GUSMER GAP Operating Manual

Download

Page 1

"Teamwork & Communication"

Model GAP

Spray Gun

Operating Manual

35943-1

December 6, 2000

Issue 5

GUSMER CORPORATION

A Subsidiaryof Gusmer MachineryGroup, Inc.

One Gusmer Drive

Lakewood, New Jersey, USA 08701-8055

Toll Free 1-800-367-4767 (USA & Canada)

Phone: (732) 370-9000

Fax: (732) 905-8968

http://www.gusmer.com

NOTICE: This manual contains important information for your GUSMER equipment. Read and retain for future reference.

Page 2

GAP Spray Gun

NOTICE:

The equipment described in this technical manual must only be operated or serviced by properly trained individuals, thoroughly familiar with the operating instructions and limitations of the equipment. For technical service, call your local distributor. Call: 1-800-FOR-GSMR (1-800-367-4767) for the name and telephone number of your local distributor.

NOTICE:

All statements, information and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty or responsibility of any kind expressed or implied. Statements or suggestions concerning possible use of GUSMER equipment are made without representation or warranty that any such use is free of patent infringement, and are not recommendations to infringe any patent. The user should not assume that all safety measures are indicated or that other measures may not be required.

2 35943-1, Issue 5

Page 3

Operating Manual Contents

CONTENTS

LIST OF FIGURES..........................................................................................................4

WARRANTY ....................................................................................................................5

GENERAL SAFETY INFORMATION..........................................................................6

CCEPTABLEEQUIPMENT USES.......................................................................................6

A O

PERATIONALSAFETY PROCEDURES...............................................................................7

MAJOR COMPONENTS................................................................................................8

OPERATION....................................................................................................................9

AFETY STOP OPERATION................................................................................................9

ANUAL VALVE OPERATION ..........................................................................................9

IR HOSE CONFIGURATIONS..........................................................................................10

NITIALSET UP PROCEDURE ..........................................................................................11

AILY START UP PROCEDURE .......................................................................................12

AILY SHUTDOWN PROCEDURE ....................................................................................12

AILY MAINTENANCE TEST PROCEDURE......................................................................13

SERVICING PROCEDURES........................................................................................14

IDE BLOCK SERVICE PROCEDURE ................................................................................14

S M

IXING CHAMBER ANDGUN BLOCK SERVICE PROCEDURE..........................................16

ND CAP AND AIR PISTON O-RING SERVICEPROCEDURE .............................................17

ND CAP O-RING AND SAFETY STOP CUPSEAL SERVICE PROCEDURE..........................19

RIGGER VALVE O-RING PROCEDURE...........................................................................21

AIR PASSAGE DIAGRAMS.........................................................................................24

APPENDIX......................................................................................................................25

PECIFICATIONS.............................................................................................................25

NOTES.............................................................................................................................26

INSTRUCTION MANUAL DISCREPANCY REPORT............................................27

12/6/00 3

Page 4

GAP Spray Gun

LIST OF FIGURES

FIGURE 1. MAJOR COMPONENTS .......................................................................................8

IGURE 2. FRONT END COMPONENTS................................................................................8

IGURE 3. ENGAGE THE SAFETY STOP................................................................................9

IGURE 4. DISENGAGE THE SAFETY STOP ..........................................................................9

IGURE 5. MANUAL VALVES ..............................................................................................9

IGURE 6. AIR HOSE CONFIGURATION.............................................................................10

IGURE 7. SIDE BLOCK COMPONENT REMOVAL /INSTALLATION.......................................14

IGURE 8. TIGHTNING THE SIDE SEAL..............................................................................15

IGURE 9. SIDE SEAL INSPECTION ...................................................................................15

IGURE 10. MIXING CHAMBER AND GUN BLOCK REMOVAL/INSTALLATION ........................16

IGURE 11. END CAP AND PISTON ASSEMBLY ...................................................................18

IGURE 12. PISTON ASSEMBLY..........................................................................................18

IGURE 13. END CAP ASSEMBLY.......................................................................................20

IGURE 14. SAFETY STOP ASSEMBLY.................................................................................20

IGURE 15. TRIGGER/AIR VALVE ASSEMBLY......................................................................22

IGURE 16. AIR CYLINDER AIR PASSAGES .........................................................................24

IGURE 17. HANDLE AIR PASSAGES..................................................................................24

4 35943-1, Issue 5

Page 5

Operating Manual Warranty

WARRANTY

Gusmer Corporation (Gusmer) provides a limited warranty to the original purchaser (Customer) of Gusmer manufactured parts and equipment (Product) against any defects in material or workmanship for a period of one year from the date of shipment from Gusmer facilities.

In the event Product is suspected to be defective in material or workmanship, it must be returned to Gusmer, freight prepaid. If Product is found to be defective in material or workmanship, as determined solely by Gusmer, Gusmer will issue full credit to Customer for the freight charges incurred in returning the defective Product, and either credit will be issued for the replacement cost of the Product or a replacement part will be forwarded no-charge, freight prepaid to Customer.

This w arranty shall not apply to Product Gusmer finds to be defective resulting from: installation, use, maintenance, or procedures not accomplished in accordance with our instructions; normal wear; accident; negligence; alterations not authorized in writing by Gusmer; use of “look alike” parts not manufactured or supplied by Gusmer; or Product used in conjunction with any other manufacturer's pumping or proportioning equipment. Further, the terms and conditions of this warranty shall not apply to services or repairs made to Product by any third party not authorized in writing by Gusmer. For such Product, a written estimate will be submitted to Customer at a nominal service charge, itemizing the cost for repair. Disposition of Product will be done in accordance withthe terms stated on the written estimate.

The warranty provisions applied to product that are not manufactured by Gusmer will be solely in accordance with the warrantyprovided by the original manufacturer of the product.

GUSMER MAKES NO WARRANTY WHATSOEVER AS TO THE MERCHANTABILITY OF, OR SUITABILITY FOR, ITS PRODUCT TO PERFORM ANY PARTICULAR PURPOSE. CREDIT FOR, OR REPLACEMENT OF, PRODUCT DEFECTIVE IN MATERIAL OR WORKMANSHI P SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUSMER OBLIGATIONS TO CUSTOMER. NO OTHER WARRANTY, EXPRESSED OR IMPLIED O N ANY PRODUCT IT MANUFACTURES AND/OR SELLS, WILL BE RECOGNIZED BY GUSMER UNLESS SAID WARRANTY IS IN WRITING AND APPR OVED BY AN OFFICER OF GUSMER.

Under no circumstances shall Gusmer be liable for loss of prospective or speculative profits, or special indirect, incidental or consequential damages. Further, Gusmer shall have no liability for any expenses including, but not limited to personal injuryor property damage resulting from failure of performance of the product, use of the product, or application of the material dispensed through the product. Any information provided by Gusmer that is based on data received from a third source, or that pertains to product not manufactured by Gusmer, while believed to be accurate and reliable, is presented without guarantee, warranty, or responsibility of any kind, expressed or implied.

Gusmer through the sale, lease, or rental of Productin no way expresses or implies a license for the use of, nor encourages the infringement of any patents or licenses.

To insure proper validation of your warranty, please complete the warranty card and return it to Gusmer withintwo weeks ofreceipt of equipment.

Revised 11/12/98

12/6/00 5

Page 6

GAP Spray Gun

GENERAL SAFETY INFORMATION

It is necessary to understand and follow the instructions in this manual to insure proper and safe operation of the equipment.

As with most mechanical equipment, certain safety precautions must be taken when the equipment discussed in this manual is operated or serviced. Severe bodily injury or damage to equipment and property mayresult if the instructions and precautions listed throughout this manual are not followed.

Needless to say, sufficient guidelines cannot be developed to eliminate the need for good common sense in the use and servicing of this equipment, and in the use and application of the products, this equipment has been designed to process. Users of this equipment must therefore, make their own determination as to the suitability of the information contained in this manual to their specific operation and requirements. There should be no assumption made that the safety measures and instructions contained herein are allinclusive, and that other safety measures may not be required for specific use or application.

The following safety guidelines are generallyapplicable to the safe and efficient use of the equipment.

Acceptable Equipment Uses

The design of this equipment allows the dispensing of polyurethan e foams, twocomponent coating systems, polyureas, and some adhesives. Under no circumstances should any acid or corrosive chemicals be used in the unit. Consult GUSMER if there is any doubt about the compatibility of the chemical system to be used with this equipment.

Any use of this equipment other than as indicated above constitutes misuse unless express written approval is obtained from GUSMER.

6 35943-1, Issue 5

Page 7

Operating Manual General Safety Information

Operational Safety Procedures

This safety information is not repeated in this manual. The symbols pertaining to this information will appear where appropriate to alert the operator to potential hazards.

Solvents and Chemicals

High Voltage

High Pressure

Personal Protective

Equipment

WARNING: T

OPERATOR TO CERTAIN HAZARDS.ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BE TAKEN SO AS TO AVOID EXCEEDING THE BEING USED

HE SOLVENTS AND CHEMICALS USED WITH THIS EQUIPMENT EXPOSE THE

THRESHOLD LIMIT VALUE (TLV) OF THE PRODUCTS

, AS ESTABLISHED BY THE OCCUPATIONAL SAFETY ANDHEALTHADMINISTRATION

(OSHA) OR OTHER QUALIFIED AGENCY.INFORMATION CONCERNING PERSONAL PROTECTION

AND PROPER HANDLING SHOULD BE OBTAINED FROM THE SUPPLIER OF SUCH CHEMICALS

WARNING: T

THE ELECTRIC CONSOLES OR OTHERWISE SERVICE THIS EQUIPMENT AND/OR EQUIPMENT USED WITH IT BEFORE SWITCHING OFF THE MAIN POWER DISCONNECT AND INTERRUPTINGSUPPLY VOLTAGE AT THE SOURCE A QUALIFIED ELECTRICIAN

WARNING:T

COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI.TO AVOID SERIOUS BODILYINJURY FROM HYDRAULIC INJECTION OF FLUID SERVICE HYDRAULIC COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO

WARNING: T

WHEN OPERATING, SERVICING, ORBEINGPRESENT IN THE OPERATIONAL ZONE OF THIS EQUIPMENT SAFETY SHOES, AND RESPIRATORY EQUIPMENT AS REQUIRED.

O PREVENT SERIOUS BODILY INJURYFROMELECTRICALSHOCK, NEVER OPEN

.THE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY

HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC

, NEVER OPEN ANY HYDRAULIC CONNECTIONS OR

O AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR MUST BE WORN

.THIS INCLUDES, BUT IS NOT LIMITED TO, EYE AND FACE PROTECTION, GLOVES,

WARNING: T

TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES.TO PREVENT SERIOUS BODILY INJURY FROM HOT FLUID OR HOTMETAL EQUIPMENT BEFORE ALLOWING IT TO COOL

HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH

, NEVER ATTEMPT TO SERVICE THE

High Temperature

WARNING:F

PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT FROM ONE OR MORE OF THE ABOVE LISTED HAZARDS

AILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN

Warning

12/6/00 7

Page 8

MAJOR COMPONENTS

In keeping with the need to gain a complete and thorough understanding of the equipment, please take time to become familiar with the major components of the GAP (Gusmer Air Purge) Gun and its Front End Components.

GAP Spray Gun

NOTE:

For a detailed account of

the components shown in

Figure 1 and Figure 2,

consult the GAP Spray Gun

Parts Identification Manual

(P/N 35943-ID).

Figure 1. Major Components

(Gun shown with Round Spray Tip)

Figure 2. Front End Components

(GunshownwithFlatSprayTipAssembly)

8 35943-1, Issue 5

Page 9

Operating Manual Operation

OPERATION

WARNING: NEVER POINT THE GUN AT OR NEAR OTHER PERSONNEL OR PLACE ANY PART OF

THE BODY IN THE PATH OF THE MATERIAL SPRAY.DO NOT LOOK INTO THE DISPENSING END OF THE GUN USING THE GUN DAMAGE FROM THE ACCIDENTAL OPERATION OF THEGUN

Safety Stop Operation

The GAP Gun has a two position Safety Stop. When engaged, it prevents accidental triggering of the gun during servicing or down time. When disengaged, it allows the gun to dispense.

1. ENGAGE THE SAFETY STOP-

.ALWAYS ENGAGE THE SAFETY STOP AND CLOSE BOTH MANUAL VALVES WHEN NOT

.DO THIS TO AVOID THE POSSIBILITY OF BODILY INJURYOR PROPERTY

Push in and turn the Safety Stop knob clockwise to place the gun in the Safety detented position.

Figure 3. Engage the Safety Stop

Manual Valve Operation

NOTE:

Triggering of the gun with the

manual valves closed may

cause crossover if there is any

residual chemical in the gun

ports.

IMPORTANT: Always engage the Safety Stop when the gun is not in use.

2. DISENGAGE THESAFETY STOP- Push in and turn the Safety

Stop knob counterclockwise to place the gun in the Open detented position.

TheGAPGunSideBlockshaveManual Valves that control the flowof each chemical component to the gun.

1. OPEN BOTH MANUAL VALVES- Using a 5/16” Spintite, turn each Manual Valve at least three full turns counterclockwise.

2. CLOSE BOTH MANUAL VALVES- Using a 5/16” Spintite, turn each Manual Valve fully clockwise.

Figure 4. Disengage the Safety Stop

Figure 5. Manual Valves

IMPORTANT: Topreventaccidental gun operation, always engage the Safety Stop and close both Manual Valves before att empti ng to service the gun or l eaveit unattended.

12/6/00 9

Page 10

GAP Spray Gun

Air Hose Configurations

TOOLS REQUIRED

• 3/16” Hex Key

• (2) 6” Adjustable Wrench

The GAP Gun design allows for two different Air Hose configurations. The standard configuration has the air connection at the base of the handle. The optional configuration has the air connection at the rear of the gun. To change to the optional configuration proceed as follows:

Figure 6. Air Hose Configuration

WARNING:B

ENGAGE THE SAFETY STOP, AND DISCONNECTTHE AIR FROM THE GUN.

1. REMOVE THE AIR HOSE- Using a 6” Adjustable Wrench remove the Air Hose from the Long Pipe Nipple at the base of the gun handle.

2. REMO VE THE LONG PIPE NIPPLE- Using a 6” Adjustable Wrench, remove the Long Pipe Nipple from the base of the gun handle.

3. REMOVE THE PIPE PLUG- Using the 3/16” Hex Key, remove the Pipe Plug from the back of the gun.

4. INSTALL THE PIPE PLUG- Using the 3/16” Hex Key, install the Pipe Plug in the base of the gun handle in the hole previously occupied bythe Air Hose.

5. INSTALL THE PIPE NIPPLE (Supplied with Gun)- Using a 6” Adjustable Wrench, install the Pipe Nipple in the back of the gun.

6. INSTALL THE AIR HOSE- Using a 6” Adjustable Wrench, connect the Air Hose to the Pipe Nipple at the back of the gun.

10 35943-1, Issue 5

EFORE ATTEMPTING THIS PROCEDURE, CLOSE BOTH MANUAL VALVES,

Page 11

Operating Manual Operation

Initial Set Up Procedure

TOOLS REQUIRED

• 5/16” Spintite • Clean Rag

• (2) 6” Adjustable Wrench • Gun Cleaner

• 5/32” Hex Key • (2) Clean Container

1. CLOSE BOTH MANUAL VALVES- Using the 5/16” Spintite, turn each valve fully clockwise.

2. ENGAGE THE SAFETY STOP- Push in and turn the Safety Stop knob clockwise to place the gun in the Safety detented position.

3. INSTALL THE FEMALE QUICK DISCONNECT FITTING- Using two 6” Adjustable Wrenches install the Female Quick Disconnect Fitting on to the Air Supply Hose which is bundled withthe Chemical Supply Hoses.

NOTE:

The A (Isocyanate) and R

(Resin) hose connection

thread sizes are different,

making it virtually impossible

to improperly connect the

hoses. The, A (Isocyanate)

thread is 1/2-20, whereas the R

(Resin) thread is 9/16-18.

4. CONNECT THE CHEMICAL HOSES- Using two 6” Adjustable Wrenches connect the Aand R Chemical Hosesto the corresponding A and R Side Blocks.

5. PRESSURIZE THE CHEMICAL HOSES- Pressurize the A and R Chemical Hoses and check for leaks.

6. REMOVE THE GUN FROM THE SIDE BLOCKS- Using the 5/32” Hex Key, remove the Side Block Mounting Screws. Carefully separate each Side Block from the Gun Block.

7. BLEED AIR FROM THE CHEMICAL HOSES- Proceed as follows: a) Hold each Side Block over a separate container. b) Open each Manual Valve with the 5/16” Spintite to allowany trapped air to

escape. Bleed each side for a short time and alternate back and forth to maintain an even pressure balance until the chemical leaving the hoses is free of air.

c) Close both Manual Valves.

8. CLEAN THESIDE BLOCKS- Wipe each Side Block and its mating surfaces clean of any chemical using a rag soaked in gun cleaner.

WARNING: D

WILL PROMOTE THE COLLECTION OF DIRT CAUSING PREMATURE WEAR OF THE SIDE SEAL AND

O NOT APPLY ANY GREASE TO THE MATINGSURFACES OF SIDEBLOCK AS IT

MIXING MODULE.

9. REINSTALL THE SIDEBLOCKS ON TH E GUN BLOCK- Using the 5/32” Hex Key secure the A and R Side Blocks to the Gun Block with the two socket head cap screws. Make sure to sufficiently tighten the screws equally to prevent leakage.

10. CHECK THE PROPORTIONINGUNIT- Check the Proportioning Unit for proper hose temperature, heater temperature, and pressure.

12/6/00 11

Page 12

GAP Spray Gun

11. CONNECT THE AIR SUPPLY- Connect the Air Hose to the Quick Disconnect Fitting on the Air Supply Hose.

12. OPEN BOTH MANUAL VALVES- Using a 5/16” Spintite, turn each Manual Valve at least three

13. DISENGAGE THE SAFETY STOP- Push in and turn the Safety Stop knob counterclockwise to place the gun in the Open detented position.

14. TEST SPRAY OFF TARGET-

full turns counterclockwise.

Daily Start Up Procedure

TOOLS REQUIRED

• 5/16” Spintite

IMPORTANT: Before attempting the following procedures, make sure the Side Blocks are properly attached to the gun, the proportioning unit is at the desired temperature and pressure, and the system is ready for operation.

1. CONNECT THE AIR SUPPLY- Connect the Air Hose to the Quick Disconnect Fitting on the Air Supply Hose.

2. OPEN BOTH MANUAL VALVES- Using a 5/16” Spintite, turn each Manual Valve at least three

3. DISENGAGE THESAFETY STOP- Push in and turn the Safety Stop Knob counterclockwise to place the gun in the Open detented position.

4. TEST SPRAY OFF TARGET-

full turns counterclockwise.

Daily Shutdown Procedure

TOOLS REQUIRED

• 5/16” Spintite

IMPORTANT: Follow this procedure whenever the gun is out of service for any length of time.

1. CLOSE BOTH MANUAL VALVES- Using the 5/16” Spintite, turn each valve fully clockwise.

2. ENGAGE THE SAFETY STOP- Push in and turn the Safety Stop knob clockwise to place the gun in the Safety detented position.

3. DISCONNECT THE AIR SUPPLY- Disconnect the Air Hose from the Quick Disconnect Fitting on the Air Supply Hose.

Proceed to the Daily Maintenance Test Procedure o n page 13.

12 35943-1, Issue 5

Page 13

Operating Manual Operation

Daily Maintenance Test Procedure

TOOLS REQUIRED

• 5/16” Spintite

IMPORTANT: This procedure checks for chemical leaks caused by a damaged Mixing Chamber and/or Side Block Seal(s). Perform it at the end of the day on a daily basis after completing the Daily Shutdown Procedure.

1. OPEN BOTH MANUAL VALVES- Using a 5/16” Spintite, turn each Manual Valve at least three

2. CONNECT AND DISCONNECT THE AIR SUPPLY- Connect the Quick Disconnect Fitting to the Air Supply Hose and then disconnect it. Wait approximately 10 to 20 seconds and then reconnect the Quick Disconnect Fitting to the Air Supply Hose.

Repeat this procedure two or three times.

3. CHECK FOR LEAKAGE- Check for material purging from the tip of the gun. If there is, check the Mixing Chamber and Side Block Seals for damage.

full turns counterclockwise.

• For Mixing Chamber maintenance see the Mixing Chamber and Gun Block

Service Procedure on page 16.

• For Side Block Seal maintenance see the Side Block Service Procedure on

page 14.

4. CLEAN AS REQUIRED- See the Servicing Procedures section of this manual on Page 14.

12/6/00 13

Page 14

SERVICING PROCEDURES

Side Block Service Procedure

NOTE:

Consult the GAP Spray Gun

Parts Identification Manual

(P/N 35943-ID) for specific

Part Numbers.

GAP Spray Gun

TOOLS REQUIRED

• 5/16” Spintite • Cotton Swabs

• 5/32” Hex Key • Clean Out Drills

• 6” Adjustable Wrench • Gun Cleaner

• 1/2” Wrench • Brass Brushes

The Side Block Components consist of the following:

Figure 7. Side Block Component Removal / Installation

( R-Side Block shown )

1. PERFORM SHUTDOWN PROCEDURE- See the Daily Shutdown Procedure on

Page 12.

2. INSPECT THE SCREEN SCREW ASSEMBLIES- Using the 6” Adjustable

Wrench remove the A- Side Block Screen Assembly. Inspect the Screen Screw Seal for damage. Thoroughly rinse the Screen and dry. Inspect the Screen by holding it up to a bright light. The Screen mesh should be free of particles and varnish buildup. Replace as required. Repeat steps for R- Side Block Screen Assembly.

3. REMOVE THE GUN FROM THE SIDE BLOCKS- Using the 5/32” Hex Key,

remove the Side Block Mounting Screws. Carefully separate each Side Block from the Gun Block. If this proves difficult, try removing any dried chemical that may have accumulated. Wipe mating surfaces clean with a r ag soaked in gun cleaner.

4. REMOVETHESIDESEALASSEMBLY-Using the 1/2” Wrench, remove the

Side Seal Assembly from the Side Block.

14 35943-1, Issue 5

Page 15

Operating Manual Servicing Procedures

5. CLEAN AND INSPECT THE SIDE SEAL ASSEMBLY COMPONENTS–

Remove the Check Valve from the Side Seal Assembly. Clean the valve with gun cleaner. Inspect, and replace if damaged. Remove the Side Block Seal from the Side Seal Assembly Insert. Inspect it, and replace if damaged. Reassemble the Seal Assembly.

WARNING: DO NOT CLEAN THE PLASTIC SIDE BLOCK SEAL(S) WITHA POCKETKNIFE, RAZOR

BLADE, BRASS BRUSH, OR ANY OTHER TOOLWHICH COULD MAR OR SCRATCH THE SUFRACE.

SE A WOODEN OR PLASTIC SCRAPER TOOL INSTEAD.

6. REINSTALL THE SIDE SEAL ASSEMBLY- Thread the Side

Seal Assembly into the Side Block by hand. Using a 1/2” Wrench tighten the Side Seal Assemblyby one quarter of a full turn and No More

WARNING: TIGHTENING ANY MORE

THAN ONE QUARTER OF A FULL TURN WILL CRUSH AND DAMAGE THE SIDE SEAL ASSEMBLY AND MAY CAUSE LEAKAGE WHEN THE GUN IS PRESSURIZED

Figure 8. Tightning the Side Seal

NOTE:

RepeatSteps4,5,6,and7for

the opposite Side Block and

proceed to Step 8.

7. INSPECT THE SIDE SEAL ASSEMBLY FOR WEARAND DAMAGE– a) Inspect the Side Seal for wear by measuring how far the seal protrudes from the

Side Seal Assembly Insert. A worn Side Seal will promote chemical leakage. Replace the Side Seal if it protrudes .065” (1.65 mm) or less.

Figure 9. Side Seal Inspection

b) Inspect the Check Valve Assembly for damage by measuring the gap between

the mating surface of the Side Block and the bottom edge of the Side Seal AssemblyInsert. A gap measurement of .018” (.46 mm) or less indicates that the Check Valve Assembly has been crushed due to over tightening and must be replaced.

8. CLEAN ALL COMPONENTS THOROUGHLY-Using the appropriate Brass Brushes, Clean Out Drills, etc. remove residual chemical from the GunBlock. This is important to insure unrestricted movement of the Mixing Chamber. Use Cotton Swabs soaked with Gun Cleaner if necessary.

12/6/00 15

Page 16

GAP Spray Gun

WARNING: DO NOT APPLY ANY GREASE TO THE MATING SURFACES OF SIDE BLOCK AS IT

WILL PROMOTE THE COLLECTION OF DIRT CAUSING PREMATURE WEAR OF THE SIDE SEAL AND

MIXING MODULE.

10. PERFORM START UP PROCEDURE- See Daily Start Up Procedure on Page 12.

Mixing Chamber and Gun Block Service Procedure

TOOLS REQUIRED

• 5/16” Spintite • 6” Pliers

NOTE:

If the gun has a Round Pattern

Spray Tip, skip Step 2 and

proceed to Step 3.

NOTE:

Consult the GAP Spray Gun

Parts Identification Manual

(P/N 35943-ID) for specific

Part Numbers.

• 3/16” Open End Wrench

• Brass Brushes

(or Needle Nose Pliers)

• 5/32” Hex Key • Clean Out Drills

• 6” Adjustable Wrench • Gun Cleaner

1. PERFORM SHUTDOWN PROCEDURE- See the Daily Shutdown Procedure on Page 12.

2. REMOVE THE FLAT SPRAY TIP ASSEMBLY- Using the 6” Adjustable Wrench remove the Flat Tip Assembly from the end of the Mixing Module.

3. REMOVE AIR CAP- Remove the Air Cap from the front of the gun by turning it counter-clockwise. If necessary, use a pair of Pliers.

4. REMOVE THE GUN FROM THE SIDE BLOCKS- Using the 5/32” Hex Key, remove the Side Block Mounting Screws. Carefully separate each Side Block from the Gun Block. If this proves difficult, try removing any dried chemical that may have accumulated. Wipe mating surfaces clean with a r ag soaked in gun cleaner. If the Side Blocks require servicing see the Side Block Service Procedure on page 14.

Figure 10. Mixing Chamber and Gun Block Removal/Installation

16 35943-1, Issue 5

Page 17

Operating Manual Servicing Procedures

5. REMOVE AND SERVICE THE GUN BLOCK- Using the 5/32” Hex Key, remove the two Gun Block Mounting Screws. Slide the block away from the gun. If removal is difficult, remove anydried chemical from the gun. Wipe mating surfaces clean with a rag soaked in gun cleaner. Clean the Gun Block with gun cleaner and Brass Brushes to remove any built up foam, crystallized Isocyanate, etc. This is important to insure unrestricted movement of the Mixing Chamber.

6. REMOVE AND SERVICE THE MIXING CHAMBER- Using the 3/16” Open End Wrench or Needle Nose Pliers, hold the end of the Piston Rod. Turn the Mixing Chamber by hand counter clockwise until it comes free. Clean the Mixing Chamber with gun cleaner and clean out drills as required. Inspect it for damage, and replace if necessary.

7. REINSTALL THE MIXING CHAMBER- Using the 3/16” Open End Wrench or Needle Nose Pliers, hold the flat end of the Piston Rod. Thread the Mixing Chamber onto the end of the Piston Rod by hand.

8. REINSTALL THE GUN BLOCK- Slide the Gun Block over the Mixing Chamber and toward the gun. Using the 5/32” Hex Key, install the Gun Block Mounting Screws. Make sure to sufficiently tighten the screws equally to prevent leakage.

End Cap and Air Piston O-Ring Service Procedure

NOTE:

If only the End Cap O-Ring

and/or Safety Stop Cup Seal

requires replacing, see the

End Cap O-Ring and Safety

Stop Cup Seal Service

Procedure on page 19.

10. PERFORM START UP PROCEDURE- See Daily Start Up Procedure on Page 12.

TOOLS REQUIRED

• 5/16” Spintite • 5/32” Hex Key

• 7/64” Ball Point Hex Key • 6” Pliers

• 3/16” Open End Wrench

(or Needle Nose Pliers)

• Lubriplate Grease

• Retaining Ring Pliers

1. PERFORM SHUTDOWN PROCEDURE- See the Daily Shutdown Procedure on Page 12.

2. REMOVE THE GUN FROM THE SIDE BLOCKS- Using the 5/32” Hex Key, remove the Side Block Mounting Screws. Carefully separate each Side Block from the Gun Block. If this proves difficult, try removing any dried chemical that may have accumulated. Wipe mating surfaces clean with a r ag soaked in gun cleaner. If the Side Blocks require servicing see the Side Block Service Procedure on page 14.

3. REMOVE THE GUN BLOCK- Using the 5/32” Hex Key, remove the Gun Block Mounting Screws. Carefully remove the Gun Block from the rest of the gun. If removal is difficult, remove anydried chemical from the gun. Wipe mating surfaces clean with a rag soaked in gun cleaner. Be sure to retain the O-Ring located between the Gun Block and Mounting Flange.

12/6/00 17

Page 18

GAP Spray Gun

4. REMOVE THE MIXING CHAMBER- Using the 3/16” Open End Wrench or Needle Nose Pliers, hold the end of the Piston Rod. Turn the Mixing Chamber by hand counter clockwise until it comes free. If chamber requires servicing, see the Mixing Chamber and Gun Block Service Procedure.

5. DISENGAGE THESAFETY STOP- Push in and turn the Safety Stop knob counterclockwise to place the gun in the Open detented position.

6. REMO VE SOCKET HEAD SCREW- Using the 7/64” Ball Point Hex Key remove the Socket Head Cap Screwfrom the rear the Air Cylinder.

NOTE:

Removing the End Cap will

require some force since the

O-Ring is tightly compressed

Figure 11. End Cap and Piston Assembly

7. REMOVE THE RETAINING RING- Using the Retaining Ring Pliers remove the Retaining Ring, which maintains the End Cap position in the Air Cylinder.

8. REMOVE THE END CAP/SAFETY STOP ASSEMBLY- Pull the Safety Stop until it, and the attached End Cap come free from the Air Cylinder. Be sure to retain the Piston Spring located inside of th e Air Cylinder.

9. INSPECT THE END CAP O-RING- Inspect the O-Ring. If damaged remove it and install a new O-Ring after lightly coating it with Lubriplate Grease.

10. REMOVE THE PISTON ASSEMBLY- Using the 6” Pliers take hold of the Piston and pull the assembly out of the Air Cylinder.

WARNING: T

REMOVING THE PISTON ASSEMBLY.

AKE CARE NOT TO DAMGE THE PISTON OR THE AIR CYLINDER WALL WHEN

11. DISASSEMBLE THE PISTON ASSEMBLY- Remove the Retainer

Ring from the Piston Assembly. Slide the Piston Shaft Assembly out from the backside of the Piston.

12. INSPECT THE O-RINGS- Inspect the O-Rings and remove if damaged. Carefully install the new O-Rings after applying Lubriplate Grease.

Figure 12. Piston Assembly

18 35943-1, Issue 5

Page 19

Operating Manual Servicing Procedures

13. REASSEMBLE THE PISTON ASSEMBLY- Slide the Piston Shaft Assembly in through the backside of the Piston, taking care not to damage the O-Rings. Install the Retainer Ring on the Piston Assembly.

14. REINSTALL THE PISTON ASSEMBLY- Insert the Piston Assembly into the Air cylinder.

15. REINSTALL THE END CAP ASSEMBLY AND PISTON SPRING- Center the Piston Spring over the raised portion of the Piston and insert the End Cap into the Air Cylinder. Press the End Cap until it moves past the undercut groove in the Air Cylinder. This groove is where the Retaining Ring nests. Maintain pressure on the End Cap, making sure the groove remains visible, and install the Retaining Ring using the Retaining Ring Pliers.

16. REINSTALL SOCKET HEAD SCREW- Using the 7/64” Ball Point Hex Key reinstall the Socket Head Cap Screw at the rear the Air Cylinder.

WARNING: INSERT THE RETAINING RING COMPLETELY INTO THE GROOVE SO THAT THE END

CAP WILL REMAIN IN THE AIR CYLINDER WHEN THE GUN HAS AIR PRESSURE APPLIED TO IT.

EEP CLEAR OF THE CAP WHEN FIRST REAPPLYING AIR PRESSURE OR TRIGGERING THE GUN

AFTER REASSEMBLY IN CASE OF IMPROPER

RETAINING RING INSTALLATION.

17. REINSTALL THE MIXING CHAMBER- Using the 3/16” Open End Wrench or Needle Nose Pliers, hold the end of the Piston Rod. Thread the Mixing Chamber onto the threaded portion of the Piston Rod by hand until it is snug.

18. REINSTALL THE GUN BLOCK- Slide the Gun Block over the Mixing Chamber and toward the gun. Using the 5/32” Hex Key, install the Gun Block Mounting Screws. Make sure to sufficiently torque the screws.

19. REINSTALL THE SIDE BLOCKS ON THE GUN BLOCK- Using the 5/32” Hex Key secure the A and R Side Blocks to the Gun Block with the two socket head cap screws. Make sure to sufficiently tighten the screws equally to prevent leakage.

20. PERFORM START UP PROCEDURE- See Daily Start Up Procedure on Page 12.

End Cap O-Ring and Safety Stop Cup Seal Service Procedure

TOOLS REQUIRED

• Retaining Ring Pliers • 6” Pliers

• 7/64” Ball Point Hex Key • 5/64” Hex Key

• 5/16” Spintite • Lubriplate Grease

• 5/32” Hex Key

1. PERFORM SHUTDOWN PROCEDURE- See the Daily Shutdown Procedure on Page 12.

12/6/00 19

Page 20

GAP Spray Gun

3. REMOVE SOCKET THE HEAD SCREW- Using the 7/64” Ball Point Hex Key remove the Socket Head Cap Screw from the rear the Air Cylinder.

4. REMOVE THE RETAINING RING- Using the Retaining Ring Pliers remove the Retaining Ring, which holds the End Cap in place in the Air Cylinder.

NOTE:

Removing the End Cap will

require some force since the

O-Ring is tightly compressed

Figure 13. End Cap Assembly

5. REMOVE THE END CAP/SAFETY STOP ASSEMBLY- Remove the End Cap and retain the Piston Spring located inside of the Air Cylinder for future use.

6. INSPECT THE END CAP O-RING- Inspect the O-Ring. If damaged remove it and install a new O-Ring after lightly coating it with Lubriplate Grease.

7. REMO VE THE SAFETY

STOP M ECHANISM-

Using the 5/64” Hex Key remove the two set screws from the Stop Knob. Slide the knob off the shaft of the Stop Pin. Retain the Shaft Spring. Pull the Stop Pin out of the End Cap.

Figure 14. Safety Stop Assembly

8. REPLACE CUP SEAL- Remove and replace the Cup Seal located in the End Cap if necessary. Lubricate the new cup seal and install it making sure to that the “cup” is facing the Air Cylinder.

9. REINSTALL THE SAFETY STOP MECHANISM- Insert the Stop Pin into the End Cap. Slide the Shaft Spring and Stop Knob onto the shaft of the Stop Pin. Using the 5/64” Hex Keyreinstall the two set screws in the Stop Knob. Make sure the knob is secure.

20 35943-1, Issue 5

Page 21

Operating Manual Servicing Procedures

10. REINSTALL THE END CAP/SAFETY STOP ASSEMBLY- Center the Piston Spring over the raised portion of the Piston. Line up the raised portion of the End Cap with the inside diameter of the Piston Spring and insert the End Cap into the Air Cylinder. Press the End Cap until it moves past the undercut groove in the Air Cylinder. This groove is where the Retaining Ring nests. Maintain force on the End Cap, m aking sure the groove remains visible, and install the Retaining Ring using the Retaining Ring Pliers.

11. REINSTALL SOCKET HEAD SCREW- Using the 7/64” Ball Point Hex Key reinstall the Socket Head Cap Screw at the rear the Air Cylinder.

WARNING: INSERT THE RETAINING RING COMPLETELY INTO THE GROOVE SO THAT THE END

CAP WILL REMAIN IN THE AIR CYLINDER WHEN THE GUN HAS AIR PRESSURE APPLIED TO IT.

EEP CLEAR OF THE CAP WHEN FIRST REAPPLYING AIR PRESSURE OR TRIGGERING THE GUN

AFTER REASSEMBLY IN CASE OF IMPROPER

RETAINING RING INSTALLATION.

12. REINSTALL THE SIDEBLOCKS ON THE GUN BLOCK-Using the 5/32” Hex Key secure the A and R Side Blocks to the Gun Block with the two socket head cap screws. Make sure to sufficiently tighten the screws equally to prevent leakage.

13. PERFORM START UP PROCEDURE- See Daily Start Up Procedure on Page 12.

Trigger Valve O-Ring Procedure

NOTE:

Guns configured with the air

supply connected to the rear

of the Gun, as opposed to the

base of the Gun Handle,

require removal of the Air

Hose and Pipe Nipple using a

6” Adjustable Wrench.

TOOLS REQUIRED

• 5/32” Hex Key • Lubriplate Grease

• 6” Adjustable Wrench • Pin Punch, 1/4” diameter or less

• 6” Pliers • Ball Peen Hammer

• 5/16” Spintite • Gun Cleaner

• 3/16” Hex Key • Clean Rags

1. PERFORM SHUTDOWN PROCEDURE- See the Daily Shutdown Procedure on Page 12.

2. REMOVE THE GUN FROM THE SIDE BLOCKS- Using the 5/32” Hex Key, remove the Side Block Mounting Screws. Carefully remove each Side Block from the Gun Block. If removal is difficult, remove any dried chemical from the gun. Wipe mating surfaces clean with a rag soaked in gun cleaner. If the Side Blocks require servicing see the Side Block Service Procedure on page 14.

3. REMO VE THE 1/8” PIPE PLUG FROM THE GUN- Using the 3/16“ Hex Key remove the 1/8” Pipe Plug from the gun.

4. REMOVE TRIGGER LEVER- Using the 6” Adjustable Wrench and the 6” Pliers remove the Screw and Locknut that hold the Trigger Lever in place. Remove the Trigger Lever.

12/6/00 21

Page 22

GAP Spray Gun

Figure 15. Trigger/Air Valve Assembly

5. REMOVE VALVE RETAINERNUT- Using the 6” Adjustable Wrench, remove the Valve Retainer Nut. This is the hex shaped nut that surrounds the brass Valve Spool and holds it in place.

NOTE:

Follow Steps 9 through 16 to

replace the O-rings on the Valve Liner. If they do not

need replacing go to Step 18.

6. REMOVE THE VALVE SPOOL- Using the 6” Pliers take hold of the end of the Valve Spool and remove it from the gun. A spring will come out with it. Make sure not to loose this spring as it belongsin the hole at the end of the Spool.

7. REPLACE THE O-RINGS- If necessary, replace the O-Rings on the Valve Spool after applying a thin coat of Lubriplate Grease to them.

8. REMOVE THE VALVE LINER- Attempt to pull the Valve Liner out of the gun handle through the trigger hole. If successful, proceed to Step 11. If unsuccessful, proceed to Step 9.

9. REMO VE THE REAR INTERNAL 1/16” PIPE PLUG- Deeper in the hole from which the 1/8” Pipe Plug(or Air Hose) was removed, locate the 1/16” Pipe Plug. Remove this Plug using the 5/32” Hex Key.

10. REMOVE THE SPRING SEAT- Looking into the hole from which both Plugs were removed the brass surface of the Spring Seat can be seen. Using the Pin Punch of ¼” diameter or less, and the Ball Peen Hammer, gently tap the Spring Seat until both it and the Valve Liner are pushed out the opposite end of the hole.

11. REMOVE & REPLACE THE O-RINGS- Remove and replace the four O-Rings on the Valve Liner. Apply a light coat of Lubriplate Grease to the O-Rings.

12. CLEAN THE VALVE HOLE AND REMOVE ANY DEBRIS- After insuring hole is free of any debris apply a thin coat of Lubriplate to the inside of the hole.

13. REINSTALL THE SPRING SEAT- Slide the brass Spring Seat back into the Gun Handle Air Valve hole tapered end first until it bottoms out in the hole.

22 35943-1, Issue 5

Page 23

Operating Manual Servicing Procedures

14. REINSTALL THE VALVE LINER- Push in the brown Valve Liner as far as it will go. Some resistance is normal, as there is interference between the O-rings on the Valve Liner and the inside diameter of the hole. Push it in until two or three internal threads in the hole are visible. These threads allow engagement of the Valve Retainer Nut which when screwed in, will align the Valve Liner and Spool to their proper depth.

NOTE:

If removing the Pipe Plug(s)or

Air Hose was not necessary,

skip Steps 15 and 16.

NOTE:

Guns configured with the air

supply connected to the rear

of the Gun, as opposed to the

base of the Gun Handle,

require reinstallation of the Air

Hose and Pipe Nipple using a

6” Adjustable Wrench.

15. REINSTALL THE 1/16” PLUG- Using the 5/32” HexKey thread the 1/16” Pipe plug back in place. Apply a small amount of pipe thread sealant to the threads prior to insertion. This helps seal the threads and prevent air leaks.

16. REINSTALL THE 1/8” PIPE PLUG- Using the 3/16“ Hex Key reinstall the 1/8” Pipe Plug in the gun.

17. REINSTALL THE VALVE SPOOL- Insert the Valve Spool, with the Valve Spool Spring in place into the Valve Liner. Screw in the Valve Retainer Nut. Be careful not to over tighten it, just tighten until it is “snug”.

18. REASSEMBLE THE TRIGGER LEVER- Reinstall the Trigger Lever using the Screw and Lock Nut. Tighten using the 6” Adjustable Wrench and the 6”Pliers.

20. PERFORM STARTUPPROCEDURE-SeeDailyStartUp Procedure onPage12.

12/6/00 23

Page 24

AIR PASSAGE DIAGRAMS

NOTE:

Be sure to use thread

sealant when reinstalling

any threaded components

removed from the gun. In

addition, all sets crews should

be reinstalled flush

to the outside surface of the

gun handle.

GAP Spray Gun

Figure 16. Air Cylinder Air Passages

Figure 17. Handle Air Passages

24 35943-1, Issue 5

Page 25

Operating Manual Appendix

APPENDIX

Specifications

Technical Data US Metric

Maximum Output:

Maximum Operating

Pressure:

Air Supply

Weight:

Dimensions:

40 lbs./min 18 kg/min

3000 psi 207 bar

100-125 psi 7-9 bar

2.34 lbs. 1.06 kg

H=7"/W=7"/D=4.4" H=17.8cm/W=17.8cm/D=11.2cm

12/6/00 25

Page 26

NOTES

GAP Spray Gun

26 35943-1, Issue 5

Page 27

Operating Manual Instruction Manual Discrepancy Report

INSTRUCTION MANUAL DISCREPANCY REPORT

Field

Number

1Date

Name

IM Number

Issue Number

Date of Issue

Page Number

Discrepancy

Field Title Description

Instructions:

Complete the above fields of the form by following the instructions listed on the reverse side of this sheet and mail to:

Gusmer Corporation One Gusmer Drive PO Box 2055 Lakewood, NJ 08701

12/6/00 27

Page 28

GAP Spray Gun

Field

Number

Field Title Description

Date

Name

IM Number

Issue Number

Enter date report is submitted.

Enter name of person making report.

Enter the Part Number of the Instruction Manual from the title page.

Enter the Issue number of the Instruction Manual from the title page. If there is no issue number, enter NONE.

Date of Issue

Enter the date of Issue of the Instruction Manual from the title page. If there is no issue date, enter NONE.

Page Number

Discrepancy

Enter the page number containing the discrepancy

Provide a brief description of discrepancy

NOTE: You may send a marked copy of the page as an attachment to your submittal.

28 35943-1, Issue 5