Part B, Section 1 Model Voltage Pump Manifold Control This section covers the following unit configurations. 3500V 3700V 3800V 3900V All Piston (F) 4-Port (A) 6-Port (B or C) -Port (S or T) Vista Standard (V) Vista Pattern (PC)
B 1-0
B 1-1 Section B 1 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 section of the manual describes how to troubleshoot and repair the hydraulic system. It includes the following information: an overview of the unit s hydraulic system troubleshooting guidelines and procedures pump, actuator, solenoid valve, and manifold repair procedures pump, actuator, solenoid valve, air pressure regulator, and manifold assembly parts lists Refer to the parts lists at the end of this section for the part numbers of any components that need to be replaced. If you try all the suggestions in this section and still need assistance solving hydraulic system problems, call your Nordson representative. Refer to the following sections of this manual for additional information on the hydraulic system: Description includes pump specifications. Installation includes the procedures for connecting the air supply to the pump and installing hoses. To replace the tank and manifold, refer to Tank. Tank includes the tank assembly parts lists.
B 1-. Overview of the Hydraulic System Two major assemblies make up the hydraulic system: an air-driven piston pump and a manifold. See Figure B 1-1. The pump assembly includes an air section, a hydraulic section, and an actuator. The manifold assembly, which is indirectly heated by the tank, includes an aluminum manifold with hose ports, a filter assembly, a drain valve, and a pressure relief valve. 1 3 4 Fig. B 1-1 1. Actuator. Pump air section Key Parts of the Hydraulic System (shown with a typical tank and manifold) 3. Pump hydraulic section 4. Manifold 4130668A
B 1-3 3. Troubleshooting The following troubleshooting table describes the kinds of hydraulic system problems you may encounter and provides corrective actions for handling those problems. When necessary, the table refers you to the Troubleshooting Procedures part of this section, which contains more detailed procedures for diagnosing hydraulic system problems. Troubleshooting Table Refer to the following table to troubleshoot hydraulic system problems. Table B 1-1Troubleshooting Hydraulic System Problems Problem Possible Cause Corrective Action 1. Pump stroking erratically (inconsistent adhesive output) (See Note A). Pump stroking too fast (little or no adhesive output) 3. Pump not stroking (no adhesive output) Adhesive level too low Adhesive temperature too low Pump siphon ball seat dirty or missing Pump hydraulic section dirty Adhesive level too low Pressure relief valve defective Pump not turned on No input air pressure to the pump Pump solenoid valve failed Check the adhesive level. Add adhesive if necessary. Refer to Checking the Adhesive Level and Filling the Tank in Operation. Check the temperature settings. Refer to System Programming Procedures in Installation. Check the siphon ball seat. Refer to Pump Siphon Ball Seat Check. Clean the pump hydraulic section. Refer to Cleaning or Rebuilding the Pump. Check the adhesive level. Add adhesive if necessary. Refer to Checking the Adhesive Level and Filling the Tank in Operation. Replace the pressure relief valve. Refer to Replacing the Pressure Relief Valve. Wait for the READY light to turn on. NOTE: For some standard Vista and Vista PC units, you may need to turn the pump on manually after the READY light turns on. If the auto-energize pump feature is enabled, the pump will turn on automatically. Check the input air pressure. Adjust if necessary. Check the solenoid valve. Refer to Pump Solenoid Valve 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
B 1-4 Troubleshooting Table Table B 1-1 Identifying and Correcting System Faults (contd.) Problem Possible Cause Corrective Action 3. Pump not stroking (no adhesive output) (contd.) Blockage in manifold Pump hydraulic section dirty Pump leaking air (causes the pump to make a loud noise) Pump actuator malfunctioning for one or more of the following reasons: Check the manifold for blockage. Refer to Manifold Blockage Check. Clean the pump hydraulic section. Refer to Cleaning or Rebuilding the Pump. Locate the leak and replace damaged seals or O-rings. Refer to Pump Air Section Check. 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 Repositioning or 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 Repositioning or Replacing the Shifter Fork. shifter fork bent or damaged Replace the fork. Refer to Repositioning or Replacing the Shifter Fork. magnet assembly dirty or damaged bumper assembly dirty or damaged Clean or replace the magnet assembly. Refer to Cleaning or Replacing the Magnet Assembly. Replace the bumper assembly. Refer to Replacing the Bumper Assembly. shifter fork magnet loose Replace the fork. Refer to Repositioning or Replacing the Shifter Fork.
B 1-5 Troubleshooting Procedures Use these procedures as directed in Table B 1-1 to further diagnose hydraulic system problems. Manifold Blockage Check 1. Reduce the pump air pressure to 0.. Make sure the READY light is lit and the pump is turned on. 3. See Figure B 1-. Place a container under the manifold drain valve, open the valve, and allow adhesive to flow from the valve. Filter Type Standard Reverse-flush Procedure for Opening Drain Valve Turn the drain valve counterclockwise. With the manifold filter in the RUN position, turn the right-side drain valve counterclockwise. 1 Fig. B 1- Opening the Manifold Drain Valve 1. A manifold (standard filter). B or S manifold (standard filter) 3 3. C or T manifold (reverse-flush filter) 4130669A
B 1-6 Manifold Blockage Check (contd) 4. Slowly increase the pump air pressure and check to see if the pump is stroking. Strokes Pump Does not stroke Action There is no blockage in the manifold. Close the drain valve and return to Table B 1-1. The manifold may be blocked. Remove and clean the manifold filter. Refer to Cleaning a Standard Manifold Filter or Cleaning a Reverse-Flush Manifold Filter in Maintenance. Pump Siphon Ball Seat Check 1. Make sure the READY light is lit and the pump is turned on.. See Figure B 1-. Place a container under the manifold drain valve and open the valve. Filter Type Standard Reverse-flush Procedure for Opening Drain Valve Turn the drain valve counterclockwise. With the manifold filter in the RUN position, turn the right-side drain valve counterclockwise. 3. Turn the pump air pressure regulator alternately counterclockwise and clockwise to increase and decrease pump air pressure. This should remove any particles lodged between the siphon ball and its seat. 4. Check to see if the pump is stroking normally or erratically. Pump strokes Normally Erratically Resume operation. Action Remove and clean the pump. Refer to Cleaning or Rebuilding the Pump
B 1-7 Actuator Check 1. Remove the pump cover.. See Figure B 1-3. Thread an M4 screw into the top of the air valve spool. 4103145A Fig. B 1-3 Manually Shifting the Air Valve 3. Alternately press down and pull up on the screw to manually shift the air valve. If the air valve does not move, refer to Pump actuator malfunctioning for one or more of the following reasons under Pump does not stroke in Table B 1-1. 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 does not stroke in Table B 1-1. 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 Cleaning or Rebuilding the Pump to clean the pump air or hydraulic section.
B 1-8 Pump Solenoid Valve Check 1. Reduce the pump air pressure to 0.. Remove the pump cover. 3. Disconnect the air input line from the actuator. 4. Make sure the READY light is lit and the pump is turned on. 5. Slowly increase pump air pressure. 6. Check the disconnected air input line for air flow. Condition Air flows. Air does not flow. Action The solenoid valve is functioning properly. Reduce the pump air pressure to 0, reconnect the air input line, and return to Table B 1-1. Go to the next step. 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. 7. Open the electrical enclosure. Refer to Opening the Electrical Enclosure in Control. 8. Locate connector J9 on the power board and measure the voltage at positions 1 and. Voltage.8 5. VDC Less than.8 VDC Action Replace the solenoid valve. Refer to Pump Solenoid Valve Repair Procedures. Replace the power board. Refer to Replacing the Power Board in Control.
B 1-9 Pump Air Section Check 1. Reduce the pump air pressure to 0.. Remove the pump cover. 3. Make sure the READY light is lit and the pump is turned on. 4. See Figure B 1-4. Slowly increase pump air pressure and check for leaks at the actuator s top or bottom exhaust port (1) at the top of the hydraulic shaft () between the air cylinder head and the air cylinder or between the air cylinder and the pump mount (3) between the actuator and air cylinder (4) 3 1 4 4130473A Fig. B 1-4 Checking for Pump Air Section Leaks 1. Exhaust ports 3. Between air cylinder head and. Top of hydraulic shaft air cylinder or between air cylinder and pump mount 4. Between actuator and air cylinder
B 1-10 Pump Air Section Check (contd) 5. Take appropriate action based on the source of the leak. Air is Not leaking Leaking from the actuator s top or bottom exhaust port Leaking from the top of the hydraulic shaft Leaking between the air cylinder head and the air cylinder or between the air cylinder and the pump mount Leaking between the actuator and the air cylinder Action Replace the pump cover and return to Table B 1-1. Replace the piston cups and washers. Refer to the appropriate procedures in Cleaning or Rebuilding the Pump. Replace the u-cup. Refer to the appropriate procedures in Cleaning or Rebuilding the Pump. Replace the air cylinder and pump mount O-rings. Refer to the appropriate procedures in Cleaning or Rebuilding the Pump. Replace the actuator O-rings. Refer to the appropriate procedures in Cleaning or Rebuilding the Pump. 4. Pump Repair Procedures Use these procedures to replace the piston pump, to replace any pump component, or to clean pump components. Refer to the parts lists at the end of this section for the part numbers of any components that need to be replaced. You can also use the pump parts list illustration as a guide as your perform the following disassembly and reassembly procedures. NOTE: If you are replacing only the actuator, you do not need to remove the pump. To replace only the actuator, complete Replacing the Actuator in Actuator Repair Procedures.
B 1-11 Cleaning or Rebuilding the Pump Use these procedures to disassemble the pump, to clean or replace pump components, and to reassemble the pump. Preparation for Pump Removal 1. Make sure the unit is at operating temperature.. Series 3800V and 3900V units only: See Figure B 1-5. Place a large container under the drain port and remove the drain plug to drain the tank until the adhesive level is below the drain port opening. 3. Reduce the pump air pressure to 0. WARNING: System or material pressurized. Relieve pressure. Failure to observe this warning may result in serious burns. 4. Relieve system pressure. Refer to Relieving System Pressure in Maintenance. 4130670 Fig. B 1-5 Draining the Tank from the Drain Port on Series 3800V and 3900V Units WARNING: Disconnect and lock out line voltage to the unit. Failure to observe this warning can result in personal injury or death. 5. Turn the unit off; then disconnect and lock out power to the unit. 6. Remove the pump cover. 7. Disconnect the air input line from the actuator.
B 1-1 Pump Removal WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 1. If you have not already done so, complete Preparation for Pump Removal.. Remove the screws and washers that secure the pump to the unit. 3. Make sure the adhesive around the pump has not solidified. Reheat if necessary. 4. Rotate the pump slightly to break the suction and pull the pump straight up to remove it. Lay the pump on a clean, flat work surface. NOTE: To install a new pump and actuator assembly, go to Pump Installation. Actuator Removal 1. Move the hydraulic shaft up or down until shifter fork is centered in the pump mount.. See Figure B 1-6. Remove the screws and washers (1) that secure the actuator (3); then remove the actuator. NOTE: Series 3500V units also have a pump cover bracket () that must be removed. 3. Inspect the O-rings (4) in the face of the air cylinder for damage. Replace if necessary.
B 1-13 3 4 1 4130840A Fig. B 1-6 Removing the Actuator 1. Screw and washer. Pump cover bracket (Series 3500V units only) 3. Actuator 4. O-ring Pump Air Section Disassembly 1. Make sure you have removed the actuator. Refer to Actuator Removal.. See Figure B 1-7. Remove the screw and washer () from the shifter fork (1); then slide the fork toward the air cylinder and off the hydraulic shaft. 1 Fig. B 1-7 Removing the Shifter Fork 1. Shifter fork. Screw and washer 413018A
B 1-14 Pump Air Section Disassembly (contd) 3. See Figure B 1-8. Remove the screws and lock washers (4) that secure the air cylinder assembly to the pump mount. 4. Remove the air cylinder head (1). 5. Inspect the air cylinder head O-ring () for damage. Replace if necessary. 6. Remove the air cylinder (3). 1 4 3 Fig. B 1-8 Removing the Air Cylinder 1. Air cylinder head. Air cylinder head O-ring 3. Air cylinder 4. Screw and lock washer 4103154A
B 1-15 7. See Figure B 1-9. Hold the hydraulic shaft with a wrench and remove the retaining nut at the top. 4130195A Fig. B 1-9 Removing the Hydraulic Shaft Retaining Nut 8. See Figure B 1-10. Remove the piston cup washers (3), the piston cups (), and the piston seal washer (1). 9. Inspect the cups and washers for damage (cracking or creasing). Replace if necessary. 3 1 3 Fig. B 1-10 Piston Cups, Piston Cup Washers, Piston Seal Washer 1. Piston seal washer 3. Piston cup washer. Piston cup 41300A
B 1-16 Pump Hydraulic Section Disassembly 1. See Figure B 1-11. Secure the pump with a vise and use a flat-blade screwdriver to straighten the lock tab on the bearing lock washer.. Use a spanner wrench or hammer and a flat-blade screw driver to loosen the bearing lock nut. Then slide the nut and washer away from the pump body. 4130193A Fig. B 1-11 Removing the Nut and Washer 3. Pull the pump mount off of the pump body.
B 1-17 4. See Figure B 1-1. Inspect the pump mount O-ring (1) and U-cup (3) for damage (cracking or creasing). 5. If necessary, remove the O-ring, the retaining ring (), and the U-cup. Replace any damaged components. 3 1 4130194A Fig. B 1-1 1. U-cup. Retaining ring Pump Mount Component 3. Pump mount O-ring
B 1-18 Pump Hydraulic Section Disassembly (contd) 6. See Figure B 1-13. Inspect the pump seal (4) and pump body O-ring (1) for damage (cracking, hardening, or creasing). 7. If necessary, use snap-ring pliers to remove the retaining ring (). Then manually stroke the hydraulic shaft (5) up and down to loosen the washer (3) and pump seal. Replace any damaged components. 1 3 4 5 Fig. B 1-13 Hydraulic Shaft Components 1. Pump body O-ring. Retaining ring 3. Washer 4. Pump seal 5. Hydraulic shaft 413084A
B 1-19 8. See Figure B 1-14. Secure the pump body with a vise or wrench and remove the crossover tube (1), the O-ring (), and the backup ring (3). 9. Inspect the O-ring and backup ring for damage. Replace if necessary. 1 3 4103181 Fig. B 1-14 Crossover Tube, O-Ring, and Backup Ring 1. Crossover tube 3. Backup ring. O-ring
B 1-0 Pump Hydraulic Section Disassembly (contd) 10. See Figure B 1-15. Remove the siphon ball seat (3), siphon ball (), and siphon ball cage (1) from the pump body. 11. Inspect the siphon ball seat for damage. Replace if necessary. 1 3 Fig. B 1-15 Siphon Ball Cage, Siphon Ball, and Siphon Ball Seat 1. Siphon ball cage 3. Siphon ball seat. Siphon ball 4103198
B 1-1 CAUTION: Risk of equipment damage. Do not scratch the hydraulic shaft or the inside of the pump body. Scratches can cause the pump to leak. 1. See Figure B 1-16. Pull the hydraulic shaft () out of the pump body (1). 1 Fig. B 1-16 Pump Body and Hydraulic Shaft 1. Pump body. Hydraulic shaft 4130054 13. See Figure B 1-17. Remove the screw (3), step washer (), and piston (1) from the hydraulic shaft. 14. Inspect the piston and step washer for damage. Replace if necessary. 1 3 4130175A Fig. B 1-17 Piston and Step Washer 1. Piston. Step washer 3. Screw
B 1- Pump Component Cleaning If necessary, use one of the following methods to clean the pump components. WARNING: Risk of fire or explosion. Do not heat Type-R cleaning fluid above 46 C (475 F). Do not heat the cleaning fluid with an open flame or in an unregulated heating device. Place the pump components, except for the O-rings, in a container of Type-R cleaning fluid and heat the fluid until it is above the melting point of the adhesive. Scrub the components with a fine-bristled brush and wipe them with a clean, dry cloth. Use a flameless, electric heat gun or compressed hot air to heat the components; then wipe the components with a clean, dry cloth. Use an ultrasonic cleaner filled with cleaning fluid to soak the components; then wipe the components with a clean, dry cloth. Pump Hydraulic Section Assembly See the illustrations in Pump Hydraulic Section Disassembly as you perform the following reassembly steps. You can also use the pump parts list illustration at the end of this section. 1. Remove all adhesive from the pump seal cavity and the retaining-ring groove.. Slip the piston onto the hydraulic shaft and place the step washer on the screw. Apply threadlocking adhesive to the screw threads; then install the screw and step washer on the hydraulic shaft. Tighten to 4.07 6.78 N m (3 5 ft-lb). 3. Insert the hydraulic shaft in the pump body. 4. Apply threadlocking adhesive to the siphon ball seat threads; then reinstall the siphon ball cage, siphon ball, and siphon ball seat. 5. Place the crossover tube O-ring and backup ring on the crossover tube, apply PTFE paste to the crossover tube threads, and reinstall the crossover tube.
B 1-3 6. If you removed the pump body O-ring, retaining ring, washer, and pump seal, then a. Apply high-temperature lubricant to the O-ring and install it on the pump body. b. Apply high-temperature lubricant to pump seal and pull the hydraulic shaft up from the top of the pump body. c. Secure the pump body with a vise. Place the pump seal, with the groove facing down, on the hydraulic shaft; then install the washer. Slide the hydraulic shaft down to help guide the seal and washer into place in the pump body. d. Install the retaining ring in its groove in the pump body. 7. If you removed the pump mount O-ring, retaining ring, and U-cup, then a. Insert the U-cup in the upper face of the pump mount with the groove facing up. b. Press the retaining ring in the upper face to secure the U-cup. c. Apply high-temperature lubricant to the pump mount O-ring and place the O-ring on the upper surface of the pump mount. 8. Apply high-temperature lubricant to the hydraulic shaft at the point where it passes through the U-cup. 9. Guide the upper part of the pump body and the hydraulic shaft through the bottom hole in the pump mount. 10. Place the bearing lock washer and nut over the hydraulic shaft and slide the hydraulic shaft through the hole in the top of the pump mount. 11. Rotate the pump body clockwise until you feel it rest against the stop in the bottom of the pump mount. Secure the pump body to the pump mount by tightening the bearing lock nut.
B 1-4 Pump Hydraulic Section Assembly (contd) 1. Using a flat-blade screwdriver, lock the bearing lock washer by bending one tab into one of the slots on the bearing lock nut. 13. Slide the fork onto the hydraulic shaft until it sits on the shoulder. Make sure the side stamped UP is facing the air cylinder. Install the screw and washer and tighten to 8 10 N m (6 7 ft-lb). Pump Air Section Assembly See the illustrations in Pump Air Section Disassembly as you perform the following reassembly steps. You can also use the pump parts list illustration at the end of this section. 1. Pull the hydraulic shaft up as far as possible and install the following parts onto the shaft in this order: a. one piston cup washer b. one piston cup with the curved edge facing down c. the piston seal washer. Slide the air cylinder over the hydraulic shaft and onto the pump mount. Be careful not to damage the piston cup. 3. Use the shifter fork to move the hydraulic shaft up to the top of the air cylinder. 4. Install the remaining piston cup, with the curved edge facing up, and piston cup washer on the hydraulic shaft. 5. Hold the hydraulic shaft with a wrench and replace the retaining nut. Tighten to 11.30 13.56 N m (8 10 ft-lb). 6. Apply high-temperature lubricant to the air cylinder O-ring and roll the O-ring into place on the air cylinder head. 7. Position the air cylinder head on the air cylinder so that the shoulder cut-out is facing the actuator. Apply anti-seize compound to the air cylinder screws and use the screws and lock washers to secure the air cylinder to the pump mount. Tighten to 5 6 N m (45 55 in.-lb).
B 1-5 Actuator Installation See the illustrations in Actuator Removal as you perform the following reassembly steps. You can also use the pump parts list illustration at the end of this section. NOTE: Series 3500V units have a pump cover bracket that must be installed when the actuator is installed. See Figure B 1-6. 1. If you removed the O-rings from the air cylinder face, coat four new O-rings with high-temperature lubricant and install them on the air cylinder.. Move the hydraulic shaft up or down until the shifter fork is in the center of the pump mount. 3. Carefully align the actuator with the shifter fork and the locating pins on the air cylinder. 4. Install the actuator with the screws and washers you removed earlier. Tighten to 3 4 N m (8 36 in.-lb). Pump Installation NOTE: If you are replacing an old pump with a new, complete pump and your old pump has a pump cover bracket, remove the bracket and install it on the new pump. 1. Make sure the pump pan is positioned correctly.. Lower the pump into the unit until the crossover tube seats in the manifold. 3. Secure the pump to the unit with the screws and washers you removed earlier. Tighten to 1.0 13.56 N m (9 10 ft-lb). 4. Connect the air input line to the actuator.
B 1-6 System Restoration 1. Replace the pump cover.. Turn the unit on and allow it to reach operating temperature. 3. See Figure B 1-18. Place a container under the manifold drain valve and open the valve. Filter Type Standard Reverse-flush Procedure for Opening Drain Valve Turn the drain valve counterclockwise. With the manifold filter in the RUN position, open the right-side drain valve. 1 Fig. B 1-18 Opening the Manifold Drain Valve 1. A manifold (standard filter). B or S manifold (standard filter) 3 3. C or T manifold (reverse-flush filter) 4130669A
B 1-7 4. Increase pump air pressure until clean adhesive flows from the drain valve. This will purge the system of trapped air. 5. Reduce the pump air pressure to 0. 6. Close the drain valve. 7. Return the air pressure to the normal operating setting and resume operation. Repositioning or Replacing the Shifter Fork Use this procedure to reposition or replace the shifter fork without removing the pump from the unit. WARNING: Disconnect and lock out line voltage to the unit. Failure to observe this warning can result in personal injury or death. 1. Turn the unit off; then disconnect and lock out power to the unit.. Reduce the pump air pressure to 0. 3. Remove the pump cover. 4. Remove the actuator: a. Move the hydraulic shaft up or down until shifter fork is centered in the pump mount. b. Remove the screws and washers that secure the actuator; then remove the actuator. NOTE: Series 3500V units have a pump cover bracket that must be removed. See Figure B 1-6.
B 1-8 Repositioning or Replacing the Shifter Fork (contd) 5. See Figure B 1-19. Remove the screw and washer () from the shifter fork (1); then slide the fork toward the air cylinder and off the hydraulic shaft. 1 4130170A Fig. B 1-19 Removing the Shifter Fork 1. Shifter fork. Screw and washer 6. Reposition the shifter fork or install a new shifter fork. Make sure the side of the fork stamped UP faces up. 7. Slide the fork down onto the hydraulic shaft shoulder. 8. Install the screw and washer. Tighten the screw to 8 10 N m (71 89 in.-lb). 9. Install the actuator: NOTE: Series 3500V units have a pump cover bracket that must be installed when the actuator is installed. See Figure B 1-6. a. Move the hydraulic shaft up or down until the shifter fork is in the center of the pump mount. b. Carefully align the actuator with the shifter fork and the locating pins on the air cylinder. c. Install the actuator with the screws and washers you removed earlier. Tighten to 3 4 N m (8 36 in.-lb). 10. Replace the pump cover, restore power and air to the unit, and resume operation.
B 1-9 5. Actuator Repair Procedures Use these procedures to clean or replace the actuator s magnet assembly, bumper assembly, or air valve. Refer to the parts lists at the end of this section for the part numbers of any components that need to be replaced. You can also use the actuator parts list illustration as a guide as your perform the following disassembly and reassembly procedures. Replacing the Actuator Use this procedure to replace the actuator without removing the pump from the unit. Actuator Removal WARNING: Disconnect and lock out line voltage to the unit. Failure to observe this warning can result in personal injury or death. 1. Turn the unit off; then disconnect and lock out power to the unit.. Reduce the pump air pressure to 0. 3. Remove the pump cover. 4. Disconnect the air input line from the actuator and remove the air line elbow. 5. Move the hydraulic shaft up or down until shifter fork is centered in the pump mount. 6. See Figure B 1-0. Remove the screws and washers (1) that secure the actuator (3); then remove the actuator. NOTE: Series 3500V units have a pump cover bracket () that must be removed. 7. Inspect the O-rings (4) in the face of the air cylinder for damage. Replace if necessary.
B 1-30 Actuator Removal (contd) 3 4 1 4130840A Fig. B 1-0 Removing the Actuator 1. Screw and washer. Pump cover bracket (Series 3100V, 3400V, and 3500V units only) 3. Actuator 4. O-ring Actuator Installation NOTE: Series 3500V units have a pump cover bracket that must be installed when the actuator is installed. See Figure B 1-0. 1. If you removed the O-rings from the air cylinder face, coat four new O-rings with high-temperature lubricant and install them on the air cylinder.. Move the hydraulic shaft up or down until the shifter fork is in the center of the pump mount. 3. Carefully align the actuator with the shifter fork and the locating pins on the air cylinder. 4. Install the actuator with the screws and washers you removed earlier. Tighten to 3 4 N m (8 36 in.-lb).
B 1-31 5. Apply PTFE paste or tape to the air line elbow threads; then install the elbow in the actuator. 6. Connect the air input line to the actuator. 7. Replace the pump cover, restore power and air to the unit, and resume operation. Cleaning or Replacing the Magnet Assembly Use this procedure to clean or replace the magnet assembly. The magnet assembly is located inside the actuator. Magnet Assembly Removal WARNING: Disconnect and lock out line voltage to the unit. Failure to observe this warning can result in personal injury or death. 1. Turn the unit off; then disconnect and lock out power to the unit.. Reduce the pump air pressure to 0. 3. Remove the pump cover. 4. Disconnect the air input line from the actuator. 5. Remove the actuator: a. Move the hydraulic shaft up or down until shifter fork is centered in the pump mount. b. Remove the screws and washers that secure the actuator; then remove the actuator. NOTE: Series 3500V units have a pump cover bracket that must be removed. See Figure B 1-0.
B 1-3 Magnet Assembly Removal (contd) CAUTION: Use a clean work surface. The actuator contains magnets that can pick up small particles. These particles can damage the actuator or cause poor actuator performance. 6. See Figure B 1-1. Remove the screws that attach the can to the valve body and pull the can straight out from the valve body. 4103175 Fig. B 1-1 Removing the Can 7. Inspect the magnet assembly. If the assembly is Dirty or has metal particles clinging to it Loose Damaged Then Remove the dirt or particles with a clean cloth and go to Magnet Assembly Installation. Go to step of Magnet Assembly Installation to tighten the assembly and reinstall the actuator. Continue with the next step. 8. Remove the valve cap screws and lift the valve cap off the bumper assembly.
B 1-33 CAUTION: Risk of equipment damage. If you use a vise to hold the valve body while removing the magnet assembly, place the vise jaws on the sides of the valve body, not on the machined surface that mounts to the air cylinder. 9. See Figure B 1-. Pull down on the magnet assembly and slip an awl through the hole in the shaft. 10. Hold the bumper flats with a wrench and unscrew the magnet assembly from the valve spool. 4103176 Fig. B 1- Removing the Magnet Assembly Magnet Assembly Installation See the illustrations in Magnet Assembly Removal as you perform the following reassembly steps. You can also use the actuator parts list illustration at the end of this section. CAUTION: Risk of equipment damage. If you use a vise to hold the valve body while removing the magnet assembly, place the vise jaws on the sides of the valve body, not on the machined surface that mounts to the air cylinder. 1. Thread the magnet assembly into the valve spool until it seats.. Slip an awl through the hole in the magnet assembly shaft. 3. Using an adjustable wrench, hold the bumper flats and screw the magnet assembly into the valve spool. Tighten to 9 11 N m (81 99 in.-lb).
B 1-34 Magnet Assembly Installation (contd) 4. Slide the can over the magnet assembly so the opening faces the pump assembly. Install the securing screws and tighten them to 3 4N m (8 36 in.-lb). 5. Install the valve cap. Tighten the valve cap screws to 3 4 N m (8 36 in.-lb). 6. Install the actuator: NOTE: Series 3500V units have a pump cover bracket that must be installed when the actuator is installed. See Figure B 1-0. a. Move the hydraulic shaft up or down until the shifter fork is in the center of the pump mount. b. Carefully align the actuator with the shifter fork and the locating pins on the air cylinder. c. Install the actuator with the screws and washers you removed earlier. Tighten to 3 4 N m (8 36 in.-lb). 7. Connect the air input line to the actuator. 8. Replace the pump cover, restore power and air to the unit, and resume operation. Cleaning or Replacing the Air Valve Use this procedure to clean or replace the air valve assembly. The air valve assembly is located inside the actuator.
B 1-35 Air Valve Removal 1. Complete Magnet Assembly Removal. NOTE: The Magnet Assembly Removal procedure includes steps for relieving system pressure, locking out power, and removing the actuator. 1 3 4. See Figure B 1-3. Remove the valve cap screws (1) and lift the valve cap () off the bumper assembly (4). 3. Remove the bumper assembly. Use an open-end wrench to hold the bumper assembly, then use another wrench to remove the retaining nut (3). 4. Remove the upper detent (8) from the bottom of the valve body (7). 5 CAUTION: Risk of equipment damage. Do not press the air valve out of the valve body by pressing on the end of the spool. 6 7 5. Use a socket or similar tool to press the air valve out of the valve body by pressing against the end of the sleeve (6). 6. Remove and discard the sleeve O-rings (5). 8 413083 Fig. B 1-3 Removing the Air Valve 1. Valve cap screw. Valve cap 3. Retaining nut 4. Bumper assembly 5. Sleeve O-ring 6. End of sleeve 7. Valve body 8. Upper detent
B 1-36 Air Valve Removal (contd) CAUTION: Risk of equipment damage. Do not clean the air valve with an abrasive, scrape the spool or sleeve, or round off the sharp edges of the spool lands. Doing so can damage the spool and sleeve and cause the pump to stall. 7. See Figure B 1-4. Remove the retaining screw (4) from the side of the sleeve (3). 8. Carefully slide the spool () out of the sleeve. 9. Inspect the spool lands (1). Spool lands are Nicked, gouged, deeply scratched, or corroded Covered with contaminants Action Replace the air valve. Go to Air Valve Installation. 1. Clean the spool and sleeve with mineral spirits or any non-chlorinated cleaning solution, and a soft cloth. Do not use abrasives, scrape the spool or sleeve, or round off the sharp edges of the spool lands.. Thoroughly wipe the valve parts with a clean cloth or rinse them with denatured alcohol. 1 4 3 4103567 Fig. B 1-4 Air Valve Components 1. Spool lands. Spool 3. Sleeve 4. Retaining screw
B 1-37 Air Valve Installation See the illustrations in Air Valve Removal as you perform the following reassembly steps. You can also use the actuator parts list illustration at the end of this section. 1. Apply SP pump lubricating oil to the spool lands. Refer to Actuator Parts List for the oil part number.. Carefully insert the spool into the sleeve and center it in the sleeve. NOTE: The spool and sleeve are a matched set and cannot be replaced with components from another air valve assembly. 3. Install the retaining screw. Tighten to 0.7 0.9 N m (6 8 in.-lb). 4. Make sure the spool slides freely in its sleeve. If not, replace the air valve and go to step 5. 5. Apply high-temperature lubricant to a new set of O-rings and install the O-rings on the sleeve. 6. See Figure B 1-5. Press the air valve into the valve body from the top by pushing down on the flange. Fig. B 1-5 Installing the Air Valve 4103180 7. Install a new bumper assembly on top of the air valve. 8. Use a wrench to hold the bumper assembly flats and tighten the retaining nut. Tighten to 9 11 N m (81 99 in.-lb).
B 1-38 Air Valve Installation (contd) 9. Install the upper detent on the bottom of the valve body with the screws removed earlier. Tighten to 1.8.7 N m (16 0 in.-lb). 10. Install the valve cap. Tighten the valve cap screws to 3 4 N m (8 36 in.-lb). 11. Complete Magnet Assembly Installation. Replacing the Bumper Assembly Use this procedure to replace the actuator bumper assembly without removing the actuator from the unit. WARNING: Disconnect and lock out line voltage to the unit. Failure to observe this warning can result in personal injury or death. 1. Turn the unit off; then disconnect and lock out power to the unit.. Reduce the pump air pressure to 0. 3. Remove the pump cover. 1 4. See Figure B 1-6. Remove the valve cap screws (1) and lift the valve cap () off the bumper assembly (4). 5. Remove the bumper assembly. Use an open-end wrench to hold the bumper assembly stationary, then use another wrench to remove the retaining nut (3). 3 4 6. Install a new bumper assembly and secure it with the retaining nut. Tighten the nut to 9 11 N m (81 99 in.-lb). 7. Install the valve cap. Tighten the valve cap screws to 3 4 N m (8 36 in.-lb). 8. Reinstall the pump cover, restore power and air to the unit, and resume operation. Fig. B 1-6 1. Valve cap screw. Valve cap 3. Retaining nut 4. Bumper assembly Replacing the Bumper Assembly 4130833
B 1-39 6. Pump Solenoid Valve Replacement Procedures Use these procedures to replace the pump solenoid valve. Refer to the parts lists at the end of this section for the part numbers of any components that need to be replaced. You can use the solenoid valve assembly parts list illustration as a guide if you need to replace other solenoid valve assembly components. Removing the Solenoid Valve Follow this procedure to remove the pump solenoid valve. The solenoid valve is located inside the electrical enclosure. WARNING: Disconnect and lock out line voltage to the unit. Failure to observe this warning can result in personal injury or death. 1. Turn the unit off; then disconnect and lock out power to the unit.. Reduce the pump air pressure to 0. 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. 3. Open the electrical enclosure. Refer to Opening the Electrical Enclosure in the Control section. 4. See Figure B 1-7. Unplug (1) the solenoid valve. 5. Disconnect the air lines (3) from the elbows () on the solenoid valve. 6. Remove the screws that secure the solenoid valve mounting bracket (4) to the unit; then remove the valve and bracket from the unit. 7. Remove the screws (5) that secure the mounting bracket to the solenoid valve and disconnect the bracket from the valve. 8. Remove the elbows from the solenoid valve.
B 1-40 Removing the Solenoid Valve (contd) 1 3 4 Fig. B 1-7 1. Plug. Elbows 3. Air lines Solenoid Valve Assembly Components 5 4. Mounting bracket 5. Screws 4130841A Installing the Solenoid Valve Follow this procedure to install the new solenoid valve and to restore the unit to operation. 1. See Figure B 1-7. Install the elbows on the new solenoid valve.. Install the mounting bracket on the new solenoid valve. 3. Install the solenoid valve and mounting bracket on the back panel of the unit with the screws you removed earlier. 4. Connect the air lines to the solenoid valve elbows.
B 1-41 5. Connect the solenoid valve plug. 6. Close the electrical enclosure and restore power to the unit. 7. Return the pump air pressure to the normal operating setting. 8. Start the unit and listen for air leaks. If you hear air leaking, check the air line connections at the elbows. 7. Manifold Repair Procedures Use these procedures to replace the pressure relief valve or the manifold drain valve. Replacing the Pressure Relief Valve Use this procedure to replace the pressure relief valve. The pressure relief valve is located in the bottom of the tank. 1. Drain as much adhesive from the tank as possible. Refer to Flushing the System in Maintenance for different ways to drain the tank.. See Figure B 1-8. Use a socket wrench to loosen the pressure relief valve (1); then carefully unscrew the valve and remove it. 1 Fig. B 1-8 Replacing the Pressure Relief Valve 1. Pressure relief valve. Typical tank 4130835 3. Screw the new valve into the tank until it is finger-tight. 4. Use a socket wrench to tighten the valve. Tighten to 14 16 N m (10 1 ft-lb). 5. Refill the tank with adhesive and resume operation.
B 1-4 Replacing the Drain Valve Use this procedure to replace the drain valve. The drain valve is located in the manifold near the manifold filter. NOTE: Units with a reverse-flush filter have two manifold drain valves. 1. Make sure the unit is at operating temperature. WARNING: System or material pressurized. Relieve pressure. Failure to observe this warning may result in serious burns.. Relieve system pressure. Refer to Relieving System Pressure in Maintenance. 3. See Figure B 1-9. Remove the drain valve alignment screw (1) and washer (); then remove the valve (3) from the unit. Some adhesive will flow from the valve. 1 3 4130836 Fig. B 1-9 Replacing the Drain Valve 1. Alignment screw. Washer 3. Drain valve 4. Screw the new drain valve into the manifold until it is secure; then adjust it as necessary to install and tighten the alignment screw and washer. 5. Resume operation. Replacing the Manifold Because the manifold has no moving parts, you should not need to replace it. However, if you need to remove the manifold for any reason, refer to Tank.
B 1-43 8. Illustrated Parts Lists To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use these five-column parts lists, and the accompanying illustrations, to describe and locate parts correctly. 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 six-digit 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. Indentions show the relationships between assemblies, subassemblies, and parts. Item Part Description Quantity Note 000 000 Assembly 1 1 000 000 Subassembly A 000 000 Part 1 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.
B 1-44 UpTime Pack for Pump F See Figure B 1-30. The UpTime pack for pump F (1:1) provides the parts that should be replaced as part of routine maintenance. Item Part Description Quantity Note 164 685 Service kit, UpTime, pump F, 1:1 1 940 111 O-ring, Viton, 0.301 x 0.70 in. 4 940 440 O-ring, Viton, 3.750 x 3.875 x 0.063 in. 3 984 09 Nut, hex, lock, torque, M6, class 10 1 4 88 116 Cup, piston, high volume 5 986 331 Retaining ring, internal, 100, push-on 1 6 95 100 Cup, U, Viton 1 7 986 711 Retaining ring, internal, 106, spiral 1 8 88 11 Washer, 1.045 x 0.819 in. 1 9 88 1 Seal, pump, high volume 1 10 940 133 O-ring, Viton, 0.46 ID x 0.70 in. 1
B 1-45 7 8 1 9 3 4 4 5 10 6 Fig. B 1-30 Pump F UpTime Pack Parts 4130184A
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B 1-47 Piston Pump Parts List See Figure B 1-31. Item Part Description Quantity Note 164 683 Service kit, pump F, SP, 1:1, UpTime, w/o pump cover bracket A 1 - - - - - - Actuator, assembly 1 B 940 111 O-ring, Viton, 0.301 ID x 0.070 in. 4 3 164 469 Head, air cylinder 1 4 98 147 Screw, hex head, cap, M6 x 10 mm 4 C 5 983 409 Washer, lock, split, M6 4 6 940 440 O-ring, Viton, 3.750 x 3.875 x 0.063 in. D 7 161 04 Cylinder, air 1 8 984 09 Nut, hex, lock, torque, M6, class 10 1 9 88 115 Washer, piston cup, high volume 10 88 116 Cup, piston, high volume 11 88 117 Washer, piston, seal, high volume 1 1 986 331 Ring, retaining, internal, 100, push-on 1 13 95 100 Cup, U, Viton 1 14 161 03 Mount, pump 1 15 98 050 Screw, hex head, cap, M8 x 35 mm 3 16 983 414 Washer, flat, narrow, M8 3 17 983 404 Washer, lock, split, M8 3 18 98 135 Screw, hex head, cap, M6 x 30 mm 1 19 170 641 Service kit, fork, 1:1, SP (shifter fork) 1 0 984 545 Nut, lock, bearing, PN-8 1 1 983 134 Washer, lock, E, bearing, 1.574 in. 1 986 711 Ring, retaining, internal, 106, spiral 1 3 88 11 Washer, 1.045 x 0.819 in. 1 4 88 1 Seal, pump, high volume 1 D NOTE A: Order this part to receive a complete piston pump. B: Refer to Actuator Assembly Parts List. C: Apply anti-seize compound, part 900 344. D: Apply high-temperature lubricant, part 900 493. Continued on next page
B 1-48 Piston Pump Parts List (contd) Item Part Description Quantity Note 5 134 657 Body, pump 1 6 973 40 Plug, pipe, socket, flush, 1 / 8 in. 1 E 7 88 031 Tube, crossover 1 C 8 954 013 Backup ring, single, 7 / 16 x 9 / 16 in. 1 9 940 133 O-ring, Viton, 0.46 ID x 0.70 in. 1 30 16 988 Shaft, hydraulic, 1:1 1 31 76 716 Piston 1 3 983 04 Washer, step, 1.0 in. diameter 1 33 98 376 Screw, socket head, low, M8 x 16 mm 1 F 34 40 533 Cage, ball, siphon 1 35 900 03 Ball, 440, stainless-steel, 0.750 in., 50 1 36 40 534 Seat, siphon ball 1 37 941 61 O-ring, Viton, 1.375 x 1.563 x 0.094 in. 1 D 38 973 466 Pipe, plug, flush, 1 / 16 in., w/ sealant 39 983 410 Washer, flat, narrow, M6 1 40 187 63 Bracket, cover, pump, 1:1, SP 1 G 41 98 98 Screw, hex head, cap, M5 x 50 mm G 4 983 408 Washer, flat, narrow, M6 G NOTE C: Apply anti-seize compound, part 900 344. D: Apply high-temperature lubricant, part 900 493. E: Apply paste, part 900 36. F: Apply retaining cylindrical adhesive, part 900 419. G: Used only on Series 3500V units.
B 1-49 3 4 5 37 6 7 3 1 4 5 38 8 6 40 9 10 11 41 4 10 9 7 6 8 15 1 13 30 9 17 16 14 31 3 19 33 18 34 0 1 39 36 35 4130499A Fig. B 1-31 Pump F Parts
B 1-50 Actuator Parts List See Figure B 1-3. Item Part Description Quantity Note 155 077 Service kit, actuator assembly, SP A 1 98 08 Screw, socket head, M5 x 0 mm 4 155 054 Cap, valve 1 3 984 090 Nut, hex, lock, torque, M8 1 4 161 4 Service kit, bumper 5 161 49 Service kit, spool/sleeve 1 B 6 940 181 O-ring, Viton, 0.739 ID x 0.070 in. 4 C 7 155 051 Body, valve 1 8 155 057 Detent, upper 1 9 98 059 Screw, socket head, M4 x 8 mm 10 164 606 Service kit, magnetic actuator (magnet assembly) 1 11 155 068 Can 1 1 155 067 Detent, lower 1 13 986 714 Retaining ring, internal, 156, bowed 1 NOTE A: Order this part to receive a complete actuator assembly. B: Apply SP pump lubricating oil, part 11 8, to the spool lands. C: Apply high-temperature lubricant, part 900 493.
B 1-51 1 3 4 5 6 7 8 9 10 11 1 1 13 4130037 Fig. B 1-3 Actuator Parts
B 1-5 Solenoid Valve Assembly Parts List See Figure B 1-33. Item Part Description Quantity Note 1 98 51 Screw, pan-head, recessed, M5 x 8 mm 338 306 Elbow, male, 3 / 8 in. tube x 1 / 4 NPT, Viton 3 3 338 307 Elbow, male, 3 / 8 in. tube x 1 / 8 NPT, Viton 1 4 10 03 Grommet, 0.375 ID in. 5 900 596 Tubing, PTFE, 3 / 8 in. 1 A 6 75 115 Adapter, 1 / 4 NPTF 1 7 98 309 Screw, pan head, recessed, M5 x 10 mm 1 8 3 648 Bracket, mounting, solenoid valve, Vista 1 9 98 94 Screw, cross-pan, #10-31 x 0.50 in. 10 37 93 Assembly, solenoid valve, way, 4 VDC, 1 / 4 NPT 1 11 - - - - - - Frame, hose end 1 B 1 - - - - - - Frame, center 1 B 13 - - - - - - Pump assembly 1 C NOTE A: Specify required length when ordering replacement tubing. B: Refer to Frame Assembly Parts List in Tank. C: Refer to Piston Pump Parts List.
B 1-53 13 3 5 1 11 7 5 5 10 5 4 6 1 9 8 Fig. B 1-33 Solenoid Valve Assembly Parts 4130553A
B 1-54 Air Pressure Regulator and Filter Assembly Parts List See Figure B 1-34. Item Part Description Quantity Note 165 873 Regulator/filter assembly, 70 psi, 4-hose A 165 874 Regulator/filter assembly, 70 psi, 6-hose B 1 165 735 Regulator, filter, air, 1 / 4 NPT 1 973 490 Nipple, brass, 40, 1 / 4 in.,.50 in. 1 A 973 491 Nipple, brass, 40, 1 / 4 in., 5.00 in. 1 B 3 901 57 Gauge, air, 1 / 8 NPT, 70 psi 1 4 165 870 Service kit, filter element 1 5 165 878 Service kit, filter bowl 1 NOTE A: Used only on 4-hose units. B: Used only on 6-hose units. 1 3 4 5 4103139 Fig. B 1-34 Air Pressure Regulator/Filter Assembly Parts