Magnum Venus Plastech Gun-60625-1 User Manual

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V

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Pro Gun Manual

5810X-1 & 60625-1

Rev. 05/2012

High Volume Pro Gun Manual

CORPORATE HEADQUARTERS and MANUFACTURING

11692 56th Court * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel [phone] * Fax [phone]

MVP Plastech UK

Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: [phone]

Fax: [phone]

www.mvpind.com

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Table of Contents

High Volume Pro Gun Manual

SECTION:

Page

TERMS & CONDITIONS OF SALE 4

SAFETY & WARNINGS 6

INTRODUCTION 15

GUN BLOCK DISASSEMBLY 18

GUN BLOCK ASSEMBLY 25

ACTUATOR REBUILD 34

GUN SPECIFICATIONS 36

PARTS DRAWINGS 39

REVISION INFORMATION 63

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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-of­rise 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, over­sprayed 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:

Generally, the HV 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.

Disassembling the HV Pro Gun™ is easy; the gun breaks down into two separate
modules which are then disassembled further into their individual parts. A special tool
kit, which includes a specially designed HV Pro Gun™ tool and a packing assembly
tool, is available to aid in performing maintenance and repair.

This manual, the HIGH VOLUME PRO GUN REPAIR MANUAL, provides information
you need to perform simple maintenance and repair on your equipment.



Step-by-step assembly and disassembly procedures are included for each
component.

Please read the manual carefully. Follow the steps in the order given, otherwise you
may damage the equipment or injure yourself.

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 High Volume Pro Gun Assemblies & Components:

58100-1-X High Volume Pro Gun Assembly – Saturator
58104-1 High Volume Pro Gun Assembly – Manual Operated
58105-1 High Volume Pro Gun Assembly – For Chopper
58107-1 High Volume Pro Gun Assembly – With Chopper Assembly
60625-1 High Volume Pro Gun Assembly – Manual Putty
60625-1-INT High Volume Pro Gun Assembly – Manual Putty International

58103-1 High Volume Pro Gun Actuator Assembly
58106-1 High Volume Pro Gun Block Assembly
58106-1-INT High Volume Pro Gun Block Assembly - International

58110-1 Repair Kit – High Volume Pro Gun
58110-1-INT Repair Kit – High Volume Pro Gun – International

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Tools required

• You will need the following tools:

• Rubber mallet

• Thread Sealant

• Adjustable wrench

• Needle-nose pliers

• Flat-end screwdriver

• Lubriplate™ lubricant (08465)

• Scribe set (08126)

• Pro Gun™ Oil (04394)

• Seal Installation tool (58198-1)

• HV Pro Gun™ packing bit (58199-1)

• Catalyst Alignment Tool (6705-3-1)

• 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 new o-rings and seals to replace the current ones in the HV

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 O-K-008 in the flush assembly, you do
not need to replace the o-ring unless it is showing obvious signs of wear. This o­ring 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.

Release Pressure

1. Turn off air supply to pumping system.

2. Release fluid pressure from lines by holding the gun over an appropriate empty
container and pulling the trigger.

3. Flush gun into appropriate container

4. Turn off air supply to the solvent tank.

5. Release any pressure in the flush tank by gently pulling upwards on the ring
attached to the pressure relief valve.

6. Place an empty container under the ball valve located at the bottom of the filter
assembly.

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7. SLOWLY open the ball valve, you can leave the ball valve open or close it when
the all the pressure has been released.

8. Open the dump / recirculation valve located on the catalyst manifold, if
appropriate.

Disable Catalyst Pump

• Slave Arm pumps

1. Remove the quick pin from the top of the catalyst pump and upper slave arm.

2. Tilt the catalyst pump away from the resin pump until the catalyst pump is
resting against the vertical connecting post.

3. Trap the catalyst pump’s upper bearing block between the vertical connecting
post and the quick pin.

• UPS

1. Remove the hairpin from the quick pin assembly.

2. Remove the quick pin assembly from the pivot link assembly

Remove Hoses

Note: Although previous steps should have removed all pressure from the lines,
there may still be trapped fluids under pressure in the lines. Read the
recommended safety procedures below.

WARNING: Wear appropriate eye protection. Pressurized fluids may cause eye
injuries.

WARNING: When removing hoses from fittings, wrap a large rag or shop towel
around the wrench and fitting as you remove the fitting. Remove fitting slowly to
allow any pressurized fluid to escape into the rag or towel.

1. Wrap a large rag or shop towel around the resin fitting and a wrench.

2. Use the wrench to loosen the fitting slowly until you can remove the resin hose
from the fitting.

3. Use this technique to remove the solvent hose, and the catalyst hose.

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Gun Disassembly:

Disassemble Gun into Modules

Note: If your HV 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 its air supply..

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. You have now disassembled the gun into modules. Next you will disassemble,
clean, and reassemble each module.

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.

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.

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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

SEAL

PUSH STEM

SPRING

FLUSH BODY

O-RING

BACK-UP RING

GRIP RING

FLUSH VALVE BODY

BARBED FITTING

HOSE CLAMP

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

FLUSH VALVE BUTTON

SEAL

O-RING

FLUSH SEAL BODY

FLUSH VALVE NECK

High Volume Pro Gun Manual

O-RING

SPRING

FLUSH VALVE BODY -

AUTO/MANUAL

SPLIT SEAL

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).

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Remove Mix Housing

1. Remove the nozzle cap from the mix housing.

2. Remove the nozzle from the cap.

3. Remove the mix housing (58132-1) by unscrewing the screws holding the mix
housing to the gun block.

NOZZLE CAP

NOZZLE

NOZZLE SEAL

HV NOZZLE ADAPTOR

HV TURBULENT MIXER

SCREW

MIX HOUSING

DISTRIBUTION RING

MIX HOUSING SEAL

INJECTOR ASSEMBLY

4. Pull the injector and injector seal out and set the injector assembly aside.

5. Remove the turbulent mixer from the mix housing.

6. Use a blunt tool to push the distribution ring™ and housing seal out of the mix
housing.

7. Inspect and clean the mix housing components with solvent.

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Disassemble the Catalyst Injector Assembly

INJECTOR PLUNGER

INJECTOR BODY

SPRING

PLUNGER RETAINER

High Volume Pro Gun Manual

INJECTOR SEAL

1. Unscrew the plunger retainer from the end of the injector plunger.

2. Remove spring (04354).

3. Remove the injector plunger from the injector body. Inspect injector plunger and
injector body for dirt or damage.

4. Clean and reassemble.

Remove Hose Fittings

1. Remove and clean the catalyst fitting and o-ring on the rear of the gun block.

2. Remove and clean the resin fitting and o-ring on the rear of the gun block.

Remove Valve Rod

1. Use the packing bit to unscrew the packing nuts (58122-1) from both the catalyst and
resin side.

Note: Use caution not to damage the packing bit. If you are unable to remove the
packing nut soak in a solvent or apply heat to the packing nuts.

2. Place the small end of the seal installation tool onto one end of the valve rod.

3. Use a rubber mallet or hammer to gently tap the valve rod out of the gun block.

4. Inspect the valve rod for damage; clean with solvent.

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CHECK VALVE

O-RING

GUN BLOCK

RELIEF SPACER

SECONDARY SEAL

VALVE ROD

High Volume Pro Gun Manual

PACKING NUT

PACKING RING

RESIN SEAL

O-RING

PLUG

PACKING RING

PACKING NUT

SECONDARY SEAL

RELIEF SPACER

CATALYST SEAL

O-RING

CENTER SPACER

RESIN FITTING

CATALYST FITTING

Remove Center Spacer

1. Use needle-nose pliers to remove the center spacer (58124-1).

Remove Catalyst and Resin 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
the resin and the catalyst sides.

2. Remove catalyst and resin seal (relief spacer and secondary seal) from the seal
installation tool. Clean with solvent.

CAUTION: Keep the components of the catalyst side separate from the
components of the resin side. Mixing the components could result in cross­contamination.

3. Clean the two relief spacers (58123-1) with solvent and allow to air dry.

4. Discard the seals and replace with new ones from repair kit.

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Remove Check Valve on International HV Pro Guns

1. Remove the check valve on the side of the gun block

Or

Remove Catalyst Plug on Domestic HV Pro Guns

1. Remove the plug (5104-32-1) from the side of the gun block

2. Check o-ring (O-E-5-125) for damage

Note: This valve serves as a check valve for the catalyst system.

DANGER: If this valve must be replaced, contact Magnum Venus Products. These
valves have undergone specific remanufacture at Magnum Venus Products for use with
the HV Pro Gun™. Using a check valve not obtained directly from Magnum Venus
Products may result in contamination and/or dangerous ignition of the catalyst.

Clean Block Assembly

• Discard o-rings and seals.

• Clean remaining components with solvent and allow to air dry.

• You have now disassembled the gun block.

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Gun Block Assembly:

Install Secondary Seals

1. Place one of the secondary seals (58135-1) into the center of the gun block where
the center spacer goes. Gently push the secondary seal into position with something
flat, flush with the gun block. Use caution not to damage the seal.

2. Repeat the process for the other secondary seal.

VALVE ROD

PACKING NUT

PACKING RING

RESIN SEAL

RELIEF SPACER

SECONDARY SEAL

GUN BLOCK

SECONDARY SEAL

RELIEF SPACER

CATALYST SEAL

PACKING RING

PACKING NUT

CENTER SPACER

Reinstall Center Spacer

1. Place the center spacer (58124-1) 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 Catalyst Components

1. Place the catalyst components onto the seal installation tool in the following
order:

• Packing ring (58146-1)

• Catalyst seal (58127-1)

• Relief spacer (58123-1)

Note: The hole in the catalyst seal should be aligned with the port in the gun
block before inserting the seal installation tool into the gun block.

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RELIEF SPACER

CATALYST SEAL

PACKING RING

2. Insert the seal installation tool with the components on it, into the catalyst 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
catalyst seal with the holes in the gun block as closely as possible.

3. The catalyst components should be seated in the interior of the gun block against
the center spacer.

4. Gently screw a packing nut (58122-1) into the catalyst side. Do not tighten.

Align Catalyst Seal

1. Hold the catalyst alignment tool (6705-3-1) (tapered drill bit) firmly with a pair of pliers.

2. Insert the catalyst alignment tool (tapered end first) into the gun block through the
catalyst side on the rear of the gun block

3. Gently press and move the alignment tool around until the holes in the catalyst
seal aligns with the hole / port in the gun block.

Note: At this point, the catalyst side packing nut should only be hand tight.

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Reassemble Resin Components

1. Place the resin components onto the seal installation tool in the following order:

• Packing ring (58146-1)

• Resin seal (58126-1)

• Relief spacer (58123-1)

Note: Before inserting the packing tool, align the hole in the resin seal with the
hole in the gun block as closely as possible

PACKING RING

RESIN SEAL

RELIEF SPACER

2. Insert the seal installation tool into the resin side of the gun block. Tap gently with
a rubber mallet or hammer, and then pull the packing tool out of the gun block.

3. The resin components should be seated in the interior of the gun block against
the center spacer.

4. Gently screw a packing nut (58122-1) into the resin side. Do not tighten.

Note: At this point, the resin side packing nut should only be hand tight.

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Install Valve Rod

1. Insert the valve rod (58125-1) into the gun block through the resin side. Use a
packing tool to center the valve rod.

Note: Make sure that the valve rod is correctly aligned; the larger hole goes on
the resin side, while the smaller hole goes on the catalyst side.

Note: 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.

VALVE ROD

HOLE WITH RELIEF

Reinstall Actuating Stem

1. Screw the actuating stem (58147-1) into the valve rod (58125-1) 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. Set the actuating stem so
that the holes are closed.

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Tighten Packing Nuts

1. Tighten both the resin and the catalyst 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 the resin and the catalyst packing nuts.

4. Repeat the above tightening process one more time

Reinstall Hose Fittings

1. Reinstall the fitting and o-ring for the resin hose on the rear of the gun block.

2. Reinstall the catalyst fitting and o-ring on the rear of the gun block

Reinstall Check Valve on International Pro Guns

DANGER: To replace this valve, contact Magnum Venus Products. These valves
have undergone specific remanufacture at Magnum Venus Products for the Pro
Gun ™. Using a check valve not obtained directly from Magnum Venus Products
may result in contamination and /or dangerous ignition of the catalyst.

1. Reinstall the check valve (5104-04-01) and o-ring (O-S-5-125) on the front side
port on the catalyst side of the gun block.

Or

Reinstall Catalyst Plug on Domestic Pro Guns

2. Thread the catalyst plug (5104-32-1) into the front side port on the catalyst side
of the gun block

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Reassemble Flush Valve

FLUSH VALVE BUTTON

FLUSH VALVE BODY

FLUSH SEAL BODY

SEAL

O-RING

High Volume Pro Gun Manual

O-RING

SPRING

FLUSH VALVE BODY ­AUTO/MANUAL

FLUSH VALVE NECK

SPLIT SEAL

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).

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Note: For systems without Auto/Manual flush assemblies skip steps 9 - 13

SEAL

PUSH STEM

SPRING

FLUSH BODY

O-RING

BACK-UP RING

GRIP RING

FLUSH VALVE BODY

BARBED FITTING

HOSE CLAMP

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).

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Assemble Mix Housing

1. Install the distribution ring (58133-1) into the mix housing

Note: Be sure the holes in the distribution ring are clean and free of debris or
hardened material.

2. Position the mix housing seal into the mix housing, against the distribution ring.

3. Insert the catalyst injector assembly (58115-1) and injector seal into the center
hole of the distribution ring. The spring should be facing up, as it will go into the
gun block and the injector seal will be against the gun block.

4. Use the socket cap screws (F-CS-05F-16-GR8) to attach the mix housing to the
gun block

WARNING: Screws and fasteners provided with this Pro Gun™ are specially
designed for this equipment. Use only Magnum Venus Product replacement
parts, or warranty may be voided.

5. Insert the turbulent mixer into the mix housing.

6. Apply some red grease to the threads of the mix housing and nozzle cap. This
will make them easier to remove later.

7. Install HV nozzle adaptor to the mix chamber.

8. Install the nozzle into the nozzle cap.

9. Screw the nozzle and nozzle cap onto the mix housing.

NOZZLE CAP

NOZZLE

NOZZLE SEAL

HV NOZZLE ADAPTOR

HV TURBULENT MIXER

SCREW

MIX HOUSING

DISTRIBUTION RING

MIX HOUSING SEAL

INJECTOR ASSEMBLY

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Mix Housing Options

• Standard Mix Housing (58132-1) – Use with all turbulent mixers and most spray
applications.

• Putty / Air Purge Mix Housing (60570-1) – Use with putty pour systems.

Optional Adaptors:

75010-1 Impregnator Adaptor
75010-3 Impregnator Adaptor with O-ring (O-V-210)
75010-5 Winder Adaptor

54830-1 HV Nozzle Adaptor – HV Mix Housing to Standard

54861-1 Mixer Union – HV Gun to 3/4" Mixer (3/4npt)
54861-3 Mixer Union – HV Gun to 5/8” Mixer (1/2-13npt)

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PISTON

BODY

O-RING

ACTUATOR

SEAL

Actuator Rebuild:

Actuator Disassembly

1. Remove the end cap from both ends of the cylinder body.

2. Push the actuator piston out the back of the cylinder body.

3. Replace the o-ring (O-V-133) on the actuator piston.

4. Check the actuator bushing and cylinder body for wear or damage.

5. Apply a light film of Pro Gun Oil (04394) to both the inside of the cylinder and
actuator piston.

6. Install the actuator piston into the cylinder body, the actuator bushing should go
in first and be off center towards the top.

7. Install the end cap onto both ends of the cylinder body.

END CAP

CYLINDER BODY

ACTUATOR BUSHING

END CAP

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Assembly the Components

1. Install the Actuator Seal on top of the Actuator Cylinder.

2. Align the Actuator Stem on the Gun Block with the Actuator Bushing in the
Cylinder Body.

3. Attach the Gun Block to the Cylinder using the four Screws, Seals.

4. Attach the Chopper Mount and chopper to the top of the gun block.

5. Install the Mounting Pad to the bottom of the Cylinder Body using the Screws.

CHOPPER MOUNT

MOUNTING SCREWS & SEALS

GUN BLOCK ASSEMBLY

ACTUATOR SEAL

ACTUATOR ASSEMBLY

MOUNTING PAD & SCREWS

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High Volume Pro Gun Manual

Gun Specifications:

3.00

5.27

6.41

2.88

4.4370 LESS CHOPPER BRKT

0.38

4.00

12.68

5.68

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Off Port

– Supply constant ai

r

On Port

– Supply constant air

Auto Flush Port

– Supply constant

Solven

t Port

– connect flush

signal to turn gun ON (min. 1bar)

air signal to activate flush cycle
(min. 1bar). Can also be activated

manually by pushing

signal to turn gun off (min. 1bar)

system here

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Parts Drawings:

58100-1-X High Volume Pro Gun Assembly – Saturator
58104-1 High Volume Pro Gun Assembly – Manual Operated
58105-1 High Volume Pro Gun Assembly – For Chopper
60625-1 High Volume Pro Gun Assembly – Manual Putty
60625-1-INT High Volume Pro Gun Assembly – Manual Putty International

58103-1 High Volume Pro Gun Actuator Assembly
58106-1-X High Volume Pro Gun Block Assembly

58742-1 Automatic Flush Valve Assembly
58742-1-INT Automatic Flush Valve Assembly – International
58715-1 Auto / Manual Flush Valve Assembly
58115-1 Catalyst Injector Assembly

58110-1 Repair Kit – High Volume Pro Gun
58110-1-INT Repair Kit – High Volume Pro Gun - International

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Revision Information:

Rev. 12/2010 Add this revision information chapter and the gun

specifications chapter. We updated the parts drawings in
the manual and the manual format.

Rev. 12/2011 Updated the Logo, Address and drawings (58104-1 &

58106-1).

Rev: 05/2012 Updated the manual format and Address. Added the

Terms & Conditions of Sale section to the manual. Added
the Optional Adaptors area.

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Assemblies Covered in this Manual:

MAGNUM VENUS PLASTECH

CORPORATE HEADQUARTERS and MANUFACTURING

11692 56th Court * Clearwater, FL 33760 * Tel [phone] * Fax [phone]

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel [phone] * Fax [phone]

MVP Plastech UK

Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: [phone]

Fax: [phone]

www.mvpind.com

58100-1-X High Volume Pro Gun Assembly – Saturator
58104-1 High Volume Pro Gun Assembly – Manual Operated
58105-1 High Volume Pro Gun Assembly – For Chopper
58107-1 High Volume Pro Gun Assembly – With Chopper Assembly
60625-1 High Volume Pro Gun Assembly – Manual Putty
60625-1-INT High Volume Pro Gun Assembly – Manual Putty International

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