Rhino SD3/XD3 Air Motor
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1 Rhino SD3/XD3 Air Motor Customer Product Manual Issued 6/18 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative. This document is subject to change without notice. Check for the latest version. NORDSON CORPORATION AMHERST, OHIO USA
2 tents Table of Contents Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations and Approvals... 1 Personal Safety... High-Pressure Fluids... Fire Safety... 3 Halogenated Hydrocarbon Solvent Hazards. 4 Action in the Event of a Malfunction... 4 Disposal... 4 Description... 5 Specifications... 6 Theory of Operation... 6 Repair... 7 Consumable Items... 7 Replace the Main Air Valve , 100-, and 15-mm Air Cylinders and 00-mm Air Cylinders... 9 Replace the Pilot Valve Replace the Air Cylinder Preventative Maintenance Parts Using the Illustrated Parts List Air Motor Packaged Kits , 100-, and 15-mm Air Motor and 00-mm Air Motor Air Motor Valve Kits... 1 Pilot Valve Kits... 1 Cylinder Kits... 1 Tools... 1 Pneumatic Schematic... Contact Us Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer Service 555 Jackson Street Amherst, OH Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 017. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks Nordson, the Nordson logo, and Rhino are registered trademarks of Nordson Corporation. All other trademarks are the property of their respective owners.
3 Change Record i Revision Date Change 01 8/17 Released. 0 6/18 Added 00-mm air motor. 03 6/18 Updated air motor BOM. Change Record
4 ii Change Record
5 Rhino SD3/XD3 Air Motor 1 Rhino SD3/XD3 Air Motor Safety Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Some examples of unintended use of equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed.
6 Rhino SD3/XD3 Air Motor Personal Safety To prevent injury follow, these instructions. Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. While operating manual spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as jewelry or tools. If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. Obtain and read Safety Data Sheets (SDS) for all materials used. Follow the manufacturer s instructions for safe handling and use of materials, and use recommended personal protection devices. Make sure the spray area is adequately ventilated. To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons. High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can also cause toxic poisoning. If you suffer a fluid injection injury, seek medical care immediately. If possible, provide a copy of the SDS for the injected fluid to the health care provider.
7 Rhino SD3/XD3 Air Motor 3 The National Spray Equipment Manufacturers Association has created a wallet card that you should carry when you are operating high-pressure spray equipment. These cards are supplied with your equipment. The following is the text of this card: WARNING: Any injury caused by high pressure liquid can be serious. If you are injured or even suspect an injury: Go to an emergency room immediately. Tell the doctor that you suspect an injection injury. Show him this card Tell him what kind of material you were spraying MEDICAL ALERT AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN Injection in the skin is a serious traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable. The seriousness of the wound depends on where the injury is on the body, whether the substance hit something on its way in and deflected causing more damage, and many other variables including skin microflora residing in the paint or gun which are blasted into the wound. If the injected paint contains acrylic latex and titanium dioxide that damage the tissue s resistance to infection, bacterial growth will flourish. The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected paint, judicious wound debridement, and immediate antibiotic treatment. Fire Safety To avoid a fire or explosion, follow these instructions. Ground all conductive equipment. Use only grounded air and fluid hoses. Check equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one megohm. Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly.
8 4 Rhino SD3/XD3 Air Motor Fire Safety (contd) Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material SDS for guidance. Do not disconnect live electrical circuits when working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage. Halogenated hydrocarbon solvents contain one or more of the following elements: Element Symbol Prefix Fluorine F Fluoro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- Check your material SDS or contact your material supplier for more information. If you must use halogenated hydrocarbon solvents, contact your Nordson representative for information about compatible Nordson components. Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the system. Disposal Dispose of equipment and materials used in operation and servicing according to local codes.
9 Rhino SD3/XD3 Air Motor 5 Description See Figure 1 and refer to Table 1 for a description of the Rhino SD3/XD3 air motor components. NOTE: Installation and operation are dependent on the unloader and application. Refer to the system documentation for detailed information. Pilot Valve Main Air Control Valve _160 Figure 1 Rhino SD3/XD3 Air Motor (160-mm Air Motor Shown) Item Main Air Control Valve Pilot Valve Table 1 Air Motor Components Description Controls the air motor shaft movement by shifting a spool; the spool exhausts air on one side of the piston and directs air pressure to the opposite side of the piston. Controls the direction of the air motor shaft.
10 6 Rhino SD3/XD3 Air Motor Specifications Refer to Table for the theoretical ratio of the air motor piston to the hydraulic section piston. All hydraulic sections have a material output of 190 cc per cycle. Table Specifications Theoretical Ratio Air Motor Cylinder 6:1 80 mm 10:1 100 mm 15:1 15 mm 5:1 160 mm 40:1 00 mm Theory of Operation See Figure. The air motor drives the hydraulic section. A five-port, three-position (5/3) main air control valve controls the direction of the air motor shaft movement. When the air motor piston moves up and down, the proximity sensor detects a magnet on the piston. The proximity sensor sends momentary signals to a pilot valve. The pilot valve sends a positive continuous signal to the main air motor control valve for each direction of travel. Main Air Control Valve _160 Figure Air Motor (160-mm Air Motor Shown)
11 Rhino SD3/XD3 Air Motor 7 Repair WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Read and understand this entire section before repairing this equipment. Some repairs can be made without breaking down the air motor. Relieve all pressure to the unloader before performing repair procedures. If necessary, contact a local Nordson representative with questions about these procedures. Consumable Items Refer to Table 3 for a list of consumable items for repair procedures. Table 3 Consumable Items Item Part Application Never-Seez Loctite Threadlocker Blue Apply to threads of applicable parts Mobil SHC Lubricates O-rings during assembly
12 8 Rhino SD3/XD3 Air Motor Replace the Main Air Valve NOTE: The main air valve can be replaced without removing the air motor from the unloader. 80-, 100-, and 15-mm Air Cylinders See Figure Remove the two screws securing the bracket to the manifold. To ensure the tubing stays connected, rotate the pilot valve bracket and assembly, as if it were on a hinge, just enough to be able to remove the main air valve from the manifold.. Remove the four screws securing the main air valve to the manifold. 3. Remove the main air valve and gasket (not shown in Figure 3). 4. Install the new main air valve to the manifold using the four new screws. NOTE: The replacement gasket and four screws are included in the new valve kit. 5. Reinstall the pilot valve bracket and assembly to the manifold with the two screws. Manifold Main Air Valve Gasket not shown Main Air Valve Screw *Pilot Valve Pilot Valve Screw Bracket *Pilot valve bracket and assembly shown out of position Figure 3 Replacing the Main Air Valve (15-mm Air Motor Shown) _15 NOTE: For clarity, tubing not shown.
13 Rhino SD3/XD3 Air Motor 9 Replace the Main Air Valve(contd) 160- and 00-mm Air Cylinders See Figure Remove the four screws securing the main air valve to the manifold.. Remove the main air valve and gasket (not shown in Figure 4). 3. Install the new main air valve to the manifold using the four new screws. NOTE: The replacement gasket and four screws are included in the new valve kit. Manifold Main Air Valve Gasket not shown Main Air Valve Screw _160 Figure 4 Replacing the Main Air Valve (160-mm Air Motor Shown) NOTE: For clarity, tubing not shown.
14 10 Rhino SD3/XD3 Air Motor Replace the Pilot Valve See Figure 5. NOTE: The pilot valve can be replaced without removing the air motor from the pump. NOTE: The procedure is the same for all air cylinder sizes. 1. Disconnect the tubing from the pilot valve (tubing not shown in Figure 5).. Remove the two pilot valve assembly screws securing the pilot valve assembly to the bracket. 3. Install the new pilot valve assembly to the bracket using two screws. 4. Reconnect the tubing. Bracket Pilot Valve Assembly Pilot Valve Screw _160 Figure 5 Replacing the Pilot Valve (160-mm Air Motor Shown) NOTE: For clarity, tubing not shown.
15 Rhino SD3/XD3 Air Motor 11 Replace the Air Cylinder See Figure 6 and refer to Tables 4 and 5. NOTE: The procedure is the same for all air cylinder sizes. NOTE: A 75-lb (68-kg) capacity lifting device is required to remove the air cylinder. NOTE: The air motor mounting plate, contained outside of the air motor assembly, is not shown. 1. Remove the button head screws (6) securing the top cover (5) to the air cylinder (7).. Remove the two socket head screws (1) securing the manifold () to the air cylinder (7). 3. Remove the manifold (), four O-rings (3, 4), and top cover (5). 4. Remove the four lock nuts (9) securing the air cylinder to the air motor mounting plate. Do not discard the lock nuts. 5. Refer to Table 4. Install the appropriate lifting eye bolt in one of the female threads of the tie rods (10) on the air motor. 6. Use the lifting device to remove the air cylinder (7). 7. Install the eye bolt into the new air cylinder (7). 8. Install a new air cylinder (7) to the air motor mounting plate. 9. Apply adhesive to the threads on the end of the set screw (8) that threads through the air motor mounting plate and into the air motor, approximately 1 in. across the threads. 10. Insert a hex key into the set screw (8) and thread it into the air motor until bottomed. Refer to Table 5 for torque specifications. 11. Remove the hex key and thread the lock nut (9) onto the set screw (8). Reinsert the hex key to prevent the set screw from rotating while tightening the lock nut. Refer to Table 5 for torque specifications. 1. Remove the eye bolt. 13. Install four new O-rings (3, 4) onto the manifold (). 14. Reinstall the two socket head screws (1) securing the manifold () to the air cylinder (7). 15. Replace the top cover (5) with the button head screws (6). Table 4 Eye Bolt Specification Chart Theoretical Ratio Air Motor Cylinder Eye Bolt 6:1 80 mm M10 x :1 100 mm M10 x :1 15 mm M1 x :1 160 mm M16 x.0 40:1 00 mm M16 x.0
16 1 Rhino SD3/XD3 Air Motor Table 5 Set Screw and Lock Nut Torque Specifications Theoretical Ratio Air Motor 6:1 80 mm 10:1 100 mm Thread Size Set Screws Lock Nuts M10 x in-lb 15 ft-lb 15:1 15 mm M1 x in-lb 5 ft-lb 5:1 160 mm M16 x.0 10 ft-lb 55 ft-lb 40:1 00 mm * 9* _160 *Not contained within the air motor assemblies. Figure 6 Replacing the Air Cylinder (160-mm Air Motor Shown) 1. Socket head screw 5. Top cover. Manifold 6. Button head screw 3. O-ring 7. Air cylinder 4. O-ring NOTE: For clarity, tubing not shown. 8. Set screw* 9. Lock nut* 10. Tie rod female thread
17 Rhino SD3/XD3 Air Motor 13 Preventative Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. NOTE: It may be necessary to adjust frequencies due to the facility environment, process parameters, material being applied, or experience. NOTE: The frequencies listed in Table 6 are only guidelines. Always perform preventative maintenance procedures according to specific facility maintenance schedules. Refer to Table 6 for a preventative maintenance schedule. Table 6 Preventative Maintenance Schedule Item Task Time to Complete Frequency Main Air Motor Control Valve Replace 15 min 8,000,000 pump strokes Pilot Valve Replace 15 min 8,000,000 pump strokes Cylinder Replace 1 hr 8,000,000 pump strokes
18 14 Rhino SD3/XD3 Air Motor Parts To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative. Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code NS (not shown) indicates that a listed part is not illustrated. A dash ( ) is used when the part number applies to all parts in the illustration. The number in the Part column is the Nordson Corporation part number. A series of dashes in this column ( ) means the part cannot be ordered separately. The Description column gives the part name, as well as its dimensions and other characteristics when appropriate. Indentations show the relationships between assemblies, subassemblies, and parts. If you order the assembly, items 1 and will be included. If you order item 1, item will be included. If you order item, you will receive item only. The number in the Quantity column is the quantity required per unit, assembly, or subassembly. The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model. Letters in the Note column refer to notes at the end of each parts list. Notes contain important information about usage and ordering. Special attention should be given to notes. Item Part Description Quantity Note Assembly Subassembly A Part 1
19 Rhino SD3/XD3 Air Motor 15 Air Motor Packaged Kits Refer to Table 7 for the part numbers for packaged air motor kits. Table 7 Air Motor Packaged Kits Part Theoretical Ratio Description :1 KIT, air motor, Rhino, SD3/XD3, 80 mm :1 KIT, air motor, Rhino, SD3/XD3, 100 mm :1 KIT, air motor, Rhino, SD3/XD3, 15 mm :1 KIT, air motor, Rhino, SD3/XD3, 160 mm :1 KIT, air motor, Rhino, SD3/XD3, 00 mm
20 16 Rhino SD3/XD3 Air Motor 80-, 100-, and 15-mm Air Motor See Figure 7 and refer to the following parts list. 1 *Item 17 replaced by item 13 for 80- and 100-mm air motors * _15 Figure 7 Rhino SD3/XD3 80-, 100-, and 15-mm Air Motors (15-mm Air Motor Shown) NOTE: For clarity, tubing not shown.
21 Rhino SD3/XD3 Air Motor 17 Item Part Part Part Description Qty Note MODULE, air motor, 80 mm MODULE, air motor, 100 mm MODULE, air motor, 15 mm 1 CYLINDER, air, 80 mm-bore 1 1 CYLINDER, air, 100 mm-bore 1 CYLINDER, air, 15 mm-bore O-RING, Viton, x x O-RING, 118, Viton, 0.86 x 0.103, brown O-RING, Viton, 13 mm inside diameter x 1.5 mm O-RING, Viton, x x 0.63 MANIFOLD, valve, supply, air motor, 80 mm 1 4 MANIFOLD, valve, supply, air motor, 100 mm 1 MANIFOLD, valve, supply, air motor, 15 mm 1 5 SCREW, socket, M1 x 1.75 x 40, Class 1.9, per ISO MUFFLER, pneumatic, R ¼, 40 db MUFFLER, R ½, 40 db VALVE, air, 5/3, VALVE, air, 5/3, 1 VALVE, air, 5/3, BRACKET, pilot valve, air motor, mm 1 9 SCREW, button, socket, M4 x 0.7 x 1, Class 1.9, per ISO VALVE, air, 5/, ⅛ 1 11 SCREW, socket, cap, M3 x 0.5 x 5, Class 1.9, per ISO VENT, breather, sintered, R ⅛ ELBOW, male, 4 mm tube x R ⅛ 7 A 14 CONNECTOR, plug-in elbow, 4 mm PLUG, push-in, 8 mm, plastic 1 16 MANIFOLD, pneumatic, 3 x 4 mm outside diameter, x 8 outside diameter, tube CONNECTOR, male, with internal hex, 4 mm T x R ⅛ SCREW, socket, cap, M4 x 0.7 x 18, Class 1.9, per ISO 476 PLUG, O-ring, straight thread, 5, port per ISO PLUG, O-ring, straight thread, 6, port per ISO PLUG, O-ring, straight thread, 8, port per ISO Continued...
22 18 Rhino SD3/XD3 Air Motor 80-, 100-, and 15-mm Air Motor (contd) Item Part Part Part Description Qty Note PLUG, O-ring, straight thread,, port per ISO CONNECTOR, male, internal hex, 4 mm T x M5 4 MUFFLER, M SENSOR, proximity, magnetic NS ADHESIVE, Loctite Threadlocker Blue 4, removable, 50 m 1 NS LUBRICANT, Mobil SHC NS ADHESIVE, pipe/thread/hydraulic sealant 1 NS TUBING, polyurethane, 4 mm outside diameter, black 3.06 ft NOTE A: Quantity 5 for 15-mm air motor. NS: Not Shown
23 Rhino SD3/XD3 Air Motor and 00-mm Air Motor See Figure 8 and refer to the following parts list _160 Figure 8 Rhino SD3/XD and 00-mm Air Motors (160-mm Air Motor Shown) NOTE: For clarity, tubing not shown.
24 0 Rhino SD3/XD3 Air Motor 160- and 00-mm Air Motor (contd) Item Part Part Description Quantity Note MODULE, air motor, 160 mm MODULE, air motor, 00 mm 1 1 CYLINDER, air, 160-mm bore 1 CYLINDER, air, 00-mm bore O-RING, Viton, x x O-RING, Viton, x x O-RING, Viton, x x MANIFOLD, valve, supply, air motor, mm 1 5 SCREW, socket, M1 x 1.75 x 40, Class 1.9, per ISO MUFFLER, pneumatic, R ¾, 40 Db 7 VALVE, air, 5/3, ELBOW, male, 4 mm tube x R ⅛ 4 9 FITTING, male elbow, 4 mm T x M PLUG, O-ring, straight thread, 8, port per ISO PLUG, O-ring, straight thread,, port per ISO CONNECTOR, plug-in elbow, 4 mm 3 13 SCREW, socket, cap, M4 x 0.7 x 18, Class 1.9, per ISO CONNECTOR, male, with internal hex, 4 mm T x M MUFFLER, M SENSOR, proximity, magnetic PLUG, push-in, 8 mm, plastic 1 18 BRACKET, pilot valve, air motor, mm 1 19 SCREW, button, socket, M4 x 0.7 x 1, Class 1.9, per ISO MANIFOLD, pneumatic, 3 x 4 mm outside diameter, x 8 outside diameter, tube 1 1 VALVE, air, 5/, R ⅛ VENT, breather, sintered R 1/8 3 CONNECTOR, male, 4 mm T x R ⅛ 3 4 SCREW, socket, cap, M3 x 0.5 x 5, Class 1.9, per ISO 476 NS ADHESIVE, Loctite Threadlocker Blue 4, removable, 50 m 1 NS LUBRICANT, Mobil SHC NS ADHESIVE, pipe/thread/hydraulic sealant 1 NS TUBING, polyurethane, 4 mm outside diameter, black.56 ft NS: Not Shown
25 Rhino SD3/XD3 Air Motor 1 Air Motor Valve Kits The air motor valve kit includes the air motor valve, gasket, and mounting screws. Refer to the following parts list. Part Description Air Motor Size KIT, valve, air, 5/3, 1 80 mm KIT, valve, air, 5/3, 100 mm KIT, valve, air, 5/3, 3 15 mm KIT, valve, air, 5/3, 4 160, 00 mm Pilot Valve Kits The pilot valve kit includes the pilot valve and attached fittings. Refer to the following parts list. Part Description Air Motor Size KIT, valve, air, 5/3, pilot, mm 80, 100, 15 mm KIT, valve, air, 5/3, pilot, mm 160, 00 mm Cylinder Kits The cylinder kits include the cylinder and replacement O-rings. Refer to the following parts list. Part Description Note KIT, cylinder, air motor, Rhino, SD3/XD3, 80 mm KIT, cylinder, air motor, Rhino, SD3/XD3, 100 mm KIT, cylinder, air motor, Rhino, SD3/XD3, 15 mm KIT, cylinder, air motor, Rhino, SD3/XD3, 160 mm 1614 KIT, cylinder, air motor, Rhino, SD3/XD3, 00 mm Tools Refer to the following parts list. Part Description Note TOOL, magnet, air motor
26 Rhino SD3/XD3 Air Motor Pneumatic Schematic 4 AIR IN X X Figure 9 Rhino SD3/XD3 Air Motor Pneumatic Schematic
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