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Operating Manual

Contents

12/6/00

3

CONTENTS

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

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

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

.......................................................................................6

...............................................................................7

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

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

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..........................................................................................9

..........................................................................................10

..........................................................................................11

.......................................................................................12

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

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..........................................16

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...........................................................................21

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

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

.............................................................................................................25

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

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

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Summary of Contents for GAP

Page 1: ...ry of Gusmer Machinery Group 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 Copyright 2000 GUSMER CORPORATION http www gusmer com NOTICE This manual contains important information for your GUSMER equipment Read and retain for future reference ...

Page 2: ...e 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 n...

Page 3: ...ITIAL SET UP PROCEDURE 11 DAILY START UP PROCEDURE 12 DAILY SHUTDOWN PROCEDURE 12 DAILY MAINTENANCE TEST PROCEDURE 13 SERVICING PROCEDURES 14 SIDE BLOCK SERVICE PROCEDURE 14 MIXING CHAMBER AND GUN BLOCK SERVICE PROCEDURE 16 END CAP AND AIR PISTON O RING SERVICE PROCEDURE 17 END CAP O RING AND SAFETY STOP CUP SEAL SERVICE PROCEDURE 19 TRIGGER VALVE O RING PROCEDURE 21 AIR PASSAGE DIAGRAMS 24 APPEND...

Page 4: ...N 10 FIGURE 7 SIDE BLOCK COMPONENT REMOVAL INSTALLATION 14 FIGURE 8 TIGHTNING THE SIDE SEAL 15 FIGURE 9 SIDE SEAL INSPECTION 15 FIGURE 10 MIXING CHAMBER AND GUN BLOCK REMOVAL INSTALLATION 16 FIGURE 11 END CAP AND PISTON ASSEMBLY 18 FIGURE 12 PISTON ASSEMBLY 18 FIGURE 13 END CAP ASSEMBLY 20 FIGURE 14 SAFETY STOP ASSEMBLY 20 FIGURE 15 TRIGGER AIR VALVE ASSEMBLY 22 FIGURE 16 AIR CYLINDER AIR PASSAGES...

Page 5: ...ill be done in accordance with the 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 warranty provided 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 REPLA...

Page 6: ... 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 all inclusive and that other safety measures may not be required for specific use or application The following safety guidelines are generally app...

Page 7: ...PPLY VOLTAGE AT THE SOURCE THE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY A QUALIFIED ELECTRICIAN High Pressure WARNING THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI TO AVOID SERIOUS BODILY INJURY FROM HYDRAULIC INJECTION OF FLUID NEVER OPEN ANY HYDRAULIC CONNECTIONS OR SERVICE HYDRAULIC COMPONENTS WITHOUT BLEEDING ALL PR...

Page 8: ...familiar with the major components of the GAP Gusmer Air Purge Gun and its Front End Components Figure 1 Major Components Gun shown with Round Spray Tip 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 2 Front End Components Gun shown with Flat Spray Tip Assembly ...

Page 9: ... position Figure 3 Engage the Safety Stop IMPORTANT Always engage the Safety Stop when the gun is not in use 2 DISENGAGE THE SAFETY STOP Push in and turn the Safety Stop knob counterclockwise to place the gun in the Open detented position Figure 4 Disengage the Safety Stop Manual Valve Operation The GAP Gun Side Blocks have Manual Valves that control the flow of each chemical component to the gun ...

Page 10: ...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 REMOVE 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 inst...

Page 11: ... 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 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 allow any trapped air to escape Bleed each side for a short time a...

Page 12: ...NNECT 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 full turns counterclockwise 3 DISENGAGE THE SAFETY STOP Push in and turn the Safety Stop Knob counterclockwise to place the gun in the Open detented position 4 TEST SPRAY OFF TARGET Daily Shutdown Procedure TOOLS REQU...

Page 13: ... 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 For Mixing Ch...

Page 14: ...MBLIES 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 build up 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 ...

Page 15: ...LY AND MAY CAUSE LEAKAGE WHEN THE GUN IS PRESSURIZED Figure 8 Tightning the Side Seal 7 INSPECT THE SIDE SEAL ASSEMBLY FOR WEAR AND 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 Chec...

Page 16: ...DURE 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 NOTE If the gun has a Round Pattern Spray Tip skip Step 2 and proceed to Step 3 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 ...

Page 17: ...E 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 10 PERFORM START UP PROCEDURE See Daily Start Up Procedure on Page 12 End Cap and Air Piston O Ring Service Procedure TOOLS REQUIRED 5 16 Spintite 5 32 Hex Key 7 64 Ball Point Hex Key 6 Pliers Lu...

Page 18: ... 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 the Air Cylinder NOTE Removing the End Cap will require some force since the O Ring is tightly compressed 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...

Page 19: ...N THE AIR CYLINDER WHEN THE GUN HAS AIR PRESSURE APPLIED TO IT KEEP 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...

Page 20: ...nd retain the Piston Spring located inside of the Air Cylinder for future use NOTE Removing the End Cap will require some force since the O Ring is tightly compressed 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 REMOVE THE SAFETY STOP MECHANISM Using the 5 64 Hex Key remove the two set screws from th...

Page 21: ... 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 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 P...

Page 22: ...6 to replace the O rings on the Valve Liner If they do not need replacing go to Step 18 9 REMOVE 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 ...

Page 23: ...Steps 15 and 16 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 ...

Page 24: ...gure 16 Air Cylinder Air Passages 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 Figure 17 Handle Air Passages ...

Page 25: ...5 APPENDIX Specifications Technical Data US Metric Maximum Output 40 lbs min 18 kg min Maximum Operating Pressure 3000 psi 207 bar Air Supply 100 125 psi 7 9 bar Weight 2 34 lbs 1 06 kg Dimensions H 7 W 7 D 4 4 H 17 8cm W 17 8cm D 11 2cm ...

Page 26: ...GAP Spray Gun 26 35943 1 Issue 5 NOTES ...

Page 27: ...mber Field Title Description 1 Date 2 Name 3 IM Number 4 Issue Number 5 Date of Issue 6 Page Number 7 Discrepancy 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 ...

Page 28: ...e Number Enter the Issue number of the Instruction Manual from the title page If there is no issue number enter NONE 5 Date of Issue Enter the date of Issue of the Instruction Manual from the title page If there is no issue date enter NONE 6 Page Number Enter the page number containing the discrepancy 7 Discrepancy Provide a brief description of discrepancy NOTE You may send a marked copy of the p...

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