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I.C.T.C. Holdings Corporation
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1100NC
User Manual
39 pgs1.1 Mb0

I.C.T.C. Holdings Corporation 1100C, 1100NC User Manual

DO NOT attempt to operate this machine until you have read and understand
ALL safety precautions and operating instructions.
Equipment and chemicals when used improperly can be dangerous.
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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H.E.R.O. WARRANTY
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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TABLE OF CONTENTS
any part, shut off power and relieve pressure.
For greatest user satisfaction, please familiarize
yourself with all maintenance and operational instructions
Important Safety Precautions ..............................................................................................3-4
Introduction ...........................................................................................................................5
Operating Instructions ...........................................................................................................5
Setting Up To Spray ..............................................................................................................6
Flushing The Unit .................................................................................................................7
Special Notes ........................................................................................................................8
Airless Spray Painting Suggestions ...................................................................................9-11
Trouble Shooting ............................................................................................................12-19
Diaphragm Replacement .....................................................................................................20
Intake Seat Replacement ......................................................................................................21
Outgo Valve ........................................................................................................................22
Piston Repairs ................................................................................................................23-24
Pressure Control Valve Repairs ...........................................................................................25
Accessories .........................................................................................................................26
Parts List And Descriptions ............................................................................................27-31
Exploded Unit Diagram ..................................................................................................32-33
Parts Depot List ..............................................................................................................34-37
IMPORTANT
NOTE: AS WITH ALL MECHANICAL EQUIPMENT, PROPER OPERATING AND MAINTENANCE PROCEDURES ARE REQUIRED TO KEEP YOUR H.E.R.O. AIRLESS PUMP PERFORMING TO YOUR SATISFACTION. THE FOLLOWING SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS ARE IMPORTANT.
Read and understand this manual completely, especially with regard to all safety precautions. Read and follow instructions on all warning labels on your equipment. Keep the warning labels clean and readable at all times. Order new labels from your local distributor or from H.E.R.O. Industries Ltd. if needed.
The manufacturer shall not be responsible for any loss, damages, or injury of any kind or nature whatsoever resulting from the use the equipment other than in strict compliance with the instructions, cautions and warnings contained in this operating and instruction manual and as displayed on the face of the equipment.
This system is capable of producing 2400 psi. ( spray pressure ). To avoid rupture and injury DO NOT operate this pump with components rated less than 3000 psi. working pressure (including but not limited to spray guns, hose and connections).
Before servicing, cleaning or removing of
IMPORTANT SAFETY PRECAUTIONS
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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WARNING NEVER PLACE FINGERS NEAR SPRAY TIP OF GUN. NEVER POINT GUN TOWARD ANY PART OF YOUR BODY, OR THAT OF ANY OTHER PERSON. MATERIAL ISSUING FROM THE SPRAY TIP IS AT HIGH PRESSURE. IF FINGERS, OR ANY PART OF THE BODY ARE PLACED NEAR THE TIP OF THE SPRAY GUN, IT IS POSSIBLE THAT THE SPRAY COULD BREAK THE SKIN AND INJECT SOME OF THE SPRAY MATERIAL. IF INJURY DOES OCCUR, SEEK THE IMMEDIATE ATTENTION OF A MEDICAL DOCTOR. BE PREPARED TO INFORM THE DOCTOR WHAT FLUID WAS INJECTED, IF THE INJURY IS OF AN INJECTION NATURE. EQUIPMENT AND CHEMICALS WHEN USED IMPROPERLY CAN BE DANGEROUS!
ý NEVER place any part of the body in front of the spray tip or aim the gun toward any part of the
body.
ý NEVER point the gun toward any individual. ý NEVER treat any injury as a simple cut. If injury does occur, seek immediate medical attention. Be
prepared to inform the doctor what fluid was injected.
ý NEVER allow another person to use the sprayer unless he is thoroughly instructed on its
operation and has read all safety precautions in this manual and all safety warning labels attached to unit.
ý NEVER use around children. ý NEVER attempt to perform any maintenance or service on any part of the unit spray system
without first;
1. Shutting off the unit.
2. Disconnecting the power cord from the outlet.
3. Relieving all pressure in the pump by triggering the gun.
4. Locking gun trigger in "LOCKED" position, with gun locked closed.
ý NEVER operate the sprayer without the tip guard complete and in place. ý NEVER spray any material in the vicinity of open flame, pilot lights, electrical outlets or any
other source of ignition.
ý NEVER spray volatile materials with flash points lower than 140 F (60 C). ý NEVER attempt to stop any leakage in the paint line or at any fitting with your hand or any part of
your body. Immediately shut off the unit should leakage occur.
ý NEVER wash an electric motor, nor operate it in the rain or in wet or damp areas, to protect
yourself from electric shock.
ý NEVER allow paint hose to become kinked, or to vibrate against rough or sharp surfaces. ý NEVER operate the unit at pressures higher than the pressure rating of the lowest rated
component in the system, or at pressure higher than factory preset.
ý NEVER spray in an enclosed area. The spraying area must be well ventilated to safely remove
chemical vapors.
ý NEVER operate the unit with worn or damaged accessories, or with accessories other than those
supplied by H.E.R.O. Industries, unless the accessories have been first specifically approved in writing by H.E.R.O. Industries Ltd.
ý NEVER allow the unit to be serviced or repaired anywhere other than an authorized H.E.R.O.
Service Center, or with other than genuine H.E.R.O. parts or components.
ý NEVER leave unit unattended without first shutting off, triggering the gun to relieve all pump
pressure, and setting the trigger lock on gun in "LOCKED" position, with gun locked closed.
ALWAYS
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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þ ALWAYS follow H.E.R.O. recommendations for operation and safety completely. þ ALWAYS ensure that switch is in off position before plugging in the electric motor. þ ALWAYS set trigger lock on gun in "LOCKED" position when not in use, with gun locked close. þ ALWAYS check connections and fittings for tightness before operating the unit. þ ALWAYS locate the unit in a well ventilated area a minimum of 25 feet from the spray area. þ ALWAYS ground the unit, the paint containers, and the object being sprayed to eliminate static
discharge. Ensure that all these objects remain grounded throughout the entire spraying operation.
þ ALWAYS use approved 3 prong grounded extension cord and approved grounded outlets of the
voltage and frequency specified on the motor. The outlet must be at least 25 feet from the spraying area.
þ ALWAYS use approved 3 prong grounded extension cord not less than # 12/3 gauge up to 50 feet,
and not less than # 10/3 gauge up to 100 feet. DO NOT exceed 100 feet of extension cord.
þ ALWAYS use accessories and components approved for at least 3000 psi (working pressure) in the
spraying system.
þ ALWAYS use accessories and components supplied by H.E.R.O. Industries Ltd., or specifically
approved in writing by H.E.R.O. Industries Ltd. on with the unit.
þ ALWAYS examine accessories for wear or damage before operating the unit. þ ALWAYS use lowest possible pressure when flushing and cleaning the unit, and hold the gun firmly
against a metal container to reduce static discharge possibility.
þ ALWAYS wear a face filter mask when operating the unit. þ ALWAYS ;
1. Turn off the motor.
2. Disconnect the power cord from the outlet.
3. Relieve all pressure in the pump by triggering the gun.
4. Lock gun trigger in "LOCKED" position, with gun locked closed before attempting to perform any maintenance or service on any part of the unit spray system.
þ ALWAYS wear safety glasses when operating the unit. þ ALWAYS ensure fire extinguishing equipment is readily available and properly maintained in the spray
area.
þ ALWAYS observe good housekeeping and keep the spray area free from obstructions. þ ALWAYS be aware that certain chemicals may react with aluminum, carbide, or other components in
the pump system. Read the manufacturer's label on all materials to be sprayed, and follow the manufacturer's recommendations. If in doubt, consult your material sup plier to be sure.
þ ALWAYS replace any damaged airless paint hose. A scratched, torn, cut or otherwise damaged outer
core of the paint hose can lead to a rupture. DO NOT attempt to repair a damaged hose.
H.E.R.O. AIRLESS SPRAY PAINTING
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Welcome to the world of H.E.R.O. airless paint spraying. We are sure you will enjoy owning and operating your new H.E.R.O. model 1100NC. With H.E.R.O. airless spray equipment you will avoid the inconvenience and mess of overspray. You are spraying paint, not air, and the paint is driven to the painting surface in a clean, fan shaped spray which penetrates all cracks and corners. To attain these results, you must adjust the pressure as low as possible. We recommend that you become familiar with your H.E.R.O. unit. Discuss with your dealer the useful accessory items he has to offer - various types of tips, extension poles for hard to reach areas, extra hose, etc. Use of accessory items is often the difference between a good job and an excellent one!
OPERATING
INSTRUCTIONS
WARNING
Do not attempt to operate this machine until you have read and understood all safety precautions and operating instructions. Equipment and chemicals when used improperly can be dangerous.
Your H.E.R.O. airless sprayer has been fully factory tested prior to shipment.
BEFORE STARTING YOUR H.E.R.O. PUMP....
CHECK to ensure that the shipping seal has been removed from under the cap on the hydraulic tank.
Hydraulic tank should be at least 3/4 full of H.E.R.O. LVO hydraulic fluid.
CHECK all fittings and connections in the pump system, hose, and gun to ensure that they are tight. CHECK to ensure that there is a spray tip in the gun, and that the tip is the correct size for the coating you
are to spray. ( There are various tips available, for each type of coating or configuration. See " Airless Spray Tip " on page 11 , for proper tip selection. CHECK to ensure that you have H.E.R.O. strainer bags, H.E.R.O. Wonder Wash, appropriate thinner for the paint, a waste container, and any other accessories you may require for the job. CHECK to ensure that you have adequate extension cord size and length if the machine cannot be situated immediately next to an electric outlet. Distances up to 50 feet require #12/3 wire grounded cord, up to 100 feet require #10/3 wire grounded cord. DO NOT exceed 100 feet of extension cord. If distance is greater, obtain and ins tall extra length of H.E.R.O. airless spray hose.
READ THIS MANUAL THOROUGHLY.
SETTING UP TO SPRAY
1. Remove unit from shipping carton.
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2. Remove shipping seal from under hydraulic tank cap.
3. Re-position paint tank lid knob from the shipping position, on the und erside of lid, and place on the lid top.
4. Attach paint hose to outgo tee (ref # 43) and gun to paint hose.
NOTE; Spray tip and tip guard should be attached to gun prior to attaching to hose.
5. To assist in clean up, use and install paint tank plastic liners ( accessory item 5 GAL PL ). Line the inner sides of tank, ensuring that the liner does not block the tank screen in the bottom of the tank. Fold excess over the outside of tank.
6. Install strainer bag (accessory item 5GAL SB) in tank and secure with large rubber band ( accessory item 106 ). NOTE; Strainer bag must remain 4 inches from the bottom of tank.
7. Trigger gun to release any pressure in the unit. Use extreme caution to ensure that the gun is not directed towards anyone or any object which may be damaged. NOTE; Unit may contain storage solution.
8. To remove storage solution, add one gallon of thinner, compatible with the type of paint to be used, to the paint tank.
9. Turn pressure control knob (ref # 71) to lowest pressure setting.
10. Be sure motor switch is in "OFF" position. Plug unit into 115V, 15 amp., grounded circuit.
NOTE; If using an extension cord, you MUST use a #12/3 wire grounded cord, up to 50 feet or #10/3 wire grounded cord, up to 100 feet. DO NOT EXCEED 100 FEET OF EXTENSION CORD. If distance is greater, purchase and install additional lengths of airless spray hose.
11. Turn motor switch "on" and increase pressure slowly. Trigger gun into a waste container. Continue spraying until pump runs dry and all thinner and holding solution has been removed. Keep pressure low.
12. Pour paint through strainer bag into paint tank. NOTE; Pour paint (particularly thick paints ) slowly, to allow paint to
enter the intake hose while at the same time allowing air the opportunity to escape up the intake tube. Pouring paint in quickly can trap air in the intake tube ( air lock ) and make priming difficult.
13. Replace paint tank lid. Keep tank covered at all times to prevent contaminates from falling into the paint.
14. Increase the pressure, slowly at first, by turning the pressure control knob clockwise. Spray a test pattern. NOTE; Begin by spraying a test pattern onto old newspaper or other scrap
material. Continue increasing the pressure until the spray pattern is uniformed from top to bottom, with no heavy areas. Secure pressure control setting, by turning the silver lock ring (ref # 73) counter clockwise until snugly against the face of the pressure control knob. If heavy areas are still visible at maximum pressure setting, thin the paint with the correct thinner, according to the paint manufacturer's recommendations.
FLUSHING THE UNIT AT SHUTDOWN
43
Air out
Paint
Rubber
band
106
Strainer
bag
5GAL SB
Liner
5GAL PL
Tank
outline
Paint
in
70
OR COLOR CHANGE
If shutting down for a short period of time, it is sufficient to trigger the gun to
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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relieve pressure. Then set the safety lock on gun to "locked" position with the gun locked closed and immerse the gun in a container of the correct thinner for the paint you are spraying.
If shutting down at job completion, for the night, or to change colors;
1. Turn pressure control knob counter clockwise to low pressure setting.
2. Switch unit “OFF”. Remove spray tip from gun and trigger gun back into paint tank. Direct against side of tank.
3. Remove and discard strainer bag.
4. To remove any remaining paint from the paint tank, tip unit as shown and pour into original container. Allow plastic liner to fall into container. Remove and discard liner.
5. Upright unit and add one(1) gallon of the correct thinner, for the paint being used, to the paint tank.
6. Re-start unit and trigger gun back into the paint tank. Direct against the sides of the tank. Use the stream to clean the sides and bottom. Circulate the thinner for several minutes.
7. Remove dirty thinner, per step 4 and repeat steps 5 & 6 with fresh thinner. Trigger gun into waste container until tank runs dry.
8. Repeat procedure using a gallon of pre-mixed H.E.R.O. Equipment Wonder Wash solution. If not using Wonder Wash, unit must not be stored with water. Only store with a non corrosive material ( Paint thinner, solvent ).
9. Switch unit "off" and trigger gun to relieve remaining pressure.
10. Remove and rinse gun handle filter in correct thinner.
SPECIAL STORAGE INSTRUCTIONS
In areas where the sprayer is NOT used 12 months of the year, special preparations must be used for winter or off season storage. Because solvents evaporate quickly, they should not be used for long term storage. A petroleum based solution ( solvent and oil ) should be used as an extended storage material. DO NOT allow storage solution to freeze in the sprayer.
H.E.R.O. Equipment Wonder Wash, available from your H.E.R.O. distributor, will provide the added cleaning benefits of solvent at a much lower cost. Suitable as a short term ( 1-2 days ) storage solution only
SPECIAL NOTES AND
GENERAL MAINTENANCE INSTRUCTIONS
NEVER LEAVE THE UNIT UNDER PRESSURE WHEN NOT SPRAYING (MOTOR TURNED OFF). RELIEVE PRESSURE BY TRIGGERING GUN. NEVER STORE THE UNIT WITH PAINT OR WATER IN THE PUMP
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SYSTEM, EVEN OVERNIGHT.
250’ total length of paint hose = 3 of 50’ x 1/4” paint hose and 2 of 50’ x 3/8 paint hose.
ý NEVER attempt to start the motor when the unit is under pressure. Relieve pressure and follow instructions in "Setting up to spray"
ý NEVER attempt to run the motor on longer or lighter extension cord than specified. ý Avoid operating the unit while tilted. Keeping it level assures greater operating efficiency. þ If motor's thermal overload switch has opened, unplug unit and allow it to cool. ý DO NOT attempt to resume spraying before determining and correcting the cause of overheating. þ Always follow flushing and cleaning instructions exactly. þ In hot weather, locate unit in shade. þ Regularly check the level of H.E.R.O. LVO hydraulic fluid in the hydraulic tank. It should be kept near
full, top up as needed with only genuine H.E.R.O. LVO hydraulic fluid. þ Crankshaft eccentric bearing should be greased at regular intervals consistent with hours of use. Use MO-2 grease (i.e. common auto grease) approximately every 10 hours of operation.
þ Check drive belt ( part # 66/100 ) tension frequently. The belt will stretch with use, and should be
adjusted after 20 hours of operation and again after 50 hours. Periodic checks after 50 hours should be made. A slipping belt will reduce sprayer performance and the tension should be checked frequently.
þ Regularly check fittings, bolts, nuts and connections for damage. Tighten, adjust or replace as required. þ Check crankshaft alignment often. An out of alignment crankshaft will cause the damage to the
eccentric bearing.
þ If you wish to power your H.E.R.O. airless sprayer with a generator, it must be a minimum of a 5000 watt generator, in good operating condition. NOTE; An electric tool must be powered by a generator which has an output wattage of at least three times the maximum draw of the motor under full load. þ A minimum 50’ and a maximum of 300’ of airless spray hose may be used. NOTE: 50’ x 3/8” paint hose ( part # 117 ) should be used for every 50’ x 1/4” paint hose ( part # 114 ) over 100’. 100’ total length of paint hose = 2 of 50’ x 1/4” paint hose. 150’ total length of paint hose = 2 of 50’ x 1/4” paint hose and 1 of 50’ x 3/8 paint hose. 200’ total length of paint hose = 2 of 50’ x 1/4” paint hose and 2 of 50’ x 3/8 paint hose.
300’ total length of paint hose = 3 of 50’ x 1/4” paint hose and 3 of 50’ x 3/8 paint hose. þ Product viscosity, altitude ( feet above sea level ) and vertical reach can effect pump performance and special accessories may be required. Product viscosity may have to be further reduced at higher elevations. The larger diameter 3/8” paint hose should also be used, to aid in the movement of spray materials.
AIRLESS SPRAY PAINTING SUGGESTIONS AND TECHNIQUE
A good airless spray applic ation is the result of many factors. Surface preparation, which includes cleaning and degreasing, priming, material compatibility, quality finish product and correct application technique. All are all important to the finished results.
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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The key to all good applications is a good spray gun technique. The finished results are what the client will look at and base his opinion on. Your skill and abilities are as important as good equipment and good paint. Proper application techniques can easily be learned by using the following simple guidelines. If you are not familiar with the basic spray techniques we recommend that you study this portion of the manual and practice the techniques shown. Practice your technique on scrap cardboard or old newspaper until you feel confident.
FOR EXCELLENT RESULTS, READ AND PRACTICE THESE TECHNIQUES
1. Always strain all paint through a H.E.R.O. strainer bag. The most common reason for airless sprayers to malfunction is foreign matter jamming the valves or plugging the tip. Always strain the paint before putting through the pump.
2. Always spray at the lowest pressure setting which will provide a uniform spray fan. (fig. 1, page 10) Adjust pressure control knob so that paint is completely atomized . Insufficient pressure will result in "tailing". Too much pressure will result in excess fog and over spray, excess tip wear, and increased sprayer wear and tear. See setting up to spray, page 5.
3. Always spray at right angles to the surface being sprayed. (fig. 2, page 10) Angling or arcing the nozzle toward the surface will cause uneven coverage and excessive overspray.
4. Always hold spray gun 12-15 inches from spray surface. (fig. 3, page 10) Too close and the fan width will be reduced and material will be applied too heavily (runs). Too far from the surface and you will have excessive overspray and light coverage (transparent).
5. Always move the gun parallel to the surface being sprayed, at a consistent speed. This avoids uneven coverage (thick or thin areas).
6. Always start the spray stroke before triggering the gun and release the trigger before completing the stroke. (fig. 4, page 10) This avoids heavy build up of paint at either end of the spray stroke.
7. Always lap your spray pattern by one half. (fig. 5, page 10) This assures full coverage of the surface being painted.
AIRLESS SPRAY PAINTING SUGGESTIONS AND TECHNIQUE SPRAY TIP SELECTION
TIP SIZE FOR APPLICATION OF .021 Exterior Latex on large unobstructed areas. ( 60 OZ. )
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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.018 Interior Latex, Exterior Latex, Shake Paint, Exterior Flat Paints. ( 46 OZ. ) .015 Alkyd Flat Enamel, Interior Latex, Semi-Gloss Enamel, Stains. ( 30 OZ. )
FIG.
Poor Good Tailing Good Pattern Fog, Overspray
FIG.
FIG. FIG.
FIG.
FIG.
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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.013 Fine ground Gloss Enamels, and good quality Stains. ( 23 OZ. ) .011 Clear Varnishes and Lacquers. ( 15 OZ. ) .009 Clear Varnishes and Lacquers. ( 10 OZ. )
NOT: The above volumes achieved with gun wide open for 1 minute and pump spraying at 2000psi. All volumes are approximate. To test worn tips, spray water through the tip at 2000 psi. for 1 minute. Spray into bucket and weigh amount (less weight of bucket). If it is substantially greater than what is listed above, the n the tip should be discarded or reclassified. As a tip wears, the hole gets larger and the fan pattern becomes narrower.
ORIFICE SIZE
All tips are rated by the size of the orifice or bore size. The bore size is measured in thousandths of an inch ( .018 = 18 thousandths of an inch ). The size of tip required is based on the consistency of the material to be sprayed. The thicker the paint, the larger the tip size required. Always consult the product label or ask the paint retailer for the manufacturer's recommendations with regard to proper tip sizes.
FAN WIDTH
Fan width or pattern width is determined by the spray tip's "fan width" classification. This size is measured in inches, and is determined when spraying 12 inches from the spray surface. Various methods of noting the fan widths are used by tip manufacturers. Ask your distributor for assistance. NOTE: Two tips having the same tip size, but different fan widths will deliver the same amount of paint over a different area (wider or narrower strip). A spray tip with a narrow pattern width makes it easy to spray in tight places. Use only good quality, high-pressure tungsten carbide spray tips.
SPRAY TIP REPLACEMENT
During use, especially with Latex paint, high pressure and material abrasion will cause the orifice to grow larger. As the orifice grows larger, the fan width grows smaller. Replace tips before they become excessively worn. Worn tips waste paint, cause overspray, make cutting in difficult, and decrease sprayer performance. NOTE: When using Latex paint, a spray tip will wear at the rate of one size for approximately every 100 gallons of material spraye d.
An excessively worn tip can be the cause of apparent operating problems with the unit. If a tip is worn
past the aperture size which the unit can support, pulsation will become evident in the spray fan/pattern. Added strain is placed on the Diaphragm as it attempts to keep the spray pressure consistent. When the tip wears beyond .031, its is releasing more material than the unit is bringing in. The natural reserve of product in the paint chamber is reduced and harm to the membrane begins. ALWAYS check your tips for wear when trouble shooting the equipment. The 1100NC can support up to a maximum of a one .026 tip or two 017 tips.
TROUBLESHOOTING
Hydraulic Energy Regulated Output (H.E.R.O.) is more than just our name, it is the bases for the
operation of the pump. It is the regulation or control, of hydraulic energy, which allows the equipment to build and then deliver or have an output of pressure. Once you have a basic understanding of the operation of the equipment and the effect created in one area and how it will effect operation in another area, you will be better able to diagnose and make repairs. All H.E.R.O. diaphragm pumps are made up of two (2) distinct pumps. The first, and most important pump is the hydraulic pump. The hydraulic system is made up of two valves, the hydraulic intake valve (ref#
59) and the hydraulic outgo valve, known as the hydraulic pressure control valve (ref # 70). The second
H.E.R.O. INDUSTRIES 1100C & 1100NC OWNERS MANUAL
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