GUSMER H-2000 User manual

"Teamwork & Communication"
H-2000 Third
Component Pump
Installation Instructions and
Parts Identification Manual
15810-INST
November 10, 1998
Issue 1
GUSMER CORPORATION ®
A Subsidiary of Gusmer Machinery Group, Inc.
One Gusmer Drive
Lakewood, New Jersey, USA 08701-8055
Toll Free 1-800-367-4767 (USA & Canada)
Phone: [phone]
Fax: [phone]
Copyright 1999, GUSMER CORPORATION ®
http://www.gusmer.com
NOTICE:This manual contains important information for your GUSMER equipment. Read and retain for future reference.

H-2000 Third Component Pump
215810-INST, Issue 1
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

Installation Instructions and Parts ID Manual Contents
1/7/99 3
CONTENTS
WARRANTY.....................................................................................................................................................................4
GENERAL SAFETY INFORMATION............................................................................................................................5
ACCEPTABLE EQUIPMENT USES .........................................................................................................................................5
OPERATIONAL SAFETY PROCEDURES..................................................................................................................................6
INSTALLATION...............................................................................................................................................................7
PREPARATION...................................................................................................................................................................7
INSTALLATION OF THE RETRO-FIT KIT...............................................................................................................................8
INSTALLATION OF THE AUXILIARY PUMP............................................................................................................................9
NORMAL OPERATING PROCEDURE........................................................................................................................11
PARTS IDENTIFICATION............................................................................................................................................12
AUXILIARY PUMP RETRO-FIT KIT.....................................................................................................................................12
AUXILIARY PUMP MOUNTING ASSEMBLY.........................................................................................................................14
AUXILIARY PUMP PROPORTIONING PUMP ASSEMBLY 10 SIZE PUMPS.................................................................................16
CATALYST SUPPLY TANK .........................................................................................................................................18
PRE-MIX CHAMBER ASSEMBLY..............................................................................................................................20
INSTRUCTION MANUAL DISCREPANCY REPORT................................................................................................21
LIST OF FIGURES
FIGURE 1. H-2000 PROPORTIONING PUMP ASSEMBLY ............................................................................................................7
FIGURE 2 HEX LOCK NUT.....................................................................................................................................................8
FIGURE 3. TYPICAL ASSEMBLY..............................................................................................................................................9
FIGURE 4. AUXILIARY PUMP ADJUSTMENT DETAILS .............................................................................................................11
FIGURE 5. AUXILIARY PUMP RETRO-FIT KIT (PART NO. 15810-10-KIT), EXPLODED VIEW ....................................................12
FIGURE 6. AUXILIARY PUMP MOUNTING ASSEMBLY (PART NO. 15828), EXPLODED VIEW.....................................................14
FIGURE 7. AUXILIARY PROPORTIONING PUMP ASSEMBLY (PART NO. 15800A-10), EXPLODED VIEW......................................16
FIGURE 8. CATALYST SUPPLY TANK (PART NO. OP902-R) EXPLODED VIEW........................................................................18
FIGURE 9. PRE-MIX CHAMBER ASSEMBLY (PART NO. 17857) EXPLODED VIEW ...................................................................20
LIST OF TABLES
TABLE 1. AUXILIARY PUMP RETRO-FIT KIT (PART NO. 15810-10-KIT), PARTS.....................................................................13
TABLE 2. AUXILIARY PUMP MOUNTING ASSEMBLY (PART NO. 15828), PARTS......................................................................15
TABLE 3. AUXILIARY PROPORTIONING PUMP ASSEMBLY (PART NO. 15800A-10), PARTS ......................................................17
TABLE 4. CATALYST SUPPLY TANK, (PART NO. OP901-ID), PARTS.....................................................................................19
TABLE 5. PRE-MIX CHAMBER ASSEMBLY, (PART NO. 17857), PARTS..................................................................................20

H-2000 Third Component Pump
415810-INST, Issue 1
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. Further, the terms and conditions of this
warranty shall not apply to services or repairs made to Product by any third party not authorized in
writing by Gusmer. For such Product, a written estimate will be submitted to 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, EXPRESSED 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, expressed 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 insure proper validation of your warranty, please complete the warranty card and return it to
Gusmer within two weeks of receipt of equipment.
Revised 11/12/98

Installation Instructions and Parts ID Manual General Safety Information
1/7/99 5
GENERAL SAFETY INFORMATION
It is necessary to understand and follow the instructions in this manual to insure 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, and some two-component epoxy systems, specifically polyureas. 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.

H-2000 Third Component Pump
615810-INST, Issue 1
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 SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE
OPERATOR TO CERTAIN HAZARDS.ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BETAKEN
SO AS TO AVOID EXCEEDING THE THRESHOLD LIMIT VALUE (TLV) OF THE PRODUCTS BEING
USED, AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OR OTHER QUALIFIED AGENCY. INFORMATION CONCERNING PERSONAL PROTECTION AND
PROPER HANDLING FROM THE SUPPLIER OF SUCH CHEMICALS.
High Voltage
WARNING: TO PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK, NEVER OPEN THE
ELECTRIC CONSOLES OR OTHERWISE SERVICE THIS EQUIPMENT AND/OR EQUIPMENT USED WITH
IT BEFORE SWITCHING OFF THE MAIN POWER DISCONNECT AND INTERRUPTING SUPPLY VOLTAGE
AT THE SOURCE. THE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY A
QUALIFIED ELECTRICIAN.
High Pressure
WARNING: THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC
COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI. TO AVOID SERIOUS BODILY INJURY
FROM HYDRAULIC INJECTION OF FLUID, NEVER OPEN ANY HYDRAULIC CONNECTIONS OR SERVICE
HYDRAULIC COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO.
Personal Protective
Equipment
WARNING: TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR MUST BE WORN
WHEN OPERATING, SERVICING, OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS
EQUIPMENT.THIS INCLUDES, BUT IS NOT LIMITED TO, EYE AND FACE PROTECTION, GLOVES,
SAFETY SHOES, AND RESPIRATORY EQUIPMENT AS REQUIRED.
High Temperature
WARNING:THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH
TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES. TO PREVENT
SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL, NEVER ATTEMPT TO SERVICE THE
EQUIPMENT BEFORE ALLOWING IT TO COOL.
Warning
WARNING:FAILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN
PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT FROM ONE OR MORE OF THE ABOVE
LISTED HAZARDS

Installation Instructions and Parts ID Manual Installation
1/7/99 7
INSTALLATION
IMPORTANT: Before you begin turn off all electrical power to the machine. Drain all
chemical from the machine. Suggested method is by forced air.
PREPARATION
Figure 1. H-2000 Proportioning Pump Assembly
1. Close both Supply Valves.
2. Bleed all chemical pressure to zero.
3. Remove Polyethylene Pipe Plug from the Iso proportioning pump lube cylinder.
4. Position the Clevis Pin for removal from the Lube Cylinder.
5. Remove the Clevis Pins from both the Iso and Resin pumps with the Clevis
Extractor Tool.
6. Remove all hoses from both proportioning pumps.
7. Detach each Proportioning Pump Assembly from the pump line by unscrewing the 4
Socket Head Cap Screws.
8. Remove the Iso Lube Cylinder by manually pulling it off.
9. Unscrew the Resin and Iso Cylinder Clevis by using a wrench on both sides and
simultaneously break loose both clevis's.
10. Remove the Activator Plate.
Important: If Hydraulic Cylinder Standoffs are removed they must be re-torqued to
200 inch/lbs.

H-2000 Third Component Pump
815810-INST, Issue 1
INSTALLATION OF THE RETRO-FIT KIT
IMPORTANT: It is recommended to use a thread sealant on all pipe fittings prior
to any installation to prevent leakage.
ON RESIN SIDE ONLY:
1. Install the Bronze Bushing on to the Activator Plate
2. Slide the Bronze Bushing on the Activator Plate over Reversing Switch Pump
Spacer.
3. Install the replacement Clevis onto Resin side of the Hydraulic Shaft.
4. Mount the Activator Plate to the replacement Clevis with a flat head cap screw.
ON ISO SIDE ONLY:
5. Reinstall the Clevis with the Hex Lock
Nut onto Iso side of the Hydraulic Shaft as
shown in figure 2.
6. Reinstall original Iso Lube Cylinder.
NOTE:
Position the clevis on the resin side for
attaching to the arm from the Auxiliary
Pump. Position the clevis on the Iso
side to line up with the access hole on
the Lube Cylinder in order to attach the
Proportioning Pump Clevis and
Hydaualic Cylinder Clevis with the
Clevis Pin.7. Secure the Iso Proportioning Pump
Assembly back onto the pump line by
reinserting the Clevis pin with the Clevis
tool. Figure 2Hex Lock Nut
8. Install and tighten the Proportioning Pump assembly to the pump line with 4 Socket
Head Cap Screws.
9. Cover the Clevis pin access hole with the Polyethylene Pipe Plug.
ON RESIN SIDE ONLY:
10. Secure the Resin Proportioning Pump Assembly back onto the pump line by
inserting the Clevis pin with the Clevis tool.
11. Install and tighten the Proportioning Pump Assembly to the Pump Line with 4
Socket Head Cap Screws.

Installation Instructions and Parts ID Manual Installation
1/7/99 9
INSTALLATION OF THE AUXILIARY PUMP
Figure 3. Typical Assembly
1. Remove the four round head machine screws from the top of the Resin
Proportioning Pump and set aside.
2. Mount the Pump Mounting Assembly to the top of the Resin Proportioning Pump by
aligning the bracket bolt pattern with the existing holes and secure with the four
replacement socket head cap screws.
3. Align the lower pivot point of the Drive Arm with the upper pivot point of the
replacement Clevis and use the Clevis tool to insert the replacement Clevis Pin.
4. Remove the two side pivot screws from the Auxiliary Pump Assembly.
5. Align the yoke on the Auxiliary Pump with the adjustable pivot on the drive arm
bracket and insert the Yoke Pin.

H-2000 Third Component Pump
10 15810-INST, Issue 1
6. Snap Tru-Arc Rings onto both ends of the Yoke pin.
7. Attach the Auxiliary Pump to the bracket using the two side pivot screws.
8. Install Hex Nipple in the side of the pump flange.
9. Install the Check Valve and Hose Elbow; and orient as shown.
10. Install Male Elbow onto the Auxiliary Pump.
11. Install the Interconnect and Supply hoses as shown.
12. Insure all tubing and hoses are properly aligned and tightened before attempting
any start-up procedures.
You may now restart the Proportioning Unit using initial start up procedures
located in your operator’s manual.
Please retain the following remaining parts for future use:
Part Number. Description Qty
15514 Clevis 1
1501A-7-1 Activator Plate 1

Installation Instructions and Parts ID Manual Normal Operating Procedure
1/7/99 11
NORMAL OPERATING PROCEDURE
The Auxiliary Pump operates the same as the Isocyanate and Resin Proportioning
Pumps. When a Third Component is required for a particular application: adjusting the
stroke length controls the exact amount being proportioned into the system.
Figure 4. Auxiliary Pump Adjustment Details
Changing the stroke length of the piston varies the output on the Auxiliary Pump. To
do this loosen the adjusting nut and align the indicator arrow on the Adjustable pivot
with the desired percentage marked on the Drive Arm and retighten the adjusting nut.

H-2000 Third Component Pump
12 15810-INST, Issue 1
PARTS IDENTIFICATION
AUXILIARY PUMP RETRO-FIT KIT
Figure 5. Auxiliary Pump Retro-Fit Kit (Part No. 15810-10-Kit), Exploded View

Installation Instructions and Parts ID Manual Parts Identification
1/7/99 13
TABLE 1.AUXILIARY PUMP RETRO-FIT KIT (PART NO. 15810-10-KIT), PARTS
Part Number Description Quantity
0373 Male Elbow 2
0381-2 Nipple 1
0466A Hex Nipple 1
1327 Interconnect Hose 1
5512-8 Socket Head Cap Screw 4
6303-17 Jic Fitting 1
15750-6 Baffle Lock Nut (Not Shown) 1
15800A-10 Auxiliary Proportioning Pump Assembly 1
15828 Pump Mounting Assembly 1
15851 Check Valve Assembly 1
17857 Pre-Mix Chamber Assembly 1

H-2000 Third Component Pump
14 15810-INST, Issue 1
AUXILIARY PUMP MOUNTING ASSEMBLY
Figure 6. Auxiliary Pump Mounting Assembly (Part No. 15828), Exploded View

Installation Instructions and Parts ID Manual Parts Identification
1/7/99 15
TABLE 2.AUXILIARY PUMP MOUNTING ASSEMBLY (PART NO. 15828), PARTS
Part Number Description Quantity
0370-1 Hex Nut 1
1521-1-2 Flat Head Cap Screw 1
15515 Clevis Pin 2
15829-1 Idler Link 1
15829-10 Pump Clevis 1
15829-2 Drive Arm 1
15829-3 Adjustable Pivot 1
15829-4 Washer 1
15829-5 Yoke Pin 1
15829-6 Pivot Pin 2
15829-7 Tru Arc 1
15829-8 Hydraulic Cylinder Clevis 1
15829-9 Reversing Plate 1
15830 Main Bracket Assembly 1

H-2000 Third Component Pump
16 15810-INST, Issue 1
AUXILIARY PUMP PROPORTIONING PUMP ASSEMBLY
10 SIZE PUMPS
Figure 7. Auxiliary Proportioning Pump Assembly (Part No. 15800A-10), Exploded View

Installation Instructions and Parts ID Manual Parts Identification
1/7/99 17
TABLE 3.AUXILIARY PROPORTIONING PUMP ASSEMBLY (PART NO. 15800A-10), PARTS
Part Number Description Quantity
15813 Valve Cover Bracket 1
0461 Snap Ring 1
15805-2 O-Ring 2
0352A-1 Socket Head Cap Screw 4
1417-24 Wave Spring 2
15503 0-3000 PSI Liquid Fill Gauge 1
15801-10 Piston Rod 1
15802-10 Pump Cylinder Block 1
15803-10 Pump Flange 1
15804A Pump Base 1
15805-S Check Valve 2
15806 Inlet Valve Cover 1
15807 Outlet Valve Cover 1
15808 Pivot 2
15809-10 Yoke 1
1707-15-8 Lockwasher 1
15811 Packing Set 1
1812 Packing Support Washer 2
1813 Packing Set 1
1814 Spring Retainer Washer 1
1815 Conical Spring 1
1816 Packing Retainer Washer 1
1817 Packing Support Washer 1
1818 Socket Head Cap Screw 1
4406-16 Socket Head Cap Screw 4
0807 O-Ring 1
9403-N O-Ring 1
9405-N O-Ring 1
9412 Pressure Gauge Adapter 1
9462 Pump Screen 1
9463 Socket Head Cap Screw 2
9464 Screen Screw 1
OP219-4 Socket Head Cap Screw 1
15810 Hose Nipple 1
6465 Pipe Tee 1
15516-2200 Pressure Switch 1

H-2000 Third Component Pump
18 15810-INST, Issue 1
CATALYST SUPPLY TANK
Figure 8. Catalyst Supply Tank (Part No. OP902-R) Exploded View

Installation Instructions and Parts ID Manual Parts Identification
1/7/99 19
TABLE 4. CATALYST SUPPLY TANK, (PART NO. OP902-R), PARTS
Part Number Description Quantity
0381-2 Nipple 1
0487A Ball Valve 1
1128 Needle Valve 1
1142 R-Swivel Fitting 1
2130 Air Hose 1
2145-1 Quick Disconnect Plug 1
2145-2 Quick Disconnect Coupler 1
OP156-30 Hex Nipple 1
OP202-6 Bushing 1
OP901-2 Elbow 1
OP901-3-1 Pressure Relief Valve Assembly (Plastic) 1
OP901-3-2 Pressure Relief Valve Assembly (Metal) 1
OP901-4 O-Ring (Lid) 1
OP901-5 3 Gal. Tank Lid 1
OP901-8 Street Elbow 45 1
OP901-9 Bushing 1

H-2000 Third Component Pump
20 15810-INST, Issue 1
PRE-MIX CHAMBER ASSEMBLY
Figure 9. Pre-Mix Chamber Assembly (Part No. 17857) Exploded View
TABLE 5. PRE-MIX CHAMBER ASSEMBLY, (PART NO. 17857), PARTS
Part Number Description Quantity
0377 Pipe Plug 1
0576 Pipe Plug 1
0855B-2 Pre-Mixer 4
9452-15-2 Pipe Plug 1
17857-1 Pre Mix Chamber 1