iSP M2000 Owner's Manual

Download

Page 1

ISP

A Division Of Samuel Strapping Systems

Stitching & Bindery Products

M2000

OWNERS

MANUAL

ISP

Stitching & Bindery Products

Page 2

CONTENTS

Section 1 INTRODUCTION

1. Model and Serial Number

2. Product Specifications

Section 2 SAFETY PRECAUTIONS

AND PROCEDURES

3. Safety

3. Safety Guards/Cover

Section 3 ASSEMBLIES,

LUBRICATION, INSTALLATION

4. Before Unpacking

4. After Unpacking

4. Assembly

4. Threading wire and adjusting wire straighteners

5. Lubrication-Felt Pads

6. Lubrication-Stitcher Head

Section 4 OPERATION

7. General Stitching

7. Changing Work Thickness

Section 5 MAINTENANCE, TROUBLE

SHOOTING AND ADJUSTMENT

8. General

8. Recommended Spare Parts

8. Cleaning and oiling

8. Stitching Adjustments

8. To Equalize Both Legs of Stitch

9. Trouble Shooting-M2000 Head

12. Insufficient or Excessive Compression

12. Clincher

13. Head/Clincher Alignment

13. Bender bar

14. Bender bar Friction Plug

14. Driver Bar

15. Bender Bar Latch

15. Grip, Grip Release Slide and Faceplate

16. Wire Cutters

17. Wire cutter Operating Slide

17. Proper Wire

17. Rotator

18. Wire Straighteners

19. Supporter

19. Tension Pawl

20. Dismantling M2000 Head

USE ONLY REPLACEMENT

PARTS DESIGNED AND

MANUFACTURED BY ISP

SPECIFICALLY FOR YOUR

M2000 STITCHER

Section 6 PARTS LIST

22. M2000 Head Stitcher

Page 3

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 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.

Stitcher Head Wire Size____________________

Page 4

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

Page 5

Section 2

SAFETY PRECAUTIONS

AND PROCEDURES

SAFETY

1. Make sure electrical power is turned off before performing any adjustment or maintenance.

2. Keep hand, tools, hair, and clothing clear of stitching area.

3. Become familiar with the moving components of your machine. Keep fingers away from areas that could pinch or cut.

4. Wear adequate safety equipment for eye and face protection. Observe your plant safety rules.

5. Practice good housekeeping in your work area. Keep it as clean and uncluttered as possible.

6. A well maintained machine is a safer machine. Clean and lubricate the machine at regular intervals. Check machine daily for broken or worn parts. Replace as necessary. DO NOT attempt to operate the machine if a part is broken.

7. Route all electrical cables away from pedestrian transportation lanes.

DANGER

KEEP HANDS CLEAR OF STITCHING AREA

CAUTION

FOR YOUR SAFETY, MAKE SURE ALL COVERS ARE PROPERLY IN PLACE BEFORE OPERATING MACHINE

8. 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.

Page 6

Section 3

ASSEMBLY,LUBRICATION,

INSTALLATION

Note:

These instructions must be followed to insure proper installation, efficient operation and the prevention of serious damage to your stitcher.

Before Unpacking: Examine the outside of the crate or carton for any

visible damage. If damaged DO NOT UNPACK THE STITCHER. Notify the carrier who delivered the stitcher.

After Unpacking: Examine your stitcher carefully for any damage in

transit. If damaged, DO NOT INSTALL THE STITCHER. Notify your nearest representative and the carrier who delivered your stitcher.

B C

A (From wire coil)

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).

Figure 1

(CTTT2605 Scene 3, Scene 4)

3. Release the rotator operating spring (Index H) from the rotator and swing it to the left. Remove Rotator (Index K).

4. Thread the wire between the tension pawl and tension roll (Index G). Feed the wire through the wire cutter lead-in hole (Index I) in the bottom of the face plate.

5. Push grip post to left to open the grip (Index J). Insert wire and release the post so that the grip engages the wire for feeding into the rotator.

6. To check adjustment, hold open grip (Index J and pull about 1 1\2 feet of wire from below face plate. Cycle machine once by hand to cut wire. Cycle machine again by hand to observe wire straightness. The wire (Index L) should point straight down, prior to being cut.

Page 7

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.

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.

1. After every wire

spool, rotate the dirty area of the pads slightly so that a clean area can be used for the next wire spool.

Rotate

Figure 2

(CTTT2605 Scene 7)

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.

Page 8

Figure 3

(CTTT2605 Scene 5)

STITCHING HEAD

LUBRICATION:

(FIGURES 3 & 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.

Page 9

Section 4

Changing Work Thickness:

OPERATION

General:

After having properly installed and set up the machine, it is now ready for stitching. It is recommended that each operator be instructed as to correct operating procedure and normal adjustments necessary for varying work conditions.

WARNING

Prevent accidents by following these rules:

(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:

1. Switch off power, loosen the face plate screw (Index A).

2. 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.

3. Retighten faceplate screw.

1. Do not put your hands near area to be stitched when machine is operating.

2. Turn the power off when the stitcher is not in use.

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.

2. Do not drive one stitch on top of an other.

Figure 5

(CTTT2605 Scene 5)

Page 10

Section 5

MAINTENANCE,TROUBLE

SHOOTING AND

ADJUSTMENTS

General

The M2000 Stitcher is a friction-type head which depends on smooth sliding friction and proper timing to function correctly. Preventative maintenance will go far to insure trouble-free operation. Avoid production down time by keeping your stitcher lubricated 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 following listing includes all the parts required for minimum maintenance and good operation.

Figure 6

(CTTT2605 Scene 8)

Figure 7

(CTTT22605 Scenes 5 & 9)

Caution

MAKE ALL ADJUSTMENTS WITH THE POWER OFF AND THE STITCHING HEAD IN NEUTRAL POSITION! (Fig. 6)

In neutral position, the wire grip assembly (Index A) is stopped at the top of the slot in the face plate.

PART NAME QTY.

Wire Cutters 2 Grip 1 Grip Spring 1 Tension Roll Clip 2 Rotator 1 Clincher Points 2

Stitching Adjustments

Best stitching performance will be assured if all adjustments are made so that you get the following results:

1. Good Cut-Off

2. Uniform Wire Draw

3. Equal Leg Length

4. Proper Clincher Alignment

5. Sufficient Compression

To Equalize Both Legs of Stitch

(Figure 7)

1. Loosen the wire guide locking bolt (Index C).

2. Turn adjusting screw (Index D) clockwise to shorten left leg of stitch; counter clockwise to lengthen left leg.

3. Tap bracket (Index E) down before tightening screw (Index C).

Page 11

M2000 Head Trouble Shooting

HERE'S HOW A PERFECT STITCH LOOKS

Should stitches appear in any form other than illustrated, one or more kinds of mechanical trouble may have caused the malformation. The possible causes and remedies are given for each kind of mechanical trouble and are listed under each section. The remedies are indexed to the Adjustments Section which gives more detailed information about your stitcher, the mechanical trouble that may occur and suggested remedies. Unless you recognize the correct cause, check each possible cause given.

TROUBLE

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, always remove two or more stitches to see which is occurring.

2. Wrinkled crown.

3. Length of one leg varies

POSSIBLE CAUSE

1. Clincher is worn or improperly aligned.

2. Insufficient compression.

3. Unequal leg length

4. Burred stitch leg.

5. Incorrect wire size.

6. Worn bender bar.

1. Leg Lengths not adjusted properly

2. Gripper is worn or dirty

3. Grip release slide is worn

4. Broken wire guide spring (Figs 20 page 22)

5. Excessive tension on wire straightener

6. Worn Driver bar

7. Worn Tension Pawl or weak tension pawl spring

8. Weak or broken grip spring

REMEDY

"B,C" Page 12,13

"A Page 12 See "To Equalize Both Legs of

Stitch" Page 8 "I" Page 16 "K" Page 17 "D" Page 13

See "To Equalize Both Legs of Stitch" Page 8 "H" Page 15 "H" Page 15 Replace

"M" Page 18

"F" Page 14 "O" Page 19

"H" Page 15

Page 12

M2000 Head Trouble Shooting

TROUBLE

4. Corner of crown distorted or fractured

5. Stitch crown not flat and legs not bent into work

6. One or both legs turn out

7. Flat piece of wire

POSSIBLE CAUSE

1. Excessive compression

2. Broken driver end

3. Worn bender bar

4. Clincher improperly aligned or worn

5. Incorrect wire size

1. Insufficient compression

1. Clincher improperly aligned

2. Dull cutters

1. Rotator is dirty

2. Improperly adjusted lower wire straightener

3. Broken or worn rotator

4. Improperly aligned rotator

REMEDY

"A" Page 12 "G" Page 15 "D" Page 13 "B,C" Page 12,13

"K" Page 17

"A" Page 12

"C" Page 13

"I" Page 16

"L" Page 17 "M" Page 18

"L" Page 17 "L" page 17

8. Stitches come out in pieces

9. Both stitcher legs are either too long or too short

1. Improperly aligned rotator

2. Weak rotator operating spring

3. Improperly adjusted upper wire straightener

4. Incorrect wire size

5. Wire jammed in bender bar grooves

Face plate not adjusted properly

"L" Page 17 "L" Page 17 "M" Page 18

"K" Page 17 "D" Page 13

See "Changing Work Thickness" Page 7

Page 13

M2000 Head Trouble Shooting

TROUBLE

B. WIRE BUCKLES

1. Wire buckles above the grip and below the tension pawl

(CTTT2605 Scene 10 VA)

2. Wire Buckles above the wire cutters and below the grip

POSSIBLE CAUSE

1. Worn driver bar

2. Worn bender bar latch

3. Worn or broken bender bar friction plug and/or spring

1. Improperly aligned rotator

2. Worn or broken wire cutters

REMEDY

"F" Page 14

"G" Page 15

"E" Page 14

"L" Page 17

"I" Page 16

(CTTT2605 Scene 10 VB)

C. GRIP

1. Grip does not close

3. Burrs on rotator

4. Improperly adjusted lower wire straightener

5. Worn or broken wire cutter operating slide

6. Wire cutter slot in face plate worn

1. Face plate is too high See "Changing Work Thickness"

"L" Page 17

"M" Page 18

"J" Page 17

"I" Page 16

Page 7.

Page 14

CAUTION

Turn Power OFF Before making Any Adjustments

A. Insufficient or Excessive

STITCH

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 instances, either one or all of the conditions may exist: with insufficient compression, stitch legs overlap, 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 clinch.

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 corners of the crown to fracture.

With the Activated (moving) Type clincher, the stitch legs must enter the clincher at the same time and with equal spacing from each side. When the

ACTIVATED

STITCH

SOLID

Figure 8

(SK852F)

stitch legs have penetrated the work material, the moving clinchers are raised to bend the legs towards 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, causing the stitch legs to buckle and/or the corners of the crown to fracture. Examine 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.

Page 15

Inject lube into cutter operating slide.

Figure 9

(CTTT2605 Scene 11)

Figure 11

(SK852I)

Figure 10

(CTTT2605 Scene 12)

C. Head/Clincher Alignment

(Figure 9, 10)

To test alignment: Drive several stitches into a section 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 alignment 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.

2. To adjust for side-to-side alignment: (Fig. 10) a. Turn power off. Cycle the stitcher by 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).

Page 16

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 insufficient, 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 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.

E C

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 assembly 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 assembly reaches the lower contact 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

Page 17

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 corners 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 results. 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 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, producing uneven wire draw.

Page 18

When the face plate (Index E) is adjusted (See "Changing Work Thickness", page 7) a pivotal action (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 remain 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, feeding 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 continue 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 cutter (Index A) receives wire from the grip through the wire cutter lead-inhole (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 rotator. 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:

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 wire 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).

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.

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.

Page 19

8. Push two face plate retaining clips (Index F) outward while lifting face plate up, or remove retaining clips to release face plate.

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 actuated. Replace the operating slide.

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 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 corners 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)

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.

3. 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.

6. Pull the rotator forward.

7. Loosen the two face plate retaining clips (Index A, Figure 16) and rotate them downward.

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.

Page 20

The magnets in the rotator hold the wire firmly in 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 rotator. 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 operating 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 position of the rotator holder and the tension applied by the rotator operating spring. Make any necessary adjustment of the rotator holder or replace the rotator operating spring if weak.

The wire is fed into the rotator and held for forming. 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 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, Figure15).

4. Adjust the rotator holder.

5. Reassemble.

Figure 17

(CTTT2605 Scenes 3 &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 straightener (Index B) on all M2000 Model Stitchers. See "Threading Wire and Adjusting Wire Straighteners" page 4.

The upper wire straightener should feed wire parallel 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

Page 21

Figure 18

(CTTT2605 Scene 11)

the wire points straight down as in figure 17. Improper straightening of the wire can also cause the stitch legs to buckle or turn out because they strike the clincher improperly. Excessive 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. As 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.

O. 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 resulting in a short wire draw. Reverse or replace the tension pawl and/or spring.

Page 22

DISMANTLING M2000 STITCHING HEAD

CAUTION

(CTTT2605 Scene 19)

CAUTION

The rotator operating cam can be installed backwards. Be sure to read and follow the instructions "F"on page 21 before reassembling.

3. Slip rotator operating cam off stud.

2. Swing spring up to disengage. Lift out

1. Lift end of spring out of rotator

4. Pull rotator forward

As a precautionary measure-When removing the head from any stitching machine make SURE that the power to the machine has been turned OFF or disconnected.

11. Remove grip release slide.

(CTTT2605 Scene 20)

5. Remove the upper face plate clips.

8. Remove face plate by sliding face plate to the left and lifting up.

7. Position grip spring housing between tension pawl spring retainer and cutter housing

6. Remove the two lower clips.

9. Remove the cutter operating slide

10. Remove friction plug and spring.

12. Remove rotator holder.

(CTTT2605 Scene 21)

Page 23

DISMANTLING/REASSEMBLING M2000 HEAD

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 place. This must be assembled as a complete unit.

17. Loosen face plate clamp screw and slide out face plate locating block.

15. Remove screw

13. Remove rotator operating cam stud screw.

14. Remove rotator operating cam stud.

(CTTT2605 Scene 22)

OR ADJUST

THESE TWO

NOT

REMOVE

SCREWS.

The screws are factory set to control the supporter lever location.

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.

(CTT2605 Scene 5)

(CTTT2605 Scene 23)

Page 24

Section 6

PARTS LIST

(CTTT2605 Scene 25) (SK885 Scene 2) (SK885 Scene 1)

(CTTT2605 Scene 24, CB75B Iso View)

Bolt-On and Clamp-On Heads Figures 20

Figure 19

Bolt-On-Type HeadClamp-On-Type Head Bolt-On-Type Head

Page 25

Adjustable Stroke Position Components

26A

25A

Special Components Figures 21

(SK852R)

B11

(CTT2604L Layout 2) (CA44 Layout 2)

B10

Page 26

M2000 HEAD

ITEM PART NO. DESCRIPTION QTY

1 CAA9074Z WIRE GUIDE BRACKET ASSEMBLY 1 1A CTT2615B WIRE GUIDE BRACKET ASSEMBLY 1 2 CA9076 WIRE GUIDE SPRING BRKT ADJ SCREW 1 2A CT56 WIRE GUIDE SPRING BRKT ADJ SCREW 1 3 CA9077 WIRE GUIDE SPRING BRKT SET SCREW 1 4A CT1060 SET SCREW 1 5A CT2616 WIRE GUIDE BRACKET ADJ. SCREW STUD 1 6A CT2614 FACE PLATE ADJ. SLIDE GUIDE STUD 1 7A CT2612 FACE PLATE LOCATING BLOCK STUD 1 8A CT2610 FACE PLATE ADJUSTING SLIDE 1

9 See TABLE 1 DRIVING SLIDE ASSEMBLY 1

NOTE: The Driving Slide Assembly includes the following parts:

DRIVING SLIDE (ONLY) 1 a,c,d,f CA-2623 (standard) b CT-2623 (2 sheets to .125 in. thick work) e CA-2623-B (pin holds in driving slide spring)

DRIVING SLIDE SPRING PLUNGER 1 a,b,c,d,f CA-2007 e CA-2007-A

DRIVING SLIDE SPRING 1 a,b,c,d,f CA-9006 e CA-9006-A

DRIVING SLIDE SPRING SCREW 1 a,b,c,d,f CA-9021-A

DRIVING SLIDE SPRING PIN 1 e D-37327-F

DRIVING SLIDE ROTATOR OP. PIN 1 all CA-9028

DRIVING SLIDE SPRING SCREW LOCK PIN 1 a,b,c,d,f CA-9028-A

PARTS LIST

ITEM PART NO. DESCRIPTION QTY

11 CA9115 BENDER BAR FRICTION PLUG BUSHING 1 12 CA9113A BENDER BAR FRICTION PLUG SPRING 1 13 CA9112A BENDER BAR FRICTION PLUG 1

14 CAA9026 SUPPORTER ASSEMBLY, 1/2" Cr. 1

15 CA9029 SUPPORTER PIVOT PIN 1 16 CA168 EXTERNAL GRIP SPRING 1 17 CB371K LOCKWASHER 1 18 CA9024A GRIP HOUSING RETAINING SCREW 1 19 CT413A GRIP SPRING HOUSING 1 20 CA9015D GRIP 1 21 CA173 PLASTIC PIN CAP 1 22 BENDER BAR LATCH 1

CAA9014J Standard CAA9014N Special for CAAA9013D3 & CAAA9013M3

Bender Bar Assemblies (McCain)

23 DRIVER BAR 1

CA9012M 1/2" Cr. CA9012N 1/2" Cr. (McCain)

24 BONNET CASTING SUB ASSEMBLY 1

M2000 Heads that use bonnet sub assembly

CAA2004 CAAA2005,B,R CAA2004B CAAA2005J CAA2004E CAAA2005F, G (R.H. HEAD) CTT2604 CTTT2605,A2,C,G,O,R2,R3,R10 CTT2604F CTTT2605F4 CTT2604L CTTT2605Q3 CTT2604P CTTT2605P2,P4

10 BENDER BAR ASSY. COMPLETE 1 a CAAA9013Z2 1/2" Cr., 25 to 30 rd. wire b CAAA9013D3 1/2" Cr., 25 to 30 rd. wire (McCain) c CAAA9013H3 1/2" Cr., 24 rd. wire d CAAA9013K3 1/2" Cr., 20-21 x 25 wire e CAAA9013M3 1/2" Cr., 24 rd. wire (McCain) f CAAA9013R3 1/2" Cr., 22 Rd. wire

NOTE: The above Bender Bar Assembly includes the following items

through item 23

BENDER BAR SUB ASSEMBLY 1 a CAA9013U 1/2" Cr., 25 to 30 rd. wire b CAA9013Z 1/2" Cr., 25 to 30 rd. wire (McCain, Macey) c CAA9013F2 1/2" Cr., 24 rd. wire d CAA9013H2 1/2" Cr., 20-21 x 25 wire e CAA9013K2 1/2" Cr., 24 rd. wire (McCain) f CAA9013P2 1/2" Cr., 22 rd. wire

25 FACE PLATE LOCATING BLOCK SCREW 1

CT2608 Slotted head (shown)

CT2608A 5mm Hexagonal socket head (not shown) 25A CT2613 FACE PLATE LOCATING BLOCK NUT 1 26 CT2606 FACE PLATE LOCATING CLAMP 1 26A CT2611 FACE PLATE ADJ. SLIDE BLOCK 1 27 CT2607 FACE PLATE LOCATING BLOCK 1 28 CA9075 WIRE GUIDE BRACKET SCREW 1 29 CA9127 ROTATOR OPERATING CAM STUD 1 30 CA9058 ROTATOR OPERATING CAM STUD SCREW 1 31 CA9056C FACE PLATE RETAINING CLIP 3 32 CA2081 FACE PLATE RETAINING CLIP SCREW 4 33 CA9056A FACE PLATE RETAINING CLIP 1 34 CT9109 BONNET ALIGNING SCREW 0 to 2 as req'd. 35 CA9032C SUPPORTER SPRING 1 36 CA9037 SUPPORTER SPRING BUSHING 1

TABLE 1

(For use in determining customer's Driving Slide Assembly)

ITEM PART NO. DESCRIPTION

9 DRIVING SLIDE ASSEMBLY Driving Slide Style/Use Lug Style a CTT2623 standard, raised lug .187 lg. rectangular (CT2602) b CTT2623A lowered lug for 2 sheets to .125 in. thick work .187 lg. rectangular (CT2602) c CTT2623C standard, raised lug .25 lg. rectangular (CT2602A) d CAA2623 standard, raised lug round (CA2103) w/.031 thk. washer (CT32B) e CAA2623C pin (D37327F) holds in driving slide spring round (CA2103) w/.031 thk. washer (CT32B) f CAA2623D standard, raised lug round (CA2103B) w/.079 thk. washer

* Contact ISP customer service for M2000 heads not listed

Page 27

M2000 HEAD

PARTS LIST

ITEM PART NO. DESCRIPTION QTYITEM PART NO. DESCRIPTION QTY

37 SUPPORTER SPRING LEVER ASSEMBLY 1

CAA9036 Standard (1.625 in. long) CAA9036A Special (1.494 in. long) CAA9036B Special (1.312 in. long)

38 CA9034 SUPPORTER SPRING LEVER SCREW 1

39 SUPPORTER GUIDE PLATE 2

CA9030 All except listed below. CA9030A CTTT2605A2 (McCain)

40 CA9081 SUPPORTER GUIDE PLATE SCREW 2 41 CA9051A WIRE CUTTER OPERATING SLIDE 1

FRICTION PLUG SPRING

42 CA9050A WIRE CUTTER OPERATING SLIDE 1

FRICTION PLUG

43 WIRE CUTTER OPERATING SLIDE 1

CA9049 1/2" Cr. (All 1/8", .155", 3/16" capacity heads, and

CTTT2605F4,H4 heads.)

CA9049A 1/2" Cr. (All other 1/2" Cr Heads not listed above)

44 CA9022J GRIP RELEASE SLIDE, 1/2" Crown 1

45 FACE PLATE ADJUSTING LEVER 1

CA9025 For Non-Slotted Face Plates CA9025D For Sl ott ed Face Plates

46 CA9048 WIRE CUTTER 2

47 FACE PLATE ASSEMBLY 1

CAAA2132V 1/2" Crown, Slotted CAAA2132W 1/2" Crown, No Slot CAAA2132Y 1/2" Crown, Fixed (Bypass)

NOTE: The above face plate assemblies include indexes 47 to55

47 FACE PLATE SUB ASSEMBLY 1

CAA2132V 1/2" Crown, Slotted CAA2132W 1/2" Crown, No Slot

CAA2132Y 1/2" Crown, Fixed (By-Pass) 48 CA9134 TENSION PAWL SPRING 1 49 CA9124 TENSION ROLL CLIP 4 50 CA9103A CHECK PAWL ROLLER 1 51 CA9103C WIRE STRAIGHTENER ROLL 2 52 CA9098 TENSION PAWL 1 53 CA9065A STRAIGHTENER ECCENTRIC ROLL 1 54 CA9066A WIRE STRAIGHTENER ECCENTRIC 1 55 CA172 ECCENTRIC FRICTION LOCKING SCREW 1

56 ROTATOR HOLDER 1

CA9043M 1/2" CR., 25 TO 30 RD. WIRE, TAPERED END

CA9043L 1/2" CR., 25 TO 30 RD. WIRE

CA9043N 1/2" CR., 20-21X25 WIRE

CA9043P 1/2" CR., 25 TO 30 RD. WIRE, R.H. (Not Shown)

57 CB75B KEY, WOODRUFF 1

(for use with CA-9043-M Rotator Holder only)

58 CAA9038E M2000 ROTATOR, 1/2" CROWN 1

59 ROTATOR HOLDER SCREW 1

CA9044A all except below

CA9044B CTTT2605W2,Y2,Z2,A3,X3,R7

CAAA2005K

60 ROTATOR OPERATING CAM 1

CA9163C standard oiling

CA9163D inverted oiling

61 CAA9046D ROTATOR OPERATING SPRING ASSEMBLY 1 62 CA44 HEAD OPERATING LINK 1

(For use only with round lug driving slide assemblies)

TABLE 2

(For use in determining customer's special components)

ITEM PART NO. DESCRIPTION QTY USAGE

B1 CTT9003C BONNET CLAMP LEVER 1 CTTT2605,C,G,R3,F4 B2 CTT9002 BONNET CLAMP ASSEMBLY 1 CTTT2605,C,G,R3,F4 B3 CB157 BONNET BINDER SCREW 1

B4 CB835Q ROLL PIN 1 CTTT2605P2,P4,Q3,R2

B5 BONNET BINDER STUD 1

CT9002A .500-13 NC Thread CTTT2605R2 CT9002F M8 X 1.25-8g Thread CTTT2605P2,P4,Q3

B6 TEE BAR 1

CT9002G .625 Long CTTT2605P2 CT9002L .841 Long CTTT2605Q3

B7 CB175 WASHER 1 CTTT2605P2,Q3 B8 CB145A NUT, .500-13 NC 1 CTTT2605R2 B9 CT9109A BONNET ALIGNMENT PIN 2 CTTT2605Q3 B10 CT9111 CONE POINT SET SCREW 2 CTTT2605Q3 B11 CA44 HEAD OPERATING LINK 1 CTTT2605R2 (For use only with round lug driving slide assemblies)

Page 28

CLINCHER PLATE ASSEMBLIES

30°

Chamfered

TYPE A1, A2, A3 A1 A2 A3

(CTT9086A Layout 2, CTT9086M Layout 2, CTT9086V Layout 2)

CROWN CLINCHER TYPE CLINCHER SIZE POINT PLATE ASSY.

1/2 CA-9083 Thin A1 CTT-9086 1/2 CA-9083-A Thick A1 CTT9086-A 1/2 CA-9083 Thin A1 CTTT-9086* 1/2 CA-9083-A Thick A1 CTTT9086-A** 1/2 CA-9083-A Thick A2 CTTT9086-M*** 1/2 CA-9083-A Thick A2 CTT9086-M 1/2 CA-9083-A Thick A3 CTTT9086-V**** 1/2 CA-9083-A Thick A3 CTT9086-V 1/2 CA-9083 Thin B CTT-9086-B 1/2 CA-9083-A Thick B CTT9086-F 1/2 CA-9083 Thin C CAA-2089 1/2 CA-9083-A Thick C CAA-2089-A

TYPE B TYPE C

(SK852G2) (SK852H2)

CA9085A Clincher Guide Plate

(CA9085A Layout 2)

CA-2090 CT-9088 CA-2091 Stud Binderbolt Nut

(SK852J2) (SK852K2) (SK852L2)

* 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.

CLINCHER POINT

1/16 Nominal, CA-9083-A, Thick, 1/2 Crown 1/32 Nominal, CA-9083, Thin, 1/2 Crown

(SK852I2)

CLINCHER SLIDES

D E F G H J

(SK852M2) (SK852N2) (SK85202) (SK852P2) (SK852Q2) (SK852R2)

TYPE L CLINCHER CLINCHER

SLIDE POINT

D 3-17/32 CT-9093 Thin D 3-37/64 CT-9093-A Thick E 5-9/16 CT-9093-R Thin E 5-9/16 CT-9093-S Thick F 3-31/64 CA-2095-G Thick G 12-25/32 CA-2095-A Thick H 12-25/32 CA-2095 Thin J 3-17/32 CTT-9093-Y Thin/Thick

Adjustable

Page 29

WIRE GUIDE SPRING COMPONENTS

Figure 22

(SK883 Scene 5)

ITEM PART NO. DESCRIPTION QTY

1 See Figures 20 WIRE GUIDE SPRING ASSEMBLY 1 a CAAA2133W b CAAA2133L4 c CAAA2133B2 d CAAA2133L5 e CAAA2133R2 f CTTT2133A2 g CTTT2133C2 h CTTT2133D2

NOTE: Most of the above Wire Guide Spring Assemblies include the

following parts through 12:

WIRE GUIDE SPRING SUB. ASSY. 1 a,b,d CAA2133W f CTT2133A2 c CAA2133B2 g CTT2133C2 e CAA2133R2 h CTT2133D2

ITEM PART NO. DESCRIPTION QTY

2 CB651E SCREW, 10-32 x 2.000 1 3 CA9651 WASHER 2 4 CA9652 FELT WASHER, THICK 1 5 CA9653 FELT WASHER, THIN 1 6 CA9032C SPRING, COMPRESSION 1 7 CB860B NUT, 10-32, ELASTIC STOP 1 8 CA9065A ROLLER, ECCENTRIC 1 9 CA172 SCREW, NYLON TIP 1 10 CA9103C ROLLER, WIRE STRAIGHTENER 2 11 CA9124 CLIP, ROLLER 2 12 CA9066A ECCENTRIC 1

CAAA2133W, L4, L5

(CAAA2133W View A)

CAAA2133R2

(CAAA2133W View A)

CTTT2133A2

(CTTT2133A2 Layout 2)

CTTT2133D2

(CTTT2133D2 Layout 2)

CTTT2133C2

(CTTT2133C2 Layout 2)

CAAA2133B2

(CAAA2133B2 Layout 2)