ROCK STAR Windshield Repair System Part# RSR800 User Guide 2012 Equalizer Industries, Inc. Revision 11/10/17 www.equalizer.com
11. Clean the area that you have worked on with a good glass cleaner and a paper towel. VBA1443 Cleaning & Maintenance 1. Clean the resin off of (and out of) your injector, o-rings and bridge with our cleaning solution. *Keeping these items clean and free of build up assures no contamination on you next repair, proper functioning of the tools, and will increase the longevity of the tools. Failure to properly clean and maintain these items could result in voiding your warranty! 3.5 mm thick 13 mm outer diameter 6 mm inside diameter 2.5 mm thick 10 mm outer diameter 4 mm inside diameter 2 mm thick 13 mm outer diameter 10 mm inside diameter 2 mm thick 12 mm outer diameter 8 mm inside diameter 1 VOR1468 10
Always wear safety glasses and nitrile gloves when repairing a windshield! Inspection And Assessment - 1. Examine the damaged area from the inside and outside of the vehicle. Look for hidden cracks, moisture, contamination or previous repair attempts. 2. Determine if the damage is within the scope of your technical experience to repair. 3. Assess to make sure that the windshield is at the appropriate temperature. Ideal temperature is between 65 F to 85 F plus or minus 5 F. Preparing the Rock Chip - 1. Place the mirror on the inside of the windshield, under the damaged area. 2. Clean around the damaged area. Be sure to place a nitrile glove-covered finger over the rock chip in order to keep from contaminating the break. 2
3. Using the probe, remove broken glass debris from the chip. 4. If moisture is present in the break, dry out by using the windshield chip moisture evaporator. 5. If the rock chip area is not open, consider drilling the chip. At a slow setting start to drill into the glass but be careful not to drill into the PVB (Poly Vinyl Butyral) Preparing the Bridge and Injector Assembly - 1. Place the injector tip o-ring on the end of the injector assembly. To do so, use a small drop of resin to wet the injector assembly tip and then put the o-ring in place. 3
2. Screw the injector assembly into the bridge. If the rock chip area is larger than the o-ring on the injector assembly tip, then add the large pit adaptor onto the unit. 3. Place a light film of vacuum cup lubricant onto the vacuum cup of the bridge and on the two bridge adjusting screws. Once the bridge and injector assembly is set up on the glass this will help to move the unit if the o-ring placement needs to be adjusted. 4
4. Make sure that the injector assembly and bridge adjusting screws are backed out enough so that they do not make contact with the glass until the vacuum cup is fully engaged on the glass. Note: If the injector assembly and bridge adjusting screws are not backed far enough out, this could result in applying pressure and causing further damage to the break. Setting Up the Bridge and Injector Assembly - 1. Place the bridge and injector assembly onto the glass so that the injector tip o-ring is over the rock chip. 2. Secure the bridge by flipping the vacuum cup lever. 3. Screw the injector assembly down until the o-ring makes contact with the surface of the glass. 4. Screw the bridge adjusting screws down equally until the o-ring has a flat look to its appearance. This will ensure that the o-ring is snug enough to create an airtight seal. Note: Always make sure not to over-tighten the injector assembly or the bridge adjusting screws. This could cause further damage to the break. 5
Injection Procedure - 1. Loosen the injector pressure rod. 2. Remove the injector from the barrel. 3. Place between 3 to 5 drops of resin into the injector barrel. *Always make sure to use the right resin for the job. If the temperature of the work area is warm or the job is at high altitude; always use a thicker resin. If the temperature of the work area is cool or at sea level use a thinner resin. 4. Wet the two o-rings on the injector tip using resin. 5. Place the injector back into the injector barrel making sure that the groove on the injector lines up with the retaining screw. Adjust the retaining screw so that the threaded end of the screw slips into the groove and is just tight enough for the injector to move freely up and down but not be removed from the barrel (the end of the groove on the injector will catch the retaining screw and stop). 6
6. Now push the injector in until it hits the bottom of the barrel. 7. Tighten the injector pressure rod. 8. Pull the injector up until the end of the groove makes contact with the retaining screw. Fully tighten the retaining screw. You are now in the vacuum phase. 9. Hold vacuum for one minute. 10. Next, release the vacuum by loosening the injector pressure rod. 11. Then re-tighten the injector pressure rod to secure the seal. 12. Next, loosen the retaining screw and push the injector in a downward motion until the point when you feel resistance. Then tighten the retaining screw. You are now in the pressure phase. 13. Hold pressure for two minutes. Note: For stubborn breaks, you might have to repeat the vacuum to pressure cycle until the break is fully filled. Applying a little pressure on your break with your probe will flex the break and help move resin into the tight areas. 7
Curing Procedure - 1. When the repair is to your satisfaction, release the pressure by loosening the injector pressure rod. 2. Release the lever on the vacuum cup. 3. Remove the bridge and injector assembly. 4. Wipe away any residual resin. 5. Apply a drop of pit filler resin. 6. Place a mylar square cure sheet onto the pit filler resin. Be sure to gently place the cure sheet in a downward laying motion and let gravity do the rest. 8
7. Cure the break for approximately three minutes using either an ultra violet lamp or the use of natural sun light. *Always make sure to let the break cure to the required allotted time. Do Not rush this process. The outer part of the break might be cured but the actual pit may not be. It is very important that it be cured all the way through. 8. Remove the mylar square cure sheet. 9. With the use of a new razor blade, scrape the cured resin in a back and forth, up and down motion until the resin is even and level with windshield. 10. Apply a small amount of pit polish and vigorously buff with a soft cloth or paper towel until the pit resin is shiny. 9
11. Clean the area that you have worked on with a good glass cleaner and a paper towel. VBA1443 Cleaning & Maintenance 1. Clean the resin off of (and out of) your injector, o-rings and bridge with our cleaning solution. *Keeping these items clean and free of build up assures no contamination on you next repair, proper functioning of the tools, and will increase the longevity of the tools. Failure to properly clean and maintain these items could result in voiding your warranty! 3.5 mm thick 13 mm outer diameter 6 mm inside diameter 2.5 mm thick 10 mm outer diameter 4 mm inside diameter 2 mm thick 13 mm outer diameter 10 mm inside diameter 2 mm thick 12 mm outer diameter 8 mm inside diameter 1 VOR1468 10
Additional Accessories RB497 VUV1447 VCD1464 VPT1489 MS492 DL1093 BNG418 BNL820 VTR1448 VTL1449 VMR1450 VML1451 VPF1452 VPL1453 VAF1471 VAL1472 TRR652 TRO653 VPO1455 VCB1454 AVL209 2611 Oakmont Drive Round Rock Texas 78665 Toll Free USA & Canada: 800.334.1334 International: 512.388.7715 Fax: 512.388.4188 Email: sales@equalizer.com www.equalizer.com