chapter 1 air-powered gun washer/recycler operation … · use whichever support suits the...

Chapter 1

AIR-POWERED GUN WASHER/RECYCLER

Operation Manual

W/DIAPHRAGM PUMP

SPECIFICATION

Gun Capacity………….. 2

Dimensions………….… 0.47m(W)×0.65m(L)×1m(H)

Pump…………………... Pneumatic Diaphragm Pump

Air Pressure…………… 2.8~4.2kg/cm2 (40-60 psi)

Air Consumption……… 0.06~0.11 m3/min (2~4 CFM)

◎HONGE SHEN◎

Air-Powered Gun Washer/Recycler

Model: 39500

Weight: 33.5kg

Pressure: 2.8~4.2 kg/cm2

Air consumption: 0.06~0.11 m3/min

HONGE SHEN CO., LTD.

1stFl., No.57, Lane Fu Guang 5,Wuguang Rd., Wurih

Township, Taichung County, 414 Taiwan (R.O.C)

TEL : 8 8 6 -4 -2 3 3 8 8 4 1 8 ; FA X: 8 8 6 -4 -2 3 3 6 0 7 2 2

MODEL: 39500 (LP-2)

FLAMMABLE LIQUID

FLAMMABLE LIQUID

EXCLUSIVE IMPORTER IN BRAZIL: EURO TECHNIKER LTDA.

AAiirr--PPoowweerreedd GGuunn WWaasshheerr//RReeccyycclleerr OOppeerraattiioonn MMaannuuaall

MMOODDEELL:: 3399550000 wwwwww..eettkk..ccoomm..bbrr PPaaggee 22 ooff 2200

Contents Page

1. Safety instructions 3

2. Instruction & specification 4

3. Assembly (also see Annex I) 4

4. Air supply 4

5. Operation instructions 5

6. Solvent change & maintenance 6

Parts Diagram 7

Annex I-Installation 8

Annex II-Operation position 14

Annex III-Pneumatic chart 18

Annex IV-Toluene instruction 16

Annex V-Regulator explode chart 20



INSTRUCTION FOR SPRAY GUN WASHER－MODEL 39500

Thank you for purchasing 39500. Manufactured to a high standard this product will, if used according

to these instructions and properly maintained, give you years of trouble free performance.

1. SAFETY INSTRUCTIONS 1-1.WARNING! Ensure Health & Safety, local authority and general workshop practice regulations

are adhered to when using equipment.

1-2.WARNING! Installation site must be equipped with suitable fire extinguishers (water must not

be used) and escape routes.

1-3.WARNING! Disconnect the air supply from the tank before changing accessories, servicing or

performing any maintenance.

1-4.Maintain the tank in good condition (use an authorized service agent).

1-5.Replace or repair damaged parts using genuine parts only. Non-authorized parts may be

dangerous and will invalidate the warranty.

1-6.Locate the tank in an adequate working area. Ensure the tank stands on a firm level surface.

Keep area clean and tidy and free from unrelated materials. Ensure the area is well ventilated

and has adequate lighting.

1-7.WARNING! Ensure correct air pressure is maintained and not exceed. Recommended pressure

is 2.8~4.2kg/cm2.

1-8.Keep air hose away from heat, oil and sharp edges. Check air hose for wear before each use, and

ensure that all connections are secure.

1-9.WARNING! This tank is recommended for use only with solvents.

1-10.WARNING! We suggest the user can use xylene based or organic or water based solvents, but

user has to see MSDS (see 1.30.) first and ask the agent for safety reason, and cannot disobey

the local laws.

1-11.Keep the tank clean. Clean the suction filter inside tank regularly for best performance.

1-12.WARNING! Never smoke and keep sources of ignition, such as heaters, lamps, etc. away from

the unit, together with flammable or combustible materials, as there is an explosion risk.

1-13.WARNING! Wear approved safety eye protection, respirator and gloves. If solvent gets on

skin or in eyes wash thoroughly with clean water and take any other action as required by the

solvent instructions.

1-14.Remove ill fitting clothing, ties, watches, rings and other loose jewelry, contain long hair, and

wear appropriate protective clothing.

1-15.Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.

1-16.Keep non-essential persons away from the working area.

1-17.In case of fire in the tank, do not attempt to move the unit when it is running.

1-18.DO NOT use the tank with the lid open and DO NOT use it for spray gun testing.

1-19.DO NOT use the tank for any purpose other than for which it is designed.

1-20.DO NOT operate the tank if any parts are missing or damaged as this may cause failure and/or

possible personal injury.

1-21.DO NOT over-fill the tank (less than 19 liters).

1-22.DO NOT direct air from the air hose at yourself or others.

IMPORTANT: Please read the following instructions carefully. Note the safe

operation requirements, warnings and cautions. Use this product correctly and with

care for the purpose of which it is intended. Failure to do so may cause damage

and/or personal injury and will invalidate the warranty. Please keep instructions safe

for future use.

!



1-23.DO NOT operate the tank when you are tired or under the influence of alcohol, drugs or

intoxicating medication.

1-24.When cleaning is completed, ensure all controls are in the off position and that the air supply is

turned off.

1-25.WARNING! It is operator’s responsibility to ensure that there is no uncontrolled discharge of

any fluids used with this unit and that appropriate arrangements have been made for

correct-disposal of waste in accordance with government/local authority regulations.

1-26.WARNING! The operator should be a trained and qualified technician.

1-27.WARNING! DO NOT run the machine without screen platform inside the tank. It may cause

the solvent spilling when opening the lid.

1.28.DO NOT open the lid when just finished the clean. Turn the machine off by the ball valve (67),

and wait about 30 seconds, let the solvent droplet condense to avoid inhalation of solvent

vapor.

1.29.WARNING! Breath a large amount of solvent may cause physical damage, and it may also do

harm to pregnancy women.

1.30.You can visit this website to see more information about MSDS: http://www.ilpi.com/msds/.

1.31.WARNING! Disregarding of earth may cause fire.

1.32.WARNING! Before opening the lid of tank to insert the spray gun, earth the metal body of the

spray gun to bear metal contact on the cleaning machine to discharge any static electricity.

2. INSTRUCTION & SPECIFICATION

The 39500 is suitable for the busy medium sized body shop. The tank is robustly manufactured and

delivers sufficient solvent to clean two guns and pots in each washing cycle. The air supply is

automatically cut off when the lid is opened. If it does not stop, you can just turn off the valve at the

air inlet.

SPECIFICATION:

Operating pressure…………...... 2.8~4.2 kg/cm2 (40-60 psi)

Air consumption………………. 0.06~0.11 m3/min (2-4CFM)

Capacity…………………...….. 2pots+2guns

Width × Depth × Height….… 0.47m ×0.65m ×1m(18-1/2”×25-1/2”×40”)

Weight……………………..….. 33.5 kg (74 lbs)

Life span………………………. 3 years

Noise under operation……….… 75dB

Material of inner tank…………. Polyethylene

3. ASSEMBLY (also see Annex I) Note: Item numbers in brackets are those in the attached Parts Diagram instructions should be read in

conjunction with this diagram.

3-1.Attach legs to cabinet with screws (60), washers (61) and nuts (62) provided and fit drain valve

(63) to base of tank (2).

3-2.To prevent possible static build up, run an earth wire from the frame to earth. Before

operating the machine, user has to check the earth wire.



4. AIR SUPPLY 4-1.Ensure that the air valve (64) is closed before connecting the air supply.

4-2.An air pressure of 2.8~4.2 kg/cm2, and an available air volume of 0.06~0.11 m3/min will be

required to operate the unit.

#WARNING! Ensure air supply is clean and does not exceed 4.2 kg/cm2. Too high an air

pressure and/or unclean air will shorten the product life due to excessive wear and may be

dangerous, causing possible damage and personal injury. Air supply must be equipped with

regulator, filter/separator and oiler.

4-3. Line pressure should be increased to compensate for unusually long air hoses (over 8 meters).

The minimum hose internal diameter should be l0mm and fittings must have the same internal

dimension.

4-4. Keep hose away from heat, oil and sharp edges. Check hoses for wear and make certain that all

connections are secure.

4-5. The air inlet connection is l/4” NPT.

5. OPERATION INSTRUCTIONS #WARNING! Ensure you follow the safety instructions. Wear approved safety gloves, respirator,

and suitable clothing.

#WARNING! Before using the washer always touches a suitable earthing point to dissipate any

electrostatic charge you may have.

5-1.PREPARING TANK & ITEMS FOR CLEANING

5-1-1. Before opening the lid of tank to insert the spray gun, earth the metal body of the spray

gun to bear metal contact on the cleaning machine to discharge any static electricity.

5-1-2.Ensure tank drain ball valve (63) is closed and then pour solvent into tank (2). To aid

future sludge removal approximately 2 litres of water may be added, either before or after

the solvent. Ensure final level is at least 25mm (1 inch) above pump suction strainer (59)

5-1-3.Confirm air valve (20) is closed and air supply pressure is regulated to not more than 4.2

kg/cm2. Turn on air supply.

5-1-4.Partially open air valve (20) and allow pump to run slowly for approx. 2 minutes to purge

fluid used for manufacturer's tests.

5-1-5.Check the spray gun to be cleaned, empty and store any excess paint for future use. For

best results clean immediately after use, having removed as much residual paint as

possible.

5-1-6.To clean spray guns to squeeze trigger and fit trigger lock (56) as shown in Fig l.

5-1-7.Two gun supports are provided, one short (see Fig.2 A) and another long (see Fig2 B.)

Use whichever support suits the configuration of the gun to be cleaned. In general, guns

which have top entry paint inlets (e.g. gravity feed) can be put on either support provided

they do not foul on the underside of the lid. Guns which have bottom entry paint inlets (e.g.

suction feed) will usually go onto the longer support. If required gun cleaning nozzle (8)

may be fitted directly to manifold (6) without item (9) and (10) thus providing two short

nozzles.

5-1-8.For pressure fed guns up to 2 liters capacity

place the siphon stem of the pot cover over

the short support and position the gun and hoses

on the screen platform. Over this capacity

disconnect the gun from the lines and place

on the long support.

INSERT TRIGGLE LOCK

Fig.1

Fig.2

A

B

C



5-1-9.Place pots over nozzles ‘C’, shown in Fig.2

(Fig.2- Screen (11) omitted for clarity.)

5-2.CLEANING

5-2-1.Ensure washer lid is closed and then fully open pump air valve (20).

The pump will now operate and expel an atomized spray through the nozzles in the

cleaning tank.

5-2-2.Cleaning will be complete after 60 seconds, at which time pump should be turned off by

closing air valve (20).

5-2-3.Open lid and remove cleaned equipment.

NOTE: If, during cleaning, lid is opened, cleaning process will automatically stop. Close lid to continue,

DO NOT store guns in tank.

6. SOLVENT CHANGE & MAINTENANCE #WARNING! It is operator's responsibility to ensure that there is no uncontrolled discharge of

any fluids used with this unit and that appropriate arrangements have been made for correct

disposal of waste in accordance with government/local authority regulations.

#WARNING! Disconnect the air supply from the unit before changing accessories, servicing or

performing any maintenance.

#WARNING! Wear approved safety gloves, goggles, respirator and suitable clothing.

6-1.SOLVENT REPLACEMENT

The number of guns the solvent can clean will depend upon the amount of residual paint, which

is left in spray equipment. We recommend however that the solvent is changed on a regular basis

to provide optimum cleaning performance that pain sludge is removed weekly, as detailed

below.

6-1-1.Sludge removal a) No water added－Drain 2 liters of solvent/sludge from drain valve

(63). Close valve (63). Close valve and add clean solvent to tank to

bring level up to at least 25mm above strainer.

b) Water added－Drain water until it becomes discolored, close drain

valve. Change to ‘dirty solvent’ receptacle, re-open drain valve and

drain 2 litres of solvent/sludge. Close valve, replace water in tank

and then add clean solvent to bring level up to at least 25mm above

strainer.

6-1-2.Solvent change Completely drain dirty solvent as in 6-1-1. Clean inside of tank (2) and

strainer (59) before refilling with clean solvent wipe up any spillage immediately.

6-2.MAINTENANCE

6-2-1. Regularly check that opening the washer lid automatically stops the spray.

6-2-2. Regularly check and add air tool oil to air cock (67) on monthly basis.

6-2-3. Keep the outside of the unit clean.

6-2-4. Inject lubricant into air inlet every 3 month, see appendix I Fig.11, or see 6-2-5.

6-2-5. Use a hexagonal screwdriver in tool bag to open the circular cap of the pump and inject

lubricant into it, see the picture below! (Recommended procedures see Annex I Fig.11)

Screws



PPaarrttss ddiiaaggrraamm

7

11

6 8

7 9

10

56 55 53

52

54

66 67

21

27

26

25

24

26

25

24

27

32

31

30

29 35

34

33

20

18 44

43

22

42

42

45

47

37

38

39 40 41

23

36

42

42

64

46

19 16 15

46

15

13 17

28

51 15

3 4

50

49

46

48 46

59

58 57

14

13 12

65

2

60

5

63

62



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1. LID COVER 18. CONNECTOR 35. COOL DOWN VALVE 52. SCREW 2. TANK 19. ANGLE CONNECTOR 36. SPRING 53. WASHER 3. FRAME 20. REGULATOR WITH GAUGE 37. SCREW 54. SWITCH PLATE 4. DOOR 21. ANGLE CONNECTOR 38. WASHER 55. HEX NUT 5. LEG 22. BLASTER 39. DIAPHRAGM 56. CHAIN+PLASTIC TRIGGER LOCK 6. PIPE 23. CYLINDER 40. WASHER 57. CONNECTOR 7. NOZZLE 24. WASHER 41. HEX NUT 58. HOSE CLAMP 8. LONG NOZZLE 25. BALL 42. SCREW 59. STRAINER 9. EXTENSION BAR 26. BALL STOPPER 43. SCREW 60. SCREW 10. EXTENSION BAR 27. HEX NUT 44. AIR CAP 61. WASHER 11. SCREEN PLATFORM 28. CONNECTOR 45. RETAINING RING 62. HEX NUT 12. ANGLE CONNECTOR 29. VALVE HOLDER 46. ANGLE CONNECTOR 63. BALL VALVE 13. HEX NUT 30. VALVE COVER 47. WASHER 64. PRESSURE VALVE 14. WASHER 31. VALVE PISTON 48. AUTO STOP SWITCH 65. PRESSURE HOLDER 15. WASHER 32. SCREW 49. CONNECTOR 66. CONNECTOR 16. CONNECTOR 33. FIXING BOLT 50. CONNECTOR 67. BALL VALVE 17. ANGLE CONNECTOR 34. SPRING 51. HEX NUT



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Liquid (sludge) exit

Warning sign



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Trigger lock

Trigger lock



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Top view of 39500

Air source

Lid Air source

on/off

switch



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Air sourceON/OFF switch

Relief valvewith pressure gauge

Flow control

Diaphragm pump

Tank Air source2.8~4.2kg/cm2

2

3

5 1

4

1~3: soft pipe 4~5 copper pipe

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TTOOLLUUEENNEE IINNSSTTRRUUCCTTIIOONN††

†-Reference: http://www.osha.gov/SLTC/healthguidelines/toluene/recognition.html.

1. Name:………………………… Toluene

http://www.osha.gov/SLTC/healthguidelines/toluene/recognition.html



2. Formula:………………………. C6H5CH3

3. Identifiers:…………………….. CAS: 108-88-3; RTECS: XS5250000.

4. Appearance and odor:………... Toluene is a flammable, colorless liquid with an aromatic

odor like that of benzene.

5. Freezing point:……………….. -94.5℃ (-138℉).

6. Boiling point (1atm.):………... 111℃(231℉)

7 Vapor density:……………….. 3.14(Air = 1 at boiling point of toluene)

8. Specific gravity (water = 1):….. 0.87@20℃(68℉).

9. Vapor pressure:………………. 22 torr @ 20℃(68℉)

10. Evaporation rate:……………... 2.24 (butyl acetate = 1).

11. Reactivity:…………………….. 1. Conditions contributing to instability: Heat, sparks, and

open flame.

2. Incompatibilities: Contact of toluene with strong oxidizing

agents may cause fires and explosions. In the presence of

nitric acid, and especially in the presence of sulfuric acid,

toluene produces dangerously explosive compounds.

3. Hazardous decomposition products: Toxic gases (such as

carbon dioxide and carbon monoxide) may be released in a

fire involving toluene.

4. Special precautions: Toluene attacks some coatings and

some forms of plastic and rubber.

12. Flammability:……………...….. 1. Flash point: 4℃(40℉) (closed cup).

2. Autoignition temperature: 480℃(896℉).

3. Flammable limits in air (percent by volume): Lower, 1.2;

upper, 7.1.

4. Extinguishant: Use carbon dioxide, dry chemical, or foam

to extinguish fires involving toluene. Do not use a solid

stream of water because this will scatter and spread the fire.

Water may be used to cool fire-exposed containers. If a leak

or spill has not ignited, water spray may be used to disperse

vapors and to protect persons attempting to stop the leak.

Fires involving toluene should be fought upwind and from the

maximum distance possible. Keep unnecessary people away;

isolate hazard area and deny entry. Emergency personnel

should stay out of low areas and ventilate closed spaces before

entering. Vapor explosion and poison hazards may occur

indoors, outdoors, or in sewers. Vapors may travel to a source

of ignition and flash back. Containers of toluene may explode

in the heat of the fire and should be moved from the fire area

if it is possible to do so safely. If this is not possible, cool

containers from the sides with water until well after the fire is

out. Stay away from the ends of containers. Personnel should

withdraw immediately if a rising sound from a venting safety

device is heard or if there is discoloration of a container due to

fire. Dikes should be used to contain fire-control water for

later disposal. If a tank car or truck is involved in a fire,

personnel should isolate an area of a half a mile in all



directions. Firefighters should wear a full set of protective

clothing, including a self-contained breathing apparatus, when

fighting fires involving toluene. Firefighters' protective

clothing may provide limited protection against fires

involving toluene.

13. Emergency procedures:………. In the event of an emergency, the rescuer should do

appropriate personal protective equipment, remove the victim

from further exposure, send for medical assistance, and

initiate the following emergency procedures:

1. Eye exposure: If toluene or a solution containing this

substance gets into the eyes, immediately flush the eyes

with large amounts of water for a minimum of 15 minutes,

lifting the lower and upper lids occasionally. If irritation

persists, get medical attention as soon as possible.

2. Skin exposure: If toluene or a solution containing this

substance contacts the skin, the contaminated skin should

be flushed with large amounts of water for at least 15

minutes, followed by washing with soap and water. If

irritation persists, get medical attention.

3. Inhalation: If toluene vapors are inhaled, move the victim

at once to fresh air and get medical care as soon as possible.

If the victim is not breathing, perform cardiopulmonary

resuscitation; if breathing is difficult, give oxygen. Keep the

victim warm and quiet until medical help arrives.

4. Ingestion: DO NOT INDUCE VOMITING. If toluene or a

solution containing this substance is ingested, give the

victim several glasses of water to drink. Get medical help

immediately. Keep the victim warm and quiet until medical

help arrives.

5. Rescue: Remove an incapacitated worker from further

exposure and implement appropriate emergency

procedures. All workers should be familiar with emergency

procedures, the location and proper use of emergency

equipment, and methods of protecting themselves during

rescue operations.

14. Personal hygiene procedures:.... If toluene contacts the skin, workers should immediately wash

the affected areas with soap and water.

Clothing contaminated with toluene should be removed

immediately, and provisions should be made for the safe

removal of the chemical from the clothing. Persons laundering

the clothes should be informed of the hazardous properties of

toluene, particularly its potential to cause defatting of the skin.

A worker who handles toluene should thoroughly wash hands,

forearms, and face with soap and water before eating, using

tobacco products, or using toilet facilities.

Workers should not eat, drink, or use tobacco products in

areas where toluene or a solution containing toluene is

handled, processed, or stored.



15. Personal protective equipment:. Protective clothing should be worn to prevent any possibility

of skin contact with toluene. Chemical protective clothing

should be selected on the basis of available performance data,

manufacturers’ recommendations, and evaluation of the

clothing under actual conditions of use. The following

materials have been recommended for use against permeation

by toluene and may provide protection for periods greater than

8 hours: Polyvinyl alcohol, Teflon, and Viton. A material that

may withstand permeation for more than 4 but fewer than 8

hours is a polyethylene/ethylene vinyl alcohol mixture.

If toluene is dissolved in an organic solvent, the permeation

properties of both the solvent and the mixture must be

considered when selecting personal protective equipment and

clothing.

Safety glasses, goggles, or faceshields should be worn during

operations in which toluene might contact the eyes (e.g.,

through splashes of solution). Eyewash fountains and

emergency showers should be available within the immediate

work area whenever the potential exists for eye or skin contact

with toluene. Contact lenses should not be worn if the

potential exists for toluene exposure.

16. Storage:…...…………………... Toluene should be stored in a cool, dry, well-ventilated area in

tightly sealed containers that are labeled in accordance with

OSHA's Hazard Communication Standard. Outside or

detached storage is preferred; inside storage should be in a

standard flammable liquids storage room. Containers of

toluene should be protected from physical damage and should

be stored separately from strong oxidizers, heat, sparks, and

open flame. Drums must be equipped with self-closing valves,

pressure vacuum bungs, and flame arrestors. Only

nonsparking tools may be used to handle toluene. To prevent

static sparks, containers should be grounded and bonded for

transfers. Because containers that formerly contained toluene

may still hold product residues, they should be handled

appropriately.

17. Effects on Humans:…………... Toluene is a central nervous system depressant and an irritant

of the eyes, mucous membranes, and skin in humans. In

contact with the eyes, toluene causes reversible corneal injury;

prolonged skin contact causes defatting and dermatitis

[Hathaway, Proctor, Hughes, and Fischman 1991, p. 546].

Volunteers exposed to a 200-ppm concentration of toluene for

8 hours experienced mild upper respiratory tract irritation; at

400 ppm, subjects experienced mild eye irritation and tearing

and laughed inappropriately; at 600 ppm, the volunteers

developed slight nausea and lassitude; and at 800 ppm, they

experienced drowsiness, incoordination, and a metallic taste in

the mouth [Clayton and Clayton 1981-1982, p. 3283;

Hathaway, Proctor, Hughes, and Fischman 1991, p. 546].

Some volunteers exposed to a 100-ppm concentration of



toluene for 6 hours reported eye and nose irritation, and some

reported headache and dizziness [Hathaway, Proctor, Hughes,

and Fischman 1991, p. 546]. An employee exposed to very

high (concentration not specified) levels of toluene for 18

hours collapsed and lost consciousness; this individual

showed clinical signs of liver and kidney damage but later

recovered [Clayton and Clayton 1981-1982, p. 3285]. Painters

exposed repeatedly to toluene at concentrations between 100

and 1100 ppm developed enlarged livers, macrocytosis, a

moderate decrease in erythrocyte count, and lymphocytosis,

but showed no signs of leukopenia [ACGIH 1986, p. 578].

Studies of workers chronically exposed to toluene or mixtures

of solvents containing toluene have shown minor

abnormalities in neuropsychological test results and

decrements in performance, although a recent study of

rotogravure printers exposed to an average toluene

concentration of 117 ppm for approximately 22 years detected

no significant neurophysiologic or psychological differences

compared with these parameters in controls [Hathaway,

Proctor, Hughes, and Fischman 1991, p. 546].

Methods that are effective in controlling worker exposures to toluene, depending on the feasibility of

implementation, are

* Process enclosure

* Local exhaust ventilation

* General dilution ventilation

* Personal protective equipment

†-Reference: http://www.osha.gov/SLTC/healthguidelines/toluene/recognition.html.

You can visit this website to know more about toluene and protective procedures!

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