Nerve Manifold Leak Troubleshooting [ZDSPB Tech]

Nerve manifold leak troubleshooting
This page is specifically for leaksing problems out the solenoid manifold.

Leaking from the solenoid manifold can be caused by a large number of seals and/or issues with the marker. Solenoid leaks are somewhat common and can often be very difficult to diagnose due to the large number of possible causes. In many cases, the only choice you have is to swap parts out with a working gun until you figure out which part is causing the leak. If you aren't able to find the source of the leak, you would pretty much have no choice but to send the marker off to be repaired.
Note about inspecting o-rings: various o-rings and seals may VISUALLY appear undamaged however this doesn't mean the o-ring isn't the problem! An o-ring can be leaking and look perfectly intact...just because it "looks" fine doesn't mean it is. To be 100% sure it truly is undamaged, you will have to replace it.

Please note that the information on this page is quite long and very detailed, so don't become overwhelmed. Read the page a few times if necessary. Ask if you have questions. However, as stated above the only true way to solve this problem is to swap working parts out until the leak goes away. If you can't do that (or if you replaced all the parts) the issue is still unknown and nobody will be able to help unless they had the gun in front of them (that's why I suggest sending it off).

Locating the Leak:
The first step to solving the leak is to figure out exactly where it's coming from. If you're unable to locate the exact source, or if there simply isn't one single source that you can find, you will have more work to perform while you fix the problem.

The instructions on this page are given assuming you're holding the Nerve body upside-down in your hand, facing forward, as shown by this picture:
Solenoid leak

Leaking can come from any number of locations, all around the base of the solenoid. Here are the possible locations:
· Solenoid manifold, left exhaust port.
· Solenoid manifold, right/front exhaust port.
· Solenoid housing (leak from the solenoid itself).
Once you figure out where the leak is coming from, check the appropriate leak section on this page.

Solenoid manifold, leak from the left exhaust port:
This leak is the most common and is caused by pressure within the marker leaking out through the solenoid's idle exhaust port.
· The most common cause for this is a damaged or leaking ram sail o-ring. This is the 11/70 o-ring on the middle of the ram (piston must be completely disassembled to access this).
· Piston housing outside o-rings, second o-ring from the back
· Missing open-movement bumper on the inside the piston housing (can be substituded with a 10/90 o-ring, piston must be completely disassembled to access this).
· Solenoid butterfly gasket between spool and pilot (Parker solenoid only)
· Damaged solenoid spool o-ring (o-ring three according to this diagram).
· Leaking solenoid manifold seal. It's logical for the nearest o-ring to be the cause of the leak, but this isn't always the case. For this reason, the easiest practice is to simply replace all six o-rings (three on the top, three on the bottom).
· Stripped solenoid manifold. The solenoid spacer screws must only be installed hand-tight.

Solenoid manifold, leak from the right/front exhaust port:
This exhaust port is only used while the solenoid fires, so leaking from this location is only caused by a leaking solenoid o-ring. There are a few other causes as well.
· Damaged solenoid spool o-ring (spool o-rings five or six according to this diagram).
· Leaking solenoid manifold seal. It's logical for the nearest o-ring to be the cause of the leak, but this isn't always the case. For this reason, the easiest practice is to simply replace all six o-rings (three on the top, three on the bottom).
· Stripped solenoid manifold. The solenoid spacer screws must only be installed hand-tight.

Leak from the solenoid housing:
Leaks from these locations are caused by the solenoid’s internal gaskets. Details are given for these parts on my solenoid maintenance guides.

Continuous leak from both sides:
· Continuous leaks from both vents is most often caused by a damaged solenoid manifold o-ring, generally the middle o-ring on the top or bottom of the manifold. Other manifold o-rings can cause a leak as well however them being damaged may appear as a leak out the vent closest to the damaged ring (this problem is more difficult to diagnose).