GUSMER D User manual

Model D
Spray Gun
Operating Manual
2943J-1-D
November 3, 2003
Issue 3
GUSMER CORPORATION ®
A Subsidiary of Gusmer Machinery Group, Inc.
One Gusmer Drive
Lakewood, New Jersey, USA 08701-8055
Toll Free 1-800-367-4767 (USA & Canada)
Phone: (732) 370-9000
Fax: (732) 905-8968
Copyright 2003, GUSMER CORPORATION ®
http://www.gusmer.com
NOTICE: This manual contains important information about your GUSMER equipment. Read and retain for future reference.

Model D Spray Gun
2 2943J-1-D, Issue 3
NOTICE:
The equipment described in this technical manual must only be operated or serviced by properly trained individuals,
thoroughly familiar with the operating instructions and limitations of the equipment. For technical service, call your local
distributor. Call: 1-800-FOR-GSMR (1-800-367-4767) for the name and telephone number of your local distributor.
NOTICE:
All statements, information and data given herein are believed to be accurate and reliable but are presented without
guarantee, warranty or responsibility of any kind expressed or implied. Statements or suggestions concerning possible use of
GUSMER equipment are made without representation or warranty that any such use is free of patent infringement, and are
not recommendations to infringe any patent. The user should not assume that all safety measures are indicated or that other
measures may not be required for a particular circumstance or application.

Operating Manual Contents
11/3/03 3
CONTENTS
LIST OF FIGURES.......................................................................................................... 4
WARRANTY .................................................................................................................... 5
GENERAL SAFETY INFORMATION.........................................................................6
ACCEPTABLE EQUIPMENT USES ......................................................................................6
OPERATIONAL SAFETY PROCEDURES ..............................................................................7
DESCRIPTION ................................................................................................................8
GUN SERVICE KITS.......................................................................................................... 9
SPECIFICATIONS ........................................................................................................10
OPERATION..................................................................................................................11
COUPLING BLOCK .........................................................................................................11
Manual Valves.......................................................................................................... 11
Installation and Removal.......................................................................................... 12
AIR HOSE CONNECTION ................................................................................................12
AIR CAP ADJUSTMENT VALVE ......................................................................................13
FELT WIPER...................................................................................................................13
VALVING ROD ADJUSTMENT SCREW............................................................................. 13
INITIAL SET UP PROCEDURE..........................................................................................14
DAILY START-UP PROCEDURE ......................................................................................15
DAILY SHUTDOWN PROCEDURE ....................................................................................15
SPRAY PATTERN ADJUSTMENT...................................................................................... 16
CLEANING PROCEDURE ..........................................................................................19
SERVICING PROCEDURES....................................................................................... 21
FILTER SCREEN REMOVAL AND SERVICE...................................................................... 21
CLEANING INJECTION SLOTS .........................................................................................22
VALVING ROD ADJUSTMENT (CLOSED POSITION).........................................................23
CENTERLINE COMPONENT REMOVAL ............................................................................25
CENTERLINE COMPONENT INSTALLATION.....................................................................28
APPENDIX .....................................................................................................................30
STANDARD MIXING CHAMBERS ....................................................................................30
INSTRUCTION MANUAL DISCREPANCY REPORT ...........................................31

Model D Spray Gun
4 2943J-1-D, Issue 3
LIST OF FIGURES
FIGURE 1. MAJOR COMPONENTS ........................................................................................8
FIGURE 2. CENTERLINE COMPONENTS ................................................................................8
FIGURE 3. 1-QUART GUN SERVICE KIT (P/N OP205) ........................................................9
FIGURE 4. 3-GALLON GUN SERVICE KIT (P/N OP206) ......................................................9
FIGURE 5. MANUAL VALVES..............................................................................................11
FIGURE 6. COUPLING BLOCK ..........................................................................................12
FIGURE 7. AIR HOSE CONNECTION ..................................................................................12
FIGURE 8. AIR VALVE ADJUSTMENT .................................................................................13
FIGURE 9. FELT WIPER ...................................................................................................13
FIGURE 10. VALVING ROD ADJUSTMENT SCREW...............................................................13
FIGURE 11. VALVING ROD (CLOSED POSITION).................................................................14
FIGURE 12. VALVING ROD (CLOSED POSITION).................................................................16
FIGURE 13. POINT OF VALVING ........................................................................................16
FIGURE 14. OPENING THE SPRAY PATTERN .......................................................................17
FIGURE 15. DESIRED PATTERN .........................................................................................17
FIGURE 16. SPLIT PATTERN ..............................................................................................18
FIGURE 17. FILTER SCREEN ASSEMBLY .............................................................................21
FIGURE 18. CHECK VALVES..............................................................................................22
FIGURE 19. VALVING ROD (CLOSED POSITION).................................................................23
FIGURE 20. RETAINER CASE REMOVAL..............................................................................23
FIGURE 21. VALVING ROD REMOVAL ................................................................................23
FIGURE 22. CENTERLINE COMPONENTS ............................................................................25
FIGURE 23. MIXING CHAMBER REMOVAL..........................................................................26
FIGURE 24. CHECK VALVE ...............................................................................................26
FIGURE 25. SLEEVE REMOVAL BLOCK...............................................................................27
FIGURE 26. MIXING CHAMBER INSERTION.........................................................................28
FIGURE 27. CHAMBER POSITIONING .................................................................................28
FIGURE 28. CHAMBER SEATING ........................................................................................28

Operating Manual Warranty
11/3/03 5
WARRANTY
Gusmer Corporation (Gusmer) provides a limited warranty to the original purchaser (Customer) of
Gusmer manufactured parts and equipment (Product) against any defects in material or
workmanship for a period of one year from the date of shipment from Gusmer facilities.
In the event Product is suspected to be defective in material or workmanship, it must be returned to
Gusmer, freight prepaid. If Product is found to be defective in material or workmanship, as
determined solely by Gusmer, Gusmer will issue full credit to Customer for the freight charges
incurred in returning the defective Product, and either credit will be issued for the replacement cost
of the Product or a replacement part will be forwarded no-charge, freight prepaid to Customer.
This warranty shall not apply to Product Gusmer finds to be defective resulting from: installation,
use, maintenance, or procedures not accomplished in accordance with our instructions; normal
wear; accident; negligence; alterations not authorized in writing by Gusmer; use of “look alike”
parts not manufactured or supplied by Gusmer; or Product used in conjunction with any other
manufacturer's pumping or proportioning equipment. For such Product, a written estimate will be
submitted to the Customer at a nominal service charge, itemizing the cost for repair. Disposition of
Product will be done in accordance with the terms stated on the written estimate.
The warranty provisions applied to product that are not manufactured by Gusmer will be solely in
accordance with the warranty provided by the original manufacturer of the product.
GUSMER MAKES NO WARRANTY WHATSOEVER AS TO THE MERCHANTABILITY OF,
OR SUITABILITY FOR, ITS PRODUCT TO PERFORM ANY PARTICULAR PURPOSE.
CREDIT FOR, OR REPLACEMENT OF, PRODUCT DEFECTIVE IN MATERIAL OR
WORKMANSHIP SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUSMER
OBLIGATIONS TO CUSTOMER. NO OTHER WARRANTY, EXPRESS OR IMPLIED ON
ANY PRODUCT IT MANUFACTURES AND/OR SELLS, WILL BE RECOGNIZED BY
GUSMER UNLESS SAID WARRANTY IS IN WRITING AND APPROVED BY AN OFFICER
OF GUSMER.
Under no circumstances shall Gusmer be liable for loss of prospective or speculative profits, or
special indirect, incidental or consequential damages. Further, Gusmer shall have no liability for
any expenses including, but not limited to personal injury or property damage resulting from failure
of performance of the product, use of the product, or application of the material dispensed through
the product. Any information provided by Gusmer that is based on data received from a third
source, or that pertains to product not manufactured by Gusmer, while believed to be accurate and
reliable, is presented without guarantee, warranty, or responsibility of any kind, express or implied.
Gusmer through the sale, lease, or rental of Product in no way expresses or implies a license for the
use of, nor encourages the infringement of any patents or licenses.
To ensure proper validation of your warranty, please complete the warranty card and return it to
Gusmer within two weeks of receipt of equipment.
Revised 09/02

Model D Spray Gun
6 2943J-1-D, Issue 3
GENERAL SAFETY INFORMATION
It is necessary to understand and follow the instructions in this manual to ensure proper
and safe operation of the equipment.
As with most mechanical equipment, certain safety precautions must be taken when the
equipment discussed in this manual is operated or serviced. Severe bodily injury or
damage to equipment and property may result if the instructions and precautions listed
throughout this manual are not followed.
Needless to say, sufficient guidelines cannot be developed to eliminate the need for good
common sense in the use and servicing of this equipment, and in the use and application
of the products, this equipment has been designed to process. Users of this equipment
must therefore, make their own determination as to the suitability of the information
contained in this manual to their specific operation and requirements. There should be
no assumption made that the safety measures and instructions contained herein are all-
inclusive, and that other safety measures may not be required for specific use or
application.
The following safety guidelines are generally applicable to the safe and efficient use of
the equipment.
Acceptable Equipment Uses
The equipment is designed for the dispensing of polyurethane foams, two-component
coating systems such as polyureas, and some two-component epoxy systems. Under no
circumstances should any acid or corrosive chemicals be used in the unit. Consult
GUSMER if there is any doubt about the compatibility of the chemical system to be used
in this equipment.
Any use of this equipment other than as indicated above constitutes misuse unless
express written approval is obtained from GUSMER.
Your Gusmer equipment incorporates design parameters, features, and functionality
developed in over 40 years of plural component equipment design and manufacture. It is
manufactured under the stringent standards of ISO 9001, and is backed by the Gusmer
Warranty included herein.
The use of genuine Gusmer replacement parts is recommended for your equipment.
Substitution of parts not designed, manufactured, or recommended by Gusmer may result
in reduced performance of, and/or damage to, your Gusmer equipment. Any alterations
to, or substitutions for, genuine Gusmer parts shall void the provisions of the Gusmer
Warranty.

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

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

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

Model D Spray Gun
10 2943J-1-D, Issue 3
SPECIFICATIONS
AIR SUPPLY: 90-100 psi (6-7.5 bars)
WEIGHT: 3 lbs (1.4 kilograms)
DIMENSIONS: Height: 8 inches (20 centimeters)
Length: 9.25 inches (24 centimeters)
Width (without coupling block): 2.4 inches (6 centimeters)
OPERATING PRESSURE:1000 psi maximum (70 bars)
OUTPUT: Maximum: 16 lbs./min. (7.3 kg/min) *
Minimum: 2 lbs./min. (.9 kg/min) *
MIXING: Internal direct impingement, airless atomization, solvent-free, mechanically self-
cleaning.
*Theoretical: actual results will vary with operating conditions.

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

Model D Spray Gun
12 2943J-1-D, Issue 3
INSTALLATION AND REMOVAL
WARNING: TO PREVENT THE RELEASE OF PRESSURIZED CHEMICAL, CLOSE BOTH MANUAL
VALVES COMPLETELY BEFORE ATTEMPTING TO REMOVE COUPLING BLOCK.
TOOLS REQUIRED
• 5/16” Nut driver
1. TO INSTALL THE COUPLING
BLOCK TO THE GUN:
a) Inspect coupling block gaskets for
nicks, damage and wear. Replace
if necessary.
b) With gaskets in place, fit the
coupling block to the gun block.
c) Insert the coupling block
mounting screw and tighten
securely into the gun block with
the 5/16” nut driver.
2. TO REMOVE THE COUPLING
BLOCK FROM THE GUN:
a) Disconnect the air hose.
b) Close both manual valves.
c) Remove the coupling block
mounting screw.
Figure 6. Coupling Block
d) Separate the coupling block from the gun. Take care not to lose the two
gaskets.
e) Using a clean cloth dipped in gun cleaner, wipe clean the mating surface of the
gun block and coupling block to remove residual chemical.
Air Hose Connection
Compressed air is delivered to the gun by the air supply hose that is part of the heated
hose assembly. The female “quick-disconnect” fitting on the air supply hose is coupled
with the male fitting on the gun air hose.
1. TO CONNECT THE AIR HOSES-
Pull back the sleeve of the female
fitting, insert the male fitting and slide
the sleeve forward to secure the
connection.
2. TO DISCONNECT THE AIR
HOSES- Pull back the sleeve of the
female fitting and pull out the male
fitting.
Figure 7. Air Hose Connection

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

Model D Spray Gun
14 2943J-1-D, Issue 3
Initial Set Up Procedure
TOOLS REQUIRED
• 5/16” Nut driver • Clean rag
• (2) 6” Adjustable wrench • Gun cleaner
• 5/64” Hex key • Disposable container
WITH THE COUPLING BLOCK REMOVED FROM THE GUN:
1. CHECK VALVING ROD
CLEARANCE IN THE CLOSED
POSITION- The rod should extend
approximately 1/32 inch (1mm)
beyond the tip of the mixing
chamber. If it does not, see Valving
Rod Adjustment on page 23.
Figure 11. Valving Rod (Closed
Position)
2. ADJUST VALVING ROD TRAVEL TO INITIAL SETTING- Proceed as follows:
a) Loosen the friction lock with the 5/64” hex key wrench, and then turn the
valving rod adjustment screw fully clockwise until it stops.
b) Turn the valving rod adjustment screw eleven (11) complete turns counter
clockwise.
3. INSTALL THE FEMALE QUICK DISCONNECT FITTING- Using two 6”
adjustable wrenches, install the female quick disconnect fitting onto the air supply
hose that is bundled with the chemical supply hoses.
4. CONNECT THE CHEMICAL HOSES TO THE COUPLING BLOCK- Using two
6” adjustable wrenches, connect the A-isocyanate hose (red-taped) to the notched
fitting on the coupling block. Connect R-resin hose (blue-taped) to the fitting
without notches on the coupling block.
5. CLOSE BOTH MANUAL VALVES.
6. PRESSURIZE THE CHEMICAL HOSES- Pressurize the A and R chemical hoses
and check for leaks. (See Proportioning Unit manual as required.)
7. BLEED AIR FROM THE CHEMICAL HOSES- Proceed as follows:
NOTE:
The thread sizes of the A
(Isocyanate) and R (Resin)
hose connections are
different, making it virtually
impossible to improperly
connect the hoses. The, A
(Isocyanate) thread is 1/2-20,
and the R (Resin) thread is
9/16-18.
a) Hold the coupling block with the exit ports pointed into a suitable container.
b) Open each manual valve to allow any trapped air to escape. Bleed each side for
a short time until the chemical leaving the hoses is free of air.
c) Close both manual valves.
8. CLEAN THE COUPLING BLOCK- Wipe away any chemical from the coupling
block and its mating surfaces using a clean cloth soaked in gun cleaner.
WARNING: DO NOT APPLY ANY GREASE TO THE MATING SURFACES OF THE COUPLING BLOCK
TO AVOID ACCUMULATION OF DIRT AND OTHER CONTAMINANTS IN THESE AREAS.
9. INSTALL THE COUPLING BLOCK ON THE GUN BLOCK- Proceed with the
Daily Start up Procedure or Shut down procedure as required.

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

Model D Spray Gun
16 2943J-1-D, Issue 3
Spray Pattern Adjustment
WARNING: THE FOLLOWING PATTERN TEST MAY CREATE A LARGE MASS (“BUN”) OF
URETHANE FOAM, WHICH CAN BE DANGEROUS. VERY HIGH TEMPERATURES CREATED BY
CHEMICAL REACTION INSIDE A BUN MAY NOT DISSIPATE AFTER THE OUTSIDE SURFACE HAS
COOLED. A LARGE BUN MAY CONTINUE TO REACT FOR SEVERAL HOURS AFTER SPRAYING UNTIL
THE FLASH (BURNING) POINT OF THE FOAM IS REACHED. ALWAYS BREAK APART BUNS INTO
SMALLER PIECES SO THAT HEAT INSIDE CAN ESCAPE.
1. CHECK VALVING ROD
CLEARANCE IN THE CLOSED
POSITION- The rod should extend
approximately 1/32 inch (1mm)
beyond the tip of the mixing chamber.
If it does not, see Valving Rod
Adjustment on page 23. Figure 12. Valving Rod (Closed
Position)
2. ADJUST VALVING ROD TRAVEL TO INITIAL SETTING- Proceed as follows:
a) Loosen the friction lock with the 5/64” hex key wrench, and then turn the
valving rod adjustment screw fully clockwise until it stops.
b) Turn the valving rod adjustment screw eleven (11) complete turns counter
clockwise.
3. LOCATE THE POINT OF VALVING-
Aim the gun at a disposable target.
Dispense short (one second) bursts
toward the target while simultaneously
withdrawing the valving rod adjustment
screw from the retainer case by ¼-turn
increments in a counterclockwise
direction. When the chemical stream
mists as shown in Figure 13, the point of
valving has been reached.
4. ADJUST AS SPECIFIED IN TABLE 1-
Noting the position of the notch in the
hex head of the adjustment screw, back
the screw out counterclockwise to within
the minimum and maximum number of
turns specified in Table 1. Notice the
spray pattern opening up as the
adjustment is made (See Figure 14).
Figure 13. Point of Valving

Operating Manual Operation
11/3/03 17
TABLE 1. VALVING ROD ADJUSTMENT FOR STANDARD MIXING CHAMBERS
Chamber Minimum Maximum Recommended
Distance of Gun
From Surface
Size of Pattern
46-800 1/2 turn 2 turns 12 in. (304-8 mm) 6 in. (152.4 mm)
46-810 1/2 turn 2 turns 12 in. (304-8 mm) 6 in. (152.4 mm)
55-776 1 3/4 turns 2 5/8 turns 18 to 20 in.
(457.2 to 508 mm)
8 in.
(203.2 to 228.6 mm)
62 2 turns 3 turns 18 to 20 in.
(457.2 to 508 mm)
8 to 9 in.
(203.2 to 228.6 mm)
70 2 turns 3 turns 18 to 20 in.
(457.2 to 508 mm)
10 to 12 in.
(254 to 304.8 mm)
78-851 2 turns 3 turns 24 in. (609.6 mm) 14 in. (355.6 mm)
Figure 14. Opening the Spray Pattern
5. FINE TUNE THE SPRAY PATTERN-.
After backing out the adjustment screw
the number of turns specified in Table 1,
make fine adjustments (1/8 turns or less
in either direction as required) to obtain
the type of pattern shown in Figure 15.
Moving the screw out beyond this point
may cause the pattern to split, as shown
in Figure 16.
If the full-round pattern cannot be
achieved, check to ensure that the
material temperature and spray pressure
are correct. If the pattern remains closed
upon reaching the maximum specified
number of turns out from the point of
valving, it is likely that the material
temperature is too low.
Figure 15. Desired Pattern

Model D Spray Gun
18 2943J-1-D, Issue 3
If the pattern splits or has a hollow
center, even with the adjustment screw
at the minimum number of turns from
the point of valving, it is likely that the
material temperature is too high.
After reaching a satisfactory spray
pattern, note the temperatures at the
proportioner and hose, and the position
of the notch on the adjustment screw.
As spraying proceeds, the pattern may
occasionally start to streak or change
from what was established. If this
happens, inspect the chamber tip and
remove any build-up of solid foam with
a wooden stick or brass wire brush.
Figure 16. Split Pattern
If the buildup recurs shortly after cleaning the tip, remove the air cap and make sure
it is clean on the inside, reinstall it, and ensure airflow to the air cap is properly set.
If there was no buildup on the air cap, check for the following items in this order:
a) Check the valving rod adjustment screw setting and readjust if
necessary.
b) Check the proportioning system for proper chemical pressures and
temperature settings and readjust if necessary. (See appropriate
operating manual(s) for your proportioning system.)

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

Model D Spray Gun
20 2943J-1-D, Issue 3
5. REMOVE THE SERVICE BLOCK OF THE GUN SERVICE KIT FROM THE
GUN
6. DISCONNECT THE AIR SUPPLY
7. CLEAN SCREENS, CHECK VALVES AND SCREEN SCREW- (See Filter Screen
Removal And Service on page 21.)
IMPORTANT: Inspect the air cap, mixing chamber and gun block for build up of
material and clean them as required. Do not use metal cleaning devices to clean
plastic components.
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