Series 2300 Unit End Hose Repair Kit Instruction Sheet 46-l 69 Page 1

SERIES 2300 UNIT END HOSE REPAIR KIT

KIT DESCRIPTION

This kit &s used to repair broken electrical plugs on the unit end of Nordson Series 2300 Hoses. Four types of repairs can be made with the kit:

l replacement of a broken connector pin holder (pin receptacle)

l replacement of damaged pins

l replacement of the convertible shell (plug housing)

l replacement of a damaged strain relief connector

UNPACKING INSTRUCTIONS

Carefully unpack the contents of the kit. You will find the follow- ing parts:

l five connector pin holders (pin receptacles)

l five O-rings

l five convertible shells (plug housings)

0 10 self-tapping screws

0 five strain relief connectors

0 one ratchet-type crimping tool with manufacturer’s instruction sheet, IS T7574

l two socket/pin removal tools

l 125 pins

l 45 jumper wires

In addition, the repair procedure will require a Phillips screwdriver, needle-nose pliers, two (2) 7/8 in. (22 mm) open-end wrenches, wire cutters and wire strippers.

SAFETY PRECAUTIONS

Follow the general safety guidelines for repairing Nordson equip- ment, which are found in the Safety Summary of the product manual for Series 2300 applicators. In addition, follow the specific

Publication No. 108 61% 0 NORDSON CORPORATION 1991 All Rights Reserved

Issued 3191

Instruction Sheet 46-169 Page 2

Series 2300 Unit End Hose Repair Kit

safety precautions about the repair procedure contained in this in- struction sheet.

WARNING: Even when switched off, Nordson hoses contain electrical potentials that can cause death. Before repairing or rep’lacing the electrical plug assembly, disconnect and lock out power to the main circuit breaker for the applicator input power line.

WARNING: Incorrectly wired connectors can result in electrical shock that can cause death, personal injury, equipment damage or failure, or cause uncontrolled gun heating which can result in fire. Do the following to ensure your safety:

1. Before beginning repairs, read the crimp tool manufacturer’s instruction sheet, IS 7574. Pay particular attention to the instructions in item 3, “CRIMPING PROCEDURE”.

2. Make sure to tag any wire before removing it during repair and Ibo replace it in the correct pin hole as viewed from the wire side of the pin receptacle.

3. As necessary, refer to the hose schematics, Figure 8, at the end of these instructions.

Nordson is not responsible for any equipment damage or any personal injury that may result from incorrectly wired connectors.

WARNING: Exposing excess wire strands can result in electrical shock that can cause death, personal injury, equipment damage or failure, or cause un- controlled gun heating which can result in fire. Make sure to strip only a l/8 in. (3 mm) length of insulation from any wire on which a replacement pin is being installed.

A WARNING: When using needle-nose pliers to hold

k wires, be careful qot to damage wire insulation.

+ Damaged insulation caln result in electrical shock that can cause death, personal injury, equipment

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Series 2300 Unit End Hose Repair Kit Instruction Sheet 46-169 Page 3

damage or failurle, or cause uncontrolled gun heating which can result in fire.

REPAIR INSTRUCTIONS

Preliminary Procedures

1. Disconnect and lock out power to the main circuit breaker for the applicator input psower line.

2. Follow the “DAILY SHUTDOWN” procedure located in the applicator technical manual.

3. Disconnect the hose plug that needs repair from the applicator.

4. Place one 7/8 in. (22 mm) open-end wrench on the compression fitting and a second 7/8 in. (22 mm) open-end wrench on the compression nut (Figure :I).

PIN RECEPTACLE

f O-RING

PLUG HOUSING

,SSION

STRAIN RELIEF CONNECTOR ’

COMPRESSION NUT

Figure 1 - Series 2300 Unit End Electrical Plug Assembly

Publication No. 108 615A 0 NORDSON CORPORATION 1991 All Rights Resewed

Issued 3191

Instruction Sheet 46-l 69 Page 4

Series 2300 Unit End Hose Repair Kit

5. Loosen and completely unscrew the compression nut. Slide it down the cord set.

6. (Units with Hose mounted at 90” only) Use a Phillips screwdriver to remove the two strain relief connector screws (Figure 2).

STRAIN RELIEF CONNECTOR SCREWS

Figure 2 - Plug Housing Mounted in 90” Position

NOTE: The plug housing on Series 2300 hoses produced before 1989 cannot be turned 90”. If 90” mounting is desired, replace the pre-89 plug housing with one from this kit by following t-he steps in “Pin Receptacle, Plug Housing, and/or Strain Relief Connector Replacement”.

Issued 3/91 0 NORDSON CORPORATION 1991 All Rights Reserved

Publication No. 108 61 SA

Series 2300 kit End Hose Repair Kit Instruction Sheet 46-l 69 Page 5

7. Use a Phillips screwdriver to remove the two plug housing screws (Figure 3). Slide the plug housing and strain relief connector down the cord set.

PLUG HOUSING SCREW (1 OF 2)

Figure 3 - Removing Receptacle (Plug) Housing Screws

8. If the plug housing and/or pin receptacle is broken, go to “Pin Receptacle, Plug Housing, and/or Strain Relief Connector Replacement”. If one or m,ore pins is faulty, go to “Replacing Faulty Pins”.

Pin Receptacle, Plug Housing, and/or Strain Relief Connector Replacement

If the pin receptacle, plug housing, and/or strain relief connector is broken, aZZ of the wires connected to the pin receptacle will need to be removed and replaced. Do the following:

1. Take one of the socket/pin removal tools from the kit. Holding it by the handle (Figure 41, insert the removal tool sleeve into the hole of the pin that is being removed.

2. Continue to insert the sleeve until it bottoms out. Let the push rod (Figure 4) back out of the handle as the sleeve is inserted.

3. Rotate the tool body in order to release the pin locking lance.

4. While keeping the sleeve ‘bottomed out in the pin hole, depress the push rod. This will push the pin out of the pin receptacle.

Publication No. 108 615A 0 NORDSON CORPORATION 1991 All Rights Resewed

Issued 3/91

Instruction Sheet 46-169 Page 6

Series 2300 Unit End Hose Repair Kit

SLEEVE HANDLE

PUSH ROD’-/

Figure 4 - Socket/Pin Removal Tool

NOTE: Each pin receptacle hole is numbered on both the wire side and pin side. To avoid any confusion, go strictly by the numbering on the wire side of the pin receptacle as shown in Figure 5 of these instructions.

5. Tag the wire with the number of the pin hole that it enters.

6. Repeat steps 1 through 5 for each pin.

7. Discard the damaged pin receptacle, plug housing, and/or strain relief connector.

8. If the pin receptacle is damaged, slide a new O-ring from the kit onto one of the new pin receptacles.

9. (Plug housing and/or strain relief replacement) Replace the damaged part(s) with one(s) from the kit. Connect the plug housing and strain relief by tightening the two strain relief con- nector screws.

10. Inspect all the pins for damage. If there are no damaged pins, go to step 11. If there are damaged pins, go to “Replacing Faulty Pins”.

issued 3191 G NORDSON CORPORATION 1991 All Rights Reserved

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Series 2300 Unit End Hose Repair Kit Instruction Sheet 46-169 Page 7

11. Slide the plug housing and strain relief connector along the cord set until they slide against the pin receptacle.

WIRE END VIEVV

Figure 5 - Pin Hole Numbers, Wire-end Side

12. Replace and tighten the two plug housing screws. Go to “Final Repair Procedures”,

Replacing Faulty Pins

1. Remove the O-ring (Figure 1) from the pin receptacle and replace it with a new one from the kit.

NOTE: When cutting off faulty pins, make the cut just behind the pin in order to leave as much of the wire as possible.

2. Use wire cutters to cut the faulty pin off its wire. Discard the pin.

Publication No. 108 615A 0 NORDSON CORPORATION 1991 All Rights Reserved

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Instruction Sheet 46-l 69 Page 8

Series 2300 Unit End Hose Repair ‘Kit

3. Being careful not to damage the insulation, use needle-nose pliers to hold the wire and prevent breaking. Strip l/8 in. (3 mm) of insulation off the wire.

NOTE: There are extra pins supplied in the kit. Save the extra pins for future use.

4. Attach the new pin by following step 3, “Crimping Procedure”, in the crimping tool manufacturer’s instruction sheet, IS 7574. Make sure the strip length and placement of the wires in the contact are as shown in Figure 6, below,

5. Make sure that the tag on each wire matches the number of the hole it is inserted into (see Figure 5).

6. Use needle-nose pliers to push each pin into its respective hole (Figure 7, Detail B).

7. Make sure that the pin is pushed all the way into the plug hole. When seated, pins will lock and cannot be pulled out (Figure 7, Detail C).

8. Replace any other damaged pins by repeating steps 2 through 7.

WIRE STRANDS AND INSULATION WIRE STRANDS ONLY MUST

MUST BOTH BE VISIBLE BE VISIBLE ANYWHERE

ANYWHERE IN THIS AREA IN THIS AREA

-I t- .125 IN. (3 mm)

Figure 6 - Proper Wire Stripping Length and Placement in Crimp Contact.

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Series 2300 Unit End Hose Repair Kit Instruction Sheet 46-169 Page 9

DETAIL C .

DETAIL B

DETAIL A

Figure 7 - Correct Insertion of Pin into Pin Receptacle

Publication No. 108 61 SA 0 NORDSON CORPORATION 1991 All Rights Reserved

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Instruction Sheet 46-169 Page 10

Series 2300 Unit End Hose Repair Kit

Final Repair Procedures

1. Move the plug housing along the cord set and carefully slide it over the wires and onto the pin receptacle.

2. Replace and tighten the two screws that secure the plug housing to the pin receptacle.

3. Move the strain relief connector along the cord set until it slides against the plug housing. Replace and tighten the two screws that secure the strain relief connector to the plug housing.

4. Slide the compression fitting along the cord set until it reaches the threads of the strain relief connector.

5. While holding the plug housing, screw the compression fitting onto the connector until tight.

6. Slide the compression nut along the cord set until it reaches the threads of the strain relief connector.

7. Place one 7/8 in. (22 mm) wrench on the compression fitting and a second 7/8 in. (22 mm) wrench on the compression nut.

8. Use the wrench on the compression fitting to tighten it onto the connector.

9. Reconnect the hose plug assembly to the applicator.

10. Restore power to the applicator.

11. Follow the “DAILY START-UP” procedure located in the ap- plicator technical manual to resume normal operation.

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Publication No. 108 615A

Series 2300 Unit End Hose Repair Kit

Parts List Unit End Hose Repair Kit

Instruction Sheet 46-169 Page 11

1;: / Part No. 1 Description I b

Req’d ’

139 672 Kit, Repair, Unit End, 2300 Hose ’

108 615 l Instructions, 2300 Hose UnitEind Repair

l Connector Pin, Holder (Pin Receptacle)

l O-Ring, BUNA, 0.752 x 0.063

s

i _

l Shell, Convertible Conn. (Plug Housing)

l Screw, Self Tap, 4-40

j - @ Connector, Strain Relief

/ - l Tool, Crimping, Ratchet

/ - l Removal Tool, Socket/Pin I / e Pin, Terminal, 16-18 GA

I l Wire, Jumper, 22 GA

Ref

1

5

5

5 ;

10 I I

5 j

1 j I

2 i

125 j

45 j

’ Individual parts of this kit, other than this instruction sheet, are NOT saleable.

Publication No. 108 615A 0 NORDSON CORPORATION 1991 All Rights Reserved

Issued 3/91

Instruction Sheet 46-169 Page 12

Series 2300 Unit End Hose Repair Kit

APPLICATOR GUN OR CONNECTOR HOSE ASSEMBLY CONNECT

t t &8GA -

\ , 18 GA a, *

20 18 GA

30, 22 GA

I I 12d

50, 22 GA

UNIT END scf I

. I

I- GUN HEATER

l-

GUN RTD

GUN END

A C

UNIT END

- HOSE TTD

70 18 GA

GROUND CABLES

40 18 GA’

60 18 GA

SCHEMATIC - AUTOMATIC GUN PLUGS

GROUND

,PPLICATOR ONNECTOR HOSE ASSEMBLY GUN CONNECTION

118 GA 1

.- 118 GA IRED

5% 22 GA BROWN

So/

l-ii

BLACK1

So/ GRAY

22 GA GRN/yEL 7o 18GA

w

I I GROUND CABLES

22 GA t ’ GUN

I END I

i

18 GA GROUND*

40 18 GA -BLUE I

60 18 GA

l BLU/WHT

SCHEMATIC - HANDGUN PLUGS .

Figure 8 - Hose Schematics

Issued 3/91 0 NORDSON CORPORATION 1991 All Rights Reserved

Publication No. 108 615A