Page 3 - O P E R AT I N G M A N UA L; Table of Contents
3 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Table of Contents 1 ABOUT THIS OPERATING MANUAL 5 1.1 Preface 5 1.2 Warnings, Notices, and Symbols in this Operating Manual 5 1.3 Languages 6 1.4 Abbreviations in the Text 6 2 CORRECT USE 7 2.1 Device...
Page 5 - ABOUT THIS OPERATING MANUAL; Non-observance will result in death or serious injury.; DANGER
5 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 1 ABOUT THIS OPERATING MANUAL 1.1 PREFACE 1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL Warning instructions in this operating manual highlight particular dangers to users and to the dev...
Page 6 - LANGUAGES
6 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 1.3 LANGUAGES The operating manual is available in the following languages: Language Order No. Language Order No. German 2303152 English 2303675 French 2303676 Dutch 2303677 Italian 2303678 Spanish 23...
Page 7 - CORRECT USE; DEVICE TYPES; Double diaphragm pump and spray pack:; TYPE OF USE
7 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 2 CORRECT USE 2.1 DEVICE TYPES Double diaphragm pump and spray pack: 2.2 TYPE OF USE 2.3 USE IN AN EXPLOSION HAZARD AREA The device is suitable for processing liquid materials like paints and lacquers...
Page 8 - NOTICE
8 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Application Water-dilutable productsSolvent-based lacquers and paintsTwo-component coating productsEmulsionsUV lacquersPrimersEpoxy and polyurethane lacquers, phenolic lacquersLiquid plasticsWax-based...
Page 9 - The following is prohibited:
9 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 2.6 REASONABLY FORESEEABLE MISUSE The following is prohibited: coating work pieces which are not grounded,unauthorized conversions and modifi cations to the double diaphragm pump,processing dry or sim...
Page 10 - IDENTIFICATION
10 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 3.1 EXPLOSION PROTECTION IDENTIFICATION As defi ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially explosive areas. European CommunitiesSymbol for explosion protectionD...
Page 11 - GENERAL SAFETY INSTRUCTIONS; SAFETY INSTRUCTIONS FOR THE OPERATOR
11 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 4 GENERAL SAFETY INSTRUCTIONS 4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR 4.1.1 ELECTRICAL EQUIPMENT 4.1.2 STAFF QUALIFICATIONS 4.1.3 SAFE WORK ENVIRONMENT Keep this operating manual to hand near the de...
Page 12 - SAFE HANDLING OF WAGNER SPRAY DEVICES
12 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES The spray jet is under pressure and can cause dangerous injuries.Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never re...
Page 13 - PRODUCT HOSES
13 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Ensure that the hose material is chemically resistant to the sprayed products. Ensure that the product hose is suitable for the pressure generated in the device. Ensure that the following information...
Page 14 - TOUCHING HOT SURFACES
14 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 4.2.6 TOUCHING HOT SURFACES Only touch hot surfaces if you are wearing protective gloves. When operating the device with a coating product with a temperature of > 43 °C; 109.4 °F: - Identify the d...
Page 15 - allowable surface temperature.
15 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS The pneumatic pump may be used in potentially explosive areas. The following safety regulations must be observed and followed. 4.3.1 SAFETY REGULATIONS S...
Page 16 - OPERATION WITHOUT FLUID; cient separating agent.
16 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 4.3.2 OPERATION WITHOUT FLUID Avoid running the pump so that it sucks in air (without fl uid inside). The air, combined with the vapor of fl ammable fl uids, can generate internal areas with an explo...
Page 17 - DESCRIPTION
17 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 5.1 SCOPE OF DELIVERY Inlet housing Consital (aluminum alloy) Fluid section Consital (aluminum alloy) Valve balls Stainless steel Valve seats/valve cone Carbide Diaphragms Resistant PA Valve fi tting...
Page 18 - Description; WARNING
18 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 * A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005. Reference measurements have been made by SUVA (Swiss Accident Insurance Institute). Description ...
Page 19 - MEASUREMENTS AND CONNECTIONS; Measurement
19 B_02943 G P Q N O R F B D E F H I K L M G A C B_04235 Cobra 40-10 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 5.2.3 MEASUREMENTS AND CONNECTIONS Measurement mm; inch A 505; 19.88 B 313; 12.32 C 322; 12.68 D 134; 5.28 E 55; 2.16 F 182; 7.16 G 8...
Page 20 - VOLUME FLOW; roduc; Wagner AL nozzles
20 BAR BAR BAR BAR BAR BAR "? O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 5.2.4 VOLUME FLOW 5.2.5 PERFORMANCE DIAGRAMS Stroke frequency (DH/min) P roduc t pr essur e (bar) Air c onsumption (nl/min) Water fl ow rate (nl/min) Wagner AL nozzles ...
Page 22 - General information
22 1 4 6 9 3 5 2 7 13 14 10 11 12 15 8 B_04237 Cobra 40-10 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 General information The double diaphragm pump is driven with compressed air. This compressed air moves the air piston in the air motor (4), and...
Page 23 - Positioning; Vertical positioning
23 B_01205 "? B_01207 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Positioning The Cobra pump may only be operated in a horizontal or vertical position as shown in the diagrams. Overhead operation is not permitted. Vertical positioning Horizon...
Page 24 - PRESSURE REGULATOR UNIT FOR COBRA
24 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 5.3.2 PRESSURE REGULATOR UNIT FOR COBRA B_04301 2 3 1 B_04300 2 3 1 4 5 Positions of the ball valve 1 Open : working position 2 Closed: The air motor can still be under pressure. 3 Vent: Operating pr...
Page 25 - ASSEMBLY AND COMMISSIONING; INSTALLATION AND CONNECTION; Risk of accidents if the device rolls away/falls.
25 B_04239 1 6 7 2 4 5 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 6 ASSEMBLY AND COMMISSIONING 6.1 INSTALLATION AND CONNECTION 6.1.1 INSTALLING THE PUMP Procedure: 1 Mount the pump on a base frame, trolley (6), or wall mount. 2 For AirCoat syste...
Page 26 - GROUNDING; Heavy paint mist if grounding is insuffi
26 "? 2MAX- 7 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 6.1.2 GROUNDING Grounding scheme (example) Pump Paint tank Work piece Conveyor Spraying stand Floor static dissipative Discharge of electrostatically charged components in atmospheres ...
Page 27 - Cable cross sections
27 "? O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Cable cross sections Pump 4 mm2; AWG11 Paint tank 6 mm2; AWG10 Conveyor 16 mm2; AWG5 Booth 16 mm2; AWG5 Spraying stand 16 mm2; AWG5 Procedure: 1 Screw on grounding cable with eye.2 Clamp the g...
Page 28 - SAFETY INSTRUCTIONS; Gas mixtures can explode if there is an incompletely filled pump!
28 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 6.2.1 SAFETY INSTRUCTIONS 6.2 COMMISSIONING Every time before starting up, the following points should be observed as laid down in the operating manual: - Observe all safety regulations in accordance...
Page 30 - Cobra EMERGENCY STOP; In the event of unforeseen occurrences, the ball valve (1) should be; vented; immediately; vent; Open
30 ➁ ➀ B_04303 B_04302 1 2 B_04099 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Cobra EMERGENCY STOP In the event of unforeseen occurrences, the ball valve (1) should be vented immediately and the relief valve (2) opened. vent Open Switch position...
Page 31 - BASIC FLUSHING
31 "? 6 1 9 2 7 4 5 B_04240 3 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 6.2.2 BASIC FLUSHING V Note: During the fl ushing procedure, briefl y press both valve depressors (V). 1 Place empty tank (5) under return tube (4). 2 Place suction hos...
Page 32 - FILLING WITH WORKING MATERIAL
32 B_04301 2 3 1 B_04303 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 6.2.3 FILLING WITH WORKING MATERIAL Relief valve Circulation mode Spraying mode 1 Place suction hose (7) and return tube (4) into the tank with the working material (6). 2 Adjus...
Page 33 - SPRAYING; OPERATION; Positions of the ball valve
33 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 7.1 SPRAYING 1 Close gun. 2 Close ball valve. 3 Release the system by opening the gun. 4 Close and secure gun. If the system has been used with 2K products: 1 Secure gun and place nozzle in the gun. ...
Page 34 - DECOMMISSIONING AND CLEANING
34 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 7.3 DECOMMISSIONING AND CLEANING 7.4 LONG-TERM STORAGE Note: The device should be cleaned for maintenance purposes, etc. Ensure that no remaining product dries on and sticks to the device. Procedure:...
Page 35 - Problem
35 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 8 TROUBLESHOOTING, MAINTENANCE, AND REPAIR Problem Cause Remedy Pump does not work. Air motor does not work or stops. Open and close ball valve on the pressure regulator unit or briefl y disconnect c...
Page 36 - Install a water separator.
36 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Problem Cause Remedy Pump runs fast when the spray gun is closed. Valves worn. Replace the parts. Loss of power due to severe icing. There is a lot of condensation water in the air supply. Install a ...
Page 37 - MAINTENANCE
37 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 9 MAINTENANCE 1 Check and clean the high-pressure fi lter every day or as required. 2 Each decommissioning procedure should be carried out as described in Chapter 7.3. 3 Check hoses, pipes, and coupl...
Page 38 - HYDRAULIC STAGE MAINTENANCE; Start up the pump for a short time without any product.; Using hydraulic oil; Using the wrong hydraulic oil can cause a malfunction.
38 B_04241 1 B_04242 B_04243 A 5 X O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 9.3 HYDRAULIC STAGE MAINTENANCE 9.3.1 CHECKING THE OIL LEVEL Dismount the device onto a stand as shown in the picture and turn it upside down.Observe the fi ll level m...
Page 39 - Discharging oil; The oil should be changed after 500 service hours or once a year.
39 B_04241 1 4 3 B_04244 2 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Discharging oil Procedure: 1 Decommission and clean the device -> follow Chapter 7.3 up to and including point 6. 2 Position device as shown in the picture and dismount the...
Page 40 - Filling hydraulic stage with oil; below the upper edge of the oil tank.; Environmental pollution caused by waste oil!; CAUTION
40 B_04245 8 7 4 9 5 6 B_04246 17 mm; 0.67in O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Filling hydraulic stage with oil Procedure: 1 Turn pump (mounted on the base frame) upside down.2 Unscrew and remove threaded plug (5).3 Unscrew 2 locking sc...
Page 41 - Vent; Oil level A in the oil tank has to be within the specifi ed markings (X).
41 B_04243 A 5 X B_04247 9 1 5 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Vent Procedure: 1 Turn the pump upside down. Remove the threaded plug (5). 2 Slowly start up (vent) the pump until no air bubbles appear from the oil suction fi tting. 3 O...
Page 42 - Accessories list for Cobra 40-10; ACCESSORIES
42 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Accessories list for Cobra 40-10 Order No. Designation A 2301858 Diaphragm pump Cobra 40-10 1 322912 Hydraulic oil (for pressure stage) 250 ml; 250 cc 2 236219 Grounding cable 3 m; 9.8 ft 3 2333479 A...
Page 43 - AirCoat
43 B_04234 11 17 13 24 21 20 25 15 12 14 12 7 A 51 52 B_04285 3 Cobra 40-10 AirCoat 16 1 4 2 53 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5
Page 44 - SPARE PARTS; HOW CAN SPARE PARTS BE ORDERED?; Identifi cation in spare parts lists
44 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 11 SPARE PARTS 11.1 HOW CAN SPARE PARTS BE ORDERED? Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements carried out only by specially trained sta...
Page 45 - OVERVIEW OF THE COBRA 40-10 COMPONENTS
45 13 3 2 6 7 25 Nm; 18 lbft 10 12 11 1 9 5 4 8 7 B_04250 30 Nm; 22 lbft 16 17 14 15 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 11.2 OVERVIEW OF THE COBRA 40-10 COMPONENTS Order No. Designation 1 1 - Air motor 3/53 2 1 - Preassembled Cobra 40-10...
Page 46 - Order No. Designation
46 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 11.3 COBRA 40-10 AIR MOTOR Order No. Designation 1 1 9998718 Drive fastener 2 1 367318 Shoulder screw 4 3 1 9925033 Washer 4 1 367311 Hood 4 5 1 367319 Sound absorbing mat 4 6 1 9999152 Velcro fasten...
Page 47 - Do not dismount the piston
47 58 58 59 60 60 * 59 59 Cobra 40-10 1 2 3 4 54 5 8 9 10 31* 30 46* 32 11* 12* 13 14 15 16 52 17 18 19 20 21 34 56 56 57 27 33 35 36* 37* 38 39 40 41* D 25 22 43* D 42 44 47 48 45 44 49 51 50* 46* 26 26 55 28 29 27* 6 7 10-15 Nm; 7-11 lbft 20-25 Nm; 15-18 lbft 2-3 Nm; 1.5-2.2 lbft B_04251 53 50* O ...
Page 50 - Sealing sleeve
50 51 53 54 55 53 57 59 60 61 62 70 63 108 7 7 B_04252 29 59 30 31 32 33 34 35 109 111 111 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 11.4 COBRA 40-10 FLUID SECTION Cobra 40-10 fl uid section Order No. Designation 1 1 2329898 Sealing sleeve 2 4 ...
Page 55 - RELIEF VALVE; Relief valve, complete
55 8 5 7 3 6 4 1 2 1.5 B_01231 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 11.11 RELIEF VALVE Order No. Designation 1 1 169248 Relief valve, complete 2 1 9920602 Adjusting washer 3 1 169346 Pressure spring 4 1 9920202 Washer 5 1 9971395 O-ring 10...
Page 57 - TROLLEY
57 4 1 2 17 15 10 6 5 9 7 8 5 13 11 12 B_03932 3 14 16 A B O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 11.14 TROLLEY Distance: Order No. Designation 1 1 2325901 Trolley, complete 2 1 -- Stand, left, 4"-6" (welded) 3 1 -- Stand, right, 4&#...
Page 58 - SMALL QUANTITY CUP
58 5 4 3 7 2 10 9 8 6 1 B_03642 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 11.16 SMALL QUANTITY CUP Order No. Designation 1 2321424 Small quantity cup 1 1 2320844 Union nut with bayonet 2 1 2321426 Low-pressure mini ball valve G1/2 3 1 2320841 G...
Page 59 - +2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING; SCOPE OF GUARANTEE
59 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 The guarantee period amounts to 36 months. For industrial use or equal wear, such as shift operations in particular, or in the event of rentals, it amounts to 12 months.Systems driven by petrol or ai...
Page 60 - Guarantee claims cannot be considered; EXCLUSION OF GUARANTEE
60 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Guarantee claims cannot be considered - for parts that are subject to wear and tear due to use or other natural wear and tear, as well as defects in the product that are a result of natural wear and ...
Page 61 - CE DECLARATION OF CONFORMITY; complies with the following guidelines:; CE Certifi cate of Conformity
61 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 12.3 CE DECLARATION OF CONFORMITY Cobra 40-10 complies with the following guidelines: 2006/42/EC94/9/EC (ATEX Directive) Applied standards, in particular: DIN EN ISO 12100: 2011 DIN EN 1127-1: 2011 D...
Page 62 - Service Network in Germany; Markdorf – Headquarters
62 O P E R AT I N G M A N UA L V E R S I O N 1 0 / 2 0 1 3 O R D E R N U M B E R D O C 2 3 0 3 6 7 5 Service Network in Germany WAGNER CONTACT NET WORK GERMANY; AVAILABLE ON THE INTERNET AT: Berlin Tel. Fax Stuttgart Tel. Fax Grünstadt Tel.: +49 (0) 63 59/ 87 27 55 0Fax: +49 (0) 63 59/ 80 74 80 Muni...
Page 64 - Subject to changes and errors.; CH
C E R T I F IE D www.wagner-group.com Subject to changes and errors. A Tel. Fax DK Tel. Fax GB Fax B Tel. Fax E Tel. Fax I Tel. Fax CH Tel. Fax F Tel. Fax NL Tel. Fax D Tel.: +49 (0) 75 44 / 505 -1664Fax: CZ Tel. Fax S Tel. Fax
