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Wire stitching machines are mechanically simple, but a dirty stitching head or the wrong wire size are the two most common causes of messy stitches or a jam mid-production. Here are the maintenance habits that prevent both.

Clean the stitching heads regularly

Paper scraps and wire dust build up around the stitching heads over time. Clean this area at the end of every shift, or after a few hundred cycles depending on production volume. A dirty head is the most common cause of wire jams or crooked stitches.

Use the correct wire size

Both the 801 and 802 are built for 25# and 26# wire. Using wire outside this spec — including generic wire that ""looks similar"" — is a common cause of heads wearing out faster or stitches that don't hold tight.

Check head spacing periodically

For double-head models like the 802, the spacing between heads (a 4.9–11 cm range) needs periodic rechecking, especially after switching to a different book size. Even a small shift in spacing can throw stitches out of alignment with the book's spine.

Watch for signs a stitching head is wearing out

  • Stitches start coming out crooked even with no setting changes.
  • Wire breaks frequently mid-cycle.
  • A rougher-than-usual mechanical sound as the head moves.

If any of these keep showing up even after cleaning, the stitching head's components are likely due for replacement — don't wait until it jams completely in the middle of a large order.

Schedule routine service

For machines used daily, a thorough check-up (lubricating the mechanism, checking bolt tightness, calibrating speed) every few months helps the machine last longer and cuts down on sudden downtime when orders are piling up.

Frequently asked questions

How often should the stitching heads be cleaned?

Ideally at the end of every shift for high production volume, or at least every few hundred cycles for moderate volume.

What happens if I use the wrong wire size?

The stitching heads can wear out faster and stitches may not hold tight or come loose easily — always use 25# or 26# wire as specified for the 801/802.

Does head spacing on the 802 need resetting for every job?

It should be rechecked especially when the book size being worked on changes, since head spacing (4.9–11 cm) determines stitch position on the book's spine.

Browse all our wire stitching machines or contact Lexia Machinery in Medan for service and parts advice.

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