SP30 21:1 Piston Pump

Transcription

1 SP30 21:1 Piston Pump Installation and Maintenance Instructions Part NORDSON CORPORATION Duluth, Georgia

2 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 Lakefield Drive Duluth, GA Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright 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 AccuJet, AquaGuard, Asymtek, Automove, Autotech, Blue Box, CF, CanWorks, Century, Clean Coat, CleanSleeve, CleanSpray, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, FlexiCoat, Flexi-Spray, Flow Sentry, Fluidmove, Fluidshooter, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, JR, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, PluraFoam, Porous Coat, PowderGrid, Powderware, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, PRX, RBX, Ready Cost, Rhino, S. design stylized, Saturn, SC5, SCF, Select Charge, Select Coat, Select Cure, Shur-Lok, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure-Bond, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Veritec, Versa-Coat, Versa-Screen, Versa-Spray, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. ATS, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, CPX, Control Weave, Controlled Fiberization, EasyClean, Ebraid, Eclipse, Equi=Bead, Fillmaster, Gluie, Ink-Dot, Maxima, MicroFin, Minimeter, Multifil, OptiMix, Pattern View, PluraMix, Primarc, Prism, Process Sentry, PurTech, Pulse Spray, Seal Sentry, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Swirl Coat, Vista, Walcom, and 2 Rings (Design) are trademarks of Nordson Corporation. Viton is a registered trademark of DuPont Dow Elastomers. Loctite is a registered trademark of Loctite Corporation.

3 Table of Contents i Table of Contents SP30 21:1 Piston Pump Installation and Maintenance Instructions 1. Introduction Overview of the Hydraulic System Troubleshooting Tables Defective Adhesive Application Pump Not Working Troubleshooting Test Procedures Relieving System Hydraulic Pressure Manifold Blockage Check Actuator Check Pump Siphon Ball and Seat Check Solenoid Valve Check Testing Solenoid Voltage Air Leakage Check Pump Repair Procedures Preparing for Repairs Removing and Installing the Pump Disassembling Pump Components Removing the Upper Pump Assembly Components Removing Piston Components Removing the Siphon Ball Seat and Components Reassembling Pump Components Installing Siphon Ball Seat and Components Installing Piston Components Removing the Actuator Air Valve Assembly Maintenance

4 ii Table of Contents SP30 21:1 Piston Pump Installation and Maintenance Instructions (contd) Removing the Magnet Assembly Removing the Valve Spool and Sleeve Installing the Valve Spool and Sleeve Installing the Actuator Assembly Replacing the Shifter Fork Replacing O-rings on Hose Connectors and O-ring Plugs Replacing the Relief Valve Replacing the Solenoid Valve Replacing the Manifold :1 Piston Pump Parts List :1 Piston Pump Uptime and Uptime Plus Pack :1 Piston Pump Uptime Pack Parts List :1 Piston Pump Parts List Actuator Assembly Parts List Regulator/Filter Assembly Parts List

5 SP30 21:1 Pump 1 SP30 21:1 Pump Installation and Maintenance Instructions WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This installation and maintenance sheet covers troubleshooting procedures for adhesive application and pump operation problems. It also provides test procedures, repair procedures, and pump assembly and component parts list. However, if further assistance is needed, call your Nordson representative. 2. Overview of the Hydraulics System The hydraulics system consists of the air-driven piston pump assembly and a manifold assembly. The pump assembly includes an air motor, an actuator, and a dual-acting hydraulic pump. The manifold assembly is indirectly heated by the tank heaters. The manifold assembly consists of an aluminum manifold, a filter assembly, a drain valve, and hose ports with 45 connecting elbows Fig. 1 Main Components of the Hydraulics System 1. Air motor 3. Manifold assembly 2. Dual-acting hydraulic pump 4. Actuator assembly

6 2 SP30 21:1 Pump 3. Troubleshooting Tables These troubleshooting tables describe the kinds of adhesive application and pump-operation problems you may encounter, and provide corrective actions for handling those problems. When necessary, the tables refer to more detailed diagnostic procedures. Refer to the appropriate troubleshooting table for the type of problem you are experiencing: Defective Adhesive Application Pump Not Working WARNING: Allow only qualified personnel to perform troubleshooting procedures. Defective Adhesive Application Problem Possible Cause Corrective Action 1. Little or no adhesive output Applicator not at operating temperature Adhesive level too low Adhesive too cold Clogged manifold filter Blockage in manifold Cold hose-to-applicator or hose-to-gun joints Guns not operating properly Manifold heat exchanger (if applicable) blocked Wait for the time delay to expire and the READY light to turn on. Maintain at least 50% of the tank s holding capacity. Check the tank, hose, and gun temperature setpoints, and adjust them as necessary. Clean the manifold filter. Check for blockage. Insulate the joints. Refer to the gun manual to troubleshoot gun problems. Check manifold heat exchanger for blockage. Clean if necessary. 2. Wavy beads Adhesive too cold Check the tank, hose, and gun temperature setpoints, and adjust as necessary. Ambient temperature below freezing or guns subject to draft Nozzles too far from product Protect the applicator and guns from freezing temperature conditions and drafts. Position the guns so that the nozzles are no more than 13 mm (0.5 in.) from the product.

7 SP30 21:1 Pump 3 Problem Possible Cause Corrective Action 3. Excessive adhesive at beginning of bead Hose and gun temperature setpoints not properly balanced (for example, hose temperature too low and gun temperature too high) Nozzles too far from product Filter partially clogged (manifold filter, inline filter, etc.) Check the tank, hose, and gun temperature setpoints, and adjust them as necessary. Position the guns so the nozzles are no more than 13 mm (0.5 in.) from the product. Clean the filter. 4. Adhesive stringing Nozzle too far from product Position the guns so the nozzles are no more than 13 mm (0.5 in.) from the product. 5. Bead lays on product in concentric circles 6. Adhesive bouncing or splashing from product Adhesive too viscous Adhesive too cold Adhesive too old Adhesive too cold Adhesive too viscous Nozzle orifice too small for application, resulting in need for too much hydraulic pressure Adhesive too hot Adhesive not viscous enough Increase the hose or gun temperature setpoint or change to a compatible lower-viscosity adhesive. Check the tank, hose, and gun temperature setpoints, and adjust them as necessary. Do not exceed the recommended pot life of the adhesive. Check the tank, hose, and gun temperature setpoints, and adjust them as necessary. Change to a compatible lower-viscosity adhesive. Change to a nozzle with a larger orifice and decrease hydraulic pressure. Check the tank, hose, and gun temperature setpoints, and adjust them as necessary. Change to a compatible higher-viscosity adhesive. Continued on next page

8 4 SP30 21:1 Pump Defective Adhesive Application (contd) Problem Possible Cause Corrective Action 7. Adhesive not penetrating product 8. Gun spitting intermittently, causing erratic bead placement Adhesive too cold Special coating on product Not enough adhesive being applied Adhesive too viscous Adhesive level too low (pump ingesting air) Depending on the viscosity of the adhesive, if it (usually pellets) heats up rapidly, the layer directly above the heated adhesive partially heats up to form a bridge over the premelter grid. This prevents the rest of the adhesive from melting and being transferred from premelter to the hopper. Product wet Check the tank, hose, and gun temperature setpoints, and adjust them as necessary. Increase the temperature setpoints slightly or change adhesives. Change to a higher-flow nozzle, increase operating temperature setpoints slightly, or increase hydraulic pressure. Change to a compatible lower-viscosity adhesive. Maintain at least 50% of the tank s holding capacity. Change to a compatible lower-viscosity adhesive or to an adhesive form that is less likely to bridge, or raise the tank operating temperature setpoint to make the adhesive less viscous. Preheat the product. 9. Adhesive gelling Changing to an adhesive incompatible with the previous adhesive without first cleaning the system Adhesive heated for too long, or overheated Clean the system. Clean the system. Do not exceed the recommended adhesive pot life, or decrease the operating temperature setpoints. 10. Adhesive leaking from gun Guns not shutting off properly Refer to the gun manual to troubleshoot gun problems. Continued on next page

9 SP30 21:1 Pump 5 Problem Possible Cause Corrective Action 11. Cartons popping open (good adhesive penetration, but adhesive bond separates 12. Cartons popping open (poor adhesive transfer and penetration on married product) Adhesive not cooling fast enough Adhesive open time too long Adhesive deposit shearing Adhesive cooling too fast Decrease hydraulic pressure to decrease the bead size. Decrease the operating temperature setpoints slightly. Reduce the line speed through the compression section. Increase the length of the compression section. Cool the product. Use a stitched bead pattern. Change to an adhesive with a shorter open time. Check for twisting or other adverse movement during the compression section. Increase the hydraulic pressure to increase the bead size. Increase the operating temperature setpoints slightly. Decrease the distance between the nozzles and the product. Decrease the distance between bead application and bead compression. Heat the product. Use a higher-flow nozzle. Avoid stitched bead patterns. Protect the gun or bead from cold air. 13. Adhesive fuming or smoking Adhesive in tank too hot Check the tank operating temperature setpoint and adjust it as necessary. Unstable adhesive Keep the lid closed when the applicator is operating. Change to a more stable adhesive. 14. Adhesive charring in tank Adhesive in tank too hot Check the tank operating temperature setpoint and adjust it as necessary. Tank overheating Adhesive level too low Adhesive oxidizing in tank Check the setpoint temperature. The setpoint temperature must be 38 C (100 F) or above for the zone to heat. Maintain at least 50% of the tank s holding capacity. Keep the lid closed when the applicator is operating. Change to a more stable adhesive.

10 6 SP30 21:1 Pump Pump Not Working Problem Possible Cause Corrective Action 1. Pump stroking too fast or erratically (inconsistent or no adhesive output) (See Note A) 2. Pump not stroking (no adhesive output) Adhesive level too low Adhesive not melting as fast as it is being consumed Pump siphon ball seat missing or foreign material lodged between ball and seat Broken crossover tube O-ring Pressure relief valve defective No input air pressure to the pump Adhesive too cold in tank, hose, or guns Pump solenoid valve failed Clogged manifold filter or blockage in manifold Foreign material or gelled adhesive blocking pump intake Pump leaking air Maintain at least 50% of the tank s holding capacity. Increase the tank temperature setpoint. Check the siphon ball seat. Refer to Pump Siphon Ball Seat Check. Replace the crossover tube O-ring. Refer to Pump Repair Procedures. Replace the pressure relief valve. Check the input air pressure. Adjust if necessary. Increase the temperature setpoints and make sure the time delay has expired and the READY light is on. Check the solenoid valve. Refer to Pump Solenoid Valve Check. Check the manifold and filter for blockage. Refer to Manifold Blockage Check. Clean the tank. Locate the leak and replace damaged piston cups, seals, or O-rings. Refer to Pump Air Section Check. NOTE A: The pump should make two regularly spaced exhaust sounds. If you hear two exhaust sounds followed by a pause, the pump is stroking erratically (the hydraulic shaft is moving faster in one direction than the other). Continued on next page

11 SP30 21:1 Pump 7 Problem Possible Cause Corrective Action 2. Pump not stroking (no adhesive output) (contd.) Pump actuator malfunctioning for one or more of the following reasons: Check for a malfunctioning actuator. Refer to Actuator Check. air valve binding Disassemble and clean the air valve. Refer to Cleaning or Replacing the Air Valve. shifter fork slipped out of position Check the position of the fork and reposition if necessary. Refer to Replacing the Shifter Fork. shifter fork installed upside down Check the position of the fork and reposition if necessary. The fork should be positioned with the side stamped UP facing the air motor. Refer to Replacing the Shifter Fork. shifter fork bent or damaged Replace the fork. Refer to Replacing the Shifter Fork. magnet assembly dirty or damaged bumper assembly dirty or damaged Clean or replace the magnet assembly. Refer to Removing the Magnet Assembly. Replace the bumper assembly. shifter fork magnet loose Replace the fork. Refer to Replacing the Shifter Fork. 3. Pump is jammed Air motor is malfunctioning Clean the air motor. Hydraulic section is malfunctioning Clean the hydraulic section. 4. Air motor leaking Piston seals are leaking Replace the piston seals. U-cup seal is leaking O-ring at cylinder head and/or pump mount is leaking O-rings between the actuator and the cylinder are leaking Replace the U-cup seal. Replace the O-ring. Replace the O-ring.

12 8 SP30 21:1 Pump 4. Troubleshooting Test Procedures Test procedures are used with the troubleshooting tables to solve problems with the hydraulic section of the applicator. Relieving System Hydraulic Pressure WARNING: System or material pressurized. Release pressure. Failure to observe may result in serious burns. 1. Reduce pump air pressure to Trigger all guns to relieve the residual system pressure Fig. 2 Reducing Air Pressure 3. Open the manifold drain valve. Various types are shown. Fig. 3 Different Manifold Drain Valves A B C Manifold Blockage Check 1. Reduce the air pressure to Place a container under the manifold drain valve or valves. 3. Trigger all guns to relieve the residual system pressure. 4. Open the manifold drain valve slightly. If you have a reverse flush manifold, open the right side drain valve and turn the filter assembly counterclockwise. See Figure Slowly increase air pressure to the pump. 6. If the pump strokes, remove and clean the manifold filter.

13 SP30 21:1 Pump 9 Actuator Check 1. Remove the pump cover. 2. Grasp the top of the air valve with a long-nosed pliers and alternately press down and pull up on the valve to manually shift it. If the air valve does not move, refer to the cause Pump actuator malfunctioning for one or more of the following reasons, under Pump does not stroke in the Pump Not Working troubleshooting table. If the pump strokes when the air valve is shifted but will not stroke on its own, refer to Pump actuator malfunctioning for one or more of the following reasons, under Pump not stroking in the Pump Not Working troubleshooting table. If the pump does not stroke, then the pump is leaking air or is jammed. Refer to Pump Air Section Check to check for air leaks. If an air leak is not the problem, then the pump is jammed. Refer to Servicing the Pump to clean the pump air or hydraulic section. Pump Siphon Ball and Seat Check 1. Increase and decrease pump air pressure while triggering the guns. This frees the pump of any lodged particles holding the siphon ball off its seat. 2. If the pump is still stroking erratically, remove the pump assembly from the applicator. Refer to Removing and Installing the Pump for information on removing the pump assembly. 3. Inspect the bottom of the pump body and remove any particles holding the siphon ball off its seat Fig. 4 Siphon Ball and Seat 1. Pump body 2. Siphon ball 3. Siphon ball seat

14 10 SP30 21:1 Pump Solenoid Valve Check 1. Set the pump air regulator to Disconnect the air inlet line to the air control valve. 3. Turn the circuit breaker on. 4. Gradually increase air pressure at the regulator. 5. If air does not flow, test the solenoid voltage. Fig Disconnecting the Air Inlet Line Testing Solenoid Voltage WARNING: Risk of electrical shock. Failure to observe electrical safety procedures may result in personal injury or death. Allow only qualified personnel to perform the following procedures. Observe all high-voltage indicators. Each applicator has a different procedure for checking the solenoid voltage. If this pump is used in different applicators, such as the 3000 Multiscan, 3000 Vista, or AquaGuard, ensure that relevant instructions are used to test the solenoid voltage.

15 SP30 21:1 Pump 11 Air Leakage Check Check for air leakage in the following areas: 4 Actuator s top or bottom exhaust ports. Replace piston seals. Around the piston shaft. Replace the U-cup. 3 1 Between air motor cylinder head and air cylinder, or between air cylinder and pump mount. Replace the O-rings. Between the actuator and the cylinder. Replace the O-rings Fig. 6 Air Leakage Zones 1. Top or bottom exhaust ports 2. Top of piston shaft 3. Between air motor cylinder head and air cylinder, or between air cylinder and pump mount 4. Between actuator and cylinder 5. Pump Repair Procedures Use these procedures to service and repair the 21:1 piston pump. Refer to the 21:1 Piston Pump Parts List for the part numbers of any components that need to be replaced. The pump parts list illustration can be used as a guide to perform the following disassembly and reassembly procedures. NOTE: When disassembling equipment, retain all hardware for reassembly unless otherwise directed. Flush the system before disassembly. If the pump does not work, but the heating system does, then heat the applicator to operating temperature to facilitate disassembly. If the heating system does not work, then use a heat gun or other flameless heating device to melt the solidified adhesive in or on the system parts.

16 12 SP30 21:1 Pump Preparing for Repairs 1. Turn the circuit breaker off. 2. Remove the pump enclosure Fig. 7 Removing Pump Enclosure 3. Set the pump air regulator to 0. Turn off the air supply to the regulator. 4. Trigger guns or open the manifold drain valve to relieve hydraulic system pressure Fig. 8 Setting Pump Regulator WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. Adhesive may be released forcefully.

17 SP30 21:1 Pump Disconnect the air inlet line to the air control valve assembly Fig. 9 Disconnecting the Air Inlet Line Removing and Installing a Pump 1. Remove the bolts and washers that secure the pump to the applicator. 2. Make sure the adhesive around the pump is melted. Reheat if necessary. 3. Rotate the pump slightly to break suction and then pull straight up to disengage the crossover tube from the manifold Fig. 10 Detaching Bolts

18 14 SP30 21:1 Pump Removing and Installing a Pump (contd) 4. Ensure that the pump pan is in the correct position on the applicator. 5. Hold the new pump assembly in position over the applicator. Fig. 11 Positioning Pump Position the crossover tube in the manifold inlet port and lower the pump into position. 7. Secure the pump assembly to the applicator with the bolts and washers removed previously. Apply torque of N m (9-10 ft-lb). 8. Connect the air inlet line to the actuator assembly. 9. Replace the pump enclosure. 10. Purge the system of trapped air Fig. 12 Securing Pump to Applicator

19 SP30 21:1 Pump 15 Disassembling Pump Components Removing the Upper Pump Assembly Components 3 1. Remove the pump from the applicator. Refer to Removing and Installing a Pump given earlier Lay the pump assembly on a flat work surface Move the piston up or down until the shifter fork is in the center of the pump mount. 2 Fig. 13 Pump Components 1. Pump assembly 2. Shifter fork 3. Screws 4. Actuator Use an 8 mm wrench to remove the screws and washers holding the actuator to the air cylinder. 5. Pull the actuator assembly straight out. 6. Remove the clamping screw from the shifter fork. Slide the fork towards the air motor and off the piston shaft. 7. Remove the cylinder head from the cylinder. 8. Check the O-ring on the cylinder head for damage. Replace if necessary. 9. Remove the cylinder from the pump mount. Fig. 14 Detaching Cylinder 1. Cylinder head 2. Cylinder 3. O-ring

20 16 SP30 21:1 Pump Removing Piston Components 1. Hold the piston shaft with a wrench on the flats. Remove the nut at the top of the piston shaft. 2. Remove the two piston cup washers, the two piston cups, and the piston seal washer from the piston shaft. 3. Inspect the piston cups. Replace if they are cracked, creased, or otherwise damaged. Fig. 15 Inspecting Piston Cups Straighten the lock tab on the tab lock washer. 5. Loosen the locking nut and slide the nut and the tab lock washer away from the pump body. 6. Pull the pump body out of the pump mount. Set the locking nut and the tab lock washer aside. Fig. 16 Positioning Locking Nut and Tab Washer Inspect the U-cup seal and replace if necessary Fig. 17 Pump Mount Components

21 SP30 21:1 Pump Use a retaining-ring tool to remove the retaining ring at the top of the pump body. 9. Manually stroke the pump shaft up and down to loosen the washer and pump seal. Remove the seal and washer. Inspect the seal and replace if necessary Fig. 18 Hydraulic Shaft Components 1. Retaining ring 2. Pump shaft 3. Washer 4. Pump seal 10. Secure the pump body with an adjustable wrench on the wrench slots. 11. Remove the crossover tube. Inspect the O-ring and back-up ring. Replace if necessary Fig. 19 Other Hydraulic Components 1. Crossover tube 2. O-ring 3. Back-up ring

22 18 SP30 21:1 Pump Removing the Siphon Ball Seat and Components 1. Unscrew and pull the siphon ball seat and its cage from the pump body. 2. Inspect the siphon ball and its seat for wear or damage. Replace if necessary. 3. Pull the piston out of the pump body. WARNING: Avoid scratching the pump piston or the inside of the pump body during disassembly. Surface scratches on these parts may cause excessive leakage during operation Fig. 20 Removing Piston Components 1. Siphon ball cage 2. Siphon ball 3. Siphon ball seat 4. Unscrew the socket head screw from the bottom of the piston shaft. Remove the piston and the step washer. 5. Inspect the piston for wear or damage. Replace if necessary. 2 3 WARNING: Do not heat Type R fluid with an open flame or in an unregulated heating device. Do not heat Type R fluid above 246 C (475 F). Fig. 21 Removing the Piston 1. Socket head screw 2. Piston 3. Step washer Heat a container of Type R fluid to the melting temperature of the adhesive material being used. Clean all components of the pump.

23 SP30 21:1 Pump 19 Reassembling Pump Components Installing Siphon Ball Seat and Components 1. Slip the piston onto the piston shaft. Place the step washer on the screw. Apply Loctite to the screw threads and screw on to the piston. Apply torque of N m (3-5 ft.-lb). 2. Insert the piston shaft into the pump body. 3. Put the siphon ball onto the siphon ball seat. Attach the siphon ball cage to the seat. If the cage does not fit securely, bend the legs of the cage slightly inward by hand and then reattach. Fig. 22 Positioning Siphon Ball Apply Loctite to the threads of the seat and screw into the pump body. Use an adjustable wrench to secure the pump body Fig. 23 Installing Piston Components

24 20 SP30 21:1 Pump Installing Piston Components 1. Put the O-ring and backup ring onto the crossover tube. Apply PTFE paste to the threads of the crossover tube and insert into the pump body. NOTE: All adhesive must be removed from the seal cavity and the retaining-ring groove in the pump body before installing the seal. 2. Apply O-ring lubricant to the pump seal and pull the shaft up from the top of the pump body Fig. 24 Installing Hydraulic Components 3. Put the pump seal with the groove facing down on the shaft then put the washer on the shaft. Slide the shaft down to help guide the seal and washer into place on the pump body. 4. Use a retaining-ring tool to snap the retainer ring into place Fig. 25 Positioning Retainer Ring Insert the U-cup into the upper face of the pump mount with the groove facing up. Press the retaining ring into the upper face to secure the U-cup. Place the O-ring over the air cylinder mount on the upper surface of the pump mount Fig. 26 Installing Components on Pump Mount 1. U-cup 2. Retaining ring 3. O-ring

25 SP30 21:1 Pump Apply a small amount of high-temp O-ring lubricant, part , to the piston shaft where it passes through the U-cup. 7. Guide the upper part of the pump body and the piston shaft through the bottom hole in the pump mount. The shaft must be inserted through the tab lock washer and locking nut before it passes through the top hole in the mount. 8. Secure the pump body to the pump mount with the locking nut. Do not tighten. There is a stop in the bottom of the pump bracket. Rotate the pump body clockwise until it rests against the stop. 9. Tighten the locking nut and bend one of the tabs on the lock washer into one of the slots on the locknut Fig. 27 Positioning Pump Body 10. Slide the fork onto the piston shaft until it sits on the shoulder. The side stamped UP must face the air motor end of the pump. Insert the screw and apply torque of 8-10 N m (71-89 in.-lb). Fig. 28 Positioning Fork on Piston Shaft Pull the piston shaft up as far as possible and install one piston cup washer, one piston cup, and the piston seal washer onto the shaft in the proper order. The curved edge of the piston cup should be pointing down. 12. Slide the cylinder over the piston and onto the pump mount. Be careful not to damage the piston cup. 13. Use the fork to move the piston shaft up to the top of the cylinder Fig. 29 Placing Piston Components on Piston Shaft 1. Piston cup washer 2. Piston cup 3. Piston seal washer

26 22 SP30 21:1 Pump Installing Piston Components (contd) Put the remaining piston cup and piston cup washer on the piston shaft. The curved edge of the piston cup should be pointing up. 15. Hold the piston with a wrench and replace the hex nut. Apply torque of N m ( in.-lb) Fig. 30 Installing Piston Components 1. Piston cup washer 2. Piston cup 16. Place the O-ring into place on the air cylinder cap Set the air cylinder cap on the pump mount. Attach with the screws and washers removed earlier. Apply torque of 5-6 N m (45-55 in.-lb). 18. Place the four O-rings into the grooves in the air cylinder s mounting face Fig. 31 Installing Air Cylinder Cap on Pump Mount 1. O-ring 2. Air cylinder cap 3. Pump mount

27 SP30 21:1 Pump Carefully align the actuator with the shifter fork and the pins on the air cylinder. 20. Secure the actuator with the screws and washers removed during disassembly. Refer to Removing and Installing the Pump given earlier. Apply torque of 3-4 N m (28-36 in.-lb). 21. Ensure that the pump pan is in the correct position on the applicator. 22. Install the pump assembly. Refer to Removing and Installing the Pump given earlier. 23. Reconnect the air line to the actuator Fig. 32 Aligning Actuator with Shifter Fork Removing the Actuator 1. Heat the system to operating temperature. Turn the circuit breaker off. 2. Set the pump air pressure to 0 and turn off the air supply to the regulator. 3. Trigger all guns to relieve the residual system pressure Remove the pump enclosure. Fig. 33 Setting Pump Air Pressure 5. Disconnect the air inlet line from the actuator. 6. Move the piston up or down until the shifter fork is in the center of the pump mount Fig. 34 Disconnecting Air Inlet Line

28 24 SP30 21:1 Pump Removing the Actuator (contd) 7. Use an 8 mm wrench to remove the screws and washers holding the actuator to the air cylinder. 8. Pull the actuator assembly straight out. 9. Inspect the O-rings on the face of the air cylinder for damage. Replace if necessary. 10. Carefully align the new actuator with the shifter fork and the pins on the air cylinder. 11. Secure the actuator in place with the screws and washers removed in step 7. Apply torque of 3-4 N m (24-30 in.-lb). 12. Reconnect the air line to the actuator. 13. Replace the pump enclosure and resume operation. Fig. 35 Aligning the Actuator Air Valve Assembly Maintenance If the air valve is stuck and does not move, it may be damaged or need cleaning. Work on a clean work surface. The actuator assembly contains magnets that will pick up small particles that may damage the assembly or affect its performance. 1. Disconnect the air inlet line from the actuator. 2. Move the piston up or down until the shifter fork is in the center of the pump mount. 3. Use an 8 mm wrench to remove the screws and washers holding the actuator to the air cylinder. 4. Carefully pull the actuator straight out. Fig. 36 Disconnecting Air Inlet Line

29 SP30 21:1 Pump Remove the screws from the can. 6. Pull the can straight off of the actuator. Fig. 37 Removing Can Remove the valve cap screws with a 4 mm hex key Fig. 38 Removing Valve Cap Screws

30 26 SP30 21:1 Pump Removing the Magnet Assembly 1. Pull the magnet assembly away from the upper detent. 2. Place a suitable tool into the small hole at the top of the magnet assembly to prevent it from rotating. Fig. 39 Removing the Magnet Assembly A 3. Loosen the valve spool nut from the top of the valve assembly. NOTE: When loosening the nut from the top of the valve assembly, the magnet assembly may loosen before the valve spool nut does. If this occurs, simply unscrew the magnet assembly and set it aside. 4. Remove the valve spool nut and bumper assembly from the top of the valve assembly. 5. Place a wrench on the flats of the valve spool to prevent it from rotating. 6. Unscrew the magnet assembly and set it aside.

31 SP30 21:1 Pump Removing the Valve Spool and Sleeve 1. Stand the air manifold vertically and carefully slide the valve spool from the top of the assembly. Set the valve spool aside on a clean cloth or towel. 2. Remove the two socket-head screws securing the upper detent to the air manifold Remove the upper detent and spring. 4. Remove the flange from the top of the valve body Press the sleeve out of the air manifold with a socket or similar object against the bottom of the sleeve. NOTE: The valve spool and sleeve are a matched set and cannot be exchanged with parts from another air valve assembly. If replacement is needed, replace both A Fig. 40 Removing the Air Valve 1. Valve cap 2. Valve spool nut 3. Bumper assembly 4. Valve spool and sleeve assembly 5. Flange 6. Valve body 7. Spring 8. Upper detent 9. Magnet assembly 10. Can

32 28 SP30 21:1 Pump Removing the Valve Spool and Sleeve (contd) 6. Inspect the sleeve and spool for wear. 7. If the spool lands are nicked, gouged, deeply scratched, or corroded, replace the valve assembly. If they are not damaged, but are dirty, clean the assembly and set it aside on a clean cloth or towel. 1 2 Fig. 41 Air Valve Components 1. Spool lands 2. Spool 3 3. Sleeve A NOTE: Do not scrape the spool or sleeve. Clean them with mineral spirits or any non-chlorinated cleaning solvent and a soft cloth. Do not use abrasives such as sandpaper or emery cloth. Be careful not to round off the sharp edges of the spool lands. 8. Remove the O-rings from the sleeve. 9. Clean the sleeve and wipe the valve parts thoroughly with a clean cloth or rinse them with denatured alcohol.

33 SP30 21:1 Pump 29 Installing the Valve Spool and Sleeve 1. Install the upper detent. Fasten with screws and tighten to N m (16-20 in.-lb). 2. Install the spring. 3. Remove the valve spool from the sleeve. The valve spool can fall out during assembly and become damaged. 4. Apply O-ring lubricant to the new O-rings and install them on the sleeve. NOTE: The top of the valve body has two screw holes and the bottom has four screw holes. 5. Lie the flange over the sleeve and press the sleeve into the top of the valve body. 6. Apply one drop of oil to each spool land. Use only Nordson SP lubricating oil. NOTE: It is best to position the valve body vertically when inserting the valve spool into the sleeve. CAUTION: Carefully guide the spool into the sleeve. Do not apply pressure. Applying pressure to the valve spool can damage the valve assembly. 7. Carefully reassemble the valve spool into the sleeve. 8. Ensure that the valve spool slides freely in the sleeve. If it does not, replace the valve assembly. 9. Check the bumper assembly for wear. Replace if necessary. 10. Place the bumper assembly on the top of the valve assembly and secure it with the valve spool nut.

34 30 SP30 21:1 Pump Installing the Actuator Assembly 1. Holding the valve spool in place, screw the threaded end of the magnet assembly into the valve spool until it seats. 2. Place a suitable tool into the small hole at the top of the magnet assembly to prevent it from rotating. 3. Holding the magnet assembly in place, tighten the valve spool nut. Tighten to 9-11 N m (81-99 in.-lb). 4. Install the valve cap. Fasten the screws and tighten to 3-4 N m (28-36 in-lb). 5. Install the can. 6. Secure the can in place with screws. Tighten to 3-4 N m (28-36 in.-lb). 7. Move the piston up or down until the shifter fork is in the center of the pump mount. 8. Carefully align the actuator with the shifter fork and the pins on the air cylinder. 9. Secure the actuator with the screws and washers removed in disassembly. Apply torque of 3-4 N m (28-36 in.-lb). 10. Connect the air line to the actuator. 11. Replace the pump enclosure and resume operation Fig. 42 Aligning Actuator with the Shifter Fork

35 SP30 21:1 Pump 31 Replacing the Shifter Fork 1. Move the piston up or down until the shifter fork is in the center of the pump mount. 2. Use an 8 mm wrench to remove the screws and washers holding the actuator to the air cylinder. 3. Pull the actuator straight out and set aside. 4. Remove the clamping screw from the shifter fork. Slide the fork toward the air motor and off the piston shaft. 5. Slide the new shifter fork onto the piston shaft until it sits on the shoulder. The side stamped up must face the air motor end of the pump. Insert the screw and apply torque of 8-10 N m (71-89 in.-lb). 6. Move the piston up or down until the shifter fork is in the center of the pump mount. Fig. 43 Aligning Actuator with the Shifter Fork Inspect the O-rings on the face of the air cylinder for damage. Replace if necessary. 8. Carefully align the actuator with the shifter fork and the pins on the air cylinder. 9. Secure the actuator with the screws and washers removed during disassembly. Apply torque of 3-4 N m (28-36 in.-lb). Replacing O-rings on Hose Connectors and O-ring Plugs Replace the O-rings on the hose connectors and O-ring plugs whenever they are removed or leak. 1. Use an open end wrench to remove the hose connector. 2. Remove the O-ring on the hose connector adapter. 3. Ensure that the new O-ring and the groove are free of foreign particles. Lubricate the groove with PTFE paste. NOTE: Use only Nordson O-rings. Other O-rings may result in leakage Fig. 44 Aligning Actuator with the Shifter Fork

36 32 SP30 21:1 Pump Replacing O-rings on Hose Connectors and O-ring Plugs (contd) 4. Stretch the O-ring and roll it over the threads onto the groove in the hose connector. Do not stretch the O-ring more than necessary. 5. Lubricate the fitting threads with PTFE paste. 6. Thread the fitting by hand into the threaded port in the manifold. 7. Tighten the fitting only enough to seat, stopping when the body of the metal fitting contacts the manifold surface. Make sure the fitting is oriented properly. Apply torque of N m (7-10 in.-lb). 8. Purge the system of entrapped air by removing the nozzles on the guns and triggering the guns Resume operation. Fig. 45 Fitting O-ring on the Hose Connector Replacing the Relief Valve 1. Remove all adhesive from the tank. 2. Loosen the relief valve with a 9 / 16 in. socket wrench. 3. Remove the old relief valve. 4. Set the new relief valve in place and tighten. 5. Place several pounds of fresh, uncontaminated adhesive into the empty tank. 6. Resume operation.

37 SP30 21:1 Pump 33 Replacing the Solenoid Valve WARNING: Risk of electrical shock. Failure to observe electrical safety procedures may result in personal injury or death. Allow only qualified personnel to perform this task. Observe all high voltage indicators. Each applicator has a different procedure for replacing the solenoid voltage. If this pump is used in different applicators, such as the 3000 Multiscan, 3000 Vista, or AquaGuard, ensure that relevant instructions are used. Replacing the Manifold The manifold has no moving parts and should not need to be replaced. If the manifold needs to be removed for any reason, refer to the manifold section in the appropriate manual.

38 34 SP30 21:1 Pump 6. 21:1 Piston Pump Parts List The following tables list the Uptime and Uptime Plus packs and the component part numbers for the 2:1 Piston Pump. 21:1 Piston Pump Uptime and Uptime Plus Packs Nordson Uptime and Uptime Plus packs provide parts for fast, efficient repairs. Buying Uptime and Uptime Plus packs costs less than buying the individual parts.uptime packs consist of maintenance parts for normal wear items. They eliminate the worry and expense of out-of-stock situations for regular maintenance parts. Uptime Plus packs provide protection for additional repairs that are needed after long, hard usage. They enable quick replacement of major parts, resulting in maximum uptime. The Uptime pack for 21:1 piston pump, part is available for the complete replacement of the pump module. Pack P/N

39 SP30 21:1 Pump 35 21:1 Piston Pump Uptime Pack Parts List Item Part Description Quantity Note Service kit, SP Pump F, Uptime Pack O-ring, x x Viton O-ring, 3.75 x 3.88 x in. 2 A Nut, Hex, M Split lock washer Piston cup Push-on retaining ring 1 A U-cup Internal retaining ring, 1.05 in Washer, 1.05 x 0.82 in Pump seal 1 A Viton O-ring, 0.44 x 0.56 c A NOTE A: Apply lubricant P/N Pack P/N

40 36 SP30 21:1 Pump 21:1 Piston Pump Parts List Use the following table to order the individual items. Item Part Description Quantity Note Pump, piston, 21:1 SP Actuator assembly O-ring, x x Air cylinder cap Screw, Hex Hd, Cap, M6 x 120 mm 4 D Lock washer, Split, M6 4 D O-ring, Viton, 3.75 x 3.88 x 0.06 (pkg of 4) Air cylinder Nut, Hex, M Washer cup piston Piston cup Piston seal washer Internal retaining ring, Push-on Viton U-cup 1 A Pump mount Screw, Hex Hd, Cap, M8 x 6 mm 4 D Washer, flat, Regular, M Lock washer, Ext. M Screw, Hex Hd, Cap, M6-1 x 40 mm Shifter fork assembly Locknut, PN Lock washer, WH Internal retaining ring, Washer, 1.05 x Pump seal 1 A Hydraulic pump body Pipe plug, 1/8 inch 1 C Crossover tube 1 C Single backup ring, 7/16 x 9/ O-ring, Viton, 0.44 x 0.56 x A Hydraulic pump piston Piston Step washer, 1.00 Dia. SS Screw, Soc Hd, Low, M8 x 16 mm Siphon ball cage Ball Siphon ball seat 1 B NOTE A: Apply lubricant P/N B: Apply Loctite P/N C: Apply PTFE paste P/N D: Apply Never Seez Lubricant P/N

41 SP30 21:1 Pump

42 38 SP30 21:1 Pump Actuator Assembly Parts List Item Part Description Quantity Note Actuator assembly Screw, socket, M5 X Valve cap Bumper assembly O-ring, Viton Parker, hi-temp lubricant Air valve assembly Valve body Hex nut, lock, M Spring Upper detent Screw, socket, M4 X Magnetic actuator assembly Can, SP Lower, detent Internal retaining ring 1 NOTE A: Apply lubricant P/N

43 SP30 21:1 Pump A

44 40 SP30 21:1 Pump Regulator/Filter Assembly Parts List Order the regulator/filter assembly based on the number of hoses used on the applicator. For one through four hose applicator part For five or six hose applicator part Item Part Description Quantity Note Filter/regulator Element, filter Bowl and gasket Gage, pressure, 90 psi Nipple, pipe, 2.5 in. (for 1-4 hose applicators) 1 NS Nipple, pipe, 5.0 in. (for 5 or 6 hose applicators) 1 NS: Not Shown