instruction sheetemanuals.nordson.com/adhesives/english_manuals/1095427.pdf · 2014-09-26 ·...

Instruction Sheet P/N 1095427A

Universal Slice Applicator Rebuild Kit - P/Ns 1095522 and 1095523 7/09

Use these kits to replace the O-rings and seals on a G3 Universal� sliceapplicator. Use kit P/N 1095522 to rebuild the end plates; use kitP/N 1095523 to rebuild one slice (order this kit for each slice to berebuilt). This instruction sheet also includes drive assembly serviceprocedures. Refer to the applicator manual for component part numbers.

WARNING: Risk of personal injury or equipment damage! Refer tothe safety information provided in the applicator manual beforeservicing the applicator. Failure to comply with the safetyinformation provided can result in personal injury, including death.

Required Tools:Large surface plateService tool kit, P/N 1095524Standard tool kit (hex key set, screwdrivers,socket wrench set, etc.)

Replacement O-rings andseals (refer to the last page foran illustration of all O-ringsand seals)

Applicator-specific referencedrawing

Replacement hardware

Shaft puller tool (P/N 1014224)Pump puller tool (P/N 1035845)Filter removal tool (P/N 1058544)

2. Relieve pressure from the applicatoras follows:

� Place a drain pan under thepressure relief valve and turn therelief valve screw one turncounterclockwise.

� Open the modules.

Continue

3. Disconnect and lock out the motorcontrol to the applicator and disable thesolenoid valve power supply.

1. Heat the applicator to applicationtemperature to soften the adhesive.

Prepare for Rebuild

Disassemble the Applicator

5. Shut off the module-actuating andpattern air supplies.

1. Remove all nozzles.

2. Remove all modules (7). Keep themodule screws for later use.

3. Remove all easily accessible components,plugs, and fittings, including:

� pressure transducers (1)

� heat isolators (2)

� hose fittings (3) or recirculation plate(not shown), as applicable

� drive shaft plug (4)

� air control block plugs/fittings (5, 6)

7

1

3

4

6

5

1 10

� pressure relief valve (8)

� rupture disk (9)

� pump transducer plugs (not shown),ensuring that the crush seal isremoved and kept with the plug

� other accessible plugs and fittings (10)

2

4. Lower the adhesive temperaturesetpoints to approximately 66−93 �C(150−200 �F), depending on theadhesive type.

9

CAUTION: Risk of equipment damage.Do not disconnect or remove heaters ortemperature sensors at this time. As long asthe heaters are turned on, all sensors must beinstalled.

102

3

8

Temperature sensor andheater (do not remove at

10

this point)10

Continue

Disassemble the Applicator (cont’d)

9. Screw the shaft puller (contained inthe service tool kit) into the end of the pumpshaft. When the puller is tight, pull it straightout without turning it to remove the shaft.This will keep the hex receivers of all thepumps aligned

5. Remove the drive shaft cover plate as follows:

� Use a metric hex wrench to remove thecover plate mounting screws (1).

� Thread the mounting screws into the jackscrew holes (2) to remove the cover plate

Note: :If there is any cold adhesive inthe applicator, you may need to use a heatgun.

Note: Once the heaters are removed,proceed as quickly as possible to complete thedisassembly while the adhesive is still soft.

6. Remove the drive seal retaining plate asfollows:

� Use a metric hex wrench to remove theretaining plate mounting screws (1).

� Thread the mounting screws into the jackscrew holes (2) to remove the retainingplate

2

1

7. Using a pick tool, pull the drive retaining plateseal (1) out by the brass retaining ring (takingprecaution not to damage the seal bore with thepick tool) and install a new seal. Use the brassretaining ring to carefully press the new seal intothe bore.

4. Refer to Drive Assembly Replacementlater in this instruction sheet to remove thedrive assembly. Return here to continue.

Note: Take note of the installationconfiguration (and rotation position) of the driveassembly. Refer to the applicator-specificreference drawing or to the applicator manualas needed.

10. Turn off power to the heaters, thendisconnect and remove all heaters (1) andsensors (2) and associated hardware.

8. Use the filter removal tool (1) to remove thefilter (2). At this point, all accessible componentsshould be removed from the end plates and slices.

P/N 1014224

1

2

1

2

Note: Extra precaution must be taken toavoid seal damage and to ensure optimum seallife and performance. If you are concerned about,or incapable of, replacing the seal withoutdamaging it, please contact your Nordsonrepresentative about the ESP (rebuild) program.

1 (P/N 1014224)2

1P/N 1065512 (1)SEAL, ROTARY

Continue

Clean the Applicator Components

1. Place all slices in a cleaning solution bathheated to 38−66 �C (100−150 �F). Periodicallyreorient the parts during the soaking process sothat the cleaning fluid enters all cavities.

WARNING: Risk of explosion or fire. Anycleaning solution used must be approved foryour facility and adhesive type. The solutionmust also have a flashpoint rated above the tem-perature to which it will be heated.

Lap the Mating Surfaces

2. For either lapping method, place a sliceplate face down on the lapping surface and applylight, even pressure while moving the slice in afigure-eight pattern. Only a few figure-eightpatterns are required to properly remove anyburrs or high spots (raised material). Processonly the large left and right surfaces of eachplate.

3. After lapping, clean the slice by re-rinsing itwith solvent and then blowing off any residue ordebris with compressed air.

Note: Before the applicator isreassembled, the mating surfaces of each slicemust be flat and burr-free to ensure a goodsealing surface. A process called ”lapping” isutilized to accomplish this.

1. Depending on the availability of material,set up one of the following methods to performthe lapping process:

� Prepare a granite surface plate with600-grit sandpaper secured to the topsurface of the plate.

� Prepare an actual lapping plate with600-grit lapping compound.

4. Repeat steps 2−3 for each slice.

CAUTION: Too much pressure and/ortoo many strokes could result in excessivematerial removal.

11. Remove all pump clamps (4) and securing screws.

Disassemble the Applicator (cont’d)

13. Remove the screws that secure theright-side end plate (7, as viewed with the modulesfacing you) to the first middle slice (2).

Note: :Each slice is secured to its adjacent slicewith three screws.

12. Remove all air control blocks (1) and securing screws.

14. Begin removing slices and disassemblingthem [pump (6), diverter plate (3), air manifold (5),etc.). As each slice is removed, remove allO-rings and seals from the slice components. Ifneeded, use the pump puller tool to facilitatepump removal.

Note: Take note of theinstallation configuration of theslices (such as pump sizes anddiverter plate positions). Refer tothe applicator-specific referencedrawing for the correctconfiguration.

2. Remove the parts from the bath, carefullyscrape off any remaining char using a scouringpad, and wash them in a cleaning solution.

Note: The recommended soaking time is 24 hours.

3. Inspect parts for damage and obtainreplacement parts as needed.

7

12

4

56

3

CAUTION: If you use a metal object (suchas a pick tool) to remove old O-rings, take carenot to scratch the sides of the slice plates.

P/N 1035845

Assemble the Applicator Slices/Plates

Note: Reassembly of the applicatorinvolves reversing the actions performedto disassemble it along with thereplacement of components as needed.

3. Line up the end plates and middle slices asapplicable for your applicator:

� If the applicator has an even number ofslices, place a middle slice stampedM1 (or #1) after the left-side end plate(as viewed from the module side).

� If the applicator has an odd number ofslices, place a middle slice stampedM2 (or #2) after the left-side end plate(as viewed from the module side).

1. Obtain a copy of theapplicator-specific reference drawing andrefer to it throughout the reassemblyprocess to ensure correct assembly of theapplicator.

Note: Refer to the applicator-specificreference drawing for the correctconfiguration.

2. Ensure that you are working on a flat,clean surface. A surface plate is highlyrecommended.

4. Assemble the left-side end plate, middleslices, and right-side end plate, performing thefollowing actions for each during reassembly:

� install the new O-rings and seals fromthe rebuild kit (all slice/plate O-ringsare shown in this illustration)

� apply a light coat of high-temperatureanti-seize lubricant to allstraight-thread screws

� alternate when tightening the threeplate/slice securing screws andtighten them to the torquespecification shown

� do not use O-ring lubricant or PTFEtape

P/N 940223 (1)0.989 ID x 0.070 W

P/N 940161 (1)0.614 ID x 0.070 W

P/N 1064761 (1)SEAL, HAM

P/N 1003271 (1)SEAL, PUMP

P/N 1066296 (1)SEAL, DIVERTER PLATE

P/N 940133 (1)0.426 ID x 0.070 W

P/N 940181 (1)0.739 ID x 0.070 W

P/N 940133 (1)0.426 ID x 0.070 W

P/N 940161 (1)0.614 ID x 0.070 W

Continue

5. Install the drive alignment bushing (1) andthen install the drive seal retaining plate (2),alternating as you tighten the screws.

12

Note: For an illustration thatshows the location of all theapplicator O-rings and seals, refer toLocation of All O-Rings and Sealslater in this instruction sheet.

Note: Refer to theapplicator-specific referencedrawing throughout thereassembly process to ensurecorrect assembly of the applicator.

12.4 N�m(110 in-lb)

Note: The retaining plate seal wasreplaced in step 7 under Disassemble theApplicator earlier in this instruction sheet.

Install Diverter Plates, Pumps, Air Manifolds, and Recirculation Plates

2. Work from left to right to install the pumps (1)or pump substitution blocks (2) as applicable,inserting the new O-rings from the rebuild kit.Ensure the pumps are completely seated.

CAUTION: Excessive force used duringpump insertion will damage the pump side seals.

3. When installing the last pump, ensure that thepump side seal is fully inserted and flush with thepump surface. This will ease the installation andhelp prevent damage to the seal that could causeleakage. Installation may require lightly tapping thepump with a rubber mallet or dead blow hammer.

1. If applicable, work from left to right to installthe adhesive diverter plates, inserting the newO-rings from the rebuild kit. When installing the lastadhesive diverter plate, use a 0.005-in. feeler gaugeover the side O-ring to wedge it into position.


P/N 940081 (2)0.188 x 0.313 x 0.063

P/N 940081 (3)0.188 x 0.313 x 0.063 in.

P/N 940342 (1)2.114 ID x 0.070 W P/N 940303 (1)

1.625 x 1.750 x 0.063

P/N 1065965 (2)SEAL, HAM SCREW

P/N 1064761 (1)SEAL, HAM SIDE

P/N 1064759 (1)GASKET, HAM SEAL

Note: Each pump’s side seal must beinstalled such that the beveled edge is facingoutward toward the mating surface of the nextpump, as shown below.

10−12 N�m(89−106 in.-lb)

P/N 940081 (2)0.188 x 0.313 x 0.063


2.3 N�m(20 in.-lb)

1

2

5. If applicable, work from left to right to installthe heated air manifolds, inserting the new gasketand seals from the rebuild kit.

6. If applicable, install the internal recirculationplate, inserting the new gasket from the rebuild kit.

4. Once all the pumps are installed and fullyseated, install the pump clamps but do not tightenthe pump clamp screws.


Continue

Note: For an illustration thatshows the location of all theapplicator O-rings and seals, refer toLocation of All O-Rings and Sealslater in this instruction sheet.

24−25 N�m(213−221 in.-lb)

3. Install the filter assembly (16), lubricatingthe O-ring with O-ring lubricant. NordsonCorporation recommends installing a new filterassembly each time an applicator is rebuilt. Ata minimum, install a new filter basket.

2. Install the following components:

� pressure transducers (5)

� hose fitting(s) (6)

� air control block plugs/fittings (8, 9)

� drain valve (10)

� rupture disk (11) with adapter fitting,using a new O-ring from the rebuild kit

� pressure relief valve (12)

� heat isolators (15)

� all remaining plugs, if any

� all heaters (14) and sensors (3) andassociated hardware (heater retainingscrews and bayonet adapters)

11. Restore the system to normaloperation and test for correctoperation. Inspect for leaks,tightening connections as needed.

1. Install the new crush seals from therebuild kit on all pump pressure transducerplugs (1) and rupture port plugs (2) and theninstall them on the applicator.

8. Refer to Drive AssemblyReplacement later in this instruction sheetto install the drive assembly (4). Returnhere to continue.

5. Install the pump shaft (13) by slightlyrotating it in both directions while alsopushing to align the pumps. The shaft iscompletely installed when the shaft end isflush with the end slice. When the shaft isseated, install the plug.

7. Tighten the pump clamp screws (17)to the torque specification shown.

Complete the Reassembly

4. Turn on the heat control to the applicator,ensuring that the adhesive temperaturesetpoints are approximately 66−93 �C(150−200 �F), depending on the adhesivetype.

3

2

14

12

11

4

5

68

615 16

13

97

BACK VIEW

17

8

P/N 940141 (1)0.489 ID x 0.070 W

10

9. Work from left to right to installthe modules (7), inserting the newO-rings from the rebuild kit. Use themodule screws removed previously.

10. Install all nozzles (not shown). Note: For an illustration thatshows the location of all theapplicator O-rings and seals, refer toLocation of All O-Rings and Sealslater in this instruction sheet.


P/N 1028019 (1)SEAL, CRUSH,

P/N 1031500 (1)SEAL, CRUSH,RUPTURE PORT PLUG

TRANSDUCER PLUG

21

8

5

P/N 940111 (5)0.0.301 ID x 0.070 W

Continue

6. Insert the drive shaft cover plateO-ring and then install the cover plate (15),alternating as you tighten the screws.

P/N 9401810.739 xID x 0.070 W

15

Location of All O-Rings and Seals

P/N 940181 (1)0.739 ID x 0.070 W

P/N 940133 (1)0.426 ID x 0.070 W

P/N 940161 (1)0.614 ID x 0.070 W

P/N 940223 (1)0.989 ID x 0.070 W

P/N 940161 (1)0.614 ID x 0.070 W

P/N 1064761 (1)SEAL, HAM


P/N 1066296 (1)SEAL, DIVERTER PLATE

P/N 940133 (1)0.426 ID x 0.070 W

P/N 940342 (1)2.114 ID x 0.070 W in. P/N 940303 (1)

1.625 x 1.750 x 0.063 in.

P/N 940081 (3)0.188 x 0.313 x 0.063 in.


P/N 940081 (2)0.188 x 0.313 x 0.063 in.



TRANSDUCER PLUG


P/N 940081 (2)0.188 x 0.313 x 0.063 in.

P/N 1065965 (2)SEAL, HAM SCREW

P/N 1064761 (1)SEAL, HAM SIDE

P/N 1064759 (1)GASKET, HAM SEAL

P/N 109401810.739 xID x 0.070 WP/N 1065512 (1)

SEAL, ROTARY

P/N 940141 (1)0.489 ID x 0.070 W

P/N 940111 (5)0.0.301 ID x 0.070 W

Pump substituion block

Adhesive diverter platePump

Drive shaftcover plate

OSR recirculationplate

OSL recirculationplate

Air manifold

Rupture disk

Module

Drive sealretaining plate

End plate

Middle plate

Continue

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Continue

Replacing a Pump

Note: Follow this procedure to replace onlya pump on a fully assembled applicator. Youwill need the following new components: pump,O-rings, and seals. The rupture and transducerport plugs may be reused in the replacementpump. Refer to the parts section of theapplicator manual for part numbers.

1. Perform all the steps under Preparefor Rebuild (page 1) and then immediatelybegin pump replacement while theadhesive is soft.

2. Remove the drive shaft plug.

3. Screw the shaft puller into the endof the pump shaft. When the puller is tight,pull it straight out without turning it toremove the shaft. This will keep the hexreceivers of all the pumps aligned.

Note: If there is any cold adhesive inthe applicator, you may need to use aheat gun.

Note: After the pump shaft isremoved, pumps can be replaced asdesired. Pump sizes and part numbers areetched on the top surface of the pump; thepump size is to the right of the hyphen.

P/N 1014224

4. Use a metric open-end or socketwrench to remove the pump clamp for thepump to be replaced.

5. Screw the pump puller into thethreaded port provided on the back (clamp)side. Lightly tap the slide hammer againstthe rear of the pump puller to facilitate theremoval of the pump assembly.

Note: If the applicator and/or pumpsare not very dirty, the pumps can usually beremoved with the same T-handle used toremove the drive shaft (the threaded hole isthe same). Typically, the shaft puller is onlyneeded for pumps that have been in servicefor a long time or for very dirty applicators.

Pump Removal

Pump Installation

1. Ensure that the face seal and all O-rings on the input and outputports are intact and in good condition. Replace as necessary. ApplyO-ring lubricant to all O-rings and seals as needed to ensure that theyremain in place during installation.

2. Install the new pumpassembly, putting pressureinward and to the right to helpcompress the face seal on theadjacent pump assembly. Thiswill help prevent any face sealdamage to either pump duringinstallation.

3. After the pump is past the face seal, tapthe pump lightly with a rubber mallet toproperly seat the pump assembly into position.

4. When the pump is fully seated, reinstallthe pump clamp and screw, but do not fullytighten the screw.

5. Insert the pump shaft without rotating it untilit reaches the newly installed pumps; then slightlyrotate the shaft in both directions while alsopushing to align the pump(s). The shaft iscompletely installed when the shaft end is flushwith the end slice.

Continue

Pump Removal (cont’d)


P/N 940081 (2)0.188 x 0.313 x 0.063 in.



TRANSDUCER PLUG

7. Tighten the pump clamp screw(s) to24−25 N�m (213−221 in.-lb) and restore thesystem to normal operation.

6. When the shaft is fully seated, install thedrive shaft plug. You should be able to seat theplug without interference from the drive shaft.

Note: For a video of pump replacement,contact your Nordson representative.

P/N 1035845

Note: Extra precaution must be taken toavoid seal damage and to ensure optimumseal life and performance. If you areconcerned about, or incapable of, replacingthe seal without damaging it, please contactyour Nordson representative about the ESP(rebuild) program.

Replacing the Drive Assembly or a Drive Assembly Component

Note: Follow this procedure to replaceonly the drive assembly or a drive assemblycomponent (motor, reducer, isolator block,or drive seal) on a fully assembledapplicator. Refer to the parts section of theapplicator manual for component partnumbers.

3. Disconnect the motor cables.

Motor Replacement

1. Complete steps 1−4 under MotorReplacement to remove the motor.

Reducer Replacement

1. Remove the drive coupling accessplug (4) on the reducer.

2. Loosen the drive coupling setscrew (this screws tightens the flexcoupling around the motor output shaft).If necessary, jog the motor until the setscrew is accessible through the accessport.

4. Remove the four screws thatsecure the motor (3) to the reducer (5)and pull the motor straight out from thereducer.

5. Reverse steps 2−4 to install the newmotor. Tighten the motor screws BEFOREtightening the drive coupling set screw.

2. Remove the screws (6) that secure thereducer (5) to the heat isolation block (1) andthen remove the reducer. The heat isolationblock will remain attached to the applicator.

5. Reverse steps 1−2 to install the newreducer.

3. Remove the drive shaft adapter (2)from the old reducer and install it on the newreducer.

Note: Drive assemblies areavailable in six differentconfigurations. Refer to theapplicator-specific referencedrawing or to the drive assemblyparts illustrations in the applicatormanual throughout thereplacement process to ensurecorrect assembly of the drive.

Drive Assembly Replacement

1. Disconnect the motor cables.

2. Remove the four screws (6) thatsecure the reducer to the heat isolationblock.

3. Supporting the weight of the driveassembly, pull the assembly straight outuntil the reducer shaft is completely free ofthe shaft seal. Do not let the driveassembly sag before it clears the driveseal—doing so will damage the seal.

Heat Isolation Block Replacement

1. Complete steps 1−2 under ReducerReplacement.

Drive Retaining Plate Seal Replacement

2. Remove the four screws (7) thatsecure the heat isolation block to theapplicator end plate.

3. Reverse steps 1−2 to install the newheat isolation block.

2. Inspect the condition of the shaftadapter (2) surface finish. If the outerdiameter of the shaft adapter shows signs ofwear or is scratched, replace it to ensureoptimum seal life.

3. Complete steps 6−7 on page 2 toremove the drive seal retaining plate (8) andreplace the seal.

4. Reverse steps 1−3 to install the newdrive assembly. When installing the driveassembly, support its weight as you slidethe drive shaft adapter (2) through the driveseal until the reducer alignment boss entersits supporting gland in the heat isolationblock. The shaft and drive seal are the firsttwo components to make contact, and extraprecaution must be taken to avoid sealdamage, thus ensuring seal life andperformance.

1. Complete steps 1−3 under DriveAssembly Replacement to remove the driveassembly.

5

21

3

4

678

Servo right-angle drive assembly shown

CAUTION: Failure to tighten themotor screws before tightening the drivecoupling set screw can create excess axialload, destroying the reducer bearings.

4. Remove the motor (3) from the oldreducer and install it on the new reducer.

Note: AC drive assemblies do notinclude a reducer.

instruction sheetemanuals.nordson.com/adhesives/english_manuals/1095427.pdf · 2014-09-26 ·...

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