Nordson PermaFlo 830 Customer Product Manual Download Page 6

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Table of Contents

Part 1022914G03

2007 Nordson Corporation

Installation

B 3-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting and Connections

B 3-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Guidelines

B 3-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation

B 4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Check

B 4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solvent Cup Fill

B 4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump and System Flushing

B 4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency

B 4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Solution for Flushing

B 4-3

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Routine Startup

B 4-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation

B 4-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup B

4-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Routine Shutdown

B 4-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance B

4-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily B

4-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

As Needed

B 4-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

B 5-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Common Problems

B 5-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventing Air Valve Freezing

B 5-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Motor Repair

C 1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction C

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools and Materials Required

C 1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guidelines for O-ring and Seal Replacement

C 1-2

. . . . . . . . . . . . . . . .

Coupling Removal and Replacement

C 1-2

. . . . . . . . . . . . . . . . . . . . . . .

Coupling Removal

C 1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coupling Replacement

C 1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Motor Rebuild

C 1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Motor Removal

C 1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Pilot Valve Cartridge Replacement (Pump Revisions A

−

C) C

1-4

Air Pilot Valve Repair (Pump Revisions D and Above)

C 1-5

. . . . . .

Muffler and Air Valve Removal

C 1-6

. . . . . . . . . . . . . . . . . . . . . . . . . .

Air Motor Disassembly

C 1-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Motor Re-Assembly

C 1-9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston/Connecting Rod Assembly

C 1-9

. . . . . . . . . . . . . . . . . . . . .

U-Cup Installation

C 1-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder O-ring Installation

C 1-11

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston, Cylinder, and Cylinder Head Installation

C 1-11

. . . . . . . . .

Air Valve and Muffler Installation

C 1-13

. . . . . . . . . . . . . . . . . . . . . .

Air Motor Rebuild Completion

C 1-14

. . . . . . . . . . . . . . . . . . . . . . . . .

Air Valve Rebuild

C 1-14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Old Style Air Valve (Pump Revisions A

−

C) C

1-15

. . . . . . . . . . . . . . . .

New Style Air Valve (Pump Revisions D and Above)

C 1-16

. . . . . . .

Summary of Contents for PermaFlo 830

Page 1: ...03 Issued 8 07 NORDSON CORPORATION AMHERST OHIO USA For parts and technical support call the Finishing Customer Support Center at 800 433 9319 Check http emanuals nordson com finishing for the latest version This document is subject to change without notice ...

Page 2: ...otected by copyright Original copyright date 2002 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 PermaFlo Nordson and the Nordson logo are registered trademarks of Nordson Corporation Derlin is a registered t...

Page 3: ...uct specified conforms to the directive and standards described above Flammable Atmosphere Marking Ex II 2 G c T6 Tech File Notified Body 0518 Sira UK DNV ISO9001 ATEX Quality Notification Baseefa 2001 Ltd UK Date 28 November 2011 Mike Hansinger Manager Engineering Development Industrial Coating Systems Nordson Corporation NORDSON AUTHORIZED REPRESENTATIVE IN THE EU Contact Operations Manager Indu...

Page 4: ......

Page 5: ...1 3 Air Motor Kits A 1 4 Hydraulic Section Kits A 1 4 Recommended Spare Parts A 1 4 Adhesives Sealants and Lubricants A 1 5 Solvent Chamber Fluid A 1 5 Solvent Chamber Fluid Guide A 1 5 Options A 1 6 Safety B 1 1 Introduction B 1 1 Qualified Personnel B 1 1 Intended Use B 1 1 Regulations and Approvals B 1 1 Personal Safety B 1 2 High Pressure Fluids B 1 2 Fire Safety B 1 3 Halogenated Hydrocarbon ...

Page 6: ...d C 1 1 Guidelines for O ring and Seal Replacement C 1 2 Coupling Removal and Replacement C 1 2 Coupling Removal C 1 2 Coupling Replacement C 1 3 Air Motor Rebuild C 1 3 Air Motor Removal C 1 3 Air Pilot Valve Cartridge Replacement Pump Revisions A C C 1 4 Air Pilot Valve Repair Pump Revisions D and Above C 1 5 Muffler and Air Valve Removal C 1 6 Air Motor Disassembly C 1 7 Air Motor Re Assembly C...

Page 7: ...Pump Revisions D and Above D 1 4 Old Style Air Valve Parts Pump Revisions A C D 1 6 New Style Air Valve Parts Pump Revisions D and Above D 1 8 Service Kits D 1 10 Coupler Kit D 1 10 Old Style Air Pilot Valve Kit D 1 10 New Style Air Pilot Valve Kit D 1 10 Air Valve T Seal Kit D 1 10 Air Valve Spool and Seals Kit D 1 11 Options D 1 11 Adhesives Sealants and Lubricants D 1 11 Air Motor Accessory Gro...

Page 8: ...rs Old Style Air Motor Pump Revisions A C New Style Air Motor Pump Revisions D and Above Old Style Air Valve Pump Revisions A C New Style Air Valve Pump Revisions D and Above Old Style Hydraulic Section Pump Revisions A D New Style Hydraulic Section Pump Revisions E and Above ...

Page 9: ...ood engineering practice The product specified conforms to the directive and standards described above Flammable Atmosphere Marking Ex II 2 G c T6 Tech File Notified Body 0518 Note The year the unit is manufactured is shown in the serial number AA04A indicates the unit was built in 2004 A means month of January Certificates DNV ISO9001 2000 ATEX Quality Notification Baseefa 2001 Ltd Date 15 Octobe...

Page 10: ... Section Repair Part D Air Motor and Hydraulic Section Parts Pump Revisions The ID plate on the front of the hydraulic section contains the Nordson part number and revision letter for each pump Note the revision letter of your pump before using this manual as it may contain reference to the revision letter or a range of revisions if procedures or replacement parts were affected by a revision Speci...

Page 11: ...king Pressure 206 bar 3000 psi This pressure is stamped on the identification plate riveted to the pump Do not operate your pump at higher pressures Delivery Rates Cycles min Delivery rates l min gpm 15 3 7 0 98 30 7 4 1 96 60 14 8 3 92 Liters gallons cycle 0 24 065 1 Cycle 2 strokes 1 up and 1 down High Pressure Hose WARNING Use Nordson or equivalent nylon or PFTE fluid hoses with electrical cont...

Page 12: ...s and Applications for more information Part Description Note 1027528 KIT packing type U PermaFlo 830 A 1060458 KIT packing type F PermaFlo 830 A 1042203 KIT packing type L PermaFlo 830 B NOTE A Shipped with pumps Refer to Pump Ordering in this section and the identification plate on your pump to order the packing shipped with your pump B Optional packing type Packing Materials and Applications Ty...

Page 13: ... E and above Recommended Spare Parts Keep the following parts in inventory to avoid unplanned downtime Quantities listed support a single pump Adjust order quantities based on the number of pumps in service Part Description Quantity Note PACKING kit 1 A 1042327 PLUNGER hydraulic PermaFlo 830 1 1027525 KIT ball pressure check PermaFlo 830 1 1027526 KIT ball siphon check PermaFlo 830 1 1027527 KIT h...

Page 14: ...type S pump chamber one quart 900255 FLUID type K pump chamber one quart 140029 FLUID type T pump chamber one quart 244854 FLUID type Q concentrate 2 6 fluid ounce makes one gallon Solvent Chamber Fluid Guide Use this chart to select the proper solvent chamber fluid to use with your coating materials For more information contact your Nordson representative Solvent Type Material Application S Mixed...

Page 15: ...1042203 KIT packing type L PermaFlo 830 D 1027528 KIT packing type U PermaFlo 830 D 1060458 KIT packing type F PermaFlo 830 D NOTE A An air lubricator is not required All elastomers in the air motor are self lubricating B Refer to Section D1 Air Motor Parts for parts list C Refer to Section D2 Hydraulic Section Parts for parts list D Refer to Pump Ordering in this section and the identification pl...

Page 16: ... are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property Some examples of unintended use of equipment include S using incompatible materials S making unauthor...

Page 17: ...estart the equipment until the problem has been identified and corrected S Obtain and read Material Safety Data Sheets MSDS for all materials used Follow the manufacturer s instructions for safe handling and use of materials and use recommended personal protection devices S Make sure the spray area is adequately ventilated S To prevent injury be aware of less obvious dangers in the workplace that ...

Page 18: ...istance to infection bacterial growth will flourish The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected paint judicious wound debridement and immediate antibiotic treatment Fire Safety To avoid a fire or explosion follow these instructions...

Page 19: ... Under pressure these solvents can react with aluminum and explode causing injury death or property damage Halogenated hydrocarbon solvents contain one or more of the following elements Element Symbol Prefix Fluorine F Fluoro Chlorine Cl Chloro Bromine Br Bromo Iodine I Iodo Check your material MSDS or contact your material supplier for more information If you must use halogenated hydrocarbon solv...

Page 20: ... aid must be immediately obtained S COMPONENT RUPTURE This system is capable of producing high pressure Please refer to the data plate on the hydraulic section To avoid rupture and injury do not operate this pump at a pressure higher than the rated maximum working pressure of any component in the system including but not limited to spray guns hose hose connections and heaters S FIRE Static voltage...

Page 21: ...Safety B 1 6 Part 1022914G03 E 2007 Nordson Corporation 1300376A 1 3 2 Figure B 1 1 Safety Labels ...

Page 22: ... indicates the air motor cylinder diameter and the fluid to air ratio 815 designates an 8 inch 203 mm air cylinder and 15 1 ratio 830 designates an 8 inch 203 mm air cylinder and 30 1 ratio The hydraulic sections of the pumps are made of stainless steel They can be used with corrosive materials and materials containing halogenated hydrocarbon solvents The standard pump packings are made from Ultra...

Page 23: ...Circulating System Operation In a dead end system the pump starts when air pressure is applied It continues to operate until the fluid pressure in the system equals the pressure the pump can produce with the available air pressure The pump then stalls until the fluid pressure drops such as when a spray gun is triggered In a circulating system the pump operates continuously at a rate set by a circu...

Page 24: ...p Shown 1 Air motor 2 Air valve 3 Air valve spool 4 Lower cylinder head 5 Connecting rod 6 Air piston 7 Upper cylinder head 8 Mufflers 9 Actuator assembly air pilot valve 10 Valve assembly air pilot valve 11 Hydraulic section 12 Upper packings 13 Lower packings 14 Siphon ball check valve 15 Pressure ball check valve 16 Plunger 17 Solvent cup 18 Coupling ...

Page 25: ... filter regulator and gauge in the air supply line ahead of the pump The air filter should have a 40 micron or smaller screen Refer to Section D1 Air Motor Parts for the optional Air Motor Accessory kit that includes a filter regulator gauge assembly The air supply does not need to be lubricated The moving parts of the air motor are chemically lubricated and do not require additional lubrication ...

Page 26: ...oiding of Nordson warranties WARNING If any component of the high pressure fluid system has a maximum working pressure less than the pump s install a pressure relief valve in the hydraulic system set to open at that component s maximum working pressure This will protect against equipment rupture and personal injury WARNING The pump must be securely grounded using the strap and clamp provided An un...

Page 27: ...e and an air filter regulator gauge package Fluid Connections Refer to Section A1 Quick Reference for siphon and high pressure hose recommendations and Section D2 Hydraulic Section Parts for optional siphon hose and circulation kits Connect the optional Siphon Accessory kit and or Circulation kit to the siphon port The circulation kit includes installation instructions NOTE All siphon connections ...

Page 28: ...3 mm Fasteners 3 4 in NPTF High Pressure Fluid Outlet Port 1 in NPT Siphon Port 286 mm 11 25 in Overall length will increase if optional circulation valve valve kit is installed 918 mm 36 14 in Figure B 3 1 Mounting and Connections Male Connector Siphon Hose Siphon Rod Strainer Figure B 3 2 Installing Optional Siphon Accessory Kit Dead End System ...

Page 29: ...talling Use an air dryer and filter the air to 40 microns or better S The air drop to the pump should be plumbed from the top of the plant air line Install a drop leg and drain valve at the bottom of the drop S Install a self relieving shutoff valve in the air supply line to the pump S Always install the air filter ahead of the regulator to prevent contamination of the regulator S The air and flui...

Page 30: ... Figure B 3 4 Typical Dead End System Connections and Components 1 Plant air line 2 Drop leg 3 Drain valve 4 Air shut off valve self relieving 5 Filter Regulator Gauge 6 Air hose 7 Coating supply 8 Siphon rod and strainer 9 Siphon hose 10 High pressure fluid hose 11 Fluid filter 12 Spray gun ...

Page 31: ...nt air line 2 Drop leg 3 Drain valve 4 Air shut off valve self relieving 5 Filter Regulator Gauge 6 Air hose 7 Coating supply 8 Siphon rod and strainer 9 Siphon hose 10 High pressure fluid hose 11 Fluid filter 12 Spray gun 13 Fluid heater 14 Circulation valve 15 Drain valve 16 Drain hose and rod 17 Waste container Note To install the optional circulation valve kit refer to the instructions include...

Page 32: ...xic poisoning or death WARNING Do not remove any sheet metal covers from the pump while it is operating Moving parts under the covers could cause an injury This section covers the following procedures S system check S solvent cup fill S pump flushing S routine startup S routine shutdown S maintenance System Check Before starting the pump make sure S all fittings and connections are tightened secur...

Page 33: ...vent chamber fluid for your application Refer to Section A1 Quick Reference for compatibility information and part numbers See Figure B 4 1 Fill the solvent cup to within 12 mm 1 2 in of the top with solvent chamber fluid PermaFlo 815 270 mL 9 oz PermaFlo 830 270 mL 9 oz Solvent Cup Figure B 4 1 Solvent Cup Fill Pump and System Flushing Frequency Flush the pump or system S before you put it into s...

Page 34: ...connections are tight S air filter 2 has been drained S compressed air is available to run the pump S drain rod 10 is in a waste container 11 circulating systems only S pump coating material supply and waste container are grounded Startup 1 Use the following formula to calculate the air pressure required to produce the desired output pressure output pressure pump ratio air pressure required For ex...

Page 35: ...e heater outlet Circulate coating material through the heater until it is at desired temperature before spraying parts NOTE Overheating coating materials can cause cavitation in the pump if the solvents in the coating material boil out in the vacuum created during the siphon cycle If this happens lower the heater thermostat setting Refer to Section B5 Troubleshooting for more information Routine S...

Page 36: ...ystem Circulating System 3 2 3 7 Figure B 4 2 Typical Dead End and Circulating System Components 1 Air shutoff valve 2 Air filter regulator gauge 3 Solvent cup 4 Coating supply 5 Siphon rod and strainer 6 Fluid filter 7 Fluid heater 8 Circulation valve 9 Drain valve 10 Drain rod 11 Waster container ...

Page 37: ... Clean the fluid filter 6 screens Replace them as necessary 4 Check the level of solvent chamber fluid in the solvent cup 3 The solvent chamber fluid should be 12 mm 1 2 in from the top Add more solvent chamber fluid as needed NOTE Coating material leaking past the upper packing gland will discolor the solvent chamber fluid and cause its level to rise A small amount of leakage is normal If the sol...

Page 38: ...ve for help No Problem Page 1 Pump fails to start or stops while operating and fails to restart B 5 2 2 Excessive or constant air leakage from air motor or air valve B 5 2 3 Pump strokes irregularly when spray device is triggered B 5 3 4 Pump operates but flow is restricted or pump surges B 5 3 5 Pump fails to siphon coating material B 5 3 6 Pump continues to operate even after drain and circulati...

Page 39: ...spool hitting its stop each time it changes direction If the spool does not shift and hit the stops replace the actuator and three way valve cartridges Check the air supply for contamination Rebuild the air valve if necessary Pump revisions D and above Air valve spool stuck in middle position or air pilot actuator or valve components damaged or sticking Remove air pilot valve components from upper...

Page 40: ... Blockage in hydraulic system Refer to problem 1 Coating material too viscous Check the material viscosity Add solvent to the material to lower the viscosity Drain valve leaking Check for flow from the valve when it is closed Output from spray devices exceeds pump capacity Reduce the spray device nozzle or fluid tip size Reduce the number of spray devices connected to the pump Reduce the circulati...

Page 41: ...ulation valve in place of the return hose 7 Apply compressed air to the circulation valve If air bubbles from the siphon rod replace the circulation valve needle and seat Leaking ball check valve Rebuild the ball check valves 7 Pump does not stroke when circulation valve is opened Clogged circulation valve or blockage in system Open the circulation valve fully then close it partially If the proble...

Page 42: ... pattern has tails of unatomized coating material at the outer edges Low hydraulic pressure or partial blockage in system Increase the air pressure Flush the system with a compatible cleaning solution Refer to problem 1 Material too viscous Add solvent or heat to the coating material to lower the viscosity Damaged nozzle or fluid tip Replace the nozzle or fluid tip Preventing Air Valve Freezing As...

Page 43: ...Troubleshooting B 5 6 Part 1022914G03 E 2007 Nordson Corporation ...

Page 44: ...motor rebuild S Air valve rebuild NOTE Part numbers in illustrations match the item numbers in Section D1 Air Motor Parts Lettered parts are part of the hydraulic section and are shown in Sections C2 Hydraulic Section Repair and Section D2 Hydraulic Section Parts Tools and Materials Required The following tools and materials are needed to repair the air motor S 5 16 and 15 16 in socket wrenches S ...

Page 45: ...e it to leak Coupling Removal 1 Stop the air motor in the middle of a stroke Shut off the air supply to the pump and disconnect the air supply hose from the air valve 2 See Figure C 1 1 Loosen the two set screws 32 in the coupling sleeve 33 with a 3 16 in hex wrench 3 Slide the coupling sleeve up the connecting rod 21 and remove the two coupling halves 34 from the rod and plunger A Tap upward on t...

Page 46: ...2 with a 3 16 in hex wrench to 10 2 1 NDm 90 10 in lb Air Motor Rebuild Air Motor Removal 1 Stop the pump in the middle of a stroke 2 Shut off the air supply to the pump and relieve the remaining pressure in the air supply hose Relieve the system hydraulic pressure 3 Disconnect the air supply hose and ground clamp 4 Remove the coupling as described on page C 1 2 5 See Figure C 1 2 Remove the hex n...

Page 47: ...cylinder heads with the holes in the flats facing toward the valve cartridge bores 5 Push the valve cartridges into the air cylinder heads NOTE You may need to lightly tap on the cartridges with a soft mallet to engage the O rings When installed correctly the flat ends of the valve cartridges are flush against the actuator cartridges flats and the valve balls 10A poke through the holes in the flat...

Page 48: ...ve components are available as kits See Figure C 1 4 All components of the air pilot valves except the cup seal can be removed and replaced without disassembling the air motor 1300565A 4B 4C 4D 5A 5B 5C Apply MagnaLube G or equivalent PTFE grease to external O rings before installing 4A 4E 5D Actuator Kit 3 Way Valve Kit 4F Figure C 1 4 Air Pilot Valve Actuator and Valve Assembly Pump Revisions D ...

Page 49: ...e the four 1 4 20 x 1 375 in socket head screws A from the air valve with a 3 16 in hex wrench then remove the air valve from the cylinder heads Refer to Air Valve Rebuild in this section 5 Remove the four small O rings 12 and two large O rings 13 from the grooves in the machined faces of each cylinder head 1300389B 19 27 26 A 25 13 12 13 12 26 19 19 28 27 27 19 27 28 Figure C 1 5 Muffler and Air ...

Page 50: ...use it to leak 4 Lift the air piston 22 up off the lower cylinder head 16 carefully pulling the connecting rod 21 through the U cup seal 17 and out of the lower cylinder head 5 Remove the four socket head screws 19 and lock washers 27 from the bottom of the lower cylinder head with a 3 16 in hex wrench Remove the backup plate 18 and U cup seal 6 Remove the O rings 14 from the cylinder heads 7 If y...

Page 51: ...nder head before installing Loosen Left hand threads Turn clockwise to loosen counterclockwise to tighten Figure C 1 6 Air Motor Disassembly 1 Long hex head screws 2 Upper cylinder head 14 Large O rings 15 Air cylinder 16 Lower cylinder head 17 U cup seal 18 Backup plate 19 Short socket head screws 20 Hex nuts 21 Connecting rod 22 Air piston 23 Flat washer 24 Socket head screw 27 Lock washers 35 A...

Page 52: ...clockwise left hand threads onto the connecting rod 21 until the piston contacts the shoulder at the bottom of the connecting rod threads 2 Install the flat washer 23 on the socket head screw 24 and thread the screw into the connecting rod Tighten the screw to 27 4 NDm 20 3 ft lb 1300391B 24 23 Tighten to 27 4 NDm 20 3 ft lb 21 Left hand threads Turn clockwise to loosen counterclockwise to tighten...

Page 53: ...ips of the seal facing up toward the air pressure as shown in the cutaway drawing 3 Install the backup plate 18 and secure it with the four socket head screws 19 and lock washers 27 1300392B 18 16 17 19 18 17 27 Apply MagnaLube G or equivalent PTFE grease to U cup before installing 19 27 16 Figure C 1 8 U Cup Installation 16 Lower cylinder head 17 U cup seal 18 Backup plate 19 Socket head screws 2...

Page 54: ...of the air piston 22 and the inside diameter of the cylinder 15 2 Insert the end of the connecting rod through the lower cylinder head 16 and carefully through the U cup seal 3 Slide the cylinder over the air piston and seat it firmly on the lower cylinder head Tap on the cylinder rim with a rubber mallet if necessary to work the cylinder over the O ring on the lower cylinder head 4 Install the up...

Page 55: ...m 30 4 ft lb 1300394B 1 20 22 2 15 Apply MagnaLube G or equivalent PTFE grease to connecting rod rubber part of piston and ID of cylinder before installing Tighten to 40 5 4 NDm 30 4 ft lb Do not over tighten or you will damage cylinder Machined faces must be parallel to each other 16 21 Figure C 1 10 Piston Cylinder and Cylinder Head Installation 1 Long hex head screws 2 Upper cylinder head 15 Cy...

Page 56: ...grease and install them in the grooves in the side of the air valve 4 Hook the mufflers 28 into the slots in the front of the air valve and swing the mufflers back against the sides of the air valve 5 Secure the mufflers to the air valve with the four short socket head screws 19 and lock washers 27 1300389B 19 27 26 A 25 13 12 13 12 26 19 19 28 27 27 19 27 28 Apply MagnaLube G or equivalent PTFE g...

Page 57: ... Connect the air hose to the air valve 6 Connect the ground clamp to a true earth ground 7 Supply compressed air to the pump and check the air motor operation Check for air leaks Air Valve Rebuild Pumps revision D and above use a new air valve assembly See Figure C 1 13 for the old style air valve and Figure C 1 14 for the new style air valve Refer to Section D1 Air Motor Parts for air valve servi...

Page 58: ... O rings and T seals before installing Figure C 1 13 Air Valve Rebuild Pump Revisions A C 1 Socket head screws 2 End caps 3 Large O rings 4 Brass sleeves 5 Small O rings 6 Shuttle valve 7 Valve body 8 T seals 9 Aluminum sleeves 10 Spool Note Item 6 shuttle air pilot valve must be ordered separately Items 3 5 8 and 10 are available in service kits All other parts are only available as part of a new...

Page 59: ...paste to muffler threads before installing Figure C 1 14 Air Valve Rebuild Pump Revisions D and Above 1 Socket head screws 2 End caps 3 Large O rings 4 Brass sleeves 5 Small O rings 6 Shuttle valve 7 Valve body 8 T seals 9 Aluminum sleeves 10 Spool 11 6 mm air tubing 12 1 8 inch air tubing Note Item 6 shuttle valve must be ordered separately Items 3 5 8 and 10 are available in service kits Air tub...

Page 60: ...in Section D2 Hydraulic Section Parts Lettered parts are part of the air motor and are shown in Sections C1 Air Motor Repair and Section D1 Air Motor Parts Tools Required The following tools are needed to repair the hydraulic section S Small and large adjustable wrenches NOTE Do not use pipe wrenches as they may mar the parts Wrenches with non marring jaws such as engineer s or monkey wrenches are...

Page 61: ...the U cup seal and cause it to leak Coupling Removal 1 Stop the air motor in the middle of a stroke and disconnect the air supply hose from the air valve 2 See Figure C 2 1 Loosen the two set screws B in the coupling sleeve A with a 3 16 in hex wrench 3 Slide the coupling sleeve up the connecting rod C and remove the two coupling halves D from the rod and plunger 8 Tap upward on the sleeve with a ...

Page 62: ...ld The hydraulic section can be removed from the pump and rebuilt without removing the pump from its mounting Preparation 1 Flush the hydraulic section with a compatible solvent 2 Remove the coupling as described in Coupling Removal and Replacement in this section 3 Shut off and lock out the compressed air supply to the pump and relieve the system fluid pressure 4 Disconnect the siphon and high pr...

Page 63: ... the plunger 8 out of the pressure housing If the plunger won t come out leave it in until step 7 5 Unscrew the siphon housing 18 from the pressure housing 6 If you couldn t pull the plunger out of the pressure housing in step 4 you can now use a rubber mallet to drive the plunger down through the pressure housing If no rubber mallet is available place a wood block on the end of the plunger to pro...

Page 64: ...ings 11 and the black Buna N O ring 13 from the pressure housing 1 2 4 3 6 7 3 8 4 2 9 10 11 12 13 11 14 15 16 17 18 5 7 1 Pump Revisions A D Only 2 3 4 Pump Revisions E and Above Figure C 2 3 Hydraulic Section Disassembly 1 Solvent cup 2 Female adapter 3 V rings 4 Male adapter 5 Solvent cup adapter 6 Lip seal 7 Upper housing 8 Plunger 9 Ball small 10 Pressure ball seat 11 O rings white PTFE 12 Pr...

Page 65: ...ower Packing Assemblies 1 Lubricate the new V rings A and B with O ring lubricant Assemble the V rings and male and female adapters as shown S Type U V rings 10 UHMWPE 6 upper and 4 lower S Type F upper V rings 3 PTFE 3 leather alternating S Type F lower V rings 2 PTFE 2 leather alternating S Type L upper V rings 3 UHMWPE 3 leather V rings alternating S Type L lower V rings 2 UHMWPE 2 leather alte...

Page 66: ...ard the bottom S Pump revisions E and above Install the upper packing assembly into the upper housing 7 6 5 Apply Parker O Lube or equivalent before installing 7 Pump Revisions A D Pump Revisions E and Above Packing Assembly Packing Assembly Figure C 2 5 Installing the Upper Packing Assemblies 5 Solvent cup adapter 6 Lip seal 7 Upper housing 3 Install the lower packing assembly onto the pressure b...

Page 67: ...the pressure ball seat 10 into a soft jawed vise Be careful not to damage the packings 2 Clean the mating parts with a residue free cleaner or degreaser then apply Loctite 242 removable thread adhesive to three to four threads all the around the ball seat 3 Place the small ball 9 on top of the pressure ball seat between the cage ears 4 Thread the plunger 8 onto the ball seat 5 Tighten the plunger ...

Page 68: ...C 2 8 Installing Upper Housing on Air Motor 7 Upper housing A Air motor studs B Hex nuts 3 See Figure C 2 9 Lubricate new white PTFE O rings 11 and a new black Buna N O ring 13 with O ring lubricant and install them onto the pressure housing 12 The white PTFE O rings 11 go into the end grooves while the black Buna N O ring 13 goes into the groove between the flats and the threads 4 Apply a thin fi...

Page 69: ... over the connecting rod B 10 Pull the connecting rod down to touch the plunger 11 Finish installing the coupling as described in Coupling Removal and Replacement on page C2 2 12 Tighten the solvent cup 1 1 8 to 1 4 turn to compress the upper packings and form a seal against the plunger 7 11 12 13 11 Apply Parker O Lube or equivalent before installing Apply thin film of Parker O Lube or equivalent...

Page 70: ...te PTFE O ring 17 lubricate first with O ring lubricant b Siphon ball seat 16 c Large ball 15 d Cage 14 2 Thread the siphon housing onto the pressure housing 12 and tighten snugly 14 15 16 17 18 12 Apply Parker O Lube or equivalent before installing Figure C 2 10 Siphon Housing Assembly and Installation 12 Pressure housing 14 Cage 15 Ball large 16 Siphon ball seat 17 O ring white PTFE 18 Siphon ho...

Page 71: ...e Install the circulation kit if used and connect the siphon and high pressure fluid hoses Connect the air supply hose to the air motor Refer to Section B3 Installation for connections and circulation valve installation Flush the pump with a compatible cleaning solution and resume production ...

Page 72: ...le components The cartridges are still available as replacement parts refer to Old Style Air Motor parts list The upper and lower air motor heads used with the cartridges are obsolete and no longer available If you replace either cylinder head you must also order new 3 way valve and actuator kits refer to New Style Air Motor parts list Air Valve Assembly The original air valve assembly had a separ...

Page 73: ... 2 063 x 2 250 in 2 14 1023598 S O RING Buna N 7 734 x 8 012 x 0 139 in 265 2 15 1021425 S CYLINDER air 8 inch 1 16 S HEAD cylinder lower 8 inch 1 17 952101 S CUP U polyurethane 1 3 16 x 1 11 16 x 5 16 in 1 18 1021442 S PLATE back up 1 19 S SCREW socket 1 4 20 x 0 50 in cap 8 20 S NUT hex flanged serrated 5 8 in clear zinc 4 21 1021440 S ROD connecting piston 1 22 1021428 S PISTON air 8 inch carbo...

Page 74: ...cription Part Item NOTE A Noted parts are included in the Pilot Valve Kit part 1030558 B Noted parts are included in the Coupler Kit part 1024892 C New style air valve Figure D 1 4 used on pump revisions D and above D New style mufflers Figure D 1 2 replaces old style curved mufflers ...

Page 75: ...5 14 16 13 12 17 18 19 32 33 34 24 23 22 21 20 35 36 26 28 29 27 7 9 6 10 11 4 5 31 NOTE Two sets of actuator and valve cartridges 6 and 10 are used one set in upper cylinder head 2 and one set in lower cylinder head 16 Old Style Air Motor Pump Revisions A C Figure D 1 1 Old Style Air Motor Parts Pump Revisions A C ...

Page 76: ...lear zinc 4 21 1021440 S ROD connecting piston 1 22 1021428 S PISTON air 8 inch carboxylated nitrile 1 23 1021441 S WASHER 0 38 x 2 00 x 0 06 in stainless steel 1 24 S SCREW low head socket 3 8 16 x 1 00 zinc nylok 1 25 1021635 S VALVE air 4 way 7 port 2 position 1 A 26 942230 S O RING hotpaint 1 625 x 1 875 x 0 125 in 4 B 27 S WASHER lock split 0 25 in stainless steel 8 B 28 1021444 S KIT muffler...

Page 77: ...n Corporation 1300564A 25 1 19 27 19 27 30 3 12 2 13 14 15 14 16 13 12 17 18 19 32 33 34 24 23 22 21 20 35 36 26 28 29 27 New Style Air Motor Pump Revisions D and Above 31 4 26 26 26 4 5 Figure D 1 2 New Style Air Motor Parts Pump Revisions D and Above ...

Page 78: ...RING 4 B C 4 S SLEEVE brass 2 5 S O RING 2 B C 6 901166 S VALVE 2 position 4 way air pilot 1 7 S BODY valve 1 8 S SEAL T 6 B C 9 S SLEEVE aluminum 5 10 S SPOOL 1 C 11 S SCREW socket 1 4 20 x 1 375 in stainless steel 4 NOTE A If you order a new air valve assembly you will receive the new style valve shown in Figure D 1 4 B Noted parts are included in the T Seal Kit part 1029057 C Noted parts are in...

Page 79: ...Air Motor Parts D 1 8 Part 1022914G03 E 2007 Nordson Corporation 1300398A 1 2 3 8 6 7 5 2 1 10 9 8 9 9 8 9 8 9 8 4 3 5 3 4 3 8 11 OLD STYLE AIR VALVE Figure D 1 3 Old Style Air Valve Pump Revisions A C ...

Page 80: ... tube elbow 6 mm x 1 4 in NPT 3 13 342268 S SPACER threaded male female steel hex 6 32 x 1 in 2 14 981577 S SCREW pan head 6 32 x 1 in slotted zinc 2 15 972126 S CONNECTOR male elbow 6 mm tube x 1 8 in unithread 3 16 971291 S CONNECTOR male 1 8 in tube x 1 8 in NPT 2 17 1065193 S ELBOW male 1 8 in tube x 1 8 in unithread 2 18 900586 S TUBING polyethylene 6 mm blue AR 19 900609 S TUBING nylon 0 125...

Page 81: ...2914G03 E 2007 Nordson Corporation 1300563A 1 2 3 8 7 5 2 1 10 9 8 9 9 8 9 8 9 8 4 3 5 3 4 3 8 11 6 12 12 12 13 14 15 15 15 18 19 19 16 18 20 NEW STYLE AIR VALVE 17 17 16 18 Figure D 1 4 New Style Air Valve Pump Revisions D and Above ...

Page 82: ...Quantity Note 1030558 KIT pilot valve PermaFlo 1 6 1021378 S ACTUATOR cartridge assembly 2 10 1021313 S VALVE 3 way cartridge assembly 2 New Style Air Pilot Valve Kits Pump Revisions D and Above See Figure D 1 2 Item Part Description Quantity Note 4 1063996 KIT actuator 1 5 1063997 KIT 3 way valve 1 Air Valve T Seal Kit See Figures D 1 3 and D 1 4 Item Part Description Quantity Note 1029057 KIT T ...

Page 83: ...ts and Lubricants Use these adhesives sealants and lubricants when servicing your air motor Refer to Section C1 Air Motor Repair for application instructions Part Description Quantity 900464 ADHESIVE threadlocking Loctite Removable 242 1 900349 LUBRICANT TFE grease 0 75 oz tube MagnaLube G 1 Air Motor Accessory Group Item Part Description Quantity Note 1029320 ACCESSORY GROUP air motor PermaFlo 1 ...

Page 84: ... Note 1030529 KIT muffler PermaFlo 1 1 4 in NPT 1 1 S MUFFLER PermaFlo 1 1 4 in NPTF fitting 2 2 S SCREW socket head 1 4 20 x 0 50 in stainless steel 4 3 S WASHER lock split 1 4 in stainless steel 4 4 942230 S O RING hotpaint 1 625 x 1 875 x 0 125 in 4 1300433A 4 1 2 2 3 3 1 2 3 2 3 4 Figure D 1 6 Remote Exhaust Muffler Kit ...

Page 85: ...eans 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 S If you order the assembly items 1 and 2 will be included S If you order item 1 item 2 will be included S If you order item 2 you will receive item 2 only The number i...

Page 86: ...900023 S BALL 440 stainless steel 0 750 in 50 1 C 10 S SEAT ball pressure PermaFlo 830 1 C 11 S O RING PTFE 2 234 x 2 512 x 0 139 in 2 B 12 1021892 S HOUSING pressure hydraulic PermaFlo 830 1 13 942310 S O RING 231 Buna N 70 duro 1 B 14 1021896 S CAGE ball siphon PermaFlo 830 1 15 900050 S BALL 440 stainless steel 1 250 in 100 1 D 16 S SEAT ball 1 25 in diameter 1 D 17 S O RING PTFE 2 050 x 2 256 ...

Page 87: ...draulic Section Parts D 2 3 Part 1022914G03 E 2007 Nordson Corporation 1 2 4 3 6 7 3 8 4 2 9 10 11 12 13 11 14 15 16 17 18 5 Pump Revisions A D Only Figure D 2 1 Hydraulic Section Parts Pump Revisions A D ...

Page 88: ...in 50 1 D 10 S SEAT ball pressure PermaFlo 830 1 D 11 S O RING PTFE 2 234 x 2 512 x 0 139 in 2 C 12 1021892 S HOUSING pressure hydraulic PermaFlo 830 1 13 942310 S O RING 231 Buna N 70 duro 1 C 14 1021896 S CAGE ball siphon PermaFlo 830 1 15 900050 S BALL 440 stainless steel 1 250 in 100 1 E 16 S SEAT ball 1 25 in diameter 1 E 17 S O RING PTFE 2 050 x 2 256 x 0 103 in 1 C E 18 1021950 S HOUSING si...

Page 89: ...ts D 2 5 Part 1022914G03 E 2007 Nordson Corporation 1 2 4 3 7 3 8 4 2 9 10 11 12 13 11 14 15 16 17 18 Type U Packings Pump Revisions E and Above Figure D 2 2 Hydraulic Section with Type U Packings Pump Revisions E and above ...

Page 90: ...teel 0 750 in 50 1 D 10 S SEAT ball pressure PermaFlo 830 1 D 11 S O RING PTFE 2 234 x 2 512 x 0 139 in 2 C 12 1021892 S HOUSING pressure hydraulic PermaFlo 830 1 13 942310 S O RING 231 Buna N 70 duro 1 C 14 1021896 S CAGE ball siphon PermaFlo 830 1 15 900050 S BALL 440 stainless steel 1 250 in 100 1 E 16 S SEAT ball 1 25 in diameter 1 E 17 S O RING PTFE 2 050 x 2 256 x 0 103 in 1 C E 18 1021950 S...

Page 91: ... 1022914G03 E 2007 Nordson Corporation 1 2 4 7 8 4 2 9 10 11 12 13 11 14 15 16 17 18 Type F Packings Pump Revisions E and Above 3A 3B 3A 3B 3A 3B 3A 3B 3A 3B Figure D 2 3 Hydraulic Section with Type F Packings Pump Revisions E and above ...

Page 92: ...DAPTER male PermaFlo 830 2 Type F Packing Kit Standard on 1065202 pump with 1074994 hydraulic section Item Part Description Quantity Note 1060458 KIT packing Type F PermaFlo 830 1 2 S ADAPTER female PermaFlo 830 2 A S RING V leather 1 422 x 2 028 x 0 083 5 C S RING V 1 420 x 2 030 PTFE 5 4 S ADAPTER male PermaFlo 830 2 Type L Packing Kit Optional packings Item Part Description Quantity Note 104220...

Page 93: ...gure D 2 1 Item Part Description Quantity Note 1027527 KIT hydraulic seal PermaFlo 830 1 6 S SEAL lip 2 546 x 2 286 x 0 170 in PTFE 1 11 S O RING PTFE 2 234 x 2 512 x 0 139 in 2 13 S O RING 231 Buna N 70 duro 1 17 S O RING PTFE 2 050 x 2 256 x 0 103 in 1 Hydraulic Seal Kit Pump Revisions E and Above See Figure D 2 2 Item Part Description Quantity Note 1063360 KIT hydraulic seal PermaFlo 830 1 11 S...

Page 94: ... 2 Item Part Description Quantity Note 1027526 KIT ball siphon check PermaFlo 830 1 15 900050 S BALL 440 stainless steel 1 250 in 100 1 16 S SEAT ball 1 25 in diameter 1 17 S O RING PTFE 2 050 x 2 256 x 0 103 in 1 Options Adhesives Sealants and Lubricants Use these adhesives sealants and lubricants when repairing the hydraulic section Refer to Section C2 Hydraulic Section Repair for application in...

Page 95: ...s Item Part Description Quantity Note 170120 ACCESSORY GROUP siphon stainless steel 1 1 972724 S CONNECTOR male 37 1 5 16 12 x 1 in stainless steel 1 2 249363 S HOSE siphon 1 in ID 8 ft stainless steel 1 3 249362 S ROD siphon stainless steel 1 in pipe 1 4 249355 S STRAINER siphon stainless steel 1 in pipe 1 5 981279 S S SCREW thumb 1 4 20 x 1 in stainless steel 1 1 2 3 4 5 Figure D 2 5 Siphon Acce...

Page 96: ...e 1 5 16 12 x 1 in stainless steel 1 2 1029259 S TUBE FITTING 37 degree tee female 1 in NPT stainless steel 1 3 336843 S CONNECTOR male 1 2 x 1 in stainless steel 1 4 336842 S ADAPTER female 1 2 x 1 2 in stainless steel 1 5 972177 S ELBOW male 37 1 2 20 x 1 4 in stainless steel 1 6 750222 S VALVE circulation stainless steel 1 7 973971 S NIPPLE hex 3 8 x 1 4 x 1 406 stainless steel 1 8 750130 S VAL...

Page 97: ...d with Air Valve 942230 O RING 1023598 O RING 1021425 CYLINDER SCREW SCREW KIT C LOCKWASHER KIT C 1021444 MUFFLER KIT C SCREW KIT C LOCKWASHER KIT C 1023598 O RING 1021593 LOWER HEAD 1021428 PISTON 1021440 CONNECTING ROD HEX NUT 1021508 STUD 941373 O RING 941080 O RINGS 1024892 COUPLER KIT KIT B HEX NUT 952101 U CUP 1021442 BACKUP PLATE LOCKWASHER SCREW Manual 1022914 Foldout 1 of 6 1021441 WASHER...

Page 98: ...98 O RING 1021593 LOWER HEAD 1021428 PISTON 1021440 CONNECTING ROD HEX NUT 1021508 STUD 941373 O RING 941080 O RINGS 1024892 COUPLER KIT KIT B HEX NUT 952101 U CUP 1021442 BACKUP PLATE LOCKWASHER SCREW Manual 1022914 Foldout 2 of 6 1021441 WASHER SETSCREW Manual 1032967 Foldout 2 of 6 SERVICE KITS KIT B 1024892 COUPLER KIT OPTIONS 1030529 REMOTE EXHAUST KIT KIT A 1021441 MUFFLER KIT 1021444 MUFFLE...

Page 99: ...of 6 SOCKET HEAD SCREWS O RING KITS A B END CAP BRASS SLEEVE O RING KITS A B O RING KITS A B 901166 VALVE 1 4 20 x 1 375 in STAINLESS STEEL SCREW VALVE BODY O RING KITS A B T SEAL KITS A B ALUMINUM SLEEVE T SEAL KITS A B T SEAL KITS A B T SEAL KITS A B T SEAL KITS A B T SEAL KITS A B ALUMINUM SLEEVE ALUMINUM SLEEVE ALUMINUM SLEEVE ALUMINUM SLEEVE SPOOL KIT B O RING KITS A B END CAP SOCKET HEAD SCR...

Page 100: ...S A B SPOOL KIT B O RING KITS A B BRASS SLEEVE O RING KITS A B END CAP SOCKET HEAD SCREWS SERVICE KITS KIT A 1029057 T SEAL KIT KIT B 1029058 SPOOL AND SEAL KIT Manual 1032967 Foldout 4 of 6 O RING KITS A B 1 4 20 x 1 375 in STAINLESS STEEL SCREW T SEAL KITS A B O RING KITS A B O RING KITS A B 1062392 AIR PILOT VALVE 1080618 FITTING 1080618 FITTING 342268 SPACERS 981577 SCREWS 972126 CONNECTOR 105...

Page 101: ...ESSURE SEAT KIT C O RING KIT B 1021892 PRESSURE HOUSING O RING KIT B O RING KIT B CAGE 900050 BALL KIT D SIPHON SEAT KIT D O RING KITS B D 1021950 SIPHON HOUSING SERVICE KITS KIT A PACKING KIT SEE LIST BELOW KIT B 1027527 HYDRAULIC SEAL KIT KIT C 1027525 PRESSURE BALL CHECK KIT KIT D 1027526 SIPHON BALL CHECK KIT PACKING KITS 1042203 TYPE L PACKING KIT UHMWPE LEATHER V RINGS 1060458 TYPE F PACKING...

Page 102: ...IT C O RING KIT B 1021892 PRESSURE HOUSING O RING KIT B O RING KIT B CAGE 900050 BALL KIT D SIPHON SEAT KIT D O RING KITS B D 1021950 SIPHON HOUSING SERVICE KITS KIT A PACKING KIT SEE LIST BELOW KIT B 1063360 HYDRAULIC SEAL KIT KIT C 1027525 PRESSURE BALL CHECK KIT KIT D 1027526 SIPHON BALL CHECK KIT 1022596 MALE ADAPTER KIT A 1022046 FEMALE ADAPTER KIT A PACKING KITS 1042203 TYPE L PACKING KIT UH...

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