permaflo 815 pump - nordsonemanuals.nordson.com/finishing/files/cont-liq/1032967g03.pdf · use the...

PermaFlo� 815 Pump

Customer Product ManualPart 1032967G03

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.

Part 1032967G03 � 2007 Nordson Corporation

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2002. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

PermaFlo, Nordson, and the Nordson logo are registered trademarks ofNordson Corporation.

Derlin is a registered trademark of E. I. DuPont de Nemours andCompany.

Loctite is a registered trademark of Loctite Corporation.

MagnaLube is a registered trademark of Carleton-Stuart Corporation.

Viton is a registered trademark of DuPont Dow Elastomers. L.L.C.

Table of Contents i

Part 1032967G03� 2007 Nordson Corporation

Table of ContentsCE Declaration of Conformity

Quick Reference A 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction A 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications A 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dimensions and Weight A 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Sound Levels A 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Requirements A 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fluid Pressures, Delivery Rates, and Hoses A 1-2. . . . . . . . . . . . . .

Maximum Working Pressure A 1-2. . . . . . . . . . . . . . . . . . . . . . . . . .Delivery Rates A 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .High Pressure Hose A 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Siphon Hose A 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Ordering A 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Kits A 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Packing Kits A 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Packing Materials and Applications A 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 Solvent Hazards B 1-4. . . . . . . . . . . . . . .Action in the Event of a Malfunction B 1-4. . . . . . . . . . . . . . . . . . . . . . . . .Disposal B 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Labels B 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description B 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction B 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Components B 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump Operation B 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dead-End and Circulating System Operation B 2-2. . . . . . . . . . . . . .Plunger Lubrication B 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Filtration and Lubrication B 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii


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 1-4Air 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. . . . . . .

Table of Contents iii


Hydraulic Section Repair C 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction C 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tools Required C 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guidelines for O-ring and Seal Replacement C 2-2. . . . . . . . . . . . . . . .Coupling Removal and Replacement C 2-2. . . . . . . . . . . . . . . . . . . . . . .

Coupling Removal C 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coupling Replacement C 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Section Rebuild C 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation C 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal C 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly C 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning and Inspection C 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ball Check Test C 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly C 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper and Lower Packing Assemblies C 2-6. . . . . . . . . . . . . . . . .Solvent Cup Installation C 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Ball Valve Assembly C 2-8. . . . . . . . . . . . . . . . . . . . . . . .Upper Housing, Plunger, and Pressure Housing Assembly C 2-9Siphon Housing Assembly and Installation C 2-11. . . . . . . . . . . . .

Return To Service C 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Motor Parts D 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction D 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Change Notice D 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Old Style Air Motor (Pump Revisions A−C) D 1-2. . . . . . . . . . . . . . . . . . .New Style Air Motor (Pump Revisions D and Above) D 1-4. . . . . . . . . .Old Style Air Valve (Pump Revisions A−C) D 1-6. . . . . . . . . . . . . . . . . .New Style Air Valve (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 Kits 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 Group D 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote Exhaust Muffler Kit D 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Section Parts D 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction D 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List D 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Section Parts − Revisions A−D D 2-2. . . . . . . . . . . . . . . . . . . .Type U Hydraulic Section Parts − Revisions E and Above D 2-4. . . . . .Type F Hydraulic Section Parts − Revisions E and Above D 2-6. . . . . .Packing Kits D 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type U Packing Kit D 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Type F Packing Kit D 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Type L Packing Kit D 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Kits D 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Seal Kits D 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Ball Check Kit D 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Siphon Ball Check Kit D 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Options D 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adhesives, Sealants, and Lubricants D 2-10. . . . . . . . . . . . . . . . . . . . .Siphon Accessory Group D 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circulation Kit D 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsiv


Parts PostersOld 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)

DECLARATION of CONFORMITY

Model : PermaFlo Series Air Operated Liquid Pump

Applicable Directives :94/9/EC (ATEX equipment for use in potentially explosive atmospheres)98/37/EEC (Machinery)

Standards Used for Compliance :IEC60417 EN1127-1 EN13463-5EN12100 EN13463-1

Principles :This product has been manufactured according to good engineering practice.The product specified conforms to the directive and standards described above.

Flammable Atmosphere Marking : Ex II 2 G c T6Tech File : Notified Body #0518Note : The year the unit is manufactured is shown in the serial number “AA04A” indicatesthe unit was built in 2004, “A” means month of January.

Certificates :DNV ISO9001: 2000ATEX Quality Notification – Baseefa (2001) Ltd.

Date: 15 October 2007

Joseph SchroederEngineering ManagerFinishing Product Development

Nordson Corporation � Westlake, Ohio DOC13004B02

Service Kits

1032967-QR02©2006 Nordson Corporation

®PermaFlo 815 Pump

1030558Pilot Valve Kit

Pump Versions A-C Only

1063996Actuator KitPump Versions D and above

10639973-Way Valve Kit

Pump Versions D and above

1029057T-Seal Kit1029058

Spool and T-Seal Kit

1029666Pressure Ball Check Kit

1029667Siphon Ball Check Kit

1029668Hydraulic Seal Kit

(Versions A-D)1063201

Hydraulic Seal Kit(Pump Version E and above)

Packing Kits

Packing Kits:1029669 Type U (UHMWPE V-Rings)1060457 Type F (PTFE/Leather V-Rings)1037841 Type L (UHMWPE/Leather V-Rings)

Solvent Chamber Fluid

Solvent Chamber Fluids:248831 Type S, 1 Quart (for solvent-base)900255 Type K, 1 Quart (solvent-base, except catalyzed alkyd urea)140029 Type T, 1 Quart (waterborne)244854 Type Q Concentrate (waterborne)

1024892 Coupler Kit

For parts and technical support call (800) 433-9319 Refer to PermaFlo 815 Pump Manual 1032967 for complete service and parts information.

Quick Reference A 1-1


Section A 1Quick Reference

Introduction Use this section for quick reference for the following information on thePermaFlo 815 pump:

� specifications

� service kits

� recommended spare parts

� adhesives, sealants and lubricants used for service

� solvent chamber fluids

� options

Refer to the following sections for more information:

Part B: Safety, Description, Installation, Operation, and TroubleshootingPart C: Air Motor and Hydraulic Section RepairPart D: Air Motor and Hydraulic Section Parts

Pump Revisions The ID plate on the front of the hydraulic section contains the Nordson partnumber and revision letter for each pump.

Note the revision letter of your pump before using this manual, as it maycontain reference to the revision letter or a range of revisions, if proceduresor replacement parts were affected by a revision.

Specifications

Dimensions and Weight

Dimension/Weight PermaFlo 815

Length 918 mm (36.14 in.)

Width (Revisions A−C) 351 mm (13.82 in.)

Width (Revisions D and above) 419 mm (16.50 in.)

Depth (front to back) (Revisions A−C) 391 mm (15.41 in.)

Depth (front to back) (Revisions D and above) 366 mm (14.4 in.)

Weight 48 kg (106 lb)

Quick ReferenceA 1-2


Operating Sound Levels

Air Pressurebar (psi)

Sound LeveldB A (maximum)

Sound LeveldB C (maximum)

7 (100) 83 83

Air Requirements � Maximum air pressure: 7 bar (100 psig)

� Air supply hose minimum ID: 19 mm (3/4 in.)

� Volume requirement at 15 cycles/minand 50 psig air input pressure: 2.8 l/sec (18.0 scfm)

Fluid Pressures, Delivery Rates, and Hoses

Maximum Working Pressure 103 bar (1500 psi)

This pressure is stamped on the identification plate riveted to the pump. Donot operate your pump at higher pressures.

Delivery Rates

Cycles*/min. Delivery rates, l/min. (gpm)

15 7.7 (2.04)

30 15.4 (4.08)

60 30.8 (8.16)

Liters (gallons)/cycle* 0.51 (0.136)

* 1 Cycle = 2 strokes (1 up and 1 down)

High Pressure Hose

WARNING: Use Nordson or equivalent nylon or PTFE fluid hoses, withelectrical continuity between fittings. Fluid hose connected to the highpressure port must be capable of withstanding 103 bar (1500 psi).

High Pressure Hose ID: 6 or 10 mm (1/4 or 3/8 in.)High Pressure Port Threads: 3/4-in. NPTF



Siphon Hose Siphon Hose ID: 25 mm (1 in.) minimumSiphon Hose Port Threads: 1-in. NPTF

An optional siphon accessory group is available that includes a siphon hosewith stainless steel swivel fittings, a stainless steel siphon rod, and astrainer. Refer to Optional Kits in this section.

Pump OrderingUse the part number below to order a new PermaFlo 815 pump.

Part Description1024648 PUMP, PermaFlo 815, Type U

1065204 PUMP, PermaFlo 815, Type F

Service Kits

Packing Gland Kits Packing gland kits replace both upper and lower packings. Type L packingsare optional. Order the correct packing type for your pump and application.Refer to Packing Materials and Applications for more information.

Part Description Note1029669 KIT, packing, Type U, PermaFlo 815 A1060457 KIT, packing, Type F, PermaFlo 815 A1037841 KIT, packing, Type L, PermaFlo 815 B

NOTE A: Refer to Pump Ordering in this section and the identification plate on your pump to order the packingshipped with your pump.

B: Optional packing type.

Packing Gland Materials and ApplicationsType Material Applications

F PTFE V-rings stacked withleather V-rings

Most commonly used packing in the finishing industry. Usefor strong solvents and abrasive materials.

L UHMWPE V-rings stackedwith leather V-rings

Good for thin or abrasive materials. Compatible withwaterborne and most solventborne materials.

U Ultra-High Molecular WeightPolyEthylene (UHMWPE)

Good for highly abrasive materials. Compatible withwaterborne and most solventborne materials. Slightswelling may occur when exposed to hydrocarbon solvents.



Air Motor Kits Refer to Part D1, Air Motor Parts for kit parts breakdowns.

Part Description Note1024892 KIT, coupler, PermaFlo1030558 KIT, pilot valve, PermaFlo A1063996 KIT, actuator B1063997 KIT, 3-way valve B1029057 KIT, T-seal (air valve)1029058 KIT, spool and T-seals (air valve)

NOTE A: Pilot valve kit used only on pump revisions A−C that have air motors with cartridge-type air pilot valves.

B: Noted kits used only on pump revisions D and above.

Hydraulic Section Kits Refer to Part D2, Hydraulic Section Parts for kit parts breakdowns.

Part Description Note1029666 KIT, ball, pressure check, PermaFlo 8151029667 KIT, ball, siphon check, PermaFlo 8151029668 KIT, hydraulic, seal, PermaFlo 815 A1063201 KIT, hydraulic, seal, PermaFlo 815 A

NOTE A: Use 1029668 kit for pump revisions A−D, 1063201 kit for revisions E and above.

Recommended Spare PartsKeep the following parts in inventory to avoid unplanned downtime.Quantities listed support a single pump. Adjust order quantities based onthe number of pumps in service.

Part Description Quantity Note− PACKING KIT 1 A

1042396 PLUNGER, hydraulic, PermaFlo 815 11029666 KIT, ball, pressure check, PermaFlo 815 11029667 KIT, ball, siphon check, PermaFlo 815 11029668 KIT, hydraulic, seal, PermaFlo 815 1 D1063201 KIT, hydraulic, seal, PermaFlo 815 1 D1030558 KIT, pilot valve, PermaFlo 1 B1063996 KIT, actuator 1 C1063997 KIT, 3-way valve 1- - - - - - SOLVENT CHAMBER FLUID (refer to Solvent Chamber Fluid in

this section for the correct type for your application)As Required E

NOTE A: Order correct packings for your application. Refer to Packing Materials and Applications in this section formore information.

B: Pilot valve kit used only on pump revisions A−C that have air motors with cartridge-type air pilot valves.

C: Noted kits used only on pump revisions D and above.

D: 1029668 kit used on pump revisions A−D, 1063201 kit used on revisions E and above.

E: Refer to Solvent Chamber Fluid in this section for the correct type for your application.



Adhesives, Sealants, and LubricantsUse these adhesives, sealants, and lubricants when servicing your pump.Refer to Solvent Chamber Fluid for plunger lubrication information.

Part Description Quantity900464 ADHESIVE, threadlocking (Loctite Removable 242) 1

900223 LUBRICANT, O-ring, Parker (Parker O-Lube), 4 oz 1

900349 LUBRICANT, TFE, grease, 0.75 oz tube (MagnaLube-G) 2

Solvent Chamber FluidSolvent chamber fluid lubricates the plunger and reduces upper packingwear. Solvent chamber fluid is not shipped with the PermaFlo pump,since the pump can be used with either water-based or solvent-basedcoating materials. Refer to the Solvent Chamber Fluid Guide for applicationinformation.

Part Description248831 FLUID, 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 GuideUse this chart to select the proper solvent chamber fluid to use with yourcoating materials. For more information contact your Nordsonrepresentative.

Solvent Type Material Application

S Mixed aliphatic dimethylesters

Most commonly used fluid for solvent-based coatings.Compatible with most solvent-based coatings.

K Epoxidized soybean oil Use with solvent-based coatings, except those containingcatalyzed alkyd urea.

T Mixed propylene glycol Most commonly used fluid for water-based coatings.Requires no mixing, thinner and easier to pour thanType Q.

Q Liquid anionic flocculantmixed with distilledwater

Use with water-based coatings. Requires mixing withdistilled water. Thicker and harder to pour than Type T, butprovides better lubrication in tough applications.



OptionsThese kits can be ordered with the pump and installed in the field.

Part Description Note1029320 ACCESSORY group, air motor A, B

170120 ACCESSORY group, siphon, stainless steel C

1030529 KIT, muffler, PermaFlo, 1 1/4 in. NPT B

1029257 KIT, circulation valve, stainless steel, PermaFlo C

NOTE A: An air lubricator is not required. All elastomers in the air motor are self-lubricating.

F: Refer to Section D1, Air Motor Parts, for parts list.

G: Refer to Section D2, Hydraulic Section Parts, for parts list.

Safety B 1-1


Section B 1Safety

Introduction Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, including these instructions, isaccessible to persons operating or servicing equipment.

Qualified PersonnelEquipment owners are responsible for making sure that Nordson equipmentis installed, operated, and serviced by qualified personnel. Qualifiedpersonnel are those employees or contractors who are trained to safelyperform their assigned tasks. They are familiar with all relevant safety rulesand regulations and are physically capable of performing their assignedtasks.

Intended UseUse of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury to personsor damage to property.

Some examples of unintended use of equipment include

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards or interlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximum ratings

Regulations and ApprovalsMake sure all equipment is rated and approved for the environment in whichit is used. Any approvals obtained for Nordson equipment will be voided ifinstructions for installation, operation, and service are not followed.

SafetyB 1-2


Personal SafetyTo prevent injury follow these instructions.

� Do not operate or service equipment unless you are qualified.

� Do not operate equipment unless safety guards, doors, or covers areintact and automatic interlocks are operating properly. Do not bypass ordisarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicing movingequipment, shut off the power supply and wait until the equipmentcomes to a complete stop. Lock out power and secure the equipment toprevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjusting orservicing pressurized systems or components. Disconnect, lock out,and tag switches before servicing electrical equipment.

� While operating manual spray guns, make sure you are grounded.Wear electrically conductive gloves or a grounding strap connected tothe gun handle or other true earth ground. Do not wear or carry metallicobjects such as jewelry or tools.

� If you receive even a slight electrical shock, shut down all electrical orelectrostatic equipment immediately. Do not restart the equipment untilthe problem has been identified and corrected.

� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling and useof materials, and use recommended personal protection devices.

� Make sure the spray area is adequately ventilated.

� To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces, sharpedges, energized electrical circuits, and moving parts that cannot beenclosed or otherwise guarded for practical reasons.

High-Pressure FluidsHigh-pressure fluids, unless they are safely contained, are extremelyhazardous. Always relieve fluid pressure before adjusting or servicing highpressure equipment. A jet of high-pressure fluid can cut like a knife andcause serious bodily injury, amputation, or death. Fluids penetrating theskin can also cause toxic poisoning.

If you suffer a fluid injection injury, seek medical care immediately. Ifpossible, provide a copy of the MSDS for the injected fluid to the health careprovider.

The National Spray Equipment Manufacturers Association has created awallet card that you should carry when you are operating high-pressurespray equipment. These cards are supplied with your equipment. Thefollowing is the text of this card:

Safety B 1-3


WARNING: Any injury caused by high pressure liquid can be serious. Ifyou are injured or even suspect an injury:

� Go to an emergency room immediately.

� Tell the doctor that you suspect an injection injury.

� Show him this card

� Tell him what kind of material you were spraying

MEDICAL ALERT—AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN

Injection in the skin is a serious traumatic injury. It is important to treat theinjury surgically as soon as possible. Do not delay treatment to researchtoxicity. Toxicity is a concern with some exotic coatings injected directly intothe bloodstream.

Consultation with a plastic surgeon or a reconstructive hand surgeon maybe advisable.

The seriousness of the wound depends on where the injury is on the body,whether the substance hit something on its way in and deflected causingmore damage, and many other variables including skin microflora residingin the paint or gun which are blasted into the wound. If the injected paintcontains acrylic latex and titanium dioxide that damage the tissue’sresistance to infection, bacterial growth will flourish. The treatment thatdoctors recommend for an injection injury to the hand includes immediatedecompression of the closed vascular compartments of the hand to releasethe underlying tissue distended by the injected paint, judicious wounddebridement, and immediate antibiotic treatment.

Fire SafetyTo avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment. Use only grounded air and fluidhoses. Check equipment and workpiece grounding devices regularly.Resistance to ground must not exceed one megohm.

� Shut down all equipment immediately if you notice static sparking orarcing. Do not restart the equipment until the cause has been identifiedand corrected.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Do not heat materials to temperatures above those recommended bythe manufacturer. Make sure heat monitoring and limiting devices areworking properly.

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile particles or vapors. Refer to local codes or your material MSDSfor guidance.

� Do not disconnect live electrical circuits when working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

SafetyB 1-4


� Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth, immediatelyshut off the spray system and exhaust fans.

� Shut off electrostatic power and ground the charging system beforeadjusting, cleaning, or repairing electrostatic equipment.

� Clean, maintain, test, and repair equipment according to the instructionsin your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for parts informationand advice.

Halogenated Hydrocarbon Solvent HazardsDo not use halogenated hydrocarbon solvents in a pressurized system thatcontains aluminum components. Under pressure, these solvents can reactwith aluminum and explode, causing injury, death, or property damage.Halogenated hydrocarbon solvents contain one or more of the followingelements:

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 moreinformation. If you must use halogenated hydrocarbon solvents, contactyour Nordson representative for information about compatible Nordsoncomponents.

Action in the Event of a MalfunctionIf a system or any equipment in a system malfunctions, shut off the systemimmediately and perform the following steps:

� Disconnect and lock out system electrical power. Close hydraulic andpneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction and correct it before restarting thesystem.

DisposalDispose of equipment and materials used in operation and servicingaccording to local codes.

Safety B 1-5


Safety LabelsTable B 1-1 contains the text of the safety labels on the pump. The safetylabels are provided to help you operate and maintain your pump safely. SeeFigure B 1-1 for the location of the safety labels.

Table B 1-1 Safety Labels

Item Part Description

1 600179WARNING

� HIGH PRESSURE DEVICE

Read instruction manual before operation and observe allwarnings.

� INJECTION HAZARD

Airless spray painting equipment can cause serious injury if thespray penetrates the skin. Do not point the gun at anyone or anypart of the body. In case of penetration, adequate medical aidmust be immediately obtained.

� COMPONENT RUPTURE

This system is capable of producing high pressure. Please referto the data plate on the hydraulic section. To avoid rupture andinjury, do not operate this pump at a pressure higher than therated maximum working pressure of any component in thesystem (including but not limited to spray guns, hose, hoseconnections and heaters).

� FIRE

Static voltage is developed by airless spraying. The pump,associated system, and object being sprayed must be groundedto prevent static discharge sparks which could start a fire.

� SERVICING

Before servicing, cleaning, or removal of any part, set trigger lockon gun, and always shut off power source; then carefully releasepressure in fluid portions of the system.

2 181147 MAXIMUM INPUT 6.9 BAR (100 PSI)

3 − MAXIMUM OPERATING PRESSURE 103 BAR (1500 PSI)

SafetyB 1-6


1

3

2

Figure B 1-1 Safety Labels

Description B 2-1


Section B 2Description

IntroductionThe Nordson PermaFlo pumps are air-operated, demand-type,double-acting, reciprocating pumps designed to be mounted vertically on awall, stand, or dolly. They can be used in dead-end or circulating systems.

The PermaFlo model number indicates the air motor cylinder diameter andthe fluid-to-air ratio:

815 designates an 8 inch (203 mm) air cylinder and 15:1 ratio830 designates an 8 inch (203 mm) air cylinder and 30:1 ratio

The hydraulic sections of the pumps are made of stainless steel. They canbe used with corrosive materials and materials containing halogenatedhydrocarbon solvents. The standard pump packings are made fromUltra-High Molecular Weight PolyEthylene (UHMWPE), suitable for use withmost coatings.

Figure B 2-1 PermaFlo Pump (Version D Pump Shown)

DescriptionB 2-2


Pump ComponentsSee Figure B 2-2.

The pumps consist of an air motor (1) and hydraulic section (11). The airmotor powers the pump. The air pilot valves, each consisting of an actuator(9) and valve(10), reverse the direction of air motor travel. The air valve (2)controls the flow of compressed air to move the piston (6), connectingrod (5), and hydraulic plunger (16). Upper and lower packings (12 and 13)prevent coating material from leaking past the plunger. A removablecoupling (18) connects the connecting rod to the plunger. The siphon ballcheck (14) and pressure ball check (15) valves control the flow of fluidthrough the hydraulic section.

Pump Operation The PermaFlo pumps are demand-type, double acting pumps. Ademand-type pump starts when the fluid pressure in the system falls belowthe pressure the pump can produce with the available air pressure. Thepump stops when the fluid pressure equals the pressure the pump canproduce with the available air pressure. A double-acting pump pressurizesand pumps coating material on both the suction stroke and the pressurestroke.

Dead-End and Circulating System OperationIn a dead-end system, the pump starts when air pressure is applied. Itcontinues to operate until the fluid pressure in the system equals thepressure the pump can produce with the available air pressure. The pumpthen stalls until the fluid pressure drops, such as when a spray gun istriggered.

In a circulating system, the pump operates continuously at a rate set by acirculation valve. Opening the valve causes the pump to operate faster;closing the valve slows the pump. The normal operating rate is 5 to 10strokes per minute.

Plunger LubricationThe solvent cup (17) contains lubricating fluid (solvent chamber fluid). Thisfluid lubricates the upper part of the plunger to prevent the upper packingsfrom wearing excessively. The coating material being pumped lubricatesthe lower packings.

NOTE: Coating material leaking past the upper packing gland will discolorthe solvent chamber fluid and cause its level to rise. A small amount ofleakage is normal. If the solvent cup fills quickly and overflows, you cantighten the solvent cup to compress the packings and stop the leaking. (Totighten the solvent cup use a 3/8-in. pin punch, which can be purchasedfrom an industrial supply company.) If the leaking continues the packingsneed to be replaced. Both upper and lower packings should be replaced atthe same time.

Description B 2-3


3

4

5

6

78

9

10

12

13

2

15

16

17

18

1

11

14

Figure B 2-2 PermaFlo Pump Cutaway (Version E Pump Shown)

1. Air motor2. Air valve3. Air valve spool4. Lower cylinder head5. Connecting rod6. Air piston

7. Upper cylinder head8. Mufflers9. Actuator assembly − air pilot valve

10. Valve assembly − air pilot valve11. Hydraulic section12. Upper packings

13. Lower packings14. Siphon ball check valve15. Pressure ball check valve16. Plunger17. Solvent cup18. Coupling

DescriptionB 2-4


Air Filtration and LubricationTo prevent contamination of the air motor valves and regulate the airpressure to the pump, install an air filter, regulator, and gauge in the airsupply line ahead of the pump. The air filter should have a 40 micron orsmaller screen. Refer to Section D1 Air Motor Parts for the optional AirMotor Accessory kit that includes a filter/regulator/gauge assembly.

The air supply does not need to be lubricated. The moving parts of the airmotor are chemically lubricated and do not require additional lubrication.

Installation B 3-1


Section B 3Installation

WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

Suitable for installation in Zone 1, Zone 2, or normal usage areas.

Mounting and Connections See Figures B 3-1 through B 3-5. Follow all safety instructions.

WARNING: Install the pump according to all local codes and ordinances.Failure to do so is dangerous and could result in loss of agency approvalsand voiding of Nordson warranties.

WARNING: If any component of the high pressure fluid system has amaximum working pressure less than the pump’s, install a pressure reliefvalve in the hydraulic system set to open at that component’s maximumworking pressure. This will protect against equipment rupture and personalinjury.

WARNING: The pump must be securely grounded, using the strap andclamp provided. An ungrounded or poorly grounded pump can store anelectrostatic charge that can give personnel a severe shock, or arc andcause a fire or explosion.

WARNING: Static electricity is created by the flow of high pressure fluids.Use only grounded fluid hoses with continuity between fittings. Failure touse grounded hoses could result in a fire or explosion.

InstallationB 3-2


Mounting and Connections (contd)

Task Instructions

Mounting Mount the pump vertically on a wall, stand, or wheeled dolly able to support the pumpweight and withstand vibration.

Use 1/2-in. or 13-mm bolts and washers in the mounting slots so the air motor orhydraulic section can be removed without removing the pump from its mounting.

If you use threaded studs in place of bolts in the two lower mounting slots you will notbe able to remove the hydraulic section without dismounting the entire pump.

Grounding Connect the ground clamp to a true earth ground. The resistance to ground should notexceed 20 ohms.

AirConnections

Connect a 19-mm (3/4-in.) ID minimum air supply hose to the air inlet port. Do not userigid tubing, which transmits vibration.

Refer to Section D1 Air Motor Parts for the optional Air Motor Accessory kit, whichincludes a hose and an air filter/regulator/gauge package.

FluidConnections

Refer to Section A1 Quick Reference for siphon and high pressure hoserecommendations, and Section D2 Hydraulic Section Parts for optional siphon hoseand 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 must be air-tight. Air leaks will affect pump priming andcause cavitation.

Connect a high-pressure fluid hose to the high pressure fluid outlet port. Do not userigid tubing, which transmits vibration.

RemoteExhaustOption

Refer to Section D1 Air Motor Parts for the optional remote exhaust muffler kit. Thesemufflers are equipped with 1 1/4 in. NPT fittings, for use in a header system to conductexhaust air away from the pump and reduce noise levels.

Remove the standard mufflers and replace them with the optional mufflers.

Connect flexible hose to the muffler fittings.

Slope the exhaust line downward away from the pump, to prevent moisture fromcollecting in the line and draining back into the air motor.

Installation B 3-3


248 mm(9.75 in.)

> 508 mm (20 in.)clearance

3/4 in. NPTFAir Inlet

GroundClamp

1/2 in. or13 mm

Fasteners

3/4 in. NPTF HighPressure Fluid Outlet Port

1 in. NPTSiphon 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)

InstallationB 3-4


Mounting and Connections (contd)

Return HoseFrom SprayGuns

Connect siphon hose directlyto circulation valve kit tee

Circulation Valve Kit

Siphon Accessory Kit

Figure B 3-3 Installing Optional Siphon Accessory and Circulation Valve Kits(Circulating System)

Note: To install the optional circulation valve kit, refer to the instructions includedwith the kit.

Installation Guidelines Figures B 3-4 and B 3-5 show typical dead-end and circulating systems.When installing your pump, follow these guidelines:

� Supply the pump with clean, dry air. Moisture-laden air can freeze in theair motor, causing poor performance and stalling. Use an air dryer andfilter the air to 40 microns or better.

� The air drop to the pump should be plumbed from the top of the plant airline. Install a drop leg and drain valve at the bottom of the drop.

� Install a self-relieving shutoff valve in the air supply line to the pump.

� Always install the air filter ahead of the regulator, to preventcontamination of the regulator.

� The air and fluid hoses connected to the pump must be electricallyconductive. Do not use rigid plumbing, which will conduct pumpvibration to the rest of the system.

� Make sure the siphon connections are tight and leak-free. A leak willpull air into the pump, causing cavitation and poor performance.

� High-pressure fluid connections must be tight and leak-free. Refer toSection B1 Safety for information on high pressure fluid hazards. Checkall connections for leaks before beginning production.

Installation B 3-5


1

2

3

4

5 6

8

9

10

12

11

10

7

Figure B 3-4 Typical Dead-End System Connections and Components

1. Plant air line2. Drop leg3. Drain valve4. Air shut off valve (self-relieving)

5. Filter/Regulator/Gauge6. Air hose7. Coating supply8. Siphon rod and strainer

9. Siphon hose10. High-pressure fluid hose11. Fluid filter12. Spray gun

InstallationB 3-6


Installation Guidelines (contd)

1

2

3

4

5 6

89

10

13 1110

12

1014

15

177

16

Figure B 3-5 Typical Circulating System Connections and Components

1. Plant air line2. Drop leg3. Drain valve4. Air shut off valve (self-relieving)5. Filter/Regulator/Gauge6. Air hose

7. Coating supply8. Siphon rod and strainer9. Siphon hose

10. High-pressure fluid hose11. Fluid filter12. Spray gun

13. Fluid heater14. Circulation valve15. Drain valve16. Drain hose and rod17. Waste container

Note: To install the optional circulation valve kit, refer to the instructions included with the kit.

Operation B 4-1


Section B 4Operation


WARNING: High-pressure fluids are extremely hazardous. Do not placeany part of your body in front of a spray device, drain, or leak in ahigh-pressure system. A jet of high-pressure fluid can cause a seriousinjury, toxic poisoning, or death.

WARNING: Do not remove any sheet-metal covers from the pump while itis operating. Moving parts under the covers could cause an injury.

This section covers the following procedures:

� system check

� solvent cup fill

� pump flushing

� routine startup

� routine shutdown

� maintenance

System Check Before starting the pump, make sure

� all fittings and connections are tightened securely

� the air shutoff valve and the circulation and drain valves (if used) areclosed and the air regulator is set to zero pressure

� the system components (such as the heater and filter) have beeninstalled according to the instructions in their manuals

OperationB 4-2


Solvent Cup Fill Solvent chamber fluid lubricates the plunger and upper packings. SincePermaFlo pumps can be used with either water-based or solvent-basedcoating materials, they are not shipped with solvent chamber fluid. Orderthe proper solvent chamber fluid for your application. Refer to Section A1Quick 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 topwith solvent chamber fluid:

PermaFlo 815: 270 mL (9 oz)PermaFlo 830: 270 mL (9 oz)

SolventCup

Figure B 4-1 Solvent Cup Fill

Pump and System Flushing

FrequencyFlush the pump or system

� before you put it into service for the first time

� after you rebuild the hydraulic section

� when you change coating material

Operation B 4-3


Cleaning Solution for Flushing

WARNING: Do not use halogenated hydrocarbon solvents in pressurizedsystems that contain aluminum components. Refer to Section B1 Safety formore information.

When you flush the pump or system, use a cleaning solution compatiblewith your pump’s construction, packing gland type, the construction of othercomponents of your system, and the coating material you will be using.

Routine Startup See Figure B 4-2.

PreparationCheck levels of the

� coating material supply (4)

� solvent chamber fluid (3)

Make sure that the

� siphon rod and strainer (5) are submerged in coating material

� fluid and air connections are tight

� air filter (2) has been drained

� compressed air is available to run the pump

� drain rod (10) is in a waste container (11) (circulating systems only)

� 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 example, you want an output pressure of 1200 psi. Calculate therequired air pressure as follows:

PermaFlo 815: 1200 psi � 15 = 80 psi air pressure required.PermaFlo 830: 1200 psi � 30 = 40 psi air pressure required.

NOTE: The fluid pressure at the spray gun(s) will vary, depending on manyfactors, including material viscosity and temperature, the number of filtersand heaters, and fluid hose ID and length. Install a fluid pressure gauge atthe spray gun(s) to determine the actual fluid pressure.

OperationB 4-4


Startup (contd)

2. Start the pump by opening the air shutoff valve (1) and adjusting the airpressure regulator (2) to the air pressure that will produce the desiredoutput pressure.

3. Purge air from the system:

� Dead-end system: Trigger the spray guns and watch for spitting asair is purged. Stop when the spray pattern is continuous and even.

� Circulating system: Close the circulation valve (8) and open thedrain valve (9). Watch the flow from the drain rod (10). When nomore air bubbles are seen, shut the drain valve and slowly open thecirculation valve until the pump is running at the desired number ofcycles per minute. Trigger the spray device(s) to purge air fromthem.

NOTE: The more the circulation valve is opened, the more potentialthere is for fan pattern collapse or “wink” at the spray device when thepump changes direction or shifts. Open the circulation valve justenough to maintain the required fluid temperature and agitation in thecirculation loop.

4. Turn on the fluid heaters (7), if used, and watch the thermometer at theheater outlet. Circulate coating material through the heater until it is atdesired temperature before spraying parts.

NOTE: Overheating coating materials can cause cavitation in the pumpif the solvents in the coating material boil out in the vacuum createdduring the siphon cycle. If this happens, lower the heater thermostatsetting. Refer to Section B5 Troubleshooting for more information.

Routine Shutdown See Figure B 4-2.

1. If fluid heaters (7) are used, turn them off 10 to 15 minutes beforeshutting down the pump. This prevents coating material from curinginside the heaters.

2. Stop the pump by closing the air shutoff valve (1) or adjusting the airpressure regulator (2) to zero.

3. Relieve the system hydraulic pressure by triggering the spray guns oropening the drain valve (9).

NOTE: Normally, you can leave the system filled with coating materialovernight. If the material contains solids that easily settle out, circulatematerial through the system for several minutes before beginningproduction the next day. Do not leave the system open to air, as the coatingmaterial could cure and clog the system. If the system will be shut down formore than a few days, flush it and leave it filled with cleaning solution.

4. Perform daily maintenance as described in Maintenance in this section.

Operation B 4-5


1

2

5

6

4

1

5

6

8

9

114

10

Dead-End System

Circulating System

3

23

7

Figure B 4-2 Typical Dead-End and Circulating System Components

1. Air shutoff valve2. Air filter/regulator/gauge3. Solvent cup4. Coating supply

5. Siphon rod and strainer6. Fluid filter7. Fluid heater8. Circulation valve

9. Drain valve10. Drain rod11. Waster container

OperationB 4-6


Maintenance WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

WARNING: Stop the pump and relieve air and hydraulic pressures beforedisconnecting air or fluid hoses, or before disassembling any equipment.

See Figure B 4-2.

Daily Do the following daily:

1. Make sure that all conductive equipment in the spray area, including thepump and waste container (11), are securely connected to a true earthground.

2. Drain the air filter (2). Check the filter element and replace it ifnecessary. Open the drop leg drain valve and drain collected moisture.

3. Clean the fluid filter (6) screens. Replace them as necessary.

4. Check the level of solvent chamber fluid in the solvent cup (3). Thesolvent chamber fluid should be 12 mm (1/2 in.) from the top. Add moresolvent chamber fluid as needed.

NOTE: Coating material leaking past the upper packing gland will discolorthe solvent chamber fluid and cause its level to rise. A small amount ofleakage is normal.

If the solvent cup fills quickly and overflows, relieve the hydraulicpressure, then tighten the solvent cup approximately 1/8 to 1/4 turnclockwise with a round steel bar or screwdriver. This should compress thepackings and stop the leaking. If the leaking continues the packings needto be replaced. Both upper and lower packings should be replaced at thesame time.

As Needed Flush the pump and system with a compatible cleaning solution. Changethe solvent chamber fluid regularly. Clean the exterior of the pump.

Troubleshooting B 5-1


Section B 5Troubleshooting


This section contains troubleshooting procedures. These procedures coveronly the most common problems that you may encounter. If you cannotsolve the problem with the information given here, contact your localNordson representative for help.

No. Problem Page

1. Pump fails to start or stops while operating and fails torestart

B 5-2

2. Excessive or constant air leakage from air motor or airvalve

B 5-2

3. Pump strokes irregularly when spray device istriggered

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 andcirculation valves are closed and spray devices areshut off

B 5-4

7. Pump does not stroke when circulation valve opened B 5-4

8. Solvent cup overflows often B 5-4

9. Fading or narrowing spray pattern B 5-5

10. Spray pattern has tails of unatomized coating materialat the outer edges

B 5-5

TroubleshootingB 5-2


Common Problems

Problem Possible Cause Corrective Action

1. Pump fails to start orstops while operatingand fails to restart

No compressed air supply, or airpressure too low

Check the air supply at the drop-legdrain valve. Make sure the airregulator is working correctly.

Blockage in fluid system Check for flow from each componentand hose, working from the spraydevice to the pump, as follows:

1. Shut off the air to the pump andrelieve the hydraulic pressure.

2. Break the connection.

3. Turn on the air to the pump. If thepump starts, the blockage is inthe component or hose after thebroken connection.

Pump revisions A−C: Air valvespool stuck in middle position, orair pilot actuator or three-wayvalve cartridge damaged orsticking

Press and release the top button onthe shuttle valve mounted on thefront of the air valve, then press andrelease the bottom button on theshuttle valve. Repeat this process,listening for the sound of the air valvespool hitting its stop each time itchanges direction. If the spool doesnot shift and hit the stops, replace theactuator and three-way valvecartridges.

Check the air supply forcontamination. Rebuild the air valveif necessary.

Pump revisions D and above: Airvalve spool stuck in middleposition, or air pilot actuator orvalve components damaged orsticking

Remove air pilot valve componentsfrom upper or lower cylinder heads.Clean and and inspect components,replace any that are worn ordamaged. Check the air supply forcontamination. Rebuild the air valveif spool is sticking.

2. Excessive or constantair leakage from airmotor or air valve

Worn U-cup seal in underside oflower cylinder head

Stop the pump during an upstrokeand check for air leaking around theconnecting rod. Replace the U-cupseal if it is leaking.

O-rings sealing air valve tocylinder heads leaking

Check for air leaking at the airvalve-to-cylinder head joint. Replacethe O-rings if they are leaking.

O-rings sealing cylinder to cylinderheads leaking.

Check for air leaking around thecylinder heads. Replace the O-ringsif they are leaking.

Air valve seals worn Replace the seals.

Air piston seal worn or damaged Replace the air piston.

Continued...



Corrective ActionPossible CauseProblem

3. Pump strokesirregularly when spraydevice is triggered

Air in hydraulic system Purge the air from the hydraulicsystem. Refer to Pump and SystemFlushing in Operation. Adddefoaming agents to coating material.

Coating material temperature toohigh, causing cavitation

As coating material temperature isincreased, vacuum created by pumpsiphon can cause solvents to boil andcause cavitation. Lower heaterthermostat setting.

Worn or clogged ball check valve Flush the pump and system with acompatible cleaning solution. If theproblem continues, rebuild the ballcheck valves.

Worn packings Replace the packings.

4. Pump operates butflow is restricted, orpump surges

Air motor or air valve leak Refer to problem 2.

Volume of supply air is inadequate Check for a restriction in the air lines,regulator or filter. Make sure the airlines are the correct size.

Blockage in hydraulic system Refer to problem 1.

Coating material too viscous Check the material viscosity. Addsolvent to the material to lower theviscosity.

Drain valve leaking Check for flow from the valve when itis closed.

Output from spray devicesexceeds pump capacity

Reduce the spray device nozzle orfluid tip size. Reduce the number ofspray devices connected to thepump. Reduce the circulation rate.

5. Pump fails to siphoncoating material

Blocked siphon strainer screen,rod, or hose

Check and clean the hose, rod, andstrainer.

Air leak in siphon system Check the siphon hose for leaks.Break apart all connections in thesiphon system. Remove old sealantfrom the fitting threads and wrapthem with PTFE tape beforereconnecting them.

Coating material too viscous Check the material viscosity. Addsolvent to the material to lower theviscosity.

Siphon hose too long, hose ID toosmall, or strainer screen too finefor coating material

Use a correctly sized siphon hose.Check the strainer screen. If thestrainer screen is clogged withpigment, use a coarser mesh screenor a strainer without a screen.Contact your Nordson representativefor advice.

Continued...




6. Pump continues tooperate even afterdrain and circulationvalves are closed andspray devices areturned off

Coating material supply low, pumpsiphoning air

Fill the supply container.

Leaking drain valve Rebuild or replace the drain valve.

Leaking circulation valve Check for a damaged or worncirculation valve as follows:

1. Shut off the pump air supply.

2. Open the drain valve to relievethe hydraulic pressure.

3. Close the drain valve.

4. Immerse the siphon rod in coatingmaterial.

5. Disconnect the return hose fromthe circulation valve.

6. Connect an air hose to thecirculation valve in place of thereturn hose.

7. Apply compressed air to thecirculation valve. If air bubblesfrom the siphon rod, replace thecirculation valve needle and seat.

Leaking ball check valve Rebuild the ball check valves.

7. Pump does not strokewhen circulationvalve is opened

Clogged circulation valve, orblockage in system

Open the circulation valve fully, thenclose it partially. If the problemcontinues, flush the system with acompatible cleaning solution. Referto problem 1.

No compressed air supply, or airpressure is too low

Check the air supply at the drop-legdrain valve. Make sure the regulatoris working correctly.

8. Solvent chamberoverflows often

Upper packings worn Shut off pump, relieve hydraulicpressure, and tighten solvent cup 1/8to 1/4 turn. If leaking continues,replace the packings. Upper andlower packings should be replaced atthe same time.

Continued...




9. Spray pattern fades ornarrows

Compressed air pressure is toolow

Make sure the air pressure regulatoris working correctly. The pump airmotor requires at least 1.38 bar(20 psi) air pressure to operate.Increase the air pressure. Check fora restriction in the air supply line.

Blockage in hydraulic system Refer to problem 1.

Nozzles or fluid tips too large, ortoo many spray devices connectedto system

Reduce the nozzle or fluid tip size, orthe number of spray devicesconnected to the pump.

Spray device nozzle plugging Remove the fluid filter screen andinspect it. If the screen is damaged,replace it. If the screen isundamaged, replace it with one witha smaller mesh size.

Circulation valve opened too far Close the circulation valvecompletely, then reopen until pump isstroking 5 to 10 strokes per minutewith guns turned off.

10. Spray pattern hastails of unatomizedcoating material at theouter edges

Low hydraulic pressure or partialblockage in system

Increase the air pressure. Flush thesystem with a compatible cleaningsolution. Refer to problem 1.

Material too viscous Add solvent or heat to the coatingmaterial to lower the viscosity.

Damaged nozzle or fluid tip Replace the nozzle or fluid tip.

Preventing Air Valve FreezingAs compressed air is exhausted from the air valve, it expands rapidly andcools the air valve. The PermaFlo air motor exhaust paths have beendesigned to minimize blockage due to freezing. A coating of frost on themuffler surfaces is typically the result of moisture in the air.

If the valve does get cold enough for water vapor to condense and freezeon or in the mufflers and interfere with the operation of the valve, try one ofthe following actions:

� Run the pump at no more than 8−10 strokes per minute.

� If you are operating the pump at high speed in a humid environment,lubricate the compressed air with a glycol-based antifreeze fluid. Do notuse an antileak-type antifreeze fluid.

� Install an air dryer to remove moisture from the air supply.

Air Motor Repair C 1-1


Section C 1Air Motor Repair


WARNING: Shut off and lock out the compressed air supply to the pumpand relieve system fluid pressure before servicing the pump or other systemcomponents. Failure to observe this warning may result in serious personalinjury.

Introduction This section contains procedures for:

� Coupling removal and replacement

� Air motor rebuild

� Air valve rebuild

NOTE: Part numbers in illustrations match the item numbers in Section D1Air Motor Parts. Lettered parts are part of the hydraulic section and areshown in Sections C2 Hydraulic Section Repair and Section D2 HydraulicSection Parts.

Tools and Materials Required The following tools and materials are needed to repair the air motor:

� 5/16- and 15/16-in. socket wrenches

� Small and large adjustable wrenches

� 3/16-in. hex wrench

� Flat-bladed screwdriver

� Rubber mallet

� Large pliers or vice grips

� Large, flat, clean work bench

� MagnaLube-G or equivalent PTFE-impregnated grease (Nordsonpart 900349)

� Loctite 242 Removable thread adhesive or equivalent (Nordsonpart 900464)

� Replacement parts or kits (refer to Section D1 Air Motor Parts)

Air Motor RepairC 1-2


Guidelines for O-ring and Seal Replacement CAUTION: When removing O-rings and seals from grooves, use a tool thatwill not scratch the machined surfaces of the grooves. Scratches can causeleaks.

When rebuilding the air motor, replace all seals and O-rings. Lubricate allO-rings and seals with MagnaLube-G or equivalent PTFE-impregnatedgrease as instructed.

Coupling Removal and Replacement CAUTION: Do not scratch or score the connecting rod. Any burrs willdamage the U-cup seal and cause 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 couplingsleeve (33) with a 3/16-in. hex wrench.

3. Slide the coupling sleeve up the connecting rod (21) and remove the twocoupling halves (34) from the rod and plunger (A). Tap upward on thesleeve with a rubber mallet to loosen it, if necessary.

4. Push the connecting rod up away from the plunger and remove thecoupling sleeve.

33

32

21

34

A

Tighten to 10.2 ± 1 N�m(90 ± 10 in.-lb)when re-installing coupling.

Figure C 1-1 Coupling Removal and Replacement

21. Connecting rod32. Set screws33. Coupling sleeve

34. Coupling halvesA. Plunger



Coupling Replacement 1. See Figure C 1-1. Install the coupling sleeve (33) over the connecting

rod (21), making sure the arrow on the side of the sleeve is pointing up.

2. Pull the connecting rod down until it contacts the plunger (A).

3. Install the two coupling halves (34) around the connecting rod andplunger.

4. Slide the coupling sleeve over the coupling halves. Drive the sleevecompletely over the coupling halves with a rubber mallet.

5. Tighten the two set screws (32) with a 3/16-in. hex wrench to 10.2 ± 1 N�m (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 inthe 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 nuts (36) from the air motorstuds (35), and the fasteners securing the lower cylinder head (16) tothe pump mount. Lift the air motor off the hydraulic section and move itto a clean, flat work surface.

35

16

Customer-suppliedfasteners

36

Figure C 1-2 Air Motor Removal

16. Lower cylinder head35. Air motor studs

36. Hex nuts



Air Pilot Valve Cartridge Replacement (Pump Revisions A−C) NOTE: The air pilot valves on pump revisions A through C consisted of anactuator cartridge and a valve cartridge. One valve set is installed in eachcylinder head. Use this procedure to replace the cartridges. For air motorswithout cartridges, refer to the procedure on the following page.

See Figure C 1-3.

1. Remove the screws (4) and flat washers (5) securing the actuator andvalve cartridges (6 and 10) in the cylinder heads.

2. Remove the valve cartridges, then the actuator cartridges. Use pliers ifnecessary. Do not damage the housings.

3. Lubricate the external O-rings of the new cartridges with PTFE grease.

4. Install the actuator cartridges into the cylinder heads with the holes inthe 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 toengage the O-rings. When installed correctly the flat ends of the valvecartridges are flush against the actuator cartridges flats and the valveballs (10A) poke through the holes in the flats to contact the actuatorplungers (6A).

6. Re-install the screws and flat washers to secure the cartridges.

7. Make sure the plastic caps (7) are installed on the actuator cartridgeheads to prevent debris from entering the cartridge.

6

4

5

10

5

4

Apply MagnaLube-G or equivalentPTFE grease to external O-ringsbefore installing.

6

10

7

10A

6A

Figure C 1-3 Air Pilot Valve (Actuator and Three-Way Valve Cartridge) Replacement − Pump Revisions A−C

4. Washer-head screws5. Flat washers6. Actuator cartridge

6A. Actuator plunger7. Plastic cap

10. Valve cartridge10A. Valve ball



Air Pilot Valve Repair − Pump Revisions D and Above NOTE: The pilot valves on pump revisions D and above consist ofindividual components assembled into the upper and lower cylinder heads.For air motors with cartridges, refer to the procedure on the preceding page.

The actuator and 3-way valve components are available as kits.

See Figure C 1. All components of the air pilot valves, except the cup seal,can be removed and replaced without disassembling the air motor.

4B

4C

4D5A

5B

5C

Apply MagnaLube-G or equivalentPTFE grease to external O-ringsbefore 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 and Above

4A. Plug cap4B. Plug with spring guide4C. Spring4D. Plunger assembly

4E. Cup seal4F. Plug5A. Plug with O-ring

5B. Spring5C. Valve cartridge5D. Ball



Muffler and Air Valve Removal See Figure C 1-5. These steps apply to both old- and new-style air motors.

1. Remove the four short socket-head screws (19) and lock washers (27)from the mufflers (28) with a 3/16-in. hex wrench.

2. Swing the mufflers away from the air cylinders and unhook them fromthe air valve (25).

3. Remove the four large O-rings (26) from the air valve.

4. Remove the four 1/4−20 x 1.375 in. socket-head screws (A) from the airvalve with a 3/16-in. hex wrench, then remove the air valve from thecylinder heads. Refer to Air Valve Rebuild in this section.

5. Remove the four small O-rings (12) and two large O-rings (13) from thegrooves in the machined faces of each cylinder head.

1927

26

A

25

13

12

13

12

26

19

19

28

27

27

19 27

28

Figure C 1-5 Muffler and Air Valve Removal − Mufflers and Air Valve for Pump Revision D and Above Shown

12. Small O-rings13. Large O-rings19. Short socket-head screws

25. Air valve26. Large O-rings27. Lock washers

28. MufflersA. 1/4−20 x 1.375 in.

socket-head screws



Air Motor Disassembly See Figure C 1-6.

1. Remove the hex nuts (20) and long hex-head screws (1) from thecylinder heads (2 and 16).

CAUTION: See Figure C 1-3. If you did not remove the actuator cartridgesfrom the cylinder heads, be careful when handling the cylinder heads so youdo not damage or break off the actuator plunger (6A) pins.

2. Lift the upper cylinder head (2) off the air cylinder (15).

3. Slide the air cylinder off the air piston (22).

CAUTION: Do not scratch or score the connecting rod. Sharp edges willdamage the U-cup seal and cause it to leak.

4. Lift the air piston (22) up off the lower cylinder head (16), carefullypulling the connecting rod (21) through the U-cup seal (17) and out ofthe lower cylinder head.

5. Remove the four socket-head screws (19) and lock washers (27) fromthe 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 you are replacing the air piston:

a. Remove the socket-head screw (24) and flat washer (23).

b. Unscrew the air piston (22) clockwise (left-hand threads) from theconnecting rod (21).

NOTE: Unless the air motor studs (35) are damaged, there is no need toremove them. If you replace them, apply Loctite 242 Removable threadadhesive to the threads that screw into the lower cylinder head beforeinstalling the studs.



24

1

20

16

19

18

17

14

14

1521

22

27

2

23

35

If removed, apply Loctite 242Removable thread adhesiveto threads that screw intolower cylinder head beforeinstalling.

Loosen

Left-hand threads: Turnclockwise to loosen,counterclockwise to tighten.

Figure C 1-6 Air Motor Disassembly

1. Long hex-head screws2. Upper cylinder head

14. Large O-rings15. Air cylinder16. Lower cylinder head17. U-cup seal

18. Backup plate19. Short socket-head screws20. Hex nuts21. Connecting rod22. Air piston

23. Flat washer24. Socket-head screw27. Lock washers35. Air motor studs



Air Motor Re-Assembly Clean all reusable parts thoroughly before re-assembling the air motor.Inspect all parts and replace any that are worn, scored, or damaged beyondrepair.

Piston/Connecting Rod Assembly See Figure C 1-7.

1. Thread the new piston (22) counterclockwise (left-hand threads) ontothe connecting rod (21) until the piston contacts the shoulder at thebottom of the connecting rod threads.

2. Install the flat washer (23) on the socket-head screw (24), and threadthe screw into the connecting rod. Tighten the screw to 27 ± 4 N�m(20 ± 3 ft-lb).

24

23

Tighten to 27 ± 4 N�m(20 ± 3 ft-lb)

21

Left-hand threads: Turnclockwise to loosen,counterclockwise to tighten.

Tighten

22

Figure C 1-7 Piston/Connecting Rod Assembly

21. Connecting rod22. Air piston

23. Flat washer24. Socket-head screw



U-Cup Installation See Figure C 1-8.

1. Lubricate all surfaces of the U-cup seal (17) with PTFE grease.

2. Install the U-cup seal in the lower cylinder head (16), with the lips of theseal facing up (toward the air pressure), as shown in the cutawaydrawing.

3. Install the backup plate (18) and secure it with the four socket-headscrews (19) and lock washers (27).

18

16

17

19

18

17

27

Apply MagnaLube-G orequivalent PTFE grease toU-cup before installing.

1927

16

Figure C 1-8 U-Cup Installation

16. Lower cylinder head17. U-cup seal18. Backup plate

19. Socket-head screws21. Connecting rod27. Lock washers



Cylinder O-ring Installation See Figure C 1-9.

Apply a liberal coating of PTFE grease to the two large O-rings (14), theninstall them into the grooves in the cylinder heads (2 and 16).

16

14

14

2

Apply MagnaLube-G orequivalent PTFE grease toO-rings before installing.

Figure C 1-9 Cylinder O-ring Installation

2. Upper cylinder head14. O-rings

16. Lower cylinder head

Piston, Cylinder, and Cylinder Head Installation See Figure C 1-10.

1. Apply a thin film of PTFE grease to the connecting rod (21), the rubberpart 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 lowercylinder 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 upper cylinder head (2) on the cylinder, making sure themachined faces of the cylinder heads are parallel with each other. Tapon the upper cylinder head with a rubber mallet, if necessary, to work thecylinder over the O-ring on the upper cylinder head.

5. Install the four long hex-head screws (1) through the upper and lowercylinder heads and thread the hex nuts (20) loosely on the screws.



6. Place the assembly on the work bench with the machined faces of thecylinder heads flat against the work surface and parallel with each other.

7. Tighten the hex nuts in a criss-cross pattern to 40 ± 5.4 N�m (30 ± 4 ft-lb).

1

20

22

2

15

Apply MagnaLube-G orequivalent PTFE grease toconnecting rod, rubber part ofpiston, and ID of cylinder beforeinstalling.

Tighten to 40 ± 5.4 N�m (30 ± 4 ft-lb). Do not over-tighten or you will damagecylinder.

Machined faces must beparallel to each other.

16

21

Figure C 1-10 Piston, Cylinder, and Cylinder Head Installation

1. Long hex-head screws2. Upper cylinder head

15. Cylinder

16. Lower cylinder head20. Hex nuts

21. Connecting rod22. Air piston



Air Valve and Muffler Installation See Figure C 1-11. These steps apply to both old- and new-style airmotors.

1. Lubricate the four small O-rings (12) and two large O-rings (13) withPTFE grease, then install them in grooves in the cylinder head faces.

2. Install the air valve (25) on the cylinder heads with the four 1/4−20 x1.375 in. socket-head screws (A). Tighten the screws securely.

3. Lubricate the four large O-rings (26) with PTFE grease and install themin the grooves in the side of the air valve.

4. Hook the mufflers (28) into the slots in the front of the air valve andswing the mufflers back against the sides of the air valve.

5. Secure the mufflers to the air valve with the four short socket-headscrews (19) and lock washers (27).

1927

26

A

25

13

12

13

12

26

19

19

28

27

27

19 27

28

Apply MagnaLube-G orequivalent PTFE greasebefore installing.

Figure C 1-11 Muffler and Air Valve Installation − Mufflers and Air Valve for Pump Revision D and Above Shown

12. Small O-rings13. Large O-rings19. Short socket-head screws

25. Air valve26. Large O-rings27. Lock washers

28. MufflersA. 1/4−20 x 1.375 in.

socket-head screws



Air Motor Rebuild Completion 1. See Figure C 1-12. Install the air motor on the hydraulic section.

2. Install the hex nuts (36) on the air motor studs (35) and tighten them to136 ± 14 N�m (100 ± 10 ft-lb).

3. Secure the lower cylinder head (16) to the pump mounting surface.

35

16


36

TIghten to 136 ± 14 N�m (100 ± 10 ft-lb).

Figure C 1-12 Air Motor Installation

16. Lower cylinder head35. Air motor studs

36. Hex nuts

4. Pull down on the connecting rod until it contacts the plunger and installthe coupling as described on page C 1-2.

5. 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 FigureC 1-13 for the old style air valve and Figure C 1-14 for the new style airvalve. Refer to Section D1 Air Motor Parts for air valve service kits and airpilot valve part numbers.

1. Perform the Muffler and Air Valve Removal procedure on page C 1-6.

2. Remove the socket-head screws and end caps from the air valve.

3. Disassemble the air valve, inspect and replace any damagedcomponents, and reassemble the air valve.

4. If replacing the air pilot valve on a new style air valve assembly, installthe fittings and connect the air tubing as shown in Figure C 1-14.



Old Style Air Valve (Pump Revisions A−C)

1

2 3

8

6

7

5

2

1

10

98

9

98

98

98

43

5

34

3

8

Apply MagnaLube-G orequivalent PTFE grease toO-rings and T-seals beforeinstalling.

Figure C 1-13 Air Valve Rebuild − Pump Revisions A−C

1. Socket-head screws2. End caps3. Large O-rings4. Brass sleeves

5. Small O-rings6. Shuttle valve7. Valve body

8. T-seals9. 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. Allother parts are only available as part of a new valve assembly.



New Style Air Valve (Pump Revisions D and Above)

1

23

8

6

7

5

2

1

10

98

9

98

98

98

43

5

34

3

8

Apply MagnaLube-G orequivalent PTFE grease toO-rings and T-seals beforeinstalling.

6

11

11

12

12

12

Top(As Mounted on Air Motor)

Bottom(As Mounted on Air Motor)

Apply PTFE paste to mufflerthreads before installing.

Figure C 1-14 Air Valve Rebuild − Pump Revisions D and Above

1. Socket-head screws2. End caps3. Large O-rings4. Brass sleeves

5. Small O-rings6. Shuttle valve7. Valve body8. T-seals

9. Aluminum sleeves10. Spool11. 6-mm air tubing12. 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 tubing,tube fittings, mufflers, and pilot valve mounting parts are available separately. All other parts are only available aspart of a new valve assembly.

Hydraulic Section Repair C 2-1


Section C 2Hydraulic Section Repair


WARNING: Shut off and lock out the compressed air supply to the pumpand relieve system fluid pressure before servicing the pump or other systemcomponents. Failure to observe this warning may result in serious injury.

Introduction This section contains procedures for:

� Coupling removal and replacement

� Hydraulic section rebuild

NOTE: Part numbers in illustrations match the item numbers in Section D2Hydraulic Section Parts. Lettered parts are part of the air motor and areshown in Sections C1 Air Motor Repair and Section D1 Air Motor Parts.

Tools Required The following tools are needed to repair the hydraulic section:

� 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 monkeywrenches, are recommended. These wrenches can be purchased froman industrial supply company.

� 15/16 in. socket wrench

� Rubber mallet

� English hex wrench set

� Flat-bladed screwdrivers

� Large, flat, clean work surface

� Soft-jawed vise

� Parker O-Lube or equivalent O-ring lubricant (Nordson part 900223)

� Loctite 242 Removable thread adhesive or equivalent (Nordson part 900464)

� Parts and kits to replace damaged components. Refer to Section D2Hydraulic Section Parts.

Hydraulic Section RepairC 2-2


Guidelines for O-ring and Seal Replacement CAUTION: When removing O-rings and seals from grooves, do not scratchthe machined surfaces of the grooves. Scratches can cause leaks.

When rebuilding the hydraulic section, replace all seals and O-rings.Lubricate all O-rings and packing V-rings with Parker O-Lube or equivalentO-ring lubricant.

Coupling Removal and Replacement CAUTION: Do not scratch or score the connecting rod. Any burrs willdamage 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 couplingsleeve (A) with a 3/16-in. hex wrench.

3. Slide the coupling sleeve up the connecting rod (C) and remove the twocoupling halves (D) from the rod and plunger (8). Tap upward on thesleeve with a rubber mallet to loosen it, if necessary.

4. Push the connecting rod up away from the plunger and remove thecoupling sleeve.

A

B

C

D

8

Tighten to 10.2 ± 1 N�m(90 ± 10 in.-lb)when re-installing coupling.

Figure C 2-1 Coupling Removal and Replacement

8. PlungerA. Coupling sleeveB. Set screws

C. Connecting rodD. Coupling halves



Coupling Replacement 1. See Figure C 2-1. Install the coupling sleeve (A) over the connecting

rod (C), making sure the arrow on the side of the sleeve is pointing up.

2. Pull the connecting rod down until it contacts the plunger (8).

3. Install the two coupling halves (D) around the connecting rod andplunger.

4. Slide the coupling sleeve over the coupling halves. Drive the sleevecompletely over the coupling halves with a rubber mallet.

5. Tighten the two set screws (B) with a 3/16-in. hex wrench to 10.2 ± 1 N�m (90 ± 10 in.-lb).

Hydraulic Section Rebuild The hydraulic section can be removed from the pump and rebuilt withoutremoving the pump from its mounting.

Preparation 1. Flush the hydraulic section with a compatible solvent.

2. Remove the coupling as described in Coupling Removal andReplacement in this section.

3. Shut off and lock out the compressed air supply to the pump and relievethe system fluid pressure.

4. Disconnect the siphon and high-pressure fluid hoses, and the air supplyhose from the air motor. Remove the circulation valve kit, if installed inthe siphon port.

Removal 1. See Figure C 2-2. Remove the customer-supplied fasteners securing

the upper housing (7) to the pump mounting surface.

2. Have someone support the hydraulic section while you remove the threehex nuts (B) from the air motor studs (A).

3. Lower the hydraulic section off the studs.



A 7


B

Figure C 2-2 Hydraulic Section Removal

7. Upper housingA. Air motor studs

B. Hex nuts

Disassembly

CAUTION: Do not scratch or score the plunger shaft or the pressurehousing ID. Any burrs will damage the packing V-rings and cause leaks.

1. See Figure C 2-3. Loosen the solvent cup (1).

2. Place the pressure housing (12) flats in a soft-jawed vise.

3. Unscrew the upper housing from the pressure housing and lift it off theplunger.

4. Pull the plunger (8) out of the pressure housing. If the plunger won’tcome 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, youcan now use a rubber mallet to drive the plunger down through thepressure housing. If no rubber mallet is available, place a wood blockon the end of the plunger to protect it from damage.

7. Place the flats of the pressure ball seat (10) in a soft-jawed vise.Unscrew the plunger from the ball seat. Set the small ball (9) aside.

8. Remove the male and female adapters and V-rings (2, 3, and 4) fromthe ball seat.

9. Remove the ball cage (14), large ball (15), siphon ball seat (16), andwhite PTFE O-ring (17) from the siphon housing.



10. Pump revisions A−D only: Unscrew the solvent cup adapter (5) from theupper housing (7) and remove the lip seal (6).

11. Remove the male adapters, female adapters, and V-rings (2, 3, and 4)from the solvent cup adapter (pump revisions A−D) or upper housing(pump revisions E and above).

12. Remove the white PTFE O-rings (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 cup2. Female adapter3. V-rings4. Male adapter5. Solvent cup adapter6. Lip seal

7. Upper housing8. Plunger9. Ball (small)

10. Pressure ball seat11. O-rings (white PTFE)12. Pressure housing

13. O-ring (black Buna-N)14. Cage15. Ball (large)16. Siphon ball seat17. O-ring (white PTFE)18. Siphon housing

Note: Items 5 and 6 used on pump revisions A−D only.



Cleaning and Inspection 1. Clean all parts in a compatible solvent.

2. Inspect all parts for damage. Replace any parts that are worn, cracked,pitted, or scored.

Ball Check TestTest the pressure and siphon ball checks for leaks by placing the seats ontop of the balls and pouring a small quantity of solvent into each seat. If thesolvent does not leak from the seats, you do not need to replace the seatsor balls.

Assembly

Upper and Lower Packing Assemblies 1. Lubricate new V-rings with O-ring lubricant. Assemble the V-rings and

male and female adapters as shown.

� Type U V-rings: 10 UHMWPE, 6 upper and 4 lower

� Type F upper V-rings: 3 PTFE, 3 leather, alternating

� Type F lower V-rings: 2 PTFE, 2 leather, alternating

� Type L upper V-rings: 3 UHMWPE, 3 leather V-rings, alternating

� Type L lower V-rings: 2 UHMWPE, 2 leather, alternating

Upper Packing AssembliesType U

Lower Packing Assemblies

Types F and L

NOTE: Apply Parker O-Lube or equivalent to allV-rings before assembling.

Pressure

2

A

4

B

B A

2

4

2

4

4

2

B

Pressure

B

Figure C 2-4 Packing Assemblies

2. Female adapterA. Leather V-rings

4. Male adapter B. PTFE or UHMWPE V-rings



2. Install the upper packing assembly:

� Pump revisions A−D only: Install the upper packing assembly intothe solvent cup adapter (5). Lubricate a new lip seal (6) and install iton the solvent cup adapter with the exposed spring facing down,toward the bottom.

� Pump revisions E and above: Install the upper packing assemblyinto the upper housing (7).

6

5

Apply Parker O-Lube orequivalent 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 ball seat (10) asshown.

10

Packing Assembly

Figure C 2-6 Installing the Lower Packing Assembly

10. Pressure ball seat



Solvent Cup Installation See Figure C 2-7.

NOTE: Do not tighten the solvent cup until you install the plunger throughthe upper packings. Tightening the solvent cup expands the upper packingsand makes it difficult to install the plunger.

1. Pump revisions A−D: Thread the solvent cup adapter (5) into the upperhousing and tighten it snugly.

2. Thread the solvent cup (1) into the solvent cup adapter (5) (pumprevisions A−D), or into the upper housing (pump revisions E and above)until the solvent cup just bottoms out against the packings.

Pressure Ball Valve Assembly 1. See Figure C 2-7. Place the flats of 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 thenapply Loctite 242 removable thread adhesive to three or four threads allaround the ball seat.

3. Place the small ball (9) on top of the pressure ball seat, between thecage ears.

4. Thread the plunger (8) onto the ball seat.

5. Tighten the plunger until you feel metal-to-metal contact.

1

5

78

9

10

Clean the mating parts with aresidue free cleaner ordegreaser then apply Loctite 242removable thread adhesive orequivalent to three or four of thethreads all the way around.

Revisions A−DONLY

Figure C 2-7 Solvent Cup and Siphon Check Valve Assembly

1. Solvent cup5. Solvent cup adapter

(w/packings)7. Upper housing

8. Plunger9. Ball (small)

10. Pressure ball seat(w/packings)

Note: Item 5 used on pump revisions A−D only.



Upper Housing, Plunger, and Pressure HousingAssembly 1. See Figure C 2-8. Install the upper housing (7) on the air motor

studs (A). Tighten the hex nuts (B) to 136 ± 14 N�m (100 ± 10 ft-lb).

2. Secure the upper housing to the pump mounting surface.

A

7

B

TIghten to 136 ± 14 N�m (100 ± 10 ft-lb).


Figure C 2-8 Installing Upper Housing on Air Motor

7. Upper housingA. Air motor studs

B. Hex nuts

3. See Figure C 2-9. Lubricate new white PTFE O-rings (11) and a newblack Buna-N O-ring (13) with O-ring lubricant and install them onto thepressure housing (12). The white PTFE O-rings (11) go into the endgrooves, while the black Buna-N O-ring (13) goes into the groovebetween the flats and the threads.

4. Apply a thin film of O-ring lubricant to the ID of the pressure housing andthe OD of the plunger.

5. Place the pressure housing in a vice, with the end that has the blackBuna-N O-ring pointing down.



Upper Housing, Plunger, and Pressure HousingAssembly (contd)

6. Install the plunger into the pressure housing, packing end first. Use arubber mallet to drive the plunger about half way into the pressurehousing.

7. Insert the coupling end of the plunger into the upper housing andthrough the upper packings.

8. Thread the pressure housing into the upper housing (7) and tightensnugly.

9. Install the coupling sleeve (A) 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 andReplacement on page C2-2.

12. Tighten the solvent cup (1) 1/8 to 1/4 turn to compress the upperpackings and form a seal against the plunger.

7

11

12

13

11

Apply Parker O-Lube or equivalentbefore installing

Apply thin film of Parker O-Lube orequivalent to OD of plunger and IDof pressure housing before installingplunger in housing.

8

A

1

B

Figure C 2-9 Installing Plunger and Pressure Housing

1. Solvent cup7. Upper housing8. Plunger

11. O-rings (white PTFE)12. Pressure housing13. O-ring (black Buna-N)

A. Coupling sleeveB. Connecting rod



Siphon Housing Assembly and Installation 1. See Figure C 2-10. Install the following into the siphon housing (18), in

order:

a. New white 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 tightensnugly.

14

15

16

17

18

12

Apply Parker O-Lube orequivalent before installing.

Figure C 2-10 Siphon Housing Assembly and Installation

12. Pressure housing14. Cage15. Ball (large)

16. Siphon ball seat17. O-ring (white PTFE)18. Siphon housing



Return To Service Install the circulation kit, if used, and connect the siphon and high-pressurefluid hoses. Connect the air supply hose to the air motor. Refer toSection B3, Installation, for connections and circulation valve installation.

Flush the pump with a compatible cleaning solution and resume production.

Air Motor Parts D 1-1


Section D 1Air Motor Parts

Introduction To order parts, call the Nordson Finishing Customer Support Center at(800) 433−9319 or your local Nordson representative. Use these partslists and illustrations to locate and describe parts correctly.

Change Notice This notice details changes made to the air motor on revision D of thePermaFlo 830 pump assembly. The revision letter follows the pump partnumber on the ID plate on the front of the hydraulic section.

Mufflers:

The mufflers were redesigned from a curved design to a flat design. Themuffler bolt hole pattern and part number did not change.

Air Pilot Valves:

The original air pilot valves consisted of two sets of cartridges. The new airpilot valves are individually replaceable components. The cartridges are stillavailable as replacement parts (refer to Old Style Air Motor parts list).

The upper and lower air motor heads used with the cartridges are obsoleteand no longer available. If you replace either cylinder head, you must alsoorder new 3-way valve and actuator kits (refer to New Style Air Motor partslist).

Air Valve Assembly:

The original air valve assembly had a separate pilot valve (shuttle valve)mounted on the front of the air valve body and connected directly to thevalve body air passages. The revised air valve assembly has a differentpilot valve mounted on the underside of the air valve and connected to thevalve body by air tubing and fittings.

The original pilot valve is still available as a replacement part for the oldstyle air valve assembly.

The air valve assembly part number has not changed. The revised air valveassembly is a one-for-one replacement for the original assembly. Thevalve repair kits can be used on either version of the valve.

Air Motor PartsD 1-2


Old Style Air Motor (Pump Revisions A−C)See Figure D 1-1.

Item Part Description Quantity Note− - - - - - - AIR MOTOR, 8-inch, assembly 11 - - - - - - � SCREW, hex, cap, 5/8−11 x 9.50 in., steel, clear

zinc4

2 - - - - - - � HEAD, cylinder, upper, 8-inch 13 - - - - - - � BOLT, eye, 3/8−16 x 0.750 in. shank, steel 1

4 - - - - - - � SCREW, hex washer head, 10-32 x 0.375,stainless steel

4

5 983058 � WASHER, flat, 0.219 x 0.50 x 0.049 in.,stainless steel

4

6 1021378 � ACTUATOR, cartridge, assembly 2 A7 - - - - - - � � CAP/PLUG, SH38, 3/8-in socket 1 A8 940180 � � O-RING, hot paint, 0.75 x 0.875 x 0.063 in. 1 A9 940154 � � O-RING, Buna-N, 0.563 x 0.688 x 0.063 in. 1 A10 1021313 � VALVE, 3-way, cartridge, assembly 2 A11 - - - - - - � � O-RING, hot paint, 0.813 x 0.938 x 0.063 in. 4 A12 941080 � O-RING, Buna-N, 0.250 x 0.438 x 0.094 in. 413 941373 � O-RING, Viton, black, 2.063 x 2.250 in. 214 1023598 � O-RING, Buna-N, 7.734 x 8.012 x 0.139 in.

(-265)2

15 1021425 � CYLINDER, air, 8-inch 116 - - - - - - � HEAD, cylinder, lower, 8-inch 117 952101 � CUP, U, polyurethane, 1-3/16 x 1-11/16 x 5/16 in. 118 1021442 � PLATE, back-up 119 - - - - - - � SCREW, socket, 1/4−20 x 0.50 in., cap 820 - - - - - - � NUT, hex, flanged serrated, 5/8 in., clear zinc 421 1021440 � ROD, connecting, piston 122 1021428 � PISTON, air, 8-inch, carboxylated nitrile 123 1021441 � WASHER, 0.380 x 2.00 x 0.060 in., stainless

steel1

24 - - - - - - � SCREW, low head, socket, 3/8-16 x 1.00, zinc,nylok

1

25 1021635 � VALVE, air, 4-way, 7-port, 2-position 1 C26 942230 � O-RING, hotpaint, 1.625 x 1.875 x 0.125 in. 427 - - - - - - � WASHER, lock, split, 0.25 in., stainless steel 828 1021444 � MUFFLER, PermaFlo 2 D29 132154 STUD, ground 130 240976 CLAMP, ground, with wire 131 132054 RETAINER, wire 132 - - - - - - SCREW, socket set, 0.375−24 x 0.250 in., cup

point, stainless steel2 B

33 - - - - - - COUPLING, shaft, retainer sleeve 1 B34 - - - - - - COUPLING, shaft 2 B35 1021508 STUD, air motor, PermaFlo 336 - - - - - - NUT, hex, flanged serrated, 5/8 in., clear zinc 3



NoteQuantityDescriptionPartItemNOTE 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.



25

1

1927

1927

30

3

8

4

5

12

2

13

14

15

14

16

13

12

17

18

19

32

33

34

24

23

22

2120

35

36

26

28

29

27

7

9

6

1011

45

31

NOTE: Two sets of actuator and valvecartridges (6 and 10) are used, one setin upper cylinder head (2) and one setin 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)



New Style Air Motor (Pump Revisions D and Above)See Figure D 1-2.

Item Part Description Quantity Note− - - - - - - AIR MOTOR, 8-inch, assembly 11 - - - - - - � SCREW, hex, cap, 5/8−11 x 9.50 in., steel, zinc 42 1063118 � HEAD, cylinder, upper, 8-inch 13 - - - - - - � BOLT, eye, 3/8−16 x 0.75 in. shank, steel 1

4 1063996 � KIT, actuator 25 1063997 � KIT, 3-way valve 212 941080 � O-RING, Buna-N, 0.250 x 0.438 x 0.094 in. 413 941373 � O-RING, Viton, black, 2.063 x 2.25 in. 214 1023598 � O-RING, Buna-N, 7.734 x 8.012 x 0.139 in. 215 1021425 � CYLINDER, air, 8-inch 116 1063117 � HEAD, cylinder, lower, 8-inch 117 952101 � CUP, U, polyurethane, 1-3/16 x 1-11/16 x 5/16 in. 118 1021442 � PLATE, back-up 119 - - - - - - � SCREW, socket, 1/4−20 x 0.50 in., cap 8 B20 - - - - - - � NUT, hex, flanged serrated, 5/8 in., clear zinc 421 1021440 � ROD, connecting, piston 122 1021428 � PISTON, air, 8-inch, carboxylated nitrile 123 1021441 � WASHER, 0.38 x 2.00 x 0.06 in., stainless steel 124 - - - - - - � SCREW, low head, socket, 3/8-16 x 1.00, zinc,

nylok1

25 1021635 � VALVE, air, 4-way, 7-port, 2-position 1 A26 942230 � O-RING, hotpaint, 1.625 x 1.875 x 0.125 in. 4 B27 - - - - - - � WASHER, lock, split, 0.25 in., stainless steel 8 B28 1021444 � KIT, muffler, PermaFlo 2 B29 982482 SCREW, pan head, slotted, M4 x 10, stainless

steel1

30 240976 CLAMP, ground, with wire 131 983047 WASHER, flat, 4 mm, stainless steel 132 - - - - - - SCREW, socket set, 0.375−24 x 0.25 in., cup

point, stainless steel2 C

33 - - - - - - COUPLING, shaft, retainer sleeve 1 C34 - - - - - - COUPLING, shaft 2 C35 1021508 STUD, air motor, PermaFlo 336 - - - - - - NUT, hex, flanged serrated, 5/8 in., clear zinc 3

NOTE A: For parts breakdown, refer to New Style Air Valve Parts in this section.

B: Muffler Kit, part 1021444, includes 1 muffler, 2 screws, 2 lockwashers, and two O-rings.

C: Noted parts are included in the Coupler Kit, part 1024892.



25

1

1927

1927

30

3

122

13

14

15

14

16

13

12

17

18

19

32

33

34

24

23

22

2120

35

36

26

28

29

27

New Style Air MotorPump Revisions Dand Above

31

4

26

26

26

4

5

Figure D 1-2 New Style Air Motor Parts (Pump Revisions D and Above)



Old Style Air Valve (Pump Revisions A−C) See Figure D 1-3.

Item Part Description Quantity Note− 1021635 VALVE, air, 4-way, 7-port, 2-position A

1 - - - - - - � SCREW, socket head 8

2 - - - - - - � CAP, end 2

3 - - - - - - � O-RING 4 B, C

4 - - - - - - � SLEEVE, brass 2

5 - - - - - - � O-RING 2 B, C

6 901166 � VALVE, 2 position, 4 way, air pilot 1

7 - - - - - - � BODY, valve 1

8 - - - - - - � SEAL, T 6 B, C

9 - - - - - - � SLEEVE, aluminum 5

10 - - - - - - � SPOOL 1 C11 - - - - - - � SCREW, socket, 1/4−20 x 1.375 in., stainless

steel4

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 included in the Spool and Seals Kit, part 1029058.



1

23

8

6

7

5

2

1

10

9

89

98

98

98

43

5

34

3

8

11

OLD STYLE AIR VALVE

Figure D 1-3 Old Style Air Valve (Pump Revisions A−C)



New Style Air Valve (Pump Revisions D and Above) See Figure D 1-4.

Item Part Description Quantity Note− 1021635 VALVE, air, 4-way, 7-port, 2-position A

1 - - - - - - � SCREW, socket head 8

2 - - - - - - � CAP, end 2

3 - - - - - - � O-RING 4 B, C

4 - - - - - - � SLEEVE, brass 2

5 - - - - - - � O-RING 2 B, C

6 1062392 � VALVE, 4 way, air pilot 1

7 - - - - - - � BODY, valve 1

8 - - - - - - � SEAL, T 6 B, C

9 - - - - - - � SLEEVE, aluminum 5

10 - - - - - - � SPOOL 1 C11 - - - - - - � SCREW, socket, 1/4−20 x 1.375 in., stainless

steel4

12 1080618 � FITTING, tube, elbow, 6 mm x 1/4 in. NPT 313 342268 � SPACER, threaded, male/female, steel, hex,

#6−32 x 1 in.2

14 981577 � SCREW, pan head, #6−32 x 1 in., slotted, zinc 215 972126 � CONNECTOR, male, elbow, 6 mm tube x 1/8 in.

unithread3

16 971291 � CONNECTOR, male, 1/8 in. tube x 1/8 in. NPT 217 1065193 � ELBOW, male, 1/8 in. tube x 1/8 in. unithread 218 900586 � TUBING, polyethylene, 6 mm, blue AR19 900609 � TUBING, nylon, 0.125 x 0.016 in. AR20 1058165 � MUFFLER, 1/8 in. NPT, low profile 2

NOTE A: This version of the air valve assembly replaces the old style valve shown in Figure D 1-3.

B: Noted parts are included in the T-Seal Kit, part 1029057.

C: Noted parts are included in the Spool and Seals Kit, part 1029058.



1

23

8

7

5

2

1

10

9

89

98

98

98

43

5

34

3

8

11

6

12 12

12

1314 1515

1518

19

19

16

18

20NEW STYLEAIR VALVE

17

17

16

18

Figure D 1-4 New Style Air Valve (Pump Revisions D and Above)



Service Kits

Coupler Kit See Figure D 1-1.

Item Part Description Quantity Note− 1024892 KIT, coupler, PermaFlo 1

32 - - - - - - � SCREW, socket set, 0.375−24 x 0.25 in. cuppoint, stainless steel

2

33 - - - - - - � COUPLING, shaft, retainer sleeve 1

34 - - - - - - � COUPLING, shaft 2

Old Style Air Pilot Valve Kits (Pump Revisions A−C)See Figure D 1-1.

Item Part Description Quantity Note− 1030558 KIT, pilot valve, PermaFlo 1

6 1021378 � ACTUATOR, cartridge, assembly 2

10 1021313 � 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 Note4 1063996 KIT, actuator 15 1063997 KIT, 3-way valve 1

Air Valve T-Seal KitSee Figures D 1-3 and D 1-4.

Item Part Description Quantity Note− 1029057 KIT, T-seal 1 A

3 - - - - - - � O-RING 4

5 - - - - - - � O-RING 2

8 - - - - - - � SEAL, T 6NOTE A: The air valve T-seal kit may include an extra spring and two balls. These parts are not required to rebuild

the valve and should be discarded.



Air Valve Spool and Seals KitSee Figures D 1-3 and D 1-4.

Item Part Description Quantity Note− 1029058 KIT, spool and seals 1 A

3 - - - - - - � O-RING 4

5 - - - - - - � O-RING 2

8 - - - - - - � SEAL, T 6

10 - - - - - - � SPOOL 1NOTE A: The air valve spool and seals kit may include an extra spring and two balls. These parts are not required

to rebuild the valve and should be discarded.

Options

Adhesives, Sealants, and LubricantsUse these adhesives, sealants, and lubricants when servicing your airmotor. Refer to Section C1 Air Motor Repair for application instructions.

Part Description Quantity900464 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

1 972583 � ELBOW, male, 37, 11/16−12 x 3/4-in. NPT, steel 22 802060 � HOSE, 5 foot 13 1029321 � REGULATOR assembly with filter 1 A

4 901236 � GAUGE, air, 0−100 psi, 0−7 kg/cm2 1

13

24

Figure D 1-5 Air Motor Accessory Group



Remote Exhaust Muffler Kit

Item Part Description Quantity Note− 1030529 KIT, muffler, PermaFlo, 1 1/4 in. NPT 1

1 - - - - - - � MUFFLER, PermaFlo, 1 1/4 in. NPTF fitting 2

2 - - - - - - � SCREW, socket head, 1/4−20 x 0.50 in.,stainless steel

4

3 - - - - - - � WASHER, lock, split, 1/4 in. stainless steel 4

4 942230 � O-RING, hotpaint, 1.625 x 1.875 x 0.125 in. 4

4

1

2

2

3

3

1

23

2

3

4

Figure D 1-6 Remote Exhaust Muffler Kit

Hydraulic Section Parts D 2-1


Section D 2Hydraulic Section Parts

Introduction To order parts, call the Nordson Finishing Customer Support Center at(800) 433−9319 or your local Nordson representative. Use these partslists and illustrations to locate and describe parts correctly.

Using the Illustrated Parts List 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 part numberapplies to all parts in the illustration.

The number in the Part column is the Nordson Corporation part number. Aseries of dashes in this column (- - - - - -) means the part cannot be orderedseparately.

The Description column gives the part name, as well as its dimensions andother characteristics when appropriate. Indentions show the relationshipsbetween assemblies, subassemblies, and parts.

� 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 the partnumber is a bulk item ordered in quantities or if the quantity per assemblydepends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list. Notescontain important information about usage and ordering. Special attentionshould be given to notes.

Item Part Description Quantity Note— 0000000 Assembly 1

1 000000 � Subassembly 2 A

2 000000 � � Part 1

Hydraulic Section PartsD 2-2


Hydraulic Section Parts − Pump Revisions A−DSee Figure D 2-1 for part locations.

Item Part Description Quantity Note1024432 PUMP, hydraulic, assembly, PermaFlo 815 1

1 1023813 � CUP, solvent, PermaFlo 815 1

2 - - - - - - � ADAPTER, female, PermaFlo 815 2 A

3 - - - - - - � RING, V 10 A

4 - - - - - - � ADAPTER, male, PermaFlo 815 2 A

5 1023810 � ADAPTER, cup, solvent, PermaFlo 815 1

6 - - - - - - � SEAL, lip, 3.442 x 3.182 x 0.170 in., PTFE 1 B

7 1023565 � HOUSING, upper, hydraulic, PermaFlo 815 1

8 1042396 � PLUNGER, hydraulic, PermaFlo 815 1

9 900014 � BALL, 440 stainless steel, 0.875 in., 100 1 C

10 - - - - - - � SEAT, ball, pressure, PermaFlo 815 1 C

11 - - - - - - � O-RING, PTFE, 3.109 x 3.387 x 0.139 in. 2 B

12 1023738 � HOUSING, pressure, hydraulic, PermaFlo 815 1

13 - - - - - - � O-RING, −341, Buna-N, 70 duro 1 B

14 - - - - - - � CAGE, ball, siphon, PermaFlo 815 1

15 900006 � BALL, 440 stainless steel, 1.50 in., 100 1 D

16 - - - - - - � SEAT, ball, 1.50 in. diameter 1 D

17 - - - - - - � O-RING, PTFE, 2.050 x 2.256 x 0.103 in. 1 B,D

18 1023870 � HOUSING, siphon, PermaFlo 815 1

NOTE A: Noted parts are included in packing kits. Refer to Packing Kits in this section.

B: Noted parts are included in the Hydraulic Seal Kit, part 1029668.

C: Noted parts are included in the Pressure Ball Check Kit, part 1029666.

D: Noted parts are included in the Siphon Ball Check Kit, part 1029667.



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 − Pump Revisions A−D



Type U Hydraulic Section − Revisions E and AboveSee Figure D 2-2 for part locations.

Item Part Description Quantity Note− 1024432 PUMP, hydraulic, assembly, PermaFlo 815, Type U 1



3 - - - - - - � RING, V 10 A






11 - - - - - - � O-RING, PTFE, 3.109 x 3.387 x 0.139 in. 2 B



14 1024235 � CAGE, ball, siphon, PermaFlo 815 1





NOTE A: Noted parts are included in packing kits. Refer to Packing Kits in this section. Order the correct kit foryour pump.






1

2

4

3

7

3

8

4

2

9

10

11

12

13

11

14

15

16

17

18

Pump Revisions E and Above

Figure D 2-2 Hydraulic Section with Type U Packings − Pump Revisions E and Above



Type F Hydraulic Section − Revisions E and AboveSee Figure D 2-3 for part locations.

Item Part Description Quantity Note− 1074995 PUMP, hydraulic, assembly, PermaFlo 815, Type F 1



3A - - - - - - � RING, V, leather 5 A

3B - - - - - - � RING, V, PTFE 5 A






11 - - - - - - � O-RING, PTFE, 3.109 x 3.387 x 0.139 in. 2 B



14 1024235 � CAGE, ball, siphon, PermaFlo 815 1





NOTE A: Noted parts are included in packing kits. Refer to Packing Kits in this section. Order the correct kit foryour pump.






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



Packing KitsSee Figure D 2-4. One kit replaces both upper and lower packings.

Type U Packing Kit Standard on 1024648 pump with 1024432 hydraulic section.

Item Part Description Quantity Note− 1029669 KIT, packing, type U, PermaFlo 815 1

2 - - - - - - � ADAPTER, female, PermaFlo 815 2

B - - - - - - � RING, V, 2.054 x 2.936, UHMWPE 10

4 - - - - - - � ADAPTER, male, PermaFlo 815 2

Type F Packing Kit Standard on 1065204 pump with 1074995 hydraulic section.

Item Part Description Quantity Note− 1060457 KIT, packing, Type F, PermaFlo 815 1


A - - - - - - � RING, V, leather, 2.059 x 2.928 x 0.083 5

C - - - - - - � RING, V, 2.054 x 2.936, PTFE 5


Type L Packing Kit Type L packings are optional.

Item Part Description Quantity Note− 1037841 KIT, packing, Type L, PermaFlo 815 1


A - - - - - - � RING, V, leather, 2.059 x 2.928 x 0.083 5

B - - - - - - � RING, V, 2.054 x 2.936, UHMWPE 5




Upper Packing AssembliesType U

Lower Packing Assemblies

Types F and L

4

2

4

2

4

4

2

A

A

B

B B or C

B or C

A − Leather V-ringsB − UHMWPE V-ringsC − PTFE V-rings

2

Figure D 2-4 Packing Kits

Service Kits

Hydraulic Seal Kit − Pump Revisions A−D See Figure D 2-1.

Item Part Description Quantity Note− 1029668 KIT, hydraulic, seal, PermaFlo 815 1

6 - - - - - - � SEAL, lip, 3.442 x 3.182 x 0.170, PTFE 1

11 - - - - - - � O-RING, PTFE, 3.109 x 3.387 x 0.139 in. 2

13 - - - - - - � O-RING, −341, Buna-N, 70 duro 1

17 - - - - - - � 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− 1063201 KIT, hydraulic, seal, PermaFlo 815 1

11 - - - - - - � O-RING, PTFE, 3.109 x 3.387 x 0.139 in. 2

13 - - - - - - � O-RING, −341, Buna-N, 70 duro 1

17 - - - - - - � O-RING, PTFE, 2.050 x 2.256 x 0.103 in. 1



Pressure Ball Check Kit See Figure D 2-1 or D 2-2.

Item Part Description Quantity Note− 1029666 KIT, ball, pressure check, PermaFlo 815 1

9 900014 � BALL, 440 stainless steel, 0.875 in., 100 1

10 - - - - - - � SEAT, ball, pressure, PermaFlo 815 1

Siphon Ball Check Kit See Figure D 2-1 or D 2-2.

Item Part Description Quantity Note− 1029667 KIT, ball, siphon check, PermaFlo 815 1

15 900006 � BALL, 440 stainless steel, 1.50 in., 100 1

16 - - - - - - � SEAT, ball, 1.50 in. diameter 1

17 - - - - - - � O-RING, PTFE, 2.050 x 2.256 x 0.103 in. 1

Options

Adhesives, Sealants, and LubricantsUse these adhesives, sealants, and lubricants when repairing the hydraulicsection. Refer to Section C2 Hydraulic Section Service for applicationinstructions.

Part Description Quantity900464 Adhesive, threadlocking (Loctite Removable 242) 1

900223 Lubricant, O-ring, Parker (Parker O-Lube), 4 oz 1



Siphon Accessory Group See Figure D 2-5. This kit can be installed in the field. Use it with bothdead-end and circulating systems.

Item Part Description Quantity Note− 170120 ACCESSORY GROUP, siphon, stainless steel 1

1 972724 � CONNECTOR, male, 37, 1 5/16−12 x 1 in.stainless steel

1

2 249363 � HOSE, siphon, 1 in. ID, 8 ft, stainless steel 13 249362 � ROD, siphon, stainless steel, 1 in. pipe 14 249355 � STRAINER, siphon, stainless steel, 1 in. pipe 15 981279 � � SCREW, thumb, 1/4−20 x 1 in., stainless

steel1

1

2

3

4

5

Figure D 2-5 Siphon Accessory Group



Circulation Kit See Figure D 2-6. This kit can be installed in the field. Use it withcirculating systems. The instruction sheet included with the kit includesinstructions for assembling the kit components and installing it on the pump.

Item Part Description Quantity Note− 1029257 KIT, circulation, stainless steel, PermaFlo

1 1029258 � SWIVEL, 37 degree, 1 5/16−12 x 1 in. stainlesssteel

1

2 1029259 � TUBE FITTING, 37 degree, tee, female, 1 in.NPT, stainless steel

1

3 336843 � CONNECTOR, male, 1/2 x 1 in., stainless steel 1

4 336842 � ADAPTER, female, 1/2 x 1/2 in., stainless steel 1

5 972177 � ELBOW, male, 37, 1/2−20 x 1/4 in. stainlesssteel

1

6 750222 � VALVE, circulation, stainless steel 1

7 973971 � NIPPLE, hex, 3/8 x 1/4 x 1.406, stainless steel 1

8 750130 � VALVE, ball, stainless steel 1

9 972103 � CONNECTOR, male, 37, 3/4−16 x 3/8 in.stainless steel

2

10 823060 � HOSE, drain off, 3/8 in. ID, 5 ft 1

11 750250 � ROD, drain off 1

1

23

45

6

7

8

9

10

119

Figure D 2-6 Circulation Valve Kit

PermaFlo� 815 and 830 Pumps Revisions A−CAir Motor PartsNordson Customer Service: (800) 433-9319

SCREW

983058WASHER

1021378ACTUATOR(KIT A)

CAP/PLUG

940180O-RING

940154O-RING

EYE BOLT132054RETAINER

240976GROUND CLAMP

SCREW

1021559UPPER HEAD

132154GROUND STUD

O-RINGS

SCREW

983058WASHER

941080O-RINGS

941373O-RING

1021635AIR VALVE

SCREW(included with Air Valve)

942230O-RING

1023598O-RING

1021425CYLINDER

SCREW

SCREW(KIT C)

LOCKWASHER(KIT C)

1021444MUFFLER(KIT C)

SCREW(KIT C)

LOCKWASHER(KIT C)

1023598O-RING

1021593LOWER HEAD

1021428PISTON

1021440CONNECTINGROD

HEX NUT

1021508STUD

941373O-RING

941080O-RINGS

1024892COUPLER KIT

(KIT B)

HEX NUT

952101U-CUP

1021442BACKUP PLATE

LOCKWASHER

SCREW

Manual 1022914 Foldout 1 of 6

1021441WASHER

SETSCREW


KIT A: 1030558 PILOT VALVE KITSERVICE KITS

1021313THREE-WAY VALVE

(KIT A)

KIT B: 1024892 COUPLER KITKIT C: 1030529 MUFFLER KIT

PermaFlo� 815 and 830 Pumps Revision D and AboveAir Motor PartsNordson Customer Service: (800) 433-9319

240976GROUND CLAMP

1021559UPPER HEAD

941080O-RINGS

941373O-RING

1021635AIR VALVE

SCREWS(included with Air Valve)

942230O-RINGS(KIT A)

1023598O-RING

1021425CYLINDER

SCREW

SCREWS(KIT A)

LOCKWASHERS(KIT A) 1021444

MUFFLER(KIT A)

SCREWS(KIT A)

LOCKWASHERS(KIT A)

1023598O-RING

1021593LOWER HEAD

1021428PISTON

1021440CONNECTINGROD

HEX NUT

1021508STUD

941373O-RING

941080O-RINGS

1024892COUPLER KIT

(KIT B)

HEX NUT

952101U-CUP

1021442BACKUP PLATE

LOCKWASHER

SCREW


1021441WASHER

SETSCREW


SERVICE KITS

KIT B: 1024892 COUPLER KIT

OPTIONS1030529 REMOTE EXHAUST KIT

KIT A: 1021441 MUFFLER KIT

1021444MUFFLER(KIT A)

PLUG(KIT C)

982482SCREW983047FLAT WASHER

1063996ACTUATOR KIT

(KIT C)

10639973-WAY VALVE KIT

(KIT D) SCREW

EYE BOLT

KIT C: 1063996 ACTUATOR KIT

KIT D: 1063997 3-WAY VALVE KIT

PermaFlo� 815 and 830 Pumps Revisions A−CAir Valve PartsNordson Customer Service: (800) 433-9319


SERVICE KITSKIT A: 1029057 T-SEAL KITKIT B: 1029058 SPOOL AND SEAL KIT


SOCKET-HEADSCREWS

O-RING(KITS A, B)

END CAP

BRASSSLEEVE

O-RING(KITS A, B)

O-RING(KITS A, B)

901166VALVE

1/4−20 x 1.375 in.STAINLESS STEEL SCREW

VALVE BODY

O-RING(KITS A, B)

T-SEAL(KITS A, B)

ALUMINUMSLEEVE

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)

ALUMINUMSLEEVE

ALUMINUMSLEEVE

ALUMINUMSLEEVE

ALUMINUMSLEEVE

SPOOL(KIT B)

O-RING (KITS A, B)

END CAP

SOCKET-HEADSCREWS

O-RING(KITS A, B)

BRASSSLEEVE

PermaFlo� 815 and 830 Pumps Revision D and AboveAir Valve PartsNordson Customer Service: (800) 433-9319


SOCKET-HEADSCREWS

END CAP

BRASSSLEEVE

VALVE BODY

O-RING(KITS A, B)

ALUMINUMSLEEVE T-SEAL

(KITS A, B)


(KITS A, B)


(KITS A, B)

ALUMINUMSLEEVE

T-SEAL(KITS A, B)


(KITS A, B)

SPOOL(KIT B)

O-RING (KITS A, B)

BRASSSLEEVE

O-RING(KITS A, B)

ENDCAP

SOCKET-HEADSCREWS

SERVICE KITSKIT A: 1029057 T-SEAL KITKIT B: 1029058 SPOOL AND SEAL KIT


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)

1062392AIR PILOT

VALVE

91080618FITTING

1080618FITTING

342268SPACERS

981577SCREWS

972126CONNECTOR

1058165MUFFLERS

972126CONNECTOR

972126CONNECTOR

971291CONNECTOR

971291CONNECTOR

1080618FITTING

6-MM TUBING: 9005861/8-IN. TUBING: 900609

1065193ELBOW

1065193ELBOW

PermaFlo� 815 Hydraulic Section Parts − Pump Revisions A−DNordson Customer Service: (800) 433-9319


1023813SOLVENT CUP

1023953FEMALE ADAPTER(KIT A)

V-RINGS(KIT A)

1023952MALE ADAPTER(KIT A)

1023810CUP ADAPTER

LIP SEAL(KIT B)

1023565UPPER HOUSING

1042396PLUNGER

V-RINGS(KIT A)

900014BALL(KIT C)

PRESSURE SEAT(KIT C)

O-RING(KIT B)

1023738PRESSUREHOUSING

O-RING(KIT B)

O-RING(KIT B)

1024235CAGE

900006BALL(KIT D)

SIPHON SEAT(KIT D)

O-RING(KITS B, D)

1023870SIPHONHOUSING

SERVICE KITSKIT A: PACKING KIT (SEE LIST BELOW)KIT B: 1029668 HYDRAULIC SEAL KITKIT C: 1029666 PRESSURE BALL CHECK KITKIT D: 1029667 SIPHON BALL CHECK KIT

PACKING KITS1037841 TYPE L PACKING KIT (UHMWPE/LEATHER V-RINGS)1060457 TYPE F PACKING KIT (PTFE/LEATHER V-RINGS)1029669 TYPE U PACKING KIT (UHMWPE V-RINGS)



PermaFlo� 815 Hydraulic Section Parts − Pump Revisions E and AboveNordson Customer Service: (800) 433-9319


1023813SOLVENT CUP


V-RINGS(KIT A)


1023565UPPER HOUSING

1042396PLUNGER

V-RINGS(KIT A)

900014BALL(KIT C)

PRESSURE SEAT(KIT C)

O-RING(KIT B)

1023738PRESSUREHOUSING

O-RING(KIT B)

O-RING(KIT B)

1024235CAGE

900006BALL(KIT D)

SIPHON SEAT(KIT D)

O-RING(KITS B, D)

1023870SIPHONHOUSING

SERVICE KITSKIT A: PACKING KIT (SEE LIST BELOW)KIT B: 1063201 HYDRAULIC SEAL KITKIT C: 1029666 PRESSURE BALL CHECK KITKIT D: 1029667 SIPHON BALL CHECK KIT

PACKING KITS1037841 TYPE L PACKING KIT (UHMWPE/LEATHER V-RINGS)1060457 TYPE F PACKING KIT (PTFE/LEATHER V-RINGS)1029669 TYPE U PACKING KIT (UHMWPE V-RINGS)



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