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Sprayjet-87 : Operation & Maintenance Manual

MANUAL FOR OPERATION

& MAINTENANCE OF

CORRSPRAY

COMBUSTION WIRE

SPRAY GUN


CAUTION

Before using the equipment,

read & understand this operating manual. In particular, refer to the

Safety precautions.

Under NO circumstances should any modifications

be made to the equipment without prior written approval from PPS.


CONTENTS SECTION 1. INTRODUCTION

1.1 SPRAYJET 87 gun 1.2 Principle of operation

SECTION 2. SAFETY MEASURES

2.1 General safety measures 2.2 Use of equipment 2.3 Reduction of fire & explosion hazards 2.4 Gases 2.5 Equipment maintenance 2.6 Backfire 2.7 Metal dusts 2.8 Gas cylinders precautions 2.9 Reduction of respiratory hazards 2.10 Reduction of noise hazards 2.11 Eye protection

SECTION 3. FLAME SPRAY EQUIPMENT

3.1 Air compressor 3.2 PPS Air control unit 3.3 PPS Gas glow meter 3.4 PPS Gas control unit 3.5 PPS Hose kit 3.6 Trolley with wire reel stand

SECTION 4. INSTALLATION

4.1 Spray booth 4.2 Check

SECTION 5. OPERATION

5.1 Operating controls 5.2 Hookup & Initial adjustments 5.3 Lighting 5.4 Spraying 5.5 Start-stop operation 5.6 Shutting down 5.7 Different sizes of wire 5.8 Different gases 5.9 Nozzles 5.10 Siphon plugs


SECTION 6. PART LIST OF SPRAYJET 87

6.1 Drive roll carrier & related parts, Wire grip PPShanism system 6.2 Gas Head Assy, Siphon plug & related parts 6.3 Drive unit with wire grip PPShanism removed, turbine & Speed control assy 6.4 Counter Shaft Assembly, Gear cover, Central Housing, Handle Drive Shaft Parts 6.5 Snubber Assy, Wire Grip Valve 6.6 Tool Post Fixture with Tools & Lubricants

SECTION 7. CONSTRUCTION & ASSEMBLY

7.1 Gas head 7.2 Valve core positioning 7.3 Gas siphon plug 7.4 Wire grip PPShanism 7.5 Lower drive rolls & gear 7.6 Rear wire guide & snubber 7.7 Turbine & speed control 7.8 Gear cover & Transmission gears 7.9 Drive shaft assembly 7.10 Counter shaft assembly 7.11 Central housing & gun handle 7.12 Wire grip valve 7.13 Gear case lubrication 7.14 Turbine bearing lubrication

SECTION 8. AVOIDING TROUBLE

8.1 Spraying 8.2 General gun care 8.3 Hoses 8.4 Difficult lighting 8.5 Backfire 8.6 Siphon plug 8.7 Wire nozzles 8.8 Gas head Valve 8.9 Sticking wire 8.10 Drive rolls 8.11 Speed control 8.12 Threads 8.13 Over heating

SECTION 9. ROUTINE MAINTENANCE SCHEDULE SECTION 10. METALLIZING WIRES


SECTION 11. WIRE GUIDE AND ROLL SELECTION CHART SECTION 12. SPRAYING TABLES & GENERAL COST DATA

12.1 How to use tables 12.2 How to compute sprayed area 12.3 Area formulae 12.4 How to calculate costs

SECTION 13. PERFORMANCE CHART

LIST OF FIGURES FIGURE 6 (A) DRIVE ROLL CARRIER & RELATED PARTS, WIRE GRIP PPSH. FIGURE 6 (B) 1 SIPHON PLUG & RELATED PARTS FIGURE 6 (B) 2 GAS HEAD ASSY FIGURE 6 (C) TURBINE & SPEED CONTROL ASSY FIGURE 6 (D) COUNTER SHAFT ASSY, GEAR COVER, DRIVE SHAFT ASSY, CENTRAL HOUSING AND GUN HANDLE FIGURE 6 (F) 1 TOOL POST FIXTURE FIGURE 6 (F) 2 TOOLS & LUBRICANTS


SECTION 1

INTRODUCTION 1.1 THE GUN The Sprayjet-87 Gun has been designed and built to be one of the worlds best hand guns for producing flame sprayed coatings with metallizing wires. The PPS-87 Flame Spray Gun is designed for the High Speed application of corrosion-resistant coatings. It sprays 1/8 (3.17mm) and 3/16 (4.76mm) soft metallizing wires such as zinc, aluminium, lead, tin and babbitt, with low melting points. Converting from one size of wire to another is quick and easy. The Sprayjet-87 Gun is not suitable for spraying wires made of hard metal with high melting points. Although the Sprayjet-87 Gun has been designed primarily for hand-held operation, a simple, rugged tool post fixture is supplied with each unit to permit mounting on a machine tool such as a lathe. 1.2 PRINCIPLE OF OPERATION The wire is pulled into the rear of the gun by an automatic feed PPShanism powered by a self-contained turbine driven by compressed air. The wire is fed through the gun into a fuel gas / oxygen flame. A stream of compressed air restricts the flame and blasts the molten tip of the wire, producing a fine metal spray. The Sprayjet-87 Gun offers many outstanding design features. Some of these are described below:

1. An improved version of Sprayjet-87 Guns siphon jet gas head produces high spray rates, low gas consumption and extreme resistance to backfire and its effects.

2. Nozzle-to siphon plug seals are O Rings, instead of being lapped surfaces, which are difficult to maintain.

3. The gas head valve provides long service life with limited maintenance. Worn or damaged valve parts can be replaced in the field without lapping or other precise fitting.

4. New-design nozzle and air caps provide excellent coatings at very high spraying speeds and without loading.

5. The nozzle, siphon plug and front wire guide assemble as a unit which can be quickly and easily removed and replaced, when changing wire size or servicing.

6. The Sprayjet-87 Guns controlled power governor provides increased power and stability of wire speed.


7. The drive rolls and wire guides are made of hardened stainless steel for high resistance to wear and corrosion.

8. A thumb-operated wire grip control starts and stops the wire feed. It is conveniently located for ease of operation.

9. A simple, rugged wire snubber is incorporated in the wire from accidentally pulling out of the gun.

SIZE & WEIGHT The PPS-87 Flame Spray Gun is approximately 9 (229mm) long, 9 (229mm) high and 5 (133mm) thick. It weighs approximately 2.6 Kgs. The gun is the heart of the complete flame spray installation. In the Sprayjet-87 Gun, you have the worlds best wire spray gun. It is built for continuous hard service and will perform efficiently and economically when operated and maintained accordingly to the instructions in this manual.


SECTION 2

SAFETY MEASURES 2.1 GENERAL Flame Spraying can be hazardous because it requires the use of combustible gases, containers and hoses under high pressure and potentially irritating or toxic spray materials. It may involve air contaminated by dusts and mists etc. However, it is a completely safe process when performed by a capable operator with proper understanding of flame spraying practices, knowledge of the equipment, care in operation and one who follow the recommended precautionary measures. 2.2 USE OF EQUIPMENT Sprayjet-87 Flame Spray Equipment has been expressly designed for flame spraying. Never use if for any other purpose such as welding, soldering, brazing and their like. 2.3 REDUCTION OF FIRE AND EXPLOSION HAZARDS Remember that the stream of sprayed metal is HOT. Point the lighted gun away from yourselves and away from materials, which will burn. Carelessness in pointing the gun at paper, wood or oily rags can result in fire. Be especially careful not to spray on the hoses, when lighting the gun. Hoses will burn. Keep them out of the way. 2.4 GASES All gas equipment such as fuel gas, oxygen and airlines, compressors regulators etc., should be inspected regularly for leaks and loose connection. 2.5 EQUIPMENT MAINTENANCE Maintain the flame spray equipment in first class condition. Follow the maintenance recommendations in the Sprayjet-87 Manual. 2.6 BACKFIRE Spray gun backfire can be prevented by proper maintenance. Inspect the gun and related equipment before starting to spray. Backfire may be caused by a leak at the nozzle, dirt in the nozzle, use of the wrong air cap etc. A gun will not backfire unless something is wrong. See the section on BACKFIRE in the AVOIDING TROUBLE Chapter in this Instruction Manual. 2.7 METAL DUSTS All dust having considerable calorific value can be explosive. This dust includes - flour, starch, hard rubber dust, wood flour, aluminium dust and the dust of other metals. Aluminium and magnesium dusts are particularly hazardous.


Care must be taken in handling them. To minimize the danger of dust explosion resulting from flame spraying, adequate ventilation must be provided for spray booths and other confined spaces, to prevent the accumulation of fumes and dust. Good housekeeping in the work area is essential. Inspect and clean regularly to ensure that there is no potentially dangerous accumulation of dust. Bag or filter type collectors are not suitable for metal spray dust. A water wash wet collector should be used. All of the dust must be wetted down and remain immersed in water. No accumulation of dry or partially wet dust should be permitted. A PPS Spray booth is recommended. All closed collectors should be provided with blow out holes or relief panels. All fans, pipes, dust arresters and motors should be electrically grounded. 2.8 GAS CYLINDERS PRECAUTIONS Charged gas cylinders are potentially dangerous. Never put a gas cylinder in a hazardous position. Keep cylinders away from heat and moisture. Always chain them to keep them from toppling. Put the valve caps on the cylinders when they are not connected for use. Do not hang a flame spray gun or its hoses or regulators or cylinder valves as a fire or explosion may result. 2.9 REDUCTION OF RESPIRATORY HAZARDS Fumes or dusts of lead, babbitts, chromium, zinc can be toxic and hazardous. Efficient spray booth and exhaust system are therefore essential while spraying these. Besides, if the operator feels any discomfort a suitable mask with respirating facility may be used. 2.10 REDUCTION OF NOISE HAZARD The operator and other personnel close to the flame spray operation should be protected from prolonged exposure to noise. If possible, the flame spray operation should be isolated. FAQ : The noise level of sprayjet-87 gun ranges from 120 140 dBA. 2.11 EYE PROTECTION Always wear Eye Protectors while operating, or watching the flame spray operating. Inspect the eye protectors frequently. Lenses and cover plates, which are scratched, pitted or damaged, can impair vision and seriously reduce protection.


SECTION 3

FLAME SPRAY EQUIPMENT A complete flame spray installation requires equipment to supply and control compressed air, oxygen, fuel gas and metallizing wire. 3.1 AIR COMPRESSOR A minimum of 33 CFM of free air delivery is required at 4.5 Kg/cm2 (65 psig). Taking into consideration the pressure in the piping, connections and regulator the line pressure of at least 5.0 Kg/cm2 (75 psig) at the regulator should be provided during spraying. 3.2 PPS AIR CONTROL UNIT This unit includes filters, regulator and plumbing hardware, designed for increased capacity, easier airflow and low maintenance. It assures proper control of air pressure to the gun and removes line condensate, oil and dirt. 3.3 PPS GAS FLOW METER This indicates the flow of oxygen and fuel gas to the gun. This is a balanced twin-tube instruction with easy to read scales, to ensure maximum efficiency through correct flame balance. 3.4 PPS GAS CONTROL UNIT This unit includes precision two-stage regulators for accurate adjustment of oxygen and fuel gas pressure. Where continuous, high speed spraying is required; manifolding is recommended for connecting several gas cylinders together. 3.5 PPS HOSE KIT This is a group of three-matched high quality, lightweight flexible hoses equipped with proper fittings for Sprayjet-87 Gun. It consists of a black air hose and a dual hose for gases; green or blue for oxygen and red for acetylene. The hoses have proper fittings to connect to the flowmeter at one end to the gun at the other. The meter end should be connected first and the hoses blown out at low pressure before the gun is connected. Air & Oxygen hose has right hand thread and the fuel gas hose has a left hand thread. Connector size of gas hoses: Flowmeter input- oxy/acety 1/2" UNF ON regulator outlet- oxy/acety 1/2" UNF Flowmeter to the gun 3/8" UNF Air input to the gun 1/2" UNF


3.6 TROLLEY WITH WIRE REEL STAND This is specially designed on four castor wheel to hold the coil of wire and with panel to mount the gas flowmeter, air control unit, gun mounting stand and tools tray. There is a provision on the trolley to keep a number off wire coils not in use.


SECTION 4

INSTALLATION Mount the Sprayjet-87 Gun in position for use. The gas flowmeter, the gas and air control units must be mounted without reach of the gun hoses. Position the fuel gas and oxygen cylinders with regulators in place. Gas cylinders should always be strapped or chained to the wall to prevent their being knocked over. Always blow out the gas cylinder valves before attaching the regulators. Always back out the pressure regulating screws before opening cylinder valves. Open the cylinder valves slowly. Do not let regulators stand under pressure when not in use. Failure to observe these precautions may result in damage to the regulators. Place the wire reel on the stand so that the wire will feed as straight as possible into the wire guide of the flame spray gun. When the flame spray gun is stationary, place the wire reel up with its position adjusted to feed the wire in a straight line into the rear wire guide. When the flame spray gun is mounted so that it moves, as on the carriage of a lathe, the wire control should be placed as far away from the gun as is practicable in order to reduce the bend in the wire as it passes into the rear wire guide. 4.1 SPRAY BOOTH Metal dust, fumes and the fuel combustion products call for an effective exhaust and dust collection system. In production installations, if the spraying station is enclosed, make sure that there is enough opening for inlet air so that the exhaust system is not starved. Under some conditions, metal dusts can be quite hazardous. For this reason, it is advisable to install a spray booth, especially designed for metal spraying. Dust collectors designed primarily for other kinds of dust may be found to be very ineffective and, in some cases, dangerous, if used for metal dust. 4.2 CHECK Good shop practice and sound engineering require that the installation should be checked before it is put into operation. Check the power line voltage connections, the fuel gas, oxygen and air connections, and the installation of the exhaust system before turning on a valve.


SECTION 5

OPERATION 5.1 OPERATING CONTROLS There are three operating controls on the gun:

1. The Gas Head Valve controls the flow of gases and air to both the gas head and the turbine.

2. The Speed Control Ring adjusts the rate of wire feed.

3. The Wire Grip Valve causes the drive rolls to grip or release the wire.

Each gun is given an operating test at the factory and is ready to be hooked up when received. When putting the Sprayjet-87 Gun into operation: -

1. Use the nozzle and air cap shown in the performance chart for the wire to be sprayed.

2. Set the siphon plug flange firmly against the gas head. Make sure the mating surfaces are clean and free of chips.

3. Make sure that the nozzle nut is tight. Tightening by hand is sufficient.

4. Tighten the air cap body. Tightening by hand is sufficient.

5. Check the gas head valve for smooth, easy action. Relubricate if necessary.

6. Check for proper gear case lubricant level. Add as needed.

7. Read and understand the chapter on SAFETY MEASURE before lighting the gun.

5.2 HOOK UP & INITIAL ADJUSTMENTS Connect the hoses to the air and gas flowmeters. Turn on the exhaust system. Blow the hoses out and connect them to the gun. The air and oxygen hose nuts have right-hand threads. The fuel gas hose has a left-hand thread. These nuts must be tight enough to prevent gas leaks. Do not overtighten, as this may crush the hose stems. Set up the gun to point into the spray booth. Open the gas head valve by turning the valve handle straight up. Adjust the air regulator unit the gauge shows the pressure specified in the performance chart. When the valve is turned off (horizontal) the regulator gauge should not show a pressure increase of more than 10 psi (0.69 bar). A greater pressure rise usually indicates regulator trouble, or a restriction upstream from the air control unit. In either case, the trouble should be corrected before proceeding.

Turn the valve handle up to 45 until it clicks. In this position air is fed to the turbine but not to the air cap. This is the LIGHTING POSITION. Turn the valve handle all the way up. A strong blast of air will come out of the air cap. This is the RUNNING POSITION.


It the gun has not been used for some time, speed it up and slow it down several times by turning the speed control ring. The WIRE-GRIP VALVE has two positions; forward (off) and rearward (on). To change settings, push the side wing button or rear button on the thumb bar all the way forward and release it. With the gas head valve in the running position and the wire-grip valve in the off position, insert the wire into the rear wire guide and push it through the gun. Set the wire-grip valve in the on position. The wire will begin to feed. Adjust the speed control ring to obtain a slow feed for large, stiff wire, such as 3/16 aluminium, or a fast feed for smaller, soft wire such as 1/8 zinc. With the gas head valve open, quickly set the oxygen and fuel gas pressures to the figures shown in the performance chart under LIGHTING PRESSURES. Adjust the flowmeter gas flow control valves to obtain the flow values shown in the table. Then close the gas head valve. 5.3 LIGHTING When you are ready to start spraying:

1. Take up the gas lighter and open the gas head valve all the way (straight up)

2. Pause about three seconds

3. Close the valve halfway until you feel it click into the lighting stop

4. Spark the lighter in front of the nozzle.

5. Immediately open the valve all the way as soon as the gun lights.

There is no need for a new operator to hurry the several motions required except that the valve must be opened completely immediately after lighting. After the gun is lighted

1. Wait for a few seconds for the turbine to come up to speed, and then start the wire feed. (If the wire feed is started too soon the cap may load with sprayed metal)

2. Set the speed control to obtain the highest wire speed, which will allow the wire to melt off to a point without spattering. The wire should extend in from of the air cap about 5mm. The length, however, will vary, depending upon the kind of coating desired and the metal being sprayed.

3. Readjust the fuel gas and oxygen regulators until the readings on the Gas Flow Meter correspond to the performance chart.

Caution: Do Not Light Gun Without Wire In The Nozzle.


5.4 SPRAYING The gun should be held from 12.5cm to 20cm away from the surface being sprayed. For small work, such as shafts less than 2.5 cm in diameter, it is advisable to cool the work with air blast. For information on surface preparation and for general information on application of the flame spray process, refer to the handbook. 5.5 START - STOP OPERATION The wire feed can be stopped temporarily when spraying, by simply pushing the wire grip valve to the OFF position to release the grip of the above drive rolls. The WIRE SNUBBER at the gun will keep the wire from slipping out of the gun. Make sure the outer sleeve of the snubber is in the rear position (not locked out). Caution: Do not operate the gun with wire snubber locked out. If, during

operation, the wire grip is released with the snubber locked out, the wire may pull back out of the gun. If this happens, the gun flame may flash back through the rear wire guide. The hot tip of the wire and the back flash of the flame can cause personal injury.

To start the wire feed again, return the wire grip valve to the ON Position. 5.6 SHUTTING DOWN To shut the gun down, turn OFF the gas head valve. To release the wire:

1. Push the wire grip valve off.

2. Push the snubber outer sleeve forward. (The sleeve can be locked in this position by twisting it in the direction of the arrow).

If the gun will not be used again for several hours, shut off the oxygen and fuel gas at the cylinders and shut off the air at the regulator on the air control unit. Back out the pressure regulating screws on the gas regulators and bleed off pressure in the hoses and gun by opening the gas head valve momentarily. 5.7 DIFFERENT SIZES OF WIRE The Sprayjet-87 Gun is equipped to spray 3.17mm wire. It may be ordered set up to spray any size standard metallizing wire from 4.76mm down to 1.6mm. It is also frequently desirable to purchase nozzles and air caps for a number of different sizes in order to be able to handle a wider variety of jobs. Changing wire size will require a change of nozzle and air cap. Follow the recommendation in the appropriate performance chart towards the end of this manual.


Drive rolls and wire guides may also have to be changed. See the wire guide and drive roll selection chart for proper combination of parts. 5.8 DIFFERENT GASES Sprayjet-87 Gun is equipped with a universal gas head. It may be used with oxygen and any combustible gas such as acetylene, propane, natural gas, manufactured gas, or hydrogen. The proper nozzle and siphon plug must be used. 5.9 NOZZLES There are two types of wire nozzles for acetylene, propane (or LPG). The nozzles for acetylene are flat on the small end. The propane nozzle is centerboard on the small end. Each nozzle has its wire size mark on it. 5.10 SIPHON PLUG Different siphon plugs are required for various wire sizes and fuel gases. See the nozzle and siphon plug selection chart for the proper combination of parts.


SECTION 6

PART LIST OF SPRAYJET-87 6.1 DRIVE ROLL CARRIER & RELATED PARTS; WIRE GRIP PPSHANISM

CAT. No. GENERAL DESCRIPTION

87-26 UPPER DRIVE ROLL AXLE SCREW (not shown)

87-30 DRIVE ROLL CARRIER PIVOT PIN (INCLUDES 87-139)

87-30A SPRING FOR 88-30 (not shown)

87-32 UPPER DRIVE ROLL

87-33 UPPER DRIVE ROLL GEAR

87-34 UPPER DRIVE ROLL GEAR SCREW

87-37 UPPER DRIVE ROLL AXLE

87-93 PISTON STOP SCREW

87-127 SUPPORT BLOCK MOUNTING SCREW

87-129 O RING

87-136 DRIVE ROLL CARRIER

87-138 PISTON ROD

87-139 LOCKING PIN (not shown)

87-177 PISTON RETURN SPRING

87-180 "O" RING

87-189 RETAINER RING (not shown)

87-206 CYLINDER SUPPORT BLOCK ASSEMBLY

87-207 PISTON

87-208 PISTON "O" RING

87-209 CYLINDER


DRIVE ROLL CARRIER & RELATED PARTS

WIRE GRIP PPSHANISM

FIGURE 6(A)

87-136

87-37

87-30

87-32

87-34

87-33

87-206 87-208

87-93 87-209 87-207 87-138 87-177

87-129

87-127

87-180


6.2 GAS HEAD ASSEMBLY; SIPHON PLUG & RELATED PARTS


87-1 AIR CAP BODY

87-2-1 ACETYLENE SIPHON PLUG (1)*

87-2-2 SIPHON PLUG, PROPANE (1)*

87-2-3 ACETYLENE SIPHON PLUG (2)*

87-2-4 SIPHON PLUG, PROPANE (2)*

87-3-AH AIR CAP 3/16 WIRE

87-3-CH AIR CAP 1/8 WIRE

87-4-AB FAN SPRAY CAP 3/16 WIRE

87-4-CD FAN SPRAY CAP 1/8 WIRE

87-5 GAS HEAD ASSEMBLY

87-6 WIRE NOZZLE NUT

87-7-1 NOZZLE ACETYLENE 3/16 WIRE (1)*

87-7-2 NOZZLE PROPANE 3/16 WIRE (1)*


87- 7-4 NOZZLE PROPANE 1/8 WIRE (1)*




87-7-8 NOZZLE PROPANE 3/16 WIRE (2, 3)*







87-7-14 NOZZLE ACETYLENE 1/8 WIRE (2, 3)*



87-14 O RING (COUNTER SHAFT PLUG "O" RING)



87-18 GAS HEAD VALVE "O" RING SET (not shown)

87-23 FRONT WIRE GUIDE

87-31 VALVE HANDLE SCREW

87-40 MOUNTING STUD

87-41 MOUNTING STUD ROLL PIN

87-43 VALVE CORE

87-44 VALVE CORE O RING

87-45 VALVE HEAD ASSEMBLY

87-96 GAS HEAD MOUNT SCREW, REAR (not shown)

87-97 GAS HEAD MOUNT SCREW, FRONT (not shown)

87-108 NOZZLE O RING (L)

87-109 NOZZLE O RING (S)

87-145 GAS HEAD SUB ASSEMBLY

87-157 HOSE CONNECTION MOUNTING BLOCK SCREW

87-165 PLUNGER (FUEL GAS & SCREW)

87-166 PLUNGER (AIR)

87-167 PLUNGER O RING (AIR)

87-168 PLUNGER O RING (GAS & OXY.)

87-169 PLUNGER SEAL O RING (AIR)

87-170 PLUNGER SEAL O RING (GAS & OXY.)

87-171 PLUNGER SPRING

87-173 DETENT PIN

87-174 DETENT PIN SPRING

87-176 HOSE CONNECTION BLOCK ASSEMBLY

87-179 VALVE CORE STOP SCREW

87-200-1 SIPHON PLUG ASSEMBLY 3/16 & 5/32 WIRE (1, 4)*

87-200-2 SIPHON PLUG ASSEMBLY PROPANE 1/8 WIRE (1, 4)*

87-200-3 SIPHON PLUG ASSEMBLY ACTY 1/8 WIRE (1, 4)*

87-200-4 SIPHON PLUG ASSEMBLY PROPANE 3/16 & 5/32 WIRE (1, 4)*

87-200-5 SIPHON PLUG ASSEMBLY ACTY 3/16 & 5/32 WIRE (2, 4)*

87-200-6 SIPHON PLUG ASSEMBLY PROPANE 3/16 & 5/32 WIRE (2, 4)*



87-200-7 SIPHON PLUG ASSEMBLY ACTY 1/8 WIRE (2, 4)*

87-200-8 SIPHON PLUG ASSEMBLY PROPANE 1/8 WIRE (2, 4)*

87-200-9 SIPHON PLUG ASSEMBLY ACTY 3/16 WIRE (2, 3, 4)*

87-200-10 SIPHON PLUG ASSEMBLY PROPANE 3/16 WIRE (2, 3, 4)*

87-200-11 SIPHON PLUG ASSEMBLY ACTY 1/8 WIRE (2, 3, 4)*

87-200-12 SIPHON PLUG ASSEMBLY PROPANE 1/8 WIRE (2, 3, 4)*

NOTE : (1)* = ANNULAR NOZZLE FOR LOW MELTING WIRE (2)* = JETTED NOZZLE FOR HIGH MELTING WIRE (3)* = NON LOADING NOZZLE FOR BABBIT, LEAD & TIN WIRES (4)* = INCLUDES SIPHON PLUG, NOZZLE O-RING, NOZZLE NUT & FRONT WIRE GUIDE


SIPHON PLUG & RELATED PARTS

FIGURE 6(B) 1

87-23 87-14 87-6 87-7 87-3 87-2

includes 87-108 & 87-109


87-5 GAS HEAD ASSEMBLY FIGURE 6(B) 2

88-14

87-44 87-14 87-43

87-165 87-166

87-168

87-167

87-171

87-44

87-179 87-176 87-157

87-41

87-1

87-145

87-173

87-45

87-31

87-174

87-170

87-169 87-40


6.3 DRIVE UNIT WITH WIRE GRIP PPSHANISM REMOVED, TURBINE & SPEED

CONTROL ASSEMBLY


87-25 SET SCREW FOR REAR WIRE GUIDE

87-31 BEARING COVER MOUNTING SCREW

87-35 LOWER DRIVE ROLL

87-36 LOWER DRIVE GEAR

87-47 BEARING COVER

87-48 BEARING COVER GASKET

87-50 GREASE PLUG SCREW

87-53 GEAR COVER SCREW

87-57 FRONT PLUG SCREW

87-67 SET SCREW FOR TURBINE

87-71 TURBINE ROTOR (Inclu. 87- 67)

87-72 TURBINE SHAFT

87-73 RIGHT BALL BEARING FOR TURBINE SHAFT

87-74 WASHER FOR BRAKE DISC SPRING

87-75 TURBINE SHAFT RIGHT NUT

87-76 BRAKE DISC SPRING

87-77 TURBINE COVER

87-78 BRAKE DISC

87-79 "O" RING

87-80 OIL SEAL BOBBIN

87-81 OIL SEAL SLEEVE

87-82 OIL SEAL WASHER

87-85 CONTROL RING

87-86 SPIDER ASSEMBLY

87-87 DETENT SPRING

87-88 RING NAME PLATE

87-89 SCREW FOR RING NAME PLATE

87-99 O-RING

87-160 OIL SEAL ASSEMBLY


TURBINE AND SPEED CONTROL ASSEMBLY FIGURE 6(C)

87-73 87-72 87-78 87-67

87-81

87-76

87-82 87-80 87-71 88-74 88-75 87-79

87-160

87-86 87-77 87-85 87-50 87-87 87-88 87-89

87-47

87-48

87-31


6.4 COUNTERSHAFT ASSEMBLY, GEAR COVER, CENTRAL HOUSING, HANDLE,

DRIVE SHAFT PARTS


87-10 OIL SIGHT PLUG

87-14 COUNTER SHAFT PLUG "O" RING

87-27 GUN HANDLE

87-28 GUN HANDLE SCREW

87-46 BEARING RETAINER O-RING

87-49 O-RING OIL SIGHT PLUG

87-51 REAR BEARING RETAINER

87-52 RETAINER PLUG

87-53 GEAR COVER SCREW

87-54 GEAR COVER

87-55 GEAR COVER GASKET

87-59 CENTRAL HOUSING

87-60 PUMP HOUSING

87-61 PUMP HOUSING MOUNTING SCREW

87-62 PUMP HOUSING LOCK WASHER

87-63 DOWEL PIN FOR MOUNTING GEAR COVER

87-65 DRIVE SHAFT

87-66 DRIVE SHAFT GEAR

87-67 GEAR SET SCREW

87-68 DRIVE SHAFT SEAL

87-69 BALL BEARING FOR DRIVE SHAFT

87-70 FRONT & REAR BALL BEARING FOR COUNTERSHAFT; LEFT BALL BEARING FOR DRIVE SHAFT & TURBINE SHAFT

87-84 NUT FOR COUNTERSHAFT FRONT BEARING

87-91 COUNTERSHAFT

87-92 COUNTER SHAFT GEAR

87-97 GAS HEAD MOUNTING SCREW FRONT

87-99 TURBINE CONNECTING TUBE O-RING

87-180 "O" RING


COUNTER SHAFT ASSY

GEAR COVER

DRIVE SHAFT ASSY

87-70

87-55

87-54

87-68 87-69 87-65 87-84

87-67 87-66

87-52 87-84 87-46 87-92

87-14 87-70 87-51 87-67 87-91


CENTRAL HOUSING & HANDLE

FIGURE 6 (D)

87-53

87-60

87-61

87-27

87-97

87-63

87-99

87-62

87-59

87-28


6.5 SNUBBER ASSEMBLY; WIRE GRIP VALVE


87-67 SET SCREW

87-118 SNUBBER ASSEMBLY

87-129 SHAFT SEAL "O" RING

87-131 VALVE SHAFT ASSEMBLY

87-132 VALVE SHAFT SPRING

87-133 CAM FOLLOWER SCREW

87-134 "O" RING (not shown)

87-150 WIRE GRIP VALVE BLOCK

87-180 "O" RING

87-187 GUIDE INSERT

87-188 SNUBBING GUIDE

87-241 SPRING RETAINER

87-242 ROLLER

87-243 SPRING HOUSING

87-245 SPRING


(87-118) SNUBBER ASSY & WIRE GRIP VALVE FIGURE 6 (E)

87-67 87-245 87-243 87-188 87-67

87-242

87-187

87-241

87-133 87-132 87-129 87-131

87-150 87-180


6.6 TOOLS AND LUBRICANTS


87-98 FACE BLOCK

87-99 SPRING

87-100 NUT DRIVER

87-101 LIGHTER

87-102 ALLEN WRENCH

87-104 DRIVE ROLL TOOL

87-105 SCREW DRIVER

87-107 WIRE CUTTER

87-107A SPANNER

87-107B SPANNER

87-110 GEARLUBE

87-111 VALVELUBE

87-114 CLEANING WIRE KIT

87-124 TOOL POST FIXTURE ASSEMBLY

87-126 CLAMP SHAFT HOUSING

87-127 CLAMP SHAFT

87-128 PIN

87-129 WASHER

87-130 HANDLE ASSEMBLY

87-140 ALLEN CAP SCREW WRENCH

87-150 FIXTURE BAR


TOOL POST FIXTURE ASSY FIGURE 6(F) 1

TOOLS & LUBRICANTS

FIGURE 6(F) 2

87-101

87-105

87-100

87-111

87-110

87-107-B

87-107-A 87-104

87-140 87-102

87-107 87-114

87-128 87-99 87-126 87-98 87-129

87-127 87-150

87-130


SECTION 7

CONSTRUCTION & ASSEMBLY The Sprayjet-87 Gun is made up of two main sections: 1. The Gas Head, which melts and sprays the wire. 2. The Drive Unit which feeds the wire to the Gas head The Drive Unit consists of: 1. The Air Turbine and Speed Control Assembly 2. The Transmission (reduction gearing drive rolls) 3. The Wire Grip PPShanism. 7.1 GAS HEAD The Gas Head 87-5 is fastened to the gun by three screws: Two Front Screws 87-97 and one Rear Screw 87-96. A Cylindrical Valve Core 87-43, centrally located in the Gas Head is held in place of both the Valve Handle 87-45 and Screw 87-179, which hold Hose Connection Block 87-176 to the bottom of the Gas Head. To disassemble the Valve cleaning and lubrication:

1. Clean the outside of the valve thoroughly to remove dirt and grit.

2. Remove the valve handle and hose connection block.

A. Lighting Detent Pint 87-173 and Spring 87-174, trapped by the valve handle, can now be removed.

B. Rings 87-44 in grooves on the hose connection block can be lifted out. These seal against leakage at the mounting face.

3. Remove Plunger Spring 87-171.

4. Remove Two Plungers 87-165 and one Plunger 87-166 by pulling on the Plunger Stem. Do not twist. Each Plunger is keyed against rotation.

5. Slide Valve Core 87-43 out of the Gas Head. Never try to take out the Valve Core before removing the Hose Connection Block. 4 O Rings 87-44 and one O Ring 87-14 on the valve core seal of the Oxygen, Fuel Gas and Air from each other and from leakage to the outside.

6. Two Plunger Seal O Rings 87-170 and one Plunger Seal O Ring 87-169, normally squeezed against the valve core by the front ends of the spring loaded plungers, may stick to the plungers when the plungers are removed. If not, these rings will be found in the gas head holes, which house the plungers. Push these rings into the valve bore and take them out for servicing.


Before Reassembling The Valve Parts:

1. Examine all O Rings and replace those, which are worn or damaged. Use only authorised replacements. If cleaning is needed, use a clean cloth slightly dampened with cleaning solvent. Never soak the O Rings in solvent or any other liquid.

2. Wash the metal parts with cleaning solvent as required. Full Flow and bleeder ports are machined into the valve core for proper control of the gases. These ports should be clean and free of any hard residue.

3. Lubricate valve O Rings and sliding metal parts with a thin coat of Valvelube.

When putting back the plungers, align the plunger keyway with the mating key pin in the gas head. Slide each plunger into its hole and press firmly all the way home to seat each seal ring against the valve core. When properly installed, the large diameter of each plunger will be completely inside its hole. If it is not, it means they key pin is not engaging the plunger keyway and the valve will not seal properly. A dowel pin in the hose connection block fits into a mating hole at the bottom of the gas head to preserve proper orientation. The long nose on the connection block mounting screw 87-179 (next to air hose fitting) engages a groove in the valve core. Make sure to put this screw back in its proper place. Check that the connection block O Rings are in their retaining grooves before tightening the connection block screws. 7.2 VALVE CORE POSITIONING One end of the valve core has an aluminium knob. With the valve core in place in the gas head, before mounting the valve handle, turn the core so that a hole appears pointing towards the back of the gas head. Point the valve handle forward and screw it on to the stem of the valve core. When properly mounted, the head of the valve handle screw will be in line with the hole of the valve core. If they are opposite in line, the valve will not feed air to the turbine when you try to spray. 7.3 GUN SIPHON PLUG The Gas Siphon Plug 87-2 fits into the large hole through the upper part of the gas head. The flange of the siphon plug has two slots, which mate with two pins in the head. 4 O Rings 87-14 seal against gas leakage. The front wire guide 87-23 threads into the back of the siphon plug. The WIRE NOZZLE 87-7 is held on to the front of the siphon plug by nozzle nut 87-6. Air Cap 87-3 slips into the front recess of the nozzle nut and Air Cap Body 87-1 holds this entire assembly in place of the head. With the air cap body off, the entire assembly of front wire guide, siphon plug, nozzle nut and air cap can be quickly removed. It will help to place the blade of your screwdriver between the drive roll and the front wire guide and push forward. This will ease the assembly forward. Once the O Ring seals break away, the assembly can easily be pulled forward out of the gas head by hand.


Whenever the siphon plug is removed, examine the O Rings for nicks and cuts. If they are damaged, replace them. When reinstalling the siphon plug, lubricate the O Rings with valvelube. Make sure the slots in the siphon plug flange engage the two gas head pins. The front wire guide must be threaded into the siphon plug as far as it will go. Push the siphon plug assembly in until the flange of the siphon plug is firmly seated against the gas head with the two dowels. Air Cap Body 87-1 must be on tight before spraying. 7.4 WIRE GRIP PPSHANISM The wire grip PPShanism is held on the gun by 3 Screw 87-127. Complete disassembly of this PPShanism will be needed only for major cleaning and overhaul. To disassemble:

1. Remove the drive roll carrier.

2. Unscrew Cylinder 87-209. Screw 87-93 at the back of the cylinder acts as a piston stop in the wire release position keeping the upper and lower drive roll gears from coming out of mesh. The screw is set at the factory. Do not tamper with it.

3. Pull the piston and push rod assembly out of Support Block 87-206. Check O Rings for wear or damage. Replace with new ones if required and lubricate with Valvelube before reassembling.

7.5 LOWER DRIVE ROLLS & GEAR Lower Drive Roll 87-35 and Lower Drive Gear 87-36 are threaded on the Drive Shaft 87-65. Both have left hand threads. Use spanner wrench 87-104 to unscrew these parts. To replace the roll and gear:

1. Use Tool 87-103. The projecting button on the tool fits the centre hole of each part.

2. Slip the part on the tool, line it up with the end of the drive shaft and spin it counter clock wise (left hand threads) on to the shaft.

3. Use the spanner Wrench for tightening.

7.6 REAR WIRE GUIDE & SNUBBER Snubber Assembly 87-118, consisting of a read guide and wire snubbing PPShanism, is held in place at the back of the gun by Set Screw 87-25. With the gun completely assembled, this setscrew can be reached through an access hole in the mounting flange of the wire grip PPShanism. 7.7 TURBINE & SPEED CONTROL The speed adjustment parts are mounted on Turbine Cover 87-77. The entire assembly is removed from the right side of the gun by taking out three screws 87-53 and pulling the unit away from the mounting flange. Do not push the turbine cover off. For easy removal, loose the cover screws and tap lightly on the screw heads.


The speed adjustment parts consist of:

1. Ring Name Plate 87-88

2. Speed Control Ring 87-85

3. Detent Spring 87-87 (Washer Type Flat Spring)

4. Spider Assembly 87-86

The Spider Assembly can be removed by turning the control ring counter-clockwise until the spider drops out. The rest of the parts can be separated by removing three Ring Name Plate Screws 87-89. When reassembling, clean the parts thoroughly. Lubricate the thread and detent surface of the control ring with Valvelube. The spider ring has a ring brake shoe mounted to it with four screws. Do not take off the shoe, nor the brake disc, which runs against it. Do not lubricate the shoe. These parts are designed to run dry. Any grease of oil on them should be removed by wiping down with Cleaning Solvent. After the Turbine Cover is removed, the Turbine Assembly and Speed Governor Parts can be taken from the gun by first removing Bearing Cover 87-47 which is held in place of two Screw 87-31. Bearing Cover Gasket 87-48 seals the surface under the Bearing Cover. Lift if off carefully. When reinstalling, coat both sides of the gasket with a thin layer of valve lube. Hold the turbine rotor by hand and remove Turbine Shaft Nut 87-84. The Turbine Assembly can now be pulled out of the housing. The Turbine Shaft Left Bearing 87-70 will stay in the housing. Take off Nut 87-75 at the right end of the turbine shaft. The following parts will slide off the shaft:

1. Right Bearing 87-73

2. Spring Washer 87-74

3. Spring 87-76

4. Brake Disc Assembly 87-78

Turbine Rotor Assembly 87-71 is fastened to the turbine shaft by Set Screw 87-67 and holds Oil Seal Assembly 87-160 in place. Never take apart the brake disc assembly or the turbine rotor assembly. Each of these assemblies is carefully balanced at the factory. When reassembling, pay particular attention to the following instructions:

1. The parts and bearing must be clean. Dirt or grit will cause rapid wear.

2. The end of the turbine rotor set screw must seat in the spot provided for it on the turbine shaft.


3. Be sure to place the bent ears of the brake disc assembly over the button weights, which are on the governor spring attached to the turbine rotor.

4. The turbine shaft right bearing has a shield on one side. Put the bearing on the shaft with the shield towards the turbine rotor.

7.8 GEAR COVER & TRANSMISSION GEARS The gears for the wire drive unit are enclosed by a gasketed Gear Cover 87-54, which is held in place with 4 Screws 87-53. Continuing from the point of disassembly described so far, the gear cover can be removed as follows:

1. Take off Drive Shaft Nut 87-84 (under the bearing cover) on the left end of Drive Shaft 87-65.

2. Remove the countershaft assembly by unscrewing bearing retainer 87-51 located at the back of the gear cover. The retainer has milled wrench flats for this purpose.

3. Remove the 4-gear cover mounting screws and ease the cover off the gun. The drive shaft Left Bearing 87-70, the turbine shaft Left Bearing 87-70 and the countershaft Front Bearing 87-70 will come of the gear cover.

Note that the gear cover mounts on two dowel pins and is sealed against leakage by Gasket 87-55. When reinstalling the gasket, coat both sides with a thin layer of Valvelube. 7.9 DRIVE SHAFT ASSEMBLY When the gear cover is removed, the drive shaft assembly will stay in the gun housing. With the lower drive roll and drive gear removed as previously described, the entire assembly can be pulled out of the housing as a unit. The parts consist of

1. Drive Shaft 87-65

2. Drive Shaft Gear 87-66

3. Right Drive Shaft Bearing 87-69

4. Drive Shaft Seal 87-68

The gear is fastened to the shaft by Set Screw 87-67. Right Bearing 87-69 is pressed on to the drive shaft and should not be removed. If it becomes necessary to replace this bearing, make certain to push on the inner race when pressing the new bearing on to the shaft. 7.10 COUNTER SHAFT ASSEMBLY When the countershaft assembly is removed as discussed above, Front Bearing 87-70 will stay in the gear cover. (It may slip out of the socket and drop into the gear chamber). The rest of this assembly can be taken apart as follows:

1. Unscrew Plug 87-52 from the Bearing Retainer 87-51. O Ring 87-14 and 87-46 on these parts help seal the gear case against grease leakage.

2. Remove Countershaft Nut 87-84 located on the end of the shaft under the plug. When doing this, hold the gear by hand with a cloth. Never hold it with a wrench.


Bearing 87-70 can be pushed out of the retainer and countershaft 87-91 with countershaft gear 87-92 fastened to it can be pulled free. Take the gear off the shaft by loosening Set Screw 87-67. When putting the gear back on, be sure the setscrew goes into the hole provided for it on the shaft. 7.11 CENTRAL HOUSING & GUN HANDLE The centrally located casting on which all the assemblies are mounted is Central Housing 87-59. Two Dowel Pins 87-63 are pressed in place. Pump Housing 87-60 is fastened to the side of the central housing with 2 Screw 87-61 and 2-lock washer 87-62. Do not remove these parts. With the gun completely assembled, the countershaft passes through the pump housing and pumps gear lubricant to the back or the gun to lubricate the high-speed bearings and gears. The pump housing has been specially aligned for proper clearance over the countershaft to ensure efficient pumping action. 7.12 WIRE GRIP VALVE To disassemble the wire grip valve, remove Cam Screw 87-133 and pull out Valve Shaft 87-131. Inspect the O Rings, cam screw and cam (on the valve shaft) for wear or damage and replace as needed. Since the cam cannot be removed from the valve shaft, the entire valve shaft must be replaced if the cam is damage. When reassembling, lubricate with Valvelube. Turn the cam Screw until it hits the root of the cam. Then back off about 1/2 turn. 7.13 GEAR CASE LUBRICATION The most important point in lubricating the gun is cleanliness. Dirt, grit and metal dust in the PPShanism will cause quick wear of gears and bearings. The lubricant for the gears and bearings is Gearlube. To lubricate a dry gun, one full tube of Gearlube should be squeezed into the gear case. To do this, wipe the back of the central housing clean and remove oil sight plug 87-10. After cleaning the screw end of the Gearlube Tube, screw it into the filter screw hole and squeeze the tube until empty. With the gun upright and level, the lubricant should be visible in the lower half of the sight plug. After adding lubricant, wait for a short while before checking the level because the lubricant settles slowly. 7.14 TURBINE BEARING LUBRICATION The right side turbine shaft bearing, located in the turbine cover, and parts of the governor PPShanism located just behind this bearing, are lubricated through the centre of the turbine cover. Follow the same cleaning procedure described above. Remove Filter Screw 87-50, put the end of the Gearlube tube into the hole and squeeze out a strip of lubricant about 6mm long. Do not over lubricate.


SECTION 8

AVOIDING TROUBLE 8.1 SPRAYING Refer to Chapter SAFETY MEASURES for a summary of common sense precautions to be observed when flame spraying. 8.2 GENERAL GUN CARE The most important point in the care and lubrication of Sprayjet-87 Metallizing Gun is cleanliness. Dirt, Grit and metal dust in the PPShanism can cause quick wear. Before lubrication or overhaul, wipe the gun thoroughly to remove all loose dust. Use a clean bench for disassembly and be sure the lubricant tube is free of dirt. There is a chart showing a suggested maintenance schedule at the end of this chapter. This chart is based on average use and conditions. Gun receiving hard use should be serviced at shortest intervals. The main factors affecting service frequency are:

1. Speed and load of the gun.

2. Frequency off lighting

3. Temperature in which the gun operates.

The higher each is, the more often the gun should be serviced. 8.3 HOSES

1. Obstructions in the hoses reduce the flow of oxygen and gas and upset the flame balance.

2. Do not get oil in the hoses. Oil in the oxygen hose is very dangerous. In any hose, oil will soften the rubber.

3. In an old, worn hose the lining may come loose and plug the hose.

4. If hose fitting are over-tightened, the holes in the fittings may collapse. This reduces the flow of gases and causes the same troubles as obstructions in the hoses.

8.4 DIFFICULT LIGHTING If the gun is hard to light, make sure that the nozzle and siphon plug jets are clean and undamaged. If the trouble persists, screw out the regulator handles to shut off the gases and then disconnect the hoses. Inspect hoses and gun fittings for dirt or other obstruction. Blow out the hoses before reconnecting them.


If the gun has been idle for some time or after the valve just been lubricated, it is advisable, before lighting, to work the valve ON and OFF a few times with gases and air turned on. This will blow out any excess valve lubricant from the small bleeder holes in the valve. Plugged bleeder holes will cause lighting trouble. 8.5 BACKFIRE If the gun backfires, it will appear to go out with a pop and will burn back in the siphon plug. Shut the gun OFF immediately and wait for about thirty seconds before relighting. The following may cause backfiring:

1. Leak at the wire nozzle seat (see wire nozzles)

2. Dirt in the nozzle jets.

3. Oversized or rugged nozzle jet holes.

4. Plugged siphon plug bleeder holes (see siphon plug)

5. Use of wrong air cap.

It is possible for a single jet to backfire and the others to burn normally. The flame will suddenly become slightly one-sided. Correction must be made immediately to prevent overheating of the siphon plug and gas head. Replacing the nozzle and cleaning the siphon plug is the best and most economical procedure. Excessive backfire or permitting the gas to burn back in the siphon plug too long, makes it necessary to clean the jets in the siphon plug and nozzle. It may also cause the nozzle nut to loosen. The cause of the backfire should be found and corrected. The gun will not backfire unless something is definitely out of adjustment. 8.6 SIPHON PLUG This part should be cleaned occasionally. Instruction for removing and replacing it are given in the section on CONSTRUCTION & ASSEMBLY. When cleaning the siphon plug wipe out the grooves clean the jets with the proper size wires in the cleaning wire kit. Do not use drills. Do not use oversize wires. Do not rotate the wires. Do not wash the O Rings with strong solvent. Inspect them for damage and replace them if necessary. Do not stretch new O Rings more than necessary when putting them on the siphon plug. Lubricate the O Rings with a generous film of PPS Valvelube before reassembling the siphon plug. Wipe any excess Valvelube of the plug, to avoid getting it in the jets. 8.7 WIRE NOZZLES The nozzle must be tight on the siphon plug. Firm tightening by hand is sufficient.


The tip of the nozzle at the flame should be kept clean. To clean the jet holes, remove the nozzle and plug the proper size cleaning wire carefully into the jet hole from the back end. Do not use a drill. Select a wire that fits the holes. Push the wire straight in and out. Do not rotate it. Wash the nozzle in cleaning solvent before and after cleaning. Blow out the holes from the flame and with compressed air. 8.8 GAS HEAD VALVE The gas head valve is designed for long service life with minimum maintenance. It has a cylindrical rather than the old-style tapered core and relies upon special elastomeric O Rings for proper sealing. Lapping or other precise fitting is not required. One of the two acetylene holes is stepped, having larger diameter at the periphery of valve. Do not disassemble the valve for cleaning and relubricating, unless it has become excessively stiff and difficult to turn or a leak has developed. Instruction for taking it apart are given in CONSTRUCTION & ASSEMBLY If the valve develops a leak, examine all O Rings carefully and replace any which are worn or damaged. The ring materials are specially selected for proper service in this valve. Use only authorised replacements. The metal parts of the valve can be washed with cleaning solvent. Make sure that the small bleeder holes in the cylindrical valve core are clean and free of any hard residue. Do not enlarge them. Never soak the O Ring in solvent. Lubricate all valve O Rings and sliding metal parts with a thin coat of Valvelube. Wipe excess Valvelube of the nozzle to avoid getting it in the jet holes. 8.9 STICKING WIRE Kinked or badly bend wire cause trouble. The drive rolls will gauge the wire and it may stop feeding. If the wire melts into the end of the nozzle it can be removed by twisting and forcing the wire through from the back with pliers. The nozzles are bushed with a special alloy, which resists fusing with any common metal. To reduce sticking due to kinks and bends, especially with 3.17mm and 4.76mm hard wire, locate the wire control unit so the wire feeds straight to the gun. Do not overtighten the brake on the wire control unit. 8.10 DRIVE ROLLS If the teeth on the drive rolls become packed with chips from the wire they will not work efficiently. Keep them clean with wire brushing. 8.11 SPEED CONTROL Clean air is required for uniform, steady wire fed. Any oil between the turbine brake disc and brake shoe may cause fluctuation in the wire speed. Clean these parts with a rag moistened with cleaning solvent if the wire feed becomes unstable. Do not lubricate them.


8.12 THREADS Valvelube is an excellent thread lubricant. It should be used on the threads of the air cap body, nozzle nut, rear countershaft bearing retainer and control ring to keep the threads smooth running. 8.13 OVER HEATING The increased spraying speeds of the Sprayjet-87 Gun are the result of greatly increased heating capacity. Be sure to observe recommended procedures to prevent overheating of the work or damage of the coating.


SECTION 9

ROUTINE MAINTENANCE SCHEDULE No. Maintenance Operation Interval Hr. Remarks

01. Clean Outside of Gun 08

02. Clean of Drive Rolls 08 Brush off & blow out dirt & chips

03. Clean Air Cap 08 Wipe out soot.

04. Clean Nozzle Jets 16 Use nozzle cleaning wire kit.

05. Clean siphon plug jets & 40 Use nozzle cleaning wire kit bleeder holes.

06. Oil upper drive roll bushing 40 Machine Oil - 2 drops

07. Oil upper drive roll carrier hinge 40 Machine Oil - 1 drop

08. Lube turbine cover bearing 40 Gearlube 6mm strip

09. Lube gear case 80 Gearlube - makeup level

10. Clean & relube control ring 200 Valvelube thread

11. Clean & relube power control 200 Gearlube - thin film spider

12. Clean and lube gas head valve 500 Valvelube thin film

13. Complete overhaul 1000 Wash out and replace all lubricants


SECTION 10

METAL SPRAYING WIRES

Wire & Their Characteristics

Applications

Stainless Spray I 18/8 types Chromium-Nickel, Austenite Machinable Rb 80-90 AISI 304

A general purpose stainless for corrosion protection. Resistant against seawater and slightly corrosive acids. Wear resistant also. Applications include pump shafts in shipbuilding and fish processing industry, textile rolls.

Stainless spray II Chrome alloyed. Grinding only. Rc 42-48 AISI 420

Chromium steel for the application of hard layers, good wear resistance and emergency running characteristics. Substitute for hard chrome plating, fair corrosion-resistance, e.g. plungers, hydraulic piston, sliding surfaces, shafts and machine elements.

Stainless spray III Chrom-Nickel-Moly-Austenite Steel. Machinable Rb 94-98 AISI 316

As stainless spray I, but with higher corrosion and wear resistant. Bright and shining finish.

Spray Steel 80 High carbon steel, Grinding Rc 42-48

A low shrink, high carbon steel wire developed for applying hard wear resistant coating such as crankshafts, camshafts etc.

Spray Steel 25 Mild steel, Machinable Rc 30-35

This is carbon steel similar to No. 10, except that it is harder and has a lower shrink factor. Machinability and wear characteristic are both good.

Spray Steel 10 Low carbon steel, Machinable

General-purpose carbon steel for rebuilding worn steel parts where excellent machinability is the main consideration. Fair wear resistance. Suitable for press fit mis-machined parts, ball bearings seat etc.

Molybdenum 99% Moly. Grinding Rc 44-45

It is frequently used as a bonding undercoat between the surface of base metal and sprayed metal. Being the hottest and cleanest wire, it provides a firm bond. it provides anti-oxidant bonding surface. Though molybdenum is a costly wire, the sprayed thickness required for excellent bonding is only 0.015. It is also used as a finishing material due to low fraction characteristics and high particle hardness, such as on syncro rings, piston rings, clutch parts etc.



Applications

Aluminium - Bronze Bronze containing about 9% aluminium. Resistant against wear and corrosion through seawater, low shrinkage, used in shipbuilding, engine and machine construction.

Nickel-Aluminide Hardness 20-25 HRC

A unique prealloyed wire of nickel and aluminium. Good resistance to high temperature oxidation and thermal shock. Excellent self-bonding to many substrates. Use as bond coat also. Useful for brazing jigs, heating crucibles, casting ladles etc.

Tin - Bronze As above very good surface quality, limited corrosion resistance, e.g., for sea water main pumps, centrifugal pump shafts.

Phos - Bronze A phosphor bronze for special repair of phosphor bronze items. Machine well.

Tin Based Babbit Suitable for bearings, segment rings and bushes, can be subjected to high dynamic and static loads, extremely silent-running characteristics, also with tight fit, excellent emergency running characteristics.

Lead Based Babbit To be used as explained above, but only structural parts of less precision and with higher dimensional tolerance.

Copper Hardness 37 - 40 Rb

For coatings to serve as electrically conductive layers on non-conductive materials. For rolls and cylinders used in paper and textile industry.

Pure Nickel (99.9%) For high-quality surface protection.

Pure Tin (99.9%) For surface protection of food industry equipment.

Tin - Zinc For obtaining solderable and conductive surface on non-conductive substrate. Also suitable for preparation of moulds for low-pressure injection moulding.

Zinc (99.9%) Time-tried anti-corrosion material for practically unlimited use in the field of ship building machine and container construction and pipe or conduit manufacture, for steel structures of all types and sizes, internal coating of tanks, bridges, dam sections etc..

Aluminium (99.5%) Corrosion protection against seawater, hot water and industrial atmospheres. Also for heat resistant for crucibles, firebox and doors and burner tubes.



Applications

Brass Surface finishing in apparatus and machine construction. Coating may be applied on shaft or rolls, eliminating use of solid brass.

Monel For anti corrosion and special applications.


SECTION 11

WIRE GUIDE & DRIVE ROLL SELECTION CHART OF SPRAYJET-87

Wire Size Wire Guide Drive Rolls Lower

(mm) Front Guide Rear Guide & Snubber Assy

Note 1.

Plain Rear Guide Note 2

Upper Lower Drive Roll Gears Note 3

4.76mm 87-23-4.76 87-118-4.76 87-24-4.76 87-32-4.76 87-35-4.76 87-36-4.76

3.17mm & 2.0 mm 87-23-3.17 87-118-3.17 87-24-3.17 87-32-3.17 87-35-3.17 87-36-3.17

1.6mm 87-23-1.6 87-118-1.6 87-24-1.6 87-32-1.6 87-35-1.6 87-36-1.6

NOTE:

1. For the individual parts which make up the rear guide and snubber assembly. see the replacement parts list. 2. Never use the plain rear guide on start stop operation. 3. Use the upper drive roll gear 87-33 for all set-ups.


SECTION 12

SPRAYING TABLES & GENERAL COST DATA 12.1 HOW TO USE THE TABLES The Spraying Tables on the following pages list the information needed to set up and operate the gun. There are separate tables for acetylene and propane, in both US and Metric Systems. In addition, the table shows basic data for calculating costs. To use the tables, first select the table for the fuel gas and system you are using. Then, in Column 1 Find the metal to be sprayed. Column 2 Find the size of wire to be used. Column 3 Air Cap - Use the air cap shown here. The wrong air cap will cause backfiring

or faulty spraying. Always check the Air Cap. Columns 4, 5 & 6 Lighting Pressure - These are the pressure to be set on the oxygen,

fuel gas and air regulators before lighting the gun. The rules of the National Board of Fire Underwriters have set the maximum pressure for the use of Acetylene at 15 psi.

Columns 7, 8 & 9 Flowmeter Readings - These columns list the flow readings, which

should show on the air and gas flowmeters. Air, oxygen and fuel gas flowmeters and pressure regulators should be adjusted as necessary to obtain these readings with the spraying. Additional information is given in the Instruction Manual, which accompany the PPS Type 2AF Air Flowmeter and Type 2GF Gas Flowmeter.

Columns 10, 11 & 12 Consumption/Hr - These 3 columns show the consumption of

wire, oxygen and fuel gas per hours. If you know the time necessary to do a job and the cost of wire and gases, the cost of the job can be calculated from these figures.

Column 13 Speed - This column shows the area which can be covered with a 0.001 or

0.1mm thick commercial coating in one hour of continuous spraying time. This figure takes into account the density of the sprayed coating and deposit efficiency losses but does not include overspray losses. Dividing the area to be sprayed by the figure in this column will give the number of hours required to put down each 0.001 or 0.1mm of coating thickness. If a total thickness of 0.005 or 0.5mm is required, the total time will be the above hours multiplied by 5.

Column 14 Weight - This column shows the weight of wire which must be sprayed to

cover a square foot of area with a 0.001 to 0.1mm thick coating. It includes deposit efficiency losses but does not include overspray losses.


12.2 HOW TO COMPUTE SPRAY AREA When estimating the area of surface, an allowance for loss the edges must be made. A good rule is to add one inch (25mm) to each dimension when is an edge, to compensate for this loss. This also applies when estimating the cost of building. In this case add 2 inches (50mm) to the length to build up [one inch (25mm) at each end]. 12.3 AREA FORMULA

1. Circumference of a circle = D

2. Area of a circle = R2

3. Area of a cylinder = DL

4. Area of sphere = D2

5. Area of a triangle = bh / 2

6. Area of a parallelogram = bh

7. Area (lateral of a cone) = r2 r2 + h2

Where: = 3.1416; R = Radius D = Diameter; b = Base;

h = Altitude; r = Radius of base; L = Length 12.4 HOW TO CALCULATE COSTS An important factor to take into account when calculating costs is the normal variation in coating thickness between the thinnest spot and the thickest spot. The extent of this variation depends on the particular job and the manner in which is sprayed. For all ordinary corrosion-resistant coatings, the average thickness of the coating should be used in calculating costs. However, if a minimum thickness of coating is specified, be sure to spray the coating thick enough so that no spot will be thinner than the specified minimum. If this thickness is not known from experience, spray a test area to determine the average thickness required. Example (US System) Find the cost of flame spraying a rectangular process tank 3 X 10 X 47 high open top, outside only, with PPS Aluminium 0.010 minimum thickness. Assume that to get the minimum thickness, it is necessary to spray an average thickness of 0.013. Since the top is open there will be edge loss, so 1 is added to the height, making it an even 4. Acetylene gas at 15 psi and 3/16 PPS Aluminium will be used in the gun. Find the cost as follows: 1. Calculate area to be sprayed

Bottom : 03 X 10 = 30 Sq Ft.

Two Narrow Sides : 03 X 04 x 02 = 24 Sq. Ft.

Two Wide Sides : 10 X 04 X 02 = 80 Sq. Ft.

Total Area : 134 Sq. Ft.


2. Calculate time required

To find the hours needed to cover 134 Sq. Ft. with a 0.001 thick coating, divided 134 by the rate of coverage shown in column 13. Since a 0.013 thick coating is actually required, it will take 13 times longer, so multiply the above result by 133 (134 -- 1070) X 13 = 1.6 Hours.

3. Calculate weight of Wire Needed

Pounds = Hours to do the job times hourly wire consumption shown in Column 12 of the Spray Table = 1.6 hours X 15 lb./hour = 24 lb. The weight of wire required can also be calculated by multiplying (area X coating thickness X 1000) times the number shown in column 14 = 134 X 0.013 X 1000 X 0.014 = 24 lb. (rounded off). Both methods for calculating weight of wire include proper compensation for deposit efficiency.

4. Calculate total air, Oxygen and Acetylene required Air = Hours times 1800 cubic feet per hours

Oxygen & acetylene = Hours times hourly consumption given in Columns 10 and 11 of the spraying table.

Air : 1.6 X 1800 = 2880 Ft3

Oxygen : 1.6 X 105 = 168 Ft3

Acetylene : 1.5 X 50 = 80 Ft3

5. Figure total cost of spraying

Total Cost = Cost of Wire used + Cost of Air, Oxygen & Acetylene used + Cost of Labour

Total Cost of Wire = Cost per Pound X Total Pounds used

Total Cost of Gases = Cost per Cubic Feet of each Gas X Total Volume of Each Gas used.

Total Cost of Labour = Labour cost per hour X Total Hours

SPRAYING TABLES & GENERAL COST DATA Note that the above information relates to the cost of SPRAYING ONLY. The cost of the entire job also includes:

1. The cost of surface preparation before spraying.

2. The cost of machining or other finishing needed after spraying

3. Where finish machining or grinding of the coating is required, allow for the material removal when deciding how thick to spray the coating.


SOME CONVERSION FACTORS

22 B&S = 0.6438 mm

20 B&S = 0.8118 mm

18 B&S = 1.0240 mm

15 B&S = 1.4500 mm

11 B&S = 2.3030 mm

1/8 = 3.175 mm

5/32 = 3.969 mm

3/16 = 4.762 mm

1 = 25.4 mm

1 = 0.3048 mtr.

1 Ft2 = 0.0929 m2

1 Ft3 = 0.0283 m3

1 US Quart = 0.947 I

1 Imp. Quart = 1.1365 I

1 US Gallon = 4.546 I

1 Ounce = 28.35 Gms

1 Pound (lb.) = 453.59 Gms

1 Kg = 2.2046 lb.

Example (Metric System) Find the cost of spraying a rectangular process tank 900mm X 3000mm X 1175mm high, open top, outside only with Aluminium, 0.25mm minimum thickness. Assume that to get the minimum thickness, it is necessary to spray an average thickness of 0.33mm. Since the top is open, there will be an edge loss so 25mm is added to the height, making it an even 1200mm high. Acetylene gas at 15 psi and 3/16 Aluminium will be used in the gun. Find the cost, as follows: 1. Calculate area to be sprayed (in millimeters)

Bottom : 900 X 3000 = 2700000 mm2

Two Narrow sides : 900 X 1200 X 2 = 2160000 mm2

Two Wide sides : 3000 X 1200 X 2 = 7200000 mm2

2. Calculate time required

To find the number of hours required to cover 12m2 with a coating 0.1mm thick, divide 12 by the value shown in Column 13, Table 10-7. Since a coating 0.33 mm thick is actually required, multiply by (12 -- 25.3) X 3.3 = 15.7 or 1.6 hours (approx.)


3. Calculate Weight of Wire required

Weight equals time required multiplied by Spray rate shown in Column 12, Table 12-7 = 6 hours X 6.8 Kg = 11 Kgs. (approx.)

4. Calculate total Air, Oxygen & Acetylene required Air = Time multiplied by consumption in m3 per hours (51)

Oxygen & Acetylene = Time multiplied by consumption in m3 per hour from columns 10 & 11

Air = 1.6 X 51 = 82 m3

Oxygen = 1.6 X 3.0 = 4.8 m3

Acetylene = 1.6 X 1.4 = 2.2 m3

5. Calculate total cost of Spraying

Total Cost = Wire cost + Cost of Air, Oxy & Acety + Cost of Labour.

Wire Cost = Cost per Kg X Kg. used.

Gas Cost = Cost per m3 of each Gas X m3 used.

Labour Cost= Cost per hour X time required.

Note that these cost relate to the cost of SPRAYING ONLY. The cost of the entire job also includes:

1. The cost of surface preparation before spraying.

2. The cost of machining or other finishing needed after spraying.

Where finish machining or grinding of the coating is required, allow for this material removal when deciding how thick to spray the coating.


SECTION 13

PERFORMANCE CHART: TYPE CORROSPRAY GUN - ACETYLENE

Wire Wire Size

Air Cap

Lighting Pressure Gas Flowmeter Readings

Consumption / Hour Speed M2

/Hr. Wire

Weight

Oxy Acety Air Oxy Acety Oxy Acety Wire 0.1mm Kg/M2 Kg/cm2 Kg/cm2 Kg/cm2 M3 M3 Kg. Thick 0.1mm Thick

1 2 3 4 5 6 7 8 9 10 11 12 13

Aluminium 3/16 AH 3.10 1.03 5.17 48 48 3.00 1.40 6.8 25.3 0.27 1/8 CH 2.76 1.03 5.17 45 42 2.80 1.30 5.0 18.6 0.27

Babbit 3/16 AH 2.07 1.03 5.17 35 59 1.70 1.80 43.5 41.3 1.06 1/8 CH 1.72 1.03 5.17 24 35 0.96 0.88 22.7 22.7 1.00

Lead 1/8 CH 1.72 1.03 5.17 24 35 0.96 0.88 36.3 17.7 2.06

Tin 1/8 CH 1.72 1.03 5.17 24 35 0.96 0.88 22.7 23.6 0.96

Zinc 3/16 AH 3.10 1.03 5.17 48 48 3.00 1.40 29.5 29.5 1.00 1/8 CH 2.76 1.03 5.17 45 42 2.80 1.30 21.8 23.1 0.94

NOTES: Above parameters are only for reference. Actual parameters depend upon the geometry & size of the job. 01. The Figures in Columns 9, 10 & 11 are optimum. Skilled operators can obtain them with all equipment in first class condition. 02. One cubic centimeter of coating covers A. 100 cm2 of surface area, 100 micron (0.1 mm) thick. B. 1000 cm2 of surface area, 10 micron (0.01 mm) thick. C. 40 cm2 of surface area, 250 micron (0.25 mm) thick. 03. Sprayjet-87 can also spray ceramics and cermets available in the form of flexible cords. 04. Figures in column 13 are approximate.


PERFORMANCE CHART: TYPE CORROSPRAY GUN -- PROPANE

Wire Wire Size

Air Cap

Lighting Pressure Gas Flowmeter Readings

Consumption / Hour Speed M2

/Hr. Wire

Weight

Oxy Prop. Air Oxy Prop. Oxy Prop. Wire 0.1mm Kg/M2 Kg/cm2 Kg/cm2 Kg/cm2 M3 M3 Kg. Thick 0.1mm Thick

1 2 3 4 5 6 7 8 9 10 11 12 13

Aluminium 3/16 AH 3.45 3.45 5.17 68 34 4.7 1.00 6.8 25.3 0.27 1/8 CH 3.79 3.45 5.17 68 34 4.7 1.00 5.0 18.6 0.27

Babbit 3/16 AH 2.41 2.76 5.17 52 32 2.8 0.85 43.5 41.3 1.06 1/8 CH 2.41 2.41 5.17 53 30 2.8 0.70 22.7 22.7 1.00

Lead 1/8 CH 2.41 2.41 5.17 53 30 2.8 0.70 36.3 17.7 2.06

Tin 1/8 CH 2.41 2.41 5.17 53 30 2.8 0.70 22.7 23.6 0.96

Zinc 3/16 AH 3.45 3.45 5.17 68 34 4.7 1.00 29.5 29.5 1.00 1/8 CH 3.45 3.45 5.17 68 34 4.7 1.00 21.8 23.1 0.94

NOTES: Above parameters are only for reference. Actual parameters depend upon the geometry & size of the job. 01. The Figures in Columns 9, 10 & 11 are optimum. Skilled operators can obtain them with all equipment in first class condition. 02. One cubic centimeter of coating covers A. 100 cm2 of surface area, 100 micron (0.1 mm) thick. B. 1000 cm2 of surface area, 10 micron (0.01 mm) thick. C. 40 cm2 of surface area, 250 micron (0.25 mm) thick. 03. Sprayjet-87 can also spray ceramics and cermets available in the form of flexible cords. 04. Figures in column 13 are approximate.


SPRAYJET-87 WIRE SPRAY SYSTEM

COMPRESSED AIR

SPRAYJET 87 GUN

OXY. & FUEL CYLINDERS WITH GAS

REGULATORS

WIRE

FLO

WM

ET

ER

AIR CONTROL UNIT


This publication could include technical

inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions of the publications. PPS welcomes your suggestions in respect of product quality.

Plasma Powders & Systems Inc. 228 Boundary Road, P.O. Box 132

Marlboro, NJ 07746 732-431-0992 ~ Fax 732-308-1075 Email [email protected]

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