Krautzberger KS-1, KS-1M, KS-1D, KS-1L, KS-2 Operating Instructions Manual

Operating instructions

and spare parts list

- keep for future use -

Airless Spray Gun

Typ: KS-1 Art. no.: 071. -00001

KS-1D Art. no.: 20.. -00001
KS-1L Art. no.: 071. -00001
KS-1M Art. no.: 079. -000
KS-2 Art. no.: 07.. -000

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Contents

Hazard and warning notes Page 3

1. Use for intended purpose 6

2. Basic design, functional principle 7

3. Startup 8

3.1 Preparations

3.2 Function test and startup

4. Operational interruptions, work breaks 9

5. Finishing work 10

6. Operating faults, spray profile errors 10

7. Replacing parts 11

8. Cleaning, maintenance 12

9. Disposal 13

10. Technical data 13
Declaration of Conformity 13
Spare parts for KS-1/KS-1L/KS-2 17/18

Spare parts for KS-1M 19/20
Spare parts for KS-1D 21/22
Accessories 24

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Hazard and warning notes!
Only start up the spray gun type: KS after carefully reading the operating instructions

in full!
Prevent unauthorised persons, in particular children and youths, from gaining access

to the hazard zone!
Always store the spray gun well out of the reach of children! In particular during work

breaks and when processing hazardous substances, take measures to prevent
misuse by children and youths as well as other unauthorised persons! Clean
thoroughly before storing and/or transporting!

Take measures to prevent accidental pulling or activation of the trigger (22 or 25 ­e.g. on the edge of a bench or similar)! During work breaks and after finishing work,
immediately fold the safety latch (29) forward (lock) and make sure that the trigger is
blocked and that no material can escape by pulling the trigger (22 or 25). During
work breaks, hang the spray gun on the bracket (B) out of the reach of children!

Above 4 MPa (40 bar), there is a noticeably greater kickback with increasing material
pressure!

Connection of the material feed may only be performed by suitably qualified
personnel! Only use tubes and tube connections which can withhold the pressures
and any other occurring loads!

Prior to each repeat startup (e.g. after work breaks), monitor the spray gun for seal
tightness (no uncontrolled material, no porous or old hoses!). Check connections,
pressure hoses and wearing parts and replace if necessary! Check for material
fatigue at regular intervals! Ensure that hose lines cannot fly around if they are
accidentally disconnected. Route hose lines in such a way that they cannot become
stuck or driven over.

Always wear the protective equipment (e.g. protective clothing, goggles, breathing
protection, gloves etc.) recommended by the supplier of the coating substance
during maintenance, cleaning or repair work and when changing materials! Wear ear
mufflers if necessary, in particular during continuous operation, when using large
nozzles, and when working at high material pressures!

Ensure that no parts of the body (in particular fingers) can come between the trigger
(22 or 25) and handle of the main element (12)! Risk of crushing.

Comply with the explosion protection regulations when using potentially flammable
and explosive coating substances! Keep away from sources of ignition and open
flames!

Comply with the warning and hazard instructions of the supplier of the coating
material and the detergent with regard to emission, fire or explosion hazard or other
hazards (where applicable)! In case of doubt, consult the supplier(s) of the
components in question!

When mixing different components and/or when using solvents or thinning agents to
make coating materials, take steps to ensure that no substances with increased
hazard potential are created (e.g. flammability, explosion hazard, increased
explosive tendency through spraying in air, toxicity, increased toxicity due to
chemical reaction with air etc.)! Avoid increased hazard potential caused by
undesired chemical reactions! In case of doubt, consult the supplier(s) of the

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components in question! Where necessary, take protective measures and effect
special notification of the particular hazard(s)!

When using substances such as solvents which can generate an increased
explosion potential due to atomisation or spraying in air, take protective measures
and effect special notification of the particular hazard! In case of doubt, consult the
supplier of the components!

The compatibility of the parts of the spray gun which come into contact with the
material cannot be guaranteed with all potential coating substances (see chart "Parts
in contact with the material" in Section 10, Technical Data). In case of doubt, consult
Krautzberger GmbH!

(!)
Under no circumstances should the spray jet be directed at people or animals!

The jet can penetrate the skin, enter the body and force air into the organism. Risk of
fatal embolism!

The material jet is particularly dangerous if no airless nozzle is mounted and
the jet is discharged directly from the valve seat screw!

There is also the risk of poisoning when using poisonous coating substances or
detergents!

Preventive measures: set up an emergency first aid unit in the plant (e.g. first aid
training of suitable employees).

What do to in the case of an accident:
Immediate measures: correct treatment of wounds.
Further measures: immediate treatment by an emergency service doctor who has

been informed of the substance used.
Do not stand in the area of the material jet!
Never direct the spray jet at electrical systems or equipment!
Do not spray workpieces or surfaces which are insufficiently stable! The high-

powered spray jet is powerful enough to cause parts of the workpiece or surface to
fly around in the working zone.

During spraying and due to rebound off the workpiece, coating material is discharged
into the surrounding atmosphere. Depending on the coating material used, this can
result in environmental hazards, fire and explosion risk, and health hazards. For this
reason, only use spraying equipment in specially designated areas!

Only work in adequately ventilated areas! If necessary, use suitable extraction
systems!

Ensure adequate earthing (e.g. connection to building earth)!
Radiators or water pipes do not provide sufficient earth contact!

During lengthy breaks in operation or when shutting down the equipment as well as
prior to dismantling or the start of repair and maintenance work, close the shutoff
valve at the material source and press the trigger (22 or 25) until the material
pressure has fully dissipated!

5

During every - even a very brief - break in operation, push the safety lever (29)
forward and check to make sure that the trigger is blocked.

Adhere to the pressures and temperatures listed under "Technical Data"!
If high temperatures are exceeded for a certain period (e.g. > 8 hours at > 43°C, > 10

mins. at > 48°C, or > 1 min. at > 51°C, attach suit able protective devices and post
notification concerning the risk of combustion due to coating substance, and draw
particular attention to risks resulting from leakage or bursting of the spray gun and
the hoses and/or hose connections! If necessary, wear suitable protective clothing
(e.g. goggles, gloves etc.).

In the event of unforeseen occurrences, release the trigger (22 or 25) to interrupt the
material flow! Then immediately push the safety catch (29) to block the trigger. Close
the shutoff valve on the pump.

In the event of unforeseen material discharge (e.g. due to loosening of a material
hose connection or bursting of the material hose), close the shutoff valve at the
material source as quickly as possible! It is advisable to mount the shutoff valve
within reach of the operator of the spray gun to ensure that the unforeseen discharge
of material can be stopped quickly - particularly when using hazardous substances.

Ensure that neither spraying nor material discharge can be activated accidentally or
by defects in the unit as long as one or more persons are in the hazard zone. Take
steps to ensure that no alterations can occur or be made to the material pressure
during setting and maintenance work without the knowledge or consent of the setup
technician!

Ensure adequate illumination of the operating zone!
When using flammable and/or potentially explosive materials, ensure that a fire can

be rapidly extinguished!
Only use spare parts and accessories from Krautzberger GmbH! Krautzberger

GmbH assumes no liability for damage if any external parts are used.
The instructions and notes of EN 1953 "Spraying Equipment for Coating Substances;

Safety Requirements" are to be adhered to, in particular the warning, hazard and
safety notes pertaining to risks and safety requirements and/or measures.

Hazards which exceed those normally expected with the use of spraying equipment
have not come to our attention in the handling of the spray gun type KS or versions
KS-1, KS-1D, KS-1L, KS-1M or KS-2. If, however, accidents or hazardous situations
occur during practical applications, please notify us accordingly.

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1. Use for intended purpose
The airless spray gun type KS is designed to allow coating of metal, plastic,

ceramics, wood and similar materials as well as other suitable surfaces. Typical
coating substances are, for example, lacquers, paints, water-soluble lacquer
systems, adhesives, oil, release agents etc. It is also suitable for the application of
abrasive materials at operating pressures below 5 MPa (50 bar).

The coating substance to be used is applied to the surface by moving the spray gun
by hand over the surface to be coated and pressing the trigger at the desired point.
The coating substance is fed to the spray gun in liquid form under high material
pressure.

SW = spray angle
TSB = theoretical spraying width
ESB = actual spraying width

The spray gun works on the airless
principle - in other words, the spray jet is
generated exclusively by the material
pressure pressing the material through a
nozzle. After being discharged from the
nozzle, the spray jet takes on the shape
dictated by the nozzle. It is then directed
at the workpiece. The effective spray jet is
not quite as wide as theoretically possible.

The particles of the spray jet reach far
higher speeds than with pneumatically
operated spray guns. The material
throughput is correspondingly higher and
the jet more concentrated (in other words,
the "swirling zone" is smaller). The size
and shape of the jet can only be changed
by changing the nozzle. The diameter of
the nozzle borehole determines the
material flow volume. The size and
geometry of the constantly elliptically
shaped nozzle opening determine the
height and width of the jet (shape of an
elliptical cone).

A wide range of airless nozzles are available and can be obtained from Krautzberger
GmbH.

The nozzle can be rotated steplessly by
360° in the axis of the spray jet and
secured in any position. This allows
optimum adjustment of the angle at which
the jet hits the workpiece to the respective
condition.

The spray gun is particularly suitable for use when relatively large material volumes per
time unit are to be processed. A further advantage compared to pneumatically operated
spray guns is that less spraying mist is created and a far higher percentage of the
material therefore reaches the workpiece. Circulation connection is also possible.

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(i) Note
The coating substances approved by the manufacturer of the coating substance for
spraying may be used; however, Krautzberger GmbH offers special designs for
o substances dissolved in CFC-containing solvents
o abrasive or
o corrosive materials.

2. Basic design, mode of operation
The design of the airless spray gun type KS as well as typical equipment features and

accessories are shown is the diagrams 140-0059, 140-0060, 140-0128 and 140-0064. A
pump supplies the material at a pressure of max. 35 MPa (350 bar) for the versions KS­1, KS-1L, KS-1M and KS-2 or max. 25 MPa (250 bar) for the version KS-1D and KS-2D
(400bar for the KS-1D with stainless-steel head section) through a sufficiently pressure­resistant hose to the material connection (27). Pulling the trigger (22 or 25) towards the
handle of the main element (12) pushes the valve needle (16) or the needle
reinforcement backwards against the pull-back pressure of the valve spring (19). The
sealing ball of the valve needle or needle reinforcement lifts from the valve seat of the
valve seat screw (4), thus releasing the material flow to the material nozzle (102), from
which the material is sprayed in the form of an elliptical cone jet. The volume of material
discharged depends solely on the nozzle size and the material pressure.

(!) Warning note!
In the risk or the event of an accident, the spray jet can be shut down quickly by

releasing the trigger (22 or 25).
The airless spray gun type KS is supplied in aluminium as standard; the parts coming

into contact with the material are available in stainless steel on request.

Order/Article nos. for the airless spray gun type KS

Material connection

Version

rigid swivel rigid swivel

(without material nozzle)

short trigger (22) long trigger (25)

Article no.

KS-1 (standard version) 0710-090-0522 0712-090-1128
KS-1D (processing of thick substances) 2007-090-2671 2013-090-1036
KS-1L (long trigger) 0711-090-0526 0713-090-0874
KS-

1M

(material pipe to handle) 0798-090-0531

0799-090-0535

KS-2 (circulation connection) 0718-090-.... 0720-090-.... 0719-090-.... 0721-090-....

(i) Notes
The version KS-1D is equipped with material ducts with enlarged cross-section. Highly

viscous materials can be processed using appropriate material nozzles. During lengthy
use, fatigue is alleviated by the favourable power transmission (version KS-1L) or the
shift in the centre of gravity towards the handle ((i.e. towards the back) in the version KS­1M).

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In the version KS-2, the coating substance can be circulated through the head section.
Circulation connection is recommended, for example, when using coating substances
which have a tendency to settle or materials whose temperature has to be kept constant.

A swivel-type material connection facilitates handling of the spray gun, as the
hose/hoses do not have to be turned when the user turns the gun.

3. Startup

3.1 Preparations

> Push the safety catch (29) forward and make sure that the trigger (22 or 25) can
no longer be activated.
> If necessary, install a suitable spring (19) for 25MPa
> Install the material nozzle (102)
> Earth the spray gun
> Connect the pressure hose to the material connection (27) - or, in the case of
circulation connection, connect both pressure hoses to the material connections (27)
> Prepare the coating substance and the accessories for material feed
> Switch on the material pump
> Set the material pressure on the regulator or on the material pump or in the return

section of the circulation line

> Open the shutoff valve at the material source
No material should be discharged at any point.

(!) Caution!
The material feed should only be connected up by suitably trained personnel! Ensure
that the pressures and temperatures listed under "Technical Data" are not exceeded!
Installation or replacement of the nozzles, springs etc. must be performed by suitably
trained personnel!

3.2 Function test and startup
> Push the safety catch (29) upwards (unlock)

> Point the nozzle of the spray gun at a test surface
> Start the spraying process by pressing the trigger (22 or 25)
> Assess spray profile and, if necessary,
> after securing the gun using the safety catch (push forwards),
> change the nozzle (see Krautzberger GmbH order catalogue for available airless

nozzles)
> If necessary, loosen the nozzle nut (1) again
> Turn the material nozzle (102) in the desired direction (it can be rotated by 360°)
> Tighten the nozzle nut (1)
> Push the safety catch (29) upwards (unlock)
> Guide the spray jet across the workpiece using even movements
> Terminate spraying by releasing the trigger (22 or 25)

(i) Notes
Only use accessories from Krautzberger GmbH!

Only use sufficiently sturdy hoses! Check (and, if necessary, replace) older hoses before
starting up the spray gun.