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1.8 Quart (1.7 Liter) Polymer Nylon Canisters 1 Oz (30 ml) Maximum Dispense Pumps Modular stand for easy conversion from countertop to floorstand Automatic electric time controled bottom agitation Floor Stand Manual Rotary Dispenser Countertop SAFETY AND OPERATING MANUAL WARNING: DO NOT OPERATE THIS EQUIPMENT WITHOUT READING AND UNDERSTANDING ALL SAFETY AND OPERATING INSTRUCTIONS SEE PAGES 6 - 14 I.C.T.C. Holdings Corporation: 720 Eaton Way Delta, B.C., Canada V3M 6J9 PHONE: (604) 522-6543 HERO Manual Series Colorant Dispenser U.S.A Mailing Address: P.O. BOX 75 Custer, WA 98240-0075 FAX: (604)Page 522-8735 1 TOLL FREE: (800) 494-4376 D18PR Owners Manual Rev. July 08 HERO D18 Series Colorant Dispensers WARRANTY & CLAIM PROCEDURES HERO Products Group is proud to offer an industry leading " 2 Year Warranty " on all of its HERO D18 Series Colorant Dispensers. HERO Products Group warrants all it’s Manual Series Colorant Dispensers to be free of defects in materials and workmanship, to the original user, for a period of Two (2) Years. The warranty entitles the owner to parts replacement at no charge. The parts warranty is valid for any necessary replacement, whither caused by material or workmanship defect or simple wear. Electric motors, timers and pneumatic motors warranted for twelve (12) months only. The warranty is applicable to the original owner only and is non-transferable. The equipment must be used, operated and maintained in accordance with all instructions, precautions and warnings contained in the owner’s manual. For the purpose of this warranty, damage caused by accident, abuse, improper cleaning or lack thereof, or improper operation, is not covered. Cleaning and general maintenance is the responsibility of the owner / operator and is not covered by the warranty. HERO’s liability is limited to the replacement of parts found to be defective or worn and does not include; damage or other expenses of any kind incurred in connection with the purchase and use of the dispenser. All parts required for warranty service are invoiced to the client, with credit provided upon submission of a valid warranty claim. A valid claim lists model number, serial number, date of installation, lists all parts used and provides provisions for parts installation labor charges. Major parts replacement may require the return of defective parts. If uncertain, call for further instructions. All returns must be authorized and no return will be accepted without a Return Goods Authorization ( RGA ) number. HERO Manual Series Colorant Dispenser Page 2 D18PR Owners Manual Rev. July 08 TABLE OF CONTENTS Introduction 4 Unpacking 5 Assembly 6-7 Dispenser Preparation - Canister Filling & Priming Procedures 8 Tinting Instructions - Getting Started – Setting Gauges - Charging The Cylinder - Discharging or Dispensing Colorant 9 10 10 Care & Maintenance Instructions - Do’s & Don’ts - Daily & Weekly Maintenance - Periodic & Annual Maintenance 11 12 13 Problem Solving 14 Service & Repairs - Nozzle & Nozzle O-Ring Replacement - Paddle Replacement - Gauge Calibration Instructions 15 15 16 Parts Lists & Schematic - Canister Parts - Turntable – 12 or 16 Position - Floorstand - Countertop Stand - Wiring Diagram and Automatic Timer 17-19 20 21 22-23 24-25 HERO Manual Series Colorant Dispenser Page 3 D18PR Owners Manual Rev. July 08 INTRODUCTION HERO Products Group is pleased to introduce the model D18PR. The D18PR colorant dispenser, features; ♦ 1 ounce(30ml) (maximum dispense pump, 1/4 shot minimum dispense capability ♦ 1.5 quart (1.8L) maximum colorant capacity polymer nylon canister ♦ Locking “notched” measuring gauge ( maintains the valued “repeatability“ feature found on other models) ♦ Solid Teflon™ piston seal ♦ Spring” loaded, wear compensating, dispense valve ( patent pending ) ♦ Stainless steel cylinder ♦ Stepped “Assured” agitation paddles ♦ Automatic, electric, bottom of the canister agitation, or ♦ Manual, top of the canister agitation available ( optional ) All HERO D18 Series Colorant Dispenser’s are precision measuring devices and must be treated as such. When operated and maintained in conjunction with the instructions contained within this manual, the equipment will provide a long and trouble free life. To ensure your complete satisfaction, please familiarize yourself with all maintenance and operating instructions and procedures. Please retain this manual in a convenient location for future reference and the training of new store personnel. HERO Manual Series Colorant Dispenser Page 4 D18PR Owners Manual Rev. July 08 UNPACKING Your model D18PR, a member of the HERO Manual Series colorant dispenser family, has been carefully inspected and the pumps calibrated to measure colorant with a high degree of accuracy. Each component has been tested and is ready for immediate use. Carefully examine each item while unpacking, to ensure the equipment has not suffered any freight damage. If any parts are found to be broken or damaged, immediately contact the freight carrier and arrange for an inspection of the concealed damage. Claims for damage must be made by you, the consignee, and not by the shipper. The carrier accepts full responsibility for the safe delivery of all merchandise upon pick-up from the shipper. Please read all instructions before using your HERO D18 Series Colorant Dispenser. COUNTERTOP MODELS ( One (1) shipping carton. Partial Assembly Provided ) Box ( which contained this owners manual ) contains; 1 x Turntable 1 x Drive Plate Assembly 1 x Drive Cover 1 x Countertop Stand __ x Canisters complete with calibrated gauges ( Gauge increment as specified on order ) 1 x Bag containing canister mounting hardware ( Part # HW3062P x 36 ) 1 x Bag containing pre-lubricated crankshaft and washer ( Part # BL-2010 & BL-2020 ) 1 x Envelop which contained this manual, plus “Lettering”, if specified FLOORSTAND MODEL. ( Two (2) shipping cartons. ) Carton one (1) contains 1 x Turntable 1 x Drive Plate Assembly 1 x Drive Cover 1 x Countertop Stand __ x Canisters complete with calibrated gauges ( Gauge increment as specified on order ) 1 x Bag containing canister mounting hardware ( Part # HW3062P x 36 ) 1 x Envelop which contained this manual, plus “Lettering”, if specified Carton two ( 2 ) contains the following; 1 x Floorstand 2 x Support legs, c/w mounting hardware. 1 x Five gallon shelf, c/w mounting hardware. 1 x Bag containing pre-lubricated crankshaft and washer ( Part # BL-2510 ) Check off each component as removed from shipping carton. If any parts are missing, contact your supplier or HERO Products Group as soon as possible. DO NOT commence set-up until all required parts or components are available. HERO Manual Series Colorant Dispenser Page 5 D18PR Owners Manual Rev. July 08 ASSEMBLY Prior to assembling your unit, prepare adequate working area to easily work with and operate your machine. For “Countertop” model, base may be placed in desired location and begin assembly procedures at step 5. For “Floor stand” model begin assembly procedures at step 1. “DO NOT PLUG UNIT IN UNTIL ASSEMBLY IS COMPLETE.” 1.) Place floor stand base assembly into desired location, ensuring base is level. 2.) Attach support legs to base of cabinet. Support legs should extend towards the front of the cabinet and secure with screws provided. 3.) Place adjustable tray into shelf rails noting the arrows on the nylon guides are pointing up. 4.) Install the counter top assembly on to the floor stand and secure with the four screws supplied. ( Install two self tapping screws in the front of the cabinet, and two in the back.) 5.) Remove the crankshaft and the turntable nut from the center ( brass ) swivel body. 6.) Place the turntable onto the swivel body, with the rolled edge of the turntable facing down. NOTE; Ensure that the turntable rotates freely on the small step on the swivel and not on the threaded portion of the swivel. Brake should be engaged in the “J” slot to allow constant rotation. Replace turntable nut and tighten. 7.) Install the pre-lubricated crankshaft complete with nylon washer into swivel body. Ensure the crankshaft fits completely over the motor’s square drive shaft. The motor drive shaft extends from inside the floor stand up into the center of the swivel. When positioned correctly the crankshaft will rest directly on the swivel. 8.) Place the drive plate onto the crankshaft, ensuring the crankshaft rotating arm is correctly located in the center bearing of drive plate. Take note of the “This side up” sticker on the drive plate. Place drive cover over the drive plate. NOTE: Drive cover must be installed prior to mounting canisters. 9.) Rotate turntable until one drive plate arm and a canister mounting location are in line with one another. Attach one canister, ensuring that the canister drive shaft is engaged in the hole of the drive plate black plastic bushing at the end of each arm. NOTE; The drive plate turns in an oscillating pattern, rather than a circle. 10.) With the canister correctly positioned, secure with self tapping screws, into the three (3) holes. DO NOT OVER TIGHTEN. With one canister secured to the turntable, move to the position directly across from it and secure a second. See diagram on page 5. Continue mounting canisters in the order shown in illustration, rotating turntable as required. 11.) When all canisters are attached, gently rotate turntable. Ensure all paddles are rotating freely and no binding or chattering is evident. NOTE; If the paddles fail to complete an entire rotation, the canister drive shaft may not have been correctly installed in the drive plate. Remove canister and correct. 12.) Plug in unit. WARNING; This unit is equipped with an automatic timer and is scheduled to activate as soon as after the unit is plugged in. To avoid accidental breakage or personal injury, ensure all assembly procedures ( steps 1-12 ) have been completed prior to plugging in. Your dispenser is now ready to be filled with colorant! Please fill out and mail in your Warranty Registration Card. HERO Manual Series Colorant Dispenser Page 6 D18PR Owners Manual Rev. July 08 ASSEMBLY Steps 5 – 10 Ref #1 Drive Cover Drive Plate Adjustable Tray Washer Crankshaft Nut Legs Turntable Canister Mounting 2 Steps 12 – 14 12 Steps 11 – 12 6 9 1 3 8 7 4 11 5 10 HERO Manual Series Colorant Dispenser Page 7 D18PR Owners Manual Rev. July 08 DISPENSER PREPARATION Canister Filling & Priming Instructions The following steps should be carried out to ensure that your machine is properly prepared for accurate and trouble-free dispensing. The canisters have a capacity of 1.5 quarts, use one (1) quart of colorant on the initial filling. 1 Place each can of colorant into a mixer or shaker for approximately 5 minutes ( or as specified by the colorant manufacturer ) to re-incorporate any settled pigment. Allow the can to stand for at least one (1) hour to remove aeration of the colorant due to mixing. 2 Remove canister lids. 3 Pour the contents of each can of colorant into individual canisters. Note; Affix the canister identification letters on each canister as the colorant is added. Affixing the letter to the stainless steel cylinder tube, of the canister, provides the easiest reference. 4 Set the gauge ( Ref # 2 ), of each pump to the 1Y setting ( by depressing the spring loaded button, ( Ref # 3 ), and lifting the gauge by its handle ). 5 Remove the air from each cylinder ( PRIMING ) by completing the following procedure: 5A Lift the black plunger assembly handle ( Ref # 1 ) to its maximum travel allowed by the gauge. This draws colorant from the canister into the cylinder. Discharge the colorant back into the canister by pressing the plunger handle downward fully, WITHOUT OPERATING OR OPENING THE VALVE! Repeat this Process 5-6 times. 5B Lift the plunger handle ( Ref # 1 ) to its maximum travel. Place a clean can or paper cup under the dispense nozzle ( Ref # 5 ). Open the discharge valve by pulling the valve handle (Ref # 4) downward its full travel. Push the plunger handle down fully to dispense colorant into the cup. Return the valve lever to the closed position. Repeat this procedure until the colorant emerges as an unbroken stream. 5C Lift the plunger handle to its maximum travel. Hold at top for a moment to allow the vacuum to fill completely. Release hand from plunger handle. If the plunger handle drops on its own, air is still present in the cylinder. Continue to perform step 5A until the plunger handle no longer drops. 6 Once the cylinder is free of air, repeat these procedures for all remaining canisters. Return all dispensed colorant to its respective canisters. Your machine is now ready for use! Shake colorant to mix Plunger Handle Gauge Ref # 2 Ref # 1 Color ID A A X Gauge Release Button Ref # 3 Plunger Handle ( Ref # 1 ) Valve Handle ( Open ) ( Ref # 4 ) Nozzle ( Ref # 5 ) NOTE: If after correctly priming the canisters a vacuum or slippage is felt while charging the cylinder ( up ), the movement is being performed too rapidly. A slow, easy motion is required. HERO Manual Series Colorant Dispenser Page 8 D18PR Owners Manual Rev. July 08 TINTING INSTRUCTIONS Getting Started – Setting Gauges 1 Identify the color you wish to supply, either by name or code number. 2 Refer to your color formula reference book for the tint formula and note the tint base required ( clear, deep, white etc ). 3 Determine the formula required for the size of paint can being sold. For this exercise we will use the formula; AXX = 1Y12, C = 31, D = 12, KX = 3Y + 1/2. ( Formula shown is a sample only and your color system may not contain these colors ) 4 Ensure all gauges are set to zero before beginning. 5 Place the open can of base paint under the dispensing nozzle. Pull brake chain and rotate the turntable until the canister of the appropriate canister is directly over the can of paint. Release brake handle and engage turntable. If we start with “AXX”, we find a formula which can not be measured in one dispense. Multiple dispenses will be required. It is always best to divide the required formula into equal dispense, even if it requires more dispenses than what might otherwise be required. EXAMPLE; AXX-1Y12 = 48/48 + 12/48 = 60/48 ( Sample shown uses the 1/48 scale ) A For simple formulas like this, it is best to make two (2) equal dispenses of 30. Although you must still make 2 dispenses they are of equal amounts and no change in the gauge settings are required. This is particularly important if tinting more than one can of paint. Miss-tints are generally created as a result of operator error in setting the measuring gauges. The fewer changes in the gauge settings, the lower the chances of errors. B The alternative is to make 1 dispense of 1Y and a second of 12. 6 Push in the gauge lock button ( Ref # 3 ) firmly to release gauge. While the button is depressed, lift the gauge to the 30 dispense level. The gauge is correctly positioned when the number selected is fully exposed above the black plunger handle and the gauge locking plate engages the notches in the gauge. ( See Do’s & Don’ts on page 13 ) 7 The color C may be set to 31. 8 The color D to 12. 9 Once again the KX will require multiple dispenses. For formulas requiring a 1/4 or 1/2 part dispense, these fractions must be performed as an individual dispense. In this case set KX to 1Y and make three (3) equal dispenses. A fourth (4) dispense of 1/2, is required to complete this formula. NOTE: The 1/2 shot is the only dispense which does not have the locking design. The gauges will automatically reset to 1/4 after a 1/2 shot dispense. NOTE: It is always best to divide the required formula into equal dispense, even if it requires more dispenses than what might otherwise be required. Miss-tints are generally created as a result of operator error in setting the measuring gauges. The fewer changes in the gauge settings, the lower the chances of errors. HERO Manual Series Colorant Dispenser 5 6 7 Gauge Release Button Ref # 3 Page 9 D18PR Owners Manual Rev. July 08 TINTING INSTRUCTIONS CHARGING THE CYLINDER 1 With the gauge correctly set, slowly and gently lift the plunger handle until it reaches the gauge knob. Continue to hold for a few seconds to ensure that the cylinder has completely filled with colorant. CAUTION: DO NOT open or operate the dispensing valve lever while charging the cylinder. If the valve is opened, even the slightest amount, air will be drawn into the cylinder chamber resulting in an inaccurate dispense. If the valve is accidentally opened during CHARGING, close valve and press the plunger handle down to return the colorant to the canister. The cylinder must be re-primed. Refer to PRIMING INSTRUCTIONS on page 6. NOTE: If the colorant level is low in the canister, air can also be sucked into the cylinder. Press the plunger handle down to return the colorant to the canister. Add 1 quart of new colorant. The cylinder must be re-primed. Refer to PRIMING INSTRUCTIONS on page 6. DISCHARGING OR DISPENSING COLORANT 1 With the plunger at the top and the cylinder full, using your left hand, pull the valve handle ( Ref # 4 ) forward its full travel. 2 Using your right hand, push the plunger handle ( Ref # 1 ) down completely until is rest on the endcap. 3 Slowly return valve handle to the upright, closed position. 4 Repeat the charging and discharging process for the required strokes ( total formula ). Continue with the next required color. 5 When the entire paint order is complete, gently lower gauges to zero position. DO NOT push gauge release button and allow gauges to drop down. Lower manually to avoid damage. Down To Dispense Plunger Handle Ref # 1 Valve Handle ( Open ) ( Ref # 4 ) Valve Handle in open / dispense position HERO Manual Series Colorant Dispenser Page 10 D18PR Owners Manual Rev. July 08 CARE & MAINTENANCE Keep the machine clean and practice good housekeeping to promote accuracy in colorant dispensing. Stir the colorant after each addition to re-incorporate the new with old. For best results, additions should be made just prior to the regularly scheduled agitation cycle. Post or be aware of the automatic agitation cycle. Clean nozzles often to prevent drying colorant from blocking the nozzle and making dispensing difficult. A moist cloth and cotton swabs work well for cleaning nozzles. Thorough cleaning of nozzles, requiring nozzle removal, should be made quarterly ( Every 3 months ). Nozzles are easily removed for cleaning. Push gauge release button firmly, so that no clicking noise is heard while raising or lowering measuring gauges. A clicking sound heard while raising or lowering the gauge, is an indication that the button has not been pushed firmly enough. Damage to the gauge notches will result from improper activation of the gauge lock button. Gauges are precision measuring devices and must be treated as such. Keep this copy of the HERO D18 Series Operating Manual in a convenient place to assist in regular maintenance and for the training of new store personnel Ensure all new staff are fully trained in the operation and maintenance of equipment. DON’T allow the equipment to become messy from lack of maintenance or service repairs. Attend to repair or service issues immediately to ensure accurate and trouble free operation. DON’T use the valve of each pump as a handle when rotating the turntable. Gentle pressure to the cylinder, or the edge of the turntable is all that is required. DON’T over agitate colorant. The automatic timer provides 10 minutes of agitation every 8 hours. DON’T use metal or hard objects to clear blocked nozzles. Avoid removing nozzles to clean. Frequent nozzle removal can result in the miss-placement or damage to the nozzle sealing o-ring. DON’T allow the gauge locking plate to touch the gauge‘s notched teeth while raising or lowering gauge. Engage the gauge lock button fully while setting gauges. A clicking sound heard while raising or lowering the gauge, is an indication that the button has not been pushed firmly enough. Damage to the gauge’s notches will result from improper activation of the gauge lock button. Gauges are precision measuring devices and must be treated as such. NEVER force the operation of the plunger handle or valve handle. Difficult operation of these items, indicates the need for service or maintenance. See repair / maintenance instructions on page 16, item 6. HERO Manual Series Colorant Dispenser Page 11 D18PR Owners Manual Rev. July 08 CARE & MAINTENANCE Daily Maintenance Each day, take a few moments to clean the equipment. Attention must be paid to the area around the dispensing nozzle. Use a cloth ( moistened with a thinner compatible with the colorant ) to remove any residual or accumulative colorant found in this area. A cotton swab can be used to clean / clear the dispensing nozzle. Remove any spills or drips which occur during canister filling. Clean equipment instills customer confidence and is easier and more enjoyable to use. If the unit is not used on a regular daily basis, the following procedures are also recommended: 1 Check the colorant level and top up if required. All colorants have different evaporation or drying properties. Keeping colorant levels full within the canister, reduces the rings of dried colorant from forming low down in the canister shell, allowing easier cleaning. 2 Open and close each valve 5 times. Valves work best when in constant use and operation. Infrequent use can lead to colorant drying in valve, making operation / rotation of valve barrel difficult. 3 Set gauge to maximum 1Y dispense level and stroke the plunger assembly up and down three (3) times without operating or touching the valve handle. Pump inactivity can cause colorant to dry in pump and on cylinder walls. This can cause operational problems and rapid seal wear if permitted to form. 4 Check valve area for signs of colorant leakage. Any colorant leakage from any part of the valve assembly other than the nozzle, indicates the need for service. 5 Dispense 1 to 2Y of colorant into paper cup and return to canister. Constant movement of colorant is required to prevent the drying of colorant in nozzle and valve assembly. Weekly Maintenance 1 Check unit for loose canisters. Tighten canister mounting screws ( Ref # 37 ) to correct. 2 Check canisters for loose screws, connections or fittings. Tighten appropriate connections as required. 3 Set gauge to 1Y. Raise plunger assembly and examine the lower plunger shaft and gauge decal for signs of colorant. The appearance of colorant in this area, indicates worn piston seal, which will require replacement. Leaking seals will cause inaccurate dispenses. 4 Check gauge decal for signs of wear or discoloration ( Stained with colorant ). Replace gauge decals that have become difficult to read, regardless of why. Try to determine cause of decal defect, and correct the problem, so that the problem is not repeated with the new decal. HERO Manual Series Colorant Dispenser Page 12 D18PR Owners Manual Rev. July 08 CARE & MAINTENANCE Periodic Maintenance 1 Remove lids during the agitation cycle, to ensure paddles are rotating correctly. If a paddle is not rotating correct colorant mixing is not being maintained and must be corrected. Possibility #1; The paddle drive shaft may have become unthreaded from paddle. Remove canister from turntable and re-connect drive shaft to paddle. Possibility #2 ; Brass bushing in paddle shaft may have stripped, allowing bushing to rotate, without paddle rotation. Replace paddle. Annual Maintenance Colorants are heavy bodied fluids containing particles of pigment. During the plunger operation, a minimum amount of colorant sticks to the cylinder walls, which after a period of time, may cause drag or stiffness in the operation of the plunger. A small amount of stiffness should cause no concern, particularly with brand new equipment. If however, the stiffness of operation becomes noticeable or unreasonable, complete and thorough cleaning of the canister will be required. Effective cleaning can be obtained without dismantling canister. To clean without dismantling; 1 Remove canister from turntable. 2 Pour colorant out into clean container. 3 Rinse the inside of canister with a solvent, compatible with the colorant, to remove the majority of colorant. NOTE: Solvent based colorants, must be cleaned with mineral spirits / solvent, while latex based colorants can be cleaned with warm soapy water. Consult colorant supplier for product information. 4 Safely discard waste solvent/colorant combination. Observe all local environmental regulations. 5 Re-affix canister to turntable. 6 Add an additional quart of the applicable cleaning material to the canister. 7 Set measuring gauge to 1Y ( maximum dispense volume ). 8 Place a waste container under the dispense nozzle. 9 Operate the canister as if dispensing colorant. Drawing the cleaner into the cylinder and discharging into the waste container. Continue to repeat this procedure until all the cleaner is used or until it runs clean. 10 Repeat steps 6 – 9 as many times as required to clean canister completely. The dirty cleaner can be recycled through the canister 1-3 times if necessary. Make a final rinse with new, clean solvent / cleaner. 11 Allow canister to dry out before replacing colorant. 12 Original colorant should only be used if it is free of lumps or dried particles. If uncertain, error on the side of caution and refill with new colorant. NOTE: The canister can be dismantled and each component cleaned individually if desired. A bottle brush will be beneficial in cleaning cylinder and valve body. HERO Manual Series Colorant Dispenser Page 13 D18PR Owners Manual Rev. July 08 TROUBLESHOOTING 1 Intermittent spurts of colorant from the nozzle during dispensing. - Indicates the presents of air bubbles. Operate the plunger several times, without opening the valve, to drive air back into canister. Allow a few minutes for air bubbles to escape. Check colorant levels. See PRIMING INSTRUCTIONS, page 6, for details. 2 Endcap lifts during operation. This may result in inaccurate dispensing. - Lightly tighten the two set screws in the end cap ( Ref # 1 ) , until it no longer can be moved or lifted by hand. Endcap should be pushed down onto the cylinder. 3 Canister is loose on turntable. - Tighten the mounting screws. 4 Colorant appears on the piston shaft, and or gauge. This indicates worn seals. - Plunger assembly needs to be serviced. Call Hero Technical Service. End cap set screws ( Ref # 1) 5 Colorant is difficult to dispense, but plunger moves up or down easily when not operating the valve ( closed ). - Nozzle is clogged or obstructed. Clear nozzle of obstructions. If the problem continues use larger nozzle. Three alternative sizes are available. 6 Plunger handle is difficult to move up or down when not operating the valve ( closed ) - Colorant has been allowed to harden on cylinder walls making operation of plunger difficult. Empty canister of colorant, strip and clean well. Replenish with fresh colorant only. Replacement of piston seals may also be required. 7 Paddles do not turn during the agitation period. - Two (2) possibilities exist for this situation. 1 – The paddle drive shaft has unscrewed from paddle. Remove canister from turntable and re-thread drive shaft to paddle. 2 – If during the agitation period the brass bushing, found on the top of the paddle, can be seen rotating and the paddle is not, then the paddle will require replacement. See page 21. 8 Colorant leakage is observed around the valve nozzle. - Nozzle o-ring is missing or damaged and can no longer provide the required seal. Replace as required. 9 Colorant leakage is observed around the valve body, near handle ( left side ) and nozzle wiper arm ( right side ). - Any colorant leaking from the area described is a result of worn or defective valve barrel o-rings. Replace per instructions provided on page 18 – 19. HERO Manual Series Colorant Dispenser Page 14 D18PR Owners Manual Rev. July 08 SERVICE & REPAIRS Nozzle & Nozzle O-ring Replacement A sealing o-ring ( Ref # 1 ) is used to prevent leakage between the two surfaces. Colorant collecting in the area of the nozzle may be the result of a damaged or missing o-ring. The nozzle SHOULD NOT be removed for general cleaning. Frequent removal of nozzle causes damage to o-ring, and leads to the greater possibilities of loosing or miss placing of o-ring. Replace any missing nozzle o-ring or those which have nicks, cuts or flat spots. Left Side View O-ring (Ref # 1) 1 Pull valve handle into the downward dispense position. 2 Slide the nozzle side ways, to the right, to remove. 3 Examine o-ring for damage or flat spots. Ensure o-ring is present. 4 Fit new o-ring into nozzle. 5 Apply a small amount of lubricant ( Vaseline ) to o-ring. 6 Slide nozzle back into valve, from right to left. When fully inserted a snap or click sound will be heard, indicating that the nozzle has been installed fully into position. Right Side View Paddle Replacement Paddle replacement will be required if the brass bushing located in the top of the paddle should become stripped inside the plastic paddle. This is determined by watching the paddles during agitation. If a paddle is not rotating, clean the paddle top and watch for rotation of the bushing within the paddle. If the bushing turns, but the paddle does not, replace paddle. To remove paddle with a stripped bushing; 1 Place locking pliers on the top 1/2” of paddle. Use as much clamping pressure as possible. The pressure applied from the outside will hold the bushing stationary to allow it to be unthreaded from drive shaft. 2 Using pliers, turn paddle counter-clockwise to unscrew. 3 Raise paddle out of colorant. Hold vertically over canister to allow excess colorant to drain from paddle. Do not allow colorant to drip into the center tube shaft. 4 Insert defective paddle into plastic bag and discard. 5 Insert new paddle over center shaft and turn clockwise to secure to drive shaft. Tighten firmly. Bushing Paddle NOTE: The colorant does not have to be removed to replace paddles HERO Manual Series Colorant Dispenser Page 15 D18PR Owners Manual Rev. July 08 GAUGE CALIBRATION Gauges are precise measuring devices and are designed for use with one specific canister, the one it is originally installed in and calibrated to. Moving gauges from one canister to another can cause inaccurate dispenses if the calibration is not verified or re-set. To verify current settings or when installing NEW Gauges for the first time, the following instructions must be followed closely. Each gauge must be calibrated to one specific canister, and should remain in that specific canister. Calibration is the setting of gauges to a specific travel distance, ensuring the accurate dispense of fluid as specified by a specific gauge. Each dispense volume ( 1/48, 1/32 & 1/64 have their own “travel” specifications. TOOL REQUIRED 5 / 64 Allan Key Gauge Type = Feeler Gauge @ Gauge Increment or Setting 1/48 US = .032” @ 1/4 1/48 USM =.034” @ 1/4 1/32 US = .046” @ 1/4 1/64 US = .046” @ 1/2 1. To verify existing calibration, set your gauge to the dispense volume, shown in the chart above, that is correct for your gauge type. 2. Raise plunger and attempt to fit the feeler gauge, as shown in the chart, between the endcap body ( Ref # 1 ) and the plunger handle set screw ( Ref # 2 ).A snug fit is desired. 3. If a snug fit is found, calibration is correct. 4. If the fit is loose, too tight and the feeler gauge can not fit, or installing new gauges, use the instructions to follow beginning at step 5. 5. Remove gauge. 6. With the Allan key, raise the set screw until fully within the plunger handle ( Ref # 1). 7. Insert gauge into canister and set gauge to calibration setting as specified in chart above. 8. Raise plunger handle ( Ref # 2 ) until it contacts the gauge stop. 9. Insert the feeler gauge, per chart above, into the gap between the plunger handle and the endcap. Ensure feeler gauge is directly below the set screw. 10. Turn set screw ( Ref # 2) clockwise until contact with the feeler gauge is made. Do Not over tighten. NOTE: Access to the set screw is limited. Removing the gauge while making adjustments to the set screw position is required. Several attempts of repeating steps 10 – 12 may be required to complete the calibration. F.Y.I. The feeler gauge thickness is equal to the plunger travel distance required to make a 1/4 or 1/2 shot dispense. Example– A 1/48 US gauge must travel .032 of an inch to dispense 1/192 or one quarter ( 1/4) shot of colorant ). 3 Set Clearance 2 Gauge Feeler Gauge 1 HERO Manual Series Colorant Dispenser Page 16 D18PR Owners Manual Rev. July 08 CANISTER SCHEMATIC & PARTS LIST HERO Manual Series Colorant Dispenser Page 17 D18PR Owners Manual Rev. July 08 CANISTER PARTS LIST Ref # 1 Part # Description Qty BK-1800 18P Canister / Pump Assembly Less Gauge ( Ref # 1 to 17, as illustrated on page 21 ) Assy BK-1508 18P Plunger Assembly Assy 2 Gauge see page 22 1 3 BK-1024 18P End Cap Sleeve 1 4 BK-1509 Cylinder, 1 Oz 1 5 BK-1079 Cylinder Nut 1 6 BK-1521 Canister & Valve Assembly, Includes Ref # 7,8,11-16 7 BK-1094 Canister Center Tube Bushing 1 8 BK-1104 Canister Paddle Bushing O-Ring 1 9 BK-1114 Paddle Drive Shaft 1 10 BK-1528 Paddle Assembly 1 11 BK-1181 Nozzle O-Ring 1 12 BK-1184 Nozzle, Small, .094 1 13 HW30054P Screw, Sheet Metal, #8 x 3/8 Pan Head Phillips SS 1 14 HW5032 Washer, Flat, #10 1 15 BK-1165 Nozzle Wiper Arm 1 16 BK-1164 Wiper, Nozzle 1 17 BL-1085 Lid 1 HW30629P Canister Mounting Screws ** Not Shown ** Screw, Machine, #14 x 1”, Type B, Phillips 3 HERO Manual Series Colorant Dispenser Page 18 Assy D18PR Owners Manual Rev. July 08 DISPENSER GAUGE LIST Gauges BK-4505 BK-4006 BK-4520 BK-4021 Dispenser- 18P Gauge Complete, 1/48 US, 1 oz. Dispenser- 18P Gauge Decal, 1/48 US, 1 oz. 1 Dispenser- 18P Gauge Complete, 1/48 USM, 1 oz. Dispenser- 18P Gauge Decal, 1/48 USM, 1 oz. Gauge Assembly sold complete. Includes all items shown. Additional dispense increments will be made available as required / requested. HERO Manual Series Colorant Dispenser Assy Assy 1 Gauge Decal available separately as required for replacement purposes. Page 19 D18PR Owners Manual Rev. July 08 TURNTABLE SCHEMATIC AND PARTS LIST Please identify or order parts by the appropriate part number and not by reference number. The parts description indicates the quantity of each part per canister, if more than one is required 1 3 2 5/6 7 4 9 8 12 11 10 REF # 1 2 3 4 5 6 7 8 9 10 11 12 PART # BL-2050W BL-2060W BL-2520 BL-2540 BL-2515 BL-2047 HW3041P HW5010P BL-2020 BL-2010A BL-2510 BL-2075 BL-3000W BL-3010W BL-1850 HERO Manual Series Colorant Dispenser DESCRIPTION Drive Cover, 12 Position, White Drive Cover, 16 Position, White Drive Plate Assembly, 12 Position Drive Plate Assembly, 16 Position Center Plate Assembly Bushing, Drive Plate, Screw Washer, Shake Proof Nylon Crankshaft Washer Crankshaft Crankshaft & Washer Assembly Turntable Nut Turntable, 12 Position, Turntable, 16 Position, Dispenser -Blank Position Covers Page 20 D18PR Owners Manual Rev. July 08 FLOORSTAND SCHEMATIC AND PARTS LIST Please identify or order parts by the appropriate part number and not by reference number. The parts description indicates the quantity of each part per assembly, if more than one is required. 4 2 9 3 5 1 9 6 1 7 9 REF # 1 2 3 4 5 6 7 8 9 10 8 PART # BL-3760 BL-3355 BL-3359 BL-3358 BL-3357 BL-3501 BL-3351 BL-3352 BL-3354 BL-3300 HW-3066P BL-3353 HERO Manual Series Colorant Dispenser DESCRIPTION Floor stand complete, with electrics Shelf, 12 Position Shelf, 16 Position Glide Support rod Counter top assembly (see page 25 for parts) Side panel, right Side panel, left Front panel Support leg, 2 required Screw Rear panel Page 21 QTY 1 1 1 2 1 1 1 1 1 2 22 1 D18PR Owners Manual Rev. July 08 COUNTER TOP SCHEMATIC Please identify or order parts by the appropriate part number and not by reference number. The parts description indicates the quantity of each part per assembly, if more than one is required. 9 8 6 7 10 21 13 17 14 12 15 16 27 8 11 1 20 2 18 22 2 BLACK 1 BLACK 4 EMPTY 3 WHITE 23 25 19 4 3 HERO Manual Series Colorant Dispenser 5 Page 22 D18PR Owners Manual Rev. July 08 COUNTER TOP PARTS LIST Please identify or order parts by the appropriate part number and not by reference number. The parts description indicates the quantity of each part per assembly, if more than one is required. REF # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 export 19 20 21 22 23 24 25 export 26 27 28 PART # BL-3501 BL-3500 BL-3210 BL-3215 HW3032P BL-3505 HW3032P BL-3511 BL-2075 BL-2070 BL-3512 BL-3600 67/17 BL-3110 BL-3100 BL-3105 HW6086 BL-2004 BL-2005 BL-2003 BL-2008 HW3050P BL-3605 BL-3615 BL-3610 BL-2000 BL-2001 85-15 BL-3620 85-16 DESCRIPTION Counter Top Stand, c/w electrics, Counter Top Stand, metal only less electrics Counter base, bottom plate Counter base, bumper Screw Roller wheel assembly Screw Swivel assembly, Includes Ref # 9 - 11 Nut, turntable Swivel nut Swivel body and bearing, Brake assembly, Includes Ref #13 - 17 Cotter pin Spring Brake lever Knob, brake handle Cotter pin Motor, AC, Includes Ref # 22, 110V, 60 HZ Motor, AC, Includes Ref # 22, 220V, 50HZ Fan Spacer, motor mounting Screw Wire, c/w connectors, white Wire, c/w connectors, black, timer to motor, Wire, c/w connectors, black, Not Shown Timer, automatic, 10 min. On / 7 Hrs. Off, 110V, 60 HZ Timer, automatic, 10 min. On / 7 Hrs. Off, 220V, 50HZ Connector, wire joint, insulated, white, Not Shown Power Cord, 6 feet Bushing, strain relief, Not Shown HERO Manual Series Colorant Dispenser Page 23 QTY 1 1 1 4 4 4 8 1 1 1 1 1 1 1 1 1 2 1 1 1 4 4 2 1 1 1 1 1 1 1 D18PR Owners Manual Rev. July 08 AUTOMATIC TIMER & WIRING SCHEMATIC Illustrations and special instructions are for 110V, 60HZ models. Units with 220V, 50 HZ power sources, are supplied with an on/off switch . Local standards apply for electrical installation. Motor # 4 Terminal Not Used Timer Power Cord 2 1 4 2 1 43 3 Black Green = Ground White IMPORTANT GROUNDING INSTRUCTIONS This product should be grounded. In the event of an electrical short circuit, grounding reduces the risk of electrical shock by providing an escape for the electrical current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. DANGER: Improper installation of the grounding plug can result in a risk of electrical shock. If repair or replacement of the cord is necessary, do not connect the grounding wire to either flat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire. Check with a qualified electrician or serviceman if the grounding instructions are not completely understood, or if in doubt as to whether the product is properly grounded. Do not modify the plug provided; if it will not fit the outlet, have a proper outlet installed by a qualified electrician. This product is for use on a nominal 120-volt circuit and has a grounding plug that looks like the plug illustrated in sketch A in figure 65.1 of UL Standard 1450. Make sure that the product is connected to an outlet having the same configuration as the plug. No adapter should be used with this product. Only use a 3-wire extension cord that has a 3-blade grounding plug, and a 3-slot receptacle that will accept the plug on the product. Make sure that your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Refer to the following table: Length 25 50 100 150 200 250 300 400 500 Gauge 18 16 14 12 10 10 8 8 6 HERO Manual Series Colorant Dispenser Page 24 D18PR Owners Manual Rev. July 08 AUTOMATIC TIMER Every HERO D18 Series Colorant Dispenser is equipped with an automatic timer. The timer operates for every 10 min every 7 hours at 110V 60Hz or 4 hours at 220V 50Hz. The timer requires no adjustment or attention on the part of the operator. When shipped the timer has been set to initiate agitation as soon as it is plugged in. The timer is located on the cabinet / base, next to the power cord. A decal is located next to the timer, indicating the location of the start position. In order to rotate the timer adjustment knob you will require a flat end screw driver as the knob is inset into the machine for protection. By rotating the adjustment knob, the timer can be advanced to the start time. While rotating the knob, a faint clicking sound will be heard. Rotate the dial through the “off” cycle until agitation begins. The “on” cycle is very short so rotation of the adjustment knob must be done very slowly. You should hear a loud click during rotation, this will start the agitation. Once the ten (10) minute agitation cycle is complete the timer will then activate agitation every seven (7) or (4) hours from this point. 2000 COLORANT DISPENSERS 2000 DISTRIBUICES DE COLORANTS MODEL # 23PR_ _ _ _ _ _ _ _ _ _ SERIAL # 0101_ _ _ _ _ _ _ _ _ VOLTS A.C. 110 AMP 3 Hz 60 TOLL FREE 1-800-494-4376 U.S. & Canada CAUTION ATTENTION ARCING PARTS ÉTINCELLES ÉLECTRIQUES Keep the unit at least 20 feet Away from explosive vapors Ne Pas placer l’unite á moins de 20 pieds desvapeurs explosives READ OPERATING INSTRUCTIONS LIRE DE MODE D’EMPLOI High pressure device. Read instruction manual before operating and observe all warnings. Matériel á haute pression. Lire les instruction du fabricant avant de mettre en marche, et observer toutes les consignes de sécurité. TO TURN TIMER ON SLOWLY ROTATE CLOCKWISE UNTIL FIRST LOUD CLICK ADJUST TIMER with flat blade screwdriver DAILY ROUTINE CARE OF THE DISPENSER It is recommended that the following daily routine be adopted to ensure trouble free operation of the dispenser. 1. Check the level of the colorant and top up if required. 2. Set all gauges to maximum dispense. Raise and lower each plunger without opening valve. Repeat the procedure 10 times slowly. 3. With a damp cloth, wipe down stand, canisters and pumps, paying particular attention to pump nozzles to prevent accumulation of excess colorant which may dry out and cause erratic discharge or blockage. Located on right side of cabinet / base ( when facing unit ) VANCOUVER, B.C. CANADA MADE IN CANADA - FRABRIQUE DU CANADA PAR HERO Manual Series Colorant Dispenser Page 25 D18PR Owners Manual Rev. July 08 Manual valid for all D18PR units to a maximum of 20 canisters and any gauge increment, both counter top & floor stand Serial Number: _______________ Date Installed: _______________ Purchased From: _____________ ___________________________________ HERO Manual Series Colorant Dispenser Page 26 D18PR Owners Manual Rev. July 08