GYS 057654 Windshield Removal System User Manual

Introduction

The GYS 057654 Windshield Removal System is an innovative tool designed for the safe and efficient removal of vehicle windshields. This system minimizes the risk of damage to painted surfaces, interior components, and the vehicle's headliner. Its design allows for single-person operation, making the process of windshield removal quicker and simpler. The system utilizes a durable nylon cord for precise cutting of the adhesive, offering a safer alternative to traditional metal wires and preventing corrosion on aluminum bodywork.

Safety Information

Always prioritize safety when using this tool. Read all instructions carefully before operation. Wear appropriate personal protective equipment (PPE), including safety glasses and gloves, to prevent injury. Ensure the work area is clear and stable. Keep children and bystanders away from the work area. The nylon cord, while safer than metal wire, can still cause injury if not handled properly. Avoid direct contact with the cutting cord during operation.

Components Included

The GYS 057654 Windshield Removal System kit includes the following components:

• T-shaped awl
• Nylon cutting wire roll (65 m)
• Pulling system with suction cup
• Anchoring hook
• Utility knife
• Flexible extension
• Mounting wedge
• Deflection tool

Setup

1. Prepare the Vehicle: Ensure the vehicle is clean and stable. Remove any trim or components that might obstruct the windshield removal process, if necessary. However, the system is designed to minimize the need for interior component removal.
2. Inspect Components: Before each use, inspect all components of the kit for any signs of wear or damage. Ensure the nylon cord is intact and free of frays.
3. Attach Suction Cup: Securely attach the pulling system's suction cup to a clean, smooth surface on the windshield, ensuring a strong vacuum seal.
4. Thread the Nylon Cord: Use the T-shaped awl to carefully create a small opening in the adhesive bead around the windshield. Thread the nylon cord through this opening.
5. Connect to Pulling System: Connect one end of the nylon cord to the pulling system and the other end to the deflection tool or anchoring hook, depending on the cutting direction and access.

Operating Instructions

The GYS 057654 system is designed for efficient single-person operation. The process typically takes approximately one hour.

1. Initial Cord Insertion: Using the T-shaped awl, carefully pierce the adhesive bead at a corner of the windshield. Feed the nylon cord through this hole.
2. Positioning the System: Attach the suction cup of the pulling system to the exterior of the windshield. Route the nylon cord around the windshield's perimeter, ensuring it is positioned correctly along the adhesive bead.
3. Cutting with Cordless Screwdriver: Connect the free end of the nylon cord to a cordless screwdriver (not supplied). The screwdriver will act as the pulling mechanism, winding the cord and drawing it through the adhesive.
4. Controlled Cutting: Slowly operate the cordless screwdriver, allowing the nylon cord to cut through the adhesive. Maintain steady tension and guide the cord along the windshield's edge. The flexibility of the nylon cord allows it to adapt precisely to the vehicle's contours, ensuring a clean cut without damaging paintwork or interior panels.
5. Corner Management: When reaching corners, use the deflection tool or adjust the pulling system to guide the cord smoothly around the curve. The system is designed to handle windshields of all sizes due to its 65m nylon cord capacity.
6. Windshield Removal: Once the adhesive is completely cut around the perimeter, the windshield can be carefully lifted and removed.

Maintenance

Proper maintenance ensures the longevity and optimal performance of your GYS 057654 system.

• Cleaning: After each use, clean all components, especially the suction cup and any parts that came into contact with adhesive, to prevent residue buildup. Use a damp cloth and mild detergent if necessary.
• Cord Storage: Store the nylon cord neatly on its roll to prevent tangling and damage.
• Inspection: Regularly inspect the nylon cord for any signs of wear, fraying, or damage. Replace the cord if any degradation is observed to ensure safe and effective cutting.
• Storage: Store the entire kit in its original carrying case in a dry, clean environment, away from direct sunlight and extreme temperatures.

Troubleshooting

This section addresses common issues you might encounter during the use of the GYS 057654 Windshield Removal System.

• Cord Not Cutting Effectively:
  • Ensure the nylon cord is properly tensioned by the cordless screwdriver.
  • Verify that the cord is correctly positioned within the adhesive bead.
  • Check if the cord is worn or damaged; replace if necessary.
• Suction Cup Losing Grip:
  • Ensure the windshield surface is clean, dry, and free of debris before attaching the suction cup.
  • Re-apply the suction cup, ensuring a strong vacuum seal.
  • Check the suction cup for any damage or cracks.
• Difficulty Threading Cord:
  • Use the T-shaped awl to create a sufficiently sized pilot hole in the adhesive.
  • Ensure the awl is sharp and clean.

Specifications

Warranty and Support

Information regarding specific warranty terms for the GYS 057654 Windshield Removal System is not provided in this manual. For warranty details, technical support, or to inquire about spare parts, please contact GYS directly through their official website or authorized distributors. Keep your purchase receipt as proof of purchase.