DuraMAX Gun Manual DMX-3000 Rev.
DuraMAX Gun Manual CORPORATE HEADQUARTERS and MANUFACTURING th 11692 56 Court * Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666 MVP Plastech UK Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: +44 (0) 1822 832621 Fax: +44 (0) 1822 833999 www.mvpind.com Rev.
DuraMAX Gun Manual Table of Contents SECTION: Page TERMS & CONDITIONS OF SALE 4 SAFETY & WARNINGS 6 INTRODUCTION 15 DISASSEMBLY 16 ASSEMBLY 20 NEEDLE ADJUSTMENT 25 TROUBLESHOOTING 26 PARTS DRAWINGS 29 REVISION INFORMATION 53 Rev.
DuraMAX Gun Manual Terms & Conditions of Sale: • Customs duties, import and export licenses and certificates, if required, and all local taxes are excluded from this offer. If US state and local taxes are applicable and not included in equipment invoice, such amount may be invoiced later. • Delivery dates or shipping schedules are approximate and based upon the most recent information available at the time of order. Dates may be adjusted upon receipt of subsequent information or modification of order.
DuraMAX Gun Manual against the Seller in respect of the goods, the liability of the Seller shall be limited to the value of the goods. • Many factors beyond Seller’s control contribute to the success of Buyer’s finished products, such as raw materials used to manufacture the product. Equipment is warranted to perform to specifications detailed in quotation, but Seller is not liable for quality or quantity of finished products produced by Buyer. • The country of origin is the United States of America.
DuraMAX Gun Manual 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.
DuraMAX Gun Manual 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”.
DuraMAX Gun Manual 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.
DuraMAX Gun Manual 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.
DuraMAX Gun Manual 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.
DuraMAX Gun Manual G. Adequate ventilation (as covered in OSHA Section 1910.94 and NFPA No.91) is important wherever solvents are stored or used, to minimize, confine and exhaust the solvent vapors. H. Solvents should be handled in accordance with OSHA Section 1910.106 and 1910.107. 2.4 Catalyst Diluents Magnum Venus Plastech spray-up and gel-coat systems currently produced are designed so that catalyst diluents are not required. Magnum Venus Plastech, therefore, recommends that diluents not be used.
DuraMAX Gun Manual 2.7 Toxicity of Chemicals A. Magnum Venus Plastech recommends that you consult OSHA Sections 1910.94, 1910.106, 1910.107 and NFPA No.33, Chapter 14, and NFPA No.91. B. Contact your chemical supplier(s) and determine the toxicity of the various chemicals used as well as the best methods to prevent injury, irritation and danger to personnel. C. Also determine the best methods of first aid treatment for each chemical used in your plant. 2.
DuraMAX Gun Manual 3.0 Equipment Safety WARNING Magnum Venus Plastech suggests that personal safety equipment such as EYE GOGGLES, GLOVES, EAR PROTECTION, and RESPIRATORS be worn when servicing or operating this equipment. Ear protection should be worn when operating a fiberglass chopper to protect against hearing loss since noise levels can be as high as 116 dB (decibels).
DuraMAX Gun Manual 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.
DuraMAX Gun Manual Introduction: This manual, the DURAMAX GUN MANUAL, provides information you need to perform simple maintenance and repair on your equipment. Step-by-step assembly and disassembly procedures are included for each component. Please read the manual carefully. Follow the steps in the order given, otherwise you may damage the equipment or injure yourself. DANGER: Always wear proper safety equipment, including eye protection and gloves when performing service and repair on this equipment.
DuraMAX Gun Manual Disassembly: WARNING: Always remove fluid pressures before working on the unit. WARNING: Be careful not to bend the catalyst and resin needles. Built in shut off valves The MVP DuraMAX gun incorporates Rapid Access Design (R.A.D.). With fewer parts and maintenance-friendly access, routine replacements take only minutes. This rugged gun features a carbide needle and seat (standard), and is the only gun on the market with built-in shut-off valves for resin and catalyst.
DuraMAX Gun Manual Gun Handle Disassembly 1. Remove Spring Retainers (54000-1) and Springs (04039-1) from handle. 2. Remove Valve Body Assembly (54440-1) from Handle (54350-3). 3. Remove Spring (04070-1) and Poppet Assembly (MG-2031). 4. Unscrew Retainer (54420-1) from Valve Body (54440-1) 5. Remove O-Ring (O-S-104A) Gun Head Disassembly 1. Remove Needle Guide (53900-1) and Jam Nut (53800-1) from Catalyst Piston Needle (DMX-3008-01) 2.
DuraMAX Gun Manual 14. Remove the Mix Housing (MAX-2017-T) by removing the two Cap Screws (F-CS1024-09). 15. Take the Catalyst Injector (5104-03-01) out of the Distribution Ring (5104-18-1) (see Catalyst Injector Disassembly and Assembly for reference) 16. Remove the O-ring (O-S-018) and Distribution Ring (5104-18-1) from Mix Housing (MAX-2017-T). 17. Remove Flush Valve Assembly (5104-01-01) from the side of the gun block. 18.
DuraMAX Gun Manual Catalyst Injector Disassembly 1. Remove Injector Seal (5104-13-1) from Injector Body (5104-15-1) 2. Unscrew Plunger Retainer (5104-14-1) from Injector Plunger (5104-16-1) 3. Remove Compression Spring (9203-2-2) from Injector Plunger (5104-16-1) 4. Remove Injector Plunger (5104-16-1) from Injector Body (5104-15-1) 5. Reassemble with new parts as required. NOTE: Discard all parts to be replaced by the repair kit.
DuraMAX Gun Manual Assembly: Gun Handle Assembly 1. Apply lubricant to Springs (04039-1) and insert into Gun Handle (54350-3) 2. Thread Spring Retainers (54000-1) over Springs (04039-1) into Gun Handle (54350-3) 3. Slide Spring (04070-1) onto the end of the Poppet Assembly (MG-2031) 4. Insert Poppet Assembly (MG-2031) into Valve Body (54440-1) 5. Slide O-ring (O-S-104A) over Poppet Assembly (MG-2031) and retain with Packing Retainer (54420-1) 6.
DuraMAX Gun Manual 8. Install Needle (DMX-3004) into Needle Housing (DMX-3003) and place a new Oring (O-T-010) onto the end sticking out of the needle housing. GUN HEAD NEEDLE O-RING O-RING PACKING NUT NEEDLE HOUSING 9. Screw Packing Nut (DMX-3002) onto Needle Housing (DMX-3003) over the Oring and needle. NOTE: Repeat steps 8 and 9 for both Needle Housings (DMX-3003). 10. Screw both assembled Needle Housings (DMX-3003) into both the catalyst and resin sides of the gun head. 11.
DuraMAX Gun Manual 13. Insert Catalyst Piston Needle (DMX-3008-01) into the Catalyst Needle Housing (DMX-3009-02). NEEDLE GUIDE JAM NUT PACKING NUT CATALYST NEEDLE PACKING SEAL SEAL RETAINER NEEDLE HOUSING CATALYST SEAL O-RING O-RING GUN HEAD Install Seal Retainer (MAX-2009) over the catalyst needle into catalyst needle housing. 14. Next install a new Packing Seal (MAX-2008) over the catalyst needle into the needle housing. 15.
DuraMAX Gun Manual PACKING NUT NEEDLE GUIDE JAM NUT PACKING SEAL O-RING SEAL RETAINER SEAL HOUSING RESIN NEEDLE O-RING CARBIDE SEAT GUN HEAD 20. Install Resin Needle (MAX-2010-01) thru Seal Housing (MAX-2013) 21. Slide Seal Retainer (MAX-2009) then Packing Seal (MAX-2008) over the Resin Needle (MAX-2010-01). 22. 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. 23.
DuraMAX Gun Manual Assemble Flush Valve 1. Place the O-ring (O-K-008) on the flush valve button (5104-25-1). 2. Insert the spring (9203-2-3) onto the flush valve button. 3. Push the button and spring into the flush valve body (5104-24-1). 4. Place the O-ring (O-A-007) on the flush seal body (5104-23-1). 5. Insert a flush seal body (5104-23-1) into the end of the flush valve body and screw it onto the button. 6. Place a flush valve seal (5104-26-1) on the flush valve body. 7.
DuraMAX Gun Manual Needle Adjustment: 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.
DuraMAX Gun Manual Troubleshooting: Catalyst Problems 1. 2. 3. 4. 5. 6. 7.
DuraMAX Gun Manual 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.
DuraMAX Gun Manual General Problems 1. Material leaking from around the mix chamber Replace Mix Housing Seal (O-S-018) Replace Catalyst Injector Seal (5104-13-1) 2. Air leaking from around poppet needle 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 Tighten Poppet Valve Body (54440-1) into Gun Handle (54350-3) 4.
DuraMAX Gun Manual Parts Drawings: PARTS DRAWINGS: DMX-3000 DMX-3000-A DMX-3000-ITW DMX-3000-SIG DMX-3000-ST DMX-3000-W DMX-3000-W-SIG DMX-3000-ITW-SK DMX-3000-SK DMX-3000-ST-SK FILLED RESIN INTERNAL MIX GUN AUTO DURAMAX GUN ASSEMBLY FILLED RESIN INTERNAL MIX GUN FILLED RESIN CHOPPER WITH SIGNAL DURAMAX GUN ASSEMBLY – FIT MIX CHAMBER INTERNAL MIX WETOUT GUN INTERNAL MIX WETOUT GUN WITH SIGNAL SEAL KIT - DURAMAX GUN ASSEMBLY SEAL KIT - DURAMAX GUN ASSEMBLY SEAL KIT - DURAMAX GUN ASSEMBLY Rev.
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DuraMAX Gun Manual Revision Information: Rev. 12/2012 Add this revision information section. We updated the parts drawings in the manual and the manual format. Added the Terms & Conditions section and updated the Safety & Warning information. Rev.
DuraMAX Gun Manual MAGNUM VENUS PLASTECH CORPORATE HEADQUARTERS and MANUFACTURING th 11692 56 Court * Clearwater, FL 33760 * Tel 727-573-2955 * Fax 727-571-3636 TECHNOLOGY CENTER and MANUFACTURING 1862 Ives Ave. * Kent, WA 98032 * Tel 253-854-2660 * Fax 253-854-1666 MVP Plastech UK Chilsworthy Beam, Gunnislake, Cornwall, PL18 9AT UK, * Tel: +44 (0) 1822 832621 Fax: +44 (0) 1822 833999 www.mvpind.
