Service Manual Master Gun
Contents
1. Remove the side block mounting bolts on the Polyol side and carefully separate it from the gun block Clean the contact surfaces using a cloth dampened in gun cleaning solvent Unscrew the filter housing and remove the seal and the filter screen Carefully clean the filter with gun cleaning solvent and check that the mesh is completely free from contaminants Replace the filter screen as required Remove the check valve retainer from the side block Remove the plastic metal non return unit and clean it with gun cleaning solvent Replace it if damaged Remove the parts and clean with gun cleaning solvent or replace them as required Clean all of the components meticulously to eliminate the remains of product using a cloth dampened with gun cleaning solvent and a brass brush Sin tea Q SD Check Valve N Retainer w O Ring Side Seal Metallic Manual Valve Y ___ Assembly _ Spring Check Valve Swivel Fitting Assembly Metallic Sy Screen Screw Screen Screw Seal PRECAUTION Use wooden or plastic utensils or a brass brush for cleaning Do not use metal utensils that can scratch the contact surfaces 12 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual Reassemble the check valve and side seal assembly In the model with a metal seal you must fit the spring and the check valve into the retainer To facilitate assembly use a little grease to fit the o ring in2. Service Manual For better knowledge of the elements forming the MASTER series gun the main components and their description are shown For more precise identification see the Components Manual ref NR O0004 ENG 1 2 3 4 5 6 7 8 9 Gun block unit Polyol input block unit Metal sealing kit Polyol filter body Polyol manual valve lsocyanate input block unit lsocyanate filter body lsocyanate manual valve Mix chamber Trigger Diffuser Blocking device a eh O n b iY 6 20 1 5 Issue http Avwww gamapur com Ref NR 00008 ENG Service Manual INSTALLATION AND START UP PRECAUTION When working with the gun or performing maintenance work on it wear suitable protection in accordance with the recommendations and specifications provided by the product suppliers GAMA provides a series of tools and accessories KT 00013 that are necessary for assembling the gun The tool kit is made up of the following elements 49gr Tube of grease 1x BI O0009 5 16 Tube spanner 1x HT 00054 bits for cleaning 1x HT 00060 air hose supply 1x MA 00027 quick connect 1x RA 00109 adapter 1x RA 00110 Service Manual 1x NR 00008 and Parts Identification 1x NR 00004 1 Close the manual valves by turning them to the full clockwise position The manual valves control the flow of each product to the chamber and are located on the Isocyanate input block and the Polyol input block 2 Press th
3. Perform a test projection in a vessel WARNING Before performing maintenance repair or cleaning work press the safety stop and turn it clockwise to set it to the blocking position close the manual valves completely and disconnect the air supply to avoid possible accidents 8 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual SHUTDOWN PROCEDURES 1 Perform the Unit Shutdown Procedures following the method indicated in the Machine Service Manual 2 Close the manual valves of each product by turning them to the full clockwise position 3 To eliminate the pressure from the gun pull the trigger and project the gun until the projection fan starts to reduce 4 Press the safety stop and turn it clockwise to set it to the blocking position 5 Disconnect the air supply from the gun 6 Remove the cap and lubricate the mixing chamber with the grease gun supplied in the tool kit this action will prevent the cleaning air of the gun from reacting with the ISOCYANATE product and avoiding crystallization which may damage the chamber and cap Plug Grease Point NB The use of injecting lubrication into the gun at the end of the day will avoid maintenance time as it will not be necessary to remove the chamber each day to clean it PRECAUTION To avoid possible contamination by the product remains deposited in the components of the gun do not exchange the Isocyanate parts with the Polyol parts The
4. Warranty for the remainder of original Warranty Period or for three 3 months from the repair or replacement date whichever is longer No Rights Implied Nothing in the sale lease or rental of any Product by GAMA shall be construed to grant any right interest or license in or under any patent trademark copyright trade secret or other proprietary right or material owned by anyone nor does GAMA encourage the infringement of same Exclusive Warranty This writing is the final complete and exclusive expression of the Warranty covering the Product Any statements made by GAMA its employees or agents that differ from the terms of this Warranty shall have no effect It is expressly understood that Customer s acceptance of this Warranty by performance or otherwise is upon and subject solely to the terms and conditions hereof and any additional or different terms and conditions proposed or expressed by Customer or anyone whether in writing or otherwise are null and void unless specifically agreed to in writing by an Officer of GAMA 2 20 1 5 Issue Ref NR 00008 ENG http AWvwww gamapur com Service Manual SAFETY AND HANDLING This chapter contains important information on the safety handling and use of your GAMA MASTER series gun Before installing the Master gun and starting it up carefully read all the technical and safety documentation included in this manual Pay special attention to the information to know and understand the
5. accessories with the Product that have not been approved or manufactured by GAMA e Failure to follow the operating instructions and recommendations provided by GAMA e Cosmetic damage e Fire flood acts of God or other contingencies beyond the control of GAMA THE WARRANTY DESCRIBED HEREIN IS THE EXCLUSIVE REMEDY FOR THE CUSTOMER AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS IMPLIED STATUTORY OR OTHERWISE AND THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES ARE HEREBY DISCLAIMED TO THE FULLEST EXTENT PERMITTED BY LAW GAMA SHALL NOT BE RESPONSIBLE WHETHER BASED IN CONTRACT TORT INCLUDING WITHOUT LIMITATION NEGLIGENCE WARRANTY OR ANY OTHER LEGAL OR EQUITABLE GROUNDS FOR ANY CONSEQUENTIAL INDIRECT INCIDENTAL LOST PROFITS SPECIAL PUNITIVE OR EXEMPLARY DAMAGES WHETHER TO PERSON OR PROPERTY ARISING FROM OR RELATING TO THE PRODUCT EVEN IF GAMA HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH LOSSES OR DAMAGES Non Warranty Service by GAMA If GAMA determines that the suspected Defect of the Product is not covered by this Warranty disposition of the Product will be made pursuant to the terms and conditions of GAMA s written estimate on a time and materials basis Continuing Warranty for Products Repaired or Replaced under Warranty Following the repair or replacement of a Product covered by this Warranty such Product will continue to be subject to the original
6. block unit using a cloth dampened with gun cleaning solvent Remove the o ring Use a spanner to lock the end of the pneumatic cylinder shaft and unthread the mixing chamber Clean the mixing chamber and if you consider it necessary use a brush to go over the passage holes Remove the cylinder clamp Using the snap ring pliers remove the retaining ring holding the end cap Pull hard on the blocking device to remove the whole unit from the cylinder bore Also remove the spring and the piston assembly from inside the cylinder Using the snap ring pliers remove the snap ring from the piston shaft and separate it from the piston Check the state of the o rings of the shaft and piston Replace them if they are damaged Apply a little grease to facilitate the fitting Fit the piston by sliding it onto the shaft taking special care not to damage the o rings Fit the retention ring Fit the piston assembly into the cylinder bore Insert safety stop assembly into the cylinder bore until it passes the insertion groove of the retention ring Fit the retention ring using the snap ring pliers 18 20 1 5 Issue Ref NR 00008 ENG http www gamapur com Service Manual WARNING To Warranty that the cylinder block is well fitted make sure that the retention ring is perfectly fitted in the fixing groove To avoid possible errors in assembly avoid approaching the end cap when applying pressure to the gun after cleaning repair or maintenance
7. is at a complete standstill that all of the buttons and the main switch are turned off and that the unit is disconnected from the main power supply The gun is a component that works under pressure no connection must be opened or maintenance work done on components subject to pressure until the pressure has been completely eliminated Air Pipe Nipple Air Hose Supply _ O Rings Retaining Ring gt D _ Trigger Mounting Valve Spool Y Valve Retainer Nut Quick Connect f chang Air Supply Valve Spring Trigger Lever 200P Remove the side blocks and carefully separate them from the gun block Clean the contact surfaces using a cloth dampened in gun cleaning solvent Disconnect the air hose supply with the quick connect Unscrew the trigger stop bolt Remove the retention ring and extract the pin holding the trigger Unscrew the nut of the trigger valve Remove the trigger shaft and hold it carefully for the end with a few pliers to extract it from the hole The trigger shaft has a spring in the base Make sure you do not lose it Check the o rings of the trigger shaft Replace them if they are damaged Apply a little grease to make assembly easier 14 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual Verify that the accommodation of the trigger shaft is free of dirt and wall light a small fat layer in his interior Mount the air hose in the rear part of the gun using
8. the metal seal cap make sure that it is not damaged and replace it if necessary Press the metal seal cap into the retainer until the o ring is fitted in its groove Hand tighten the metal seal and retainer into the side block If you use a spanner do not over tighten the retainer more than 1 4 of a turn PRECAUTION Do not tighten the check valve retainer excessively Tightening more than 1 4 of a turn can damage the plastic metal check valve and cause leaks Check the wear on the metal seal by measuring the distance that it stands out from the cap housing If the seal is worn knocked or scratched it can cause leaks Replace the seal if it stands out less than 1 65 mm 1 16 inch To check whether the metal check valve is damaged as a result of excessive tightening make sure the separation between the support face of the side block and the bottom of the cap housing once fitted is 0 46 mm 1 64 inch If the separation is smaller the check valve must be replaced Assemble the screen screw and screw it into the side block Fix the Polyol side block onto to the gun block with the corresponding bolts Tighten alternately to avoid possible leaks Perform the same steps with the side block on the Isocyanate side The gun is now ready for service 13 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Annie Service Manual Trigger and valve WARNING Before performing maintenance work on the gun make sure that the unit
9. Aft Service Manual Spray Gun Series Master 1 5 Issue 7 18 2013 Ref NR 00008 ENG Before installing the Master Gun and starting it up carefully read all the technical and safety documentation included in this manual Pay special attention to the information to know and understand the operation and the conditions of use of the gun All of the information is aimed at enhancing User Safety and avoiding possible breakdowns derived from the incorrect use of the Gun Service Manual WARRANTY GARRAF MAQUINARIA S A hereinafter GAMA provides this LIMITED WARRANTY hereinafter Warranty to the original purchaser hereinafter Customer covering this equipment and the original GAMA manufactured accessories delivered with the equipment hereinafter Product against defects in material or workmanship of the Product hereinafter Defect or Defective for a period of two 2 years from the date of first purchase as shown on the original GAMA invoice hereinafter Warranty Period If during the Warranty Period under normal use the Product is suspected by Customer to be Defective in material or workmanship it is Customer s responsibility to contact GAMA and return the Product to GAMA as directed by GAMA freight prepaid If GAMA determines that the Product is Defective and that such Defect is covered by this Warranty GAMA will credit Customer for the reasonable freight charges incurre
10. d by Customer in returning the Defective Product to GAMA and GAMA or its authorized agent will at GAMA s option repair or replace the Product subject to the following Original Invoice The original invoice must be kept as proof of the date of first sale and the Product serial number The Warranty does not cover any Product if the Original Invoice appears to have been modified or altered or when the serial number on the Product appears to have been altered or defaced Product Maintenance It is the Customer s responsibility to maintain the Product properly See your maintenance schedule and owner s manual for details The Warranty does not cover an improperly maintained Product Non GAMA Components and Accessories Non GAMA manufactured components and accessories that are used in the operation of the Product are not covered by this Warranty Such components and accessories shall be subject to the warranty offered to the Customer if any by the original manufacturer of such component or accessory Other Warranty Exclusions The Warranty does not cover any Product that GAMA determines has been damaged or fails to operate properly due to misuse negligence abuse carelessness neglect or accident By way of example only this includes Normal wear an tear e Improper or unauthorized installation repair alteration adjustment or modification of the Product Use of heating devices pumping equipment dispensers or other parts or
11. d carefully separate them from the gun block Clean the contact surfaces with a cloth dampened in gun cleaning solvent Unscrew the bolt fixing the clamp on the rear of the gun Remove the retaining ring from the cylinder using the snap ring pliers Pull hard on the safety stop to remove the whole unit from the cylinder Also remove the plunger spring Check the state of the o ring seal on the end cap Replace it if it is damaged Apply a little grease to facilitate the placement of the o ring Loosen the two set screws on the safety stop Remove the stop pin and the stop spring from the device Remove the end cap from the stop pin Remove the lip seal from the end cap and replace it if it is damaged Apply a little grease to facilitate the fitting Pay attention to the correct installation of the lip seal The seal lips must face forward Fit the end cap onto the stop pin Slide the spring and the safety stop onto the stop pin Tighten the two set screws making sure that they are perfectly aligned with the flats on the end of the stop pin Make sure that the blocking device is well fitted Insert the spring in the rear housing of the plunger Insert the end cap into the cylinder bore by pressing until it passes the insertion groove of the retention ring Fit the retention ring using snap ring pliers 16 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual WARNING To assure that the end cap is well fitted mak
12. e sure that the retention ring is perfectly fitted in the fixing groove To avoid possible errors in assembly avoid approaching the cylinder block when applying pressure to the gun after cleaning repair or maintenance operations Fit the clamp and fix it with the bolt to the rear of the gun Fix the side blocks to the gun block with the corresponding bolts Tighten alternately to avoid possible leaks The gun is now ready for service 17 20 1 5 Issue http AWwww gamapur com Ref NR 00008 ENG KaLa Service Manual Pneumatic cylinder WARNING Before performing maintenance work on the gun make sure that the unit is at a complete standstill that all of the buttons and the main switch are turned off and that the unit is disconnected from the main power supply The gun is a component that works under pressure no connection must be opened or maintenance work done on components subject to pressure until the pressure has been completely eliminated Mixing Chamber Retainer Ring Piston Piston Assembly Piston Shaft Piston Spring P End Cap a Safety Stop at l Piston O Ring Assembly i Piston Shaft d O Ring Cap Screw Cylinder Clamp Retaining Ring Unscrew the air cap Remove the side blocks from the gun block Clean the contact surfaces using a cloth dampened with gun cleaning solvent Remove the gun block from the gun by sliding it over the chamber To eliminate the remains of product clean the gun
13. e safety stop and turn it clockwise to set it to the blocking position 3 Fit the air supply pipe and connect it to the connector on the rear of the gun 4 Connect the lsocyanate hose red terminal to the connection on the lsocyanate input block letter A 5 Connect the Polyol hose blue terminal to the connection on the Polyol input block letter R NB The product hoses are identified in red and blue allowing the user to rapidly recognise them The red corresponds to the Isocyanate hose and the blue to the Polyol hose To avoid connection errors the coupling connections of the Isocyanate and Polyol hoses are different sizes which makes it impossible to swap connections 6 Connect the air supply to the gun Product Manual Valve Blocking Device Air Supply Connector Product Inlet Connector Air Hose Supply Quick Connect Air Supply 7 Pressurise the gun and make sure there are no leaks 8 Pull the trigger several times to check the correct movement of the mixing chamber 9 Check that the pressure in the machine and the temperature of the heaters and the hoses is correct see the Machine Service Manual 10 Open the manual valves of each product by turning them to the full counter clockwise position 7 20 1 5 Issue Ref NR 00008 ENG http www gamapur com Service Manual 11 Press the safety stop and turn it counter clockwise to set it to the spray position 12
14. gun has the Isocyanate side identified with the letter A If the product hoses maintain the pressure follow the Standstill Method indicated in the Machine Service Manual To eliminate the pressure from the hoses with the gun removed fit the product input blocks in a suitable container keep a reasonable distance away and very carefully and very slowly open the manual valves Under pressure the product will come out of the side of the blocks 9 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual MAINTENANCE To obtain maximum output from your MASTER gun it is necessary to periodically perform certain maintenance operations 10 20 To prevent possible injury caused by incorrect handling of the raw materials and solvents used in the process carefully read the safety data sheet provided by your supplier Deal with the waste caused according to current regulations To prevent serious damage caused by the impact of pressurised fluids never open a connection or perform maintenance work on components subject to pressure until all pressure has been eliminated Use suitable protection when operating maintaining or being present in the area where the equipment is functioning This includes but is not limited to the use of protective goggles gloves shoes and safety clothing and breathing equipment The equipment includes components that reach high temperatures and can cause burns Hot parts of the equi
15. ing it over the chamber To eliminate the residual product clean the gun block unit using a cloth dampened with gun cleaning solvent and a brass brush Remove the o ring Use a spanner to lock the end of the pneumatic cylinder shaft and unthread the mixing chamber Clean the mix chamber and if necessary use a brush to go over the product passage holes Make sure that the chamber is not scratched or marked Replace the chamber if there are any small faults screw the chamber back onto the end of the pneumatic cylinder shaft Fit the gun block unit by sliding it over the chamber and fix it to the gun with the bolts Make sure to fit the o ring between the block and the fixing plate Replace the o ring if it is damaged Tighten alternately to avoid possible leaks Fit the side blocks to the gun block with the corresponding bolts Tighten alternately to avoid possible leaks Screw on the Air Cap The gun is now ready for service 11 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual Side block unit WARNING Before performing maintenance work on the gun make sure that the unit is at a complete standstill that all of the buttons and the main switch are turned off and that the unit is disconnected from the main power supply The gun is a component that works under pressure no connection must be opened and no maintenance work must be done on components subject to pressure until the pressure has been completely eliminated
16. lly explosive atmospheres or the pressure and temperature limits described in the technical specifications of this manual to be exceeded Always use liquids and solvents that are compatible with the unit In the event of doubt consult the GAMA technical service 3 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual When working with the gun it is recommended that the operator wear suitable clothing and elements of personal protection including without limitation gloves protective goggles safety footwear and face masks Use breathing equipment when working with the gun in enclosed spaces or in areas with insufficient ventilation The introduction and follow up of safety measures must not be limited to those described in this manual Before starting up the gun a comprehensive analysis must be made of the risks derived from the products to be dispensed the type of application and the working environment 4 20 To prevent possible injury caused by incorrect handling of the raw materials and solvents used in the process carefully read the safety data sheet provided by your supplier Deal with the waste caused according to current regulations To avoid damage caused by the impact of pressurized fluids do not open any connection or perform maintenance work on components subject to pressure until the pressure has been completely eliminated Use suitable protection when operating maintaining or being present in
17. operation and the conditions of use of the unit All of the information is aimed at enhancing User Safety and avoiding possible breakdowns derived from the incorrect use of the gun WARNING establishes information to alert on a situation that might cause serious injuries if the instructions are not followed PRECAUTION establishes information that indicates how to avoid damage to the gun or how to avoid a situation that could cause minor injuries NB is relevant information on a procedure being carried out Careful study of this manual will enable the operator to know the characteristics of the gun and the operating procedures By following the instructions and recommendations contained herein you will reduce the potential risk of accidents in the installation use or maintenance of the gun you will provide a better opportunity for incident free operation for a longer time greater output and the possibility of detecting and resolving problems fast and simply Keep this Service Manual for future consultation of useful information at all times If you lose this manual ask for a new copy from your GAMA local distributor or directly contact Garraf Maquinaria S A Important Safety Information The master gun has been designed and built for the application of polyurea chemical systems polyurethane foam chemical systems and some two component epoxy systems WARNING The design and configuration of the gun do not allow its use in potentia
18. operations Install the cylinder clamp Hand tighten the mix chamber while holding the end of the pneumatic cylinder with a spanner Assemble the gun block by sliding it over the chamber and fix it to the gun with the bolts Make sure to fit the o ring between the block and the fixing plate and replace it if it is damaged Tighten alternately to avoid possible leaks Assemble the side blocks to the gun block with the corresponding bolts Tighten alternately to avoid possible leaks Screw on the diffuser The gun is now ready for service 19 20 1 5 Issue http AWwww gamapur com Ref NR 00008 ENG CONTENT Warranty Safety and Handling Important Safety Information Characteristics Technical Specifications General Description Installation and Start up Shutdown Procedures Maintenance Gun block unit and mix chamber Side block unit Trigger and valve Cylinder block and safety stop Pneumatic cylinder Content 20 20 http AWwww gamapur com Service Manual N OO 88 OFF WwW W ND S A 12 14 16 18 20 Ref NR 00008 ENG
19. pment must not be handled or touched until they have cooled completely To prevent serious injury through crushing or amputation do not work with the equipment without the safety guards installed on the moving parts Make sure that all the safety guards are correctly reinstalled at the end of the repair or maintenance work of the equipment 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual Gun block unit and mix chamber WARNING Before proceeding to carry out maintenance work on the gun make sure that the unit is at a complete standstill that all the buttons and the general switch are turned off and that the unit is disconnected from the main power supply The gun is a component that works under pressure no connection must be opened and maintenance work must not be performed on components subject to pressure until the pressure has been totally eliminated O Ring Mixing Chamber Air Seal A Side Block Gun Block Assembly Cap R Side Block Assembly Gun Block Screw Side Block Screw Unscrew the diffuser Remove the bolts fixing the product input blocks to the gun block and carefully separate both blocks from the gun Clean the contact surface using a cloth dampened in gun cleaning solvent PRECAUTION Use wooden or plastic utensils or a brass brush for cleaning Do not use metal utensils that can scratch the contact surfaces Remove the gun block mounting bolts and separate the gun block by slid
20. sealing paste in the thread to avoid air escapes Insert the trigger shaft in to the spring and insert it inside the handle taking special care not to damage the o rings You will note a certain resistance caused by the interference of the seals with the housing wall screw down the trigger valve nut until it does ceiling in the fund Fit the trigger with the pin and hold it with the retention ring Place the trigger stop bolt It must be tight up to eliminating the roominess of the trigger shaft without to displace the shaft Fix the product input blocks to the gun block with the corresponding bolts Tighten alternately to avoid possible leaks The gun is now ready for service 15 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual Cylinder block and safety stop WARNING Before performing maintenance work on the gun make sure that the unit is at a complete standstill that all of the buttons and the main switch are turned off and that the unit is disconnected from the main power supply The gun is a component that works under pressure no connection must be opened or maintenance work done on components subject to pressure until the pressure has been completely eliminated Piston Spring Ri Stop Pin i End Cap End Cap O Ring Safety Stop gt 4 Assembly Stop Spring A amp a Cup Seal Retaining Ring End Cap Socket Head Cap Screw Set Screws Cylinder Clamp Remove the side blocks an
21. the area where the equipment is functioning This includes but is not limited to the use of protective goggles gloves shoes and safety clothing and breathing equipment The equipment includes components that reach high temperatures and can cause burns Hot parts of the equipment must not be handled or touched until they have cooled completely To prevent serious injury through crushing or amputation do not work with the equipment without the safety guards installed on the moving parts Make sure that all the safety guards are correctly reinstalled at the end of the repair or maintenance work of the equipment 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com Service Manual CHARACTERISTICS Internal mixture due to high pressure Automatic cleaning with pressurized air No solvents needed Mechanical spraying Exterior lubrication of the mix chamber Approximate weight 1 Kg 2 2 Ibs Dimensions H 19 cm W 10 cm L19cm TECHNICAL SPECIFICATIONS Maximum working pressure Air pressure required Maximum production ratio 1 1 Minimum production ratio 1 1 210 Kgf cm2 20 6 MPa 3000 psi 6 8 Kgf cm2 0 6 0 8 MPa 85 114 psi 18 Kg min 40 b min 1 5 Kg min 3 3 Ib min Opening force 6 bar 90 Kg 200 Ib Closing force 6 bar 93 Kg 205 Ib Approximate air consumption 6 bar 50 cycles min 307 litres minute 5 20 1 5 Issue Ref NR 00008 ENG http AWwww gamapur com GENERAL DESCRIPTION
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