EXTERNAL MIX GEL COAT GUN Repair Manual EMG-1000 & EMG-1500

EXTERNAL MIX GEL COAT GUN Repair Manual EMG-1000 & EMG-1500 MAGNUM VENUS PLASTECH GEL COAT GUN REPAIR MANUAL Rev. 04/04/2007

EMG-1000 & EMG-1500 Gel Coat Gun Manual TABLE OF CONTAINS: WARNING AND SAFETY INFORMATION CHAPTER 1 GUN DISASSEMBLY AND ASSEMBLY CHAPTER 2 GUN BLOCK AND HANDLE ASSEMBLY CHAPTER 3 GUN ADJUSTMENT AND START UP CHAPTER 4 TROUBLESHOOTING CHAPTER 5 PARTS DRAWINGS

AIRLESS EQUIPMENT SAFETY Injection Hazard DO NOT POINT THE GUN AT ANY PERSON NEVER LOOK AT THE GUN FROM THE FRONT (NOZZLE END) NEVER trigger an airless gun while it is aimed at a person. The hydraulic pressure may inject fluid into the flesh, causing injury or death. If the fluid penetrates the skin it WILL cause serious injury. Clothing, such as gloves will NOT provide protection. The system is capable of fluid pressure high enough to cause a LETHAL INJECTION. TREAT THE APPLICATOR AS YOU WOULD A LOADED WEAPON. Before applying pressure to the system, ALWAYS: Follow the manufacturer s operating instructions and maximum pressure recommendations. Secure the trigger in the OFF position and check all pressure connections. Use grounded, high pressure fluid lines. Check that the pump is properly grounded. Before disassembly of ANY part of the pressure system (including the applicator or its nozzle) ALWAYS: Shut the pump OFF. Discharge the residual fluid and pressure from the applicator. Secure the trigger in the OFF position. Follow these same three procedures anytime that operation is discontinued. Do NOT undertake any of the following until pressure is relieved from the entire system: Loosen or remove the nozzle. Disassemble any part of the applicator. Loosen or disconnect any fluid line fittings. Disassemble any part of the pump.

Be sure that the power to the pump is OFF before undertaking ANY repair, maintenance or adjustment. If it is necessary to adjust or clean the nozzle on site, be sure that it is aimed away from all personnel so that it may discharge safely if there is residual pressure in the system. Do NOT use any replacement part that does not meet the manufacturer s specifications. Correct packing or valve seal leaks IMMEDIATELY. Frequently check the condition of all pressurized components, especially fluid lines. Replace worn lines and parts before they fail. If nozzle clogging occurs frequently, use a fluid filter with proper mesh size.

PUMPING SYSTEM SAFETY INSTRUCTIONS Use MVP replacement parts to assure compatible pressure rating. Read ALL warning and safety instructions carefully before operation of this unit. Heed all warnings. WARNING: Never allow any part of the human body to come in front of, or in direct contact with, the material outlet. Accidental operation of the pump could cause an injection into the flesh. If injection occurs, medical aid must be immediately obtained from a physician. Component Rupture: This unit is capable of producing high fluid pressure as stated on the pump model plate. To avoid component rupture, and possible injury, do not exceed 75 cycles per minute or operate at an air inlet pressure greater than 150 PSI (10 bar). Servicing: Before servicing, cleaning or removing any component, ALWAYS disconnect or shut off power source and carefully relieve all fluid pressure from the system. CAUTION: When pumping, flushing or recirculating volatile solvents, the area must be adequately ventilated. CAUTION: Materials and solvent being pumped must be compatible with the parts of the pump that becomes wetted when in contact with material or solvent. Wetted parts consist of the following: stainless steel, copper, brass, steel, gray iron, leather, Teflon and Velluloid. CAUTION: Keep solvents away from heat, sparks and open flames. Keep containers closed when not in use. Prevent Static Sparking: If static sparking occurs, fire or explosion could result. The pump, dispensing valve, and containers must be grounded when handling flammable fluids such as solvents, paints, lacquers, etc., and wherever discharge of static electricity is a hazard. Use grounded hoses (static wire) and be sure the object being serviced is grounded if it can produce a static charge. Continuity (a good static wire connection) of a hose can be checked by using an ohmmeter. Place one probe on one hose fitting and the other probe on the other hose fitting, continuity or proper grounding through hose is good when a reading is obtained on the ohmmeter. Air and Lube Requirements: Excessive air pressure will shorten the life of the pump. Do not operate pump above recommended maximum air pressure. If necessary, an air regulator should be installed to maintain the desired pressure when the pump is in operation.

Filtered air will allow the pump to operate more efficiently and yield a longer life to operating parts and mechanisms. A filter capable of filtering particles larger than 50 microns should be used. Maintenance: If the pump is to be inoperative for a lengthy period of time (even for a few hours) disconnect air and relieve all pressure from system. Periodically flush pump with a solvent that is compatible with the material being pumped. Pour a little throat seal lubricant into the solvent cup to keep upper packings pliable and to keep material drag-thru soft. Material drag-thru that is allowed to harden, will score the piston rod. This will create excessive leakage and rapid packing wear. Disassembly should be done on a clean work bench with clean cloths to keep parts clean. If replacement parts are necessary, consult Parts List for identification. Before assembling, lubricate parts where required. When assembling O-rings, or parts adjacent to O-rings, care must be exercised to prevent damage to O-ring and O-ring groove surfaces. If you have any questions about safety or procedures, contact your Magnum Venus Plastech representative. CAUTION: Materials and solvent being pumped must be compatible with the parts of the pump that becomes wetted when in contact with material or solvent. Wetted parts consist of the following: stainless steel, copper, brass, steel, gray iron, leather, Teflon and Vellumoid. CAUTION: Keep solvents away from heat, sparks and open flames. Keep containers closed when not in use.

Fire Solvent Important safety information The below potential hazards may cause an injury or loss of life HAZARD CAUSE SAFEGUARD Inhaling Toxic Substances Explosion Hazard Incompatible Materials General Safety Solvent and coatings can be highly flammable or combustible, especially when sprayed. During cleaning and flushing, solvents can be forcefully expelled from fluid and air passages. Some solvents can cause eye injury. Certain materials may be harmful if inhaled or if there is contact with skin. Halogenated hydrocarbon solvents (for example; Methylene chloride and 1,1,1-Thrichloroethane) can chemically react with aluminum. The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion. Improper operation or maintenance of equipment. Adequate exhaust must be provided to keep air free of accumulations of flammable vapors. Smoking must NEVER be allowed in the spray area. Fire extinguishing equipment must be present in the spray area. Wear eye protection. Follow the requirements of the Material Safety Data Sheet supplied by your coating material manufacturer. Adequate exhaust must be provided to keep the air free of accumulations of toxic materials. Guns with Stainless Steel internal passageways may be used with these solvents. However, aluminum is widely used in other spray application equipment such as material pumps, regulators, valves & cups. Check all equipment items before use and make sure they can also be used safely with these solvents. Read the label or data sheet for the material you intend to spray. If in doubt as to whether or not a coating or cleaning material is compatible, contact your material supplier. Operators should be given adequate training in the safe use & maintenance of the equipment (in accordance with the requirement of NFPA-33 Chapter 15). Users must comply with all local & national codes of practice and insurance company requirements governing ventilation, fire precaution, operation, maintenance and house keeping. These are OSHA Section 1910.94 and 1910.107 and NFPA-33. Risk is reduced by avoiding or lessening factors 1-7. All equipment must be grounded for static electricity in accordance with NFPA-77. Be sure to relieve all pressure from system before performing any maintenance. Spray equipment shall be used in spray areas in accordance with NFPA, OSHA and Country/State/local requirements.

Static Spark Injection Hazard Hazardous pressure Excessive inlet pressure WARNING Can Cause explosion resulting severe injury or death. Any material injected into flesh can cause severe injury or death. Sudden pressure release can cause severe injury or death. Can cause severe injury or death Ground pump and pumping system Keep body parts away from outlet device. If an injection occurs, immediately obtain medical attention. Pumping system can remain pressurized when pump is not operating. Do not exceed the maximum inlet pressure as stated on the model plate. INSPECTION AND MAINTENANCE OF UNIT 1) Check solvent cup to be sure it is 1/3 full. 2) Check catalyst and material levels. 3) Inspect material spray tip and o-ring. Replace if necessary. 4) Inspect catalyst tip assembly and o-rings. Replace if necessary. 5) Inspect tip pin o-rings on front of gun head and replace if nicked or worn. 6) Assemble catalyst tip and material tip onto gun. 7) Lubricate threads on retaining ring and assembly onto gun. 8) Inspect hose assemblies and connections for leaks and wear and tear. Replace if necessary. Do not wait until hose is so worn that it may burst. 9) Check roving quantity (if applicable). 10) Inspect and replace if necessary: a) Chopper Blades b) Anvil Sleeve c) Cutter Head Bearing d) Idler Bearing 11) Inspect and adjust if necessary: a) Cutter head to Anvil Sleeve tension b) Idler Bearing to Anvil Sleeve tension c) Check Chopper position for most efficient disbursement of chop into spray pattern. 12) Oil Cutter assembly Air Motor with Magnum Air Motor Oil as necessary (normally 2 3 drops daily, depending on usage).

PREPARATION AND PRIMING OF NEW SYSTEM 1. Be sure all air regulators are turned completely to the left, shutting off air to the components. 2. Slowly open main air. 3. Prime empty catalyst line: a. Disengage catalyst pump b. Open ball valve on catalyst manifold (if applicable) c. Eliminate air pockets by manually hand pumping the catalyst 5-10 short strokes (2-3 in.). After eliminating air pockets, and while continuing to hand pump, close ball valve on catalyst manifold. d. Pull and hold trigger on gun while hand pumping catalyst pump with short strokes until there is a solid, steady catalyst flow from the head of the gun. This will ensure that all air is purged from the line. Release trigger. e. Continue to hand pump the catalyst with short strokes until catalyst is fully primed and pressurized (generally within 5 additional strokes or less). NOTE: Do NOT engage slave pump until material pump has been primed. 4. Material Pump: (be sure catalyst pump is disengaged) Place a container or bucket under ball valve located at the bottom of the resin filter assembly to catch material while priming. Open ball valve. Slowly bring up pressure on material pump regulator just enough to allow pump to stroke up and down evenly. After a smooth flow of material is flowing from the valve, turn regulator off and close the valve. 5. Pull trigger on gun and allow gun to hang above waste container. Slowly bring up pump pressure again to allow material to flow out of gun. Release trigger to close gun. Pump will cycle until it is fully primed and then will stall out. 6. Engage slave pump.

PREPARATION AND PRIMING OF PREVIOUSLY USED (shut down) SYSTEM 1. Slowly open main air. 2. Material Pump: (be sure catalyst pump is disengaged) Place a container or bucket under ball valve located at the bottom of the resin filter assembly to catch material while priming. Open ball valve. Slowly bring up pressure on material pump regulator just enough to allow pump to stroke up and down evenly. After a smooth flow of material is flowing from the valve, turn regulator off and close the valve. 3. Catalyst Slave Pump: a. Disengage slave pump. b. Open ball valve of catalyst manifold (if applicable). c. Eliminate all air pockets in feed lines by manually pumping catalyst pump until catalyst exits ball valve. Close ball valve. e. Open gun by pulling trigger and continue hand pumping until catalyst exits gun. f. Leave Catalyst Pump disengaged. 4. Pull trigger on gun and allow gun to hang above waste container. Slowly bring up pump pressure again to allow material to flow out of gun. Release trigger to close gun. Pump will cycle until it is fully primed and then will stall out. 6. Engage slave pump.

SHUT DOWN PROCEDURES FOR SPRAY EQUIPMENT 1. Trigger gun until pump shaft is in the full down position (at bottom of stroke position). 2. Engage gun trigger lock. 3. Relieving pressures: a. Close main air valve to system. b. Purge excess air from system by relieving air from the bottom of the air filter or water trap. c. Catalyst pressure: Dump or relieve catalyst pressure at catalyst manifold (if applicable) by opening catalyst ball valve. Pressure will immediately be relieved. Close the ball valve at once to avoid draining of catalyst from catalyst line. d. Material pressure: Place a container under material ball valve at bottom of fluid filter assembly to catch material flow when relieving pressure. Slowly open material ball valve to relieve pressure. Remember - the pump is under extreme pressure. Use the utmost caution when opening the valve to avoid injury or being sprayed with material. Once material pressure is relieved, close ball valve. 5. Remove catalyst and material tip assemblies from head of gun and clean thoroughly. 6. Thoroughly clean the front of gun head. 7. Inspect entire gun and equipment for over spray and clean. Important Notes: System is now shut-down and ready for the next start-up Proper cleanliness habits of your spray equipment go a long way in keeping down unnecessary maintenance and repair costs.

1. Air requirement recommendations: AIR PRESSURES a. A minimum of 100 psi on main air. b. 20-30 CFM for chopper systems 2. Material pump: 30-50 psi TESTING SPRAY PATTERN 1. Testing of your spray pattern should be performed away from original part. Use paper or cardboard to check the following: (see Testing & Adjusting Manual ) 2. Spray pattern width and output 3. Catalyzation 4. Spray pattern definition (fingers and tails): 5. Adjust as necessary with the MVP Air Assist adjustment screw to give the finest pattern available by eliminating fingers and tails. After completion of the above procedures, you may now confidently use your MVP system

CHAPTER 1 EMG-1000 & EMG-1500 Gel Coat Gun Disassembly WARNING: Always remove fluid pressures before working on the unit. WARNING: Be careful not to bend the catalyst and resin needles. Initial Disassembly... 1. Remove Catalyst, Resin and Air pressure from system before disassembly. 2. Remove Catalyst, Resin and Air lines from the Gun Block Assembly. 3. Remove Screw (00145) from Trigger Stud (54630-1). 4. Remove Trigger Stud (54630-1) from Gun Handle and Trigger (MAX-2040). 5. Remove Trigger (MAX-2040) from gun assembly. 6. To remove the Gun Block Assembly (EMG-1001-01) from Gun Handle remove Cap Screw (F-CS-04C-12) located at the back center, just above the Gun Block Assembly. You now have two components, the Gun Block Assembly and Gun Handle Assembly.

Gun Handle Disassembly 1. Remove Spring Retainers (54000-1) and Springs (04039-1) from handle. PROCEDURES 1-4 BELOW FOR EMG-1500 ONLY 1. Remove Valve Body Assembly (54440-1) from Handle (54350-3). 2. Remove Spring (04070-1) and Poppet Assembly (54501-1). 3. Unscrew Retainer (54420-1) from Valve Body (54440-1) 4. Remove O-Ring (O-S-104A) Gun Handle Assembly 1. Apply lubricant to Springs (04039-1) and insert into Gun Handle. 2. Thread Spring Retainers (54000-1) over Springs (04039-1) into Gun Handle. PROCEDURES 1-4 BELOW FOR EMG-1500 ONLY 1. Slide Spring (04070-1) onto the end of the Poppet Assembly (54501-1) 2. Insert Poppet Assembly (54501-1) into Valve Body (54440-1) 3. Slide O-ring (O-S-104A) over Poppet Assembly (54501-1) and retain with Packing Retainer (54420-1) 4. Screw Assembled Valve Body (54440-1) into the Gun Handle (54350-3)

Gun Head Disassembly 1. Remove the Retaining Ring (VPA-1003) from the front of the Gun. 2. Remove the Catalyst Tip and Nozzle from the front of the Gun. 3. If necessary remove the Thread Adapter (EMG-1002-01) by loosening the two Screws (F-HBCS-832-06). 4. Remove the O-ring (O-S-006) from the front of the Thread Adapter (EMG-1002-01). 5. Remove Needle Guide (53900-1) and Jam Nut (53800-1) from Catalyst Piston Needle (DMX-3008-01) 6. Pull Catalyst Needle (CPR-2005-01) from the Needle Housings (CPR-2003-02). 7. Remove O-ring (O-S-006) from the end of the Catalyst Needle (CPR-2005-01). 8. Unscrew Catalyst Needle Housing (CPR-2003-02) from Gun Head (EMG-1001-01). 9. Remove Catalyst Seat (CPR-2012-02) and O-ring (O-S-012) from the gun block 10. Unscrew Resin Seal Housing (MAX-2013) from Gun Head (EMG-1001-01) 11. Remove Needle Guide (53900-1) and Jam Nut (53800-1) from Needle (MAX- 2010-01) 12. Unscrew Packing Nut (MG-1022) from Seal Housing (MAX-2013) 13. Pull Needle (MAX-2010-01) from Seal Housing (MAX-2013) 14. Remove Packing Seal (MAX-2008) and Seal Retainer (MAX-2009) from Seal Housing (MAX-2013) 15. Unscrew Carbide Seat (MAX-2011-01) from Gun Head (EMG-1001-01) using a 9/64 hex Allen wrench. 16. Remove O-ring (O-T-010) from the gun block 17. Remove Catalyst fitting / Check Valve from the gun block 18. Remove Material Fitting (55500-1) from the gun block. 19. Remove Check Valve Cap (EMG-1010) and Push Fitting (06977) from the Check Valve Body (EMG-1008). 20. Remove the Check Valve Body assembly (EMG-1008) from the gun block.

Check Valve Body Disassembly 1. Using a wrench or vice hold the hex of the Check Valve Stem (EMG-1007) and using a flat blade screw driver remove the Check Valve Nut (EMG-1009). 2. Remove the Check Valve Stem (EMG-1007) and Check Valve Spring (EMG- 1001) from the Check Valve Body (EMG-1008). Check Valve Body Assembly 1. Replace O-ring (O-S-007) on Check Valve Stem (EMG-1007). 2. Install the Check Valve Stem (EMG-1007) into the front of the Check Valve Body (EMG-1008). 3. Install the Check Valve Spring into the back of the Check Valve Body (EMG- 1008). 4. Using your finger hold the hex of the Check Valve Stem (EMG-1007) and using a flat blade screw driver install the Check Valve Nut (EMG-1009) onto the end of the Check Valve Stem (EMG-1007). 5. Using a wrench or vice hold the hex of the Check Valve Stem (EMG-1007) and using a flat blade screw driver hand tighten the Check Valve Nut (EMG-1009). Check Valve Disassembly (EMG-1097-01 & EMG-1097-01-03J) 1. Remove Spring Housing (EMG-1097-04) from the O-ring Housing. 2. Remove Spring (CV-1097-05) and Piston (CV-1097-03). 3. Remove O-ring (O-S-009A), replace o-ring as necessary. Check Valve Assembly (EMG-1097-01 & EMG-1097-01-03J) 1. Install O-ring (O-S-009A) into the O-ring Housing. 2. Install Spring (CV-1097-05) and Piston (CV-1097-03) into Spring Housing. 3. Thread Spring Housing (EMG-1097-04) into O-ring Housing.

Gun Head Assembly 1. Install a new O-ring (O-S-012) onto Check Valve Assembly and thread it into the catalyst fitting position. 2. Place a new O-Ring (O-S-012) on Resin Fitting (55500-1) and install into the gun block. 3. Install new O-Ring (O-S-012) into Catalyst Needle Seat area of the Gun Head (EMG-1001-01). 4. Install the new Catalyst Needle Seat (CPR-2012-02) onto the end of the Catalyst Needle Housing (CPR-2003-02). 5. Install new O-Ring (O-S-012) on Catalyst Needle Housing (CPR-2003-02) and thread into Gun Block (EMG-1001-01). 6. Thread Jam Nut (53800-1) then Needle Guide (53900-1) onto catalyst needle end. 7. Install new O-ring (O-S-006) onto the Catalyst Piston Needle (CPR-2005-01). 8. Insert Catalyst Piston Needle (CPR-2005-01) into the Catalyst Needle Housing (CPR-2003-02). 53900-1 NEEDLE GUIDE 53800-1 JAM NUT CPR-2005-01 CATALYST NEEDLE O-S-006 O-RING CPR-2003-02 NEEDLE HOUSING O-S-012 O-RING CPR-2012-02 CATALYST NEEDLE SEAT NOTE: Use caution not to bend the catalyst needle while performing the remaining assembly procedures.

9. Install new O-Ring (O-T-010) into Resin Needle Seat area of the Gun Head (EMG-1001-01) 10. Firmly thread Carbide Seat (MAX-2011-01) into Gun Head (EMG-1001-01). 11. Install new O-Ring (O-S-012) on Seal Housing (MAX-2013) and lightly grease threads. NEEDLE GUIDE PACKING NUT JAM NUT PACKING SEAL SEAL RETAINER O-RING SEAL HOUSING RESIN NEEDLE O-RING CARBIDE SEAT GUN HEAD 12. Install Resin Needle (MAX-2010-01) thru Seal Housing (MAX-2013). 13. Slide Seal Retainer (MAX-2009) then Packing Seal (MAX-2008) over the Resin Needle (MAX-2010-01). 14. Slide Packing Nut (MG-1022) over the Resin Needle (MAX-2010-01) and thread into Seal Housing (MAX-2013). Just a little over finger tight do not over tighten. 15. Thread Jam Nut (53800-1) then Needle Guide (53900-1) onto resin needle end. 16. Thread Seal Housing and Resin Needle Assembly into the Gun Head (EMG- 1001-01). NOTE: Use caution not to bend the catalyst and resin needle while performing the remaining assembly procedures.

CHAPTER 2 EMG-1000 & EMG-1500 Gel Coat Gun WARNING: Be careful not to bend the catalyst and resin needles. Assembly Gun Block and Gun Handle 1. Attach the Gun Head Assembly (EMG-1001-01) to the Gun Handle (54350-3) using Cap Screw (F-CS-04C-12). 2. Slide Trigger (MAX-2040) into place against the needles and line up the holes with the handle. 3. Push Trigger Stud (54630-1) thru both the Trigger (MAX-2040) and the Gun Handle (54350-3) and retain with Screw (00145).

CHAPTER 3 EMG-1000 & EMG-1500 Gel Coat Gun Gun Adjustment and Start Up 1. Make sure trigger and trigger bar are not worn, loose or damaged before adjusting gun or needle guides. 2. Adjust the Resin Needle Guide and Jam Nut so they will open just before the Catalyst Needle, never catalyst first. How much you open the resin needle before you open the catalyst needle will depend on the resin viscosity and may have to be changed as the resin temperature changes. See the Testing and Adjusting Manual (12016-2) for testing your gun. 3. Test the gun by putting 100psi of air to the catalyst and resin fittings and putting the gun in a tub of water.

CHAPTER 4 EMG-1000 & EMG-1500 Gel Coat Gun Troubleshooting Catalyst Problems 1. Catalyst leaking around Needle (inside packing nut) Replace O-ring (O-S-006) on the Catalyst Needle. Check for excessive pressure in catalyst system Check that the needle is not bent 2. Catalyst leaking around Needle Housing Replace O-Ring (O-S-012) on Needle Housing (CPR-2003-02) 3. Catalyst leaking from the front of the gun Check Catalyst Piston Needle (CPR-2005-01) for wear or damage Replace Catalyst Seat (CPR-2012-02) Replace O-Ring (O-S-012) under the catalyst seat Damaged or Weak Return Spring (04039-1), replace as needed Check for excessive pressure in catalyst system Check to see if the Catalyst Piston Needle (CPR-2005-01) is bent 4. No catalyst from the gun Make sure trigger is pulling catalyst needle back / open Check gun block for blockages Check catalyst pump for proper operation (See catalyst pump manual) 4. Catalyst leaking between Check Valve (EMG-1097-01 or EMG-1097-01-3J) and gun block Replace O-Ring (O-S-012) on check valve 5. Catalyst leaking from around the catalyst air in Check Valve Body (EMG-1008) Lightly tighten Check Valve Body (EMG-1008) into gun block Replace O-Ring (O-S-3-904) 6. Catalyst leaking from around the catalyst air in Check Valve Cap (EMG-1010) Lightly tighten Check Valve Cap (EMG-1010) Replace O-Ring (O-S-3-904) Replace O-Ring (O-S-007) on Check Valve Stem

Resin Problems 1. Resin leaking around Needle (inside Needle Housing CPR-2004-01) Check that the needle is not bent Lightly tighten Packing Nut (MG-2022) Replace Packing Seal (MAX-2008) 2. Resin leaking around Needle Housing Replace O-Ring (O-S-012) on Needle Housing (MAX-2013) 3. Resin leaking from the front of the gun Check Piston Needle (MAX-2010-01) for wear or damage, replace as needed Check Carbide Seat (MAX-2011-01) for wear or damage, replace as needed Replace O-Ring (O-T-010) under the Carbide Seat (MAX-2011-01) Damaged or Weak Return Spring (04039-1), replace as needed Check for excessive pressure in resin system 4. No Resin from the gun Make sure trigger is pulling resin needle back / open Check gun block for blockages Check resin pump for proper operation (See resin pump manual) 5. Resin leaking between fitting and gun block Replace O-Ring (O-S-012) on fitting General Problems 1. Air leaking from around poppet needle on EMG-1500-X Tighten Retainer (54420-1) (caution do not over tighten, this will make the poppet needle move slowly or not move at all). Replace O-Ring (O-S-104A) 3. Air leaking from around poppet valve body on EMG-1500-X Tighten Poppet Valve Body (54440-1) into Gun Handle (54350-3) 4. Air leaking out of the fitting on handle Retainer (54420-1) may be too tight and holding valve open Check Needle (54501-1) for wear or damage Check Poppet Valve Body (54440-1) seat area for wear or damage 5. Material leaking from around nozzle or nozzle retaining ring Tighten Retaining Ring (VPA-1003) (caution do not over tighten) Replace O-rings (O-S-006) on the studs Replace O-rings (O-E-012) on the Nozzle 6. Trigger Action stiff or hard Check Trigger (54360-1) for damage Check Trigger Stud (54630-1) and Screw (00145) for damage, remove and lubricate as needed. Check Needle Guides (53900-1) and Springs (04039-1) for damage, remove and lubricate as needed Check Spring Retainer (54000-1) for wear or damage Check Needles and Needle Housings for hardened or sticky material

CHAPTER 5 EMG-1000 & EMG-1500 Gel Coat Gun PARTS DRAWINGS: EMG-1000-X EMG-1500-X EMG-1097-01 EMG-1097-01-03J EXTERNAL MIX GEL COAT GUN ASSEMBLIES EXTERNAL MIX GEL COAT GUN W/SIGNAL CHECK VALVE ASSEMBLY CHECK VALVE ASSEMBLY 3J FITTING

11 45 1 3 12 4 28 9 13 2 10 15 7 16 17 8 21 5 6 14 26 18 23 19 24 26 32 20 47 26 25 36 34 22 35 26 37 48 43 42 44 31 41 30 27 40 24 34 46 27 39 MAGNUM VENUS PRODUCTS External Gelcoat Gun Assy EMG-1000 External Gelcoat Gun Assy EMG-1000-FIT External Gelcoat Gun Assy (International) EMG-1000-INT External Gelcoat Gun Assy (International) REV. A = DWG WAS EMB-1000 ADDED -FIT, -INT, & -FIT-INT 3/21/03 JEM B = COMBINED ITEMS 37 & 38, EMG-1002 & EMB-1003 10/16/03 JEM C = ITEM 2 WAS 54360-1, ADDED ITEMS 28 AND 29 11/12/04 BT2 D = ITEM 28. WAS F-MS-832-08 01/30/06 BT2 33 EMG-1000-FIT-INT

Common Parts for the Assy of; External Gelcoat Gun Assy EMG-1000 External Gelcoat Gun Assy EMG-1000-FIT External Gelcoat Gun Assy EMG-1000-INT Enternal Gelcoat Gun Assy EMG-1000-FIT-INT PARTS LIST * * * * ITEM PART NO. QTY DESCRIPTION 1 54350-EMG 1 GUN HANDLE 2 MAX-2040 1 TRIGGER 3 54630-1 1 TRIGGER STUD 4 54000-1 2 SPRING RETAINER 5 53900-1 2 NEEDLE GUIDE 6 53800-1 2 JAM NUT 7 56190-1 1 TRIGGER LOCK SCREW 8 56100-1 1 TRIGGER LOCK NUT 9 02883-8 1 TRIGGER LOCK PIN 10 04420-1 1 TRIGGER LOCK SPRING 11 00145 1 TRIGGER STUD SCREW 12 04039-1 2 SPRING 13 F-HN-1024 1 TRIGGER LOCK JAM NUT 14 CPR-2005-01 1 PISTON NEEDLE 15 MG-1022 1 PACKING NUT 16 MAX-2008 1 PACKING SEAL 17 MAX-2009 1 SEAL RETAINER 18 MAX-2010-01 1 NEEDLE 19 MAX-2011-01 1 CARBIDE SEAT 20 CPR-2003-02 1 CATALYST NEEDLE HOUSING 21 MAX-2013 1 SEAL HOUSING 23 55500-1 1 MATERIAL FITTING 24 O-S-006 3 O-RING 25 O-T-010 1 O-RING 26 O-S-012 5 O-RING 27 O-E-012 2 O-RING 28 F-MS-832-04 2 MACHINE SCREW 29 CPR-2060-01 1 TRIGGER STOP 30 O-S-007 1 O-RING 31 O-S-3-904 2 O-RING 32 F-CS-04C-12 1 SCREW 33 VPA-1003 1 RETAINING RING 34 F-BHCS-832-06 2 BUTTON HEAD SCREW 35 06977 1 1//4 X 10-32 PUSH FITTING 36 EMG-1001-01 1 GUN BLOCK 37 EMG-1002-01 1 THREAD ADAPTER ASSY 40 EMG-1007 1 CHECK VALVE STEM 41 EMG-1008 1 CHECK VALVE BODY 42 EMG-1009 1 CHECK VALVE NUT 43 EMG-1010 1 CHECK VALVE CAP 44 EMG-1011 1 CHECK VALVE SPRING 45 PF-AP-02 1 ALLEN PLUG 47 CPR-2012-02 1 CATALYST NEEDLE SEAT External Gelcoat Gun Assy EMG-1000 ITEM PART NO. QTY DESCRIPTION 22 EMG-1097-01 1 CHECK VALVE ASSY 39 EMG-35402 1 CATALYST TIP 46 UCT-521 1 SPRAY TIP External Gelcoat Gun Assy EMG-1000-FIT ITEM PART NO. QTY DESCRIPTION 22 EMG-1097-01 1 CHECK VALVE ASSY 39A EMG-35402-FIT 1 CATALYST TIP 46A UGT-2220 1 SPRAY TIP External Gelcoat Gun Assy EMG-1000-INT ITEM PART NO. QTY DESCRIPTION 22A EMG-1097-01-03J 1 CHECK VALVE ASSY 39B EMG-35402-INT 1 CATALYST TIP 46 UCT-521 1 SPRAY TIP External Gelcoat Gun Assy EMG-1000-FIT-INT ITEM PART NO. QTY DESCRIPTION 22A EMG-1097-01-03J 1 CHECK VALVE ASSY 39B 46A EMG-35402-FIT-INT 1 UGT-2220 1 CATALYST TIP SPRAY TIP OPTIONAL PARTS AND ASSEMBLIES PARTS LIST * REPAIR KITS PART NO. DESCRIPTION EMG-1000-SK SEAL KIT ITEM PART NO. QTY DESCRIPTION 48 7304-3-1 1 SEAL ITEMS INCLUDED IN SEAL KIT

1 11 3 12 4 49 50 28 9 10 7 51 52 53 13 15 8 2 16 17 21 6 26 5 14 18 19 23 24 26 32 20 47 26 25 36 34 22 35 26 37 48 43 42 44 31 41 30 27 40 24 34 46 27 39 MAGNUM VENUS PRODUCTS External Mix Gelcoat Gun W/ Signal External Mix Gelcoat Gun W/ Signal External Mix Gelcoat Gun W/ Signal External Mix Gelcoat Gun W/ Signal REV. 01/31/07 BT2 33 EMG-1500 EMG-1500-FIT EMG-1500-INT EMG-1500-FIT-INT

Common Parts for the Assy of; External Mix Gelcoat Gun EMG-1500 External Mix Gelcoat Gun EMG-1500-FIT External Mix Gelcoat Gun EMG-1500-INT External Mix Gelcoat Gun EMG-1500-FIT-INT PARTS LIST * * * * ITEM PART NO. QTY DESCRIPTION 1 54350-3 1 GUN HANDLE 2 MAX-2040 1 TRIGGER 3 54630-1 1 TRIGGER STUD 4 54000-1 2 SPRING RETAINER 5 53900-1 2 NEEDLE GUIDE 6 53800-1 2 JAM NUT 7 56190-1 1 TRIGGER LOCK SCREW 8 56100-1 1 TRIGGER LOCK NUT 9 02883-8 1 TRIGGER LOCK PIN 10 04420-1 1 TRIGGER LOCK SPRING 11 00145 1 TRIGGER STUD SCREW 12 04039-1 2 SPRING 13 F-HN-1024 1 TRIGGER LOCK JAM NUT 14 CPR-2005-01 1 PISTON NEEDLE 15 MG-1022 1 PACKING NUT 16 MAX-2008 1 PACKING SEAL 17 MAX-2009 1 SEAL RETAINER 18 MAX-2010-01 1 NEEDLE 19 MAX-2011-01 1 CARBIDE SEAT 20 CPR-2003-02 1 CATALYST NEEDLE HOUSING 21 MAX-2013 1 SEAL HOUSING 23 55500-1 1 MATERIAL FITTING 24 O-S-006 3 O-RING 25 O-T-010 1 O-RING 26 O-S-012 5 O-RING 27 O-E-012 2 O-RING 28 F-MS-832-04 2 MACHINE SCREW 29 CPR-2060-01 1 TRIGGER STOP 30 O-S-007 1 O-RING 31 O-S-3-904 2 O-RING 32 F-CS-04C-12 1 SCREW 33 VPA-1003 1 RETAINING RING 34 F-BHCS-832-06 2 BUTTON HEAD SCREW 35 06977 1 1//4 X 10-32 PUSH FITTING 36 EMG-1001-01 1 GUN BLOCK 37 EMG-1002-01 1 THREAD ADAPTER ASSY 40 EMG-1007 1 CHECK VALVE STEM 41 EMG-1008 1 CHECK VALVE BODY 42 EMG-1009 1 CHECK VALVE NUT 43 EMG-1010 1 CHECK VALVE CAP 44 EMG-1011 1 CHECK VALVE SPRING 45 MPH-2534 1 ELBOW 47 CPR-2012-02 1 CATALYST NEEDLE SEAT 49 04070-1 1 SPRING 50 54501-1 1 NEEDLE 51 54440-1 1 VALVE BODY 52 O-S-104A 1 O-RING 53 54420-1 1 RETAINER OPTIONAL PARTS AND ASSEMBLIES PARTS LIST * * REPAIR KITS PART NO. DESCRIPTION EMG-1000-SK SEAL KIT ITEM PART NO. QTY DESCRIPTION 48 7304-3-1 1 SEAL External Mix Gelcoat Gun EMG-1500 ITEM PART NO. QTY DESCRIPTION 22 EMG-1097-01 1 CHECK VALVE ASSY 39 EMG-35402 1 CATALYST TIP 46 UCT-521 1 SPRAY TIP External Mix Gelcoat Gun EMG-1500-FIT ITEM PART NO. QTY DESCRIPTION 22 EMG-1097-01 1 CHECK VALVE ASSY 39A EMG-35402-FIT 1 CATALYST TIP 46A UGT-2220 1 SPRAY TIP External Mix Gelcoat Gun EMG-1500-INT ITEM PART NO. QTY DESCRIPTION 22A EMG-1097-01-03J 1 CHECK VALVE ASSY 39B EMG-35402-INT 1 CATALYST TIP 46 UCT-521 1 SPRAY TIP External Mix Gelcoat Gun EMG-1500-FIT-INT ITEM PART NO. QTY DESCRIPTION 22A EMG-1097-01-03J 1 CHECK VALVE ASSY 39B 46A EMG-35402-FIT-INT 1 UGT-2220 1 CATALYST TIP SPRAY TIP

2 1 4 5 3 MAGNUM VENUS PRODUCTS Check Valve Assembly EMG-1097-01 REV. 2/25/03 JEM

Check Valve Assembly EMG-1097-01 PARTS LIST ITEM PART NO. QTY DESCRIPTION 1 O-S-009A 1 O-RING 2 EMG-1097-02 1 O-RING HOUSING 3 EMG-1097-04 1 SPRING HOUSING 4 CV-1097-03 1 PISTON 5 CV-1097-05 1 SPRING

2 1 4 5 3 MAGNUM VENUS PRODUCTS Check Valve Assembly EMG-1097-01-03J REV. 3/21/03 JEM

Check Valve Assembly EMG-1097-01 PARTS LIST ITEM PART NO. QTY DESCRIPTION 1 O-S-009A 1 O-RING 2 CV-1097-02 1 O-RING HOUSING 3 EMG-1097-04 1 SPRING HOUSING 4 CV-1097-03 1 PISTON 5 CV-1097-05 1 SPRING

MAGNUM VENUS PLASTECH CORPORATE HEADQUARTERS and MANUFACTURING 5148 113 th Ave. N. *Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636 WEST COAST MANUFACTURING 1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666 www.mvpind.com