StediFlo 3:1 and 6:1 Low Pressure Pumps

Transcription

1 StediFlo 3:1 and 6:1 Low Pressure Pumps Customer Product Manual Issued 7/12 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) This document is subject to change without notice. Check for the latest version. NORDSON CORPORATION AMHERST, OHIO USA

2 Table of Contents Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations and Approvals... 1 Personal Safety... 2 High-Pressure Fluids... 2 Fire Safety... 3 Halogenated Hydrocarbon Solvent Hazards. 4 Action in the Event of a Malfunction... 4 Disposal... 4 Description... 5 Specifications :1 Pump Dimensions :1 Pump Dimensions... 8 Installation... 9 Dead-End System Diagram... 9 Circulating System Diagram Mounting Connections Air Supply Connections Hydraulic Connections Grounding Solvent Fluid Air Lubricator Oil Operation Checking the System Solvent Fluid Fill Adjusting the Air Lubricator Flushing Daily Operation Changing Colors or Material Shutdown Maintenance Daily Maintenance Adjusting the Upper Packings As Needed Maintenance Troubleshooting General Troubleshooting Air Motor Troubleshooting Hydraulic Section Repair Preparation Disassembly Pressure Ball Check Disassembly Lower Packing Replacement Upper Packing Replacement Siphon Ball Check Repair Hydraulic Section Assembly Air Motor Repair Tools and Materials Required Preparation Muffler and Control Housing Removal Cylinder Head Disassembly Cylinder Head Removal Cylinder/Lower Housing Disassembly Piston Disassembly Cleaning and Inspection Piston Assembly Cylinder/Lower Housing Assembly Cylinder Head Installation Toggle Installation Control Cylinder Assembly and Installation Muffler Cover and Muffler Installation Air Motor to Hydraulic Section Connection Parts Information Pump Part Numbers Hydraulic Section Parts List Air Motor Parts List Options Declaration of Conformity 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 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 and the Nordson logo are registered trademarks of Nordson Corporation. StediFlo is a trademark of Nordson Corporation. All other trademarks are the property of their respective owners.

3 StediFlo 3:1/6:1 Pumps 1 StediFlo 3:1/6:1 Pumps 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.

4 2 StediFlo 3:1/6:1 Pumps 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 Material Safety Data Sheets (MSDS) 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 MSDS for the injected fluid to the health care provider.

5 StediFlo 3:1/6:1 Pumps 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.

6 4 StediFlo 3:1/6:1 Pumps Fire Safety (contd) Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MSDS 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 MSDS 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.

7 StediFlo 3:1/6:1 Pumps 5 Description The StediFlo 3:1 and 6:1 fluid pumps are air-operated, stainless-steel pumps suitable for solvent-based and waterborne coatings. They are double-acting pumps that deliver pressurized coatings on both the pressure and suction strokes. Coatings are siphoned into the pumps only on the suction stroke. The pumps can be used in both dead-end and circulating systems. In dead-end systems, the pump stops when the pressure in the system equals the pressure the pump can output given the input pressure. In circulating systems, the pump strokes continuously to keep coating material moving through the system at a rate set by the circulation valve. Two sets of adjustable packings prevent coatings from leaking from the pump during operation. The upper packings and plunger are lubricated by solvent fluid in the solvent chamber. The lower packings are lubricated by the coating material in the pump. Filtered and lubricated compressed air operates the air motor and air value. A safety relief valve in the air motor head prevents over-pressurization. 3:1 6:1 Air Regulator/ Filter/ Lubricator Air Motor Solvent Chamber Hydraulic Section Suction Inlet Suction Hose Suction Rod Figure 1 StediFlo Low Pressure Fluid Pump Components

8 6 StediFlo 3:1/6:1 Pumps Specifications Specification 3:1 6:1 Weight 40 kg (88 lb) 40 kg (88 lb) Air inlet G 1/2 in. G 1/2 in. Maximum air input pressure 8 bar (116 psi) 8bar (116 psi) Fluid outlet size 1.0 in. NPT male 1.0 in. NPT male Maximum operating pressure 24 bar (348 psi) 48 bar (696 psi) (fluid output) Output per cycle 600 cm 3 (20 fluid oz) 600 cm 3 (20 fluid oz) Sound pressure levels: At idle 84 (L pad ) (db) Running with load 80 (L pad ) (db) ATEX Marking Ex II 2G ct4 WARNING: Do not operate the pump at a higher operating pressure than the lowest maximum operating pressure of any component in the system. Failure to observe this warning could result in equipment damage or personal injury.

9 StediFlo 3:1/6:1 Pumps 7 3:1 Pump Dimensions B B A A M10 (3X) B B 10 (3X) A A 60 M12 (2X) Figure 2 StediFlo 3:1 Pump Dimensions

10 8 StediFlo 3:1/6:1 Pumps 6:1 Pump Dimensions B B A A B B 10 (3X) A A M12 (2X) 119 M10 (3X) Figure 3 StediFlo 6:1 Pump Dimensions

11 StediFlo 3:1/6:1 Pumps 9 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Dead-End System Diagram Figure 4 Typical Dead-End System Configuration 1. Plant air line 6. Air hose 2. Drop leg 7. Coating supply 3. Drain valve 8. Suction rod and strainer 4. Air shut off valve (self-relieving) 9. Suction hose 5. Filter/Regulator/Lubricator 10. High-pressure fluid hose 11. Fluid filter 12. Spray gun 13. Drain valve

12 10 StediFlo 3:1/6:1 Pumps Circulating System Diagram Figure 5 Typical Circulation System Configuration 1. Plant air line 7. Coating supply 2. Drop leg 8. Suction rod and strainer 3. Drain valve 9. Suction hose 4. Air shut off valve (self-relieving) 10. High-pressure fluid hose 5. Filter/Regulator/Lubricator 11. Fluid filter 6. Air hose 12. Filter drain valve 13. Spray gun 14. Fluid heater 15. Circulation valve 16. Drain valve 17. Drain hose and rod 18. Waste container Mounting If the pump is mounted on a cart, make sure the cart is parked on a level and solid surface. Leave space around the cart to work. If mounting the pump on a wall or fixed stand, use M12 screws, class 8.8. Mount the pump so that at least 10 cm (4 in.) of free space is left between the floor and the suction fitting. Refer to Options in the Hydraulic Section Parts section for an optional wall mounting bracket.

13 StediFlo 3:1/6:1 Pumps 11 Connections Air Supply Connections Connect the air regulator to the air motor inlet, either directly or by way of an appropriate hose, which should be at least the same size as the air inlet fitting. If the air supply to the pump is hard-plumbed, install a short air hose in the line ahead of the air motor or regulator to serve as a vibration damper. The air supply should be clean and dry. Hydraulic Connections NOTE: Use hydraulic pipe thread sealant/adhesive where required. 1. Connect the suction hose and strainer to the suction fitting. The connections must be air-tight to prevent the pump from siphoning air. 2. Connect an appropriate high pressure hose to the fluid outlet and route it to the fluid filter or fluid heater. NOTE: Fluid heaters can only be used in circulating systems. The fluid filter must be installed between the heater and the spray gun. Grounding WARNING: The high flow of fluid through the pump can create a dangerous static electricity charge. Sparks caused by a static discharge can cause a fire or explosion. The pump and all conductive equipment in the spray area must be grounded. All hoses must be conductive. Connect the ground cable shipped with the pump to the pump; connect the opposite end to a true earth ground. Solvent Fluid Before using the pump for the first time, fill the solvent chamber with approved solvent fluid, through the hole in the side of the solvent chamber, until the fluid is visible approximately 1 cm (0.4 in.) below the hole. Air Lubricator Oil Remove the air lubricator fill cap and fill the lubricator with oil. The maximum oil level is indicated by a line on the reservoir. When you start the pump, run it at a slow speed and adjust the lubricator to deliver one drop of oil for every cycles of the pump. NOTE: If high humidity causes icing of the air motor, you can replace the lubricator oil with a pure anti-freeze solution, or heat the air supply. In all cases, the air supply should be clean and dry.

14 12 StediFlo 3:1/6:1 Pumps Operation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: The spray area must be adequately ventilated according to local regulations. The operator should wear appropriate protective breathing equipment at all times when spraying. WARNING: All conductive equipment in the spray area must be connected to a true earth ground. Inspect all ground connections regularly. Checking the System Before starting the pump, make sure the system components (such as the heater and filter) have been installed according to the instructions in their manuals. all fluid and air fittings and connections are tightened securely. the air shutoff valve and the circulation and drain valves (if used) are closed and the air regulator is set to zero pressure. Solvent Fluid Fill Fill the solvent chamber with solvent fluid, through the hole in the side of the solvent chamber, until fluid is visible approximately 1 cm (0.4 in.) below the hole. Adjusting the Air Lubricator Using a screwdriver, adjust the lubricator screw to deliver one drop of oil for every cycles of the pump. Fill the lubricator daily before starting production. The maximum oil level is indicated by a line on the reservoir. If high humidity causes icing of the air motor, fill the lubricator with pure anti-freeze solution, or heat the air. Flushing Before starting production, a new pump and spray system must be flushed with a solvent or waterborne cleaning solution compatible with the coating material you are using. This ensures that all oils and contaminants left during the manufacturing and installation process are flushed out of the system. NOTE: Turn off the fluid heater (If used) before flushing the system. Requirements: Flushing solvent or waterborne cleaning solution Coating material Grounded waste container

15 StediFlo 3:1/6:1 Pumps Place the suction strainer in the flushing material, or supply it through a pressure feed system. 2. Place the waste container under the filter or circulation drain valve, then open the valve. 3. Start the pump and adjust the input air pressure to 2 bar (30 psi). 4. Run the pump until flushing material flows from the filter drain valve, then close it. NOTE: If using a circulating system, a drain valve should be connected to the circulation valve. Place a ground waste container under this valve and open it after closing the filter drain valve. When flushing material flows from this valve, close it. 5. Ground the manual spray gun against the side of the waste container and spray into the container for at least 1 minute. If using automatic guns, turn them on and spray into the spray booth. 6. Shut off the spray gun. 7. Increase the air pressure to the maximum allowable (8 bar, 116 psi). Check all system connections and seals: hoses, gun, heater, filter. If leaks are present anywhere, stop the pump, relieve the fluid pressure, and fix the leak. 8. Increase the air pressure to approximately 10% above the maximum pressure. The safety valve on the air motor should open. This ensures that the valve works properly. 9. Adjust the air pressure so that when the spray gun is triggered the pump runs very slowly. Remove the suction strainer from the solvent, then trigger the gun to flush the remaining solvent out of the system. 10. Stop the pump and shut off the pump air. 11. Open the drain valves to relieve the pressure and drain any remaining solvent from the system. Daily Operation 1. Check the solvent fluid level and fill if necessary. 2. Place the suction strainer into a container of coating material, or supply coating material to the pump through a pressure feed system. 3. Adjust the pump air pressure to 2 bar (30 psi) so that it is running slowly. 4. Place a waste container under the filter drain valve and open the valve. Close the valve when coating material starts to flow into the waste container. 5. Ground the spray gun against the side of the waste container and spray into the container until all air is purged from the system and coating material flows smoothly from the gun, without spitting.

16 14 StediFlo 3:1/6:1 Pumps 6. Adjust the pump air pressure to produce the desired fluid pressure. The pressure should be no more than is necessary to produce an even spray pattern with graduated edges at a distance of approximately cm (12 16 in.). Desired output pressure pump ratio = air pressure required If you have a 3:1 pump, and you want an output pressure of 200 psi you would calculate the required air pressure as follows: 200 psi 3 = 66 psi air pressure required. NOTE: If the fluid pressure is too high, excessive material consumption and overspray will occur. If the fluid pressure is too low, spray pattern fingering and uneven coating thicknesses will occur. 7. If using a fluid heater, turn on the heater only after all air is out of the system and coating material is circulating freely. WARNING: If using a fluid heater, always keep the coating material circulating through the heater while it is on. Without a continuous flow through the heater, the coating materials can cure inside the heater and clog it. The heat could also cause solvents in the coating materials to vaporize, expand, and damage the heater and other system equipment. This could result in an explosion, causing property damage and personal injury. Changing Colors or Material 1. Flush the pump and system with a solvent or waterborne cleaning solution compatible with the coating material used. 2. Clean the gun nozzle, suction strainer, and filter as necessary. 3. If changing material type, flush the pump and system again with a flushing solution compatible with the new coating material. 4. Place the suction strainer into the new coating material. Open the filter drain valve. When the new coating is flowing out of the valve, close it. 5. Ground the spray gun against the side of the waste container and spray into the container until all air is purged from the system and coating material flows smoothly from the gun, without spitting. Shutdown 1. If a fluid heater is used, turn it off 10 to 15 minutes before shutting down the pump. This prevents coating material from curing inside the heater. 2. Shut off the air supply to the pump. 3. Relieve the system hydraulic pressure by triggering the spray device(s) or carefully opening a drain valve.

17 StediFlo 3:1/6:1 Pumps 15 NOTE: Normally, you can leave the system filled with coating material overnight. If the material contains solids that easily settle out, circulate material through the system for several minutes before spraying. Do not leave the system open to air. The coating material could cure and clog the system. If the system will be shut down for more than a few days, flush it and leave it filled with clean solvent or waterborne cleaning solution. Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Stop the pump and relieve air and hydraulic pressures before disconnecting air or fluid hoses, or before disassembling any equipment. Daily Maintenance Do the following daily: 1. Make sure that all conductive equipment in the spray area, including the pump and waste container, are securely connected to a true earth ground. 2. Drain the air filter. Check the filter element and replace it if necessary. Open the drop leg drain valve and drain collected moisture. 3. Clean the fluid filter screens. Replace them as necessary. 4. Check the level of solvent fluid in the upper housing. Add more solvent fluid as needed. NOTE: Coating material leaking past the upper packing gland will discolor the solvent fluid and cause its level to rise. A small amount of leakage is normal. Drain and refill as needed. The upper and lower packings are adjustable. If the solvent fluid quickly discolors, or if the discoloration is excessive, adjust the upper packings as described below. If the adjustment does not slow the leakage of coating material, then the packings are worn and need to be replaced. Both upper and lower packings should be replaced at the same time. 5. Flush the pump and system at each material change. Adjusting the Upper Packings 1. Stop the pump at the bottom of the downstroke. 2. Relieve the air and hydraulic pressure in the system. 3. See Figure 6. Use the pin supplied with the pump to tighten the packing nut (5) as necessary. 4. Refill the solvent chamber with clean solvent fluid.

18 16 StediFlo 3:1/6:1 Pumps As Needed Maintenance Troubleshooting Flush the pump and system with a compatible flushing material. Change the solvent fluid regularly. Clean the exterior of the pump. Check all system grounds regularly. WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. These troubleshooting procedures cover only the most common problems. If you cannot solve a problem with the information given here, contact your local Nordson representative for help. General Troubleshooting Problem Possible Cause Corrective Action 1. Pump fails to start or stops while operating and fails to restart 2. Pump strokes irregularly when spray gun is triggered No compressed air supply, or air pressure too low Blockage in fluid system Air motor or air valve defective Air in hydraulic system Worn or clogged pump ball check valve Worn packings Check the compressed air supply. Adjust the air pressure as necessary. Check for flow from each component and hose, working from the spray device to the pump, as follows: Shut off the air to the pump and relieve the hydraulic pressure. Break the connection. Turn on the air to the pump. If the pump starts, the blockage is in the component or hose after the broken connection. Rebuild or replace as necessary. Purge air from system. Refer to Flushing on page 12. Flush the system with a compatible flushing material. If the problem persists, rebuild the ball valves. Replace the pump packings. Continued...

19 StediFlo 3:1/6:1 Pumps 17 Problem 3. Pump operates, but flow is restricted, or pump surges 4. Pump fails to suction coating material 5. Pump continues to operate after spray guns are shut off, or after drain and circulation valves are closed. Possible Cause Air motor or valve leak Volume of compressed air is not adequate Corrective Action Rebuild or replace as necessary. Check air supply hoses, filter, or regulator for restrictions. Blockage in fluid system Refer to Problem 1. Coating material too viscous Check the material viscosity. Add solvent to the material to lower the viscosity. Drain valve leaking Check drain valves for leaks. Spray gun output exceeds system capacity Blocked suction strainer, rod, or hose Air leak in suction system. Coating material too viscous. Siphon hose too long, hose ID too small, or strainer screen too fine for coating material Siphon ball check stuck Coating material supply low, pump is siphoning air Drain valve or circulation valve leaking Leaking ball check valve Reduce the spray device nozzle or fluid tip size. Reduce the number of spray guns connected to the pump. Check and clean as necessary. Check the suction hose for leaks. Break apart all connections in the suction system. Remove the old pipe thread sealant from the threads and apply new sealant before reconnecting the fittings. Check material viscosity. Add solvent to the material to lower the viscosity. Use the suction hose shipped with pump, or contact your Nordson representative. Check the strainer screen. If the strainer screen is clogged with pigment, use a coarser mesh screen or a strainer without a screen. Relieve pressure, remove suction hose, and push up on ball to free it. If it problem continues, remove and clean ball and seat. Supply coating material to pump. Check valves and clean or replace as necessary. Clean or rebuild ball check valves. Continued...

20 18 StediFlo 3:1/6:1 Pumps Problem 6. Pump does not stroke when circulation valve is opened 7. Upper body overflows often 8. Fading or narrowing of the spray pattern Possible Cause Clogged circulation valve, or blockage in system No compressed air supply, or air pressure is too low Upper packings worn Compressed air pressure is too low Corrective Action Open the circulation valve fully, then close it partially. If the problem continues, flush the system with a compatible cleaning solution. Refer to problem 1. Check the air supply at the drop-leg drain valve. Make sure the regulator is working correctly. Replace the packings. Make sure the air pressure regulator is working correctly. The pump air motor requires at least 1.38 bar (20 psi) air pressure to operate. Increase the air pressure. Check for a restriction in the air supply line. Blockage in hydraulic system Refer to problem Spray pattern has tails of unatomized coating material at the outer edges Nozzles or fluid tips too large, or too many spray guns connected to system Spray gun nozzle plugging Low hydraulic pressure or partial blockage in system Material too viscous Damaged nozzle or fluid tip Reduce the nozzle or fluid tip size, or the number of spray guns connected to the pump. Remove the filter screen and inspect it. If the screen is damaged, replace it. If the screen is undamaged, replace it with one with a smaller mesh size. Increase the air pressure. Flush the system with a compatible cleaning solution. Refer to problem 1. Add solvent to the coating material to lower the viscosity. Replace the nozzle or fluid tip.

21 StediFlo 3:1/6:1 Pumps 19 Air Motor Troubleshooting These troubleshooting procedures cover only problems with the air motor. See Figure 7 for item numbers. Problem Possible Cause Corrective Action 1. Air is leaking from the Control piston (15) is worn. Replace the control piston. control piston into the mufflers, motor runs but slows down. Seal (30) is worn. Replace the seal. O-ring (38 or 41) is worn. Replace the O-ring(s). 2. Air blows out of the Guide bushing (52) is worn. Replace the guide bushing. lower motor housing (51) drain hole, motor continues to run. 3. Air is leaking from the Toggle (32) is no longer seated in Repair. control piston into the muffler (5), motor does not run. either the toggle bearing (33) or the carrier (20). Guide axle spring (43) is broken. Replace the guide axle. 4. Air motor does not run. See Problem Air motor is not able to perform as expected Insufficient compressed air volume or pressure. Muffler (5) is clogged. Check the compressor output and size of air line. Increase air line diameter if necessary. Replace the muffler.

22 20 StediFlo 3:1/6:1 Pumps Hydraulic Section Repair WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. NOTE: Loctite thread adhesive is used during the assembly of the hydraulic section components. When disassembling the hydraulic section, it may be necessary to apply heat to soften the adhesive and prevent thread galling. Make sure all flammable materials have been removed from the hydraulic section and the work area. When rebuilding the hydraulic section, have the following tools, kits, and materials available: Repair kit (includes the seal kit) O-ring grease (p/n ) Hydraulic pipe thread adhesive/sealant (p/n ) Removable threadlock adhesive (p/n , Loctite 242 or equivalent) Bench vise Metric open end wrenches and hex wrenches Fold out Figure 6 while performing the following tasks. Preparation Disassembly 1. Flush and drain the pump. 2. Disconnect the air and fluid hoses. 3. Disconnect the suction hose. 4. Remove the pump from its mounting. 5. Drain any solvent remaining in the solvent chamber (4). 1. Unscrew the lower check housing (36) from the pressure housing (18). Remove the seal ring (19). 2. Unscrew the pressure housing from the upper housing (16) and pull it off the plunger. Remove the seal ring (17). 3. Remove the nuts (3) and washers (2) from the tie rods (1). 4. Pull the upper housing and solvent chamber away from the air motor and disconnect the plunger (21) from the coupling (20). 5. Pull the plunger out of the upper housing. Pressure Ball Check Disassembly 1. Clamp the plunger flats in a bench vise. 2. Use a hex wrench to remove the threaded plug (33) from the bottom of the plunger. 3. Remove the ball seat (32), seal (31), and ball (30).

23 StediFlo 3:1/6:1 Pumps 21 Lower Packing Replacement 1. Clamp the upper check housing (29) in a bench vise. Hold the lock nut (22) with one wrench and unscrew the plunger (21) with a second wrench. CAUTION: If the plunger is too tight to unscrew from the lock nut, apply heat to the plunger directly above the packing rings to soften the threadlocking adhesive used during assembly. Failure to follow this procedure will cause thread galling and destroy the upper check housing, plunger, or lock nut. 2. Remove the counter ring (23) and packing rings (24 27). 3. Clean the plunger, upper check housing, lock nut, and counter ring thoroughly. Inspect the pin (28). If it is damaged, replace it with a new one. 4. Install new packing rings on the upper check housing in the order shown, with the V pointing down. Pay special attention to the material type and location of each packing ring. 5. Install the counter ring (23) on top of the packing rings. 6. Apply removable threadlock adhesive to the threads of the upper check housing. 7. Screw the lower packing nut onto the upper check housing. Tighten securely. 8. Screw the upper check housing into the plunger. Tighten it securely. Upper Packing Replacement 1. Unscrew the solvent chamber (4) from the upper packing nut (5). 2. Unscrew the upper packing nut from the upper housing (16). 3. Remove the rings (6 14) and spring (15) from the upper housing. 4. Clean the solvent chamber, packing nut, upper housing, and spring thoroughly. 5. Install a new spring and packing rings as shown into the upper housing. Grease the O-ring before installing it. 6. Apply hydraulic pipe thread adhesive/sealant to the bottom threads of the packing nut, then screw it into the upper housing and tighten it securely. 7. Apply removable threadlock adhesive to the upper threads of the packing nut, then screw the solvent chamber onto the nut.

24 22 StediFlo 3:1/6:1 Pumps Siphon Ball Check Repair 1. Unscrew the inlet adapter (40) from the lower check housing (36). 2. Remove the ball seat (39), seal (38), and ball (37) from the lower check housing. 3. Clean all parts and inspect them for wear and damage. Replace any that are worn or damaged. 4. Inspect the pin (35). If it is damaged, remove the set screw (34) and replace the pin. Apply removable threadlock adhesive to the set screw before re-installing it. 5. Install the ball, seal, and seat in the housing. 6. Apply hydraulic pipe thread adhesive/sealant to the threads of the inlet adapter and screw it into the lower check housing. Tighten it securely. Hydraulic Section Assembly 1. Coat the plunger with solvent fluid, then install it through the upper packings. 2. Mate the upper housing/plunger assembly with the air motor, fitting the head of the plunger into the coupling (20) and the tie rods into the upper housing. 3. Install the washers and nuts (2, 3) on the tie rods and tighten them evenly. 4. Grease a new seal ring 17) and install it in the upper pressure housing (18). 5. Apply hydraulic pipe thread adhesive/sealant to the threads of the pressure housing, then install it over the plunger and screw it into the upper housing. Tighten the pressure housing securely. 6. Grease a new seal ring (19) and install it on the lower check housing (36). 7. Apply hydraulic pipe thread adhesive/sealant to the threads of the lower check housing (36), then screw it into the pressure housing and tighten it securely.

25 StediFlo 3:1/6:1 Pumps 23 Air Motor Repair WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Tools and Materials Required Have the following tools and materials available: Seal kit or repair kit (repair kit includes seal kit) Metric open-end wrench set Metric socket wrench set Screwdriver set Punch set, with 15 and 20-mm punches Retaining ring pliers Small regular pliers Rubber mallet O-ring grease, Parker O-Lube or equivalent (p/n ) Removable threadlock adhesive, Loctite 242 or equivalent (Nordson p/n ) Hydraulic pipe thread sealant/adhesive (p/n ) NOTE: Use O-ring grease (Parker O-Lube or equivalent) whenever instructed to grease a part. Fold out Figure 7 while performing the following tasks. Preparation 1. Turn off the compressed air supply and relieve air and fluid pressure. 2. Disconnect the air line, and the filter, regulator, and lubricator (if used), if attached to the air motor. 3. Remove the pump from its mounting and move it to a clean workbench. 4. Disconnect the hydraulic section from the air motor as follows: a. See Figure 6. Remove the nuts and washers (2, 3) from the tie rods (1). b. Pull the hydraulic section away from the air motor until the coupling (20) is accessible, then disconnect the plunger (21) from the coupling. c. Drive the pin out of the coupling, then unscrew the coupling from the motor axle.

26 24 StediFlo 3:1/6:1 Pumps Muffler and Control Housing Removal 1. Clamp the lower housing (51) in a bench vise. 2. Remove the three cap nuts and washers (2, 3). 3. Remove the cover (4) and muffler (5). 4. Remove the three studs (7, 10) from the control housing (13). 5. Remove the two washers (8) and safety plate (11). 6. Remove the control housing (13) from the control axle (16). 7. Remove the muffler plate (6). 8. Press the control cylinder (12) out of the control housing (13). 9. Carefully remove the four O-rings (9) from the control cylinder with a flat-bladed screwdriver. Cylinder Head Disassembly 1. Remove the six O-rings (24) from the upper cylinder plate (29). 2. Use two wrenches to loosen the two nuts (14) and remove them from the control axle (16). 3. Lift the control piston (15) off the control axle. 4. Remove the lock nuts (37). 5. Unscrew the two set screws (36) with a hex wrench. CAUTION: Spring retainers are under spring tension and may shoot out of the housing when the set screws (36) are removed. 6. Remove the spring retainer (35), spring (34), toggle bearing (33), and toggle (32) from both sides of the cylinder head. Use pliers, if necessary. 7. Remove the alignment bushing (17) with an open-end wrench. 8. Remove the upper dampening spacer (18) from the control axle (16). 9. Pull the control axle up and push the dampening spacer (21), two washers (19) and carrier (20) away to expose the axle wrench flats. 10. Use two wrenches to unscrew the control axle from the guide axle (43). If the control axle cannot be turned, heat the connection to soften the threadlock adhesive. 11. Remove the carrier (20) and washers (19). Cylinder Head Removal 1. Remove the cap nuts (25) and washers (26). 2. Lift the upper cylinder plate (29) off the cylinder (46). 3. Use retaining ring pliers to remove the retaining ring (31). 4. Use a small screwdriver to carefully remove the lip seal (30). 5. Remove the dampening spacer (21).

27 StediFlo 3:1/6:1 Pumps Use retaining ring pliers to remove the retaining ring (22) and washer (23). 7. Turn the cylinder plate over and remove the O-ring (45) from the bottom groove. Cylinder/Lower Housing Disassembly 1. Pull the air inlet tubes (49) and O-rings (48) out of the lower housing (51). Remove the O-rings from the tubes. 2. Remove the cylinder (46) and piston (39) from the lower housing. 3. Press the piston out of the cylinder. 4. Remove the O-ring (47) from the lower housing. 5. Use retaining ring pliers to remove the retaining ring (54) and washer (53) from the lower housing. 6. Turn the lower housing over and use a punch to press the guide bushing (52) out of the lower housing. 7. Unscrew the tie rods (50) from the lower housing if they require replacement. Piston Disassembly 1. Clamp the piston (39) vertically in a bench vise. 2. Unscrew the motor axle from the piston. If the axle cannot be turned, heat the connection to soften the threadlock adhesive. 3. Pull the guide axle (43) out of the motor axle. 4. Remove the O-ring (41) and disc (42) from the piston (39). 5. Use a flat-bladed screwdriver to remove the O-ring (38) and guide ring (40) from the piston. Cleaning and Inspection Clean all air valve and motor parts thoroughly. Carefully inspect all parts, especially the motor axle (44), guide axle and spring (43), and cylinder (46). Replace parts that are worn, cracked, pitted, or scored. Replace all parts included in the seal kit and repair kit. The parts lists notes both the wear items and items included in the kits. NOTE: Refer to the Service Notes on Figure 7 while re-assembling the air motor.

28 26 StediFlo 3:1/6:1 Pumps Piston Assembly 1. Install the O-ring (41) and disc (42) into the piston (39). 2. Clamp the piston vertically into a bench vise. 3. Lightly grease the guide axle barrel and spring (43). 4. Install the guide axle into the motor axle (44). 5. Press the guide axle through the disc (42) in the piston. 6. Apply removable threadlock adhesive to the outer threads of the motor axle, then screw it into the piston and tighten it securely. 7. Grease the grooves in the outer rim of the piston. 8. Install a new O-ring (38) and guide ring (40) in the groove in the rim of the piston plate. 9. Grease the O-ring again. Cylinder/Lower Housing Assembly 1. Lightly grease the guide bushing (52) and install it into the lower housing (51). 2. Install the washer (53) in the lower housing, then use retaining ring pliers to install the retaining ring (54) in the lower housing. 3. Grease the O-ring groove in the lower housing and install the O-ring (47). 4. Lightly and evenly grease the inner wall of the cylinder (46). 5. Install the cylinder on top of the O-ring (47) in the groove in the lower housing. 6. Install the piston into the cylinder, guiding the motor axle through the lower housing. Use a rubber mallet if necessary to push the piston into the cylinder. 7. Install the air inlet tubes (49) and greased O-rings (48) into the lower housing. Position the tubes vertically. 8. If removed, thread the tie rods (50) into the lower housing and tighten them securely. Cylinder Head Installation 1. Grease the O-ring (45) and install it into the groove in the bottom of the upper cylinder plate (29). 2. Install the lip seal (30) into the bottom of the upper cylinder plate. Secure the lip seal with the retaining ring (31), using retaining ring pliers. 3. Turn the cylinder plate over and install the washer (23). Secure the washer with the retaining ring (22), using retaining ring pliers. 4. Install the upper cylinder plate on the cylinder, guiding the guide axle (43) through the washer (23), and orient the cylinder plate so that the grease plug is located vertically over the solvent chamber filler neck in the lower housing and the air inlet tubes slide into their ports in the upper cylinder plate.

29 StediFlo 3:1/6:1 Pumps Apply removable threadlock adhesive to the threads of the tie rods (50). 6. Install the washers (26) and cap nuts (25). Tighten the cap nuts in a criss-cross pattern. 7. Position the air inlet tubes (52) vertically. Push up on the motor axle if necessary so that the guide axle projects out of the cylinder head. 8. Install a dampening spacer (21), with the peak facing down, into the cylinder plate. 9. Install a washer (19), carrier (20), and a second washer (19) onto the short end of the control axle (16). 10. Apply removable threadlock adhesive to the threads on the short end of the control axle (16), then screw the control axle into the guide axle (43) and tighten them with a wrench. 11. Lightly grease the larger cross-section of the control axle and press it down lightly by hand. 12. Push a second dampening spacer (18) with peak facing up over the control axle and into the cylinder plate. 13. Install the the alignment bushing (17) on top of the spacer and tighten it with a wrench. 14. Pull and push the control axle up and down to check the assembly. The control axle should move up and down easily. Toggle Installation 1. Position the carrier (20) in the middle of the holes for the toggle bearings. The carrier grooves must face the holes. 2. Lightly grease the springs (34), toggle bearing (33), and toggle (32), then install the toggles, toggle bearings, springs, and spring retainers (35) in the holes on both sides of the cylinder head. 3. Check the toggle seating in the carrier by moving the control axle up and down. To check visually, remove the grease plug from the cylinder head. 4. Position the spring retainers (35) so that the expansion holes face up. 5. Use a screwdriver to press the spring retainers (35) into the cylinder head and tighten the set screws (36) with a hex wrench. The set screws must rest in the grooves in the retainers. Unscrew the screws slightly to give the retainers a little play, then tighten the lock nuts (37). Control Cylinder Assembly and Installation 1. Install the control piston (15), groove facing up, on the control axle (16). 2. Thread a nut (14) onto the control axle, until it is 2-mm away from the piston. Install a second nut (14) onto the axle, and use two wrenches to lock the two nuts together while maintaining the 2-mm spacing. 3. Install the six O-rings (24) into the grooves in the upper cylinder plate (27). 4. Install the muffler plate (16), with the groove facing up, onto the upper cylinder plate. 5. Install four O-rings (9) onto the control cylinder (12). Leave the upper groove empty.

30 28 StediFlo 3:1/6:1 Pumps Control Cylinder Assembly and Installation (contd) 6. Lightly grease the control cylinder and press it into the control housing (13). Make sure these parts are positioned as follows: Control cylinder free groove facing up Control housing 5 holes facing up 7. Install the control housing (13) over the control axle (16) and onto the upper cylinder plate (29). 8. Position the control housing so that the three small holes are aligned with the corresponding threaded holes in the cylinder head. 9. Install the safety plate (11) directly over one of the five holes in the control housing (13) with the end of the plate in the free groove on the control cylinder (12). 10. Install washers (8) on the two remaining holes in the control housing (13). 11. Install the three stud assemblies (7, 10) into the control housing (13), thread them into the cylinder plate, and tighten them using two wrenches. Muffler Cover and Muffler Installation 1. Install the muffler (5) and cover (4) on the cylinder plate. Make sure the ends of the studs (4) project through the cover. 2. Install the washers (3) and cap nuts (2) on the studs and tighten them securely. Air Motor to Hydraulic Section Connection Connect the air motor to the hydraulic section as follows: 1. See Figure 6. Screw the coupling (20) all the way onto the motor axle, then back it off until the holes in the coupling line up with the holes in the motor axle. Drive a pin through the coupling and motor axle. 2. Connect the coupling to the hydraulic section plunger, while guiding the tie rods (1) through the holes in the upper housing flange. 3. Install the washers and nuts (2, 3) and tighten the nuts evenly and securely.

31 StediFlo 3:1/6:1 Pumps 29 Parts Information To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative. Pump Part Numbers Part Description Note Pump, StediFlo, 3: Pump, hydraulic, StediFlo, 3/6: Motor, air, StediFlo, 3: Pump, StediFlo, 6: Pump, hydraulic, StediFlo, 3/6: Motor, air, StediFlo, 6:1 Hydraulic Section Parts List Fold out Figure 6 for reference while using this parts list. Item Part Description Quantity Note Rod, tie, hyd. section, StediFlo Washer, tie rod, hyd. section, StediFlo Nut, stud, hyd. section, StediFlo Chamber, solvent, LP, StediFlo Nut, packing, LP, StediFlo 1 6 O-ring, hyd. section, StediFlo 1 A, B Ring, counter, upper, hyd. section, StediFlo 1 8 Packing ring, leather 1 B, C 9 Ring, saddle, dual 1 B 10 Ring, packing, PTFE 1 B, C 11 Ring, packing, leather 1 B, C 12 Ring, packing, PTFE 1 B, C 13 Ring, packing, PTFE 1 B, C Ring, counter, upper, hyd. section, StediFlo Spring, upper packing, hyd. section, StediFlo Housing, upper, hyd. section, StediFlo 1 17 Ring, seal 1 A, B Housing, pressure, hyd. section, StediFlo 1 19 Ring, seal 1 A, B Coupling, 3:1, 6:1, hyd. section, StediFlo Plunger, hyd. section, StediFlo 1 C Nut, lower packing, hyd. section, StediFlo Ring, counter, lower, hyd. section, StediFlo 1 Continued...