YAMADA 686427, 686428, 686429, 686430, 686431 Instruction
...
Doc. No. 100-494YO-00
INSTRUCTION
METERING GUN
MODEL. KGK-100 series
WARNING
Prior to operating this pump, be sure to read this operation manual for safety. After reading the manual, please keep it at
hand any time for your quick reference.
[Introduction]
This instruction manual contains important safety information and operational instructions.
Read this manual before installation, operation, maintenance, and repair.
Do not use the product without reading this manual. Thoroughly read and understand all of the product
information, safety information, and warning information in the manual.
If you have any questions, please contact the store you purchased the product or our business office.
[For Safe Operation]
According to the hazard level, all safety notes in this manual are classified into “DANGER”,
“WARNING”, and “CAUTION”.
Be sure to read and observe the safety notes to ensure safety and correct use of this product.
indicates a potentially hazardous situation which, if not avoided, WILL result in
death or serious injury.
indicates a potentially hazardous situation which, if not avoided, COULD result in
death or serious injury.
indicates a potentially hazardous situation which, if not avoided, could result in
injury or property damage.
DANGER
WARNING
CAUTION
－ Table of Contents －
[Introduction] ........................................................................................... 1
[For Safe Operation] ................................................................................. 1
1. Precautions on Use ............................................................................. 2
2. Product Description ............................................................................ 3
3. Principle of Operation ......................................................................... 4
4. Installation and Connection ................................................................ 5
5. Adjustment and Discharge Test ........................................................... 5
6. Troubleshooting .................................................................................. 6
7. Disassembly and Assembly .................................................................. 7
8. Product and Part List for Grease Metering Gun ................................... 9
9. Product and Part List for Adhesive Metering Gun ................................ 14
10. Limited Warranty ............................................................................... 19
1
1. Precautions on Use
The following warnings and cautions are very important. Be sure to observe them.
[Operating condition]
- For your safety, read and understand all information provided in this manual.
If you have lost or damaged your instruction manual, please contact us or our distributor to place an
order.
- Never let anyone operate this unit without understanding this manual.
[Installation and piping]
- Before maintenance operation, be sure to stop air, and release the internal pressure (both air and
material) of the product.
- Immediately stop using the product if there is any danger or defect. Be sure to eliminate the cause and
confirm safety before restarting.
- Follow the safety instructions for installation and be sure to use appropriate piping material and size to
avoid leakage and damage.
[Operating method]
CAUTION
CAUTION
WARNING
- Understand this manual completely before operating the machine.
Operators and maintenance personnel are required to read this manual thoroughly before operating or
servicing. Do not handle this machine without understanding the instructions.
- Do not handle unspecified material with this product. It may cause a product failure.
- Do not use this product for improper purposes.
- During operation, high pressure is continuously applied to the inside of the gun. Thus, even when
supply air to the gun is shut off, residual pressure may be trapped inside. Be sure to release residual
pressure completely BEFORE disassembly and repair for maintenance and inspection.
Also, be sure to stop air supply and power supply before disassembly and repair.
2
[Disassembly, maintenance and inspection]
WARNING
- Shut off air supply to the product and remove residual pressure completely BEFORE disassembling.
- Alternating the unit may result in personal injury or product malfunction. Please do not try to alter,
modify, or change the machine.
[Shutdown and storage]
- When leaving the product unused for a long time (more than a week) or shutting it down;
- remove material inside completely and wash the product and
- release material supply pressure.
CAUTION
2. Product Description
KGK metering guns are able to apply metered shots of media such as greases and adhesives. By
replacing a built-in metering cylinder, KGK metering valves cover metered shot volumes between 0.3mL
to 20mL. One metered shot is discharged by pulling the lever once and thus material will not be
discharged more than necessary.
Fig.1
Nozzle Metering Cylinder
Lever
Material Connection (Rc1/8)
Gun body
3
3. Principle of Operation
① Charge (standby)
Material, under pressure from a supply
pump, flows into the rear side of the piston
and constantly pushes the piston forward. At
the same time, material passes through Port
A, lifts up the ball to close Port B, and flows
into the metering chamber. Material in the
metering chamber pushes the piston
backward and thus a metered shot is
charged. The amount of material can be
adjusted to your desirable value with the
adjustment screw. (Fig. 2)
② Discharge
Once the lever is pulled, the piston rod
pushes down the ball to close Port A. Then,
the metering chamber is connected to the
discharge port. The piston is pushed forward
by material pressure from the rear side and
thus a metered shot in the chamber is
finally discharged. (Fig.3)
Fig.4
Fig.5
Fig.6
Adjustment screw Rod
Metering chamber
Lock nut
Port B
Port A
Three way directional valve
① Material comes from the bottom seat lifts up
the ball and flows out of the middle path. The
ball is pressed against the upper seat to close
the outlet so that material will not be
discharged from the upper side.
② The piston rod pushes the ball down. Since
the ball goes down, being sealed by the
rubber in the middle, material will not flow
out even after the ball moves away from the
upper seat.
③ Furthermore, the ball passes through the
path in the middle and seals the inlet on the
bottom seat to stop the flow of material.
Accordingly, the middle path and outlet on
the upper seat are connected and finally
material flows out.
Fig. 2
Fig. 3
4
4. Installation and Connection
① Connect a material supply pump or an outlet of a pipe to the metering gun using a hose. (The connecting port
of the gun is Rc1/8.)
It is recommended to attach 850K513 Swivel (sold separately) to the connecting port of the gun for easy
operation. (Fig.7)
② Install your metering gun as close as possible to the equipment or its inlet port you are going to work on.
③ Trapped air in material being metered will be compressed through a pump, pipe, hose, and metering gun
and expand when material is discharged. As a result, the metering gun will have difficulty stopping
discharge and thus it may seem to be leaking. Also, each shot will vary.
Since air is discharged together with material, be sure to expel trapped air completely when using the gun
for the first time and after replacing a material container.
CAUTION
- Dust and dirt, if contained in material, will damage the sealing part of the valve and cause material leak.
Be sure to keep material clean.
5. Adjustment and Discharge Test
① Supply material to the gun. The rod lifts up
the lever with material pressure and the
lever opens. At this time, if material leaks
from the nozzle, check if the lever has a
slight play back and forth at first. Then, if
the lever touches connector, loosen connector.
If material still leaks, loosen the adjustment
screw using a hex wrench until leak stops
and then tighten the locknut temporarily.
② With the lever pulled, perform a discharge
test. If a desired metered shot is discharged,
tighten the locknut. When material flows
out persistently, tighten the locknut with the
lever pulled until material flow stops.
Fig.7
Hex wrench
Adjustment screw
Lock nut
Connector
Te e
High pressure
ball valve
Material feed pump
5
- Be sure to shut off the air supply to a supply pump and set the material pressure (primary pressure) to
zero. Leaving a metering valve under pressure will be a cause of material leak or some other problem.
- Once a metered shot is dispensed, be sure to put the valve back to the standby condition.
- Do not use material which contains dirt and dust. Seal parts will be damaged, causing a material leak.
PRECAUTION FOR USE
6. Troubleshooting
<Problem>
- Material cannot be discharged.
- Material comes out during Recharge or Standby.
- Material leaks.
<Possible Cause>
Metering gun (external factor)
- Material is not being delivered.
- Material supply pressure (primary pressure)
exceeds the specified pressure of the metering gun.
- Adjustment at the initial use or after repair was
not done.
- Air inside the gun is not released.
Metering gun body
- Ball or valve seat is damaged or worn out
- O ring is damaged or worn out.
- Side ring is damaged or worn out.
- Adjustment screw is loose.
Metering cylinder
- Inner surface of cylinder is damaged or worn out.
- Outer surface of piston, packing, or sleeve is
damaged or worn out.
- O ring is damaged or worn out.
- Adjustment screw is over tightened.
<Solution>
- Check the supply pump and supply
air.
- Check air pressure in the supply
pump (primary pressure = pump
ratio × air pressure)
- Perform Adjustment and Discharge
Test on the previous section.
- Release air completely.
- Replace with new ones.
- Replace with new ones.
- Replace with new ones.
- Readjust the screw and securely
tighten it with a locknut.
- Replace with new ones.
- Replace with new ones.
- Replace with new ones.
- Adjust the adjustment screw to your
desirable shot amount and then
secure it with a locknut.
6
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