YAMADA KGK-100 Series User manual

Doc. No. 100-494YO-00

METERING GUN

MODEL. KGK-100 series

WARNING

Prior to operating this pump, be sure to read this operation manual for safety. After reading the manual, please keep it at

hand any time for your quick reference.

INSTRUCTION

[Introduction]

This instruction manual contains important safety information and operational instructions.

Read this manual before installation, operation, maintenance, and repair.

Do not use the product without reading this manual. Thoroughly read and understand all of the product

information, safety information, and warning information in the manual.

If you have any questions, please contact the store you purchased the product or our business office.

[For Safe Operation]

According to the hazard level, all safety notes in this manual are classified into “DANGER”,

“WARNING”, and “CAUTION”.

Be sure to read and observe the safety notes to ensure safety and correct use of this product.

DANGER indicates a potentially hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, COULD result in

death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in

injury or property damage.

－ Table of Contents －

[Introduction]........................................................................................... 1

[For Safe Operation]................................................................................. 1

1. Precautions on Use ............................................................................. 2

2. Product Description ............................................................................ 3

3. Principle of Operation......................................................................... 4

4. Installation and Connection ................................................................ 5

5. Adjustment and Discharge Test ........................................................... 5

6. Troubleshooting .................................................................................. 6

7. Disassembly and Assembly.................................................................. 7

8. Product and Part List for Grease Metering Gun................................... 9

9. Product and Part List for Adhesive Metering Gun................................14

10. Limited Warranty ...............................................................................19

1. Precautions on Use

The following warnings and cautions are very important. Be sure to observe them.

[Operating condition]

[Installation and piping]

[Operating method]

CAUTION

- For your safety, read and understand all information provided in this manual.

If you have lost or damaged your instruction manual, please contact us or our distributor to place an

order.

- Never let anyone operate this unit without understanding this manual.

CAUTION

- Before maintenance operation, be sure to stop air, and release the internal pressure (both air and

material) of the product.

- Immediately stop using the product if there is any danger or defect. Be sure to eliminate the cause and

confirm safety before restarting.

- Follow the safety instructions for installation and be sure to use appropriate piping material and size to

avoid leakage and damage.

WARNING

- Understand this manual completely before operating the machine.

Operators and maintenance personnel are required to read this manual thoroughly before operating or

servicing. Do not handle this machine without understanding the instructions.

- Do not handle unspecified material with this product. It may cause a product failure.

- Do not use this product for improper purposes.

- During operation, high pressure is continuously applied to the inside of the gun. Thus, even when

supply air to the gun is shut off, residual pressure may be trapped inside. Be sure to release residual

pressure completely BEFORE disassembly and repair for maintenance and inspection.

Also, be sure to stop air supply and power supply before disassembly and repair.

[Disassembly, maintenance and inspection]

[Shutdown and storage]

2. Product Description

KGK metering guns are able to apply metered shots of media such as greases and adhesives. By

replacing a built-in metering cylinder, KGK metering valves cover metered shot volumes between 0.3mL

to 20mL. One metered shot is discharged by pulling the lever once and thus material will not be

discharged more than necessary.

Fig.1

WARNING

- Shut off air supply to the product and remove residual pressure completely BEFORE disassembling.

- Alternating the unit may result in personal injury or product malfunction. Please do not try to alter,

modify, or change the machine.

CAUTION

- When leaving the product unused for a long time (more than a week) or shutting it down;

- remove material inside completely and wash the product and

- release material supply pressure.

Nozzle Metering Cylinder

Lever

Gun body

Material Connection (Rc1/8)

3. Principle of Operation

①Charge (standby)

Material, under pressure from a supply

pump, flows into the rear side of the piston

and constantly pushes the piston forward. At

the same time, material passes through Port

A, lifts up the ball to close Port B, and flows

into the metering chamber. Material in the

metering chamber pushes the piston

backward and thus a metered shot is

charged. The amount of material can be

adjusted to your desirable value with the

adjustment screw. (Fig. 2)

②Discharge

Once the lever is pulled, the piston rod

pushes down the ball to close Port A. Then,

the metering chamber is connected to the

discharge port. The piston is pushed forward

by material pressure from the rear side and

thus a metered shot in the chamber is

finally discharged. (Fig.3)

Adjustment screw Rod

Metering chamber

Fig. 3

Fig.4

Fig.5

Fig.6

Three way directional valve

①Material comes from the bottom seat lifts up

the ball and flows out of the middle path. The

ball is pressed against the upper seat to close

the outlet so that material will not be

discharged from the upper side.

②The piston rod pushes the ball down. Since

the ball goes down, being sealed by the

rubber in the middle, material will not flow

out even after the ball moves away from the

upper seat.

③Furthermore, the ball passes through the

path in the middle and seals the inlet on the

bottom seat to stop the flow of material.

Accordingly, the middle path and outlet on

the upper seat are connected and finally

material flows out.

Fig. 2

Lock nut Port B

Port A

4. Installation and Connection

①Connect a material supply pump or an outlet of a pipe to the metering gun using a hose. (The connecting port

of the gun is Rc1/8.)

It is recommended to attach 850K513 Swivel (sold separately) to the connecting port of the gun for easy

operation. (Fig.7)

②Install your metering gun as close as possible to the equipment or its inlet port you are going to work on.

③Trapped air in material being metered will be compressed through a pump, pipe, hose, and metering gun

and expand when material is discharged. As a result, the metering gun will have difficulty stopping

discharge and thus it may seem to be leaking. Also, each shot will vary.

Since air is discharged together with material, be sure to expel trapped air completely when using the gun

for the first time and after replacing a material container.

5. Adjustment and Discharge Test

①Supply material to the gun. The rod lifts up

the lever with material pressure and the

lever opens. At this time, if material leaks

from the nozzle, check if the lever has a

slight play back and forth at first. Then, if

the lever touches connector, loosen connector.

If material still leaks, loosen the adjustment

screw using a hex wrench until leak stops

and then tighten the locknut temporarily.

②With the lever pulled, perform a discharge

test. If a desired metered shot is discharged,

tighten the locknut. When material flows

out persistently, tighten the locknut with the

lever pulled until material flow stops.

CAUTION

- Dust and dirt, if contained in material, will damage the sealing part of the valve and cause material leak.

Be sure to keep material clean.

Fig.7

High pressure

ball valve

Connector

Adjustment screw

Lock nut

Material feed pump

Hex wrench

Tee

6. Troubleshooting

- Material cannot be discharged.

- Material comes out during Recharge or Standby.

- Material leaks.

Metering gun (external factor)

- Material is not being delivered.

- Material supply pressure (primary pressure)

exceeds the specified pressure of the metering gun.

- Adjustment at the initial use or after repair was

not done.

- Air inside the gun is not released.

Metering gun body

- Ball or valve seat is damaged or worn out

- O ring is damaged or worn out.

- Side ring is damaged or worn out.

- Adjustment screw is loose.

Metering cylinder

- Inner surface of cylinder is damaged or worn out.

- Outer surface of piston, packing, or sleeve is

damaged or worn out.

- O ring is damaged or worn out.

- Adjustment screw is over tightened.

PRECAUTION FOR USE

- Be sure to shut off the air supply to a supply pump and set the material pressure (primary pressure) to

zero. Leaving a metering valve under pressure will be a cause of material leak or some other problem.

- Once a metered shot is dispensed, be sure to put the valve back to the standby condition.

- Do not use material which contains dirt and dust. Seal parts will be damaged, causing a material leak.

- Check the supply pump and supply

air.

- Check air pressure in the supply

pump (primary pressure = pump

ratio × air pressure)

- Perform Adjustment and Discharge

Test on the previous section.

- Release air completely.

- Replace with new ones.

- Readjust the screw and securely

tighten it with a locknut.

- Replace with new ones.

- Adjust the adjustment screw to your

desirable shot amount and then

secure it with a locknut.

7. Disassembly and Assembly

7-1. Disassembly

①Unscrew the metering cylinder to remove it from the metering gun

body. Remove two O rings from the body. (Fig.8)

②Unscrew connector and remove it from the body with the nozzle

attached. (Fig.9)

CAUTION

- Be sure to use material compatible with the material used in the O ring and packing. Use of

inappropriate material can cause a leak or product malfunction.

- When using a special kind of material, adjustment of the joint of the valve and sleeve may be needed. In

such case, please contact us or your local retailer.

CAUTION

- Release residual pressure completely BEFORE disassembling metering valves.

- Wash the parts with wash oil and apply a thin layer of lithium grease BEFORE reassembling.

Be extremely careful not to let dust and dirt attach to any of the parts.

③Remove the E type retaining ring on the one

side of the pivot pin connecting the hook and

lever and pull put the pivot pin from the link.

Then, the hook and lever can be removed.

④Remove the E type retaining ring on the one

side of the pivot pin connecting the link and

body and pull out the pivot pin from the body.

Then, the link can be removed.

⑤Unscrew the lock nut on the lever and remove

it from the lever.

Hex wrench

Metering cylinder O ring

Lever

djustment scre

O ring Connector

Lock nut

Washer

Hook

E type retaining

ring

Pivot pin

Nozzle

Connector

Lever

djustment scre

Washer

E type retaining ring

Fig.8

Fig.9

⑥Unscrew to remove the gland bushing and remove the rod and

O ring from the body. (Fig.10)

⑦Unscrew to remove the grip and remove the O ring.

⑧Remove the valve seat, O ring, side ring, and ball from the body.

7-2. Assembly

①Put the parts on the bottom hole of the body in the following order:

valve seat, O ring, side ring with ball inside, o ring, and valve set.

Then securely tighten the grip with o ring attached.

②Put the O ring on the upper hole of the body first, then screw the

gland bushing tightly, and finally insert the rod.

③Attach the retaining ring, washer, and link in this order to one side

of the pivot pin and insert the pin into body. Then secure the other

side with the link, washer, and the retaining ring.

④Attach the adjustment screw to the lever and secure it with a lock

nut.

⑤Set the hook first and then the lever to the inside of the link. Then,

secure with the pivot pin attached on ③above. Be sure to fit the

rod head in the tapered hole of the adjustment screw. If failed, the

lever will not work.

⑥Screw to insert the connector with the nozzle attached into the body

through the hole on the side of the lever.

⑦Insert the o ring to the side hole of the body and securely tighten

the metering cylinder.

CAUTION

- When reassembling the disassembled meter valve, be sure to replace O Rings and Packings with new

ones at the same time as defective parts.

Fig.10

O ring

Grip

alve seat

Side ring

O ring

Retaining ring

Washer

Link Rod

O ring

Ball valve

alve seat

Gland bushing

Pivot pin

Retaining ring

Washer

Link

8. Product and Part List for Grease Metering Gun

8-1 Metering Gun

8-2 Dimensions

MODEL LIST

Size Product No. ①Switching

Valve ②Cylinder

1mL 686427 800K365 800K856

3mL 686428 800K365 800K857

5mL 686429 800K365 800K858

10mL 686430 800K365 800K859

20mL 686431 800K365 800K860

Size A B C*D

1mL 49 38 29.5 101

3mL 49 55 27.5 101

5mL 49 73 30.5 101

10mL 49 96 39.5 101

20mL 49 144 64.5 101

*set a maximum value

1 2

(181)

(137) ＡＢＣ

(1)

Ｄ

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