Model D Spray Gun. Operating Manual 2943J-1-D. November 3, 2003 Issue 3 GUSMER CORPORATION

Transcription

1 Model D Spray Gun Operating Manual 2943J-1-D November 3, 2003 Issue 3 GUSMER CORPORATION A Subsidiary of Gusmer Machinery Group, Inc. One Gusmer Drive Lakewood, New Jersey, USA Toll Free (USA & Canada) Phone: (732) Fax: (732) Copyright 2003, GUSMER CORPORATION NOTICE: This manual contains important information about your GUSMER equipment. Read and retain for future reference.

2 Model D 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: FOR-GSMR ( ) 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 for a particular circumstance or application J-1-D, Issue 3

3 Operating Manual Contents CONTENTS LIST OF FIGURES...4 WARRANTY...5 GENERAL SAFETY INFORMATION...6 ACCEPTABLE EQUIPMENT USES...6 OPERATIONAL SAFETY PROCEDURES...7 DESCRIPTION...8 GUN SERVICE KITS...9 SPECIFICATIONS...10 OPERATION...11 COUPLING BLOCK...11 Manual Valves...11 Installation and Removal...12 AIR HOSE CONNECTION...12 AIR CAP ADJUSTMENT VALVE...13 FELT WIPER...13 VALVING ROD ADJUSTMENT SCREW...13 INITIAL SET UP PROCEDURE...14 DAILY START-UP PROCEDURE...15 DAILY SHUTDOWN PROCEDURE...15 SPRAY PATTERN ADJUSTMENT...16 CLEANING PROCEDURE...19 SERVICING PROCEDURES...21 FILTER SCREEN REMOVAL AND SERVICE...21 CLEANING INJECTION SLOTS...22 VALVING ROD ADJUSTMENT (CLOSED POSITION)...23 CENTERLINE COMPONENT REMOVAL...25 CENTERLINE COMPONENT INSTALLATION...28 APPENDIX...30 STANDARD MIXING CHAMBERS...30 INSTRUCTION MANUAL DISCREPANCY REPORT /3/03 3

4 Model D Spray Gun LIST OF FIGURES FIGURE 1. MAJOR COMPONENTS...8 FIGURE 2. CENTERLINE COMPONENTS...8 FIGURE 3. 1-QUART GUN SERVICE KIT (P/N OP205)...9 FIGURE 4. 3-GALLON GUN SERVICE KIT (P/N OP206)...9 FIGURE 5. MANUAL VALVES...11 FIGURE 6. COUPLING BLOCK...12 FIGURE 7. AIR HOSE CONNECTION...12 FIGURE 8. AIR VALVE ADJUSTMENT...13 FIGURE 9. FELT WIPER...13 FIGURE 10. VALVING ROD ADJUSTMENT SCREW...13 FIGURE 11. VALVING ROD (CLOSED POSITION)...14 FIGURE 12. VALVING ROD (CLOSED POSITION)...16 FIGURE 13. POINT OF VALVING...16 FIGURE 14. OPENING THE SPRAY PATTERN...17 FIGURE 15. DESIRED PATTERN...17 FIGURE 16. SPLIT PATTERN...18 FIGURE 17. FILTER SCREEN ASSEMBLY...21 FIGURE 18. CHECK VALVES...22 FIGURE 19. VALVING ROD (CLOSED POSITION)...23 FIGURE 20. RETAINER CASE REMOVAL...23 FIGURE 21. VALVING ROD REMOVAL...23 FIGURE 22. CENTERLINE COMPONENTS...25 FIGURE 23. MIXING CHAMBER REMOVAL...26 FIGURE 24. CHECK VALVE...26 FIGURE 25. SLEEVE REMOVAL BLOCK...27 FIGURE 26. MIXING CHAMBER INSERTION...28 FIGURE 27. CHAMBER POSITIONING...28 FIGURE 28. CHAMBER SEATING J-1-D, Issue 3

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 warranty 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. For such Product, a written estimate will be submitted to the Customer at a nominal service charge, itemizing the cost for repair. Disposition of Product will 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 REPLACEMENT OF, PRODUCT DEFECTIVE IN MATERIAL OR WORKMANSHIP SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUSMER OBLIGATIONS TO CUSTOMER. NO OTHER WARRANTY, EXPRESS OR IMPLIED ON ANY PRODUCT IT MANUFACTURES AND/OR SELLS, WILL BE RECOGNIZED BY GUSMER UNLESS SAID WARRANTY IS IN WRITING AND APPROVED 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 injury or 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, express or implied. Gusmer through the sale, lease, or rental of Product in no way expresses or implies a license for the use of, nor encourages the infringement of any patents or licenses. To ensure proper validation of your warranty, please complete the warranty card and return it to Gusmer within two weeks of receipt of equipment. Revised 09/02 11/3/03 5

6 Model D Spray Gun GENERAL SAFETY INFORMATION It is necessary to understand and follow the instructions in this manual to ensure 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 may result 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 generally applicable to the safe and efficient use of the equipment. Acceptable Equipment Uses The equipment is designed for the dispensing of polyurethane foams, two-component coating systems such as polyureas, and some two-component epoxy systems. 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 in this equipment. Any use of this equipment other than as indicated above constitutes misuse unless express written approval is obtained from GUSMER. Your Gusmer equipment incorporates design parameters, features, and functionality developed in over 40 years of plural component equipment design and manufacture. It is manufactured under the stringent standards of ISO 9001, and is backed by the Gusmer Warranty included herein. The use of genuine Gusmer replacement parts is recommended for your equipment. Substitution of parts not designed, manufactured, or recommended by Gusmer may result in reduced performance of, and/or damage to, your Gusmer equipment. Any alterations to, or substitutions for, genuine Gusmer parts shall void the provisions of the Gusmer Warranty J-1-D, Issue 3

7 Operating Manual General Safety Information Operational Safety Procedures This safety information will not be repeated in the text of this manual. The symbols pertaining to this information will appear where appropriate to alert the operator to potential hazards. Solvents and Chemicals WARNING: THE SOLVENTS AND CHEMICALS USED WITH THIS EQUIPMENT EXPOSE THE OPERATOR TO CERTAIN HAZARDS. ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BE TAKEN SO AS TO AVOID EXCEEDING THE THRESHOLD LIMIT VALUE (TLV) OF THE PRODUCTS BEING USED, AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) OR OTHER QUALIFIED AGENCY. OBTAIN INFORMATION CONCERNING PERSONAL PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH SOLVENTS AND CHEMICALS. High Voltage WARNING: TO PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK, NEVER OPEN THE ELECTRIC CONSOLES OR OTHERWISE SERVICE THIS EQUIPMENT AND/OR EQUIPMENT USED WITH IT BEFORE SWITCHING OFF THE MAIN POWER DISCONNECT AND SHUTTING OFF AND LOCKING OUT SUPPLY 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 AND CHEMICAL COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI. TO AVOID SERIOUS BODILY INJURY FROM EJECTION OF FLUID, NEVER OPEN OR SERVICE ANY CONNECTIONS OR COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO. Personal Protective Equipment WARNING: TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR, APPROPRIATE FOR THE TASK BEING ACCOMPLISHED, MUST BE WORN WHEN OPERATING, SERVICING, OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS EQUIPMENT. THIS INCLUDES, BUT IS NOT LIMITED TO, EYE AND FACE PROTECTION, GLOVES, SAFETY SHOES, AND RESPIRATORY EQUIPMENT AS REQUIRED TO PROVIDE PERSONAL PROTECTION FROM SOLVENTS AND CHEMICALS; HIGH PRESSURE RELEASES; HIGH TEMPERATURES; ELECTRIC SHOCK; AND OTHER HAZARDS ASSOCIATED WITH HYDRAULIC/ELECTRO-MECHANICAL EQUIPMENT. REFER TO THE APPROPRIATE WARNINGS ON THIS PAGE FOR FURTHER INFORMATION. High Temperature WARNING: THIS EQUIPMENT HAS, OR IS USED WITH EQUIPMENT THAT HAS, HIGH TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES. TO PREVENT SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL, NEVER ATTEMPT TO SERVICE THE EQUIPMENT BEFORE ALLOWING IT TO COOL. WARNING: FAILURE TO READ AND FOLLOW THE INFORMATION ASSOCIATED WITH THIS SYMBOL MAY RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT. Warning 11/3/03 7

8 Model D Spray Gun DESCRIPTION In order to gain a thorough understanding of the Model D Spray Gun, please take time to become familiar with its Major Components (see Figure 1) and its Centerline Components (see Figure 2). This will be helpful later when these items are covered in the manual. See Model D Spray Gun Parts Identification Manual (P/N 2943J-ID) for complete part number information. Figure 1. Major Components Figure 2. Centerline Components J-1-D, Issue 3

9 Operating Manual Operation Gun Service Kits Cleaning the Model D Spray Gun with the 1-Quart Gun Service Kit (P/N OP205) or the 3-Gallon Gun Service Kit (P/N OP206) is essential to its proper operation. Both kits are available separately. Figure 3. 1-Quart Gun Service Kit (P/N OP205) See 1-Quart Gun Service Kit Parts Identification Manual (P/N OP205-ID) for complete part number information. Figure 4. 3-Gallon Gun Service Kit (P/N OP206) See 3-Gallon Gun Service Kit Parts Identification Manual (P/N OP206-ID) for complete part number information. 11/3/03 9

10 Model D Spray Gun SPECIFICATIONS AIR SUPPLY: WEIGHT: DIMENSIONS: OPERATING PRESSURE: psi (6-7.5 bars) 3 lbs (1.4 kilograms) Height: 8 inches (20 centimeters) Length: 9.25 inches (24 centimeters) Width (without coupling block): 2.4 inches (6 centimeters) 1000 psi maximum (70 bars) OUTPUT: Maximum: 16 lbs./min. (7.3 kg/min) * Minimum: 2 lbs./min. (.9 kg/min) * MIXING: Internal direct impingement, airless atomization, solvent-free, mechanically selfcleaning. *Theoretical: actual results will vary with operating conditions J-1-D, Issue 3

11 Operating Manual Operation OPERATION WARNING: BODILY INJURY AND/OR PROPERTY DAMAGE MAY RESULT FROM ACCIDENTAL OPERATION OF THE GUN. DO NOT POINT THE GUN AT OR NEAR OTHER PERSONNEL OR PLACE ANY PART OF THE BODY IN THE PATH OF THE MATERIAL SPRAY. DO NOT AT ANY TIME LOOK INTO THE DISPENSING END OF THE GUN. ALWAYS CLOSE BOTH MANUAL VALVES AND DISCONNECT THE AIR SOURCE WHEN THE GUN IS NOT IN USE. Please familiarize yourself fully with the following procedures, which are required for proper set-up, operation and servicing of this gun, and which will be referred to frequently throughout this manual. Coupling Block The chemical hoses are joined to the gun block by a coupling block to ease installation and removal of the gun. MANUAL VALVES Two manual valves located on the coupling block control the flow of each chemical component to the gun. TOOLS REQUIRED 5/16 Nut driver NOTE: Triggering of the gun with the manual valves closed may cause crossover if there is any residual chemical in the gun ports. 1. TO OPEN MANUAL VALVE- Using the 5/16 nut driver, turn manual valve clockwise approximately three full turns. WARNING: NEVER OPEN A MANUAL VALVE UNLESS THE COUPLING BLOCK IS SECURED TO THE GUN, OR THE EXIT PORT IS DIRECTED INTO A SUITABLE CONTAINER. Figure 5. Manual Valves 2. TO CLOSE MANUAL VALVE- Using the 5/16 nut driver, turn manual valve fully counterclockwise. WARNING: TO PREVENT ACCIDENTAL GUN OPERATION, ALWAYS DISCONNECT THE AIR SUPPLY BEFORE SERVICING THE GUN, OR ANY TIME THE GUN IS NOT IN USE. 11/3/03 11

12 Model D Spray Gun INSTALLATION AND REMOVAL WARNING: TO PREVENT THE RELEASE OF PRESSURIZED CHEMICAL, CLOSE BOTH MANUAL VALVES COMPLETELY BEFORE ATTEMPTING TO REMOVE COUPLING BLOCK. TOOLS REQUIRED 5/16 Nut driver 1. TO INSTALL THE COUPLING BLOCK TO THE GUN: a) Inspect coupling block gaskets for nicks, damage and wear. Replace if necessary. b) With gaskets in place, fit the coupling block to the gun block. c) Insert the coupling block mounting screw and tighten securely into the gun block with the 5/16 nut driver. 2. TO REMOVE THE COUPLING BLOCK FROM THE GUN: a) Disconnect the air hose. b) Close both manual valves. c) Remove the coupling block mounting screw. Figure 6. Coupling Block d) Separate the coupling block from the gun. Take care not to lose the two gaskets. e) Using a clean cloth dipped in gun cleaner, wipe clean the mating surface of the gun block and coupling block to remove residual chemical. Air Hose Connection Compressed air is delivered to the gun by the air supply hose that is part of the heated hose assembly. The female quick-disconnect fitting on the air supply hose is coupled with the male fitting on the gun air hose. 1. TO CONNECT THE AIR HOSES- Pull back the sleeve of the female fitting, insert the male fitting and slide the sleeve forward to secure the connection. 2. TO DISCONNECT THE AIR HOSES- Pull back the sleeve of the female fitting and pull out the male fitting. Figure 7. Air Hose Connection J-1-D, Issue 3

13 Operating Manual Operation Air Cap Adjustment Valve The knurled knob inside the gun handle controls the amount of air that passes through the air cap and over the mixing chamber tip. This airflow helps keep the tip free of sprayed chemical. Too much air can adversely effect spray pattern and create undesirable amounts of overspray. Too little air can allow material build-up on the mixing chamber tip. Experiment to determine what airflow works best for the application. 1. TO OPEN THE VALVE- Turn the knob approx. 1/8 turn counterclockwise. 2. TO CLOSE THE VALVE- Turn the knob full clockwise. Figure 8. Air Valve Adjustment Felt Wiper 1. ADJUST FELT WIPER- Use the 5/16 open-end wrench to loosen the retainer case slightly. Then slowly tighten the case into the chamber by hand until it just begins to feel snug. Further tighten another 1/2 turn with the wrench. 2. SOAK FELT WIPER WITH GUN CLEANER- Insert the nozzle of the flush can into the holes of the felt wiper and saturate the felt with gun cleaner. Figure 9. Felt Wiper Valving Rod Adjustment Screw Use the valving rod adjustment screw to regulate the amount of valving rod travel when the gun trigger is depressed with air supply connected (clockwise to decrease travel, counterclockwise to increase travel). Use the 5/64 hex key wrench to loosen the friction lock. Turn the adjustment screw as required and tighten the friction lock until the screw can no longer be easily turned by hand. Check the friction lock periodically and tighten as required to prevent the screw from slipping during operation. Figure 10. Valving Rod Adjustment Screw 11/3/03 13

14 Model D Spray Gun Initial Set Up Procedure TOOLS REQUIRED 5/16 Nut driver Clean rag (2) 6 Adjustable wrench Gun cleaner 5/64 Hex key Disposable container WITH THE COUPLING BLOCK REMOVED FROM THE GUN: 1. CHECK VALVING ROD CLEARANCE IN THE CLOSED POSITION- The rod should extend approximately 1/32 inch (1mm) beyond the tip of the mixing chamber. If it does not, see Valving Rod Adjustment on page 23. Figure 11. Valving Rod (Closed Position) 2. ADJUST VALVING ROD TRAVEL TO INITIAL SETTING- Proceed as follows: a) Loosen the friction lock with the 5/64 hex key wrench, and then turn the valving rod adjustment screw fully clockwise until it stops. b) Turn the valving rod adjustment screw eleven (11) complete turns counter clockwise. 3. INSTALL THE FEMALE QUICK DISCONNECT FITTING- Using two 6 adjustable wrenches, install the female quick disconnect fitting onto the air supply hose that is bundled with the chemical supply hoses. NOTE: The thread sizes of the A (Isocyanate) and R (Resin) hose connections are different, making it virtually impossible to improperly connect the hoses. The, A (Isocyanate) thread is 1/2-20, and the R (Resin) thread is 9/ CONNECT THE CHEMICAL HOSES TO THE COUPLING BLOCK- Using two 6 adjustable wrenches, connect the A-isocyanate hose (red-taped) to the notched fitting on the coupling block. Connect R-resin hose (blue-taped) to the fitting without notches on the coupling block. 5. CLOSE BOTH MANUAL VALVES. 6. PRESSURIZE THE CHEMICAL HOSES- Pressurize the A and R chemical hoses and check for leaks. (See Proportioning Unit manual as required.) 7. BLEED AIR FROM THE CHEMICAL HOSES- Proceed as follows: a) Hold the coupling block with the exit ports pointed into a suitable container. b) Open each manual valve to allow any trapped air to escape. Bleed each side for a short time until the chemical leaving the hoses is free of air. c) Close both manual valves. 8. CLEAN THE COUPLING BLOCK- Wipe away any chemical from the coupling block and its mating surfaces using a clean cloth soaked in gun cleaner. WARNING: DO NOT APPLY ANY GREASE TO THE MATING SURFACES OF THE COUPLING BLOCK TO AVOID ACCUMULATION OF DIRT AND OTHER CONTAMINANTS IN THESE AREAS. 9. INSTALL THE COUPLING BLOCK ON THE GUN BLOCK- Proceed with the Daily Start up Procedure or Shut down procedure as required J-1-D, Issue 3

15 Operating Manual Operation Daily Start-Up Procedure TOOLS REQUIRED 5/16 Nut driver WARNING: BEFORE ATTEMPTING THE FOLLOWING PROCEDURES, MAKE SURE THE GUN IS ATTACHED TO THE COUPLING BLOCK AND AIR HOSE, THE PROPORTIONING UNIT IS AT THE DESIRED TEMPERATURE AND PRESSURE, AND THE SYSTEM IS READY FOR OPERATION. PROPERLY GROUND EQUIPMENT TO AVOID STATIC SPARKING THAT COULD RESULT IN FIRE OR EXPLOSION. 1. CONNECT THE AIR SUPPLY TO THE GUN 2. ADJUST THE AIR CAP VALVE 3. OPEN BOTH MANUAL VALVES 4. TEST SPRAY- Test spray on a disposable surface and adjust spray pattern as required. (See Spray Pattern Adjustment on page 16.) Daily Shutdown Procedure TOOLS REQUIRED 5/16 Nut driver IMPORTANT: Follow this procedure whenever the gun is to be out of service for any length of time. For mid/end of day service, see CLEANING PROCEDURE on page CLOSE BOTH MANUAL VALVES 2. DISCONNECT THE AIR SUPPLY FROM THE GUN 3. SHUT DOWN PROPORTIONING UNIT AS REQUIRED 4. CLEAN AS REQUIRED- See CLEANING PROCEDURE on page 19. IMPORTANT: Disassembling the gun daily for cleaning is not recommended if it has been operating properly. However, if the gun is removed from the coupling block, it must be flushed and cleaned thoroughly. 11/3/03 15

16 Model D Spray Gun Spray Pattern Adjustment WARNING: THE FOLLOWING PATTERN TEST MAY CREATE A LARGE MASS ( BUN ) OF URETHANE FOAM, WHICH CAN BE DANGEROUS. VERY HIGH TEMPERATURES CREATED BY CHEMICAL REACTION INSIDE A BUN MAY NOT DISSIPATE AFTER THE OUTSIDE SURFACE HAS COOLED. A LARGE BUN MAY CONTINUE TO REACT FOR SEVERAL HOURS AFTER SPRAYING UNTIL THE FLASH (BURNING) POINT OF THE FOAM IS REACHED. ALWAYS BREAK APART BUNS INTO SMALLER PIECES SO THAT HEAT INSIDE CAN ESCAPE. 1. CHECK VALVING ROD CLEARANCE IN THE CLOSED POSITION- The rod should extend approximately 1/32 inch (1mm) beyond the tip of the mixing chamber. If it does not, see Valving Rod Adjustment on page 23. Figure 12. Valving Rod (Closed Position) 2. ADJUST VALVING ROD TRAVEL TO INITIAL SETTING- Proceed as follows: a) Loosen the friction lock with the 5/64 hex key wrench, and then turn the valving rod adjustment screw fully clockwise until it stops. b) Turn the valving rod adjustment screw eleven (11) complete turns counter clockwise. 3. LOCATE THE POINT OF VALVING- Aim the gun at a disposable target. Dispense short (one second) bursts toward the target while simultaneously withdrawing the valving rod adjustment screw from the retainer case by ¼-turn increments in a counterclockwise direction. When the chemical stream mists as shown in Figure 13, the point of valving has been reached. 4. ADJUST AS SPECIFIED IN TABLE 1- Noting the position of the notch in the hex head of the adjustment screw, back the screw out counterclockwise to within the minimum and maximum number of turns specified in Table 1. Notice the spray pattern opening up as the adjustment is made (See Figure 14). Figure 13. Point of Valving J-1-D, Issue 3

17 Operating Manual TABLE 1. VALVING ROD ADJUSTMENT FOR STANDARD MIXING CHAMBERS Chamber Minimum Maximum Recommended Distance of Gun From Surface Operation Size of Pattern /2 turn 2 turns 12 in. (304-8 mm) 6 in. (152.4 mm) /2 turn 2 turns 12 in. (304-8 mm) 6 in. (152.4 mm) /4 turns 2 5/8 turns 18 to 20 in. (457.2 to 508 mm) 62 2 turns 3 turns 18 to 20 in. (457.2 to 508 mm) 70 2 turns 3 turns 18 to 20 in. (457.2 to 508 mm) 8 in. (203.2 to mm) 8 to 9 in. (203.2 to mm) 10 to 12 in. (254 to mm) turns 3 turns 24 in. (609.6 mm) 14 in. (355.6 mm) Figure 14. Opening the Spray Pattern 5. FINE TUNE THE SPRAY PATTERN-. After backing out the adjustment screw the number of turns specified in Table 1, make fine adjustments (1/8 turns or less in either direction as required) to obtain the type of pattern shown in Figure 15. Moving the screw out beyond this point may cause the pattern to split, as shown in Figure 16. If the full-round pattern cannot be achieved, check to ensure that the material temperature and spray pressure are correct. If the pattern remains closed upon reaching the maximum specified number of turns out from the point of valving, it is likely that the material temperature is too low. Figure 15. Desired Pattern 11/3/03 17

18 Model D Spray Gun If the pattern splits or has a hollow center, even with the adjustment screw at the minimum number of turns from the point of valving, it is likely that the material temperature is too high. After reaching a satisfactory spray pattern, note the temperatures at the proportioner and hose, and the position of the notch on the adjustment screw. As spraying proceeds, the pattern may occasionally start to streak or change from what was established. If this happens, inspect the chamber tip and remove any build-up of solid foam with a wooden stick or brass wire brush. Figure 16. Split Pattern If the buildup recurs shortly after cleaning the tip, remove the air cap and make sure it is clean on the inside, reinstall it, and ensure airflow to the air cap is properly set. If there was no buildup on the air cap, check for the following items in this order: a) Check the valving rod adjustment screw setting and readjust if necessary. b) Check the proportioning system for proper chemical pressures and temperature settings and readjust if necessary. (See appropriate operating manual(s) for your proportioning system.) J-1-D, Issue 3

19 Operating Manual Cleaning Procedure CLEANING PROCEDURE TOOLS REQUIRED 5/16 Nut driver 1-Quart Gun Service Kit or 3-Gallon Gun Service Kit Flush can The gun block must be thoroughly flushed with gun cleaner before removing the valving rod or mixing components from the gun block. Cleaning ensures that any residue left from the two components will be diluted, eliminating further chemical reaction of the components when the gun block components are removed. Allow the chemicals in the gun to cool before cleaning. This procedure makes use of the 1-Quart (or 3-Gallon) gun service kit and is the recommended procedure for several reasons: 1) The cleaning is more efficient and uses less gun cleaner. 2) The gun does not have to be disassembled. 3) It can be used as a quick and efficient end-of-day procedure. WARNING: PROPERLY GROUND ALL EQUIPMENT INVOLVED IN THE CLEANING OPERATION TO AVOID STATIC SPARKING, WHICH COULD RESULT IN FIRE OR EXPLOSION. DO NOT CLEAN ON OR NEAR FOAMED OR COATED SURFACES OR OTHER FLAMMABLE SURFACES OR OBJECTS. 1. CLOSE BOTH MANUAL VALVES 2. REMOVE THE GUN FROM THE COUPLING BLOCK 3. ATTACH THE SERVICE BLOCK OF THE GUN SERVICE KIT TO THE GUN Using the 5/16 nut driver; fasten the service block to the gun. Pressurize the container to 100 psi. WARNING: BODILY INJURY OR PROPERTY DAMAGE MAY RESULT IF CONTAINER IS OVER- PRESSURIZED: DO NOT PRESSURIZE ABOVE 100 PSI. 4. CLEAN THE GUN- Proceed as follows: a) Open either one of the manual valves on the service block. b) With the gun aimed into an appropriate container, trigger the gun service kit and the gun simultaneously. (A fine, unobstructed mist of cleaner should exit the tip.) c) Release both triggers and close the manual valves on the service block. d) Repeat steps a) through c) for the other side of the gun. e) After the initial cleaning, remove the air cap and flush a second time to ensure a thorough cleaning. 11/3/03 19

20 Model D Spray Gun 5. REMOVE THE SERVICE BLOCK OF THE GUN SERVICE KIT FROM THE GUN 6. DISCONNECT THE AIR SUPPLY 7. CLEAN SCREENS, CHECK VALVES AND SCREEN SCREW- (See Filter Screen Removal And Service on page 21.) IMPORTANT: Inspect the air cap, mixing chamber and gun block for build up of material and clean them as required. Do not use metal cleaning devices to clean plastic components J-1-D, Issue 3

21 Operating Manual Servicing Procedures SERVICING PROCEDURES WARNING: SHUT DOWN PROPORTIONER AND ALLOW CHEMICALS TO COOL BEFORE ATTEMPTING SERVICING PROCEDURES. Filter Screen Removal And Service TOOLS REQUIRED 5/16 Nut driver Pin vise w/collets Clean out drill assortment Flush can WARNING: PROPERLY GROUND ALL EQUIPMENT INVOLVED IN THE CLEANING OPERATION TO AVOID STATIC SPARKING, WHICH COULD RESULT IN FIRE OR EXPLOSION. DO NOT CLEAN ON OR NEAR FOAMED OR COATED SURFACES OR OTHER FLAMMABLE SURFACES OR OBJECTS. 1. PERFORM GUN CLEANING PROCEDURE- See CLEANING PROCEDURE on page REMOVE THE FILTER SCREEN ASSEMBLY- Using the 5/16 nut driver, unthread the screen mounting screw and remove it and the assembly from the gun block. Remove the screen screw retainer (the snap ring at the end of the screen screw), and remove the screen. If the screen is dirty and clogged, replace it. 3. CLEAN AND INSPECT THE SCREEN CAVITY- If any particles are visible, remove them with the clean out drills mentioned above and flush thoroughly with gun cleaner. Figure 17. Filter Screen Assembly WARNING: ANY MATERIAL LEFT IN THE CAVITY ON THE DOWNSTREAM SIDE OF THE SCREEN WILL GO DIRECTLY INTO THE MIXING CHAMBER AND CLOG IT. 4. INSPECT THE SEAL- Replace if worn or damaged. 5. REINSTALL THE FILTER SCREEN ASSEMBLY- With the seal in place, install the screen and retainer clip on the screen screw. Install the screen assembly to the gun block. Make sure the screw is tight to prevent leakage. 6. FLUSH THE GUN- Flush the gun after cleaning the cavity and screen (see CLEANING PROCEDURE on page 19). This ensures that all particles are expelled from the gun block, preventing blockage of the chamber ports. 11/3/03 21

22 Model D Spray Gun Cleaning Injection Slots The injection slots in the mixing chamber must be cleaned when dirt or material builds up in the slot, resulting in spray pattern deformation. The slots may be cleaned without disassembly of the gun as follows: 1. CLOSE BOTH MANUAL VALVES. 2. REMOVE BOTH CHECK VALVES- Loosen with the 5/16 nut driver. (See Figure 18). Inspect the parts to make sure the sleeve is still secured, and then place the check valves in separate containers of gun cleaner. 3. FLUSH CLEANOUT PORTS WITH GUN CLEANER. 4. TURN VALVING ROD ADJUSTMENT SCREW ONE (1) FULL TURN COUNTER CLOCKWISE- This ensures that the valving rod will be withdrawn completely past the injection slot for a proper cleaning. Figure 18. Check Valves 5. CLEAN MIXING CHAMBER INJECTION SLOTS- With the air supply connected to the gun, depress and hold the trigger to keep the valving rod in the open position. Insert the appropriate cleanout spade into the cleanout hole and mixing chamber slot(s). WARNING: DO NOT RELEASE THE TRIGGER WHILE THE CLEANOUT SPADE IS IN THE CHAMBER SLOT OR DAMAGE TO THE CHAMBER WILL RESULT. 6. FLUSH INJECTION SLOTS- With the valving rod in the open position, flush each injection slot with gun cleaner. Press the flush can needle firmly into the cleanout hole to create a seal. This will develop the pressure required to flush the slot. Continue until gun cleaner is spraying out of the chamber tip, indicating that the slot is clean. 7. INSPECT AND CLEAN CHECK VALVES-(See step 13 on page 26.) 8. REPLACE CHECK VALVES- Install the tall hex on the Isocyanate side, and short hex on the resin side. Tighten with the 5/16 nut driver. 9. RESET VALVING ROD ADJUSTMENT SCREW-Adjust the screw one (1) turn clockwise. Proceed to Daily Start Up procedure or disconnect and store gun as appropriate J-1-D, Issue 3

23 Operating Manual Servicing Procedures Valving Rod Adjustment (Closed Position) TOOLS REQUIRED 5/16 Nut driver 6 Adjustable Wrench WARNING: PROPERLY GROUND ALL EQUIPMENT INVOLVED IN THE CLEANING OPERATION TO AVOID STATIC SPARKING, WHICH COULD RESULT IN FIRE OR EXPLOSION. DO NOT CLEAN ON OR NEAR FOAMED OR COATED SURFACES OR OTHER FLAMMABLE SURFACES OR OBJECTS. In the closed position, the valving rod should extend approximately 1/32 inch (1mm) beyond the tip of the mixing chamber. If it does not, the valving rod positioner must be adjusted as follows: Figure 19. Valving Rod (Closed Position) 1. PERFORM GUN CLEANING PROCEDURE- See CLEANING PROCEDURE on page CLOSE BOTH MANUAL VALVES. 3. DISCONNECT THE AIR SUPPLY FROM THE GUN 4. REMOVE THE GUN FROM THE COUPLING BLOCK. 5. REMOVE SPRING RETAINER CASE- Firmly grasping the knurled knob of the spring retainer case, push in and rotate counter clockwise to remove from the air cylinder. Pull the spring out of the air cylinder. 6. LOOSEN THE FELT WIPER RETAINER- Loosen the retainer 2-3 turns (DO NOT REMOVE). Figure 20. Retainer Case Removal 7. REMOVE THE VALVING ROD- Push backward firmly on the piston rod until the end of the valving rod stop bar emerges from the cylinder. Figure 21. Valving Rod Removal 11/3/03 23

24 Model D Spray Gun 8. LOOSEN THE VALVING ROD POSITIONER- Use the 6 adjustable wrench on the positioner, while holding the valving rod stop bar with 5/16 nut driver. Turn the positioner to adjust the length of the valving rod as required. Retighten the stop bar against the positioner. 9. REPLACE VALVING ROD, SPRING AND SPRING RETAINER CASE-Grasping the knurled knob firmly, push in all the way and turn clockwise to lock in place. 10. ADJUST FELT WIPER AND SOAK WITH GUN CLEANER. 11. CONNECT THE AIR SUPPLY TO THE GUN. 12. CHECK ACTION OF VALVING ROD- With the manual valves closed, press the trigger several times and make sure the valving rod moves freely J-1-D, Issue 3

25 Operating Manual Servicing Procedures Centerline Component Removal TOOLS REQUIRED 5/16 Nut driver Adjustable wrench 5/16 x 3/8 Open-end wrench 4 oz. Ballpein hammer Mixing chamber knockout tool Check valve sleeve removal block Cleanout tools and pin vise Check valve sleeve extractor tool Razor knife Flush can The centerline components consist of the following (see Figure 22): (See also D Gun Parts Identification Manual 2943J-ID for complete part number information.) Figure 22. Centerline Components 1. PERFORM GUN CLEANING PROCEDURE- See CLEANING PROCEDURE on page REMOVE THE AIR CAP- Remove the air cap by hand by turning it counterclockwise. 3. REMOVE SCREEN SCREW ASSEMBLY-Flush and place in gun cleaner. 4. REMOVE CHECK VALVES-Flush and place them in gun cleaner. 5. FLUSH SCREEN SCREW AND CHECK VALVE PORTS. 6. REMOVE SPRING RETAINER CASE- Firmly grasping the knurled knob of the spring retainer case, push in and rotate counter clockwise to remove from the air cylinder. Pull the spring out of the air cylinder. 7. LOOSEN THE FELT WIPER RETAINER- Loosen the retainer 2-3 turns (DO NOT REMOVE). 11/3/03 25

26 Model D Spray Gun 8. REMOVE VALVING ROD- Push backward firmly on the piston rod until the end of the valving rod stop bar emerges from the cylinder. 9. REMOVE GUN BLOCK FROM FRAME- Loosen the mounting screw with the 5/16 nut driver. 10. REMOVE FELT WIPER ASSEMBLY- Unscrew the felt wiper assembly from the rear of the mixing chamber. When removing the wiper assembly, use care to keep the rear of the mixing chamber in an upright position to prevent possible loss of internal chamber parts. Make sure the brass retaining sleeve has not stuck to the felt wiper. Place the wiper assembly in gun cleaner. 11. REMOVE THE MIXING CHAMBER- Hold the gun block in one hand with the chamber tip pointing into your palm. Insert the mixing chamber knockout tool into the rear of the gun block and tap it with the 4 oz. ballpein hammer until the chamber ejects into your hand (see Figure 23). Place the chamber into a container of gun cleaner. Figure 23. Mixing Chamber Removal WARNING: THE MATCHING TAPERS ON THE MIXING CHAMBER AND CENTER HOLE IN THE GUN BLOCK ARE MACHINED TO AN EXACT FIT TO HOLD THE CHAMBER IN PLACE AND CREATE A LEAK-PROOF SEAL. WHEN HANDLING OR CLEANING THESE PARTS, BE EXTREMELY CAREFUL NOT TO MAR OR DAMAGE THE FINISH. DO NOT USE METAL TOOLS TO CLEAN THESE PARTS. 12. CLEAN THE GUN BLOCK AND INSPECT FOR DAMAGE- Remove the closure screw in the top of the block. Place the screw in gun cleaner. Clean the entire gun block using the appropriate cleanout tools, brass brushes, etc. and flush thoroughly with gun cleaner. 13. DISASSEMBLE CHECK VALVE ASSEMBLIES (See Figure 24): a) REMOVE BALL AND SPRING ASSEMBLY- Hold the ball and carefully unscrew it by turning it counterclockwise. If dirt or material build-up prevents complete removal of the spring, screw it back in, soak the assembly in gun cleaner and try to remove it again. If the ball and spring assembly cannot be removed undamaged, it will be necessary to pull it out damaged and replace it. Figure 24. Check Valve b) CLEAN INSIDE OF CLOSURE SCREW- Use the check valve cleanout drill provided in the tool kit. Insert the flattened end of the cleanout drill into the opening at the end of the screw, avoiding the spurs in the closure screw. Do not spin the drill until the flat on the drill has cleared the spurs. Spin the drill with your fingers to loosen any buildup, then remove the drill and flush out the inside of the screw with gun cleaner. Next, check the area where the ball seats for damage. Also check the sleeve for damage- it should fit tightly on the end of the screw. If there is damage or if the sleeve fits loosely, replace it J-1-D, Issue 3

27 Operating Manual Servicing Procedures The sleeve should be replaced when the check valve can be threaded all the way into the gun block by hand. A good check valve will require the use of the 5/16 nut driver to make the last 1/4 turn, compressing the sleeve. This compression is required to create an internal seal in the gun block. c) TO REMOVE DAMAGED CHECK VALVE SLEEVE-Remove the ball and spring. Insert the check valve into the check valve sleeve removal block (see Figure 25). Holding the block, and keeping pressure on the head of the check valve, slice the check valve sleeve with the razor knife at a degree angle relative to the plane of the removal block. Remove the check valve from the block and peel the sleeve off. Figure 25. Sleeve Removal Block If the check valve sleeve remains in the gun block after removing the check valve, an extractor tool has been included in the tool kit. To remove the sleeve, insert the threaded end of the tool into the cleanout port and, while pressing the tool into the gun block, turn it clockwise several times. Withdraw the tool from the gun block. The sleeve should slide out with it. d) INSTALL THE BALL AND SPRING ASSEMBLY- Check the underside of the ball. If damage or deformation is seen, use a new ball and spring assembly. Insert the assembly into the check valve and turn the screw clockwise. When the spring is fully inserted, the stem will jump over the spurs in the screw and make a clicking sound. Make sure the ball is pulled fully against the seat in the check valve. If not, remove the ball and spring assembly and install a new one. 14. REPLACE FELT WIPER- Remove the retaining ring and felt wiper from the retainer, flush the retainer with gun cleaner, insert a new felt and install the retaining ring. Loosely thread the felt wiper retainer into the rear of the mixing chamber (DO NOT TIGHTEN DOWN). If not installing to the gun block, store the assembly in its plastic vial with the corresponding cleanout spade. 11/3/03 27

28 Model D Spray Gun Centerline Component Installation TOOLS REQUIRED 5/16 Nut driver 4 oz. Ballpein hammer Mixing chamber insertion block Flush can 5/16 x 3/8 Open-end wrench 1. INSPECT GUN BLOCK AND GUN BLOCK PARTS BEFORE ASSEMBLY- All parts must be completely clean and free of damage. 2. INSTALL MIXING CHAMBER- Remove the felt wiper assembly from the rear of the mixing chamber. Make sure the internal chamber parts are in place. a) Insert the chamber into the gun block, using care to align the keyway in the chamber with the pin protruding from the top of the hole in the block (See Figure 26). b) Press the chamber into the block so that the flange is 1/32 to 1/16 inch above the face of the gun block (See Figure 27). Figure 26. Mixing Chamber Insertion 3. THREAD FELT WIPER ASSEMBLY INTO BACK OF MIXING CHAMBER- Do not tighten the felt wiper down, just turn it by hand until it seats against the internal components of the chamber. 1/32" 1/16" Figure 27. Chamber Positioning WARNING: FAILURE TO INSTALL THE FELT WIPER IN THE REAR OF THE CHAMBER WILL ALLOW INTERNAL CHAMBER PARTS TO FALL OUT WHEN THE CHAMBER IS TAPPED INTO PLACE, RENDERING THE CHAMBER USELESS. 4. TAP CHAMBER INTO PLACE- With the rear of the gun block facing the palm of your hand, place the mixing chamber insertion block over the nose of the chamber so that it rests squarely on the chamber flange. Firmly tap the insertion block with the 4 oz. ballpein hammer until the flange of the chamber is flush with the face of the gun block (see Figure 28). Figure 28. Chamber Seating J-1-D, Issue 3

29 Operating Manual Servicing Procedures 5. MOUNT GUN BLOCK ON GUN FRAME- With the O-ring in place on the underside of the gun frame, assemble the block to the frame and tighten the mounting screw using the 5/16 nut driver. 6. INSTALL VALVING ROD ASSEMBLY- If a new felt wiper is being used, push the valving rod through the felt with the retainer case off the chamber, remove the felt wiper and remove any felt buildup on the tip. Install the wiper into the rear of the chamber in the gun block, and then insert the valving rod through the piston in the air cylinder, guiding it through the center of the felt wiper retainer. Using firm pressure, carefully push the valving rod into the mixing chamber until the piston of the air cylinder bottoms out. 7. CHECK VALVING ROD CLEARANCE- The rod should extend approximately 1/32 inch (1mm) beyond the tip of the mixing chamber. If it does not, the valving rod positioner must be adjusted (see Valving Rod Adjustment (Closed Position) on page 23). 8. REPLACE VALVING ROD SPRING AND SPRING RETAINER CASE- Grasping the knurled knob firmly, push in all the way and turn clockwise to lock in place. 9. REPLACE AIR CAP. 10. REPLACE CHECK VALVES AND SCREEN SCREW ASSEMBLY. 11. REPLACE THE CLOSURE SCREW IN THE TOP OF THE GUN BLOCK. 12. MOUNT GUN ONTO COUPLING BLOCK. 13. CONNECT AIR SUPPLY TO THE GUN 14. ADJUST FELT WIPER AND SOAK FELT WITH GUN CLEANER. 15. CHECK ACTION OF VALVING ROD- With the manual valves closed, press the trigger several times and make sure the valving rod moves freely. Proceed to Daily Start Up procedure or disconnect and store gun as appropriate. 11/3/03 29

30 Model D Spray Gun APPENDIX Standard Mixing Chambers Six standard mixing chambers are available for use with the GUSMER Model D Spray Gun. Below is a general description of the use and operational performance of each chamber. Actual pattern sizes and outputs achieved may vary depending on material viscosity, hose length, condition of equipment, environment, working pressure, etc Designed for operation in confined areas and for spraying 3/8 to 1/2-in. (.7 to 1.3 cm) thicknesses. The gun may be held within 4 in. (10.2 cm) of the target without blowing away the freshly applied foam. Pattern diameter is approximately 4 in., with gun 4-in. (10.2-cm) distance from the target. Output is approximately 2 to 3-1/4 pounds/min. (.9 to 1.5 kg/min.) For the same uses as the above. The has an increased output of approximately 3 to 4-1/2 pounds/min. (1.4 to 2.0 kg/min.) Designed for stud areas of trucks and small to medium-sized wall applications. Pattern diameter is about 8 in. (20.3 cm), with gun 18 to 20 in. (45.7 to 50.8 cm) from target. Output is approximately 6 to 8 pounds/min. (2.7 to 3.6 kg/min.). 62 Widely used for large applications such as large wall surfaces, tanks, roofs, etc. Pattern diameter is about 9 in. (22.9 cm) with gun 18 to 20 in. (45.7 to 50.8 cm) from target. Output range is about 7 to 10 pounds/min. (3.2 to 4.5 kg/min.). 70 Also for large area applications. Pattern diameter is about 10 in. (25.4 cm) with gun 18 to 20 in. (45.7 to 50.8 cm) from the target. Output is approximately 9 to 12 pounds/min. (4.1 to 5.4 kg/min.) For very large area applications. Pattern diameter is about 14 in. (35.6 cm) with gun 24 in. (60.9 cm) from target. Output range is about 13-1/2 to 16-1/2 pounds/min. (6.1 to 7.5 kg/min.) J-1-D, Issue 3

31 Operating Manual Instruction Manual Discrepancy Report INSTRUCTION MANUAL DISCREPANCY REPORT Field Number 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 /3/03 31

32 Model D Spray Gun Field Number Field Title 1 Date Enter date report is submitted. Description 2 Name Enter name of person making report. 3 IM Number Enter the Part Number of the Instruction Manual from the title page. 4 Issue 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 page as an attachment to your submittal J-1-D, Issue 3