CSI GamaJet V User manual

V. 3/03C
GamaJet V
OWNER'S MANUAL
MANUFACTURING,
SALES & SERVICE
© Gamajet Cleaning Systems, Inc 2003, All Rights Reserved

TABLE OF CONTENTS
1. Introduction
1.1 Description
1.2 Installation of New Machines
1.2.1 Assembl
y
1.2.2 Inlet Connections
1.2.3 Mounting
1.2.4 Location inside the Tan
k
1.2.5 Entry Openin
g
1.2.6 Drainage
1.2.7 Filters or Strainers
1.2.8 Capacity of Supply Pum
p
1.3 Safety
2. Disassembly, Repair, and Reassembly
2.1 Tools required
2.2 General Disassembly
2.3 Inspection & Service of Components
2.3.1 Nozzle Housing
2.3.2 Tee Housing
2.3.3 Gearbox
2.3.4 Gearbox Nose
2.3.5 Stem
2.4 Reassembly
3. Preventative Maintenance
3.1 Storage
3.2 Gearbox Maintenance
3.3 Inspection Interval
3.4 Tips
4. Troubleshooting Guide
4.1 Tee Housing does not rotate
4.2 Nozzle Housing rotates slowly or not at all
4.3 Cleaning Solution leakage
4.4 Poor cleaning performance
5. Appendi
x
A. Dimensional Data & Technical Specifications
B. Parts List & Exploded View
C. Performance Data

1© Gamajet Cleaning Systems, Inc. 10/24/01
1. INTRODUCTION
1.1 DESCRIPTION
The Gamajet V is a fluid-driven (turbine-driven) 360° or 180°
Directional rotary nozzle
machine designed for cleaning the interior surfaces of a wide variety of small process,
transport and storage tanks or tanks with a minimum opening of 3 inches (76.2 mm) in
diameter. It is powered entirely by the cleaning solution; it requires no electricity or
compressed air or lubricant for operation. The Gamajet V is designed primarily for
portable service; the unit may also be permanently installed in a vessel. If the Gamajet V
is permanently mounted inside a tank, we strongly recommend that you inspect the unit
every few hundred hours of operation (see section 3 for details about Preventative
Maintenance).
WARNING:Under no conditions whatsoever should the Gamajet V ever be
immersed in anything. Failure to comply with this restriction will void the
warranty!!
To handle the broadest possible range of applications, the Gamajet V is available in
stainless steel construction with dual and triple nozzles, and an extensive selection of
nozzle sizes, stators, O-ring material and gear ratios. Gamajet nozzles are available in
seven interchangeable sizes - 0.110", 0.125", 0.135", 0.150", 0.165", 0.187", and 0.200".
Longer nozzles are available for tougher deposits but require a 3-1/2" opening; optional
smaller and larger orifice diameters are also available. The standard 0.187" nozzle is
recommended for normal use in tank cleaning. The Gamajet wash cycle time can be
adjusted for special applications by changing the stators, nozzle sizes, and gears.
Interchangeable stators (non-rotating turbine), nozzle sizes, and gears are available for
either low or high pressures and/or flow rates. The performance capabilities of these
options are detailed in Appendix C. A complete description of the technical
specifications and materials of construction of the Gamajet V is contained in Appendix
A.
1.2 INSTALLATION OF NEW MACHINES
1.2.1 ASSEMBLY
Every Gamajet is operationally tested before shipment and is ready to run after
unpacking. No assembly is required prior to use. Your Gamajet has also been
configured to meet the operating conditions that you have given us, e.g. pressure,
flow, temperature, cycle time, etc.
1.2.2 INLET CONNECTIONS
The Gamajet V is supplied with a 1-1/4" NPT female inlet connection. It is
recommended that the mating male thread should be wrapped with PTFE pipe

2© Gamajet Cleaning Systems, Inc. 10/24/01
joint tape prior to mounting. This will minimize any chance of leakage and will
make subsequent removal much easier.
1.2.3 MOUNTING
While the dual nozzle unit is hydraulically balanced, the Gamajet V should be
mounted on a rigid pipe. In most applications, the Gamajet V will be mounted in
the "upright" position (inlet connection pointing up); however, if required, the
Gamajet will function equally well inverted or horizontally. We do not
recommend this form of mounting since the hose is not rigid and, thus, will not
maintain the Gamajet's position should it become unbalanced due to clogging of
the nozzles.
NOTE: When attaching the Gamajet V onto the supply pipe, ALWAYS use the
wrench flats on the Inlet Collar at the top or inlet of the unit. Never place the
wrench on the outside of the gearbox, or bottom, of the unit to tighten the
unit onto the pipe. If you do, you'll unscrew the unit or break internal screws or
both.
1.2.4 LOCATION INSIDE THE TANK
Generally, a single Gamajet should be positioned in the approximate center of the
tank in order to equalize the cleaning radius in all directions. Some tanks may
have specific cleaning problems such as coils or heavy deposits such as the liquid
level line (bathtub ring). In these situations the Gamajet will need to be located
closer to the difficult area for the best cleaning results.
Tanks with internal mechanisms or structures such as an agitator shaft or
impellers or baffles will require careful positioning to minimize the "shadow" on
areas which do not receive direct jet impact. Sometimes, more than one machine
or more than one placement of a single machine may be necessary to completely
avoid shadow problems or “striping.”
Refer to Appendix A for dimensions describing the Gamajet's operating
clearances.
1.2.5 ENTRY OPENINGS
When using the Gamajet V, the tanks being cleaned must provide entry openings
large enough to avoid interference during insertion and removal. The minimum
opening size required for the Gamajet V is 3.0 inches in diameter (76.2 mm).
1.2.6 DRAINAGE
If it is necessary to clean the floor of a tank, remember that standing liquid will
diminish the effectiveness of the jet by covering any soils underneath. Wherever
possible, the tank floor should be pitched toward the drain and the drainage
opening should be large enough to eliminate or reduce any liquid buildup or
puddling. If gravity alone is insufficient, a scavenger or stripper pump should be

3© Gamajet Cleaning Systems, Inc. 10/24/01
connected to the drain to suck out the wash fluid as fast as the Gamajet is putting
it in. In extreme cases, it may be necessary to mount smaller nozzles on the
Gamajet, or even to operate it intermittently to allow time for draining.
1.2.7 FILTERS OR STRAINERS
All tank cleaning systems should be equipped with a filter or strainer that will trap
solids 1/16" or larger, as these will not pass through the Gamajet. These large
particles will not harm the machine, but they can become caught in the turbines or
nozzles and cause it to stop turning or to reduce its cleaning effectiveness due to
loss of flow. It will then be necessary to disassemble the Gamajet and remove the
blockage.
In recirculating cleaning or any other application where the cleaning solution may
carry abrasive solids in suspension, adequate filtration is a must. These particles
can be extremely destructive to the Gamajet, as well as pumps, valves, and other
system components. Filters, properly installed and maintained, will more than pay
for themselves with lower overall operating costs in these applications.
Furthermore, to ensure that clogged filters or strainers are cleaned, we recommend
that you use automatic self-cleaning models.
1.2.8 CAPACITY OF SUPPLY PUMP
The Gamajet V should be sized to match the pressure and flow capability of the
supply pump at its best efficiency point (BEP). For example, if the pump is rated
for 23 GPM at 250 PSI, then the nozzles for the Gamajet V must be configured
for the same 23 GPM at 250 PSI. If not, then you will increase the probability of
experiencing premature failure of Gamajet V parts as well as shaft seals on the
pump the farther away from the BEP that you operate the pump. You may void
the Gamajet V warranty.
For high-pressure applications (over 300 psig), the pump must “ramp up”
slowly (at least 15 seconds) to its operating pressure. If the pump goes from a
standstill to operating pressure in about 1 second or less and if there is no
dampening or slow-opening valve between the pump and the Gamajet, you will
experience premature failure of Gamajet V parts (most likely, certain gears). This
is because of a water hammer effect or a pressure spike.
1.3 SAFETY
When Gamajets are operating, there should be covers over any tank openings. These
covers should be sealed well enough to withstand the full force of the jet striking the
cover plate. If the cleaning solution is hot, corrosive, or toxic a leak would present a
serious hazard to any personnel in the immediate vicinity or to any exposed electrical
equipment.

4© Gamajet Cleaning Systems, Inc. 10/24/01
WARNING
Any tank cleaning machine can develop a static electricity charge while in
operation. If the tank being cleaned contains a combustible liquid or
vapor having a considerable risk of ignition or explosion, it is imperative
to that the Gamajet be properly grounded.

5© Gamajet Cleaning Systems, Inc. 10/24/01
2. DISASSEMBLY, REPAIR, AND REASSEMBLY
2.1 TOOLS REQUIRED
Point Head Pliers (Needle Nose Pliers)
9/64", 7/64", and 5/64” Hex Ball-point L-wrenches (7/64" Allen Wrench)
Screwdrivers (both Slotted (flat blade) & Phillips)
11/32" Hex Deep Socket
7/16" Hex Deep Socket
Socket Wrench Ratchet Handle
2" Socket Extension
Bench Vise (4-6" jaw opening)
No. 3 Arbor Press (3 ton) or Hammer
Micrometer (0-6" Digital or Dial Calipers)
2.2 GENERAL DISASSEMBLY
Note: The reference numbers appearing below may be used to identify parts in the
exploded view (numbers enclosed in circular box) in Appendix B.
2.2.1 Remove the Stem Collar Retainer Screw #36 with the appropriate Hex Ball-point
L-wrench. If not removed, be sure to unscrew the Retainer Screw far enough so that
its top extends beyond the surface of the Inlet Stem Collar.
Do not mistake or confuse the Gearhead Retainer Screw #2, at the bottom of the unit,
with the Stem Collar Retainer Screw, at the top. If you do, immediately tighten the
Gearhead Retainer Screw before twisting or rotating any parts of the unit.
2.2.2 Unscrew the Inlet Stem Collar #37 from the Stem #24.
WARNING:This is a left-hand thread, so turn the Collar CLOCKWISE to
unscrew it! The unit must be in the vertical position, standing on its base when
unscrewing the Inlet Stem Collar; otherwise, the threads will gall.
If the Collar feels like it is binding on the threads, DO NOT force the Collar to turn by
applying more force with a wrench as you will damage the threads; rather, keep spraying
a Teflon-based penetrating solution into the threads and work the solution into the threads
by turning the collar back and forth until it works loose. Lift out the Stator #28.
2.2.3 Insert a Screwdriver between the vanes of the Rotor #25 (to prevent it from
turning) and unscrew the Rotor Retaining Nut #27 with 11/32" Deep Socket and 2"
Extension. Lift out the Rotor with the Pliers or invert the machine and shake it out.
2.2.4 Lift the Tee Housing #35 (#55 for Directional) off the Stem #24. If the Tee
Housing cannot be removed easily, pry carefully at the gap between the Tee Housing and
the Gearbox Nose #14.

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2.2.5 Remove the two Nameplate Screws #47 with a Slotted Screwdriver and pull the
Nozzle Housing #44 (#56 for Directional) off the Tee Housing #35/#55. If tight Bearings
prevent removal, pry carefully between the Nozzle Housing and Tee Housing.
2.2.6 Unscrew the four Gearbox Screws #22 with a 7/64" Hex Ball-point L-wrench and
pull the Gearbox #1 off the Gearbox Nose #14.
2.2.7 Unscrew the four Gearbox Nose-Stem Screws #10 with a 7/64" Hex Ball-point L-
wrench and pull the Gearbox Nose #14 off the Stem #24.
2.3 INSPECTION AND SERVICE OF COMPONENTS
2.3.1 NOZZLE HOUSING #44/#56
2.3.1.1 Nozzle #45
Unscrew the Nozzle Tips with a 7/16" Socket and inspect for debris
plugging the Stream Straightener #49. Remove the Stream Straighteners
for cleaning by pressing them out with a small rod inserted through the
Nozzle bore.
The Nozzle bores must be smooth, round, and free of damage (especially
any nicks) for maximum jet impact. Replace worn or oversized nozzles if
the original flow rate is required. The Stream Straighteners must be
reinstalled in the Nozzle Tips if they were removed for cleaning.
2.3.1.2 Bevel Gear #42 (#58 Spur Gear in Directional)
Remove the Bevel Gear Retaining Ring #41 with a Slotted Screwdriver
and lift off the Nozzle Housing Bevel Gear #42/#58. Inspect the Bevel
Gear for wear such as sharp/pointed or broken teeth, and replace as
required.
2.3.1.3 Clutch O-ring #43 [Not Used in New Production]
Removing the Nozzle Housing Bevel Gear #42/#58 will expose the Clutch
O-ring #43 on the Nozzle Housing. Inspect the O-ring and replace it if it
is worn out (deeply sunken into its groove or chemically eroded), or if it
has become hardened or deformed. Inspect also for wear (such as the
presence of metal shavings) caused by slippage between the Nozzle
Housing Bevel Gear and the Nozzle Housing #44/#56. Slippage can result
from incorrectly installed Nozzle Housing Bearings #38/#59 (#59 for
Directional), deposit build-up, or anything else that could make the Nozzle
Housing difficult to turn.
2.3.1.4 Nozzle Housing Bearings #38/#59
Inspect the Nozzle Housing Bearings #38/#59 and discard any that are
broken, cracked, or deeply scored. Clean any deposits from the bearings

7© Gamajet Cleaning Systems, Inc. 10/24/01
and check their fit in the Nozzle Housing Cup #40 (#60 for Directional
Machine). While they should turn freely in their Cups, the Nozzle
Housing Bearings should be replaced if the diameter of the outside wall is
less than 0.990" to avoid shortening the life of the Seals or Bevel Gears.
2.3.1.5 Nozzle Housing Seals #39 (#61 for Directional)
Examine the Nozzle Housing Seals #39/#61 for loss of spring tension
(indicated by excessive dry deposits of dirty or abrasive cleaning solution
on the spring) or excessive wear on the sealing lips (the sealing lips are
worn smooth) and replace as required. When installing the Seal, make
sure that the spring side of the Seal faces towards the Nozzle Housing Cup
#40/#60.
2.3.1.6 Nozzle Housing Cups #40/#60
Clean any deposits from the Cups and examine for excessive wear. Light
scoring is acceptable, but the Cups should be replaced if they are grooved
in the seal contact area or if the diameter of their inside wall is greater
than 1.020".
If you have many Gamajet units (about 2 dozen or more), you will be
replacing many cups as part of a good maintenance program. Therefore, it
may be worthwhile to make or obtain press tools for pressing the Cups off
of the Nozzle Housing. The press tools are available from Gamajet
Cleaning Systems as part of the repair kit.
Before installing new Cups, clean the housing bores and remove any burrs
resulting from Cup removal. Lubricate the outside of the new Cups and
press them in so that their flanges are fully and flush-seated against the
Housing.
2.3.1.7 Reassembly
If the Nozzle Housing Bearing Cups #40/#60 need to be replaced, refer to
section 2.3.1.6 for installation. If the Clutch O-ring #43 was removed,
replace the old one with a new one and use a flat screwdriver blade to
press it evenly all the way around into its groove. Place the Nozzle
Housing Bevel Gear #42/#58 on the Nozzle Housing, install the Bevel
Gear Retaining Ring #41 and verify that it is fully seated in its groove all
the way around; also verify that the I.D. of the Ring does not extend
inwards into the path of the teeth of the Bevel Gear. Screw in the Nozzle
Tip #45 and tighten with a 7/16" socket. The Nozzle Housing Bearings
#38/#59 and Nozzle Housing Seals #39/#61 will be assembled later when
the Nozzle Housing #44/#56 is remounted onto the Tee Housing #35/#55;
refer to steps 2.4.3 to 2.4.6 for details.
2.3.2 TEE HOUSING #35/#55

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2.3.2.1 Disassembly
Remove the Ring Gear Retaining Ring #29 with a Slotted Screwdriver and
lift out the Ring Gear #30. If the Gear is tight in the Tee Housing #35/#55,
carefully pry it out with flat screwdrivers. Next, lift out the Tee Housing
Bevel Gear #31, Tee Housing Bearings #32, and Tee Housing Seals #33.
2.3.2.2 Tee Housing #35/#55
Inspect the Tee Housing #35/#55 for damage to the Tee Housing key way
that engages the Ring Gear #30. If the Ring Gear was difficult to remove,
check to see if the Tee Housing is out-of-round (as the result of an external
blow, such as dropping) where the Gear seats.
2.3.2.3 Bevel Gear #31
Inspect the Tee Housing Bevel Gear #31 for worn, damaged or
sharp/pointed teeth, and for damage to the key that engages the slot on the
Gearbox Nose #14.
2.3.2.4 Ring Gear #30
Inspect the Ring Gear #30 for worn, damaged or sharp/pointed teeth, and
for damage to the key that engages the slot on the Tee Housing #35/#55.
2.3.2.5 Tee Housing Bearing #32
Inspect the Tee Housing Bearings #32 and discard any that are broken,
cracked, or deeply scored. Clean any deposits from the Bearings and
check their fit in the Tee Housing Bearing Cups #34. While they should
turn freely in their Cups, the Tee Housing Bearings should be replaced if
the diameter of the outside wall is less than 1.490" to avoid shortening
the life of the Seals or Bevel Gears.
2.3.2.6 Tee Housing Seals #33
Examine the Seals for loss of spring tension (indicated by excessive dry
deposits of dirty or abrasive cleaning solution on the spring) or excessive
wear on the sealing lips (the sealing lip is worn to a smooth surface) and
replace as required. When installing the Seals, make sure that the spring
side of the Seal faces towards the Tee Housing Bearing Cup #34.
2.3.2.7 Tee Housing Bearing Cups #34
Clean any deposits from the Cups and examine for excessive wear. Light
scoring is acceptable, but the cups should be replaced if they are grooved
in the seal contact area or if the diameter of their inside wall is greater
than 1.520". If the Bearing Cups require replacement, follow the
procedure given for the Nozzle Housing Cups #40/#60 in section 2.3.1.6.

9© Gamajet Cleaning Systems, Inc. 10/24/01
Replacement Cups must be fully seated in order for the Tee Housing to
turn freely when the machine is reassembled.
2.3.2.8 Reassembly
Install the first of the two Tee Housing Seals #33 in the Tee Housing
Bearing Cup #34 with its spring side facing into the Cup (the second Tee
Housing Seal will be installed later in section 2.4.10). Next, install the
Tee Housing Bearing #32 and, then, the Tee Housing Bevel Gear #31.
Locate the key on the Ring Gear #30 and install the Gear so that the key
engages the key slot on the Tee Housing #35/#55. Finally, install the Ring
Gear Retaining Ring #29.
2.3.3 GEARBOX #1
2.3.3.1 Disassembly
Unscrew the Gearhead Retainer Screw #2 with the appropriate Hex Ball-
point L-wrench and pull the Gear Train Assembly out of the Gearbox #1.
2.3.3.2 Inspection
Check for liquid (wash fluid, water, etc.) in the Gearbox #1. If there is just
a slight amount (dampness or vapor) of liquid in the Gearbox, wipe out the
water with a towel or paper towel and replace the Output Pinion Seal #12
in the Gearbox Nose #14. (Refer to section 2.3.4. Gearbox Nose for
replacement of the Output Pinion Seal #12). If the Gearbox is much more
than damp (about 1/4 or more filled with liquid), it is possible that the
liquid will get inside the Planetary Gearhead #4. If so, refer to section
2.3.3.5 for service details.
2.3.3.3 Output Pinion #8
Inspect the Output Pinion #8 for worn or damaged or sharp/pointed teeth.
Check for any wear, such as scoring, or cracks in the seal contact area
(Chromium Oxide coating area). Examine the Input Shaft Seal #11 for
loss of spring tension (indicated by excessive dry deposits of dirty or
abrasive cleaning solution on the spring) or excessive wear on the back of
the seal and the sealing lips (the sealing lips are worn smooth), and replace
as required.
To replace the Output Pinion, remove the four Planetary Gearhead Screws
#3 with a Phillips Screwdriver and pull out the Output Pinion #8. Remove
the Input Shaft #6 from the old Output Pinion. Inspect the Input Shaft
Seal #11 for damage or wear (the sealing lips are worn smooth/there is no
drag between the Seal #11 and the Input Shaft #6) and replace as needed.
In the new version (Gamajet V with Serial No.V700 or later), the Output
Pinion has two components, the Output Pinion Housing Assembly (8-

10 © Gamajet Cleaning Systems, Inc. 10/24/01
511-H) and the Output Pinion Gear (8-511-B). Therefore, if the gear of
the Output Pinion Assembly is worn out, unscrew the Gear (8-511-B)
and replace the Gear only. Refer to Step 1 of the Assembly Procedure at
the end of the Manual for details.
2.3.3.4 Input Shaft #6 & Input Pinion #5
Inspect the Input Pinion #5 for worn or damaged or sharp/pointed teeth.
Check for any wear (scoring) or cracks on the Input Shaft #6, especially in
the seal contact area. The Pinion is both pressed on tightly and then
welded onto the Shaft and should not be able to be rotated around the
Shaft.
2.3.3.5 Planetary Gearhead #4
WARNING:Proceed in a cautious manner when performing any work
to the Planetary Gearhead due to the complexity and size of the internal
parts.
Inspect the Planetary Gearhead by rotating the Input Shaft #6 by hand. If
the Input Shaft does not turn smoothly in both directions or feels stuck,
return the entire Gamajet unit to Gamajet Cleaning Systems, Inc. for
service.
The Planetary Gears can be inspected by loosening the Planetary Gearhead
Screws #3 and lifting the Output Pinion Assembly #8 from the Gearhead.
If the grease inside the Gearhead is completely or partially filled with
liquid (cleaning fluid, water, etc.) or if the inside of the Gearhead is dry,
the grease lubricant inside the Gearhead may have dissolved. If this is the
case, please refer to the below steps for adding grease to the Gearhead. In
this case, it is also recommended that the 524-S seal be checked for
failure. If the Gearhead rotates freely and is adequately greased, the
Gearhead can be reassembled by lining up and tightening the Planetary
Gearhead Screws #3.
If the Gearhead rotates freely, but lacks adequate grease as
lubrication, the following steps can be taken to adequately grease the
planetary Gearhead.
Please note that the following steps must be taken in a cautious manner.
If you have any concerns, please return the unit to Gamajet for service.
In order to adequately grease the planetary gears, the Planetary Ring Gear
must be removed. When removing the Planetary Ring Gear, the top tier of
Planetary Gears must be held in place with downward pressure. The
Planetary Ring Gear can then be pulled away. The internal components
(three individual tiers of planetary gears) of the Planetary Gearhead must
remain together as a single unit.

11 © Gamajet Cleaning Systems, Inc. 10/24/01
If the planetary gears are removed as a single unit, any debris can be
loosened and removed using an aerosol degreaser and air to dry. Once dry,
the Planetary Gears can be lightly hand packed with grease. Gamajet
recommends using a Chevron FM NLGI 2 grease for food grade
applications and a Fuch’s ST-80 grease for aggressive chemical
environments. Please consult your lubricant specialist for compatibility.
Once the planetary gears are packed with grease, the planetary ring gear
can be reinstalled by aligning the Planetary Gears with the Planetary Ring
Gear on tier at a time. The Output Pinion Assembly #8 can then be secured
using the Planetary Gearhead Screws #3.
If any of the Planetary Gears are damaged, Gamajet can supply
reconditioned individual gears.
2.3.3.6 Reassembly
If the Output Pinion #8 was removed for replacement, install the Input
Shaft Seal #7 into the Output Pinion Housing #8D so that the spring side
of the Seal faces inwards (towards) the Output Pinion Housing #8D.
Apply grease around the O-ring of the Seal #7 before installing for easy
installation. Insert the Input Shaft Assembly #6 into the Output Pinion
Assembly. Mount this assembly onto the Planetary Gearhead #4. Align
the four holes on the Output Pinion with the four holes on the Planetary
Gearhead by rotating the Output Pinion while holding the Gearhead still.
Attach the Gearhead onto the Output Pinion with the four Planetary
Gearhead Screws #3.
Then insert the entire Planetary Gearhead assembly into the Gearbox #1
while lining up the flat side of the Output Shaft of the Gearhead with the
Retainer Screw #2. Make sure that the Gearhead fully seats in the
Gearbox before tightening the Retainer Screw. The Gearhead assembly is
fully seated when the distance from the face of the Output Pinion #8 to the
rim or top of the shoulder of the Gearbox #1 is 0.09"-0.10". The flat side
of the Output Shaft is darker than the rest of the shaft so you can also
locate the flat side visually by rotating the Gearhead inside the Gearbox
until the darker color is visible.
2.3.4 GEARBOX NOSE #14
2.3.4.1 Disassembly
Remove the Idler Shaft #18 with a Slotted Screwdriver and take out the
Idler Gear #16 and the Idler Gear Thrust Washer #15. Pull the Rotor Shaft
Upper Bearing #20 off the Gearbox Nose #14 with the Pliers.
2.3.4.2 Inspection
Inspect the Gearbox Nose for any sign of being bent. Check for any sign
of damage to the key slot that engages the Tee Housing Bevel Gear #31.

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2.3.4.3 Idler Gear #16
Inspect the Idler Gears for any worn, damaged or sharp/pointed teeth, or
worn bushing flanges (the thickness of the flange or the lip should not be
less than 0.050"). Check the Idler Bushings #17 for looseness. If the
diameter of the inside wall of the Bushing is greater than 0.215", replace
the Bushing. Also, check the Thrust Washer #15 for wear (the thickness
of the washer should not be less than 0.050") and replace if necessary.
2.3.4.4 Idler Shaft #18
Examine the Idler Shaft for damage or wear (scoring) and replace if the
outside diameter of the Shaft is less than 0.196". The original O.D. of
the Shaft is 0.200" ±0.001".
2.3.4.5 O-rings #9, #19 & #21
Inspect the O-rings #9, #19, and #21 for deterioration (they have become
hardened or deformed) or damage and replace if necessary.
2.3.4.6 Output Pinion Bearing #7 and Seal #12
If the Output Pinion Seal #12 needs replacement (the seal is loose (it
should not be able to be rotated in the bore without any resistance) in the
Gearbox Nose bore or if the sealing lip has worn smooth), carefully pry
the Output Pinion Seal #12 out of the Gearbox Nose. Check the Seal #12
for wear or damage and replace if necessary. The Carbide Bearing #7
should not be loose in the Gearbox Nose. Replace the Bearing if it is
cracked or worn.
Check the Input Shaft Seal #11, in the bottom of the Output Pinion, for
wear and replace if the I.D. of the seal is worn smooth.
2.3.4.7 Rotor Shaft Upper Bearing #20 & Lower Bearing #13
Check both Bearings for wear, damage or looseness. If the inside
diameter of either Bearing is greater than 0.190" or either Bearing is
cracked, they should be replaced.
To replace the Lower Bearing, insert a small rod (with an O.D. of 0.200 to
0.250") in the Gearbox Nose, support the Gearbox Nose on its thick base
(the base that has four holes) against the Arbor Press base, and carefully
press the Bearing out with the Arbor Press. If the Bearing is extremely
tight and resists removal, lubricate the Bearing before pressing it out. If an
Arbor Press is not available, press the Bearing out by gently tapping the
small rod, above, with a Hammer.

13 © Gamajet Cleaning Systems, Inc. 10/24/01
2.3.4.8 Reassembly
Install the Rotor Shaft Lower Bearing #13 if it was removed. Before
pressing the Bearing, be sure to clean the bore and remove any burrs
resulting from Bearing removal, lubricate the outside of the Bearing and
press it in until the flange is fully and flush-seated against the Gearbox
Nose #14.
Install the Output Pinion Seal #12 with its spring side facing towards the
Rotor Shaft Lower Bearing #13 until its flange is fully and flush-seated
against the Gearbox Nose. Reinstall the Idler Gears #16 and Idler Gear
Thrust Washers #15 so that the Thrust Washers are at the side of the hole
with thread. Refer to the Exploded View of the Gamajet V for a pictorial
illustration of the location of these Washers. Then screw the Idler Shaft
#18 into the Gearbox Nose.
Replace the O-ring #19 if necessary and then press the Rotor Shaft Upper
Bearing #20 into the Gearbox Nose.
2.3.5 STEM #24
2.3.5.1 Inspection
Inspect the Stem #24 for damaged threads and wear. The Stem should be
replaced if it is grooved in the seal contact area or bent or its threads are
damaged.
2.3.5.2 Gearbox Nose Screw O-ring #23
Remove the four O-rings #23 from their seats around the screw holes in
the bottom of the Stem and discard them. These should always be
replaced with new ones whenever the machine is disassembled.
2.4 REASSEMBLY
Note:All parts must be cleaned thoroughly before reassembling. Any deposits
remaining on the parts can cause difficult disassembly the next time the Gamajet needs
servicing.
Apply a dab of a Teflon-based anti-seize compound to all threads (especially the threads
on the Stem) when reassembling; this will prevent galling of threads and ease any future
disassembly.
Whenever lubrication of parts is required for assembly, lithium-based soap grease
(Calypsol SF 3-097) is satisfactory.

14 © Gamajet Cleaning Systems, Inc. 10/24/01
2.4.1 Lubricate the Gearbox-Nose Stem O-ring #21 on the Gearbox Nose #14. Place the
four Gearbox Nose Screw O-rings #23 on their seats at the bottom of the Stem #24. Slide
the assembled Gearbox Nose into the Stem. Rotate one of them until the four holes line
up. Attach the Gearbox Nose to the Stem with the four Gearbox Nose-Stem Screws #10
and Lockwashers #51.
2.4.2 Lubricate the Gearbox O-ring #9 on the Gearbox Nose. Slide the assembled
Gearbox #1 into the assembled Stem-Gearbox Nose. Rotate the Gearbox to line up the
four holes. Fasten the assembly with the four Gearbox Screws #22 and Lockwashers #51.
2.4.3 Install the Nozzle Bearing #38/#59 on the Tee Housing nose #35/#55. Then place
the first Nozzle Housing Seal #39/#61 next to the Bearing with its spring side facing
away from the Tee Housing body.
2.4.4 Place the assembled Nozzle Housing #44/#56 onto the Tee Housing #35/#55.
Rotate the Nozzle Housing #44/#56 slightly to mesh the Bevel Gears #31 and #42/#58.
2.4.5 Install the second Nozzle Housing Seal #39/#61 onto the Tee Housing with its
spring side facing the Nozzle Housing Bearing Cup #40/#60.
2.4.6 Insert the Nozzle Housing Bearing #38/#59 into the Nameplate #46 (#57 for
Directional). While keeping the Nameplate and Bearing together, push them all the way
onto the Tee Housing #35/#55. Rotate the Nameplate to align the two screw holes.
Install the two Nameplate Screws #47 and tighten with a Slotted Screwdriver.
2.4.7 Slide the above assembly onto the Gearbox-Stem assembly. While firmly pressing
down the above assembly, rotate the Nozzle Housing #44/#56 until the Tee Housing
Bevel Gear #31 engages with the key slot on the Gearbox Nose #14 (you'll feel it click or
engage). Now that everything is properly lined up, press the above assembly all the down
until it is firmly seated. You will know you've got it seated properly when the gap
between the Tee Housing and the base of the Gearbox Nose is about 0.050", and the
Nozzle Housing can not be rotated more than a few degrees.
2.4.8 Stand the machine upright. Place the Rotor #25 on the Input Shaft #6 followed by
the Rotor Shaft Lockwasher #26 and Rotor Retaining Nut #27. Insert a Screwdriver
downward through its blades to prevent the Rotor from turning, then tighten the Nut, very
tightly, with an 11/32" Hex Deep Socket and 2" Extension. If you do not hold the Rotor
still by this method, you run the risk of not tightening the Rotor tight enough, which,
eventually will allow the Rotor to turn freely on the Input Shaft. This means both that the
unit will not rotate properly and the Tee Housing Seals may become damaged.
2.4.9 Test for proper assembly by turning the Rotor with a pencil or Screwdriver. The
Input Shaft should turn very easily and the Rotor vanes must not strike the stem wall.
Continue turning and check to see that the Tee Housing turns also.
2.4.10 Place the second Tee Housing Seal #33 onto the Stem #24 with its spring side
facing the Tee Housing Bearing Cup #34. Then place the Tee Housing Bearing #32
above it.

15 © Gamajet Cleaning Systems, Inc. 10/24/01
2.4.11 Drop the Stator #28 onto the top of the Stem #24. Make sure that the Stator
doesn't touch any part of the Input Shaft assembly when it is fully seated.
2.4.12 Screw the Inlet Stem Collar #37 onto the Stem #24 until the Stator #28 stops it.
The Collar needs to be only hand-tight; do NOT tighten by using a wrench as you'll
damage the threads. Insert and tighten the Stem-Collar Retainer Screw #36 with the
appropriate Hex Ball-point L-wrench to lock the Collar.
This completes the assembly process.

16 © Gamajet Cleaning Systems, Inc. 10/24/01
3. PREVENTATIVE MAINTENANCE
Note:A rigorously implemented preventative maintenance program will significantly
reduce repair costs over the life of the Gamajet. The foundation of such a program is
regularly scheduled inspections to discover and replace worn or damaged parts before
they can cause the failure of other, more costly, components. The inspection intervals
required will depend on the severity of the application, but 100 hours is recommended
initially.
Note:Reference numbers appearing below may be used to identify parts on the exploded
view in Appendix B .
3.1 STORAGE
The Gamajet should be washed out with clean water after each use to remove any foreign
material or soft substances left in the machine that may harden during storage and cause
the Gamajet to seize or lock up. A clean water rinse through the Gamajet will also wash
out any residues of chemical cleaners or recirculated wash water that could adversely
affect the seals and O-rings during prolonged contact in storage. The best position to
store the Gamajet is to stand it up side down with the inlet connection facing down.
3.2 GEARBOX MAINTENANCE
3.2.1 Disassemble the machine by following the instructions in section 2.2.
3.2.2 Inspect the condition of the Gearbox. If cleaning solution is present, refer to
section 2.3.3 Gearbox and disassemble the Gamajet to replace the Seal #12 and other
parts as required. If the Gearbox is free of contamination, go to step 3.2.3.
3.2.3 Reassemble the machine.
3.2.4 Return the machine to service.
3.3 INSPECTION INTERVALS
The Gamajet V should be inspected every 100-300 hours of operation, depending on the
severity of use. An interval of 100 hours is recommended initially.
3.4 TIPS
3.4.1 All the Bearings, Bushings, Seals and O-rings are wear parts. Ideally, they should
all be replaced, as a group, every 300-40/#600 hours of operation, depending on the
severity of use. At first, an interval of 300 hours is recommended.

17 © Gamajet Cleaning Systems, Inc. 10/24/01
3.4.2 If just one Bearing or Seal is worn or damaged, replace both it and its mate, not
just the worn or damaged part.
3.4.3 Reminder to never retighten Gearbox Nose Stem & Gearbox Screws, P/N 8-542
& 8-543. ALWAYS use new screws. Also, always resplit or use new Lockwashers, P/N
8-552.

18 © Gamajet Cleaning Systems, Inc. 10/24/01
4. TROUBLESHOOTING GUIDE
Note:Reference numbers appearing below may be used to identify parts on the exploded
view in Appendix B .
4.1 TEE HOUSING DOES NOT ROTATE
4.1.1 INSUFFICIENT FLOW
Are the assumed operating conditions being met? Your Gamajet was built to
meet certain operating conditions that your firm supplied to us. These are
conditions such as gpm, psi, temperature, chemical content of the wash fluid,
cycle time, etc. If the Nozzle size is too small and/or the opening at the bottom of
the Stator is too large, the Tee Housing will not turn.
Look for restrictions in the fluid supply such as a clogged filter, kinked hose, or
deposits in the piping. Inspect also for partially plugged Nozzle Tips, as that will
have the same effect.
4.1.2 TIGHT CLEARANCES
In low-flow applications (below 10 gpm), a newly-overhauled Gamajet V may fail
to operate when first returned to service. If the machine seems otherwise fine, try
running it with at least one Nozzle Tip removed. The additional flow will
invariably be enough to overcome the extra resistance of new Bearings and Seals.
A few minutes of operation should loosen tight the clearances enough for the
machine to run normally with the Nozzle(s) remounted.
Note: When following the corrective actions in steps 4.1.1 and 4.1.2, be sure to allow
enough time (about 1/2 to 2 minutes) for any accumulated liquid to drain completely from
the inside of the Gamajet V before resuming operation.
4.1.3 DEBRIS INSIDE
Loosen the Stem-Collar Retainer Screw #36, and remove the Inlet Stem Collar
#37, then lift out the Stator #28. Look for and remove any debris caught between
the Stator and Rotor vanes. Remove any material wound around the Input Shaft
#6.
4.1.4 INPUT SHAFT BINDING
After completing step 4.1.3., try to spin the Rotor #25 by hand. The Input Shaft
should turn very easily with a pencil and should be approximately centered in the
Stem bore. If the Rotor is difficult to turn or is visibly off-center, look for a bent
Gearbox Nose #14 or Stem #24. This kind of damage is particularly likely if the
Gamajet has been struck hard or dropped.