GRAPHIC WHIZARD GW 6000 Reference Manual

Graphic Whizard GW

6000 Number/Perf/

Score/Slit Machine

Instruction Manual

6635 Kitimat Road, Unit 34; Mississauga, Ontario; Canada L5N 6J2;

Web Site: www.graphicwhizard.com

GW 6000

Reference

Manual

Tel: [phone] Fax: [phone] Toll Free 1-800-265-3376

Shown with optional second head & optional stand

Mississauga, Ontario L5N 6J2

Phone # [phone] Fax # [phone]

Web Site: www.graphicwhizard.com

GRAPHIC WHIZARD

6635 Kitimat Road, Unit 34

Toll Free: 1-800-265-3376

Version 99-07

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TABLE OF CONTENTS

1.0 General Operation 3

1.1 Technical Data 3

1.2 Safety Regulations 3

1.3 Cautions Concerning Machine 4

2.0 Machine Assembly 5

2.1 Feed and Exit Trays 5

2.2 Numbering Heads 6

2.3 Optional Conveyor Outfeed Plate 7

2.4 Additional Switches and Control 7

3.0 Operating Keyboard 8

3.1 Running a Job 8

3.2 Stopping a Job 8

3.3 Clearing a Program 9

3.4 Changing and Programming a Job 9

3.5 Speed Control 10

4.0 Setting Up a Job 10

4.1 Aligning the Feed Tray Guides 10

4.2 Setting Feed Tire Pressure 10

4.3 Perforating/Slitting 12

4.4 Scoring 13

4.5 Idler Wheel Holders 14

4.6 Main Rollers 14

4.7 Installing Ink Pads 14

4.8 Locating the Numbering Heads 15

4.9 Stripper Assemblies 15

4.10Setting Impression Control 15

4.11Flatness of Impression 16

4.12Exit Rollers 17

5.0 Running a Job 17

5.1 Setting the Start Number 17

5.2 Setting the Repeat Selector 17

5.3 Fanning 18

6.0 Maintenance 19

6.1 Numbering Heads 19

6.2 Machine Cleaning 19

6.3 Lubrication 20

6.4 Friction Feed 20

7.0 Troubleshooting 21
Friction Feeder 21
Print Quality 21
Registration 22
Numbering Heads 22
Error codes 24
Parts List 25

GW 6000 PARTS LIST 25
GW 6000 PARTS DIAGRAM 29

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1.0 GENERAL OPERATION

The GW 6000 is a numbering, perforating, scoring, and slitting system. It operates at three speeds that is
factory programmed to print 6000 sheets per hour, assuming 1 hit per page and a 15 millisecond
solenoid pulse width. The operation of the machine is controlled by a microprocessor with an LED
display and keypad interface.
The system allows for a maximum of two numbering heads, which can independently turn off or on for
a maximum of 1 job with ten hits per head that, are stored and recalled for future use. Numbering can be
done on single sheets (13# bond to 12 point card or 45 to 250 gsm paper) or multi-part carbonless forms
(up to 10 parts) while simultaneously perforating, slitting and/or scoring. The unique friction feeder
sends through one set at a time, even from the unglued side of a padded set. The pressure adjustable
feed shaft ensures consistent registration. Perforations are done between the feed and main rollers
producing a straight perforation, slit or score, avoiding tail whip. Perforating wheels are offered in a
wide range of teeth configurations and can be quickly changed using the retaining ring pliers supplied.
A photocell recognises the lead edge of the sheet and the microprocessor stops the sheet at the specific
location(s) where numbers are required. The numbering heads are electrically operated. All this, in a
compact design.

1.1 TECHNICAL DATA

Areas of use:

Paper weight: 12# - 12 point (45-250 gsm)
Paper formats: max. 18” x 18” (45 x 45 cm)

min. 3” x 5” (7.6 x 12.7 cm)

Electrical configuration:

Voltage: 90-135 VAC or

180-270 VAC

Frequency: 60 Hz or

50 Hz

Fusing: 115/230V, 3/5A

1.2 SAFETY REGULATIONS

• Before using the machine, you must read the operating instructions.

• Professionals must only eliminate damage or extraordinary malfunctions.

• Never insert your hand into the machine while it is running.

• Do not wear loose fitting clothing when working with the machine.

• Make sure that the machine stands on a level and well-ventilated positions.

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1.3 CAUTIONS CONCERNING MACHINE

CAUTION – The solenoids may get hot during
operation. Do not touch the solenoid case while the
machine is running and until it has been given enough

time to cool down.

CAUTION – The motor may get hot during normal
operation use. Do not touch any vicinity near motor.

CAUTION – On Electric Solenoid machines the noise levels can
be excessive and hearing protection may be required.

CAUTION – Machine should never be left unattended.

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2.1 Feed and Exit Trays

2.0 MACHINE ASSEMBLY

The feed and exit tray assemblies are comprised of

four components each: the tray, two tray side guides and a
centre slot cover (see Figure 1a).

SIDE GUIDE

CENTER SLOT GUIDE

The trays sit in the machine on mounting pins inside

the machine's side frames as shown in Figure 1b and 1c. The
trays can be easily removed and stored elsewhere when not in
use.
Place the tray side guides, bottom flange towards the centre

Tray Assembly

Figure 1a

and the centre slot cover on the tray as shown in Figure 1a and
screw on the nylon wing nuts to secure the pieces on the tray. The operator side tray guide of both the
feed and exit tray should be pulled all the way over to the operator side before tightening its two wing
nuts.

Note: It is critical that the operator side tray guide be moved all the way over to the
operator side of the machine to ensure that the stock being processed through the
machine passes directly underneath the photocell. If the stock does not pass directly
underneath the photocell, the machines will not recognise sheets and the program
being run will not be initiated.

Place a pile of the stock to be processed in the feed tray and use it to align the non-operator side

tray guide to the pile. Allow a fraction of an inch so that the pile flows freely up and down the tray if
released from the top. Set the exit tray in a similar manner, although the accuracy of the non-operator
side guide position is not critical.

As a backstop to finished stock, there are two magnets included with the machine (unless

equipped with the conveyor outfeed) that are set inside the side tray guides on the exit tray. Relative

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position of the magnets depends on the stock being processed, but the magnets should be set such that
the stock does not slide down the exit tray too far, possibly causing sheets to get in uncollated order.

2.2 Numbering Heads

The numbering heads are already secured
to the drive unit by two screws through
the numbering head mount block as
shown in Figure 2. The drive unit is then
mounted to the drive unit mount block
using the hand knob provided. While
installing the drive unit, make sure the
screw cap on the back of the drive unit
fits in the cavity on the drive unit mount
block so that the rubber plug provides
some pressure against the screw cap. You
may have to back out the left/right pitch
screw in order to do this. Plug in the cord
from the drive unit into the appropriate
receptacle on the non-operator side cover
(closest head to the closest receptacle). If
your machine is equipped with more than
one head, by convention, the numbering
head and drive will refer to unit closest to
the operator control panel as head #1(H1)
and the other will be head #2 (H2).

Drive Unit

Numbering Head
Mount Block

Numbering Head
Rotation Lock Screw

Numbering Head

Platen

Figure 2: Numbering Heads

Drive Unit Mount Block

Hand Knob
(Left/Right Pitch)

Left/Right Pitch Screw

Forward/Back
Pitch Screw

Hand Knob
(Forward/Back Pitch)

Drive Unit Mount Shaft

Anti-Pitch Block

Change Stylus: Numbering
Head should be approx. 1/4"
from the platen, or the
thickness of a change stylus

The height of the numbering head has been factory set and it is critical to the proper performance

of the drive unit and numbering head. This distance is approximately 3" or the thickness of a numbering
wheel change stylus. However, the numbering head must be levelled to ensure that the numbering
wheels strikes the sheet square to provide a quality inked impression and a flat crash impression on
carbonless sets. This will be discussed later (Section 4.11).

The numbering heads can operate through 360Ε. This is done by loosening the numbering head

rotation screw (using the large hexdriver supplied) located on the front of the numbering head mount
block. Once the screw is loose, the head is free to rotate. Tighten the screw once the desired position is
achieved in order to prevent any movement during machine operation.
The standard numbering head is 3/16" (4.5mm) Gothic style, reverse order, 6 digits with 2 drop wheels.
The numbering head employs a pre-inked pad, which can be purchased in red or black. These ink pads
will supply you with approximately 15,000 impressions. Uninked pads may be purchased if a different
colour is required (Note: any ink used must be a non-metal corrosive one, labelled numbering machine
ink).

The numbering head comes standard with six numbering wheels (a seventh numbering wheel is

optional), the last two of which are drop wheels (this will be discussed later). The first 5 digits may be
activated automatically. The 6th (or 7th) digit must be changed manually. Also available are letter
prefix wheels (A-J; K-R; S-Z) and a µ prefix wheel. Modifications are possible with new numbering
head orders or by special order.

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The numbering heads also have a repeat

function. The repeat selector (see Figure 3) allows a
number to be repeated from one to four times. By
leaving the repeat selector in the "0" position, the
number will not change when the head returns to the
print position. Using the "0" position prevents you
from having to re-set the starting number when you
are programming a new job (this will be discussed

C-Clip

Spring
Bushing

Repeat
Selector

Print
Head
Frame

Locking

Repeat
Selector
Adjustment
Screws

Numbering

3

2

4

Head

1

0

Frame

Tab

Comb
Spring

later). Position "1" changes the number
consecutively with each stroke and positions "2",
"3" and "4" repeat the number 2, 3 or 4 times
respectively. The repeat functions are achieved by a
mechanical ratchet action in the numbering head.
When trying to use these functions, you may have to
cycle the numbering head manually in order to
match the number of repeats on a page to the

Ink Pad Holder Mount Bracket

Figure 3: Numbering Heads

number positions on a page.

2.3

O

ptional Conveyor Outfeed Plate

The conveyor outfeed plate sits in the machine in the same fashion as the exit tray. Make sure

that the spur gears mesh and do not force the conveyor outfeed plate into position. The pile tray is
mounted on the end of the conveyor outfeed plate, with two Phillips screws and acts as a backstop for
the finished stock.

2.4

Additional Switches and Controls

The main on/off switch module is located under the feed tray on the back of the operator side

plate. This module also houses the main fuseholder and power cord.

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