVING SLIDE ASSEMBLY Driving Slide Style Use Lug Style CTT2623 standard raised lug 187 lg rectangular CT2602 CTT2623A lowered lug for 2 sheets to 125 in thick work 187 lg rectangular CT2602 CTT2623C standard raised lug 25 lg rectangular CT2602A CAA2623 standard raised lug round CA2103 w 031 thk washer CT32B CAA2623C pin D37327F holds in driving slide spring round CA2103 w 031 thk washer CT32B CAA2623D standard raised lug round CA2103B w 079 thk washer Contact ISP customer service for M2000 heads not listed 24 M2000 HEAD PARTS LIST ITEM PART DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 34 CT9109 BONNET ALIGNING SCREW 0 to 2 as req d 47 FACE PLATE SUB ASSEMBLY 35 CA9032C SUPPORTER SPRING 1 CAA2132V 1 2 Crown Slotted 36 CA9037 SUPPORTER SPRING BUSHING 1 CAA2132W 1 2 Crown No Slot CAA2132Y 1 2 Crown Fixed
5. Head Clincher Alignment INSTALLATION 13 Bender bar 4 Before Unpacking 14 Bender bar Friction Plug 4 After Unpacking 14 Driver Bar 4 Assembly 15 Bender Bar Latch 4 Threading wire and adjusting wire 15 Grip Grip Release Slide and Faceplate straighteners 16 Wire Cutters 5 Lubrication Felt Pads 17 Wire cutter Operating Slide 6 Lubrication Stitcher Head 17 Proper Wire 17 Rotator Section 4 OPERATION 18 Wire Straighteners 7 General Stitching al 9 Her 7 Changing Work Thickness I9 Tension Pawl 20 Dismantling M2000 Head USE ONLY REPLACEMENT Section 6 PARTS LIST PARTS DESIGNED AND 22 M2000 Head Stitcher MANUFACTURED BY ISP SPECIFICALLY FOR YOUR M2000 STITCHER 28 NOTES 29 CD DELUXE STITCHER COMPANY INC ISP Stitching amp Bindery Products 3747 N Acorn Lane Franklin Park IL 60131 Phone 847 455 4400 800 634 0810 Fax 847 455 4900 800 417 9251 http www deluxestitcher com QF76P 0613
6. Prevent accidents by following these rules 1 Do not put your hands near area to be stitched when machine is operating Turn the power off when the stitcher is not in use CAUTION AVOID DAMAGE TO YOUR STITCHER BY FOLLOWING THESE RULES 1 Never operate your stitcher with wire feeding unless you have work material between the clinchers and formers Do not drive one stitch on top of another Changing Work Thickness Figure 5 Changing work thickness will probably require a change of the wire draw length used to make a stitch This is done by raising or lowering the face plate Change face plate position as follows Switch off power loosen the face plate screw Index A Turn grip release lever Index B clockwise to raise face plate for more wire draw or counter clockwise to lower face plate for less wire draw NOTE Raising face plate too high may 1 Prevent the grip from closing and drawing wire 2 Prevent proper compression resulting in a loose stitch Retighten faceplate screw Figure 5 CTTT2605 Scene 5 Section 5 MAINTENANCE TROUBLE SHOOTING AND ADJUSTMENTS General The M2000 Stitcher is a friction type head which depends on smooth sliding friction and proper tim ing to function correctly Preventative maintenance will go far to insure trouble free operation Avoid production down time by keeping your stitcher lu bri
7. cutter Index A receives wire from the grip through the wire cutter lead in hole Index B It also serves as the cutoff die The lower wire cutter Index C is the cutting knife If the cutter breaks it will cover the lead in hole This prevents the wire from feeding into the rota tor If the cutting surfaces become worn burrs will result on the end of the wire This prevents the wire from feeding into the rotator As a result the wire buckles between the cutters and the wire grip Reverse interchange or replace the cutters To Reverse Interchange or Replace the Wire Cutters 1 Loosen both face plate retaining clips Index D at bottom of bonnet 2 Spring the face plate out 1 8 while holding the cutter slide in position Index E 3 Slide the cutters out to the left 16 gt X FS Figure 15 CTTT2605Scene 16 4 Reverse interchange or replace the cutters NOTE While installing the cutters make sure that 1 lip on upper cutter Index F fits into the recess behind the face plate Index G and 2 that the lip on the bottom cutter fits into the slot Index H in the wire cutter operating slide Index I The wire cutter operating slide actuates the lower wire cutter If the slide is worn or broken the wire cutter is not actuated Replace the operating slide The slot in the lower part of the face plate contains the wire cutter and maintains a close fit for wir
8. hand until legs of the stitch appear just below the bender bar to determine how far the head or clincher should be moved to the side b Loosen clincher plate binder nuts Index A c Move clincher to left or right as required d Tighten binder nuts D Bender Bar Figure 11 The bender bar bends the wire over the rotator and forms it into an unclinched stitch The legs of the stitch are guided towards the work material by the bender bar grooves The legs of the unclinched stitch should be perpendicular to the crown When the bender bar grooves become worn the legs tend to flare out Figure 11 as they emerge from the grooves This causes the legs to strike the clincher improperly As a result one or both legs will crumple and a broken driver bar or a broken bender bar can result If the lower end of the bender bar grooves become chipped it will not support the wire and may cause the stitch to break at the crown Replace the bender bar assembly See G page 15 or Fig 12 Other bender bar functions are related to wire cutting I page 16 and driving F page 14 13 Figure 12 CTTT2605 Scene 13 E Bender Bar Friction Plug And Or Spring Fig 12 Two parts furnish pressure to coordinate movement of driver bar and bender bar If pressure is insuffi cient proper timing is not maintained for the action of the grip As a result wire feeds backwards Replace the plug and or spring To replace bender
9. 2 23 M2000 HEAD PARTS LIST ITEM PART DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY CAA9074Z WIRE GUIDE BRACKET ASSEMBLY BENDER BAR SUB ASSEMBLY CTT2615B WIRE GUIDE BRACKET ASSEMBLY CAA9013U 1 2 Cr 25 to 30 rd wire CAAA9074A2 WIRE GUIDE BRACKET ASSEMBLY CAA9013Z 1 2 Cr 25 to 30 rd wire McCain Macey NOTE The above Wire Guide Bracket assembly CAA9013F2 1 2 Cr 24 rd wire includes the following items h through s CAA9013H2 1 2 Cr 20 21 x 25 wire CAA9074A2 WIRE GUIDE SRACKET SUB ASSEMBLY CAA9013K2 1 2 Cr 24 rd wire McCain CA9146A ECCENTRIC SCREW CAA9013P2 1 2 Cr 22 rd wire CA9068 ECCENTRIC FRICTION BUSHING CA9115 BENDER BAR FRICTION PLUG BUSHING CA9065 ECCENTRIC ROLL CA9113A BENDER BAR FRICTION PLUG SPRING CA9070 ECCENTRIC POINTER CA9112A BENDER BAR FRICTION PLUG CA9069 ECCENTRIC SPRING CA9067 ECCENTRIC NUT CAA9026 SUPPORTER ASSEMBLY 1 2 Cr D31028F SET SCREW CA9103C WIRE STRAIGHTENER ROLL CA9029 SUPPORTER PIVOT PIN CA9124 TENSION ROLL CLIP CA168 EXTERNAL GRIP SPRING CA9076 WIRE GUIDE SPRING BRKT ADJ SCREW CB371K LOCKWASHER CA9024A GRIP HOUSING RET SCREW CA9076 WIRE GUIDE SPRING BRKT ADJ SCREW CA9024E GRIP HOUSING RET SCREW CAAA9013Z5 CT56 WIRE GUIDE SPRING BRKT ADJ SCREW CT413A GRIP SPRING HOUSING CA9077 WIRE GUIDE SPRING BRKT SET SCREW 413 GRIP SPRING HOUSING 901325 CT1060 SET SCREW CA9015D GRIP CT2616 WIRE GUIDE BRACKET ADJ SCREW STUD CA173 PLASTIC PIN CAP CT2614 FACE PLATE ADJ SLIDE
10. By Pass 37 SUPPORTER SPRING LEVER ASSEMBLY 1 CA9134 TENSION PAWL SPRING CAA9036 Standard 1 625 in long CA9124 TENSION ROLL CLIP CAA9036A Special 1 494 in long CA9103A CHECK PAWL ROLLER CAA9036B Special 1 312 in long CA9103C WIRE STRAIGHTENER ROLL CA9098 TENSION PAWL CA9034 SUPPORTER SPRING LEVER SCREW CA9065A STRAIGHTENER ECCENTRIC ROLL CA9066A WIRE STRAIGHTENER ECCENTRIC SUPPORTER GUIDE PLATE CA172 ECCENTRIC FRICTION LOCKING SCREW CA9030 All except listed below CA9030A CTTT2605A2 McCain ROTATOR HOLDER CA9043M 1 2 CR 25 TO 30 RD WIRE TAPERED END CA9081 SUPPORTER GUIDE PLATE SCREW CA9043L 1 2 CR 25 TO 30 RD WIRE CA9051A WIRE CUTTER OPERATING SLIDE CA9043N 1 2 CR 20 21X25 WIRE FRICTION PLUG SPRING CA9043P 1 2 CR 25 TO 30 RD WIRE R H Not Shown CA9050A WIRE CUTTER OPERATING SLIDE FRICTION PLUG CB75B KEY WOODRUFF for use with CA 9043 M Rotator Holder only WIRE CUTTER OPERATING SLIDE CA9049 1 2 Cr All 1 8 155 3 16 capacity heads and CAA9038E M2000 ROTATOR 1 2 CROWN CTTT2605F4 H4 heads CA9049A 1 2 Cr All other 1 2 Cr Heads not listed above ROTATOR HOLDER SCREW CA9044A all except below CA9022J GRIP RELEASE SLIDE 1 2 Crown CA9044B CTTT2605W2 Y2 Z2 A3 X3 R7 CAAA2005K FACE PLATE ADJUSTING LEVER CA9025 For Non Slotted Face Plates ROTATOR OPERATING CAM CA9025D For Slotted Face Plates CA9163C standard oiling CA9163D inverted oiling CA9048 WIRE CUTTER CAA9046D ROTATOR OPERATING SPRING ASSEMBLY FACE
11. GUIDE STUD BENDER BAR LATCH CT2612 FACE PLATE LOCATING BLOCK STUD CAA9014J Standard CT2610 FACE PLATE ADJUSTING SLIDE CAA9014N Special for CAAA9013D3 amp CAAA9013M3 Bender Bar Assemblies McCain See TABLE 1 DRIVING SLIDE ASSEMBLY NOTE The Driving Slide Assembly includes the following parts DRIVER BAR DRIVING SLIDE ONLY CA9012M 1 2 Cr 25 Round Wire a c d fCA 2623 standard CA9012N 1 2 Cr McCain 25 Round Wire CT 2623 2 sheets to 125 in thick work CA9012R 1 2 Cr 20x25 amp 21x25 Flat Wire CA 2623 B pin holds in driving slide spring DRIVING SLIDE SPRING PLUNGER 24 BONNET CASTING SUB ASSEMBLY CA 2007 2007 M2000 Heads that use bonnet sub assembly DRIVING SLIDE SPRING CAA2004 CAAA2005 B R CA 9006 CAA2004B CAAA2005J CA 9006 A CAA2004E CAAA2005F G R H HEAD DRIVING SLIDE SPRING SCREW CTT2604 CTTT2605 A2 C E3 G 0 R2 R3 R10 CA 9021 A CTT2604F CTTT2605F4 DRIVING SLIDE SPRING PIN CTT2604L CTTT2605Q3 D 37327 F CTT2604P CTTT2605P2 P4 DRIVING SLIDE ROTATOR OP PIN CA 9028 DRIVING SLIDE SPRING SCREW LOCK PIN FACE PLATE LOCATING BLOCK SCREW a b c d f CA 9028 A CT2608 Slotted head shown CT2608A 5mm Hexagonal socket head not shown 10 BENDER BAR ASSY COMPLETE CT2613 FACE PLATE LOCATING BLOCK NUT a CAAA9013Z2 1 2 Cr 25 to 30 rd wire CT2606 FACE PLATE LOCATING CLAMP b CAAA9013D3 1 2 Cr 25 to 30 rd wire McCain CT2611 FACE PLATE ADJ SLIDE BLOCK CAAA9013H3 1 2 Cr 24 rd wire CT2607 FACE PLATE LOCATING
12. Gb DeLuxe STITCHER lt p SSRERYT INE OWNERS co ISP Stitching amp Bindery Products MANUAL M2000 ISP Stitching amp Bindery Products Includes Parts for CTTT2606R3 Section 1 INTRODUCTION Here are the instructions on how to install operate maintain and make repairs on your M2000 STITCHER HEAD Stitcher Head Serial Number Stitcher Head Wire Size Stitcher Head Part Number Stitcher Head Crown Width When ordering parts or requesting information please state Quantity required part number part name model wire size crown width stitcher head part number and stitcher head serial number The M2000 Stitching Head has been engineered and developed to provide you with the finest equipment available for your stitching needs With proper care and maintenance it will give you years of satisfactory efficient service This manual shows you how to get top performance from your stitcher and is divided into 6 major sections Read the M2000 Manual thoroughly Study it carefully Best stitching performance will be assured if all the adjustments are made as instructed PRODUCT SPECIFICATIONS Unit Weight Lbs 4 5 lbs Unit Envelope Size Height Length Width M2000 Head Without Wire Guide 11 in 3 12 in 1 82 in Notes Section 2 SAFETY PRECAUTIONS AND PROCEDURES SAFETY Make sure electrical power is turned off before performing any adjustment or ma
13. PLATE ASSEMBLY CA44 HEAD OPERATING LINK CAAA2132V 1 2 Crown Slotted For use only with round lug driving slide CAAA2132W 1 2 Crown No Slot assemblies CAAA2132Y 1 2 Crown Fixed Bypass NOTE The above face plate assemblies include indexes 47 to55 TABLE 2 For use in determining customer s special components PART NO DESCRIPTION CTT9003C BONNET CLAMP LEVER CTTT2605 C G R3 F4 CTT9002 BONNET CLAMP ASSEMBLY CTTT2605 C G R3 F4 CB157 BONNET BINDER SCREW CB835Q ROLL PIN CTTT2605P2 P4 Q3 R2 BONNET BINDER STUD CT9002A 500 13 NC Thread CTTT2605R2 CT9002F M8 X 1 25 8g Thread CTTT2605P2 P4 Q3 TEE BAR CT9002G 625 Long CTTT2605P2 CT9002L 841 Long CTTT2605Q3 CB175 WASHER CTTT2605P2 Q3 145 NUT 500 13 NC CTTT2605R2 CT9109A BONNET ALIGNMENT PIN CTTT2605Q3 CT9111 CONE POINT SET SCREW CTTT2605Q3 CA44 HEAD OPERATING LINK CTTT2605R2 For use only with round lug driving slide assemblies 25 E 2 Al A2 CLINCHER PLATE ASSEMBLIES 2 V Channtered CTT9086A Layout 2 CTT9086M Layout 2 CTT9086V Layout 2 CROWN SIZE SK852M2 SK852N2 26 CLINCHER POINT CA 9083 Thin CA 9083 A Thick CA 9083 Thin CA 9083 A Thick CA 9083 A Thick CA 9083 A Thick CA 9083 A Thick CA 9083 A Thick CA 9083 Thin CA 9083 A Thick CA 9083 Thin CA 9083 A Thick lt SK85212 TYPE CLINCHER PLATE ASSY
14. ays remove two or more stitches to see which is occur ring SS 2 Wrinkled crown 3 Length of one leg varies M2000 Head Trouble Shooting HERE S HOW A PERFECT STITCH LOOKS Should stitches appear in any form other than illustrated one or more kinds of mechanical trouble may have caused the malformation The possible causes and remedies are given for each kind of mechanical trouble and are listed under each section The remedies are indexed to the Ad justments Section which gives more detailed information about your stitcher the mechanical trouble that may occur and suggested remedies Unless you recognize the correct cause check each possible cause given REMEDY Clincher is worn or improperly B C Page 12 13 aligned Insufficient compression A Page 12 3 Unequal leg length See To Equalize Both Legs of Stitch Page 8 Burred stitch leg I Page 16 5 Incorrect wire size K Page 17 Worn bender bar D Page 13 Leg Lengths not adjusted See To Equalize Both Legs of properly Stitch Page 8 Gripper is worn or dirty H Page 15 Grip release slide is worn H Page 15 Broken wire guide spring Replace Figs 20 page 22 Excessive tension on wire M Page 18 straightener Worn Driver bar F Page 14 Worn Tension Pawl or weak O Page 19 tension pawl spring Weak or broken grip spring H Page 15 M2000 Head Trouble Shooting TROUBLE POSSIBLE CAUSE REMEDY 4 Corner of crown distorted 1 E
15. bar friction plug and or bender bar friction spring 1 Remove bender bar assembly by following steps 1 through 18 of Dismantling M2000 Stitching Head Pages 20 and 21 2 Remove bender bar friction bushing Index A Bender bar friction plug Index C and spring Index B will be released forward from bender bar assembly 3 Replace plug and or spring and reassemble F Driver Bar Figure 13 The driver bar Index A has several functions 1 It imparts the downward thrust from the driving slide assembly Index B to the bender bar assembly Index C 2 It returns these parts to the neutral position on the upstroke 14 Figure 13 CTTT2605 Scene 14 3 In conjunction with the grip release slide Index D it controls the movement of the bender bar latch Index E that opens and closes the grip Index F If the notches Index G at the top left side of the driver bar become worn the grip will not remain open on the upstroke As a result the wire feeds backwards and buckles above the grip and below the tension pawl Worn notches can also cause uneven wire draw Replace the driver bar The notches shown on left side of driver bar play an important part in function of bender bar assem bly therefore corners should be free of dirt and notches not marred The driver bar rides within the bender bar grooves as part of the bender bar assembly As this assem bly reaches the lower co
16. by hand to cut wire Cycle machine again by hand to observe wire straightness The wire Index L should point straight down prior to being cut 7 Adjust the upper wire straightener beginning at position shown Index E so that the wire points straight down Adjust the lower wire straightener beginning at the 3 00 o clock position Index F so that the wire Index L feeds straight down 8 Replace the rotator and rotator operating spring NOTE When changing coils or wire sizes check straighteners to insure proper wire feed CAUTION Do not operate stitcher until operating instructions have been read and understood do not operate stitcher at anytime without work under the head After every wire spool rotate the dirty area of the pads slightly so that a clean area can be used for the next wire spool FELT WIPE PADS LUBRICATION AND MAINTAINANCE FIGURE 2 IMPORTANT In order for the stitchers to operate properly the felt wire wipes MUST be rotated and dampened with SAE 20W oil before each new spool of wire 50 000 to 70 000 stitches Replace felt pads when they become so dirty that they cannot be rotated to a clean spot 2 Dampen both pads about 30 to 40 drops using an SAE 20W oil Dirty area of pads has been slightly rotated so that a clean area of pads can be used for the next wire spool Figure 2 CTTT2605 Scene 7 3 CTTT2605 Scene 5
17. cated and in top working condition at all times Recommended Spare Parts Like any equipment that has moving parts certain parts of your stitcher will be subjected to more wear than others and require replacement The follow ing listing includes all the parts required for mini mum maintenance and good operation PART NAME QTY Wire Cutters 2 Grip 1 Grip Spring 1 Tension Roll Clip 2 Rotator 1 Clincher Points 2 Figure 6 Figure 7 CTTT2605 Scene 8 CTTT22605 Scenes 5 amp 9 Caution MAKE ALL ADJUSTMENTS WITH THE POWER OFF AND THE STITCHING HEAD IN NEUTRAL POSITION Fig 6 In neutral position the wire grip assem bly Index A is stopped at the top of the slot in the face plate Stitching Adjustments Best stitching performance will be assured if all adjustments are made so that you get the following results Good Cut Off Uniform Wire Draw Equal Leg Length Proper Clincher Alignment Sufficient Compression BWN To Equalize Both Legs of Stitch Figure 7 1 Loosen the wire guide locking bolt Index 2 Turn adjusting screw Index D clockwise to shorten left leg of stitch counter clockwise to lengthen left leg 3 Tap bracket Index E down before tightening screw Index C TROUBLE A Defective Stitches 1 One or both legs buckled NOTE Since buckled legs are often concealed in the work and may appear the same as a short leg alw
18. ce This must be assembled as a complete unit D CTTT2605 Scene 22 DO NOT REMOVE OR ADJUST THESE TWO SCREWS The screws are factory set to control the Supporter lever location CTT2605 Scene 5 m Remove rotatorl operating cam stud F CTTT2605 Scene 23 13 Remove rotator operating cam stud screw Caution When reassembling make certain that pin Index A is visible and is aligned with slot Index B of rotator operating cam Index C If not assembled in this way the bonnet casting will crack or break on the next cycle under power It is recommended that the stitcher be cycled by hand to test that proper reassembly procedure has been followed 21 Section 6 PARTS LIST SA 58 56 Clamp On Type Head CTTT2605 Scene 25 MS 22 A CTTT2605 Scene 24 CB75B Iso View Bolt On and Clamp On Heads Figures 20 Bolt On Type Head 7 2 N 33 32 7 3 Bolt On Type Head SK885 Scene 1 25 CAAA9074A2 Layout 2 CTTT2606R3 Assembly NS N CT413E B3 19 gs Sy ucc Full Assembly 901325 also includes items 11 12 13 14 15 21 22 CAA9013U5 Special Components Figures 21 CTT2604L Layout 2 CA44 Layout
19. e shearing If this slot becomes oversized the wire will not be cut off Replace face plate To Re place Face Plate See Steps 1 through 10 J page 17 NOTE Figure 16 The lug Index C in the faceplate must match the slot Index D in the grip release adjusting lever Index E or damage to the head may result Figure 16 CTTT2605 Scene 17 J Wire Cutter Operating Slide The wire cutter operating slide actuates the lower wire cutter which acts as the cutting knife If the slide is worn or broken the wire cutter is not actu ated Replace the operating slide To Replace The Wire Cutter Operating Slide 1 Cut the wire at the bracket and pull the loose end out 2 Remove the stitcher head assembly Lift end of spring Index L Figure 15 out of rotator 4 Swing the spring up to disengage it and lift out 5 Slip the rotator operating cam Index M Figure 15 forward and off the stud Pull the rotator forward Loosen the two face plate retaining clips Index A Figure 16 and rotate them downward 8 Push two face plate retaining clips Index F outward while lifting face plate up or remove retaining clips to release face plate 9 Position grip spring housing Index G between tension pawl spring retainer Index H and cutter housing Index I 10 Remove face plate Index B by sliding face plate to the left and lifting up 11 Remove the cutter operating
20. her carefully for any damage in transit If damaged DO NOT INSTALL THE STITCHER Notify your nearest representative and the carrier who delivered your stitcher Make certain that you get a signed copy of the Carrier Inspector s Report of the damage incurred ASSEMBLY 1 Clamp or bolt the M2000 head to your machine 2 Install Wire Guide Spring into wire guide bracket of M2000 Head THREADING WIRE AND ADJUSTING WIRE STRAIGHTENERS See fig 1 1 Draw wire Index A by hand from the coil 2 Thread the wire through the slot Index B at the end of the wire guide spring through the wire guides Index C between the thin and thick felt wire wipes Index D through the upper wire straightener Index E and through the lower wire straightener Index F From wire Figure 1 CTTT2605 Scene 3 Scene 4 Release the rotator operating spring Index H from the rotator and swing it to the left Remove Rotator Index K Thread the wire between the tension pawl and tension roll Index G Feed the wire through the wire cutter lead in hole Index I in the bottom of the face plate Push grip post to left to open the grip Index J Insert wire and release the post so that the grip engages the wire for feeding into the rotator To check adjustment hold open grip Index J and pull about 1 1 2 feet of wire from below face plate Cycle machine once
21. igned rotator Worn or broken wire cutters Burrs on rotator Improperly adjusted lower wire straightener Worn or broken wire cutter operating slide Wire cutter slot in face plate worn 1 Face plate is too high F Page 14 G Page 15 E Page 14 L Pase 17 I Page 16 L Pape T7 M Page 18 J Page 17 I Page 16 See Changing Work Thick ness Page 7 11 CAUTION Turn Power OFF Before making Any Adjustments A Insufficient or Excessive Compression Proper compression of work between the clincher and the bender bars is necessary so that the stitch penetrates the work material and clinches correctly To test for compression drive several stitches into sample work material With proper compression stitches hold the work together firmly and the clinched legs do not overlap In the following in stances either one or all of the conditions may exist with insufficient compression stitch legs over lap crown of the stitch is fractured and the work mutilated The method for obtaining proper wire draw and compression is detailed in the Operation Section on Page 7 under the heading Changing Work Thickness B Clincher Figure 8 The purpose of the clincher is to turn the legs of the stitch back after they have penetrated the work material There are two types of clinchers 1 Solid stationary Type makes a loop clinch 2 Activated moving Type makes a flat c
22. ine the clincher points clincher slide for possible binding Clean and oil If clincher points rise to high they fracture the stitch legs and or mar the work If the points do not rise high enough the legs will not clinch flat Adjust the height of the clincher points For most work the clincher points should rise to be level with the top of the clincher housing Inject lube into cutter operating slide Figure 9 CTTT2605 Scene 11 Figure 10 CTTT2605 Scene 12 C Head Clincher Alignment Figure 9 10 To test alignment Drive several stitches into a sec tion of material identical to that which is to be stitched The clinched legs should be identical and aligned with each other If the legs are not in align ment make one of the following adjustments 1 To adjust for front to rear alignment Fig 9 a Turn power off Cycle the stitcher by hand until legs of the stitch appear just below the bender bar to determine if the head should be moved to the front or rear b Remove stitcher from machine c Turn the head aligning screw Index D clockwise to move the head backward coun terclockwise to move the head forward d Install stitcher head on machine Figure 11 5 8521 To adjust for side to side alignment Fig 10 a Turn power off Cycle the stitcher by
23. intenance Keep hand tools hair and clothing clear of stitching area Become familiar with the moving components of your machine Keep fingers away from areas that could pinch or cut Wear adequate safety equipment for eye and face protection Observe your plant safety rules Practice good housekeeping in your work area Keep it as clean and uncluttered as possible A well maintained machine is a safer machine Clean and lubricate the machine at regular intervals Check machine daily for broken or worn parts Replace as necessary DO NOT attempt to operate the machine if a part is broken Route all electrical cables away from pedestrian transportation lanes Make sure adequate safety guards and covers are in place If you are unsure how to safely operate or maintain your Stitcher contact your Service Representative DANGER KEEP HANDS CLEAR OF STITCHING AREA CAUTION FOR YOUR SAFETY MAKE SURE ALL COVERS ARE PROPERLY IN PLACE BEFORE OPERATING MACHINE Section 3 ASSEMBLY LUBRICATION INSTALLATION Note These instructions must be followed to insure proper installation efficient operation and the prevention of serious damage to your stitcher Before Unpacking Examine the outside of the crate or carton for any visible damage If damaged DO NOT UNPACK THE STITCHER Notify the carrier who deliv ered the stitcher After Unpacking Examine your stitc
24. linch With the Solid stationary Type clincher the legs of the stitch must strike the clincher at the same time and with equal spacing from the outside edges of the grooves The grooves in the clincher should be smooth Any interference particularly worn or pitted grooves which change the original radii will cause the stitch legs to buckle and or the cor ners of the crown to fracture With the Activated moving Type clincher the stitch legs must enter the clincher at the same time 12 STITCH NY ACTIVATED La STITCH 4 2 7 Figure 8 SK852F and with equal spacing from each side When the stitch legs have penetrated the work material the moving clinchers are raised to bend the legs to wards each other and up flat against the work The clincher points must bend both legs of the stitch against the work with the same force Clincher points must always move freely and not bind Dirt wire chips etc will cause the points to bind The clincher points are in a retracted position in the clincher box until the stitch legs penetrate the work material After the legs penetrate the clincher points move upward to give a neat flat clinch against the bottom surface of the work material If the clincher points remain in the up position the legs of the next stitch cannot penetrate the work material caus ing the stitch legs to buckle and or the corners of the crown to fracture Exam
25. n the rotator If a magnet is broken or chipped the wire may fall out To determine if the rotator has the proper holding strength remove the rotator and insert a cut length of wire in the rotator Hold rotator between thumb and forefinger Attempt to jar wire loose by hitting heel of hand on top of table or against other hand With proper magnetic holding force wire will remain in rotator With insufficient holding force wire will fall from rota tor Replace the rotator The rotator holder and rotator operating spring are responsible for alignment of the wire beneath the bender bar grooves The position of the rotator holder determines how far the rotator is pushed forward under the bender bar by the rotator operat ing spring Index L Figure 15 A weak spring will not push the rotator in far enough and with this improper alignment the bender bar will knock the wire from the rotator or will shear the wire into pieces To secure proper alignment check the po sition of the rotator holder and the tension applied by the rotator operating spring Make any neces sary adjustment of the rotator holder or replace the rotator operating spring if weak The wire is fed into the rotator and held for form ing If the rotator is dirty the wire is not gripped securely enough and drops out Remove and clean the rotator If the edges over which the wire is formed are sharp the corners of the stitch crown will fracture Remove the rotator and polish
26. ntact point of the cam in the grip release slide the bender bar latch is forced inward releasing the wire grip and permitting the bender bar assembly to continue downward with the end of the driver riding on top of the formed Figure 14 CTTT2605 Scene 15 stitch When the bender bar is stopped against the work material the driver bar continues downward to exert pressure on the crown of the stitch driving it through the work material If the end of the driver bar is chipped it allows the legs of the stitch to back up into the broken area This causes the corner of the crown to fracture or a spike section to protrude above the crown A chipped driver bar is usually the result of driving a stitch on top of another stitch A worn driver often causes deformed stitches or fracturing at the cor ners of the crown G Bender Bar Latch The bender bar latch opens and closes the grip and is actuated by the grip release slide and driver bar If the contact points of the latch become worn tim ing of the grip is erratic and uneven wire feed re sults A dirty latch will decrease preassure of the grip on the wire This causes wire slippage Clean or replace the latch H Grip Grip Release Slide and Face Plate Figure 14 The grip spring Index A exerts pressure on the benderbar latch Index B to close the grip Index C at the start of the down stroke The grip release
27. resulting in a short wire draw Reverse or replace the tension pawl and or spring 19 DISMANTLING M2000 STITCHING HEAD CAUTION CAUTION As a precautionary measure When re The rotator operating cam can be moving the head from any stitching ma a Beisure to read chine make SURE that the power to the and follow the instructions F on page 21 before reassembling machine has been turned OFF or discon nected 3 Slip rotator operating cam off stud 11 Remove grip release slide 2 Swing spring up to disengage Lift out 1 Lift end of spring out of rotator A CTTT2605 Scene 19 4 Pull rotator forward 9 Remove the cutter operating slide 5 Remove the upper face plate clips 8 Remove face plate by sliding face plate to the left and lifting up 10 Remove friction plug and spring 7 Position grip spring housing between tension pawl spring retainer and cutter housing 12 Remove rotator holder CTTT2605 Scene 20 6 Remove the two lower clips CTTT2605 Scene 21 20 DISMANTLING REASSEMBLING M2000 HEAD 17 Loosen face plate clamp screw and slide out face plate locating block 16 Slide tension spring bracket and adjusting lever from top 18 Slide the driving slide and bender bar assemblies from the top When reassembling hook bender bar to driving slide before sliding into pla
28. slide Index D actuates the bender bar latch at point X to open the grip after the correct amount of wire has been fed to make a stitch The serrated teeth on the grip must be sharp or slippage will occur pro ducing uneven wire draw 15 When the face plate Index E is adjusted See Changing Work Thickness page 7 a pivotal ac tion at point F changes the position of the grip slide When the face plate is raised it moves the grip release slide down The gripper can then re main closed longer on the down stroke feeding more wire for the stitch When the face plate is lowered it moves the grip release slide up The gripper will open sooner on the down stroke feed ing less wire for the stitch If the grip is weak uneven wire draw will result Replace the grip spring If the contact points on the grip release slide and or the bender bar latch are worn wire adjustment will not remain accurate The face plate stops the bender bar assembly at the top of its stroke and allows the bender bar latch to close the grip When the face plate is too high too much of the upstroke has been used before the bender bar hits the face plate In the remaining portion of the upstroke the driver bar cannot con tinue upward enough to release the bender bar latch so that it can close the grip I Wire Cutters Figure 15 The purpose of the wire cutters is to shear the wire cleanly There are two wire cutters upper and lower The upper wire
29. slide Index I Figure 15 12 Insert a new cutter operating slide 13 Reassemble K Proper Wire Depending on which M2000 head is being used the wire range may be 25 to 30 gauge round 24 gauge round 20x25 or 21x25 flat 120 000 to 159 000 psi tensile strength bookbinders wire should be used If the wire used is larger than the bender bar grooves were designed for it will fracture at the stitch cor ners and come out in pieces Also serious damage to the stitcher may result If the wire used is smaller than the bender bar grooves were designed for the legs of the stitch do not fit snugly in the grooves and may tend to buckle when they strike the work material because they are not fully supported L Rotator Figure 15 The rotator Index J 1 receives the wire from the cutoff die 2 holds the wire while it is being cut then 3 turns it to a horizontal position moves it under the bender bar grooves and 4 supports the wire while it is being formed into a U shaped stitch The wire lead in funnel of the rotator must be aligned with the wire as it comes through the wire cutters If the rotator is improperly aligned the wire hits the rotator and buckles Adjust upper two wire straighteners until wire slips past rotator Burrs on the rotator prevent the wire from entering the rotator This causes wire buckling Remove the rotator and polish the lead in radius 17 The magnets in the rotator hold the wire firmly i
30. the edges with a fine emery cloth To remove Adjust or Replace the Rotator Holder 1 Swing the rotator operating spring to the left 2 Remove the rotator 3 Loosen the rotator holder screw Index N Figurel5 4 Adjust the rotator holder Reassemble 18 CTTT2605 Scenes 3 amp 4 M Wire Straighteners Figure 17 All coils of stitching wire have a certain amount of bundle curve The purpose of a wire straightener is to remove this curve There is both an upper wire straightener Index A and a lower wire straight ener Index B on all M2000 Model Stitchers See Threading Wire and Adjusting Wire Straighten ers page 4 The upper wire straightener should feed wire paral lel to the faceplate This insures that the wire will properly enter the rotator and will be aligned with the grooves in the bender bar If the wire is not parallel to the face plate the wire is sheared in the rotator as the bender bar descends Adjust the upper wire straightener The lower wire straightener directs the wire straight down so that it enters the rotator Index C If the wire is not straight enough it hits the rotator and buckles Adjust the lower wire straightener so that Figure 18 CTTT2605 Scene 11 the wire points straight down as in figure 17 Im proper straightening of the wire can also cause the stitch legs to buckle or turn out because they strike the clincher improperly E
31. xcessive compression A Page 12 fractured 2 Broken driver end G Page 15 3 Worn bender bar D Page 13 4 Clincher improperly aligned B C Page 12 13 Ll o or worn 5 Incorrect wire size K Page 17 5 Stitch crown not flat and 1 Insufficient compression A Page 12 not bent into work 6 One or both legs turn out 1 Clincher improperly aligned Page 13 2 Dull cutters I Page 16 7 Flat piece of wire 1 Rotator is dirty L Page 17 2 Improperly adjusted lower wire M Page 18 straightener 3 Broken or worn rotator L Page 17 4 Improperly aligned rotator L page 17 8 Stitches come out in pieces 1 Improperly aligned rotator L Page 17 2 Weak rotator operating spring L Page 17 3 Improperly adjusted upper wire M Page 18 straightener 4 Incorrect wire size K Page 17 5 Wire jammed in bender bar D Page 13 grooves 9 Both stitcher legs are either f Face plate not adjusted properly See Changing Work Thick too long or too short ness Page 7 10 TROUBLE M2000 Head Trouble Shooting POSSIBLE CAUSE REMEDY B WIRE BUCKLES 1 Wire buckles above the grip and below the tension pawl 5 N al 4 0 VA 2 Wire Buckles above the wire cutters and below the grip CTTT2605 Scene 10 VB C GRIP 1 Grip does not close Worn driver bar Worn bender bar latch Worn or broken bender bar friction plug and or spring Improperly al
32. xcessive tension on the wire straightener prevents the grip Index D from feeding the wire smoothly This causes variation in leg length NOTE Check the wire straighteners when changing the coils to insure the accurate feeding of wire N Supporter The supporter furnishes the necessary support to the inside surface of the stitch so that it does not buckle as it is being driven into the work material A lack of or insufficient support will often cause the stitch crown to wrinkle or the legs of the stitch to buckle Tighten the supporter spring bushing Index A Figure 18 or replace the spring Figure 19 CTTT2605 Scene 18 If the corners of the top surface of the supporter are too sharp or nicked the corners of the stitch crown will fracture If operating properly the supporter should function as follows 1 When the bender bar touches the work material and the legs of the stitch are about to leave the bender bar grooves the supporter should be touching the underside of the crown 2 the stitch is driven through the work the supporter is gradually retracted by the driver It should remain under the crown of the stitch until the last instant before the crown touches the work material Tension Pawl Figure 19 The tension pawl Index A and spring Index B apply pressure on the wire to prevent back feed If the pawl becomes worn or the spring becomes weak the wire feeds backwards
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