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High-Output Pro-Meter �

Gear Pump

Customer Product ManualPart 303 803A

NORDSON CORPORATION � AMHERST, OHIO � USA

� 1998 Nordson CorporationAll rights reserved

303 803AIssued 8/98

Manual 24-8

Nordson Corporation welcomes requests for information, comments and inquiries about its products.

Address all correspondence to

Nordson Corporation555 Jackson StreetAmherst, OH 44001

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1998. No part ofthis 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

100 Plus, Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat,Excel 2000, Flow Sentry, Isocoil, Isocore, Iso-Flo, Nordson, the Nordson logo, PRX, Pro-Flo, Pro-Meter, RBX,

Ready-Coat, Rhino, Select Coat, Select Cure, Shur-Lok, Smart Spray, System Sentry, Thread Coat, Tribomatic, andVersa-Spray are registered trademarks of Nordson Corporation.

CPX, CanWorks, Excel 2000, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, Package of Values, andSwirl Coat are trademarks of Nordson Corporation.

Never Seez is a registered trademark of Bostik Corporation.

Viton is a registered trademark of E.I. DuPont de Nemours & Co.

Table of Contents i


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Table of Contents

1. Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety Symbols 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Qualified Personnel 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Intended Use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Installation 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Operation 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Less-Obvious Dangers 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Action in the Event of a System or Component Malfunction 1-7. . . . .

9. Maintenance and Repair 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Material and Solvent Precautions 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Disposal 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Components 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer Ring Sensors 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Reducer 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Transducers 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Gauges 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Installation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Specifications 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Gear Pump Replacement 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Gear Pump Seal Replacement 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Manifold and O-Ring Replacement 3-6. . . . . . . . . . . . . . . . . . . . . . . . . .

5. Pressure Transducer Replacement 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .

6. Pressure Gauge Replacement 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Coupling Replacement 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Speed Reducer Replacement 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1Safety

Section 2Description

Section 3Repair

Table of Contentsii


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9. Tachometer Ring and Sensor Replacement 3-15. . . . . . . . . . . . . . . . . .

10. Motor Replacement 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Pro-Meter Gear Metering Pump Parts List 4-2. . . . . . . . . . . . . . . . . . . .

Section 3Repair (contd.)

Section 4Parts


Issued 11/95 24–8s1

Section 1

Safety

Safety1-0


Issued 11/9524–8s1

Safety 1-1


Issued 11/95 24–8s1

Section 1Safety

This section contains general safety instructions for using your Nordsonequipment. Task- and equipment-specific warnings are included in othersections of this manual where appropriate. Note all warnings and followall instructions carefully. Failure to do so may result in personal injury,death, or property damage.

To use this equipment safely,

� read and become familiar with the general safety instructionsprovided in this section of the manual before installing, operating,maintaining, or repairing this equipment.

� read and carefully follow the instructions given throughout this manualfor performing specific tasks and working with specific equipment.

� store this manual within easy reach of personnel installing, operating,maintaining, or repairing this equipment.

� follow all applicable safety procedures required by your company,industry standards, and government or other regulatory agencies.

� obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Contact your material supplier for this information.

Become familiar with the safety symbols presented in this section. Thesesymbols will alert you to safety hazards and conditions that may result inpersonal injury, death, or property and equipment damage.

WARNING: Failure to observe this warning may result inpersonal injury, death, or equipment damage.

1. Introduction

2. Safety Symbols

Safety1-2


Issued 11/9524–8s1

WARNING: Risk of electrical shock. Failure to observe thiswarning may result in personal injury, death, or equipmentdamage.

WARNING: Disconnect equipment from line voltage. Failure toobserve this warning may result in personal injury, death, orequipment damage.

WARNING: Risk of explosion or fire. Fire, open flames, andsmoking prohibited.

WARNING: Wear protective clothing, safety goggles, andapproved respiratory protection. Failure to observe may resultin serious injury.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles with side shields and/or heat-protective glovesdepending on the symbol shown.

WARNING: System or material pressurized. Relieve pressure.Failure to observe this warning may result in serious injury ordeath.

WARNING: Injection hazard. Do not point this device atyourself or other personnel. Failure to observe this warningmay result in serious injury or death.

CAUTION: Failure to observe may result in equipmentdamage.

CAUTION: Hot surface. Failure to observe may result inburns.

2. Safety Symbols (contd.)

Safety 1-3


Issued 11/95 24–8s1

“Qualified personnel” is defined here as individuals who thoroughlyunderstand the equipment and its safe operation, maintenance, andrepair. Qualified personnel are physically capable of performing therequired tasks, familiar with all relevant safety rules and regulations, andhave been trained to safely install, operate, maintain, and repair theequipment. It is the responsibility of the company operating theequipment to see that its personnel meet these requirements.

WARNING: Use of this equipment in ways other thandescribed in this manual may result in personal injury, death, orproperty and equipment damage. Use this equipment only asdescribed in this manual.

Nordson Corporation cannot be responsible for injuries or damagesresulting from nonstandard, unintended applications of its equipment.This equipment is designed and intended only for the purpose describedin this manual. Uses not described in this manual are consideredunintended uses and may result in serious personal injury, death, orproperty damage. Unintended uses may result from taking the followingactions:

� making changes to equipment that have not been recommended ordescribed in this manual or using parts that are not genuine Nordsonreplacement parts

� failing to make sure that auxiliary equipment complies with approvalagency requirements, local codes, and all applicable safety standards

� using materials or auxiliary equipment that are inappropriate orincompatible with your Nordson equipment

� allowing unqualified personnel to perform any task

Read the installation section of all system component manuals beforeinstalling your equipment. A thorough understanding of systemcomponents and their requirements will help you to install the systemsafely and efficiently.

� Allow only qualified personnel to install Nordson and auxiliaryequipment.

� Use only approved equipment. Using unapproved equipment in anapproved system may void agency approvals.

3. Qualified Personnel

4. Intended Use

5. Installation

Safety1-4


Issued 11/9524–8s1

� Make sure all equipment is rated and approved for the environment inwhich you are using it.

� Follow all instructions for installing components and accessories.

� Install all electrical, pneumatic, gas, and hydraulic connections tolocal code.

� Install locking, manual shutoff valves in the air supply lines to thesystem. This allows you to relieve air pressure and lock out thepneumatic system before undertaking maintenance and repairs.

� Install a locking disconnect switch or breaker in the service line aheadof any electrical equipment.

� Use only electrical wire of sufficient gauge and insulation to handlethe rated current demand. All wiring must meet all applicable codes.

� Ground (and fuse, if necessary) all electrically conductive equipmentwithin 10 feet (3 meters) of the spray area or according to its ratedcurrent consumption. (See the ID plate on your equipment.)Ungrounded conductive equipment can store a static charge whichcould ignite a fire or cause an explosion if a hot spark is discharged.

� Route electrical wiring, cables, hoses, and air supply tubing along aprotected path. Make sure they will not be damaged. Do not bendcables or hoses around a radius of less than 6 in. (152 mm).

� Use only designated lifting points or lugs to lift and move heavyequipment. Always balance and block loads when lifting to preventshifting. Lifting devices must be inspected, certified, and rated for agreater weight than the equipment being lifted.

� Do not use unapproved fluid hoses. Solvents may cause them todeteriorate rapidly and allow flammable liquids or pressurizedmaterial to escape.

� Protect components from damage, wear, and harsh environmentalconditions.

� Allow ample room for maintenance, material supply container drop-offand loading, panel accessibility, and cover removal.

� Protect equipment with safety devices as specified by applicablesafety regulations.

� If safety devices must be removed for installation, install themimmediately after the work is completed and check them for properfunctioning.

5. Installation (contd.)

Safety 1-5


Issued 11/95 24–8s1

Only qualified personnel, physically capable of operating the equipmentand with no impairments to their judgement or reaction times, arepermitted to operate this equipment.

Read all component manuals before operating your Nordson equipment.A thorough understanding of components and their operation will helpyou operate the system safely and efficiently.

� Before starting this equipment, check all safety interlocks,fire-detection systems, and protective devices such as panels andcovers. Make sure all devices are fully functional. Do not operate thesystem if these devices are not working properly. Do not deactivateor bypass automatic safety interlocks, locked-out electricaldisconnects, or pneumatic valves.

� Never operate equipment with a known malfunction or leak.

� Do not attempt to operate electrical equipment if standing water ispresent.

� Know where EMERGENCY STOP buttons, safety shutoffcomponents, and fire extinguisher are located. Make sure they work.If a component malfunctions, shut down and lock out the equipmentimmediately.

� Know the pinch points, temperatures, pressures, and dispensematerial composition for all equipment that you are working with.Recognize potential hazards associated with these and exerciseappropriate caution.

� Use this equipment only in the environments for which it is rated. Donot operate this equipment in humid, flammable, or explosiveenvironments unless it has been rated for safe operation in theseenvironments.

� Before operating, make sure all equipment, objects being sprayed,and fluid containers are connected to a true earth ground.

� Do not remove guards while unit is in operation. Failure to observemay cause personal injury from moving mechanical parts under theguards.

6. Operation

Safety1-6


Issued 11/9524–8s1

� Never touch exposed electrical connections or equipment while thepower is ON.

� If you notice electrical arcing in a spray area, shut down the systemimmediately. An arc can cause a fire or explosion.

� Do not operate the equipment at pressures higher than the ratedmaximum working pressure of any component in the system.

� Keep parts of the body or loose clothing away from movingequipment or parts. Remove jewelry and cover or tie back long hair.

� Shut off moving equipment before taking measurements or inspectingworkpieces.

� Wear National Institute of Occupational Safety and Health (NIOSH)approved respirators while operating spray equipment and whenperforming maintenance and cleaning tasks.

� Wear gloves, eye protection, and protective clothing to protect yourskin when operating equipment.

� If your skin has been exposed to dispense materials or solvents washfrequently with soap and water, especially before eating or drinking.Do not use solvents to remove coating materials from your skin.

� Do not use high-pressure compressed air to blow dust or powder offyour skin or clothes. High-pressure compressed air can be injectedunder the skin and cause serious injury or death. Treat allhigh-pressure fittings and hoses as if they could leak and causeinjury.

� Never point handguns or applicator nozzles at yourself or otherpersons.

� Do not smoke in the spray area. A lit cigarette could ignite a fire orcause an explosion.

� Keep paint pumps, pressure pots, and containers of flammablematerials far enough away from spray booths to prevent theirinclusion in a booth fire.

� Make sure the liquid in the heater is circulated to the external circuitwhen the heater is operating.

� Do not use fluids that will corrode the equipment.

6. Operation (contd.)

Safety 1-7


Issued 11/95 24–8s1

Operators should also be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated:

� exposed surfaces on the equipment which may be hot or have sharpedges and cannot be practically safeguarded

� ungrounded conductive equipment which may continue to store anelectrostatic charge after the equipment has been shut off

� vapors and materials which may cause allergic reactions or otherhealth problems

� automatic hydraulic, pneumatic, or mechanical equipment or partsthat may move without warning

� unguarded, moving mechanical assemblies

Do not operate a system that contains malfunctioning components. If acomponent malfunctions, turn the system OFF immediately.

� Disconnect and lock out electrical power. Close and lock out hydraulicand pneumatic shutoff valves and relieve pressures.

� Allow only qualified personnel to make repairs.

Allow only qualified personnel to perform maintenance, troubleshooting,and repair tasks.

� Always wear appropriate protective clothing and use safety deviceswhen working on this equipment.

� Follow the recommended maintenance procedures in your equipmentmanuals.

� Do not service or adjust any equipment unless another person trainedin first aid and CPR is present.

� Use only genuine Nordson replacement parts. Using unapprovedparts or making unapproved modifications to equipment may voidagency approvals and create safety hazards.

7. Less-Obvious Dangers

8. Action in the Event of aSystem or ComponentMalfunction

9. Maintenance and Repair

Safety1-8


Issued 11/9524–8s1

� Refer to MSDS before using solvents to clean this equipment. TheMSDS will provide use, storage, and disposal information about thesolvent. Read this information carefully and follow all instructions.

WARNING: Note the flash point of the cleaning solvent used.Only use controlled methods and equipment, such astemperature-controlled or explosion-protected heaters, to heatcleaning solvent. Observe explosion-prevention regulationsand follow applicable safety instructions.

� Never use an open flame to clean the unit or components of the unit.

� Do not store flammable materials in the spray area or room. Keeppaint pumps, pressure pots, and containers of flammable materialsfar enough away from spray booths to prevent their inclusion in abooth fire. If a fire or explosion occurs, flammable materials in thearea will increase the chances and the extent of personal injuries andproperty damage.

� Make sure that the room where you are working is sufficientlyventilated. Avoid breathing vapors over prolonged periods of time.

� Check interlock systems periodically to ensure their effectiveness.

� Check all ground connections periodically with a megohm meter.Resistance to ground must not exceed one megohm. If sparks orarcing occur, shut down the system immediately.

� Make sure the spray area floor is conductive to ground and that theoperator’s platform is grounded.

� Connect all disconnected equipment ground cables and wires afterservicing the equipment. Ground conductive equipment.

� Disconnect, lock out, and tag electrical power at a disconnect orbreaker in the service line ahead of electrical equipment beforeservicing.

WARNING: Service lines connected to panel disconnectswitches may still be energized unless they are disconnected.Make sure the power is off before servicing. Wait five minutesfor the capacitors to discharge after shutting off the electricalpower.

� If a “power on” test is required, perform the test carefully and thenshut off and lock out power as soon as the test is over.

9. Maintenance and Repair (contd.)

Safety 1-9


Issued 11/95 24–8s1

� Never troubleshoot a power supply without first disconnecting allexternal power supplies and discharging the high-voltage capacitorswith an insulated screwdriver.

� Do not attempt to service electrical equipment if there is standingwater present. Do not service electrical equipment in a high-humidityenvironment.

� Use tools with insulated handles when working with electricalequipment.

� Keep high-voltage connection points clean and protected withdielectric grease or oil.

� Relieve air and fluid pressures before servicing equipment. Follow thespecific instructions in this manual.

� Do not attempt to service a moving piece of equipment. Shut off theequipment and lock out power. Secure the equipment to preventuncontrolled movement.

� If you must disassemble a spring-loaded component, carefullypreload the spring first if it is possible to do so.

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles with side shields and/or heat-protective gloves.

Heated materials may cause severe burns on contact. Remember thatsome materials, even solid materials, may retain heat for some time. Ifyou are burned by a heated material, immediately cool the affected skinwith lots of cool, clean water. Do not try to remove hot, melted materialfrom the skin. Seek immediate medical attention.

High-pressure fluids, unless they are safely contained, are extremelyhazardous. A jet of high-pressure fluid can act like a knife or needle,penetrate skin and muscle, and inject itself into your body. Injected fluidscan cause toxic poisoning.

9. Maintenance and Repair (contd.)

10. Material and SolventPrecautions

Safety1-10


Issued 11/9524–8s1

Do not treat an injection injury as minor. Seek medical care immediately.Inform the medical staff at the hospital that you have an injection injuryand identify the fluid that was injected. If possible, give the doctor copiesof the MSDS for the injected fluid and for any additives, such as solvents,that are in the injected fluid.

Nordson recommends that you carry a National Safety EquipmentManufacturers Association (NSEMA) wallet card to give to emergencymedical staff in the event of an injection injury. These cards are suppliedwith the equipment. Additional cards are available free from NordsonCorporation.

WARNING: Injection hazard. Do not go near a known leak in ahose or fitting, and stay clear of all dispensing device nozzles ororifices. Do not point a dispensing device at yourself or otherpersonnel. The high-pressure fluid stream can penetrate skinand inject fluid into the body causing serious injury or death.

� Always handle fluid dispensing devices carefully. Do not point thenozzle of a pressurized device at yourself or other personnel.

� Never place hands, fingers, or other parts of your body directly over anozzle or near a leak in a high-pressure system.

� Never “back-flush” the nozzles. Blocking a nozzle causes thehigh-pressure fluid to change direction. An injection injury mayresult.

� Always relieve system pressure before servicing equipment. Triggerall dispensing devices and bleed off system pressure.

Halogenated hydrocarbon solvents can cause an explosion when usedwith aluminum components in a pressurized fluid pumping system(pumps, heaters, filters, valves, spray guns, and tanks). The explosioncould cause serious bodily injury, death, or substantial property damage.No available stabilizers will prevent this violent reaction from happening.

WARNING: Never use halogenated hydrocarbon solvents toclean aluminum parts or to flush any system. Cleaning agents,coatings and paints, or adhesives may contain halogenatedhydrocarbon solvents. Obtain and read MSDS for eachmaterial and solvent being used.

� Use nonhalogenated solvents.

10. Material and SolventPrecautions (contd.)

Safety 1-11


Issued 11/95 24–8s1

� Contact your solvent supplier to determine whether your existingmaterials and solvents contain halogenated hydrocarbons or to obtaina suitable, nonhalogenated hydrocarbon solvent for cleaning andflushing your system.

� See Table 1-1. Check the labels on your solvent containers.Halogenated hydrocarbon solvents can be recognized if any of thefollowing elements are listed in the name of the product or or as aningredient:

Element Symbol Prefix

Flourine F “Flouro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

� Pump the system empty, shut off the pumps, and relieve the systempressure.

� Disassemble and inspect the system components. Replace anydamaged or corroded parts.

� Thoroughly clean all noncorroded parts with nonhalogenatedhydrocarbon solvents before reassembling the system.

� Contact your coatings, solvent, or adhesive supplier for anonhalogenated solvent to thoroughly flush the entire system beforeoperating it.

� If you must use halogenated hydrocarbon solvents, consult yourNordson representative about compatible Nordson components.


Safety1-12


Issued 11/9524–8s1

Table 1-1 Solvents Containing Halogenated Fluids

Chlorinated Solvents Iodinated Solvents Brominated Solvents Fluorocarbon Solvents

Carbon Tetrachloride Ethyl Iodide Ethylene Dibromide Dichlorofluoromethane

Chloroform Methyl Iodide Methyl Bromide Trichlorofluoromethane

Ethylene Dichloride N-butyl Iodide Methylene Chlorobromide Freon

Methylene Chloride Propyl Iodide

1-1-1 Trichloroethane

Monochlorobenzene

Orthodichlorobenzene

Perchloroethylene

Trichloroethylene

Dispose of equipment and materials used in operation and cleaningaccording to your local regulations.


11. Disposal


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Section 2

Description

Description2-0


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Description 2-1


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Section 2Description

See Figure 2-1.

The High Output Pro-Meter gear metering pump is designed to deliverand meter pressurized materials.

A bulk unloader pump supplies material to the inlet manifold of the highpressure, positive-displacement gear pump. The gear pump is poweredby a motor and is driven by a speed reducer. The speed reducer usesthe motor input to increase the torque and decrease the speed. Atachometer ring monitors motor speed; material flow can be determinedfrom the motor speed.

The gear pump package is used with a system controller. The systemcontroller may vary depending on the application. Adjustments at thesystem controller enclosure can be used to change the motor speed andaffect the desired pump flow rate. For information on the systemcontroller, refer to the appropriate system controller manual.

1. Introduction

Description2-2


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2408001A

10

9

2

3

4

5

6

87

1

Fig. 2-1 High-Output Pro-Meter Gear Metering Pump

1. Encoder connector2. Encoder connector3. Tachometer ring4. Speed reducer

5. Gear pump6. 11/2 in. outlet manifold7. 11/2 in. inlet manifold

8. Pressure transducer9. Motor connector

10. Gear pump motor

This section describes the components that make up the High-OutputPro-Meter gear metering pump. Options include zero to two pressuregauges and pressure transducers. Refer to the Parts section for partnumbers and illustrations. Contact your local Nordson Corporationrepresentative if you need additional information about these options.

The tachometer ring sensor includes two encoder sensors.

1. Introduction (contd.)

2. Components

Tachometer Ring Sensors

Description 2-3


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Manual 24-8

The gear pump motor is an AC induction type. Refer to Table 2-1 forspecifications.

Table 2-1 Gear Metering Pump Motor Specifications

Motor Maximum rpm Voltage Horsepower Full load amps

AC 1750 480 Vac 3 4.1

Refer to Table 2-2 for torque and output speed for the 39:1 speedreducer.

Table 2-2 Speed Reducer Torque and Speed

Speed reducer ratio Maximum torque output,N•m(lb-in.)

Output speed,rpm

Motor Input Speed, rpm

39:1 475.9 N•m (4212 lb-in.) 44.9 1750

One or two 344.8 bar (5000 psi) pressure transducers may be used withthe gear pump.

The gear pump may be equipped with one or two 413.1 bar (6000 psi)pressure gauges.

A Nordson Corporation representative will install the High-OutputPro-Meter gear metering pump. For information on installation,maintenance, and troubleshooting, refer to the appropriate systemcontroller manual.

Motor

Speed Reducer

Pressure Transducers

Pressure Gauges

3. Installation

Description2-4


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The specifications for the High Output Pro-Meter gear metering pump areshown in Table 2-3.

Table 2-3 Gear Metering Pump Specifications

Dimensions cm in.

Height 33 13

Width 33 13

Length 107 42

kg lbs

Weight 136 300

4. Specifications


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Section 3

Repair

Repair3-0


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Repair 3-1


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Section 3Repair

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

WARNING: System or material pressurized. Relieve pressure.Failure to observe this warning may result in personal injury,death, or equipment damage.


This section provides procedures for replacing the High-Output Pro-Metergear metering pump parts listed below.

� gear pump� gear pump seal� manifolds and O-rings� pressure transducer� pressure gauge� coupling� speed reducer� tachometer ring and sensors� motor

1. Introduction

Repair3-2


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To replace the gear pump, do the following:

1. Shut down all power and air pressure to the bulk unloader pump andgear metering pump.

2. Check to see that all material supply pressure from the unloader hasbeen relieved. Make sure that all residual pressure has been relievedbetween the gear pump and gun by manually actuating the gun overa waste container.

3. See Figure 3-1. Remove the safety cover (1), which protects thecoupling (11).

4. Loosen the set screws (6) on the coupling hub.

5. Slide the coupling hub back towards the pump and remove thecoupling center plate.

6. Remove the coupling hub and drive keys from the gear pumpshaft (10).

7. Support the material supply line and the material outlet line so themanifolds (8) may be safely removed from each side of the pump.Remove the screws (7) from the manifolds. Remove and discard theO-rings (9).

8. Remove the screws (15), lockwashers (13), and nuts (12) securingthe pump mounting block (14) to the pump mounting base. Carefullyremove both the pump and pump mounting block as a singleassembly.

9. Remove the two screws connecting the pump mounting block to thepump.

10. Install the pump mounting block to the new pump.

11. Install the screws, washers, and nuts that secure the pump mountingblock with the new pump to the pump mounting base.

2. Gear Pump Replacement

Repair 3-3


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2408002A

1

4

5

17

15

8

7

9

10

14

8 9

12

7 11

18

16

2

3

6

13

Fig. 3-1 Gear pump

1. Safety cover2. Nut3. Washers4. Motor5. Speed reducer6. Set screw

7. Screws8. Manifolds9. O-rings

10. Gear pump shaft11. Coupling12. Nut

13. Lockwashers14. Mounting block15. Screw16. Screw17. Base18. Set screw

Repair3-4


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Manual 24-8

12. Install new O-rings on the manifolds. Install the manifolds on thepump assembly.

13. Install the coupling on the gear pump shaft. Refer to the couplingreplacement procedure in this manual.

14. Tighten the set screw on the coupling hub connected to the gearpump shaft.

15. Install the safety cover.

16. Restore power and air pressure to the system and test the pumpoperation.

The gear pump seal kit includes a seal housing as well as the seals,spacers, and a snap ring. All kits include a seal lubricant.

NOTE: The pump must be sufficiently cleaned using an appropriatesolvent before seal installation.

Replace both sets of seals for the drive end and back end be at the sametime, if possible. This reduces downtime, since seal wear is oftenidentical on both ends of the pump.



WARNING: Use protective clothing and gloves to protectagainst contact with pump material. Contact with material maycause injury from chemical reaction or burns.

2. Gear Pump Replacement(contd.)

3. Gear Pump SealReplacement

Repair 3-5


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Manual 24-8

Perform the following to replace seals in each seal housing:

1. Shut down all power and air pressure to the bulk unloader and gearmetering pump.

2. Shut down the pump and bleed off pressure from both supply anddischarge lines of the gear pump.

3. See Figure 3-1. Remove the coupling safety cover (1).

4. See Figure 3-2. Remove the pump coupling, hub, and keys (5) fromthe drive end of the pump (4). Refer to Coupling Replacement.

NOTE: Seal change does not normally require that the pump beremoved from its base. However, if accessibility is a problem, performthe replacement procedure for the gear metering pump and remove thepump. Refer to Gear Pump Replacement.

2408003A

2

1

3 4

6

1

2

5

Fig. 3-2 Seal housing (exploded view

1. Cap screws2. Set screws

3. Seal housing (back end)4. Pump

5. Keys6. Seal housing (drive end)

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5. Remove four cap screws (1) from the seal housing (3, 6). Find thetwo jacking set screws (2) in the seal housing, and tighten them toremove the seal housing from the pump.

6. Place a small amount of grease (included with each seal kit) on theinside diameter of the housing and the seals.

7. Make sure the set screws of the seal housing are screwed back intothe housing so they do not contact the pump when the housing isinstalled. Install the seal housing on the shaft and tighten cap screwsto 13.50 N•m (10 ft-lb).

8. Install the keys, hub, and coupling assembly. (If the pump wasremoved, refer to the procedure for installing the gear pump.) Referto Coupling Replacement.


10. Power up the pump assembly and ensure proper pump and sealoperation. A small amount of leakage is often present when thepump is fully pressured. Disregard this leakage unless it interfereswith pump operation.



Perform the following to replace the manifolds and O-rings:



3. Remove hoses from the manifold.

4. See Figure 3-3. Remove the screws (1) securing the manifolds (2,4)to the gear pump (3).

3. Gear Pump SealReplacement (contd.)

4. Manifold and O-RingReplacement

Repair 3-7


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Manual 24-8

2408004A

1

3

1

4

2

5

Fig. 3-3 Manifolds and O-rings

1. Screws2. Manifold3. Gear Pump

4. Manifold5. O-rings

5. Remove the manifolds and O-rings (5).

6. Apply Parker O-ring lubricant to the new O-rings and install them onthe manifolds.

7. Install the screws to secure the inlet and outlet manifolds to the gearpump. Tighten the screws to 203 N•m (150 ft-lb).

8. Connect the hoses to the gear pump.

Repair3-8


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Manual 24-8



Perform the following to replace the pressure transducer:



3. Disconnect the transducer cables.

4. See Figure 3-4. Unscrew the pressure transducer (2) from the 1/4-in.port on the manifold.

2408005A1

2

Fig. 3-4 Pressure transducer and gauge

1. Pressure gauge 2. Pressure transducer

5. Pressure TransducerReplacement

Repair 3-9


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Manual 24-8

5. Pack the transducer port and transducer tip with Parker lubricant.

6. Screw the new transducer into the 1/4-in. port on the manifold.

7. Install transducer cables.



Perform the following to replace the pressure gauge:

1. Shut down all power and air pressure to the bulk unloader pump andthe gear metering pump.


3. See Figure 3-4. Disconnect the pressure gauge (1) from the gearpump.

4. Pack gauge port and stem hole with Parker lubricant.

5. Connect a new pressure gauge to the pump.



NOTE: A key(s) on the pump end is required when replacing thecoupling. Order all three keys to guarantee obtaining the correct key.Refer to the Parts section for ordering information.

6. Pressure GaugeReplacement

7. Coupling Replacement

Repair3-10


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Manual 24-8

Perform the following to replace the coupling:



3. See Figure 3-5. Remove the safety cover (1).

2408006A

1

4

3

2

2

56

7

8

Fig. 3-5 Coupling

1. Safety cover2. Set screw (gear pump end)3. Coupling4. Set screw (speed reducer end)

5. Screw6. Speed reducer7. Speed reducer shaft8. Gear pump shaft

7. Coupling Replacement(contd.)

Repair 3-11


303 803AIssued 8/98

Manual 24-8

4. Loosen the set screws (2, 4) on the coupling (3).

5. Slide the coupling hub back toward the pump and remove thecoupling center plate.

6. Remove the coupling hubs from the pump and speed reducer.

CAUTION: When installing the coupling on the pump, do notplace great force on it or strike it with a hammer. Striking thehub with a hammer could damage the hub and the externalseals of the pump.

7. Install the new coupling hubs on the pump shaft and speed reducershaft using the appropriate keys to match the pump and speedreducer shafts (7).

8. Secure the gear pump coupling hub first, making sure that the gapbetween the coupling hub and gear pump seal housing is 0.75-in.,and that the drive keys are fully engaged in the shaft keyways, asshown in Figure 3-6. Torque both set screws (2) to 23 N•m (17 ft-lb).

9. Place the coupling center plate in position over the gear pumpcoupling hub. The cam follower bearings in the gear pump couplinghub will fit into the slot in the coupling center plate.

10. Slide the speed reducer coupling hub into the coupling center plate.Manually rotate the gearbox shaft to align the cam follower bearingsin the speed reducer coupling hub with the slot in the coupling centerplate.

11. When viewed from overhead, the coupling hubs and center plateshould appear concentric and rest flat against each other. Ifadjustment is necessary, loosen the speed reducer screws (5) andmove the speed reducer/motor assembly to align the coupling.

12. Tighten the screws (5) and re-verify alignment.

NOTE: See Figures 3-5 and 3-6. The gear pump shaft (8) and speedreducer shaft should be in line and parallel.

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13. See Figure 3-6. Space the speed reducer coupling hub away fromthe coupling center plate using a 0.020–0.030-in. shim. Torque theset screw to (4) to 23 N•m (17 ft-lb) and remove the shim.


2408007A

0.75 in.0.0300.020in.

Fig. 3-6 Aligning Coupling Hubs

7. Coupling Replacement(contd.)

Repair 3-13


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Perform the following to replace the speed reducer:



3. See Figure 3-7. Remove the safety cover (1).

8. Speed ReducerReplacement

Repair3-14


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Manual 24-8

2408008A

9

2

3

8

1

4

5

67

Fig. 3-7 Speed Reducer

1. Safety cover2. Nut3. Washers

4. Motor5. Tachometer ring6. Screw

7. Speed reducer8. Screw9. Set screw

8. Speed ReducerReplacement (contd.)

Repair 3-15


303 803AIssued 8/98

Manual 24-8

4. Remove the screws (6) securing the speed reducer (7) to themotor (4) and tachometer ring (5). Remove the motor andtachometer ring.

5. Loosen the set screw (9) on the speed reducer coupling hub. Slidethe hub back and remove the coupling center plate.

6. Remove the screws (8), washers (3), and nuts (2) securing the speedreducer to the base. Remove the speed reducer.

7. Remove the coupling hub from the old speed reducer and install it onthe new speed reducer.

8. Install the new speed reducer. Insert screws, nuts, and washers toconnect the new speed reducer to the base. Refer to CouplingReplacement for proper coupling alignment and setting.

NOTE: Do not try to tighten the screws connecting the new speedreducer to the base until the coupling is lined up.

9. Reinstall the motor and tachometer ring.


11. Restore power to the system and test the pump operation.



Perform the following to replace the tachometer ring and sensor(s):

1. Shut down all power and air pressure to the bulk unloader pump andgear metering pump and disconnect the tachometer cables.


3. See Figure 3-8. Remove the screws (4) securing the motor (6),tachometer ring (5), and speed reducer (1).

9. Tachometer Ring andSensor Replacement

Repair3-16


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Manual 24-8

2408009A

1

3

2

4

7

8

5

6

Fig. 3-8 Removing Motor and Tachometer Ring

1. Speed reducer2. Speed reducer input quill slot3. Speed reducer input quill

4. Screw5. Tachometer ring6. Motor

7. Motor shaft8. Motor shaft key

4. Remove the motor and tachometer ring from the speed reducer inputquill (3).

5. See Figure 3-9. Solder the connector wires (3) on to newtachometer ring connectors (2) according to the pin and socketdesignations in Table 3-1.

9. Tachometer Ring andSensor Replacement(contd.)

Repair 3-17


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Manual 24-8

2408010A

2 2

44

3

5

3

1

5

Fig. 3-9 Tachometer Ring and Connector

1. Tachometer ring2. Encoder connector3. Encoder connector wires

4. Encoder sensor5. Black centerline marked on

encoder sensor

NOTE: The encoder sensor has a black line (5) along the sensorcylinder.

Table 3-1 Encoder Sensor Pin Connector Designations

Pin Number Color

A Red

B White

C Black

D – – – – – –

E Shield Drain

Repair3-18


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Manual 24-8

6. Replace with new tachometer ring (1). Insert the sensors (4) andconnectors (2) into the tachometer ring.

NOTE: Refer to the Parts section for ordering information.

7. See Figure 3-10. Check to make sure that the gear face iscentered (3) on the sensor (4).

NOTE: The air gap (5) of each sensor should be from 0.003–0.009 in.from the gear. In addition, the black line (3) on each encoder sensor (4)must be in line with the gear (1) on the motor shaft (2).

2406016A

1

5

243

Fig. 3-10 Adjusting air gap between gear and sensor(s)

1. Gear2. Motor shaft3. Black centerline

4. Sensor5. Air gap (from 0.003–0.009 in.)

9. Tachometer Ring andSensor Replacement(contd.)

Repair 3-19


303 803AIssued 8/98

Manual 24-8

8. See Figure 3-8. Insert the motor shaft key (8) in the motor shaft (7).

9. Connect the motor and tachometer ring to the speed reducer inputquill.

10. Turn the speed reducer input quill slot (2) to the top position so thatthe motor shaft key fits in the speed reducer input quill slot.

11. Install screws to secure the motor and tachometer ring to the speedreducer.

The following describes procedures for replacing the AC motor.



1. Shut down the motor power source.

2. See Figure 3-11. Disconnect the motor power cable from the motorconnector (1) at the motor (2).

10. Motor Replacement

Repair3-20


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Manual 24-8

2408014A

5

4

6

7

3

2

1

Fig. 3-11 AC Motor

1. Motor connector2. Motor3. Tachometer ring

4. Screws5. Speed reducer

6. Motor shaft7. Motor shaft key

10. Motor Replacement(contd.)

Repair 3-21


303 803AIssued 8/98

Manual 24-8

3. Remove the screws (4) securing the motor to the speed reducer (5).

4. Support the motor and remove the motor and tachometer ring (3)from the speed reducer (5).

5. Remove the motor shaft key (7) from the shaft (8).

6. Remove the tachometer ring gear from the old motor and install onthe new motor. Refer to Tachometer Ring and Sensor Replacement.

7. Remove the tachometer ring (3) and install it on the new motor.

8. Place the motor shaft key in the shaft of the new motor, and mountthe motor to the speed reducer, tightening the mounting boltsgradually.

9. Connect the power cable to the motor connector.

10. Power up the system and ensure that the new motor has the properrotation. If required, shut down the system and switch the motorleads for proper direction of rotation.

11. Power up the system and ensure that the new motor has the properrotation. If required, shut down the system and switch the motorleads for proper direction of rotation.

Repair3-22


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Manual 24-8


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Section 4

Parts

Parts4-0


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Manual 24-8

Parts 4-1


303 803AIssued 8/98

Manual 24-8

Section 4Parts

To order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the partnumber applies to all parts in the illustration.

The six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � Part 1

� If you order the assembly, items 1 and 2 will be included.� If you order item 1, item 2 will be included.� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly 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. Specialattention should be given to notes.

1. Introduction

Using the Illustrated PartsList

Parts4-2


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Manual 24-8

See Figures 4-1 and 4-2.

Item Part Description Quantity Note

— - - - - - - Module, High-Output Pro-Meter gear metering pump 1

1 306 432 � Pump, gear, urethane 1 A

2 327 120 � Seal kit, service, urethane pump 2

3 981 556 � Screw, socket head, 1/4-20 x 1.500 in. 8

4 900 493 � Lubricant, High Temp AR A

5 327 104 � Key, 0.3125 x 0.75 in. long (dowel pin) 1 A

6 325 294 � Motor, AC, electric, gear pump 1 A

7 325 292 � Speed reducer, 39:1 inline 1 A

8 308 723 � Coupling 1 A

9 182 325 � Block, mounting 1

10 135 943 � Transducer, 5000 psi 2 A, B

11 325 282 � Manifold, aluminum, SAE thread 2 A

12 941 271 � O-Ring, Viton, 1.424 inside diameter x 0.103 width 2 A

13 981 449 � Screw, socket head, 5/8-11 x 2.000 in. 4 A

14 900 344 � Lubricant, Never Seez AR A

15 131 031 � Gauge, pressure, 6000 psi 2 A, C

16 325 293 � Ring, encoder, dual pickup 1 A, D

17 186 479 � Connector, encoder (pins) 1 (2) A, D, E

18 982 984 � Screw, socket head, 1/2-13 x 2.500 in. 4

NS 900 464 � Adhesive, threadlock AR

19 325 223 � Base, gear 1

NOTE A: Recommended spare part.

B: The gear metering pump may use one, two, or no transducers. When not using a transducer, only thepipe plug is necessary.

C: The gear metering pump may use one, two, or no transducers. When not using a transducer, only thepipe plug is necessary.

D: The gear metering pump may use an encoder sensor, magnetic pickup sensor, both encoder andmagnetic pickup sensors, or dual encoder sensors.

E: The magnetic and encoder pickup ring uses one encoder connector; the dual encoder pickup ring usestwo encoders.

AR: As Required

NS: Not Shown

2. Pro-Meter Gear MeteringPump Parts List

Parts 4-3


303 803AIssued 8/98

Manual 24-8

2408011A

3

2

1

2

3

5 11

11

1314

9

412

412

10

10

1314

1

15

15

Fig. 4-1 High Output Pro-Meter Gear Metering Pump

Parts4-4


303 803AIssued 8/98

Manual 24-8

2408012A

6

16

18

8

719

17

Fig. 4-2 High Output Pro Metering Pump

2. Pro-Meter Gear MeteringPump Parts List (contd.)

high-ouput pro-meter gear pumpemanuals.enordson.com/automotive/zfiles/303803a.pdf · high-output...

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