Advanjet HV-2100 Setup guide

Repair
HV-2100 Jet
Maintenance and Repair
3A6326A
Diaphragm-Jet™Technology EN
For non-contact dispensing of viscous material in industrial environments.
For professional use only.
Models - See page 3 for model information.
Important Safety Instructions
Read all warnings and instructions in this manual and all related
manuals before using this equipment. Save these instructions.
Model 25B310
PROVEN QUALITY. LEADING TECHNOLOGY.

Table of Contents
KITS ...........................................................................................................................................4
RELATED MANUALS ................................................................................................................4
WARNINGS................................................................................................................................5
1. REQUIRED TOOLS AND PARTS...................................................................................6
1.1 Maintenance Kits....................................................................................................6
1.1.1 Bushing Kit (P/N BK-2001)......................................................................6
1.1.2 Heater Kit (P/N HK-2100)........................................................................7
1.1.3 Jet Repair Kit (P/N JK-2001)....................................................................8
1.2 Required Tools.......................................................................................................9
2. JET DISASSEMBLY.....................................................................................................10
2.1 Overview..............................................................................................................10
2.2 Disassembled Jet.................................................................................................11
2.3 Remove Mounting Plates and Top Cover.............................................................12
2.4 Remove Heater Block Assembly..........................................................................13
2.4.1 Disconnect the Heater Block (BK & HK)................................................13
2.4.2 Remove the Heater Block (HK only)......................................................13
2.5 Remove Spacer Assembly...................................................................................14
2.5.1 Remove the Spacer...............................................................................14
2.5.2Loosen the Air Cylinder Locking Screw .................................................14
2.5.3 Remove the Jet Hammer Cylinder.........................................................14
2.6 Remove Solenoid.................................................................................................15
2.6.1 Remove the Solenoid ............................................................................15
2.6.2 Remove the Silencer .............................................................................15
2.7 Check Parts Set Aside .........................................................................................16
3. INSTALL NEW PARTS AND REASSEMBLE THE JET ...............................................17
3.1 Overview..............................................................................................................17
3.2 Install the Solenoid...............................................................................................18
3.2.1 Install the Silencer.................................................................................18
3.2.2 Install the Solenoid................................................................................18
3.3Assemble the Spacer...........................................................................................19
3.3.1 Install the Air Cylinder............................................................................19
3.3.2 Tighten the Setscrew.............................................................................19
3.3.3 Assemble the Spacer Parts ...................................................................19
3.3.4 Check the Lever Assembly....................................................................19
3.3.5 Attach the Spacer..................................................................................19
3.3.6 Align the Lever with the Shoulder Bolt...................................................20
3.3.7 Install the Shoulder Bolt.........................................................................20
3.4 Reassemble the Heater Block..............................................................................21
3.4.1 Install the Heater Seal ...........................................................................21
3.4.2 Install the Washer..................................................................................21
3.4.3 Install the Jet Spring..............................................................................21
3.4.4 Heater Block Bushing............................................................................21
3.5 Attach the Heater Block........................................................................................22
3.5.1 Heater Block and Cable.........................................................................22
3.5.2 Position Heater Block ............................................................................22
3.5.3 Install Heater Block Screws...................................................................22
Page 2 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

Table of Contents
3.6 Reassemble the Jet..............................................................................................23
3.6.1 Insert the Nozzle Plate Screws..............................................................23
3.6.2 Attach Solenoid Connector....................................................................23
3.6.3 Attach the Top Cover.............................................................................23
3.6.4 Tie the Cables.......................................................................................24
3.6.5 Tuck the Cables.....................................................................................24
3.6.6 Position Heater Block Cable..................................................................24
3.6.7 Attach the Mounting Plate......................................................................24
3.6.8 Attach the Dovetail Plate .......................................................................25
3.6.9 Attach the Syringe Holder......................................................................25
4. SET THE JET HAMMER GAP ......................................................................................26
4.1 Using the Gap Set Fixture....................................................................................26
4.2 Prepare the Gap Set Fixture.................................................................................27
4.2.1 Check the Zeroing Plate........................................................................27
4.2.2 Zero the MIcrometer..............................................................................27
4.2.3 Remove the Zeroing Plate.....................................................................27
4.2.4 Attach the Jet ........................................................................................27
4.3 Measure the Gap .................................................................................................28
4.3.1 Connect the Jet .....................................................................................28
4.3.2 Reading the Dial....................................................................................28
4.4 Adjust the Gap .....................................................................................................28
GRACO STANDARD WARRANTY..........................................................................................30
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 3 of 30

Models
Part Number
Model
25B310
HV-2100 Jet, 30 cc syringe
25B311
HV-2100 Jet, 30 cc syringe, heated feed tube
25B312
HV-2100 Jet, 6 oz syringe, heated feed tube
Kits
This manual accompanies these HM-2100 Jet Repair kits:
Part Number
Kit
BK-2001
Bushing Kit
HK-2100
Heater Kit
JK-2001
Jet Repair Kit
Related Manuals
Manuals are available at www.graco.com. Component manuals below are in English:
Part Number
Manual
3A6244
HV-2100 Jet Setup and Operation
3A6226
HV-2100C Jet Controller Setup and Operation
3A5937
Jet Dispensing Parameters Supplement
3A5908
Jet Maintenance Tool Kits
Page 4 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of
this equipment. The exclamation point symbol alerts you to a general warning and the
hazard symbols refer to procedure-specific risks. When these symbols appear in the
body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the
body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
Turn off and disconnect power cord before servicing equipment.
Connect only to grounded electrical outlets.
Use only 3-wire extension cords.
Ensure ground prongs are intact on power and extension cords.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns: Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes
but is not limited to:
Protective eyewear, and hearing protection.
Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request SDSs from distributor or retailer.
Turn off all equipment and relieve air pressure when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
Make sure all equipment is rated and approved for the environment in which it is used.
Use equipment only for its intended purpose. Contact your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 5 of 30

1. Required Tools and Parts
For optimal jet performance, it is suggested to perform periodic preventive maintenance.
These HV-2100 jet maintenance kits are available for this purpose:
BK-2001: Replaces just the heater block bushing, jet spring, washer, and heater
seal.
HK-2100: Replaces the heater block assembly (heater block with bushing and
cable assembly). Also includes the jet spring, washer and heater seal.
JK-2001: Replaces the jet hammer cylinder, lever, shoulder bolt, solenoid,
muffler, and heater block assembly.
This document describes procedures for installing the HV-2100 jet maintenance kits.
Whenever the jet hammer spring is removed, as in these maintenance kits, the jet
hammer gap must be set before dispensing can proceed. The gap set fixture and
specific tools required for this procedure are included in the Advanjet Jet Maintenance
Kit (P/N JKT-2000).
1.1 Maintenance Kits
1.1.1 Bushing Kit (P/N BK-2001)
JET SPRING P/N 60-2102
WASHER P/N 60-2116
HEATER SEAL P/N 03-2261-00
BUSHING P/N 03-2162-00
Page 6 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

1.1 Maintenance Kits (continued)
1.1.2 Heater Kit (P/N HK-2100)
HK-2100 (STANDARD, 10W)
HEATER CABLE ASSEMBLY 06-1088-00
HEATER BLOCK SCREWS (2) M3 X 25 FHMS
- and –
JET SPRING P/N 60-2102
WASHER P/N 60-2116
HEATER SEAL P/N 03-2261-00
BUSHING P/N 03-2162-00
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 7 of 30

1.1 Maintenance Kits (continued)
1.1.3 Jet Repair Kit (P/N JK-2001)
MAIN AIR VALVE P/N 60-2030
MAIN AIR (JET HAMMER)
CYLINDER ASSEMBLY P/N 60-2266
SILENCER P/N 60-2107
LEVER P/N 03-2281-00
PIVOT BOLT P/N 60-2104
HEATER SEAL P/N 03-2261-00
WASHER P/N 60-2116
JET SPRING P/N 60-2102
BUSHING P/N 03-2162-00
Page 8 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

1.2 Required Tools
Jet Maintenance Tool Kit (P/N JKT-2000)
Loctite® 242 small screw
threadlocker
(P/N 113500)
2 mm (5/64 in.) hex wrench
(P/N 60-2293)
0.050 in. hex wrench
(P/N 60-2294)
Solenoid torque tool
(P/N 60-2302)
Awl
(P/N 60-2296)
Gap Set Fixture
(P/N 90-0010)
Other Tools
#1 Phillips screwdriver
#2 Phillips screwdriver
3 mm hex wrench
150 mm adjustable wrench
13-mm open end wrench
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 9 of 30

2. Jet Disassembly
2.1 Overview
Note: It is important to flush and clean the jet prior to making repairs. Follow the steps
for cleaning the jet in the HV-2100 Jet Setup and Operation manual 3A6244.
To avoid personal injury:
Move the nozzle close to the collection device
so there is minimal misting of the solvent
during flushing.
Be sure there is proper ventilation and wear appropriate
eye and skin protection as
instructed by the solvent manufacturer.
Material inside the applicator can be near setpoint temperature. Wear protective clothing to
avoid severe burns.
Turn off the power switch and the air switch on the HV-2100C Jet Controller before
beginning disassembly of the jet. Refer to the HV-2100C Jet Controller Setup and
Operation manual 3A6226.
The extent of jet disassembly depends on which kits are being installed.
For all repair kits, remove and keep:
Nozzle plate and two screws with two washers each
Top cover and two screws
Mounting plate and two screws
For the Bushing and Heater Kits (BK-2001 and HK-2100):
Detach the Heater Block; keep for BK-2001, discard for HK-2100
Remove and discard the heater seal, washer, and jet hammer spring
For the Jet Maintenance Kit (JK-2001), remove and discard jet parts in this order:
Heater block and cable
Heater seal, washer, and jet hammer spring
Hammer air cylinder
Pivot bolt
Lever
Bullet solenoid valve
Muffler
When noted, use the tool specified.
Section 2.7 provides a checklist of parts and screws that should be set aside. Take care
to set aside screws as they are removed so they can be easily located for installing the
new parts.
Page 10 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

2.2 Disassembled Jet
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 11 of 30

2.3 Remove Mounting Plates and Top Cover
KEEP these parts and screws to set aside and reinstall. A checklist is provided in
section 2.7.
If a heated feed tube enclosure is installed, loosen the thumbscrew to remove the lower feed tube
enclosure. Use the 2.5 mm driver to remove and set aside the two screws securing the upper feed tube
enclosure.
If a syringe is still in place, remove the feed tube from the nozzle plate fluid barb, loosen the syringe
holder thumbscrew, and remove the fluid syringe.
Using the 3 mm driver, remove and set aside:
The four screws securing the dovetail plate
The two screws securing the mounting plate
The two screws securing the syringe holder
The two screws securing the top cover
The two nozzle plate screws
KEEP
KEEP
KEEP
Page 12 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

2.4 Remove Heater Block Assembly
KEEP these parts and screws to set aside and reinstall. A checklist is provided in
section 2.7.
BK-2001 or HK-2100 kit replaces these parts. Do not discard screws.
Use the #1 PH to remove the two screws securing the heater block; set the screws
aside. Remove the hammer spring, the heater block bushing, and the heater seal and
washer.
2.4.1 Disconnect the Heater Block (BK & HK)
Use the #1 PH to remove the two screws
securing the heater block. For the BK-2001,
set the heater block screws aside.
Remove and discard the heater block bearing,
heater seal and washer, and the jet
compression spring.
If only installing the BK-2001,
do not remove the heater block.
Skip to section 3.5
2.4.2 Remove the Heater Block (HK only)
Cut the cable ties bundling the heater cable
assembly with the Jet Pressure line.
Disconnect the heater cable assembly from the
solenoid (pull the white connector up and out).
Discard the heater block.
KEEP FOR
BK-2001
DISCARD
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 13 of 30

2.5 Remove Spacer Assembly
KEEP these parts and screws to set aside and reinstall. A checklist is provided in
section 2.7.
JK-2001 kit replaces these parts. If you are not replacing the jet hammer air cylinder
and related cylinder parts as part of the JK-2001 kit, skip to section 3.5.
2.5.1 Remove the Spacer
Remove and set aside the spacer screws
(#1 PH), the nylon spacer, and the automatic
shutoff spring. Do not lose the shutoff spring.
A new shutoff spring is not included with the
JK-2001, and the shutoff spring and the jet
spring are not interchangeable.
Remove and discard the shoulder bolt (2 mm
hex) and the lever.
2.5.2 Loosen the Air Cylinder Locking Screw
Use the 2 mm hex driver to loosen the setscrew
that locks the jet hammer air cylinder in place.
2.5.3 Remove the Jet Hammer Cylinder
Use a 13-mm wrench to remove the jet hammer air
cylinder; discard.
DISCARD
KEEP
DISCARD
DISCARD
Page 14 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

2.6 Remove Solenoid
JK-2001 kit replaces these parts. If you are not replacing the solenoid and silencer as
part of the JK-2001 kit, skip to section 3.
2.6.1 Remove the Solenoid
Use the torque tool with adapter tip to remove the solenoid; discard the solenoid.
2.6.2 Remove the Silencer
Use an adjustable wrench to remove the silencer;
discard the silencer.
DISCARD
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 15 of 30

2.7 Check Parts Set Aside
Check that these parts have been set aside. If necessary, remove built-up threadlocker.
DOVETAIL PLATE
(4) M4 X 10 SHCS
MOUNTING PLATE
(2) M4 X 10 SHCS
NOZZLE PLATE
(2) M4 X 55 SHCS
TOP COVER
(2) M4 X 40 SHCS
HEATER BLOCK
(2) M3 X 20 FHMS
SPACER
(1) M3 X 16
(2) M3 X 25
SHUTOFF SPRING
Page 16 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

3. Install New Parts and Reassemble the Jet
3.1 Overview
In general, parts are reinstalled in the reverse order that they were removed.
Gather the screws set aside as shown in Section 2.7.
Install the Solenoid
Attach the solenoid
Attach the silencer
Assemble the
Install the hammer air cylinder.
Assemble the lever and lever spring
Attach the spacer
Align the lever
Install the pivot (shoulder) bolt
Attach the Heater
Install the heater seal, washer, and hammer spring
Install the bushing
Connect heater cable (HK-2100)
Align and attach heater block
Reassemble the Jet
Insert nozzle plate screws
Attach top cover
Fasten cable ties
Attach the mounting plate
Attach solenoid connector
NOTICE
Use Loctite®242 or 243 threadlocker as indicated. To avoid damage to
the jet, do not substitute with other products.
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 17 of 30

3.2 Install the Solenoid
3.2.1 Install the Silencer
Apply a small amount of Loctite 242 to the silencer and install into the jet body.
Install finger tight into the valve mount.
The fit should be snug, but not so tight that it crushes the rubber washer.
3.2.2 Install the Solenoid
Inspect the cylinder bore for the solenoid. Clean if necessary.
Install the new solenoid using the solenoid torque tool.
Page 18 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A

3.3 Assemble the Spacer
3.3.1 Install the Air Cylinder
Use the 13-mm wrench to
tighten to a hard stop.
3.3.2 Tighten the Setscrew
Apply a small amount of Loctite
242 to the air cylinder setscrew
and tighten with the 2 mm hex
driver until the setscrew is tight
against the air cylinder.
3.3.3 Assemble the Spacer
Parts
Locate the new lever and
shoulder bolt, and also the nylon
spacer, spacer screws, and
automatic shutoff spring that
were set aside.
3.3.4 Check the Lever Assembly
Install the lever, observing the orientation of the
lever and washers as shown:
The shutoff spring rests in the bore in the
lever.
There is one washer on the shutoff cylinder
below the lever.
Proper positioning is critical.
3.3.5 Attach the Spacer
Install the spacer screws (#1PH).
Note: For proper engagement of the spacer
screws, the spacer and jet body must be
squeezed firmly together to keep the shutoff
spring compressed.
VERIFY
THAT
THE
BORE IN
THE
LEVER
FACES
THE
SPRING.
3A6326A Advanjet HV-2100 Jet Maintenance and Repair Page 19 of 30

3.3 Assemble the , continued
3.3.6 Align the Lever with the Shoulder Bolt
Use an awl to line up the hole in the lever with the hole for the shoulder bolt.
Insert the 2 mm driver from the opposite side and line it up with the awl.
Push out the awl with the driver.
3.3.7 Install the Shoulder Bolt
Apply a light coating of Loctite 242 to the threads of the shoulder bolt and wipe off any excess.
Insert the shoulder bolt and push out the driver.
Screw in the shoulder bolt with the driver until it is barely snug. Verify that the lever is not binding—
the hammer cylinder hat should move up and down freely.
Note: Do not allow Loctite from the shoulder bolt tip to transfer to the lever, as this will impede jet valve
operation. For proper operation of the shoulder bolt, do not over-tighten.
HAT MOVES
UP & DOWN
Page 20 of 30 Advanjet HV-2100 Jet Maintenance and Repair 3A6326A