Magnum Venus Plastech FRP-4102-00-01 User Manual

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FRP SystemOne

4102-00-01 Metering Pump

MAGNUM VENUS PRODUCTS

Maintenance & Repair Manual

Part No. M6704-2-1

Revision 06.25.01

FRP SystemOne

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FRP SystemOne

Maintenance & Repair Manual

Metering Pump Module

FRP SystemOne

MAGNUM VENUS PRODUCTS

1862 Ives A venue, Kent, WA 98032 USA

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

Fax: (253) 854-1666

Email: info@venusmagnum.com

Web: www .venusmagnum.com

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T able of Contents

FRP SystemOne

Maintenance & Repair Manual

Metering Pump Module

CHAPTER 1 - GETTING ST ARTED T ools Required

CHAPTER 2 - INSTRUCTIONS Disassembly of Metering Pump

CHAPTER 3 - INSTRUCTIONS Disassembly of Catalyst Surge Chamber

CHAPTER 4 - INSTRUCTIONS Reassembly of Metering Pump

CHAPTER 5 - INSTRUCTIONS Reassembly of Catalyst Surge Chamber

CHAPTER 6 - APPENDIX Parts Drawings

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Chapter

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Metering Pump Getting Started

Tools Required

1. 1” Open End Wrench

2. 3/4” Open End Wrench

3. 5/8” Open End Wrench

4. 6” Adjustable Wrench (2 required)

5. 12” Adjustable Wrench

6. 1/4” Wood Dowel – 6” long

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Chapter

FRP SystemOne

Disassembly of Metering Pump

WARNING

Before removing Metering Pump and Surge Chamber assemblyBefore removing Metering Pump and Surge Chamber assembly

Before removing Metering Pump and Surge Chamber assembly

Before removing Metering Pump and Surge Chamber assemblyBefore removing Metering Pump and Surge Chamber assembly from the Slide Drive, be sure to bleed the fluid pressure from thefrom the Slide Drive, be sure to bleed the fluid pressure from the

from the Slide Drive, be sure to bleed the fluid pressure from the

from the Slide Drive, be sure to bleed the fluid pressure from thefrom the Slide Drive, be sure to bleed the fluid pressure from the

system; before disconnecting any hoses or tubes. System may besystem; before disconnecting any hoses or tubes. System may be

system; before disconnecting any hoses or tubes. System may be

system; before disconnecting any hoses or tubes. System may besystem; before disconnecting any hoses or tubes. System may be

under prunder pr

under pr

under prunder pr

essuressur

e and could cause injure and could cause injur

essur

e and could cause injur

essuressur

e and could cause injure and could cause injur

1. Remove 4101-15-1 (Check V alve Body) from 4101-14-1 (Outlet Body) and remove and discard the two 7301-4-013 (O-Rings).

2. Remove the 4107-17-1 (Spring Retainer) and 4101-16-1 (Compression Spring) from the 4101-15-1 (Check Valve Body), and remove and discard the 9201-1-7 (7/32” SS Ball).

3. Loosen 4101-1-1 (Lock Nut) and unscrew the 4101-14-1 (Outlet Body) from the 4102-6-1 (Cylinder).

4. Remove the 4102-9-1 (Seal Retainer) from the 4102-7-1 Piston Body .

5. Remove and discard the 7304-1-1 (Piston Seal).

6. Remove the 4102-7-1 (Piston Body) from the 4102-2-1 (Piston Rod).

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WARNING

Use wrench flats provided in order to avoid damaging the PistonUse wrench flats provided in order to avoid damaging the Piston

Use wrench flats provided in order to avoid damaging the Piston

Use wrench flats provided in order to avoid damaging the PistonUse wrench flats provided in order to avoid damaging the Piston Rod.Rod.

Rod.

Rod.Rod.

7. Remove and discard the 9201-1-5 (5/32” SS Ball).

8. Remove and retain the 4101-3-1 (Piston Rod Spring).

9. Unscrew the 4102-3-1 (Packing Nut) and pull the 4102-2-1 (Piston Rod) out of the 4101-14-1 (Outlet Body). Carefully pull the Piston Rod out of Cylinder to avoid damaging the interior surface of Cylinder . Inspect the Piston Rod for scratches or other damage and replace if necessary .

NOTE

Carefully pull the Piston Rod out of Cylinder to avoid damagingCarefully pull the Piston Rod out of Cylinder to avoid damaging

Carefully pull the Piston Rod out of Cylinder to avoid damaging

Carefully pull the Piston Rod out of Cylinder to avoid damagingCarefully pull the Piston Rod out of Cylinder to avoid damaging the interior surfthe interior surf

the interior surf

the interior surfthe interior surf scrscr

tctc

hes or other damahes or other dama

scr

hes or other dama

scrscr

tctc

hes or other damahes or other dama

ace oface of

ace of

ace oface of

Cylinder Cylinder

Cylinder

Cylinder Cylinder

R R

Inspect the Piston R Inspect the Piston R

Inspect the Piston R

Inspect the Piston R Inspect the Piston R

place ifplace if

place if

place ifplace if

necessar necessar

necessar

necessar necessar

od fod f

od f

od fod f

oror

10. Insert a 1/4” dia. Dowel into the bottom of the 4101-14-1 (Outlet Body), force the 4102-5-01 (Piston Rod Packings) and 4102-4-1 (Upper Guide) out through the top of the Outlet Body and discard.

NOTE

CarCar

e me m

Car

CarCar

ust be takust be tak

e m

ust be tak

e me m

ust be takust be tak

en to not damaen to not dama

en to not dama

en to not damaen to not dama

e the inside ofe the inside of

e the inside of

e the inside ofe the inside of

the Outlet Bod the Outlet Bod

the Outlet Bod

the Outlet Bod the Outlet Bod

11. Unscrew the 4102-6-1 (Cylinder) from the 4101-7-1 (Inlet Body). Remove and discard the two 7301-9-014 (O-Rings). Inspect the Cylinder for scratches, or other damage, and replace if necessary .

12. Remove and discard the 9201-1-14 (7/16” SS Ball). Inspect the seat inside the 4101-7-1 Inlet Body , for nicks, scratches, or other damage, and lap, or replace if necessary .

13. Remove the 4101-8-1 (Inlet Tube Fitting). Remove and discard the 7301-9-013 (O-Ring).

FRP SystemOne

NOTE

Once disassembly is complete all parts should be flushed inOnce disassembly is complete all parts should be flushed in

Once disassembly is complete all parts should be flushed in

Once disassembly is complete all parts should be flushed inOnce disassembly is complete all parts should be flushed in distilled water and inspected for damage and replaced ifdistilled water and inspected for damage and replaced if

distilled water and inspected for damage and replaced if

distilled water and inspected for damage and replaced ifdistilled water and inspected for damage and replaced if necessarnecessar

necessar

necessarnecessar

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Chapter

FRP SystemOne

Catalyst Surge Chamber Disassembly

1. Loosen the 4101-18-1 (Jam Nut), and remove the 4104-7-1 (Gauge Adapter) from the 4104-4-1 (Surge Relief V alve Body).

2. Remove and discard the 7301-4-013 (O-Ring).

3. Remove the 4104-6-1 (Return T ube Fitting) from the 4104-4-1 (Surge Relief Valve Body).

4. Remove and discard the 7301-4-013 (O-Ring), and the 9201-1-4 (1/8” SS Ball).

NOTE

This is all the disassembly that is required to install the repairThis is all the disassembly that is required to install the repair

This is all the disassembly that is required to install the repair

This is all the disassembly that is required to install the repairThis is all the disassembly that is required to install the repair kit. Further disassembly is required if there is a problem withkit. Further disassembly is required if there is a problem with

kit. Further disassembly is required if there is a problem with

kit. Further disassembly is required if there is a problem withkit. Further disassembly is required if there is a problem with the 8701-1-1 (Burst Disc).the 8701-1-1 (Burst Disc).

the 8701-1-1 (Burst Disc).

the 8701-1-1 (Burst Disc).the 8701-1-1 (Burst Disc).

NOTE

Once disassembly is complete all parts should be flushed inOnce disassembly is complete all parts should be flushed in

Once disassembly is complete all parts should be flushed in

distilled water and inspected for damage and replaced if

distilled water and inspected for damage and replaced ifdistilled water and inspected for damage and replaced if necessarnecessar

necessar

necessarnecessar

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Chapter

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Reassembly of Metering Pump

Assembly Procedures:

1. Install 7301-9-013 (O-Ring), and 4101-8-1 (Inlet T ube Fitting) onto 4101-7-1 (Inlet Body).

2. Insert the 9201-1-14 (7/16” SS Ball) into the 4101-7-1 (Inlet Body).

NOTE

Care must be taken to not scratch or dent SS Ball.Care must be taken to not scratch or dent SS Ball.

Care must be taken to not scratch or dent SS Ball.

Care must be taken to not scratch or dent SS Ball.Care must be taken to not scratch or dent SS Ball.

3. Position a 7301-9-014 (O-Ring) onto the notched end of the 4102-6-1 (Cylinder).

NOTE

akak

e care car

akak

4. Screw the notched end of the 4102-6-1 (Cylinder) into the 4101-7-1 (Inlet Body). Turn by hand until it bottoms on the Inlet Body, “snug tight”.

e not to damae not to dama

e car

e not to dama

e care car

e not to damae not to dama

e the O-ring on the thre the O-ring on the thr

e the O-ring on the thr

e the O-ring on the thre the O-ring on the thr

eadseads

eads

eadseads

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5. Thread the 4101-1-1 (Lock Nut) onto the 4102-6-1 (Cylinder) until it bottoms on the Cylinder shoulder .

6. Install a 7301-9-014 (O-Ring) onto the long threaded end of the 4102-6-1 (Cylinder).

7. Install the 4102-3-1 (Packing Nut), 4102-4-1 (Upper Guide) and 4102-5-1 (Packing Set) onto the 4102-2-1 (Piston Rod).

NOTE

See drawing for proper orientation.See drawing for proper orientation.

See drawing for proper orientation.

See drawing for proper orientation.See drawing for proper orientation.

8. Carefully insert the 4102-2-1 (Piston Rod) through the 4101-14-1 (Outlet body).

NOTE

Care must be taken to not scratch the Piston Rod.Care must be taken to not scratch the Piston Rod.

Care must be taken to not scratch the Piston Rod.

Care must be taken to not scratch the Piston Rod.Care must be taken to not scratch the Piston Rod.

9. Carefully press the 4102-5-1 (Piston Rod Packings), and 4102-4-1 (Upper Guide) into 4101-14-1 (Outlet Body).

NOTE

Care must be taken to not damage the Piston Rod Packings.Care must be taken to not damage the Piston Rod Packings.

Care must be taken to not damage the Piston Rod Packings.

Care must be taken to not damage the Piston Rod Packings.Care must be taken to not damage the Piston Rod Packings.

10. Screw the 4102-3-1 (Packing Nut) into the 4102-14-1 (Outlet Body). Screw the Packing Nut until the Packings bottom in the Outlet Body cavity . Lightly snug the Packing Nut with a wrench.

11. Insert the 4101-3-1 (Piston Rod Spring) into the end of the 4102-2-1 (Piston Rod).

12. Insert the 9201-1-5 (5/32” SS Ball) into the 4102-7-1 (Piston Body).

13. Screw the 4102-7-1 (Piston Body) onto the 4102-2-1 (Piston Rod), compressing the 4101-3-1 (Piston Rod Spring) onto the 9201-1-5 (5/32” SS Ball).

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14. Install the 7304-1-1 (Piston Seal) onto the treaded end of the 4102-7-1 (Piston Body) spring side up.

NOTE

Note orientation of seal on drawing.Note orientation of seal on drawing.

Note orientation of seal on drawing.

Note orientation of seal on drawing.Note orientation of seal on drawing.

15. Install the 4102-8-1 (Piston Guide) onto the 4102-7-1 (Piston Body) below the 7304-1-1 (Piston Seal).

16. Screw the 4102-9-1 (Seal Retainer) onto the 4102-7-1 (Piston Body) hand tight.

17. Hold the 4102-2-1 (Piston Rod) with a wrench on the wrench flats, and tighten the 4102-9-1 (Seal Retainer) with another wrench.

18. Insert the Piston Rod assembly into the 4102-6-1 (Cylinder) screwing the 4101-14-1 (Outlet Body) onto the cylinder threads.

NOTE

Screw the Outlet body down until you feel the O-Ring start toScrew the Outlet body down until you feel the O-Ring start to

Screw the Outlet body down until you feel the O-Ring start to

Screw the Outlet body down until you feel the O-Ring start toScrew the Outlet body down until you feel the O-Ring start to compress.compress.

compress.

compress.compress.

19. Align the 4101-14-1 (Outlet Body) so the outlet port is one hex flat to the left of the inlet port of the 4101-7-1 (Inlet body). See Fig. 4.1.

Fig. 4.1

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Offeset intake and outlet ports one flat hex as shown in figure.

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20. Place the 9201-1-7 (7/32” SS Ball) down inside the 4101-15-1 (Check Valve Body) through the double threaded side.

21. Install the 4101-16-1 (Compression Spring) into the 4101-15-1 (Check V alve Body) onto the top of the 9201-1-7 (7/32” SS Ball).

22. Screw the 4101-17-1 (Spring Retainer) into the inside of the 4101-15-1 (Check Valve Body) compressing the Spring between the Retainer and the SS Ball.

23. Place a 7301-9-013 (O-Ring) over the single threaded end of the 4101-15 1 (Check Valve Body), and screw the Check Valve into the 4101-14-1 (Outlet Body).

24. Place a 7301-9-013 (O-Ring) over the double threaded end of the 4101-15-1 (Check Valve Body) until it is in the thread relief area between the two sets of threads and against the end of the 4101-18-1 (Jam Nut).

The Metering Pump Assembly is Complete.

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Chapter

FRP SystemOne

Catalyst Surge Chamber Reassembly

1. Install a 7301-9-013 (O-Ring) over the threaded end of the 4104-6-1 (Return Tube Fitting).

2. Insert the 9201-1-4 (1/8” SS Ball) into the 4104-4-1 (Surge Relief V alve Body).

3. Insert the 4104-5-1 (Relief V alve Spring) into the 4104-6-1 (Return Tube Fitting) over the SS Ball.

4. Thread the 4104-6-1 (Return Tube Fitting) into the 4104-4-1 (Surge Relief V alve Body) compressing the Spring between the Tube Fitting and the Ball.

5. Fasten the Catalyst Surge Chamber Assembly to the Metering Pump Assembly .

The Surge Chamber Assembly is complete

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