Manual de Mantenimiento Cabezal.

MAINTENANCE INSTRUCTIONS
Machine designation
Metering unit
Type designation
DosP016
ORIGINAL MAINTENANCE INSTRUCTIONS

Table of Contents
1. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Safety information and symbols used . . . . . . . . . . . . . . . . . . . . 7
1.1.1 Safety instruction – Prevent of personal injury . . . . . . . . . . . . 7
1.1.2 Safety instruction – Prevent of damage to property. . . . . . . . . 7
1.1.3 Text format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.1 Protective cover - piston-type dispenser . . . . . . . . . . . . . . . . . 10
2.1.2 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.3 Parts carrying hazardous substances . . . . . . . . . . . . . . . . . . . 10
2.2 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Residual Risk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 Drive motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.3 Electrical current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.4 Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Casting resin processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4.2 Workplace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 Personal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.5 Procedure in the case of emergency . . . . . . . . . . . . . . . . . . . . 18
2.5 Water protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6.1 Measurements on energized components. . . . . . . . . . . . . . . . 20
3. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Maintenance schedule - piston-type dispenser . . . . . . . . . . . . . 26
4.2 Maintenance schedule - lifting unit . . . . . . . . . . . . . . . . . . . . . . 28
5. Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Checking pneumatic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6. Lifting unit and dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Mounting dispenser on lifting unit . . . . . . . . . . . . . . . . . . . . . . . 32
6.2 Unmounting metering head from lifting unit . . . . . . . . . . . . . . . . 33
6.2.1 Proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7. Pneumatics/mass diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1 Changing mass diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.1.1 Preparations for changing diaphragm . . . . . . . . . . . . . . . . . . . 39
7.1.2 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.3 Vulkollan 70 shore/Viton mass diaphragm. . . . . . . . . . . . . . . . 40
7.1.4 Location of compound diaphragm . . . . . . . . . . . . . . . . . . . . . . 42
7.1.5 Replacing mass diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Changing pneumatic diaphragm . . . . . . . . . . . . . . . . . . . . . . . . 43
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7.2.1 Preparations for changing diaphragm . . . . . . . . . . . . . . . . . . . 44

7.2.2 Replacing pneumatic diaphragms . . . . . . . . . . . . . . . . . . . . . . 44
8. Dispenser - construction plunger / mass pistons. . . . . . . . . . 46
8.1 Dispenser with compound piston and plunger. . . . . . . . . . . . . . 47
8.2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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8.3 Changing variseal rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3.1 Replacement criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3.2 Position of sealing rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.3.3 Seal maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.4 Disassemble of pneumatic unit . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.4.1 Remove metering head's pneumatic unit . . . . . . . . . . . . . . . . 55
8.4.2 Remove compound diaphragm . . . . . . . . . . . . . . . . . . . . . . . . 56
8.4.3 Remove piston plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.4.4 Remove pressure springs and pneumatic pistons. . . . . . . . . . 59
8.4.5 Remove pneumatic diaphragm . . . . . . . . . . . . . . . . . . . . . . . . 60
8.4.6 Remove O-rings from valve plate . . . . . . . . . . . . . . . . . . . . . . 61
8.5 Assemble of pneumatic unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.5.1 Pneumatic unit’s individual parts . . . . . . . . . . . . . . . . . . . . . . . 63
8.5.2 Fit seal and pneumatic diaphragm . . . . . . . . . . . . . . . . . . . . . 63
8.5.3 Fit pneumatic pistons, pressure spring and piston plate . . . . . 66
8.5.4 Screw down pneumatic unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.5.5 Testing pneumatics unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.5.6 Lay mass diaphragm on top . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.5.7 Fit pneumatic unit to metering head . . . . . . . . . . . . . . . . . . . . 76
8.6 Disassemble of dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.6.2 Disassembling outlet - conical outlet . . . . . . . . . . . . . . . . . . . . 78
8.6.3 Separating dispenser body and cylinder block . . . . . . . . . . . . 83
8.6.4 Separate cylinder block and rinsing fluid tank . . . . . . . . . . . . . 84
8.6.5 Remove cylinder pipes from cylinder block . . . . . . . . . . . . . . . 85
8.6.6 Remove mass pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.6.7 Dismantling of Variseal on mass piston . . . . . . . . . . . . . . . . . . 87
8.7 Assemble of dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.7.1 Individual parts of the piston-type dispenser . . . . . . . . . . . . . . 90
8.7.2 Assemble base and cylinder block . . . . . . . . . . . . . . . . . . . . . 91
8.7.3 Assemble rinsing fluid tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.7.4 Installation of rod seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.7.5 Assemble of retainng plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.7.6 Fitting seals on compound piston . . . . . . . . . . . . . . . . . . . . . . 102
8.7.7 Fitting cylinder barrels in cylinder block . . . . . . . . . . . . . . . . . . 108
8.7.8 Insert material piston in cylinder pipe . . . . . . . . . . . . . . . . . . . 112
8.7.9 Mounting flushing fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . 114
8.7.10 Insert plunger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.7.11 Installation of exhaust air filter and separator . . . . . . . . . . . . 117
8.7.12 Mounting pneumatics unit on dispenser . . . . . . . . . . . . . . . . 118
8.7.13 Assembling outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.7.14 Metering head assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9. Washing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.1 Check rinsing fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.2 Removing flushing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10.1 Lifting unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10.1.1 Lubrication of spindle nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10.1.2 Lubrication of linear slides . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
11. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
11.1 Cleaning dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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11.1.1 Cleaning agents and solvents . . . . . . . . . . . . . . . . . . . . . . . . 136
11.1.2 Dispenser cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . 137
11.2 Cleaning dispenser in ultrasonic bath . . . . . . . . . . . . . . . . . . . 138
12. If metering problems appear . . . . . . . . . . . . . . . . . . . . . . . . . . 142
12.1 Using the measuring adapter. . . . . . . . . . . . . . . . . . . . . . . . . . 142
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1. PREFACE
Copyright and Edition

Copyright and Edi- The information contained in this documentations is part of our product know-
tion how transfer and is for the exclusive use by the machine user.
It shall not be copied or otherwise duplicated or transmitted to a third party with-
out he express written consent of company Scheugenpflug.
The user may make as many copies of these documentation as necessary for in-
house purposes.
Any suggestion as to how the information content of this document could be im-
proved will be gratefully received at any times.
Editorial informations
Editorial informa-
tions
Editorial informations
Department Editor
Technical documentation Dagmar Helmers & Thomas Brandl
PREFACE
Date of documentation: July – 2014
14. September 2015
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Safety information and symbols used
Safety instruction – Prevent of personal injury
1.1 Safety information and symbols used
Introduction
Introduction The main objective of the safety instructions is to prevent personal injury.
NOTICE
 Always observe the safety instruction to prevent injury.
1.1.1 Safety instruction – Prevent of personal injury
Introduction
Introduction Safety instructions in this documentation, which should prevent personal injury,
are given by a safety symbol and priority level.
Follow always the safety instructions to prevent personal injury!
Used priority level

Priority level Safety instruction are used with following priority level and color:
PREFACE
DANGER!
 Death or permanent health damage is result of ignoring this safety instruc-
tion.
WARNING!
 Death or permanent health damage can be result of ignoring this safety in-
struction.
CAUTION!
 Health damage can be result of ignoring this safety instruction.
1.1.2 Safety instruction – Prevent of damage to property
Safety instruction to prevent damage to property are given with following signal
words:
ATTENTION
 No health damage, only damage to property is result of ignoring this safety
instruction.
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Text format
NOTICE
 Tips, information and notice.
1.1.3 Text format
Pushbutton, but- [Text]

tons, control texts The labelling of pushbuttons and buttons as well as control texts are set in square
brackets.
PREFACE
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Text format
PREFACE
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Safety equipment
Protective cover - piston-type dispenser
2. SAFETY
Introduction
Introduction The machine has been designed and build while taking into account the relevant
standards and other technical specifications. It thus meet the most up-to-date
state of technology and guarantees operational safety.
2.1 Safety equipment
2.1.1 Protective cover - piston-type dispenser
The dispenser has a protective cover to prevent fingers being crushed between
the dispenser and lifting unit.
Sicherheitshinweis
WARNING!
Hazard of crush injuries at dispenser!
SAFETY
If the dispenser is operated without its protective cover, there is a danger of
crushing fingers between metering head and the pressure segment of the lifting
unit. At worst, fingers can be severed.
 Only remove the protective cover when the dispenser is de-energised.
 Re-install the protective cover immediately on completion of maintenance
work.
 Always check that the protective cover is fitted correctly and the screw con-
nections are tight before starting the machine.
2.1.2 Safety labels
Safety labels The instructions, given by the safety labels on the machine, must be followed in
any case. Should safety labels be damaged or faded, order new labels. If the
safety labels can not be read clearly any more, the machine must be taken out
of service until new safety labels are put on the machine.
2.1.3 Parts carrying hazardous substances
Introduction Parts of the machine that carry hazardous substances are identified by a safety
14. September 2015
warning to avoid the parts carrying hazardous substances being opened without
appropriate safety equipment.
Safety information Observe the following safety information:
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Safety equipment
Parts carrying hazardous substances
WARNING!
Hazardous substances!
Inadvertent intake of dispensing materials or their components can permanently
damage health.
The intake of hazardous substances may even occur through skin contact.
Dispensing materials are treated as hazardous substances when at least 1 risk
phrase is specified in the safety datasheet.
When the machine is designed for processing hazardous substances, all hose
connectors are marked yellow and all material-carrying parts are identified with
GHS labelling [health hazard] and [irritant, sensitising].
 Read the manufacturer's material safety datasheet for dispensing material.
 When filling the material tanks and performing maintenance work on materi-
al-carrying parts, wear personal protective equipment corresponding to the
manufacturer's material safety datasheet.
Hose connector
marking for hazard-
ous substances
SAFETY
Fig. 2-1: Yellow hose connector
GHS labelling - haz-

ards
Fig. 2-2: GHS labelling - health hazard
Fig. 2-3: GHS labelling - sensitising/irritant
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Cleaning
Pneumatic
2.2 Cleaning
Cleaning personnel The cleaning procedure should only be carried out by technical personnel who
• have read and understood the section on Safety and Maintenance in the
technical documentation.
• have the necessary qualifications to operate complex machinery.
Safety advice Follow the safety advice below.
DANGER!
Danger of explosion by halogenised hydrocarbons!
Halogenised hydrocarbons (trichlorethane, methylene chloride / dichlorometh-
ane) dissociate causing an explosion if contacting aluminium and galvanized sur-
faces. In this machine, aluminium and galvanized surfaces are used.
 Never use solvents or cleaning agents that use halogenised hydrocarbons!
 Only use solvents or cleaning agents without this chemicals! Before you use
a solvent or cleaning agent, check its ingredients!
2.3 Residual Risk
SAFETY
2.3.1 Pneumatic
Safety instruction Note following safety instruction:
CAUTION!
Spiraling pressure hoses can cause injury. Pneumatic tubes are in operation un-
der high pressure.
 Pressurized modules and pressure tubes have to be made pressure-less be-
fore you start with maintenance or repair.
 After end of work on pneumatic open pressure-supply slowly and pay atten-
tion to sound of exhausting pressure air.
Demands on staff On pneumatic devices may only work personnel with appropriate expertise
2.3.2 Drive motors

14. September 2015
Introduction Electric motors are used as drive systems.
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Residual Risk
Electrical current
Motor type and You will find data on the motor type and manufacturer on the motor type identifi-
manufacturer cation plate and in the parts lists.
Working on the mo- Only technical personnel are permitted to work on the motor! The manufacturer's
tor safety information must be observed!
Replacing motor Observe the following if a motor is defective:

• Always replace the defective motor by a motor of the same type and manu-
facturer! You can order the motor through our After-Sales Service.
• Always have the motor replaced by technical personnel!
• Make sure that you connect the new motor correctly. Connect the new motor
in the precisely the same way as the defective motor! (If necessary, note
down the terminal connection layout.)
• Refer to the information provided in the motor manufacturer's documentation.
Repairing motor Never attempt to repair the motor! Opening the motor will invalidate all warranty
and liability claims.
Please contact our Service department.
Hot surfaces Observe the following safety information:

SAFETY
CAUTION!
Acute danger of injury by hot surfaces!
 The surface temperature may be above 50 °C, thus posing a risk of burn in-
juries.
 Do not touch the housing during or shortly after operation.
 Allow the servomotor to cool down for at least 15 minutes after switching off.
 Check with a thermometer whether the surface has cooled down sufficiently.
Motor Observe the manufacturer's technical documentation relating to the motor.
2.3.3 Electrical current
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Residual Risk
Heaters
DANGER!
Electric shock!
Defective electrical components may be live (under voltage). Danger to life on
contact with these components.
 Defects found on electrical components and operating equipment must be
rectified immediately.
 The system must be taken out of operation and secured to prevent it being
switched on again for as long as defects have not been rectified.
 The system must not be placed in operation before defects have been reli-
ably rectified.
 Work according to the wiring diagram!
 Check that all electrical connections are made and secure before starting up
the machine. Corresponding to their design, the electrical connections may
have to be screwed down or locked.
2.3.4 Heaters
Optional compo- This is an optional component.

nent The machine can be retrofitted with this component. Please contact our Sales
Department.
SAFETY
General safety information on heaters
CAUTION!
Heaters and hot surfaces.
Danger of burn injuries at heaters and on hot surfaces.
 Wait until heaters have cooled down before working on them.
 Wear suitable protective gloves if contact with hot surfaces is unavoidable!
Safety instruction for metering head heaters

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Casting resin processing
Safety information
CAUTION!
In operation, the metering head heater becomes as hot as 80°C. The dis-
pensing material can thus also be hot
 Delay tasks on the metering head, until the metering head heater has cooled
down.
 If it is not possible to wait until the metering head heater has cooled down,
then take suitable measures to prevent injuries.
2.4 Casting resin processing
Directive 98/24/EC Please note the following information:
NOTICE
 The requirements of Directive 98/24/EC must be observed when processing
casting resins! The operating company must be aware of the requirements
stipulated in the Directive 98/24/EC and proceed accordingly.
SAFETY
Safety datasheets Please note the following information:
NOTICE
 Always carefully read the safety datasheets relating to the casting resins to
be processed!
2.4.1 Safety information
Fire hazard
DANGER!
Fire!
 Observe the information on fire hazard and fire fighting stipulated in the safe-
ty datasheet relating to the casting resin to be processed.
 No smoking! No naked flame!
Extinguishing Keep extinguishers with the appropriate extinguishing agent, as specified in the
agent safety datasheet, in the immediate vicinity.
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Safety information
Respiratory protec- Toxic gases can be produced by the combustion of casting resins. Refer to the
tion information in the safety datasheet and draw up and display corresponding
codes of conduct in the case of fire at the workplace.
If specified in the safety datasheet, wear breathing apparatus when extinguishing
a fire.
Explosion hazard
DANGER!
Explosion!
 Observe the information specified in the safety datasheet on the casting resin
to be processed! If, for example, the casting resin releases hydrogen gas it
will form an explosive mixture on contact with air.
Health hazard
CAUTION!
Health hazard!
 Observe the information specified in the safety datasheet on the casting resin
SAFETY
to be processed!
 If the hardener component of the dispensing material contains isocyanate,
also refer to the requirements stipulated by TRGS 430: Isocyanate. This re-
quirement also applies to handling a mixture of resin component and a hard-
ener component containing isocyanate that has not yet reacted.
Carefully read the information in the safety datasheet on

• Eye contact
• Skin contact
• Inhalation
• Eating/swallowing
Exposure to hazardous substances

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Workplace
WARNING!
There is a risk of substantially higher exposure to hazardous substances
particularly when changing material tanks or refilling material1 .
 Follow the information on handling the material and using personal protective
equipment as provided in the manufacturer's safety datasheet.
 Personal protective equipment must be worn!
2.4.2 Workplace
CAUTION!
 Observe the following information relating to the workplace and its design
layout.
Ventilation If the system has no extractor connection, corresponding measures must be im-
plemented to ensure adequate ventilation of the workplace. The vapours given
off by the dispensing material can have an adverse effect on the health of staff.
SAFETY
Observe the safety datasheets of the casting resin to be processed. They may
stipulate special requirements with regard to ventilation (maximum workplace
concentration). These special requirements must be observed. If no special re-
quirements are stipulated, the general codes of practice for ensuring an ade-
quate supply of fresh air at the workplace shall apply.
Eating and drinking Do not eat or drink at the workplace. Keep casting resins away from foodstuff,
beverages and feedstuff. The possibility of substances in the casting resin to be
processed contaminating food and drink cannot be ruled out.
Cleanliness and ti- Keeping the workplace clean and tidy is the prerequisite for ensuring casting res-
diness in components are handled correctly and safely.
Temperature Casting resins can give off dangerous compounds at temperatures above the
processing temperature. Pay attention to corresponding information in the safety
datasheet. Make sure that the casting resin is processed in the permissible tem-
perature range.
Safety datasheet Keep safety datasheets for the dispensing material (for both components of 2-
component materials) and operating fluids and lubricants clearly visible and ac-
cessible at the workplace.
1
Exposure: "placing oneself at risk to harmful environmental influences such as
toxic, chemical elements or compounds" (source: Wikipedia)
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Storage
2.4.3 Storage
Storage conditions Store cool and dry in well sealed containers.

Protect from heat and direct sunlight.
Environment Casting resins must not escape into the environment.
Solvents Avoid the casting resin making contact with solvents - including water -. Chemical
reactions can cause casting resin and especially its components to decompose.
This can consequently produce dangerous compounds.
Food Casting resins must not be stored together with foodstuffs, beverages and feed-
stuffs. Contamination with the substances in the casting resin to be processed
cannot be ruled out.
After processing The casting resin can still give off solvents or reaction products immediately after
processing. Avoid skin contact with freshly cast material.
2.4.4 Personal protection
Introduction Avoid skin contact or any other physical contact with casting resins and their
SAFETY
components. This requirement applies both during processing as well as during
storage and transportation.
Personal protection The following personal protection equipment is necessary:

equipment • Protective clothing (overall, coat)
• Rubber gloves. See safety datasheet for information on material and perme-
ation time.
• Protective goggles.
• Face protection if necessary
The protective equipment is to be provided by the operating company and used
accordingly by the staff.
Working with sol- As a particular safety and preventative measure, an eye wash facility is to be
vents (cleaning made available when working with solvents (cleaning agents)/corrosive chemi-
agents)/corrosive cals.
chemicals
2.4.5 Procedure in the case of emergency
Safety information Observe the following information in the case of emergency.

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Water protection
NOTICE
 Immediately seek medical assistance if health problems occur while handling
casting resins and their components! With the aid of the safety datasheet, in-
form the doctor of the type of casting resin used.
 Remove contaminated items of clothing
 In the case of accidental skin contact, immediately wash the affected area
with soap and ample water. Consult a doctor if skin irritation persists.
 If casting resin gets into the eyes, thoroughly flush open eyes under flowing
water. Consult a doctor.
For further information see corresponding safety datasheet.
2.5 Water protection
DANGER!
Environmental hazard!
By introduction of chemicals into waters can be caused serious environmental
SAFETY
damage.
 The operator must ensure that the used chemicals being properly disposed.
If the operator does not have knowledgeable personnel, then a specialist firm
must be ordered by the operator for that work.
 For disposal or accidental release of chemicals the data sheets of the man-
ufacturer contains guidelines for this case.
 When casting resin gets spilled then materials with capable of absorbing liq-
uids (e.g. sand, sawdust) must be used immediately. The polluted material
must be disposed in accordance to the rules of the manufacturer of casting
resin.
2.6 Maintenance
Technical qualifica- Maintenance work requires that the personnel carrying out the work has a high
tions and require- level of technical knowledge and reliability.
ments The person entrusted with the maintenance work must have the appropriate
technical knowledge. The basic qualifications must at least correspond to those
of a skilled worker in a technical profession. Steps must be taken to ensure that
the authorised person can safely and reliably carry out maintenance work on de-
vices and equipment used in automation engineering.
The maintenance work must be carried out such that the system or machine is
restored to its original operating condition.
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Maintenance
Measurements on energized components
Maintenance work must be performed in accordance with the wiring diagrams.
Safety devices Safety devices may only be disabled by technical personnel if absolutely neces-
sary as part of the maintenance work. The safety devices must be placed into op-
eration again on completion of the maintenance work. Check the safety devices
to ensure they are fully functional.
Safety components Safety components such as limit switches and other control components must
not be disabled. If, however, it is necessary to disable such safety components
for maintenance purposes, they must be reliably placed into operation again on
completion of the maintenance work. Check the safety components to ensure
they are fully functional.
2.6.1 Measurements on energized components
Introduction If measurements on energized components have to be done, then work with an-
other person. In emergency situation this person can switch off the machine and
pull the plug. If necessary this person can call for help and can help you.
Requirement on Only use voltage isolated tools. Tool must be regularly checked.
tool
SAFETY
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Maintenance
Measurements on energized components
SAFETY
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Maintenance
3. TECHNICAL DATA
Tightening torque for pneumatics unit

Tightening torque The tightening torque is specified in the technical data in the annex to these op-
for pneumatics unit erating instructions.
TECHNICAL DATA
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Maintenance
TECHNICAL DATA
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Maintenance
4. MAINTENANCE SCHEDULE
Who is to carry out maintenance work?

Who is to carry out The maintenance schedules specify who can carry out the maintenance tasks.
maintenance work? • Operator:operating personnel appointed by operating company. The opera-
tor may carry out basic maintenance tasks.
• Specialist personnel: personnel with well-founded technical knowledge, en-
abling them to carry out specific servicing and maintenance tasks safely and
reliably.
NOTICE
 Please refer to Safety.
The operating company is free to make its own arrangements in terms of who is
to carry out the maintenance work.
MAINTENANCE SCHEDULE
WARNING!
Risk of injury!
When several maintenance jobs are being performed on the machine at the
same time, there is a risk that one person could trigger a machine movement that
could injure another person.
 If possible, switch off machine for maintenance work and secure to prevent it
being inadvertently switched on again.
 Perform maintenance jobs, where larger parts of the machine need to be
moved, one after the other.
Maintenance interval
Maintenance inter- The intervals at which maintenance work is to be carried out are specified in the
val maintenance schedule.
The times specified in the maintenance schedule are non-binding reference val-
ues for normal operation. Unfavourable ambient conditions and/or aggressive
media may greatly shorten the maintenance intervals.
The maintenance intervals are specified in
• Operating hours: number of operating hours, after which maintenance is
necessary.
• Period of time: period of time (day/.../year), after which maintenance is nec-
essary.
Carry out maintenance when the number of operating hours or the period of time
14. September 2015
is reached.
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Maintenance
Adapting length of maintenance interval

Adapting length of Observe the following safety information
maintenance inter-
val
WARNING!
Functions critical to safety!
You must test functions that protect you from harm in the case of emergency at
the intervals specified in the maintenance schedule.
 Under no circumstances extend the maintenance intervals for functions crit-
ical to safety, such as EMERGENCY STOP for example.
The maintenance intervals can be extended if no signs of wear and tear (damage
to seals or changes to the barrier fluid) are determined within the specified main-
tenance intervals.
Proceed as follows:
• If no signs of wear and tear are determined, extend the maintenance interval
by 20 % (or by 1 day if 20 % is less than 1 day).
• As soon as signs of wear and tear become visible, shorten the maintenance
interval by 20 %. Retain this maintenance interval as standard.
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Maintenance schedule - piston-type dispenser
4.1 Maintenance schedule - piston-type dispenser

Maintenance Maintenance schedule - piston-type dispenser
schedule - piston-
type dispenser
Specialist personnel Maintenance interval
Task
Operating hours
Every 3 months
Every 6 months
Operator
Annually
Monthly
Weekly
Daily
× Check barrier fluid. 10 ×
See 9. Washing fluid, Seite 132 (cross
reference).
× Visual inspection of O-ring at outlet.a 8.2 10 ×
Safety, Seite 48
× Visual inspection of pneumatic lines, re- 200 ×

placing if necessary.
See 5. Pneumatic, Seite 30
× Replace mass diaphragm. 200 ×

See 7.1 "Changing mass diaphragm"
(cross reference).
Note: Determine suitable maintenance in-
tervals at the start of productionb.
× Replace pneumatics diaphragm. 500 ×

See 7.2 "Changing pneumatic diaphragm"
(cross reference).
Note: Determine suitable maintenance in-
tervals at the start of productionc.
× Change barrier fluid 9., Seite 132 (cross 500 ×

reference).d
× Metering head 500 ×

• Completely dismantle 8.6 Disassem-
ble of dispenser, Seite 77
• Clean 11. Cleaning, Seite 136
• Change seals/diaphragms 7.1
14. September 2015
Changing mass diaphragm, Seite 38

7.2 Changing pneumatic
diaphragm, Seite 43
• Reassemble 8.7 Assemble of
dispenser, Seite 89
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a. A conical outlet with O-ring seal is provided only on dispensers with mixing tube for 2
or more components. No O-ring is necessary if the metering needle is secured directly to
the outlet.
b. Maintenance intervals depend on the type of dispensing material used. Wear is largely
determined by the dispensing material
c. see a.
d. Use correct type of barrier fluid.
Tab. 4-1: Maintenance schedule - piston-type dispenser
Description of For descriptions of the tasks: see 8. Dispenser - construction plunger / mass
tasks pistons, Seite 46
(cross reference)
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Maintenance schedule - lifting unit
4.2 Maintenance schedule - lifting unit

Maintenance Maintenance schedule - lifting unit
schedule - lifting
unit
Specialist personnel Maintenance interval
Task
Operating hours
Every 3 months
Every 6 months
Operator
Annually
Monthly
Weekly
Daily
× Clean motors. 200 ×
Remove dirt and dust deposits. Cooling
ribs must be clean.
× Check motors for unusual noise and tem- 200 ×
perature, if necessary, additionally mea-
sure power consumption and compare
against ratings plate.
Note: Unusual noise and temperature in-
dicate bearing damage. Replace motor!
× Lubricate spindle nut on lifting unit. 500 ×
× Lubricate spindle bearing on lifting unit. 500 ×
× Lubricate linear slide on lifting unit. 500 ×
Tab. 4-2: Maintenance schedule - lifting unit
Description of For descriptions of the tasks: see 10. Lubrication, Seite 134.
tasks (cross reference)
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Checking pneumatic lines
5. PNEUMATIC
Kink-resistant pneumatic hoses

Kink-resistant Kink-resistant pneumatic hoses are installed ex-factory in the metering unit.
pneumatic hoses Should they ever need to be replaced, you must use kink-resistant pneumatic
hoses again.
Observe the following safety information:
CAUTION!
Material can emerge from the dispenser unchecked if non-kink-resistant
pneumatic hoses burst!
Pneumatic hoses that are not kink-resistant can be damaged when subjected to
bending load. The build-up in pneumatic pressure will then cause them to burst.
Dispensed material will then emerge unchecked from the dispenser outlet. The
hot dispensed material can cause skin irritations and burn injuries.
 Always use kink-resistant pneumatic hoses! Always replace the pneumatic
hoses by kink-resistant pneumatic hoses.
PNEUMATIC
5.1 Checking pneumatic lines
Procedure Check the pneumatic system for the sound of leaking air and visible damage.
• Renew leaking hoses and connecting elements. The pneumatic hoses on the
dispenser must always be replaced by kink-resistant hoses.
• Reconnect loose connections. Pay particular attention to the labelling on the
connection and hose. They must match.
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Checking pneumatic lines
PNEUMATIC
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Mounting dispenser on lifting unit
6. LIFTING UNIT AND DISPENSER
Table of Contents
6.1 Mounting dispenser on lifting unit
Note Please note the following notice:
NOTICE
 May only be done by suitably trained personnel.
Illustration
LIFTING UNIT AND DISPENSER

Illustration Description of metering unit and metering head:
• A: Metering head
• B: Lifting unit
A
1
2
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5 4 3
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Unmounting metering head from lifting unit
Fig. 6-1: Mounting metering head to lifting unit

(1) Connection data communication.
(2) Pneumatic connection: Lifting unit – metering head
(3) Screw.
(4) Material line connection.
(5) Pneumatic connection: Metering head – lifting unit.
Mounting dispenser on lifting unit

Mounting dispens- Precondition:
er on lifting unit  (Axis system) mode/ Service Position mode started.
 Compressed air supply to system shut off.
 Emergency stop button pressed.
To mount dispenser on lifting unit:
Proceed as follows:
1 Place dispenser (Item A) on lifting unit (Item B).
2 Secure dispenser to lifting unit with screws (Item 3).
3 Connect data communication line at data communication socket (Item 1).

4 Connect material lines to material connection (Item 4) on dispenser.
5 Make pneumatic connection between dispenser (Item A) and lifting unit (Item
B).
Connect lifting unit pneumatic connection (Item 2) to dispenser pneumatic
connection (Item 5).
NOTICE
 Always connect the lower connections to each other and the upper connec-
tions to each other.
 Lines must run parallel, i.e. they must not cross!
6 Connect compressed air supply to system. Connect the compressed air sup-
ply to the system at the lifting unit connection.
Result: Dispenser is supplied with compressed air.
6.2 Unmounting metering head from lifting unit
NOTICE
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Proceeding
Illustration Illustration metering unit
1 1

2 2
3
6 6
5 4
Fig. 6-2: Lifting unit with metering head
(1) Ball cocks
(2) Material lines
(3) Screws - on both sides
(4) Pneumatic connectors
(5) Pneumatic connectors
(6) KF connector
6.2.1 Proceeding
Prepare machine
14. September 2015
Prepare machine Proceed as follows:

1 Start (axis system-) Operating mode Service position.
Result: In- and outlet valves of metering head closed. Metering unit is in its
upper dead centre
2 Press Emergency Stop button.
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Proceeding
3 Switch off machine. Switch main switch to position off. This position is
marked by a 0.
Result: Machine is switched off.
Take out mixing tube

Take out mixing Tools and material:
tube  Container to place below the outlet.
Proceed as follows:
1 Close ball valves (Pos.1).
Result: Connection metering head to material lines is closed.
2 Put container below mixing tube to catch escaping dispensing material.
3 Take out mixing tube. See description in chapter Commissioning.
Remove material lines

Remove material Dispenser and material lines are connected with each other by a KF connector
lines (Pos. 6).
Requirement:
 Ball cocks (Pos. 1) closed.
Proceed as follows:
1 Open KF connector (Pos. 6).
ATTENTION
 Do not remove ball cocks (Pos. 1) from material line.
 Ball cock (Pos. 1) remains on material line.
2 Disconnect material line and dispenser.
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Proceeding
ATTENTION
Dispensing material can escape from the metering head.
Result: Material line with ball valve removed from dispenser.

Unmount metering head
Unmount metering Requirement:
head  Material lines removed from dispenser.
Proceed as follows:
1 Switch off pressurized air supply of the metering head at the pneumatic ser-
vice unit.
2 Unmount pressurized air lines from the pneumatic connectors (Pos. 4 and 5).
Result: Pressurized air lines separated from metering head.
3 Unmount metering head
ATTENTION
Washing fluid may escape.
 Keep metering head upright.
Remove screws (Pos. 3) on both sides of the metering head. Remove meter-
ing head from lifting unit.
Result: Metering head removed from lifting unit
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Proceeding
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Changing mass diaphragm
7. PNEUMATICS/MASS DIAPHRAGM
Table of Contents
7.1 Changing mass diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.1.1 Preparations for changing diaphragm. . . . . . . . . . . . . . . . . . . 39
7.1.2 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1.3 Vulkollan 70 shore/Viton mass diaphragm . . . . . . . . . . . . . . . 40
7.1.4 Location of compound diaphragm . . . . . . . . . . . . . . . . . . . . . 42
7.1.5 Replacing mass diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Changing pneumatic diaphragm . . . . . . . . . . . . . . . . . . . . . . 43
7.2.1 Preparations for changing diaphragm. . . . . . . . . . . . . . . . . . . 44
7.2.2 Replacing pneumatic diaphragms . . . . . . . . . . . . . . . . . . . . . 44
7.1 Changing mass diaphragm
PNEUMATICS/MASS DIAPHRAGM
Introduction
Introduction If the dispenser is equipped with inlet valve monitoring sensors (inlet valve mon-
itoring), they must not be removed.
Do not remove the inlet valve monitoring sensors!
Illustration Illustration: Inlet valve monitoring sensors
Fig. 7-1: Inlet valve monitoring sensors
Safety information
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Preparations for changing diaphragm
NOTICE
Never remove the inlet valve monitoring sensors from the valve plate!
The inlet valve monitoring sensors will no longer be correctly calibrated if the po-
sition of the sensors in the valve plate is changed. For this reason, the sensors
are adhered in the valve plate. The inlet valve monitoring sensors must be reca-
librated if they work loose out of their position.
 Leave the inlet valve monitoring sensors in the valve plate when cleaning the
pneumatics unit.
 Do not clean the valve plate in a solvent bath. Use a cloth to carefully clean
the valve plates
 In the event of a defect, never simply replace the inlet valve monitoring sen-
sors by the same sensors! Always replace the complete valve plate. Please
contact us for further details!
7.1.1 Preparations for changing diaphragm

Preparations for Preparations for changing diaphragm:

changing dia- Proceed as follows:
phragm
1 Start home run.
2 If dispenser is mounted on axis system: Start Service Position mode.
Result: The axis system moves into a position that makes it possible to work
on the dispenser.
3 Close ball valves on dispenser.
4 Press emergency stop button on the machine.
5 Place suitable container under mixing tube.
6 Remove mixing tube from outlet.
7.1.2 Technical description
Description Inlet and outlet valves are designed as diaphragm valves. If the valve closes, the
mass diaphragm (Pos. 7) is pressed onto a ring surface by pneumatic pistons
(Pos. 5).
The pneumatic diaphragm (Pos. 6) seals protects the pneumatic piston (Pos. 5)
off from the compressed air.
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Vulkollan 70 shore/Viton mass diaphragm
Illustration Illustration: Dispenser
2 1
4
5 6 7
Fig. 7-2: Dispenser
(1) Piston plate
(2) Valve plate
(3) Forcing screws
(4) Hexagon socket head cap screws
(5) Pneumatic pistons
(6) Pneumatics diaphragm
(7) Compound diaphragm
(8) Pneumatics unit
7.1.3 Vulkollan 70 shore/Viton mass diaphragm
Introduction For the GapFiller 1500 dispensing material, Scheugenpflug provides a special
Vulkollan-Viton combination as a mass diaphragm.
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Vulkollan 70 shore/Viton mass diaphragm
Illustration Illustration of mass diaphragm - two parts
 Vulkollan  Viton
Fig. 7-3: Special mass diaphragm

(1) Mass diaphragm for base body side
(2) Mass diaphragm for valve side
Installation Install mass diaphragm as follows:

 Viton  Vulkollan
Fig. 7-4: Assemble of diaphragm

(1) Mass diaphragm on base body side
(2) Mass diaphragm on valve side
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Location of compound diaphragm
7.1.4 Location of compound diaphragm
Introduction
Introduction The illustration on the basis of a Dos P016 – 2 component, shows the mass dia-
phragm’s position.
Note Please observe the following safety information:
NOTICE
 The basic structure is the same for all the metering heads in this series.
Illustration Illustration: Location of compound diaphragm
1
4
5 2
6
Fig. 7-5: Location of compound diaphragm
(1) Dispenser
(2) Pneumatics unit
(3) Compound diaphragm – rests on the pneumatics unit
(4) Piston plate
(5) Valve plate
(6) Pneumatics unit – located between piston plate and valve plate
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Changing pneumatic diaphragm
Replacing mass diaphragm
7.1.5 Replacing mass diaphragm
Procedure To replace the mass diaphragm:

Proceed as follows:
1 Remove pneumatics unit from dispenser.
Result: Mass diaphragm is freely accessible.
2 Remove old mass diaphragm and fit new mass diaphragm on pneumatics
unit.
3 Reattach pneumatics unit on dispenser.
The steps are described under Removing Pneumatics Unit (see 8.4, Seite 54)
and Installing Pneumatics Unit (see 8.5, Seite 62).
Please note that you do notneed to carry out all the actions described under
these sections! Only carry out the steps that are required to replace the mass di-
aphragm.
7.2 Changing pneumatic diaphragm

Introduction
Safety information
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Preparations for changing diaphragm
NOTICE
pneumatics unit.
the valve plates
7.2.1 Preparations for changing diaphragm
Preparations for Preparations for changing diaphragm:
changing dia- Proceed as follows:
phragm
1 Start home run.
2 If dispenser is mounted on axis system: Start Service Position mode.
Result: The axis system moves into a position that makes it possible to work
on the dispenser.
3 Close ball valves on dispenser.
4 Press emergency stop button on the machine.
5 Place suitable container under mixing tube.
6 Remove mixing tube from outlet.
7.2.2 Replacing pneumatic diaphragms
Procedure To replace the pneumatic diaphragms:

Proceed as follows:
1 Remove pneumatics unit from dispenser.
2 Completely dismantle pneumatics unit.
3 Renew pneumatic diaphragms.
4 Assemble pneumatics unit with new pneumatic diaphragms.
5 Reinstall pneumatics unit on dispenser.
The steps are described under Removing Pneumatics Unit (see 8.4, Seite 54)
and Installing Pneumatics Unit (see 8.5, Seite 62).
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Replacing pneumatic diaphragms
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8. DISPENSER - CONSTRUCTION PLUNGER / MASS PISTONS
Table of Contents
8.2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.3 Changing variseal rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3.1 Replacement criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3.2 Position of sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.3.3 Seal maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.4 Disassemble of pneumatic unit . . . . . . . . . . . . . . . . . . . . . . . 54
DISPENSER - CONSTRUCTION PLUNGER / MASS PISTONS

8.4.2 Remove compound diaphragm. . . . . . . . . . . . . . . . . . . . . . . . 56
8.4.3 Remove piston plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.4.4 Remove pressure springs and pneumatic pistons . . . . . . . . . 59
8.4.5 Remove pneumatic diaphragm. . . . . . . . . . . . . . . . . . . . . . . . 60
8.4.6 Remove O-rings from valve plate . . . . . . . . . . . . . . . . . . . . . . 61
8.5 Assemble of pneumatic unit . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.5.1 Pneumatic unit’s individual parts. . . . . . . . . . . . . . . . . . . . . . . 63
8.5.2 Fit seal and pneumatic diaphragm . . . . . . . . . . . . . . . . . . . . . 63
8.5.3 Fit pneumatic pistons, pressure spring and piston plate. . . . . 66
8.5.3.1 Single parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5.3.2 Pneumatic pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5.3.3 Prepare piston plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.5.3.4 Align pneumatic pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.5.3.5 Fit pressure springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.5.4 Screw down pneumatic unit . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.5.5 Testing pneumatics unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.5.6 Lay mass diaphragm on top . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.5.7 Fit pneumatic unit to metering head . . . . . . . . . . . . . . . . . . . 76
8.6 Disassemble of dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.6.2 Disassembling outlet - conical outlet . . . . . . . . . . . . . . . . . . . 78
8.6.3 Separating dispenser body and cylinder block . . . . . . . . . . . . 83
8.6.4 Separate cylinder block and rinsing fluid tank. . . . . . . . . . . . . 84
8.6.5 Remove cylinder pipes from cylinder block . . . . . . . . . . . . . . 85
8.6.6 Remove mass pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.6.7 Dismantling of Variseal on mass piston . . . . . . . . . . . . . . . . . 87
8.7 Assemble of dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.7.1 Individual parts of the piston-type dispenser. . . . . . . . . . . . . . 90
8.7.2 Assemble base and cylinder block . . . . . . . . . . . . . . . . . . . . . 91
8.7.3 Assemble rinsing fluid tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.7.3.1 Fit inspection glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.7.4 Installation of rod seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
14. September 2015
8.7.4.1 Install the Variseal ring on the underside of the rinsing tank 96
8.7.4.2 Install the Variseal rings on the topside of the rinsing tank . . 98
8.7.5 Assemble of retainng plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.7.6 Fitting seals on compound piston . . . . . . . . . . . . . . . . . . . . . . 102
8.7.6.1 Individual parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.7.6.2 Push Variseal onto aligning punch . . . . . . . . . . . . . . . . . . . . 104
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Dispenser with compound piston and plunger
8.7.6.3 Fit Variseal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.7.7 Fitting cylinder barrels in cylinder block . . . . . . . . . . . . . . . . . 108
8.7.7.1 Information on installing the cylinder barrel . . . . . . . . . . . . . 108
8.7.7.2 Fit cylinder pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
8.7.8 Insert material piston in cylinder pipe . . . . . . . . . . . . . . . . . . . 112
8.7.9 Mounting flushing fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . 114
8.7.10 Insert plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.7.11 Installation of exhaust air filter and separator . . . . . . . . . . . . 117
8.7.12 Mounting pneumatics unit on dispenser . . . . . . . . . . . . . . . . 118
8.7.13 Assembling outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.7.13.1 Individual parts of outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8.7.13.2 Assembling outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8.7.13.3 Mounting outlet on dispenser . . . . . . . . . . . . . . . . . . . . . . . 129
8.7.14 Metering head assembled . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Note
Note This section describes:
• Replacement of the Variseal rings
• Removal of the pneumatics unit
• Installation of the pneumatics unit
• Removal of the dispenser
• Installation of the dispenser
For information which wearing parts from the service kit are to be used, refer to
the parts lists and assembly drawings in the Annex.
The service kit parts list can be found under Spare Parts List.
8.1 Dispenser with compound piston and plunger
Description In this dispenser, one component is metered by means of a compound piston and
the other component by a plunger. For this reason, both halves of the dispenser
have a different layout.
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Safety
Illustration Illustration: Dispenser
7
4 3
8
1 2
9
5 6

Fig. 8-1: Dispenser
(1) Compound piston
(2) Plunger with stopper
(3) Air filter
(4) Seal for flushing fluid reservoir (Variseal ring).
(5) Seal for compound piston (Variseal ring). The dispenser must be dismantled
and cleaned if this seal is damaged.
(6) Cylinder barrel
(7) Stopper for plunger and flushing fluid reservoir cap
(8) Top seal for flushing fluid reservoir (Variseal ring)
(9) Bottom seal for flushing fluid reservoir (Variseal ring)
8.2 Safety
Close off ball valve at dispenser

WARNING!
The pressure in the material lines is applied at the dispenser.
 Always first close off the ball valve of the material line that is connected to the
dispenser (see illustration). If there are two material lines connected to the
dispenser, close the ball valves of both material lines.
 Only then should you begin the maintenance work.
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Safety
Illustration Illustration of metering head and ball valves

2
1
3
Fig. 8-2: Metering head and ball valves
(1) Ball valve
(2) Material line
(3) Metering head connection
Safety instruction for metering head heaters

CAUTION!
In operation, the metering head heater becomes as hot as 80°C. The dis-
pensing material can thus also be hot
 Delay tasks on the metering head, until the metering head heater has cooled
down.
 If it is not possible to wait until the metering head heater has cooled down,
then take suitable measures to prevent injuries.
Introduction
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Changing variseal rings
Replacement criteria

Safety information
NOTICE
pneumatics unit.
the valve plates
8.3 Changing variseal rings
Introduction The Variseal rings are the seals on the mass pistons and in the flushing fluid res-
ervoir.
8.3.1 Replacement criteria

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Flushing fluid Observe the following criteria:
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Position of sealing rings
Criteria: Flushing fluid
Flushing fluid Cause/reason
Flushing fluid used: • Flushing fluid level in reservoir rises

(visible at sight glass).
No flushing fluid used: • Dispensing material visible at sight

glass.
• Mass pistons stationary/piston rods sta-
tionary
Other criteria
Other criteria The following additional causes must be ruled out before replacing the seals:
Other criteria
Cause Procedure/corrective measures
2-component dispensing ma- Renew mixing tube

terial:
Content of mixing tube hard-
ened
Outlet openings partially Check outlet. Completely remove hardened

clogged material from outlet openings. If this is not
possible, use new outlet!
Air in lines Observe dispensing procedure. Air bubbles

in the lines cause irregular outlet of dispens-
ing material from the mixing tube.
Corrective measure: Bleed lines.
Weight check
Weight check Leaks at the seals can be a cause of insufficient dispensed material. Therefore
perform a weight check on systems equipped with this facility.
8.3.2 Position of sealing rings
Introduction The Illustration on the basis of a Dos P016 – 2 component, shows the Variseal
ring’s position.
Note Please observe the following safety information:
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Position of sealing rings
NOTICE
 The basic structure is the same for all the metering heads in this series.
Illustration Illustration of position of sealing rings

2
Fig. 8-4: Position of sealing rings

(1) Sealing ring
(2) Mass piston
(3) Cylinder pipe
(4) Sealing ring on mass piston
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Seal maintenance intervals
Illustration Illustration: Position of sealing rings
2
1
Fig. 8-5: Position of sealing rings

(1) Plunger
(2) Bottom sealing ring
(3) Top sealing ring
8.3.3 Seal maintenance intervals
Introduction The maintenance intervals for the seals depend on several factors.
For example:
• Cycle time and
• Dispensing material
Maintenance inter- The seals must be replaced before they are damaged.
val
NOTICE
 Record the time at which the seals were last changed.
 If the seals suffer damage before the scheduled maintenance, the mainte-
nance interval should be shortened.
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Disassemble of pneumatic unit
Why are the maintenance intervals not specified? No recommendation can be

made here as the maintenance intervals largely depend on the cycle time and
type of dispensing material.
You yourself should determine the intervals at which the seals need to be
changed.
Example of maintenance intervals

Example of mainte- Seals are damaged after 10 weeks. Shorten maintenance interval. In future
nance intervals change the seals after 8 weeks. (10 weeks - 20 % = 8 weeks)
Shorten the determined maintenance interval by 20 % if the seals are already
damaged before the scheduled maintenance interval.

Completely dismantle and clean the metering head to change the Variseals. If the
metering head is only partially dismantled, dispensing material (resin and hard-
ener) could come in contact with other parts of the dispenser, thus leading to
damage in the long term.
For procedure see: 8.6 Disassemble of dispenser, Seite 77
8.4 Disassemble of pneumatic unit
Table of Contents
Introduction

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Safety information
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Remove metering head's pneumatic unit
NOTICE
pneumatics unit.
the valve plates
8.4.1 Remove metering head's pneumatic unit
Introduction Pneumatic unit is fitted on the metering unit.

Procedure Proceed as follows:
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Remove compound diaphragm
1 Remove cheese head screws.

2 Remove metering head pneumatic unit
Result: Metering head's pneumatic unit removed.
8.4.2 Remove compound diaphragm

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Remove piston plate
1 Remove compound diaphragm.

Result: Compound diaphragm removed from pneumatic unit.
Use compound dia- Check the compound diaphragm's condition meticulously. If the compound dia-
phragm again? phragm has damage to it or is slit, dispose of it. Use a new compound diaphragm.
8.4.3 Remove piston plate
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Remove piston plate
1 Loosen screws. Do not remove screws completely!
2 Press valve plate’s piston plate in. Used a screwdriver to screw in the forcing
screws.

Result: Piston plate is released from valve plate.
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Remove pressure springs and pneumatic pistons
3 Remove screws.
Result: Remove piston plate.
8.4.4 Remove pressure springs and pneumatic pistons
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Remove pneumatic diaphragm
1 Remove pressure springs.

2 Remove pneumatic pistons.
Result: Pressure springs and pneumatic pistons removed. Pneumatic dia-

phragm is on top and is accessible.
8.4.5 Remove pneumatic diaphragm

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Remove O-rings from valve plate
1 Remove the pneumatic diaphragm.

Result: Pneumatic diaphragm removed.
8.4.6 Remove O-rings from valve plate
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Assemble of pneumatic unit
1 Remove O-rings

Result: O-rings have been removed from valve plate.
8.5 Assemble of pneumatic unit
Table of Contents
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Pneumatic unit’s individual parts
8.5.1 Pneumatic unit’s individual parts
Pneumatic unit´s individual parts

Fig. 8-7: Pneumatic unit’s individual parts

(1) Cylinder head screws
(2) Valve plate Dos P016
(3) O-rings
(4) Pneumatic diaphragm
(6) Pressure springs
(7) Piston plate
(8) Cylinder head screws
(9) Mass diaphragm
8.5.2 Fit seal and pneumatic diaphragm
Procedure Fit seal and pneumatic diaphragm

Proceed as follows:
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Fit seal and pneumatic diaphragm
1 Lay O-ring on the valve plate according to the diameter.

Result: O-rings laid on valve plate.
2 Lay pneumatic membrane on the valve plate according to the hole diameter.
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Fit seal and pneumatic diaphragm
Pay attention to the hole diameter!

Result: The pneumatic diaphragm has been laid on top.
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Fit pneumatic pistons, pressure spring and piston plate
8.5.3 Fit pneumatic pistons, pressure spring and piston plate
8.5.3.1 Single parts
Single parts Single parts

Fig. 8-8: Fit pneumatic pistons, valve plate and piston plate
(1) Valve plate
(3) Piston plate
8.5.3.2 Pneumatic pistons

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1 Lay pneumatic pistons on top, to fit the valve plate's hole diameters.
Result: Pneumatic pistons have been laid on top.
8.5.3.3 Prepare piston plate
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1 Slacken all the grub screws. Use a suitable tool. There must be no grub
screws protruding from the pistol plate!

Result: All the grub screws have been tightened in the piston plate.
8.5.3.4 Align pneumatic pistons
Requirements All the grub screws have been tightened in the piston plate. Grub screws are not
protruding from the piston plate.
ATTENTION
Metering head is not functioning properly after assembly, if one grub screw
is protruding from the piston plate.
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 Tighten grub screws in the piston plate. There must be no grub screws pro-
truding from the pistol plate!
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1 Take the piston plate. Lay it on top. Pay attention to the hole diameter.
Result: Valve pistons have been aligned.
2 Carefully take the piston plate off again.
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Note: Take care to ensure that the pneumatic diaphram does not catch on the
cylindrical pins.

Result: Pneumatic pistons have been aligned.
8.5.3.5 Fit pressure springs
Requirements All the grub screws have been tightened in the piston plate. Grub screws are not
protruding from the piston plate.
ATTENTION
Metering head is not functioning properly after assembly, if one grub screw
is protruding from the piston plate.
 Tighten grub screws in the piston plate. There must be no grub screws pro-
truding from the pistol plate!
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1 Lay the pressure springs on top of the pneumatic pistons. Pay attention to the
pneumatic piston and pressure spring diameters.
Result: Pressure springs have been laid on top of pneumatic pistons.
2 Lay piston plate on top.
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Screw down pneumatic unit
Note: Carefully insert pressure springs in the piston plate holes.

Carefully insert pneumatic pistons with pressure springs in the piston plate
holes.
Result: Piston plate has been laid flush.
8.5.4 Screw down pneumatic unit

1 Screw down valve and piston plates.
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Testing pneumatics unit
ATTENTION
 Tighten cheese head screws alternately, in diagonal order!
 Do not damage pneumatic piston surfaces!
Result: Valve and piston plates are screwed together.
8.5.5 Testing pneumatics unit

1 Connect pneumatic hoses.
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Testing pneumatics unit
Note: Connect one compressed air hose on either side.

2 Apply compressed air to the pneumatics unit and check that it is functioning
correctly.
Note: The piston plate is fitted correctly when all pneumatic pistons extend
by approx. 2 mm. If not, fit the piston plate correctly.
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Lay mass diaphragm on top
3 Disconnect compressed air hoses.

8.5.6 Lay mass diaphragm on top
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Fit pneumatic unit to metering head
1 Lay the mass diaphragm on top.

Result: Mass diaphragm has been laid on top of pneumatic unit.
8.5.7 Fit pneumatic unit to metering head

1 You can now fit the pneumatic unit onto the metering head.
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Disassemble of dispenser
Note: The description how to fit pneumatic unit onto metering head you find
in chapter Assemble of dispenser (see ExternalLink: ).
Result: Pneumatic unit fitted to metering head.
Fig. 8-9: Pneumatic unit fitted to metering head
8.6 Disassemble of dispenser
Table of Contents
8.6.1 Remove metering head's pneumatic unit
Introduction Pneumatic unit is fitted on the metering unit.

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Disassembling outlet - conical outlet
1 Remove cheese head screws.

2 Remove metering head pneumatic unit
Result: Metering head's pneumatic unit removed.
8.6.2 Disassembling outlet - conical outlet
Note: Needle/mix- The needle/mixing tube retainer is fitted on the dispenser only when required for
ing tube retainer the metering task.
Refer to separate instruction in Annex for assembly and disassembly of the nee-
dle/mixing tube retainer. The instructions directly follow after these installation in-
structions.
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Note The outlet should only be disassembled when:

• The seals are damaged or worn
• The outlet openings are clogged
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NOTICE
 Always check whether the O-ring at the adapter is worn. See last step in
the following description for this purpose.
Procedure The procedure for completely disassembling the outlet is described in the follow-
ing. This procedure is to be carried out only when the seals are to be replaced.
Disassembling outlet:
Proceed as follows:
1 Unscrew outlet from dispenser.
2 Remove seal from adapter plate.
Result:
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3 Remove screws from adapter with adapter plate.

Result:
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4 Separate adapter from adapter plate.
Result:
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5 Remove seals from adapter.

Result:
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Separating dispenser body and cylinder block
6 Remove O-ring from adapter.
Result:
8.6.3 Separating dispenser body and cylinder block

1 Separate dispenser body (Item (3) ) and cylinder block (Item (2) ). Undo
screws (Item 4) all round.
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Separate cylinder block and rinsing fluid tank
Note: The barrier fluid reservoir (Item (1) ) remains on the cylinder block.

(1) Barrier fluid reservoir
(2) Cylinder block
(3) Dispenser body
(4) Screws
8.6.4 Separate cylinder block and rinsing fluid tank

1 Schrauben entfernen.
2 Trennen Sie Zylinderblock und Spülflüssigkeitsbehälter voneinander.
Proceed as follows:
1 Remove screws.
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Remove cylinder pipes from cylinder block
2 Separate cylinder block and rinsing fluid tank.

8.6.5 Remove cylinder pipes from cylinder block

1 Remove O-rings.
Result: O-rings removed.
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Remove cylinder pipes from cylinder block
2 Remove cylinder pipe from cylinder block.

Result: Cylinder pipe removed from cylinder block.
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Remove mass pistons
8.6.6 Remove mass pistons

1 Pull out mass piston.
Result: Mass pistons removed.
8.6.7 Dismantling of Variseal on mass piston
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Dismantling of Variseal on mass piston
1 Grip Variseal with suitable tongs.

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Assemble of dispenser
2 Remove Variseal from the mass piston.

Result: Variseal removed from mass piston
NOTICE
 Dispose of Variseal. Do not use it again!
 For assembly, always use new a Variseal.
8.7 Assemble of dispenser
Table of Contents
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Individual parts of the piston-type dispenser
8.7.1 Individual parts of the piston-type dispenser
Individual parts of Individual parts of piston-type dispenser

piston-type dis-
penser
8 9

6
4 5
1 2 3
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Assemble base and cylinder block
Fig. 8-10: Individual parts of piston-type dispenser

(1) Outlet with screws1
(2) Rinsing fluid reservoir with screws
(3) Pneumatics unit with screws
(4) Cylinder block with seals and screws
(5) Body with screws
(6) Cylinder barrel
(7) Seals
(8) Pistons
(9) Plunger
(10)Spacer block
(11)Stopper
8.7.2 Assemble base and cylinder block

1 Insert O-ring in cylinder block.
Result: O-ring inserted in cylinder block.
1
Standard outlet
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2 Join cylinder block and base

Result: Cylinder block and base are joined together.
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3 Screw cylinder block to base

Result: Cylinder block screwed to base.
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4 Check whether there is a small shaft of light visible between the cylinder
block and the base. When screws are tightened, a shaft of light indicates that
an O-ring is jammed.

Safety instruction Note following safety instruction
ATTENTION
Malfunction of dispenser!
When screws are tightened, a shaft of light indicates that an O-ring is jammed.
 Change jammed O-rings immediately! Otherwise, there can be no guaran-
tee that the metering head will function correctly.
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Assemble rinsing fluid tank
8.7.3 Assemble rinsing fluid tank
8.7.3.1 Fit inspection glass

1 Fit O-ring in sealing groove.
Result: O-ring is in the sealing groove.
2 Fasten inspection glass frame with screws. Tighten screws evenly and gen-
tly, alternately in diagonal order.
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Installation of rod seals.
NOTICE
 Do not over-tighten screws, otherwise the inspection glass will be damaged.
 The O-rings must be pressed in, across their entire surface.
 Tighten screws evenly and gently, in diagonal order, in order to avoid damag-
ing inspection glass.

Result:
8.7.4 Installation of rod seals.
Introduction
Introduction This section describes the fitting of the Variseals on the rinsing tank.
8.7.4.1 Install the Variseal ring on the underside of the rinsing tank
Proceed as follows:
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1 Insert plunger into the rinsing fluid tank. Take care that the plunger is inserted
into the correct hole!
2 First slide the Variseal ring and then the cover panel onto the plunger. The
Variseal spring points towards the bracket. Slide the Variseal ring on with
even pressure.
ATTENTION
Variseal rings are delicate and can easily be damaged.
 Avoid twisting the Variseal rings. The sealing lip of the Variseal rings is very
sensitive.
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3 Press the Variseal ring into the brass bushing with the bracket.

Result: Variseal ring is installed. You can then withdraw the plunger.
8.7.4.2 Install the Variseal rings on the topside of the rinsing tank
Introduction Here, the mass pistons and the plunger serve as an aid for fitting the Variseal
rings onto the topside of the rinsing tank.
Installation of the Variseal ring on the plunger side.

Installation of the The following describes how to install the Variseal ring on the plunger side of the
Variseal ring, rinsing tank.
plunger side. Proceed as follows:
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1 Place the plunger on an even surface.

2 Slide the bracket onto the plunger.
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3 Fit Variseal ring to plunger. The Variseal ring spring points forwards i.e. not
towards the bracket.
4 Guide the plunger into the bushing. Take care that you are using the correct
brass bushing.
5 Press the Variseal ring into the brass bushing with the bracket.
Result: Variseal is installed.

6 Hold the bracket in place and withdraw the plunger upwards.
Result: Variseal ring installed on the plunger side of the rinsing tank.
7 Check the Variseal thus fitted for any damage.
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Note: If the Variseal ring could have been damaged during the installation
then this must be replaced! Only an undamaged Variseal ring guarantees the
correct functioning of the metering head.
Installation of the Variseal ring on the piston side.

Installation of the The following describes how to install the Variseal ring on the piston side of the
Variseal ring on the rinsing tank.
piston side. Proceed as follows:
1 Push retaining plate onto the mass piston.
2 Push Variseal onto mass piston. Ensure that the Variseal is in the correct po-
sition! Variseal spring is visible from underneath.

3 After pulling Variseal onto the mass piston, feed this into the brass bush for
the rinsing tank.
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Assemble of retainng plate
4 Now press the retaining plate evenly onto the rinsing tank until you see that
the Variseal slides into the brass bush.
5 Next, hold the retaining plate firmly on the rinsing tank. Pull the piston out of
the brass bush.
6 Check the Variseal thus fitted for any damage.
Note: If the Variseal ring could have been damaged during the installation
then this must be replaced! Only an undamaged Variseal ring guarantees the
correct functioning of the metering head.
8.7.5 Assemble of retainng plate
Procedding Proceed as follows:

1 Fit retaining plate.
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Fitting seals on compound piston
Tighten oval-head screws slightly.

Result:
8.7.6 Fitting seals on compound piston
Notice Mass piston seals may be:

• Variseal rings
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• KD-seals
Fitting of Variseal rings or KD-seals is done in the same way.
Die Montage von Varisealring oder KD-Dichtring verläuft in gleicher Weise.
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The correct position of the seals must be observed. The following side of the seal
must point into the direction of the material, so that it points upwards when placed
onto the aligning punch:
• for Variseal ring: spring
• for KD-seal: wider side of the seal
8.7.6.1 Individual parts
Mass piston with

variseal ring
1
(1) Variseal
(2) Aligning punch
(3) Mass piston
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Mass piston with

KD-seal

1
(1) KD-seal
(2) Aligning punch
(3) Mass piston
8.7.6.2 Push Variseal onto aligning punch

1 Stand aligning punch on even surface.
Note: The small diameter points upwards.
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2 Push new Variseal onto aligning punch. The Variseal spring is pointing up-
wards.
3 Push Variseal over aligning punch, as far as the end with the large diameter.
8.7.6.3 Fit Variseal
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1 Fit compound piston onto aligning punch.

2 Push Variseal onto compound piston.
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Variseal is fitted on compound piston.

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Fitting cylinder barrels in cylinder block
8.7.7 Fitting cylinder barrels in cylinder block
Fitting seal
1 Fit seal in cylinder block.

Result: Seal fitted in cylinder block.
8.7.7.1 Information on installing the cylinder barrel
Introduction When installing, make sure the cylinder barrel is the right way round! The cylinder
barrel must be installed the right way round in the cylinder block, otherwise the
dispenser will not function correctly.
Note on cylinder • Top: The inside of the cylinder barrel is chamfered. This makes it possible to
barrel insert the compound pistons in the cylinder barrel without wear.
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• Bottom: The inside of the cylinder barrel is not chamfered.
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Top of cylinder barrel

Top of cylinder bar- Top of cylinder barrel: Inner chamfer.
rel
Fig. 8-11: Top of cylinder barrel
Bottom of cylinder barrel

Bottom of cylinder Bottom of cylinder barrel: No inner chamfer.
barrel
Fig. 8-12: Bottom of cylinder barrel
How to install? The cylinder barrel must be installed bottom first in the cylinder block.
The top with the inner chamfer is then at the top. The cylinder barrel is thus in-
stalled correctly.
Fig. 8-13: Cylinder barrels installed in cylinder block1
Cylinder barrel installed the wrong way round

Cylinder barrel in- The Variseal will not function correctly if the cylinder barrel is installed the wrong
stalled the wrong way round.
way round
1
Example illustration. The basic principle is that the chamfer must always be at
the top after installation, irrespective of how the dispenser is built up.
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In the case shown below the cylinder barrel was installed top first in the cylinder
block. The chamfer thus produces a cavity. The Variseal does not seal the cyl-
inder barrel from the compound piston.

Fig. 8-14: Cylinder barrel installed the wrong way round
Consequence: Dispensing material leaks from the compound piston and enters
the area behind the compound piston. No sealing effect
Cylinder barrel installed the right way round

Cylinder barrel in- The Variseal will function correctly when the cylinder barrel is installed the right
stalled the right way round. The Variseal seals the cylinder barrel from the compound piston.
way round
Fig. 8-15: Cylinder barrel installed the right way round

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8.7.7.2 Fit cylinder pipe

1 Insert cylinder pipe into holes of cylinder block.
ATTENTION
 Fit cylinder pipe the right way round! The hole with the interior bevel on the
cylinder pipe must be on top.
Result:
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Insert material piston in cylinder pipe
8.7.8 Insert material piston in cylinder pipe

1 Insert material piston in the cylinder pipe.

Result:
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Insert material piston in cylinder pipe
2 Place O-rings in the ring groove of the cylinder pipe.

Result: O-ring is located in the ring groove of the cylinder pipe.
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Mounting flushing fluid reservoir
8.7.9 Mounting flushing fluid reservoir

1 Place flushing fluid reservoir on cylinder block.

Result:
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Mounting flushing fluid reservoir
2 Screw down flushing fluid reservoir onto cylinder block. Tighten screws even-
ly and crosswise.
Result: Flushing fluid reservoir secured to cylinder block.
Checking for gap

Checking for gap Check whether a gap is visible between the flushing fluid reservoir and cylinder
block.
If you have mounted the flushing fluid reservoir correctlyno gap should be visi-
ble!
ATTENTION
Dispenser malfunction!
A detectable gap after the screws have been tightened indicates that the reser-
voir has been mounted incorrectly. The dispenser will not function correctly!
 Remove the flushing fluid reservoir again and repeat the mounting proce-
dure.
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Insert plunger
8.7.10 Insert plunger

1 Guide the plunger into the plunger side of the metering head.

Result: Plunger installed.
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Installation of exhaust air filter and separator
8.7.11 Installation of exhaust air filter and separator

1 Screw the exhaust air filter and separator onto the rinsing tank.
Result: Exhaust air filter and separator installed.
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Mounting pneumatics unit on dispenser
8.7.12 Mounting pneumatics unit on dispenser
Introduction
Introduction Note: The distance block is to be screwed to the base from the front. The screws
for the installation of the distance block are no longer accessible once the pneu-
matic unit has been installed! First install the distance block and then the pneu-
matic unit.
Install distance block.

Install distance The distance block is to be installed before the pneumatic unit.
block. Proceed as follows:
1 Place the distance block on the base. Pay attention to the locating pins on

the base.
Result: Distance block inserted into the base.

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2 Screw distance block to base.

Result: Distance block screwed to base.
Mounting pneumatics unit

Mounting pneumat- Precondition:
ics unit  Spacer block mounted on the dispenser! Note: After mounting the pneumat-
ics unit the related screws are no longer accessible.
Required tools:
 Torque wrench
Mounting pneumatics unit on dispenser:
Proceed as follows:
1 Check whether the forcing screws are protruding on the pneumatics unit.
They should not protrude and must be screwed in.
ATTENTION
The dispenser will malfunction if the forcing screws are not screwed in.
 Screw in forcing screws.
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2 Place compound diaphragm on pneumatics unit.

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3 Only lightly tighten the screws holding the pneumatics unit to the body of the
dispenser.
Result: Pneumatics unit mounted.
4 Connect pneumatic hoses to the pneumatics unit. Pressurise pneumatics

unit.
5 Screw down pneumatics unit on dispenser body.
Use torque wrench! Tightening torque: see technical datasheet
6 Shut down pressure. Remove pneumatic hoses from pneumatics unit.
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7 Screw down pneumatics unit on dispenser body. Retighten screw connec-

tions.
Use torque wrench! Tightening torque: see technical datasheet
Result:

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Assembling outlet
8.7.13 Assembling outlet
Note: Needle/mix- The needle/mixing tube retainer is fitted on the dispenser only when required for
ing tube retainer the metering task.
Refer to separate instruction in Annex for assembly and disassembly of the nee-
dle/mixing tube retainer. The instructions directly follow after these installation in-
structions.
8.7.13.1 Individual parts of outlet
Individual parts Individual parts of outlet

Fig. 8-16: Individual parts of outlet

(1) O-ring
(2) Cheese head screws
(3) Adapter
(4) O-ring
(5) Cheese head screws
(6) Junction
(7) O-ring
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Assembling outlet
8.7.13.2 Assembling outlet

1 Fit O-ring on adapter.

Result:
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Assembling outlet
2 Fit seals in adapter.

Result:
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Assembling outlet
3 Connect adapter and adapter plate.

Result:
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Assembling outlet
4 Screw down adapter to adapter plate.

Result:
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Assembling outlet
5 Fit seal in adapter plate.

Result: Outlet assembled.
The outlet can now be reinstalled on the dispenser.

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Assembling outlet
8.7.13.3 Mounting outlet on dispenser

1 Screw outlet to dispenser.
Result: Outlet mounted.
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Metering head assembled
8.7.14 Metering head assembled
Illustration Illustration of assembled metering head

Fig. 8-17: Assembled metering head
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Metering head assembled
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Check rinsing fluid.
9. WASHING FLUID
9.1 Check rinsing fluid.
Interval It is necessary to check the fill level and quality of the rinsing fluid every day.
Quality
Quality Any black discolouration or cloudiness in the rinsing fluid may be caused by fric-
tion on the gaskets.
Quality of the rinsing fluid
If this is happening Do this
If rinsing fluid changes colour in the • Dismantle dispenser completly

colour of the dispensing material and • Change variseal rings
the fill level is rising,
WASHING FLUID
If rinsing fluid changes colour in the then change the rinsing fluid.
colour of the dispensing material and
the fill level is not rising,
If rinsing fluid contains lumps of dis- • Dismantle dispenser completly

pensing material, • Change variseal rings
If there are signs of chemical reaction then change the rinsing fluid.
such as foaming of the formation of
crystals in the rinsing fluid,
If the rinsing fluid contains solids, then change the rinsing fluid.
Tab. 9-1: Quality of the rinsing fluid
9.2 Removing flushing fluid
Tools You require:

 A syringe with a long hollow needle. The hollow needle must reach at least
reach the base of the flushing fluid reservoir.
Preparation Proceed as follows:

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1 Move the dispenser pistons into the upper end position.

The procedure for moving the pistons into the upper end position is described in
section Commissioning - Flushing Fluid1.
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Removing flushing fluid

1 Unscrew and remove the air filter for component A from the flushing fluid res-
ervoir.
2 Extract the flushing fluid with the syringe.
3 Empty the syringe. Make sure that no flushing fluid with material residue re-
mains in the syringe.
4 Start with Step 1 for component B.
Adding flushing flu- For information on adding flushing fluid, see the dispenser installation instruc-
id tions under Commissioning.
WASHING FLUID
1
Under Maintenance - Flushing Fluid only in older descriptions
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Lifting unit
Lubrication of spindle nut
10. LUBRICATION
10.1 Lifting unit
Illustration Illustration: Lifting unit
LUBRICATION
Fig. 10-1: Lifting unit
(1) Spindle nut lubrication points
(2) Linear slide lubrication point
10.1.1 Lubrication of spindle nut
Lubrication service point (Pos. 1): Drive lifting unit into position so that the lubri-
cation service point can be reached.
Lubrication should be done quarterly.
Recommended lubricant: MICROLUBE GB 0.
10.1.2 Lubrication of linear slides

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The lubrication points (Item 2) are accessible without the need for disassembly
work.
Lubricate every 3 months.
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Lifting unit
Lubrication of linear slides
Recommended lubricant: MICROLUBE GB 0

LUBRICATION
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Cleaning dispenser
Cleaning agents and solvents
11. CLEANING
11.1 Cleaning dispenser
NOTICE
11.1.1 Cleaning agents and solvents
Introduction This section describes which cleaning agents and solvents can be used.
The safety information must be observed.
Cleaning agent
CLEANING
Cleaning agent Which cleaning agent you can use depends on the type of dispensing material
used.
NOTICE
 Consult the manufacturer of the dispensing material as to the most suitable
cleaning agent.
 Refer to the specifications in the material datasheet.
Apart from the valve plate if inlet valve monitoring sensors 1 are installed in it, the
following solvents can be used for the metal parts of the metering head.
• Ethanol
• Benzine
• Cellulose thinner This solvent leaves a residue on the metal surfaces which
must be completely removed with a neutral agent, e.g. cleaner solvent, after
cleaning.
Safety information on Ethanol

Safety information Observe the following safety information
14. September 2015
on Ethanol
1
Refer to Technical Description
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Cleaning dispenser
Dispenser cleaning procedure
WARNING!
Ethanol is easily flammable.
 No smoking and no naked flame permitted in a 5 m radius while cleaning with
ethanol.
 Read and observe the safety information in the safety datasheet on ethanol.
Safety instructions for organic solvents

Safety instructions Please observe the following safety information:
WARNING!
Organic solvents are a health hazard.
Organic solvents irritate the eyes and skin. They are partially poisonous. Vapour
inhalation constitutes a health hazard and may cause drowsiness and thus seri-
ous accidents.
 Provide good workplace ventilation for working with solvents.
 For working with solvents, wear long-sleeved protective clothing, suitable
safety gloves and goggles.
 See a doctor immediately if health complaints occur during work with sol-
vents.
CLEANING
 Comply with all the safety instructions provided in the solvent safety data
sheet.
11.1.2 Dispenser cleaning procedure
Cleaning dispenser
Procedure Cleaning dispenser
ATTENTION
 Do not allow solvents to come in contact with plastic components! This in-
clude seals, diaphragms and sight glass.
 The valve plate must be cleaned by hand with a cloth if inlet valve monitoring
sensors1 are installed in it.
Preconditions:
 Dispenser completely disassembled.
 Coarse soiling removed.
 Check valve plate. If inlet valve monitoring sensors are installed in it, remove
the valve plate and clean it by hand. On no account include the valve plate in
the following process as it would damage the inlet valve monitoring sensors!
1
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Cleaning dispenser in ultrasonic bath
The following tools are required:

 Steel wool
 Round brushes
 Scraper
 Tray with cover for the parts of the dispenser.
To clean dispenser:
Proceed as follows:
1 Place the metal parts of the dispenser in a container with solvent such that
all parts are covered by the solvent.
2 Close off the container to reduce the escape of solvent vapours.
3 Leave the parts in the solvent bath for 15-30 minutes.
Note: Remove the parts just before you start the mechanical cleaning.
4 Use steel wool, round brusher and scraper to clean the parts mechanically.
NOTE: You can use a drill of suitable diameter to carefully remove any soiling
in small holes. Guide the drill by hand. Do not use a drilling machine!
5 After cleaning, use compressed air to completely remove all traces of solvent
residue.
Compressed air cleaning

Compressed air Compressed air cleaning
CLEANING
cleaning
ATTENTION
Ethanol causes crystal formation in the hardener components.
 Thoroughly remove all ethanol residue, before you reassemble the metering
head and put it into operation again.
1 Thoroughly remove the solvent from the individual components of the meter-
ing head. No solvent must remain on the individual components.
11.2 Cleaning dispenser in ultrasonic bath
NOTICE
Introduction The cleaning procedure described here solely serves the following purpose:
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To clean a metering head that is used for silicone materials!
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The manufacturer shall accept no claims whatsoever if the procedure is used for
any other than the intended purpose.

Precondition The dispenser must be completely dismantled.
Step 1: Ultrasonic bath

Step 1: Ultrasonic
bath
ATTENTION
 Do not place plastic parts in the ultrasonic bath! This include seals, dia-
phragms and sight glass. Only place metal parts in the ultrasonic bath.
 The valve plate must be cleaned by hand with a cloth if inlet valve monitoring
sensors are installed in it!
Apart from the valve plate if inlet valve monitoring sensors 1 are installed in it,
place all metal parts of the dispenser in an ultrasonic bath filled with benzine.
• Cylinder block
• Flushing fluid tank without seals and sight glass
CLEANING
• Piston plate
• Valve plate - only if no inlet valve monitoring sensors are installed in it!
• Cylinder barrels
• Pneumatic pistons of valve plate
• Mass piston or plunger
The parameters for the ultrasonic bath are:
• Time: 3 h
• Temperature: 45 ?
• Ultrasonic frequency: 35 kHz
Step 2: Cleaning with ethanol

Step 2: Cleaning Clean all parts that were in the ultrasonic bath with ethanol.
with ethanol
WARNING!
Ethanol is easily flammable.
 No smoking and no naked flame permitted in a 5 m radius while cleaning with
ethanol.
 Read and observe the safety information in the safety datasheet on ethanol.
1
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Apart from the valve plate if inlet valve monitoring sensors 1 are installed in it,
thoroughly clean all parts with ethanol. Completely remove all traces of benzine
on the parts.
Compressed air cleaning

Compressed air Compressed air cleaning
cleaning
ATTENTION
Ethanol causes crystal formation in the hardener components.
 Thoroughly remove all ethanol residue, before you reassemble the metering
head and put it into operation again.
1 Thoroughly remove the solvent from the individual components of the meter-
ing head. No solvent must remain on the individual components.
CLEANING
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1
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CLEANING
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Using the measuring adapter
12. IF METERING PROBLEMS APPEAR
12.1 Using the measuring adapter
Note The measuring adapter is an optional component. It is not supplied as standard.

Should you have any questions, please contact Scheugenpflug AG.
Function The measuring adapter is used if quality problems appear such as:
• Dispensing material does not harden properly
• Dosed amount too low
IF METERING PROBLEMS APPEAR

CAUTION!
Dispensing material can be harmful to health!
Dispensing material can be harmful to health due to its high chemical reactivity
and, after being heated, due to its high temperature, high thermal capacity and
adhesivity.
This applies particularly if the dispensing material gets into the eyes.
 Make sure that no material is dispensed while you are working at the dis-
penser outlet.
 Press the Quick Stop button before starting work.
 Wear protective gloves while working. See safety datasheet of the dispens-
ing material manufacturer for recommended protective glove material.
 Wear safety goggles.
Procedure Preconditions:
 Sufficiently large container placed under the outlet(s) of the metering head.
For metering heads with several outlets: Bear in mind that material is always
dispensed out of all the outlets but you measure only at one of the outlets.
 Dispensing stopped and machine secured to prevent inadvertent start-up.
Tools:
 Measuring adapter (supplied with dispenser)
 Ten cups of known weight (milligram range). The volume of a cup must be at
least 1.5 times the dispensed quantity.
Proceed as follows:
14. September 2015
1 Unscrew mixing tube from metering head.

2 Clean outlet.
3 Fit union nut over measuring adapter and connect measuring adapter with
union nut to the outlet.
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Using the measuring adapter
4 Place each tube of the measuring adapter in a cup.

5 Determine weight of dispensed material. Repeat the following steps at least
5 times.
5.1 Start dispensing
5.2 At the end of the dispensing procedure, weigh filled cups.
5.3 Place tubes of the measuring adapter in new cups.
6 Disconnect measuring adapter from the outlet and thoroughly clean. Keep
measuring adapter in a safe place for further use.
7 Fit tapered plugs in outlets, fit protective cap on outlet.
IF METERING PROBLEMS APPEAR
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MAINTENANCE INSTRUCTIONS

ORIGINAL MAINTENANCE INSTRUCTIONS

7.2.1 Preparations for changing diaphragm . . . . . . . . . . . . . . . . . . . 44

Copyright and Edition

Technical documentation Dagmar Helmers & Thomas Brandl

1.1 Safety information and symbols used

1.1.1 Safety instruction – Prevent of personal injury

Used priority level

1.1.2 Safety instruction – Prevent of damage to property

1.1.3 Text format

Pushbutton, but- [Text]

2.1 Safety equipment

2.1.1 Protective cover - piston-type dispenser

2.1.2 Safety labels

2.1.3 Parts carrying hazardous substances

Safety information Observe the following safety information:

Fig. 2-1: Yellow hose connector

GHS labelling - haz-

Fig. 2-2: GHS labelling - health hazard

Fig. 2-3: GHS labelling - sensitising/irritant

Safety advice Follow the safety advice below.

2.3 Residual Risk

Safety instruction Note following safety instruction:

2.3.2 Drive motors

Introduction Electric motors are used as drive systems.

Replacing motor Observe the following if a motor is defective:

Hot surfaces Observe the following safety information:

Motor Observe the manufacturer's technical documentation relating to the motor.

2.3.3 Electrical current

Safety information Observe the following safety information:

Optional compo- This is an optional component.

Safety instruction for metering head heaters

2.4 Casting resin processing

Directive 98/24/EC Please note the following information:

Safety datasheets Please note the following information:

2.4.1 Safety information

Carefully read the information in the safety datasheet on

Exposure to hazardous substances

Safety information Observe the following safety information:

Storage conditions Store cool and dry in well sealed containers.

Environment Casting resins must not escape into the environment.

2.4.4 Personal protection

Personal protection The following personal protection equipment is necessary:

2.4.5 Procedure in the case of emergency

Safety information Observe the following information in the case of emergency.

For further information see corresponding safety datasheet.

2.5 Water protection

Safety instruction Note following safety instruction:

Maintenance work must be performed in accordance with the wiring diagrams.

2.6.1 Measurements on energized components

Tightening torque for pneumatics unit

Who is to carry out maintenance work?

Adapting length of maintenance interval

4.1 Maintenance schedule - piston-type dispenser

Maintenance schedule - piston-type dispenser

Specialist personnel Maintenance interval

× Visual inspection of O-ring at outlet.a 8.2 10 ×