Henkel Loctite User manual

Henkel Corporation
MMD System 1000
Machine Manual

SAFETY
• Always wear safety glasses when operating.
• 100-PSI maximum inlet air pressure. Use a known
regulated dry air source only.
• Hazardous Noise! Agitator air motors run at 86 dBA.
Pumps cycle is peak 75 dBA. Always wear hearing
protection.
• The installation of the SYSTEM 1000 should include a
system air disconnect accessible by the operator.
• Read all material manufacturer’s product information. Always
follow material manufacturers specific recommendations
regarding dispensing even if they may differ from these
general instructions.
• Keep the MSDS accessible to the work area as it lists
valuable emergency information.
• Consult local, state and federal laws before disposing of
mixers or material.
• Do not operate if any of the SYSTEM 1000
components are missing or damaged.
• Danger Labels: Indicate an
imminently hazardous situation, which,
if not avoided, could result in death or
serious injury.
• Warning Labels: Indicate potentially
hazardous situations which, if not
avoided could result in death or
serious injury.
• Caution Labels: Indicate an unsafe
practice that may result in moderate or
minor injury.
• Notice Labels: State a company
policy.

Safety Precautions
This manual provides installation, operation, and maintenance instructions for Loctite meter, mix, and dispense
machines. Read this manual before you install and operate your machine. Use your machine only as directed.
Safety Terms within our manuals
Cautions are given where failure to observe the instruction could result in damage to the equipment, associated
equipment, and/or process. Warnings are given where failure to observe the instruction could result in injury or death
to people.
Some examples follow.
Safety Labeling on our machinery
All our machines carry the following safety labels wherever necessary:
• Danger Labels indicate an imminently hazardous situation, which, if not avoided, could result in death or serious
injury.
• Warning Labels indicate potentially hazardous situations which, if not avoided, could result in death or serious
injury.
• Caution Labels indicate an unsafe practice that may result in moderate or minor injury.
• Notice Labels state a company policy. Some examples are:
Snuff-back can be monitored with D
V
MODE in AUTO, but must be
adjusted with DV MODE in OPEN
Caution
Make sure EMERGENCY STOP is
locked in before manually aligning
the ratio block to the ratio beam.
WARNING
DO NOT OPERATE THIS
MACHINE WITH
GUARD(S) DETACHED
DANGER
UNPLUG MACHINE
BEFORE OPENING
ENCLOSURE
WARNING
OVERCURRENT
PROTECTION
PROVIDED AT MACHINE
SUPPLY TERMINALS
NOTICE
WEAR EAR
PROTECTION
CAUTION
WEAR EYE
PROTECTION
CAUTION

Table of Contents
WARRANTY.................................................................................................................................................1
SYSTEM 1000 GENERAL DESCRIPTION ..............................................................................................2
DIAGRAMS OF COMMON VALVES AND PARTS...............................................................................3
MACHINE FEATURES...............................................................................................................................5
REASSEMBLY AND INSTALLATION ....................................................................................................6
ADJUSTING THE SHOT SIZE ..................................................................................................................7
LOADING THE MACHINE WITH MATERIALS ..................................................................................8
PRIMING THE MATERIAL VALVES .....................................................................................................9
PHASING THE PUMPS ............................................................................................................................10
RATIO CHECK..........................................................................................................................................11
RATIO ADJUSTMENT .............................................................................................................................12
DAILY OPERATION.................................................................................................................................13
SHUTDOWN...............................................................................................................................................14
PISTON REPLACEMENT........................................................................................................................15
PERIODIC MAINTENANCE ...................................................................................................................16
TROUBLESHOOTING .............................................................................................................................17
ADDITIONAL INFORMATION ..............................................................................................................21
PUMP REBUILD ......................................................................................................................................A-1

WARRANTY
PROPRIETARY EQUIPMENT AND COMPONENTS
MANUFACTURED BY SELLER
The warranties contained herein are not made in regard to auxiliary equipment and components (see Section below). Unless
otherwise specifically stated in writing, warranties are limited to the following: All proprietary goods designed, manufactured and
sold by Seller are guaranteed against defective workmanship or material for a period of three (3) years after date of shipment
from the factory, provided the goods were operated under the condition for which they were sold. This warranty does not cover
seals or components that are out of specification due to normal wear and tear or improper maintenance of the equipment. All
claims pursuant to the warranties must be made within such three (3) year period. If Buyer claims the goods are defective
within the three (3) year period, Buyer shall notify Seller immediately, in writing. Seller may inspect, by authorized agent, the
defective claim or issue shipping instructions for return of the goods to its factory. Seller shall have the option, at its sole
discretion, if the goods are found to be defective, to correct the defect or defects by repair or replacement or refund the
purchase price. Seller's obligation, with respect to such goods, shall be limited to the replacement or repair F.O.B. Seller's
facility, or refund of the purchase price, and in no event shall Seller be liable for consequential or special damages, or for
transportation installation, adjustment or other expenses which may arise in connection with such goods. The liability of Seller
arising out of supplying said goods and services, or their use, whether on warranties or otherwise, shall not in any case exceed
the cost of the equipment and parts involved, and upon the expiration of said three (3) years, all such liabilities shall terminate.
Seller assumes no liability for damages or expenses of any character, including those arising out of the installation, use or
resale of such goods. No representation or other affirmation of fact not set forth herein, including, but not limited to, statements
regarding capacity, or suitability for use, or performance of the goods, shall be deemed to be a warranty or representation by
Seller for any purpose, nor give rise to any liability or obligation of Seller whatsoever. NO WARRANTY OR GUARANTEE,
EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY AS TO MERCHANTABILITY OR FITNESS FOR ANY PURPOSE,
IS MADE, EXCEPT AS SPECIFICALLY PROVIDED IN THIS AGREEMENT.
AUXILIARY EQUIPMENT AND COMPONENTS
NOT MANUFACTURED BY SELLER
To the extent that auxiliary equipment and components of other manufacturers (e.g. logic control hardware, valves, transfer
pumps, motors, etc.) are included as part of the machine or system it is understood that these products which are not
manufactured by Seller are subject to the original manufacturer’s warranty policy. FURTHER, SELLER MAKES NO
WARRANTIES OR GUARANTEES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTIES AS TO MERCHANTABILITY
OR FITNESS FOR ANY PURPOSE AND ASSUMES NO LIABILITIES WITH RESPECT TO AUXILIARY EQUIPMENT AND
COMPONENTS WHICH ARE MANUFACTURED BY OTHERS.

SYSTEM 1000 General Description
The SYSTEM 1000 meter, mix, and dispense machine is a ratio proportioning pump designed
specifically to meter two liquids or pastes in a precise ratio. The volumetric positive displacement
piston pump referred to as the Posiload pump is a unique development in the course of pump
design, and because of the ability to interchange pump metering tubes from 10 mm to 55 mm in
0.001 mm increments, allows the selection of many fixed ratios.
The Posiload pump can be used for transfer of precise ratios, metering to a hand held or fixed head
mixer, or injection of the metered materials through a mixer into open or closed molds.
The complete system is totally enclosed and mixing of the liquids only takes place at the final
stage of the equipment within the mixing chamber. Flushing is achieved by an air and solvent
purge system or with one material component with a secondary component bypass.
It is recommended that this manual be read thoroughly by all personnel charged with the
responsibility of operating, maintaining, or cleaning the equipment.
CAUTION
Due to the precise nature of the SYSTEM 1000, we recommend consulting
Henkel’s technical service department
@ (800) LOCTITE before making any major adjustments.

3
Diagrams of Common Valves and Parts
The below diagrams depict common 2-way and 3-way ball valves and the handle styles are likely
to be encountered on this machine. Also, shown in the following diagrams are miscellaneous parts
likely to be used by this machine. These diagrams are for reference only and may not show all
types and styles of ball valves and other parts.
The 2-way ball valves are shown in the OPENED and CLOSED positions. The 3-way ball valves
are shown in both flow direction conditions (see arrows). In some cases, a 3-way ball valve may
be adjusted to a NEUTRAL position, 90 degrees from the positions shown below. These
NEUTRAL positions may or may not stop flow through the valves and should not be used as
operating positions unless specified elsewhere in this manual. In some cases this machine may
contain a 3-way diverted ball valve which will appear identical to the 3-way ball valves shown
below. In the case of a diverted ball valve, the handle only turns 90 degrees (not 180 degrees) and
there is no NEUTRAL position.
Figure 1-Common Ball Valves

4
Figure 2-Common Valves and Parts Cont.

5
Machine Features
Logic Features:
PUMP MODE Switch
The PUMP MODE switch is used to provide power to the machine.
OFF: The pumps will not operate when pressing the start device.
ON: The pumps will operate when the start device is pressed.
PUMP AIR PRESSURE Gauge and Regulator
The PUMP AIR PRESSURE regulator controls how much air pressure is fed to the air
cylinder, driving the pumps. Turning the center knob of the regulator locks or unlocks
the outer regulator knob. Turning the center knob clockwise will lock the regulator in
place. Turning the center knob counterclockwise will unlock the regulator and allow
adjustment. Turning the outer knob clockwise increases pressure, which permits the air
cylinder to cycle more rapidly and pump more material in a given time. Turning the
outer knob counterclockwise decreases pressure, which limits the air cylinder's cycle rate
and therefore pumps less material in a given time.
The PUMP AIR PRESSURE can be monitored on the PUMP AIR PRESSURE gauge.
Dispense Valve Trigger
This device is used to initiate a pump cycle. Throughout this manual, the Dispense Valve
Trigger will be referred to as the start device.
When pressing and releasing the start device causes the machine to cycle once then stop.
Pressing and holding the start device causes the machine to cycle as long as the start
device is held.
Other Features:
Ratio Check Ball Valve Assemblies
At each pump outlet, after the check valve, is a ratio check ball valve assembly. Each
assembly consists of two ball valves, a tee fitting, a couple of elbows, and some other
miscellaneous fittings to connect them all together. One of the elbows will have a plastic
nozzle threaded to one side. This is the ratio check outlet. The ball valve connected to
this outlet (the lower of the two) is the ratio check ball valve. The other ball valve (the
higher of the two) is the material hose ball valve.
Air Dryer (Desiccant)
Used to feed dry air to material reservoirs to prevent moisture contamination.

6
Reassembly and Installation
The Posiratio Mini SYSTEM 1000 machine is completely factory assembled and tested.
However, due to packing convenience, some on-site reassembly may be required.
1. Turn the PUMP MODE switch to the OFF position.
2. Close all ball valves.
3. Fill the lubricating device with grease.
4. Place an air shut off valve between the main air supply and the machine.
5. Connect a 3/8" or large diameter air supply line.
This should deliver a minimum 1 cfm at 80 psi for the machine to cycle up to 10 times per
minute, or 3 cfm at 80 psi for the machine to cycle up to 30 times per minute. Refer to the
machine logic drawing for more detailed information.
The maximum air input to the machine is 100 psi. If plant air exceeds 100 psi, use an in-line
regulator.
6. Connect the material hoses to the proper ratio check ball valve assemblies. Secure the
remaining ends in the inlet ports of the dispense valve.
7. If the machine; is equipped with mild steel and stainless steel pump assemblies, make sure the
hose fitting material matches the pump material.

7
Figure 3-Stroke Adjust
Adjusting the Shot Size
The RETRACT limit switch enables the
machine logic to retract the air cylinder and
pumps when tripped. Follow these
instructions to adjust the position of this
switch for your desired shot size.
Loosen the knurled knob securing the
RETRACT limit switch.
1. Unlock the vernier Stroke Adjust lock
by sliding the lever to the left.
2. Turn the vernier Stroke Adjust lock knob until the RETRACT limit switch is in the desired
position.
If the RETRACT limit switch is set to a point BEFORE the opening of the metering tubes,
no material will dispense.
3. Lock the vernier Stroke Adjust lock by sliding the lever to the right.
4. Tighten the RETRACT limit switch.
The Variable SYSTEM 1000 will produce the most accurate ratio only if between 15% and
100% of the maximum shot. Smaller shot sizes may produce less accurate ratios.
Retract Limit Switch

8
Loading the Machine with Materials
A Gravity Feed Tank uses the force of gravity to draw material into the pump.
Test all machine features and controls before loading material for the first time.
1. Remove the lid from the material reservoir.
2. Slowly pour or ladle the material into the tank, down the sidewall preferably, to entrap as little
air as possible.
3. Allow sufficient time for any air to vent from the pump.
4. Replace and secure the material tank lid.

9
Priming the Material Valves
Load the machine with materials described above before proceeding.
1. Turn the PUMP MODE to OFF and adjust the pump air pressure to 0 psi.
2. Set the STROKE ADJUST for a large shot.
3. Position a waste container under the material nozzles.
4. Turn the PUMP MODE to ON and slowly increase pump air pressure until the machine
begins to cycle.
Increase pump air pressure slowly to control thin viscosity material.
5. Look across both nozzle outlets: once air-free material is flowing, turn the PUMP MODE to
OFF.
Air may get trapped between the flowing material and the material hose ball valves.
This trapped air could cause inaccurate ratio checks and pump phasing.

10
Phasing the Pumps
1. Turn the PUMP MODE to OFF and adjust pump air pressure to 0 psi.
2. Place clean containers under the material nozzles.
3. Turn the PUMP MODE to ON and slowly increase pump air pressure until the machine
begins to cycle.
Increase pump air pressure slowly to control thin viscosity material.
4. Look across both nozzle outlets, when material begins to flow, turn the PUMP MODE to
OFF.
If material does not start flowing simultaneously, both pistons
are not entering the metering tubes at exactly the same time.
5. Repeat the above steps until the material begins to flow from both material outlet ports at
exactly the same time.
6. If the material from the A pump flows before the material from the B pump,
a) Loosen the jam nut and set screw.
b) Rotate the shaft of the B piston counterclockwise a quarter turn with an open-end wrench
positioned on the wrench flats.
c) Cycle the machine again and, as before, look across both outlet ports.
7. If the material in the B pump begins to flow before the material in the A
pump(overcompensation),
a) Rotate the shaft of the B piston clockwise in quarter-turn increments
b) Cycle the machine again and, as before, look across both outlet ports.
Always retighten the jam nuts and set screws, securing both pump shafts in the phased piston.

11
Ratio Check
Phase the pumps before proceeding.
Since your machine is designed to process two components, it is important to monitor the actual
ratio of "A" material to "B" material that is being dispensed. Metering pumps are mechanical
devices that have seals, O-rings, pistons, metering tubes, check valves and a variety of components
that are subject to wear and/or failure. This can result in metering error and off-ratio material
being dispensed. The ability to monitor for a potential off-ratio condition and its subsequent quick
repair is essential in keeping rejects and production downtime to a minimum.
It is difficult to determine exactly when certain components will wear out resulting in an off-ratio
condition. Ratio checking or monitoring is thus mandatory to provide the quality assurance most
industry demand of manufacturing processes. The conducting of ratio-checking tests and proper
recording of results is an important preventive maintenance procedure. The frequency of doing
ratio checks depends on many factors. It is recommended that a schedule be set and maintained to
provide the quality assurance factor needed. A ratio check log is included with this manual to
record the date, time, and various machine settings for each ratio check procedure. When
completed, this ratio check record can be stored in a separate three-ring binder to serve as a
maintenance reminder and trouble shooting aid. It is recommended that three sets of samples be
taken for each ratio check.
A ratio check is simply a procedure where individual samples of "A" and "B" material are
collected, weighed, and compared to the manufacturers specification sheet for uniformity. To
perform a ratio-check, proceed as follows:
1. Turn the PUMP MODE to OFF.
2. Adjust the pump air pressure to 0 psi.
3. Set the STROKE ADJUST for a large shot.
4. Weigh six small empty cups and label as indicated. Record on the Ratio Check Form.
5. Place clean containers under the material nozzles and cycle the machine once, dispensing a
shot of material before taking ratio samples.
6. Place cups A1 and B1 under the material nozzles.
7. Turn the PUMP MODE to ON and slowly increase the pump air pressure until the machine
completes one cycle. Machine should complete one cycle and then stop. A shot of metered
material will dispense into each cup. Proceed in the same manner with all three sets of
cups.
Increase pump air pressure slowly to control thin viscosity material.
8. Turn the PUMP MODE to OFF.
9. Reweigh all six cups and record results on the Ratio Check forms.
10. Complete the ratio calculations. If significantly different, see the Troubleshooting section.
11. See the Ratio Adjustment section, if you want to adjust your ratios.

12
Ratio Adjustment
NOTE: If your System 1000 is a fixed ratio machine continue to the next page.
If the ratio samples obtained in the Ratio Check section are very close to each other, but outside
the manufacturer tolerances, then you need to adjust the ratio.
1. Reduce the air pressure to 0 psi.
2. Lift the control console by turning the quarter-turn fastener counterclockwise.
3. Turn PUMP MODE to ON.
4. Slowly increase air pressure until the ratio block becomes parallel with the ratio beam. It
maybe needed to manually align the ratio block and ratio beam.
5. Quickly reduce the air pressure to 0 psi.
Never adjust the ratio by moving the pump shaft.
6. Loosen the socket head cap screws located on the ends of the ratio beam.
7. Slide the ratio beam and variable ratio pointer so that the pointer moves freely, but in small
increments, in the direction closest to your ratio. Repeat until the desired ratio is reached.
8. Tighten the two socket head cap screws locking the ratio beam.
9. Turn PUMP MODE to OFF.

13
Daily Operation
1. Turn the PUMP MODE to OFF and adjust the pump air pressure to 0 psi.
2. Position waste containers under the material nozzles.
3. Turn the PUMP MODE to ON.
4. Press and hold the start device.
5. Adjust the pump air pressure until the machine cycles slowly.
Increase pump air pressure slowly to control thin viscosity material.
6. Allow machine to cycle until all signs of air have disappeared.
7. Once air-free material is flowing from the material nozzles, release the start device.
During production, the flow can be controlled by simply pressing and releasing the start device.
Remember, as pump air pressure increases, so does the material flow rate.

14
Shutdown
1. Turn the PUMP MODE to OFF.
2. Adjust the pump air pressure to 0 psi.
3. Disconnect the main air supply.
4. Bleed air from the machine by pushing off-center the valve stem on the bottom of the air
filter. This also empties the filter of water collected from the air supply.
5. Remove mix nozzle, purge machine with 3-5 complete strokes. Remove lower portions of
valve body, clean nose assembly and upper spools with solvent and cotton swabs (ensure nose
assembly is clear of product), wipe rods, spools, and seals clean of all material and lubricate
with compatible lubricant. If clean re-assemble and lubricate valve through grease fitting. If
not completely clean, soak in solvent until next production day, clean loosened particles
again, re-assemble and grease.
Water contamination will dramatically shorten, if not end, pneumatic valve life!

15
Piston Replacement
1. Set the STROKE ADJUST for a full shot.
2. Turn the PUMP MODE to OFF.
3. Reduce the pump air pressure to 0 psi.
4. Place clean containers beneath the material nozzles to collect recyclable materials.
5. Turn the PUMP MODE to ON
6. Press the start device slowly increases pump air pressure until the machine begins to cycle.
Increase pump air pressure slowly to control thin viscosity material.
7. Look across both material outlets; when both pumps are empty, turn PUMP MODE to OFF
and reduce pump air pressure to 0 psi. Traces of material will remain in the bottom of the
pump, even when flow ceases.
Before proceeding, note the location of the O-rings and the metering tube tapered edge.
8. Remove the four screws from the front of the metering tube retaining plate.
9. Remove the metering tube, piston, and O-rings.
10. Turn the PUMP MODE to ON
11. Press the start device and slowly increase pump air pressure until the piston moves forward
close to the end of the open pump housing.
12. Quickly return pump air pressure to 0 psi.
13. Remove and replace the piston, locknut, and washers. Tighten the locknut until the piston
cannot be rotated by hand. Then tighten an additional quarter-turn more.
14. Turn the PUMP MODE to OFF and increase the pump air pressure to the previous level.
15. Lubricate the new metering tube O-rings.
16. Reinstall the metering tube and retaining plate. Perform all Loading, Priming, Phasing, and
Ratio Check procedures before resuming production.

16
Periodic Maintenance
Daily
Air Filter Check air circuit water trap valve and release any water, as
necessary, through the base outlet.
Air Lubricator Check that bowl has oil level above the bottom of the pipe
within the bowl and refill as necessary. Bleed off main air
supply before removing bowl. Flow rate of oil should be
approximately one drop per thirty cycles.
Dispense Head Remove mix nozzle, purge machine with 3-5 complete
strokes. Remove lower portions of valve body, clean nose
assembly and upper spools with solvent and cotton swabs
(ensure nose assembly is clear of product), wipe rods, spools,
and seals clean of all material and lubricate with compatible
lubricant. If clean re-assemble and lubricate valve through
grease fitting. If not completely clean, soak in solvent until
next production day, clean loosened particles again, re-
assemble and grease.
Pump Shafts Clean both pump shafts with solvent and lubricate them with
Mesamoll.
Material Reservoirs Check material levels in reservoirs and refill as necessary.
Ratio Take three consecutive ratio check samples and compare the
data of each sample for repeatability.
Lubricating Device Fill the lubricating device with grease.
Weekly
Dispense Head Remove mix nozzle, purge machine with 3-5 complete
strokes. Remove lower portions of valve body, clean nose
assembly and upper spools with solvent and cotton swabs
(ensure nose assembly is clear of product), wipe rods, spools,
and seals clean of all material and lubricate with compatible
lubricant. If clean re-assemble and lubricate valve through
grease fitting. If not completely clean, soak in solvent until
next production day, clean loosened particles again, re-
assemble and grease.
Machine Exterior Generally clean the machine exterior.
Shaft Seal Area Clean around the shaft area. If dripping excessively, replace
shaft seal.