H.I.S. TM Troubleshooting Manual

Transcription

1 Magnum Venus Products H.I.S. TM Troubleshooting Manual The ABC s of the most economical method of applying material for the fiberglass industry

2 TABLE OF CONTENTS Chapter 1: Materials Page 1 Chapter 2: Cautions Page 1 Chapter 3: Catalyst Pump Troubleshooting Page 2 Chapter 4: General Troubleshooting Page 5 Chapter 5: Gun Troubleshooting Page 12 Chapter 6: Chopper Troubleshooting Page 16 Chapter 7: Resin Pump Troubleshooting Page 19 Chapter 8: Flush Hose Installation Page 25 Chapter 9: Flush System Trouble Shooting Page 25 Chapter 10: Airlift Trouble Shooting Page 26 Chapter 11: Hose Trouble Shooting Page 27 Chapter 12: Filled Systems Page 28

3 CHAPTER 1 CAUTION!! Before attempting to disassemble any portion of catalyst or resin system: 1. The air supply to power head of pump should be turned off. 2. The fluid pressure in the system should be relieved by triggering gun and allowing fluid to drain into proper receptacle. 3. The air charge on both resin and catalyst accumulators should be released through charging valves on top of accumulators. 4. Air to solvent tank should be turned off and the pressure relieved from tank. (Only after flushing gun clean of all resin and catalyst.) 5. If pressure is trapped in system by a fluid block, plugged filter, set-up gun, etc., remove pressure by disconnecting resin line prior to suspected blockage. Note: A large rag or shop towel should be held tightly around wrench and fitting as fitting is removed. Remove fitting slowly allowing fluid pressure to escape into rag or towel. CHAPTER 2: STOP!!! Before attempting to perform maintenance on the Magnum Venus System: 1. Protective clothing should be worn at all times. 2. Safety glasses should be worn at all times. 3. Maintenance should not be performed unless others are in attendance to render assistance in case of an emergency. 4. Should any parts of the body come in contact with MEKP, the area should be washed immediately with large amounts of clean water. Page 1

4 SHOULD THE EYES OR INTERNAL PARTS OF THE BODY COME IN CONTACT WITH MEKP, A PHYSICIAN SHOULD BE CONTACTED IMMEDIATELY. CHAPTER 3 Note: parts of catalyst system should always be cleaned with clean water only. Catalyst pump: Problem Cause Action No cure catalyst pump No catalyst. Supply below outlet fitting on catalyst jug. Replenish supply. No cure, catalyst pump not delivering Quick pin in slave arm not fixed to catalyst pump. Install Quick Pin. Catalyst Pump failure* A. Piston Seal Failure Remove catalyst hose, catalyst feed tube and relief valve tube from catalyst pump. Remove pump from slave arms. Loosen locknut on pump cylinder and unscrew cylinder from outlet body. Slide cylinder down from piston rod and piston assembly. Remove seal retainer and remove and replace piston seal. Be sure spring in piston seal faces the top of the pump. Remove O-ring from inside of outlet body and place on end of cylinder above lock nut. Reassemble unit. Page 2

5 Catalyst pump failure* B. Ball valve in piston not seating. Remove catalyst hose, catalyst feed tube and relief valve tube from catalyst pump. Remove pump from slave arms. Loosen locknut on pump and unscrew cylinder down from piston rod and piston assembly. Remove piston from piston rod, remove spring and ball from piston. Visually examine ball seat, ball and spring for contamination or damage. Clean piston and parts with clean water, blow dry with air. Replace any questionable parts. Replace ball and spring in piston and secure piston-to-piston rod. Remove O- ring from inside of outlet body. Place locknut on cylinder and reassemble pump. Catalyst pump failure* C. Pup ball valve in inlet body not seating. Remove catalyst hose, catalyst feed tube and relief valve tube from catalyst pump. Remove pump from slave arms. Unscrew inlet body form cylinder. Remove ball from inlet body. Visually examine ball and ball seat in inlet body for contamination and damage. Clean with fresh water and blow dry with air. Remove O-ring from inside inlet body and place on O-ring seat on cylinder. Replace any questionable parts and reassemble pump. Catalyst pump failure* D. Air lock Remove catalyst hose from nipple on catalyst accumulator after relieving pressure from the system. Remove quick pin from catalyst bearing block and upper slave arm. Loosen packing nut on top of catalyst pump. Tilt pump back toward resin pump and pump catalyst into a suitable container until catalyst spurts from nipple an equal amount on both up and down stroke. Reconnect catalyst hose to nipple and with trigger open, hand pump catalyst out through the gun. Reestablish pump in slave arm and retighten packing nut. Page 3

6 No cure Catalyst relief valve on catalyst accumulator leaking Relieve pressure from catalyst system. Remove return tube form from fitting. Remove tube-fitting spring and ball from relief valve body on accumulator. Check interior of relief valve body for foreign material contaminant. Install new ball, existing spring and tube fitting with O-ring in place. Reinstall return tube on tube fitting. Whenever compressed air is used to air dry or to blow off parts, insure that there is no moisture or oil in air line. *To determine the cause of catalyst pump failure, the following test is suggested: 1. Bleed pressure from unit by closing shut-off valve for air to power head on resin pump and running pressurized material out of the lines by squeezing the trigger on the gun. Relieve pressure. Release trigger. Flush gun. 2. Remove quick pin from catalyst pump bearing block and upper slave arm. Release packing pressure by loosening packing nut at the top of the catalyst pump. 3. Using the priming knob on the bearing block of the pump, hand pump the piston rod up and down several times. The pressure build up should be felt. If a pressure build up cannot be felt, and the pump action feels spongy, air is in the pump. If the pressure build up is felt stop pumping 4. Use charging pump to put 250 psi (test figure only) charge in catalyst accumulator, if fluid is more than 1 in accumulator, re-bleed system as described in #1. 5. Hand pump catalyst up into the accumulator. The fluid level should raise in the accumulator glass tube an equal amount on both the up and down strokes. 6. If the fluid does not rise in the down stroke, use corrective action for C (Ball Valve in Inlet Body Not Seating) above. 7. If the fluid does not rise on the up stroke, use corrective action for B (Piston Seat Failure) above. 8. When the fluid level in the accumulator is in the upper 25% of the glass tube and the fluid ceases to rise on the up-stroke, use corrective action for A (Piston Seal Failure) above. Page 4

7 CHAPTER 4: General Trouble Shooting: Problem Cause Action No Cure Catalyst hose plugged. Relieve pressure from catalyst system. Disconnect catalyst hose from fitting on gun. Attempt to hand pump catalyst through hose. If none emerges from end of hose, place a clean rag over the hose fitting and nipple on the catalyst accumulator and with a wrench under rag, remove hose fitting from nipple. CAUTION: PRESSURE BUILDUP IS IN ACCUMULATOR AND CATALYST WILL BE SPRAYED FROM HOSE FITTING WHEN FITTING IS LOOSENED. Remove catalyst hose fitting from gun end of hose. Remove solid core from inside catalyst hose. Run clean water through the hose. If hose fitting on accumulator end of hose will not accept fluid, remove and examine fitting. Note: It may be necessary to cut off 2 of hose to re-install fitting properly. If hose is less than 30 feet long and 2 of catalyst hose is cut off, cut 2 of core off also. On hose lengths longer than 30 it is not necessary to cut off core. When water flows freely through hose, Page 5

8 No cure. Gun head plugged on catalyst side. Page 6 blow air through hose to dry it. Wipe core clean with a clean, dry rag; insert core back in hose. Inspect fitting on gun end of hose. If fitting is clear and clean, reassemble it on catalyst hose. Check hose for free flow of air through it before reassembling hose on unit. It may take in excess of 60 psi to get air through hose. If hose still indicates blockage, remove and replace. Release pressure from catalyst system. Remove catalyst hose form gun. Remove adapter and catalyst hose nipple from gun. Visually inspect cavity and exposed retainer and needle in this area for contamination or gelled material. Remove side and front plug from gun head on catalyst side. Care must be exercised when removing front plug so spring and ball will not be dropped. Examine cavity in this section for contaminants or gelled material. Remove injector and inspect. Blow air through injector to insure that fluid passage is free and clear. Examine interior of mix chamber through nozzle port. Area must be free of any material. Reassemble all components after thorough examination. Replace any worn or damaged parts. Uncured area in laminate Trigger not properly Trigger must be set to

9 Spotty Cure adjusted Catalyst accumulator not properly charged. Page 7 activate resin needle just before catalyst needle. NEVER CATALYST FIRST. To adjust, position locknuts on needles so the locknut on the resin needle makes contact with the flat bar on the trigger and the locknut on the catalyst needle is within 1/32 of making contact with trigger. Trigger must be squeezed firmly and fully. Release pressure from the catalyst system. Be sure no fluid is in the accumulator. Gun must be in open position prior to releasing pressure in accumulator. Using suitable square end rod, release air from accumulator by depressing ball in valve at top of accumulator. Vent charging pump by moving handle up and down several times before attaching it to the accumulator. Before attaching ¼ hose with quick disconnect to charging pump, place handle of pump in the extreme up position. Using the pressure indicated on the gauge of the regulator for air to the powerhead, hand pump the charging pump to the following values. On 4:1 power head, apply 3 times the operating pressure. On 7:1 power head, apply 5 times the operating pressure. On 10:1 and

10 Spotty cure Resin accumulator not properly charged. Page 8 11:1 power head, apply 7 times the operating pressure for spraying condition; for pouring, 4 times the operating pressure. Remove charging pump. Check valve on accumulator for leak by placing saliva on top of valve. If saliva does not produce bubble, replace valve cap. Release pressure from the system. Gun must be in open position prior to releasing pressure in accumulator. Release any existing charge of air in resin accumulator by depressing ball in valve at the top of the accumulator with a suitable flat end rod. It may be advisable to remove accumulator by turning counter-clockwise and unscrewing it from the nipple. Examine interior of accumulator to be assured it is clean and empty. Clean nipple and O-ring. Immerse polyproplene ball in clean uncatalyzed resin and place on ball seat in nipple. Clean threads in accumulator on nipple hand tight only. Vent charging pump by pumping up and down a few strokes before attaching it to valve at top of accumulator. Hand tighten only. Connect the ¼ hose with quick disconnect from manifold to charging pump when the pump handle is

11 extended to it s full, upright position. Using the pressure indicted on the gauge of the regulator for air to the power head, hand pump the charging pump to the following values; on the 4:1 power head, apply 3 times the operating pressure. On the 7 1 power head, apply 5 times the operating pressure. On the 10:1 and 11:1 power head, apply 7 times the operating pressure. Note: For correct accumulator charge, accumulators must be charged when empty of all material and both accumulators must be charged the same. Spotty cure Fluid leak Check all fittings and needles. Hydraulic system must be fluid tight. Needle seats need periodic replacement. Needle packing and seals need periodic replacement. Leakage of material affects proper mix and cure. Spotty cure Poor mixing Insure proper accumulator charge in both resin and catalyst accumulators. Check injector for damage, and check turbulent mixer for cleanliness and damage. Slow gel time Insufficient catalyst Check placement of pump in slave arms. Adjustable from lowest setting to (farthest position from resin pump) to highest setting (closest position to resin pump). Settings are marked on slave arm. Page 9

12 Keep pump vertical in related holes. Increase setting if gel time is too slow. Cold resin Low room temperature Page 10 For best results of material usage, keep material at 78º F. (25º C). Proper temperature control of resin should be physically checked with thermometer. Maintain an even room temperature of approximately 70º F. Mold should be ion draft free location. Auxiliary heat directed on lay-up can be used to hasten gel time. Run out (SAG) Resin Consult resin supplier for proper gun type resin and different thixotropic qualities. Excessive gel time Increase percentage of catalyst to shorten gel time. Excessive misting Resin Reduce power head pressure. No resin fan Obstruction in resin filter Turn air to power head off. Bleed fluid pressure from system. Unscrew tank from filter. Clean tank, screen and core with solvent. Clean inside of filter body. With special red grease, wipe O-ring, inside of body and external threads on body. Reassemble filter; hand tighten tank slowly open air to power head valve. Unit is now ready to

13 Dry glass Chopper not properly aligned Page 11 function. Using swivel between gun handle and chopper base plate move and fix chopper so glass is directed in the middle of resin fan pattern. Keep chopper down close to gun head to allow glass to enter resin fan between nozzle and turbulence halo approximately 2 from nozzle tip. Excessive over-shoot Operator error Run horizontal fan, depositing material to within 1 of the edge of the mold. Run fan vertically just within the edge of the mold. With laminating roller, skid material deposited in vertical application past the edge of the mold for minimum trim. Poor saturation Low resin volume Increase powerhead pressure and nozzle size or decrease chopper pressure. Note: Excessive power head pressure will create misting and over-spray. Resin-rich and resin-poor areas. No pre-wet Operator error. Pre-wet mold or gel coat mold prior to chopper or laying mat or woven roving. Adjust chopper for slightly more dispensed glass to resin ration to compensate for pre-wet resin applied to mold to have corrected finished glass to resin ratio. Check gun and chopper for proper dispensing of materials. Resin fan should be wide with slight fingers on both edges. Glass should enter fan in

14 center and close to nozzle to broadcast fiber from finger to finger of fan. Gun should be operated equal distance from part at all times and moved at a rhythmic, constant speed. Mold lay-up plan should be exercised to control natural tendency or resin to run out from high to low place. See Problem, Run out. Flighty Glass Check ceramic guides on boom. If worn, they could be causing static. Note: Clamp-on, replaceable guides are available. Whenever compressed air is used to air dry or to blow off parts, insure that there is no moisture or oil in air line. To Remove Catalyst Injector Nozzle: Remove side plug and front plugs, spring and check ball. Install Magnum Venus Products drill Bushing ST-82 ( ) (Figure 1) from tool kit. Install #4 drill (00002) in drill chuck (Figure 1) and drill injector out. Remove #4 drill bushing from gun head, clean threads with ¼-28 tap (00001) (Figure 2). To Clean Gelled Resin from Chamber: Install drill bushing ST-80 ( ) in gun head. Install 1/8 (.125) diameter drill (ST-81) ( ) in drill chuck (Figure 3). Drill full 2-3/8 inches. CAUTION: Damage could result if drill is forced deeper than 2-3/8 inches. Remove drill and drill bushing. Clean head thoroughly. Install new injector and reassemble gun head. Note: For proper installation, port on flush seal retainer must be in line with port for catalyst injector. CHAPTER 5 Gun Trouble Shooting: Problem: Cause: Action: Leak in nozzle area Worn needle seat. Determine which material Page 12

15 Worn needle/ Weak return spring in gun handle. is leaking by removing the following parts: plug on resin side of gun head, side plug on catalyst side of gun head, nozzle cap, nozzle and turbulent mixer from front of gun. Visually examine areas now exposed to determine source of leak. Remove and replace worn part. Nozzle cap leak Distorted fan Hardened resin in gun head Worn or damaged turbulent mixer or damaged gun block Orifice in nozzle worn, clogged or damaged Improper flushing Page 13 Remove and replace turbulent mixer. Check for damage on outlet of gun block. Nozzle cap should be tightened by hand only. Push fine wire through nozzle orifice from back side of nozzle to clear orifice. Pick with fingernail to clean resin from V shaped indentation on front of nozzle. Hardened resin on nozzle may be softened by soaking in solvent. If milled V shaped indentation on front of nozzle appears rough or worn, replace nozzle. At the end of every use, push trigger forward to clean mix chamber. If gun is not to be used for ½ hour or more during work day, follow this procedure: remove nozzle (or static mixer), nozzle cap and turbulent mixer and front plug on resin side. These parts may be rinsed with the gun by pushing forward on trigger. With finger over nozzle

16 Resin fan without catalyst Cavity on catalyst side of gun has gelled or hardened resin. outlet, push forward on trigger to flush resin cavity out front plug hole on resin side. Visually examine mix chamber for cleanliness. Hang gun with mix chamber down until next use. For overnight or weekend inactivity, use the following procedure: remove nozzle cap, turbulent mixer or static mixer. Clean these parts rinsing with solvent by pushing forward on the trigger. Additionally, flush mix chamber. Remove front plug on resin side of gun head. With finger over nozzle outlet, push forward on trigger to flush resin cavity out front plug hole on resin side. Examine visually the mix chamber and resin chamber for cleanliness. Remove side plug from catalyst side of gun head and with clean rag or paper towel, blot excess catalyst off gun to prevent fume generated curing of any un-purged resin. Hang gun with mix chamber down. Before restart of unit, inspect catalyst cavity and resin cavity for evidence of leakage. Also inspect mix chamber for signs of solvent leakage. Remove front plug and side plug from catalyst side of gun head. Pick gelled and hardened resin Page 14

17 from well with suitable tool being careful not to damage threads in plug ports. Free and remove spring and ball. Remove injector (see picture of tool application). Clean the entire cavity thoroughly. Run tap water through injector port to clean threads. Replace all worn or damaged parts. Leak in packing Leak from nipples on gun head Trigger action stiff Needle packing worn (see drawing next page) Tighten needle packing by turning packing nut clockwise on flush, resin or catalyst needle packing where leak is evident. If leak persists, remove and replace packing. Keep needles lubricated to prevent over-spray from forming on needles and being forced into packing with trigger action. O-ring failure Remove and replace O- ring for seal between nipple and gun head where leak is detected. Loose hose connection Catalyst nipple pipe thread worn. Trigger bent, needles bent, spring, spring screw or needle guide worn Tighten hose fitting on nipple. Remove catalyst hose nipple from adaptor. Apply Teflon tape to nipple pipe fitting. Screw nipple back into adapter. Remove trigger and straighten tangs so holes for stud and nut align. Remove and replace bent needles or worn needle guides. Remove spring screw and spring from gun handle for inspection. Replace deformed springs or worn spring screws. Page 15

18 Broken Trigger CHAPTER 6: Pulling trigger back further than needle guides allow. Apply lubricating grease liberally to spring and interior of spring screw before reassembling. Coat needles with suitable grease before replacing trigger. Be sure trigger stud and screw are tight and trigger is riding free on stud and stud shoulder. Readjust trigger setting before operating gun. Be sure trigger does not hit against band on catalyst hose or resin hose fitting. Do not pull trigger back this far. Use screw adjustment on trigger catch for correct adjustment. Do not apply more tension to trigger than necessary to activate needles. Proper Chopper Adjustment Procedure The following adjustments, when carefully made, will allow the chopper to perform very well with any major manufacturer s chopper roving (2 strands of glass are normally recommended). Proper adjustments will assure uniformity to cut strand and the longest possible life of the rubber roll and blades. An understanding of the operation of the chopper operating design will help to clarify the need for good chopper adjustment. The ribbon of glass is passed through carbide rings in the roving guide where the restrictive action separates the strands and starts the break down of the fiber. The strands are then passed over the idler bearing at the nip point of the bearing and rubber roll with just enough compression to lay them flat, side by side. The strand is then pulled by the pinch grip between the rubber roll and blade rotor to the point of impact between the blade and the rubber roll. The broken strands are then thrown from the chopper by the inertia created by the velocity of the glass strands. Chopper Adjustments: Page 16

19 Be assured, before making adjustments, that there is no glass build up between the robber roll mandrel, idler bearing and rotor and the chopper base plate. Check to see that all rotating parts are free running. Note: New blades should be dulled by whetting on a piece of cardboard to remove sharp edges. Holding the eccentric nut for the idler bearing at the chopper base plate, with a suitable socket wrench loosen the cap screw and rotate the bearing away from the rubber roll. Follow the same procedure to loosen the rubber roll and rotate it away from the blade rotor. Turning the eccentric nut in the direction that will position the off-center hole toward the gun handle mounting hole on the chopper base plate, position the rubber roll against the blade rotor so it touches the rotor area between two blades. Tighten the cap screw while holding the eccentric nut. Physically check the adjustment by holding the blade rotor and rotating the rubber roll. The tension should be adjusted so the rubber roll will skid with a little drag against the rotor. The idler bearing can now be properly positioned in relation to the rubber roll. Rotate the eccentric nut for the idler bearing so the off-center hole in the eccentric will face toward the chopper mounting of on the gun handle and the idler bearing sleeve is against the rubber roll. Back the idler bearing off and away from the rubber roll a very slight amount. The idler bearing should look like it touches the rubber roll but will not rotate when the rubber roll is turned. A final check to assure the components are properly assembled on the base plate should be made before the cover is secured. A washer should be between the roll mandrel and the base and between the idler bearing and the base plate. The blade rotor should be aligned edge to edge with the rubber roll. The blade retainer and spring should approach the rubber roll prior to the blade. The blade should be supported against the high side of the blade slot in the rotor (i.e. on the center line). The rotor should be secured to the air motor shaft with the set screws turned down against the flat on the shaft. Align the step in cover with the slot on the chopper base plate. Push the cover retainer in the receptacle and turn ¼ of a turn to secure cover. Chopper Trouble Shooting: Problem Cause Action Air motor will not run Regulator on manifold not on. Set regulator so gauge reads more than 20 psi Manifold block Speed control thumbscrew on chopper manifold block should be turned counter clockwise until fully opened. Air valve on gun handle not activated by trigger bar Squeeze trigger to full on position to move poppet stem to on position. Trigger must depress poppet stem 1/8 for full on of air to Chopper. Page 17

20 Blade rotor stalls during start and stop operation Chopped strands not uniform length Motor frozen Rubber roll too tight against blade rotor. Blade not fully depressed on rotor Worn or damaged blades or rubber roll. Remove and repair motor. Air motor in operating condition should be oiled with light-weight machine oil, two drops every 4 hours of operation through the blower thumb screw (air control valve). Loosen cap screw on roll mandrel and turn eccentric nut to loosen pressure between rubber roll and blade rotor. Correct tension is applied when rubber roll can be skidded on blade rotor when blade rotor is held in position and roll is turned. Push blade to bottom of blade slot in rotor with small block of wood. Blades must be free of nicks and breaks. New blades should be dulled by whetting on cardboard to remove keen hair edges prior to installation. Grooves, glass cuts in rubber roll, or other irregular markings on surface caused by worn blades requires a change in rubber roll. Clam Shells Magnum Venus Pump Packing Removal Tool: The clam shells are tools to assist the removal of the packing in the center casting of the resin pumps. The proper tool for your pump is supplied with the pump. The following will explain their use: 1. Remove the piston cylinder from the bottom of the pump and the spring retainer and spring above the pump piston. 2. Slowly apply air to the pump to raise the piston to the top of the stroke. Page 18

21 3. Insert Clam Shell sections into the hole around the piston rod at the bottom of the oil well in the center casting, one half of the shell on either side of the piston rod. A. On HIS 11:1, 10:1, 7:1, 5:1 or 4:1 pumps by slowly applying air to the power head, the slave arm will move downward, pushing the clam shell down which in turn will move the packing down and out of the center casting. 4. Clam shells can/will be removed with packing set out of bottom of pump. CHAPTER 7: Resin Pump Trouble Shooting: Problem Cause Action Worn Spool Remove nuts from tie rods on center section and withdraw tie rods. Raise cylinder head above cylinder and with proper wrench, remove piston keeper from power head piston rod. Lift cylinder head assembly from the unit. Remove snap ring from bushing on under-side of cylinder head. Remove the two detent trip spring retainers, detent trip springs and balls. Remove cylinder head cap. Pull valve spool assembly and bushing out of lower side of the cylinder head. Examine valve spool O-rings and replace any worn or damaged parts. Push bronze valve sleeve down and out through lower side of cylinder head. Care must be exercised not to scratch or nick polished bronze valve sleeve. Examine O-rings now Page 19

22 Valve spool assembly out of adjustment exposed for damage. Remove and replace any worn or damaged O-rings. Examine spool for excessive wear. Replace it if worn or damaged. Replace damaged or broken springs. Reassemble following procedure in manual. Remove power head assembly from pump. Remove spring retainers, detent trip springs, and balls from power head. Turn power head upside down and remove snap ring. Pull entire valve spool assembly out of power head. Place valve spool assembly in vise (valve spool facing up) and remove in order; lock nut, upper valve keeper, and valve spool. Loosen jam nut and remove upper valve rod from lower valve rod. Clean threads of upper valve rod and screw rod back into lower valve rod until it bottoms out. Use serviceable locktite. Tighten jam nut against lower valve keeper. Place valve spool over upper valve rod until it rests on lower valve keeper (O-ring end of valve spool facing down). Screw upper valve keeper onto upper valve rod hand tight against valve spool. Screw lock nut on to upper valve rod. With suitable wrench back off upper valve keeper from valve spool approximately Page 20

23 Pump fails at top or bottom of stroke will not restart Pump exhausts excessive oil through silencers Broken or worn detent trip spring. Loose detent trip spring retainer. Valve trip collar missing or hole dirty so cannot reach bottom. Lack of lubrication Excessive Lubrication. One drop of oil falls in sight Page 21 1/3 of a turn and holding upper valve keeper with wrench in that position, tighten lock nut against upper valve keeper with another wrench. This should allow valve spool to spin freely but not move up or down. Reassemble assembly to power head and to pumping system using assembly procedure as outlined in manual. Check detent trip spring retainers for tightness. Retainers must be secure in cylinder head. If retainers are in place and pump will not operate, remove retainers and springs. Replace any worn or broken springs. Examine balls for wear or damage. Liberally lubricate inside of retainer with suitable grease. Reassemble balls, springs and retainers. Fully tighten spring retainers. Remove head and piston keeper and check valve trip spring. Check piston rod to see hole is free of rust or dirt and trip collar is in place. Pump oiler must provide adequate lubrication. Follow instructions carefully as given on original bottle provided with system. Note: Oiler is pre-set at factory and under normal usage should not need adjustment. Turn oiler off for a short period of time to allow

24 Resin in oil well in center section glass on top of lubrication every 3 rd stroke Worn packing Worn or scored piston rod. Page 22 excessive oil to exhaust from power head. Replace Teflon packing set in lower unit. Remove nuts from tie rod and foot valve collar from foot valve. Remove cylinder and foot valve assembly from center section by pulling down on cylinder. Remove piston body assembly from piston rod (4:1 and 7:1 units with long pump remove foot valve and pump tube, piston cup assembly, 2 bolts and collar and adapter). Slide spring retainer and packing spring down piston rod to remove. Place packing assembly removable tool, ( clamshells ) one section on either side of piston rod below upper slave arm in oil well area of center section. Disconnect catalyst pump from upper slave arm, and by pushing down on slave arm, extract female ring, Teflon packing and male ring from piston rod. Clean all components well before reassembling with new Teflon packing set. Follow assembly procedure prescribed in manual. Note: a small amount of resin will leak by seal area. With rag or paper towel, roll up and out occasionally. Continued use of a piston rod that is scored or it s had chrome plate is wearing off must be replaced. New packings to prevent leak at

25 No resin delivery on down stroke No resin delivery on up stoke Air entering pump during running. Foot valve, spring, spring retainer, or foot valve ball worn or dirty Piston cups, piston ball or pump cylinder worn. Fittings on wand assembly not tight. Page 23 this stage are not effective. Remove, clean/replace parts as necessary. Remove, clean/replace parts as necessary. Check all fittings from filter on bottom of wand to union on pump and retighten. No flush solvent at gun. No air Set regulator air on manifold to flush solvent tank to 30 psi for resin and for gel coat spraying. Set regulator at 40 psi for casting and hydrajecting operations. Be sure valve cock is on ¼ turn. No solvent in tank. Blockage in flush hose or gun. Turn regulator to flush tank off. Release air form tank by pulling up on ring on relief valve on lid of flush tank. Release and remove lid. Fill tank with solvent. Take care to position O-ring on cover before sealing tank. Turn regulator to flush tank to off. Release pressure from tank. Disconnect hose from tank and gun and blow through with air. IF hose does not readily pass air, it should be replaced. Check nipple to hose connection on gun. Remove elbow and nipple from gun and check their cleanliness. Visually examine cavity in gun head for obstructions. All ports and openings in needle area of flush system must be clean of foreign matter. Clean all areas and replace any and all worn or damaged parts.

26 Air relief valve bleeds constantly Too high regulator pressure Reduce pressure to flush tank. Air pressure to tank should not exceed 50psi (Relief valve is set at 60psi) Valve not sealing Page 24 Reset relief valve by lifting ring on relief valve and letting it reseat. If this fails to remedy malfunction, remove relief valve counter clockwise and remove it. Inspect valve and valve seat for contamination. Replace any worn or damaged parts and reassemble. Pump will not start No air Check air source to manifold for supply. Check regulator for air to power head supply. Regulator must read minimum of 20 psi. Open air valve to power head from regulator. Assure air direction indicator on oiler is honoring air input. Check oiler for obstructions. Resin set up in lower unit Non-primed system with wand Remove nuts and foot valve collar from tie rods. Pull cylinder down from center section casting. Clean and/or replace any damaged or worn parts. Reassemble. (4:1 units and 7:1 units with long tube, remove foot valve and pump tube, piston cup assembly, 2 bolts and collar and adaptor. Clean and/or replace any damaged or worn parts. Check all connections between pump and end of resin pick up and for leaks. Pour resin down wand to

27 Pump cycles when gun is not in use Pumps stops air continuously exhausts. Worn piston cups O-ring failure foot valve of pump. Immerse wand into resin. Throttle air to pump slowly until pump responds to drawing resin. Remove tie rod, nuts, and foot valve collar. Remove cylinder and foot valve from center section of pump. (4:1 and 7:1 units with long pump tube, remove foot valve and pump tube). Hold piston body secure and remove piston keeper, back-up ring, piston cup, spacer ring and second piston cup. Replace cups by installing assembly in reverse order of tear down. Valve spool or valve sleeve O-rings ruptured. Push pump piston rod to the extreme up position before disassembling power head. CHAPTER 8: Flush Hose Installation: 1. Install solvent line before catalyst and resin hoses. 2. Apply 30psi to solvent pressure pot and check retainer for leak. CHAPTER 9: Flush System Trouble Shooting: Problem Cause Action Flush needle seat leak Resin in solvent hose or flush tank Page 25 Apply more spring pressure to flush needle by holding needle with screwdriver, through the mix chamber and tightening the spring retainer for the flush needle by turning it clockwise with a suitable

28 wrench. Check to see packing nut is not too tight to overcome force of spring. If leak condition persists it is necessary to remove and replace the flush needle seat. Clean solvent tank, hose, elbows and nipples prior to reassembling system. CHAPTER 10: Airlift Trouble Shooting: Problem Cause Action Air-lift will not rise Insufficient Air Check air to unit. Set regulator on manifold at 50psi and attach quick disconnect to air lift connector. Increase air pressure on regulator until Leaks. Page 26 air lift rises. Make sure all connections are tight. Leaking air reduces efficiency of equipment. Over tightened bracket If bracket or bracket U- bolts have been overtightened, cylinders will seize on post. Loosen until cylinder rides smoothly on post. Worn Packing cups Remove and replace. Remove pump from airlift. Disconnect flush pot and remove. Unscrew post from base; unscrew stop sleeve from cylinder and slide cylinder from post. Replace cup. Care must be taken, after reassembling new cup, washer and screw, when inserting post into cylinder. Be sure cup is not

29 disfigured when It is pushed into cylinder. Replace stop sleeve and reassemble unit. Caution: Be sure stop ring is in place. CHAPTER 11: Hose Trouble Shooting: Problem Cause Action Hose leaks at fittings Loose fitting Tighten fitting. Check fittings for leakage before Damaged fitting or nipple Crimped hose Page 27 operation. Damaged threads or damaged male and female seats between fittings and nipples can cause leakage. Remove and replace any damaged parts. Note: a leak proof system must be maintained for proper performance of equipment. If hose has been sharply bent, the plastic liner can be ruptured or separated causing restriction or blockage of flow. Remove and replace hose. Resin hose plugged Hardened or gelled resin System is sealed and filtered. If resin gels or hardens in hose, gun has not been properly flushed and/or needles are not fully closing on seat. See: Gun Trouble Shooting, Chapter 8 to correct this. Check filter to determine if screen is in place. Maintain cleanliness of screen at all times.

30 Hardened area will generally be confined to ship section (1/4 x 34 hose). If resin is in a gelled state, it is possible this can be pushed through, using pump pressure and then flushed clean with solvent. If resin is hardened, remove and replace hose. Catalyst hose plugged. Contamination Make sure lid is on catalyst jug at all times. Maintain clean supply of catalyst. Be sure screen is intact and clean on end of catalyst gravity flow hose. When catalyst pump has been dismantled, be sure all parts are clean and free of any foreign particles. Catalyst flow area through homes is very limited and can be restricted by any foreign matter. Catalyst leak back through gun Remove hose fittings on ends of catalyst hose and make sure small orifices in fittings are free and clear. If necessary, remove catalyst hose core, wash clean with clear water. See Catalyst Pump and General Trouble Shooting; Catalyst hose plugged & Gun head plugged on catalyst side. CHAPTER 12: Instructions and Procedures for Filled Resin Systems: Certain processes and economic factors may call for a filler of some type (such as calcium carbonate, alumina trihydrate, glass bubbles, shell flour, etc.) to be used Page 28

31 with resin. Many factors should be considered when deciding to use these materials. One, not often considered, is the additional wear and tear on equipment. Fillers do increase wear. To what extent, is based on many factors such as amount and type of filler, volume dispensed and type of system used (spray, pour, etc.). The following adjustments to the equipment and procedures are recommended for systems using filled resins. 1. Magnum Venus Products has available the following parts for longer wear: A. Carbide gun needles. B. Carbide gun seats. C. Carbide spray tips. D. Hardened resin pump cylinders. 2. Reversing the direction of the bottom piston cup in the resin pump will increase pump stroke efficiency with filled systems only. 3. Remove or increase the mesh size of all resin pump filler screens to prevent flow restrictions or filler separation. 4. Auxiliary heat applied to the filled resin may be needed to create a spray fan. Note: consult a Magnum Venus Products representative if in doubt. 5. Never leave filled resin in a system long enough for the filler to separate and settle on balls/seats in the system. 6. Never use improperly mixed filler in a system. (Consult your resin/filler representative for proper materials and mixing procedures.) It is important to keep filled resin systems under constant agitation. 7. Never flush a filled system with solvent. This will usually remove the resin and leave the filler. Always pump non-filled resin through the system to remove filled resin, and then flush with solvent. This information and procedures are only an aid to assist you in using your Magnum Venus Products equipment properly. Not all Magnum Venus systems can be used with fillers, nor can all fillers be used with Magnum Venus systems. Always consult your Magnum Venus Products representative when considering a filled system. Page 29