WireJet -98 Metalizing Gun - Website Designnovastardesign.com/pp/equipment/2016-01 PPS WIREJET...

Plasma Powders & Systems, Inc.

WireJet-98Operation and Maintenance Manual

Plasma Powders & Systems, Inc. 228 Boundary Road Marlboro NJ 07746Ph. (732) 431-0992 Fax (732) 308-1075

www.plasmapowders.com [email protected] V2016-01

WireJet-98 Metalizing Gun

http://www.plasmapowders.com/

mailto:[email protected]





Table of Contents

Section Description Section Description

1 Introduction

1. Wirejet-98 Gun2. Design Highlights3. Specifications4. System Components: Air Compressor PPS 2GF Gas

Flowmeter PPS 3AF Air

Flowmeter PPS AT-100 Air Trio PPS Fuel Regulators Hose Kit Auxiliary & Optional

Equipment

4 Operation

1. Operating Controls2. Connections/Initial

Adjustment3. Lighting4. Spraying5. Start-Stop Operation6. Shutting Down7. Wirejet-98 Variations

8. Hardware SelectionCharts Wire Guide/Drive

Rolls Gas Head Hardware Air Caps

9. Spray Tables US Acetylene Jetted Metric Acet Jetted US Propane Jetted Metric Propane Jetted

2 Safety

1. Use of Equipment2. Fire & Explosion

Hazards3. Gases4. Equipment Maintenance5. Metal Dust6. Gas Cylinders7. Respiratory Hazards8. Personal Protection9. Noise Hazards10. Eye Protection

5 Construction & Assembly

1. Air Cap/Nozzle/Siphon Plug2. Gas Head Assembly3. Valve Core Positioning4. Wire Drive Unit5. Wire Grip Mechanism6. Lower Drive Rolls & Gear7. Rear Wire Guide & Snubber8. Turbine & Speed Control9. Gear Cover & Transmission

Gears

10. Drive Shaft Assembly11. Counter Shaft Assembly12. Gun Handle/Wire Feed

Valve13. Central Housing14. Lubrication15. High/Std Speed

Conversion16. Exploded Part Views

3 Installation

1. Prerequisites2. Connections3. System Check4. System Flow Diagram

6 Avoiding Trouble

1. General Gun Care2. Backfire3. Siphon Plug4. Nozzles5. Gas Head Valve

6. Lighting (Flows)7. Oxy/Fuel Connections8. Hoses Lubrication9. Wire Feed Issues10. Routine Maintenance11. Revision History







CAUTION:

Read and understand this entire manual before attempting to use this equipment. Safety precautionsmust be strictly adhered to in order to maintain a safe environment for the user and surrounding area.Under NO circumstances should any modifications be made to this manual or the equipment without

prior written approval from Plasma Powders & Systems, Inc.

DISCLAIMER:

This document represents a collective effort involving a substantial number of volunteer specialists.Great care has been taken in the compilation and production of this document, but it should be madeclear that no warranties, express or implied, including without limitation, warranties of merchantabilityor fitness for a particular purpose are given in connection with this document.Although this information is believed to be accurate, Plasma Powders cannot guarantee that favorableresults will be obtained from the use of this document alone. This document is intended for use bypersons having technical skill, at their sole discretion and risk.No claim of any kind, whether as to products or information in this document, and whether or not basedon negligence, should be greater in amount than the purchase price of this product or publication inrespect of which damages are claimed. The remedy hereby provided should be the exclusive and soleremedy of buyer, and in no event should either party be liable for special, indirect, or consequentlydamages whether or not caused by or resulting from the negligence of such party.Nothing contained in this document should be construed as a grant of any right of manufacture, sale,use, or reproduction, in connection with any method, process, apparatus, product, composition, orsystem, and nothing contained in this document should be construed as a defense against any alleged.Failure to observe the information provided herein may result in risk to personnel health and safety, aswell as damage to equipment and surrounding area.The document must be stored by a person charged to do so. In case of loss or damage, replacement ofthis documentation must be made by a request to Plasma Powders & Systems, Inc.







Section 1: Introduction

1.1 Introduction:

The WireJet-98 Gun has been designed and built to be one of the world’s best hand guns for producingflame sprayed coatings with metalizing wires. It has a universal gas head, which can be adapted to useany fuel gas. The standard gun is set up to spray 1/8” wire using acetylene as the fuel gas. Suitablehardware is available for handling standard wire sizes ranging from 1/16” to 3/16”. The controlled speedrange of the WireJet-98 Gun is from about 2 to 15 feet wire per minute with standard gears toapproximately 5 to 15 feet per minute with a special, easily installed, high speed gear set. The high-speed gear set is for continuous high speed spraying of the lower melting point metals such as zinc,babbit and tin.

Although the WireJet-98 Gun has been designed primarily for hand-held operation, a simple, ruggedtool post fixture is supplied with each unit to permit mounting on a machine tool such as a lathe.The gun will provide many years of service when kept clean and properly maintained. This documentwill provide the information necessary for a user to select proper hardware, operate and break down,clean and service the unit.

1.2 Design highlights:

The WireJet-98 Gun offers many outstanding design features. Some of these are described below:

An improved version of the WireJet-98 Gun’s siphon jet gas head produces high spray rates, lowgas consumption and extreme resistance to back-fire and its effects.

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

The gas head valve provides long service life with minimum maintenance. Worn or damagedvalve parts are easily replaced in the field.

New design nozzles and air caps provide excellent coatings at various spraying speeds andaccommodate start/stop operation.

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

WireJet-98’s controlled-power governor provides increased power and more stable wire speed. The gear chamber contains a built-in pump for circulating the gear lubricant. This coupled with

large rugged gears and improved gear chamber sealing provides longer gear life.







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

For convenience when changing wires, or to stop the wire feed momentarily while spraying, thegun has a quick action wire grip-release trigger. A simple, effective wire snubber is provided atthe back of the gun to keep the wire from slipping out of the gun when operating on a start-stopbasis.

The gun has an independent, simple wire grip adjustment for varying the bite of the drive rolls onthe wire.







1.3 Specifications:

* Compressed air tank pressure should be approx. 75 psi to prevent fluctuations in air pressure to thetorch depending on piping, valves and compressor cut-in settings.

Feature: SI Units US UnitsWeight 2.77 Kgs. 6.12 Lbs.Wire Feed Rate:StandardHigh Speed

0.6 – 4.6 m/Min1.4 – 11.7 m/Min

2 – 15.1 ft/Min4.5 – 38.5 ft/Min

Spray Distance 130 – 205 mm 5 – 8 in.Compressed Air Requirement 0.85 m3/min @ 4.5 bar 30 cfm @ 70 psi * See below

Process gases:OxygenAcetylenePropane

3.45 bar @ 85.4 NLPM1.03 bar @ 21.9 NLPM3.45 bar @ 18.4 NLPM

50 psi @ 195 SCFH15 psi @ 50 SCFH50 psi @ 42 SCFH

Wire Sizes: 0.812 through 4.76 mmStandard – 3.175 mm

20 ga. through 3/16 inStandard – 1/8 in







1.4 System Components:

A complete flame spray installation requires equipment to supply and control compressed air, oxygen,fuel gas and metalizing wire.

Air Compressor

A minimum of 30 cfm of free air delivery is required at 4.5 Kg/Cm2 (70 psig). Taking into considerationthe pressure in the pipe connections and regulator, a line pressure of at least 5.0Kg/Cm2 (75 psig) at theregulator should be provided during spraying.

** IMPORTANT:This gun is cooled by Air. The material is sprayed by an Air jet. The gun’s gears areoperated by an Air turbine.

Failure to supply adequate Air to this gun WILL WITH ABSOLUTE CERTAINTYcause equipment breakdown and coating problems!! Equipment can burn almostinstantly. Never restrict air flow by using Quick Connect hose ends, sub standardcompressors or worn or undersized hoses. Always check flows of Air and Gasesbefore lighting the unit.

PPS 2GF Gas Flowmeter

The PPS 2GF Gas Flowmeter is a balanced two-tube flowmeter with easy-to-read scales for the accurateadjustment of gas flows. It can also be extremely useful in detecting trouble in the gas lines or nozzle.The PPS 2GF Gas Flowmeter indicates the flow of oxygen and fuel gas to the Gun. In a flame sprayGun, highest efficiency is obtained when the flow of gases is precisely balanced. Slight changes in theproportions of oxygen and fuel gas can decrease the efficiency of the flame and cause a host of problemsincluding damage to equipment.The flowmeter measures the flow of oxygen and fuel gas delivered to the flame spray Gun. It takes intoaccount all of the variables, such as gas passages and nozzles, and shows the actual flow of gas to theflame. If the flow control valves are adjusted to give the correct reading on the flowmeter, the flow ofoxygen and fuel gas will be in balance even though the pressure gauges may be inaccurate, or the hosediameter is altered by aging or pinching. The gas flowmeter provides a very reliable method ofmaintaining proper flame balance and high operating efficiency and allows for accurate preset flows formultiple materials.







PPS 3AF Air Flowmeter

The 3AF Air flowmeter helps the user monitor and maintain consistent air flow to the gun. It providesthe same accuracy and precision for air as the 2GF provides for the gases.

PPS AT-100 Air Trio

Clean, dry pressure-regulated air is mandatory. The AT-100 has been designed especially for flamespraying. It consists of a rugged, reliable pressure regulator and two filters. The regulator provides ameans for adjusting the pressure of air to the air flowmeter. It will hold that pressure constant regardlessof fluctuations in line pressure. One filter is placed ahead of the regulator to remove pipe scale, oil andwater. The second filter is placed downstream to trap additional oil and water, which condense out as aresult of pressure drop through the regulator. The filters use fine mesh screens, which are easy to inspectand clean. A large, quarter-turn stop cork at the output of the air control provides for quick and easy cut-off of air to the air flowmeter, hose and Gun.

PPS Fuel Regulators

Gas cylinders must be equipped with proper pressure regulators and gauges to reduce the gas pressure tothe correct working values. The PPS Fuel regulators are multi-stage oxygen and fuel gas regulators,ideal for this purpose.The regulators are of the two-stage type with a metal diaphragm in the high-pressure stage and a largediameter diaphragm in the low-pressure stage, for easy and precise regulation of the outlet pressure.These are high capacity regulators. Low capacity, light-duty, welding regulators may cause trouble andare not recommended for this service.

PPS Hose kits

Hoses are required to connect the flowmeter to the gas regulators. Two hose units are available for thisservice. The “F” Type Hose Unit includes an oxygen hose and a fuel gas hose, both 2 meters long. The"G" Type Hose Unit includes an oxygen hose and fuel gas hose, both 5 meters long. In countries, whichrequire oxygen lines to be green, the oxygen hoses in these units are green. In countries, which requireoxygen lines to be blue, the oxygen hoses in these units are blue. In all countries the fuel gas hoses arered.

PPS Auxiliary & Optional Equipment







o Your particular operation may require a suitable spray booth

o Most applications require an adequate exhaust system to dispose of dust and fumes. PPS offers acomplete line of spray booths, dust collectors and exhaust units. Also available is an exhaust unitfor installation on a lathe carriage.

o To protect personnel in the vicinity of the flame spray operation against excessive noise a PPSAcoustical Flame Spray Room is available.

o For preparing the surface to be sprayed, PPS has grit-blasting equipment available.

o PPS also offers a line of handing equipment and robotics for production line installations to aidin the spraying of high quality, uniform, reproducible flame sprayed coatings.

o A heavy duty Wire stand and Straightener is available.

o Extensions are available for ID coatings







2 Safety

Flame spraying can be hazardous because it requires the use of combustible gases, containers and hosesunder high pressure, and potentially irritating, combustible and toxic spray materials and fumes. It mayinvolve/produce air contaminated by dusts and mists, etc. However, it can be a completely safe processwhen performed by a capable operator with proper understanding of flame spraying practices,knowledge of the equipment, care in operation, and one who follows the recommended precautionarymeasures.

2.1 Use of Equipment

PPS Wirejet-98 has been expressly designed for flame spraying. Never use it for any other purpose suchas welding, soldering, brazing, and the like.

2.2 Reduction of Fire and Explosion Hazards

Remember that the stream of sprayed metal is hot. Always point the lighted Gun away from personneland materials. Carelessness in pointing the Gun at paper, wood or oily rags can result in fire. Beespecially careful not to spray on hoses as they will burn. Keep them out of the way.

2.3 Gases

All gas equipment such as fuel gas, oxygen and airlines, compressors, regulators, flashback arrestersetc., should be inspected regularly for leaks and loose connections.

2.4 Equipment Maintenance

Maintain all flame spray equipment in first class condition. Follow the maintenance recommendationsgiven.Spray Gun backfire can be prevented by proper maintenance. A Gun will not backfire unless somethingis wrong. See the “Construction” and “Troubleshooting” sections for detailed descriptions.







2.5 Metal Dusts

All dust having considerable calorific value can be explosive. This dust includes: flour, starch, hardrubber dust, wood flour, aluminum dust, and the dust of other metals. Aluminum and magnesium dustsare particularly hazardous. The greatest care should be used in handling them. A dust collection method,designed specifically for your application/circumstances is highly recommended.

Metal dust, fumes and the fuel combustion products call for an effective exhaust and dust collectionsystem. In production installations, if the spraying station is enclosed, make sure that there is enoughopening for inlet air so that the exhaust system is not starved (make up or replacement air). Under someconditions, 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 befound to be very ineffective and, in some cases, dangerous if used for metal dust.

2.6 Gas Cylinder Precautions

Charged gas cylinders are potentially dangerous. The following points should be kept in mind.

Never put a gas cylinder in a hazardous position. Keep cylinders away from heat. Always chain themto 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 on regulators or cylinder valves as a fire or explosion mayresult.

Before moving any cylinder, shut the valve, discharge and remove the regulator and put on the valvecap.

Never use oil or grease on oxygen equipment.

2.7 Reduction of Respiratory Hazards

A suitable spray booth and an adequate exhaust system are required to avoid the toxic or noxious effectsof dust, fumes and mists which may be generated by flame spraying. Masks or Respirators are arecommended additional precaution. Minimum protection for your particular materials can be found onthe MSDS (Material Safety Data Sheet) that accompanies your material order.







Any finely divided material may damage the respiratory system in varying degree. Whenever fumeconcentration is high enough to cause operator discomfort, (dizziness, nausea, etc.) stop spraying. Checkthe ventilating, exhaust systems and related equipment. If this equipment is adequate and operatingproperly, respiratory equipment must be provided regardless of the material being sprayed. If operatordiscomfort continues even with the added protection, something is wrong! Stop spraying and recheck allequipment and engineering guidelines for your circumstances. Do not resume spraying until allpossibility of discomfort has been completely tested and eliminated.

Dusts and fumes of lead, lead alloys, cadmium, chromium and beryllium are highly hazardous. Whenspraying these metals, completely sealed mask type pressurized respiratory protection and protectiveclothing must be provided for the operator and other workers in the fume area.

Fumes of zinc and its alloys (brasses and bronzes) are toxic. Hood type, pressurized respiratoryprotection should be provided when fume concentration is high enough to need it. Fumes of nickel andits alloys are potentially hazardous also requiring pressurized respiratory devices.

**This is not a complete list. If you don’t know, don’t spray!** Consult the MSDS for EACH SPRAY MATERIAL **

2.8 Personal Protection

Possible allergic reaction to dusts, fumes and the like or other unknown causes of health impairment dueto contact with the body cannot, in most cases, be predicted. To avoid such reaction, never permit spraydust to enter the eyes, mouth, cuts scratches, or open wounds. After spraying and especially beforeeating or handling food, wash hands thoroughly.

2.9 Reduction of Noise Hazard

The noise from PPS WireJet-98 is quite high. Except for short periods of operation, the operator andother personnel close to the flame spray operation must be protected from excessive noise. If possible,the flame spray operation should be isolated. If this is not possible, personnel should be rotated. Hearingprotection should be used. Do not rely on wads of cotton for hearing protection. They are ineffectiveagainst high intensity noise. The noise level of Wirejet-98 gun ranges up to 125 dBA.

2.10 Eye Protection







Always wear adequate eye protection when operating or watching the flame spray operation. Inspect theeye protectors frequently. Lenses and cover plates, which are scratched, pitted or damaged, can impairvision and seriously reduce protection and overall safety.

3 Installation

3.1 Prerequisites:

Read this manual in its entirety before attempting to use this equipment!

Plasma Powders Inc. provides free training to anyone who purchases this system and is willing to travelto our Marlboro, NJ location. On-Site training is available for purchase. Phone support is also availablea no charge. We highly recommend making use of these options!

Unpack all components and identify each piece using packing lists and material in the enclosed manuals.

Your system has been tested at Plasma Powders and is ready for operation when all safety procedures,connections and prerequisites are complete as specified in this manual and other literature/trainingmaterials. Be sure you are well versed in the proper operation and procedures necessary to use thissystem in a safe and effective manner before attempting to complete installation and use this system.

3.2 Connections:

Choose a suitable location for your air and gas control units.Distance is limited only by the length of the hoses ordered with your system and regulations regardingplacement of cylinders. However, the gauges on these items will need to be visually verified duringoperation of the gun until consistent, desired settings are achieved.

Mount the WireJet-98 Gun in Position for use.

Position the fuel gas and oxygen cylinders with regulators in place. Gas cylinders should always bestrapped or chained to the wall to prevent their being knocked over.Always blow out the gas cylinder valves before attaching the regulators.Attach the regulators to your cylinders.

Mount all control units and make all necessary connections.







3.3 System Check

Before putting the gun into operation: Use the nozzle and air cap shown in the performance chart for the wire to be sprayed.

Make sure that the nozzle nut is tight. Tightening by hand is sufficient. The siphon plug flange must be firmly seated against the gas head.

Make sure the mating surfaces are clean and free of chips. The air cap body must be tight. Tightening by hand is sufficient. Check the gas head valve for smooth, easy action. Re-lubricate if necessary.

Verify all connections are tight and won’t leak. Verify all parts to be coated are properly prepared.

Make sure all necessary safety points are checked including operator safety equipment andventilation/dust collection is in place and working properly.

Be sure the gas head valve is in the closed position.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 coil on the wire stand or on the floor or a cart near the gun and out of the operators’ way.Always try to position wire so that it will feed as straight as possible into the rear wire guide of theflame spray gun.

When the gun is mounted so that it moves, i.e. on the carriage of a lathe, the wire coil should be placedas far away from the gun as is practical in order to reduce the bend in the wire as it passes into the rearwire guide.







3.4 Typical System Flow Diagram







4 Operation

4.1 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 drive turbine.

2. The speed control ring adjusts the rate of wire feed.

3. The wire valve thumb slide (trigger) causes the drive rolls to grip or release the wire.

In addition to the above control, the gun has a spring cap, which adjusts the bite of the drive rolls on thewire. Turning the cap clockwise increases the bite. Do not adjust for more pressure than needed toassure smooth, steady wire feed. The wire grip adjustment cap is set at the factory and does not requiredaily adjustment. When an adjustment is necessary, you will find that it will be easier to turn the cap ifthe wire grip handle is turned to the horizontal position.Each gun is given an operating test before leaving the factory and is ready to be hooked up whenreceived. If several months have elapsed between the time the gun is received and is first put intoservice, it may be necessary to re-lubricate the valve before the unit will operate smoothly. If the gun hasbeen out of use for sometime it is recommended that you cycle the speeds up and down a few times,when first starting up, by turning the speed control ring.

4.2 Connections & Initial Adjustments

Connect hoses to the air and gas control units. Blow out the hoses and then connect to the gun. Air andoxygen hose must have right hand threads and the fuel gas hose has a left hand thread. The hose nutsmust be drawn up tight enough to prevent leakage but should not be over tightened as this may crush thehose stem. Point the gun into the spray booth or towards the job.

Open the gas head valve by turning the valve handle straight up and adjust the air pressure at theregulator until the gauge shows the pressure specified in the spray tables or your desired setting.If the valve is now turned off (horizontal) the pressure gauge should not show more than a 0.7Kg/Cm2 (10 psig) increase. A greater pressure rise usually indicates regulator trouble or arestriction upstream from the air control unit. In either case the trouble should be correctedbefore proceeding.

Open the gas head valve to full on. Check the gas pressures and flows against the Spray table orfor our desired setting. Make sure Air and Gas flows and pressures are acceptable BEFORElighting the gun.







Turn the valve handle up at 45 degrees until it clicks. In this position air is fed to the turbine but not tothe air cap. This is the lighting position. Turn the valve handle all the way up and a strong blast of airwill come out of the air cap. This is the running position.

With the gas head valve in the running position and the wire grip trigger off (in the wire-release or offposition) insert the wire into the rear wire guide and push it through the gun. Push the wire grip triggerforward (it will “toggle” into the on position, it doesn’t need to be held). The wire will begin to feed.

Adjust the speed control ring to a slow feed for hard wire such as steel or bronze, or a fast feed for softwires such as aluminum or zinc.

With the gas head valve open, re-check the Air and Gas flows against the Lighting Flows chart. Adjustthe flow with the help of gas regulators to the flow values shown in the chart. Then close the gas headvalve.

4.3 Lighting

CAUTION: Do not light gun without wire in the nozzle. Wire should extend up to about 1/8” beyond the

nozzle. Be sure there is compressed air inside the gas head. (Air cools most thermal spray guns) 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, thegun flame may flash back through the rear wire guide. The hot tip of the wire and the back flashof the flame can cause personal injury.

When you are ready for spraying:

Make sure the wire feed is off. Hold the igniter and open the gas head to full open (run position).

Pause for about three seconds. Close the valve halfway until you feel it click into the lighting stop. Spark the lighter in front of the nozzle. The gun will ignite loudly.

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

There is no need for an operator to rush the steps required except that the valve must be openedcompletely immediately after lighting. Remember flammable gas will build up if there is no airmovement when gas is flowing.







After the gun is lighted:

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

Set the speed control to obtain the appropriate wire speed, which will allow the wire to melt offto a point without spattering. The wire should extend in front of the air cap about 5mm. Thislength, however, will vary, depending upon the kind of coating desired and the metal beingsprayed.

Readjust the fuel gas and oxygen regulators until the reading on the gas flow meter correspond tothe values given in the spray tables.

4.4 Spraying

The gun should be held from 5 to 8 inches away from the surface being sprayed. For small work, such asshafts less than 2.5cm in diameter, it is advisable to cool the work with an air blast.

For general information on surface preparation and Thermal Spray processes or specific informationregarding your particular application, please contact Plasma Powders & Systems, Inc. by phone or emailand someone will be able to assist you.

4.5 Start/Stop Operation

The wire feed can be temporarily stopped while spraying by simply toggling the thumb switch to releasethe grip of the drive rolls. The wire snubber located at the back of the gun will keep the wire fromslipping free of the gun. Make sure that the outer sleeve of the snubber is in the operating position(rearward).

To start the wire feed again, toggle the trigger to the ON position.

When spraying low melting point wires in occasional start - stop operation, the standard nozzles and aircaps will be satisfactory. However, frequent start and stop may cause these parts to load with sprayedmetal. For this type of operation, special non-loading nozzles and air caps are available.

Plain rear guides (without the snubber Mechanism) are available. These should not be used whenoperating start – stop to minimize risk of wire sliding out of the back of the gun.







4.6 Shutting Down

Turn off the wire feed. (Toggle the thumb trigger).

Turn off the gas head valve (full forward position).

To release the wire:

1. Make sure the thumb trigger is in the “Off” (rearward) position.2. Push the snubber outer sleeve forward. (The sleeve can be locked in the forward position by

twisting it in the direction of its arrow)

If the gun will not be used again for several hours shut off the oxygen and fuel gas at the cylinders andshut off the air at the regulator on the air control unit.

It is also good practice to back out the pressure regulating screws on the gas pressure regulators andbleed off pressure in the hoses and gun by momentarily opening the gas head valve.

4.7 Wirejet-98 Variations

SPECIAL GEARS

For production spraying of high-speed wires (such as zinc), which would require the standard Wirejet-98 Gun to be run at or near top speed, a special high-speed turbine worm and countershaft gear setshould be installed. . Refer to the chapter on “Construction and Assembly” for instructions on how toreplace the turbine shaft and countershaft gear.

Use of this special gear set has the following advantages: It will permit the maximum spray rate for those wires such as lead, tin and Babbitt, which can be

sprayed faster than the standard WireJet-98 can feed them. Wear on the gears; turbine bearings and governor parts will be reduced.

Speed adjustment will be easier to make.

DIFFERENT GASES

The Wirejet-98 Gun is equipped with a universal gas head. When used with the proper Nozzle andSiphon Plug, it may be used with oxygen and various combustible gases such as acetylene or propane.







Your Gun should be set up for your fuel gas before leaving the factory. Never attempt to switch gasseswithout using the appropriate nozzle and siphon plug!

NOZZLES

There are two types of wire nozzles, acetylene, propane (or LPG). The nozzles for acetylene are flat onthe small end. The propane nozzle is counter bored on the small end. Each nozzle has its wire size markon it.

SIPHON PLUGS

Different siphon plugs are required for various wire sizes and fuel gases. See the nozzle and siphon plugselection chart below for the proper combination of parts or contact Plasma Powders and speak with oneof our technicians.







4.8 Hardware Selection Charts

Wire Guide and Drive Rolls

Wire SizeWire Guides Drive Rolls

Lower DriveRoll GearsFront

GuideRear Guide &

Snubber AssemblyPlain Rear

GuideUpper Lower

3/16” 98-23-3/16 N/A98-24-3/16 &98-187-3/16

98-32-3/16 98-35-3/16 98-36-3/16

1/8” &11Ga.

98-23-1/8 98-118-1/8 98-24-1/8 98-32-1/8 98-35-1/8 98-36-1/8

15 Ga. 98-23-15 98-118-15 98-24-15 98-32-1/8 98-35-15 98-36-1/8

Notes:1. For individual parts to the Rear Guide & Snubber Assembly, see part list.2. Never use the plain Rear Guide for start/stop operation.3. Use Upper Drive Roll Gear 98-33 for ALL setups.

Gas Head Hardware Selection

Fuel GasWireSize

Jetted Jetted Non-Loading

Nozzle Siphon Plug Air Cap NozzleSiphon

Plug Air Cap

Acetylene

3/16 98-7-42 98-2-5 98-3-EA 98-7-45 98-2-5 98-3-AH1/8 98-7-48 98-2-5 98-3-EC 98-7-26 98-2-5 98-3-CH11 Ga. 98-7-35 98-2-5 98-3-J 98-7-36 98-2-5 98-3-JH15 Ga. 98-7-29 98-2-7 98-3-M 98-7-30 98-2-7 98-3-JH or

MH

Propane orNatural Gas

3/16 98-7-43 98-2-6 98-3-EA 98-7-46 98-2-6 98-3-AH1/8 98-7-49 98-2-6 98-3-EC 98-7-27 98-2-6 98-3-CH11 Ga. 98-7-37 98-2-6 98-3-J 98-7-38 98-2-6 98-3-JH15 Ga. 98-7-31 98-2-8 98-3-M 98-7-32 98-2-8 98-3-JH or

MH

Standard/Non Loading Air Cap Equivalency Chart - Acetylene and Propane

Standard Air CapEquivalent Non-Loading

Air CapEA AHEC CHJ JHM JHC CH







4.9 Spray TablesSPRAYING TABLE – US SYSTEM - Acetylene Jetted Hardware

METAL

RecommendedHardware(Note 1)

LightingPressure

Settings (psi)

Flowmeterreading

Consumption perhour (Note 4) Lbs/

wireReq.

per CuIn of

coating

Depositedcoating

build-upspeed (Cu

In/Hr)Notes4 & 5

Noz.W

ireSize

Air cap size

Gears

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Lbs.

Wire

Cu. F

t. Oxy

Cu. F

t. Acet

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Aluminum (note 7)

3/16 EA

Std

33 15 70 48 48 51 16 95 50

.10

1601/8 EC 30 15 70 43 40 52 12 83 40 12011 J 25 15 60 33 30 48 5.5 60 30 5515 M 25 15 55 24 24 40 2 42 22 20

Aluminum Bronze3/16 EA

Std33 15 70 48 48 53 19 95 50

.3555

1/8 EC 30 15 70 44 40 52 15 86 40 4311 J 30 15 60 38 28 46 7.5 60 30 21

Babbitt

3/16 EAStd

30 15 70 38 48 53 95 65 40

.35

2701/8 EC 30 15 65 29 29 53 40 44 25 1153/16 EA

High35 15 70 43 55 53 185 85 60 530

1/8 EC 35 15 65 28 41 53 90 48 40 255

1/8 EC Std 30 15 70 44 39 52 5 86 48 .30 16

Copper

3/16 EA

Std

33 15 70 48 48 53 30 95 50

.35

851/8 EC 30 15 70 44 40 52 24 86 40 7011 J 25 15 60 33 30 46 10 60 30 2915 M 25 15 60 24 24 43 6 42 22 17

Stainless (1 thru 5)3/16 EA

Std33 15 70 48 45 53 16 98 46

.3250

1/8 EC 30 15 70 44 40 50 13 84 40 4011 J 25 15 60 33 30 48 7.5 60 30 25

Zinc

3/16 EAStd

33 15 70 48 45 51 65 97 47

.35

1851/8 EC 30 15 70 45 40 53 32 86 40 901/8 EC

High30 15 70 45 42 53 45 86 40 130

11 J 25 15 60 33 30 48 20 55 30 5515 M 25 15 60 24 24 43 12 42 22 35

Notes:Hardware

1. Refer to the Gas Head Hardware selection chart for additional hardware recommendations before spraying.Operating Parameters:

2. Columns 5, 6 & 7 show lighting pressures only. After lighting, adjust flowmeter settings to flows listed in columns8, 9 & 10.

3. Adjust the Air PRESSURE for lighting and running to column 7 psi. At this PRESSURE, the FLOW reading shouldbe adjusted to column 10 reading.

Performance:4. The figures in columns 11, 12, 13 and 15 are optimum. They can be achieved by skilled operators with all

equipment in excellent condition.5. One cubic inch of deposited coating covers 100 square inches of surface @ .010” thick or 7 feet of surface area @

.001” thick6. Fan spray air cap spray rates will be lower than charted7. Use non-loading nozzles and air caps when spraying Babbit A, tin, zinc or aluminum alloys in start/stop operation8. When using type AF or GF flowmeters, reduce pressures shown as necessary to obtain flowmeter readings shown.







SPRAYING TABLE – METRIC SYSTEM - Acetylene Jetted Hardware

METAL


LightingPressure

Settings (bar)

Flowmeterreading

Consumption perhour (Note 4) Kgs/

wireReq.per

CM3 ofcoating

Depositedcoating

build-upspeed (CM3

/Hr)Notes4 & 5

Noz. W

ireSize

Air cap size

Gears

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Kg..

Wire

M3O

xy

M3. A

cet

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Aluminum (note 7)

3/16 EA

Std

2.28 1.03 4.83 48 48 51 7.3 2.7 1.4

.0028

26221/8 EC 2.07 1.03 4.83 43 40 52 5.4 2.3 1.1 196611 J 1.72 1.03 4.14 33 33 48 2.5 1.7 .85 90115 M 1.72 1.03 4.14 24 24 45 0.9 1.2 .62 328


Std2.28 1.03 4.83 48 48 53 8.6 2.7 1.4

.0097901

1/8 EC 2.07 1.03 4.83 44 40 52 6.8 2.4 1.1 70511 J 2.07 1.03 4.18 38 28 46 3.4 1.7 .85 344

Babbitt

3/16 EAStd

2.07 1.03 4.83 38 48 53 43.0 1.8 1.1

.0097

44251/8 EC 2.07 1.03 4.48 29 29 53 18.0 1.2 .71 18853/16 EA

High2.41 1.03 4.83 43 55 53 84.0 2.4 1.7 8685

1/8 EC 2.41 1.03 4.48 28 41 53 41.0 1.4 1.1 4179

1/8 EC Std 2.07 1.03 4.83 44 39 52 2.3 2.4 1.4 .0083 262

Copper

3/16 EA

Std

2.28 1.03 4.83 48 48 53 13.6 2.7 1.4

.0097

13931/8 EC 2.07 1.03 4.83 44 40 52 10.9 2.4 1.1 114711 J 1.72 1.03 4.14 33 30 46 4.5 1.7 .85 47515 M 1.72 1.03 4.14 24 24 43 2.7 1.2 .62 279


Std2.28 1.03 4.83 48 45 53 7.3 2.8 1.3

.0089819

1/8 EC 2.07 1.03 4.83 44 40 50 5.9 2.4 1.1 65611 J 1.72 1.03 4.14 33 30 48 3.4 1.7 .85 410

Zinc

3/16 EAStd

2.28 1.03 4.83 48 45 51 29.5 2.7 1.3

.0097

30321/8 EC 2.07 1.03 4.83 45 40 53 14.5 2.4 1.1 14751/8 EC

High2.07 1.03 4.83 45 42 53 20.4 2.4 1.1 2130

11 J 1.72 1.03 4.14 33 30 48 9.1 1.6 .85 90215 M 1.72 1.03 4.14 24 24 43 5.4 1.2 .62 574

Notes:Hardware


2. Columns 5, 6 & 7 show lighting pressures only. After lighting, adjust flowmeter settings to flows listed in columns8, 9 & 10.

3. Adjust the Air PRESSURE for lighting and running to column 7 psi. At this PRESSURE, the FLOW reading shouldbe adjusted to column 10 reading.


equipment in excellent condition.5. One cubic centimeter of deposited coating covers 100 square centimeters of surface @ .01 mm thick or 1 square

meter of surface area @ .0001mm thick6. Fan spray air cap spray rates will be lower than charted7. Use non-loading nozzles and air caps when spraying Babbit A, tin, zinc or aluminum alloys in start/stop operation8. When using type AF or GF flowmeters, reduce pressures shown as necessary to obtain flowmeter readings shown.







SPRAYING TABLE – US SYSTEM - Propane Jetted Hardware

METAL


LightingPressure

Settings (psi)

Flowmeterreading

Consumption perhour (Note 4) Lbs/

wireReq.

per CuIn of

coating

Depositedcoating

build-upspeed (Cu

In/Hr)Notes4 & 5

Noz. W

ireSize

Air cap size

Gears

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Lbs.

Wire

Cu. F

t. Oxy

Cu. F

t. Acet

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Aluminum (note 7)

3/16 EA

Std

45 40 70 69 35 53 16 172 34

.10

1601/8 EC 50 40 70 72 33 52 12 194 33 12011 J 40 35 60 54 24 48 5.5 120 23 5515 M 35 35 60 46 18 45 2 95 15 20


Std50 40 70 70 35 53 21 180 35

.3558

1/8 EC 50 40 70 68 33 53 18 175 35 5111 J 40 35 60 54 24 48 8 120 23 23

Babbitt

3/16 EAStd

30 30 70 60 26 53 95 130 20

.35

2701/8 EC 25 25 70 45 17 53 40 80 12 1153/16 EA

High45 35 70 72 35 53 185 185 35 530

1/8 EC 25 20 70 50 22 53 90 90 17 255

1/8 EC Std 50 45 70 68 35 53 5 176 38 .30 16

Copper

3/16 EA

Std

50 40 70 70 35 53 33 180 35

.35

951/8 EC 50 40 70 68 33 53 25 175 35 7511 J 40 35 60 54 24 48 14 120 23 4015 M 35 35 60 46 18 43 8 95 15 23


Std55 50 70 68 38 53 20 180 42

.3260

1/8 EC 55 50 70 68 36 53 15 181 40 4811 J 45 35 70 50 25 48 8 97 22 26

Zinc

3/16 AHStd

45 35 70 68 32 53 60 161 30

.35

1621/8 CH 50 40 70 68 34 53 32 175 35 901/8 CH

High50 40 70 68 34 53 45 175 35 130

11 J 40 35 60 54 24 48 20 120 23 5515 M 35 35 60 46 18 43 12 95 15 35

Notes:Hardware


2. Columns 5, 6 & 7 show lighting pressures only. After lighting, adjust flowmeter settings to flows listed incolumns 8, 9 & 10.

3. Adjust the Air PRESSURE for lighting and running to column 7 values. At this PRESSURE, the FLOWreading should be adjusted to column 10 reading.


equipment in excellent condition.5. One cubic inch of deposited coating covers 100 square inches of surface @ .010” thick or 7 feet of surface area

@ .001” thick6. Fan spray air cap spray rates will be lower than charted7. Use non-loading nozzles and air caps when spraying Babbit A, tin, zinc or aluminum alloys in start/stop

operation8. When using type AF or GF flowmeters, reduce pressures shown as necessary to obtain flowmeter readings

shown.







SPRAYING TABLE – METRIC SYSTEM - Propane Jetted Hardware

METAL


LightingPressure

Settings (bar)

Flowmeterreading

Consumption perhour (Note 4) Kgs/

wireReq.per

CM3 ofcoating

Depositedcoating

build-upspeed (CM3

/Hr)Notes4 & 5

Noz. W

ireSize

Air cap size

Gears

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Oxy

note 2

Acet

note 2

Air N

otes2 &

3

Kg..

Wire

M3O

xy

M3. A

cet

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Aluminum (note 7)

3/16 EA

Std

3.10 2.76 4.83 69 35 53 7.3 4.9 0.96

.0028

26221/8 EC 3.45 2.76 4.83 72 33 52 5.4 5.5 0.93 196611 J 2.76 2.41 4.14 54 24 48 2.5 3.4 0.65 90115 M 2.41 2.40 4.14 46 18 45 .91 2.7 0.42 328


Std3.45 2.76 4.83 70 35 53 9.5 5.1 0.99

.0097951

1/8 EC 3.45 2.76 4.83 68 33 53 8.2 5.0 0.99 83611 J 2.76 2.41 4.14 54 24 48 3.6 3.4 0.65 377

Babbitt

3/16 EAStd

2.07 2.07 4.83 60 26 53 43.1 3.7 0.57

.0097

44251/8 EC 1.72 1.72 4.83 45 17 53 18.1 2.3 0.34 18853/16 EA

High3.10 2.41 4.83 72 35 53 83.9 5.2 0.99 8687

1/8 EC 1.72 1.38 4.83 50 22 53 40.8 2.5 0.48 4179

1/8 EC Std 3.45 3.10 4.83 68 35 53 2.3 5.0 1.1 .0083 262

Copper

3/16 EA

Std

3.45 2.76 4.83 70 35 53 15.0 5.1 0.99

.0097

15571/8 EC 3.45 2.76 4.83 68 33 53 11.3 5.0 0.99 122911 J 2.76 2.07 4.14 54 24 48 6.4 3.4 0.65 65615 M 2.41 2.07 4.14 46 18 13 3.6 2.7 0.42 377


Std3.79 3.45 4.83 68 38 53 9.1 5.1 1.2

.0089983

1/8 EC 3.79 3.45 4.83 68 36 53 6.8 5.1 1.1 78711 J 3.10 2.41 4.83 50 25 48 3.6 2.8 0.63 426

Zinc

3/16 AHStd

3.10 2.41 4.83 68 32 53 27.2 4.6 0.85

.0097

26551/8 CH 3.45 2.76 4.83 68 34 53 14.5 5.0 0.99 14751/8 CH

High3.45 2.76 4.83 68 34 53 20.4 5.0 0.99 2131

11 J 2.76 2.41 4.14 54 24 48 9.1 3.4 0.65 90115 M 2.41 2.41 4.14 46 18 43 5.4 2.7 0.42 574

Notes:Hardware


2. Columns 5, 6 & 7 show lighting pressures only. After lighting, adjust flowmeter settings to flows listed incolumns 8, 9 & 10.

3. Adjust the Air PRESSURE for lighting and running to column 7 psi. At this PRESSURE, the FLOW readingshould be adjusted to column 10 reading.


equipment in excellent condition.5. One cubic centimeter of deposited coating covers 100 square centimeters of surface @ .01 mm thick or 1 square

meter of surface area @ .0001mm thick6. Fan spray air cap spray rates will be lower than charted7. Use non-loading nozzles and air caps when spraying Babbit A, tin, zinc or aluminum alloys in start/stop

operation8. When using type AF or GF flowmeters, reduce pressures shown as necessary to obtain flowmeter readings

shown.







5 Construction & Assembly

Refer to “Exploded Part Views” at the end of this section.

Normal operation of the WireJet-98 Gun will eventually require the replacement of various parts andassemblies. These are the major components.

1. Gas Head Assembly consists of: air cap, nozzle, siphon plug, gas head, and valve core and hoseconnection block.

2. Wire Drive Assemblies consists of: The drive roll carrier (upper drive gear and roll), wire gripMechanism, lower drive gear and roll and rear guide and snubber assembly.

3. Gun Handle and Wire Feed Thumb Valve are self contained assemblies. The wire feed valvecontrols the wire drive assemblies (drive roll carrier and wire grip Mechanism).

4. Speed control and Turbine Assemblies consists of: the speed control, turbine rotor shaft, andgovernor assembly.

5. Transmission Gear Cover and Drive Shaft Assemblies consist of: transmission bearingassemblies, countershaft assembly, and drive shaft assembly.

5.1 Air Cap/Nozzle/Siphon Plug

The gas siphon plug 98-2 fits into the large hole through the upper part of the gas head. The flange of thesiphon plug has two slots, which mate with two pins in the head. Four O-rings 98-14 seal against gasleakage. The front wire guide 98-23 threads into the back of the siphon plug. The wire nozzle 98-7-xx isheld on to the front of the siphon plug by nozzle nut 98-6. The Air cap 98-3-xx slips into the front recessof the nozzle nut and air cap body 98-1 holds this entire assembly in place.

To disassemble:

1. Turn the Air Cap Body (98-1) counterclockwise and remove.2. Pull the Air Cap away from the nozzle/siphon plug assembly.3. Loosen the Nozzle Nut (98-6) Do not remove at this time.4. Gently pull nozzle and siphon plug from the gun.5. Now remove the nozzle nut and nozzle (98-7-xx)6. Unscrew the Front Wire Guide (98-23-xx) from the back of the siphon plug.7. Inspect O-rings, nozzle and wire guide for wear. Make sure all holes are clean and clear of

debris.

To Re-assemble:

1. Lubricate all O-rings, Thread front wire guide into rear of siphon plug and tighten.2. Insert the Nozzle (98-7-xx) into the front of the Siphon Plug making sure it is fully seated.3. Hand-tighten the nozzle nut on the siphon plug and insert into gas head.







4. Make sure the flange of the Siphon Plug is seated firmly against the gas head.5. Insert the Air Cap over the nozzle.6. Hand-Tighten the Air Cap body to the gun. Be sure this is tight each time you prepare to spray.

.

5.2 Gas Head Assembly

A cylindrical valve core 98-43, centrally located in the gas head is held in place of both the valve handle98-45 and screw 98-179 which holds hose connection block 98-176 to the bottom of the gas head

The Gas head (98-5) is fastened to the gun by three screws: Two front screw 98-97 & one rear screw 98-96.

A cylindrical valve core 98-43, centrally located in the gas head is held in place of both the valve handle98-45 and screw 98-179 which holds hose connection block 98-176 to the bottom of the gas head. TheValve Core CANNOT be removed with the Hose Connection Block In-Place.

To disassemble the valve for 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 (98-176).3. The Detent Pin 98-173 and spring 98-174, behind the valve handle, can now be removed.4. O-Rings 98-44, in grooves on the hose connection block, can be lifted out. These seal against

leakage at the mounting face.5. Remove plunger springs 98-171.6. Remove two plungers 98-165 and one plunger 98-166 by pulling on the plunger stem. Do not

twist. Each plunger is keyed against rotation.7. Slide the valve core 98-43 out of the gas head. Never try to take out the valve core before

removing the hose connection block. Four O-Rings 98-44 and one O-Ring 98-14 on the valvecore seal off the oxygen, fuel gas and air from each other and from leakage outside the gun.

8. Two oxy/fuel plunger seal O-Rings 98-170 and one air plunger seal O-Ring 98-169, normallypressed against the valve core by the spring loaded plungers, may stick to the plunger when theplungers are removed. If not, these rings will be found in the gas head holes, which house theplungers. Push these rings into the valve bore and take them out for servicing or replacement.

Before reassembling the valve parts:

1. Examine all O-Rings and replace those which are worn or damaged. Use only authorizedreplacements. 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 machinedinto the valve core for proper control of the gases. These ports should be clean and free of anyhard residue.

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

5.3 Valve Core Positioning

One end of the valve core (98-43) has an aluminum 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 thegas head. Point the valve handle forward and screw it on to the stem of the valve core. When properlymounted, the head of the valve handle screw will be in line with the hole of the valve core. If they areopposite instead of in line, the valve will not feed air to the turbine when you try to spray.

When replacing the plungers, align the plunger keyway with the mating key pin in the gas head. Slideeach plunger into its hole and press firmly all the way to seat each seal ring against the valve core. Whenproperly installed, the large diameter of each plunger will be completely inside the hole. If it is not, itmeans the 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 topreserve proper orientation. The long nose on the connection block mounting screw 98-179 (next to airhose fitting) engages in the deep groove in the valve core. Make sure to put this screw back in its properplace. Check that the connection block O-Rings are in their retaining grooves before tightening theconnection block screws.

5.4 Wire Drive Unit

To remove the Drive Roll Carrier (98-136) from the front end of the wire grip Mechanism, toggle off thewire grip trigger (98-131) to relieve the spring pressure on the carrier. Then twist the pivot pin (98-30)one-quarter turn clockwise and pull it out. The carrier can then be lifted up and off the wire gripMechanism.

The upper drive gear 98-33 is fastened to the upper drive roll 98-32 by three screws 98-34. This gear androll ride freely on axle 98-37 which is held in the carrier by screw 98-26. A bronze bushing ispermanently pressed into the drive roll. Do not try to remove it.

Inside the carrier is a slotted wall. When reinstalling:

1. Leave the wire grip trigger in the “Off” or rearward position.2. Slide the carrier wall slot over the neck of the push rod, which sticks out at the front end of the

wire grip Mechanism.3. Line up the carrier-mounting hole with the mating hole in the wire grip Mechanism.







4. Slide the pivot pin into place so that its projecting key pin enters the keyway in the carrier.5. Press the pin inward and twist it one-quarter turn counter-clock-wise to lock it in place.

5.5 Wire Grip Mechanism

The wire grip Mechanism (Cylinder Support Block 98-206) is held on the gun by 3 screws 98-117.Complete disassembly of this mechanism is required only for major cleaning and overhaul.

To disassemble:1. Remove the drive roll carrier by removing the Pivot Pin.2. Unscrew the wire grip adjustment cap 98-209.3. Push back on the front end of the piston rod 98-138 & slip it out of support block 98-209.4. Remove the cylinder support block 98-206 by removing the three screws 98-117.

To reassemble:

1. Re-install the cylinder support block 98-206 with the three 98-117 screws.2. Lubricate all O-ring surfaces on the piston rod with valve lube.3. Insert the return spring and piston rod into the support block.4. Replace the Wire grip adjustment cap and Drive roll carrier.5. Adjust wire grip if necessary using the Wire Grip Adjustment Cap.

5.6 Lower Drive Roll & Gear

The Lower Drive Roll 98-35-xx and Lower Drive Gear 98-36-xx are threaded on to Drive Shaft 98-65.Both have left hand threads. Use the spanner wrench 98-104 to unscrew these parts. To replace the rolland gear:

1. Use Tool 98-103. The projecting button on the tool fits the center 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.

5.7 Rear Wire Guide & Snubber

Snubber Set Screw 98-67 holds Assembly 98-118-xx, consisting of a rear wire guide and wire snubbingmechanism, in place at the back of the gun. With the gun completely assembled, this set screw can bereached through an access hole in the mounting flange of the wire grip Mechanism.Remove Set screw and pull entire assembly out of gun.







5.8 Turbine & Speed Control

Before attempting to remove the speed control assembly, first remove the Upper Drive rolls, gun handleand rear wire guide and snubber. This will expose the 3 mounting screws 98-53.The Speed control parts are mounted on turbine cover 98-77. The entire assembly is removed from theright side of the gun by taking out three screws 98-53 and pulling the unit away from the mountingflange. For easy removal, loosen the cover screws and tap lightly on the screw heads.

The spider assembly can be removed by turning the speed control ring counter-clockwise until the spiderdrops out. Removing the three nameplate screws 98-89 will separate the rest of the parts. Whenreassembling, clean the parts thoroughly. Lubricate the thread and detent surface of the control ring withvalve lube.

The spider ring 98-86 has a ring brake shoe mounted to it with four screws. Do not take off the shoe, orthe brake disc, which runs against it. Do not lubricate the shoe. These parts are designed to run dry. Anygrease or oil on them should be removed by wiping down with cleaning solvent.

After the turbine cover 98-77 is removed, the turbine assembly and speed governor parts can be takenfrom the gun by first removing bearing cover 98-47 which is held in place of two screws 98-31.

When lifting off the bearing cover, be careful not to drop the bearing follower assembly 98-39. This is asmall assembly located just under and held in place by the bearing cover. It consists of a thin, precisiondisc spring permanently joined to a supporting steel plug. It is an important part of the precise governingsystem. Do not take this assembly apart. Always re-install it with the disc towards the bearing cover.

The Bearing cover gasket 98-48 seals the surface under the bearing cover. Lift it off carefully. Whenreinstalling, coat both sides of the gasket with a thin layer of valve lube.

Turbine shaft nut 98-84 is located behind the bearing follower assembly and mounts on the left end ofturbine shaft 98-92-x. Hold the turbine rotor by hand (never hold it with a wrench or screw driver) whentaking off this nut. After the nut has been removed, the turbine assembly can be pulled out of thehousing. The turbine shaft left bearing 98-70 will stay in the housing. This bearing has a deep cup onone side and a flush face on its other side. If it is removed from the housing, always put it back with thedeep cap towards the bearing cover.

Take off nut 98-102 at the right end of the turbine shaft. The following parts will slide off the shaft.

Finger Spring 98-64Right Bearing 98-73Spring Washer 98-74Spring 98-76Brake Disc Assembly 98-78







Turbine Rotor Assembly 98-54 is fastened to the turbine shaft by set-screw 98-67 and holds oil sealassembly 98-160 in place.

Never take apart the brake disc assembly or the turbine rotor assembly. Each of these assemblies iscarefully balanced at the factory.

When reassembling, pay particular attention to the following instructions:

1. The parts and bearings must be clean. Dirt or grit will cause rapid wear.2. The end of the turbine rotor set screw 98-67 must seat in the spot provided for it on the turbine shaft.3. If it is necessary to take the oil seal assembly apart, reassemble it exactly as it was, with the bobbins

between the washers, bobbin cups facing each other, spring over the sleeve and spring ends in thebobbin cups.

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

5. The turbine shaft right bearing has a shield on one side. Put the bearing on the shaft with the shieldtowards the turbine rotor. Assemble the left turbine bearing with the deep cup towards the bearingcover. When worn turbine bearings are replaced, the new bearings must slide freely in the housingsockets for proper speed governing.

6. Slide on the Brake disc, spring washer, bearing and finger spring.7. Finger spring 98-64 must be assembled with the bent up fingers towards the bearing. Make sure the

center hole rides freely on the shank of nut 98-84 and the spring fingers rest on the outer race of thebearing. Tighten nut.

8. Lubricate transmission cover gasket & place on transmission cover.9. Install bearing follower into bearing cover (disc side first) and install cover on transmission cover.

Check that the turbine rotor rotates freely.10. Reinstall the Speed Control Assembly by putting the Speed control ring and turbine cover together.11. Fasten the detent spring and nameplate to the control ring (detents must face turbine cover).12. Place the spider in the turbine cover with brake shoe facing up.13. Turn control ring clockwise threading spider into control ring.14. Position speed control assembly over turbine and align attaching holes for the screws.

5.9 Gear Cover & Transmission Gears

The gears for the wire drive unit are enclosed by a gear cover 98-56, which is held in place with fourscrews 98-53. Continuing from the point of disassembly described so far, the gear cover can be removedas follows: (i.e. with Speed control and turbine removed)

1. Take off drive shaft nut 98-84 (under the bearing cover) on the left end of drive shaft 98-65.2. Remove the countershaft assembly by unscrewing bearing retainer 98-51 located at the back of

the gear cover. The retainer has milled wrench flats for this purpose.







3. Remove the four gear cover mounting screws and ease the cover off the gun. The drive shaft leftbearing 98-70, the turbine shaft left bearing 98-70 and the countershaft front bearing 98-70 willcome off with the gear cover, gear oil will come out when removed.

Note that the gear cover mounts on two dowel pins and is sealed against leakage by gasket 98-55. Whenreinstalling the gasket, coat both sides with a thin layer of valve lube.Reinstalling:

1. Inspect bearings for wear, replace as needed.2. Place all bearings but remember the Turbine Shaft bearing must be installed with the shielded side

inward.3. Coat gasket with Valvelube and place over dowels.4. Mount gear cover on dowels and attach with 4 screws.5. After inspecting countershaft assembly for wear, install in gear cover.6. Secure nut to drive shaft.7. Install speed control and turbine assembly.8. Lubricate transmission gear case !!

5.10 Drive Shaft Assembly

To remove the Drive Shaft assembly, the entire gun must be taken apart.

1. Remove the handle, wire grip, lower drive roll and gear, speed control and turbine, countershaft andtransmission gear cover.

2. With the gear cover removed, the drive shaft assembly will stay in the gun housing. After removingparts as stated above, the entire assembly can be pulled out of the housing as a unit.

3. The gear 98-66 is fastened to the shaft by setscrew 98-67. Right bearing 98-69 is pressed on to thedrive shaft and should not be removed. If it becomes necessary to replace this bearing, make certainto push on the inner case when pressing the new bearing on to the shaft.

4. Inspect and replace worn parts.

Reinstalling:

1. Replace drive gear so drive-teeth are facing the bearing. Be sure set screw is seated properly.2. Place the drive shaft seal 98-68 on the shaft and slide it against the bearing.3. Insert into central housing until bearing bottoms.

Replace other parts in this sequence:1. Transmission gear cover2. Countershaft, turbine shaft and bearing cover3. Speed control assembly handle and wire feed valve







4. Lower gear and drive roll5. Wire grip mechanism, rear wire guide/snubber6. Gas head and drive roll carrier.

5.11 Counter Shaft Assembly

Remove the Speed Control and Turbine Assemblies.When the counter shaft assembly is removed, the front bearing 98-70 will stay in the gear cover. (If itslips out, remove the cover to re-install). The rest of this assembly can be taken apart as follows:

1. Unscrew plug 98-52 from the bearing retainer 98-51. O-rings 98-14 and 98-46 on these partshelp seal the gear case against grease leakage.

2. Remove counter shaft nut 98-84 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 98-70 can be pushed out of the retainer and counter shaft 98-91, with countershaft gear 98-93fastened to it, can be pulled free. Take the gear off the shaft by loosening set screw 98-67. When puttingthe gear back on, be sure the set screw goes into the groove provided for it on the shaft and the gear goeson tooth side first.

5.12 Gun Handle/Wire Feed Valve

The Handle is assembled in two parts.

1. To take off the gun, first remove the screw 98-28 from the front half.2. Then remove the two screws 98-31 that attach the handle and wire feed to the gun.

Reverse to install. Check wire feed valve for movement, Loosen wire feed cam screw if necessary.

Wire Feed Valve:

1. Loosen cam screw 98-133 and pull out valve shaft and spring 129/132.2. Inspect O-Rings and cam for wear or damage and replace as needed.

When re-assembling, apply valve lube.

1. Insert the valve shaft completely into the valve body 98-250.2. Holding the valve shaft all the way in, turn the cam screw until it stops then back off approximately

½ turn.3. Check that the valve operates freely and does not come out.







5.13 Central Housing

The centrally located casting on which all the assemblies are mounted is the Central Housing 98-59.Two dowel pins 98-63 are pressed in place. Do not remove them. O-rings 98-13 seal the turbine airpassage at the gas head to central housing mating face.

Pump housing 98-60 is fastened to the side of the central housing with two screws 98-61 and two lockwashers 98-62. Do not remove these parts. With the gun completely assembled, the counter shaft passesthrough the pump housing and pumps gear lubricant to the back or the gun to lubricate the high-speedbearings and gears. The pump housing is aligned for proper clearance over the countershaft to insureefficient pumping action.

5.14 Lubrication

Gear CaseBe careful not to introduce any foreign material into the reservoir.The lubricant for the gears and bearing is gear lube. To lubricate a dry gun, one full tube of gear lubeshould be squeezed into the gear case. To do this, wipe the back of the central housing clean and removethe oil plug screw 98-10 and washer 98-49. Also remove plug 98-52 to allow air to vent from the gearcase as the gear lube is added. After cleaning the screw end of the gear lube tube, screw it into the filterscrew hole and squeeze the tube until empty. With the gun upright and level, the lubricant should bevisible in the lower half of the sight plug. After adding lubricant, wait a short while before checking thelevel because the lubricant settles slowly, especially in colder conditions.

Turbine BearingThe right side turbine shaft bearing, located in the turbine cover, and parts of the governor mechanismlocated just behind this bearing, are lubricated through the center of the turbine cover. Follow the samecleaning procedure described above, Remove filter screw 98-50, put the end of the gear lube tube intothe hole and squeeze out a strip of lubricant about 6mm long. Do not over lubricate.







5.15 High/Standard Speed Conversion

Instructions for changing from Standard gearing to High Speed Gearing in WireJet-98:

1. Loosen the set screw holding the Snubber Assembly 98-67.2. Remove the 3 screws and pull out the Turbine Cover 98-53/98-773. On the opposite side of the gun remove the screws and bearing cover 98-31/98-474. Lift the bearing follower 98-39, from the turbine shaft bearing 98-70 on the left side. Hold the

turbine rotor with one hand and remove the brass nut 98-84 on the bearing cover 98-47 side.5. Tap this end of the Turbine Shaft 98-92H/S to get it out of the left bearing and then pull out

complete turbine/rotor assembly. Caution: There are threads on both sides of the TurbineShaft.

6. Loosen and remove the transmission gear cover 98-56 and pull the complete countershaftassembly out. 98-91 and 98-93 etc.

Reassembly with High (or Standard) Speed Gears:

1. Insert the High-Speed countershaft 98-93H gear on the Countershaft 98-91.2. Install the new speed Turbine Shaft, then the Countershaft bearing assembly into transmission

cover and hand-turn the Turbine shaft assembly to allow gears for both parts to engage.3. Put the brass nut on the left side of the gun, replace the bearing follower and close the

transmission cover with gasket, and tighten the two screws.4. Re-install the Turbine cover and tighten the 3 screws to hold it in place.5. Insert the Snubber assembly and tighten the set screw.6. Remember to reset speed control and flows based on material/fuel.







5.16 Exploded Part Views







6 Avoiding Trouble

6.1 General Gun Care

For starters… The following list represents the most common mistakes new users make.

1. Quick Disconnects: DON’T EVER USE ANY ADDITIONAL HARDWARE ON HOSES FOR GAS,AIR OR OXYGEN!! Any restriction in air flow/pressure will cost you parts.

2. IGNITION: If the gun “backfires” or “Pops” while lighting, immediately turn off the gas lever anddetermine the cause !

3. Acetylene Gas Pressure: 50 PSI MINIMUM supply side pressure. Lower pressures will pull acetonefrom Acetylene gas!

4. Connections: Never over-tighten hose connections.5. Acetylene: Minimum 300 cu/ft cyls. are recommended. Manifolding is also a good idea. Smaller

tanks, even with manifold, may draw acetone from fuel!

There is a suggested maintenance schedule at the end of this chapter. This chart is based on average use andconditions. Use common sense when considering your particular usage and what maintenance interval fits yourapplication.

Keep ALL of your equipment, filters, hoses and maintenance area clean and well maintained. This willextend the service life of all the associated components and ultimately, the WireJet-98 Gun.

Use only parts supplied by Plasma Powders & Systems, Inc. We provide factory authorized parts thatare made specifically for your equipment.

Keep recommended spare parts readily available. Changing or lubricating a nozzle or a few O-rings ismuch faster and cheaper then holding up production for a new siphon plug to arrive.

Before lubrication or overhaul, blow off or wipe the gun thoroughly to remove all loose dust. Use aclean bench for disassembly and be sure that the lubricant tube is free of dirt.

Keep the following items in mind when considering service intervals and ordering spare parts.

1. Speed and load of the gun2. Frequency of lighting3. Temperature in which the gun operates

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







6.2 Backfire

If the Gun backfires, it will appear to go out with a loud “pop” and will burn back in the siphon plug.

*** Shut off the Gun immediately and determine the cause of backfire ***

Backfire may be caused by the following:1. A leak at the nozzle O-rings (See nozzles)2. Dirt in the nozzle jets.3. Oversized or ragged nozzle jet holes.4. Dirt in the siphon plug jets.5. Improper gas/air flow

Frequent backfire, or permitting the gases to burn back in the siphon plug too long, makes it necessary to cleanthe jets in the siphon plug and nozzle. It may also cause the nozzle nut to loosen and part damage. The cause ofthe backfire should be found and corrected. The Gun will not backfire unless something is worn or out ofadjustment.

6.3 Siphon Plug

The siphon plug should be cleaned occasionally. Instructions for removing and replacing it are given in thesection CONSTRUCTION & ASSEMBLY. When cleaning it, wipe out the grooves. Clean the jets with theproper size wires in the cleaning wire kit. Do not use drills. Do not use oversize wires. Do not rotate the wires.There are two small air bleeder holes in the siphon plug just back of the nozzle seat. These holes permit air tocirculate around the wire. If they plug up, the wire nozzle may overheat, causing backfire or sticking wire.When servicing the siphon plug, be sure to clean these bleeder holes with the proper size cleaning wire.Never soak the siphon plug O-Rings in strong solvent. Inspect them for damage and replace as necessary. Donot stretch the O-rings more that necessary when putting them on the siphon plug. Lubricate the O-rings withPPS Valve lube after assembling on the siphon plug. Wipe any excess valve lube off the siphon plug to avoidgetting it in the jets.

6.4 Nozzles

When a nozzle is installed on the Gun, the bore of the siphon plug should be wiped clean. Coat the nozzle O-rings with a thin film of PPS Valve lube. The nozzle nut must be firmly hand tightened on the siphon plug. Donot use tools!! The tip of the nozzle at the flame end should be kept clean. To clean the jet holes, remove thenozzle and push 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 hole. Push the wire straight in and out. Do not rotate it. Wash the nozzle in CleaningSolvent before and after cleaning. Blow out the holes from the back end with clean & dry compressed air.For proper lighting, the nozzle and siphon plug jets must be clean and undamaged.







6.5 Gas Head Valve

The gas valve is designed for long service life with minimum maintenance. It has a cylindrical core and reliesupon special elastomeric O-rings for proper sealing. At periods of major overhaul the valve can be disassembledfor cleaning and lubrication. Instructions for taking it apart are given in the section CONSTRUCTION &ASSEMBLY. The hose connection block on the back of the valve must be removed before the rest of the valvecan be taken apart. Any valve part that becomes worn or damaged can be replaced in the field.If the valve develops a leak, examine all O-rings carefully and replace any which are worn or damaged. Thering materials are specially formulated for proper service in this valve. Use only authorized replacement.The metal parts of the valve can be washed with Cleaning Solvent. Make sure that the small bleeder holes inthe cylindrical valve core are clean and free of any hard residue. Use only the 0.13” (0.3mm) diameter cleaningwire.If the Gun has been idle for some time, or after the valve has been lubricated, it is advisable, before lighting, towork the valve on and off a few times with gases turned on. This will blow out any excess valve lubricant fromthe small bleeder holes in the valve. Plugged bleeder holes may cause trouble.Lighting with the valve opened past the lighting position may cause some gas jets to break away from thenozzle face, particularly if the lighter is held to one side of the nozzle. Throttling back the valve will reset thejets, after which the valve can be fully opened again.

6.6 Normal Lighting Flow

Normal gas flow ranges with the gas valve in the lighting position are given. Flows lower than those shown mayindicate a blockage in a valve core bleeder port. Higher flows may indicate a leak in a valve seal.

Fuel Gas Wire Size

(in)

Lighting Pressure PSI

Oxy Fuel

Lighting Flow

Oxy Fuel

Acetylene 3/16” 38 15 22-30 3 – 5

1/8” 28 15 22-30 3 – 5

Propane 3/16” 42 38 26-33 4 - 6

1/8” 47 42 26-33 4 - 6







6.7 Oxygen/Fuel Gas Connections

Perform the following test in order to check for leaks and obstructions in either the oxygen or fuel gasconnections. The test is based on pressurizing each circuit to insure that it is normal. Too low a flow indicates ablockage; too high a flow indicates a leak. Make sure that the Gun is pointed into the spray booth and the exhaust system is on. Connect the oxygen and acetylene hoses to the Gun. CAUTION: Do not over-tighten hose

connections Turn the gas valve on the Gun to the running position. Do not light the Gun. Adjust the oxygen and fuel gas pressures to the values shown on the “Check Flow Chart”. Close the fuel gas control valve on the PPS 2GF Flowmeter. Open the oxygen flow control valve on the Flowmeter all the way. Oxygen flow should read within 5 points

of the value shown on the chart. Close the oxygen flow control valve. Open the fuel gas control valve all the way. Fuel gas flow should read within 5 points of the value shown on

the chart. If either oxygen or fuel gas flow value is not within 5 points of chart value, check equipment and hoses for

leaks or obstruction.

CHECK FLOW CHARTWire Size FUEL SYSTEM PRESSURE (psi) FLOW

1/8 Oxygen

Acetylene

40

15

53

85

3/16 Oxygen

Acetylene

30

15

54

88

1/8 Oxygen

Propane

40

40

76

37

3/16 Oxygen

Propane

40

40

77

37

6.8 Hoses

Obstruction in the hoses reduces the flows of oxygen and fuel gas and upset the flame balance. Do not get oil in the hoses. Oil in the oxygen hose is very dangerous. In any hose, oil will soften the rubber. In an old, worn hose the lining may come loose and plug up the hose. If hose fitting are over-tightened, the hoses in the fitting may collapse. The reduced flow of gases causes the

same troubles as obstructions in the hoses. The Gun-end connections of the two gas hoses are most apt to be







damaged. The back of a 2.2mm diameter drill should slip easily into the stems at the Gun end of the gashoses if the hole in the stem is the correct size.

6.9 Lubrication

Lubricate gas valve O-rings and sliding surfaces with PPS Valve lube. Lubricate valve core, valve handle camand detent pin with Valve lube.Always lubricate the siphon plug back O-rings whenever the plug is removed from the Gun body. Lubricate thesiphon plug front O-rings whenever the fluted sleeve is removed. The practice will help to prevent O-ring nicksand cuts.Valve lube is an excellent thread lubricant. It should be used on the threads of the air cap body, nozzle nut, rearcountershaft bearing retainer and control ring to keep the threads smooth running.

6.10 Wire Feed Issues

Jams

Kinked or badly bent wire causes trouble. The drive rolls will gauge the wire and it may stop feeding. If thewire melts into the end of the nozzle it can be removed by twisting and forcing the wire from the back withpliers. The nozzles are bushed with a special alloy, which resists fusing with any common metal.To reduce wire jams due to kinks and bends, especially with 1/8” and 3/16” hard wire, locate the wire controlunit so the wire feeds straight to the gun. Use of a PPS Heavy Duty Wire Straightener is recommended. Do notover tighten the brake on the wire control unit.

Wire Grip Adjustment

Do not use more drive roll pressure on the wire than needed for a smooth, steady feed. Too much pressure willshorten the life of the drive rolls, gear and bearings. With soft wires, high pressure may flatten the wire andcause it to jam in the nozzle.

Drive Rolls

If the teeth on the drive rolls become packed with chips from the wire they will not work efficiently. Keep themclean with wire brushing.

Speed Control

Clean air is required for uniform, steady wire feed. Any oil between the turbine brake disc and brake shoe maycause fluctuation in the wire speed. Clean these parts with a rag moistened with cleaning solvent if the wire feedbecomes unstable. Do not lubricate them.







6.11 Routine Maintenance

Maintenance Operation Interval Hrs. RemarksClean outside of Gun <8 After Each Use is bestClean off drive rolls 8 Brush off & blow out dirt & chipsClean air cap 8 Wipe out soot.Clean nozzle jets 16 Use nozzle cleaning wire kit.Clean siphon plug jets and bleeder holes 40 Use nozzle cleaning wire kit.Oil upper drive roll bushing 40 Gear lube - 2 dropsOil upper drive roll carrier hinge 40 Gear lube - 1 drop.Lube turbine cover bearing 40 Gear lube 6mm stripLube gear case 80 Gear lube - Makeup level.Clean turbine brake disc and shoe. 200 Wipe down with cleaning. Solvent do not lubricateClean and re-lube control ring thread. 200 Valve lubeLube wire grip cam assembly 200 2 drops of gear lube through set screw hole in side

of bushing.Heavy coat of valve lube on cam.

Lube cam follower 200 Heavy Coat of valve lube on washer-end of camfollower and thin coat of valve lube on inner wall oflarge hole in support block.

Clean and lube gas head valve 500 Apply thin film of valve lube.Complete overhaul 1000 Wash out and replace all lubricants.

6.12 Revision History

Date Section Description10/6/14 Maintenance Changed machine oil to gear lube in all areas.

Specifications Added section1/1/16 Revision hist Added section1/1/16 Part List Added 98-180 O-Ring to part list (Wire grip mechanism)







This publication could include technical inaccuracies or typographical errors.Changes may be made to the information herein. These changes will beincorporated in later editions of the manual. Persons and organizations that mayalready possess the equipment and or a copy of this manual are responsible torequest periodic updates of this document in writing from Plasma Powders &Systems, Inc. at the address indicated below.

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

Marlboro, NJ 07746732-431-0992 ~ Fax 732-308-1075Email – [email protected] – www.plasmapowders.com





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