operation manual ˇ˙ ˆˇ˘ - wiwa llc

Operation manual

Originalbetriebsanleitung1302_Herkules_DBK_en • ski

WIWA AIRLESS HERKULES

Type: 35061 35075 48046 48057 60028 60036

Serial-No._ _ _ _ _ _ _ _

Translation of the original operation manual Airless 3•Herkules_BAoDB_en_1201•ski

1.1 Table of contents1 Contents 31.1 Tableofcontents 31.2 Preface 41.3 Firstread,thenstart 4

2 Safety 52.1 Descriptionofsymbols 52.2 Warninginstructionslocatedonthemachine 52.3 Dangersarisingfromtheequipment 52.4 Applicationofthemachine 62.5 Machinesurroundings 62.6 Sourcesofdanger 72.7 Operating staff 82.8 Installation site 82.9 Behaviorincaseofemergency 92.10 Safetyfeatures 92.11 Pumphandlingandauxiliarymaterials 102.12 Transporting 10

3 Component description 11

4 Erection and assembly 12

5 Start-up 145.1 Firstcleaning 145.2 Checkingpressure 15

6 Operation 166.1 Equipmentpreparation 166.2 Sprayoperaton 176.3 Changeofmaterial 17

7 Shutting down 18

8 Processing Instructions for 1K PFP-Unit 19

9 Maintenance 229.1 Regularinspections 229.2 Maintenanceplan 229.3 Highpressurefilter 229.4 Maintenanceunit 23

10 Malfunctions and troubleshooting 25

11 Appendix 2611.1 Technicalspecifications 2611.2 Auxiliarymaterials 2611.3 Machinecard 2711.4 Certificateoftrainingandoperation 27

Contents 1

4 Translation of the original operation manual Airless •Herkules_BAoDB_en_1201•ski

1 Contents

1.2 Preface This User’s Handbook must always be avai-lable to operating staff The operating authority of the equipment must ensure, that a user`s handbook is available to the operator, in a language which he unders-tands.

Dearcustomer!Thankyouforyourdecisiontopurchase equip-ment.Intheuser’shandbook,youcanfindallinformationrequi-redfortheproperhandlingofyour AirlessPaintSprayingMachine.However,forsafeoperation,therearefurtheressentialdetailswhichyoushouldadhereto:Pleasereadandobservetheguidlinesvalidforyourcountry.InGermany,the"Richtlinien für Flüssigkeitsstrahler"(Guidelinesforfluidsprayers)publishedby:HauptverbandderGewerblichenBerufsgenossenschaften(IndustrialEmployer'sLiabilityInsuranceAssociation),arevalid.Manufacturer’snotesandoperatingguidelinesforcoatingandpumpingmaterialsshouldbeobservedatalltimes.Nomethodofoperationshouldbeexercisedwhichimpairsthesafetyof productsandtheoperatingperson-nel.Wewishyoumuchsuccessandexcellentworkingresultswhenappliyingyour AirlessPaintSprayingMachine.WIWA Wilhelm Wagner GmbH & Co. KG.

Copyright©2009WIWA

CopyrightownershipforthisusermanualremainswithWIWAWILHELMWAGNERGmbH&Co.KGGewerbestr.1-3•35633LahnauPhone:+49(0)6441609-0•Fax:+49(0)6441609-50E-mail:[email protected]•Internet:www.wiwa.de

Thisoperatingmanualissolelyintendedforpersonnelinvolvedinprepa-ration,operationandservicing.Itisprohibitedtopassonthisoperatingmanualforreproduction,utili-sationorcommunicationofitscontents,unlessthishasbeenexplicitlypermitted.Infringementsincuranobligationtopaydamagecompensati-on.Allrightsreservedintheeventofregistrationofthepatenteddesign,industrialdesignorregistereddesign.

Thisoperatingmanualonlyappliesinconjunctionwiththemachinecardthatwasgiventoyouwiththeusermanualforyourequipment.Pleasecheckthatthetypeplatedataisidenticalwiththeinformationonthemachinecard.Pleasenotifyusimmediatelyiftherearediscrepancies,iftheusermanualhasbeenincorrectlycompiledorifthetypeplateismissing.

1.3 First read, then startRememberthatAirlessPaintSprayingEquipmentworksunderextremepressureandthathighlevelsofsprayingpressurearecreated! Neverholdyourfingerorhandinfrontofthegunandneverreachintothespray.

Neverpointthesprayguntowardsyourself,otherpeo-pleorotherlivingcreatures.

Alwayspaycloseattentiontothereferencesandspe-cificationsfoundintheuser'shandbook!

Before each usage, be especially certain to: Checkthegroundingconditions(fortheunitandtheobjecttobesprayed).

Checkthesealofallconnectingandmountedparts. Observethemaximalallowedpressureoftheunitandaccessoryparts.

Beforebeginning any work on the equipment and at any pause during operation, be absolutely required to: Turnoffthesprayingequipmentattheairpressurestopvalve.

Releasethepressurefoundinthesprayinggunandhose.

Securethesprayinggun.

Pay attention to safety!Theaccidentpreventionregulation"HandlingofCoatingMaterials"(BGVB3)andtheguidelinescoveringfluidsprayersZH1/406fromtheGermanEmployer'sLiabilityInsuranceAssociationaretobeobservedwithoutfail.Toensureasafeoperatingenvironment,theconditionoffluidsprayersmustbeinspectedbyanexpertevery12monthsorsooner,ifdeemednecessary.Awrittenrecordoftheinspectionresultsistobekept.

Remainingpaintandsolventaretobedisposedofac-cordingtolegalregulations.Thisalsoappliesforenviron-mentlyfriendlywaterlacquerorenamelsystems.

Incaseofinjuries,consultaphysicianorgotothenexthospitalwithoutdelay.Ifpaint/materialorsolventhasgoneintotheskin,thephysicianhastobeinformedaboutthetypeofpaint/materialorthesolventapplied.Therefore,alwaysensurethattheproductspecificationsheet,withaddressandtelephonenumberofthemanufacturer,isatyourdisposal!


2.1 Description of symbolsThesignsandsymbolsusedinthisUser'sHandbookhavethefollowingmeaning:

NOTEThismarksasectionoftextwhichisespeciallyre-levanttosafety.Specialattentionshouldbepaidtothissectionandthecontentsstrictlyobserved.

SMOKING PROHIBITEDThismarksasituationinwhichafirehazardarisesthroughtheuseofflammableorexplodablesolid,fluidorgaseousmaterials.

WARNINGThismarksasituationwhichcouldbedangerous.Ifnotobserved,deathorveryseriousinjuriescouldresult.

DANGER OF EXPLOSIONThismarksasituation,wherethereisdangerofexplosion.Observationofthisinformationisabso-lutelyessential.

ELECTRICAL VOLTAGEThismarksasituation,wherethereisadangerofexplosionthroughanelectostaticcharge.Observationofthisinformationisabsolutelyessential.

USE EAR PLUGSForhealthreasons,itisveryimportanttopayattentiontothiswarning.

USE BREATHING PROTECTIONForhealthreasons,itisveryimportanttopayattentiontothiswarning.

HEALTH DANGERThismarksmaterialswhicharehazardoustoyourhealth.Observationofthisinformationisabsolutelyessential.

FIRST AIDIncaseofinjuriesoraccidents,theseinstructionsshouldbeabsolutelyadheredto.

2.2 Warning instructions located on the machine

Warningsignsandsymbolswhichhavebeenplacedonthemachinearetheretoinformofpossibledangersandmustbeobserved.

Warningsignsandsymbolsmaynotberemovedfromthemachine.Damagedandillegiblewarningsignsandsymbolsaretobereplacedimmediately.

The following signs are located on the machine: Onthehighpressurefilter:Warningsigncoveringthegroundingofthemachine (picture2.2.1)

The propietor is re-quired according to the German Accident Prevention Regulation(Unfallverhütungsvorschrift), BGR 500, Kap. 2.29, to ensure that the machine is proper-ly grounded. Please, observe our instruction manual.

On the material pump cylinder: Nameplate (picture2.2.2) Pleaseobservethattheinformationlocatedonthenameplatecorrespondstodatafoundonthemachinecard.Werequestimmediatenotificationshouldtherebeanydiscrepanciesorifthenameplateismissing.

Picture2.2.2 Safetyinformation This sign lists the most importantsafetyguidlinesforoperatingthispieceofequipment. Pleasereadthisinforma-tioncarefullyaswellasadheringtoallinstructionslocatedinthisUser'sHandbook!

2.3 Dangers arising from the equip-ment

Thismachinewasdesignedandbuiltinaccordancewithallsafetyaspects.Itcorrespondswiththepresentstandardsoftechnicalregulationsandcurrentrulesforaccidentprevention.

Picture2.2.1

Picture2.2.2

Picture2.2.3

Safety 2


2 Safety

Itleftthefactoryinperfectconditionandwarrantsahighlevelofsafety.However,thefollowingdangersexistifoperatedincorrectlyorusedinappropriately: tolifeandlimbofoperator orthirdpersonsor forthemachineandotherpropertybelongingtoownerofmachine

fortheefficientworkingofthemachine

Allpersonnelinvolvedinthestarting,operationandmaintenanceofthemachinemustreadthefollowingnotescarefullyandobservethem.Itisamatteroftheirsafety!Werecommendthatthemachineoperationmanagementhavethisconfirmedinwriting.

2.4 Application of the machineTheseunitshavebeendesignedtospraylacquersandvarnishes,paints,high-viscosity,coarselypigmentedtwo-componenttarandepoxymaterials,bitumen,high-builtmaterials,lowsolventandsolvent-freecoatings,insulatingmaterial,antifoulings,glassflakematerials,flameresistantandfibre-filledcoatings.Theyareoptimalforcoatinglargesurfacesandprovidingthickcoatings.Aparticularadvangeoftheseunitsistheadditionalairhoseleadingtotheairmotor,whichpreventsicingfromoccuring..

Using this equipment in areas requiring protection from explosions

Marking: II 2G cT4

This equipment fulfills the explosion-proof require-ments found in the guideline 94/9/EC for the type of explosion, equipment catagory and temperature class found on the nameplate). ThisequipmentisabletobeinstalledinareasrequiringZoneIexplosionprotection.Duetothepossibilitythatex-plosivegasesandoverspraymaybecreated,thisunitistobeconsideredasGroupII,EquipmentCatagory2G.Theflashpointforthematerialsbeingsprayed,aswellasthesolventbeingused,mustbeabove200°C.Whenoperatingthisequipment,theUser‘sHandbookmustbefollowedclosely.Therequiredinspectionandmaintenanceintervalsmustbeadheredtostrictly.All information found on the unit‘s signs or plates must be adhered to and not exceeded. Do not allow this unit to be overloaded. Itistheresponsibilityoftheoperatorofthisequipmenttodeterminetheexplosionrisk(zonedeterminationaccordingtoECregulation94/9/EC,AppendixII,Nr.2.1-2.3)intheareaofusage,inaccordan-cewithlocalregulatoryauthorityguidelines.Furthermo-re, it is the responsibility of the operator on-sight to check and ensure that the technical specifications and

markings according to ATEX are compliant with local requirements.PleaseobservethatsomecomponentshavetheirownnameplatewithseparatemarkingsaccordingtoATEX.The marking with the lowest rating for explosion protection becomes valid for the entire system. If the intendedapplicationcouldleadtoinjuryofpersonnelifthisequipmentmalfunctions,on-sightprecautionsandpreven-tivemeasuresmustbeimplementedIf this equipment appears to be malfunctioning or behaving strangely during operation, the unit must be shut down immediately and Customer Service contacted as soon as possible.

Itmustbeensuredthattheunitisgroundedeitherseparatelyortogetherwiththeequipmentitismountedto(maximumresistance106Ω,picture2.4.1ground/potentialequalization).

Spayingmachineswhicharenotprotectedagainstexplo-sionsmaynotbeusedinworkplaceswhichfallundertheregulationcoveringexplosionprotection.Pneumaticallydrivenairlesssprayingmachinesarenotaffectedbythis.Should,however,additionalelectricallydrivenaccesso-riesbemountedtothesemachines,suchasagitatorsorheaters,theregulationcoveringexplosionpreventionmustbecheckedforcompliance.Plugsforheaters,agitators,etc.whicharenotprotectedagainstexplosionsmayonlybepluggedintosocketsloca-tedoutsideofareasthatfallundertheregulationcoveringexplosionprevention,eveniftheaccessorybeingusedisexplosionprotected.

Otherusageisnotinlinewithregulations.Beforeequipmentisusedforotherpurposesorwith

othermaterials,and,therefore,notaccordingtotheregu-lations,permissionshouldbeobtainedfromthemanufac-turer,astheguaranteeisotherwiseinvalid.Theobserva-tionoftechnicaldocumentationandthecompliancewithspecifiedoperational,maintenanceandstartingguidelinesaremanditoryinaccordancewiththevalidregulations.

2.5 Machine surroundingsRebuilds and changesForsafetyreasons,itisnotallowedtocarryoutrebuildsorchangeswithoutauthorization.

Picture2.4.1


Warning!Unintentionaltriggeringofthesprayguncanleadtoinjuryordamagetoproperty. Alwaysapplythespraygunsafetycatch,regardlesshowshortthepauseinsprayingis.

Beforeoperation,alwayscheckthefunctionofthespraygunsafetycatch.

Warning!Componentsthatdonotcorrespondtothemaximumpres-surecreatedbythepumparequicklypronetorupture,leadingtoseriousinjuries. Fluidhosesmustberatedtocorrespondtothemaxi-mumoperatingpressureoftheunit,withanappropri-atesafetyfactorallowance.

Nohosesmayshowsignsofleaks,kinks,wearorblisters.

Allhoseconnectionsmustbetight.

Themaximumoperatingpressurestatedbyusmustcorrespondtoall componentsandacces-soryitemswithinthesystem(i.e.pumps,heaters,hoses,sprayguns,safetyvalves).

Ifthepressureratingsdiffer,thelowestratedmax.pres-surebecomesvalidfortheentiresystem.Example:Pump max.420bar(6090psi)Fluidhose max.600bar(8700psi)Spraygun max.500bar(7250psi)Themaximumallowableoperationpressurefortheentiresystemis420bar(6090psi).

Warning!Ifusedoutdoors,alightningstrikecouldleadtoinjury. Neveroperatetheunitoutdoorsduringathunderstorm.

Warning!Itispossibleforastaticchargetooccurduetothehighflowspeedsduringtheairlesssprayingprocedure.Staticchargescanleadtofireandexplosions.Alwaysuseanopencontainer. Never spraysolventsormaterialscontainingsolventsintonarrow-neckedcansorbarrelswithbungholes!

Ensurethatthespraygunhascontactwiththecontai-nerwallswhenworkingwithmetalcontainers.

Danger of explosion!Heatedsolventcanleadtoanexplosionwithinthepump.Thiscouldresultinseriousinjuries,includinglossofvi-sion,andpropertydamage.Alwaysobservetheflashpointandignitiontemperatureforthesolventbeingused!

Protectiveequipmentmaynotbedismounted,changedorneglected.Ifusingcomponentswhicharenotproducedordeliveredby ,warrantycoverageisnegatedaswellasliability.Themachinemayonlybeoperatedwithintheprescribedlimitsandmachineparameters.

Danger caused by attachments and spare partsIfyouuseoriginalattachmentsandoriginalsparepartsfrom ,thecompatabilitywithourequipmentisguaranteed.Itis,however,essentialthatthesafetyregu-lationsoftheattachmentsandsparepartsareobserved.YoucanfindthesesafetyregulationsintheUser’sHand-booklocatedwiththesparepartslists.Ifyouuseattachmentsandsparepartsfromanothersour-ce, cannotguaranteethesafetyoftheentiresystem.Inthiscase,ourguaranteedoesnotcoveranydamageorinjurycausedbysuchattachmentsandspareparts.

EmissionsItispossibleforsolventvapourstooccur,dependingonthematerialsused.Therefore,pleaseensurethework-placeissufficientlyventilatedinordertoavoiddamagetohealthandproperty.Alwaysobservetheprocessinginformationgivenbythematerialmanufacturer.Thesoundpressureleveloftheequipmentisbelow85db(A).Nevertheless,appropriatemeansofnoiseprotectionshouldbemadeavailabletotheoperatingstaff.Theoperatorisresponsibleforcompliancewiththerulescoveringthepreventionofaccidentsdueto„noise“(BGVB3).Therefore,payspecialattentiontotheenvironmentalconditionsatthesite,e.g.noisecanbeincreasedifthemachineisinstalledinoronhollowbodies.ExactdetailsregardingnoiseemissionarementionedintheChapter"Technicalspecification".

2.6 Sources of dangerRememberthat AirlessPaintSprayingMachineworkunderextremepressureproceduresandthattheycancauselife-endangeringinjuriesifusedinappropriately.

Warning!Materialexitsthespraygunatveryhighpressurelevels.Thesprayjetcancutorbeinjectedundertheskinoreyes,resultinginseriousinjuries. Never pointthesprayguntowardsyourself,otherpeopleorotherlivingcreatures.

Never holdyourfingerorhandinfrontofthespraygunandnever reachintothesprayjet.

Safety 2


2 Safety

Turnoffthefluidheaterwheneverthefollowingworkisperformedonthepump: Flushing/Cleaning Pressurecheck Preparationforoperation Shuttingdown

Dangerouschemicalreactionscanoccurifclosedorpressurizedsystemswithaluminumorgalvanizedpumpcomponentscomeintocontactwithsolventssuchas1.1.1-trichlorethyleneormethylenechloridethatcontainhalogenatedchlorofluorocarbons(CFC).Ifsuchsolvents,orpaintsorlacquresthatcontainthem,aretobeused,werecommendcontacting CustomerServiceorthe

factorydirectlyforfurtherinformation.Pleasenotethattherearestainless-steelAirlesspumpsthataredesignedforusewithsuchmaterials.

Danger!Ifbeingoperatedinclosedrooms,explosiveatmospherescanbecreated.Thiscouldleadtoseriousinjuriesandpro-pertydamage.Smoking,usingopenfiresorotherignitablesourcesisprohibitedintheentireareaofoperation!

2.7 Operating staffAuthorised OperatorsPeopleundertheageof16shouldnotoperatethisequip-ment.Themanagementinchargeoftheoperationofthemachi-nemustmaketheUser’sHandbookavailabletotheope-ratorandmustmakesurethathehasreadandunders-toodit.Onlythenmaythesystembeputintooperation.We recommend the manager has this confirmed in writing.Theoperatorofthemachineisobligedtoreportanychangesinthemachinewhichmightaffectitssafetytothemanager,ashemustensurethatthemachineisfunctional.Theresponsibilitiesforthedifferentactivitiesonthesystemmustbelaiddownclearlyandadheredto.Nounclearcompetencesmayremainasthesecouldendan-gerthesafetyoftheusers.Theoperatormustmakesurethatonlyauthorisedpersonsworkonthemachine.Heisresponsibletothirdpartiesintheworkingvicinityofthesystem.Theoperatoroftheequipmentisobligedtorepeatinstruc-tionsaboutdangersandsafetymeasuresatregularinter-vals(atleastonceayear,foryoungpersonstwiceayear).

Personal protective equipment

Wecalltoyourattentionthatthevalidguidelinesandre-quirementsinaccordancewithworksurroundings(mi-ning,closedareasetc.)mustbeabsolutelyadheredto. Theprescribedprotectiveclothingmustbewornatalltimes,assolventvapoursandsolventsplashescannotbecompletelyavoided

Thesoundpressureleveloftheequipmentisbelow85db(A). Nevertheless,appropriatenoiseprotectionmeansshouldbemadeavailabletotheoperatingstaff.

Althoughsprayingfogiskepttoaminimumwhenthecorrectpressuresettingandpropermethodofoperationareobserved,theoperatingpaintershouldwearaprotectivebreathingmask.

Whenworkingwithheatedmaterials,theoutersurfaceofthepumpcanbecomehot. Protectiveglovesmustbewornatalltimes.

Neverusesolventorothermaterialswhichpresentahealthhazardforcleaningskin.Onlysuitableskinprotective,skincleansingandskincarematerialsmaybeused.

2.8 Installation site Thesystemmusthaveafixedpositionandsufficientspacetoensuresafeoperating.Thepassagetothesafetyfittingsmustnotbeblocked.

Keeptheworkingarea,especiallyallgangwaysandstandingareas,clean.Removespilledpaintorsolventimmediately.

Ensurethereissufficientventilationattheworkplacetopreventdamagetohealthandproperty.Observethemanufacturer’sprocessinginstructionsatalltimes.

Despitethefactthatnolegalregulationsexistcoveringthelow-fogairlesssprayingmethod,dangeroussol-ventfumesandparticlesofpaintshouldberemovedofpervaccuum.

Theowner/operatorofthisequipmentisrequiredtoensurethatproperprotectionagainstlightningstrikesisavailable.

Complystrictlywiththecurrentrulesforaccidentprevention.


2.10 Safety featuresThisequipmentisdeliveredwiththefollowingsafetyfeatures:

Safety valve (Picture2.10.1)Thesafetyvalveprohibitsthemaximumallowableinboundairpressurefrombeingexceeded.Iftheinboundairpressureexceedsthemaximumallowablevalue,thesafetyvalvewillblowoff.

Warning!The safety valve is factory mounted and sealed to the air motor. To ensure safe operation: Never remove the safety valve. Never change the safety valve setting.

Newsafetyvalvesmustcorrespondtothemaximumall-owableinboundairpressureandbesealedappropriately.Thepartnumberandmaximumallowableinboundairpressurecanbefoundinthemachinecardfortheunit.

Air tap lock (Picture2.10.2)ThecompressedairtaplockmakesitpossibletoshutAirtaplock.Thecompressedairtaplockmakesitpossibletoshutdowntheunitimmediately.

Ground cable connection (Picture2.10.3)DuetothehighflowspeedcreatedbyAirlessequip-ment,staticchargingcanoccur.Astaticchargecanleadtofiresorexplosion.

Theunitmust,therefore,alwaysbegroundedproperly.Factory-delivered Airlesssprayingequipmentcomesstandaredwithagroundcable.Iflostordefective,itmustbereplaced(partno.0474487).

Picture2.10.1

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Picture2.10.2

Picture2.10.3

2.9 Behavior in case of emergency

LeaksIf leaks occur in hoses or hose connections, material is expelled under very high pressure. This can result in very serious injuries to hands, arms or eyes. Nevertrytosealleakswithhandsorbybining Neverpatchfluidhoses. Shouldaleakoccur,thewholesystemistobeshutdownanddepressurizedimmediately: Closetheairtaplocktocutofftheinboundairsupply.

Holdthedrainhoseintoanappropriatecontainerandensurethatitcannotslip.

Openthedrainvalve. Replacethedefectivepartsimmediatelyorcontact

CustomerService.

Injuries Shouldaninjuryoccur(i.e.sprayjetcutorinjection),werecommendadoctorbecalledimmediately.

Informthedoctorofthematerialsprayed(e.g.paint)andthesolvent(thinner).Havetheproductdatasheetathand(adressandtelephonenumberofsupplierormanufacturer,nameofmaterialandmaterialnumber).

Memorizewhereaidcanbefound. Memorizethelocalemergencyphonenumbers. Becomefamilierwiththefirst-aidmeasures

Fires Readandandobservetheinstructionsforfirealarmandescaperoutesputupinyourfactory.

Donotuseanyotherextinguishingagentsthanthosewhichareprescribedbythecoatingsmanufacturer.

Safety 2


2 Safety

Activity Personnel QualificationRepairwork personneltrainedby

Customerservice

Afterworkiscompleted Checktheproperfunctionofallsafetyfeatures. Checktheproperfunctionoftheentireunit.

Handling of auxiliary materials Whenhandlingauxillarymaterialssuchaspaint,solvent,oil,greaseandotherchemicalsubstances,complywiththesafetyanddosinginstructionsofthemanufacturerandthegenerallyapplicableregulations.

Leftoversolvents,oils,greaseandotherchemicalsubstancesmustbecollectedaccordingtothelegalregulationsforrecyclingandwastedisposal.

Thelocalofficiallawsfortheprotectionofwastewatermustbeobserved.

2.12 Transporting Disconnecttheunitfromthemainairsupplyandfromanyelectricaloutletsforaccessoryitems,eveniftheunitisonlytomemovedashortdistance.

Emptytheunitbeforetransporting. Becarefulwhenusingahoisttoloadthisequipment! Ifusingahoist,ensurethattheweightcapacityisnotexceededandthatproperliftingattachmentsareemployed.

Attachthehoistsecurelytotheunit. Neverstandunderorneartheunitwhenitissuspen-ded.Seriousinjurycouldresult!

Onlyuseappropriatehoistingequipmentwithsufficientloadcapacity.

Securetheunittothetransportingvehicleinsuchawaythatitcannotslideorfalloff.

Whenliftingorloadingtheunit,donottransportanyfurtheritems(i.e.paintcansorpails)alongwithit.

Anycomponentsoraccessoriesthathadtoberemo-vedfortransportmustberemountedbyskilledandtrainedpersonnelbeforebeginningoperation

Tworingscrewsarelocatedonthemachine'sairmotor(picture2.12.1)toensuresafeliftingwithhoistingdevices.

Picture2.12.1

Spray gun safety catch (Picture2.10.4)Thespraygunsafetycatchisusedtoavoidunintentio-naltriggeringofthespraygun.Applythesafetycatch("on")atanypauseinspraying!

All safety devices must be checked: Beforecommissioningthesystem! Beforebeginningtoworkwiththesystem! Afteranymodificationshavebeenmadetotheunit! Afterflushingorcleaningthesystem! Afteranyrepairormaintenanceworkonthesystem!

Checklist for checking the safety devices with the system depressurized Checktoseewhetherthesealonthesafetyvalveisdamaged.

Checkthesafetyvalveforsignsofdamage. Checkthegroundcablefordamage. Checktheconnctionsforthegroundcableontheunitandtheconductiveobjectitisconnectedto.

Checkwhethertheairtaplockisfunctioningproperly. Checkthespraygunsafetycatchtoensureitfunctonsproperly.

Ifoneofthesafetydevicesisnotfunctioningproperlyorifanyothermalfunctionisfound,theairsupplytotheunitmustbecutoffandthedrainvalveopened.Theunitmayonlyberestartedoncetheproblemhasbeensolvedandthesystemisfunctioningperfectlyagain.

2.11 Pump handling and auxiliary mate-Pump handling and auxiliary mate-rials

Adjusting, servicing, cleaning, maintenance and repair of the unit Beforestartinganyoftheabove:

Turn off the unit Depressurizethesystem.Payattentiontoresidualpressure.

Activity Personnel QualificationAdjustingwork trainedoperatorServicingwork trainedoperatorCleaningwork trainedoperatorMaintenancework personneltrainedby

Customerservice

Picture2.10.4

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TranslationoftheoriginaloperationmanualAirless 11 11•Herkules_BAoDB_en_1201•ski

Component description 3

5

1

16

15

14

1110

9

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6

4

3

2

18

13

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17

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Positions1 savetyvalve2 t-handlescrew3 maintenanceunit4 airtap5 airinlet6 cart7 materialpump8 air motor9 airmuffler10 Releaseagent-fillerneck

11 venthole12 Releaseagent-drainscrew13 highpressurefilter14 highpressurevalve15 dumphose16 spraygun17 materialhose18 suctionpipe19 suctionhose20 fluidseive


4 Erection and assembly

JobTheunitistobeinstalledatthejobsiteandpreparedforoperation.

Prerequisite Thematerialtobeworkedwithisprepared. Allmaterialstobesprayedshouldbemarkedwithinformationonviscosity,processingtemperatures,mixingproportionsetc.Ifthisisnotthecase,pleaseacquirethisdatafromtherelevantmanufacturer.

Thematerialtobesprayedmustbeslowlybuttho-roughlystirredbeforebeginningtowork.

offersabroadselectionofaccessoriesfortheoptimisedpreparationofsprayingmaterials,i.e.: agitatorsinvarioussizes materialpre-heatingcontainersinvarioussizes fluidhester

Ifworkingwithpluralcomponentmaterials,thepotlifemustbeobserved.

Toinsurethatthenecessaryvolumeofairissupplied,thecompressorcapacitymustcomplywiththeaircon-sumptionrequirementsofthepump. Thediameteroftheairsupplyhosesmustcorrespondtotheconnectiononthepump.

Procedure1. Set up the pump

Highpressuresprayingmachinesandsystemscanbeintegratedintosprayingchamberseitherinsideoroutsideofproductionfacilities.Toavoidpossiblesoiling,anoutsideinstallationisprefe-rable.DimensionsandweightsoftheequipmentareindicatedinChapter"Technicalspecification".

Thepumpmustbesetupsecurelyonalevelandsolidsurface

Payattentiontotheinformationcoveringtherequiredfloorspacefoundinmachincard. Operatingelementsmustbeeasilyaccessible Safetyfeaturesmustbeeasilyaccessible

Wall-mounted versions: Tofixthewall-mount,useM12screws-class8.8 Besuretouseanchoringdevicesinaccordancewiththenatureofthewallbeingused.

Ensurethatatleast10cm(4in.)freespaceisleftbet-weenthesuctionelbowandtheflooraftermounting.

2. Mount accessoriesDifferentcomponentsofthemachineweredismountedandpackedinaseparatecartonforshipping:1. materialhose(picture4.1.1)2. airlesssprayinggun(picture4.1.2)3. maintenanceunit,(picture4.1.3)aswellasIfthemachineisdeliveredonatrolley,themaintenanceunitandcompressedairregulatorremainmounted..

Addthesecomponentsaspictured(pictures4.1.1to4.1.3).

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Pictures4.1.3

Pictures4.1.1

Pictures4.1.2

Warning!Material leaks at connections can lead to se-rious injury of property damage.Check all turnable parts, nuts, screws and hose connections and tighten them securely.

Checkthepermissiblemaximumairpressureforthesprayhose,spraygunandaccessories.Itmustbegreaterthanorequaltothemaximumoperationalpressureshownonthepump'snameplateoronthemachinecard.

Comparethemaximumoperatingpressureofthesa-fetyvalvewiththeinformationonthemachinecardorthetypeplate.Thisinformationmustcorrespond.


Erection and assembly 4

3. Ground the unit Warning! Due to the high flow speed created by Airless equipment, static charging can occur. A static charge can lead to fires or explosionA static charge can lead to fires or explosion. The pump and object to be coated must be

grounded properly Only use conductive hoses Note: sprayhosesareconductiveandcompatiblewith pumps.

4. Open the anti-vacuum hole Whenbeingusedforthefirsttime,thestickerwiththetext„removebeforeuse“andthesealingplugistoberemovedfromtheventilationhole(overflow). Theventilationholeislocatedintheelbowwiththeopeneingfacingdownward(picture4.2.1).

5. Check the release agent level Checkthelevelofreleaseagent-refertoChapter9.2"Maintenanceplan". Theunitisfilledwithreleaseagentpriortodelivery.

6. Maintenance unit prepare Fillthemaintenanceunitwithpneumaticoiloranti-freezeandtakethesettingasdescribedinchapter9.4"Maintenanceonthemaintenanceunit.

ResultThemachineisnowreadyforoperation.Continuewiththefirstcleaning(chapter5.1).

Pictures4.1.4


5 Start-up

3. Connect the compressed air line (Picture5.1.1) Closetheairtaplock. Turnthecontrolknob

on the air pressure regulatorcounter-clockwiseuntilitturnsfreely.

Connecttheairsupplylinetotheinboundairconnection.

4. Remove the filter insert Removethefilterinsertfromthehighpressurefilterinaccordancewithchapter9.3.

Holdthedrainhose(Picture5.1.2,Pos.2)intocontai-ner"B"andsecureitagainstslipping.

Opentherelieftaponthehighpressurefilter(Picture5.1.2,Pos.1).

Openthemainairsupplytap.(Picture5.1.1). Adjusttheairregulatortoamaximumof2bar(30psi)byslowlyturningtheregulatingscrewtotheright.

AllowtheWashThinner,soiledwiththetest-medium,torunoutofthereliefhoseintotheopencontainer„B“ foratleast10seconds.

Close the relief tap (Picture5.1.2,Pos.1).

Recommendedcleaningtime:

Picture5.1.2

mind. 10 secondsmax. 2 bar (30 psi)

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Picture5.1.1

P-

5.1 First cleaningJobThismachinewasfactorytestedafterassemblyforperfectfunctioningwithatest-medium.Theentiresystemshouldbeflushedwithwashthinnerbeforesprayoperationbeginssothatthematerialtobesprayedisnotaffectedbythetest-medium.

Prerequisite Required:

1opencontainerwithcleaningmaterial(atleast5liters/1.3gal.ofwashthinnerorsol-vent),calledcontainer"A"below.

1empty,opencontainerforthemixtureofcleaningmaterialandtest-medium,calledcontainer"B"below.

Please,checkwhetherthematerialhosescomplywiththemaximumworkingpressureandtheprescribedsafetyfactor.Theyshouldnothaveanyleaks,kinks,signsofwearorbulges.Thehosefittingsmustbesecurelyattachedandalsocomplywithmaximumpressure.

Whenusingafluidheater,please,besuretoobservethatitiscoldduringthecleaningprocess.

Please wear protective clothing at all times, as solvent vapours and splashes of solvent cannot be avoided completely.

Procedure1. Prepare the spray gun for operation Closeandapplythesafetycatch. Removethetipfromthespraygun. Observeandfollowtheinstructionsfoundinthespraygun'sUser'sHandbook.

Attachthematerialhosetothesecuredairlessspraygun.

Connectthematerialhosewithattachedgun(withoutthenozzle)totheoutletofthehighpressurefilter.

2. Prepare the solvent container Placethesuctionpipewithstrainerintothe"A"contai-ner.


5. Clean the spray gun Holdthespraygunintocontainer"B". Sprayforaminimumof10secondsagainsttheinnerwallofthecontainer. Ensurethatthespraygunhascontactwiththecontainerwallswhenworkingwithmetalcontainers.

We recommend a cleaning period of approx. one minute for a good cleaning result. In order to avoid the danger of explosion caused by the heating of cleaning material, it should not be pumped for longer periods (a maximum of 5 minutes) of time.

5. Openthede-icingsystemonairmotor Activatethede-icingsystembyslowlyturningthecon-trolscrewtotheright(availableoption).

Werecommend: minimum1completeturn maximum3completeturns

Adjustthede-icingsystemaccordingtoyourindividualrequirements,asfactorssuchaspres-sure,numberofcyclesperminute,humidityandambienttemperaturecanaffecttheamountofairthatisrequiredtoavoidicebuild-up.

ResultThemachineisnowcompletelycleansed.Continuewiththepressurecheck(foundinchapter5.2)

5.2 Checking pressureJobYouwanttoinspectthesealallsystemcomponents.

If using a fluid heater, the heater may not be turned on at any time while making the pressure test. The entire machine must be cooled completeley.DANGER OF EXPLOSION! Observe the flash point for the solvent being used!

Procedure1. Close the spray gun Closethespraygunandapplythesafetycatch.

2. Set the maximum pressure Setthemaximumallowablepressurebyturningtheairpressureregulatorcontrolknobclockwise(Picture5.1.1).

Start-up 5

Observethemaximumallowableoperatingpres-sureforallsystemcomponents.Iftheratingsvary,thelowestpressureratingbecomesthemaximumallowablepressurefortheentiresystem(refertotheexambleinChapter2.6).

3. Check the safety valve Brieflyraisethepressureapproximately10%abovethemaximumallowableinboundairpressure. Thesafetyvalvemustblowoff

4. Check the seal of the system components Checkthesealofthefollowingcomponents:

Sprayhose Spraygun High-pressurefilter Connections

5. Pump out the remaining solvent in the system Turntheairpressureregulatorcontrolknobcounterc-lockwiseuntilthepumponlyrunsveryslowly.

Removethesuctionpipefromthecontainer"A". Holdthespraygunintocontainer"B". Disengagethesafetycatchandopenthespraygun. Pumpanyremainingsolventoutofthesystem. Turntheairpressureregulatorcontrolknobcounterc-lockwiseuntilitturnsfreely.

Closetheairtaplock. Closethespraygunandapplythesafetycatch. Holdthedrainhoseintocontainer"B"andsecureitagainstslipping.

Depressurizethepumpbybrieflyopeningthedrainvalve/drainscrewonthehigh-pressurefilter.

ResultTheunitisnowreadyforoperation..


6 Operation

4. Feed preparation / Bleeding air from the unit Placethesuctionpipeintocontainer"C". Holdthedrainhoseintocontainer"B"andsecureitagainstslipping.

Openthedrainvalveonthehigh-pressurefilter. Opentheairtaplock. Turntheairpressureregulatorcontrolknobclockwiseuntilthepumpslowlycycles.

Assoonascoatingsmaterialcomesoutofthedrainhose,closethedrainvalve/drainscrewtightly.

Disengagethesafetycatchandtriggerthespraygun. Spraytheremainingsolventintheunitintocontainer

"B"untilonlycoatingsmaterialexitsthegun. Closethegunandapplythesafetycatch. Cleanthegunoutletwithsolventandabrush. Mountasprayingtiporareversibleguardwiththeappropriatetip.

ObserveandfollowtheinstructionsfoundintheUser'sHandbookforthespraygunbeingused.

RISK OF EXPLOSION! When using a fluid heater, the following steps must be stricktly adhered to: Before allowing the fluid heaters to heat,

the materials to be sprayed must be cir-culated in a cold condition as there may be solvent residue in the fluid heaters or somewhere else in the systems.

Be certain to ensure that the fluid heaters are turned off during preparation.

Always observe the flash point of the sol-vent being used as stated in the manufac-turer's data sheet!

Settherequiredoperatingpressurebyadjustingtheairpressureregulatorcontrolknobaccordingly.

ResultTheunitisnowreadyforcoatingsoperation.BeginsprayingaccordingtoChapter6.2.

6.1 Equipment preparationJobPreparetheunitforoperation.


1opencontainerwithcleaningmaterial(sol-ventbelongingtothecoatingmaterialandrecommendedbythematerialmanufacturer),calledcontainer"A“below

1empty,opencontainerforthesoiledcleaningmaterial/materialmixture,abbreviatedascon-tainer "B“below.

1materialcontainer,calledcontainer"C“ below.

Inspectthesealofallsystemcomponentsandtightentheconnections,ifnecessary.


Do not use narrow-necked cans or barrels with bung holes

Procedure1. Connect the inbound compressed air line

(Picture6.1.1) Closetheairtaplock. Turntheairpressureregulatorcontrolknobcounterc-lockwiseuntilitturnsfreely.

Connecttheinboundairlinetothefittingontheairmotor.

I

0

Picture6.1.1

P-

2. Pressure check CompletethepressurecheckdescribedinChapter5.2.

3. Place a filter element into the high-pressure filter Depressurizethesystem. PlaceafilterelementaccordingtoChapter9.3intothehigh-pressurefilter.


Picture6.2.1 Picture6.2.2

Pauses in work Applythespraygunsafetycatchatanypauseinwork.(Picture6.2.3)Im-mersethetipinacontai-nerofappropriatesolvent.

Thiswillavoidresiduecoatingsmaterialfromhardeningandblockingthetipopening.

Exchanging the spray tip Exchangethespraytipbeforeitisworn. Worntipsresultinincreasedpaintconsumptionandreducedspraycoatingquailty.

6.3 Change of material1. Shut down the unit CompleteallstepsforshuttingdownthepumpfoundinChapter7.

2. Clean or replace the filter insert Cleanthefilterinsertorreplaceitifitisdamaged. Placethecleanedorreplacementfilterinsertintothehigh-pressurefilteraccordingtoChapter9.3.

3. Clean the suction strainer Cleanthesuctionstrainerusingthesolventrecom-mendedbythemanufacturerofthecoating,orreplaceitifnecessary.

4. Operation CompleteallthestepsfoundinChapters6.1+6.2Operation.

Picture6.2.3

I

0

6.2 Spray operaton Disengagethesafetycatchandbeginspraying.

Explosion DangerIf the feed of material is interrupted during operation, the unit can run dry.The resulting friction can lead to an explosion that results in injuries and/or property dama-ge. Therefore: Do not allow the pump to cycle if the feed

container is empty. Do not allow the suction assembly to beco-

me plugged, kinked or otherwise defect. If no coatings material exits the gun, shut

the unit down immediately.

Set the operating pressure Theoptimaloperatingpressureisreachedwhencoa-tingappliesevenlywithgraduatededges. Onlyuseasmuchpressureasisnecessarytoachieveagoodspraypatternatadistanceofapprox.30-40cm(12-16in.)totheobjectbeingcoated.

Ifthepressureistoohigh,excessivematerialconsumptionandsprayfogwillresult.Ifthepressureistoolow,fingeringandunevencoatingthicknesseswillresult.

Coating / Finishing tips Holdthespraygunata90°angletothesurfacebeingcoated.Ifheldatadifferentangle,thecoveragewillbeunevenandspotted(Picture6.2.1).

Thesprayer'sarmmustmoveevenlybackandforth. Anevenspeedmustbemaintained. Movethespraygunparalleltothesurfacebeingcoated.

Movethespraygunwiththearmandnotwiththewrist.Wavingthespraygunwillleadtounevencoatingresults(Picture6.2.2).

Beginmovingthespraygunbeforethetriggerispulled.Thisensureseven,smoothoverlappingresultsandavoidshighercoatingbuildswhenthetriggerisfirstpulled.

Releasethetriggerbeforeceasingarmmovement.

Operation 6


7 Shutting down

JobTheunitistobecleanedandtakenoutofserviceafterworkiscompleted.


1opencontainerwithatleast5liters(1.3gal.)ofcleaningmaterial(thesolventmustcorre-spondtothecoatingmaterialandberecom-mendedbythematerialmanufacturer),calledcontainer"A"below.

1empty,opencontainerforthesolvent/coa-tingmaterialmixture,calledcontainer"B" below.

1materialcontainer,calledcontainer"C" below


Do not use narrow-necked cans or barrels with bung holes

Procedure1. Turn off and depressurize the unit Closetheairtaplock. Turntheairregulatorcontrolknobcounterclockwiseasfaraspossible.Thepressuregaugemustread0bar(psi).

Closethespraygunandapplythesafetycatch. Holdthedrainhoseintocontainer"B"andsecureitagainstslipping.

Brieflyopenthedrainvalveonthehigh-pressurefiltertodepressurize.

2. Tip dismount and clean Dismountthestandardtipandcleanitthoroughly.

Werecommendstoringthetip(standardorreversible)inthesolventrecommendedbythecoatingsmanufacturer.Thiswillavoidresidualpaintfromdryingandcloggingthetip.

3. Clean the high-pressure pump Removethesuctionpipefromcontainer"C". Wiperesidualpaintonthesuctionpipeandstrainerintothecontainer.

Placethesuctionpipewithstrainerintocontainer"A". Opentheairtaplock. Slowlyturntheairregulatorcontrolknobclockwiseuntil1-2bar(15-30psi)operatingpressureisreached.

Holdthedrainhoseintocontainer"B"andsecureitagianstslipping.

Openthedrainvalveonthehigh-pressurefilteruntilcleansolventexitsthehose.

Closethevalvetightly Holdthespraygunagainsttheinnerwallofcontainer"B".

Triggerthegununtilcleansolventisemitted.Besuretomaintaincontactwiththeinnerwallofthecontainer.

Closethespraygunandapplythesafetycatch. Lifttheunitoutofcontainer"A". Again,holdthedrainhoseintocontainer"B"andsecu-reitagianstslipping.

Openthedrainvalveonthehigh-pressurefilteruntilthepumprunsdry.

Turnthecontrolknobcounterclockwiseuntilitturnsfreely.Thepressuremustread0bar/psionthepres-suregauge.

Toavoidunnecessarylossofmaterialstillinthehose,werecommendsprayingthecoatingbackintocontainer"C"untilsolventemergesfromthegun.

Ifworkingwithpluralcomponentmaterials,thepotlifemustbeobserved.Allsystemcomponentsthatcomeintocontactwiththemixedmaterialmustbecleanedwiththeappropriatesolventwithinthepotlifegivenbythecoatingsmanufactuerer.Observe: Warmtemperaturesreducethepotlife. Allowthesolventtocirculateforawhile. Nopaintresiduemayremaininthepumporhigh-pressurefilter.

4. Removing the filter insert Removetheelementfromthehigh-pressurefilterac-cordingtotheinstructionsfoundinChapter7.3.

Wipetheinsideofthehigh-pressurefiltercompletelyclean.

Closethehigh-pressurefilterwithonlythenutmoun-tedinside(withoutthefilterelement!).

If taken out of service for a long period Cleantheunitasdescribed. Donot,however,completelyemptythepumpofsol-vent.

Assoonascleansolventexitsthespraygunandhigh-pressurefilter,reducethepressureto0bar/psi.

Holdthespraygunagainsttheinnerwallofcontainer"B"andtiggerbriefly.

Todepressurizethehigh-pressurefilter: Holdthedrainhosesecurelyintocontainer"B" Brieflyopenthedrainvalve

Thesolventthatisleftinthematerialpumpistore-mainuntilthenexttimethepumpisused.

Whenrestartingthepump,besuretoflushthesystemthoroughly.


Preparing material and equipment Connectthe3/4“x10mand½”x5mhosestothefluidpump.

Connectthespraygunwiththemitmaterialhoses. WarmthesupplycontainersfortheA&Bcomponents-asnecessary(theworkingtemperaturedependsontheparticularapplication.Observethemanufacturer’sinstructions!)

Whenpermissableforthematerialused,slightlysol-slightlysol-ventintocomponentAusingthehandmixer(Observetheinstructionsgivenbythematerialmanufacturer).

MixcomponentBintothecomponentA/solventmixture(picture8.1).

Cleanthehandmixerwithsolventandleavestandinginthecontainerwithsolvent.Thisworkisbestdonebyasecondpersonsothatthereisnolossofworkingtimeforthemixedmaterial.

Centerthecontainerwithmixedmaterialunderthefollowplate.

Lowertheliftsteadily,withoutstopping,with2-3barairpressure

Opentheballvalveonthefollowplatetobleedthetrappedair(picture8.2),whenthefollowplateent-ersthecontainer.

Closetheballvalvewhennomoreairisreleased. Atfirstfilling:allowthepumptorununtilmaterialexitsthespraygun(notipinstalled!).Useacatchcontainertocollectthematerial.

Installa435or535tiponthespraygun. Increasetheairinletpressureuntilthedesiredspraypressureisreached.

ResultYoumaybeginwiththecoatingwork.

Picture8.1

Picture8.2

Exchanging containerExchangethecontainerbeforeitiscompletelyempty.

Reducethepressuretothepumpcompletely. Carefullyopentheballvalveontheregulator,forcingairintothe(empty)materialcontainer.theballvalveonthefollowplateremainsclosed.

Raisethelift. Closetheballvalveontheregulator(picture8.3)atthemomentthefollowplateexitsthecontainer.

Removetheemptycontainerandtransferanymaterialremainingintothenewcontainer.

Afterprocessingof6containersofmaterial,thepumpmustbeflushed(seeIntermediateFlus-hing).

Tousethenewcontainer,proceedasin“PreparingMaterialandEquipment“

Finishing workDAILY (at end of shift) Performcompleteflush(seebelow) Disassembleandcleanthepump. Thoroughlycleanthefollowplate,hoses(incl.drainhose),spraygunandtip

Intermediate flushAfterprocessingof6containersofmaterial,thepumpmustbeflushedinordertoremovematerialdepositsfromthesystemandpreventablockageofthepump.

Raisethepumpandunscrewthefollowplate. Removethe(empty)materialcontainerfrombelowthepump.

Replaceacontainerwith10-15ltr.solventbelowthepump

Lowerthepumpuntilitcansuctionthesolvent.

Picture8.3

Processing Instructions for 1K PFP-Unit 8


Holdthedrainhoseinacontainerforwastemate-rialandopenthedrainballvalve(picture8.4).

Startthepumpwithmax.1-2bar. Do not trigger the spray gun during the inter-

mediate flush to prevent mixing of the solvent with the material in the spray hose.

Allowthepumptorununtilthesolventrunsoutofthedrainhose.

Placethedrainhoseinthesolventcontainer(belowthepump)andallowtheunittorunfor2-3minutes,sothatallremainingmaterialisflushedoutofthesystem.

Raisethepump. Allowthepumptorundry. Placethe(new)materialcontainerunderthepumpandfilltheunitwithmaterial. Placethedrainhoseinacontainerforwastematerialtocollecttheremainingsolventinthesystem.

Assoonasmaterialappears,lowertheairinletpres-sureofthepump.

Closethedrainvalve. Proceedwithcoatingwork.

Complete flushFlush the pump, hoses, spray gun, tip and drain hose thoroughly before disassembling.

Flushthepumpatfirstthroughthedrainhose,asinintermediateflushing.

Afterthesolventhasbeenpumpedthroughthedrainhose,closethedrainvalve.

Lockthetriggeronthespraygunandremovethespraytip. Cleanthetipbyhand.

Holdthegun(lesstip)inacontainerforwastematerialandsprayuntilsolventappears.

Holdthesprayguninthesolventcontainerunderthepumpandallowthepumptocirculatesolventthroughthegunfor2-3min.

Exchangethesolventcontainerforacleanonewithnewsolventandrepeatthecompleteflushingprocedu-re(throughthedrainhoseandthespraygun).

Picture8.4

Disassembling and cleaning pump Theunitmustbethoroughlyflushed. Emptytheunitandreleaseallpressure. Unscrewthematerialoutletandthedrainhose. Dismountthefollowplateandcleanthoroughly. WARNING!Theblackrubbersealisnotsolventre-sistant.Donotsoakinsolvent,butonlywipethesealclean.

Takecarethatthesealinthecen-terofthefollowplateisnotlost(picture8.5).

Drainthereleaseagent(Mesamoll)intoacatchcon-tainer.

Unscrewthenutsonthe6threadedbolts(picture8.6).

Prythepressurecylinderfrom the spring housing usingascrewdriverorprybar(picture8.7).

WARNING! The parts are heavy. At best, work In pairs and position a soft mat to catch falling parts.

Picture8.5

Picture8.6

Picture8.7

8 Processing Instructions for 1K PFP-Unit


Proceedlikewisewiththespring housing (picture8.8). Lowerthedualpistontoitslowestpositionusingbriefincreasesintheairpressure.

Prytheintermediatebodyfromtheairmotor. Itwillbecaughtbythedualpiston.

Unscrew2-3ofthethrea-dedboltstoallowremovalofthedualpistonfromthecoupling(picture8.9).

Thoroughlycleanthepiston,pistonvalve,bottomvalve,pressurecylinder,intermediatebody,springhousing,threadedboltsandnuts.

WARNING!Take care that the dual piston, packings, seals and threads are not damaged.

Assembling pumpThedrawinginthesparepartslistcanbeveryhelpfulforassemblingthefluidpump(OrderNo.0641416). Placethecounterringonthedualpiston/springhou-sing(notecorrectdirection!),followedbytheinterme-diatebody(don’tforgettheseal!).

↑ intermediatebody

↓ dualpiston

Pushthedualpistonsidewardsintothecouplingontheairmotor.

Screwinthethreadedbolts. Placethecounterringontothelowerpacking,followedbythespring.

Placethespringhousing(materialoutlettowardsthetop)looselyoverthespringontothepressurecylinder.

Placethe2ndspringinthetopofthespringhousing.

Picture8.8

Picture8.9

Lowertheliftcarefullyuntilthedualpistonslidesthroughthespringhousingintothepressurecylinder.Allthreadedboltsmustpasssufficientlythroughtheconnectingringtoavoiddamagingthethreads.

Placethewashersontheboltsandscrewonthenuts. Tightenthenutsstep-wiseinacrossingpatterntopullthepumpevenlytogether. Torquefinallyto110Nmandaddthelocknuts.

Screwonthefollowplatewithseal.

Processing Instructions for 1K PFP-Unit 8


9.1 Regular inspectionsAccordingtotherulesforthepreventionofaccidents„Workingwithliquidjetsystems“BGR500,Kap.2.36theequipmentmustbecheckedandoverhauledatregularintervalsbyaspecialist( Service).

The equipment must be checked: beforethefirststart-up, afterchangesandrepairsofequipmentpartshavinganeffectonsafety,

afteraninterruptionofoperationofmorethan6months,

howeveratleastevery12months.

Forequipment,whichhasbeentakenoutofoperation,thecheckcanbepostponeduptothenextstart-up.Theresultsofthechecksmustberecordedinwritingandkeptuntilthenextcheck.Thecheckingcertificateoracopyofitmustbeavailableattheplacewheretheequip-mentisused.

9.2 Maintenance planWarning!Dismantling the pump under pressure can lead to serious body and/or eye injury.

Before perfoming any maintenance or repairs, the pump must be turned off.

Depressurize the entire system. Disassemble the high-pressure filter, fluid hoses

and spray gun very carefully. Cover the hose connections with a rag before dis-

mantling to avoid paint splashes.

Check the release agent amount Beforeeverystart-upchecktheamountofreleaseagentinthereleaseagentchamber.(Picture9.2.1) Thereleaseagentlevelmustbeatleasthalfthesightglass.

Checkregularlytherelease agentfordiscolorationcausedbycontactwiththespraymaterial Thediscolorationcanbemonitoredbydrainingasmall amount ofrelease agent.Afterchecking,addacorrespondingamountofcleanrelease agent to the chamber.

Heavy discoloration and material contermination:Thesestepsmayonlybeperfomedbypersonneltrainedby or CustomerService.

Replacethematerialpumppackingsets(refertothesparepartslistforthematerialpump)

Cleanthereleaseagentchamber. Fillthechamberwithcleanreleaseagent.

drainreleaseagent

sight glass

fillreleaseagent air motor

material pump

Picture9.2.1

High-pressure filter maintenanceCleanthefilterinsertbeforeeverychangeofspraymate-rialordaily,atthelatest.ObserveandfollowtheinstructionsfoundinChapter6.3"Changeofmaterial".

9.3 High pressure filterJob Cleanorreplacethefilterinsert:

1. aftershuttingdowntheunit(daily).2. beforeeverychangeofspraymaterial.3. ifthepumpdoesnotcyclealthoughthespraygunis

triggered(withouttip)orthedrainvalve/drainscrewforthehigh-pressurefilterisopened.

Prerequisite Requiredare:

Anempty,opencontainerforthemixtureofsolvent/spraymaterial,hereaftercalledcontainer"B".

1open-endwrench Size13

Warning!If blockages occur, residual pressure may still be in the system even after depressurizing. Residual pressure can lead to serious injuries to the body or eyes.

Beforestartinganyworkonthehigh-pressurefilter,thepumpmustbeturnedoff.

Brieflytriggerthespraygun. Todrainpressure,openthedrainvalve/screwonthehigh-pressurefilter.

9 Maintenance


Maintenance 9

Filter insert selectionTheinsertmust: correspondtothematerialbeingsprayed becompatiblewiththespraytipused Themeshshouldalwaysbealittlefinerthattheboreofthetipbeingused:

Filter insert Tip size (mm/")from to

M200 (white) - 0,23/.009M150 (red) 0,23/.009 0,33/.013M100 (black) 0,33/.013 0,38/.015M70 (yellow) 0,38/.015 0,66/.026M50 (orange) 0,66/.026 -

Ifworkingwithheavilypigmentedorfiber-filledmaterials: donotuseafilterinsert. thestandardsuctionsievemayneedtobere-placedwithasievehavingalargermeshsize.

use a reversibletip

9.4 Maintenance unit

Picture9.4.1

Lubricant and/or anti-freezing agent Checktheairmotor'slubricantinthebowloftheairmaintenanceunitandrefill,ifrequired.

Highairhumiditycancauseicingofthemotor. Incaseoficing,onlyusepureanti-freezingagent.

Disassemblethehigh-pressurefilterverycarefully! Replacewornpartswithnewones..

Procedure Holdthedrainhoseintocontainer"B". Closetheairtaplockforthepump. Todepressurize,openthedrainvalve(Picture8.3.1,pos.6).

Picture9.3.1

Removing the filter insert Unscrewthecap(Picture9.3.1,pos.1)withthespanner (Picture9.3.1,pos.2).

Unscrewthenut(Picture9.3.1,pos.3)withaforkwrenchandremovethefilterinsert(Picture9.3.1,pos.4)).

Cleanthefilterinsert. Useonlytheappropriatesolventforthematerialbeingworkedwith. Replacethefilterinsertshouldanysignofdamagebepresent..

Replacetheo-ring(Picture9.3.1,pos.5)shouldanysignofleakagebepresent

Mounting the filter insert Mountthehighpressurefilterinreserveorder.

Instructions

Before restarting the pump ensure that the unit is properly grounded.

R(corrosionresistant)+RS(stainless)versions:Lightlygreaseallthreadstoeaseassembly/disassembly.


9 Maintenance

Adjustment of the fog oiler on the air maintenance unit Lettheairmotorrunslowlyatanairinletpressureofapprox.4bar.

Checkthesightglassonthefogoilertoensurethatonedropoflubricantisfedintothecompressedairatevery10-15doublestrokesoftheairmotor.Ifthisnotthecase,theadjustingscrewonthefogoilerhastobesetaccordingly.

Checktheoillevelinthereservoirdaily.

Theairmaintenanceunitmaynotbeoperatedwithoutoil.Themaximumoillevelismarkedwithalinearoundthereservoir. Tofillthereservoir,removethefillerscreworremovethereservoirandfilldirectly.

Onlyusethelubricantsandanti-freezingagentasindi-catedinChapter"Appendix/Auxiliarymaterials".

Condensed water drain Thecollectedcondensationwillbeautomaticallydrai-nedbythedrainvalve.Placethehoseintoanemptycatchbasin.

Checkthereservoirsregularlyforcontaminationandcleanasnecessary.

Notes to the oil reservoir/water cutoff Toremovereservoir:

Pressreleasedownwards. Turnreservoircounter-clockwise.

Montage: TakecareduringassemblythattheO-ringisseatedproperlyinthehousing!


Malfunctions and troubleshooting 10

Fault Possible Cause SolutionThepumpdoesnotcyclewhetherthespraygunistriggered(withouttip)orthedrainvalve/screwisopened.

Airtaplockisclosed. Opentheairtaplock. High-pressurefilterisclogged. Cleanorreplacethefilterinsert. Airmotorisdefect. Repairtheairmotoraccordingto

thesparepartslist-ContactCu-stomerServiceifnecessary.

Pumpcycles,butnomaterialreachesthetip..

Suctionsieveisclogged. Cleanthesieve. Suctionhoseisblocked. Replacethehose. Bottomvalveballdoesnotrise(stuck).

Triggerthespraygunwithouttip. Openthehigh-pressurefilterdrainvalve/screw

Lightlyhitthebottomvalvefromtheside(hammer).

Removethesuctionassemblyandpressontheballfrombe-lowusingapegorscrewdriveruntilloose.

Bottomvalvedoesnotclose. Removethebottomvalveandcleantheballandseatthoroughly.

Pumpcyclesbutdoesnotstopwiththespraygunisclosed.

Packingand/orvalveworn. Replace.

Pumpcyclesevenlybuttherequiredoperatingpressurecannotberea-ched

Airsupply/pressureistoolow. Increasetheinboundairpressurewiththeregulatorandcheckthediameteroftheinboundairhose.

Tip(new)istoobig. Useasmallertiporlargerpump. Tipisworn(toobig). Replace. Airmotorisfrozen(runstooslow). Ifpossible,reducetheinboundair

pressure. Ifnotalreadyinuse,mountanairmaintenanceunitwithoiler.Filltheoilerwithanti-freeze(Glysantine)andsetitaccordingtotheinstruc-tionsintheUser'sHandbook:Averagesetting:1dropevery10cycles

Pumpcyclesunevenly(differentstrokespeedsontheupwardanddownwardstrokes)andtherequiredspraypressurecannotbereached..

Theviscosityofthecoatingistoohigh(suctionloss).

Thinthecoating. Usealargerpump.

Suctionassemblyleakage(sprayjetfluctuates).

Checkthesealofallsuctionas-semblyconnectionsandreplaceifnecessary.

Bottomvalveleaks(pumponlystopsontheupwardsstrokewhenthespraygunisclosed).

Removethebottomvalveandcleantheballandseatthoroughly.

Pistonvalveleaks(pumponlystopsonthedownwardsstrokewhenthespraygunisclosed).

Cleantheballandseatinthedualpistonandreplaceifnecessary.

Upperorlowerpackingsleak(wear).

Replace.

Coatings material spills out of the air motoranti-vaccumhole.

Packingsareworn. Replace. Note:Donotcloseorblocktheanti-vaccumhole!


11.1 Technical specifications

Model 35061 35075 48046 48057 60028 60036 38032

Airmotorpistondiamater(mm) 300 333 300 333 300 333 200Airmotorpistonstroke(mm) 120 120 120 120 120 120 120Pumpratio 61:1 75:1 46:1 57:1 28:1 36:1 32:1Max.free-flowoutput(ltr/min) 35 35 48 48 60 60 38 Outputpercycle(cm3) 275 275 360 360 550 550 235Max.inputairpressure(bar) 7 6 8 7 8 8 8Max.operatingpressure((bar) 427 420 368 399 224 288 255Max.tipsize(highpressurefilter)(inch) 1/4NPSM(A)2x3/8Airinlet(maintenanceunit)(inch) 1DimensionsLxWxHcartmounted(cm) 70x80x140wallmounted(cm)Netweight(cartmounted)(kg) 170 161 85 86 90SoundpressurelevelemittedattheworkplaceRunningatidle(LpAd)(dB) 84Runningwithload(LpAd)(dB) 80

11.2 Auxiliary materialsRelease agent OrderNo.0163333Pneumatik-oil(0,5liter) OrderNo.0632579Antifreeze OrderNo.0631387Threadsealant(50ml/1.7fl.oz.)*

OrderNo.000015

Grease(acid-free)* OrderNo.000025* Softenerforfillingthereleaseagentchamberofthefluidpump.** formaintenanceunit*** Requiredformaintenanceand/orrepairs

11 Appendix


Appendix 11

11.3 Machine cardThis User’s Handbook is valid only in connection with the following machine card:

Themachinecardincludesallmachinespecificationsanddetailswhichareimportantandrelevantforsafety: exactdesignationandmanufacturingdata technicalspecificationandlimitvalues equipmentandinspectioncertificate detailsandordernumbersforspareparts machinefeatures(machinecomponentsandaccesso-riessuppliedwithsparepartsnumber)

Pleasepayattentionthatthemachinecardspeci-ficationsareinaccordancewiththenameplate.Incaseofanydeviationsorifthenameplateismiss-ing,wewouldaskyoutoadviseuswithoutdelay.

11.4 Certificate of training and operation

ThiscertificatecorrespondstotheEUguidelineforwor-kingsubstances85/655/EWG,ParagraphII,Article7.The owner of the following machine has trained the operating personnel.

……………………………………………………………(Make,Model,YearofConstruction,OrderNumber)

The training was conducted by the following designa-ted person: ……………………………………………………………(ForemanorresponsibleSuperior,Name,Department

The persons trained have read and understood the user's handbook for the above mentioned machine, especially the chapter Safety, and are certain that they can operate this machine safely.

……………………………………………………………(OperatingPersonnel,Date,Name)

……………………………………………………………(PersonnelforMaintenanceandRepair,Date,Name)

……………………………………………………………(PersonnelElectric/Electronics,Date,Name)

operation manual ˇ˙ ˆˇ˘ - wiwa llc

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