WAGNER Cobra 40-10, Original Operating Manual

Page 1: ...B_04233 B_04234 Cobra 40 10 Cobra 40 25 High pressure Double Diaphragm Pumps Version 01 2018...

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Page 3: ...Equipment 12 4 1 2 A Safe Work Environment 12 4 1 3 Personnel Qualifications 13 4 2 Safety Instructions for Staff 13 4 2 1 Personal Safety Equipment 13 4 2 2 Safe handling of WAGNER spray devices 14 4...

Page 4: ...ssioning and Cleaning 33 8 1 3 Long term storage 33 8 2 Maintenance 34 8 2 1 Maintenance staff 34 8 2 2 Maintenance Instructions 34 8 2 3 Safety checks and maintenance intervals 35 8 2 4 Emptying pump...

Page 5: ...sure Filter up to 530 bar 7687 psi 70 14 13 Inline Filter 90 up to 270 bar 3916 psi 72 14 14 Straight Inline Filter up to 270 bar 3 916 psi 73 14 15 AirCoat Regulator and AirCoat Filter Regulator 74 1...

Page 6: ...OLS IN THESE INSTRUCTIONS Warning instructions in this operating manual highlight particular dangers to users and to the device and state measures for avoiding the hazard These warning instructions fa...

Page 7: ...pressure tank Staff qualifications Trained person Is instructed in the tasks assigned to him her the potential risks associated with improper behavior as well as the necessary protective devices and...

Page 8: ...cation into explosion classes IIA or IIB see Chapter 2 4 WAGNER explicitly prohibits any other use The device may only be operated under the following conditions Use the device only to work with the p...

Page 9: ...e product valves etc as indicated in Chapter 5 5 Check if the fluids and solvents used are compatible with the pump construction materials as indicated in Chapter 5 5 1 Use suitable combinations of de...

Page 10: ...apter 5 5 2 Technical Data Safe handling of WAGNER spray devices Mechanical sparks can form if the device comes into contact with metal In an explosive atmosphere Knocking or pushing metal against met...

Page 11: ...ruck Fluid pressure Pression fluid bersetzungsverh ltnis Ratio Rapport F rdermenge DH Delivery DS D bit CD Max Luftdruck Air pressure Pression d air Max Temp Material Fluid Baujahr Serie Nr Year of ma...

Page 12: ...al devices 4 1 2 A SAFE WORK ENVIRONMENT Hazard due to dangerous fluids or steam Severe or fatal injuries due to explosion hazard or inhalation swallowing or contact with the skin or eyes Ensure that...

Page 13: ...about the required personnel qualifications 4 2 SAFETY INSTRUCTIONS FOR STAFF Always follow the information in this manual particularly the safety instructions and the warning instructions Always foll...

Page 14: ...Chapters 2 29 and 2 36 For shut down devices the check can be postponed until the next start up In the event of skin injuries caused by lacquer or flushing agents Note the lacquer or flushing agent t...

Page 15: ...ever run over by vehicles e g fork lift trucks or that the hoses are never put under pressure from the outside in any other way Ensure that the hoses are never kinked Observe maximum bending radii Ens...

Page 16: ...d components of equipment depending upon the used coating product depending on the flushing agent solvent used explosive mixture inside the lines and items of equipment Only electrically conductive ta...

Page 17: ...and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun high pressure hoses and all devices Secure the spray gun...

Page 18: ...iston in the air motor 4 and consequently the piston rod in the pressure stage 9 up and down At the end of each stroke the compressed air is redirected by a reversing valve and the control piston The...

Page 19: ...ing of Fluid section air motor connection elements 1 2329523 Diaphragm pump Cobra 40 25 consisting of Fluid section air motor connection elements 1 2329525 Frame mounted diaphragm pump Cobra 40 25 con...

Page 20: ...at maximum permissible air pressure dB A 74 76 Sound pressure level at 0 45 MPa 4 5 bar 65 27 psi air pressure dB A 72 74 Sound pressure level at 0 3 MPa 3 bar 43 5 psi air pressure dB A 69 71 Air mot...

Page 21: ...25 K M B D E F H I K L M G A C B_04235 Cobra 40 10 A 505 19 88 605 23 82 B 313 12 32 379 14 92 C 322 12 68 373 14 69 D 134 5 28 E 55 2 16 F 182 7 16 G 80 3 15 H M6 I 25 0 98 K G1 4 L M36 2 M G 3 8 A N...

Page 22: ...50 60 80 0 5770 0 6720 0 8130 0 017 0 43 20 30 40 50 60 70 0 7310 0 7860 1 0640 0 019 0 48 20 30 40 50 60 70 80 0 9260 1 0920 1 3700 0 021 0 53 20 40 50 60 80 1 1430 1 3600 1 6900 0 023 0 58 20 40 50...

Page 23: ...0 120 160 200 240 A A B B C Product pressure Air consumption Water flow rate A 6 bar 0 6 MPa 87 psi air pressure B 4 5 bar 0 45 MPa 65 psi air pressure C 3 bar 0 3 MPa 44 psi air pressure Stroke frequ...

Page 24: ...Positions of the ball valve B_04301 2 3 1 1 Open working position 2 Closed the air motor can still be under pressure 3 Vent Operating pressure in the air motor is vented control pressure is still pres...

Page 25: ...d commissioned 6 2 STORAGE CONDITIONS Until the point of assembly the device must be stored in a dry location free from vibrations and with a minimum of dust The device must be stored in closed rooms...

Page 26: ...al or vertical position as shown in the diagrams Overhead operation is not permitted B_01205 B_01206 Horizontal positioning Vertical positioning B_06832 Overhead positioning This pump can be used as p...

Page 27: ...3 PRODUCT SUPPLY LINES DANGER Bursting hose bursting threaded joints Danger to life from injection of product Ensure that the hose material is chemically resistant to the sprayed products Ensure that...

Page 28: ...of the Cobra pump is only guaranteed with a grounding connection Connect all ground cables using a short and direct route B_01214 Procedure 1 Screw on grounding cable with eye 2 Clamp the grounding c...

Page 29: ...8 2 3 Fill the pump with flushing agent The devices are tested during manufacturing with emulsifying oil pure oil or solvent Possible residues must be flushed out of the circuits with a solvent flushi...

Page 30: ...ff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures Before work commences the operating staff must receive appropria...

Page 31: ...in after the spray gun is closed 7 4 PRESSURE RELIEF WORK INTERRUPTION The pressure must always be relieved when after the spraying tasks are finished Before servicing the system before carrying out c...

Page 32: ...pprox 0 05 MPa 0 5 bar 7 25 psi Flushing via return tube 5 Open relief valve 3 6 Slowly open the ball valve 2 7 Adjust the air pressure on the pressure regulator 1 so that the pump runs smoothly 8 Rin...

Page 33: ...d check the suction system and the suction filter 6 When using a product filter check filter insert and filter housing and clean or replace them Section 8 2 6 3 7 Clean the outside of the system WARNI...

Page 34: ...e only WAGNER original spare parts and accessories Only repair and replace parts that are listed in the Spare parts chapter and that are assigned to the unit Before all work on the device and in the e...

Page 35: ...pressure generator and application device is reduced due to environmental influences even when handled correctly Check hoses pipes and couplings every day and replace if necessary Before every commiss...

Page 36: ...pty using return line 5 Open relief valve 3 6 Slowly open the ball valve 2 7 Slowly turn air pressure up on the pressure regulator 1 and only until the pump is running normally approx 0 05 MPa 0 5 bar...

Page 37: ...lator 1 0 MPa 0 bar 0 psi 5 Open relief valve 3 6 Slowly open the ball valve 2 7 Slowly turn the air pressure up on the pressure regulator 1 and only until the pump is running normally approx 0 0 05 M...

Page 38: ...inlet housing 2 and outlet housing 5 with two size 19 wrenches 11 If necessary screw the hose back on 12 Fill the pump in accordance with Chapter 8 2 5 Order No see Chapter 13 Order No see Chapter 10...

Page 39: ...nd lift slightly so that it does not get dirty in the next step 7 Remove the filter housing 2 with the union nut 3 The cone spring 12 remains in the filter housing 2 If the O ring 5 is not damaged it...

Page 40: ...in the picture and turn it upside down Observe the fill level marking X on the oil tank Oil level A in the oil tank 1 has to be within the specified markings X If the level deviates from these markin...

Page 41: ...rderno 322912 250mlor15cuinch 8 2 9 1 DISCHARGING OIL B_04241 1 4 3 B_04244 2 Procedure 1 Decommission and clean Chapter 8 1 2 up to and including point 6 2 Position device as shown in the picture and...

Page 42: ...ing screws 4 and replace with 2 screw fittings 6 from the oil filling set 4 Connect hoses with Y pieces 7 5 Fill syringe 8 with hydraulic oil and insert into hose 6 Move piston 9 into front end positi...

Page 43: ...ded plug 5 2 Slowly start up the pump vent until no more air bubbles rise from the oil intake tube 3 Oil level A in the oil tank has to be within the specified markings X 4 Screw in threaded plug 5 an...

Page 44: ...h Thin spraying product Spraying pressure is too low Increase incoming air pressure Use a smaller nozzle Valves are clogged Press valve depressor Clean product pump and leave to soak in cleaning agent...

Page 45: ...parts that are listed in the Spare parts chapter and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun high pre...

Page 46: ...es 10 5 ASSEMBLY OF THE DEVICE In Chapter 14 the order numbers for device spare parts can be found as well as for wearing parts such as seals Defective parts O rings and seal sets must always be re pl...

Page 47: ...e frame trolley and between the individual components of the frame trolley 100k Ohmmeter Check conductivity between the piston and the grounding connection 100k These inspections are relevant 4 Testin...

Page 48: ...e differentiate the disposal of the waste materials The following materials have been used Stainless steel Aluminum Elastomerics Plastics Carbide Consumable products Consumable products lacquers adhes...

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Page 50: ...COBRA 40 10 ACCESSORIES B_04234 11 17 13 24 21 20 25 15 12 14 12 7 A 51 52 B_04248 3 AirCoat 1 4 2 53 26 28 27 29 30 31 32 22 16 14 6 9 10 19 8 18 55 56 57 33 34 58 Note When the fitting at the produc...

Page 51: ...g RF FM G3 8 3 8NPSM 530 bar SSt 20 322052 Frame complete 21 2332143 Wall mount 4 complete 22 2349756 Wall mounting long 24 2323396 Air suction filter DN16 25 2325901 Trolley 4 complete 26 2344741 2 L...

Page 52: ...ACCESSORIES 28 27 29 30 31 21 20 25 6 1 A 51 4 2 B_04249 11 17 13 24 12 12 53 52 7 33 34 18 9 8 10 19 55 56 32 57 58 60 61 22 59 55 3 AirCoat 16 14 15 Note When the fitting is replaced at the product...

Page 53: ...78 20 liter tank 28 2345265 Exhaust pipe 20L 29 3767 Filter disk D51 30 2304620 Drum cover 365 B 31 2304439 Drumcover 365 E 32 2341375 Cobra trolley complete 33 2324558 Inline filter DN6 PN270 G1 4 SS...

Page 54: ...lists Wearing parts Wearing parts are not included in the warranty terms Included in service set Notice Note These parts are not covered by warranty terms Not part of standard equipment available howe...

Page 55: ...36 Air motor casing 4 1 322437 Pressure stage casing 5 1 322235 Hood 4 with air outlet 6 3 9907224 Hexagon socket cylinder head screw 7 4 9920106 Washer 8 1 9900107 Hexagon screw 9 1 2332077 Warning l...

Page 56: ...27 33 35 36 37 38 39 40 41 22 25 43 42 44 47 48 45 44 49 51 50 46 26 26 55 28 29 27 10 15 Nm 7 11 lbft 20 25 Nm 15 18 lbft 2 3 Nm 1 5 2 2 lbft 50 25Nm 24 53 B_06851 Do not dismount the piston Order N...

Page 57: ...4 1 368038 Detent body complete ISO 1 2 35 2 9907126 Screw SFS Plastite 45 36 2 9974089 O ring 37 2 9974115 O ring 38 1 322432 Control air pipe 39 1 322430 Cylinder pipe 40 1 322431 Compressed air pip...

Page 58: ...97 96 95 94 18 93 17 35 33 34 32 31 46 47 49 50 41 101 27 102 26 66 67 38 40 16 91 19 69 20 21 22 23 92 24 25 67 26 102 27 4 89 90 78 110 110 13 112 105 78 70 Nm 52 lbft 90 Nm 66 lbft 30 Nm 22 lbft 50...

Page 59: ...2338520 Pressure stage D19 53 24 3 9907041 Hexagon screw 25 1 322402 Piston rod D19 53 26 2 9941502 Ball 27 2 9971189 O ring 29 1 9962028 Permaglide bushing 30 1 322403 Pressure stage flange 31 2 9974...

Page 60: ...322408 Oil valve pressure ring 103 1 9992590 Loctite 222 50 ml 50 cc 104 1 9992831 Loctite 542 50 ml 50 cc 105 1 9971395 O ring 10x1 25 106 1 2312288 Service set for Cobra 40 10 fluid section 107 1 32...

Page 61: ...air outlet 5 3 2308693 Hexagon socket cylinder head screw 6 1 9900107 Hexagon screw without shaft 7 1 2332077 Warning label 8 1 2332082 Fluid warning label 9 2 9920104 Washer 10 2 9900152 Hexagon scr...

Page 62: ...2 17 18 19 20 21 34 56 56 57 27 33 35 36 37 38 39 40 41 26 26 55 28 29 27 10 15 Nm 7 11 lbft 20 25 Nm 15 18 lbft 2 3 Nm 1 5 2 2 lbft 67 24 63 25Nm 63 B 06852 42 44 43 64 65 25 22 62 60 49 61 48 50 26...

Page 63: ...body complete ISO 1 2 35 2 9907126 Screw SFS Plastite 45 36 2 9974089 O ring 37 2 9974084 O ring 38 1 367305 Control air pipe 39 1 2306127 Cylinder pipe 40 1 367304 Compressed air pipe 41 2 9971448 O...

Page 64: ...24 92 25 67 26 102 27 4 71 13 100 Nm 74 lbft 8 x 120 Nm 89 lbft 2 x 50 Nm 37 lbft 2 Nm 1 5 lbft 105 104 20 Nm 15 lbft 20 Nm 14 8 lbft 40 Nm 29 5 lbft 110 110 110 110 110 110 72 28 17 81 80 104 1 5 Nm...

Page 65: ...valve 29 1 2306146 Permaglide bushing 30 1 2308870 Pressure stage flange 31 2 2306143 Rod sealing profile BS 32 2 2306144 Rod sealing set 33 2 2306145 O ring 34 2 9971446 O ring 35 2 2306139 Pressure...

Page 66: ...ctite 270 50 ml 50 cc 107 1 2312289 Service set for Cobra 40 25 fluid section 108 1 2314671 Service set for Cobra 40 25 piston incl items 16 25 31 32 33 59 and 109 109 1 2314670 Piston rod assembly pi...

Page 67: ...clamp 3 2 344334 Spring guide 4 2 190304 Pressure spring 5 2 158333 Guide 6 4 341331 Sealing ring 7 2 344322 Valve housing 8 2 340346 Valve seat 10 1 9992528 Loctite 270 50 ml 50 cc 11 2 340342 Valve...

Page 68: ...ring 5 2 341344 Valve guide 6 2 341330 Sealing ring 7 2 Valve housing 8 2 341385 Valve seat 9 2 341331 Sealing ring 10 1 9992528 Loctite 270 50 ml 50 cc 11 2 341395 Valve cone Wearing part 14 11 RELIE...

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Page 70: ...UMBER DOC 2340851 Cobra 40 10 40 25 14 12 HIGH PRESSURE FILTER UP TO 530 BAR 7687 PSI 90 Nm 66 lbft 140 Nm 103 lbft 12 21 11 10 1 4 7 33 2 3 5 B_05065 23 36 35 36 34 34 20 34 Identification of the fil...

Page 71: ...tion housing for ball valve 10 1 9894245 Filter support 11 1 Filter sieve 295721 Filter sieve 200 3514068 Filter sieve 100 3514069 Filter sieve 50 291564 Filter sieve 20 12 1 3514058 Cone spring 20 1...

Page 72: ...00 mesh per inch 3 1 2315723 Filter insert red fine 200 mesh per inch 10 pieces 3 1 2315724 Filter insert blue middle 150 mesh per inch 10 pieces 3 1 2315725 Filter insert yellow middle 100 mesh per i...

Page 73: ...er insert yellow middle 100 mesh per inch 4 1 2315723 Filter insert red fine 200 mesh per inch 10 pieces 4 1 2315724 Filter insert blue middle 150 mesh per inch 10 pieces 4 1 2315725 Filter insert yel...

Page 74: ...nt via container coating Order No Order No Designation 1 1 2328611 AirCoat regulator set 2 1 2382997 AirCoat filter regulator set 3 1 2309972 Pressure regulator LR 1 4 D O l Mini 4 1 2331950 Filter co...

Page 75: ...ddle feet for round tubes 6 2 9910204 Self locking hexagon nut M6 7 2 9900202 Hexagon screw M6x40 8 4 9900126 Hexagon screw M6x45 Wearing part 14 17 COBRA 40 25 FRAME COMPLETE Order No Designation 1 1...

Page 76: ...76 VERSION 01 2018 ORDER NUMBER DOC 2340851 Cobra 40 10 40 25 14 18 HORIZONTAL COBRA TROLLEY Axle setting Cobra trolley B_05001 4 3 1 2 5 6 8 7 14 12 11 9 15 10 16 5 A A 13 17 18...

Page 77: ...nut M6 6 2 2304440 Wheel D250 7 4 340372 Washer 8 4 9995302 Cotter pin 9 1 Wheel axle 4 6 complete 10 2 367943 Connecting part 4 6 11 2 Tube plug ribbed 12 4 9998685 Saddle feet for round tubes 13 2 P...

Page 78: ...6 welded 4 4 9907140 Hexagon screw DIN931 M6x75 5 6 9910204 Self locking hexagon nut M6 6 2 2304440 Wheel D250 7 4 340372 Washer 8 4 9995302 Cotter pin 9 1 Wheel axle 4 6 10 2 367943 Connecting part 4...

Page 79: ...3 7 Order No Designation 1 1 2344505 Hopper set Ex 5 L 1 3 gal 2 2 9902313 Cylinder self tapping screw 3 1 3756 Filter disk mesh 0 4 mm 0 02 inch 3a 1 37607 Filter disk mesh 0 8 mm 0 03 inch 4 1 3402...

Page 80: ...r No Designation 1 2344741 2L Cobra tank 1 1 2320844 Union nut with bayonet 2 1 2321426 Low pressure mini ball valve G1 2 3 1 2341277 2 l tank 4 1 2341532 Cover 5 2 2321676 Sieve insert SPA easy line...

Page 81: ...ress of the purchaser We do not provide warranty for damage that has been caused or contributed to for the following reasons Unsuitable or improper use faulty assembly or commissioning by the purchase...

Page 82: ...2006 A1 2010 EN 809 1998 A1 2009 AC 2010 EN 1127 1 2011 EN ISO 4413 2010 EN ISO 80079 36 2016 EN ISO 4414 2010 EN ISO 80079 37 2016 EN ISO 13732 1 2008 EN ISO IEC 80079 34 2011 EN 14462 2015 Applied n...

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Page 84: ...84 CERTI F I E D ts liquid wagner group com www wagner group com Document No 11156044 Version B Order No 2340851 Edition 01 2018...