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Magnum Venus Plastech
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CPD-PRTM
User Manual
103 pgs5.81 Mb0

Magnum Venus Plastech CPD-PRTM User Manual

CPD / PRTM - 1:1
Pro Gun Manual
Rev: 05/2012
CORPORATE HEADQUARTERS and MANUFACTURING
11692 56th Court * Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636
TECHNOLOGY CENTER and MANUFACTURING
1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666
MVP Plastech UK
Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: +44 (0) 1822 832621
Fax: +44 (0) 1822 833999
www.mvpind.com
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Table of Contents
SECTION: Page
TERMS & CONDITIONS OF SALE 4 SAFETY & WARNINGS 6
INTRODUCTION 15 GUN BLOCK DISASSEMBLY 19 GUN BLOCK ASSEMBLY 24
ACTUATOR REBUILD 31 CLASSIC PRO GUN HANDEL REBUILD 32
PARTS DRAWINGS 38 REVISION INFORMATION 102
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Terms & Conditions of Sale:
Customs duties, import and export licenses and certificates, if required, and all
local taxes are excluded from this offer. If US state and local taxes are applicable and not included in equipment invoice, such amount may be invoiced later.
Delivery dates or shipping schedules are approximate and based upon the most
recent information available at the time of order. Dates may be adjusted upon receipt of subsequent information or modification of order. Seller will ship prior to the delivery date if possible, but not without Buyer’s consent on Advanced Equipment sales.
All contract dates and timelines begin upon receipt at MVP of customer purchase
order, signed Terms and Conditions of Sale (if applicable), and down payment per quotation (if applicable).
If shipments are delayed by the Buyer, or because the Buyer’s account is in
arrears, payments shall become due on the date when the Seller is prepared to make shipment. Products held by the Seller for the Buyer shall be at the risk and expense of the Buyer.
Damages, defects or shortages must be communicated immediately to MVP.
Discrepancy in pricing and/or quantities on invoices must be reported within 30 days of the invoice date. Claims made 30 days or more following the invoice date will not be honored.
Permission to return items must be requested and granted in advance. No credit
will be given if items are returned prior to requesting and receiving permission. All returns are subject to a restocking fee. The standard 15% charges may be increased or decreased depending on the reason for the return. Special ordered items may not be returned.
Seller warrants that the mechanical operation of the goods as specified shall be
free from faults in respect to materials and workmanship for a period of 12 months for parts from the date of invoice. For systems, 12 months from start-up or, if earlier, 18 months from the date of the Bills of Lading. The warranty does not cover
general wear and tear or damage due to negligence or improper use. Seller’s
liability under the warranty shall be limited solely to repair or replacement costs, and has no responsibility for reimbursing repair cost incurred by Buyer in connection with equipment without first giving written authorization for such charges. Seller makes no express warranties except those set forth in this agreement, and disclaims all other warranties, expressed or implied, including without limitation, implied warranties of non-infringement merchantability and fitness for a particular purpose. Seller accepts no liability for loss of production, loss of profits, or other direct or indirect damages. In any claim by the Buyer
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against the Seller in respect of the goods, the liability of the Seller shall be limited to the value of the goods.
Many factors beyond Seller’s control contribute to the success of Buyer’s finished
products, such as raw materials used to manufacture the product. Equipment is warranted to perform to specifications detailed in quotation, but Seller is not liable for quality or quantity of finished products produced by Buyer.
The country of origin is the United States of America. Sale, installation and all
rights of the parties are governed by the laws of the state of Florida. Venue with regard to any litigation shall be in Pinellas County, Florida. The parties agree to waive all rights to trial by jury as to any and all disputes.
The goods remain the property of the Seller until full payment is received. Sale of equipment is subject to application and issuance of proper US Government
export license and regulations, if applicable.
Installation of equipment is responsibility of Buyer and Seller, with cost
responsibility and number of days provided as detailed in original customer Quotation. Seller will provide installation supervision personnel within 30 days of customer request. If installation is delayed by the Buyer more than six months from the date of shipment, or if customer facility or material/parts are not prepared for installation, seller will invoice full installation costs, up to $1,250 a day plus expenses, for each MVP installation technician on site. Seller has the option to waive this fee at its discretion.
Parties shall be excused for delays caused by embargoes, acts of civil or military
authorities, Acts of God, or other circumstances beyond the reasonable control of the parties. Notification of such delays must be made in writing within ten days of occurrence.
Our agreement supersedes any previous agreement and applies in full.
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SAFETY & WARNING INFORMATION:
OPERATING YOUR POLYESTER SYSTEM SAFELY
1. Introduction
Any tool, if used improperly, can be dangerous. Safety is ultimately the responsibility of those using the tool. In like manner, safe operation of polyester processes is the responsibility of those who use such processes and those who operate the equipment. This manual outlines procedures to be followed in conducting polyester operations safety. This system has been specifically designed for use of Polyester Resin, Gel-Coat, and Methyl Ethyl Ketone Peroxides (MEKP) applications. Other formulations or blends considered for use in this equipment is strictly prohibited without the expressed consent by Magnum Venus Plastech Inc. Magnum Venus Plastech cannot eliminate every danger nor foresee every circumstance that might cause an injury during equipment operation. Some risks, such as the high pressure liquid stream that exits the spray tip, are inherent to the nature of the machine operation and are necessary to the process in order to manufacture the end-product. For this reason, ALL personnel involved in polyester operations should read and understand the Safety Manual. It is very important for the safety of employees involved in the operation that equipment operators, maintenance and supervisory personnel understand the requirements for safe operation. Each user should examine his own operation, develop his own safety program and be assured that his equipment operators follow correct procedures. Magnum Venus Plastech hopes that this manual is helpful to the user and recommends that the precautions in this manual be included in any such program. Magnum Venus Plastech recommends this Safety Manual remain on your equipment at all times for your personnel safety. In addition to the manual, Magnum Venus Plastech recommends that the user consult the regulations established under the Occupational Safety & Health Act (OSHA), particularly the following sections:
1910.94 Pertaining to Ventilation.
1910.106 Pertaining to flammable liquids
1910.107 Pertaining to spray finishing operations, particularly Paragraph (m) Organic Peroxides and Dual Component Coatings.
Other standards and recognized authorities to consult are the National Fire Protection Association (NFPA) bulletins as follows:
NFPA No.33 Chapter 14, Organic Peroxides and Dual Component Materials NFPA No.63 Dust Explosion Prevention NFPA No.70 National Electrical Code NFPA No.77 Static Electricity NFPA No.91 Blower and Exhaust System NFPA No.654 Plastics Industry Dust Hazards
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Type of Fire Extinguishing equipment recommended: Fire Extinguisher – code ABC, rating number 4a60bc.
Extinguishing Media – Foam, Carbon Dioxide, Dry Chemical, Water Fog. Copies of the above bulletins are available, at a nominal charge from:
National Fire Protection Association 470 Atlantic Avenue Boston, MA 02210
Research Report No.11 of the American Insurance Association deal with “Fire, Explosion and
Health Hazards of Organic Peroxides”. It is published by:
American Insurance Association 85 John Street New York, NY 10038
Local codes and authorities also have standards to be followed in the operation of your spraying equipment. Your insurance carrier will be helpful in answering questions that arise in your development of safe procedures.
1.2 Personal Safety Equipment
Magnum Venus Plastech recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems:
Magnum Venus Plastech recommends that the user consult the state and local regulations established for all Safety equipment listed.
2.0 Material Safety
2.1 Hazards Associated with Laminating Operations
The major hazards which should be guarded against in polyester laminating operations are those associated with:
1. The flammability and explosion dangers of the catalyst normally used – Methyl Ethyl Ketone Peroxide (MEKP).
2. The flammability dangers of clean-up solvents sometimes used (Magnum Venus Plastech recommends that clean-up solvents be non-flammable), and of resin diluents used, such as styrene.
3. The flammability dangers of catalyst diluents, if used. (Magnum Venus Plastech recommends that catalyst not be diluted.
4. The flammability dangers of the uncured liquid resins used.
5. The combustibility dangers of the cured laminate, accumulations of over spray, and laminate sandings.
6. The toxicity dangers of all the chemicals used in laminating operations with respect to ingestion, inhalation and skin and eye hazards.
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2.2 Catalyst (Methyl Ethyl Ketone Peroxide)
MEKP is among the more hazardous materials found in commercial channels. The safe
handling of the “unstable (reactive)” chemicals presents a definite challenge to the plastics
industry. The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins also produces the hazards which require great care and caution in its storage, transportation, handling, processing and disposal. MEKP is a single chemical. Various polymeric forms may exist which are more or less hazardous with respect to each other. These differences may arise not only from different molecular structures
(all are, nevertheless, called “MEKP”) and from possible trace impurities left from the
manufacture of the chemicals, but may also arise by contamination of MEKP with other materials in its storage or use. Even a small amount of contamination with acetone, for instance, may produce an extremely shock-sensitive and explosive compound.
Contamination with promoters or materials containing promoters, such as laminate sandings, or with any readily oxidizing material, such as brass or iron, will cause
exothermic “redox” reactions which can become explosive in nature. Heat applied to
MEKP, or heat build-up from contamination reactions can cause it to reach what is called its Self-Accelerating Decomposition Temperature (SADT).
Researchers have reported measuring pressure rates-of-rise well in excess of 100,000 psi per
second when certain MEKP’s reach their SADT. (For comparison, the highest pressure rate-of-
rise listed in NFPA Bulletin NO.68, “Explosion Venting”, is 12,000 psi per second for an
explosion of 12% acetylene and air. The maximum value listed for a hydrogen explosion is 10,000 psi per second. Some forms of MEKP, if allowed to reach their SADT, will burst even an open topped container. This suggests that it is not possible to design a relief valve to vent this order of magnitude of pressure rate-of-rise. The user should be aware that any closed container, be it a pressure vessel, surge chamber, or pressure accumulator, could explode under certain conditions. There is no engineering substitute for care by the user in handling organic peroxide catalysts. If, at any time, the pressure relieve valve on top of the catalyst tank should vent, the area should be evacuated at once and the fire department called. The venting could be the first indication of a heat, and therefore, pressure build-up that could eventually lead to an explosion. Moreover, if a catalyst tank is sufficiently full when the pressure relief valve vents, some catalyst may spray out, which could cause eye injury. For this reason, and many others, anyone whose job puts them in an area where this vented spray might go, should always wear full eye protection even when laminating operations are not taking place.
Safety in handling MEKP depends to a great extent on employee education, proper safety instructions and safe use of the chemicals and equipment. Workers should be thoroughly informed of the hazards that may result from improper handling of MEKP, especially in regards to contamination, heat, friction and impact. They should be thoroughly instructed regarding the proper action to be taken in the storage, use and disposal of MEKP and other hazardous materials used in the laminating operation. In addition, users should make every effort to:
A. Store MEKP in a cool, dry place in original containers away from direct sunlight and away from other chemicals.
B. Keep MEKP away from heat, sparks and open flames.
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C. Prevent contamination of MEKP with other materials, including polyester over spray and sandings, polymerization accelerators and promoters, brass, aluminum and non-stainless steels.
D. Never add MEKP to anything that is hot, since explosive decomposition may result. E. Avoid contact with skin, eyes and clothing. Protective equipment should be worn at all times.
During clean-up of spilled MEKP, personal safety equipment, gloves and eye protection must be worn. Firefighting equipment should be at hand and ready.
F. Avoid spillage, which can heat up to the point of self-ignition. G. Repair any leaks discovered in the catalyst system immediately, and clean up the leaked
catalyst at once in accordance with the catalyst manufacturer’s instructions. H. Use only original equipment or equivalent parts from Magnum Venus Plastech in the catalyst
system (i.e.: hoses, fitting, etc.) because a dangerous chemical reaction may result between substituted parts and MEKP.
I. Catalyst accumulated from the purging of hoses or the measurement of fluid output deliveries should never be returned to the supply tank, such catalyst should be diluted with copious
quantities of clean water and disposed of in accordance with the catalyst manufacturer’s
instructions. The extent to which the user is successful in accomplishing these ends and any additional
recommendations by the catalyst manufacturer determines largely the safety that will be present in his operation.
2.3 Clean-Up Solvents and Resin Diluents
WARNING
A hazardous situation may be present in your pressurized fluid system! Hydrocarbon Solvents can cause an explosion when used with aluminum or galvanized components in a closed (pressurized) fluid system (pump, heaters, filters, valves, spray guns, tanks, etc.). The explosion could cause serious injury, death and/or substantial property damage. Cleaning agents, coatings, paints, etc. may contain Halogenated Hydrocarbon Solvents. Some Magnum Venus Plastech spray equipment includes aluminum or galvanized components and will be affected by Halogenated Hydrocarbon Solvents.
A. There are three key elements to the Halogenated Hydrocarbon (HHC) solvent hazard.
a. The presence of HHC solvents. 1,1,1 – Trichloroethane and Methylene Chloride are
the most common of these solvents. However, other HHC solvents are suspect if used; either as part of paint or adhesives formulation, or for clean-up flushing. b. Aluminum or Galvanized Parts. Most handling equipment contains these elements. In contact with these metals, HHC solvents could generate a corrosive reaction of a catalytic nature.
b. Equipment capable of withstanding pressure. When HHC solvent contacts aluminum
or galvanized parts inside a closed container such as a pump, spray gun, or fluid handling system, the chemical reaction can, over time, result in a build-up of heat and pressure, which can reach explosive proportions.
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When all three elements are present, the result can be an extremely violent explosion. The reaction can be sustained with very little aluminum or galvanized metal; any amount of aluminum is too much.
A. The reaction is unpredictable. Prior use of an HHC solvent without incident (corrosion or explosion) does NOT mean that such use is safe. These solvents can be dangerous alone (as a clean-up or flushing agent) or when used as a component or a coating material. There is no known inhibitor that is effective under all circumstances. Furthermore, the mixing of HHC solvents with other materials or solvents, such as MEKP, alcohol, and toluene, may render the inhibitors ineffective.
B. The use of reclaimed solvents is particularly hazardous. Reclaimers may not add any inhibitors. Also, the possible presence of water in reclaimed solvents could feed the reaction.
C. Anodized or other oxide coatings cannot be relied upon to prevent the explosive reaction. Such coatings can be worn, cracked, scratched, or too thin to prevent contact. There is no known way to make oxide coatings or to employ aluminum alloys, which will safely prevent the chemical reaction under all circumstances.
D. Several solvent suppliers have recently begun promoting HHC solvents for use in coating systems. The increasing use of HHC solvents is increasing the risk. Because of their exemption from many State Implementation Plans as Volatile Organic Compounds
(VOC’s), their low flammability hazard, and their not being classified as toxic or carcinogenic
substances, HHC solvents are very desirable in many respects.
WARNING: Do not use Halogenated Hydrocarbon solvents in pressurized fluid systems having aluminum or galvanized wetted parts.
NOTE: Magnum Venus Plastech is aware of NO stabilizers available to prevent Halogenated Hydrocarbon solvents from reaction under all conditions with aluminum components in closed fluid system. TAKE IMMEDIATE ACTION… Halogenated Hydrocarbon solvents are dangerous when used with aluminum components in a closed fluid system.
A. Consult your material supplier to determine whether your solvent or coating contains Halogenated Hydrocarbon Solvents.
B. Magnum Venus Plastech recommends that you contact your solvent supplier regarding the best non-flammable clean-up solvent with the heat toxicity for your application.
C. If, however, you find it necessary to use flammable solvents, they must be kept in approved, electrically grounded containers.
D. Bulk solvent should be stored in a well-ventilated, separate building, 50 feet away from your main plant.
E. You should allow only enough solvent for one day’s use in your laminating area. F. “NO SMOKING” signs must be posted and observed in all areas of storage or where solvents
and other flammable materials are used.
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G. Adequate ventilation (as covered in OSHA Section 1910.94 and NFPA No.91) is important wherever solvents are stored or used, to minimize, confine and exhaust the solvent vapors.
H. Solvents should be handled in accordance with OSHA Section 1910.106 and 1910.107.
2.4 Catalyst Diluents
Magnum Venus Plastech spray-up and gel-coat systems currently produced are designed so that catalyst diluents are not required. Magnum Venus Plastech, therefore, recommends that diluents not be used. This avoids the possible contamination which could lead to an explosion due to the handling and mixing of MEKP and diluents. In addition, it eliminates any problems from the diluents being contaminated through rust particles in drums, poor quality control on the part of the diluents suppliers, or any other reason. If, however, diluents are absolutely required, contact your catalyst supplier and follow his instructions explicitly. Preferable, the supplier should premix the catalyst to prevent possible “on the job” contamination while mixing.
WARNING
If diluents are not used, it should be remembered that catalyst spillage, gun, hose and packing leaks are potentially more hazardous, since each drop contains a higher concentration of catalyst, and therefore will react quicker with over spray and the leak.
2.5 Cured Laminate, Overspray and Laminate Sandings Accumulation
A. Remove all accumulations of overspray, FRP sandings, etc. from the building as they occur. If this waste is allowed to build up, spillage of catalyst is more likely to start a fire; in addition, the fire would burn hotter and longer.
B. Floor coverings, if used, should be non-combustible. C. Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product, over-
sprayed chop or resin, FRP sandings or any other material with MEKP. To prevent this spillage and leakage, you should:
1. Maintain your Magnum Venus Plastech System. Check the gun several times daily for catalyst and resin packing or valve leaks. REPAIR ALL LEAKS IMMEDIATELY.
2. Never leave the gun hanging over, or lying inside the mold. A catalyst leak in this situation would certainly damage the part, possibly the mold, and may cause a fire.
3. Inspect resin and catalyst hoses daily for wear or stress at the entry and exits of the boom sections and at the hose and fittings. Replace if wear or weakness is evident or suspected.
4. Arrange the hoses and fiberglass roving guides so that the fiberglass strands DO NOT rub against any of the hoses at any point. If allowed to rub, the hose will be cut through, causing a hazardous leakage of material which could increase the danger of fire. Also, the material may spew onto personnel in the area.
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2.7 Toxicity of Chemicals
A. Magnum Venus Plastech recommends that you consult OSHA Sections 1910.94, 1910.106,
1910.107 and NFPA No.33, Chapter 14, and NFPA No.91. B. Contact your chemical supplier(s) and determine the toxicity of the various chemicals used as
well as the best methods to prevent injury, irritation and danger to personnel. C. Also determine the best methods of first aid treatment for each chemical used in your plant.
2.8 Treatment of Chemical Injuries
Great care should be used in handling the chemicals (resins, catalyst and solvents) used in polyester systems. Such chemicals should be treated as if they hurt your skin and eyes and as if they are poison to your body. For this reason, Magnum Venus Plastech recommends the use of protective clothing and eye wear in using polyester systems. However, users should be prepared in the event of such an injury. Precautions include:
1. Know precisely what chemicals you are using and obtain information from your chemical supplier on what to do in the event the chemical gets onto your skin or into the eyes, or is swallowed.
2. Keep this information together and easily available so that it may be used by those administering first aid or treating the injured person.
3. Be sure the information from your chemical supplier includes instructions on how to treat any toxic effects the chemicals have.
WARNING
Contact your doctor immediately in the event of any injury and give him the information you have collected. If your information includes first aid instructions, administer first aid immediately while you are contacting your doctor.
Fast treatment of the outer skin and eyes that contact such chemicals generally includes immediate and thorough washing of the exposed skin and immediate and continuous flushing of the eyes with lots of clean water for at least 15 minutes or more. These general instructions of first aid treatment, however, may be incorrect for some chemicals; that is why you must know the chemicals and treatment before an accident occurs. Treatment for swallowing a chemical frequently depends upon the nature of the chemical.
NOTE: Refer to your System User Manual for complete and detailed operating instructions and service information.
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3.0 Equipment Safety
WARNING
Magnum Venus Plastech suggests that personal safety equipment such as EYE GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn when servicing or operating this equipment. Ear protection should be worn when operating a fiberglass chopper to protect against hearing loss since noise levels can be as high as 116 dB (decibels). This equipment should only be operated or serviced by technically trained personnel!
WARNING
Never place fingers, hands, or any body part near or directly in front of the spray gun fluid tip. The force of the liquid as it exits the spray tip can cause serious injury by shooting liquid through the skin. NEVER LOOK DIRECTLY INTO THE GUN SPRAY TIP OR POINT THE GUN AT OR NEAR ANOTHER PERSON. (TREAT THE GUN AS IF IT WERE A LOADED PISTOL.)
3.1 Emergency Stop Procedures
The following steps should be followed in order to stop the machinery in an emergency situation
1. The ball valve located where the air enters the power head of the resin pump, should be moved to the “OFF” or closed position. To do this, simply rotate the lever on the ball valve 90 degrees. Doing this will cause all the system air to bleed out of the system in a matter of a few seconds, making the system incapable of operating
NOTE: Step 2 is a precautionary step and should be followed whenever the above mentioned ball valve is activated to the stop mode. Failure to do so, can damage the
regulators and components on reactivating to the “ON” position.
2. Turn all system regulators to the “OFF” position (counter-clockwise) position
NOTE: Verify that the Catalyst relief line, located on the catalyst manifold, and the resin return line, located on the resin filter, are secured relieving catalyst and resin fluid pressure.
3. Catalyst pressure in the catalyst pump can be eliminated by rotating the ball valve on the catalyst manifold 90 degrees to the “open” or “on” position.
Note: The “open” or “on” position is when the ball valve handle is parallel (in line) with the ball valve body. The “closed” or “off” position is when the ball valve handle is
perpendicular (across) the ball valve body.
4. Resin pressure in the resin pump can be eliminated by rotating the ball valve on the resin
filter 90 degrees to the “open” or “on” position. Place a container under the ball valve to
catch any resin that is ejected out of the valve.
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3.2 Grounding
Grounding an object means providing an adequate path for the flow of the electrical charge from the object to the ground. An adequate path is one that permits charge to flow from the object fast enough that it will not accumulate to the extent that a spark can be formed. It is not possible to define exactly what will be an adequate path under all conditions since it depends on many variables. In any event, the grounding means should have the lowest possible electrical resistance. Grounding straps should be installed on all loose conductive objects in the spraying area. This includes material containers and equipment. Magnum Venus Plastech recommends grounding straps be made of AWG No.18 stranded wire as a minimum and the larger wire be used where possible. NFPA Bulletin No77 states that the electrical resistance of such a leakage path may be as low as 1 meg ohm (10 ohms) but that resistance as high as 10,000 meg ohms will produce an adequate leakage path in some cases. Whenever flammable or combustible liquids are transferred from one container to another, or from one container to the equipment, both containers or container and equipment shall be effectively bonded and grounded to dissipate static electricity. For further information, see National Fire Protection Association ( NFPA) 77, titled “Recommended Practice on Static Electrical”. Refer especially to section 7-7 titled “Spray Application of Flammable and Combustible Materials”. Check with local codes and authorities for other specific standards that might apply to your application. NEVER USE HARD MATERIALS SUCH AS WIRE, PINS, ETC., TO CLEAR A PLUGGED GUN. HARD MATERIALS CAN CAUSE PERMANENT DAMAGE. DAB WITH A BRISTLE BRUSH, BLOW BACKWARDS WITH AIR UNTIL CLEAR WHILE WEARING A PROTECTIVE EYE SHIELD. REPEAT AS MANY TIMES AS NECESSARY. DO NOT PERFORM ANY MAINTENANCE OR REPAIRS UNTIL YOU HAVE FOLLOWED THE PRECAUTIONS STATED ABOVE. IF YOU, AS AN EQUIPMENT OPERATOR OR SUPERVISOR, DO NOT FEEL THAT YOU HAVE BEEN ADEQUATELY TRAINED OR INSTRUCTED AND THAT YOU LACK THE TECHNICAL KNOWLEDGE TO OPERATE OR PERFORM MAINTENANCE ON A PIECE OF MAGNUM VENUS PLASTECH EQUIPMENT, PLEASE CALL MAGNUM VENUS PLASTECH BEFORE OPERATING OR PERFORMING MAINTENANCE ON THE EQUIPMENT. IF YOU HAVE ANY QUESTIONS REGARDING THE ABOVE PRECAUTIONS OR ANY SERVICE OR OPERATION PRECEDURES, CALL YOUR MAGNUM VENUS PLASTECH DISTRIBUTOR OR MAGNUM VENUS PLASTECH.
NOTICE: All statements, information and data given herein are believed to be accurate and reliable but are presented without guaranty, warranty or responsibility of any kind express or implied. The user should not assume that all safety measures are indicated or that other measures are not required.
DANGER: Contaminated catalyst may cause Fire or Explosion. Before working on the catalyst pump or catalyst accumulator, wash hands and tools thoroughly. Be sure work area is free of dirt, grease or resin. Clean catalyst system components with clean water only.
DANGER: Eye, skin and respiration hazard. The Catalyst, MEKP, may cause blindness, skin irritation or breathing difficulty. Keep hands away from face. Keep food and drink away from work area.
WARNING: Please refer to your catalyst manufacturer’s safety information regarding the
safe handling and storage of catalyst. Wear appropriate safety equipment as recommended.
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Introduction:
The Pro Gun is an air trigger gun; meaning when the trigger is pulled an air cylinder pushes on the actuator stem and rotates the gun block into the on position. The Pro Gun works very similar to a dual ball valve in that the valve rod rotates and the catalyst and resin holes line up with the ports in the gun block allowing material to flow. The actuator is an air cylinder and as the piston moves back and forth it rotates the valve rod 90 degrees to the ON or OFF position.
Generally, the Pro Gun ™ will not need to be completely disassembled for daily
cleaning. However, the entire gun should be disassembled and the o-rings and seals replaced approximately every six months to a year depending on use and material being used.
Disassembling the Pro Gun™ is easy; the gun breaks down into four separate modules which are then disassembled further into their individual parts. A special tool kit, which includes a specially designed Pro Gun™ tool, is available to aid in performing maintenance and repair.
Note: The subtle differences between the Pro Gun™ used for chopping, gel coating and pour applications are noted at appropriate places in this manual.
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During Disassembly:
As you disassemble the equipment, lay out the components on a clean surface in the correct order and direction. This will help you to reassemble them.
This manual covers the following 1:1 Pro Gun Assemblies, Components & Repair Kits:
CPD-4000 1:1 Pro Gun Assembly - Spray CPD-4000-A Auto 1:1 Pro Gun Assembly PRTM-RG-1000-A Pro Innovator Automatic Recirculation Gun CPD-4000-A-INV Innovator Automatic Recirculation Gun CPD-5000 1:1 Pro Gun Assembly – Disposable Mixer CPD-5000-A Auto 1:1 Pro Gun Assembly – Disposable Mixer CPD-5000-SILO 1:1 Pro Gun Assembly – Silicone CPD-5000-SNZ 1:1 Pro Gun Assembly – Spatter Nozzle CPD-6000 1:1 Pro Gun Assembly – Disposable Mixer – Solvent / Air Purge CPD-6000-A Auto 1:1 Pro Gun Assy – Disposable Mixer – Solvent / Air Purge
CPC-1200-A Pro Gun Actuator Assembly - Automatic CPD-4100-A Auto 1:1 Pro Gun Block Assembly CPD-5100 1:1 Pro Gun Block Assembly – Disposable Mixer CPD-5100-A Auto 1:1 Pro Gun Block Assembly CPD-5100-SILO Auto 1:1 Pro Gun Block Assembly – Silicone CPD-5100-SNZ Auto 1:1 Pro Gun Block Assembly – Spatter Nozzle CPD-5200-SILO Auto Pro Gun Actuator Assembly CPD-6100 Auto 1:1 Pro Gun Block Assembly – Disposable Mixer CPD-6300 Classic Pro Gun Handle – 1:1 Adhesive 58603-1 Classic Pro Gun Handle 58604-1 Pro Gun Actuator Assembly 58751-1 1:1 Pro Gun Block Assembly 58761-1 1:1 Pro Gun Block Assembly – BPO 58742-1 Automatic Flush Valve Assembly 58742-1-INT Automatic Flush Valve Assembly – International PRTM-RG-1100 Recirculation Gun Block PRTM-RG-1200-A Actuator Assembly
CPD-4000-A-INV-RK Repair Kit Auto 1:1 Pro Gun Assembly – Innovator CPD-4000-A-RK Repair Kit Auto 1:1 Pro Gun Assembly CPD-4000-RK Repair Kit 1:1 Pro Gun Assembly CPD-5000-A-RK Repair Kit Auto 1:1 Pro Gun Assembly CPD-5000-RK Repair Kit 1:1 Pro Gun Assembly CPD-5000-SILO-RK Repair Kit 1:1 Pro Gun Assembly CPD-5000-SNZ-RK Repair Kit 1:1 Pro Gun Assembly CPD-6000-A-RK Repair Kit Auto 1:1 Pro Gun Assembly CPD-6000-RK Repair Kit 1:1 Pro Gun Assembly 58744-1 Repair Kit 1:1 Pro Gun Block Assembly 58744-1-INT Repair Kit 1:1 Pro Gun Block Assembly - International
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Tools required
You will need the following tools:
Rubber mallet Removable Thread Lock Compound Adjustable wrench Needle-nose pliers Flat-end screwdriver Lubriplate™ lubricant (08465)  Scribe set (08126) Pro Gun ™ Oil (04394)  Turbulent Mixer Puller (6705-2-1) Seal Installation tool (58661-1) Alignment tool for resin seals (58663-1) Pro Gun ™ screwdriver (9301-3-2) and packing bit (6705-1-1)
You should also have appropriate cleaning materials such as solvent, clean shop towels or rags, a small brush, and empty containers into which you will flush the gun.
Also, you will need the appropriate Seal kit for the gun you have and other items that may need to be replace the current ones in the Pro Gun™. Please refer to the parts drawings to obtain proper parts numbers for the o-rings and seals to be replaced.
Note: If you are using o-ring part number 01128 in the gun block, you do not need to replace the o-ring unless it is showing obvious signs of wear. This o-ring is specially designed to handle most solvents.
DANGER: To prevent accidental injection injury, disconnect all air and electrical power to the unit before beginning repair or maintenance on this equipment.
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Release System Pressure
1. Properly Flush and remove the mixer and nozzle from the front of the gun.
2. Turn OFF air supply to pumping system (pump pressure to zero).
3. Release fluid pressure from lines by holding the gun over an appropriate empty container and pulling the trigger.
4. Flush gun into appropriate container
5. Turn OFF air supply to the solvent tank.
6. Release any pressure in the flush tank by gently pulling upwards on the ring attached to the pressure relief valve.
7. Place an empty container under the ball valve located at the bottom of the filter assembly.
8. SLOWLY open the ball valve, you can leave the ball valve open or close it when all the pressure has been released.
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Gun Disassembly:
WARNING: To prevent injury, be sure all air is disconnected from the gun and that all pressure has been relieved before attempting to remove trigger guard.
Note: The bolt that secures the trigger guard to the air cylinder also serves as a plug for the end cap. Removing this bolt can result in injury from escaping pressurized air if air pressure is not relieved.
Note: The automatic versions of the Pro Gun do not have a handle; instead have a mounting plate attached to the bottom of the actuator.
1. Check to be sure all air is disconnected from the gun
2. Be sure all pressure is relieved from the gun.
3. Disconnect the trigger guard by using a wrench to remove the nut securing the top of the trigger guard to the end cap on the gun’s actuating cylinder.
Disassemble Gun into Modules
Note: If your Pro Gun™ is used for chopping, perform the two steps, A and B:
A. Detach the chopper assembly by removing the air tube that connects the
chopper to the gun handle.
B. Remove the hex cap screw securing the chopper to the top of the gun block. Use
caution not to lose the eccentric stud in the chopper mount.
1. Remove the four screws that secure the gun block to the actuator. Set gun block aside for now
2. Remove the two mounting screws which secure the handle to the actuator. For the automatic version remove the Mounting plate (58704-1).
3. You have now disassembled the gun into modules. Next you will disassemble, clean, and reassemble each module.
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FLUSH BODY
PUSH STEM
O-RING
BACK-UP RING
GRIP RING
SPRING
FLUSH VALVE BODY
HOSE CLAMP
BARBED FITTING
SEAL
Remove & Disassemble Flush Valve Assembly
1. Unscrew the flush valve body from the gun block.
2. Remove the split seal from the flush valve body.
3. Remove the flush valve body from the flush valve neck.
4. Remove the flush valve seal from the flush valve body.
Note: For systems without Auto/Manual flush assemblies skip steps 5 - 7
5. Unscrew the auto/manual flush body assembly from the flush valve body.
6. Remove the grip ring from the push stem of the auto/manual flush body assembly. Use caution not to lose the spring in the flush body.
7. Remove the back-up ring and o-ring from the push stem.
8. Unscrew the flush seal body (5104-23-1) from the flush valve button (5104-25-01).
9. Remove the spring (9203-2-3).
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FLUSH VALVE BODY -
AUTO/MANUAL
SPRING
SEAL
O-RING
O-RING
FLUSH SEAL BODY
FLUSH VALVE NECK
FLUSH VALVE BUTTON
SPLIT SEAL
FLUSH VALVE BODY
10. Use a scribe to remove the o-ring (O-K-008) from the flush valve button.
11. Remove the o-ring (O-A-007) from the flush seal body (5104-23-1).
12. Set parts aside for now or go down to flush valve assembly
13. Discard and replace the flush valve’s o-rings and seals, after reading the note below.
Note: Do not replace o-ring (O-K-008) unless it is worn or damaged. This o-ring is designed for use with all solvents. In some cases O-K-008 o-ring can be replaced
with the more economical o-ring (O-E-008).
Remove Actuating Stem
1. Unscrew the actuating stem from the valve rod. Tightly clamp the actuating stem into a soft jawed vise and rotate the whole gun block.
Note: The screw driver slot in the end of the actuating stem should not be used for removal as if it becomes damaged the stem will not fit into the actuator bushing. Make sure the actuating stem is smooth or it will wear out the actuator bushing.
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ACTUATOR STEM
Remove Mix Housing
1. Remove the Nozzle cap or Mixer assembly from the Mix housing.
2. Use the turbulent mixer puller to remove the turbulent mixer by inserting the
puller and giving a slight twist. (if applicable to this unit)
3. Remove the Plugs (58696-1) and Seals (58695-1) from the Mix housing.
4. Remove the Springs (04319) and Balls (03199) from the Mix housing.
5. Remove the Plugs (7102-5-6) and Seals (02441-1) on the side of the mix chamber.
6. Remove the four Screws (02959-5) from the Mix housing (58692-3) and remove the Mix housing (58692-3) from the gun block.
7. Remove the Face Seals (58694-1)
8. Inspect and clean the Mix housing
NOTE: Putty systems using BPO do not use 04319 (spring) and 03199 (ball) on the putty side of the gun block.
Remove Hose Fittings
1. Remove and clean the Hose fitting and O-ring on the rear of the gun block. See
Remove Valve Rod
1. Remove the Actuating stem (5104-11-1) from the Valve rod (58693-1), if this has
2. Remove the two Packing nuts (5104-8-1) located on each side of the gun block.
“Gun Fitting” document in the back of this manual for fitting numbers.
not already been done.
Clean the packing nut threads.
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PACKING NUT
VALVE ROD
SEAL INSTALLATION TOOL
CENTER SPACER
Remove Center Spacer
1. Use needle-nose pliers to remove the Center spacer (5104-10-1).
Remove Seals
1. Insert the seal installation tool into one of the side ports and gently tap it completely through the gun block with a rubber mallet or hammer. As the tool is tapped through the interior of the gun block it will remove the seal sets for both sides of the gun block.
2. Remove Seals (relief spacer and secondary seal) from the seal installation tool. Clean with solvent.
CAUTION: Keep the components of the A side separate from the components of the B side. Mixing the components could result in cross-contamination.
3. Clean the two Relief spacers (5104-4-1) with solvent and allow to air dry.
4. Discard the seals and replace with new ones from repair kit.
Prepare the repair kit and any items that need replacing on hand before continuing. Lay all the parts out and check for any damage or wear and replace as necessary.
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Gun Block Assembly:
Clean Block Assembly
Discard o-rings and seals that are going to be replaced. Clean remaining components with solvent and allow to air dry.
Install Secondary Seals
1. Place the two Secondary seals (5104-3-1) into the center of the gun block where the center spacer goes. Gently push the secondary seal into position with something flat, flat to the gun block. Use caution not to damage it the seal.
Secondary Seals
Center Spacer
Reinstall Center Spacer
1. Place the Center spacer (5104-10-1) in the gun block, making sure that the center spacer is aligned as accurately as possible with the slot facing up. Use caution not to damage the secondary seals, already installed
Reassemble Seal Components
1. Place the catalyst components onto the seal installation tool in the following order:
Packing ring (5104-7-1) Seal (5104-6-1) Relief spacer (5104-4-1)
Note: The hole in the seal should be aligned with the port hole in the gun block before inserting the seal installation tool into the gun block.
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Valve Rod
Relief Spacer Packing Nut Resin Seal Packing Ring Packing Ring Resin Seal Packing Nut Relief Spacer
2. Insert the seal installation tool with the components on it into the side of the gun block. Press firmly, or tap with a rubber mallet, then pull the packing tool out of the gun block.
Note: Again before inserting the seal installation tool, align the holes in the seal with the holes in the gun block as closely as possible.
3. The components should be seated in the interior of the gun block against the center spacer.
4. Gently screw a packing nut (5104-8-1) into the side of the gun block. Do not tighten.
Repeat this process for the other side of the gun block.
Align Seals
1. Hold the Seal alignment tool (6705-4-1) (tapered drill bit) firmly with a pair of pliers.
2. Insert the Seal alignment tool (tapered end first) into the gun block through the fitting port at the rear of the gun block
3. Gently press and move the alignment tool around until the holes in the Seal aligns with the hole / port in the gun block.
Note: At this point, the packing nut should not be tight.
Repeat this process on both sets of seals.
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Install Valve Rod
1. Insert the Valve rod (58693-1) into the gun block. Use the seal installation tool to center the valve rod.
Note: Make sure that the valve rod is correctly aligned. The slotted end of the valve rod should be on the left side of the gun block with the hole for the actuating stem pointing down. The middle hole, into which the actuating stem will be inserted, must also be correctly aligned. One end of the hole has a relief; and this relief should face out of the gun block, as this is where the actuating stem will be installed.
Reinstall Actuating Stem
1. Screw the Actuating stem (5104-11-1) into the Valve rod (58693-1) thru the center spacer.
Note: Make sure the actuating stem is screwed into the side of the valve rod with the larger hole (thread relief).
2. Look down the front of the gun while moving the actuating stem back and forth. You should be able to see the holes open and close. The holes should be open when the actuating stem is at the back of the gun block and closed when the actuating stem is forward towards the front of the gun block.
Tighten Packing Nuts
1. Tighten both packing nuts. Do not damage the packing bit
2. Move the actuating stem back and forth, opening and closing the gun.
3. Again tighten both packing nuts.
4. Repeat the above tightening process one more time
Reinstall Hose Fittings
1. Reinstall the appropriate fitting and o-ring into the rear of the gun block in both locations.
Rev. 05/2012 Page | 26
FLUSH VALVE BODY -
AUTO/MANUAL
SPRING
SEAL
O-RING
O-RING
FLUSH SEAL BODY
FLUSH VALVE NECK
FLUSH VALVE BUTTON
SPLIT SEAL
FLUSH VALVE BODY
Reassemble Flush Valve
1. Place the o-ring (O-K-008) on the flush valve button (5104-25-1).
2. Insert the spring (9203-2-3) onto the flush valve button.
3. Push the button and spring into the flush valve body (5104-24-1).
4. Place the o-ring (O-A-007) on the flush seal body (5104-23-1).
5. Insert the flush seal body (5104-23-1) into the end of the flush valve body and screw it onto the button.
6. Place a flush valve seal (5104-26-1) on the flush valve body.
7. Install the flush valve body (5104-24-1) into the flush valve neck (5104-22-1).
8. Install the split seal (5104-21-1) onto the flush valve body (5104-24-1).
Note: For systems without Auto/Manual flush assemblies skip steps 9 - 13
Rev. 05/2012 Page | 27
FLUSH BODY
PUSH STEM
O-RING
BACK-UP RING
GRIP RING
SPRING
FLUSH VALVE BODY
HOSE CLAMP
BARBED FITTING
SEAL
9. Install the spring and push stem into the flush body.
10. Install a new o-ring onto the end of the push stem sticking out of the flush body.
11. Install the back-up ring onto the end of the push stem against the new o-ring.
12. Install the grip ring onto the end of the push stem.
13. Thread the auto/manual flush body assembly into the flush valve body.
14. Screw the flush valve assembly (5104-01-01) into the front side port on the resin side of the gun block
Note: If using o-ring part number O-K-008 (o-ring is used on the flush button), you do not need to replace the o-ring unless it is showing obvious signs of wear or damage. This o-ring is specially designed for use with all solvents.
Note: In some cases O-K-008 o-ring can be replaced with the more economical o­ring (O-E-008).
Assemble Mix Housing
1. Install the new Face seals (58694-1) into the front of the gun block.
2. Mount the Mix chamber (58692-3 or DUO-4101) to the gun block using the four Cap screws (FS-832-10-GR8).
Note: the hardener side of the mix chamber is marked with an “H” and the mix chamber should be mounted so that the hardener side is on the right hand side of the gun.
Rev. 05/2012 Page | 28
3. Install the proper Restrictor into the Hardener side of the gun block through the side port.
4. Using a new Seal (02441-1) install the Plug / Screw (7102-5-6) into the side of the mix chamber.
5. Install the Ball (03199) and Spring (04319) into the front ports of the mix chamber
6. Using a new Plug Seal (58695-1) install the Plug (58696-1) into the front of the mix chamber on top of the spring.
Mix Housing Options
Mix Housing (58692-1) – Use with all turbulent mixers and most
applications.
Mix Housing (DUO-4101) – Use with disposable mixer
assemblies (07550 3/8 ID Disposable mixer or 07551 1/4 ID Disposable mixer) for Pour or Spatter applications.
Ratio Housing (DUO-4201) – Use to separate the two streams
(Catalyst & Resin) – Check ratios & recirculation.
Turbulent Mixer Selection
There are two different turbulent mixers, in two different materials.
Standard Turbulent Mixer 5107-27-3 – Use for most applications where
outputs are not critical. Use with chopper and saturator applications.
Critical Mix Turbulent Mixer 5107-27-2 – Use for low output applications such
as gel coat. In low flow application the critical mix turbulent mixer will work best.
Glass Filled Critical Mix Turbulent Mixer 5107-27-5 – Use in low flow
applications where the material is abrasive and durability is required.
Rev. 05/2012 Page | 29
Actuator Rebuild:
1. Remove the two O-rings (O-V-013) from the underside of the Cylinder body (58631-1).
2. Unscrew the Cylinder caps (5106-4-1) from each end of the cylinder body.
3. Remove the O-ring (O-V-020) from each of the cylinder caps
4. Remove the Actuating piston (5106-7-1) by pushing it out the back end (long end) of the cylinder body with your fingers or a blunt tool.
5. Remove the actuating bushing (5106-5-1) from the piston.
CAUTION: Avoid damaging the actuating piston when using the scribe in the next step.
6. Use a scribe to remove the o-ring (O-V-020) from the actuating piston.
Note: O-rings should be replaced each time the gun is disassembled.
Clean Components
Discard the used o-rings Clean the cylinder assembly components with solvent and allow to air dry. Do
not soak actuating piston or cylinder caps in solvent as they will swell.
Assemble Classic Pro Gun Actuator Cylinder
1. Place a new o-ring (O-V-020) on the actuating piston (5106-7-1).
2. Insert the actuating bushing (5106-5-1) into the actuating piston.
Note: The hole in the actuating bushing must be facing up so the bushing hole can receive the actuating stem when the gun block is assembled.
3. Use MVP Pro Gun Oil (6706-3-1) to lubricate the interior of the cylinder body and the actuating piston.
Rev. 05/2012 Page | 30
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