MVP CB-5000-PRV Operation Manual

Pro Rider Gel Coater

Operations Manual

Rev. 10/2014

Pro Rider Operations Manual

CORPORATE HEADQUARTERS and MANUFACTURING

200A Perimeter Park Road · Knoxville, TN 37922 · USA · Tel: +1 (865) 321-8809

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666

E-mail: [email protected]

· www.mvpind.com

Rev. 10/2014 Page | 2


Table of Contents

SECTION: Page

TERMS & CONDITIONS OF SALE

SAFETY & WARNINGS

INTRODUCTION

GETTING STARTED

PRIMING the UNIT

DAILY START-UP & SHUT-DOWN

TROUBLE SHOOTING GUIDE

AIR LOCK IN THE CATALYST PUMP

PUMP REPAIR PROCEDURES

CATALYST PUMP REPAIR PROCEDURES

GEL COAT GUN REPAIR PROCEDURES

PARTS DRAWINGS

REVISION INFORMATION

4

6

15

16

18

20

21

28

30

31

32

33

45

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Terms & Conditions of Sale:

GSSC, Inc.’s Terms & Conditions of Sale (“Terms & Conditions”) 588284v4

1. ACCEPTANCE: Acceptance of any purchase order from a customer or potential customer (“Buyer”) is subject to credit approval by GSSC, Inc.

(“Seller”), acceptance of the purchase order by Seller and, when applicable, any manufacturer, vendor, or other third party that provides goods to Seller for resale to Buyer (“Vendor”). If Seller, in its sole discretion, determines that Buyer's credit becomes unsatisfactory or it has reasonable grounds for insecurity, Seller reserves the right, upon notice to Buyer, to demand adequate assurance of due performance from Buyer and/or terminate any purchase order with no liability to Seller. BY REQUESTING A QUOTE FROM SELLER, ACCEPTING AN INVOICE FROM SELLER, OR

PRESENTING A PURCHASE ORDER TO SELLER, BUYER CONFIRMS THAT THESE TERMS & CONDITIONS SHALL GOVERN ALL

PURCHASES OF PRODUCTS OR MATERIALS PROVIDED TO BUYER BY SELLER (“GOODS”). GOODS SOLD BY SELLER ARE EXPRESSLY

SUBJECT TO THE TERMS AND CONDITIONS SET FORTH HEREIN AND ANY DIFFERENT OR ADDITIONAL TERMS OR CONDITIONS SET

FORTH IN A PURCHASE ORDER OR SIMILAR COMMUNICATION RECEIVED FROM BUYER ARE OBJECTED TO AND SHALL NOT BE BINDING

UPON SELLER UNLESS SPECIFICALLY AGREED TO IN WRITING BY AN AUTHORIZED CORPORATE OFFICER OF SELLER.NO SELLER

EMPLOYEE OR AGENT HAS THE AUTHORITY TO MODIFY THESE TERMS & CONDITIONS VERBALLY. SELLER OBJECTS TO AND REJECTS

ANY TERMS BETWEEN BUYER AND ANY OTHER PARTY, AND NO SUCH TERMS, INCLUDING BUT NOT LIMITED TO ANY GOVERNMENT

REGULATIONS OR “FLOWDOWN” TERMS, SHALL BE A PART OF OR INCORPORATED INTO ANY PURCHASE ORDER FROM BUYER TO

SELLER, UNLESS AGREED TO IN WRITING BY AN AUTHORIZED REPRESENTATIVE OF SELLER.

2. PRICES AND TAXES: Buyer agrees to pay the prices quoted by Seller or listed on any related invoice, and is responsible for additional applicable shipping and handling charges, taxes, duties, and charges for import and export licenses and certificates. All prices quoted by Seller are subject to change without notice. Seller will generally collect applicable taxes along with the purchase price unless Buyer submits a valid tax exemption certificate, and indicates which Goods are covered by it. Prices on special-order Goods may be subject to change before shipment. In order to be corrected, any discrepancies in pricing and/or quantities on invoices must be reported by Buyer within thirty (30) days of the invoice date.

3. PAYMENT: Payment terms are 30 days net from the invoice date or upon such other terms approved by Seller in writing. Retainage shall not apply, and Buyer shall not hold back any retainage from Seller, even if retainage is part of any contract between Buyer and any other party. Payment is not contingent on Buyer’s ability to collect or obtain funds from any other party. Credit card sales are billed at the time of purchase. Buyer expressly represents it is solvent at the time it places any purchase order with Seller. Seller, in its sole discretion, may determine that Buyer’s financial condition requires full or partial payment prior to manufacture or shipment. If Buyer fails to make any payment when due, Seller reserves the right to suspend performance. Buyer agrees to pay a charge on all amounts past due at the rate of 1 ½% per month (18% per year) or the maximum lawful rate, whichever is less. In the event of non-payment, Buyer agrees to pay Seller’s reasonable attorney fees and court costs, if any, incurred by Seller to collect payment, and all applicable interest charges. Seller may apply payments to any outstanding invoices unless Buyer provides specific payment direction.

4. TITLE AND RISK OF LOSS OR DAMAGE: As to Goods delivered directly by Seller, title passes upon delivery at the place Buyer receives possession; and, thereafter, all risk of loss or damage shall be on Buyer. All other sales are F.O.B., point of shipment, and Buyer takes title and assumes responsibility for risk of loss or damage at the point of shipment for such sales. Claims for Goods damaged in transit are Buyer’s sole responsibility when not delivered directly by Seller.

5. QUOTATIONS: All quotations expire thirty (30) days from the date of the quotation unless otherwise noted on the quotation. This time limit applies even if Buyer uses the quotation to submit a job or project bid to any other party.

6. ASSIGNMENT: The Buyer’s rights and responsibilities under any purchase order or these Terms & Conditions shall not be assigned by Buyer without the express written consent of the Seller.

7. RETURN OF GOODS: 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. Subject to the foregoing, Seller shall accept returns of Goods for any reason for a period of thirty (30) days following shipment for exchange or refund of the purchase price; provided, that such Goods must be unused and are subject to a 15% restocking charge, which may be increased or decreased, in the Seller’s sole discretion, depending on the reason for such return. Any Goods which were special ordered by Buyer are may not be returned, and any such Goods which are returned are subject to a restocking/cancellation fee of 100% of the cost of the Goods. Goods shall be deemed accepted by Buyer (and cannot thereafter be returned), if Buyer fails to object to the Goods within thirty (30) days after the Goods are received by Buyer.

8. CANCELLATION: The Buyer may cancel any purchase order prior to shipment of the Goods by mutual agreement of the parties and upon payment to Seller of reasonable and proper cancellation charges.

9. TERMINATION: Seller may terminate the whole or any part of any purchase order if there is a material breach of these Terms & Conditions. In the event of any such breach, the Seller will provide Buyer with written notice of the nature of the breach and the Seller’s intention to terminate for default.

In the event Buyer does not cure such failure within ten (10) days of such notice, Seller may, by written notice, terminate the purchase order; provided, that Buyer shall continue its performance to the extent not terminated.

10. CHANGE IN BUYER’S FINANCIAL CONDITION: Seller reserves the right to cancel any order or to require full or partial payment in advance without liability to Seller in the event of: (i) insolvency of the Buyer; (ii) the filing of voluntary petition in bankruptcy by Buyer; (iii) the appointment of a

Receiver or Trustee for the Buyer; (iv) the execution by Buyer of an assignment for benefit of creditors; or (v) past due payment on previous shipments to Buyer by Seller. Seller reserves the right to cancel Buyers credit at any time for any reason.

11. INTERPRETATION RESPONSIBILITY; PRODUCT USE AND SAFETY: Seller does not guarantee that the Goods it sells conform to any plans and specifications or intended use. When plans and specifications are involved, Buyer is solely responsible for verifying Seller’s interpretations of such plans and specifications, and it is Buyer’s sole responsibility to assure that Seller’s Goods will be acceptable for any specific job. When Seller offers substitute Goods on any proposal, Buyer is solely responsible for confirming their acceptability.

12. DELIVERY: Shipping dates given in advance of actual shipment are approximate and not guaranteed. All contract dates and timelines begin upon receipt by Seller of a purchase order, Buyer’s acceptance of these Terms & Conditions, and the payment of any required down payment.

13. EXCUSABLE DELAYS: Seller shall have no liability if its performance is delayed or prevented by causes beyond its reasonable control, including, without limitation, acts of nature, labor disputes, government priorities, transportation delays, insolvency or other inability to perform by any Vendor, or any other commercial impracticability. In the event of any such delay, the date of delivery or performance shall be extended for a period equal to the time lost by reason of delay. If Goods are held or stored beyond the delivery date for the convenience of Buyer, such Goods shall be so stored at the risk and expense of Buyer.

14. CLAIMS: Claims for any nonconforming Goods must be made by Buyer, in writing, within ten (10) days of Buyer’s receipt of such Goods and must state with particularity all material facts concerning the claim then known to Buyer. Failure by Buyer to give notice within such ten (10) day period shall constitute an unqualified acceptance of such Goods by Buyer, and a waiver of any right to reject or revoke acceptance of such Goods.

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15. WARRANTIES:

(a) SELLER’S WARRANTIES: Seller warrants that all Goods sold shall mechanically operate as specified and shall be free from faults in respect to materials and workmanship for a period of: (i) for parts, twelve (12) months from the date of invoice, and (ii) for systems, twelve (12) months from startup, or, if earlier, eighteen (18) months from the date of the bill of lading. Seller also warrants that the Goods shall, upon payment in full by Buyer for the

Goods, be free and clear of any security interests or liens. Buyer’s exclusive remedy for breach of such warranties shall be limited to repair or replacement costs or termination of any security interests or liens, and Seller shall have no responsibility for reimbursing repair costs incurred by Buyer in connection with Goods without first giving written authorization for such charges. In any claims by the Buyer against the Seller in respect of the

Goods, the liability of the Seller shall be limited to the value of the Goods. This warranty applies only to Goods properly used and maintained and does not apply to any Goods which are misused or neglected, or which has been installed, operated, repaired, altered or modified other than in accordance with instructions or written authorization by Seller. This warranty does not apply to any Goods not manufactured by Seller, and Buyer's sole warranty with respect to such Goods shall be that of the Seller’s Vendor, if any.

(b) VENDOR’S WARRANTIES: Seller shall assign to Buyer any Vendor warranties and/or remedies provided to Seller by its Vendor.

(c) INTELLECTUAL PROPERTY INFRINGEMENT: SELLER DISCLAIMS ANY AND ALL WARRANTIES AND/OR INDEMNIFICATIONS AGAINST

INFRINGEMENT OF ANY INTELLECTUAL PROPERTY RIGHTS OF ANY NATURE. SELLER SHALL, IF GIVEN PROMPT NOTICE BY BUYER OF

ANY CLAIM OF INTELLECTUAL PROPERTY INFRINGEMENT WITH RESPECT TO ANY GOODS SOLD HEREUNDER, REQUEST THE

APPLICABLE VENDOR TO GRANT FOR THE BUYER SUCH WARRANTY OR INDEMNITY RIGHTS AS SUCH VENDOR MAY CUSTOMARILY

GIVE WITH RESPECT TO SUCH GOODS.

(d) LIMITATIONS: THERE ARE NO OTHER WARRANTIES WRITTEN OR ORAL, EXPRESS, IMPLIED OR BY STATUTE. SELLER SPECIFICALLY

DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NO REPAIR OF GOODS OR

OTHER COSTS ARE ASSUMED BY SELLER UNLESS AGREED TO, IN ADVANCE, IN WRITING.

16. LIMITATIONS OF LIABILITY: UNLESS APPLICABLE LAW OTHERWISE REQUIRES, SELLER’S AND ANY VENDOR’S TOTAL LIABILITY TO

BUYER, BUYER’S CUSTOMERS OR TO ANY OTHER PERSON, RELATING TO ANY PURCHASES GOVERNED BY THESE TERMS &

CONDITIONS, FROM THE USE OF THE GOODS FURNISHED OR FROM ANY ADVICE, INFORMATION OR ASSISTANCE PROVIDED BY

SELLER (BY ANY METHOD, INCLUDING A WEB SITE), IS LIMITED TO THE PRICE OF THE GOODS GIVING RISE TO THE CLAIM. NEITHER

SELLER NOR ITS VENDORS SHALL BE LIABLE FOR ANY SPECIAL, INCIDENTAL, DIRECT, CONSEQUENTIAL OR PENAL DAMAGES,

INCLUDING, BUT NOT LIMITED TO BACKCHARGES, LABOR COSTS, COSTS OF REMOVAL, REPLACEMENT, TESTING OR INSTALLATION,

LOSS OF EFFICIENCY, LOSS OF PROFITS OR REVENUES, LOSS OF USE OF THE GOODS OR ANY ASSOCIATED GOODS, DAMAGE TO

ASSOCIATED GOODS, LATENESS OR DELAYS IN DELIVERY, UNAVAILABILITY OF GOODS, COST OF CAPITAL, COST OF SUBSTITUTE

GOODS, FACILITIES OR SERVICES, DOWNTIME, OR CLAIMS FROM BUYER’S CUSTOMERS OR OTHER PARTIES. IF SELLER FURNISHES

BUYER WITH ADVICE OR OTHER ASSISTANCE WHICH CONCERNS ANY GOODS SUPPLIED HEREUNDER, OR ANY SYSTEM OR

EQUIPMENT IN WHICH ANY SUCH GOODS MAY BE INSTALLED, AND WHICH IS NOT REQUIRED PURSUANT TO THESE TERMS &

CONDITIONS, THE FURNISHING OF SUCH ADVICE OR ASSISTANCE WILL NOT SUBJECT SELLER TO ANY LIABILITY, WHETHER BASED ON

CONTRACT, WARRANTY, TORT (INCLUDING NEGLIGENCE) OR OTHER GROUNDS.

17. BUYER’S USE OF GOODS: Many factors beyond Seller’s control contribute to the success of the Buyer’s finished products, such as raw materials used to manufacture the products. Seller is not liability for the quality or quantity of finished products produced by Buyer with the use of the Goods.

18. EXPORTS: If Goods are sold for export, Seller’s standard terms & condition for export sales, if any, shall also apply. Acceptance of export orders is not valid unless confirmed in writing by Seller. Buyer, and not Seller, is responsible for compliance with all United States export control rules and regulations. Buyer shall not name Seller as shipper or exporter of record in connection with the export of any Goods purchased from Seller.

19. INSTALLATION: Installation of the Goods is the responsibility of Buyer, unless otherwise indicated in the quotation or invoice provided to Buyer.

Notwithstanding the foregoing, however, Seller will provide installation supervision personnel within thirty (30) days of Buyer’s request. If an installation for which the Seller is to participate is delayed by the Buyer more than six (6) months after the date of shipment of the Goods, or if Buyer’s facility, materials, or parts are not prepared for installation for such period of time, Seller shall be entitled to invoice the Buyer for the anticipated installation costs, up to $1,250 per day plus expenses, for each of Seller’s installations technicians which are on site.

20. ANTI-MONEY LAUNDERING RESTRICTIONS: Seller rejects questionable purchase orders and payments: Except for pre-approved credit arrangements, Seller rejects third-party payments, cashiers' checks, money orders and bank drafts. Seller accepts only checks imprinted with Buyer’s name; wire transfers originated in Buyer's account; letters of credit with Buyer as account party; and credit or debit cards in Buyer’s name. All payments must be by single instrument in the amount of the invoice, less credits, from banks acceptable to Seller.

21. GOVERNING LAW: These Terms & Conditions and all disputes related to it shall be governed by the laws of the State of Florida, United States of

America, without giving effect to its conflict of law rules.

22. JURISDICTION AND VENUE: The parties hereby irrevocably submit to the jurisdiction of the state courts of the State of Florida and to the jurisdiction of the United States District Court for the Middle District of Florida, for the purpose of any suit, action, or other proceeding related to, arising out of or based upon these Terms & Conditions or in any way related to, arising out of or involving sale of Goods hereunder; waive and agree not to assert by way of motion, as a defense, or otherwise, in any such suit, action, or proceeding, any claim that it is not subject personally to the jurisdiction of the above-named courts, that its property is exempt or immune from attachment or execution, that the suit, action, or proceeding is brought in any inconvenient forum, that the venue of the suit, action, or proceeding is improper, or that these Terms & Conditions or the subject matter hereof may not be enforced in or by such court; and waive and agree not to seek any review by any court of any other jurisdiction which may be called upon to grant an enforcement of the judgment of any such Florida state or federal court. The parties hereby consent to service of process by registered mail at the address to which notice is to be given. The exclusive venue for any proceeding under these Terms & Conditions shall be solely in any state court in

Pinellas County, Florida, or the Federal District Court for the Middle District of Florida, Tampa Division, sitting in Tampa, Florida. Buyer acknowledges that the prices for Goods offered hereunder are in part dependent on Buyer’s consent to jurisdiction in Florida and exclusive venue in Pinellas County,

Florida or the Federal District Court for the Middle District of Florida, Tampa Division, sitting in Tampa, Florida, and without Buyer’s consent to this jurisdiction and venue provision the prices for the Goods may be higher.

23. GENERAL: Any representation, affirmation of fact and course of dealing, promise or condition in connection therewith or usage of trade not contained herein, shall not be binding on either party. If any provision hereof shall be unenforceable, invalid or void for any reason, such provision shall be automatically voided and shall not be part of these Terms & Conditions and the enforceability or validity of the remaining provisions of these Terms

& Conditions shall not be affected thereby.

TO THE EXTENT NOT CONTRARY TO APPLICABLE LAW, THE FOLLOWING SHALL APPLY:

24. Buyer waives any available homestead exemption as well as any and all requirements or rights with regard to notice, demand, presentment

IMPORTANT NOTICE: THIS INSTRUMENT PERMITS SELLER TO OBTAIN AND USE YOUR INDIVIDUAL CREDIT HISTORY FOR CREDIT EVALUATION

PURPOSES.

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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 Products Inc. Magnum

Venus Products 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 Products 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 Products recommends this Safety Manual remain on your equipment at all times for your personnel safety. In addition to the manual, Magnum Venus

Products 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 Products recommends the following Personal Safety Equipment for conducting safe operations of the Polyester Systems:

Magnum Venus Products 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 Products 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 Products 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 Products 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 Products 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 Products 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 Products 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 Products spray-up and gel-coat systems currently produced are designed so that catalyst diluents are not required. Magnum Venus Products, 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 Products 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.

Rev. 10/2014 Page | 11


2.7 Toxicity of Chemicals

A. Magnum Venus Products 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 Products 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.

Rev. 10/2014 Page | 12


3.0 Equipment Safety

WARNING

Magnum Venus Products 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.

Rev. 10/2014 Page | 13


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 Products 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 PRODUCTS EQUIPMENT, PLEASE CALL MAGNUM VENUS PRODUCTS 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 PRODUCTS DISTRIBUTOR OR MAGNUM

VENUS PRODUCTS.

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.

Rev. 10/2014 Page | 14


Introduction:

This manual provides information needed to properly operate and perform simple maintenance and repair on this equipment.

Step-by-step operations procedures are provided. 

 This manual includes Installation, Start-up and Shut-Down instructions.

 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.

Major Components:

The Pro Rider Gel Coater consists of the following major components:



Resin Pump Fluid section and Air Motor



Shift Block Assembly



Catalyst Pump Assembly



Gun Assembly

Description of Controls for Spray unit:

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

 PUMP PRESSURE gauge and regulator. This controls the main air pressure to the resin pump Air Motor.

 ATOMIZING-AIR gauge and regulator. This controls the air pressure to the catalyst nozzle on the gun. This is normally set to 18 – 25psi (1 -1.5 bar)

 RESIN DUMP VALVE – This is located on the Filter Body. This is used to relieve gel coat pressure.

Rev. 10/2014 Page | 15


Getting Started:

Air Requirements:

Clean, dry compressed air must be available at 90 – 100 psi (6 – 7 bar) and a minimum volume of 10 CFM (0.3 m 3 ). Air must be provided through an air hose with a diameter of 0.5 inch (1.3 cm) or greater.

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). 

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

Other Supplies:

 Solvent for cleaning.

 A small Chip / Paint Brush for cleaning.

 Small cup or container for the solvent.

 Wet Gel Gauge to determine Gel Coat thickness.

Rev. 10/2014 Page | 16


Installation and Setup:

1. Unpack unit & components – report any damaged or missing items

2. Assemble unit – mount Pump to the cart, install Catalyst Pump onto the Slave

Arms

3. Install Catalyst Jug into the Catalyst jug bracket

4. Connect the Relief Valve tube to the top port in the Catalyst Jug.

5. Connect the Feed tube from the Catalyst jug outlet to the Catalyst pump Inlet.

6. Connect the Catalyst hose to the Catalyst Pump outlet

7. Install Gel coat Filter & Surge Chamber assembly

8. Attach the Gel coat hose to the Outlet of the Filter assembly

9. Install Air Manifold - connect Air Hose to Powerhead & Air Supply to the Shift

Block.

10. Attach hose fittings, catalyst atomizing hose and gun air supply

11. Attach Pickup Hoses to the Inlet of the pump

12. Double check all hose fittings and connections are tight.

Note: it is important to be sure all fittings and connections are tight to prevent catalyst or gel coat leaking.

Rev. 10/2014 Page | 17


Priming the Unit:

Priming Gel Coat to Gun:

NOTE: The resin pump was tested using oil. It may require up to 1/2 gallon (1 – 2 liters) of gel coat to be run through the unit to purge any remaining oil from the

system.

1. Fill the Reservoir cavity 1/2 full with TSL oil or suitable oil.

2. Insert the gel coat suction wand into container of gel coat. Clamp or tape the return hose coming from the bottom of the in-line filter to the pickup wand and into the drum / pail.

3. Remove the Catalyst Tip and Spray Tip from the front of the gel coat gun.

4. Position the gun over an appropriate container and with the gun trigger locked in the open position, slowly increase pump regulator pressure until pump is running at a slow but steady rate. Allow pump to run until a steady stream of gel coat is being dispensed.

5. Close the gun and brush the front of the gun head clean with solvent.

6. Slowly increase gel coat pump pressure to 100 psi (7 bar). Allow the unit to set under static load for 15 to 30 minutes to seat the resin packing set.

Turn the pump regulator to zero. Slowly open the ball valve at the bottom of the resin filter to drain the fluid pressure

Rev. 10/2014 Page | 18


Priming Catalyst to Gun:

1. Remove the catalyst tip and spray tip from the front of the gun.

2. Tighten the catalyst packing nut – 1/8 to 1/4 of a turn to snug packing.

3. Fill the catalyst jug ¾ full, purge the air out of the catalyst feed line by slightly tilting the catalyst jug toward the outlet fitting.

4. Lock or hold the gun trigger in the open position over an appropriate container.

5. Remove the pin from the slave arm and catalyst pump bearing block. Use the priming knob to hand prime catalyst out to the gun until a steady stream is achieved.

6. Release the trigger to close the gun.

7. Replace the pin into the slave arm and catalyst pump bearing block – be sure that the catalyst pump is positioned at the correct percentage.

Note: Be sure the top and bottom of the catalyst pump are set to the same percentage on the slave arm to prevent damage to the catalyst pump.

Gun Set-Up & Spray:

Note: Use a little red grease on the o-rings and threads before installing the spray tip, catalyst tip and retainer.

1. Install the Gel Coat Spray Tip into the front of the gun block.

2. Install the Catalyst Tip over the Spray Tip. Use caution not to damage the o-rings on the front of the gun block.

3. Install the retainer to secure Catalyst Tip and Spray Tip in place.

4. Spray a test pattern: Slowly make gel coat pump pressure adjustments until a fairly uniform pattern is achieved. There should be slight horns (lines) on either side of the spray fan. For the ATG-3500 Gel Coat Gun - Slowly open the air-assist needle valve located on the side of the gun handle until a soft uniform pattern is achieved.

One of the most important concepts is to use just enough pressure to the power head to establish a good spray fan, and no more. Then use the Air Assist to fine tune or do final adjustment to the spray pattern.

Rev. 10/2014 Page | 19


Daily Start-up & Shut-down:

Daily Start-Up:

1. Check all hoses for damage.

2. Check all material supplies and fill or replace as needed.

3. Open main inlet air valve on the manifold.

4. Check pump pressure: if adjustment is needed, remove the pin from the slave arms & catalyst pump bearing block – this will prevent over pressure in the catalyst system. Slowly turn up the pump air pressure to the operating pressure.

Note: Always lean the catalyst pump away from the gel coat pump (towards the connecting arm) when it is unpinned from the slave arms – this will help prevent damage to the catalyst pump.

5. Replace the Pin into the Slave arm and catalyst pump bearing block.

6. Check atomizing air pressure, adjust as necessary. It should be set to 18 – 25psi

(1 -1.5 bar)

7. Lubricate the spray tip o-rings, stud o-rings and gun front threads

8. Install nozzle, catalyst tip and retaining ring onto the front of the gun.

Daily Shut-Down:

1. Wipe the face of the nozzle and catalyst tip with solvent.

2. Turn off the main air ball valve at the air manifold.

3. Remove the Catalyst tip and Spray tip clean with solvent.

4. Wipe the gun face clean with a rag or brush clean with solvent.

5. Hang the gun with the gun block exit holes facing downwards

Rev. 10/2014 Page | 20


Trouble Shooting Guide:

The most common problems with the equipment are diagnosed by analyzing the cured part.

NOTE: Many problems are the direct result of a failure to maintain the equipment.

PROBLEM CAUSE

Slow cure during upstroke S.S. Ball in catalyst pump piston body not seating

Slow cure during down stroke

No cure or slow over-all cure

S.S. Ball in catalyst pump inlet body not seating.

Catalyst Check Valve (CV-

2000) not working correctly.

Catalyst pump set at too low or too high of a percentage.

Catalyst supply below outlet fitting on jug.

Quick pin not attached to pump or slave arm.

SOLUTION

Clean ball and inspect seat.

Replace ball, piston seal or piston body if questionable.

Clean ball and inspect seat.

Replace ball or have seat repaired if questionable.

Check and Repair the Catalyst

Check Valve (CV-2000).

Move catalyst pump to a higher setting (closer to the gel coat pump). Be sure to attach the catalyst pump in a vertical position.

Fill catalyst jug 1/3 full.

Catalyst leak.

Catalyst relief valve on catalyst pump is leaking.

Catalyst suction screen in catalyst jug clogged.

Install quick pin. Be sure to attach the catalyst pump vertically.

Check all fittings. The catalyst system must be fluid tight.

Relieve pressure from Pro pump. Clean and repair the

Relief Valve

Clean catalyst suction screen and ensure that catalyst supply is not contaminated.

Rev. 10/2014 Page | 21


PROBLEM CAUSE

Air lock in catalyst pump.

Catalyst pump piston seal worn or damaged

Catalyst pump outlet body damaged.

SOLUTION

Remove air lock. See

Appendix: Air Lock in the

Catalyst Pump.

Replace piston seal. During reassembly, be sure spring in seal faces top of pump

Replace catalyst pump outlet body and piston seal. During reassembly, be sure spring in seal faces top of pump.

Prevent by connecting catalyst pump vertically.

Disassemble check valve and remove blockage.

Relieve pressure from the system. Replace the catalyst hose with new one.

Catalyst pump check valve blocked or stuck.

Catalyst hose plugged.

Danger: In the next steps you will be dealing with fluids under high pressure.

Catalyst will be sprayed from the hose fitting when the fitting is loosened.

Follow safety instructions read the Safety & Warning section in the beginning of this manual.

Gel coat too cold.

Piston cups, piston ball, or pump cylinder worn.

Low output on upstroke of

Pro pump

No fan, constant low output,

or fast cure

Screen of pump pick-up wand blocked.

Resin filter blocked.

Consult your materials supplier for proper temperature.

Maintain a draft-free environment of about 70 degrees F. An auxiliary heat source may be required to reduce gel time.

Inspect the piston cups, piston ball, and pump cylinder. Clean and replace any damaged components. See Chapter 6:

Pro Pump.

Unscrew screen from hose and clean.

Disassemble and clean filter body and screen, with solvent

Rev. 10/2014 Page | 22


PROBLEM

Narrow Fan

Wide Fan

CAUSE

Resin hose plugged.

Danger: To prevent injury, always relieve fluid pressure before attempting to remove components.

SOLUTION

Flush hose with solvent. If material is hard, replace hose.

Pick-up wand assembly leaking.

Resin filter clogged.

Material too cold or air pressure low.

Material too cold, nozzle too large or air pressure low.

Tighten assembly fittings.

Disassemble and clean the resin filter. See Chapter 7:

Accumulator & Filter.

Heat material or increase pump pressure.

Heat Material, use smaller nozzle, or as a last resort increase pump pressure.

Resin filter clogged.

Air pressure too high.

Disassemble and clean the resin filter.

Lower pressure then increase pressure to the desired fan.

Nozzle too small or too wide. Change nozzle.

Round fan

Excessive Misting

Orifice in nozzle worn, clogged, or damaged.

Push fine wire through orifice from back side. Use fingernail to clean material form “V” shaped notch in front.

Soak hardened material in solvent. If notch is rough or worn, replace nozzle.

Air-assist pressure too high. Decrease air-assist pressure.

Pump air pressure too high. Reduce air pressure to gel coat pump.

Disassemble accumulator and clean.

Heavy pulsation Resin accumulator plugged.


Pump jumps on upstroke Piston ball worn or not seating properly.

Replace piston ball and piston cups. Be sure to lubricate ball and cups thoroughly with Red

Grease. See Chapter 6: Pro

Pump.

Rev. 10/2014 Page | 23


PROBLEM

Pump dives on down stroke Foot valve, spring retainer, or

Low output on upstroke

Pump does not run

Material in oil reservoir

No Gel coat delivery on down stroke

Hose leaks at fittings

CAUSE foot valve ball damaged or dirty.

Pick-up wand assembly not tight.

Air in material.

Piston cups, piston ball, or pump cylinder worn.

Silencers on valve block plugged.

Actuator valve or socket cap screw at shift block broken.

SOLUTION

Clean or replace foot valve, spring retainer and foot valve ball. Be sure to lubricate ball thoroughly with Red Grease.

See Chapter 6: Pro Pump.

Tighten or seal joints of pick-up wand.

Agitate material to remove air.

Inspect the piston cups, piston ball, and pump cylinder. Clean and replace any damaged components. See Chapter 6:

Pro Pump.

Turn off air to pump and unscrew silencers. Clean silencers and re-install.

Replace the broken cartridge valve or socket cap screw. See

Chapter 6: Pro Pump.

Disassemble and clean Pro pump. Replace any worn parts.

Replace hose as required.

Pro pump or hose plugged.


Air not connected.

Air restricted.

Packing worn.

Piston rod worn or scored.

Foot valve, spring retainer, or foot valve ball damaged or dirty.

Fitting loose

Check that air hose is connected at manifold, and regulator is at 20 psi or more.

Straighten any kinks in air hoses.

Replace packing set in lower part of the pump. See Chapter

6: Pro Pump.

Replace piston rod. See

Chapter 6: Pro Pump.

Clean or replace foot valve, spring retainer, and foot valve ball. Be sure to lubricate ball thoroughly with Red Grease.

See Chapter 6: Pro Pump.

Tighten fitting. Check all fittings for leaks before operating.

Rev. 10/2014 Page | 24


PROBLEM

Slow Cure on one side of the fan.

Fingers – heavy lines in the spray fan.

Pump has short travel – stuttering near top or bottom of stroke

CAUSE

Fitting or nipple damaged.


Crimped hose.


Turbulent Mixer partly clogged or damaged.

Distribution Ring partly clogged.

SOLUTION

Replace damaged parts.

If the hose has been sharply bent, the plastic liner may be ruptured. Remove and replace hose.

Clean or replace the Turbulent

Mixer.

Remove the mix chamber and clean the distribution ring.

Mix Housing damaged

Gel Coat too cold

Pump air pressure too low

Replace as needed.

Increase gel coat temperature.

Use Inline resin heater.

Slowly increase the pump pressure in 5psi (1/2 bar) increments and check spray fan.

Air- Assist pressure is too low Slowly Increase Air- Assist

Valve block is not shifting all the way or shifting before completing a full stroke. pressure as needed.

Check air supply to shift block it should be 90 -100psi (6 –

7bar). Replace Actuator Valve

(MPM-2589) or Valve (VPRO-

2003) as needed.

Rev. 10/2014 Page | 25


Basic Troubleshooting for AT Guns:

Problem Possible Cause(s)

O-ring material worn or cut.

Recommended Solution

Air leaking from exhaust port on back handle while trigger is OFF position.

O-rings on catalyst piston worn or cut.

O-rings on trigger valve worn or cut.

Replace O-rings.

Air leaking from exhaust port on back of handle while trigger in OFF or ON position.

Catalyst leaking from catalyst tip while gun is sitting, not being triggered.

O-rings on trigger valve worn or cut.

O-rings on catalyst valve and/or material piston worn or nicked.

Replace O-rings.

O-rings on catalyst valve worn or cut.

Catalyst leaks from week hole on catalyst side of gun.


Replace O-rings.

Replace O-rings.

Catalyst leaks from week hole on catalyst side of gun.


Replace O-rings.

No catalyst is coming from gun.

Material is leaking from tip

(front of gun).

Catalyst air piston is not actuating.

Check for clogged catalyst air passages (small holes underneath back cylinder).

Note: There is more than one passageway from holes.

Plugged catalyst restrictor (Hex head screw with orifice located in front of catalyst valve).

Clean and clear orifice in front of catalyst valve.

Plugged catalyst passageway in head of gun or catalyst tips.

No catalyst flow to gun.

Inspect, clean and clear passageways.

Loose diffuser seat.

See “Slave Pump-Trouble

Shooting”

Tighten diffuser seat 1/4 to 1/2 turn at a time until snug and then one more 1/4 turn. Over tightening of diffuser seat may cause bindng of material needle.

Worn needle and/or seat. Replace worn items.

O-ring on diffuser nicked or cut. Replace O-rings.

Rev. 10/2014 Page | 26

Loose diffuser seat.

Material is leaking from weep hole on material side of gun.

Worn needle packing

Rev. 10/2014


Adjust until snug. Then turn 1/4 to 1/2 turn more. Don’t over tighten.

Replace packing and adjust as indicated above.

Page | 27


Catalyst Pump - Air Lock:

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.

What is an Air Lock?

An air lock is an air bubble in the catalyst pump that prevents catalyst flow. The piston body moves inside the bubble of air instead of pumping catalyst.

If you have determined that there is an air lock in your catalyst pump, follow the procedures in this section.

1. Relieve line pressure from the catalyst pump by locking the gun open over an empty bucket. Leave the gun in this position.

WARNING: Relieve pressure from the catalyst pump before continuing.

2. Remove the catalyst hose from the nipple on the catalyst pump.

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

3. Remove the quick pin from the catalyst bearing block and upper slave arm.

4. Tilt the pump toward the resin pump to release the bubble.

NOTE: If the bubble does not appear in the inlet tube, remove the lower quick pin and turn the pump upside-down.

5. Slowly hand-pump the catalyst into a suitable container until catalyst spurts from the nipple an equal amount on both the upstroke and down stroke.

6. Reconnect the catalyst hose to the nipple.

7. Hand-pump the catalyst pump until catalyst comes out through the gun.

8. Install the pump and quick pin into the slave arm.

9. Close the gun

Rev. 10/2014 Page | 28


Optional Process:

The air bubble can be quickly removed if the PRO-RECIRC option is installed on this equipment. Simply open the recirculation valve and hand prime catalyst back to the catalyst jug until there is a bubble free flow, then return the recirculation valve back to flow out the gun.

Rev. 10/2014 Page | 29


Pump Repair Procedures:

The Pro Rider Gel Coat system uses the VPRO-45220-NPR Pump assembly – for repair and maintenance instructions reference the manual “VPRO-45220 Series Pump

Manual”.

Rev. 10/2014 Page | 30


Catalyst Pump Repair:

The Pro Rider Gel Coat system uses the PCP-2000-RV-PR Catalyst Pump assembly – for repair and maintenance instructions reference the manual “PCP-2000 Catalyst

Pump Manual - Low Range”.

Rev. 10/2014 Page | 31


Gel Coat Gun Repair:

The Pro Rider Gel Coat system comes standard the ATG-3500 Gel Coat Assembly – for repair and maintenance instructions reference the manual “ATG-3500 Repair and

Maintenance Manual”.

Rev. 10/2014 Page | 32


Parts Drawings:

PRO-RIDER

MA-NPR-ATG

NPR-1054-ASY

22:1 PRO RIDER GEL COATER

PRO RIDER AIR MANIFOLD – ATG GUN

CATALYST CONTAINER

PRO RIDER FILTER ASSEMBLY

AIR MANIFOLD – PRO RIDER

FF-NPR-100

MA-NPR

Rev. 10/2014 Page | 33

This page is left intentionally.


Rev. 10/2014 Page | 34

1

8

7

17

PART OF

ITEM 1

22

20

18

19

21


15

23

25

24

1000

500

100

6

5

26

PART OF

ITEM 1

16

9

13

MAGNUM VENUS PRODUCTS

22 : 1 PRO RIDER PUMP

REV. - 11/03/05 BT2

REV. A - ADDED ITEMS 24, 25, AND 26 04/24/06 BT2

REV. B - ITEM 2 WAS ATG-3500, ITEM 4 WAS MA-NPR, ITEM 13 WAS MPM-2052-1, ITEM 14 WAS MS-2052-1 09/31/06 BT2

PRO-RIDER

Rev. 10/2014 Page | 35

10

11

12

13

14

15

16

17

6

7

8

9

3

4

5

1

2

18

19

20

21

22

23

24

25

26

22 : 1 PRO RIDER PUMP PRO-RIDER

PARTS LIST

ITEM PART NO.

QTY DESCRIPTION

VPRO-45220-NPR PRO PUMP ASSY

ATG-3500

FF-NPR-100

1

1

GELCOAT GUN

SURGE CHAMBER

MA-NPR-ATG 1

PR-1053 1

NPR-1054-ASY 1

PCP-2000-RV 1

RV-1000-500 1

HSA-1000-PR 1

AIR MANIFOLD

CATALYST JUG BRACKET

CATALYST JUG ASSY.

CATALYST PUMP

RELIEF VALVE

SUCTION WAND ASSY.

HAW-0444M-20 1

HAW-0344-5 1

HC-0224-25

HA-0344-25

HA-0224-25

1

1

1

RESIN HOSE

RESIN WHIP

CATALYST HOSE

AIR REFINEMENT HOSE

ATOMIZING AIR HOSE

F-HB-04C-16-GR5 HEX BOLT

F-LN-04C 2 LOCK NUT

F-HB-05C-16-GR5 HEX BOLT

F-HB-05C-12 3 HEX BOLT

F-SW-05 5 LOCK WASHER

F-HN-05C

NPR-1003

NPR-1001

NPR-1002

5

3

1

1

F-SW-04

F-HN-04C

2

2

F-HB-04C-24 2

HEX NUT

LEG - PAIL COVER

PAIL COVER

HANDLE

LOCK WASHER

NUT

HEX BOLT


Rev. 10/2014 Page | 36


3

8

5

10

4

17

13


Air Manifold for Pro Rider

REV - 09/01/06 BT2

REV A - DELETED ITEM 20 M-AGD-1044 09/12/06 BT2

Rev. 10/2014

9

18

MA-NPR-ATG

Page | 37


AIR MANIFOLD - PRO RIDER MA-NPR-ATG

PARTS LIST

ITEM

10

11

12

13

14

15

16

17

18

19

8

9

6

7

3

4

1

2

5

PART NO.

QTY DESCRIPTION

HA-0666-3 1

PF-ME-06-04 1

PR-1035

PF-SE-02

2

2

PR-1030

PF-AP-02

2

1

PF-AP-04 1

PF-SW-02M-04F 1

PF-ME-04 2

F-LN-04C

PR-1019

2

1

AIR HOSE

MALE ELBOW

AIR-GAUGE

STREET ELBOW

REGULATOR

ALLEN PLUG

ALLEN PLUG

SWIVEL

MALE ELBOW

LOCK NUT

AIR MANIFOLD

PR-1032

BOS-3009

PR-1020

F-HB-04C-28

1

2

1

2

SLIDE VALVE

SPACER WASHER

MOUNTING PLATE

HEX BOLT

PF-MT-04

7701-6-10

1

1

MALE TEE

POLY FITTING

MPM-2052-1 1.5 FT.

TUBING

PF-SE-04 1 STREET ELBOW

OPTIONAL PARTS AND ASSEMBLIES

ITEM

22

23

PART NO.

7701-6-11

7701-6-12

QTY

1

1

DESCRIPTION

POLY-FLO FERRULE & NUT

POLY-FLO NUT

Rev. 10/2014 Page | 38

3

3



CATALYST JUG FOR PRO RIDER

REV - 06-28-05 BT2

Rev. 10/2014

NPR-1054-ASY

Page | 39

CATALYST JUG NPR-1054-ASY

PARTS LIST

ITEM

1

2

3

PART NO.

QTY DESCRIPTION

PR-1054

MS-1017

1

1

BOTTLE AND CAP

FILTER

MS-2052-1 5.5 FT TUBING


Rev. 10/2014 Page | 40

3



Fluid Filter for Pro Rider

FF-NPR-100

REV A - ITEM 7 WAS QTY. OF 2, ITEM 10 WAS PF-RB-08-06, DELETED ITEM 11 PF-SE-06 AND ITEM 12 PF-HN-08L 10-31-05 BT2

Rev. 10/2014 Page | 41

Fluid Filter - Pro Rider FF-NPR-100

PARTS LIST

ITEM

7

8

5

6

3

4

1

2

9

10

PART NO.

QTY

PF-AP-04

FF-5002

O-V-022

FF-5099-100

PF-HN-08-04 2

FF-5001 1

2

1

1

1

1

PF-SE-08

BV-44-HP 1

PF-HN-04-04S 1

PF-HN-08-06 1

DESCRIPTION

PLUG

FILTER CAP

O-RING

FILTER SCREEN

HEX NIPPLE

FILTER BODY

STREET ELBOW

BALL VALVE

HEX NIPPLE

HEX NIPPLE


Rev. 10/2014 Page | 42


3

8

5

10

4

17

13


Air Manifold for Pro Rider

REV - 06/29/05 BT2

9

18

MA-NPR

Rev. 10/2014 Page | 43

ITEM

11

12

13

14

15

16

17

18

19

20

21

5

6

7

8

9

10

3

4

1

2

AIR MANIFOLD - PRO RIDER MA-NPR

PARTS LIST

PART NO.

QTY DESCRIPTION

HA-0666-3 1

PF-ME-06-04 1

PR-1035

PF-SE-02

PR-1030

PF-AP-02

2

1

2

2

PF-AP-04

7701-6-14

PF-ME-04

F-LN-04C

2

2

1

1

AIR HOSE

MALE ELBOW

AIR-GAUGE

STREET ELBOW

REGULATOR

ALLEN PLUG

ALLEN PLUG

POLY FITTING

MALE ELBOW

LOCK NUT

PR-1019

PR-1032

1

BOS-3009

PR-1020 1

F-HB-04C-28 2

PF-MT-04 1

1

2

7701-6-10 2

AIR MANIFOLD

SLIDE VALVE

SPACER WASHER

MOUNTING PLATE

HEX BOLT

MALE TEE

POLY FITTING

MPM-2052-1 1.5 FT.

TUBING

PF-SE-04

M-AGD-1044

PF-SW-04

1

1

1

STREET ELBOW

CONTROL VALVE

SWIVEL FITTING

OPTIONAL PARTS AND ASSEMBLIES

ITEM

22

23

PART NO.

7701-6-11

7701-6-12

QTY

3

3

DESCRIPTION

POLY-FLO FERRULE * NUT

POLY-FLO NUT


Rev. 10/2014 Page | 44


Revision Information:

Rev. 04/2010 Assembled This Manual

Rev: 09/2012 Updated the manual format and Address. Added the

Terms & Conditions of Sale section to the manual.

Updated the drawing.

Rev. 10/2014 Updated the Address, name and the Terms & Conditions of Sale section. Removed references to Plastech.

Removed references to the EMG-1000 gun.

Rev. 10/2014 Page | 45


CORPORATE HEADQUARTERS and MANUFACTURING

200A Perimeter Park Road · Knoxville, TN 37922 · USA · Tel: +1 (865) 321-8809

TECHNOLOGY CENTER and MANUFACTURING

1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666

E-mail: [email protected]

· www.mvpind.com

Included with this operations manual are the following component manuals:

 VPRO-45220 PRO PUMP MAINTENANCE AND REPAIR MANUAL

 PCP-2000 PRO LOW RANGE CATALYST PUMP MANUAL

 ATG-3500 REPAIR AND MAINTENANCE MANUAL

Rev. 10/2014 Page | 46

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