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B1EN-02-[3V-X-AFXX]-5

Part B, Section 1

Hydraulics

This section covers the following unit configurations.

Model 3500V3700V3800V3900V

Voltage All

Pump Piston (F)

Manifold 4-Port (A)6-Port (B or C)2-Port (S or T)

Control Vista Standard (V)Vista Pattern (PC)

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Section B 1Hydraulics

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

This section of the manual describes how to troubleshoot and repair thehydraulic system. It includes the following information:

� an overview of the unit’s hydraulic system

� troubleshooting guidelines and procedures

� pump, actuator, solenoid valve, and manifold repair procedures

� pump, actuator, solenoid valve, air pressure regulator, and manifoldassembly parts lists

Refer to the parts lists at the end of this section for the part numbers ofany components that need to be replaced.

If you try all the suggestions in this section and still need assistancesolving hydraulic system problems, call your Nordson representative.

Refer to the following sections of this manual for additional information onthe hydraulic system:

� Description includes pump specifications.

� Installation includes the procedures for connecting the air supply tothe pump and installing hoses.

To replace the tank and manifold, refer to Tank. Tank includes the tankassembly parts lists.

1. Introduction

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Two major assemblies make up the hydraulic system: an air-drivenpiston pump and a manifold. See Figure B 1-1. The pump assemblyincludes an air section, a hydraulic section, and an actuator. Themanifold assembly, which is indirectly heated by the tank, includes analuminum manifold with hose ports, a filter assembly, a drain valve, and apressure relief valve.

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Fig. B 1-1 Key Parts of the Hydraulic System (shown with a typical tankand manifold)

1. Actuator2. Pump air section

3. Pump hydraulic section4. Manifold

2. Overview of theHydraulic System

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The following troubleshooting table describes the kinds of hydraulicsystem problems you may encounter and provides corrective actions forhandling those problems. When necessary, the table refers you to theTroubleshooting Procedures part of this section, which contains moredetailed procedures for diagnosing hydraulic system problems.

Refer to the following table to troubleshoot hydraulic system problems.

Table B 1-1Troubleshooting Hydraulic System Problems

Problem Possible Cause Corrective Action

1. Pump stroking erratically(inconsistent adhesiveoutput)(See Note A)

Adhesive level too low Check the adhesive level. Add adhesiveif necessary. Refer to Checking theAdhesive Level and Filling the Tank inOperation.

Adhesive temperature too low Check the temperature settings. Referto System Programming Procedures inInstallation.

Pump siphon ball seat dirty ormissing

Check the siphon ball seat. Refer toPump Siphon Ball Seat Check.

Pump hydraulic section dirty Clean the pump hydraulic section.Refer to Cleaning or Rebuilding thePump.

2. Pump stroking too fast(little or no adhesiveoutput)

Adhesive level too low Check the adhesive level. Add adhesiveif necessary. Refer to Checking theAdhesive Level and Filling the Tank inOperation.

Pressure relief valve defective Replace the pressure relief valve. Referto Replacing the Pressure Relief Valve.

3. Pump not stroking (noadhesive output)

Pump not turned on Wait for the READY light to turn on.

NOTE: For some standard Vista andVista PC units, you may need to turn thepump on manually after the READY lightturns on. If the auto-energize pumpfeature is enabled, the pump will turn onautomatically.

No input air pressure to the pump Check the input air pressure. Adjust ifnecessary.

Pump solenoid valve failed Check the solenoid valve. Refer toPump Solenoid Valve Check.

NOTE A: The pump should make two regularly spaced exhaust sounds. If you hear two exhaust sounds followedby a pause, the pump is stroking erratically (the hydraulic shaft is moving faster in one direction thanthe other).

Continued on next page

3. Troubleshooting

Troubleshooting Table

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Table B 1-1 Identifying and Correcting System Faults (contd.)

Problem Possible Cause Corrective Action

3. Pump not stroking (noadhesive output) (contd.)

Blockage in manifold Check the manifold for blockage. Referto Manifold Blockage Check.

Pump hydraulic section dirty Clean the pump hydraulic section.Refer to Cleaning or Rebuilding thePump.

Pump leaking air (causes the pump tomake a loud noise)

Locate the leak and replace damagedseals or O-rings. Refer to Pump AirSection Check.

Pump actuator malfunctioning for oneor more of the following reasons:

Check for a malfunctioning actuator.Refer to Actuator Check.

� air valve binding Disassemble and clean the air valve.Refer to Cleaning or Replacing the AirValve.

� shifter fork slipped out of position Check the position of the fork andreposition if necessary. Refer toRepositioning or Replacing the ShifterFork.

� shifter fork installed upside down Check the position of the fork andreposition if necessary. The fork shouldbe positioned with the side stamped UPfacing the air motor. Refer toRepositioning or Replacing the ShifterFork.

� shifter fork bent or damaged Replace the fork. Refer to Repositioningor Replacing the Shifter Fork.

� magnet assembly dirty ordamaged

Clean or replace the magnet assembly.Refer to Cleaning or Replacing theMagnet Assembly.

� bumper assembly dirty ordamaged

Replace the bumper assembly. Refer toReplacing the Bumper Assembly.

� shifter fork magnet loose Replace the fork. Refer to Repositioningor Replacing the Shifter Fork.

Troubleshooting Table

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Use these procedures as directed in Table B 1-1 to further diagnosehydraulic system problems.

Manifold Blockage Check

1. Reduce the pump air pressure to 0.

2. Make sure the READY light is lit and the pump is turned on.

3. See Figure B 1-2. Place a container under the manifold drain valve,open the valve, and allow adhesive to flow from the valve.

Filter Type Procedure for Opening Drain Valve

Standard Turn the drain valve counterclockwise.

Reverse-flush With the manifold filter in the RUN position, turnthe right-side drain valve counterclockwise.

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Fig. B 1-2 Opening the Manifold Drain Valve

1. A manifold (standard filter)2. B or S manifold (standard filter)

3. C or T manifold(reverse-flush filter)

Troubleshooting Procedures

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Manifold Blockage Check (contd)

4. Slowly increase the pump air pressure and check to see if the pumpis stroking.

Pump Action

Strokes There is no blockage in the manifold. Close thedrain valve and return to Table B 1-1.

Does not stroke The manifold may be blocked. Remove andclean the manifold filter. Refer to Cleaning aStandard Manifold Filter or Cleaning aReverse-Flush Manifold Filter in Maintenance.

Pump Siphon Ball Seat Check


2. See Figure B 1-2. Place a container under the manifold drain valveand open the valve.



Reverse-flush With the manifold filter in the RUN position, turnthe right-side drain valve counterclockwise.

3. Turn the pump air pressure regulator alternately counterclockwiseand clockwise to increase and decrease pump air pressure. Thisshould remove any particles lodged between the siphon ball and itsseat.

4. Check to see if the pump is stroking normally or erratically.

Pump strokes… Action

Normally Resume operation.

Erratically Remove and clean the pump. Refer to Cleaningor Rebuilding the Pump

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Actuator Check

1. Remove the pump cover.

2. See Figure B 1-3. Thread an M4 screw into the top of the airvalve spool.

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Fig. B 1-3 Manually Shifting the Air Valve

3. Alternately press down and pull up on the screw to manually shift theair valve.

� If the air valve does not move, refer to Pump actuatormalfunctioning for one or more of the following reasons underPump does not stroke in Table B 1-1.

� If the pump strokes when the air valve is shifted but will not strokeon its own, refer to Pump actuator malfunctioning for one or moreof the following reasons under Pump does not stroke inTable B 1-1.

� If the pump does not stroke, then the pump is leaking air or isjammed. Refer to Pump Air Section Check to check for air leaks.If an air leak is not the problem, then the pump is jammed. Referto Cleaning or Rebuilding the Pump to clean the pump air orhydraulic section.

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Pump Solenoid Valve Check



3. Disconnect the air input line from the actuator.


5. Slowly increase pump air pressure.

6. Check the disconnected air input line for air flow.

Condition Action

Air flows. The solenoid valve is functioning properly.Reduce the pump air pressure to 0, reconnectthe air input line, and return to Table B 1-1.

Air does not flow. Go to the next step.

WARNING: Risk of electrical shock. Failure to observeelectrical safety procedures may result in personal injury ordeath. Allow only qualified personnel to perform the followingprocedures. Observe all high voltage indicators.

7. Open the electrical enclosure. Refer to Opening the ElectricalEnclosure in Control.

8. Locate connector J9 on the power board and measure the voltage atpositions 1 and 2.

Voltage Action

22.8−25.2 VDC Replace the solenoid valve. Refer to PumpSolenoid Valve Repair Procedures.

Less than22.8 VDC

Replace the power board. Refer to Replacingthe Power Board in Control.

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Pump Air Section Check




4. See Figure B 1-4. Slowly increase pump air pressure and checkfor leaks

� at the actuator’s top or bottom exhaust port (1)

� at the top of the hydraulic shaft (2)

� between the air cylinder head and the air cylinder or between theair cylinder and the pump mount (3)

� between the actuator and air cylinder (4)

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Fig. B 1-4 Checking for Pump Air Section Leaks

1. Exhaust ports2. Top of hydraulic shaft

3. Between air cylinder head andair cylinder or between aircylinder and pump mount

4. Between actuator and aircylinder

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Pump Air Section Check (contd)

5. Take appropriate action based on the source of the leak.

Air is… Action

Not leaking Replace the pump cover and return toTable B 1-1.

Leaking from theactuator’s top orbottom exhaustport

Replace the piston cups and washers. Refer tothe appropriate procedures in Cleaning orRebuilding the Pump.

Leaking from thetop of thehydraulic shaft

Replace the u-cup. Refer to the appropriateprocedures in Cleaning or Rebuilding the Pump.

Leaking betweenthe air cylinderhead and the aircylinder orbetween the aircylinder and thepump mount

Replace the air cylinder and pump mountO-rings. Refer to the appropriate procedures inCleaning or Rebuilding the Pump.

Leaking betweenthe actuator andthe air cylinder

Replace the actuator O-rings. Refer to theappropriate procedures in Cleaning or Rebuildingthe Pump.

Use these procedures to replace the piston pump, to replace any pumpcomponent, or to clean pump components. Refer to the parts lists at theend of this section for the part numbers of any components that need tobe replaced. You can also use the pump parts list illustration as a guideas your perform the following disassembly and reassembly procedures.

NOTE: If you are replacing only the actuator, you do not need to removethe pump. To replace only the actuator, complete Replacing the Actuatorin Actuator Repair Procedures.

4. Pump Repair Procedures

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Use these procedures to disassemble the pump, to clean or replacepump components, and to reassemble the pump.

Preparation for Pump Removal

1. Make sure the unit is at operating temperature.

2. Series 3800V and 3900V units only: See Figure B 1-5. Place a largecontainer under the drain port and remove the drain plug to drain thetank until the adhesive level is below the drain port opening.


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

4. Relieve system pressure. Refer to Relieving System Pressure inMaintenance.

Fig. B 1-5 Draining the Tank fromthe Drain Port on Series3800V and 3900V Units

WARNING: Disconnect and lock out line voltage to the unit.Failure to observe this warning can result in personal injury ordeath.

5. Turn the unit off; then disconnect and lock out power to the unit.



Cleaning or Rebuilding thePump

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Pump Removal

WARNING: Hot! Risk of burns. Wear heat-protective clothing,safety goggles, and heat-protective gloves.

1. If you have not already done so, complete Preparation for PumpRemoval.

2. Remove the screws and washers that secure the pump to the unit.

3. Make sure the adhesive around the pump has not solidified. Reheatif necessary.

4. Rotate the pump slightly to break the suction and pull the pumpstraight up to remove it. Lay the pump on a clean, flat work surface.

NOTE: To install a new pump and actuator assembly, go to PumpInstallation.

Actuator Removal

1. Move the hydraulic shaft up or down until shifter fork is centered inthe pump mount.

2. See Figure B 1-6. Remove the screws and washers (1) that securethe actuator (3); then remove the actuator.

NOTE: Series 3500V units also have a pump cover bracket (2) thatmust be removed.

3. Inspect the O-rings (4) in the face of the air cylinder for damage.Replace if necessary.

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Fig. B 1-6 Removing the Actuator

1. Screw and washer2. Pump cover bracket (Series

3500V units only)

3. Actuator4. O-ring

Pump Air Section Disassembly

1. Make sure you have removed the actuator. Refer to ActuatorRemoval.

2. See Figure B 1-7. Remove the screw and washer (2) from the shifterfork (1); then slide the fork toward the air cylinder and off thehydraulic shaft.

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Fig. B 1-7 Removing the Shifter Fork

1. Shifter fork 2. Screw and washer

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Pump Air Section Disassembly (contd)

3. See Figure B 1-8. Remove the screws and lock washers (4) thatsecure the air cylinder assembly to the pump mount.

4. Remove the air cylinder head (1).

5. Inspect the air cylinder head O-ring (2) for damage. Replace ifnecessary.

6. Remove the air cylinder (3).

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Fig. B 1-8 Removing the Air Cylinder

1. Air cylinder head2. Air cylinder head O-ring

3. Air cylinder4. Screw and lock washer

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7. See Figure B 1-9. Hold the hydraulic shaft with a wrench and removethe retaining nut at the top.

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Fig. B 1-9 Removing the Hydraulic Shaft Retaining Nut

8. See Figure B 1-10. Remove the piston cup washers (3), the pistoncups (2), and the piston seal washer (1).

9. Inspect the cups and washers for damage (cracking or creasing).Replace if necessary.

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Fig. B 1-10 Piston Cups, Piston Cup Washers, Piston Seal Washer

1. Piston seal washer2. Piston cup

3. Piston cup washer

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Pump Hydraulic Section Disassembly

1. See Figure B 1-11. Secure the pump with a vise and use a flat-bladescrewdriver to straighten the lock tab on the bearing lock washer.

2. Use a spanner wrench or hammer and a flat-blade screw driver toloosen the bearing lock nut. Then slide the nut and washer awayfrom the pump body.

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Fig. B 1-11 Removing the Nut and Washer

3. Pull the pump mount off of the pump body.

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4. See Figure B 1-12. Inspect the pump mount O-ring (1) and U-cup (3)for damage (cracking or creasing).

5. If necessary, remove the O-ring, the retaining ring (2), and the U-cup.Replace any damaged components.

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Fig. B 1-12 Pump Mount Component

1. U-cup2. Retaining ring

3. Pump mount O-ring

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Pump Hydraulic Section Disassembly (contd)

6. See Figure B 1-13. Inspect the pump seal (4) and pump bodyO-ring (1) for damage (cracking, hardening, or creasing).

7. If necessary, use snap-ring pliers to remove the retaining ring (2).Then manually stroke the hydraulic shaft (5) up and down to loosenthe washer (3) and pump seal. Replace any damaged components.

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Fig. B 1-13 Hydraulic Shaft Components

1. Pump body O-ring2. Retaining ring3. Washer

4. Pump seal5. Hydraulic shaft

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8. See Figure B 1-14. Secure the pump body with a vise or wrench andremove the crossover tube (1), the O-ring (2), and the backupring (3).

9. Inspect the O-ring and backup ring for damage. Replace ifnecessary.

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Fig. B 1-14 Crossover Tube, O-Ring, and Backup Ring

1. Crossover tube2. O-ring

3. Backup ring

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Pump Hydraulic Section Disassembly (contd)

10. See Figure B 1-15. Remove the siphon ball seat (3), siphon ball (2),and siphon ball cage (1) from the pump body.

11. Inspect the siphon ball seat for damage. Replace if necessary.

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Fig. B 1-15 Siphon Ball Cage, Siphon Ball, and Siphon Ball Seat

1. Siphon ball cage2. Siphon ball

3. Siphon ball seat

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CAUTION: Risk of equipment damage. Do not scratch thehydraulic shaft or the inside of the pump body. Scratches cancause the pump to leak.

12. See Figure B 1-16. Pull the hydraulic shaft (2) out of the pumpbody (1).

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Fig. B 1-16 Pump Body and Hydraulic Shaft

1. Pump body 2. Hydraulic shaft

13. See Figure B 1-17. Remove the screw (3), step washer (2), andpiston (1) from the hydraulic shaft.

14. Inspect the piston and step washer for damage. Replace ifnecessary.

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Fig. B 1-17 Piston and Step Washer

1. Piston2. Step washer

3. Screw

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Pump Component Cleaning

If necessary, use one of the following methods to clean the pumpcomponents.

WARNING: Risk of fire or explosion. Do not heat Type-Rcleaning fluid above 246 �C (475 �F). Do not heat the cleaningfluid with an open flame or in an unregulated heating device.

� Place the pump components, except for the O-rings, in a container ofType-R cleaning fluid and heat the fluid until it is above the meltingpoint of the adhesive. Scrub the components with a fine-bristledbrush and wipe them with a clean, dry cloth.

� Use a flameless, electric heat gun or compressed hot air to heat thecomponents; then wipe the components with a clean, dry cloth.

� Use an ultrasonic cleaner filled with cleaning fluid to soak thecomponents; then wipe the components with a clean, dry cloth.

Pump Hydraulic Section Assembly

See the illustrations in Pump Hydraulic Section Disassembly as youperform the following reassembly steps. You can also use the pumpparts list illustration at the end of this section.

1. Remove all adhesive from the pump seal cavity and the retaining-ringgroove.

2. Slip the piston onto the hydraulic shaft and place the step washer onthe screw. Apply threadlocking adhesive to the screw threads; theninstall the screw and step washer on the hydraulic shaft. Tighten to4.07−6.78 N�m (3−5 ft-lb).

3. Insert the hydraulic shaft in the pump body.

4. Apply threadlocking adhesive to the siphon ball seat threads; thenreinstall the siphon ball cage, siphon ball, and siphon ball seat.

5. Place the crossover tube O-ring and backup ring on the crossovertube, apply PTFE paste to the crossover tube threads, and reinstallthe crossover tube.

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6. If you removed the pump body O-ring, retaining ring, washer, andpump seal, then

a. Apply high-temperature lubricant to the O-ring and install it on thepump body.

b. Apply high-temperature lubricant to pump seal and pull thehydraulic shaft up from the top of the pump body.

c. Secure the pump body with a vise. Place the pump seal, with thegroove facing down, on the hydraulic shaft; then install thewasher. Slide the hydraulic shaft down to help guide the seal andwasher into place in the pump body.

d. Install the retaining ring in its groove in the pump body.

7. If you removed the pump mount O-ring, retaining ring, andU-cup, then

a. Insert the U-cup in the upper face of the pump mount with thegroove facing up.

b. Press the retaining ring in the upper face to secure the U-cup.

c. Apply high-temperature lubricant to the pump mount O-ring andplace the O-ring on the upper surface of the pump mount.

8. Apply high-temperature lubricant to the hydraulic shaft at the pointwhere it passes through the U-cup.

9. Guide the upper part of the pump body and the hydraulic shaftthrough the bottom hole in the pump mount.

10. Place the bearing lock washer and nut over the hydraulic shaft andslide the hydraulic shaft through the hole in the top of the pumpmount.

11. Rotate the pump body clockwise until you feel it rest against the stopin the bottom of the pump mount. Secure the pump body to the pumpmount by tightening the bearing lock nut.

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Pump Hydraulic Section Assembly (contd)

12. Using a flat-blade screwdriver, lock the bearing lock washer bybending one tab into one of the slots on the bearing lock nut.

13. Slide the fork onto the hydraulic shaft until it sits on the shoulder.Make sure the side stamped UP is facing the air cylinder. Install thescrew and washer and tighten to 8−10 N�m (6−7 ft-lb).

Pump Air Section Assembly

See the illustrations in Pump Air Section Disassembly as you perform thefollowing reassembly steps. You can also use the pump parts listillustration at the end of this section.

1. Pull the hydraulic shaft up as far as possible and install the followingparts onto the shaft in this order:

a. one piston cup washerb. one piston cup with the curved edge facing downc. the piston seal washer

2. Slide the air cylinder over the hydraulic shaft and onto the pumpmount. Be careful not to damage the piston cup.

3. Use the shifter fork to move the hydraulic shaft up to the top of the aircylinder.

4. Install the remaining piston cup, with the curved edge facing up, andpiston cup washer on the hydraulic shaft.

5. Hold the hydraulic shaft with a wrench and replace the retaining nut.Tighten to 11.30−13.56 N�m (8−10 ft-lb).

6. Apply high-temperature lubricant to the air cylinder O-ring and roll theO-ring into place on the air cylinder head.

7. Position the air cylinder head on the air cylinder so that the shouldercut-out is facing the actuator. Apply anti-seize compound to the aircylinder screws and use the screws and lock washers to secure theair cylinder to the pump mount. Tighten to 5−6 N�m (45−55 in.-lb).

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Actuator Installation

See the illustrations in Actuator Removal as you perform the followingreassembly steps. You can also use the pump parts list illustration at theend of this section.

NOTE: Series 3500V units have a pump cover bracket that must beinstalled when the actuator is installed. See Figure B 1-6.

1. If you removed the O-rings from the air cylinder face, coat four newO-rings with high-temperature lubricant and install them on the aircylinder.

2. Move the hydraulic shaft up or down until the shifter fork is in thecenter of the pump mount.

3. Carefully align the actuator with the shifter fork and the locating pinson the air cylinder.

4. Install the actuator with the screws and washers you removed earlier.Tighten to 3−4 N�m (28−36 in.-lb).

Pump Installation

NOTE: If you are replacing an old pump with a new, complete pump andyour old pump has a pump cover bracket, remove the bracket and installit on the new pump.

1. Make sure the pump pan is positioned correctly.

2. Lower the pump into the unit until the crossover tube seats in themanifold.

3. Secure the pump to the unit with the screws and washers youremoved earlier. Tighten to 12.20−13.56 N�m (9−10 ft-lb).

4. Connect the air input line to the actuator.

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System Restoration

1. Replace the pump cover.

2. Turn the unit on and allow it to reach operating temperature.

3. See Figure B 1-18. Place a container under the manifold drain valveand open the valve.



Reverse-flush With the manifold filter in the RUN position, openthe right-side drain valve.

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Fig. B 1-18 Opening the Manifold Drain Valve

1. A manifold (standard filter)2. B or S manifold (standard filter)

3. C or T manifold(reverse-flush filter)

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4. Increase pump air pressure until clean adhesive flows from the drainvalve. This will purge the system of trapped air.


6. Close the drain valve.

7. Return the air pressure to the normal operating setting and resumeoperation.

Use this procedure to reposition or replace the shifter fork withoutremoving the pump from the unit.





4. Remove the actuator:

a. Move the hydraulic shaft up or down until shifter fork is centeredin the pump mount.

b. Remove the screws and washers that secure the actuator; thenremove the actuator.

NOTE: Series 3500V units have a pump cover bracket that mustbe removed. See Figure B 1-6.

Repositioning or Replacing theShifter Fork

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5. See Figure B 1-19. Remove the screw and washer (2) from theshifter fork (1); then slide the fork toward the air cylinder and off thehydraulic shaft.

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Fig. B 1-19 Removing the Shifter Fork

1. Shifter fork 2. Screw and washer

6. Reposition the shifter fork or install a new shifter fork. Make sure theside of the fork stamped UP faces up.

7. Slide the fork down onto the hydraulic shaft shoulder.

8. Install the screw and washer. Tighten the screw to8−10 N�m (71−89 in.-lb).

9. Install the actuator:


a. Move the hydraulic shaft up or down until the shifter fork is in thecenter of the pump mount.

b. Carefully align the actuator with the shifter fork and the locatingpins on the air cylinder.

c. Install the actuator with the screws and washers you removedearlier. Tighten to 3−4 N�m (28−36 in.-lb).

10. Replace the pump cover, restore power and air to the unit, andresume operation.

Repositioning or Replacingthe Shifter Fork (contd)

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Use these procedures to clean or replace the actuator’s magnetassembly, bumper assembly, or air valve. Refer to the parts lists at theend of this section for the part numbers of any components that need tobe replaced. You can also use the actuator parts list illustration as aguide as your perform the following disassembly and reassemblyprocedures.

Use this procedure to replace the actuator without removing the pumpfrom the unit.

Actuator Removal





4. Disconnect the air input line from the actuator and remove the air lineelbow.

5. Move the hydraulic shaft up or down until shifter fork is centered inthe pump mount.

6. See Figure B 1-20. Remove the screws and washers (1) that securethe actuator (3); then remove the actuator.

NOTE: Series 3500V units have a pump cover bracket (2) that mustbe removed.

7. Inspect the O-rings (4) in the face of the air cylinder for damage.Replace if necessary.

5. Actuator RepairProcedures

Replacing the Actuator

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Actuator Removal (contd)

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Fig. B 1-20 Removing the Actuator

1. Screw and washer2. Pump cover bracket (Series

3100V, 3400V, and 3500Vunits only)

3. Actuator4. O-ring

Actuator Installation


1. If you removed the O-rings from the air cylinder face, coat four newO-rings with high-temperature lubricant and install them on the aircylinder.

2. Move the hydraulic shaft up or down until the shifter fork is in thecenter of the pump mount.

3. Carefully align the actuator with the shifter fork and the locating pinson the air cylinder.

4. Install the actuator with the screws and washers you removed earlier.Tighten to 3−4 N�m (28−36 in.-lb).

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5. Apply PTFE paste or tape to the air line elbow threads; then installthe elbow in the actuator.



Use this procedure to clean or replace the magnet assembly. Themagnet assembly is located inside the actuator.

Magnet Assembly Removal






5. Remove the actuator:

a. Move the hydraulic shaft up or down until shifter fork is centeredin the pump mount.

b. Remove the screws and washers that secure the actuator; thenremove the actuator.

NOTE: Series 3500V units have a pump cover bracket that mustbe removed. See Figure B 1-20.

Cleaning or Replacing theMagnet Assembly

HydraulicsB 1-32


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Magnet Assembly Removal (contd)

CAUTION: Use a clean work surface. The actuator containsmagnets that can pick up small particles. These particles candamage the actuator or cause poor actuator performance.

6. See Figure B 1-21. Remove the screws that attach the can to thevalve body and pull the can straight out from the valve body.

4103175

Fig. B 1-21 Removing the Can

7. Inspect the magnet assembly.

If the assembly is… Then…

Dirty or has metal particlesclinging to it

Remove the dirt or particles with a cleancloth and go to Magnet AssemblyInstallation.

Loose Go to step 2 of Magnet AssemblyInstallation to tighten the assembly andreinstall the actuator.

Damaged Continue with the next step.

8. Remove the valve cap screws and lift the valve cap off the bumperassembly.

Hydraulics B 1-33


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CAUTION: Risk of equipment damage. If you use a vise tohold the valve body while removing the magnet assembly, placethe vise jaws on the sides of the valve body, not on themachined surface that mounts to the air cylinder.

9. See Figure B 1-22. Pull down on the magnet assembly and slip anawl through the hole in the shaft.

10. Hold the bumper flats with a wrench and unscrew the magnetassembly from the valve spool.

4103176

Fig. B 1-22 Removing the Magnet Assembly

Magnet Assembly Installation

See the illustrations in Magnet Assembly Removal as you perform thefollowing reassembly steps. You can also use the actuator parts listillustration at the end of this section.

CAUTION: Risk of equipment damage. If you use a vise tohold the valve body while removing the magnet assembly, placethe vise jaws on the sides of the valve body, not on themachined surface that mounts to the air cylinder.

1. Thread the magnet assembly into the valve spool until it seats.

2. Slip an awl through the hole in the magnet assembly shaft.

3. Using an adjustable wrench, hold the bumper flats and screw themagnet assembly into the valve spool. Tighten to9−11 N�m (81−99 in.-lb).

HydraulicsB 1-34


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Magnet Assembly Installation (contd)

4. Slide the can over the magnet assembly so the opening faces thepump assembly. Install the securing screws and tighten them to3−4 N�m (28−36 in.-lb).

5. Install the valve cap. Tighten the valve cap screws to3−4 N�m (28−36 in.-lb).

6. Install the actuator:


a. Move the hydraulic shaft up or down until the shifter fork is in thecenter of the pump mount.

b. Carefully align the actuator with the shifter fork and the locatingpins on the air cylinder.

c. Install the actuator with the screws and washers you removedearlier. Tighten to 3−4 N�m (28−36 in.-lb).



Use this procedure to clean or replace the air valve assembly. The airvalve assembly is located inside the actuator.

Cleaning or Replacing the AirValve

4130832

1

2

3

4

5

6

7

8

Hydraulics B 1-35


41-3000VIssued 5/00


Air Valve Removal

1. Complete Magnet Assembly Removal.

NOTE: The Magnet Assembly Removal procedure includes steps forrelieving system pressure, locking out power, and removing theactuator.

2. See Figure B 1-23. Remove the valve cap screws (1) and lift thevalve cap (2) off the bumper assembly (4).

3. Remove the bumper assembly. Use an open-end wrench to hold thebumper assembly, then use another wrench to remove the retainingnut (3).

4. Remove the upper detent (8) from the bottom of the valve body (7).

CAUTION: Risk of equipment damage. Do not press the airvalve out of the valve body by pressing on the end of the spool.

5. Use a socket or similar tool to press the air valve out of the valvebody by pressing against the end of the sleeve (6).

6. Remove and discard the sleeve O-rings (5).

Fig. B 1-23 Removing the Air Valve

1. Valve cap screw2. Valve cap3. Retaining nut4. Bumper assembly5. Sleeve O-ring6. End of sleeve7. Valve body8. Upper detent

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Air Valve Removal (contd)

CAUTION: Risk of equipment damage. Do not clean the airvalve with an abrasive, scrape the spool or sleeve, or round offthe sharp edges of the spool lands. Doing so can damage thespool and sleeve and cause the pump to stall.

7. See Figure B 1-24. Remove the retaining screw (4) from the side ofthe sleeve (3).

8. Carefully slide the spool (2) out of the sleeve.

9. Inspect the spool lands (1).

Spool lands are… Action

Nicked, gouged, deeplyscratched, or corroded

Replace the air valve. Go to Air ValveInstallation.

Covered withcontaminants

1. Clean the spool and sleeve withmineral spirits or any non-chlorinatedcleaning solution, and a soft cloth. Donot use abrasives, scrape the spool orsleeve, or round off the sharp edgesof the spool lands.

2. Thoroughly wipe the valve parts witha clean cloth or rinse them withdenatured alcohol.

4103567

4

2

3

1

Fig. B 1-24 Air Valve Components

1. Spool lands2. Spool

3. Sleeve4. Retaining screw

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Air Valve Installation

See the illustrations in Air Valve Removal as you perform the followingreassembly steps. You can also use the actuator parts list illustration atthe end of this section.

1. Apply SP pump lubricating oil to the spool lands. Refer to ActuatorParts List for the oil part number.

2. Carefully insert the spool into the sleeve and center it in the sleeve.

NOTE: The spool and sleeve are a matched set and cannot bereplaced with components from another air valve assembly.

3. Install the retaining screw. Tighten to 0.7−0.9 N�m (6−8 in.-lb).

4. Make sure the spool slides freely in its sleeve. If not, replace the airvalve and go to step 5.

5. Apply high-temperature lubricant to a new set of O-rings and installthe O-rings on the sleeve.

6. See Figure B 1-25. Press the air valve into the valve body from thetop by pushing down on the flange.

4103180

Fig. B 1-25 Installing the Air Valve

7. Install a new bumper assembly on top of the air valve.

8. Use a wrench to hold the bumper assembly flats and tighten theretaining nut. Tighten to 9−11 N�m (81−99 in.-lb).

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1

3

4

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Air Valve Installation (contd)

9. Install the upper detent on the bottom of the valve body with thescrews removed earlier. Tighten to 1.82−2.27 N�m (16−20 in.-lb).


11. Complete Magnet Assembly Installation.

Use this procedure to replace the actuator bumper assembly withoutremoving the actuator from the unit.





4. See Figure B 1-26. Remove the valve cap screws (1) and lift thevalve cap (2) off the bumper assembly (4).

5. Remove the bumper assembly. Use an open-end wrench to hold thebumper assembly stationary, then use another wrench to remove theretaining nut (3).

6. Install a new bumper assembly and secure it with the retaining nut.Tighten the nut to 9−11 N�m (81−99 in.-lb).


8. Reinstall the pump cover, restore power and air to the unit, andresume operation.

Fig. B 1-26 Replacing the BumperAssembly

1. Valve cap screw2. Valve cap3. Retaining nut4. Bumper assembly

Replacing the BumperAssembly

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Use these procedures to replace the pump solenoid valve. Refer to theparts lists at the end of this section for the part numbers of anycomponents that need to be replaced. You can use the solenoid valveassembly parts list illustration as a guide if you need to replace othersolenoid valve assembly components.

Follow this procedure to remove the pump solenoid valve. The solenoidvalve is located inside the electrical enclosure.




WARNING: Risk of electrical shock. Failure to observeelectrical safety procedures may result in personal injury ordeath. Allow only qualified personnel to perform the followingprocedures. Observe all high voltage indicators.

3. Open the electrical enclosure. Refer to Opening the ElectricalEnclosure in the Control section.

4. See Figure B 1-27. Unplug (1) the solenoid valve.

5. Disconnect the air lines (3) from the elbows (2) on the solenoid valve.

6. Remove the screws that secure the solenoid valve mountingbracket (4) to the unit; then remove the valve and bracket from theunit.

7. Remove the screws (5) that secure the mounting bracket to thesolenoid valve and disconnect the bracket from the valve.

8. Remove the elbows from the solenoid valve.

6. Pump Solenoid ValveReplacementProcedures

Removing the Solenoid Valve

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4130841A

4

2

2

1

3

5

Fig. B 1-27 Solenoid Valve Assembly Components

1. Plug2. Elbows3. Air lines

4. Mounting bracket5. Screws

Follow this procedure to install the new solenoid valve and to restore theunit to operation.

1. See Figure B 1-27. Install the elbows on the new solenoid valve.

2. Install the mounting bracket on the new solenoid valve.

3. Install the solenoid valve and mounting bracket on the back panel ofthe unit with the screws you removed earlier.

4. Connect the air lines to the solenoid valve elbows.

Removing the Solenoid Valve (contd)

Installing the Solenoid Valve

Hydraulics B 1-41


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5. Connect the solenoid valve plug.

6. Close the electrical enclosure and restore power to the unit.

7. Return the pump air pressure to the normal operating setting.

8. Start the unit and listen for air leaks. If you hear air leaking, check theair line connections at the elbows.

Use these procedures to replace the pressure relief valve or the manifolddrain valve.

Use this procedure to replace the pressure relief valve. The pressurerelief valve is located in the bottom of the tank.

1. Drain as much adhesive from the tank as possible. Refer to Flushingthe System in Maintenance for different ways to drain the tank.

2. See Figure B 1-28. Use a socket wrench to loosen the pressure reliefvalve (1); then carefully unscrew the valve and remove it.

4130835

1

2

Fig. B 1-28 Replacing the Pressure Relief Valve

1. Pressure relief valve 2. Typical tank

3. Screw the new valve into the tank until it is finger-tight.

4. Use a socket wrench to tighten the valve. Tighten to 14−16 N�m(10−12 ft-lb).

5. Refill the tank with adhesive and resume operation.

7. Manifold RepairProcedures

Replacing the Pressure ReliefValve

HydraulicsB 1-42


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Use this procedure to replace the drain valve. The drain valve is locatedin the manifold near the manifold filter.

NOTE: Units with a reverse-flush filter have two manifold drain valves.

1. Make sure the unit is at operating temperature.

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

2. Relieve system pressure. Refer to Relieving System Pressure inMaintenance.

3. See Figure B 1-29. Remove the drain valve alignment screw (1) andwasher (2); then remove the valve (3) from the unit. Some adhesivewill flow from the valve.

41308361 2

3

Fig. B 1-29 Replacing the Drain Valve

1. Alignment screw2. Washer

3. Drain valve

4. Screw the new drain valve into the manifold until it is secure; thenadjust it as necessary to install and tighten the alignment screw andwasher.

5. Resume operation.

Because the manifold has no moving parts, you should not need toreplace it. However, if you need to remove the manifold for any reason,refer to Tank.

Replacing the Drain Valve

Replacing the Manifold

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

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

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

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

Item Part Description Quantity Note

— 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � Part 1

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

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

8. Illustrated Parts Lists

Using the Illustrated Parts List

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See Figure B 1-30. The UpTime pack for pump F (21:1) provides theparts that should be replaced as part of routine maintenance.


— 164 685 Service kit, UpTime, pump F, 21:1 —

1 940 111 � O-ring, Viton, 0.301 x 0.70 in. 4

2 940 440 � O-ring, Viton, 3.750 x 3.875 x 0.063 in. 2

3 984 092 � Nut, hex, lock, torque, M6, class 10 1

4 288 116 � Cup, piston, high volume 2

5 986 331 � Retaining ring, internal, 100, push-on 1

6 952 100 � Cup, U, Viton 1

7 986 711 � Retaining ring, internal, 106, spiral 1

8 288 121 � Washer, 1.045 x 0.819 in. 1

9 288 122 � Seal, pump, high volume 1

10 940 133 � O-ring, Viton, 0.426 ID x 0.70 in. 1

UpTime Pack for Pump F

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4130184A

2

1

3

4

4

2

6

7

8

9

105

Fig. B 1-30 Pump F UpTime Pack Parts

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This page left intentionally blank

Hydraulics B 1-47


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See Figure B 1-31.


— 164 683 Service kit, pump F, SP, 21:1, UpTime, w/o pumpcover bracket

— A

1 - - - - - - Actuator, assembly 1 B

2 940 111 O-ring, Viton, 0.301 ID x 0.070 in. 4

3 164 469 Head, air cylinder 1

4 982 147 Screw, hex head, cap, M6 x 120 mm 4 C

5 983 409 Washer, lock, split, M6 4

6 940 440 O-ring, Viton, 3.750 x 3.875 x 0.063 in. 2 D

7 161 204 Cylinder, air 1

8 984 092 Nut, hex, lock, torque, M6, class 10 1

9 288 115 Washer, piston cup, high volume 2

10 288 116 Cup, piston, high volume 2

11 288 117 Washer, piston, seal, high volume 1

12 986 331 Ring, retaining, internal, 100, push-on 1

13 952 100 Cup, U, Viton 1

14 161 203 Mount, pump 1

15 982 050 Screw, hex head, cap, M8 x 35 mm 3

16 983 414 Washer, flat, narrow, M8 3

17 983 404 Washer, lock, split, M8 3

18 982 135 Screw, hex head, cap, M6 x 30 mm 1

19 170 641 Service kit, fork, 21:1, SP (shifter fork) 1

20 984 545 Nut, lock, bearing, PN-8 1

21 983 134 Washer, lock, E, bearing, 1.574 in. 1

22 986 711 Ring, retaining, internal, 106, spiral 1

23 288 121 Washer, 1.045 x 0.819 in. 1

24 288 122 Seal, pump, high volume 1 D

NOTE A: Order this part to receive a complete piston pump.

B: Refer to Actuator Assembly Parts List.

C: Apply anti-seize compound, part 900 344.

D: Apply high-temperature lubricant, part 900 493.

Continued on next page

Piston Pump Parts List

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25 134 657 Body, pump 1

26 973 402 Plug, pipe, socket, flush, 1/8 in. 1 E

27 288 031 Tube, crossover 1 C

28 954 013 Backup ring, single, 7/16 x 9/16 in. 1

29 940 133 O-ring, Viton, 0.426 ID x 0.70 in. 1

30 162 988 Shaft, hydraulic, 21:1 1

31 276 716 Piston 1

32 983 024 Washer, step, 1.0 in. diameter 1

33 982 376 Screw, socket head, low, M8 x 16 mm 1 F

34 240 533 Cage, ball, siphon 1

35 900 023 Ball, 440, stainless-steel, 0.750 in., 50 1

36 240 534 Seat, siphon ball 1

37 941 261 O-ring, Viton, 1.375 x 1.563 x 0.094 in. 1 D

38 973 466 Pipe, plug, flush, 1/16 in., w/ sealant 2

39 983 410 Washer, flat, narrow, M6 1

40 187 632 Bracket, cover, pump, 21:1, SP 1 G

41 982 298 Screw, hex head, cap, M5 x 50 mm 2 G

42 983 408 Washer, flat, narrow, M6 2 G

NOTE C: Apply anti-seize compound, part 900 344.

D: Apply high-temperature lubricant, part 900 493.

E: Apply paste, part 900 236.

F: Apply retaining cylindrical adhesive, part 900 419.

G: Used only on Series 3500V units.

Piston Pump Parts List (contd)

Hydraulics B 1-49


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4130499A

6

2

38

9

10

11

12

22

23

24

29

7

3 4

5 37

25

26

28

27

30

31

32

33

34

35

36

14

8

16

17

15

1

40

41

4210

9

6

13

20

21

39

18

19

Fig. B 1-31 Pump F Parts

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See Figure B 1-32.


— 155 077 Service kit, actuator assembly, SP — A

1 982 028 Screw, socket head, M5 x 20 mm 4

2 155 054 Cap, valve 1

3 984 090 Nut, hex, lock, torque, M8 1

4 161 422 Service kit, bumper 2

5 161 429 Service kit, spool/sleeve 1 B

6 940 181 O-ring, Viton, 0.739 ID x 0.070 in. 4 C

7 155 051 Body, valve 1

8 155 057 Detent, upper 1

9 982 059 Screw, socket head, M4 x 8 mm 2

10 164 606 Service kit, magnetic actuator (magnet assembly) 1

11 155 068 Can 1

12 155 067 Detent, lower 1

13 986 714 Retaining ring, internal, 156, bowed 1

NOTE A: Order this part to receive a complete actuator assembly.

B: Apply SP pump lubricating oil, part 211 228, to the spool lands.

C: Apply high-temperature lubricant, part 900 493.

Actuator Parts List

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4130037

1

2

3

4

5

6

7

8

9

10

11

12

13

1

Fig. B 1-32 Actuator Parts

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See Figure B 1-33.


1 982 251 Screw, pan-head, recessed, M5 x 8 mm 2

2 338 306 Elbow, male, 3/8 in. tube x 1/4 NPT, Viton 3

3 338 307 Elbow, male, 3/8 in. tube x 1/8 NPT, Viton 1

4 102 032 Grommet, 0.375 ID in. 2

5 900 596 Tubing, PTFE, 3/8 in. 1 A

6 275 115 Adapter, 1/4 NPTF 1

7 982 309 Screw, pan head, recessed, M5 x 10 mm 1

8 232 648 Bracket, mounting, solenoid valve, Vista 1

9 982 924 Screw, cross-pan, #10-31 x 0.250 in. 2

10 237 293 Assembly, solenoid valve, 2 way, 24 VDC, 1/4 NPT 1

11 - - - - - - Frame, hose end 1 B

12 - - - - - - Frame, center 1 B

13 - - - - - - Pump assembly 1 C

NOTE A: Specify required length when ordering replacement tubing.

B: Refer to Frame Assembly Parts List in Tank.

C: Refer to Piston Pump Parts List.

Solenoid Valve Assembly PartsList

Hydraulics B 1-53


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4130553A

5

11

5

8

26

12

13

3

9

4

2 10

21

5

5

7

Fig. B 1-33 Solenoid Valve Assembly Parts

HydraulicsB 1-54


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See Figure B 1-34.


— 165 873 Regulator/filter assembly, 70 psi, 4-hose — A

— 165 874 Regulator/filter assembly, 70 psi, 6-hose — B

1 165 735 � Regulator, filter, air, 1/4 NPT 1

2 973 490 � Nipple, brass, 40, 1/4 in., 2.50 in. 1 A

2 973 491 � Nipple, brass, 40, 1/4 in., 5.00 in. 1 B

3 901 257 � Gauge, air, 1/8 NPT, 70 psi 1

4 165 870 Service kit, filter element 1

5 165 878 Service kit, filter bowl 1

NOTE A: Used only on 4-hose units.

B: Used only on 6-hose units.

4103139

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4

5

2

Fig. B 1-34 Air Pressure Regulator/Filter Assembly Parts

Air Pressure Regulator andFilter Assembly Parts List

Hydraulics - Welcome to Nordson...

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