GAMA Master III Series User manual

Service Manual
Spray Gun
Series Master III
1.4 Issue 20/04/2017
Ref. NR-00073-ENG
Before installing and operating the MASTER III gun, carefully read the
technical and safety documentation in this manual. Special attention
should be paid to the information in order to know and understand the
handling and conditions of use of the Unit. All of the information is aimed
at enhancing User Safety and avoiding possible faults due to incorrect
use of the Unit.

Service Manual
2/25 1.4 Issue Ref. NR-00073-ENG
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GARRAF MAQUINARIA, S. A. (hereinafter “GAMA”) grants this Guarantee limited to the original purchaser
(hereinafter “Client”) for the equipment and the original accessories delivered with the equipment
(hereinafter “Product”) against any fault in design, materials or manufacture of the Product at the time of
the first purchase by the users and for a period of two (2) years there from.
If during the guarantee period and under normal conditions of use, the Product should fail to work correctly
due to defects of design, material or manufacture, the authorised distributor of the country where the
GAMA Product or technical assistance service has been purchased shall repair or replace the Product in
accordance with what is established in the following
CONDITIONS
a) The validity of this guarantee will be subject to the presentation of the original invoice issued by
the GAMA authorised distributor for the sale of the Product along with the Product handed over
for repair or replacement, which must show the date of purchase and the serial number. GAMA
reserves the right to refuse to give the guarantee service when the indicated data fail to appear
on the invoice or have been modified after the purchase of the Product.
b) The repaired or replaced Product will continue to maintain the original guarantee for the time
remaining until the end of the guarantee or for three (3) months from the repair date, if the
remaining period of the original guarantee were shorter.
c) This guarantee will not be applied to the faults in the Product caused by its faulty installation, the
natural wear and tear of the components, any use other than that considered normal for this
Product or which should fail to strictly comply with the instructions of use provided by GAMA; due
to accident, carelessness, adjustments, alterations or modifications of the Product not authorised
by GAMA or due to the use of accessories, heating devices, pumping equipment and/or
dispensers that have not been approved or manufactured by GAMA.
d) The guarantee applicable to the components and accessories forming part of the Product and
which have not been made by GAMA will be limited to the guarantee offered by the original
manufacturer thereof.
GAMA WILL NOT RECOGNISE ANY EXPRESS ORAL OR WRITTEN GUARANTEES OTHER THAN THIS PRINTED LIMITED
GUARANTEE. ALL IMPLICIT GUARANTEES, INCLUDING, WITHOUT LIMIT, ADAPTATION FOR A SPECIFIC USE, ARE SUBJECT
TO THE DURATION OF THIS WRITTEN GUARANTEE. GAMA DOES NOT ASSUME ANY KIND OF COMMITMENT OR
RESPONSIBILITY FOR ALL POSSIBLE DAMAGE OR EXPENSE CAUSED BY FAULTS IN THE OUTPUT OF THE PRODUCT, ITS
WORKING OR THE DISPENSING OF MATERIAL THROUGH THE PRODUCT, INCLUDING, WITHOUT LIMITATION, ALL
EXPENSES CAUSED BY DAMAGE TO PEOPLE OR PROPERTY. EQUALLY, GAMA WILL IN NO CASE ACCEPT LIABILITY FOR
THE LOSS OF SPECULATIVE PROFITS OR COMMERCIAL LOSSES. ALL REPAIRS OR REPLACEMENT OF FAULTY PRODUCTS
WILL CONSTITUTE THE COMPREHENSIVE FULFILMENT OF GAMA'S OBLIGATIONS WITH RESPECT TO THE CLIENT. GAMA
DOES NOT IN ANY WAY GUARANTEE THE SUITABILITY OR APTITUDE OF ITS PRODUCT FOR ANY PARTICULAR PURPOSE
OR APPLICATION.
All of the information provided on components which have not been manufactured by GAMA and which is
based on reports received from the original manufacturer, though considered precise and reliable, is
provided without any guarantee or responsibility of any explicit or implicit kind.
All concession, sale or financial leasing of the Product by GAMA in no case explicitly or implicitly
constitutes any authorisation, acceptance or concession for the use of any rights or patents, nor does it
encourage, nurture or back their infringement.
The restrictions on the guarantee suppose no limitation on the legal rights of the consumer established in
applicable national legislation, nor do they affect any rights derived from the bargain and sale agreement
between the consumer and supplier.
WARRANTY

Service Manual
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All of the information provided in this Service Manual has been included in the confidence that it
is true, although it does not constitute any responsibility or implicit or explicit guarantee. GAMA
reserves the right at any time without forewarning to make all necessary improvements and
modifications to this Service Manual in order to rectify any possible typographical errors,
increase the information contained and enter the changes made to the characteristics and
performances of the gun.
This chapter contains important information on safety, handling and use of your GAMA New
MASTER IIIgun.
Before installing and operating the GDI gun, carefully read the technical
and safety documentation in this manual. Special attention should be paid
to the information for knowing and understanding the handling and
conditions of use of the gun. All of the information is aimed at enhancing
User Safety and avoiding possible faults due to incorrect use of the gun.
A WARNING! establishes information for alerting you on the situations which could
cause serious injury if the instructions are not followed.
A PRECAUTION! establishes information which indicates how to avoid damage to the
gun and how to avoid a situation which could cause minor injuries.
A NOTE is relevant information on the procedure being carried out.
Careful study of this manual will help you to become more acquainted with the gun and the
procedures. Following the instructions and recommendations here will reduce the potential risk
of accidents in installing, using or maintaining the gun, and will give you the problem-free
operation for a longer time, greater output and the possibility of detecting and resolving
problems quickly and simply.
Keep this Service Manual for future consultation of useful information at all times. If you lose the
manual, ask for a new copy from your local GAMA distributor or make direct contact with Garraf
Maquinaria, S. A.
WARNING: The gun's design and configuration do not allow it to be used in potentially
explosive atmospheres or to exceed the pressure and temperature limits described in the
technical specifications of this manual.
Always use liquids and solvents that are compatible with the unit. In the event of doubt, consult
the GAMA technical service.
SAFETY AND HANDLING

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When working with the gun, it is essential to dress suitably and use personal protection
equipment, including the unlimited use of gloves, protective goggles, safety footwear and face
masks. Use breathing equipment when working with the gun in enclosed or insufficiently
ventilated atmospheres. The introduction and follow-up of safety measures must not be limited
to those described in this manual. Before starting to use the gun, a rigorous analysis must be
made of the risks derived from the products to be dispensed, the type of application and the
working environment.
The gun forms part of the projection equipment, which is why all safety measures must be taken
that are provided for the start-up use of the equipment, in addition to all specific measures for
the use of the gun.
Carefully read the safety data sheet provided by your supplier to prevent
any possible injury caused by incorrect handling of the raw materials and
solvents used in the process.
Deal with the waste caused according to current regulations.
To prevent serious damage caused by the impact of fluids under
pressure, never open a connection or do maintenance work on
components subject to pressure until you are sure that all pressure has
been eliminated.
Use suitable protection when operating, maintaining or simply being in
the area where the equipment is working. This includes, but is not limited
to, the use of protective goggles, gloves, shoes and safety clothes and
breathing equipment.
The equipment includes components which reach high temperatures and
may cause burns. The hot parts of the unit must not be handled or
touched until they have completely cooled.
To prevent serious injury caused by crushing or amputations, do not work
with the equipment if the moving part safety protections are not duly
installed. Make sure that all safety protections are correctly fitted after
carrying out repair or maintenance work on the equipment

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* High-pressure internal mixture
* Automatical cleaning by pressurised air
* No solvents required
* Mechanical spraying
* Exterior greasing of the mix chamber
Approximate weight: 1 Kg
Dimensions: H 19 cm / W 9 cm / L 19 cm
Maximum working pressure:_________________________246 Kgf/cm2 (24 MPa) / 3500 psi
Required air pressure:_________________________6-8 Kgf/cm2 (0.6-0.8 MPa) / 85-114 psi
Maximum production ratio 1:1:________________________________ 18 Kg/min / 40 lb/min
Minimum production ratio 1:1: _______________________________ 1.5 Kg/min / 3.3 lb/min
Opening force @ 6 bar: ____________________________________________ 99 Kg / 218 lb
Closing force @ 6 bar:____________________________________________ 119 Kg / 260 lb
Approximate air consumption @ 6 bar (50 series/min):________________307 litres/minute
CHARACTERISTICS
SPECIFICATIONS

Service Manual
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The main components and their description are given for better knowledge of the elements of
the NEW MASTER III gun. For a more precise identification, see the Components Manual ref.
NR-00072.
1. Head Unit.
2. Polyol Side Cartridge Unit
3. Isocyanate Side Cartridge Unit
4. Polyol Non-Return Cartridge Unit.
5. Isocyanate Non-Return Cartridge Unit.
6. Head Fixing Nut.
7. Polyol Manual Valve
8. Isocyanate Manual Valve
9. Mix chamber
10. Trigger
11. Diffuser.
12. Blocking Device
13. Coupling block.
GENERAL DESCRIPTION

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PRECAUTION: When working with the gun or doing maintenance on it, all suitable
protection must be used in accordance with the recommendations and specifications
given by the product suppliers.
GAMA provides a series of tools and accessories which are necessary for assembling the gun.
The unit is made up of the following elements:
Tube spanner, chuck holder, grease tube, air connection pipe, fast plug, cleaning chucks,
operations manual and components manual.
1. Completely close the manual valves by turning them clockwise. The manual valves control
the input flow of each product to the chamber and are located on the Coupling Block.
2. Connect the air supply pipe to the connector at the rear of the gun.
3. Connect the Isocyanate hose (red terminal) to the Isocyanate input connector (letter A) on
the Coupling Block.
4. Connect the Polyol hose (blue terminal) to the Polyol input connector (letter R) on the
Coupling Block.
NOTE: The product
hoses have been
distinguished with red
and blue in order to
allow them to be
rapidly identified. The
red corresponds to the
Isocyanate hose and
the blue corresponds
to the Polyol hose. To
avoid connection
errors, the Isocyanate
and Polyol hose
coupling connectors
are of different sizes,
which makes it
impossible for
connections to be
swapped.
INSTALLATION AND START-UP

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5. Open the manual air valve
6. Pressurise the unit and make sure there are no leaks.
7. Activate the trigger several times to make sure the mix chamber moves correctly.
8. Make sure that the pressure in the machine and the temperature of the heaters and the
hoses are correct (see the Machine Service Manual).
9. Completely open the manual valves of each product by turning them anti-clockwise.
10. Press the blocking device and turn it anticlockwise to leave it in projection mode or
position.
11. Perform a test projection in a vessel
WARNING: Before carrying out maintenance, repair or cleaning work, press the
blocking device and turn it clockwise to leave it in blocking position or mode. Always
remove the coupling block from the gun, completely close the manual product input
valves and disconnect the air supply to avoid any possible accident.

Service Manual
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This NEW MASTER III model comes with a head turning mechanism so that it can be turned
according to the inlet position of the product hoses.
Do the following to make the change:
1. Completely close the manual valves by turning them clockwise.
2. To eliminate the pressure from the gun, press the trigger and project with the gun until the
projection fan begins to narrow.
3. Press the blocking device and turn it clockwise to leave it in blocking position or mode.
4. Close the air inlet valve.
5. Remove the coupling block from the gun. Use a cloth dampened in solvent to clean the
contact surfaces and the seals of the non-return cartridges.
6. Turn the isocyanate cartridge one turn anticlockwise.
7. Turn the polyol cartridge one turn anticlockwise.
8. Turn the locknut half a turn anticlockwise.
9. Pull lightly on the mix head and turn it 180º (half a turn).
10. Gently press the head until it is seated on the throat of the sleeve and cannot turn. If you
do not find the fixing position, leave the head in its theoretical position and tighten the fixing
nut slightly.
11. Make sure the head is seated and tighten the sleeve throat fixing nut to fix the head.
12. Tighten the two side cartridges.
13. Connect the coupling block to the mixhead and fix it firmly with the central screw.
14. To leave the gun operative, carry out the following steps for Installation and Start-up.
N.B. To pass from one position to another, do not loosen the head fixing nut more than
half a turn.

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1. Perform the Unit Standstill Method with the procedure indicated in the Machine Service
Manual.
2. Completely close the manual valves of each product by turning them clockwise.
3. To eliminate the pressure from the gun, press the trigger and project with the gun until the
projection fan begins to narrow.
4. Press the blocking device and turn it clockwise to leave it in blocking position or mode
5. Remove the coupling block from the gun. Use a cloth dampened in solvent to clean the
contact surfaces and the seals of the non-return cartridges.
6. Remove the non-return unit with bottom
filter and the friction bushing unit on the
Polyol side located in the mixing block or
head. Clean the unit with gun cleaning
solvent.
7. Remove the non-return unit with bottom
filter and the friction bushing unit on the
Isocyanate side located in the mixing block
or head. Clean the unit with gun cleaning
solvent.
NOTE: To remove the check valve and filter
cartridges, use a flat screwdriver to lever and
remove the assemblies. Be careful not to
damage the O-rings. If for any reason, it is
not possible to remove the cartridges by this
procedure, you can alternatively use a
threaded rod or M4 screw, and use them as
an extractor.
8. Remove the filters. Clean them carefully with gun-cleaning solvent, making sure that the
mesh is completely free of product remains.
PRECAUTION: To avoid spilling the rest of the product which has accumulated in the
side cartridges and in the non-return cartridges onto the floor, always remove the
coupling block and the side cartridges on a waste vessel.
9. Loosen the head by turning the fixing nut anti-clockwise. Turn the head 45º clockwise. Pull
on the head to remove it from the gun body. Clean the block with gun cleaning solvent.
10. Remove the diffuser and extract the chamber from the rear of the head.
11. Clean the two contact surfaces of the mix chamber.
PRECAUTION: Use wooden or plastic utensils or a brass brush for cleaning. Do not
use metal utensils that can scratch the contact surfaces.
12. Fit all the components and put the coupling block in the gun.
STANDSTILL METHOD

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13. Remove the stopper and grease the mix
chamber with the greasing pump supplied in
the kit with the gun. this will prevent the
cleaning air of the gun from drying the
ISOCYANATE product, and will therefore
prevent it from crystallising and scratching
the chamber and the bushing.
NB.: The action of lubricating 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 product remains on the gun
components, do not swap Isocyanate parts with Polyol parts. The gun has the Isocyanate
side marked with the letter A.
If the product hoses still have pressure, follow the Standstill Method
indicated in the Machine Service Manual.
To eliminate the pressure from the hoses with the gun dismantled, put the
product inlet coupling block in a suitable container, remain at a careful
distance and very carefully, very slowly open the manual valves. With
pressure, the product will come out of the top of the coupling block.

Service Manual
12/25 1.4 Issue Ref. NR-00073-ENG
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To get the most of your MASTER III gun, periodical maintenance must be carried out.
Carefully read the safety data sheet provided by your supplier to prevent
any possible injury caused by incorrect handling of the raw materials and
solvents used in the process.
Deal with the waste caused according to current regulations.
To prevent serious damage caused by the impact of fluids under
pressure, never open a connection or do maintenance work on
components subject to pressure until you are sure that all pressure has
been eliminated.
Use suitable protection when operating, maintaining or simply being in
the area where the equipment is working. This includes, but is not limited
to, the use of protective goggles, gloves, shoes and safety clothes and
breathing equipment.
The equipment includes components which reach high temperatures and
may cause burns. The hot parts of the unit must not be handled or
touched until they have completely cooled.
To prevent serious injury caused by crushing or amputations, do not work
with the equipment if the moving part safety protections are not duly
installed. Make sure that all safety protections are correctly fitted after
carrying out repair or maintenance work on the equipment
MAINTENANCE

Service Manual
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Gun block unit and mix chamber
WARNING: Before carrying out maintenance work on the gun, make sure that the unit
has been completely stopped, that all of the push buttons and the main switch are turned
off and that the unit is disconnected from the main power supply. The gun is a
component which works under pressure. No connection must be opened or
maintenance work be done on component subject to pressure until the pressure has
been completely eliminated.
1. Remove the coupling block.
2. Use a cloth dampened in solvent to clean the contact surfaces and the seals of the non-
return cartridges.
PRECAUTION: To avoid spilling the rest of the product which has accumulated in the
cartridges onto the floor, always remove the coupling block and the side cartridges on a
waste vessel.

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3. Remove the lower check valve cartridges as shown on page 10 with the help of a
screwdriver, threaded rod or screw.
4. Loosen the head fixing nut by turning it anti-clockwise and then remove the central block or
head by turning it 45º clockwise and pulling on it so that it separates from the rest of the
gun. Inspect the o-ring on the fixing nut and replace it if necessary.
5. Unscrew and remove the isocyanate cartridge
6. Unscrew and remove the polyol cartridge
7. Unscrew the diffuser and inspect the internal seal.
Round Jet Assembly
8. Make sure the air holes for projection are not obstructed. If they are blocked or dirty, clean
them with suitable brushes of the right size.
Cleaning “Round” Diffuser Projection
Air Holes
N.B.: the diffuser cleaning chucks are attached with it in the spare parts and in the gun
tool kit.
9. Remove the mixing chamber from the rear of the head. Inspect it and replace it if it is
damaged.

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10. To clean the product holes of the chamber, use suitable brushes of the right size for the
holes. It is not necessary to remove the head chamber to do this operation.
Cleaning “Round” Chamber Product Input
Holes
Cleaning “Round” Chamber Product
Output Hole
N.B.: the chamber cleaning chucks are attached with them in the spare parts and in the
gun tool kit.
11. Put the block in a vessel with gun cleaning liquid.
12. To eliminate all product remains, put the gun block unit in a vessel with gun cleaning liquid
and rub it with a brass brush.
PRECAUTION: Use wooden or plastic utensils or a brass brush for cleaning. Do not
use metal utensils that can scratch the contact surfaces.
Rearm the gun according to the following procedure:
13. Screw on the friction bushing cartridges by hand, paying attention to the location of each
one (“A” ISO side and “R” POL side).

Service Manual
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14. Insert the mixing chamber in the head
paying attention to its position (“A” ISO
side “R” POL side). Make sure the notch
on the head of the chamber is always
turned to the “A” side ISO.
15. Fit the seal and the PCD if you are
working with the “Flat” chamber.
16. Screw the diffuser onto the chamber by
hand.
17. Fit the gun block unit or head by inserting
the head of the chamber in the housing at
the end of the plunger shaft turned 45º.
18. Turn the head until it is in vertical position
and push it down so that the positioning
grooves fit on to the sleeve.
19. If you fail to find this position, place the
head in the theoretical position and lightly press the fixing nut. Make sure the head is
unable to turn and tighten the fixing nut.
20. Use a spanner first to tighten the isocyanate cartridge and then the polyol cartridge.
21. Fit the filters and non-return cartridges on the head, paying attention to the location of each
one (“A” ISO side and “R” POL side).Take care not to damage the cartridge seals when
inserting them on the head (use grease for easier insertion).
22. Fit the coupling block.

Service Manual
17/25 1.4 Issue Ref. NR-00073-ENG
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Side cartridge unit
WARNING: Before carrying out maintenance work on the gun, make sure that the unit
has been completely stopped, that all of the push buttons and the main switch are turned
off and that the unit is disconnected from the main power supply. The gun is a
component which works under pressure. No connection must be opened or
maintenance work be done on component subject to pressure until the pressure has
been completely eliminated.
1. Perform the Unit Standstill Method with the procedure indicated in the Machine Service
Manual.
2. Completely close the manual valves of each product by turning them clockwise.
3. To eliminate the pressure from the gun, press the trigger and project with the gun until the
projection fan begins to narrow.
4. Disconnect the air supply from the gun.
5. Unscrew the isocyanate side cartridge by turning it anticlockwise and remove it from its
housing. Clean the housing with gun cleaning solvent and make sure no loose particles
remain inside.
PRECAUTION! Use wooden or plastic utensils or a brass brush for cleaning. Do not
use metal utensils that can scratch the surface.
Before cleaning the cartridge housing and contact bushing with cleaning fluid, remove
all of the o-rings in these components to avoid them being damaged by the cleaning fluid
or the brass brush.
6. Check the seals of the cartridge and the contact bushing. Replace them if they are worn or
damaged.
7. Check the metal friction bushing for wear and measure its complete length. Replace it if
the length is under 7 mm.
8. Grease all of the components and refit them in the cartridge.
9. Screw the isocyanate cartridge unit into its housing until it blocks. Make sure it is correctly
tightened to avoid product leaks.
10. Do the same with the polyol
cartridge. (points 5-9).

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11. Carry out the projection procedure indicated in the start-up section.
12. Start the gun.
PRECAUTION: Use wooden or plastic utensils or a brass brush for cleaning. Do not
use metal utensils that can scratch the contact surfaces.
Filter and Non-Return cartridge unit
WARNING: Before carrying out maintenance work on the gun, make sure that the unit
has been completely stopped, that all of the push buttons and the main switch are turned
off and that the unit is disconnected from the main power supply. The gun is a
component which works under pressure. No connection must be opened or
maintenance work be done on component subject to pressure until the pressure has
been completely eliminated.
1. Perform the Unit Standstill
Method, following the
procedure indicated in the
Machine Service Manual.
2. Completely close the manual
valves of each product by
turning them clockwise.
3. To eliminate the pressure
from the gun, press the
trigger and project with the
gun until the projection fan
begins to narrow.
4. Disconnect the air supply
from the gun.
5. Remove the lower check
valve cartridges as shown on
page 10 with the help of a
screwdriver, threaded rod or
screw.
6. Unscrew the stopper and
remove the spring and the
non-return ball. Clean them
with gun-cleaning solvent.
7. Separate the filter and clean it with gun cleaning solvent. Make sure that it is not blocked. If
you see that the mesh is obstructed over more than 20% of its filter surface, replace it.
8. Clean all of the components meticulously to eliminate all product remains using a cloth
dampened with gun cleaning solvent and a brass brush.
9. Make sure the holes of the filter holder cartridge are not blocked by remains of crystallised
product. If you should see any dirt on the head, clean the communicating drill holes with a
drill and a brass brush.

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Trigger and valve
WARNING: Before carrying out maintenance work on the gun, make sure that the unit
has been completely stopped, that all of the push buttons and the main switch are turned
off and that the unit is disconnected from the main power supply. The gun is a
component which works under pressure. No connection must be opened or
maintenance work be done on component subject to pressure until the pressure has
been completely eliminated.
1. Remove the coupling block.
2. Use a cloth dampened in cleaning fluid to clean the contact surfaces and the seals of the
non-return cartridge bases.
3. Disconnect the air pipe.
4. Remove the trigger stop screw.
5. Remove the lock nut and extract the screw holding the trigger.
6. Unscrew the nut of the trigger valve.
7. Remove the trigger shaft and carefully hold it by the end with pliers to remove it from its
housing. The trigger shaft has a spring in the base. Make sure you do not lose it.
8. Check the o-rings of the trigger shaft. Replace them if they are damaged. Apply a little
grease to make it easier to assemble.

Service Manual
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9. Make sure the trigger shaft housing is clean and apply a small layer of grease inside.
10. Fit the air hose to the rear of the gun with sealing paste on the thread to avoid air leaks.
11. Insert the trigger shaft in the spring and insert it inside the grip 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.
12. Screw on the trigger valve nut until it comes up against the base.
13. Fit the trigger with the screw and hold it with the lock nut.
14. Fit the trigger stop screw. Screw it to eliminate the play in the trigger (without moving the
shaft).
15. Fix the mixing block according to the procedure described in the pistol block unit and mix
chamber assembly section.
16. Start the gun.