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XV2 Cross-Over Valve Rebuild Kit
 

The following rebuild instructions apply to Fluidic Systems' XV2 Valve assemblies:

  • 100-XV-AL-051-A, 100-XV-AL-051-BC, 100-XV-AL-056-A, 100-XV-AL-056-BC
  • 100-XV-SS-061-A, 100-XV-SS-061-BC, 100-XV-SS-063-A, 100-XV-SS-063-BC

Note: In order to mount to the left or right side of the cabinet, the XV2 is built with two different orientations, 'A' and 'BC'. Before disassembly and assembly XV2 valves take note of port orientation.
 
Warning: Allow only qualified personnel to perform the following tasks.
Warning: Shut-off and lock out power and compressed air before removing components from any PK system.
 
Fluidic PK3S Spray System
     

Remove the XV2 Cross-over Valve

  1. With tape or marker identify where each airline is currently connected.
  2. Disconnect air lines from the XV2.
  3. Disconnect fluid lines from the XV2.
  4. While preventing the XV2 from falling, remove the two 5/16-18 fasteners located on the outside of the cabinet.
  
   

Disassemble the Cross-Over Valve

  1. Remove the air fittings (23) with a 15mm wrench.
  2. Remove the eight #10-32 fasteners (21).
  3. Remove the Cylinder Cap (19) by gripping socket head with visegrips and pulling.
  
   
  1. Remove the eight ¼-20 fasteners (22).
  2. Lift off the Top Cylinder Plate (7), two #22 O-rings (12), and the two Top Ball seats (10).
  
   
  1. Lift off the two Center Blocks (5)(6) and two #22 O-rings (12).
  
   
  1. Just beneath the ball on each Ballrod is a 9mm wrench flat. Separate the Drive Cylinder Pistons (16) from the Ballrods (15) by removing the two Countersunk #10-32 fasteners (18) while holding the Ballrod at the wrench flat.
  
   
  1. Remove the two Ballrods (15).
  
   
  1. Remove the two Bottom Ball seats (9), the Bottom Cylinder Plate (4), two O-rings (11), and the two energized lip seals (3).
  
   
  1. Remove the six ¼-20 SHCS (8) to remove the two Mounting Blocks.
  2. Remove two O-rings (11), two energized lip seals (3) from the mounting blocks (2).
  3. Using a 3/8” EZ-out, remove the two rod bearings (14) from the Dual Cylinder Block (1).
  4. Finally, remove the two O-rings (13) from the
    Dual Cylinder Block (1).
  
     

Reassemble the Cross-Over Valve

Note: Lubricate all o-rings and seals with all-purpose grease supplied with the PK unit and available from Fluidic Systems.
Note: Thoroughly clean all components before reassembly.

  1. Install the new O-rings (13) and the new rod bearings (14) into
    the Dual Cylinder Block (1).
  
     
  1. Install two of the new energized lip seals (3) into each Mounting
    Block (2) by placing them on a flat, level surface and pressing
    the Mounting Blocks down to seat each seal.
    Note: Seal lips must face into the Mounting Block (2).
  2. Place a new O-ring (11) into the o-ring groove on each Mounting
    Block (2).
  
     
  1. 21. Fasten the Mounting Blocks (2) to the Dual Cylinder Block (1)
    with the six ¼-20 SHCS’s.
  
     
  1. Install two of the energized lip seals (3) into the Bottom Cylinder
    Plate (4) by placing them on a flat surface and pressing the
    Bottom Cylinder Plate down to seat each seal.
    Note: Seal lips must face into the Mounting Block (2).
  2. Place a new O-ring (11) into each o-ring groove on the Bottom
    cylinder Plate (4).
  3. Place the two new Bottom Ball Seats (9) onto the Bottom
    Cylinder Plate (4).
  
     
  1. Apply a small amount of grease to the surface of each new
    Ballrod (15) and insert through the Bottom Ball Seat (9) so that
    the Ballrod (15) passes into the Dual Cylinder Block (1).
  2. If excess grease exists in or around the threads of the Ballrod
    (15), clean with rubbing alcohol.
  3. Replace the Quad Seal O-ring (17) on the Drive Cylinder Piston
    (16) with the new Quad Seal O-ring.
  
     
  1. Apply a small amount of Lo-Strength Loc-tite to the threads of
    the Countersunk #10-32 SHCS (18) and fasten each Drive
    Cylinder Piston (16) to the corresponding Ballrod (15).
  2. Before proceeding to the next step, physically cycle (move) each
    piston (16) several times to ensure that the piston o-ring seals
    properly.
  
     
  1. Place a new O-ring (12) into the o-ring groove on each Center
    Plate (5)(6).
  2. Place the Inlet Center Plate (6) so that the port faces toward the mounting holes of the Mounting Block (2).
  3. Place the Outlet Center Plate (5) so that the port aligns with the
    port of the Bottom Cylinder Plate (6).
  4. Press in one of the two new Top Ball Seats (10) on each of the
    Center Plates (5)(6).
  
     
  1. Place a new O-ring (12) into each o-ring groove on the Top
    cylinder plate (7).
  2. Position the Top cylinder plate (7) on the valve assembly and
    fasten in place using the eight ¼-20 SHCS (22).
  3. Replace the O-Ring (20) on the Drive Cylinder Cap (19) with the
    new O-ring.
  
     
  1. Install the Drive Cylinder Cap (19) and secure in place using the
    eight #10-32 BSHCS (21).
  2. Install the Air Supply Elbows (23) in the Dual Cylinder Block (1).
  
     

Install the Cross-Over Valve

  1. Align the XV2 valve inside the PK cabinet so that the Inlet Port
    on the Center Plate (6) and the mounting hole on the Mounting
    Block (2) align with the thru hole on the side of the PK cabinet.
  2. While holding the XV2 valve in place, fasten the valve to the side
    of the cabinet using the two 5/16-18 fasteners.
  3. Connect the fluid lines to the XV2 valve.
  4. Connect the previously marked air lines to the Air Supply Elbows
    (23) on the XV2 valve.
  5. Prior to placing the XV2 valve into service, lubricate the
    energized seals by pumping grease through the grease fittings
    (24) until an air free stream comes out the lube exhaust port.
  
     
 
Routine Maintenance
   

 

  • Periodically refreshing the grease in the lube plate will extend seal life. Lubricate the energized lip seals by pumping grease through the grease fittings (24).
  • Lubricate the XV2 Cross-Over Valve as required.
  • Abrasive compounds or moisture sensitive materials such as isocyanate catalysts will require more frequent lubrication.
  • Inspection of the purged grease will help gauge the lubrication interval. Thickened or discolored grease from the purge port is an indicator for the lubrication interval.
  • Lubricate with Fluidic grease (3oz cartridge) PN 012-AC-GC-014.
   
 
XV2 Bushing Removal Tool 013-PR-BT-023-FP
 
 
 
XV2 CROSS-OVER VALVE A versus BC pump orientation
 

Gold Block Alignment at TOP
Block Alignment for A pump configuration

Gold Block Alignment at TOP
Block Alignment for BC pump configuration
 
 
 
LINEAR DISPLACEMENT PUMP (LDP) - CROSS OVER VALVE (XV2)
 
LINEAR DISPLACEMENT PUMP (LDP)
CROSS OVER VALVE (XV2)
FUNCTIONALITY
 
 

Top LDP Rods are fixed. Top LDP Cylinders reciprocate on center carriage.

Bottom LDP Cylinders are fixed. Bottom LDP Rods reciprocate on center carriage.

Each LDP cylinder set is filled and dispensed from a single port. This is facilitated by Fluidic's patent pending XV2 4-way cross-over valve that redirects fill and dispense port orientations. This design eliminates separate fill and dispense ports utilizing check valves. Check valves are not efficient and malfunction affecting metering accuracy. When the LDP changes direction, the XV2 is simultaneously actuated to reverse the Fill and Dispense porting. The LDP reciprocation and XV2 actuation happens in milli-seconds to provide a continuous fluid dispense output. Additionally, the fill input pressure is balanced to match the dispense output pressure so there is no differential fluid pressure during LDP reciprocation. The combination of the simultaneous LDP reciprocation/XV2 actuation and balanced fill/dispense pressures provides continuous and virtually pulse-free metered flow.

 
 
 
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