Magnum Venus Plastech VPRO-45110 User Manual

11:1 PRO PUMP ASSEMBLY

MAINTENANCE AND REPAIR MANUAL

VPRO-45110

MAGNUM VENUS PRODUCTS

MAINTENANCE & REPAIR MANUAL - VPRO-45110

Rev. 8/2006

PRO PUMP MAINTENANCE & REPAIR MANUAL

Warranty Information

DANGER DANGER DANGER DANGER DANGER

This equipment operates under pressure and can inject chemicals under the skin if triggered near the skin. Any injury caused by high pressure liquid can be serious. If you are injured, or even suspect an injury:

1. Take this page and go to the hospital emergency room NOW!

2. Tell the doctor you suspect an injection injury.

3. Show the doctor this page.

4. Tell him what kind of material you were spraying. Note to physician: Injection in the skin is a serious traumatic injury. TREAT THE INJURY SURGICALLY AS

SOON AS POSSIBLE. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream.

NOTE: Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable.

The seriousness of the wound depends on where on the body the injury occurred, whether the substance hit something on its way in and deflected causing more damage, and other variables. If injected material contains acrylic latex and titanium dioxide it may damage the tissue’s resistance to infection, and bacterial growth will flourish.

The treatment that doctors recommend for an injection injury to the hand includes:

immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected material, judicious would debridement and immediate antibiotic treatment.

Reprinted and adapted from a warning issued by: National Spray Equipment Manufacturers Association.

IMPORTANT WARRANTY INFORMATION

Please note that components used on this equipment are made of specially developed, high-strength material.

 Only authentic Magnum Venus Products replacement parts are acceptable

for use with this equipment.

 Use of unacceptable replacement parts will void our liability and warranty of

this equipment.

Please contact your Magnum Venus Products distributor for more information.

TABLE OF CONTENTS

Chapters

1. INTRODUCTION

2. REQUIREMENTS

3. MAINTENANCE

4. PRO PUMP

5. ACCUMULATOR & FILTER

6. OPERATOR VALVE.

7. TROUBLE SHOOTING CHART

Appendix

1. AIR LOCK IN THE CATALYST PUMP

Drawings

1. VPRO-45110 11:1 PRO PUMP ASSEMBLY

2. FF-5000-XXX FILTER ASSEMBLY

3. VPRO-2000 SHIFT BLOCK ASSEMBLY

4. VPRO-1000 SLAVE ARM ASSEMBLY

5. VPRO-45110-SK SEAL KIT

CHAPTER

Introduction

This manual, the PRO PUMP MAINTENANCE & 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.

 A troubleshooting guide helps you diagnose and perform common repair

situations.

 A comprehensive maintenance schedule provides a detailed list for

performing daily, weekly, monthly, three-month and annual maintenance.

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

DANGER: Always wear proper safety equipment, including eye protection and gloves when performing service and repair on this equipment.

During Disassembly:

As you disassemble the equipment, lay out the components in the correct order and direction. This will help you to reassemble them.

Especially note the order of the piston cup (3101-12-1), piston cup spacer ring (3101-13-1), piston cup backup ring (3101-14-1) and compression ring (15936-1) and the directions they face. These directions are critical to proper functioning of this equipment.

Lubrication:

Throughout this manual, directions are given for lubricating various parts of the Pro Pump. There are three types of lubricant used:

 If the part contacts resin, use MVP Red Grease (6706-2-1).  If the part is located where it will contact air, use Lubriplate

(08465).

DANGER: FIRE AND EXPLOSION HAZARD. Never use any lubrication on the components of the catalyst system. Contact your catalyst manufacturer for additional material handing information.

 Throat Seal Oil (TSL-3200) used in the oil reservoir of the pump.

Major Components:

Your Pro Pump consists of the following major components:

 Resin pump Fluid section.  Resin pump Air motor.  Shift Block Assembly.

Description of Controls for Spray unit:

Familiarize yourself with the manifold controls, which consist of the following regulators and gauges:

 PUMP PRESSURE gauge and regulator. These control main air pressure to

the resin pump.

 ATOMIZING-AIR gauge and regulator. This controls the air pressure to the

catalyst nozzle on the gun.

Hazard Information:

Please note the following safety and informational designations used throughout this manual:

DANGER: Indicates hazards or unsafe practices that are likely to result in severe personal injury or death.

WARNING: Indicates hazards or unsafe practices which could result in severe personal injury or extensive equipment damage.

CAUTION: Indicates hazards or unsafe practices which could result in minor injury or damage to equipment.

NOTE: Indicates additional information including explanations of certain procedures or helpful suggestions. Notes do not contain safety information.

CHAPTER

REQUIREMENTS: Air Requirements:

Clean, dry compressed air must be available at up to 90 psi (6.3 kg/cm2) and a minimum volume of 12 CFM (340 l / min.). Air must be provided through an air hose with a diameter of 0.5 inch (1.3 cm) or greater.

Tool and Supplies Requirements:

When performing service and repair on the Pro Pump, you should have the following tools, spare parts and supplies available before beginning.

NOTE: Items followed by a * may be purchased from Magnum Venus Products.

 One table vise  Loctite™ (removable)  One small hammer  Needle-nose pliers  Solvent or emulsifier for cleaning  One clean work table  Anti-seize thread sealant  Set of hex wrenches * (08469)  One 5/8-inch wrench * (08474)  One 9/16-inch wrench * (08476)  One 5/16-inch wrench * (08477)  Empty buckets for cleaning  Clean ¼-inch plastic dowel or rod  One 8-inch adjustable wrench * (08467)

 One 12-inch adjustable wrench * (08468)  One 7/16-inch open-end wrench  One ½-inch socket wrench  One 7/16-inch socket wrench * (08472)  Wooden sticks or tongue depressors (for testing)  Labels and pens (for marking pneumatic lines)  Clean rags and paint brushes for cleaning equipment  One tube of medium-weight lithium grease (such as Lubriplate  Large (approximately 3 feet by 10 feet or 1 meter by 3 meters) strips of paper for

performing spray tests.

 One pin wrench * (45031-1) (comes with catalyst jug)  One scribe * (08126)  Red Grease * (6706-2-1)  Seal Kit * (VPRO-45110-SK)

NOTE: Lubriplate® is a registered trademark of the Lubriplate division of Fiske Brothers Refining Company.

NOTE: Loctite™ is a trademark of the Loctite Corporation. NOTE: Teflon® is a registered trademark of E.I. DuPont de Nemours and Co.

lubricant * (08465))

CHAPTER

MAINTENANCE:

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: FLUIDS UNDER HIGH PRESSURE. Before performing any service and repair on this equipment, be sure to relieve air and fluid pressure.

DANGER: Always wear appropriate eye protection when working with this equipment.

WARNING: When removing hoses, place a rag over the hose before loosening it.

Performing proper maintenance at the recommended time intervals maximizes your

equipment’s productivity and efficiency. This section describes recommended maintenance

procedures to be performed daily, weekly, monthly, every three months, twice per year and once per year. Please follow the maintenance schedules recommended in this manual. This schedule is based on a one-shift, 5-day work week, using standard general purpose resin. An idle unit left with resin in it requires more frequent parts replacement.

DAILY MAINTENANCE CHECKLIST

PART PROCEDURE

Air Filter (“Water Trap”) Drain the air filter by holding a container under the filter

Hoses Check for kinks or leaks. Pro Pump Check the oil reservoir and add oil if needed. Nozzle Cap Coat nozzle cap and threads with Red Grease. Materials Check and fill catalyst jug and gel coat / resin. Never

and turning the valve at the bottom.

run out

WEEKLY MAINTENANCE CHECKLIST

PART PROCEDURE

Air Filter (“Water Trap”) Drain Hoses Check for kinks or leaks. Gauges and Regulators Check for damage and proper operation. Accumulator Remove and clean inside. Danger: Never attempt to

remove an accumulator until you have relieved pressure. See Chapter 5: Accumulator & Filter.

Filter Clean and inspect filter screen for plugging. Note:

Clean the screen weekly and when changing from one material to another. Use proper screen mesh size according to the material being used.

Pro Pump Check the oil reservoir and add oil if needed. If

necessary, clean and dry the silencers.

Pro Pump Lower Assembly Check the pickup hose and wand for leaks and

damage. Check for packing leaks.

Air Lines Check for leaks, wear and kinks. Replace if necessary.

MONTHLY MAINTENANCE CHECKLIST

PART PROCEDURE

Air Filter (“Water Trap”) Drain. Hoses Check for kinks or leaks. Gauges and Regulators Check for damage and proper operation. Accumulator Remove and clean inside. Danger: Never attempt to

remove an accumulator until you have relieved pressure. See Chapter 5: Accumulator & Filter.

Filter Clean and inspect filter screen for plugging. Note: Clean the

screen weekly and when changing from one material to another. Use proper screen mesh size according to the material being used.

Pro Pump Check the oil reservoir and add oil if needed. If necessary,

clean and dry the silencers.

Pro Pump Lower Assembly Check the pickup hose and wand for leaks and damage.

Check for packing leaks.

Catalyst Jug Check and clean tubes and filter screens if necessary.

Danger: Fire and explosion hazard. Never allow solvent or grease to contact any part of the catalyst system.

Air Lines Check for leaks, wear and kinks. Replace if necessary.

SIX MONTH MAINTENANCE CHECKLIST

PART PROCEDURE

Air Filter (“Water Trap”) Drain. Hoses Check for kinks or leaks. Gauges and Regulators Check for damage and proper operation. Accumulator Remove and clean inside. Replace the O-Rings.

Danger: Never attempt to remove an accumulator until you have relieved pressure. See Chapter 5:

Accumulator & Filter.

Filter Clean and inspect filter screen for plugging. Note:

Clean the screen weekly and when changing from one material to another. Use proper screen mesh size according to the material being used.

Pro Pump Replace the oil in the oil reservoir. If necessary, clean

and dry the silencers. Check piston rod, cylinder head, piston and trip sleeve for wear and damage, replace as needed. Replace O-Rings, cups, and packing set.

Pro Pump Lower Assembly Check the pickup hose and wand for leaks and

damage. Check for packing leaks. Check piston rod and pump cylinder for wear, replace as needed. Replace the packing set, piston cups and O-Rings.

Catalyst Jug Check and clean tubes and filter screens if necessary.

Danger: Fire and explosion hazard. Never allow solvent or grease to contact any part of the catalyst system.

Air Lines Check for leaks, wear and kinks. Replace if necessary. Catalyst Pump Replace all soft parts of the catalyst pump. Be sure to:

check bushings and pump cylinder and replace S.S. balls, O-Rings, springs, piston seal and packing set.

ANNUAL MAINTENANCE CHECKLIST

PART PROCEDURE

Air Filter (“Water Trap”) Drain. Repair any leaks or damage. Gauges and Regulators Check for damage and proper operation. Accumulator Remove and clean inside. Replace the O-Rings.

Danger: Never attempt to remove an accumulator until you have relieved pressure. See Chapter 5:

Accumulator & Filter.

Filter Clean and inspect filter screen for plugging. Note:

Clean the screen weekly and when changing from one material to another. Use proper screen mesh size according to the material being used.

Pro Pump Replace the oil in the oil reservoir. Clean and dry the

silencers. Check piston rod, trip sleeve, cylinder head and piston for wear or damage, replace as required. Replace the O-Rings, piston cups and packing set.

Pro Pump Lower Assembly Rebuild lower assembly. See Chapter 4: Pro Pump.

CHAPTER

Pro Pump

NOTE: Flushing the pump fluid section with solvent will make it easier to clean and rebuild.

CAUTION: There are two (2) hard chrome balls in the Pro 11:1 pump assembly. If a ball drops to the floor, it will be damaged. (Even if it appears undamaged, it will contain dents and scratches that will create problems.) Damaged balls must be replaced or the pump will not work properly.

NOTE: When disassembling the Pro pump assembly, replace any O-Rings that you expose.

Maintenance:

1. For a complete maintenance schedule, please refer to Chapter 3: Maintenance.

Troubleshooting:

1. For a complete troubleshooting schedule, please refer to Chapter 7:

Troubleshooting Chart.

Parts Drawings:

1. To perform service and repair on the Pro pump assembly, please follow the

procedures below. Please refer to: Drawing VPRO-45110 – Pro Pump Assembly Drawing VPRO-2000 – Shift Block Assembly Drawing 85805-1 – Pro Series Resin Pump Assembly

Turn Off Pressure:

1. Be sure all fluid pressure and air pressure is relieved from the Pro Pump assembly.

DANGER: To avoid serious injury or equipment damage, do not proceed unless the system has been completely depressurized.

Remove Catalyst Pump:

1. Be sure the catalyst pump has been removed from the slave arms.

Remove Pro Pump:

1. Remove the air hose connected to the fitting (PF-HN-06S-04) on the Shift Block assembly.

2. Remove the pick-up wand hose (VHSA-1000) from the elbow (PF-ME-12-12J) at the bottom of the pump.

3. Remove the resin hose from the fitting (PF-ME-08-06) on the resin filter assembly (FF-5000-100).

4. Remove the air supply from the tee (MPM-2584) on the shift block assembly.

5. Remove the two screws (7101-7-6) holding the pump to the pump mount.

Remove Foot Valve Assembly:

1. Mount the Pro pump in a vise.

CAUTION: Before proceeding, note the original position of the elbow (PF-ME-12-12J) on the foot valve body (3101-19-1). When you reinstall the foot valve body, the elbow must be oriented in the same position.

CAUTION: As you disassemble the equipment, lay out the components in the correct order and direction. This will help you to reassemble them. Especially note the order of the piston cup (3101-12-1), piston cup spacer (3101-13-1), and compression ring (15936-1), and the directions they face. These directions are critical to proper functioning of this equipment.

2. Use a wrench to remove the two hex cap screws (02681-38) which secure the cylinder (15986-1) and foot valve body (3101-18-1) to the center section of the pump (85729-3).

NOTE: Loosen the hex screws alternately to prevent distorting them.

3. Remove the foot valve body (3101-18-1) and the cylinder (15986-1) from the pump.

Disassemble Foot Valve Assembly:

1. Separate the cylinder from the foot valve assembly by pulling them apart. Inspect the cylinder for damage or wear.

2. Remove built-up material from the interior.

NOTE: The two O-Rings (7301-1-137) on the cylinder will need to be replaced during reassembly.

3. Use needle-nose pliers to remove the ball stop (3101-17-1) from the interior of the foot valve.

4. Remove the spring (3101-18-1) and the ball (9201-2-36).

NOTE: The ball may need to be replaced during reassembly.

5. Check the interior of the foot valve body for material buildup or damage.

Assemble Foot Valve Assembly:

1. Lubricate the new foot valve ball (9201-2-36) with a light film of Red Grease (6706-2-1).

2. Roll the ball into the foot valve body.

NOTE: Handle the foot valve ball carefully. If it is damaged, it must be replaced.

3. Insert the spring (3101-18-1) on top of the ball.

4. Use the ball stop (3101-17-1) to secure the foot valve spring and the foot valve ball in the foot valve body.

NOTE: The ball stop (3101-17-1) should be in the groove in the foot valve body, with the ball stop on top of the spring.

5. Place the new O-Rings (7301-1-137) on the cylinder (15986-1) and lubricate them with Red Grease (6706-2-1).

6. Insert the cylinder into the foot valve body.

7. Use the palm of your hand to press the cylinder securely into the foot valve until the cylinder seats.

8. The foot valve will be installed on the pump later.

+ 35 hidden pages

Magnum Venus Plastech VPRO-45110 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual