H-2000 Third Component Pump - Empire...

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H-2000 ThirdComponent Pump

Installation Instructions andParts Identification Manual

15810-INST

November 10, 1998

Issue 1

GUSMER CORPORATION ®

A Subsidiary 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 1999, GUSMER CORPORATION ®

http://www.gusmer.com

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

H-2000 Third Component Pump

2 15810-INST, Issue 1

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

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

Installation Instructions and Parts ID Manual Contents

1/7/99 3

CONTENTS

WARRANTY ..................................................................................................................................................................... 4

GENERAL SAFETY INFORMATION............................................................................................................................ 5

ACCEPTABLE EQUIPMENT USES ......................................................................................................................................... 5OPERATIONAL SAFETY PROCEDURES.................................................................................................................................. 6

INSTALLATION............................................................................................................................................................... 7

PREPARATION ................................................................................................................................................................... 7INSTALLATION OF THE RETRO-FIT KIT ............................................................................................................................... 8INSTALLATION OF THE AUXILIARY PUMP ............................................................................................................................ 9

NORMAL OPERATING PROCEDURE........................................................................................................................ 11

PARTS IDENTIFICATION ............................................................................................................................................ 12

AUXILIARY PUMP RETRO-FIT KIT..................................................................................................................................... 12AUXILIARY PUMP MOUNTING ASSEMBLY ......................................................................................................................... 14AUXILIARY PUMP PROPORTIONING PUMP ASSEMBLY 10 SIZE PUMPS ................................................................................. 16

CATALYST SUPPLY TANK ......................................................................................................................................... 18

PRE-MIX CHAMBER ASSEMBLY .............................................................................................................................. 20

INSTRUCTION MANUAL DISCREPANCY REPORT................................................................................................ 21

LIST OF FIGURESFIGURE 1. H-2000 PROPORTIONING PUMP ASSEMBLY ............................................................................................................ 7FIGURE 2 HEX LOCK NUT..................................................................................................................................................... 8FIGURE 3. TYPICAL ASSEMBLY.............................................................................................................................................. 9FIGURE 4. AUXILIARY PUMP ADJUSTMENT DETAILS ............................................................................................................. 11FIGURE 5. AUXILIARY PUMP RETRO-FIT KIT (PART NO. 15810-10-KIT), EXPLODED VIEW .................................................... 12FIGURE 6. AUXILIARY PUMP MOUNTING ASSEMBLY (PART NO. 15828), EXPLODED VIEW ..................................................... 14FIGURE 7. AUXILIARY PROPORTIONING PUMP ASSEMBLY (PART NO. 15800A-10), EXPLODED VIEW...................................... 16FIGURE 8. CATALYST SUPPLY TANK (PART NO. OP902-R) EXPLODED VIEW........................................................................ 18FIGURE 9. PRE-MIX CHAMBER ASSEMBLY (PART NO. 17857) EXPLODED VIEW ................................................................... 20

LIST OF TABLESTABLE 1. AUXILIARY PUMP RETRO-FIT KIT (PART NO. 15810-10-KIT), PARTS ..................................................................... 13TABLE 2. AUXILIARY PUMP MOUNTING ASSEMBLY (PART NO. 15828), PARTS...................................................................... 15TABLE 3. AUXILIARY PROPORTIONING PUMP ASSEMBLY (PART NO. 15800A-10), PARTS ...................................................... 17TABLE 4. CATALYST SUPPLY TANK, (PART NO. OP901-ID), PARTS..................................................................................... 19TABLE 5. PRE-MIX CHAMBER ASSEMBLY, (PART NO. 17857), PARTS.................................................................................. 20



WARRANTY

Gusmer Corporation (Gusmer) provides a limited warranty to the original purchaser (Customer) ofGusmer manufactured parts and equipment (Product) against any defects in material orworkmanship 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 toGusmer, freight prepaid. If Product is found to be defective in material or workmanship, asdetermined solely by Gusmer, Gusmer will issue full credit to Customer for the freight chargesincurred in returning the defective Product, and either credit will be issued for the replacement costof 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; normalwear; 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 othermanufacturer's pumping or proportioning equipment. Further, the terms and conditions of thiswarranty shall not apply to services or repairs made to Product by any third party not authorized inwriting by Gusmer. For such Product, a written estimate will be submitted to Customer at anominal service charge, itemizing the cost for repair. Disposition of Product will be done inaccordance with the terms stated on the written estimate.

The warranty provisions applied to product that are not manufactured by Gusmer will be solely inaccordance 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 ORWORKMANSHIP SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUSMEROBLIGATIONS TO CUSTOMER. NO OTHER WARRANTY, EXPRESSED OR IMPLIED ONANY PRODUCT IT MANUFACTURES AND/OR SELLS, WILL BE RECOGNIZED BYGUSMER UNLESS SAID WARRANTY IS IN WRITING AND APPROVED BY AN OFFICEROF GUSMER.

Under no circumstances shall Gusmer be liable for loss of prospective or speculative profits, orspecial indirect, incidental or consequential damages. Further, Gusmer shall have no liability forany expenses including, but not limited to personal injury or property damage resulting from failureof performance of the product, use of the product, or application of the material dispensed throughthe product. Any information provided by Gusmer that is based on data received from a thirdsource, or that pertains to product not manufactured by Gusmer, while believed to be accurate andreliable, is presented without guarantee, warranty, or responsibility of any kind, expressed orimplied.

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

To insure proper validation of your warranty, please complete the warranty card and return it toGusmer within two weeks of receipt of equipment.

Revised 11/12/98

Installation Instructions and Parts ID Manual General Safety Information

1/7/99 5

GENERAL SAFETY INFORMATION

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

As with most mechanical equipment, certain safety precautions must be taken when theequipment discussed in this manual is operated or serviced. Severe bodily injury ordamage to equipment and property may result if the instructions and precautions listedthroughout this manual are not followed.

Needless to say, sufficient guidelines cannot be developed to eliminate the need for goodcommon sense in the use and servicing of this equipment, and in the use and applicationof the products, this equipment has been designed to process. Users of this equipmentmust therefore, make their own determination as to the suitability of the informationcontained in this manual to their specific operation and requirements. There should beno 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 orapplication.

The following safety guidelines are generally applicable to the safe and efficient use ofthe equipment.

ACCEPTABLE EQUIPMENT USES

The equipment is designed for the dispensing of polyurethane foams, two-componentcoating systems, and some two-component epoxy systems, specifically polyureas. Underno circumstances should any acid or corrosive chemicals be used in the unit. ConsultGUSMER if there is any doubt about the compatibility of the chemical system to be usedin this equipment.

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



OPERATIONAL SAFETY PROCEDURES

This safety information will not be repeated in the text of this manual. The symbolspertaining to this information will appear where appropriate to alert the operator topotential hazards.

Solvents and Chemicals

WARNING: THE SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE

OPERATOR TO CERTAIN HAZARDS. ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BETAKEN

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. INFORMATION CONCERNING PERSONAL PROTECTION AND

PROPER HANDLING FROM THE SUPPLIER OF SUCH 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 INTERRUPTING 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

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 PRESSURES TO ZERO.

Personal ProtectiveEquipment

WARNING: TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR 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.

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

WARNING: FAILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN

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

LISTED HAZARDS

Installation Instructions and Parts ID Manual Installation

1/7/99 7

INSTALLATIONIMPORTANT: Before you begin turn off all electrical power to the machine. Drain allchemical from the machine. Suggested method is by forced air.

PREPARATION

Figure 1. H-2000 Proportioning Pump Assembly

1. Close both Supply Valves.

2. Bleed all chemical pressure to zero.

3. Remove Polyethylene Pipe Plug from the Iso proportioning pump lube cylinder.

4. Position the Clevis Pin for removal from the Lube Cylinder.

5. Remove the Clevis Pins from both the Iso and Resin pumps with the ClevisExtractor Tool.

6. Remove all hoses from both proportioning pumps.

7. Detach each Proportioning Pump Assembly from the pump line by unscrewing the 4Socket Head Cap Screws.

8. Remove the Iso Lube Cylinder by manually pulling it off.

9. Unscrew the Resin and Iso Cylinder Clevis by using a wrench on both sides andsimultaneously break loose both clevis's.

10. Remove the Activator Plate.

Important: If Hydraulic Cylinder Standoffs are removed they must be re-torqued to200 inch/lbs.



INSTALLATION OF THE RETRO-FIT KIT

IMPORTANT: It is recommended to use a thread sealant on all pipe fittings priorto any installation to prevent leakage.

ON RESIN SIDE ONLY:

1. Install the Bronze Bushing on to the Activator Plate

2. Slide the Bronze Bushing on the Activator Plate over Reversing Switch PumpSpacer.

3. Install the replacement Clevis onto Resin side of the Hydraulic Shaft.

4. Mount the Activator Plate to the replacement Clevis with a flat head cap screw.

ON ISO SIDE ONLY:

5. Reinstall the Clevis with the Hex LockNut onto Iso side of the Hydraulic Shaft asshown in figure 2.

6. Reinstall original Iso Lube Cylinder.

NOTE:Position the clevis on the resin side for

attaching to the arm from the AuxiliaryPump. Position the clevis on the Iso

side to line up with the access hole onthe Lube Cylinder in order to attach the

Proportioning Pump Clevis andHydaualic Cylinder Clevis with the

Clevis Pin.7. Secure the Iso Proportioning Pump

Assembly back onto the pump line byreinserting the Clevis pin with the Clevistool. Figure 2 Hex Lock Nut

8. Install and tighten the Proportioning Pump assembly to the pump line with 4 SocketHead Cap Screws.

9. Cover the Clevis pin access hole with the Polyethylene Pipe Plug.

ON RESIN SIDE ONLY:

10. Secure the Resin Proportioning Pump Assembly back onto the pump line byinserting the Clevis pin with the Clevis tool.

11. Install and tighten the Proportioning Pump Assembly to the Pump Line with 4Socket Head Cap Screws.

Installation Instructions and Parts ID Manual Installation

1/7/99 9

INSTALLATION OF THE AUXILIARY PUMP

Figure 3. Typical Assembly

1. Remove the four round head machine screws from the top of the ResinProportioning Pump and set aside.

2. Mount the Pump Mounting Assembly to the top of the Resin Proportioning Pump byaligning the bracket bolt pattern with the existing holes and secure with the fourreplacement socket head cap screws.

3. Align the lower pivot point of the Drive Arm with the upper pivot point of thereplacement Clevis and use the Clevis tool to insert the replacement Clevis Pin.

4. Remove the two side pivot screws from the Auxiliary Pump Assembly.

5. Align the yoke on the Auxiliary Pump with the adjustable pivot on the drive armbracket and insert the Yoke Pin.



6. Snap Tru-Arc Rings onto both ends of the Yoke pin.

7. Attach the Auxiliary Pump to the bracket using the two side pivot screws.

8. Install Hex Nipple in the side of the pump flange.

9. Install the Check Valve and Hose Elbow; and orient as shown.

10. Install Male Elbow onto the Auxiliary Pump.

11. Install the Interconnect and Supply hoses as shown.

12. Insure all tubing and hoses are properly aligned and tightened before attemptingany start-up procedures.

You may now restart the Proportioning Unit using initial start up procedureslocated in your operator’s manual.

Please retain the following remaining parts for future use:

Part Number. Description Qty

15514 Clevis 1

1501A-7-1 Activator Plate 1

Installation Instructions and Parts ID Manual Normal Operating Procedure

1/7/99 11

NORMAL OPERATING PROCEDURE

The Auxiliary Pump operates the same as the Isocyanate and Resin ProportioningPumps. When a Third Component is required for a particular application: adjusting thestroke length controls the exact amount being proportioned into the system.

Figure 4. Auxiliary Pump Adjustment Details

Changing the stroke length of the piston varies the output on the Auxiliary Pump. Todo this loosen the adjusting nut and align the indicator arrow on the Adjustable pivotwith the desired percentage marked on the Drive Arm and retighten the adjusting nut.



PARTS IDENTIFICATION

AUXILIARY PUMP RETRO-FIT KIT

Figure 5. Auxiliary Pump Retro-Fit Kit (Part No. 15810-10-Kit), Exploded View

Installation Instructions and Parts ID Manual Parts Identification

1/7/99 13

TABLE 1. AUXILIARY PUMP RETRO-FIT KIT (PART NO. 15810-10-KIT), PARTS

Part Number Description Quantity

0373 Male Elbow 20381-2 Nipple 10466A Hex Nipple 11327 Interconnect Hose 15512-8 Socket Head Cap Screw 46303-17 Jic Fitting 115750-6 Baffle Lock Nut (Not Shown) 115800A-10 Auxiliary Proportioning Pump Assembly 115828 Pump Mounting Assembly 115851 Check Valve Assembly 117857 Pre-Mix Chamber Assembly 1



AUXILIARY PUMP MOUNTING ASSEMBLY

Figure 6. Auxiliary Pump Mounting Assembly (Part No. 15828), Exploded View


1/7/99 15

TABLE 2. AUXILIARY PUMP MOUNTING ASSEMBLY (PART NO. 15828), PARTS


0370-1 Hex Nut 11521-1-2 Flat Head Cap Screw 115515 Clevis Pin 215829-1 Idler Link 115829-10 Pump Clevis 115829-2 Drive Arm 115829-3 Adjustable Pivot 115829-4 Washer 115829-5 Yoke Pin 115829-6 Pivot Pin 215829-7 Tru Arc 115829-8 Hydraulic Cylinder Clevis 115829-9 Reversing Plate 115830 Main Bracket Assembly 1



AUXILIARY PUMP PROPORTIONING PUMP ASSEMBLY10 SIZE PUMPS

Figure 7. Auxiliary Proportioning Pump Assembly (Part No. 15800A-10), Exploded View


1/7/99 17

TABLE 3. AUXILIARY PROPORTIONING PUMP ASSEMBLY (PART NO. 15800A-10), PARTS


15813 Valve Cover Bracket 10461 Snap Ring 115805-2 O-Ring 20352A-1 Socket Head Cap Screw 41417-24 Wave Spring 215503 0-3000 PSI Liquid Fill Gauge 115801-10 Piston Rod 115802-10 Pump Cylinder Block 115803-10 Pump Flange 115804A Pump Base 115805-S Check Valve 215806 Inlet Valve Cover 115807 Outlet Valve Cover 115808 Pivot 215809-10 Yoke 11707-15-8 Lockwasher 115811 Packing Set 11812 Packing Support Washer 21813 Packing Set 11814 Spring Retainer Washer 11815 Conical Spring 11816 Packing Retainer Washer 11817 Packing Support Washer 11818 Socket Head Cap Screw 14406-16 Socket Head Cap Screw 40807 O-Ring 19403-N O-Ring 19405-N O-Ring 19412 Pressure Gauge Adapter 19462 Pump Screen 19463 Socket Head Cap Screw 29464 Screen Screw 1OP219-4 Socket Head Cap Screw 115810 Hose Nipple 16465 Pipe Tee 115516-2200 Pressure Switch 1



CATALYST SUPPLY TANK

Figure 8. Catalyst Supply Tank (Part No. OP902-R) Exploded View


1/7/99 19

TABLE 4. CATALYST SUPPLY TANK, (PART NO. OP902-R), PARTS


0381-2 Nipple 10487A Ball Valve 11128 Needle Valve 11142 R-Swivel Fitting 12130 Air Hose 12145-1 Quick Disconnect Plug 12145-2 Quick Disconnect Coupler 1OP156-30 Hex Nipple 1OP202-6 Bushing 1OP901-2 Elbow 1OP901-3-1 Pressure Relief Valve Assembly (Plastic) 1OP901-3-2 Pressure Relief Valve Assembly (Metal) 1OP901-4 O-Ring (Lid) 1OP901-5 3 Gal. Tank Lid 1OP901-8 Street Elbow 45 1OP901-9 Bushing 1



PRE-MIX CHAMBER ASSEMBLY

Figure 9. Pre-Mix Chamber Assembly (Part No. 17857) Exploded View

TABLE 5. PRE-MIX CHAMBER ASSEMBLY, (PART NO. 17857), PARTS


0377 Pipe Plug 10576 Pipe Plug 10855B-2 Pre-Mixer 49452-15-2 Pipe Plug 117857-1 Pre Mix Chamber 1

Installation Instructions and Parts ID Manual Instruction Manual Discrepancy Report

11/6/98 21

INSTRUCTION MANUAL DISCREPANCY REPORTField

NumberField 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



FieldNumber

Field Title Description

1 Date Enter date report is submitted.

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 noissue number enter NONE.

5 Date of Issue Enter the date of Issue of the Instruction Manual from the title page. If there is noissue 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 yoursubmittal.

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