MVP ULTRAMAX UPLS-2300 User manual

UltraMAX Fluid Section
Component Manual
This manual is applicable to the
following models:
 UPLS-2300
 UPLS-2300-SS
 UPLS-2400
 UPLS-2400-SS
Rev.
May 2019

UltraMAX Fluid Section Manual
Page | 2
CORPORATE HEADQUARTERS
2030 Falling Waters Rd, Suite 350, Knoxville, TN 37922 · USA · Tel: [phone]
DISTRIBUTION AND PURCHASING
642 Barbrow Ln, Knoxville, TN 37932 · USA · Tel: [phone]
TECHNOLOGY CENTER AND MANUFACTURING
1862 Ives Ave, Kent, WA 98032 · USA · Tel [phone] · Fax [phone]
E-mail: [email protected]om
For a list of international distributors, visit our website at :
www.mvpind.com/mvp-international
Use of this product confirms that Magnum Venus Products, Inc.’s standard terms and
conditions of sale apply.

UltraMAX Fluid Section Manual
Page | 3
Table of Contents
Section Page
 Table of Contents 3
 Safety & Warning Information 4
 Introduction 15
 Disassembling Fluid Section 16
 Cleaning and Inspecting 21
 Reassembling Fluid Section 22
 Reinstalling Fluid Section 28
 Starting Up and Troubleshooting 29
 Parts Drawings 29

UltraMAX Fluid Section Manual
Page | 4
Safety & Warning Information
Warnings
Due to the vast number of chemicals that could be used and their varying chemical reactions, the
buyer and user of this equipment should determine all factors relating to the fluids used, including
any of the potential hazards involved. Particular inquiry and investigation should be made into
potential dangers relating to toxic fumes, fires, explosions, reaction times, and exposure of
human beings to the individual components or their resultant mixtures. MVP assumes no
responsibility for loss, damage, expense or claims for bodily injury or property damage, direct or
consequential, arising from the use of such chemical components.
The end user is responsible for ensuring that the end product or system complies with all the
relevant laws in the country where it is to be used and that all documentation is adhered to.
Recommended Occupational Safety & Health Act (OSHA) Documentation:
 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
For Additional information, contact the Occupational Safety and Health Administration (OSHA)
at https://www.osha.gov/about.html.
Recommended National Fire Protection Association (NFPA) Documentation:
 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
Fire Extinguisher – code ABC, rating number 4a60bc using Extinguishing Media –Foam,
Carbon Dioxide, Dry Chemical, Water Fog, is recommended for this product and applications.
The following general warnings and guidelines are for the setup, use, grounding, maintenance,
and repair of equipment. Additional product-specific warnings may be found throughout this
manual as applicable. Please contact your nearest MVP Technical Service Representative if
additional information is needed.

UltraMAX Fluid Section Manual
Page | 5
Safety Precautions
 Avoid skin contact and inhalation of all chemicals.
 Review Material Safety Data Sheet (MSDS) to promote the safe handling of chemicals in
use.
 Restrict the use of all chemicals to designated areas with good ventilation.
 Chemicals are flammable and reactive.
 Noxious fumes released when combusted.
 Operate equipment in a ventilated environment only.
 Uncured liquid resins are highly flammable unless specifically labeled otherwise.
 Cured laminate, accumulations of overspray, and laminate sandings are highly combustible.
 Do not operate or move electrical equipment when flammable fumes are present.
 Ground all equipment.
 If a spark is seen or felt, immediately halt operation. Do not operate the equipment until the
issue has been identified and repaired.
 Contaminated catalyst may cause fire or explosion.
 Containers may explode if exposed to fire / heat.
 Use and store chemicals away from heat, flames, and sparks.
 Do not smoke in work areas or near stored chemicals.
 Do not mix Methyl Ethyl Ketone Peroxide (MEKP) with materials other than polyethylene.
 Do not dilute MEKP.
 Keep food and drink away from work area.

UltraMAX Fluid Section Manual
Page | 6
Physical Hazards
 Never look directly into the spray gun fluid tip. Serious injury or death can result.
 Never aim the spray gun at or near another person. Serious injury or death can result.
 Chemical compounds can be severely irritating to the eyes and skin.
 Inhalation, ingestion, or injection may damage internal organs and lead to pulmonary disorders, cancers,
lymphomas, and other diseases or health conditions.
 Other potential health effects include: irritation of the eyes and upper respiratory tract, headache, light-
headedness, dizziness, confusion, drowsiness, nausea, vomiting, and occasionally abdominal pain.
 Eye contact: Immediately flush with water for at least 15 minutes and seek immediate medical attention.
 Skin Contact: Immediately wash with soap and water and seek immediate medical attention.
 Inhalation: Move the person to fresh air and seek immediate medical attention.
 Do not remove shields, covers, or safety features on equipment that is in use.
 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 shoot liquid through the skin.
 Keep hands and body parts away from any moving equipment or components.
 Do not stand under plunger
 An improperly loaded drum may lead to an imbalance, causing a unit to tip over
Personal Protective Equipment (PPE)
 MVP recommends the use of personal safety equipment with all products in our catalog.
 Wear safety goggles, hearing protection, a respirator, and chemical resistant gloves.
 Wear long sleeve shirts or jackets and pants to minimize skin exposure.
 PPE should be worn by operators and service technicians to reduce the risk of injury.
For Additional information, contact the Occupational Safety and Health Administration
(OSHA). https://www.osha.gov/about.html

UltraMAX Fluid Section Manual
Page | 7
Symbol Definitions
Indicates the risk of
contact with chemicals
that are hazardous, which
may lead to injury or
death.
Indicates the risk of
contact with voltage /
amperage that may lead
to serious injury or death
Indicates that the
materials being used are
susceptible to combustion
Indicates the risk of
contact with moving
components that may
lead to serious injury or
death.
Indicates that the system
or component should be
grounded before
proceeding with use or
repair.
Indicates the use of lit
cigarettes or cigars is
prohibited, because the
materials being used are
susceptible to
combustion.
Indicates that the
materials and/or the
process being performed
can lead to ignition and
explosion.
A recommendation for
the use of Personal
Protective Equipment
(PPE) before using or
repairing the product.

UltraMAX Fluid Section Manual
Page | 8
Polymer Matrix Materials: Advanced Composites
Potential health hazards associated with the use of advanced composites can be controlled through
the implementation of an effective industrial hygiene and safety program.
https://www.osha.gov/dts/osta/otm/otm_iii/otm_iii_1.html#t iii:1_1
Resins
Composite Component Organ System Target
(Possible Target)
Known (Possible) Health Effect
Epoxy resins Skin, lungs, eyes Contact and allergic dermatitis,
conjunctivitis
Polyurethane resins Lungs, skin, eyes Respiratory sensitization, contact
dermatitis, conjunctivitis
Phenol formaldehyde Skin, lungs, eyes As above (potential carcinogen)
Bismaleimides (BMI) Skin, lungs, eyes As above (potential carcinogen)
Polyamides Skin, lungs, eyes As above (potential carcinogen)
Reinforcing materials
Composite Component Organ System Target
(Possible Target)
Known (Possible) Health Effect
Aramid fibers Skin (lungs) Skin and respiratory irritation, contact
dermatitis (chronic interstitial lung disease)
Carbon/graphite fibers Skin (lungs) As noted for aramid fibers
Glass fibers (continuous
filament) Skin (lungs) As noted for aramid fibers
Hardeners and curing agents
Composite Component Organ System Target
(Possible Target)
Known (Possible) Health Effect
Diaminodiphenylsulfone N/A No known effects with workplace
exposure
Methylenedianiline Liver, skin Hepatotoxicity, suspect human carcinogen
Other aromatic amines
Composite Component Organ System Target
(Possible Target)
Known (Possible) Health Effect
Meta-phenylenediamine (MPDA) Liver, skin (kidney,
bladder)
Hepatitis, contact dermatitis (kidney and
bladder cancer)
Aliphatic andcyclo-aliphatic
amines
Eyes, skin Severe irritation, contact dermatitis
Polyaminoamide Eyes, skin Irritation (sensitization)
Anhydride Eyes, lungs, skin Severe eye and skin irritation, respiratory
sensitization, contact dermatitis

UltraMAX Fluid Section Manual
Page | 9
Catalyst - Methyl Ethyl Ketone Peroxide (MEKP)
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.
WARNING
Contamination with promoters, 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 be explosive in
nature. Heat applied to MEKP or heat buildup from contamination reactions
can cause the material to reach its Self-Accelerating Decomposition
Temperature (SADT).
Researchers have reported measuring pressure rates-of-rise well over 100,000 psi per second when
certain MEKP’s reach their SADT. For comparison, the highest-pressure rate-of-rise 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 regarding
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:
 Store MEKP in a cool, dry place in original containers away from direct sunlight and away
from other chemicals.
 Keep MEKP away from heat, sparks, and open flames.
 Prevent contamination or MEKP with other materials, including polyester over spray and
sandings, polymerization accelerators and promoters, brass, aluminum, and non-stainless
steels.

UltraMAX Fluid Section Manual
Page | 10
 Never add MEKP to anything that is hot, since explosive decomposition may result.
 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.
 Avoid spillage, which can heat up to the point of self-ignition.
 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.
 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.
 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.
Clean-Up Solvents and Resin Diluents
WARNING
A hazardous situation may be present in your pressurized fluid system! Hydro
carbon 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.). An explosion could cause
serious injury, death, and/or substantial property damage. Cleaning agents,
coatings, paints, etc. may contain Halogenated Hyrdrocarbon solvents. Some
Magnum Venus Products spray equipment includes aluminum or galvanized
components and will be affected by Halogenated Hydrocarbon solvents.
There are three key elements to the Halogenated Hyrdocarbon (HHC) solvent hazard.
1. 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.
2. 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.
3. Equipment capable of
withstanding pressure.
When HHC solvent contact 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. 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.

UltraMAX Fluid Section Manual
Page | 11
 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. Mixing HHC solvents with other
materials or solvents such as MEKP, alcohol, or toluene may render the inhibitors ineffective.
 The use of reclaimed solvents is particularly hazardous. Reclaimers may not add any inhibitors.
The possible presence of water in reclaimed solvents could also feed the reaction.
 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 to safely prevent the chemical reaction
under all circumstances.
 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 (VOCs), 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 (HHC) solvents in pressurized fluid
systems having aluminum or galvanized wetted parts.
Magnum Venus Products is aware of NO stabilizers available to prevent HHC
solvents from reaction under all conditions with aluminum components in
closed fluid systems. HHC solvents are dangerous when used with aluminum
components in a closed fluid system.
 Consult your material supplier to determine whether your solvent or coating contains
Halogenated Hydrocarbon solvents.
 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.
 If, however, you find it necessary to use flammable solvents, they must be kept in approved,
electrically grounded containers.
 Bulk solvent should be stored in a well-ventilated, separate building, 50 feet away from your main
plant.
 You should only allow enough solvent for one day’s use in your laminating area.
 NO SMOKING signs must be posted and observed in all areas of storage or where solvents and
other flammable materials are used.
 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.
 Solvents should be handled in accordance with OSHA Section 1910.106 and 1910.107.

UltraMAX Fluid Section Manual
Page | 12
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 to avoid 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 diluent being
contaminated through rust particles in drums, poor quality control on the part of the diluents
suppliers, or any other reason. If diluents are absolutely required, contact your catalyst supplier
and follow his instructions explicitly. Preferably the supplier should premix the catalyst to prevent
possible “on the job” contamination while mixing.
WARNING
If diluents are not used, remember that catalyst spillage and gun, hose,
and packing leaks are potentially more hazardous since each drop
contains a higher concentration of catalyst and will therefore react more
quickly with overspray and the leak.
Cured Laminate, Overspray and Laminate Sandings Accumulation
 Remove all accumulations of overspray, Fiberglass Reinforced Plastic (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.
 Floor coverings, if used, should be non-combustible.
 Spilled or leaked catalyst may cause a fire if it comes in contact with an FRP product, over-
sprayed chop or resin, FRP sandings or any other material with MEKP.
To prevent 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.

UltraMAX Fluid Section Manual
Page | 13
Toxicity of Chemicals
 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.
 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.
 Also determine the best methods of first aid treatment for each chemical used in your plant.
Equipment Safety
Magnum Venus Products suggest 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!
CAUTION
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 OR AN ANIMAL.
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 from dirt, grease, or resin. Clean catalyst system
components with clean water daily.
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.
Treatment of Chemical Injuries
CAUTION
Refer to your catalyst manufacturer’s safety information regarding the safe
handling and storage of catalyst. Wear appropriate safety equipment as
recommended.
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.

UltraMAX Fluid Section Manual
Page | 14
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 if
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 an injury. If the product’s
MSDS includes first aid instructions, administer first aid immediately after
contacting a doctor.
Fast treatment of the outer skin and eyes that contact 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 may be incorrect for some chemicals; you must know the chemicals and treatment
before an accident occurs. Treatment for swallowing a chemical frequently depends upon the
nature of the chemical.
Emergency Stop Procedure
In an emergency, follow these steps to stop a system:
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.
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.
2. Turn all system regulators to the “OFF” position (counter-clockwise) position.
3. Verify / secure the catalyst relief line, located on the catalyst relief valve.
4. Verify / secure the resin return line, located on the resin filter.
5. Place a container under the resin pump ball valve to catch ejected resin.
6. Locate the ball valve on the resin pump.
7. Rotate the ball valve 90 degrees to the “On” or open position.
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.

UltraMAX Fluid Section Manual
Page | 15
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 should be 1 meg ohm
(106 ohms) or less.
CAUTION
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”.
Introduction
This manual provides information for the operation, maintenance, and simple repair of the MVP
UltraMAX Fluid Section. These fluid sections are used in multiple configurations. This manual
only covers the fluid section itself; generic references are used when referring to other
components that may be connected to the fluid section. Refer to the specific manual for your
components for detailed information. The following procedures for the fluid section are included:
 Step-by-step assembly and disassembly
 Parts information
Please read this manual carefully and retain for future reference. Follow the steps
in the order given, otherwise you may damage the equipment or injure yourself.
As you disassemble the equipment, lay out the components in the correct order and direction to
assist with reassembly. Refer to the current parts drawing specific to the model you are working
on to ensure you have the correct parts information.
Items Needed
 ¼” wooden dowel – 6” length
 12” adjustable wrench
 Set of open end wrenches
 Pliers
 Wire brush
 Table mounted soft-jawed vise
 Approved lubricant and grease for material being used
 Semi-permanent Loctite® (blue) or equivalent thread lock compound

UltraMAX Fluid Section Manual
Page | 16
 Fluid section repair kit (refer to drawings included with the unit for part number)
Note The seal kit (SK) only comes with seals and O-rings. The repair kit (RK) comes
with seals, O-rings, balls, and springs.
Note The Kalrez O-rings that are used on the UPLS-2300-SS fluid section are not
included in any repair or seal kit and must be ordered separately.
WARNING
Due to high pressures and temperatures associated with some materials
follow all safety precautions and proper start-up procedures before
running new or rebuilt fluid sections.
Disassembling Fluid Section
Remove Fluid Section from System
WARNING
Release all fluid pressure from the system before disconnecting hoses or
tie rods. Release surge chamber pressure before attempting to remove
surge chamber. Parts under pressure could cause injury.
1. Remove pickup wands from supply and drain or shut off supply to fluid section.
2. Switch the supply lines to approved solvent to flush the system, if possible.
3. Set operating pressure to zero (0) psi.
4. Open recirculation valve and/or gun to purge pressure from fluid sections.
5. Allow to drain until as much fluid as possible has been purged.
6. Turn air pressure to a very low setting, just enough to cycle the fluid section.
7. Cycle fluid section a few times very slowly to remove as much material from the cylinder as
possible or flush with solvent until solvent is purged out.
8. Remove pickup wand assembly/feed hose from bottom of fluid section.
9. Remove the surge chamber/filter assembly from the bottom of the fluid section.
10. Remove the upper pin from the slave arm.
11. Remove the lower pin from the base mount.
12. Remove the fluid section from the unit and take to a work area for maintenance.
Dismantle Fluid Section
13. Clamp the outlet body between the jaws of a soft-jawed table-mounted vise, as shown in
Figure 1.

UltraMAX Fluid Section Manual
Page | 17
14. Remove the rod adapter, leaving the hex nut and
ball joint rod end in place.
Note If the hex nut and ball joint rod end have
to be removed, carefully measure the
distance from the end of the ball joint
rod end to the top of the rod adapter to
ensure that it is installed back in the
same position. If this is not put back to
factory specifications with 2 threads
showing, damage to the chrome ball, foot valve spring, and ball stop can result.
15. Remove the four hex nuts, foot valve collar,
and foot valve from the bottom of the fluid
section.
Note Make note of the orientation of the
foot valve inlet relative to the outlet
body for reassembly purposes.
16. Remove the cylinder.
17. Remove and discard the two O-rings from the
cylinder.
Figure 1. Fluid Section in Vise

UltraMAX Fluid Section Manual
Page | 18
18. Remove the four cylinder tie rods from the outlet
body.
19. Remove the packing nut from the outlet body.
20. Remove the piston rod assembly from the outlet
body.
21. Using the ¼” wooden dowel, push the wave springs,
male compression ring, piston rod packing set, female
compression ring, and the guide bushing out through
the top of the outlet body.

UltraMAX Fluid Section Manual
Page | 19
Disassemble Piston Rod
UPLS-2300-SS Only
Note The UPLS-2300-SS piston body has an additional O-ring seal near the ball
seat. DO NOT remove this O-ring during disassembly! It is not included in
either the seal or repair kit and must be ordered separately. Under normal
circumstances this O-ring will not have to
be replaced, but you must replace if it is
damaged.
22. Wipe down the piston body with the approved
solvent and inspect the O-ring.
23. If the O-ring is nicked, torn, or broken, replace
with a new one.
Barrel Type Piston Seal
24. Using the appropriate wrenches, remove the piston body from the piston rod.
Note When you remove the piston body, the chrome ball may fall out. If you only
have the seal kit, the chrome ball must be reused. Do not drop or dent the ball
or it will be permanently damaged and must be replaced.
25. Remove the piston body, barrel seat, chrome ball, and piston ball spring.
26. Remove the barrel seal from the piston body.
Cup Style Piston Seal
27. Using the appropriate wrenches, remove the piston body from the
piston rod.
Note When you remove the piston body, the chrome ball
may fall out. If you only have the seal kit, the chrome
ball must be reused. Do not drop or dent the ball or it will be permanently
damaged and must be replaced.
28. Remove the piston body, barrel seat, chrome ball, and piston ball spring.

UltraMAX Fluid Section Manual
Page | 20
29. Remove the piston cup compression ring, upper piston cup, piston cup spacer, lower piston
cup, and piston cup backup ring from the piston body.
Disassemble Foot Valve
UPLS-2300-SS Only
Note The stainless-steel foot valve has an additional O-ring seal near the ball seat.
DO NOT remove this O-ring during
disassembly! It is not included in
either the seal or repair kit and
must be ordered separately.
Under normal circumstances this
O-ring will not have to be replaced,
but you must replace if it is
damaged.
30. Wipe down the foot valve body with the
approved solvent and inspect the O-ring.
31. If the O-ring is nicked, torn, or broken,
replace with a new one.
32. Using pliers, compress the ball stop and
remove from the foot valve.
33. Remove the foot valve spring and chrome ball.
Note If only using the seal kit, the chrome ball must be reused. Do not drop or dent
the ball or it will be permanently damaged and must be replaced.