Metallisation MK 73, Operating Manual / Spare Parts List

Page 1: ...Page 1 of 64 ssue 21 11 11 ...

Page 2: ...derstood before any attempt is made to operate the equipment described herein In particular refer to the Safety Warnings Risk Assessments in Section 1 Under no circumstances should any modifications be made to the equipment without prior written approval from Metallisation ...

Page 3: ...0 16 5 8 0 5 0 02E Zinc 3 16 Fast 3 16 1 8 2mm 50 0 32 0 16 0 8 2 110 0 70 0 35 0 18 0 07E 08E 09E Tin Zinc 1 8 2mm 21 3 9 1 47 0 20 0 05E 10E 15E Copper Bronzes 1 8 2mm 5 9 4 1 13 0 9 0 30E 35E 45E 55E 57E 60E 65E 80E 85E Steels Nichrome 1 8 2mm 4 3 2 7 9 0 6 0 21E Zinc Aluminium 85 15 3 16 Fast 3 16 1 8 2mm 38 0 25 0 12 5 7 5 84 0 55 0 27 0 16 0 06E Nickel 1 8 3 6 8 0 Stop start unless otherwise...

Page 4: ... 2 Breakdown 17 2 2 1 The Pistol 18 2 2 2 Flowmeter 19 2 2 3 Air Filtration Regulation Unit ARF 19 2 2 4 Pressure Regulators Flashback Arrestors 19 2 2 5 Freestanding Flamespray Control Board 19 2 2 6 Supplies Packages 20 SECTION 3 OPERATING THE EQUIPMENT 22 3 1 Preparing the System 23 3 2 Starting to Spray 23 3 3 Spraying 25 3 4 Extinguishing the Pistol 26 3 5 Emergency Shut Off Valve 26 SECTION ...

Page 5: ... 1 Dismantling the Drive Motor 41 4 7 2 Re Assembling the Drive Motor 41 4 8 Feed Roller Tension 42 4 8 1 Checking Feed Roller Tension 42 4 8 2 Adjusting Feed Roller Tension 42 SECTION 5 FAULT FINDING 43 5 1 Troubleshooting 44 5 1 2 Flowmeter Troubleshooting 46 SECTION 6 WIRE DISPENSING 48 6 1 Wire Swift 49 6 1 1 Operating Instructions 49 6 1 2 Wire Straightener 50 SECTION 7 ILLUSTRATED PARTS LIST...

Page 6: ...S RISK ASSESSMENTS 1 1 Safety Precautions 1 1 1 Equipment Dos Don ts 1 1 2 Leak Test Procedure 1 1 3 Flashback 1 2 Risk Assessments 1 3 Key Hazards 1 3 1 Noise 1 3 2 Flame 1 3 3 Particles 1 3 4 Mechanical Hazards 1 3 5 Fume Dust 1 3 6 Summary ...

Page 7: ...place for safe operation before the equipment is used Metallisation will be pleased to assist and advise as appropriate 1 1 1 Equipment Dos and Don ts Check all hoses regularly Damaged hoses must be replaced immediately Ensure that all hose connections are properly tightened and do not leak Ensure that proper extraction is available and is turned on before the gas supplies are tuned on and turned ...

Page 8: ...s then there is a leak between the regulator and the nozzle Use a leak detection spray or liquid to identify then rectify leak before using the pistol If no movement of the pressure gauges is seen then the system has no identifiable leak and is safe to use To release pressure release the fittings on the exit of the flashback arrestors Then re tighten Remove the leak test nozzle and replace with th...

Page 9: ...cks If hose protection and flashback arrestors are fitted the risk of flames reaching the fuel gas and oxygen supplies is virtually eliminated However flashback particularly if sustained can seriously damage the nozzle assembly Therefore if flashback occurs the following procedure should always be carried out 1 Immediately close the Pistol valve 2 Shut off the Oxygen Supply Valve 3 Shut off the Fu...

Page 10: ...Isolation or segregation Use of Documented Procedure Limiting exposure times dilution of exposure Safe systems of work that depend on human response Use of Warning Signs Signs instructions labels that depend on human response Use of Personal Protective Equipment PPE Depends on human response used as a sole measure only when all other options have been exhausted PPE is the last resort It is the res...

Page 11: ...ponsible for conducting their own noise assessments which must be based on the exposure of the persons in the workplace and of which a noise survey is only part Key Hazards Stress difficulty in communication long term hearing loss Tinnitus NEVER operate the system without adequate hearing protection ALWAYS ensure that ALL personnel likely to be exposed are adequately protected including those not ...

Page 12: ... the least toxic materials if present in the air in sufficient quantities can be hazardous to health Dust produced by the process produce airborne particulate matter in size ranges that can be inhaled Both inhalable and respirable matter may be produced Respirable particles are more dangerous because they can be breathed deeply into the lungs The user must therefore identify the hazards assess the...

Page 13: ...to metal fume fever Inhalation may cause muscle weakness and headache Some compounds of copper are highly toxic and may cause long term effects Iron Inhalation of iron oxides over a long period may cause scarring of the lungs without physiological symptoms Molybdenum Occupational ill health from exposure to molybdenum is unlikely Nickel Nickel is harmful Repeated skin contact may cause allergis co...

Page 14: ...his would relate directly to the consumable in use Compressed Gases Highly Flammable Extremely flammable gases Hydrogen Propane Acetylene LPG and or Oxygen fire and explosion risk Asphyxiant Gases Noise UV Radiation Fine Dusts fume and powders explosion risk Potentially toxic consumables Water borne disease water curtain fitted Mechanical Hazard automated equipment Electric Shock Cryogenic Gases B...

Page 15: ...PMENT 2 1 Introduction to the MK73 2 2 Breakdown 2 2 1 The Pistol 2 2 2 Flowmeters 2 2 3 Air Filtration Regulation Unit 2 2 4 Pressure Regulators Flashback Arrestors 2 2 5 Freestanding Flamespray Control Board 2 2 6 Supplies Packages ...

Page 16: ... designed to ensure true axial alignment of the component parts all mating faces being provided with push fit gas seals for simple leak proof assembly Excellent flame stability and easy lighting is afforded by the pneumatic self adjusting air nipple An adjustable spreader providing a wider spray pattern is available as standard on 3 16 and 1 8 systems which can be turned on off during spraying A m...

Page 17: ...zzle equipment specification available upon request The Pistol Section 2 2 1 Air Filtration Regulation Unit Section 2 2 3 Pressure Regulators Flashback Arrestors Section 2 2 4 Maximum 20m from cylinders to pistol with 1 4 short hoses 1 3 5 1 2 3 4 Flowmeter Section 2 2 2 FlowMeter Board Section 2 2 5 2 4 5 Maximum 40m from cylinders to pistol with 3 8 long hoses Supplies Pack Section 2 2 6 6 6 3m ...

Page 18: ...S73L 3 16 3 16 Long Supplies Spreader Directs air jets at the spray stream to give a wider spray pattern Nozzle Without Spreader Accurately profiled and sleeved with stainless steel insert Gas Head Fuel gas oxygen and compressed air are conveyed through the gas head from the main valve to the nozzle assembly Main Valve A diaphragm valve assembly which controls the gases to the gas head Drive Motor...

Page 19: ...ting Oil should be used 2 2 4 Pressure Regulators Flashback Arrestors The pistol should be used with Metallisation high flow two stage regulators which are supplied with the correct fittings for connection to the MK73 It is imperative that these regulators are fitted with Flashback Arrestors which will protect the Fuel Gas and Oxygen supplies in the event of a flashback a flame travelling back up ...

Page 20: ... 21502 Oxygen Hose 21503 Nozzle Air Hose 21504 Motor Air Hose SUP73 FLOW 3M 3m supplies package Consisting 21140 Propane Hose 21223 Oxygen Hose SUP73 PISTOL 10M 10m supplies package Consisting 21501 10 Propane Hose 21502 10 Oxygen Hose 21503 10 Nozzle Air Hose 21504 10 Motor Air Hose SUP73 PISTOL 10M 10m supplies package Consisting 21501 10 Propane Hose 21502 10 Oxygen Hose 21503 10 Nozzle Air Hos...

Page 21: ...Motor Air Hose SUP73L FLOW 30M 30m supplies package Consisting 21525 30 Propane Hose 21526 30 Oxygen Hose SUP73L PISTOL 10M 10m supplies package Consisting 21523 Propane Hose 21524 Oxygen Hose 21522 Nozzle Air Hose 21504 10 Motor Air Hose SUP73L PISTOL 10M 10m supplies package Consisting 21523 Propane Hose 21524 Oxygen Hose 21522 Nozzle Air Hose 21504 10 Motor Air Hose SUP73L FLOW 40M 40m supplies...

Page 22: ...Page 22 of 64 SECTION 3 OPERATING THE EQUIPMENT 3 1 Preparing the System 3 2 Starting to Spray 3 3 Spraying 3 4 Extinguishing the Pistol 3 5 Emergency Shut Off Valve ...

Page 23: ... and ARF unit to a suitable vertical surface Connect the gas and oxygen hoses between the bottom flowmeter unions and their respective flashback arrestors and regulators Connect the gas and oxygen hoses to the flowmeters and the pistol Fit the middle hose to the pistol first and tighten Connect the air hoses to the ARF unit and the pistol NOTE Before attempting to spray leak test the system Also e...

Page 24: ...sures and flowmeter readings for the wire size and type With the pistol valve open set the supply pressures in accordance with the table Check Flow Meter positions Adjust Oxygen only to trim the system Close the pistol valve If the pilot light is to be used press the valve lever inwards and turn clockwise to the first stop Release the lever and light the pilot flame Open the valve in one swift smo...

Page 25: ...ew could loosen air cover potentially resulting in damage being caused Point the pistol at the prepared work and maintain a spraying range of approximately 6 150mm Increasing spray distance will dramatically reduce efficiency In even sweeping movements to cover the area required and repeat until the desired thickness is achieved Keep the pistol as close to 90 to the spray surface as possible and n...

Page 26: ...raction system be turned off Remove the wire from the pistol taking care to secure the leading end of the coil of wire and replace identification labels Leave the pistol valve open to avoid damaging the internal diaphragms WARNING When operating with the 3 16 Continuous Spray High Throughput Nozzle System damage may occur to the nozzle parts unless the flame is extinguished by closing the valve PR...

Page 27: ...ead Valve Re Assembly 4 6 The Drive Box 4 6 1 Dismantling the Wire Drive Assembly 4 6 2 Dismantling the Air Shield Valve 4 6 3 Dismantling the Speed Control 4 6 4 Re Assembling the Speed Control 4 6 5 Re Assembling the Air Shield Valve 4 6 6 Re Assembling the Wire Feed Drive 4 7 The Drive Motor 4 7 1 Dismantling the Drive Motor 4 7 2 Re Assembling the Drive Motor 4 8 Feed Roller Tension 4 8 1 Chec...

Page 28: ... air nipple and clean the inside cone taking care not to scratch or otherwise blemish the surface Clean exposed surface of the wire nozzle carefully again taking care not to scratch or otherwise blemish the surface PART NO DESCRIPTION QUANTITY 1007 O Ring 1 1008 O Ring 1 4517 Feed Roll Gasket 1 7579 O Ring 1 4541 O Ring 2 4518 Diaphragm Large 1 4519 Diaphragm Small 1 1027 Filter 2 1028 Gasket 1 10...

Page 29: ...mbering that the pistol gas union has a left hand thread Do not allow the hose ends to fall to the floor or be contaminated with dust as this could damage the threads and introduce foreign matter into the valve upon re fitting Coil up the hoses and hang them in a safe place Leave the pistol valve open to avoid damaging the internal diaphragms NOTE In order to prevent the ingress of any dirt ensure...

Page 30: ...ing Block H NB If any difficulty is experienced in removing the Lock Ring B or the Air Cover E DO NOT force the thread Instead apply penetrating oil and ease the parts in and out until they can be removed easily Carefully pull the Nozzle Shell G from the Mixing Block H and remove and replace O Rings Remove the Screwed Insert O and replace O ring as required Remove carefully If using pliers be care...

Page 31: ...s as a unit along the extended portion of the Front Wire Guide I Apply a light smear of grease to the Air Cover thread and lock the Nozzle Shell G and Mixing Block H in place with the Air Cover E Tighten firmly by hand NB If threads bind during assembly DO NOT force the Air Cover Instead remove clean Air Cover and Gas Head apply grease and re try Slide the Air Nipple C onto the shoulder of the Noz...

Page 32: ...ve Diaphragms J Slide the Air Oxygen and Gas Plungers K including the Pilot Gas Plunger S from the Cam Spindle Housing I Gently extract the Valve Lever Plug L from the Cam Lever M Unscrew the exposed Valve Lever Screw N and remove it Remove the Washer O Cam Lever M and Lever Return Spring P taking care not to lose any of these parts DIAG 6 WHEN WHY The Gas Head and Main Valve Assembly should only ...

Page 33: ... Diaphragms J in the Diaphragm Housing H secure it to the Cam Spindle Housing I with the Diaphragm Housing Screws G Using a new Gasket X refit the Valve to the Gas Head with the Valve to Gas Head Fixing Screws E Check that Union Washers U are intact and secure the Air Union C and Oxygen Union D to the valve NOTE If the Gas Union T gets removed for whatever reason note that when re fitting it has a...

Page 34: ...Page 34 of 64 4 6 The Drive Box SUB A SUB B SUB C SUB C SUB B SUB A C4 A1 A2 DIAG 8 E1 C2 C3 C5 E2 A3 A4 A5 E3 E4 E5 E6 C1 E7 SUB D FITS IN HERE B1 B2 B4 B3 B5 B6 B7 B8 B9 E8 E9 ...

Page 35: ...l Gasket A5 Unscrew the Cover Screw B1 found on the right hand side of the pistol Screw out the Slotted Head Screw B2 retain the Threaded Spring Support B4 Plain Spring Support B3 and Springs B5 Slacken the Lock Screw E3 and withdraw the Wire Feed Lever E4 Remove the Socket Set Screw E9 Remove the Spacer E7 using one of the Gas Head Fixing Screws as an extractor Remove the Socket Set Screw E8 Extr...

Page 36: ...the Valve Retainer and Diaphragm Disc B turn the Speed Control Needle to the slow position and with compressed air connected to the motor press the trigger to lift the valve assembly by air pressure from below Push the Valve Retainer back into the cavity with the finger to release the second O Ring then remove the retainer disc and Diaphragm WHEN WHY The Air Shield Valve should only be dismantled ...

Page 37: ...htly lubricate the Needle Seating D3 and slide into the body aperture Drive it in gently up to the shoulder using a flat block of wood to avoid damaging the outer face and internal thread Fit the O Ring D2 to the Needle D1 Apply a film of grease to the needle then screw it into the sleeve Thread the Retaining Screw D4 into the sleeve outlet and lightly secure it to the Needle using the special too...

Page 38: ...ainer recess Follow with the Valve Cap F placed in with the single hole facing outwards Also ensure that the single threaded hole at the edge of the cap is positioned correctly to accept the Valve Screw G and insert the screw through the body wall DIAG 12 below right demonstrates the positions of these parts Fit the O Ring H into the groove between the body and the Valve Retainer 4 5 6 Re Assembli...

Page 39: ...ecess of the Pistol Body Match the position of the Socket Set Screw I with the Yoke Support Dimple H and tighten securely Referring to DIAG 15 above Slide the Wire Feed Lever A into the Lever Bush B lever upwards and retain with the Lock Screw C Pass the Slotted Head Screw D through the threaded aperture on the right hand side of the pistol Now pass it through the Spring Support Plain E then throu...

Page 40: ...tol and through the Feedroll Gears G Gently screw the Bearing Housing into position ensuring that the forward end of the shaft locates correctly with the front bearing Tighten securely with the supplied Peg Spanner Half fill the body cavity with Metallisation grease P N 21173 and fit the Feed Roll Gasket H over the Yoke Support collars I NB Ensure that it is correctly located in the grooves on the...

Page 41: ...lisation Grease part no 21173 and slide the Seal Housing B onto the boss of the Bevel Pinion E Screw the Bevel Pinion E and Seal Housing B onto the Motor Shaft boss first and lock Screw the motor completely into the body L H thread using the appropriate tool taking care to avoid damaging the seal O Ring The Trigger Control where fitted should be located towards the front of the pistol but where it...

Page 42: ... the feed roller tension is insufficient and should be adjusted NOTE The correct feed roller tension is the minimum which prevents roller slip in this test DO NOT apply excessive tension as this may damage the wire surface and increase wear on the pistol drive and nozzle components 4 8 2 Adjusting Feed Roller Tension Remove the cover plug on the top right hand side of the pistol Using a small flat...

Page 43: ...Page 43 of 64 SECTION 5 FAULT FINDING 5 1 Troubleshooting 5 1 2 Flowmeter Troubleshooting ...

Page 44: ...arts worn dirty or damaged Replace and insert parts Incorrect Nozzle Assembly Replace with correct parts Wire protruding too far forward from Nozzle Pull wire back until flush with Nozzle front face PROBLEM CAUSE REMEDY Pistol Backfires Leaks in Nozzle Assembly Inspect O Rings for damage or loss and tighten Air Cover Oversize gas holes in Nozzle Shell Replace Nozzle Shell Incorrect Pressures Check...

Page 45: ... a distance equal to 3 x the wire diameter outside the Air Nipple Feed roller tension insufficient Check and adjust the feed roller tension as in Section Insufficient wire clearance in Nozzle Clean out Nozzle bore with suitable drill Dirty or damaged wire Clean wire with oiled pad or replace with fresh wire if the wire surface is badly damaged Wire scuffing on Start Stop Wire Guide Check for wear ...

Page 46: ... be quite usable if the flowmeter readings are within 15 of recommended readings Spray throughput may be increased PROBLEM POSSIBLE CAUSES REMEDY OXYGEN FLOAT NORMAL GAS FLOAT LOW Restriction in Nozzle Gas hole in Mixing Block restricted Clean Nozzle with special Metallisation cleaners Clear or replace Mixing Block OXYGEN FLOAT HIGH GAS FLOAT LOW Middle O Ring at rear of Mixing Block missing damag...

Page 47: ...he higher gas and oxygen rates give slightly higher spray rates however this does lead to hotter deposits Open valve and check that gas float is spinning A vertical tube and slow valve opening may be needed If gas float are not spinning freely then reading will be approximately 0 2 divisions too high Adjust oxygen pressure to bring to top of the oxygen float to the same position relative to the to...

Page 48: ...Page 48 of 64 SECTION 6 WIRE DISPENSING 6 1 Wire Swift 6 1 1 Operating Instructions 6 1 2 Wire Straightener ...

Page 49: ...ch as 3 17mm 1 8 steel Adjustable brake to prevent over run of wire 6 1 1 Operating Instructions For loose coiled wire and standard 12 Metal Spraying Reels Slacken the thumbscrews on the Wire Retention Locking Bars and insert the Wire Retention Arms see DIAG 20 below Slide the assemblies towards the centre of the Swift and load the wire coil centrally onto the unit Slide the Wire Retention Arms ou...

Page 50: ...ift incorporates a Wire Straightener See DIAG 21 below Operating the Wire Swift Turn the adjusting screw until the moveable roller touches the wire and pushes it into contact with the two fixed rollers To adjust the Wire Straightener pull through approximately 2ft of wire and examine its curvature If the wire remains curved in the same direction as the coil screw in the adjuster If it has become c...

Page 51: ...Page 51 of 64 SECTION 7 ILLUSTRATED PARTS LIST 7 1 Gas Head Spreader Nozzle 7 2 Diaphragm Valve 7 3 Power Unit Drive Motor 7 4 Wire Drive Unit Feed Control ...

Page 52: ...Head 1250 73 MK73 Gas Head Fitted with Filters Nameplate 1008 O Ring 1017 Air Cover 1024 Flexible Spacing Washer 1253 Spreader Jet 1025 Fibre Washer 1254 Lock Ring 1027 Filter 1258 Label Mark 73 1028 Gasket 1029 Gas Head Fixing Screw 6021 Modified Grub Screw 1250 1250 73 1027 Front Wire Guide 1003A 1028 1029 Screwed Insert Nozzle Shell 1025 1066 1007 1008 1065 6021 Mixing Block Spreader Ring 1253 ...

Page 53: ... Mixing Block Variations 1018 2 00mm Air Nipple 1010 Mixing Block Propane 1020 1 8 Air Nipple 1055 Mixing Block Fine Spray 1302 Air Nipple 3 16 1056 Mixing Block 2 0mm Fine Spray 3829 Air Nipple Deflector 1270 Mixing Block Propane 3823 Air Nipple Fine Spray 1271 Mixing Block Fast Propane Front Wire Guide Variations 4509F 3 16 Front Wire Guide Fast 1429 20 Front Wire Guide 2 0mm 1429 3 16 Front Wir...

Page 54: ...Plunger 1213 Gas Pilot Plunger 1044 Oxygen Plunger 1216 1223 Air Union Air Union Pistol for 3 8 hoses 1201 1220 Diaphragm Housing Propane Diaphram Housing Propane for 3 8 hoses 1217 1222 Gas Union Gas Union for 3 8 hoses 1203 Cam Spindle Housing 1218 1221 Oxygen Union Oxygen Union for 3 8 hoses 1204 Cam Spindle Propane 6526 Washer 1204 1203 1209 1206 6526 1210 1211 1038 1201 1220 1033 35 28077 103...

Page 55: ...e Motor Parts Table PART NO DESCRIPTION 4504 Bevel Pinion 4505 Seal Housing 4534 1 4 Connector R H Thread 4538 O Ring 4550 O Ring 4852 Motor 4000 Rpm 4853 Motor 2500 Rpm 28077 Soft Copper Washer 4534 28077 4852 4853 4505 4504 4550 4538 ...

Page 56: ... SUB B SUB C SUB D AT REAR 4501 845 838 1052 1051 839 831 SUB D 4541 4513 4541 4535 4519 4518 4523 4514 4512 Rear Wire Guide Assy 811 SUB B SUB C 4502 4503 4531 4506 4533 4510 SUB E FITS HERE SUB E 849 851 833 844 843 804 841 842 848 850 804 843 844 4524 4515 4516 7579 4508 840 804 4521 ...

Page 57: ...8 Diaphragm Large 848 Spring Support Threaded 4519 Diaphragm Small 849 Spring Blackodised 4521 Disc Label 850 Spring Support Plain 4523 Spacer 851 Slotted Head Screw 4524 Exhaust Plug 856 Wire Roller 4526 Dust Excluder 857 Roller Feed Nut 4527 Hanging Loop 1051 Lever Bush 4531 Bearing 1052 Socket Set Screw 4533 Cap Retaining Screw 4501 Body 4535 Valve Screw 4502 Wormshaft 4541 O Ring x2 4503 Bevel...

Page 58: ...Page 58 of 64 SECTION 8 INFORMATION TABLES 8 1 Flowmeter Settings 8 2 Nozzle Selection Chart ...

Page 59: ...R APPOX GAS OXYGEN GAS OXYGEN ZINC ALUMINIUM STANDARD 3 16 Fast 1281 1302 1271 65 4 5 42 2 9 66 4 5 8 5 7 3 3 16 Stop Start 1288 SHELL 1302 1271 1288I 65 4 5 42 2 9 66 4 5 8 5 7 3 2mm Stop Start 1293 SHELL 1018 1010 1293I 60 4 1 25 2 7 39 2 7 4 0 3 3 2 3mm Stop Start 1293 SHELL 1018 1010 1292I 60 4 1 25 2 7 39 2 7 4 0 3 3 3mm Stop Start 1290 SHELL 1020 1270 1291I 60 4 1 45 3 1 50 3 4 4 7 5 2 1 8 S...

Page 60: ...I 1302 1256 4 3 17mm 1 8 Standard Stop Start 1270 1429 1290 SHELL 1290I 1020 4547 3 17mm 1 8 Special Low Melt Material 1256 4558 1015 N A 1020 4547 3 0mm Stop Start 1270 1429 3 1290 SHELL 1291I 1020 4547 2 3mm Stop Start 1010 1429 23 1293 SHELL 1292I 1018 4547 2 0mm Standard Stop Start 1010 1429 20 1293 SHELL 1293I 1018 4543 2 0mm Special Fine Spray 1055 4539 3804 N A 3823 4543 1 5mm Standard Stop...

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Page 64: ...isation disclaims liability for any inaccuracies or omissions that may have occurred Periodically changes are made to the information herein and Metallisation reserve the right to make improvements and or changes to the products described in this publication at any time without prior notice ...