Magnum Venus Plastech EMG-1500 User Manual

EXTERNAL MIX

GEL COAT GUN

Repair Manual

EMG-1000 & EMG-1500

MAGNUM VENUS PLASTECH

GEL COAT GUN REPAIR MANUAL Rev. 04/04/2007

EMG-1000 & EMG-1500 Gel Coat Gun Manual

TABLE OF CONTAINS:

WARNING AND SAFETY INFORMATION

CHAPTER 1 – GUN DISASSEMBLY AND ASSEMBLY
CHAPTER 2 – GUN BLOCK AND HANDLE ASSEMBLY
CHAPTER 3 – GUN ADJUSTMENT AND START UP
CHAPTER 4 – TROUBLESHOOTING
CHAPTER 5 – PARTS DRAWINGS

AIRLESS EQUIPMENT SAFETY

Injection Hazard

• DO NOT POINT THE GUN AT ANY PERSON

• NEVER LOOK AT THE GUN FROM THE FRONT (NOZZLE END)

• NEVER trigger an airless gun while it is aimed at a person. The hydraulic pressure

may inject fluid into the flesh, causing injury or death. If the fluid penetrates the skin it
WILL cause serious injury. Clothing, such as gloves will NOT provide protection. The
system is capable of fluid pressure high enough to cause a LETHAL INJECTION.

• TREAT THE APPLICATOR AS YOU WOULD A LOADED WEAPON.

Before applying pressure to the system, ALWAYS:

• Follow the manufacturer’s operating instructions and maximum pressure

recommendations.

• Secure the trigger in the OFF position and check all pressure connections.

• Use grounded, high pressure fluid lines.

• Check that the pump is properly grounded.

Before disassembly of ANY part of the pressure system (including the applicator or its
nozzle) ALWAYS:

• Shut the pump OFF.

• Discharge the residual fluid and pressure from the applicator.

• Secure the trigger in the OFF position.

Follow these same three procedures anytime that operation is discontinued.
Do NOT undertake any of the following until pressure is relieved from the entire system:

• Loosen or remove the nozzle.

• Disassemble any part of the applicator.

• Loosen or disconnect any fluid line fittings.

• Disassemble any part of the pump.

Be sure that the power to the pump is OFF before undertaking ANY repair, maintenance
or adjustment.

If it is necessary to adjust or clean the nozzle on site, be sure that it is aimed away from
all personnel so that it may discharge safely if there is residual pressure in the system.

Do NOT use any replacement part that does not meet the manufacturer’s specifications.
Correct packing or valve seal leaks IMMEDIATELY.
Frequently check the condition of all pressurized components, especially fluid lines.

Replace worn lines and parts before they fail.
If nozzle clogging occurs frequently, use a fluid filter with proper mesh size.

PUMPING SYSTEM SAFETY INSTRUCTIONS

Use MVP replacement parts to assure compatible pressure rating. Read ALL warning
and safety instructions carefully before operation of this unit. Heed all warnings.

WARNING: Never allow any part of the human body to come in front of, or in

direct contact with, the material outlet. Accidental operation of the pump could cause an
injection into the flesh. If injection occurs, medical aid must be immediately obtained
from a physician.

Component Rupture: This unit is capable of producing high fluid pressure as stated on
the pump model plate. To avoid component rupture, and possible injury, do not exceed
75 cycles per minute or operate at an air inlet pressure greater than 150 PSI (10 bar).

Servicing: Before servicing, cleaning or removing any component, ALWAYS
disconnect or shut off power source and carefully relieve all fluid pressure from the
system.

CAUTION: When pumping, flushing or recirculating volatile solvents, the area must
be adequately ventilated.

CAUTION: Materials and solvent being pumped must be compatible with the parts of
the pump that becomes wetted when in contact with material or solvent. Wetted parts
consist of the following: stainless steel, copper, brass, steel, gray iron, leather, Teflon
and Velluloid.

CAUTION: Keep solvents away from heat, sparks and open flames. Keep containers
closed when not in use.

Prevent Static Sparking: If static sparking occurs, fire or explosion could result. The
pump, dispensing valve, and containers must be grounded when handling flammable
fluids such as solvents, paints, lacquers, etc., and wherever discharge of static
electricity is a hazard.

Use grounded hoses (static wire) and be sure the object being serviced is grounded if it
can produce a static charge.

Continuity (a good static wire connection) of a hose can be checked by using an
ohmmeter. Place one probe on one hose fitting and the other probe on the other hose
fitting, continuity or proper grounding through hose is good when a reading is obtained
on the ohmmeter.

Air and Lube Requirements: Excessive air pressure will shorten the life of the pump.
Do not operate pump above recommended maximum air pressure. If necessary, an air
regulator should be installed to maintain the desired pressure when the pump is in
operation.

Filtered air will allow the pump to operate more efficiently and yield a longer life to
operating parts and mechanisms.

A filter capable of filtering particles larger than 50 microns should be used.
Maintenance: If the pump is to be inoperative for a lengthy period of time (even for a

few hours) disconnect air and relieve all pressure from system.
Periodically flush pump with a solvent that is compatible with the material being

pumped. Pour a little throat seal lubricant into the solvent cup to keep upper packings
pliable and to keep material drag-thru soft. Material drag-thru that is allowed to harden,
will score the piston rod. This will create excessive leakage and rapid packing wear.

Disassembly should be done on a clean work bench with clean cloths to keep parts
clean.

If replacement parts are necessary, consult Parts List for identification.
Before assembling, lubricate parts where required. When assembling O-rings, or parts

adjacent to O-rings, care must be exercised to prevent damage to O-ring and O-ring
groove surfaces.

If you have any questions about safety or procedures, contact your Magnum Venus
Plastech’ representative.

CAUTION: Materials and solvent being pumped must be compatible with the parts of
the pump that becomes wetted when in contact with material or solvent. Wetted parts

consist of the following: stainless steel, copper, brass, steel, gray iron, leather, Teflon
and Vellumoid.

CAUTION: Keep solvents away from heat, sparks and open flames. Keep containers
closed when not in use.

Important safety information –

HAZARD

CAUSE

SAFEGUARD

Fire

Solvent and coatings can be highly
flammable or combustible, especially
when sprayed.

Adequate exhaust must be provided to keep
air free of accumulations of flammable
vapors.
Smoking must NEVER be allowed in the
spray area.
Fire extinguishing equipment must be present
in the spray area.

Solvent

During cleaning and flushing, solvents
can be forcefully expelled from fluid
and air passages. Some solvents can
cause eye injury.

Wear eye protection.

Inhaling Toxic
Substances

Certain materials may be harmful if
inhaled or if there is contact with skin.

Follow the requirements of the Material
Safety Data Sheet supplied by your coating
material manufacturer.
Adequate exhaust must be provided to keep
the air free of accumulations of toxic
materials.

Explosion Hazard –
Incompatible
Materials

Halogenated hydrocarbon solvents
(for example; Methylene chloride and
1,1,1-Thrichloroethane) can
chemically react with aluminum. The
chemical reaction caused by these
solvents reacting with aluminum can
become violent and lead to an
equipment explosion.

Guns with Stainless Steel internal
passageways may be used with these
solvents. However, aluminum is widely used
in other spray application equipment – such
as material pumps, regulators, valves & cups.
Check all equipment items before use and
make sure they can also be used safely with
these solvents. Read the label or data sheet
for the material you intend to spray. If in
doubt as to whether or not a coating or
cleaning material is compatible, contact your
material supplier.

General Safety

Improper operation or maintenance of
equipment.

Operators should be given adequate training
in the safe use & maintenance of the
equipment (in accordance with the
requirement of NFPA-33 Chapter 15). Users
must comply with all local & national codes of
practice and insurance company
requirements governing ventilation, fire
precaution, operation, maintenance and
house keeping. These are OSHA Section

1910.94 and 1910.107 and NFPA-33. Risk is
reduced by avoiding or lessening factors 1-7.

All equipment must be grounded for static electricity in accordance with NFPA-77. Be sure to relieve all
pressure from system before performing any maintenance. Spray equipment shall be used in spray
areas in accordance with NFPA, OSHA and Country/State/local requirements.

The below potential hazards may cause an injury or loss of life

WARNING

Static Spark

Can Cause explosion resulting severe injury
or death.

Ground pump and pumping
system

Injection Hazard

Any material injected into flesh can cause
severe injury or death.

Keep body parts away from
outlet device. If an injection
occurs, immediately obtain
medical attention.

Hazardous
pressure

Sudden pressure release can cause severe
injury or death.

Pumping system can remain
pressurized when pump is not
operating.

Excessive inlet
pressure

Can cause severe injury or death

Do not exceed the maximum inlet
pressure as stated on the model
plate.

INSPECTION AND MAINTENANCE OF UNIT

1) Check solvent cup to be sure it is 1/3 full.

2) Check catalyst and material levels.

3) Inspect material spray tip and o-ring. Replace if necessary.

4) Inspect catalyst tip assembly and o-rings. Replace if necessary.

5) Inspect tip pin o-rings on front of gun head and replace if nicked or worn.

6) Assemble catalyst tip and material tip onto gun.

7) Lubricate threads on retaining ring and assembly onto gun.

8) Inspect hose assemblies and connections for leaks and wear and tear. Replace if
necessary. Do not wait until hose is so worn that it may burst.

9) Check roving quantity (if applicable).

10) Inspect and replace if necessary:
a) Chopper Blades
b) Anvil Sleeve
c) Cutter Head Bearing
d) Idler Bearing

11) Inspect and adjust if necessary:
a) Cutter head to Anvil Sleeve tension
b) Idler Bearing to Anvil Sleeve tension
c) Check Chopper position for most efficient disbursement of chop into spray

pattern.

12) Oil Cutter assembly Air Motor with Magnum Air Motor Oil as necessary (normally 2 –
3 drops daily, depending on usage).

PREPARATION AND PRIMING OF “NEW” SYSTEM

1. Be sure all air regulators are turned completely to the left, shutting off air to the

components.

2. Slowly open main air.

3. Prime empty catalyst line:

a. Disengage catalyst pump
b. Open ball valve on catalyst manifold (if applicable)
c. Eliminate air pockets by manually hand pumping the catalyst 5-10 short

strokes (2-3 in.). After eliminating air pockets, and while continuing to
hand pump, close ball valve on catalyst manifold.

d. Pull and hold trigger on gun while hand pumping catalyst pump with short

strokes until there is a solid, steady catalyst flow from the head of the gun.
This will ensure that all air is purged from the line. Release trigger.

e. Continue to hand pump the catalyst with short strokes until catalyst is fully

primed and pressurized (generally within 5 additional strokes or less).

NOTE: Do NOT engage slave pump until material pump has been primed.

4. Material Pump: (be sure catalyst pump is disengaged) Place a container or

bucket under ball valve located at the bottom of the resin filter assembly to catch
material while priming. Open ball valve. Slowly bring up pressure on material
pump regulator just enough to allow pump to stroke up and down evenly. After a
smooth flow of material is flowing from the valve, turn regulator off and close the
valve.

5. Pull trigger on gun and allow gun to hang above waste container. Slowly bring up

pump pressure again to allow material to flow out of gun. Release trigger to close
gun. Pump will cycle until it is fully primed and then will stall out.

6. Engage slave pump.

PREPARATION AND PRIMING OF PREVIOUSLY USED

(shut down) SYSTEM

1. Slowly open main air.

2. Material Pump: (be sure catalyst pump is disengaged) Place a container or

bucket under ball valve located at the bottom of the resin filter assembly to catch
material while priming. Open ball valve. Slowly bring up pressure on material
pump regulator just enough to allow pump to stroke up and down evenly. After a
smooth flow of material is flowing from the valve, turn regulator off and close the
valve.

3. Catalyst Slave Pump:

a. Disengage slave pump.
b. Open ball valve of catalyst manifold (if applicable).

c. Eliminate all air pockets in feed lines by manually pumping catalyst pump
until catalyst exits ball valve. Close ball valve.

e. Open gun by pulling trigger and continue hand pumping until catalyst exits
gun.

f. Leave Catalyst Pump disengaged.

4. Pull trigger on gun and allow gun to hang above waste container. Slowly bring up

pump pressure again to allow material to flow out of gun. Release trigger to close
gun. Pump will cycle until it is fully primed and then will stall out.

6. Engage slave pump.