GUSMER GX-8 Operating Manual

"Teamwork & Communication"

Model GX-8

Operating Manual

Spray Gun

32943-1

April 21, 1999

Issue 1

GUSMER CORPORATION

A Subsidiary of Gusmer Machinery Group, Inc.

One Gusmer Drive

Lakewood, New Jersey, USA 08701-8055

Toll Free 1-800-367-4767 (USA & Canada)

Phone: [phone]

Fax: [phone]

Copyright 1999, GUSMER CORPORATION

http://www.gusmer.com

NOTICE: This manual contains important information for your GUSMER equipment. Read and retain for future reference.

®

®

Model GX-8 Spray Gun

CONTENTS

LIST OF FIGURES..........................................................................................................3

WARRANTY ....................................................................................................................4

GENERAL SAFETYINFORMATION..........................................................................5

CCEPTABLEEQUIPMENT USES.......................................................................................5

A
O

PERATIONALSAFETY PROCEDURES...............................................................................6

DESCRIPTION.................................................................................................................7

EY FEATURES ................................................................................................................7

K
M

AJOR COMPONENTS......................................................................................................9

E

QUIPMENT SUPPLIED....................................................................................................10

G

UN SERVICE KITS........................................................................................................11

OPERATION..................................................................................................................12

AFETY POSITION OF GUN .............................................................................................12

S
M

ANUAL VALVES ..........................................................................................................12

A

IR LINE CONFIGURATION.............................................................................................13

S

TART-UP......................................................................................................................13

S

HUTDOWN....................................................................................................................14

CLEANING PROCEDURE...........................................................................................15

SERVICING PROCEDURES........................................................................................17

S

CREEN SCREW REMOVALAND SERVICE PROCEDURE ................................................. 17

C

ENTERLINE COMPONENT REMOVAL ............................................................................18

C

ENTERLINE COMPONENT INSTALLATION .....................................................................20

V

ALVINGROD ADJUSTMENT .........................................................................................21

A

IR PISTON O-RING AND CUP SEAL REPLACEMENT ......................................................23

E

ND CAP O-RING AND CUP SEAL REPLACEMENT..........................................................25

T

RIGGER VALVE O-RING REPLACEMENT.......................................................................27

APPENDIX......................................................................................................................29

PECIFICATIONS.............................................................................................................29

S

INSTRUCTION MANUAL DISCREPANCY REPORT............................................31

2 32943-1, Issue 1

Operating Manual Contents

LIST OF FIGURES

FIGURE 1. MIXING MODULE..............................................................................................8

F

IGURE 2. MAJOR COMPONENTS .......................................................................................9

F

IGURE 3. CENTERLINE COMPONENTS...............................................................................9

F

IGURE 4. STANDARD TOOL KIT ......................................................................................10

F

IGURE 5. 1 QUART GUN SERVICE KIT (P/N OP205).......................................................11

F

IGURE 6. 3 GALLON GUN SERVICE KIT (P/N OP206).....................................................11

F

IGURE 7. ENGAGE THE SAFETY STOP..............................................................................12

F

IGURE 8. DISENGAGE THE SAFETY STOP ........................................................................12

F

IGURE 9. MANUAL VALVES ............................................................................................12

F

IGURE 10. CENTERLINE COMPONENTREMOVAL..............................................................18

F

IGURE 11. CENTERLINE COMPONENTINSTALLATION .......................................................20

F

IGURE 12. PCD SPACING..............................................................................................21

F

IGURE 13. VALVING ROD ADJUSTMENTS ........................................................................22

F

IGURE 14. END CAP/SAFETY STOP ASSEMBLYAND PISTON ASSEMBLY REMOVAL............. 24

F

IGURE 15. END CAP/SAFETY STOP ASSEMBLYREMOVAL .................................................26

F

IGURE 16. TRIGGER/AIR VALVE ASSEMBLY.....................................................................27

4/21/99 3

Model GX-8 Spray Gun

WARRANTY

Gusmer Corporation (Gusmer) provides a limited warranty to the original purchaser (Customer) of
Gusmer manufactured parts and equipment (Product) against any defects in material or
workmanship for a period of one year from the date of shipment from Gusmer facilities.

In the event Pr oduct is suspected to be defective in material or workmanship, it must be returned to
Gusmer, freight prepaid. If Product is found to be defective in material or workmanship, as
determined solely by Gusmer, Gusmer will issue full credit to Customer for the freight charges
incurred in returning the defective Product, and either credit will be issued for the replacement cost
of the Product or a replacement part will be forwarded no-charge, freight prepaid to Customer.

This warranty shall not apply to Product Gusmer finds to be defective resulting from: installation,
use, maintenance, or procedures not accomplished in accordance with our instructions; normal
wear; accident; negligence; alterations not authorized in writing by Gusmer; use of “look alike”
parts not manufactured or supplied by Gusmer; or Product used in conjunction with any other
manufacturer's pumping or proportioning equipment. Further, the terms and conditions of this
warranty shall not apply to services or repairs madeto Product by any third party not authorized in
writing by Gusmer. For such Product, a written estimate will be submitted to Customer at a
nominal service charge, itemizing the cost for repair. Disposition of Product will be done in
accordance withthe terms stated on the written estimate.

The warranty provisions applied to product that are not manufactured by Gusmer will be solely in
accordance with the warranty provided by the original manufacturer of the product.

GUSMER MAKES NO WARRANTY WHATSOEVER AS TO THE MERCHANTABILITY OF,
OR SUITABILITY FOR, ITS PRODUCT TO PERFORM ANY PARTICULAR PURPOSE.
CREDIT FOR, OR REPLACEMENT OF, PRODUCT DEFECTIVE IN MATERIAL OR
WORKMANSHIP SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUS MER
OBLIGATIONS TO CUSTOMER. NO OTHER WARRANTY, EXPRESSED OR IMPLIED ON
ANY PRODUCT IT MANUFACTURES AND/OR SELLS, WILL BE RECOGNIZED BY
GUSMER UNLESS SAID WARRANTY IS IN WRITING AND A PPROVED BY AN OFFICER
OF GUSMER.

Under no circumstances shall Gusmer be liable for loss of prospective or speculative profits, or
special indirect, incidental or consequential damages. Further, Gusmer shall have no liability for
anyexpensesincluding, but not limited to personal injury or property damage resultingfrom failure
of performance of the product, use of the product, or application of the material dispensed through
the product. Any information provided by Gusmer that is based on data received from a third
source, or that pertains to product not manufactured by Gusmer, while believed t o be accurate and
reliable, is presented without guarantee, warranty, or responsibility of any kind, expressed or
implied.

Gusmer through the sale, lease, or rental of Product in no way expresses or implies a license for the
use of, nor encourages the infringement of any patents or licenses.

To insure proper validation of your warranty, please complete the warranty card and return it to
Gusmer within two weeks of receipt of equipment.

Revised 11/12/98

4 32943-1, Issue 1

Operating Manual General Safety Information

GENERAL SAFETY INFORMATION

It is necessary to understand and follow the instructions in this manual to insure proper
and safe operation of the equipment.

As withmost mechanical equipment, certain safetyprecautions must be taken when the
equipment discussed in this manual is operated or serviced. Severe bodily injury or
damage to equipment and property may result if the instructions and precautions listed
throughout this manual are not followed.

Needless to say, sufficient guidelines cannot be developed to eliminate the need for good
common sense in the use and servicing of this equipment, and in the use and application
of the products, this equipment has been designed to process. Users of this equipment
must therefore, make their own determination as to the suitability of the information
contained in this manual to their specific operation and requirements. There should be no
assumption made that the safetymeasures and instructions contained herein are all­inclusive, and that other safety measures may not be required for specific use or
application.

The following safety guidelines are generally applicable to the safe and efficient use of
the equipment.

Acceptable Equipment Uses

The equipment is designed for the dispensing of polyurethane foams, two-component
coating systems, and some two-component epoxy systems, specificallypolyureas. Under
no circumstances should any acid or corrosive chemicals be used in the unit. Consult
GUSMER if there is any doubt about the compatibility of the chemical system to be used
in this equipment.

Any use of this equipment other than as indicated above constitutes misuse unless express
written approval is obtained from GUSMER.

4/21/99 5

Model GX-8 Spray Gun

Operational Safety Procedures

This safety information will not be repeated in the text of this manual. The symbols
pertaining to this information will appear where appropriate to alert the operator to
potential hazards.

Solvents and Chemicals

High Voltage

High Pressure

Personal Protective

Equipment

WARNING: T

OPERATOR TO CERTAIN HAZARDS.ADEQUATE PERSONAL PROTECTIVE MEASURES MUST
BETAKEN SO AS TO AVOID EXCEEDING THE
PRODUCTS BEING USED

HE SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE

THRESHOLD LIMIT VALUE (TLV) OF THE

, AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION (OSHA) OR OTHER QUALIFIED AGENCY.INFORMATION CONCERNING

PERSONAL PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH CHEMICALS

WARNING: T

THE ELECTRIC CONSOLES OR OTHERWISE SERVICE THIS EQUIPMENT AND/OR EQUIPMENT USED
WITH IT BEFORE SWITCHING OFF THE MAIN POWER DISCONNECT AND INTERRUPTING SUPPLY
VOLTAGE AT THE SOURCE
A QUALIFIED ELECTRICIAN

WARNING: T

COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI.TO AVOID SERIOUS BODILYINJURY
FROM HYDRAULIC INJECTION OF FLUID
SERVICE HY DRAULICCOMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO

WARNING: T

WHEN OPERATING, SERVICING, OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS
EQUIPMENT
SAFETY SHOES, AND RESPIRATORYEQUIPMENT AS REQUIRED.

O PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK, NEVER OPEN

.THE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY

.

HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC

, NEVER OPEN ANY HYDRAULIC CONNECTIONS OR

.

O AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR MUST BE WORN

.THIS INCLUDES, BUT IS NOT LIMITED TO, EYE AND FACE PROTECTION, GLOVES,

.

WARNING: T

TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES.TO PREVENT
SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL
EQUIPMENT BEFORE ALLOWING IT TO COOL

HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH

, NEVER ATTEMPT TO SERVICE THE

.

High Temperature

WARNING:F

PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT FROM ONE OR MORE OF THE ABOVE
LISTED HAZARDS

AILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN

Warning

6 32943-1, Issue 1

Operating Manual Description

DESCRIPTION

Key Features

The design and development of the Gusmer Model GX-8 Spray Gun represents the next
step in the evolution of spray coating technology that Gusmer originated over 35 years
ago. We believe the GX-8 Spray Gun is the only mechanical purge gun in the world that
allows the spraying of polyureas and hybrids at outputs in the 1-2 pound per minute
range. Its lower output, lighter weight, fewer parts, and reduced air consumption are just
a few of its innovative enhancements. Yet, the GX-8 maintains many of the unique
design characteristics of its direct predecessor, the GX-7. These unique characteristics
include mechanical purge, a variety of durable mixing modules, interchangeable Pattern
Control Discs (PCD), and Gusmer quality.

The GX-8 design has successfully combined the proven concepts of other Gusmer
mechanical purge, direct impingement guns w ith exciting new enhancements that provide
a completely new gun that delivers:

• Unmatched low output capabilities

• Smaller gun dimensions with a 37% reduction in weight

• Increased maneuverability specifically for open mold applications

• Easy operation

• Less expensive operation

The gun is available with a variety of PCD options designed to meet most applications
that require the spraying of fast chemical systems at lowoutputs. Both your authorized
Gusmer Distributor and Gusmer Sales Engineers are available to help determine what
configurations are best for your specific application. Please contact either for additional
information.

The GX-8 is a combination of newconcepts and existing Gusmer spray gun technology.
For example, the mixing module that is contained in the GX-8 is similar in function to the
GX-7 mixing module. However, it is very different in its final design. The module’s
modified geometry supports the mixing requirements of the extremely fast chemistries
found in polyureas and hybrid polyurethanes/polyurea. This coupled with a smaller
mechanical purge valving rod and smaller PCD insure proper mixing and timely delivery
of mixed product to the work surface. The PCD now comes standard with Gusmer’s
proprietary “gold tip” finish. This space age coating improves the non-sticking
characteristics of the tip, while simultaneously improving its durability. With improved
tip durability maintaining the spray pattern, whether round or fan shaped, for longer
periods is possible. This equates into longer tip life for the user.

The Mixing Module is the only part that requires routine replacement to insure proper gun
operation. This inexpensive plastic component will wear out through normal use. The
module incorporates a small alignment pin, which insures proper chemical port alignment
during insertion into the Gun Block. The Mixing Module is a precision-machined
component made of a proprietary engineering thermoplastic. It is cleaned using an air
pressurized Gun Cleaning Kit. However, even if irregularly serviced it can still be
cleaned using the appropriate drill bit. The Valving Rod is precision ground and made
from hardened tool steel. It is designed for long life and under normal use, will not
require routine replacement.

4/21/99 7

VALVING ROD
ASSEMBLY

PATTERN

CONTROL

DISC (PCD)

Figure 1. Mixing Module

Model GX-8 Spray Gun

MIXING
MODULE

The GX-8 has been designed for low output spraying performance, durability, reliability,
and serviceability. In order to enable the gun to dispense extremely low levels of
chemical, the Mixing Module has precision-machined chemical ports incorporated into it.
To protect these ports from clogging extremely fine screen mesh filters are used. Special
material coatings and material finishing techniques were also incorporated into the design.
A thorough understanding of this manual is essential to completely insure that this gun
provides the best service possible. In addition, the experience gained through daily use of
the gun will sharpen your operational and service skills. Functional problems can be
significantlyreduced by following the techniques and service recommendations described
in this manual.

Gusmer and our Authorized Distributors have experienced, highly qualified, technical
representatives who are always available to help if a problem does occur. In most cases, a
simple telephone call to our technical representatives will provide you with a solution to
your problem. Be sure to take advantage of their experience and expertise.

IMPORTANT: Substitution of parts not designed manufactured, or recommended by
Gusmer could result in harm to the user and/or damage to the GX-8 Gun. Any
alterations to or substitutions for Gusmer parts will void the warranty provisions set
forth elsewhere in this manual

8 32943-1, Issue 1

Operating Manual Description

Major Components

In keeping with the need to gain a complete and thorough understanding of the
equipment, please take time to become familiar with the major components of the GX-8
Gun (Figure 2) and its Centerline Components (Figure 3). This will be helpful later when
these items are covered in the manual.

Safety Stop

Air Cap

Air Cap Air

Adjustment

Valve

Piston Rod

NOTE:

Both Round and Fan Mixing

Modules are available. The

Round Module provides a

round spray pattern and is

identified by a groove in its

cylindrical body. The Fan

Module provides a fan spray

pattern and is identified by its

smooth cylindrical body.

Gun Block

Manual Valves

CouplingBlock

Jam Nut

Valving Rod

Assembly

Trigger

Figure 2. Major Components

Figure 3. Centerline Components

4/21/99 9

Model GX-8 Spray Gun

Equipment Supplied

The Standard Tool Kit includes the following tools for use in servicing the GX-8.

Figure 4. Standard Tool Kit

1. 10” Adjustable Wrench (P/N 909A)

2. 6” Adjustable Wrench (P/N 0908)

3. 3/8” x 5/16” Open End Wrench

(P/N 1982A)

4. 1/2” Combination Wrench(P/N 1986)

5. 5/16” Spintite (P/N 0904A)

6. Retaining Ring 45°°°° Pliers (P/N 32982)

7. 6” Pliers (P/N 0906)

8. 9/64” Ball Point Hex Key

(P/N 0902-9/64)

9. 5/32” Hex Key (P/N 0902-5/32)

10. 3/16” Hex Key (P/N 0902-3/16)

11. 5/64” Hex Key (P/N 0902-5/64)

12. Check Valve Removal/Cleaning Tool

(P/N 1948)

13. #80 Clean Out Drill (.0135 Dia.)

(P/N 0941-45)

14. #68 Clean Out Drill (.031 Dia.)

(P/N 0941-22)

15. #60 Clean Out Drill (.040 Dia.)

(P/N 0941-29)

16. 1/8” Dia. Clean Out Drill

(P/N 0927-1/8)

17. 21/64” Dia. CleanOut Drill

(P/N 0927-21/64)

18. Pin Vise W/Collets (P/N 6902A)

19. Brush (P/N 1945)

20. Flush Can (P/N 0919A)

21. Lubriplate Grease

(P/N 0553-2) Not Shown

10 32943-1, Issue 1