Translation of original operation manual WIWA ProfessionalProfessional · DBK · en · 02.12 · jw
Operation manual
WIWA ProfessionalType: 24026
24053
24071
28023
28048
28064
38032
38042
44024
44032
Serial-No.… … … … … … … …
Translation of the original operation manual Airless 3•Professional_BAoDB_en_1011•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 72.6 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 Maintenance 198.1 Regularinspections 198.2 Maintenanceplan 198.3 Highpressurefilter 198.4 Maintenanceunit 19
9 Malfunctions and troubleshooting 22
10 Appendix 2310.1 Technicalspecifications 2310.2 Auxiliarymaterials 2310.3 Machinecard 2410.4 Certificateoftrainingandoperation 24
Contents 1
4 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•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!
Translation of the original operation manual Airless 5•Professional_BAoDB_en_1011•ski
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 (Unfallverhütungsvor-schrift), BGR 500, Kap. 2.29, to ensure that the machine is properly grounded. Please, observe our instruction manual.
On the material pump cylinder: Nameplate (picture2.2.2) Pleaseobservethattheinformationlocatedonthenameplatecorrespondsto data found on the machinecard.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
6 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
2 Safety
Itleftthefactoryinperfectconditionandwarrantsahighlevelofsafety.However,thefollowingdangersexistifoperatedincorrectlyorusedinappropriately: tolifeandlimbofoperator or third personsor forthemachineandotherpropertybelongingtoownerofmachine
fortheefficientworkingofthemachine
Allpersonnelinvolvedinthestarting,operationandmaintenanceofthemachinemustreadthefollowingnotescarefullyandobservethem.Itisamatteroftheirsafety!Werecommendthatthemachineoperationmanagementhavethisconfirmedinwriting.
2.4 Application of the machineThe AirlessPaintSprayingMachineswereespe-ciallydesignedforstrongcorrosionprotection.
Modell: 24053, 24071, 28048, 28064Theseairlesspaintsprayingunitsaresuitableforwor-kingwithbothlowandhighviscosity,high-builtmaterials,regardlesswhethertheyarewaterorsolventbased.Lowsolventandsolvent-freematerialscanbeprocessedaswell.Thesemachinesareoptimalforsprayingapplicationsusinglongerfluidhosesandlargertip-bores,aswellasforsprayingunderhighpressureconditions.
Model: 38032, 38042, 44024, 44032Theseairlesspaintsprayingmachineswereespeciallydevelopedfortheuseofcoarse-pigmentedorabrasivematerialshavingalowtomiddlelevelofviscosity,suchaszincprimer,ferricoxide,zincsilicateonasolventbasis,glassflake,printingink,flameprotectionandotherheavilypigmentedorfibrousmaterials.Thesemachinesareknownfortheirabilitytohandlealargevolumeofmaterialflow,evenwhenusinglargetipopeningsandlowpistonspeedsandtokeepunitwearataminimum.Theyareespeciallywellsuitedwhenusingautomaticpaintsprayingsystemseitherwithorwithoutcirculation.
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,thisunitisto
beconsideredasGroupII,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,inaccor-dancewithlocalregulatoryauthorityguidelines.Further-more, 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.
Itmustbeensuredthatthe unit is grounded either separatelyortogetherwiththeequipmentitismountedto(maximumresistance106Ω,picture2.4.1ground/potentialequalization).
Spayingmachineswhicharenotprotectedagainstexplo-sionsmaynotbeusedinworkplaceswhichfallundertheregulationcoveringexplosionprotection.Pneumaticallydrivenairlesssprayingmachinesarenotaffectedbythis.Should,however,additionalelectricallydrivenaccesso-riesbemountedtothesemachines,suchasagitatorsorheaters,theregulationcoveringexplosionpreventionmustbecheckedforcompliance.Plugsforheaters,agitators,etc.whicharenotprotectedagainstexplosionsmayonlybepluggedintosocketsloca-tedoutsideofareasthatfallundertheregulationcoveringexplosionprevention,eveniftheaccessorybeingusedisexplosionprotected.
Picture2.4.1
Translation of the original operation manual Airless 7•Professional_BAoDB_en_1011•ski
2.6 Sources of dangerRememberthat AirlessPaintSprayingMachineworkunderextremepressureproceduresandthattheycancauselife-endangeringinjuriesifusedinappropriately.
Warning!Materialexitsthespraygunatveryhighpressurelevels.Thesprayjetcancutorbeinjectedundertheskinoreyes,resultinginseriousinjuries. Never pointthesprayguntowardsyourself,otherpeopleorotherlivingcreatures.
Never holdyourfingerorhandinfrontofthespraygunand never reachintothesprayjet.
Warning!Unintentionaltriggeringofthesprayguncanleadtoinjuryordamagetoproperty. Alwaysapplythespraygunsafetycatch,regardlesshowshortthepauseinsprayingis.
Beforeoperation,alwayscheckthefunctionofthespraygunsafetycatch.
Warning!Componentsthatdonotcorrespondtothemaximumpres-surecreatedbythepumparequicklypronetorupture,leadingtoseriousinjuries. Fluid hoses mustberatedtocorrespondtothemaxi-mumoperatingpressureoftheunit,withanappropri-atesafetyfactorallowance.
Nohosesmayshowsignsofleaks,kinks,wearorblisters.
Allhoseconnectionsmustbetight.
Themaximumoperatingpressurestatedbyusmustcorrespondtoall componentsandacces-soryitemswithinthesystem(i.e.pumps,heaters,hoses,sprayguns,safetyvalves).
Ifthepressureratingsdiffer,thelowestratedmax.pressu-rebecomesvalidfortheentiresystem.Example:Pump max.420bar(6090psi)Fluidhose max.600bar(8700psi)Spraygun max.500bar(7250psi)Themaximumallowableoperationpressurefortheentiresystemis420bar(6090psi).
Warning!Ifusedoutdoors,alightningstrikecouldleadtoinjury. Neveroperatetheunitoutdoorsduringathunderstorm.
Warning!Itispossibleforastaticchargetooccurduetothehighflowspeedsduringtheairlesssprayingprocedure.Static
Otherusageisnotinlinewithregulations.Beforeequipmentisusedforotherpurposesorwith
othermaterials,and,therefore,notaccordingtotheregu-lations,permissionshouldbeobtainedfromthemanufac-turer,astheguaranteeisotherwiseinvalid.Theobserva-tionoftechnicaldocumentationandthecompliancewithspecifiedoperational,maintenanceandstartingguidelinesaremanditoryinaccordancewiththevalidregulations.
2.5 Machine surroundingsRebuilds and changesForsafetyreasons,itisnotallowedtocarryoutrebuildsorchangeswithoutauthorization.Protectiveequipmentmaynotbedismounted,changedorneglected.Ifusingcomponentswhicharenotproducedordeliveredby ,warrantycoverageisnegatedaswellasliability.Themachinemayonlybeoperatedwithintheprescribedlimitsandmachineparameters.
Danger caused by attachments and spare partsIfyouuseoriginalattachmentsandoriginalsparepartsfrom ,thecompatabilitywithourequipmentisgu-aranteed.Itis,however,essentialthatthesafetyregulati-onsoftheattachmentsandsparepartsareobserved.YoucanfindthesesafetyregulationsintheUser’sHandbooklocatedwiththesparepartslists.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".
Safety 2
8 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
2 Safety
chargescanleadtofireandexplosions.Alwaysuseanopencontainer. Never spraysolventsormaterialscontainingsolventsintonarrow-neckedcansorbarrelswithbungholes!
Ensurethatthespraygunhascontactwiththecontai-nerwallswhenworkingwithmetalcontainers.
Danger of explosion!Heatedsolventcanleadtoanexplosionwithinthepump.Thiscouldresultinseriousinjuries,includinglossofvi-sion,andpropertydamage.Alwaysobservetheflashpointandignitiontemperatureforthesolventbeingused!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,ashemustensurethatthemachineis
functional.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.
Translation of the original operation manual Airless 9•Professional_BAoDB_en_1011•ski
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.
Picture2.10.1
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Picture2.10.2
Picture2.10.3
Despitethefactthatnolegalregulationsexistcoveringthelow-fogairlesssprayingmethod,dangeroussol-ventfumesandparticlesofpaintshouldberemovedofpervaccuum.
Theowner/operatorofthisequipmentisrequiredtoensurethatproperprotectionagainstlightningstrikesisavailable.
Complystrictlywiththecurrentrulesforaccidentprevention.
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
10 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
2 Safety
Activity Personnel QualificationServicingwork trained operatorCleaningwork trained operatorMaintenancework personneltrainedby
CustomerserviceRepairwork 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
Theunitmust,therefore,alwaysbegroundedproperly.Factory-delivered Airlesssprayingequipmentcomesstandaredwithagroundcable.Iflostordefective,itmustbereplaced(partno.0474487)..
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 trained operator
Picture2.10.4
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TranslationoftheoriginaloperationmanualAirless 11 11•Professional_BAoDB_en_1011•ski
Component description 3
Positions1 savetyvalve2 t-handlescrew3 maintenanceunit4 airtap5 airinlet6 cart7 Releaseagent-drainscrew8 material pump9 suctionpipe10 suctionhose11 airmuffler
12 airmotor13 Releaseagent-fillerneck14 venthole15 spannerwithchain16 highpressurefilter17 highpressurevalve18 dumphose19 Groundcable20 spraygun21 materialhose22 fluidseive
12 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
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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Picture4.1.3
Picture4.1.1
Picture4.1.2
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.
TranslationoftheoriginaloperationmanualAirless 13 13•Professional_BAoDB_en_1011•ski
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-refertoChapter8.2"Maintenanceplan". Theunitisfilledwithreleaseagentpriortodelivery.
6. Maintenance unit prepare Fillthemaintenanceunitwithpneumaticoiloranti-freezeandtakethesettingasdescribedinchapter8.4"Maintenanceonthemaintenanceunit.
ResultThemachineisnowreadyforoperation.Continuewiththefirstcleaning(chapter5.1).
Picture4.1.4
14 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
5 Start-up
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Picture5.1.1
P-
4. Remove the filter insert Removethefilterinsertfromthehighpressurefilterinaccordancewithchapter8.3.
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)
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.
5.1 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.
3. Connect the compressed air line (Picture5.1.1) Closetheairtaplock. Turnthecontrolknobontheairpressureregulatorcounter-clockwiseuntilitturnsfreely.
Connecttheairsupplylinetotheinboundairconnec-tion.
TranslationoftheoriginaloperationmanualAirless 15 15•Professional_BAoDB_en_1011•ski
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).
Observethemaximumallowableoperatingpres-sureforallsystemcomponents.Iftheratingsvary,thelowestpressureratingbecomesthemaximumallowablepressurefortheentiresystem(refertotheexambleinChapter2.6).
3. Check the safety valve Brieflyraisethepressureapproximately10%abovethemaximumallowableinboundairpressure. Thesafetyvalvemustblowoff
Start-up 5
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..
16 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
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 solvent being used as stated in the manufacturer's data sheet!
Settherequiredoperatingpressurebyadjustingtheairpressureregulatorcontrolknobaccordingly.
ResultTheunitisnowreadyforcoatingsoperation.BeginsprayingaccordingtoChapter6.2.
6.1 Equipment preparationJobPreparetheunitforoperation.
Prerequisite Required:
1opencontainerwithcleaningmaterial(sol-ventbelongingtothecoatingmaterialandrecommendedbythematerialmanufacturer),calledcontainer"A“below
1empty,opencontainerforthesoiledcleaningmaterial/materialmixture,abbreviatedascon-tainer "B“below.
1materialcontainer,calledcontainer"C“ below.
Inspectthesealofallsystemcomponentsandtightentheconnections,ifnecessary.
Please wear protective clothing at all times, as solvent vapours and splashes of solvent cannot be avoided completely.
Do not use narrow-necked cans or barrels with bung holes
Procedure1. Connect the inbound compressed air line
(Picture6.1.1) Closetheairtaplock. Turntheairpressureregulatorcontrolknobcounterclo-ckwiseuntilitturnsfreely.
Connecttheinboundairlinetothefittingontheairmotor.
I
0
Picture6.1.1
P-
2. Pressure check CompletethepressurecheckdescribedinChapter5.2.
3. Place a filter element into the high-pressure filter Depressurizethesystem. PlaceafilterelementaccordingtoChapter8.3intothehigh-pressurefilter.
TranslationoftheoriginaloperationmanualAirless 17 17•Professional_BAoDB_en_1011•ski
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-pressurefilteraccordingtoChapter8.3.
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
18 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
7 Shutting down
JobTheunitistobecleanedandtakenoutofserviceafterworkiscompleted.
Prerequisite Required:
1opencontainerwithatleast5liters(1.3gal.)ofcleaningmaterial(thesolventmustcorre-spondtothecoatingmaterialandberecom-mendedbythematerialmanufacturer),calledcontainer"A"below.
1empty,opencontainerforthesolvent/coa-tingmaterialmixture,calledcontainer"B" below.
1materialcontainer,calledcontainer"C" below
Please wear protective clothing at all times, as solvent vapours and splashes of solvent cannot be avoided completely.
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"andsecureitagianstslipping.
Openthedrainvalveonthehigh-pressurefilteruntilthepumprunsdry.
Turnthecontrolknobcounterclockwiseuntilitturnsfreely.Thepressuremustread0bar/psionthepressu-regauge.
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.
TranslationoftheoriginaloperationmanualAirless 19 19•Professional_BAoDB_en_1011•ski
8.1 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.
8.2 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.(Picture8.2.1)Ifnecessary,fillreleaseagentintothefillingtubeuntilthereleaseagentisvisibleapprox.1cm(0.4in.)belowtheopening.Thechamberholdsapprox.50ml(1.7fl.oz.)ofreleaseagent.
Checkregularlytherelease agentfordiscolorationcausedbycontactwiththespraymaterial Thediscolorationcanbemonitoredbydrainingasmall amount ofrelease agent.Afterchecking,addacorrespondingamountofcleanrelease agent to the chamber.
Heavy discoloration and material contermination:Thesestepsmayonlybeperfomedbypersonneltrainedby or CustomerService.
Replacethematerialpumppackingsets(refertothesparepartslistforthematerialpump)
Cleanthereleaseagentchamber. Fillthechamberwithcleanreleaseagent.
Picture8.2.1
High-pressure filter maintenanceCleanthefilterinsertbeforeeverychangeofspraymateri-alordaily,atthelatest.ObserveandfollowtheinstructionsfoundinChapter6.3"Changeofmaterial".
8.3 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.
Maintenance 8
20 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
8 Maintenance
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
8.4 Maintenance unit
Picture8.4.1
Lubricant and/or anti-freezing agent Checktheairmotor'slubricantinthebowloftheairmaintenanceunitandrefill,ifrequired.
Highairhumiditycancauseicingofthemotor. Incaseoficing,onlyusepureanti-freezingagent.
Brieflytriggerthespraygun. Todrainpressure,openthedrainvalve/screwonthehigh-pressurefilter.
Disassemblethehigh-pressurefilterverycarefully! Replacewornpartswithnewones..
Procedure Holdthedrainhoseintocontainer"B". Closetheairtaplockforthepump. Todepressurize,openthedrainvalve(Picture8.3.1,pos.6).
Picture8.3.1
Removing the filter insert Unscrewthecap(Picture8.3.1,pos.1)withthespanner (Picture8.3.1,pos.2).
Unscrewthenut(Picture8.3.1,pos.3)withaforkwrenchandremovethefilterinsert(Picture8.3.1,pos.4)).
Cleanthefilterinsert. Useonlytheappropriatesolventforthematerialbeingworkedwith. Replacethefilterinsertshouldanysignofdamagebepresent..
Replacetheo-ring(Picture8.3.1,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.
TranslationoftheoriginaloperationmanualAirless 21 21•Professional_BAoDB_en_1011•ski
Maintenance 8
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 Thecollectedcondensationwillbeautomaticallydrainedbythedrainvalve.Placethehoseintoanemptycatchbasin.
Checkthereservoirsregularlyforcontaminationandcleanasnecessary.
Notes to the oil reservoir/water cutoff Toremovereservoir:
Pressreleasedownwards. Turnreservoircounter-clockwise.
Montage: TakecareduringassemblythattheO-ringisseatedproperlyinthehousing!
22 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
9 Malfunctions and troubleshooting
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!
TranslationoftheoriginaloperationmanualAirless 23 23•Professional_BAoDB_en_1011•ski
10.1 Technical specifications
Model 24026 24053 24071 28023 28048 28064 38032 38042 44024 44032
Air motor piston diamater (mm) 140 200 230 140 200 230 200 230 200 230Airmotorpistonstroke(mm) 120 120 120 120 120 120 120 120 120 120Pumpratio 26:1 53:1 71:1 23:1 48:1 64:1 32:1 42:1 24:1 32:1Max.free-flowoutput(ltr/min) 24 24 24 28 28 28 38 38 44 44Outputpercycle(cm3) 138 138 138 153 153 153 235 235 306 306Max.inputairpressure(bar) 8 8 6,5 8 8 7 8 8 8 8Max.operatingpressure((bar) 208 420 460 184 380 450 255 335 190 255Max.tipsize(highpressurefilter)(inch) 1/4NPSM(A)2x3/8Airinlet(maintenanceunit)(inch) 1DimensionsLxWxHcartmounted(cm) 65x70x130wallmounted(cm) 60x45x130Netweight(cartmounted)(kg) 85 86 85 86 90 91 91 92SoundpressurelevelemittedattheworkplaceRunningatidle(LpAd)(dB) 84Runningwithload(LpAd)(dB) 80
10.2 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
Appendix 10
24 Translation of the original operation manual Airless •Professional_BAoDB_en_1011•ski
10 Appendix
10.3 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.
10.4 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)