Installation and Maintenance Instructions Part NORDSON CORPORATION AMHERST, OHIO USA
Nordson Corporation welcomes requests for information, comments and inquiries about its products. Address all correspondence to Nordson Corporation 11475 Lakefield Drive Duluth, GA 30155-1511 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1994. 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 AquaGuard, Blue Box, Control Coat, Equi=Bead, FloMelt, FoamMelt, FoamMix, Helix, Hot Shot, Hot Stitch, Meltex, MicroSet, MultiScan, Nordson, the Nordson logo, OmniScan, Porous Coat, Posi-Stop, RBX, Sure-Bond, UniScan, UpTime, and Versa-Spray are registered trademarks of Nordson Corporation. BetterBook SM, CF, Controlled Fiberization, Easy-Screen, Fibermelt, Flo-Tracker, PrintGuard, and Package of Values are trademarks of Nordson Corporation. Viton is a registered trademark of DuPont Dow Elastomers. Never Seez is a registered trademark of Bostik Corporation. Parker Lubricant is a registered trademark of Parker Seal.
Table of Contents i Table of Contents Installation and Maintenance Instructions 1. Introduction................................................. 1. Overview of the Hydraulic System............................. 3. Troubleshooting Tables...................................... 3 Adhesive Not Applying Properly............................ 3 Pump Not Working........................................ 7 4. Troubleshooting Test Procedures.............................. 9 Relieving System Hydraulic Pressure........................ 9 Manifold Blockage Check................................. 10 Pump Siphon Ball and Seat Check......................... 10 Actuator Check.......................................... 11 Pump Solenoid Valve Check.............................. 11 Testing Solenoid Voltage.................................. 1 Series 3000 Applicator with MultiScan or OmniScan Control System........................... 1 Series 3000 Applicator with UniScan Control System....... 13 Air Leak Check.......................................... 13 5. Pump Repair Procedures................................... 15 Servicing the Pump...................................... 15 Preparation for Pump Removal.......................... 15 Pump Removal........................................ 15 Replacing the Air Valve................................... 16 Removing the Actuator and Air Cylinder Assembly......... 16 Removing the Magnet Assembly from the Actuator........ 17 Removing the Valve Spool and Sleeve................... 18 Installing the Valve Spool and Sleeve.................... 0 Installing the Actuator and Air Cylinder Assembly.......... 1
ii Table of Contents Installation and Maintenance Instructions (contd.) Replacing the Piston Cups................................ 1 Replacing the Shifter Fork................................ 3 Cleaning or Repairing the Pump Body...................... 4 Removing the Hydraulic Piston Components.............. 5 Removing the Siphon Ball and Floating Piston Components...................................................... 6 Installing the Siphon Ball and Floating Piston Components...................................................... 7 Installing the Hydraulic Piston Components............... 8 6. 6:1 Piston Pump Parts List.................................. 9 6:1 Piston Pump Uptime Pack............................. 30 6:1 Piston Pump Parts List................................ 3 Regulator/Filter Assembly Parts List........................ 35
1 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. CAUTION: For the most reliable operation of the pump, install an air filter (5 micron particulate filter or better) as close as possible to the applicator air pressure regulator. Refer to Regulator/Filter Assembly Parts List in this document for a list of filters to meet this requirement. 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 the suggestions in this document do not solve the problem, call the Nordson representative for assistance.
. Overview of the Hydraulic System Two major assemblies make up the hydraulic system: an air-driven piston pump and a manifold. The pump assembly includes a hydraulic section, an air motor, 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 4 3 4131138A Fig. 1 Main Components of the Hydraulic System (shown with a typical tank and manifold) 1. Air motor. Pump hydraulic section 3. Manifold 4. Actuator
3 3. Troubleshooting Tables These troubleshooting tables describe different adhesive application and pump-operation problems, as well as corrective actions. Refer to the appropriate troubleshooting table for the type of problems being experienced: Adhesive Not Applying Properly Pump Not Working WARNING: Allow only qualified personnel to perform troubleshooting procedures. Adhesive Not Applying Properly Refer to the following table to troubleshoot adhesive application problems. 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 time delay to expire and the READY light to turn on. Maintain at least 50% capacity. Check the tank, hose, and gun temperature setpoints and adjust 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 and clean if necessary.. 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 Protect the applicator and guns from freezing temperature conditions and drafts. Continued on next page
4 Adhesive Not Applying Properly (contd) Problem Possible Cause Corrective Action. Wavy beads (contd.) Nozzles too far from product Position guns so that the nozzles are no more than 13 mm (0.5 in.) from the product. 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 as necessary. Position the guns so that the nozzles are no more than 13 mm (0.5 in.) from the product. Clean the manifold filter or filters. 4. Adhesive stringing Nozzle too far from product Position the guns so that 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 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 as necessary. Do not exceed the recommended pot life of the adhesive. Check the tank, hose, and gun temperature setpoints and adjust 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 as necessary. Change to a compatible higher-viscosity adhesive. Continued on next page
5 Problem 7. Adhesive not penetrating product 8. Gun spitting intermittently, causing erratic bead placement Adhesive too cold Possible Cause 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 Corrective Action Check the tank, hose, and gun temperature setpoints and adjust as necessary. Increase the temperature setpoints or change adhesives. Change to a higher-flow nozzle, increase operating temperature setpoints, or increase hydraulic pressure. Change to a compatible lower-viscosity adhesive. Maintain at least 50% 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 reduce viscosity. 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
6 Adhesive Not Applying Properly (contd) Problem Possible Cause Corrective Action 11. Cartons popping open (good adhesive penetration, but adhesive bond separates 1. 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 reduce bead size. Decrease the operating temperature setpoints. Reduce the line speed through the compression section. Increase the length of compression. 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. Decrease the distance between the nozzles and the product. Decrease the distance between bead application and 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% capacity. Keep the lid closed when the applicator is operating. Change to a more stable adhesive.
7 Pump Not Working Refer to the following table to troubleshoot pump problems. Problem Possible Cause Corrective Action 1. Pump stroking too fast or erratically (inconsistent or no adhesive output) (See Note A). 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 Check the adhesive level. Increase the tank temperature setpoint. Check the siphon ball seat. Refer to Pump Siphon Ball Seat Check given later in this section. Replace the crossover tube O-ring. Refer to Servicing the Pump given later in this section. 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 given later in this section. 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 Air Leak Check. NOTE A: The pump should make two regularly spaced exhaust sounds. If two exhaust sounds followed by a pause is heard then the pump is stroking erratically (the hydraulic shaft is moving faster in one direction than the other). Continued on next page
8 Pump Not Working (contd) Problem Possible Cause Corrective Action. 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, or is installed upside down Check the position of the fork and reposition if necessary, or position 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 Magnet Assembly Removal and Servicing the Pump. Replace the bumper assembly. Refer to Replacing the Bumper Assembly. shifter fork magnet loose Replace the fork. Refer to Replacing the Shifter Fork.
9 4. Troubleshooting Test Procedures Test procedures are used with the troubleshooting charts to solve problems with the hydraulic section of the applicator. Relieving System Hydraulic Pressure WARNING: System or material is pressurized. Release pressure. Failure to observe may result in serious burns. 1. Reduce pump air pressure to 0.. Trigger all guns to relieve the residual system pressure. 4103143 Fig. Reducing Air Pressure 3. Open the manifold drain valve. Fig. 3 Different Manifold Drain Valves A B C 4103144
10 Manifold Blockage Check 1. Reduce the air pressure to 0.. Place a container under the manifold drain valve or valves. 3. Trigger all guns to relieve the residual system pressure. 4. Standard manifold filter: Open the drain valve. Reverse-flush manifold filter: With the manifold filter in the RUN position, open the right-side drain valve. 5. Slowly increase the pump air pressure and check to see if the pump is stroking. Refer to this table to troubleshoot any problems. Pump Does not stroke Strokes Action There is no blockage in the manifold. Close the drain valve and return to Pump Not Working troubleshooting table. The manifold may be blocked. Remove and clean the manifold filter. Pump Siphon Ball and Seat Check 1. Place a container under the manifold drain valve or valves.. Standard manifold filter: Open the drain valve. Reverse-flush manifold filter: With the manifold filter in the RUN position, open the right-side drain valve. 1 3. Turn the pump air pressure regulator clockwise to increase pump air pressure and allow the pump to cycle rapidly for several seconds. This should remove any particles lodged between the siphon ball and its seat. 4. Check to see if the pump is stroking normally. Refer to the following table to troubleshoot any pump problems. 3 Fig. 4 Pump Siphon Ball and Seat 1. Pump body. Siphon ball 3. Siphon ball seat 4103146 Pump strokes Normally Erratically Resume operation. Action Remove and clean the pump. Refer to Servicing the Pump.
11 Actuator Check 1. Remove the pump cover.. 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 Solenoid Valve Check 1. Be sure the applicator is turned on and the READY status light on.. Reduce the pump air pressure to 0. 3. Remove the pump cover. 4. Disconnect the air input line from the actuator. 5. Slowly increase pump air pressure. 6. Check the disconnected air input line for air flow. 410345 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 Pump Not Working troubleshooting table. Go to Testing Solenoid Voltage. Fig. 5 Disconnecting the Air Inlet Line
1 Testing Solenoid Voltage Follow the solenoid test procedure for a specific applicator. 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. 3 Series 3000 Applicator with MultiScan or OmniScan Control System 1. Open the electrical enclosure.. Open the main control board (PCB1) located behind the control panel. 3. Locate connector PCB1-J8 (XP8) on the main control board and measure the voltage at positions and 3. Voltage Reading with Voltage Action Applicator off: 0-10 V AC Applicator on: 160-40 V AC Matches Does not match Replace the solenoid valve. Replace the main control board. 4131139A Fig. 6 Location of Voltage Positions and 3
13 3 Series 3000 Applicator with UniScan Control System 1. Open the electrical enclosure.. Open the main control board (PCB1) located behind the control panel. 3. Locate connector PCB1-J8 (XP8) on the main control board and measure the voltage at positions and 3. Voltage Reading with Voltage Action Applicator off: 0-10 V AC Applicator on: 60-64 V AC Matches Does not match Replace the solenoid valve. Replace the main control board. 4131139A Fig. 7 Location of Voltage Positions and 3 Air Leak Check Check for air leakage in the following areas of the pump. 1. Reduce the pump air pressure to 0.. Remove the pump cover. 3. See Figure 8. Slowly increase pump air pressure and check for any air leaks: between the air motor cylinder head and the air cylinder, or between the air cylinder and the pump mount at the top of the hydraulic shaft at the actuator s top or bottom exhaust port
14 Air Leak Check (contd) 1 3 Fig. 8 Air Leakage Zones 1. Between air motor cylinder head and air cylinder or between air cylinder and pump mount. Top of hydraulic shaft 3. Actuator s top or bottom exhaust port 4131137A 4. 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 around the shaft at the bottom of the air motor Leaking between the air motor cylinder head and the air cylinder or between the air cylinder and the pump mount Action Replace the pump cover and return to the Pump Not Working troubleshooting table. Replace the piston cups and washers. Refer to the appropriate procedures in Servicing the Pump. Replace the u-cup. Refer to the appropriate procedures in Servicing the Pump. Replace the air cylinder and pump mount O-rings. Refer to the appropriate procedures in Servicing the Pump.
15 5. Pump Repair Procedures Use these procedures to service and repair the piston pump. Refer to the 6:1 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. Servicing 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 applicator is at operating temperature.. Reduce the pump air pressure to 0. 3. Open the drain valve or trigger the guns to relieve hydraulic pressure. Refer to Relieving Hydraulic Pressure in the Maintenance section. 4. Remove the pump cover. 5. Disconnect the air input line from the actuator. Pump Removal WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles, and heat-protective gloves. 1. If not already done, complete Preparation for Pump Removal.. Remove the screws and washers that secure the pump to the applicator. 3. Make sure the adhesive around the pump is melted (the READY light should be on). 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 the pump and actuator assembly, go to Pump Installation.
16 Replacing the Air Valve To replace the air valve, first remove the actuator and the air cylinder assembly from the pump body. These components are part of the upper pump assembly. Removing the Actuator and Air Cylinder Assembly 1. Remove the four hex-head cap screws and washers from the air cylinder head. 1 5 3 4 4131113A Fig. 9 Removing the Actuator and Air Cylinder 1. Air cylinder head 4. Can. Air cylinder head O-ring 5. Hex-head cap screw and lock 3. Actuator and air cylinder assembly washer. Remove the air cylinder head. 3. Check the O-ring on the air cylinder head for damage. Replace if necessary. 4. Remove the actuator and air cylinder assembly from the pump mount by lifting up on the assembly and pulling the can of the air cylinder away from the fork.
17 Removing the Magnet Assembly from the Actuator 1. Remove the two socket-head screws securing the can to the actuator. Fig. 10 Removing the Can from the Magnet Assembly. Pull the can straight off of the actuator. 3. Pull the magnet assembly away from the upper detent. 4. Place a suitable tool into the small hole at the top of the magnet assembly to prevent it from rotating. 413110A Fig. 11 Removing the Magnet Assembly from the Actuator 4131118A
18 4 3 1 Removing the Magnet Assembly from the Actuator (contd) 5. 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. 6. Remove the valve spool nut and bumper assembly from the top of the valve assembly. 7. Place a wrench on the flats of the valve spool to prevent it from rotating. 5 8. Unscrew the magnet assembly and set it aside. 6 7 Removing the Valve Spool and Sleeve WARNING: Failure to observe may result in personal injury, death, or equipment damage. 8 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.. Remove the two socket-head screws securing the upper detent to the air manifold. 3. Remove the upper detent and spring. 4. Remove the socket-head screws from the flange on the top of the air manifold. 9 4131119A Fig. 1 Removing the Air Valve 1. Valve spool nut. Bumper assembly 3. Valve spool and sleeve assembly 4. Flange 5. Air manifold 6. Spring 7. Upper detent 8. Magnet assembly 9. Can 5. 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.
19 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 dirty, clean the assembly and set it aside on a clean cloth or towel. 1 3 413111A Fig. 13 Air Valve Components 1. Spool lands. Spool 3. Sleeve 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.
0 Installing the Valve Spool and Sleeve 1. Install the upper detent. Fasten with screws and tighten to 1.8-.7 N m (16-0 in.-lb).. 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 air manifold 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 air manifold. 6. Install the flange. Fasten with screws and tighten to 3-4 N m (8-36 in.-lb). 7. 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. 8. Carefully reassemble the valve spool into the sleeve. 9. Check that the valve spool slides freely in the sleeve. If it does not, replace the valve assembly. 10. Check the bumper assembly for wear. Replace if necessary. 11. Place the bumper assembly on the top of the valve assembly and secure it with the valve spool nut.
1 Installing the Actuator and Air Cylinder Assembly 1. Holding the valve spool in place, screw the threaded end of the magnet assembly into the valve spool until it seats.. 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. Hold the bumper assembly against the flange and install the can. The cut-out side of the can should face the circular part of the air manifold. 5. Secure the can in place with screws. Tighten to 3-4 N m (8-36 in.-lb). NOTE: Refer to Replacing the Piston Cups to remove the upper piston cup before installing the actuator and air cylinder assembly onto the pump. This prevents damage to the upper piston cup. Once the air cylinder and actuator are in place, return the upper piston cup and washer to the assembly. 6. Remove the upper piston cup and washer. 7. Install the air cylinder and actuator assembly on the pump. 8. Install the upper piston cup and washer. 9. With the valve spool end centered in the opening of the cylinder head, install the cylinder head. Secure with screws and tighten to 5-6 N m (45-55 in.-lb). Replacing the Piston Cups This procedure must be performed with the actuator and air cylinder removed. If the actuator and air cylinder assembly are still installed on the pump, refer to Removing the Actuator and Air Cylinder Assembly. 1. Check to be sure the fork is at the top of its stroke.. Place a wrench on the flats of the piston to prevent it from turning.
Replacing the Piston Cups (contd) 3. Loosen the nut above the piston cups and remove the two piston cups, two piston cup washers, and the piston cup seal from the piston. 4. Install one piston cup washer, one piston cup, and the piston seal washer onto the piston in the proper order. The curved edge of the piston cup should be pointing down. 3 1 3 Fig. 14 Piston Cups, Piston Cup Washers, and Piston Seal Washer 1. Piston seal washer 3. Piston cup washer. Piston cup 4131116A 5. Carefully align the actuator and air cylinder assembly with the shifter fork and slide the assembly into place on the pump. 6. Install the remaining piston cup and piston cup washer onto the piston. The curved edge of the piston cup should be pointing up. 7. With a wrench placed on the flats of the piston, install the nut.. Tighten to 11.30-13.56 N m (100-10 in.-lb). 8. Center the valve spool end in the opening of the cylinder head and install the cylinder head. Secure with screws and tighten to 5-6 N m (45-55 in.-lb).
3 Replacing the Shifter Fork The actuator and air cylinder assembly must be removed in order to replace the shifter fork. If they are not already removed, refer to Removing the Actuator and Air Cylinder Assembly. 1. Make sure the shifter fork is in the lower half of its stroke. 1 Fig. 15 Removing the Shifter Fork 1. Shifter fork. Clamping screw and washer 4131115A. Remove the clamping screw and washer from the shifter fork. 3. Slide the fork toward the air motor and off the piston. 4. Slide the new shifter fork onto the piston until it sits on the shoulder. The side stamped UP must face the air manifold end of the pump. 5. 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. 7. Replace the actuator and air cylinder assembly. Refer to Installing the Actuator and Air Cylinder Assembly.
4 Cleaning or Repairing the Pump Body The actuator and air cylinder assembly and the shifter fork must be removed in order to access the pump body. If they are not already removed, refer to Removing the Actuator and Air Cylinder Assembly and Replacing the Shifter Fork. 1. Straighten the lock tab on the tab lock washer. 411117A Fig. 16 Removing the Lock Tab Nut and Washer. Loosen the locking nut and slide the nut and the tab lock washer away from the pump body. 3. Pull the pump mount off of the pump body. 4. Set the locking nut and the tab lock washer aside. 5. Inspect the U-cup seal and the O-ring and replace if necessary. 3 1 410355 Fig. 17 Pump Mount Components 1. O-ring. U-cup seal 3. Retaining ring
5 Removing the Hydraulic Piston Components CAUTION: Risk of equipment damage. Do not scratch the hydraulic piston or the inside of the pump body. Scratches can cause the pump to leak. 1. Use a retaining ring tool to remove the retaining ring at the top of the pump body. 1 3 4 Fig. 18 Hydraulic Shaft Components 4130114 1. Retaining ring. Washer 3. Pump seal 4. Hydraulic piston. Manually stroke the hydraulic piston up and down to loosen the washer and pump seal. 3. Remove the seal and washer. Inspect the seal and replace if necessary. 4. Secure the pump body by placing an adjustable wrench on the wrench slots of the pump body or by placing the pump body into a vise. 5. Remove the crossover tube. Inspect the O-ring and backup ring. Replace if necessary.
6 Removing the Hydraulic Piston Components (contd) 1 3 4 4103181 Fig. 19 Crossover Tube, O-ring, and Backup Ring 1. Crossover tube. O-ring 3. Backup ring 4. Pump body Removing the Siphon Ball and Floating Piston Components 1. Unscrew the siphon ball seat from the pump body.. Pull the siphon ball seat and its cage from the pump body. 1 3 Fig. 0 Siphon Ball Cage, Siphon Ball, and Siphon Ball Seat 1. Siphon ball cage 3. Siphon ball seat. Siphon ball 4103198
7 3. Unscrew the socket head screw (1) from the bottom of the piston shaft. Remove the piston () and the step washer (3). 4. Inspect the piston for wear or damage. Replace if necessary. 3 1 410361 WARNING: Do not heat Type R fluid with an open flame or in an unregulated heating device. Do not heat Type R fluid above 46 C (475 F). 5. Heat a container of Type R fluid to the melting temperature of the adhesive material in use. Clean all components of the pump. Fig. 1 Removing the Piston 1. Socket head screw. Piston 3. Step washer Installing the Siphon Ball and Floating Piston Components 1. See Figure 1. Slip the piston onto the piston shaft. Place the step washer on the screw. Apply Loctite to the screw threads and screw it on to the piston. Apply torque of 4.07-6.78 N m (3-5 ft.-lb).. Insert the piston into the pump body. 3. Place the siphon ball onto the siphon ball seat. 4. 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. 5. Apply Loctite to the threads of the seat and screw it into the pump body.
8 Installing the Hydraulic Piston Components 1. Put the backup ring and O-ring on the crossover tube. Apply Never Seez lubricant to the threads of the crossover tube and screw it into the pump body. 1 NOTE: All adhesives must be removed from the seal cavity and the retaining-ring groove in the pump body before the seal is installed.. Apply O-ring lubricant to the pump seal. Pull the piston up through the top of the pump body. 3. Put the pump seal (with the groove facing the pump body) on the piston then put the washer on the piston. 4. Slide the piston down to help guide the seal and washer into place in the pump body. 5. Use a retaining-ring tool to snap the retaining ring into place. Fig. Pump Body and Hydraulic Shaft 1. Pump body. Hydraulic piston 41311A 6. If the U-cup is being replaced, insert the U-Cup into the upper face of the pump mount with the groove facing up and install a new retaining ring to hold the U-cup in place. 7. Place the O-ring over the air cylinder mount on the upper surface of the pump mount. 8. Guide the upper part of the pump body and the piston through the bottom hole in the pump mount. NOTE: The piston must be inserted through the tab lock washer and the locking nut before it passes through the top hole in the mount. 9. 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 10. Install the shifter fork onto the piston. Refer to Replacing the Piston Fork. 11. Install one piston cup washer, one piston cup, and the piston seal washer onto the piston in the proper order. The curved edge of the piston cup should be pointing down. Refer to Replacing the Piston Cups. NOTE: To prevent damage to the upper piston cup, do not install the upper piston cup and washer before installing the air cylinder and actuator assembly on the pump. 1. Install the actuator and air cylinder assembly onto the pump. Refer to To Install the Actuator and Air Cylinder Assembly. 13. Install the upper piston cup and washer. 14. With the valve spool end centered in the opening of the cylinder head, install the cylinder head. Secure with screws and tighten to 5 6 N m (45 55 in.-lb). 15. Install the pump in the applicator and resume normal operation. 6. 6:1 Piston Pump Parts List 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 Plus packs enable quick replacement of major parts, resulting in maximum uptime. They provide protection for additional repairs that are needed after long, hard usage. Uptime packs eliminate the worry and expense of out-of-stock situations for regular maintenance parts. They consist of maintenance parts for normal wear items. The Uptime Plus Service kit for 6:1 SP pump, P/N 164 684 is available for the complete replacement of the pump.
30 6. 6:1 Piston Pump Parts List (contd) Pack P/N 164 684 410310 6:1 Piston Pump Uptime Pack Item Part Description Quantity Note 167 999 Service kit, SP Pump E, Uptime Pack 1 940 111 O-ring, 0.313 x 0.438 x 0.063 4 940 33 O-ring, Viton,.15 x.00 x.063 A 3 984 09 Nut, lock, hex, M6 1 4 983 409 Lock washer, split, M6 4 5 163 039 Piston cup 6 986 331 Push-on retaining ring 1 7 95 100 U-cup 1 A 8 986 711 Internal retaining ring, 1.05 inch 1 9 88 11 Washer, 1.05 x 0.8 1 10 88 1 Pump seal 1 A 11 940 133 O-ring, Viton, 0.44 x 0.56 x 0.063 1 A 1 954 013 Ring, back-up 7 / 16 x 9 / 16 1 13 941 61 O-ring, Viton, 1.38 x 1.56 x.094 1 A NOTE A: Apply lubricant P/N 900 493
31 13 8 9 Pack P/N 167 999 10 1 4 3 5 1 6 11 7 410359 Fig. 3 6:1 Piston Pump Uptime Pack
3 6:1 Piston Pump Parts List Item Part Description Quantity Note 1010 370 Pump, piston, 6:1 SP-30, G 1 1 941 61 O-ring, Viton, 1.375 X 1.563 X.094 1 986 711 Internal retaining ring, 106, spiral 1 3 88 11 Washer, 1.045 X 0.819 1 4 88 1 Pump seal, high volume, MPL 1 5 973 40 Pipe plug, socket, flush 1 / 8 inch 1 6 134 657 Piston pump body, 1:1, grid 1 7 88 031 Crossover tube, MPL, pump 1 8 954 013 Single back-up ring, 7 / 16 X 9 / 16 1 9 940 133 O-ring, Viton, 0.461D X 0.070 wide 1 10 155 096 Hydraulic piston pump, 6:1 SP 1 11 76 716 Piston, HMVII 1 1 983 04 Step washer, 1.00 diameter, SS 1 13 98 376 Screw socket, low, M8 X 16 1 14 40 533 Cage, ball, siphon 1 15 900 03 Stainless ball, 440, 0.750, 50 1 16 40 534 Seat, siphon ball 1 17 88 030 Pump mount, machined, 6:1 and 14:1 1 18 98 135 Hex screw cap, M6 X 30 1 19 983 410 Washer, flat, M, narrow, M6 1 0 983 184 Washer lock, E, BRG, W-08 1 1 984 545 Lock nut, BRG, PN-08 1 166 880 Magnetic fork assembly 1 3 986 714 Internal retaining ring, 156, bowed 1 4 155 067 Detent, lower SP 1 5 155 068 Can, SP 1 6 98 08 Screw, socket, M5 X 0 4 7 155 075 Magnetic actuator assembly 1 8 155 057 Detent, upper SP 1 9 333 560 Spring wave, inconel, SP pump 1 Continued on next page
33 37 47 1 6 40 46 3 4 33 45 30 31 3 44 41 6 5 9 4 8 34 35 36 43 4 41 40 7 8 9 7 39 10 19 18 38 3 11 6 5 17 1 13 14 4 1 15 3 0 16 4131169A Fig. 4 6:1 Piston Pump Parts
34 6:1 Piston Pump Parts List (contd) Item Part Description Quantity Note 30 900 344 Lubricant, Never Seez, 8 oz. can 0 31 1006 07 Valve assembly SP 1 3 900 493 Lubricant, Parker high temperature 0 33 1005 47 Bracket, cover, pump, SP, 14: and 6:1 1 34 98 059 Screw socket, M4 X 8, BL 35 983 403 Washer, lock, split, M4 1 36 983 40 Washer, flat, narrow, M4 1 37 333 137 Cylinder head, machined, SP 1 38 95 100 U-cup, Viton 1 39 986 331 Internal retaining ring, 100, push-on 1 40 940 33 O-ring, Viton,.000 X.15 X 0.063 41 983 446 Piston cup washer, SP 4 163 039 Piston cup, SP 43 983 445 Piston washer seal, SP 1 44 984 09 Nut, hex, lock, torque, M6, class 10 1 45 309 8 Air manifold, SP 1 46 983 409 Washer, lock, split, M6 4 47 98 147 Hex screw cap, M6 X 10 4 NS 900 470 Adhesive, threadlocking 0 NS: Not Shown
35 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 unit P/N 165 871 For five or six hose unit P/N 165 87 Item Part Description Quantity Note 1 165 735 Filter/regulator 1 165 870 Element, filter 1 3 165 878 Bowl and gasket 1 4 901 58 Gage, pressure, 90 psi 1 5 973 03 Nipple, pipe,.5 (for 1-4 hose units) 1 NS 973 05 Nipple, pipe, 5.0 (for 5 or 6 hose units) 1 NS: Not Shown 1 4 5 3 Fig. 5 Regulator/Filter Assembly 4103139
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