Proyección Térmica

MANUAL FOR OPERATION
& MAINTENANCE OF
CORRSPRAY
COMBUSTION WIRE
SPRAY GUN
Sprayjet-87 : Operation & Maintenance Manual
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
1.2
SECTION 2.
SAFETY MEASURES
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
SECTION 3.
Air compressor
PPS Air control unit
PPS Gas glow meter
PPS Gas control unit
PPS Hose kit
Trolley with wire reel stand
INSTALLATION
4.1
4.2
SECTION 5.
General safety measures

Use of equipment
Reduction of fire & explosion hazards
Gases
Equipment maintenance
Backfire
Metal dusts
Gas cylinders precautions
Reduction of respiratory hazards
Reduction of noise hazards
Eye protection
FLAME SPRAY EQUIPMENT

3.1
3.2
3.3
3.4
3.5
3.6
SECTION 4.
SPRAYJET 87 gun
Principle of operation
Spray booth
Check
OPERATION
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
Operating controls
Hookup & Initial adjustments
Lighting
Spraying
Start-stop operation
Shutting down
Different sizes of wire
Different gases
Nozzles
Siphon plugs
SECTION 6.
PART LIST OF SPRAYJET 87

6.1
6.2
6.3
6.4
6.5
6.6
SECTION 7.
CONSTRUCTION & ASSEMBLY

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
SECTION 8.
Drive roll carrier & related parts, Wire grip PPShanism system
Gas Head Assy, Siphon plug & related parts
Drive unit with wire grip PPShanism removed, turbine &
Speed control assy
Counter Shaft Assembly, Gear cover, Central Housing,
Handle Drive Shaft Parts
Snubber Assy, Wire Grip Valve
Tool Post Fixture with Tools & Lubricants
Gas head
Valve core positioning
Gas siphon plug
Wire grip PPShanism
Lower drive rolls & gear
Rear wire guide & snubber
Turbine & speed control
Gear cover & Transmission gears
Drive shaft assembly
Counter shaft assembly
Central housing & gun handle
Wire grip valve
Gear case lubrication
Turbine bearing lubrication
AVOIDING TROUBLE
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
Spraying
General gun care
Hoses
Difficult lighting
Backfire
Siphon plug
Wire nozzles
Gas head Valve
Sticking wire
Drive rolls
Speed control
Threads
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
12.2
12.3
12.4
SECTION 13.
How to use tables

How to compute sprayed area
Area formulae
How to calculate costs
PERFORMANCE CHART
LIST OF FIGURES
FIGURE
FIGURE
FIGURE
FIGURE
FIGURE
6
6
6
6
6
(A)
(B) 1
(B) 2
(C)
(D)
FIGURE 6 (F) 1
FIGURE 6 (F) 2
DRIVE ROLL CARRIER & RELATED PARTS, WIRE GRIP PPSH.

SIPHON PLUG & RELATED PARTS
GAS HEAD ASSY
TURBINE & SPEED CONTROL ASSY
COUNTER SHAFT ASSY, GEAR COVER, DRIVE SHAFT ASSY, CENTRAL
HOUSING AND GUN HANDLE
TOOL POST FIXTURE
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 corrosionresistant 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
ON regulator outlet- oxy/acety
Flowmeter to the gun
Air input to the gun
1/2"
1/2"
3/8"
1/2"
UNF
UNF
UNF
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
87-136
87-30
87-37
87-32
87-34
87-33
DRIVE ROLL CARRIER & RELATED PARTS
87-206
87-180
87-208
87-129
87-127
87-177
87-138
87-207
WIRE GRIP PPSHANISM

FIGURE 6(A)
87-209
87-93
6.2
GAS HEAD ASSEMBLY; SIPHON PLUG & RELATED PARTS
CAT. No.
GENERAL DESCRIPTION
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)*
87-7-3
87- 7-4
87-7-5
87-7-6
87-7-7
87-7-8
NOZZLE PROPANE 3/16 WIRE (2, 3)*
87-7-9
87-7-9
87-7-10
87-7-11
87-7-12
87-7-13
87-7-14
NOZZLE ACETYLENE 1/8 WIRE (2, 3)*
87-7-15
87-7-16
87-14
O RING (COUNTER SHAFT PLUG "O" RING)
CAT. No.
GENERAL DESCRIPTION
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)*
CAT. No.
GENERAL DESCRIPTION
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)*
(2)*
(3)*
(4)*
=
=
=
=
ANNULAR
NOZZLE FOR LOW MELTING WIRE
JETTED
NOZZLE FOR HIGH MELTING WIRE
NON LOADING NOZZLE FOR BABBIT, LEAD & TIN WIRES
INCLUDES SIPHON PLUG, NOZZLE O-RING, NOZZLE NUT &
FRONT WIRE GUIDE
87-3
87-7
87-6
includes 87-108
& 87-109
87-2
87-14
SIPHON PLUG & RELATED PARTS

FIGURE 6(B) 1
87-23
87-145
87-1
87-41
87-173
87-45
87-174
87-169
87-40
87-31
87-170
87-166
87-165
87-167
87-168
87-171
87-44
87-43
87-179 87-176
87-14
87-157
87-5 GAS HEAD ASSEMBLY

FIGURE 6(B) 2
87-44
6.3
DRIVE UNIT WITH WIRE GRIP PPSHANISM REMOVED, TURBINE & SPEED
CONTROL ASSEMBLY
CAT. No.
GENERAL DESCRIPTION
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
87-72
87-67
87-78
87-76 87-73
87-48
87-31
87-47
87-82 87-79
87-81
87-80
87-71
88-74
88-75
87-160
87-86
87-77
87-85
87-50
87-87
87-88
TURBINE AND SPEED CONTROL ASSEMBLY

FIGURE 6(C)
87-89
6.4
COUNTERSHAFT ASSEMBLY, GEAR COVER, CENTRAL HOUSING, HANDLE,

DRIVE SHAFT PARTS
CAT. No.
GENERAL DESCRIPTION
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
87-52
87-84
87-14
87-46
87-70
87-51
87-92
87-67
87-91
COUNTER SHAFT ASSY

87-70
87-55
87-54
GEAR COVER
87-66
87-68
87-69
87-67
87-65
DRIVE SHAFT ASSY
87-84
87-59
87-99
87-53
87-62
87-63
87-60
87-97
87-61
87-28
87-27
CENTRAL HOUSING & HANDLE

FIGURE 6 (D)
6.5
SNUBBER ASSEMBLY; WIRE GRIP VALVE
CAT. No.
GENERAL DESCRIPTION
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
87-67
87-245
87-243
87-188
87-241
87-242
87-187
87-133
87-132
87-129 87-131
87-150 87-180
(87-118) SNUBBER ASSY & WIRE GRIP VALVE

FIGURE 6 (E)
87-67
6.6
TOOLS AND LUBRICANTS
CAT. No.
GENERAL DESCRIPTION
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
87-150
87-127
87-130
87-128 87-99
87-126
87-98
87-129
TOOL POST FIXTURE ASSY

FIGURE 6(F) 1
87-107-A
87-101
87-104
87-105
87-100
87-110
87-140 87-102
87-107-B
87-111
87-114
87-107
TOOLS & LUBRICANTS

FIGURE 6(F) 2
SECTION 7
CONSTRUCTION & ASSEMBLY
The Sprayjet-87 Gun is made up of two main sections:
1.
2.
The Gas Head, which melts and sprays the wire.

The Drive Unit which feeds the wire to the Gas head
The Drive Unit consists of:

1.
2.
3.
The Air Turbine and Speed Control Assembly

The Transmission (reduction gearing drive rolls)
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 8714 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 877 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 8759. 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 87131. 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
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 &

bleeder holes.
40
Use nozzle cleaning wire kit
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

thread
200
Valvelube
11.
Clean & relube power control

spider
200
Gearlube
12.
Clean and lube gas head valve
500
Valvelube thin film
13.
Complete overhaul
Interval Hr.
1000
Remarks
Wash out
lubricants
and
thin
replace
film
all
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 antioxidant 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.
Wire & Their

Characteristics
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 silentrunning 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 nonconductive substrate. Also suitable for preparation of moulds
for low-pressure injection moulding.
Zinc (99.9%)
Time-tried anti-corrosion material for practically

use in the field of ship building machine and
construction and pipe or conduit manufacture,
structures of all types and sizes, internal coating
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.
unlimited
container
for steel
of tanks,
Wire & Their

Characteristics
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
(mm)
Wire Guide
Drive Rolls
Lower
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
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
2.
Area of a circle
R2
3.
Area of a cylinder
DL
4.
Area of sphere
5.
Area of a triangle
bh / 2
6.
Area of a parallelogram
bh
7.
Area (lateral of a cone)
r2
Where:
12.4
D2
r2 + h2
= 3.1416; R = Radius
D = Diameter; b = Base;
h = Altitude; r = Radius of base; L = Length
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.
5.
Air
1.6 X 1800 = 2880 Ft3
Oxygen
1.6 X 105 = 168 Ft3
Acetylene
1.5 X 50 = 80 Ft3
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

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
25.4 mm
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.
2.
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
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 127 = 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
5.
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
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
Oxy
Kg/cm2
Acety
Kg/cm2
Air
Kg/cm2
Gas Flowmeter
Readings
Oxy
Acety
Oxy
M3
Acety
M3
Wire
Kg.
Speed M2
/Hr.
0.1mm
Thick
11
12
Wire
Weight
Kg/M2
0.1mm
Thick
13
Consumption / Hour
10
Aluminium
3/16
1/8
AH
CH
3.10
2.76
1.03
1.03
5.17
5.17
48
45
48
42
3.00
2.80
1.40
1.30
6.8
5.0
25.3
18.6
0.27
0.27
Babbit
3/16
1/8
AH
CH
2.07
1.72
1.03
1.03
5.17
5.17
35
24
59
35
1.70
0.96
1.80
0.88
43.5
22.7
41.3
22.7
1.06
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
1/8
AH
CH
3.10
2.76
1.03
1.03
5.17
5.17
48
45
48
42
3.00
2.80
1.40
1.30
29.5
21.8
29.5
23.1
1.00
0.94
NOTES: Above parameters are only for reference. Actual parameters depend upon the geometry & size of the job.
01.
02.
03.
04.
The Figures in Columns 9, 10 & 11 are optimum. Skilled operators can obtain them with all equipment in first class condition.
One cubic centimeter of coating covers
A.
100 cm2 of surface area, 100 micron (0.1 mm) thick.
B.
C.
Sprayjet-87 can also spray ceramics and cermets available in the form of flexible cords.
Figures in column 13 are approximate.
PERFORMANCE CHART: TYPE CORROSPRAY GUN -- PROPANE

Wire
Wire
Size
Air
Cap
Lighting Pressure
Oxy
Kg/cm2
Prop.
Kg/cm2
Air
Kg/cm2
Gas Flowmeter
Readings
Oxy
Prop.
Oxy
M3
Prop.
M3
Wire
Kg.
Speed M2
/Hr.
0.1mm
Thick
11
12
Wire
Weight
Kg/M2
0.1mm
Thick
13
Consumption / Hour
10
Aluminium
3/16
1/8
AH
CH
3.45
3.79
3.45
3.45
5.17
5.17
68
68
34
34
4.7
4.7
1.00
1.00
6.8
5.0
25.3
18.6
0.27
0.27
Babbit
3/16
1/8
AH
CH
2.41
2.41
2.76
2.41
5.17
5.17
52
53
32
30
2.8
2.8
0.85
0.70
43.5
22.7
41.3
22.7
1.06
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
1/8
AH
CH
3.45
3.45
3.45
3.45
5.17
5.17
68
68
34
34
4.7
4.7
1.00
1.00
29.5
21.8
29.5
23.1
1.00
0.94
NOTES: Above parameters are only for reference. Actual parameters depend upon the geometry & size of the job.
01.
02.
03.
04.
The Figures in Columns 9, 10 & 11 are optimum. Skilled operators can obtain them with all equipment in first class condition.
One cubic centimeter of coating covers
A.
B.
C.
Sprayjet-87 can also spray ceramics and cermets available in the form of flexible cords.
Figures in column 13 are approximate.
FLOWMETER
OXY. & FUEL

CYLINDERS WITH GAS
REGULATORS
SPRAYJET 87 GUN
WIRE
COMPRESSED AIR
AIR CONTROL UNIT
SPRAYJET-87 WIRE SPRAY SYSTEM

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 info@plasmapowders.com
Web plasmapowders.com

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MANUAL FOR OPERATION

Sprayjet-87 : Operation & Maintenance Manual

Sprayjet-87 : Operation & Maintenance Manual

General safety measures

FLAME SPRAY EQUIPMENT

Sprayjet-87 : Operation & Maintenance Manual

PART LIST OF SPRAYJET 87

CONSTRUCTION & ASSEMBLY

ROUTINE MAINTENANCE SCHEDULE

Sprayjet-87 : Operation & Maintenance Manual

WIRE GUIDE AND ROLL SELECTION CHART

SPRAYING TABLES & GENERAL COST DATA

How to use tables

DRIVE ROLL CARRIER & RELATED PARTS, WIRE GRIP PPSH.

Sprayjet-87 : Operation & Maintenance Manual

Sprayjet-87 : Operation & Maintenance Manual

SIZE & WEIGHT

Sprayjet-87 : Operation & Maintenance Manual

REDUCTION OF FIRE AND EXPLOSION HAZARDS

Sprayjet-87 : Operation & Maintenance Manual

GAS CYLINDERS PRECAUTIONS

REDUCTION OF RESPIRATORY HAZARDS

REDUCTION OF NOISE HAZARD

Sprayjet-87 : Operation & Maintenance Manual

PPS AIR CONTROL UNIT

PPS GAS FLOW METER

PPS GAS CONTROL UNIT

PPS HOSE KIT

Sprayjet-87 : Operation & Maintenance Manual

TROLLEY WITH WIRE REEL STAND

Sprayjet-87 : Operation & Maintenance Manual

Sprayjet-87 : Operation & Maintenance Manual

There are three operating controls on the gun:

The Speed Control Ring adjusts the rate of wire feed.

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

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

HOOK UP & INITIAL ADJUSTMENTS

Sprayjet-87 : Operation & Maintenance Manual

When you are ready to start spraying:

Pause about three seconds

Spark the lighter in front of the nozzle.

Do Not Light Gun Without Wire In The Nozzle.

Sprayjet-87 : Operation & Maintenance Manual

START - STOP OPERATION

Push the wire grip valve off.

DIFFERENT SIZES OF WIRE

Sprayjet-87 : Operation & Maintenance Manual

Sprayjet-87 : Operation & Maintenance Manual

DRIVE ROLL CARRIER & RELATED PARTS; WIRE GRIP PPSHANISM

UPPER DRIVE ROLL AXLE SCREW (not shown)

DRIVE ROLL CARRIER PIVOT PIN (INCLUDES 87-139)

SPRING FOR 88-30 (not shown)

UPPER DRIVE ROLL

UPPER DRIVE ROLL GEAR

UPPER DRIVE ROLL GEAR SCREW

UPPER DRIVE ROLL AXLE

PISTON STOP SCREW

SUPPORT BLOCK MOUNTING SCREW

DRIVE ROLL CARRIER

LOCKING PIN (not shown)

PISTON RETURN SPRING

RETAINER RING (not shown)

CYLINDER SUPPORT BLOCK ASSEMBLY