User manual and parts list
Contents
1. Choke Ensaco Green tubing Bimba 4 way Valve Bimba Air Cylinder Watts Filter Watts Lubricater Watts Regulator 0 60 Watts Gage 1 47 1 1 2 Nipple 1 8 x3 nipple 1 8 Pt Street Elbow 1 8 1 4 Tube Male Connector 1 8 1 4 Tube Male Elbow 1 8 1 4 Tube Female Elbow 8 32x 1 4 Soc Hd Cap Screw 10 32x1 2 Soc Hd Cap Screw 1 4 20x1 2 Hex Hd Cap Screw 1 4 20x3 4 Hex Hd Cap Screw 1 4 20 Hex Nut 5 16 24 Hex Nut 1 4 U Bolts 13 02 Stand Assembly uy 5 Torey Q5 IPS pat DEZ S 00 D qq 14 REF 2 1 BW NWN GEM 99 0224 40 1293 40 1104 40 1068 40 1022 40 1011 40 5297 40 2106 40 3519 98 0022 40 2021 40 1520 40 2166 40 2004 98 0011 40 2161 U 2 Stand Assembly amp Parts PART 61 54A 61 233 61 168 61 171 61 409 61 410 61 22 61 9 80 32 80 31 60 217 80 25A 80 27 NAME STAND ASSEMBLY CONTROL BRACKET FOR INK FEED FLANGE FOR INK DRAIN TUBE TUBE HOLDER DRAIN TUBE STATIONARY DRAIN TUBE ADJUSTABLE INK RESERVOIR PIN BEARING HOUSING LOCKING SCREW SUPPORT POST FOR INK CAN SUPPORT FOR INK CAN PLATE FOR INK PUMP PUMP REGULATOR ASSEMBLY FOR PUMP REGULATOR AND FILTER GAGE 60 P S I BRACKET FOR REGULATOR INK INTAKE PIPE INK FILTER 3 8 FLAT WASHER 1 4 20 X 1 HEX BOLT 1 4 20 X 1 4 SOCKET HD CAP SCREW 1 4 FLAT WASHER 10 32 X 5 8 BUTTON HD SOC CAP SCREW2. Ens ICI PTT BEN HO dou DO ERE m T Tem DISC AVIDEE SUMO gers tics ca ys Wheel Saft Assembly amp 5olvent or 1 pacer Wie Guide Assembly Slide Prie CH PRGA RETI TO __ 6_6_____ _____ tas GEM U 2 Ultra Hi Speed Marker Printing seen 10 11 12 13 14 15 16 17 18 19 20 al 22 i29 Safety Information It is the responsibility of the user of this equipment to provide his employees with a safe place to work including proper tools devices and safety equipment It is essential that all personnel operating this equipment be instructed by their supervisors in safety precautions as outline on the following pages as well as proper operating procedures Introduction The high speed one side printer for long production runs on extruder lines has filled a particular need in the industry which is the capability of printing at top extruder speeds Its benefit lies in the ability to print at these speeds for full shift runs with little oper
3. 10 32 X 3 4 BUTTON HD SOC CAP SCREW 1 4 20 X 1 HEX BOLT 3 8 16 X 1 1 4 HEX HD BOLT 3 8 SPLIT LOCK WASHER 3 8 16 HEX NUT HOKE VALVE 15 21571 ell 353519 S el LV LV 110 1 MNI aly JA TIVA NA 11115 ANI 1 16 Parts Information Cover and Parts for High Speed Ink Pot Assembly Gem Generic Name 40 1505 61 115 Ink Pot Plug 40 1541 61 134 300 Ink Pot Cover 10 6 Cir Wheels 40 1545 61 134 437 Ink Pot Cover 10 6 Cir Wheels 40 1505 61 135 Ink Pot ink feed Nozzle 10 6 Cir Wheels 40 1113 61 136 Ink Pot Cover Skirt 10 6 Cir Wheels 40 1542 61 137 300 Ink Pot Cover 12 Cir Wheels 40 1546 61 137 437 Ink Pot Cover 12 Cir Wheels 40 1508 61 138 Ink Pot Ink Feed Nozzle 12 Cir Wheels 40 1106 61 139 Ink Pot Cover Skirt 12 Cir Wheels 40 1510 61 170 Ink Pot With Front Drain 10 32 x 3 8 Button Head Screw 10 32 Hex Nut 17 Gem Type AM Marker Parts Ordering Information Flat Wiper Holder Flat Wiper Holder Poly Or Nylon Wiper Materials GEM Generic Part Wheel Wheel Corresponding Wiper Material Wiper Materials Part No Width Type 40 1037 61 10A 300 300 Flat HS 152 x x 1 8 Poly or Nyl
4. 889MM 48 5 1232MM gt Ink Supply 1 GAL Code LONGITUDINAL OR VERTICAL Water Cooler OPTIONAL T Ink Filter YES 4 Stand HEAVY DUTY 0 ADJUSTABLE STAND 2 Strobe Light OPTIONAL 1 40 PSI Power Requirements N A Ld M 25 O H EI 8 11 h H EE 1 1 p Las G 5 mns ___________ 19 GEM GRAVURE COMPANY INC WORLD LEADER IN WIRE IDENTIFICATI Marking Machinery amp Equipment Gravure Printing Wheels Inks Dyes and Coatings Non contact Ink Jet Printing Systems 112 School Street P O Box 1158 West Hanover 02339 USA E mail sales gemgravure com Fax 781 871 2753 Tel 781 878 0456 6 Initial Setup Instructions Top air cylinder requires minimum 40 psi Gem marking ink is furnished in a Use as Received viscosity After unpacking roughly center the machine in your wire line so the wire passes directly over print wheel posi tion Setup and Operating Procedure Select a can of ink and place in paint shaker Upon clamping the ink can into the shaker turn on paint shaker and set it for a minimum of 10 minutes duration Raise the top concave guide wheel up by actuating the air cylinder valve The air cylinder valve is located at the upper right hand side on top of the printer Air pressure gauge should be set at 40 PSI Select the proper concave guide wheel based on the F O D of the cable being run A range of cable sizes is printed on th
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6. 98 0237 40 1020 40 1021 40 1022 96 0014 40 1024 96 0027 40 1025 40 1273 40 1266 40 1028 40 1029 40 1030 40 1031 40 1032 40 1033 40 1034 96 0702 40 4311 40 1269 40 1286 40 2146 40 1295 40 4309 40 1116 96 0216 40 1534 61 146 61 7 61 10 61 9 61 19 61 34 61 20 61 28 61 27 61 46 61 110 61 68 61 69 61 26 61 22 61 38 5000 112 R 8 61 12 60 13 61 16R 61 16L 61 17R 61 17L 61 42 61 245 33KDD5 5000 50 61 48 61 47 61 132 61 49 61 50 61 155 61 153 61 21A Overall Mechanical Parts list for High speed Marker NAME High casting base Adjusting wheel carrier Brass Plug For lock Screw Bearing Housing Locking Screw With Brass Plug Slide Plate Adjusting Knob Wiper Support Arm Flat Wiper Holder See Pages 18 For Various Sizes Of Flat Wipers 1 4 20 Jam Nut Wheel Wiper Stud Wiper Spring Tension Support Arm Short Tension Adjusting Bracket 10 32 x 3 8 Flat Hd Soc Cap Screw Knob For Wiper Blade Tension Screw Wiper Blade Tension Screw 1 4 20 x 1 4 Cup Point Soc Set Screw E Clip Tension Follow Nut 10 Internal Lock Washer Ink Reservoir Pins 1 4 20 X 1 2 Hex Hd Cap Screw See Page 12 For Ink Pot Parts Rear Rol Nut 1 4 20 X 5 16 Cup Pt Soc Set Screw TruArc Retaining Ring Wavy Spring Washer Bearing Bearing Spacer Bearing Housing Top Wheel Shaft Bottom Wheel Shaft Top Roll Nut Front Bottom Roll Nut Front Wheel Spacer 10 32 x 3 8 Butt
7. GEM GRAVURE COMPANY INC Gem Type U2 High Speed Marker Parts and Assembly Manual 13 T 4 gt d 4 u t LP A em 6 F t Copyright 2007 GEM Gravure Company Inc rights reserved This document 15 the property of GEM Gravure Company Inc and contains confidential information owned by GEM Gravure Company Inc Any unauthorized copying use or disclosure of it without the prior written permission of GEM Gravure Company Inc is strictly prohibited GEM Oravure Company Inc 112 School Street West Hanover MA 02339 Tel 781 878 0456 Fax 781 878 9360 E Mail sales gemgravure com 2 Gem Type 02 High Speed Marker Table of Contents Do LT mem Oy MOP INTO __ _________ _ ____ 6_6_ ___ ______ ___ 6 UTERE E as ee eee Initial Deu and Oper ans _ _ __ _ _6 _6_ _6_6_ _ _______________ Operon Procedures 10r GEM U2 PMI oud CE quU MA P APAS ____ ______ ____ 6_ __ 6_ ___ _ _____ ___ _ __ __ 4D STAG ____ ___ ____ _ ______ E ME
8. ator attention For top marking speeds oversized 15 circumference flat print wheels are specified to provide a high rate of Linear marking at moderate rotational speeds However the machine can be modified to accommodate 10 6 12 and 15 circumference flat wheels It should be noted that potential top printing speeds are decreased with smaller sized print wheels The unit incorporates such features as a forced ink feed system with pressure gauge check on viscosity a one gallon ink supply pneumatic action top guide wheel raising and lowering movement with fine pressure adjust ment shielded ink well to prevent ink splash and many other desirable features Please specify line direction and furnish complete print wheel legend and wire diameter when ordering the Gem Type U Ultra High Speed Marker The recommended marking ink for this printer is the Gem Ultra High Speed ink prepared in the proper viscosity for high speed extrusion marking and is ready for use as received After many hours of use check the ink pres sure gauge shows signs of the ink viscosity becoming heavier adding a small amount of thinner to the 1 gallon ink reservoir will restore the ink to its original furnished viscosity GEM Type 02 High Speed Marker Machine Specifications MINIMUM MAXIMUM Z INCH MM ii Wire Speed 0 FPM 1 000 FPM 303 MPM 3 Wire Diameter 030 77MM 3 77MM Wire Line Height 35
9. e concave guide wheel Place the concave guide wheel onto the top shaft and secure into place with wheel nut Select a print wheel based on wire gauge and F O D of cable being run Place the print wheel onto the bottom shaft and secure into place with wheel nut Proper alignment of the two wheels is necessary First align the print wheel on the bottom shaft by loosening the thumb screw at the back of the printer that locks the bottom shaft assembly Slide the bottom shaft as sembly until it is in the line with the ink spray nozzle and then lock into place with thumb screw Operating Procedures for GEM 02 Printers Align Concave guide wheel on top shaft by centering it in line with the print wheels Lock shaft assembly into place with thumb screw at back of printer at top shaft Insert a fresh flat poly wipe 1 5 x 5 x 125 into the slot of the brass wiper holder Mount wiper holder on the holder pin and position slide plate so that wiper fingers fit around the print wheel and the bottom sharp edge of the poly wipe contacts the wheel face on an angle To achieve this proper angle slide the wiper assembly up as high of an angle on the wheel as it will go then slide it back just slightly and lock into place Angle should be 10 to 15 degrees NOTE The wiper assembly must be mounted on the wire entrance side of printer Engage the coil tension spring onto the split ring fastened to the bottom of the wiper holder Crank and adjust the wiper te
10. ickly remove the ink can and replace it with a can of flushing solvent 4555 Place the can of flushing solvent up into position and allow it to pump thru the system Pour some cleaner into a bucket and place the print wheel wiper holder concave guide wheel shaft spacers and wheel nuts into bucket Using a rag dip it into the flushing solvent as it comes out of the ink nozzle and cleanup ink splatters and excessive ink with it All areas to be cleaned include the frame shafts wiper tension assemblies etc It is best to wipe with a flushing solvent soaked rag followed by wiping it clean with a dry clean rag Lower the can of flushing solvent allowing the can to catch the solvent as the pump drains the ink well then turn off pump Replace the can of flushing solvent with an empty can Use to wipe the inside of the ink well clean Remove each item soaking in the cleaner and wipe them clean with a rag one at a time Take the dirty cleaner in bucket and dispose of by placing it into a drum properly labeled with a yellow hazardous waste label 02 Exploded View Top 10 GEM CONN WN 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 40 1543 40 1002 40 1010 40 1011 40 1012 40 1268 40 1014 40 1015 40 1016 40 1285 40 1017 96 073 40 1018 40 1019 96 0028
11. nsion assembly to provide a small amount of drag on the print wheel face when it is rotated by hand With a cable stretched thru the printer adjust the entrance side adjust the small guide sheave so the sheave is on the underside of the cable and align sheave to center of cable Place a gallon of ink into position and turn on ink pump Adjust ink pressure to 5 6 PSI Rotate the print wheel by hand and check wipe With the exception of the lettering the face of the print wheel should be wiped clean Replace ink well top cover Rotate the print wheel by turning the wheel shaft at the rear of the machine and check if the print wheel rotates freely and does not scrape on slot side of the ink well cover If it rubs against the slot side make a small adjustment of the wheel position by moving the wheel shaft in or out Start up the cable line after the knots have gone thru the printer check to see that the cable is properly travel ing thru the sheave and printer Lower the concave guide wheel down into position on top of the cable by actuating the air cylinder valve Ad just the concave guide wheel with the top air lever forcing the cable to slightly contact the print wheel Check print quality Re adjust guide wheel pressure as required As the ink begins to thicken use the same series extended to thin the ink Clean Up Procedures With diaphragm air pump off lower the ink can so that the can catches the ink as the pump drains the ink well Qu
12. ntly compounded inks as indicated in the accompanying chart For printing on Specify ink l ob viny To BIOL Type Rubber natural or ccc ccc cece cece Type CV hir Polyethylene or cross link Type HCP e For hot or cold applications e Passes all standard abrasion and solvent resistant tests e Dated for shelf life and inventory control Available in Quarts Gallons 5 Gallon Pails 30 Gallon Drums 55 Gallon Drums Order shipped on day it 1s received 34 1 1150381 033 164 55 0 Ieuuru poods 50 4 Jo pews 2 Suppe Aq 10 1991102 ULI sos oJout ounssoud 16 poods 211 ot uo oinssoid Sup oouo A euorseooo UIAM Sj nso1 Sururd 1894 UOTAU 10 JUJ Sup 1epq poods enj VN uror pue s oouA Sup reui poAeJouo YNO Surureuio pue poods paud 4 5 ULI ou ONM uo 8 JO Surpeoq Aq 112 3 51 0 01 OS JO ounje
13. on 40 1038 61 10 437 437 Fla HS 1 x 32 x 1 8 Poly or Nylon poly Wipe 40 9033 Note Poly or Nylon Flat Wipes purchased in packs of 100 Note Ink Skirt Optional 18 Gem Type AM Marker Wiper Tension Assembly Gem f Generic 40 1072 61 14A Wiper Tension Assembly complete Complete Assembly includes Number Number 1 196976 90 f 1032x3 8 ButonHeadCapScrew 1 40101 10 Lock Washer O Z Z O 1 96 0028 ____ M 20x4CupPt Soc Set Screw 2 9607080 5H0 32x3 8 FlatHeadScrews 19 Gem Type AM Marker Wheel Shaft Assembly Qty Gem Part No Generic Description Part No 40 1073 61 shaft Assembly complete R H 40 1074 61 4 shaft Assembly complete L H Left to right machine operation Note When machine is operating right to left top shaft will be L H and bottom R H Complete Assembly includes Part No 2 98 098 Bearings 1 1 8 Snap Rings Bearing Spacer 1 40 1273 8 8 Wavy Spring Washer Rear Roll Nut Solvent or Ink Dripper Assembly Qty Gem Part No Generic Description Part No 40 1075 61 39 Dripper Assembly complete Complete Assembly includes bracket 40 1288 20 Gem Type AM Marker 40 1081 Wire Guide Assembly Qty Gem Part No Generic Description Part No 1 40 1081 61 5 In Out Adjusting Wire Guide L H amp R H 40 1082 61 27 Small V G
14. on Hd Soc Cap Screw Screw For Guide Wheel Bearing Internal Tru Arc Retaining Ring Post For Wire Guide Assembly Support Arm For Wire Guide Assembly Long Adjusting Nut Spec 8 32 Thumb Screw Spacer For Wire Guide Asm Stud For Wire Guide Asm Bearing Spacer Wire Guide Wheel 1400 0083 00482 Key Ring 1 4 Washer 3 8 24 x 1 1 4 Hex Hd Cap Screw High Speed A M Air Asm See Page 16 amp 17 For Parts Right Hand Shaft For Wire Direction R to L Left Hand Shaft For Wire Direction L to R 11 Air Assembly Exploded View For 02 High Speed Marker 61 21 _ 2531 4 2 Y wi 4 12 Assembly Exploded Parts View For 02 High Speed Marker 61 21 REF GEM lt 4 tor c 0t WN 2 0 4 amb c 40 1009 40 1268 40 1018 40 1105 40 1289 40 1115 40 1114 40 1120 40 1516 40 1518 40 1519 97 0010 97 0005 97 0029 96 0802 96 0705 96 0014 96 0013 96 0040 PART 61 4 61 34 61 68 61 141 61 142 61 143 61 144 61 145 61 152 4 8 13 094 1 504 2 508 2 364 2 2747 60 113 116 268 269 270 Top Roll Adjusting Screw Collar Adjusting Knob Knob Carrier Plate Top Plate Air Valve Support Plate Air Gage Support Stop Adjustinbg Screw
15. roove Roll PN 40 1080 Slide Plate Assemble Generic PN 61 26A Part No 40 1012 61 19 Slide Plate 40 1268 61 34 Adjusting Knob 1 96 0216 3 8 24 x 1147 Hex Screw 40 1014 61 20 Wiper Support Arm 21 Gem Type AM Marker Flat Print Wheels For printing on Wheel Model Type Wiper Required Wiper wire covering with Width Size Material Min Max O D Poly or Range of Nylon 040 0 080 300 Flat Hi Speed V x V x 1 8 1080 0 100 same 100 0 125 same 125 0 200 same 200 0 300 437 Flat Hi Speed same 300 0 400 same 400 0 500 same E NOTE Models GM GP and GR have same profile as Model GL differing only in dimensions T aT mg a Model G Model GL 22 Concave Guide Wheels For printing on Wheel wire covering Radius with Min Max O D Range of 045 070 3 64 070 095 1 16 095 115 5 64 115 135 2 92 135 190 1 8 190 235 235 280 3 16 280 330 TOL 330 400 1 4 400 430 9 32 430 500 13 32 Yet 1 ENS 3 375 3375 Ht d B io Model GC Model GLC 2 BLACK WHITE YELLOW 2na RED 7na GREEN 23pc BLUE 14na ORANGE 5na BROWN 4pi VIOLET 1218 GREY F PINK 6 ea SLATE 13ih AQUA 19ga SILVER GOLD Gem Type AM Marker Wire Marking Inks and Thinner Different covering materials require differe
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