I.C.T.C. Holdings Corporation 1150GSD User's Manual
Contents
1. H E R O INDUSTRIES 10 1150GSD MANUAL B VERSION SPRAY TIP SELECTION Tailing Good Pattern DISTANCE CORRECT DISTANCE FIG TOTAL SPRAYGUN MOVEMENT arm movement full sweep TRIGO R POINT TRIGGER POINT H E R O INDUSTRIES 11 1150GSD MANUAL B VERSION TIP SIZE FOR APPLICATION OF 021 Exterior Latex on large unobstructed areas max size allowed 60 OZ 018 Interior Latex Exterior Latex Shake Paint Exterior Flat Paints 46 OZ 015 Alkyd Flat Enamel Interior Latex Semi Gloss Enamel Stains 30 OZ 013 Fine ground Gloss Enamels and good quality Stains 23 OZ O11 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 then 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 requi2. NEW B SERIES Gasnon HYDRAPULSE iss SAFETY OPERATING AND MAINTENANCE INSTRUCTIONS AND PARTS LIST H E R O WARRANTY H E R O INDUSTRIES LTD guarantees this airless pump to be free of defects in materials and workmanship to the original owner for a period of one full year from the date of purchase The warranty entitles the owner to parts replacement at no charge The parts replacement warranty is valid for any necessary replacement whither caused by material or workmanship defect or simple wear The hydrapulse membrane part 4 04 22 4500 is warranted for LIFE Installation costs for the hydrapulse membrane is provided for the first 12 months only H E R O Industries Ltd offers no warranty on the intake ball outgo ball drive belt hoses gun or accessories plastic rubber other soft goods or motor used in or supplied with the H E R O sprayer Motor accessories etc which are supplied by other manufacturers and are attached to or supplied with the H E R O airless pump are warranted only to the extent that these parts are warranted by their respective manufacturers Warranty claims must be made directly to such manufacturers or their local authorized service depots The warranty is only applicable to the original purchaser and the equipment has been properly used operated and maintained in accordance with all instructions precautions and warnings contained in this manual For the purpose of this warr
3. Ref 2 7 53 55 SCREEN Siphon Coarse E NOT USED 689A TUBE Siphon Metal 5 Gal 4 7184B HOSE Siphon 30 L x 1 ID 1 75 3 CLAMP 667 27 AP BARB Hose to Elbow 1 667 26 AP ELBOW 1 HW 1087 CAPSCREW SKT HD 3 8 NC x 2 Gr 8 3 2 WASHER 3 8 Hi Collar Lock 4 02 22 2502B ENDCAP Hydrapulse Gold NEW after serial 140056 02 22 2009B WASHER Crush NEW after serial 140056 6 SEAT 3 4 Tungsten Carbide 17S BALL 3 4 Corrosion Resistant 02 22 2005 SPRING 02 22 2006 O RING Urethane 02 22 2002B BALL GUIDE NEW after serial 140056 02 22 2001B BALL STOP NEW after serial 140056 5V O RING Viton 3 CAPSCREW SKT HD 5 16 x 1 3 4 4 02 22 2501B HEAD Material Hydrapulse Gold NEW after serial 140056 02 22 2004 CUSHION Material Head mm 0 m m m m m me me me RP RE RR LR LENOIR LR 25 7C WASHER Copper Crush 1 26 4 611C OUTGO VALVE COMPLETE Ref 27 34 ASSY 27 11A 1 LOWER Valve Body 1 28 11A 3CP WASHER Copper Crush 1 29 11A 45 SEAT 3 8 Tungsten Carbide 1 30 L1A 5S BALL STEEL 3 8 1 31 11B 2 UPPER Valve Body for use with steel ball 1 H E R O INDUSTRIES 30 1150GSD MANUAL B VERSION PARTS LIST Please order parts by the appropriate part number and not by reference number The quantity required per unit is shown for each part number Part number
4. 54 FRAME Right Side 1 116 HW2040 SETSCREW Square HD 5 16NC x 1 1 2 2 117 HW4040 NUT JAM 5 16NC 2 118 4 55 FRAME Left Side 1 119 4 57 SPACER Bearing 6 1 2 x 4 2 120 HW1060P CAPSCREW HX HD 5 16NC x 3 4 12 121 HW5051P WASHER Flat 5 16 12 122 62 SPACER Round Steel 3 4 x 6 3 4 1 123 63 SPACER Round Steel 3 4 x 3 1 8 2 124 4 56 RAIL Outboard 1 H E R O INDUSTRIES 33 1150GSD MANUAL B VERSION PARTS LIST Please order parts by the appropriate part number and not by reference number The quantity required per unit is shown for each part number Part numbers in bold text indicate whole assemblies or kits These parts may also be purchased individually CHASSIS PARTS REF PART DESCRIPTION QTY 125 45B BRACKET For Hydraulic Tank 1 126 45D PAD For Hydraulic Tank NOT SHOWN 1 127 45C STRAP For Hydraulic Tank 2 128 HW1010P CAPSCREW HX HD 1 4NC x 1 2 2 129 64 BAR Motor Mounting 2 130 66 SHIM 2 131 HW1080P CAPSCREW HX HD 5 16NC x 1 3 4 8 132 4 66 10G BELTGUARD Includes ref 135 1 133 4 65 FINGERGUARD 1 134 HW3012P SCREW 6 x 3 8 4 135 HW1020P CAPSCREW HX HD 1 4NC x 3 4 2 136 4 67 21 CHART Ref 138 139 ASSY 137 2 78 HANDLE Snap On Rear 1 138 67 21 CHART Less Handle 1 139 4 67 14A FOOT PAD Includes Hardware 2 140 HW1040P CAPSCREW HX HD 1 4NC x 1 3 4 5 141 HW5
5. E R O Wonder Wash appropriate thinner for the paint a waste container and any other accessories you may require for the job READ THIS MANUAL THOROUGHLY READ THE HONDA ENGINE MANUAL SUPPLIED WITH THE UNIT FOLLOW ALL THEIR RECOMMENDED PROCEDURES FOR START UP AND OPERATION SETTING UP TO SPRAY 1 Remove unit from shipping carton 2 Attach intake siphon assembly ref 1 to intake elbow ref 8 The intake elbow provides a swiveling connection during assembly only Two wrenches are required to tighten these fittings When sufficiently H E R O INDUSTRIES 5 1150GSD MANUAL B VERSION 3 Attach prime hose ref 51 to ref 50 Secure with clamp ref 52 4 Attach paint hose to outgo tee 8 5 Attach gun to paint hose tightened the siphon hose will no longer swivel or move as such ensure the siphon hose is positioned in the desired direction prior to making the final tightening The desired position is straight back from the intake Use caution to avoid over tightening which may result in cracked or broken fittings NOTE Spray tip and tip guard attaching to hose Paint Hose 6 Place intake siphon assembly clean 5 gallon pail 7 Install strainer bag accessory item SGAL SB in pail and secure with large rubber band accessory item 106 NOTE Strainer bag must remain 4 inches from the bottom of pail 8 Trigger gun to release any pressure in the unit U
6. check prime valve return hose ref 51 for material bypass Repair prime valve using ref 42 if material is bypassing nM LOW STATIC PRESSURE LOW SPRAY PRESSURE Check with pressure gauge see page 16 for details 1 Pressure control valve stem screw ref 80 loose remove pressure control knob ref 75 and inspect screw for looseness Screw should be secured to stem ref 80 with Loc Tite If the screw turns independent of the stem than it must be re secured Secure unit so it will not move Install pressure gauge and 021 spray tip Obtain a piece of wood to use as a pusher or purchase a pressure control adjustment tool 27C 15 Remove pressure control screw and put some Loc Tite 609 on threads Turn the screw into the stem a few turns and push it in to its maximum and read pressure Turn the screw in or out until 3000 psi static pressure is obtained If you obtain a pressure which higher than 3000 psi trigger gun to release some pressure and continue adjusting screw until correct pressure is obtained Let Loc Tite set up 2 Pressure control ball ref 88 and or seat ref 87 worn remove entire pressure control valve ref 74 from sprayer Remove valve seat ball retainer ref 86 and spring ref 85 from valve Replace with pressure control repair kit ref 89 Hold valve body vertical while placing in spring followed by retainer Retainer should be below the valve body approx 3 8 when positioned correctly C
7. endcap at all times through the correct assembly of parts listed and the correct bolt torque Replace the intake washer ref 12 each time the endcap is removed See page 23 for details TROUBLESHOOTING H E R O INDUSTRIES 14 1150GSD MANUAL B VERSION PAINT OUTGO VALVE REF 26 PART 4 611C The paint outgo valve monitors and controls the flow of spray materials as it leaves the sprayer It also works together with the paint intake valve to build paint pressure as specified by the setting made by the hydraulic outgo valve pressure control valve A worn outgo valve will result in pulsation in the spray material and cause the paint hose to jump and vibrate vigorously PRIME VALVE REF 36 PART 4 603 The prime valve is used at the beginning and end of the spray operation see setting up to spray The function of the prime valve is to assist in removing air from the paint pump when beginning to spray It is necessary to remove all air from the paint pump so that the spray material can replace it The pump will function without the prime valve however the initial priming procedure would require considerably longer to complete During the priming procedure the hydrapulse membrane is exposed to its greatest amount of stress Use of the prime valve and a lightweight thinner which is compatible with the intended spray material will reduce hydrapulse membrane stress and reduce priming time The prime valve will also allow you to
8. not drain Remove hydraulic intake valve from elbow ref 62 Check hydraulic intake valve to ensure that it flows in one way only into the cylinder Replace if necessary NOTE Item cannot be repaired 2 Air lock created on hydraulic side of pump air entering hydraulic side due to loose hydraulic feed line fittings ref 67 punctured hydraulic feed line poor seal at hydraulic intake valve ref 66 or elbow ref 62 Tighten hydraulic feed line test for leaks or apply Teflon tape or pipe sealant on fittings Purge air as per detailed instructions below 3 Pressure control valve ball ref 88 worn out jammed remove hydraulic return line ref 73 from pressure control valve fitting ref 82 Remove pressure control valve ref 74 from elbow ref 62 Disassemble pressure control valve by removing valve seat ref 87 from body ref 83 Inspect for and remove foreign material Inspect ball for wear Install pressure control repair kit ref 89 if necessary 4 Piston rod ref 94 disconnected from piston ref 92 reconnect piston rod following detailed instructions on page 24 25 NO PRESSURE BLUE HYDRAULIC FLUID IN PAINT 1 Hydrapulse membrane broken replace with complete hydrapulse membrane ref 54 Closely follow detailed instructions on page 21 NOTE If and only if paint has contaminated the hydraulic side of the pump the entire hydraulic system must be cleaned and flushed Make sure to remove and c
9. paint outgo valve is drawn closed by the vacuum created by the hydrapulse membrane These operations are repeated at a rate of 750 times a minute These continuously repeated actions draw paint into the pump pressurize it and then deliver it to the gun The failure of any one valve to operate correctly will effect the overall equipment performance Each of the five valves mentioned earlier have an important function and will effect the overall performance of the unit if not performing correctly HYDRAULIC INTAKE VALVE REF 66 PART 4 30 The hydraulic intake valve is a small vacuum valve which controls the hydraulic oil entering the hydraulic pump cylinder area Once the oil has past through the valve it is prevented from returning The valve is commonly called a one way check valve Valve failure will result in the hydraulic pump being unable to build pressure and the hydrapulse membrane will stop moving Spray pressure will cease HYDRAULIC OUTGO VALVE REF 74 PART 4 27C The hydraulic outgo valve better known as the pressure control valve is used to control the units operating pressure The valve is fully adjustable from 0 psi to 3000 psi By turning the pressure control valve knob ref 75 clockwise the pressure is increased The hydraulic pump continues to build at all times and must have a means of releasing this pressure Pressure applied to the P C ball ref 88 will keep it lodged in the P C seat ref 87 until
10. to assist in moving cup washers 18 Apply grease to seals before installing in cylinder ref 61 19 Thread rod into eccentric bearing holder ref 102 until nut is flush with eccentric bearing Tighten snugly NOTE Piston rod nut must remain fully threaded onto rod if during installation the nut begins to loosen from rod re tighten to rod Place vise grips on rod to assist in tightening piston rod into eccentric 20 Slide pump assembly into side frames and guide piston into cylinder NOTE Use care not to push the piston too far into cylinder If piston rings slide in too far they will pass through cylinder into the hydraulic cavity Complete dismantling of piston will be required to remove The piston can not be pulled back if the seals have gone through cylinder 21 Reattach crossblock bolts as removed in step 2 Torque bolts to 30 foot pounds 22 Reconnect hydraulic lines as removed in step 1 23 Add new hydraulic oil to hydraulic tank using only genuine H E R O LVO hydraulic oil 24 Once the repairs have been completed the hydraulic oil will require purging to remove the trapped air See PURGING instructions on page 18 OUTGO VALVE REF 26 TOOLS REQUIRED H E R O INDUSTRIES 25 1150GSD MANUAL B VERSION 1 wrench vise Teflon tape 1 Open prime valve ref 36 in order to release pressure from the material side of pump 2 Remove pressure control knob ref 75 and pull P C stem ref
11. 0 total length of paint hose 3 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 MI 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 be used M Check drive belts 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 Failure of the drive belt is not covered by the equipment warranty so proper maintenance of the belt is important N A NARA VI Regularly check fittings bolts nuts and connections for damage Tighten adjust or replace as required MI Check crankshaft alignment often An out of alignment crankshaft will cause the damage to the eccentric bearing GAS ENGINE M Check the engine oil level daily Top up only with the manufacturer s recommended oil Running the engine with insufficient oil can cause serious engine damage I Check the engine air cleaner daily NEVER operate without an air cleaner MI Use only UNLEADED or lowleaded gasoline MI The engine requires regular operation and should not be stored for prolonged periods without operating Run for a minimum 15 minutes ea
12. 030P WASHER Flat 1 4 14 142 HW5040P LOCK Washer 1 4 7 143 HW4020P NUT 1 4 7 144 67 16A WHEEL Pneumatic 2 145 67 17 COTTER PIN 2 146 97B Quality By Design 1150GSD 1 147 92 Release Pressure Belt Guard 1 148 91 H E R O Small Engine 1 H E R O INDUSTRIES 34 1150GSD MANUAL B VERSION 1150GSD PARTS SCHEMATIC H E R O INDUSTRIES 35 1150GSD MANUAL B VERSION H E R O INDUSTRIES 36 1
13. 150GSD MANUAL B VERSION
14. 6 is used during the priming procedure see setting up to spray For correct operation all five valves must be in good working condition For this manual we will refer to the two systems as hydraulic and paint At the center of these two pumps is the hydrapulse membrane The hydrapulse membrane is a flexible nylon disc which transfers the energy pressure created by the hydraulic pump to create energy pressure in the paint pump The function of the hydrapulse membrane is to create a barrier between the hydraulic oil and the spray material and transfer the energy created To fully understand and trouble shoot a H E R O pump always keep in mind that for every action there is an opposite or corresponding re action For every action of the hydraulic intake valve ref 66 there is an opposite re action of the hydraulic outgo valve reff 74 At the same time there are corresponding re actions taking place within the paint pump This means that as the hydraulic intake valve is opening so is the corresponding paint intake valve and while the hydraulic outgo valve is closing so is the corresponding paint outgo valve The operation and function of each valve is discussed at the end of this section For correct operation to begin the hydraulic system must be fully primed and all air must be removed see purging page 18 Operation begins with piston in the backward position fig 2 At this point the hydraulic intake is open while the h
15. 78 out to internal stop thereby releasing hydraulic pressure Disconnect outgo tee ref 35 from outgo swivel ref 32 on the outgo valve Remove outgo valve from machine by turning counter clockwise Invert valve and secure upper part of valve ref 31 in vise Remove lower half of valve ref 27 Remove crush washer ref 28 seat ref 29 and ball ref 30 Clean and inspect all parts for wear Replace any worn parts NOTE Check the condition of the internal passage ways of the outgo upper ref 31 A total of five holes allow the paint to pass through the upper The center hole will become enlarged over time and cause the ball to travel a greater distance than originally intended This can cause a reduction in the response time of the valve and lead to pulsation in the spray hose and spray pattern 8 Apply Teflon tape to threads of outgo upper body 9 Invert outgo upper and drop ball in 10 Install seat beveled side down to ball Seat should fit snugly into outgo body Press on seat to ensure it will compress until it is flush with outgo body 11 Place crush washer on seat Replace crush washer if badly crushed 12 Thread outgo lower onto outgo upper until finger tight Tighten 1 2 turn with wrench NOTE Teflon tape or pipe sealant should be used 13 Attach repaired valve to machine installing a new crush washer ref 25 following steps 3 4 in reverse order Outgo swivel ref 32 Not S
16. 9 minutas SPECIAL NOTES AND INSTRUCTIONS H E R O INDUSTRIES 8 1150GSD MANUAL B VERSION NEVER LEAVE THE UNIT UNDER PRESSURE WHEN NOT SPRAYING ENGINE TURNED OFF RELIEVE PRESSURE BY TRIGGERING GUN NEVER STORE THE UNIT WITH PAINT OR WATER IN THE PUMP SYSTEM EVEN OVERNIGAT ix NEVER attempt to start the engine when the unit is under pressure Relieve pressure and follow instructions in Setting up to spray Avoid operating the unit while tilted Keeping it level assures greater operating efficiency Always follow flushing and cleaning instructions exactly In hot weather locate unit in shade 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 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 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 25
17. AT PRIME VALVE STEM 1 Prime valve stem packings ref 44 or 45 defective replace damaged packings following detailed instructions on page 27 SPRAY MATERIAL LEAKS OUT PRIME VALVE HOSE WITH VALVE CLOSED H E R O INDUSTRIES 20 1150GSD MANUAL B VERSION 1 2 Prime not closed tightly tighten valve stem ref 46 further Prime valve worn install prime valve repair kit ref 42 See page 27 for detailed instructions SPRAY PATTERN IS SPOTTY OR UNEVEN 1 2 3 4 5 Pressure is too low increase pressure slowly until problem is corrected Spray material too thick thin as recommended by material manufacturer Plugged siphon screen siphon tube gun filter or a combination inspect and clean or replace as required Plugged tip remove and clean tip Pump malfunctioning or unsuitable for the material refer to other areas of troubleshooting guide and check material requirements vs 1150GSD output abilities SPRAY PATTERN LEAVES LINES OR FINGERS 1 2 3 Pressure too low increase pressure slowly until problem is corrected Worn tip replace tip Tip too small for spray material change to larger tip or increase pressure See material manufacturers recommendations EXCESSIVE OVERSPRAY OR FOGGING eee N Pressure too high reduce pressure as required Material too thin follow material manufacturers recommendations re thinning Tip too large reduce tip size Improper applicatio
18. B STRAINER BAG 5 GALLON 10 55 ___ ZIP TIP INSERT AVAILABLE IN THE FOLLOWING SIZES 0904 1104 1304 1504 1704 1904 2104 2704 3104 0906 1106 1306 1506 1706 1906 2106 2708 3110 1108 1308 1508 1708 1908 2108 2310 2712 3112 1110 1310 1510 1710 1910 2110 2312 2912 1312 1512 1712 1912 2112 2510 OTHER FAN SIZES ALSO AVAILABLE BUT NOT ALWAYS STOCKED 4 649 WONDER WASH 48 PCS X 1 5 OZ PKG 4 650 WONDER WASH 5 OZ PKG 4 655 WONDER WASH 25 PCS X 5 OZ PKG 4 660 WONDER WASH BULK 5 LBS 4 662 WONDER COAT 1 LITRE 4 664 WONDER COAT 12 PCS X 1 LITRE 661 SPRAY TRIGGER FOR USE WITH 4 662 4 666 WONDER COAT 4 LITRE 4 668 WONDER COAT 4 PCS X 4 LITRE 4 6658B INTAKE REPAR KIT ref 12 14 15 19 4 6659B INTAKE OVERHAUL KIT ref 12 19 4 6656 OUTGO REPAIR KIT ref 25 28 30 4 6657 OUTGO OVERHAUL KIT ref 25 28 30 4 LVO 1 HYDRAULIC OIL 1 LITRE 4 LV0 4 HYDRAULIC OIL 4 LITRE 4 67 19 PRESSURE GAUGE C W FITTINGS 4 45 3 PRESSURE CAP HYDRAULIC TANK PARTS LIST REF PART DESCRIPTION QTY 1 187A Intake SIPHON SCREEN 1 2 189A 1 Intake SIPHON TUBE 5 GALLON GOLD 1 H E R O INDUSTRIES 29 1150GSD MANUAL B VERSION PARTS LIST Please order parts by the appropriate part number and not by reference number The quantity required per unit is shown for each part number Part numbers in bold text indicate whole assemblies or kits These parts may also be purchased individually INTAKE PARTS DESCRIPTION SIPHON ASSEMBLY COMPLETE
19. H E R O DISTRIBUTOR TO PURCHASE A COPY TROUBLESHOOTING H E R O INDUSTRIES 15 1150GSD MANUAL B VERSION PRESSURE TEST To verify the operation of an airless sprayer use of pressure gauge is required A pressure gauge min 3000 psi installed at the gun using a new 021 tip and not less than 50 feet of H E R O airless spray hose is needed If you do not have access to these items your local H E R O authorized service center will be able to perform this test Your model 1150GSD is manufactured to perform at 2650 psi Static pressure with lock ring ref 77 on pressure control valve ref 74 1950 psi Pressure drop when gun trigger is squeezed 2250 psi Spraying pressure after recovery time If your unit is unable to perform to the above pressure levels consult the troubleshooting guide for the required repair procedure HYDRAPULSE MEMBRANE TEST If your unit is disabled and you are unable to perform a pressure test use the following procedures for determining the area to repair This test will divide the two halves of the equipment hydraulic from paint and make identification of your solution easier to obtain This test is commonly referred to as the Hydrapulse membrane Test The solution to almost all problems can be found in the paint side valves due to the increased wear from contact with the abrasive paint spray materials Intake valve ref 11 18 Outgo valve ref 26 and Prime valve ref 36 make u
20. SEAT Piston Bronze 1 94 4 38A 2 ROD Piston C W Nut Washer O Ring Circlip 1 Nut Washer O Ring amp Circlip NOT Sold Individually R O INDUSTR 32 II50GSD MANUAL B VERSION PARTS LIST Please order parts by the appropriate part number and not by reference number The quantity required per unit is shown for each part number Part numbers in bold text indicate whole assemblies or kits These parts may also be purchased individually DRIVE PARTS REF PART DESCRIPTION QTY 95 42 BEARING Crankshaft Side 2 96 HW1090P CAPSCREW HX HD 7 16NC x 1 1 4 4 97 HW5070P WASHER Lock 7 16 4 98 HW4060P NUT HX HD 7 16 4 99 40 COUNTERWEIGHT Plain Bolt Hole 1 100 4 39 ECCENTRIC BEARING amp HOLDER Ref 101 102 ASSY 101 39 2 BEARING Eccentric Outer 1 102 4 39 3 Holder Eccentric C W Zerk 1 103 4 41 CRANKSHAFT Includes Ref 99 ASSY 104 39 1 RACE Eccentric Inner 1 105 44 COUNTERWEIGHT Tapped Bolt Hole 1 106 43 BOLT SKT HD 1 4NC x 2 1 107 4 49 KEYSTOCK 3 16 SQ x 1 5 2 108 4 65 100A SHEAVE ASSEMBLY Pump Ref 109 110 ASSY 109 65 118 SHEAVE Browning 2 110 65 120 HUB 7 8 1 111 66 150 BELT Sold Only In Pairs 2 112 4 48 101 SHEAVE ASSEMBLY Motor Ref 110 113 ASSY 113 65 119 HUB 3 4 1 114 4 62 101GS ENGINE Honda 5 5 HP With Reduction Gears 1 CHASSIS PARTS 115 4
21. UBLESHOOTING SITUATION POSSIBLE CAUSE REMEDY Accessory Item PUDDLE OF OIL APPEARING UNDER SPRAYER DURING OPERATION 1 Hydraulic fitting loose cracked or hydraulic lines are punctured examine all hydraulic lines and fittings for cracks breaks or looseness H E R O INDUSTRIES 18 1150GSD MANUAL B VERSION Replace or tighten as required 2 Piston seals ref 91 worn remove and replace piston seals following closely the detailed instructions on page 24 25 CORRECT STATIC PRESSURE BUT REDUCED SPRAYING PRESSURE Check with pressure gauge see page 16 for details 1 Spray tip worn out too large replace with new correct sized spray tip Tip most not exceed a newer condition 031 tip for 1 gun or 021 tip for 2 guns 2 Paint hose incorrect replace hose with genuine H E R O airless spray hose min 50 feet Steel braided hoses must not be used 3 Intake valve seat ref 13 worn replace intake seat closely following detailed instructions on page 23 4 Intake ball ref 14 worn replace intake balls when signs of wear deformation nicks or cuts are evident An out of round ball is the sign of a worn intake seat ref 13 and both items should be replaced Outgo seat ref 29 worn replace seat Outgo ball ref 30 worn damaged replace outgo ball 7 Prime valve ref 36 bypassing start sprayer With prime valve closed tightly stem ref 46 turned clockwise fully
22. anty damage resulting from accident abuse improper cleaning or operation fire flood or Act of God is not covered H E R O s liability is limited to replacing parts found to be defective or worn and does not include transportation costs damage or other expenses of any kind incurred in connection with the purchase and use of this sprayer Repairs claimed under warranty must be performed at an authorized H E R O Service Center using only genuine H E R O parts Parts necessary under warranty claim will be supplied by your local H E R O Service Center DO NOT return worn parts to factory without authorization To qualify for the warranty the warranty card attached to this page supplied with this H E R O airless pump must be completed with Al th th th th hh th hh hh th th hn th dhe he hh the hin the hh de hh dh H E R O INDUSTRIES 1 1150GSD MANUAL B VERSION TABLE OF CONTENTS For greatest user satisfaction please familiarize yourself with all maintenance and operational instructions Imiportant Safety Precautions 224555 ei i an cc cathe acca eie a el he cana 3 4 IntrO duction 2 siecsived tsetse Cand tek deine wade medina die ceded 5 Op ratine Struct nre an E soa D E E E sn ces AN i Ri 5 Settna Up TO Spraye niian e KERE E REEERE E GERERE ee 6 7 Blushing Th Umit iiien a i veneadsaletens 8 Special Notes es ereer aa e E na ected EA E ts A aE ETE aa 9 Airless Spray Painting Suggestions s essessssesesese
23. arts Replace any worn or damaged parts Place clean endcap in vise with o ring ref 19 groove facing up Assembly of parts is the reverse of removal washer ref 12 seat ref 13 and ball ref 14 NOTE A new compression washer should be used each time the endcap is removed 9 Ifthe ball guide ref 17 and ball stop ref 18 were separated during removal re assemble the two NOTE The step on the ball stop must face outwards Towards hydrapulse membrane 10 Place the spring ref 15 into the ball guide so the smaller end of the spring will contact the ball 11 Assemble the ball guide with spring onto the endcap over the already installed ball and seat Push down on the ball guide so that the ball guide o ring ref 16 locks the assembly together 12 Place o ring ref 19 in the groove on the face of the endcap 13 Install the entire endcap assembly onto the material head with the four bolts ref 9 Torque bolts using a crisscross pattern to 20 ft Ibs Repeat torquing procedure using 30 ft Ibs MN NOTE Effective March 1997 and beginning with serial number 140056 a new style Hydrapulse Intake assembly is used The changes effect the Endcap ref 11 Crush Washer ref 12 Ball Guide ref 17 Ball Stop ref 18 and the Material Head ref 21 The most significant change is to the endcap Gone is the o ring formerly located under the intake seat The endcap is machined flush and a new crush washer is no
24. before operating the unit MI 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 VI ALWAYS wear a face filter mask when operating the unit MI ALWAYS 1 Turn off the engine 2 Turn the engine switch to OFF position 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 V ALWAYS wear safety glasses when operating the unit MI ALWAYS ensure fire extinguishing equipment is readily available and properly maintained in the spray area VI ALWAYS observe good housekeeping and keep the spray area free from obstructions M 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 supplier to be sure H E R O AIRLESS SPRAY PAINTING 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 1150GSD With H E R O airless spray equipment you will avoid the H E R O INDUSTRIES 4 1150GSD MANUAL B VERSION inconvenience and mess of overspray You are spraying paint not air and the paint is driven to the paint
25. c horn on one end and over the shoulder of the spring locator on the other end 6 Place the hydrapulse membrane assembly back into the hydraulic head 7 Re install the material head with the eight bolts Torque to 30 ft Ibs 8 Refill hydraulic oil tank and PURGE system following instructions on page 18 9 Prime the pump with solvent or water and bring the pump up to full pressure approximately 2500 psi Run the pump on standby not triggering gun for about 20 minutes to break in new membrane 10 Installation is now complete and the pump is ready for use REPLACEMENT OF INTAKE SEAT REF 13 H E R O INDUSTRIES 22 1150GSD MANUAL B VERSION TOOLS REQUIRED 5 16 Allen wrench vise torque wrench screwdriver 1 Remove the four bolts ref 9 and pull intake endcap ref 11 from the pump The endcap should separate from the material head ref 21 with the ball guide ref 17 attached If the ball guide remains in the material head pry out with a screw driver 2 Clamp endcap in vise with the ball guide facing up 3 Pry off the ball guide and remove intake ball ref 14 and spring ref 15 4 Remove seat from endcap NOTE The seat is not secured with any Loc Tite however dried paint may cause difficulty in removing seat Remove the crush washer ref 12 Thoroughly clean and inspect all p
26. ch week while in storage MI Remove gas before storing MI Have the engine professionally serviced by an approved service technician on a regular bases as recommended by the manufacturer Honda x DO NOT adjust engine operating speed RPM The engine is factory set for optimum performance x DO NOT use engine RPM to control spray performance always adjust pressure with Pressure Control AIRLESS SPRAY PAINTING H E R O INDUSTRIES 9 1150GSD MANUAL B VERSION SUGGESTIONS AND TECHNIQUE A good airless spray application is the result of many factors Surface preparation which includes cleaning and degreasing priming material compatibility quality finish product and correct application technique are all important to the finished results 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 ai
27. enter ball on retainer turn valve seat into body until finger tight using pipe dope or Teflon tape to seal Fully tighten using wrench TROUBLESHOOTING SITUATION POSSIBLE CAUSE REMEDY FLUID BEING SPRAYED OUT OF TIP PULSATES SPRAY HOSE LIES QUIET WHEN GUN TRIGGER CLOSED 1 Spray tip worn out or too large replace with new tip of correct size Tip must not exceed a single good condition 031 tip or 2 021 tips H E R O INDUSTRIES 19 1150GSD MANUAL B VERSION 2 Paint hose incorrect type replace with genuine top quality H E R O airless spray hose Steel braided hose is not recommended 3 Too short a length of hose minimum 50 of airless spray hose is required Replace or add hose until a minimum of 50 is being used FLUID BEING SPRAYED OUT OF TIP PULSATES SPRAY HOSE CONTINUES TO MOVE VIGOROUSLY WHEN GUN TRIGGER CLOSED 1 Outgo valve ref 26 assembled incorrectly remove the outgo valve and reassemble closely following the instructions on page 26 2 Outgo valve ball ref 30 worn out or jammed inspect outgo ball to ensure that it is round and free of nicks or cuts Inspect for foreign material jamming ball Inspect seat and cage for wear Replace parts as required PUMP SPRAYS WATER OR SOLVENT AT CORRECT PRESSURES BUT WILL NOT SPRAY PAINT Check with pressure gauge see page 16 l Air leak in paint intake siphon assembly check all fittings and hose clamps in intake assembly for tightness 2 A
28. he bevel the more wear has taken place Inspect retainer for wear The retainer has a small locating hole in it The hole should be flush or slightly beveled The greater the wear on the ball seat and retainer the poorer the static pressure will be Replace parts individually or use repair kit ref 89 6 Hold P C body vertical Place spring into body place retainer onto spring Ensure retainer fits completely over spring Retainer should rest below end of body by approximately 1 4 to 3 8 Place ball onto retainer ensuring ball is located on center hole 7 Thread on seat using care not to dislodge the ball from its position on the retainer Tighten firmly 8 Apply pipe dope or Teflon tape to exterior threads of seat Install into elbow Tighten to prevent leaks and return to original position 9 Reattach hydraulic line 10 See PURGING instructions on page 18 ACCESSORIES PARTS LIST 1 4x 1 4 CONNECTOR 1 4 PAINT HOSE TO 1 4 PAINT HOSE 106 RUBBER BAN H E R O INDUSTRIES 28 1150GSD MANUAL B VERSION 114 115 117 HOSE AIRLESS PAINT 50 X 1 4 HOSE AIRLESS PAINT 25 X 1 4 HOSE AIRLESS PAINT 50 X 3 8 3 WHIPEND WHIPEND 3 X 3 8 620 VHS SERVICE VIDEO TAPE VHS FORMAT 621 BETA SERVICE VIDEO TAPE BETA FORMAT 620 H20 HOW TO OPERATE VIDEO TAPE VHS FORMAT 67 18B HEX KEY SET 5 16 1 4 5 32 1 8 10 55 01 1 2 AIRLESS SPRAY GUN ASM 2 FINGER TRIGGER 10 55 01 1 4 AIRLESS SPRAY GUN ASM 4 FINGER TRIGGER S5GAL S
29. hown D AO HU SPECIAL NOTES To check the ball for wear place against a new seat and check sealing edge against a bright light A used seat may be checked in a similar manner using a new ball Replace used part if light pass at sealing edge PRIME VALVE REPAIRS REF 36 H E R O INDUSTRIES 26 1150GSD MANUAL B VERSION TOOLS REQUIRED oe 5 16 wrench 3 64 l1 Open prime valve ref 36 to release pressure from material side of pump 2 Remove prime valve return hose ref 51 from prime valve return fitting ref 50 3 Place wrench on prime valve connector ref 37 Turn counter clockwise to remove valve from outgo tee ref 35 4 Secure valve in vise with valve stem ref 46 upward 5 To install new valve stem or valve stem seals ref 44 or 45 continue at step 6 If replacing prime valve repair kit ref 42 continue at step 9 Use Allen wrench to remove valve stem set screw ref 48 Remove stem and inspect for wear or damage Replace as required 8 Thread repaired stem into packing nut ref 43 until in closed position Turn in set screw until tight on valve stem Loosen set screw 1 2 turn or until stem moves freely in packing nut NOTE Valve stem should not be able to be removed from packing nut if set screw is adjusted correctly 9 Use wrench to remove valve stem packing nut assembly ref 49 from body ref 38 10 Remove ball from valve s
30. ing surface in a clean fan shaped spray which penetrates all cracks and comers 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 1997 HYDRAPULSE B VERSION BEGINNING AT SERIAL NUMBER OPERATING INSTRUCTIONS 140056 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
31. ir leak in paint intake check for cracked or broken intake fittings Swivel connector ref 8 or hose barb ref 7 may be damaged due to over tightening Look for small black hairline fractures Replace damaged parts 3 Partial blockage in paint intake siphon hose reff 5 clean and remove any blockages from intake siphon hose Check to insure strainer bag is not clogging intake siphon hose SPRAYER DOES NOT PRIME WITH PAINT 1 Heavy bodied paint pump dry refer to Operating Instructions and follow priming instructions using the correct thinner for the paint you are to use SPRAYER DOES NOT PRIME WITH CORRECT THINNER 1 Pump completely dry pump may experience difficulty in priming when it is completely dry First invert siphon tube and pour thinner into siphon tube to help prime dry pump 2 Intake siphon assembly ref 1 has loose damaged fittings loose clamps or damaged hose check all fittings hose clamps for tightness siphon hose for damage or holes Replace or tighten as required 3 Intake valve ball ref 14 stuck remove intake endcap ref 11 and free ball and reassemble 4 Outgo valve ball ref 30 stuck remove outgo valve ref 26 Unthread outgo valve upper body ref 31 from outgo body lower ref 27 Remove outgo seat ref 29 from upper body Free ball and reassemble following detailed instructions on page 26 TROUBLESHOOTING SITUATION POSSIBLE CAUSE REMEDY SPRAY MATERIAL LEAKS
32. it is shown for each part number Part numbers in bold text indicate whole assemblies or kits These parts may also be purchased individually HYDRAULIC PARTS REF PART DESCRIPTION QTY 63 35B CROSSBLOCK Steel 1 64 36 CAPSCREW HX HD 5 16NC x 3 Gr 5 6 65 HW5050P WASHER 5 16 SAE 6 66 4 30 VACUUM VALVE 1 67 4 31G FEED LINE LVO C W Fittings Includes ref 68 1 68 31 1 ORIFICE Metering 1 69 4 45A TANK Complete With Fittings ref 70 72 ASSY 70 4 45 1 SCREEN Tank 1 71 45 4 ELBOW Return 1 72 4 45 2 LID Vented Hydraulic Tank 1 73 4 28G RETURN LINE LVO C W Fittings 1 74 4 27C PRESSURE CONTROL VALVE Complete Ref 75 88 ASSY 75 4 27C 7 KNOB P C Includes Ref 76 ASSY 76 HW2010 SETSCREW SKT HD 5 16 NC x 5 16 1 71 27C 6 LOCK NUT Aluminum P C 1 78 4 27C 10 STEM ASSEMBLY Ref 79 81 ASSY 79 27C 10A STEM P C 1 80 27C 10B SCREW Stem P C 1 81 27C 12 O RING P C 2 82 4 27C 11 FITTING Oil Return P C 1 83 27C 8 BODY P C 1 84 27C 9 CIRCLIP P C 1 85 27C 5 SPRING P C 1 86 27C 4 RETAINER P C 1 87 27C 3 SEAT 38 40RC P C 1 88 27C 2 BALL Steel 1 89 4 27CRK REPAIR KIT Ref 85 88 KIT 90 4 38A 150 PISTON amp ROD ASSEMBLY 1 Ref 91 94 ASSY 91 4 37A 150 SEAL SET Piston 1 1 92 4 38A 150 1 PISTON Only W O Seals 1 1 93 38A 3
33. k and forth movement in the piston when you tug on it pulling it from the rod A loose fitting piston rod can be corrected by re packing the seat with grease If a pump is operated with a loose piston rod damage to the rod seat and piston can develop requiring additional repairs A pump with a loose piston rod connection will not recover hydraulic pressure quickly large pressure drop when gun is triggered and generally operate at lower levels of performance Remove piston circlip using circlip pliers Remove piston from rod NOTE Use extreme caution not to damage circlip or the internal circlip groove of piston NOTE Piston rod circlip washer o ring and nut are not available individually Parts are available with the purchase of piston rod ref 94 only NOTE The circlip will have one sharp edge and one smooth edge The smooth edge should be towards the washer If reversed the rod will continually pull out of the piston PISTON REPAIRS Remove bronze piston rod seat ref 93 from piston ref 92 H E R O INDUSTRIES 24 1150GSD MANUAL B VERSION ve Examine all parts for wear or damage Replace as required 9 Fill the center cavity of piston rod seat until flush with grease Slide seat into piston with concave side filled with grease facing out 10 Lightly grease the ball end of piston rod Push piston rod into piston until ball end of rod contacts seat 11 Slide o ring and steel washer down rod a
34. l paint flows freely NOTE Never turn prime valve back to prime position when the unit is under pressure NOTE The thicker paint will require a longer time to complete the initial prime circulation through the prime valve Leave the valve in the prime position to ensure the complete removal of all air and pre prime fluid Several minutes may be required particularly with thicker viscosity products Spray a test pattern Begin by spraying a test pattern onto old newspaper or other scrap material Increase the pressure slowly at first by turning the pressure control knob clockwise 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 77 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 Spray paint Paint Straining H E R O INDUSTRIES 7 1150GSD MANUAL B VERSION It is recommended that all products entering the sprayer be pre strained to remove any large particles and contaminants BEFORE they are drawn into the sprayer The strainer bag should remain in place throughout the painting operation This will prevent foreign matter from falling into the bucket and contaminating the previously strained paint The gun fil
35. lean the hydraulic tank screen ref 70 during this process Refill only with genuine H E R O LVO hydraulic fluid NOTE If lacquer has contaminated the hydraulic system the piston seal ref 91 must be changed in addition to flushing the system Closely follow detailed instructions on page 24 25 HYDRAULIC SIDE OF PUMP HAS BEEN REPAIRED AND REASSEMBLED HYDRAPULSE MEMBRANE NOT MOVING PURGING 1 Air lock created on hydraulic side of pump when the hydraulic side of the pump is working there is no air in it During repairs it is possible that air has been trapped in the hydraulic system It must be removed or the pump will not work To purge the air from the hydraulic system remove the pressure control knob ref 75 from the valve Gently pull the P C stem ref 82 out It will pull out about 1 8 Remove the vented hydraulic cap ref 72 from the hydraulic tank ref 69 and install accessory pressure cap item 4 45 3 With a bicycle pump apply a few pounds of air pressure to the hydraulic tank This will force the oil through the hydraulic system and push out any of the trapped air Wait a few minutes Remove pressure cap and replace with vented cap Restart the unit and install pressure control knob NOTE Unit may be running during purging procedure to speed up the procedure If a pressure cap is unavailable simply running the equipment for approximately 5 10 minutes with the P C stem pulled out will purge the system TRO
36. lse membrane 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 1150GSD can support up to a maximum of aone 031 tip or two 021 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 H E R O INDUSTRIES 12 1150GSD MANUAL B VERSION 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 hydrapulse membrane 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 66 and the hydraulic outgo valve known as the hydraulic pressure control valve ref 74 The second pump is known as the paint or material pump The paint system is made up of two basic valves the paint intake valve assembly ref 11 18 paint outgo valve ref 26 A third valve known as a prime valve ref 3
37. n technique refer to proper application techniques on page 10 12 Too windy wait for wind to let up HYDRAPULSE MEMBRANE REPLACEMENT REF 54 H E R O INDUSTRIES 21 1150GSD MANUAL B VERSION TOOLS REQUIRED 1 4 Allen wrench 1 2 Open end wrench 2 4 45 3 accessory item Torque wrench Removal 1 Remove the eight bolts securing the material head ref 21 to the hydraulic head s 2 ref t 59 2 Remove the material head cushion ref 22 and replace with the new 1 5 16 Inches 5 16 Inches cushion provided 3 Place a container under pump to catch hydraulic oil 4 Gently pull hydrapulse membrane to separate it from the hydraulic head 5 Remove the nut ref 58 on the hydrapulse membrane stem in order to separate the hydrapulse membrane from the hydraulic plastic horn ref 55 hydrapulse membrane spring ref 56 and spring locator ref 57 6 Clean all parts Assembly 1 Place hydraulic plastic horn over the new hydrapulse membrane Position the spring in the bore of the plastic horn 3 Install the spring locator over the hydrapulse membrane stem and into the spring Thread the new jam nut onto the stem 4 Tighten the jam nut until a measurement of 1 5 16 is obtained The measurement is taken from the top of the hydraulic horn ref 55 to the top of the spring locator ref 57 See diagram above 5 Check the assembly The spring must be positioned in the bore of the plasti
38. nd into piston Slide circlip down into piston and snap into the internal circlip groove of piston using circlip pliers NOTE Circlip must fully expand into groove of piston Circlip has fully expanded when there is 13 64 space between circlip eyelets NOTE If you experience difficulty installing circlip remove a small quantity of grease When installed correctly rod should move slowly and without any end play See step 5 12 If piston seals ref 91 are required they may be installed now 13 Remove and discard old piston seals 14 Piston seal kits ref 91 contain a total of four pieces 1 o ring 1 flat washer 2 cup washers Take note of their installation sequence by referring to drawing The piston has three machined grooves which have been marked on the drawing as A B amp C 15 Place flat washer one side has a contoured face into groove C then place o ring in front of flat washer so that it fits into the contoured face of the flat washer 16 Place one cup washer into groove B with open face of cup washer facing the end of piston towards hydraulic oil when installed 17 Place second cup washer into groove A NOTE Always work from the front of the piston back so that you are always moving the cup washers over filled grooves This avoids damage that can occur to the cup washers if they have to be dug out of one groove and moved to another Avoid over stretching NOTE A small dental like tool may be used
39. ng remove intake endcap ref 11 and ball guide ref 17 Remove seat ref 13 inspect inlet washer ref 12 for excessive compression Inspect for any sign of material bypass between intake seat and endcap cavity NOTE The proper alignment of intake parts condition of intake washer ref 12 combined with the correct bolt torque are critical to the correct function of the intake valve Replace the intake washer ref 12 each time the endcap is removed See page 23 for more details 4 Outgo valve ball ref 30 worn or jammed remove outgo valve ref 26 Invert valve and unthread outgo valve upper ref 31 from outgo lower ref 27 Remove crush washer ref 28 outgo seat ref 29 outgo ball ref 30 from outgo upper tunnel Inspect outgo ball to ensure that it is round and free of nicks or cuts Inspect for foreign material jamming ball Inspect ball and cage for wear Replace parts as needed 5 Outgo valve ref 26 incorrectly assembled disassemble and reassemble outgo valve closely following detailed instructions on page 26 TROUBLESHOOTING SITUATION POSSIBLE CAUSE REMEDY H E R O INDUSTRIES 17 1150GSD MANUAL B VERSION TOTAL LOSS OF PRESSURE HYDRAPULSE MEMBRANE HAS NO MOVEMENT OR MOVEMENT CAN BE STOPPED SEE HYDRAPULSE MEMBRANE TEST 1 Hydraulic intake valve ref 66 defective remove hydraulic feed line ref 67 from hydraulic intake valve Plug hydraulic feed line so hydraulic fluid does
40. on Be prepared to inform the doctor what fluid was injected 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 NEVER use around children NEVER attempt to perform any maintenance or service on any part of the unit spray system without first 1 Turn off the engine 2 Turn the engine switch to OFF position 3 Relieving all pressure in the pump by triggering the gun 4 Locking gun trigger in LOCKED position with gun locked closed NEVER operate the sprayer without the tip guard complete and in place NEVER spray any material in the vicinity of open flame pilot lights electrical outlets or any other source of ignition NEVER spray volatile materials with flash points lower than 140 F 60 C 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 NEVER allow paint hose to become kinked or to vibrate against rough or sharp surfaces 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 NEVER spray in an enclosed area The spraying area must be well ventilated to safely remove chemical vapors NEVER operate the unit with worn or damaged accessories or with accessories other than those su
41. p the three paint valves Refer to pages where exploded views of these valves are shown To eliminate the hydraulic side of the pump piston side of hydrapulse membrane as a source of problems 1 Remove the intake valve end cap ref 11 by removing the four cap screws ref 9 The intake valve assembly ref 11 18 will generally come off as an entire assembly requiringno further dismantling If the ball guide ref 17 and ball stop ref 18 remain in the paint head they can be pried free with a screwdriver 2 Start unit 3 Increase the pressure by turning the pressure control knob ref 71 clockwise to full pressure 4 Put pressure on the center of the exposed hydrapulse membrane with the handle of a screwdriver or other blunt object NOTE The hydrapulse membrane is located between the paint head ref 21 and the hydraulic head ref 59 5 If you are UNABLE to stop or alter the hydrapulse membrane s movement then the hydraulic side is operating properly The problem is located in the Paint pump See troubleshooting guide for additional information TROUBLESHOOTI SITUATION POSSIBLE CAUSE REMEDY H E R O INDUSTRIES 16 1150GSD MANUAL B VERSION GASOLINE ENGINE WON T START RUN 1 Pump under pressure reduce pressure setting by turning pressure control knob counter clockwise trigger gun to relieve pressure Fuel line valve closed open fuel line valve See Honda owners manual Engine s
42. pplied by H E R O Industries unless the accessories have been first specifically approved in writing by H E R O Industries Ltd 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 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 kh k k x k ko ko HH HH HH ES kl ALWAYS VI ALWAYS follow H E R O recommendations for operation and safety completely H E R O INDUSTRIES 3 1150GSD MANUAL B VERSION MI ALWAYS set trigger lock on gun in LOCKED position when not in use with gun locked close V ALWAYS check connections and fittings for tightness before operating the unit VI ALWAYS locate the unit in a well ventilated area a minimum of 25 feet from the spray area MI 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 VI ALWAYS use accessories and components approved for at least 3000 psi working pressure in the spraying system VI 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 VI ALWAYS examine accessories for wear or damage
43. red 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 sprayed 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 Hydrapu
44. remove any unused paint left in the pump and hose at the completion of a job When the prime valve is open the material is pumped through the paint intake and outgo and back to the source by way of the prime valve When closed no material should be escaping from the prime valve return hose ref 51 If material escapes through the prime valve return hose when the valve is closed spray pressure at the gun will be reduced The solution to almost all problems can usually be found in the paint side valves However before performing any repair or looking further the following are things which can cause an apparent sprayer failure without any mechanical problem ALWAYS check these items before preceding 1 Circuit breaker open or fuse blown 8 Gun handle filter plugged 2 Engine fuel line closed 9 Paint hose plugged 3 Engine switch set to OFF 10 Loose fitting or hole in siphon hose 4 Spark plug wire loose or disconnected 11 Intake siphon hose plugged 5 Pressure control knob loose or missing 12 Siphon screen missing or plugged 6 Spray tip plugged 13 Sprayer under pressure when restarting 7 Spray tip worn out 14 Strainer bag plugging siphon screen UNLESS YOU ARE KNOWLEDGEABLE ABOUT THE REPAIR OF HIGH PRESSURE EQUIPMENT DO NOT ATTEMPT TO REPAIR AN AIRLESS SPRAYER YOURSELF ALWAYS FOLLOW ALL SAFETY PRECAUTIONS THE H E R O SERVICE VIDEO TAPE 1 620 VHS OR 1 620 BETA WILL PROVIDE COMPLETE SERVICE TRAINING SEE YOUR
45. rless 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
46. s in bold text indicate whole assemblies or kits These parts may also be purchased individually 0 OF KOTOR VAN dS DESCRIPTION QTY 32 SWIVEL 1 33 REPAIR KIT Ref 25 28 30 KIT 34 OVERHAUL KIT Ref 25 28 30 KIT 35 TEE Female x Male x Male 1 36 PRIME VALVE COMPLETE Ref 37 50 ASSY 37 38 603 1 BODY P V 39 603 3 WASHER Copper P V 0 4 41 42 4 603 4 603 13 4 603RK 603 2 CONNECTOR 1 4 x 1 4 SEAT Tungsten Carbide P V BALL Tungsten Carbide P V REPAIR KIT P V Ref 39 41 PACKING NUT P V 1 KIT 3 44 603 8 O RING P V 5 4 603 15 WASHER Back Up P V 46 47 48 49 4 603 10 603 12 HW2013 4 603 11 STEM ASSEMBLY Includes Ref 44 45 LABEL Close Tightly SETSCREW SKT HD 4 40 x 3 16 PACKING NUT amp STEM ASSY P V Ref 43 48 52 196 53 188 HYDRAULIC PARTS 54 4 04 22 4500 HYDRAPULSE MEMBRANE Includes Ref 22 amp 58 KIT 55 04 22 4001 HORN Plastic 1 56 04 22 4005 SPRING 1 57 04 22 4004 LOCATOR 1 58 HW4032 NUT 5 15NC Hex Ny Lock 1 59 4 04 22 4501 HEAD Hydrapulse Gold 1 60 5 O RING 1 61 24 150 CYLINDER 1 1 62 25 2 ELBOW 3 H E R O INDUSTRIES 31 1150GSD MANUAL B VERSION PARTS LIST Please order parts by the appropriate part number and not by reference number The quantity required per un
47. se 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 9 To remove storage solution add one gallon of thinner compatible H E R O INDUSTRIES 6 ref 35 with the type of paint to be used to the siphon pail Strainer bag and si phon tube ALWAYS strain paint before starting prime valve ref 36 hose barb should be attached to gun prior to into a 1150GSD MANUAL B VERSION 10 11 12 13 14 15 16 17 WF 19 SETTING UP TO SPRAY CONTINUED Turn pressure control knob ref 75 counter clockwise to lowest pressure setting Observe and perform all pre operation checks as required by the engine manufacturer Honda See your Honda owner s manual Start engine See Honda owner s manual for correct procedures Turn prime valve knob ref 46 counter clockwise until fully open Allow thinner to circulate back into the siphon pail for a few minutes Then turn the prime valve knob clockwise to close the valve close tightly and direct the flow to the paint hose and gun Leave the pressure setting low Trigger gun into a waste container Remove rinse prime fluid and pour paint through strainer bag into siphon pail Repeat step 13 unti
48. sesessssesesesesestetetesesesesesesesessosesesesesesreeetes 10 12 Mirna S Fan sah aes cnc decd E E EEE ES T 13 21 Hydrapulse Membrane Replacement cz cicaiecaceasscxschusedesurcagecvees vous ctenaegctueanctsenniceseaens eanvaeaceniead 22 Intake Seat Replacement sssniccnesecironnnn nn a 23 PISUOM RG AIES scan cas csacsersa saat cersasl na ats a a r E OE 24 25 ODAC ValNera ha cedase ata ta cela Ode ce EREA ea lade la ia a E 26 Prime Valve RE Patt scisescsdiescseyset eiscsevesdensan seated aa E O EEA AREE A EAEE 27 Pressure Control Valve Rep isen renererien aeia ETE E S 28 ACCESSOS erare RE EE E E AE T EEEE EE OE ocoailen 29 Paris List And D sciptiois asena a a E E S E AIEEE 30 34 Fxploded Upit Diagrami E E E E E E ewan 35 36 Dept TSE ai esp tac cscs E E ERA A REENE E A EE ce E E a eB acted 37 40 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 wha
49. tem NOTE If ball does not drop free remove with the aid of a knife 11 Remove seat ref 40 and crush washer ref 39 from valve body 12 Install new crush washer and seat ensuring the seat is positioned correctly The seat has both a beveled inside edge and a beveled outside edge The beveled inside edge will be facing the valve ball when positioned correctly Place new ball onto end of stem 13 Rotate stem counter clockwise until fully open and valve ball is inside valve stem packing nut 14 Place packing nut assembly ref 49 into valve body Torque to 12 foot pounds 15 Complete steps 3 and 2 of removal PRESSURE CONTROL VALVE REF 74 Allen mn H E R O INDUSTRIES 27 1150GSD MANUAL B VERSION 7 Ls is bl blis Ls REQUIRED 1 wrench 11 16 wrench 1 Si es Remove pressure control knob ref 75 and pull P C stem ref 78 out to the internal stop 1 16 to 1 8 thereby releasing hydraulic pressure Remove hydraulic return line ref 73 from P C fitting ref 78 Place 11 16 wrench on P C seat ref 87 Turn counter clockwise to remove complete valve Place complete valve in vise and remove seat from body ref 83 Remove ball ref 88 retainer ref 86 and spring ref 85 from body Inspect ball for nicks or cuts and replace if damaged Inspect seat at sealing edge for signs of wear A good condition seat will have a very small beveled at the sealing edge The larger t
50. ter should not be re lied upon to do all the paint filtration Any dirt grime or other undesirable particles which reach the gun filter have passed through the entire paint pump and have possibly created unnecessary damage and inconvenience Always strain the paint before siphoning FLUSHING THE UNIT AT SHUTDOWN OR COLOR CHANGE If shutting down for a short period of time it is sufficient to trigger the gun to 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 1 Remove spray tip from gun Turn pressure control knob counter clockwise to low pressure setting Only use sufficient pressure to allow material to move through the sprayer DO NOT operate at or near full pressure 3 Remove siphon assembly from paint container 4 Trigger gun back into paint container until unit runs dry NOTE Pump and spray hose will continue to contain paint This paint may be recovered by placing prime hose into paint container and draining the remainder while re priming with cleaning fluid See step 5 and 6 5 Place siphon assembly in container of correct thinner for the spray product being used and prime the pump as shown in step 13 of Spraying See special notes from step 4 Allow thinner to circulate back into the container for a few minutes to flush the prime valve 6 Close prime
51. the internal hydraulic oil pressure is sufficient to cause it to open The point at which the oil is released is equal to the level set by the control knob As components within the pressure control valve wear the valve looses its ability to maintain or reach the required pressures see low static pressure PAINT INTAKE VALVE ASSEMBLY REF 11 18 The paint intake valve is made up of eleven items endcap ref 11 washer ref 12 seat ref 13 intake ball ref 14 spring ref 15 o ring ref 16 ball guide ref 17 and ball stop ref 18 The intake valve controls the incoming flow of spray materials and is responsible for keeping them from returning to the source The ball must be able to create a complete seal on the seat otherwise pressure will be lost A worn intake valve will permit correct static pressure but supply lower spray pressure A worn intake ball will become smaller in diameter and loose its ability to seal at the seat A worn seat will develop a large step in the area where contact with the ball is made This can cause the intake ball to distort in shape making the ball egg shaped If the valve assembly becomes warm to the touch this may be a sign of a loose or worn seat caused by wear or improper compression caused by a worn intake washer ref 12 The intake washer ref 12 acts as a compression washer insuring the seat ref 13 remains pressed into the endcap ref 11 The seat must remain firmly pressed into the
52. tsoever 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 any part shut off power and relieve pressure IMPORTANT SAFETY PRECAUTIONS H E R O INDUSTRIES 2 1150GSD MANUAL B VERSION 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 x NEVER place any part of the body in front of the spray tip or aim the gun toward any part of the body NEVER point the gun toward any individual NEVER treat any injury as a simple cut If injury does occur seek immediate medical attenti
53. valve 7 Trigger gun into paint container until thinner comes through See special notes from step 4 Re direct flow into waste container and continue spraying until thinner runs clear Heavily soiled thinners may have to be changed to complete cleaning job 8 Lift siphon assembly and allow pump to run dry 9 Repeat procedure using a gallon of 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 10 Switch unit off and trigger gun to relieve remaining pressure 11 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 eae tenant pan must be used for winter or off season storage Because solvents evaporate quickly Ee 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 CAUTION Read all directions on panel before using WONDER WASH DIRECTIONS mice is of this package with 1 gallon n of ps H E R O Equipment Wonder Wash available from your H E R O distributor aay will provide the added cleaning benefits of solvent at a much lower cost Suitable ae as a short term 1 2 days storage solution only Be oe Aa Ann sahn aat water for at Teast 1
54. w placed in before the seat crush washer is placed under the seat The seat will be held in place through the compression of parts during assembly PISTON REPAIRS H E R O INDUSTRIES 23 1150GSD MANUAL B VERSION TOOLS REQUIRED 1 2 wrench 11 16 wrench circlip pliers REF 90 SPECIAL NOTES All gas driven units must remain level at all times Tipping of the units will cause the oil from the engine crankcase to flow into the engine air cleaner carburetor and cylinder head This will cause starting and running difficulties Keep unit level during service torque wrench grease vise grips 7 Remove hydraulic feed line ref 67 from hydraulic intake valve ref 66 and also remove hydraulic return line ref 73 from the pressure control valve ref 74 Plug lines to minimize oil loss Hint golf tees work well for this Remove the bolts ref 120 passing through the side frames ref 115 118 into the crossblock ref 63 Place a drain tray under cylinder area Grasp the pump assembly and pull away from the piston Stop when piston pulls free to allow the hydraulic oil to drain into pan Completely remove pump assembly from between side frames Remove the piston ref 90 from eccentric bearing ref 100 Move to clean work bench for repairs NOTE Repairs to the rod seat piston will be required if there is end play in the rod piston connection This is evident if you can feel bac
55. witch in OFF position turn the engine switch to ON position Engine out of gasoline allow engine to cool before adding appropriate levels of unleaded gas Engine is oil contaminated Unit and engine must remain vertical or oil from the crankcase can enter the carburetor air filter etc see an authorized Honda service center Dee lS GASOLINE ENGINE STALLS QUITS 1 See GASOLINE ENGINE Won t Start Run 2 Drive belt is loose tighten drive belts by evenly turning belt tension bolts on either side of engine clockwise Check tension frequently Loose belts generally emit loud squealing noises 3 Unit primes builds pressure but pump seizes or stops when gun is triggered loose belts tighten 4 Engine requires tune up see an authorized Honda service center TOTAL LOSS OF PRESSURE HYDRAPULSE MEMBRANE MOVEMENT CANNOT BE STOPPED OR ALTERED SEE HYDRAPULSE MEMBRANE TEST 1 Paint too thick thin paint according to manufacturer s recommendations 2 Intake ball ref 14 worn or jammed opened closed remove intake endcap ref 11 and ball guide ref 17 Inspect intake ball ref 14 to ensure it is free round and has no nicks or cuts Inspect ball guide for excessive bashing out on the internal walls Excessive wear causes the ball to become lost and unable to locate the seating surface Inspect for foreign material jamming ball Replace parts as needed 3 Intake seat loose bypassi
56. ydraulic outgo valve is closed The corresponding paint valves are in similar positions As the piston moves forward it pushes hydraulic oil forward This movement of oil causes the hydraulic intake valve to close and the hydrapulse membrane to move forward fig 1 The hydraulic outgo valve will remain closed until sufficient pressure is created to cause it to open While the hydraulic valves are operating a corresponding re action is taking place in the paint valves The forward movement of the hydrapulse membrane pushes the paint causing the paint intake valve ref 11 18 to close The trapped paint requires a means of release so it forces the outgo valve ref 26 to open and paint flows to the gun H E R O INDUSTRIES 13 1150GSD MANUAL B VERSION TROUBLESHOOTING The backward movement of the piston creates a vacuum in the hydraulic system This causes the hydraulic outgo valve to close and the hydraulic intake valve to open fig 1 Opening of the hydraulic intake valve allows a new supply of hydraulic oil to enter the system replacing the oil which was used on the forward stroke Once again a corresponding re action is taking place in the paint pump The hydrapulse membrane is being pulled backward by the hydrapulse membrane spring ref 56 The backward hydrapulse membrane movement causes a vacuum in the paint pump This vacuum causes the intake valve to open allowing a new supply of paint to enter The corresponding
Download Pdf Manuals
Related Search