Magnum Venus Plastech FRP-3102-00-01 User Manual

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FRP SystemOne

3102-00-01 Gelcoat Fluid Section

MAGNUM VENUS PRODUCTS

Maintenance & Repair Manual

Part No. M3102-00-01

Revision 05.30.01

FRP SystemOne

Gelcoat

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FRP SystemOne

Maintenance & Repair Manual

Gelcoat Fluid Section Module

FRP SystemOne Gelcoat

MVP Venus

Phone: (253) 854-2660 (800) 448-6035

Fax: (253) 854-1666

Email: info@venusmagnum.com

Web: www .venusmagnum.com

MVP Magnum

Phone: (727) 573-2955

Fax: (727) 571-3636

Email: info@magind.com

Web: www .magind.com

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T able of Contents

FRP SystemOne

Maintenance & Repair Manual

Gelcoat Fluid Section Module

CHAPTER 1 - GETTING ST ARTED T ools Required

CHAPTER 2 - INSTRUCTIONS Disassembly of Fluid Section

CHAPTER 3 - INSTRUCTIONS Reassembly of Fluid Section

CHAPTER 4 - APPENDIX Fluid Section Part Drawings

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Gelcoat

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Chapter

FRP SystemOne Gelcoat Fluid Section

Getting Started

Tools Required

1. ¾” open end wrench

2. ¼” wooden dowel-6”

3. ¼” metal rod

4. 12” adjustable wrench

5. Strap wrench

6. Spanner or Ford wrench

7. 9/16” Open End W rench

8. Pliers

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Chapter

SystemOne Disassembly of FS1.29S1 Gelcoat Fluid Section

WARNING

When removing Resin Pump Fluid Section and Resin Surge Chamber, be sure to bleed pressure from the system before disconnecting hoses or tie rods. Release Surge Chamber charge before removing Surge Chamber. System may be under pressure and could cause injury.

NOTE

The resin pump can be rebuilt in place or easily removed from pump column and moved to a workbench.

To remove the Fluid Section from the SystemOne Unit:

1. Remove the 8401-5-1 (E-Ring), lift up the 8401-4-1 (Sleeve) and remove the two 8401-3-1 (Connectors).

2. Remove the 4103-1-1 (Pivot Pin Guide Bushing) to disengage from the 4103-7-1 (Slide Arm).

3. Remove the 7203-8-1 (Quick Pin) and slide the 4103-7-1 (Slide Arm) out of the 3101-8-1 (Piston Rod Adapter).

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Gelcoat

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Fluid Section Disassembly Procedures:

1. Remove the two 7101-3-52 (Hex Head Bolts) from the 3102-6-1 (Outlet Body).

2. Slide the 3102-18-1 (Foot Valve Collar), 3102-17-1 (Foot Valve Body) and 3102-14-1 (Cylinder) down off the 3102-7-01 (Piston Rod), discard the two 7301-3-129 (O-Rings).

3. Remove the 3102-15-1 (Ball Stop), 3102-20-1 (4 Lobed Ball Guide) and 9201-2-24 (3/4” Chrome Ball). Discard the Chrome Ball.

4. Clean and inspect the ball seat area of the 3102-17-1 (Foot Valve Body).

5. Loosen 3102-1-1 (Packing Nut) and slide the 3102-7-01 (Piston Rod) out through the bottom of the 3102-6-1 (Outlet Body).

6. Unscrew the 3102-13-1 (Piston Body) from the 3102-7-01 (Piston Rod). Remove the 9021-3-16 (1/2” Chrome Ball) and the 3102-8-1 (Piston Ball Spring). Discard the 1/2” Chrome Ball.

7. Slide the 3102-9-1 (Piston Cup Comp Ring), the two 3102-10-1 (Piston Cups), 3102-11-1 (Piston Cup Spacer) and the 3102-12-1 (Piston Cup Backup) from the 3102-13-1 (Piston Body). Discard the Piston Cups.

8. Remove the 3102-1-1 (Packing Nut) from the 3102-6-1 (Outlet Body). Use a 1/4” Wooden Dowel to push the 3102-2-1 (Guide Bearing), 3102-3-1 (Female Comp Ring), 3102-4-01 (Packing Set Assy), 3102-5-1(Male Comp Ring) and 9203-1-2 (Wave Spring Assy) through the top of the 3102-6-1 (Outlet Body). Discard the Packing Set Assy.

9. Clean and inspect all parts that will be reused, replace as needed.

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Chapter

SystemOne Reassembly of FS1.29S1 Gelcoat Fluid Section

1. Insert the ten 9203-1-2 (Wave Springs) into the 3102-6-1 (Outlet Body).

2. Use Venus-Gusmer 6706-2-1 (White Grease) to fill the female side of each of the four 3102-4-01 (Packings) and the 3102-3-1 (Female Comp Ring).

3. Place the 3102-4-01 (Packing Set Assy) on top of the 3102-5-1 (Male Comp Ring). Set the 3102-3-1 (Female Comp Ring) on to of the Packing Set. Insert this assembly into the 3102-6-1 (Outlet Body) with the female side of the packings facing down. See fig. 3.1.

Fig. 3.1

Packing Set

Female Comp Ring

3102-3-1

Piston Rod Pack Spa

3102-4-01

Male Comp Ring

3102-5-1

{

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Gelcoat

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4. Wipe a light coating of 6706-2-1 (White Grease) onto the 3102-2-1 (Guide Bearing) and insert into the 3102-6-1 (Outlet Body). Screw the 3102-1-1 (Packing Nut) into the Outlet Body only two or three threads.

NOTE

Do not tighten the 3102-1-1 (Packing Nut) at this time.

5. Smear 6706-2-1 (White Grease) on the inside both 3102-10-1 (Piston Cups).

6. Install the 3102-12-1 (Piston Cup Backup) onto the 3102-13-1 (Piston Body) with the side with the ridges facing up. Next install one of the 3102-10-1 (Piston Cups) followed by the 3102-11-1 (Piston Cup Spacer) followed by the second Piston Cup, followed by the 3102-9-1 (Piston Cup Comp Ring). See fig. 3.2.

Piston Cup Comp Ring

3102-9-1

Fig. 3.2

Piston Cup

3102-10-1

Piston Body Detail

Piston Cup Spacer

3102-1 1-1

Piston Cup Backup

3102-12-1

7. Install the 3102-8-1 (Piston Ball Spring) over the 7203-2-10 (Dowel Pin) inside the 3102-7-01 (Piston Rod). Put a light coating of 67062-1 (White Grease) on the 9201-3-16 (1/2” Chrome Ball) and install over the Piston Ball Spring.

NOTE

Do not drop, dent or scratch the 9201-3-16 (1/2” Chrome Ball).

8. Coat the threads of the 3102-13-1 Piston Body and screw it into

the 3102-7-01 (Piston Rod). Tighten “wrench tight”.

9. Check the 3102-7-01 (Piston Rod) for burrs, scratches or other

damage and replace if necessary . Slide the Piston Rod up through the Packing assembly in the 3102-6-1 (Outlet Body). Be careful not to damage the Packing set assembly .

10. Tighten the 3102-1-1 (Packing Nut) enough to hold the Piston Rod

in place.

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11. Lightly coat the 9201-2-24 (3/4” Chrome Ball) with 6706-2-1 (White Grease) and install it and the 3102-20-1 (4 Lobed Ball Guide) into 3102-17-1 (Foot V alve Body).

12. Compress the 3102-15-1 (Ball Stop) and insert it into the groove of the 3102-17-1 (Foot V alve Body)

13. Lightly coat the two 7301-3-129 (O-Rings) and install one in each end in the grooves on the 3102-14-1 (Cylinder). Insert one end of the Cylinder into the 3102-17-1 (Foot Valve Body).

14. Slide the 3102-14-1 (Cylinder) with the 3102-17-1 (Foot Valve Body) over the Piston Rod Assembly.

15. Lightly coat the threads of the 7101-3-52 (Hex Head Bolts) with lithium grease and thread through the 3102-18-1 (Foot Valve Collar). Screw the Hex Head Bolts, into the 3102-6-1 (Outlet Body) Tighten uniformly until “wrench tight”.

16. Use a 1/4” metal rod or Phillips screwdriver to tighten the 3102-1-1 (Packing Nut). Do not over tighten.

NOTE

3102-1-1 (Packing Nut) only needs to be tightened snug enough to put pressure on the 3102-4-01 (Packing Set Assy). The Packing Nut should only be adjusted when there is NO fluid pressure load in the fluid section.

To Reinstall Fluid Section onto SystemOne Gelcoater Unit:

17. Fasten the 3102-00-01 (FS1.29S1 Fluid Section Assy) to the 110502-01 (Pump Mount Plate Assy) using the four 7101-2-12 (Hex Head Bolts).

18. Position the 8401-4-1 (Sleeve) over the Power Cylinder Piston Shaft. Bring the Power Cylinder Piston Shaft down onto the top of the 3101-8-1 (Piston Rod Adapter). Insert the two 8401-3-1 (Connectors) then lower the sleeve over the Connectors. Install the 8401-5-1 (E-Ring) into the machined groove.

19. Slide the end of the 4103-7-1 (Slide Arm) into the slot in the 31018-1 (Piston Rod Adapter) and insert the 7203-8-1 (Quick Pin).

20. Fill the Packing Nut cavity 1/2 to 2/3 full with appropriate oil.

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Gelcoat

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