EP- Three-Piston Pump Customer Product Manual Issued 0/ For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) -99 or contact your local Nordson representative. This document is subject to change without notice. Check http://emanuals.nordson.com for the latest version. NORDSON CORPORATION AMHERST, OHIO USA
tents Table of Contents Repair Preparations... Removing the Pump... Checking Cam Shaft End Play... Draining the Oil... Fluid Section Rebuild... Disassembling the Fluid Section... Diaphragm Cartridge Installation... Check Valve Installation... 8 Assembling the Fluid Section... 9 Hydraulic Section Rebuild... 0 Pump Housing Disassembly... 0 Rebuilding the Pistons... Disassembly... Rebuilding... Pump Housing Assembly... Plunger Installation... Priming the Piston Assemblies... Assemble the Fluid Section... Pump Installation... 8 Parts... 9 Using the Illustrated Parts Lists... 9 EP- Three-Piston Pump... 0 Fluid Section Service Kits... Diaphragm Cartridge Kit... Valve Repair Kit... Hydraulic Section Service Kits... EP Pump Repair Tool Kit... Shaft Seal Kit... Piston Assembly Kit... Plunger Kit... Oil Cap... Upgrade Kit... Optional Oil Change Suction Gun... Contact Us Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service Jackson Street Amherst, OH 00 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 00. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks Nordson and the Nordson logo are registered trademarks of Nordson Corporation. Loctite is a registered trademark of Henkel Loctite Corporation. All other trademarks are the properties of their respective owners.
Change Record i Revision Date Change 0 0/ Added upgrade kit 09. Change Record
ii Change Record
EP- Three-Piston Pump EP- Three-Piston Pump Repair Preparations WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: System or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury. Before you repair the pump, perform the following procedures: Procedure Page Removing the Pump Checking Cam Shaft End Play Draining the Oil
EP- Three-Piston Pump Removing the Pump. Turn off and lock out power to the pumping system.. See Figure. Remove the screws (8) securing the shroud (9).. Loosen the set screws () on the coupling (0).. Disconnect the output and input hoses (, ).. Remove the screws (), lock washers (), and flat washers () securing the pump () to the frame (). 0 9 8 Figure Removing the Pump. Pump. Output hose. Input hose. Frame. Screw. Lock washer. Flat washer 8. Screw 9. Shroud 0. Coupling. Set screw
EP- Three-Piston Pump Checking Cam Shaft End Play Check the cam shaft end play before replacing any parts or rebuilding the pump. A dial indicator and arbor press are required to do this.. See Figure. Position the dial indicator tip () on the end of the cam shaft (). CAUTION: Use extreme care when operating the arbor press. Excessive force may cause damage to the cam shaft bearings and races.. Use the arbor press (not shown) to check cam shaft end play. If the cam shaft end play exceeds 0.8 mm (0.00 in.), replace the pump. If the cam shaft end play is less than 0.8 mm (0.00 in.), perform required maintenance. Figure Checking Cam Shaft End Play. Dial indicator tip. Cam shaft
EP- Three-Piston Pump Draining the Oil NOTE: To reduce the draining time, order the optional quick oil change kit. Refer to Optional Oil Change Suction Gun on page for the part number.. Place a pan or absorbent material under the pump. CAUTION: To prevent losing the oil prime in the piston assemblies, never rotate the pump shaft during routine oil changes.. Drain the oil from the pump housing with or without the optional oil change kit: Without the Optional Suction Gun a. See Figure. Remove the oil fill cap () from the pump. b. Remove the drain plug (). c. Install the drain plug after the oil has drained. With the Optional Suction Gun a. See Figure. Remove the oil fill cap () from the pump. b. Connect the suction gun fitting () to the drain fitting (). c. Pull the handle () to draw the oil out of the pump. d. Disconnect the suction gun fitting from the drain fitting. Without Oil Change Kit With Oil Change Kit Figure Draining the Oil. Fill cap. Drain plug. Drain fitting. Suction gun fitting. Handle
EP- Three-Piston Pump Fluid Section Rebuild Disassembling the Fluid Section. See Figure. Remove the screws (, ) and lock washers () securing the end plate () to the pump housing.. Remove the screws (8) securing the valve plate (9) to the pump housing.. Use a valve/seat removal tool to remove the inlet and outlet valve assemblies (, ) and valve seats () from the valve plate. Inspect the valves and seats for wear or obstruction. Replace or clean them as necessary.. Remove the diaphragm plates (0). 0 0 9 8 Figure Disassembling the Fluid Section. Socket head screw ( in.). Socket head screw (. in.). Lock washer. End plate. Inlet valve assembly. Outlet valve assembly. Valve seat 8. Socket head screw ( in.) 9. Valve plate 0. Diaphragm plates. Diaphragm cartridge screw. O-ring. Follower. Diaphragm cartridge. Plunger shaft
EP- Three-Piston Pump Disassembling the Fluid Section (contd). See Figure. Remove each diaphragm cartridge using the following steps: a. The keyway on the shaft corresponds to the high spot on the cam. Use the shaft rotator tool to rotate the shaft until a plunger is aligned with the keyway. b. Pull on the diaphragm cartridge screw () until you expose a drilled cross hole in the plunger shaft. Insert a wrench into the cross hole. See Figure for cross hole and wrench location. c. Remove the diaphragm cartridge screw, O-ring (), follower (), and diaphragm cartridge () from the plunger shaft. Diaphragm Cartridge Installation. See Figure. To prevent air from being drawn in through the pump plungers during priming, install the diaphragm cartridge screws () into the plunger shafts (). NOTE: The oil level must always be mm ( / in.) from the top of the fill port.. The keyway on the shaft corresponds to the high spot on the cam. Use the shaft rotator tool to rotate the shaft until a plunger is aligned with the keyway.. Install the diaphragm cartridges using the following steps: a. Pull the diaphragm cartridge screw () until you expose a drilled cross hole on the plunger shaft (). Insert a wrench () into the drilled cross hole. b. Remove the diaphragm cartridge screw from the plunger shaft. c. Remove the screws and shipping plates from the new diaphragm cartridge assemblies. Figure Installing Screws into the Plunger Shafts. Diaphragm cartridge screw. Plunger shaft. Plunger. Wrench. Shaft
EP- Three-Piston Pump d. See Figure. Install the O-ring () and follower () on the screw (). Apply adhesive (included in diaphragm kit) to the end portion of the screw. e. Insert the diaphragm cartridge screw () through the diaphragm cartridge assembly (). f. Install the diaphragm cartridge assembly on the plunger shaft (). Position the diaphragm cartridge with the plug (8) facing outward. Tighten the screw. g. Remove the wrench (). h. Repeat steps a g for the remaining diaphragm cartridges. NOTE: The oil level must always be mm ( / in.) from the top of the fill port.. Install the oil fill cap (). 8 Figure Diaphragm Cartridge Installation. Fill cap. Diaphragm cartridge. Follower. Screw. O-ring. Plunger shaft. Wrench 8. Plug
8 EP- Three-Piston Pump Check Valve Installation See Figure. Install the inlet and outlet check valves (, ) as illustrated. Each valve seat () has grooves on one side with a beveled edge (8) on the inner diameter. The valve (), spring (), cage (), and spacer () must be installed on this side. NOTE: To help support the diaphragms during operation, position the inlet valve cage so one leg partially blocks the inlet port (as illustrated). Correct Inlet Valve Cage Position 8 Figure Check Valve Installation. Inlet check valve. Outlet check valve. Spacer. Valve seat. Valve. Spring. Cage 8. Beveled edge
EP- Three-Piston Pump 9 Assembling the Fluid Section. See Figure 8. Place the diaphragm plates () on the pump.. Use the screws () to secure the valve plate () and diaphragm plates on the pump.. Use the screws (, ) and lock washers () to install the end plate (). Torque screws to 8 N m ( 0 ft-lb). Follow the torquing sequence shown in the illustration.. Prime the pump: a. Plug the pump s OUT port and connect a regulated air supply to the IN port. b. Turn the shaft / turn and remove the oil fill cap. c. Apply 0. 0. bar ( 0 psi) to the IN port. d. Turn the shaft several more rotations until no more air bubbles come out of the reservoir. e. Add EP- oil to the reservoir until the level is mm ( / in.) from the top of the fill port.. Install the pump on the frame. Refer to Pump Installation on page 8. / in. NPT OUT Port 9 8 / in. NPT IN Port Torquing Sequence Figure 8 Assembling the Fluid Section. Diaphragm plates. Valve plate. Lock washer. Socket head screw ( in.). Socket head screw (. in.). End plate. Socket head screw ( in.)
0 EP- Three-Piston Pump Hydraulic Section Rebuild Pump Housing Disassembly NOTE: Before rebuilding the hydraulic section, make sure you have all the replacement parts required, plus the EP tool kit listed on page.. Remove the pump. Refer to Removing the Pump on page.. Drain oil from the pump housing. Refer to Draining the Oil on page.. Remove the end, valve, and diaphragm plates and the diaphragm cartridges. Refer to Disassembling the Fluid Section on page.. See Figure 9. Remove the bolts () securing the cylinder casting (8). To even the load from the springs, alternate turns on the bolts.. Lift the cylinder casting off and turn it face down.. Remove the cam shaft assembly () from the pump housing (). Inspect the shaft () for burrs. If any burrs exist, smooth them out.. Inspect the cam shaft assembly bearings () and bearing race for any damage or wear. Replace the pump if they are damaged or worn. 8. Remove the O-ring () from the pump housing. CAUTION: Use extreme care when removing shaft seals to prevent scratching or denting the inside of the pump housing. 9. Place a mm ( / - to / -in.) diameter rod on the pump shaft seals (). Carefully tap the rod to remove the seals from the pump housing.
EP- Three-Piston Pump Figure 9 Pump Housing Disassembly. Pump housing. Shaft seals. O-ring. Cam shaft assembly. Shaft. Cam shaft assembly bearings 8. Bolts 8. Cylinder casting
EP- Three-Piston Pump Rebuilding the Pistons Disassembly. See Figure 0. Screw the plunger guide lifter () into the plunger ().. Lightly tap the plunger guide lifter with a hammer to slip the plunger off the shaft. Discard the plunger.. Remove the piston return spring () by pulling it outward and turning it counterclockwise.. Remove these parts from the piston case (): spring retainer () valve cylinder O-ring () valve cylinder spring () plunger stem (8) valve cylinder (9) O-ring (0) retaining washer () ball (). Inspect the parts for any damage or wear. If any parts are worn or damaged, replace the complete piston assembly.. Repeat steps through for the remaining pistons. Rebuilding. See Figure 0. Place the ball () into the piston case (). Make sure the ball seats into the hole at the bottom of the case.. Insert the retaining washer () and O-ring (0) into the piston case.. Insert the plunger stem (8) into the valve cylinder (9).. Slide the valve cylinder spring () over the plunger stem.. Insert the valve cylinder O-ring () into the spring retainer ().. Slide the valve cylinder assembly into the spring retainer. Slide this assembly into the piston case ().. Insert the piston return spring (), wide end first, into the piston case. Turn the spring until it bottoms out. 8. Repeat steps through for the remaining pistons.
EP- Three-Piston Pump 0 9 8 Figure 0 Rebuilding the Pistons. Plunger guide lifter. Plunger. Return spring. Piston case. Spring retainer. Valve cylinder O-ring. Valve cylinder spring 8. Plunger stem 9. Valve cylinder 0. O-ring. Retaining washer. Ball
EP- Three-Piston Pump Pump Housing Assembly. See Figure. Insert the pistons (8) into the cylinder casting (). Make sure the hole on the foot end of each piston is pointing toward the center of the cylinder casting.. Clean the pilot bearing race on the cylinder casting. Apply a thin film of EP- oil to its surface.. Apply O-ring lubricant to the O-ring (). Install the O-ring on the inside surface of pump housing ().. Clean the bearing race on the pump housing. Apply a thin film of EP- oil to its surface.. Carefully place the cam shaft assembly () into the pump housing. Nest the bearing into the bearing race.. Place the cylinder casting () on the pump housing. Make sure the cylinder casting and the pump housing bolt holes are aligned.. Install the draw bolts () and nuts () as illustrated. Tighten the draw bolt nuts evenly. 8. Use the shaft rotator tool () to rotate the shaft (9). If the shaft begins to bind, loosen the nuts and realign the shaft. 9. Install the cylinder casting retainer bolts (). 0. Loosen the nuts () and remove the draw bolts ().. Rotate the shaft (9) to check for proper alignment. Remove the shaft rotator tool.. Apply a thin film of O-ring lubricant to the seal protector tool (). Slide the seals () on the tool, with the spring side of the seals toward the open end of the tool. Apply a heavy coat of O-ring lubricant between the seals and press them together on the tool.. Apply a coating of Loctite high-performance pipe sealant with PTFE or a comparable product to the outer surface of the seals () and to the surface of the pump housing where the seals will be installed.. Apply a thin film of grease to the shaft (9). Slide the seal protector tool () over the end of the shaft.. Slide the seal inserter tool (0) over the seal protector tool (). Press seals () completely into place. Tap the inserter tool with a soft mallet to firmly seat the seals. Remove both tools from the shaft.
EP- Three-Piston Pump 0 9 8 Figure Pump Housing Assembly. Pump housing. O-ring. Cam shaft assembly. Nut. Draw bolt. Cylinder casting retainer bolt. Cylinder casting 8. Piston 9. Shaft 0. Seal inserter tool. Seal protector tool. Shaft rotator tool. Seals
EP- Three-Piston Pump Plunger Installation NOTE: Do not install used plungers. Use new plungers.. See Figure. Install the shaft rotator tool () on the pump shaft. The keyway on the pump shaft corresponds to the high spot on the cam. Rotate the pump shaft until a plunger stem () is aligned with the keyway.. Place a plunger () on the screw end of the plunger guide tool (). The flat side of the plunger should face the tool.. Screw the plunger guide tool into the plunger stem.. Pull the plunger guide tool until a drilled cross hole is exposed. Install the wrench () into the drilled cross hole.. Press fit the plunger to the plunger stem (): a. Tighten the plunger guide tool nut () down against the plunger () by hand. b. Use a wrench to further tighten the plunger guide tool nut until the plunger is secure against the shoulder of the plunger stem.. Remove the plunger guide tool.. Remove the wrench from the plunger stem. 8. Repeat steps through for remaining plungers. Figure Plunger Installation. Shaft rotator tool. Plunger stem. Plunger. Plunger guide tool. Plunger guide tool nut. Wrench
EP- Three-Piston Pump Priming the Piston Assemblies Prime the piston assemblies after you have assembled the hydraulic section, but before you assemble the fluid section.. With the pump in a horizontal position, fill the reservoir with EP- oil. Leave the oil cap off the pump.. See Figure. Install the diaphragm cartridge screws () into the plunger shafts ().. Use the shaft rotator tool to rotate the shaft until a bubble-free flow of oil comes from behind each plunger. Watch the oil level in the reservoir. If the oil level falls below the top of the upper piston assemblies, refill the reservoir.. When no more bubbles appear, check the oil level. The oil level should be approximately mm ( / in.) from the top of the port. Add oil if necessary and install the oil cap. Assemble the Fluid Section Perform these procedures to assemble the fluid section before installing the pump: Procedure Page Diaphragm Cartridge Installation Check Valve Installation 8 Assembling the Fluid Section 9
8 EP- Three-Piston Pump Pump Installation. See Figure. Use screws (), lock washers (), and flat washers () to install the pump () on the frame (). Tighten the screws securely.. Tighten the set screws () on the coupling (0).. Use the screws (8) to install the shroud (9). Tighten the screws securely.. Connect the input and output hoses (, ). 0 9 8 Figure Pump Installation. Pump. Output hose. Input hose. Frame. Screw. Lock washer. Flat washer 8. Screw 9. Shroud 0. Coupling. Set screw
EP- Three-Piston Pump 9 Parts For parts and technical support, call the Nordson Industrial Coating Systems Customer Service Center at (800) -99 or contact your local Nordson representative. Use the parts illustrations and lists to locate and describe the parts you need. Using the Illustrated Parts Lists Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code NS (not shown) indicates that a listed part is not illustrated. A dash ( ) is used when the part number applies to all parts in the illustration. The number in the Part column is the Nordson Corporation part number. A series of dashes in this column (- - - - - -) means the part cannot be ordered separately. The Description column gives the part name, as well as its dimensions and other characteristics when appropriate. Indentions show the relationships between assemblies, subassemblies, and parts. If you order the assembly, items and will be included. If you order item, item will be included. If you order item, you will receive item only. The number in the Quantity column is the quantity required per unit, assembly, or subassembly. The code AR (As Required) is used if the part number is a bulk item ordered in quantities or if the quantity per assembly depends on the product version or model. Letters in the Note column refer to notes at the end of each parts list. Notes contain important information about usage and ordering. Special attention should be given to notes. Item Part Description Quantity Note 0000000 Assembly 000000 Subassembly A 000000 Part
0 EP- Three-Piston Pump EP- Three-Piston Pump See Figure. Item Part Description Quantity Note 08 PUMP, EP-, three piston, dual diaphragm - - - - - - PUMP, Three Piston, 8. bar (00 psi) 09 WASHER, follower, EP- - - - - - - DIAPHRAGM/SENSOR cartridge assembly A 90080 O-RING, 0.88 x 0. x 0.0 in. A 980 SCREW, cross, flat head, #0- x / -in., stainless steel 900 ADHESIVE, threadlocking AR - - - - - - PLATE, diaphragm 8 8 PLATE, valve 9 98 SCREW, socket head / - 8 x in., black 0 - - - - - - PLATE, end 98 SCREW, socket head, / - x in., black 988 SCREW, socket head, / - x. in., black NS 09 OIL, EP-, qt NOTE A: These parts are included in the Diaphragm Cartridge Kit. Refer to the kit list on page. AR: As Required NS: Not Shown 8 0 9 Figure EP- Three-Piston Pump
EP- Three-Piston Pump Fluid Section Service Kits Diaphragm Cartridge Kit See Figure. Item Part Description Quantity Note KIT, diaphragm cartridge, EP - - - - - - DIAPHRAGM/SENSOR CARTRIDGE assembly 90080 O-RING, hotpaint, 0.88 x 0. x 0.0 in. 90 O-RING, hotpaint, 0.0 x 0.98 x 0.09 in. 900 O-RING, hotpaint,.8 x.0 x 0.09 in. 90 O-RING, hotpaint,.000 x.88 x 0.09 in. 90 O-RING, hotpaint, 0.98 x.0 x 0.0 in. Valve Repair Kit See Figure. This kit contains all parts necessary to repair the check valves in the EP- three-piston pump. Item Part Description Quantity Note 0 SERVICE KIT, EP valve repair Figure Fluid Section Service Kits
EP- Three-Piston Pump Hydraulic Section Service Kits EP Pump Repair Tool Kit Part Description Quantity Note TOOL KIT, repair, EP 99 SCREW, hex, / x.00 in., zinc 989 NUT, hex, regular, /, steel, zinc WRENCH, hex, T-handle ROTATOR, shaft PROTECTOR, seal INSERTER, seal LIFTER, plunger guide NS: Not Shown Shaft Seal Kit See Figure. Item Part Description Quantity Note SERVICE KIT, EP shaft seal 98 O-RING, Buna N, 0.8 x.0 x 0.09 in. - - - - - - SEAL, EP shaft 9 O-RING, Buna N,.00 x.88 x 0.09 in. NS 900 ADHESIVE, pipe/thread/hydraulic sealant NS: Not Shown Piston Assembly Kit See Figure. Item Part Description Quantity Note 099 SERVICE KIT, EP- piston assembly 9 O-RING, Buna N,.00 x.88 x 0.09 in. - - - - - - PISTON ASSEMBLY, EP- Plunger Kit See Figure. Item Part Description Quantity Note PLUNGER, EP- Oil Cap See Figure. Item Part Description Quantity Note CAP, oil, EP
EP- Three-Piston Pump Upgrade Kit See Figure. Item Part Description Quantity Note 09 KIT, upgrade, EP- pump - - - - - - PISTON ASSEMBLY, EP- NS 09 OIL, EP-, qt - - - - - - HOUSING, EP- piston Figure Hydraulic Section Service Kits
EP- Three-Piston Pump Optional Oil Change Suction Gun Part Description Note 990 GUN, suction, oil change
EP- Three Piston Pump Refer to the EP- Three-Piston Pump manual 099 for complete service and parts information. For parts and technical support call (800) -99. Fluid Section Kits A - Diaphragm Cartridge Kit B - 0 Check Valve Repair Kit A A B Hydraulic Section Kits C - Oil Cap D - Shaft Seal Kit 099 E - Piston Assembly Kit F - Plunger Kit - 09 Upgrade Kit C D Tool Kit Tool Kit, EP- D E F EP- Oil 09 EP- Oil, Quarts 0 Nordson Corporation Effective Manual Rev. A 00-0