SP Pump Diagnostics and Repair D-1

Appendix D
SP Pump Diagnostics and Repair
WARNING! Allow only personnel with appropriate training and experience
to operate or service the equipment. The use of untrained or inexperienced
personnel to operate or service the equipment can result in injury, including
death, to themselves and others, and damage to the equipment.

Introduction
This appendix provides comprehensive diagnostic and repair information for
the SP pump used in all ProBlue adhesive melters. Before using the
information provided in this appendix to diagnose or repair your pump,
ensure that you have eliminated all conditions that might otherwise be
mistaken for a failure of the pump. Refer to Section 6, Troubleshooting.

Pump Function
The pump is double-acting—material is discharged from the pump during
both the upward and downward stroke of the piston.

The pump consists of an air section and a hydraulic section. Air is supplied
to the pump through an air filter and a regulator. From the regulator, air
flows to an air valve inside the air section. The air valve directs air into
either the upper or lower portion of the air cylinder, which forces the piston
assembly up or down. The lower end of the piston assembly contains a
pressure ball valve. At the bottom of the hydraulic section is a siphon ball
valve.

When the air valve directs the stroke of the piston upwards, the piston
creates suction within the pump body, which opens the siphon ball valve
and closes the pressure ball valve. As the piston moves upwards, material
is simultaneously drawn into the pump below the pressure ball valve and
forced out of the pump chamber above the pressure ball valve. Material
leaving the pump chamber passes through a filter and then into a manifold,
where it is distributed to the hoses/guns.

Attached to the piston assembly is a shifter fork. The fork travels along the
shaft of the actuator assembly that has a magnet at both ends. When the
stroke of the piston carries the shifter fork upwards, a magnet in the shifter
fork attracts the magnet at the end of the actuator, which shifts the position
of the air valve. When the valve shifts, air is redirected to the opposite side
of the air cylinder, which forces the piston downwards.

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D-2 SP Pump Diagnostics and Repair

Pump Function (contd)

On the piston downward stroke, material pressure below the piston closes
the siphon ball valve and opens the pressure ball valve. As the piston
moves downwards, material below the pressure ball valve is displaced, and
forced through the pressure ball valve and out of the pump chamber, where
again, it passes through the filter and into the manifold.

Pump Isolation Valve

To prevent siphoning of the tank when the pump is removed from the
manifold, the manifold is equipped with an isolation valve.

Pressure Discharge Valve

The manifold is equipped with a pressure discharge valve. When the pump
is switched off at the control panel, air is removed from the top of the valve
causing it to open. When the valve opens, pressurized material within the
pump and manifold is bypassed through the pressure discharge valve back
to the tank.

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Pump Diagnostics
To determine why the pump has failed, you will, in most cases, have to
partially or fully disassemble the pump. To assist you in determining the
appropriate level of disassembly, Table D-1 provides a logical breakdown of
the three types of pump failures, the potential conditions that could produce
each failure, and the disassembly procedure(s) in which potential
condition(s) can be examined.

Disassembly procedures are provided in Pump Disassembly and

Reassembly.

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Table D-1 Pump Diagnostics

Problem Possible Cause Corrective Action
1. Pump not Stroking Air valve dirty or damaged Remove the Valve Spool and Sleeve

Valve sleeve O-rings damaged or Remove the Valve Spool and Sleeve
deteriorated

Air leaking from between the cylinder Remove The Actuator and the Air
head and the air cylinder or between Cylinder Assembly
the air cylinder and the pump frame

Piston cups damaged Remove the Piston Cups

Shifter fork damaged, slipped out of Removing the Shifter Fork

position on piston, installed upside
down, or magnets loose

Magnets on actuator assembly loose Remove the Magnetic Actuator Assembly

Piston damaged or has char buildup Remove the Lower Ball Seat Assembly
and the Piston

2. Pump Leaking O-ring and/or pump seal deteriorated Remove the Pump O-ring and the Pump
Adhesive or damaged Seal

O-rings on cross-over tubes or Removing the Pump from the Melter

between the pump and manifold
damaged or deteriorated

3. Pump Strokes Siphon ball, seat and/or cage is Disassemble the Lower Ball Seat and
Erratically damaged, deteriorated, or has char Pressure Ball Assemblies
buildup

Pressure ball and/or seat has char Disassemble the Lower Ball Seat and
buildup or is scratched or pitted Pressure Ball Assemblies

Piston has char buildup Remove the Lower Ball Seat Assembly
and the Piston

Pump body dirty Remove the Lower Ball Seat Assembly

and the Piston

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D-6 SP Pump Diagnostics and Repair

Pump Disassembly and Reassembly

This part provides sequential pump disassembly procedures. Unless
otherwise noted in the Special Reassembly Instructions, which are provided
in each procedure, reassembly of the pump is the reverse of the
disassembly.

Within each disassembly procedure, is a check/repair table that describes

what specific conditions (from Table D-1) to inspect for while disassembling
the pump, service details, and component part numbers.

Melter Preparation
The melter must be brought up to operating temperature before the pump
can be removed and disassembled. Once the pump is removed, the molten
material within the pump will remain workable only for a short period of time.
If necessary, use a heat gun to warm the pump assembly during
disassembly.

Required Tools and Materials

Tools
 Heat gun
 4-mm hex wrench
 5-mm hex wrench
 6-mm hex wrench
 1/8-in. steel rod or equivalent tool
 8 mm open-end wrench
 10 mm socket and ratchet
 Bench vise or suitable mount to hold the pump during repairs
 Suitable vessel to heat Type-R fluid

WARNING! Do not heat Type R fluid with an open flame or in an

unregulated heating device. Do not heat Type R fluid above 246 C
(475 F).

Service Parts
In most cases, you will need the pump service kit P/N 1028304 to complete
pump repairs. This kit contains all of the seals, O-rings, and other parts that
are necessary to service the pump. Refer to the Parts at the end of this
appendix for a complete listing of the service kit and the pump assembly
parts.

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Supplies
The following table described the lubricants and other compounds that are
required during the re-assembly of the pump. Lubricants and other
compounds are indicated in the illustrations by the symbols shown in
Table D-2.

Table D-2 Lubricants and Compounds

Description Part Number Symbol

Never-Seez 900344

Parker Hi-Temp
1029063
Lubricant

Loctite 272
900470
Threadlocking Adhesive

SP Lubricating Oil 211228

Type-R Fluid (1 gal) 270755 −−

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D-8 SP Pump Diagnostics and Repair

Remove the Pump from the Melter

1. Relieve system pressure. Refer to Relieving System Pressure in
Section 5.

See Figure D-1.

2. Isolate the pump from the manifold by rotating the isolation valve handle
to its full vertical position (valve closed).
3. Remove the three M8 pump-mounting bolts from the front of the pump
body.
4. Rotate the top of the pump slightly toward the front of the melter while
pulling the pump away from the manifold.
NOTE: The face of the pump body contains two M6 threaded holes.
Bolts can be threaded into these holes to gain leverage when removing
the pump.

5. Remove the air line from the back of the pump.

6. Lift the pump clear of the melter, and place it in a bench vise or other
suitable mount.

Check/Repair
Pump-to-manifold Inspect for nicks, Apply Parker lubricant
O-rings gouging, or swelling during reassembly
P/N 1019515
P/N 942111 Inspect for nicks, Apply Parker lubricant
Cross-over tube O-rings gouging, or swelling during reassembly
P/N 940133 (2)
Teflon back-up ring
P/N 954013

Special Reassembly Instructions

 Before reinstalling the pump, lubricate the O-rings on the cross-over

tubes and the two O-rings between the pump and the manifold.

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 SP Pump Diagnostics and Repair D-9

Figure D-1 Removing the pump

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Remove the Actuator and Air Manifold and the Cylinder Assembly
See Figure D-2.

1. Remove the four M6 screws (1) and washers (2) from the cylinder head
(3), and then separate the cylinder head from the cylinder (4).
2. Lift the cylinder off of the piston cups (7), and then rotate the
cylinder/can assembly (4 and 5) away from the shifter fork assembly (6).
3. Remove the two O-rings (8).

Check/Repair
O-rings Inspect for nicks, Apply Parker lubricant
P/N 940332 gouging, or swelling during reassembly

Special Reassembly Instructions

 Slide the cylinder over the half of the piston cup assembly (Which was
installed as described in Removing the Piston Cup Assembly, Special
Reassembly Instructions); and then remove the torque nut, assemble
the remaining piston cup (cupped side facing up) and seal washer, and
then replace the torque nut.
 Before rotating the cylinder/can assembly onto the shifter fork, center
the fork inside the pump frame.

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5–6 Nwm (45–55 in.-lb) 1

4
8

Figure D-2
1. M6 screw (4) 4. Cylinder
2. M6 washer (4) 5. Can
3. Cylinder head 6. Shifter fork assembly
7. Piston cup/seal washers
8. O-rings (2)

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D-12 SP Pump Diagnostics and Repair

Remove the Magnetic Actuator Assembly

See Figure D-3.

1. Remove the two M5 screws (3), and then pull the can (2) off of the
actuator assembly (1).

See Figure D-4.

2. Pull the actuator assembly away from the upper detent (4) to expose the
small tool hole in the shaft (3).
3. Place a 1/8-in. steel rod or similar tool into the tool hole to prevent the
actuator from rotating.
4. With the actuator assembly held in position with the 1/8-in. steel rod/tool,
remove the valve spool nut (1), and then remove the bumper assembly
(2).

See Figure D-5.

5. While holding the valve spool by the wrench flats (1) to prevent the
spool from rotating, unscrew the actuator assembly (2).

Check/Repair
Magnetic Actuator Magnets are secured to Clean, tighten the
P/N 164606 the actuator shaft, magnets, or replace as
undamaged, and free of needed
debris

Bumper assembly Check for wear Replace if worn

P/N 1014650

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 SP Pump Diagnostics and Repair D-13

3–4 Nwm (28–36 in.-lb)

3
Figure D-3
1. Actuator assembly 3. M5 screw (2)
2. Can

9–11 Nwm (81–99 in.-lb)

1

4
3

Figure D-4
1. Valve spool nut 3. Tool hole
2. Bumper assembly 4. Upper detent

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Remove the Magnetic Actuator Assembly (contd)

9–11 Nwm (81–99 in.-lb)

2

Figure D-5
1. Wrench flats
2. Actuator assembly

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D-16 SP Pump Diagnostics and Repair

Remove the Valve Spool and Sleeve

CAUTION: Handle the valve spool with care. Damaging the precision
machined surface of the spool can cause the air valve to seeze.

See Figure D-6.

1. Carefully slide the valve spool (1) out of the valve sleeve (2). Set the
valve spool aside onto a clean cloth.

See Figure D-7.

2. Remove the two M4 screws (5), and then separate the upper detent (6)
and spring (4) from the air manifold (3).
3. Remove the two M5 screws (2), and then remove the flange (1).

See Figure D-8.

4. Use a socket or similar object to push the valve sleeve out of the air
manifold.

NOTE: The valve spool and sleeve are a matched set and cannot be
exchanged with parts from another air valve assembly. If either the spool or
sleeve is damaged, they must be replaced with a new valve assembly.

CAUTION! Do not scrape the valve spool or sleeve. Clean them with
mineral spirits or any non-chlorinated cleaning solvent and a soft cloth. Do
not use abrasives such as sandpaper or emery cloth. Be careful not to
round off the sharp edges of the spool lands.

Check/Repair
Valve spool* Spool lands are nicked, Clean with mineral spirits
gouged, corroded, or or any non-chlorinated
dirty solvent and a soft cloth.
Apply SP lubricating oil
to the lands before
inserting the spool back
into the sleeve

Valve sleeve* Broken, corroded, or Clean with mineral spirits

dirty or any non-chlorinated
solvent and a soft cloth

O-rings Inspect for nicked, Apply Parker lubricant

P/N 940181 gouged, or swollen during reassembly

*Available only as part of valve assembly P/N 1006027

Special Reassembly Instructions

 Use the flange to press the sleeve back into the air manifold.
 Apply only one drop of lubricating oil to each spool land.
 Ensure that the valve spool slides freely inside the sleeve.

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 SP Pump Diagnostics and Repair D-17

1
2

Figure D-6
1. Spool lands
2. Valve sleeve

2 3.2–4.1 Nwm (28–36 in.-lb)

5 1.82–2.27 Nwm (16–20 in. lb)

Figure D-7
1. Flange 4. Spring
2. M5 screws (2) 5. M4 screws
3. Air manifold 6. Upper detent

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D-18 SP Pump Diagnostics and Repair

Figure D-8
1. Valve sleeve
2. Air manifold

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D-20 SP Pump Diagnostics and Repair

Remove the Shifter Fork

CAUTION! Handle the shifter fork with care. Dropping or otherwise
mishandling the shifter fork may damage the magnet.

See Figure D-9.

1. Remove the hex-head screw (2) and the washer (1 ) from the shifter
fork (3).
2. Remove the shifter fork from the piston by sliding the fork up to the
narrowest point on the piston.

Check/Repair
Shifter fork assembly Word “UP” is facing Replace fork if bent or
P/N 166880 upwards magnet is damaged
Securely attached to
piston
Resting on piston
shoulder
Bent
Magnets
secure/undamaged

Special Reassembly Instructions

 The fork must be resting on the shoulder of the piston (See Figure D-9,
item 4).
 The word “UP” must be facing the top of the pump frame.

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3 2
7–8.5 Nwm (60–70 in.-lb)

Figure D-9
1. Washer 3. Shifter fork assembly
2. Hex-head screw 4. Piston shoulder

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D-22 SP Pump Diagnostics and Repair

Remove the Piston Cups

See Figure D-10.

1. While holding the piston in-place by its wrench flats, remove the M6
torque nut (1).
2. Remove the two piston cups (4) and the piston seal washers (2 and 3).

Check/Repair
Piston cups Not torn or deteriorated Apply Parker lubricant
P/N 163039 Pliable during reassembly

Special Reassembly Instructions

 To prevent damage to the upper piston cup when reinstalling the

cylinder, install only the bottom seal washer, the bottom piston cup,
center seal washer, and the torque nut (loose). The remaining piston
cup and washer are not installed until after the cylinder is in-place.

Refer to Remove the Actuator and Air Manifold and the Cylinder
Assembly.

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11.3–13.6 Nwm (100–120

in.-lb) 2
1

4
2

Figure D-10
1. Torque nut
2. Piston cup washer (2)
3. Piston seal washer
4. Piston cup (2)

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D-24 SP Pump Diagnostics and Repair

Remove the Pump Frame and the Insulator

See Figure D-11.

1. Remove the four hex-head screws (1) and washers (4).

2. Lift the pump frame (2) and the insulator (3) off of the piston.

See Figure D-12.

3. If necessary (see Checks/Repairs), remove the retaining ring (1) and the
U-cup (2) from the frame.

Check/Repair
Pump insulator Cracked or warped
P/N 1017307
U-cup piston seal Nicked, cut, or Apply Parker lubricant
P/N 952100 deteriorated during reassembly

Special Reassembly Instructions

 Before reinstalling the insulator and pump frame, place the O-ring and
piston seal over the piston.
NOTE: Install the pump seal with the open side facing the pump body.

 Install the insulator with the words “This side up” facing upwards.
 Use the insulator to seat the O-ring and pump seal into the groove in the
pump body.
 The tapered end of the insulator and pump frame face the filter.

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3–3.5 Nwm (25–31 in.-

lb)
1

Figure D-11
1. Hex-head screw (4)
2. Pump frame
3. Insulator
4. Washers (4)

Figure D-12
1. Retaining ring
2. U-cup

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D-26 SP Pump Diagnostics and Repair

Remove the Lower Ball Seat Assembly and the Piston

CAUTION: Handle the piston with care. Damaging the precision machined
surface of the piston can result in failure of the pump.

See Figure D-13.

1. Unscrew the lower ball seat assembly (2) from the pump body.
2. Pull the piston (1) out of the bottom of the pump body.

Check/Repair
Pump body Remove solidified
P/N 1016863 adhesive before
reassembly

Piston Nicked or worn

P/N 1022658 Remove solidified
adhesive before
reassembly

Special Reassembly Instructions

 Apply Never-seez to the threads of the lower ball seat before reinstalling
the seat into the pump body.
 Apply O-ring lubricant to the lower ball seat O-ring.

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 SP Pump Diagnostics and Repair D-27

Figure D-13
1. Piston
2. Lower ball seat assembly

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D-28 SP Pump Diagnostics and Repair

Disassemble the Lower Ball Seat and the Pressure Ball Assemblies
See Figure D-14.

1. Pull the siphon ball cage (1) off of the lower ball seat (4), and then
remove the siphon ball (2).
2. Remove the O-ring (3) from the lower ball seat.

See Figure D-15.

3. Unscrew the pressure ball seat (3) from the piston (1), and then remove
the pressure ball (2).

Check/Repair
Siphon ball Char buildup
P/N 900001
Pressure ball
P/N 900000
Ball seats Char buildup or damage Apply Never-seez during
P/N 1017320 reassembly

Siphon ball cage Char buildup or damage

P/N 503696
Lower ball seat O-ring Nicked, gouged, Apply Parker lubricant
P/N 945037 deteriorated, or swollen during reassembly

NOTE: Clean all hydraulic components in a container of Type R fluid before

reassembling them.

Special Reassembly Instructions

 If the siphon ball cage does not fit tightly onto the lower ball seat, gently
bend the legs of the cage together to create a spring-fit onto the seat.

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 SP Pump Diagnostics and Repair D-29

Figure D-14
1. Siphon ball cage
2. Siphon ball
3. O-ring
4. Lower ball seat

3
5.6–6.78 Nwm (50–60 in.lb)

Figure D-15
1. Piston
2. Pressure ball
3. Pressure ball seat

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Remove the O-ring and the Pump Seal

See Figure D-16.

Remove the O-ring (1) and pump seal (2) from the pump body.

Check/Repair
O-ring Nicked, cut, deteriorated, Apply Parker lubricant
P/N 940172 or swollen during reassembly

Pump Seal Nicked, cut, deteriorated, Apply Parker lubricant

P/N 273139 or deformed during reassembly

Special Reassembly Instructions

 The O-ring and the pump seal are replaced after the piston is
reinstalled, but before the insulator and pump frame are installed. Refer
to Removing the Pump Frame and the Insulator for information about
reinstalling the O-ring and the pump seal.

Figure D-16
1. O-ring
2. Pump Seal

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D-32 SP Pump Diagnostics and Repair

Pump Assembly Parts List

F1

F2 F6

31
1

30
2

3
F4
4

F2 F19

15 5
28
29 6
32
F6

27

33 26 7

34 F25 8

35
25
9

24
11 10

36 23
12
20
13
37

21

14
18 22
17

19

16 4401005A

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 SP Pump Diagnostics and Repair D-33

Item Used Part Description Quantity Note

— ------ Pump, piston, 14:1 1 A
1 1006027  Service kit, valve assembly, G2SP 1
2 1021998  Manifold, air, G1/8 in. port 1
3 333560  Spring, wave, Inconel, 1
4 155057  Detent, upper 1
5 164606  Service kit, magnetic actuator 1
6 155068  Can 1
7 155067  Detent, lower 1
8 986714  Retaining ring, internal, 156, bowed 1
9 984092  Nut, hex, lock, torque, M6, class 10 1
10 983446  Washer, piston cup 2
11 163039  Cup, piston 2
12 983445  Washer, piston seal 1
13 986331  Retaining ring, internal, 100, push-on 1
14 952100  Cup, U, Viton 1
15 166880  Service kit, fork magnetic 1
16 1017320  Seat, ball, lower 1
17 900001  Ball, 440 stainless steel, 0.500 in. 1
18 503696  Cage, ball, siphon 1
19 945037  O-ring, Viton, 1 in. tube 1
20 1022658  Piston assembly 1
21 900000   Ball, 440 stainless steel, 0.375 in. 1
22 503709   Seat, ball, pressure 1
23 1016863  Body, pump filter 1
24 973543  Plug, O-ring, straight thread, 7/16–20 3
25 1021270  Plate, filter, anti-rotation 1
26 273139  Seal, pump 1
27 940172  O-ring, Viton, 0.676 x 0.070 1
28 1017307  Insulator, pump 1
29 1016339  Frame, pump 1
30 940332  O-ring, 2.000 x 2.125 x 0.063 in. 2
31 333137  Head, cylinder 1
32 ------  Filter assembly, 100-mesh, with O-ring 1 B
33 1021955   Adapter, filter assembly 1
34 1017849   Backup ring, Teflon, 0.273 x 0.045 1
35 940261  O-ring, Viton, 1.250 x 0.375 x 0.063 in. 1
36 276024  Valve assembly, drain 1
37 1022779  Chute assembly, drain 1

NOTE A: Included in service kit P/N 1028303

B: Included in service kit P/N 1028305

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D-34 SP Pump Diagnostics and Repair

Pump Service Kit

Part Description Quantity
1028304 Kit, service, pump, P4/P7/P10 —
940133  O-ring, Viton, 0.426 x 0.070 in. 2
940332  O-ring, Viton, 2.00 x 2.125 x 0.063 in. 2
1019515  O-ring, Viton, 0.50 x 0.75 x 0.125 in. 1
942111  O-ring, Viton, 0.812 x 0.062 x 0.125 in. 1
940181  O-ring, Viton, 0.739 x 0.70 in. 4
952100  Cup, U, Viton 1
954013  Backup ring, single, 7/16 x 9/16 2
163039  Cup, piston 2
273139  Seal, pump 1
986331  Retaining ring, internal, 100, push-on 1
984092  Nut, hex, lock, torque, M6 1
982147  Screw, hex, cap, M6 x 120 4
982237  Screw, hex, cap, M6 x 35 4
983410  Washer, flat, M6 8
940172  O-ring, Viton, 0.676 x 0.070 1
------  Lubrication, Parker, 1/2 oz. 1
940261  O-ring, Viton, 1.25 x 1.375 x .063 1
1017849  Backup ring, Teflon, 1.273 x .045 thick 1
945037  O-ring, Viton, 1-inch tube 1
973543  Plug, O-ring, 7/16-20 3
211228 Service kit, SP lubricating oil —

Other Pump Maintenance Kits

Part Description Quantity
1006027 Service kit, valve assembly, G2SP —
164606 Service kit, magnetic actuator —
166880 Service kit, fork magnetic —

Schedule of Fasteners
Part Description
F1  Screw, hex, cap, M6 X 120 mm
F2  Washer, flat, M, narrow, M6
F4  Screw, hex, cap, M6 X 35 mm
F6  Screw, hex, cap, M5 X 20 mm
F19  Screw, hex, cap, M4 X 8 mm

Part 1024496D04  2010 Nordson Corporation