WAGNER Cobra 40-10, Cobra 40-25 Original Operating Manual

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Cobra 40-10 Cobra 40-25

High-pressure Double Diaphragm Pumps

Version 01/2018

B_04234

B_04233

VERSION 01/2018

ORDER NUMBER DOC 2340851

Table of Contents

1 ABOUT THESE INSTRUCTIONS 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 7

1.4 Abbreviations 7

1.5 Terminology for the Purpose of this Manual 7

2 CORRECT USE 8

2.1 Device types 8

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 9

2.5 Misuse 9

3 IDENTIFICATION 10

3.1 Explosion protection identication 10

3.2 Identication "X" 10

3.3 Type plates 11

Cobra 40-10 / 40-25

4 BASIC SAFETY INSTRUCTIONS 12

4.1 Safety instructions for the operator 12

4.1.1 Electrical Devices and Equipment 12

4.1.2 A Safe Work Environment 12

4.1.3 Personnel Qualications 13

4.2 Safety Instructions for Sta 13

4.2.1 Personal Safety Equipment 13

4.2.2 Safe handling of WAGNER spray devices 14

4.2.3 Ground the Unit 14

4.2.4 Product hose 15

4.2.5 Cleaning and Flushing 16

4.2.6 Touching hot surfaces 16

4.2.7 Maintenance and Repair 17

4.2.8 Protective and monitoring equipment 17

5 DESCRIPTION 18

5.1 Components 18

5.2 Mode of operation 18

5.2.1 Air motor 18

5.2.2 Fluid section 18

5.3 Protective and monitoring equipment 19

5.4 Included items 19

5.5 Data 19

5.5.1 Materials of paint wetted parts 19

5.5.2 Technical data 20

5.5.3 Dimensions and connections 21

5.5.4 Volume ow 22

5.5.5 Performance diagrams 23

5.6 Cobra Pressure Regulator Unit 24

5.6.1 High-pressure Filter (Option) 24

6 ASSEMBLY AND COMMISSIONING 25

VERSION 01/2018

6.1 Training of Assembly/Commissioning Sta 25

6.2 Storage conditions 25

6.3 Installation conditions 25

6.4 Transportation 25

6.5 Assembly and installation 26

6.5.1 Ventilation of the spray booth 27

6.5.2 Air supply lines 27

6.5.3 Product supply lines 27

6.6 Grounding 27

6.7 Commissioning 29

7 OPERATION 30

7.1 Training the operating sta 30

7.2 EMERGENCY STOP 30

7.3 Work 31

7.4 Pressure Relief/Work Interruption 31

7.5 Basic cleaning 32

7.5.1 Filling with working material 32

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

8 CLEANING AND MAINTENANCE 33

8.1 Cleaning 33

8.1.1 Cleaning sta 33

8.1.2 Decommissioning and Cleaning 33

8.1.3 Long-term storage 33

8.2 Maintenance 34

8.2.1 Maintenance sta 34

8.2.2 Maintenance Instructions 34

8.2.3 Safety checks and maintenance intervals 35

8.2.4 Emptying pump 36

8.2.5 Filling the empty pump 37

8.2.6 Cleaning and Replacing the Filter 38

8.2.7 Maintenance Hydraulic Stage 40

8.2.8 Checking the Oil Level 40

8.2.9 Oil change 41

9 TROUBLESHOOTING AND RECTIFICATION 44

10 REPAIR WORK 45

10.1 Repair Sta 45

10.2 Repair Notes 45

10.3 Tools 45

10.4 Cleaning the parts after disassembly 46

10.5 Assembly of the Device 46

11 FUNCTION TEST AFTER THE REPAIR 47

12 DISPOSAL 48

13 ACCESSORIES 50

13.1 Cobra 40-10 Accessories 50

13.2 Cobra 40-25 Accessories 52

14 SPARE PARTS 54

14.1 How can spare parts be ordered? 54

14.2 Overview of the Cobra 40-10 Components 55

14.3 Cobra 40-10 Air Motor 56

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14.4 Cobra 40-10 Fluid Section 58

14.5 Overview of the Cobra 40-25 Components 61

14.6 Cobra 40-25 Air Motor 62

14.7 Cobra 40-25 64

14.8 Cobra 40-10 Inlet Valve 67

14.9 Inlet Valve Depressor 67

14.10 Cobra 40-25 Inlet Valve 68

14.11 Relief valve 68

14.12 High-pressure 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

14.16 Cobra 40-10 Frame, Complete 75

14.17 Cobra 40-25 Frame, Complete 75

14.18 Horizontal Cobra Trolley 76

14.19 Sliding tables 78

14.20 Complete Hopper 79

14.21 2 Liter Tank 80

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

15 GUARANTEE AND CONFORMITY DECLARATIONS 81

15.1 Important notes on product liability 81

15.2 Warranty claim 81

15.3 EU Declaration of Conformity 82

VERSION 01/2018

ORDER NUMBER DOC 2340851

1 ABOUT THESE INSTRUCTIONS

1.1 PREFACE

The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel. The device may only be operated by trained personnel and in compliance with this operating manual. Operating and service personnel should be instructed according to the safety instructions. This equipment can be dangerous if it is not operated according to the instructions in this operating manual.

1.2 WARNINGS, NOTICES AND SYMBOLS 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 fall into the following categories:

Cobra 40-10 / 40-25

DANGER

WARNING

CAUTION

NOTICE

Notice

Explanation of warning:

Immediate risk of danger. Non-observance will result in death or serious injury.

Potential risk. Non-observance can result in death or serious injury.

Potentially hazardous situation. Non-observance may result in minor injury.

Potentially hazardous situation. Non-observance may result in damage to property.

Provides information about particular characteristics and how to proceed.

LEVEL OF DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The measures for preventing the hazard and its consequences.

VERSION 01/2018

1.3 LANGUAGES

The operating manual is available in the following languages:

Original Operating Manual

Language Order No.

German 2340850

Translation of the Original Operating Manual

Language Order No. Language Order No.

French 2340852 Italian 2340853 Spanish 2340854 Russian 2345830 Japanese 2346196 Hungarian 2352542 English 2340851 -- --

Additional languages on request or at: www.wagner-group.com

1.4 ABBREVIATIONS

Order No. Order number Qty Number of pieces ET Spare part DH Double stroke K Marking in the spare parts lists SSt Stainless steel Pos Position 2K Two components

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning

agent.

Flushing Internal ushing of paint-wetted parts with ushing agent. Product pressure

generator

Sta qualications

Trained person Is instructed in the tasks assigned to him/her, the potential risks

Electrically trained person

Electrician Can assess the work assigned to him/her and detect possible

Skilled person in accordance with TRBS 1203 (2010/Revision 2012)

Pump or pressure tank.

associated with improper behavior as well as the necessary protective devices and measures.

Is instructed by an electrician about the tasks assigned to him/ her, the potential risks associated with improper behavior as well as the necessary protective devices and measures.

hazards based on his/her technical training, knowledge and experience in relevant provisions.

A person, who, based on his/her technical training, experience and recent vocational experience, has sucient technical knowledge in the areas of explosion protection, protection from pressure hazards and electric hazards (if applicable) and is familiar with the relevant and generally accepted rules of technology so that he/she can inspect and assess the status of devices and coating systems based on workplace safety.

VERSION 01/2018

ORDER NUMBER DOC 2340851

2 CORRECT USE

2.1 DEVICE TYPES

Double diaphragm pump and spray pack:

Cobra 40-10 Cobra 40-25

2.2 TYPE OF USE

The device is suitable for processing liquid products like paints and lacquers:

– Non-ammable products – Products in accordance with the classi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 products recommended by WAGNER. Do not deactivate safety xtures. Use only WAGNER original spare parts and accessories. The operating personnel must be trained on the basis of this operating manual.

Cobra 40-10 / 40-25

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).

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2.4 PROCESSIBLE WORKING MATERIALS

Fluid materials like paints and varnishes.

Application Cobra 40-10 Cobra 40-25

Water-dilutable products Solvent-based lacquers and paints Two-component coating products Emulsions UV lacquers Primers Epoxy and polyurethane lacquers, phenolic lacquers Liquid plastics Wax-based underside protection Shear-sensitive lacquers

recommended limited suitability not suitable

NOTICE

Abrasive working materials and pigments!

Greater wear of parts carrying the product.

Use the application-oriented model (ow rate/cycle, product, valves, etc.) as indicated in Chapter 5.5.

Check if the uids and solvents used are compatible with the pump construction materials as indicated in Chapter 5.5.1.

Use suitable combinations of devices (packings, valves etc.)

Wear caused by abrasive working materials is not covered by the warranty.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Typical applications

Application Cobra 40-10 Cobra 40-25

Furniture industry Kitchen manufacturers Joinery Window factories Steel-processing industry Construction of vehicles Shipbuilding

recommended limited suitability not suitable

2.5 MISUSE

Misuse can lead to physical injury and/or property damage! Special attention must be paid that:

no dry coating products, e.g. powder are processed. no food, medicine or cosmetics are processed.

It is important to note that the device's materials are not food-safe.

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ORDER NUMBER DOC 2340851

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially explosive areas.

Device types: Double diaphragm pumps Cobra 40-10 and Cobra 40-25 Manufacturer: Wagner International AG

CH-9450 Altstätten, Switzerland

CE European Communities Ex Symbol for explosion protection II Device class II 2 Category 2 (Zone 1) G Ex-atmosphere gas Ex Explosion protection h Ignition protection for non-electrical devices IIB Explosion group T6 <85 °C Gb High safety level X Special notes (see Chapter 3.2)

See the following Chapter "Identication X".

Cobra 40-10 / 40-25

3.2 IDENTIFICATION "X"

The maximum surface temperature corresponds to the permissible product temperature. This and the permissible ambient temperature can be found in Chapter 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 metal is to be avoided. Do not drop the device.

Maximum surface temperature

The maximum surface temperature of the pump depends on the operating conditions (heated product) and not on the device (frictional heat).

Ignition temperature of the coating product

Ensure that the ignition temperature of the coating product is above the maximum surface temperature.

Ambient temperature

Permissible ambient temperature: 10 °C to 60 °C; 50 °F to 140 °F.

Medium supporting atomizing

To atomize the product, use only weakly oxidizing gases, e.g., air.

Surface spraying, electrostatics

Do not spray device parts using electrostatic equipment.

Cleaning

If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge.

Remove deposits from the surfaces to maintain conductivity. Use only a damp cloth to clean the device.

VERSION 01/2018

Air in the pump uid

Flammable gas mixtures can form if air reaches the pump uid.

Prevent the pump from taking in air and running dry. If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until

the air has escaped.

Air in the pumped uid can be caused by damaged diaphragms.

Avoid operating the pump with damaged diaphragms. Periodically check that the pump is working smoothly, paying special attention to

the presence of air in the pumped uid.

Filling and emptying

Flammable gas mixtures can form in the uid section or product hoses if the pump must be emptied for maintenance.

Empty and ll the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

3.3 TYPE PLATES

Example for Cobra 40-10

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Wagner International AG CH-9450 Altstätten Made in Switzerland

Pumpentyp/ Pump type/ Type de pompe

Max. Materialdruck/ Fluid pressure/ Pression fluid

Übersetzungsverhältnis/ Ratio/ Rapport Fördermenge DH/ Delivery DS/ Débit CD

Max. Luftdruck/ Air pressure/ Pression d`air

Max. Temp. Material/ Fluid

Baujahr - Serie Nr. / Year of manufacture - Serial No.

Vor Gebrauch Betriebsanleitung beachten / Check manual before use!

B_05038

2017-3001

Example for Cobra 40-25

Wagner International AG CH-9450 Altstätten Made in Switzerland

Pumpentyp/ Pump type/ Type de pompe

Max. Materialdruck/ Fluid pressure/ Pression fluid

Übersetzungsverhältnis/ Ratio/ Rapport

Fördermenge DH/ Delivery DS/ Débit CD

Max. Luftdruck/ Air pressure/ Pression d`air

Max. Temp. Material/ Fluid

Baujahr - Serie Nr. / Year of manufacture - Serial No.

Vor Gebrauch Betriebsanleitung beachten / Check manual before use!

2017-3001

II 2G Ex h IIB T6 Gb X

40-10

25 MPa

40:1

10 ccm

0.6 MPa 80°C

II 2G Ex h IIB T6 Gb X

40-25

25 MPa

40:1

25 ccm

0.63 MPa 80°C

Designation

1 Pump type 2 Max. product pressure 3 Pump ratio 4 Delivery rate 5 Max. air pressure 6 Max. temp. product/ uid 7 Model year - serial number 8 Read the operating manual

before use

B_05039

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ORDER NUMBER DOC 2340851

4 BASIC SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident

prevention.

4.1.1 ELECTRICAL DEVICES AND EQUIPMENT

Electric shock hazard!

Danger to life from electric shock

Prepare device in accordance with the local safety requirements with regard to the operating mode and ambient inuences.

May only be maintained by skilled electricians or under their supervision. With open housings, there is a danger from line voltage.

Operate device in accordance with the safety regulations and electrotechnical regulations.

Must be repaired immediately in the event of problems. Decommission if it poses a hazard or is damaged. Must be de-energized before work is commenced. Inform sta about planned work.

Observe electrical safety regulations. Ground all devices to a common grounding point. Only operate the device with a properly installed socket with a protective ground

wire connection. Keep liquids away from electrical devices.

Cobra 40-10 / 40-25

4.1.2 A SAFE WORK ENVIRONMENT

Hazard due to dangerous uids or steam!

Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with the skin or eyes.

Ensure that the oor in the working are is static dissipative in accordance withEN61340-4-1 (resistance must not exceed 100 M).

Paint mist extraction systems/ventilation systems must be tted on site according to local regulations.

Make sure that the ground connection and potential equalization of all system parts are reliable and continuous and can withstand the expected stress (e.g. mechanical stress, corrosion).

Ensure that product / air hoses adapted to the working pressure are used. Ensure that personal protective equipment (see Chapter 4.2.1) is available and is

used. Ensure that all persons within the working area wear static dissipative shoes.

Footwear must comply with EN 20344. The measured insulation resistance must not exceed 100 M.

Ensure that during spraying, persons wear electrically conductive gloves. The grounding takes place via the spray gun handle or the trigger.

Protective clothing, including gloves, must comply with EN 1149-5. The measured insulation resistance must not exceed 100 M.

Ensure that there are no ignition sources such as naked ames, sparks, glowing wires, or hot surfaces in the vicinity. No smoking.

VERSION 01/2018

Ensure that the pipe joints, hoses, equipment parts and connections are permanently, technically leak-proof:

- Periodic preventative maintenance and service (replacing hoses, checking tightness strength of the connections etc.).

- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g., daily before commissioning, at the end of work or weekly.

Ensure that maintenance and safety checks are performed regularly. In the event of defects, immediately bring the device or system to a stop and

arrange to have repairs carried out immediately.

4.1.3 PERSONNEL QUALIFICATIONS

Hazard due to incorrect use of device!

Risk of death due to untrained personnel.

Ensure that the operating personnel has been instructed by the operator in accordance with the operating manual and the operating instructions. The device must only be operated, maintained and repaired by trained personnel. Refer to the operating instructions for information about the required personnel qualications.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

4.2 SAFETY INSTRUCTIONS FOR STAFF

Always follow the information in this manual, particularly the safety instructions and the warning instructions.

Always follow local regulations concerning occupational safety and accident prevention.

In electrostatics applications: anyone who belongs to a risk group according to EMF Directive 2013/35/EU (e.g. those with active implants), must not enter the highvoltage area.

4.2.1 PERSONAL SAFETY EQUIPMENT

Hazard due to dangerous uids or steam!

Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.

When preparing or working with paint and when cleaning the device, follow the working instructions of the manufacturer of the lacquers, solvents, and cleaning agents being used.

Take the specied protective measures. In particular wear safety goggles, protective clothing and gloves, as well as hand protection cream if necessary.

Use a mask or breathing apparatus if necessary. For sucient health and environmental safety: Operate the device in a spray booth

or on a spraying wall with the ventilation (extraction) switched on. Wear suitable protective clothing when working with hot products.

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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES

Hazard due to injection of lacquer or ushing agent into the skin!

The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or ushing agents:

Never point the spray gun at people. Never reach into the spray jet. Before any work on the device, in the event of work interruptions and malfunctions:

– Switch o the energy/compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun against actuation.

− Disconnect the control unit from the mains.

- In the event of functional faults, remedy the fault as described in the "Troubleshooting" chapter.

If necessary or at least every 12 months, the liquid ejection devices must be checked for safe working conditions by an expert (e.g. WAGNER Service Technician) in accordance with the guidelines for liquid ejection devices (ZH 1/406 and DGUV 100-500 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 ushing agents:

Note the lacquer or ushing agent that you have been using. Consult a doctor immediately.

Danger due to recoil forces!

Actuating the trigger can causes strong recoil forces. Thereby the user can lose his balance and injure himself during falling.

Avoid risk of injury from recoil forces:

Ensure that you have ﬁrm footing when operating the spray gun.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

4.2.3 GROUND THE UNIT

Hazard due to electrostatic charge!

Explosion hazard and damage to the device. Friction, owing liquids and air or electrostatic coating processes create charges. Flames

or sparks can form during discharge. Correct grounding of the entire spraying system prevents electrostatic charges.

Ensure that all devices and tanks are grounded before each spraying process. Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g., that they are

wearing static dissipative shoes. Wear static dissipative gloves when spraying. The grounding takes place via the

spray gun handle or the trigger.

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4.2.4 PRODUCT HOSE

Hazard due to bursting of product hose!

The product hose is under pressure and may cause dangerous injuries.

Ensure that the hose material is chemically resistant to the sprayed products and the ushing agents used.

Ensure that the product hose and the ttings are suitable for the pressure generated.

Ensure that the following information can be seen on the high-pressure hose:

− manufacturer

− permissible operating pressure

− date of manufacture

Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the following places under any circumstances:

− in high trafﬁc areas

− on sharp edges

− on moving parts or

− on hot surfaces Ensure that the hoses are never 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.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Ensure that the hoses are never kinked. Observe maximum bending radii.

Ensure that no work is ever performed with a damaged hose. Make sure that the hoses are never used to pull or move the equipment.

The electrical resistance of the product hose, measured at both valves, must be less than 1 M.

Suction hoses may not be subjected to pressure.

Several liquids have a high expansion coecient. In some cases their volume can rise with consequent damage to pipes, ttings, etc. and cause uid leakage.

When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank (squeeze) and can cause it to break. The tank would leak and the liquid would ow out.

The pressure created by the pump is a multiplication of the inlet air pressure.

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4.2.5 CLEANING AND FLUSHING

Hazard due to cleaning and ushing!

Explosion hazard and damage to the device.

Preference should be given to non-ammable cleaning and ushing agents. When carrying out cleaning work with ammable cleaning agents, make sure

that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded.

Observe the specications of the lacquer manufacturer. Ensure that the ash point of the cleaning agent is at least 15 K above the ambient

temperature or that cleaning is undertaken at a cleaning station with technical ventilation.

Never use chloride or halogenated solvents (such as trichloroethane and methylene chloride) with units containing aluminium or galvanized and zinc-plated parts. They may react chemically thus producing an explosion danger.

Take measures for workplace safety (see Chapter 4.1.2). When commissioning or emptying the device, please note that an explosive

mixture may temporarily exist inside the lines and components of equipment:

−depending upon the used coating product,

−depending on the ushing agent (solvent) used. explosive mixture inside the lines and items of equipment.

Only electrically conductive tanks may be used for cleaning and ushing agents. The tanks must be grounded.

An explosive gas/air mixture forms in closed tanks.

Never spray into a closed tank when using solvents for ushing.

External cleaning

When cleaning the exterior of the device or its parts, also observe the following:

Relieve the pressure from the device. De-energize the device electrically. Disconnect the pneumatic supply line. Use only moistened cloths and brushes. Never use abrasive agents or hard objects,

and never spray cleaning agents with a spray gun. Cleaning the device must not damage it in any way.

Ensure that no electric component is cleaned with or immersed into solvent.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

4.2.6 TOUCHING HOT SURFACES

Hazard due to hot surfaces because of hot coating products!

Risk of burn injuries

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 °F:

- Identify the device with a warning label "Warning – hot surface".

Order No.

9998910 Instruction label 9998911 Protection label

Note: Order the two stickers together.

VERSION 01/2018

4.2.7 MAINTENANCE AND REPAIR

Hazard due to improper maintenance and repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Use only WAGNER original spare parts and accessories. Do not change or modify the device; if change is necessary, contact WAGNER. Only repair and replace parts that are listed in the 13 "Spare parts" chapter and 14

that are assigned to the unit. Do not use any defective components. Exclusively use accessories listed in Chapter 13 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 against actuation. – Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Secure the spray gun against actuation.

Observe the operating and service manual for all work.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

4.2.8 PROTECTIVE AND MONITORING EQUIPMENT

Hazard due to removal of protective and monitoring equipment!

Danger to life and equipment damage.

Protective and monitoring equipment must not be removed, modied or rendered unusable.

Regularly check for perfect functioning. If defects are detected on protective and monitoring equipment, the system must

not be operated until these defects are remedied.

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12 15

B_06834

Cobra 40-25

5 DESCRIPTION

5.1 COMPONENTS

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Designation

1 Control housing with

Cobra 40-10

integrated silencer 2 Air pressure regulator 3 Ball valve 4 Air motor 5 Compressed air Inlet 6 Mounting ange 7 Relief valve

6 7

10 14

8 Product outlet 9 Fluid section

10 Product inlet 11 Grounding connection

12 Pressure stage casing 13 Return socket 14 Valve depressor 15 Exhaust air cap

B_06833

11 12 15

5.2 MODE OF OPERATION

The double diaphragm pump is driven with compressed air. This compressed air moves the air piston 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 up-and-down movement of both diaphragms within the uid section is produced by hydraulic oil, which is moved by the piston in the pressure stage. With every stroke of the piston rod, working material is sucked in and delivered to the spray gun at the same time.

5.2.1 AIR MOTOR

The air motor with its pneumatic reverse (1) does not require pneumatic oil. The compressed air is fed to the motor via the air pressure regulator (2) and the ball valve (3).

5.2.2 FLUID SECTION

The uid section has been designed as a double diaphragm pump with exchangeable inlet and outlet valves. Change between "spraying mode" and "circulation mode" using the relief valve (7).

VERSION 01/2018

5.3 PROTECTIVE AND MONITORING EQUIPMENT

WARNING

Overpressure!

Danger to life from bursting components.

Never change the safety valve setting.

The air motor is tted with a safety valve. The safety valve has been set and sealed at the factory. In case of pressures over and above the permissible operating pressure, the valve, which is held with a spring, automatically opens and releases the excess pressure.

5.4 INCLUDED ITEMS

Order No. Designation

1 2329519

1 2329521

1 2329523

1 2329525

The standard equipment includes:

Order No. Designation

1 322981 Sign 1 236219 Grounding cable, complete 1 341434 Double open-end wrench 1 see Chapter 15.2 Declaration of Conformity 1 2340850 Operating manual, German 1 see Chapter 1.3 Operating manual in the local language

The delivery note shows the exact scope of delivery. Accessories: see Chapter 13.

Diaphragm pump Cobra 40-10 consisting of: Fluid section, air motor, connection elements

Frame-mounted diaphragm pump Cobra 40-10 consisting of: Fluid section, air motor, connection elements

Diaphragm pump Cobra 40-25 consisting of: Fluid section, air motor, connection elements

Frame-mounted diaphragm pump Cobra 40-25 consisting of: Fluid section, air motor, connection elements

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

5.5 DATA

5.5.1 MATERIALS OF PAINT WETTED PARTS

Paint-wetted parts Product

Inlet housing Consital (aluminum alloy) Fluid section Consital (aluminum alloy) Valve balls Stainless steel Valve seats/valve cone Carbide Diaphragms Resistant PA Valve tting 1.4104

VERSION 01/2018

5.5.2 TECHNICAL DATA

Description Units Cobra 40-10 Cobra 40-25

Pump ratio 40:1 40:1 Volume ow per double stroke (DH) cm

Maximum operating overpressure MPa

Maximum possible strokes in operation DH/min 200 200 Minimum/maximum air inlet pressure MPa

Compressed air quality: free from oil and water

Air inlet (inside thread) inch G 1/2“ G 1/2“

Minimum Ø of the compressed air supply line mm

Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke NL 3.5 8.3 Sound pressure level 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 motor piston diameter mm

Product inlet (outside thread) Product outlet (inside thread) Product outlet (outside thread) Weight kg; lb 19; 41.9 33; 72.8 Product pH value pH 3.5–9 3.5–9 Maximum product pressure at pump inlet MPa

Product temperature °C

Ambient temperature °C

Allowable inclination for operation ±10 ±10 Hydraulic oil lling amount (approximate) L

*A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2015. Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).

ORDER NUMBER DOC 2340851

Quality standard 7.5.4 according to ISO 8573.1, 2010

cu inch

bar

psi

bar

psi

inch

inch mm inch inch

bar

psi

°F

cu inch

0.6 25

250

3626

0.25–0.6

2.5–6

36.3–87

7: Particle concentration 5–10mg/ m 5: Humidity: pressure dew point ≤ 7 °C 4: Oil content ≤ 5mg/m

0.51

3.15

M36×2

G 3/8“ G 3/8“

290

10–80

50–176

10–60

50–140

0.110

6.71

1.5 25

250

3626

0.25–0.6

2.5–6

36.3–87

0.75

100

M36×2

G 3/8“ G 3/8“

290

10–80

50–176

10–60

50–140

0.130

7.93

Cobra 40-10 / 40-25

WARNING

Exhaust air containing oil!

Risk of poisoning if inhaled.

Provide compressed air free from oil and water.

VERSION 01/2018

B_04235

Cobra 40-10

ORDER NUMBER DOC 2340851

5.5.3 DIMENSIONS AND CONNECTIONS

Cobra 40-10 mm; inch Cobra 40-25 mm; inch

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 149; 5.87

O 91; 3.58

P 107; 4.21

Q 175; 6.89

R 7; 0.28 S 525; 20.67 644; 25.35 T 367; 14.45 417; 16.42 U 275; 10.83

Cobra 40-10 / 40-25

Cobra 40-25

B_04236

B_02943

Cobra 40-10

B_06937

Cobra 40-25

VERSION 01/2018

5.5.4 VOLUME FLOW

Wagner AL nozzles Volume ow in l/min.*

inch mm Spray angle at at at

0.007 0.18 40° 0.1650 0.2000 0.2400

0.009 0.23 20-30-40-50-60° 0.2060 0.2500 0.3090

0.011 0.28 10-20-30-40-50-60° 0.2950 0.3450 0.4260

0.013 0.33 10-20-30-40-50-60-80° 0.4530 0.5280 0.6600

0.015 0.38 10-20-30-40-50-60-80° 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 20-40-50-60-70-80° 1.3700 1.5900 2.0100 Cobra 40-10

0.025 0.64 20-40-50-60-80° 1.6200 1.9100 2.4000

0.027 0.69 20-40-50-60-80° 1.8300 2.1300 2.6800

0.029 0.75 60° 2.1900 2.5100 3.1700

0.031 0.79 20-40-50-60° 2.4000 2.7700 3.4900

0.035 0.90 20-40-50-60° 3.2200 3.7400 4.6900 Cobra 40-25

0.043 1.10 20-50° 5.0700 6.0400 7.4600

0.052 1.30 50° 5.1200 6.5000 7.5200

Volume ow refers to water.

− Maximum ranges for continuous operation at 200 DH/min.

ORDER NUMBER DOC 2340851

7 MPa 10 MPa 15 MPa 70 bar 100 bar 150 bar

1015 psi 1450 psi 2175 psi

Cobra 40-10 / 40-25

VERSION 01/2018

NL/min

L/min

B_01203

100 (10)

<1450>

<USgpm>

ORDER NUMBER DOC 2340851

5.5.5 PERFORMANCE DIAGRAMS

Example

Stroke frequency (DH/min)

8 bar

Cobra 40-10 / 40-25

8 bar

6 bar

4 bar

Product pressure (bar)

B_00301

Cobra 40-10

bar (MPa)

<psi>

250 (25)

<3625>

200 (20)

<2900>

150 (15)

<2175>

100 (10)

<1450>

50 (5)

Product pressure

<725>

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

Water ow rate (nl/min)

Stroke frequency (DH/min)

120

160

200 240

0.4

<0.1>

0.8

1.2

<0.2>

<0.3>

1.6

<0.4>

<0.5>

Water ow rate

6 bar

4 bar

2.4

<0.6>

Air consumption (nl/min)

nl/min

<scfm>

1000

<35>

800

<28>

600

<21>

400

<14>

Air consumption

200

<7>

l/min

<gpm>

Cobra 40-25

bar (MPa)

<psi>

250 (25)

<3625>

200 (20)

<2900>

150 (15)

<2175>

Product pressure

50 (5)

<725>

B_02947

Stroke frequency (DH/min)

<0.26>

120

<0.53>

<0.79>

160

<1.06>

Water ow 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

200 240

<1.32>

<1.59>

nl/min

<scfm>

1500

<53>

1200

<42>

900

<32>

600

<21>

300

<11>

l/min

Air consumption

VERSION 01/2018

ORDER NUMBER DOC 2340851

5.6 COBRA PRESSURE REGULATOR UNIT

Designation

1 Pressure regulator 2 Ball valve 3 Pressure gauge 4 Compressed air Inlet 5 AirCoat lter regulator Cobra

(accessories)

The AirCoat lter regulator must be mounted vertically in all installation positions for the diaphragm pump (see assembly manual for Filter Regulator, order number2328614).

Cobra 40-10 / 40-25

B_04300

Positions of the ball valve

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 present).

5.6.1 HIGHPRESSURE FILTER OPTION

To ensure problem-free operation it is recommended that a WAGNER high-pressure lter be used. These have been developed especially for WAGNER pneumatic pumps. The lter inserts can be exchanged depending on the product to be used. The high-pressure lter corresponding to the device can be found in Chapter; 13 and the compatible lter inserts can be found in Chapter 14

B_04301

B_06835

VERSION 01/2018

ORDER NUMBER DOC 2340851

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING OF ASSEMBLY/COMMISSIONING STAFF

The assembly and commissioning sta must have the technical skills to safely commission the device.

When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

A skilled person must check to ensure that the device is in a reliable state after it is installed and 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.

The air temperature at the storage location must be between -20 °C and 60 °C (-4 °F and 140 °F).

The relative air humidity at the storage location must be between 10 and 95% (without condensation).

Cobra 40-10 / 40-25

6.3 INSTALLATION CONDITIONS

The air temperature at the installation site must be in a range between 0 °C and 40 °C; 32 °F and 132 °F.

The relative air humidity at the installation site must be between 10 and 95% (without condensation).

6.4 TRANSPORTATION

The pump can be moved on a trolley or manually without lifting equipment.

VERSION 01/2018

B_01205

B_01206

6.5 ASSEMBLY AND INSTALLATION

WARNING

Inclined ground!

Risk of accidents if the device rolls away/falls.

Position the trolley with the double diaphragm pump horizontally. If the surface is inclined, position the feet of the trolley towards the gradient. Secure the trolley.

National regulations

Ensure that the national explosion prevention rules and regulations are observed when setting up the device.

Positioning

The Cobra pump may only be operated in a horizontal or vertical position as shown in the diagrams. Overhead operation is not permitted.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

B_06832

Horizontal positioning

This pump can be used as part of a spraying system for Airless or AirCoat applications. The components can be found in the accessories list, provided that the system was not obtained as a spray pack. The nozzles must be selected according to the spray gun instructions.

Procedure

1. Mount the pump on a frame, trolley (6), or wall mount.

2. For AirCoat systems: Mount the additional lter pressure regulator (7) (option).

3. Mount suction system (5).

4. Mount return hose (4) (option).

5. Connect high-pressure hose and spray gun (2) according to the operating manual.

Vertical positioning

Overhead positioning

B_04239

VERSION 01/2018

6.5.1 VENTILATION OF THE SPRAY BOOTH

Operate the device in a spray booth approved for the working materials.

- or -

Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on.

Observe national and local regulations for the exhaust air speed.

6.5.2 AIR SUPPLY LINES

Ensure that only dry, clean atomizing air is used in the spray gun! Dirt and moisture in the atomizing air worsens the spraying quality and spray pattern.

WARNING

Hose connections!

Risk of injury and damage to the device.

Do not mix up hose connections of product hose and air hose.

6.5.3 PRODUCT SUPPLY LINES

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

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 the spray gun, ttings and product hose between the device and the spray gun are suitable for the pressure generated in the device.

Ensure that the following information can be seen on the high-pressure hose:

- Manufacturer – Permissible operating pressure

- Date of manufacture

6.6 GROUNDING

WARNING

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic sparks.

Clean the pump only with a damp cloth.

WARNING

Heavy paint mist if grounding is insucient!

Danger of poisoning. Insucient paint application quality.

Ground all device components. Ground the work pieces to be coated.

VERSION 01/2018

B_01214

Grounding scheme (example)

Designation

1 Conveyor 2 Work piece 3 Pump 4 Paint tank 5 Spraying stand 6 Floor, static dissipative

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

R max < 1 MΩ

B_06818

Part / workstation Cable cross section

Pump 4 mm; AWG 12 Paint tank 6 mm; AWG 10 Conveyor 16 mm; AWG 6 Booth 16 mm; AWG 6 Spraying stand 16 mm; AWG 6

Safe operation of the Cobra pump is only guaranteed with a grounding connection. Connect all ground cables using a short and direct route.

Procedure

1. Screw on grounding cable with eye.

2. Clamp the grounding cable clip to a grounding connection on site.

3. Ground the product (paint) tank to an on-site grounding connection.

4. Ground the other parts of the system to an on-site grounding connection.

Ex zone

All devices and equipment must be suitable for use in potentially explosive areas.

All paints, ushing agents and waste tanks have to be electrically conductive. All tanks must be grounded.

VERSION 01/2018

6.7 COMMISSIONING

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts.

Ensure that the pump and suction system are always completely ﬁlled with ushing agent or working medium.

Do not spray the device empty after cleaning.

NOTICE

Impurities in the spraying system!

Spray gun blockage.

Flush the spray gun and paint supply with a suitable ushing agent before commissioning.

Emergency stop, see Chapter 7.2.

Preparation

Before every start-up, the following points should be observed as laid down in the operating manual:

− Secure spray gun with safety lever.

− Check the permissible pressures.

− Check all connections for leaks.

− Check hoses for damage in accordance with Chapter 8.2.3.

Fill the pump with ushing agent

The devices are tested during manufacturing with emulsifying oil, pure oil or solvent. Possible residues must be ushed out of the circuits with a solvent (ushing agent) before commissioning.

− Fill the empty device with ushing agent in accordance with Chapter 8.2.5.

Pressure tightness test

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

WARNING

Overpressure!

Risk of injury from bursting components.

The operating pressure must not exceed the value shown on the type plate.

− Gradually increase the pressure in pump with the pressure regulator until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points for leaks.

− Depressurization in accordance with Chapter 7.4.

Verifying a Safe Operational Condition

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned. This includes:

− Carry out safety checks in accordance with Chapter 8.2.3.

Filling with working material

− According to Chapter 8.2.5.

VERSION 01/2018

B_04303

ORDER NUMBER DOC 2340851

7 OPERATION

7.1 TRAINING THE OPERATING STAFF

The operating sta must be qualied to operate the entire system.

The operating sta 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 sta must receive appropriate system training.

7.2 EMERGENCY STOP

In the case of unforeseen occurrences:

– Set ball valve (1) to vent. – Open relief valve (2).

Cobra 40-10 / 40-25

B_04099

Vent (1) Switch position Circulation (2)

B_04302

Open

VERSION 01/2018

7.3 WORK

Ensure that:

commissioning is carried out in accordance with Chapter 6.7.

Ball valve position

1 To: 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 present).

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Secure spray gun and insert valve into the spray gun.

3. Slowly open the ball valve.

4. Set the required working pressure on the pressure regulator.

5. Optimize the spray pattern as laid down in the spray gun instructions.

6. Start work process.

Note: Depending on the function, the pump may continue running for 1 - 6 DH/min. after the spray gun is closed.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

7.4 PRESSURE RELIEF/WORK INTERRUPTION

The pressure must always be relieved when:

− after the spraying tasks are nished.

− Before servicing the system.

− before carrying out cleaning tasks on the system.

− before moving the system to another location.

− before something needs to be checked on the system.

− before the nozzle is removed from the spray gun.

Process for relieving pressure

1. Close the spray gun.

2. Close ball valve.

3. Vent air motor.

4. Release the system of pressure by opening the spray gun.

5. Close and secure the spray gun.

Note:

Control air pressure is still present. If the system has been used with 2K products:

NOTICE

Hardened working material in the spraying system when 2K product is processed!

Destruction of pump and injection system.

Follow the manufacturer‘s processing rules, particularly regarding the pot life. Flush thoroughly before the end of the pot life. The pot life is decreased by warmth.

VERSION 01/2018

B_01219

7.5 BASIC CLEANING

Flush regularly

Regular ushing, cleaning and maintenance ensures the pumps' high pumping and suction capacity.

The cleaning and ushing agents used must be compatible with the working material.

WARNING

Incompatibility of ushing / cleaning agent with the working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the ushing and cleaning agents and working media on the basis of the safety data sheets.

Procedure

1. Visual check: personal safety equipment, grounding

and all devices ready to use.

2. Place empty tank (5) under return tube (4).

3. Place suction hose (7) in a tank with cleaning agent

(6).

4. Adjust the pressure regulator (1) to approx. 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. Rinse the system until the cleaning agent that ows

into the tank (5) is clean.

9. Close ball valve (2).

Flushing via spray gun

10. Reverse the relief valve (3).

11. Point the spray gun, without nozzle, into the tank (5) and open it.

12. Slowly open the ball valve (2).

13. Flush until clean cleaning agent ows from the spray gun.

14. Close ball valve (2).

15. When there is no pressure remaining in the system, close the spray gun.

16. Secure the spray gun.

17. Dispose of the contents of the tank (5) according to the local regulations.

Note:

During the ushing procedure, briey press both valve depressors (V).

ORDER NUMBER DOC 2340851

B_04240

Cobra 40-10 / 40-25

7.5.1 FILLING WITH WORKING MATERIAL

After basic ushing, the pump can be lled with working material. Proceed according to Chapter 8.2.5, but use working material instead of ushing agent.

VERSION 01/2018

ORDER NUMBER DOC 2340851

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING STAFF

Cleaning work should be undertaken regularly and carefully by qualied and trained sta. They should be informed of specic hazards during their training.

The following hazards may arise during cleaning work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable cleaning tools and aids.

8.1.2 DECOMMISSIONING AND CLEANING

The device should be cleaned for maintenance purposes, etc. Ensure that no remaining product dries on and sticks to the device.

Procedure

1. Carry out work interruption Chapter 7.4.

2. Carry out the basic ushing Chapter 7.5.

3. Empty system in a controlled manner Chapter 8.2.4.

4. Service spray gun in accordance to its operating instructions.

5. Clean and check the suction system and the suction lter.

6. When using a product lter, check lter insert and lter housing and clean or replace

them. Section 8.2.6.3

7. Clean the outside of the system.

Cobra 40-10 / 40-25

WARNING

Brittle lter pressure regulator!

The tank on the lter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury.

Do not clean the tank on the lter pressure regulator with solvent.

8. Fully assemble the system.

9. Fill the system with ushing agent in accordance with Chapter 8.2.5.

8.1.3 LONGTERM STORAGE

If storing the system for a prolonged period of time, thorough cleaning and corrosion protection are necessary. Replace the water or solvent in the product pump with a suitable preserving oil.

Procedure

1. Carry out points 1 to 8 in Chapter 8.1.2 "Decommissioning and Cleaning".

2. Fill the system with preservative in accordance with Chapter 8.2.5.

3. Empty the system in a controlled manner in accordance with Chapter 8.2.4 and seal

the openings.

VERSION 01/2018

8.2 MAINTENANCE

8.2.1 MAINTENANCE STAFF

Maintenance work should be undertaken regularly and carefully by qualied and trained sta. They should be informed of specic hazards during their training. The following hazards may arise during maintenance work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable tools and aids.

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

8.2.2 MAINTENANCE INSTRUCTIONS

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Use 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 event of work interruptions:

- Relieve the pressure from the spray gun, high-pressure hoses and all devices.

- Secure the spray gun against actuation. – Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Observe the operating and service manual for all work.

Prior to maintenance

The following state is to be ensured before carrying out any work on it:

− Flush and clean the system. Section 8.1.2

− The air supply should be interrupted.

After maintenance

− Carry out safety checks in accordance with Chapter 8.2.3.

− Put the system into operation and check for leaks as described in Chapter 6.7.

− Have the system checked for safe condition by an authorized person.

− Function test in accordance with section 11.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

VERSION 01/2018

8.2.3 SAFETY CHECKS AND MAINTENANCE INTERVALS

Every day

Check grounding: see Chapter 6.5 Check hoses, tubes and couplings: see Chapter 8.2.3.1 For each decommissioning, the process according to Chapter 8.1.2 must be

followed. If the pump has to be emptied for maintenance work, proceed according to Chapter 7.5 and Chapter 8.2.4.

Weekly

Check spraying system for damage. Check that the safety xtures function properly (see Chapter 5.3).

Yearly or as required

In accordance with DGUV regulation 100-500 Chapter 2.29 and 2.36:

– The liquid ejection devices should be checked by an expert (e.g., WAGNER

service technician) for their safe working conditions as required and at least every 12 months.

– For shut down devices, the examination can be suspended until the next start-

up.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

8.2.3.1 PRODUCT HOSES, TUBES AND COUPLINGS

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental inuences even when handled correctly.

Check hoses, pipes, and couplings every day and replace if necessary. Before every commissioning, check all connections for leaks. Additionally, the operator must regularly check the complete hoses for wear and tear as well as for damage at intervals that he/she has set. Records of these checks must be kept. The complete hose is to be replaced as soon as one of the two following intervals has been exceeded:

−6 years from the date of the hose crimping (see tting embossing).

−10 years from the date of the hose imprinting.

Fitting embossing Meaning

xxx bar Pressure yymm Crimping date (year/month) XX Internal code

Hose imprinting Meaning

Wagner Name / Manufacturer yymm Date of manufacture (year/month) xxx bar (xx MPa) e.g., 270 bar (27 MPa) XX Internal code DNxx (e.g., DN10) Nominal diameter

Pressure

8.2.3.2 CONDENSATE DRAIN FROM THE AIRCOAT FILTER REGULATOR

Frequently drain the condensate that may accumulate in the air lter.

– Make sure the water level in the lter cup never reaches the max. level marked on

the cup itself.

VERSION 01/2018

8.2.4 EMPTYING PUMP

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts. Ignition of potentially explosive surrounding atmosphere.

Empty the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

If the pumping product becomes heated, switch o all heaters and let the product cool o.

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Place grounded collection tank (5) under the return tube (4).

3. Place the suction hose (7) in an empty, grounded tank (6).

4. Close pressure regulator (1) (0MPa; 0bar; 0psi).

Empty 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; 7.25 psi).

8. Be ready for the switch from working material to air. Turn down pressure regulator (1) far enough that the pump is still running normally (approx. 0–0.05MPa; 0–0.5bar; 0–7.25psi).

9. As soon as working material is no longer owing from the return tube (4), close ball valve (2).

10. Close relief valve (3).

Empty up to the gun

11. Point the gun, without nozzle, into tank (5) and open it.

12. Slowly open the ball valve (2). Be ready for the switch from working material to air.

13. As soon as working material is no longer owing from the return tube, close the ball valve (2).

14. Close and secure gun.

15. Depressurization in accordance with Chapter 7.4.

16. Dispose of the contents of the tank (5) according to the local regulations.

ORDER NUMBER DOC 2340851

B_04240

Cobra 40-10 / 40-25

VERSION 01/2018

8.2.5 FILLING THE EMPTY PUMP

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts. Ignition of potentially explosive surrounding atmosphere.

Empty and ll the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Place grounded collection tank (5) under the return tube (4).

3. Place the suction hose (7) in a grounded tank with working material (6).

4. Close pressure regulator (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MPa; 0–0.5 bar; 0–7.25 psi). Be ready to switch from working material to air and prevent back spray.

8. Close ball valve (2) as soon as pure working material starts coming from the return tube (4).

9. Close relief valve (3).

10. Point the spray gun, without nozzle, into the tank (5) and open it.

11. Slowly open the ball valve (2). Be ready to switch from working material to air and prevent back spray.

12. As soon as pure working material without air bubbles is owing, close ball valve (2).

13. Close and secure the spray gun.

14. Depressurization in accordance with Chapter 7.4.

15. Dispose of the contents of the tank (5) according to the local regulations.

ORDER NUMBER DOC 2340851

B_04240

Cobra 40-10 / 40-25

VERSION 01/2018

B_05273

ORDER NUMBER DOC 2340851

8.2.6 CLEANING AND REPLACING THE FILTER

8.2.6.1 STRAIGHT INLINE FILTER 270 BAR

Cobra 40-10 / 40-25

1. Flush the pump and inline lter in accordance with Chapter 7.5. Flush using the gun so that the ushing agent ows through the inline lter. Maximize the ow (remove the nozzle, open the dosing valve if necessary).

2. Empty the pump in a controlled manner in accordance with Chapter 8.2.4.

3. Place the grounded collection tank under the inline lter.

4. If no swivel joint is mounted, remove the hose.

5. Unscrew the inlet housing (2) and outlet housing(5) with two size 19 wrenches.

6. Remove the lter insert (3).

7. If the inline lter has any leaks, replace the seal* (1).

8. Insert the new lter insert* (3). Note the installation position: Closed end in direction of ow.

9. If necessary, coat the thread with anti-seize paste**.

10. Screw together the 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 10.3.

8.2.6.2 ANGLED INLINE FILTER 270 BAR

Flow direction

27MPa; 270bar; 3916psi

Anti-seize paste**

B_05274

2. Empty the pump in a controlled manner in accordance with Chapter 8.2.4.

3. Place the grounded collection tank under the inline lter.

4. Unscrew the lter by turning the handle (4).

5. Remove the lter insert (3).

6. If the inline lter has any leaks, replace the seal* (1).

7. Insert the new lter insert* (3). Note the installation position: Closed end in direction of ow.

8. If necessary, coat the thread with anti-seize paste**.

9. Assemble the turning handle (4), inlet housing (2) and outlet housing(5) and tighten by turning the handle.

10. Fill the pump in accordance with Chapter 8.2.5. * Order No., see Chapter 13. ** Order No., see Chapter 10.3.

Anti-seize paste**

Flow direction

27MPa; 270bar; 3916psi

VERSION 01/2018

ORDER NUMBER DOC 2340851

8.2.6.3 HIGHPRESSURE FILTER 530 BAR

Cobra 40-10 / 40-25

1. Flush the pump and HP lter in accordance with Chapter 7.5, and while doing so:

– At the preferred lter installation position: Flush via the

return ow valve (1). This produces a large ow. As a result, the ushing agent also ows through the upper part of the lter cartridge (11). Pressure regulator approx. 0.15MPa;

1.5bar; 22psi.

– At the reversed lter installation position: Flush using the

gun. This is required in the case of a reversed installation position so that the ushing agent ows through the lter cartridge (11). Maximize the ow (remove the nozzle, open the dosing valve if necessary).

2. Empty the pump in a controlled manner in accordance with Chapter 8.2.4.

3. Place the grounded collection tank under the High-pressure lter.

4. Open ball valve (1).

5. Loosen union nut (3) with a size 70 wrench.

6. Unscrew the union nut (3) and lift slightly so that it does not get dirty in the next step.

7. Remove the lter housing (2) with the union nut (3). The cone spring (12) remains in the lter housing (2). If the O-ring (5) is not damaged, it remains on the lter housing (2).

8. Remove the lter cartridge (11) and lter support (10) from the lter housing (2).

9. Clean all parts:

– Place the lter cartridge (11) and lter support (10) in solvent.

Clean using brush.

– Fill the lter housing (2) approx. 1/3 full with solvent, secure

wearing a glove and shake well.

– Clean the distribution housing (7) using a brush.

10. If necessary, replace the O-ring (5) and/or lter cartridge (11). Order No., see Chapter 14.12.

11. Assemble all parts in reverse order. While doing so:

– Coat the thread of the distribution housing (7) with anti-seize

paste**.

– Coat the O-ring (5) and pressure ring (21) with Mobilux

EP2**.

– Observe the installation position of the lter cartridge (11):

Push the closed end with the lter identication ahead into the lter housing (2).

– Make sure that the cone spring (12) is in the lter housing

(note the installation position). Press on the cone spring after inserting the lter cartridge (11) and lter support (10); the spring action must be noticeable.

– Tighten the union nut (3) by hand.

12. Close ball valve (1).

13. Fill the pump in accordance with Chapter 8.2.5.

Filter installation position

Preferred Turned over

53MPa 530bar 7687psi

Loctite 542

Mobilux EP2**

Filter identication

Anti-seize paste**

B_06836

Loctite 542

** Order No., see Chapter 13.

VERSION 01/2018

B_04243

8.2.7 MAINTENANCE HYDRAULIC STAGE

Dismount the device onto a frame as shown in the picture and turn it upside down. Observe the ll level marking (X) on the oil tank.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

B_04241

B_04242

8.2.8 CHECKING THE OIL LEVEL

1. Start up the pump for a short time without any product.

2. Then read oil level A.

Dismount the device onto a frame as shown in the picture and turn it upside down. Observe the ll level marking (X) on the oil tank. Oil level A in the oil tank (1) has to be within the specied markings (X). If the level deviates from these markings, the hydraulic oil must be topped up.

Procedure

1. Unscrew and remove threaded plug (5).

2. Top up oil to level A = middle of marking X.

3. Start up the pump for a short time without any product and check for air bubbles.

4. Screw in threaded plug (5) and tighten with 2 Nm; 1.5 lbft.

NOTICE

Using hydraulic oil

Using the wrong hydraulic oil can cause a malfunction.

Use only original hydraulic oil - Wagner order no. 322912 (250 ml or 15 cu inch).

max.

min.

VERSION 01/2018

ORDER NUMBER DOC 2340851

8.2.9 OIL CHANGE

Perform oil change after 500 service hours or once a year.

Necessary accessories:

Order No. 322911 Oil lling set

NOTICE

Using hydraulic oil

Using the wrong hydraulic oil can cause a malfunction.

Use only original hydraulic oil - Wagner order no. 322912 (250 ml or 15 cu inch).

8.2.9.1 DISCHARGING OIL

Cobra 40-10 / 40-25

B_04241

B_04244

Procedure

1. Decommission and clean Chapter 8.1.2 up to and including point 6.

2. Position device as shown in the picture and dismount the hood and casing.

3. Unscrew piston cover (1).

4. Place empty oil collector (2) under the oil tank.

5. Unscrew oil tank (3) and drain contents.

6. Unscrew and remove locking screws (4) and seals.

7. Slowly start up the pump until no more oil ows out of the oil intake tube.

8. Screw in clean oil tank (3) and seal.

VERSION 01/2018

8.2.9.2 FILLING HYDRAULIC STAGE WITH OIL

CAUTION

Environmental pollution caused by waste oil!

Waste oil in the sewage network or spilled on the ground causes severe environmental damage. Groundwater pollution is liable to prosecution.

Collect waste oil and bring it to a collection point. Waste oil is taken back by the seller at the time of purchasing hydraulic oil.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

B_04245

17 mm; 0.67in

B_04246

Procedure

1. Turn pump (mounted on the frame) upside down.

2. Unscrew and remove threaded plug (5).

3. Unscrew 2 locking screws (4) and replace with 2 screw ttings (6) from the oil lling 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 position. Use the syringe to ll the hydraulic stage until the oil ows out of the intake tube into the oil tank (3) with no air bubbles.

7. Move piston (9) into rear end position. Use the syringe to ll the hydraulic stage until the oil ows out of the intake tube into the oil tank (3) with no air bubbles.

8. Continue to top up the oil until the level before venting is approx. 17 mm; 0.67 inches below the upper edge of the oil tank.

9. Screw in threaded plug (5) and tighten gently. Put pump on its side and dismount oil lling set. Seal the ller openings tightly with 2 locking screws (4).

VERSION 01/2018

8.2.9.3 VENT

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

B_04243

B_04247

Procedure

1. Turn the pump upside down. Remove the threaded 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 specied markings (X).

4. Screw in threaded plug (5) and tighten with 2 Nm; 1.5 lbft.

5. Mount piston cover (1) and hood with casing.

6. Return device to correct setup position.

7. The device is ready for operation again.

VERSION 01/2018

ORDER NUMBER DOC 2340851

9 TROUBLESHOOTING AND RECTIFICATION

Problem Cause Remedy

The pump does not work. Air motor does not work or stops. Open and close ball valve on the

pressure regulator unit or briey disconnect compressed air supply.

Cobra 40-10 / 40-25

No pressure indication on the pressure gauge (air pressure regulator defective).

Spray nozzle is clogged. Clean the nozzle according to the

Insucient compressed air supply. Check compressed air supply. Filter insert in spray gun or high-

pressure lter is clogged. The uid section or high-pressure hose

is blocked (e.g., the 2K product has hardened).

Grease in spool and sleeve assembly. Degrease spool and sleeve assembly. Pump stops at the stroke end

occasionally. Poor spray pattern. See spray gun instructions. Irregular operation of

product pump: spray jet collapses (pulsation)

Strongly irregular operation of product pump.

The pump runs evenly, does not however, suck up product.

Pump runs fast when the spray gun is closed.

Loss of power due to severe icing.

If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

Viscosity is too high. Thin spraying product.

Spraying pressure is too low. Increase incoming air pressure.

Valves are clogged. Press valve depressor.

Foreign body in suction valve. Dismantle suction valve housing, clean

Diameter of compressed air line too

small.

Valves, packings, or pistons are worn

out.

Control air lter or work air lter is

clogged.

Diaphragms "blocked" because

suction is too fast.

The suction system's union nut is

loose; the pump is taking in air.

Suction lter is clogged. Clean lter.

Valves are clogged. Press valve depressor.

Valves worn. Replace the parts.

There is a lot of condensation water in

the air supply.

Disconnect compressed air supply briey or repair or change pressure regulator.

instructions.

Clean the parts and use a suitable working material.

Dismount and clean uid section, replace high-pressure hose.

Check detent body.

Use a smaller nozzle.

Clean product pump and leave to soak in cleaning agent if necessary.

and check valve seat. Assemble a larger supply line

Technical data, see Chapter 5.5.2. Replace the parts.

Check lter and clean it if necessary.

Operate pump with ball valve opened a minimal amount for a while.

Tighten.

Clean product pump and leave to soak in cleaning agent if necessary.

Install a water separator.

VERSION 01/2018

ORDER NUMBER DOC 2340851

10 REPAIR WORK

10.1 REPAIR STAFF

Repair work must be carried out carefully and by qualied and trained personnel. They should be informed of specic hazards during their training. The following hazards may arise during repair work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable tools and aids.

A skilled person must check to ensure that the device is in a reliable state after it is repaired. Carry out function test in accordance with Chapter 11.

10.2 REPAIR NOTES

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Use 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 event of work interruptions:

- Relieve the pressure from the spray gun, high-pressure hoses and all devices.

- Secure the spray gun against actuation. – Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Observe the operating and service manual for all work.

Before a Repair

− Flush and clean the system. Section 8.1.2

− The air supply should be interrupted.

After a Repair

− Carry out safety checks in accordance with Chapter 8.2.3.

− Put the system into operation in accordance with Chapter 6.7 and check for leaks in accordance with Chapter 11.

− Function test in accordance with section 11.

Cobra 40-10 / 40-25

10.3 TOOLS

The following tools are required for carrying out the repair work described below on the Cobra pump:

– Open-end wrenches, size 3; 5; 7; 8; 10; 12; 13; 14; 15; 16; 17; 18; 19; 22; 24; 27; 36; 50. – Allen wrench, size 10. – Screwdriver, size 3. – Torque wrench 40 Nm; 29.5 lbft.

VERSION 01/2018

10.4 CLEANING THE PARTS AFTER DISASSEMBLY

WARNING

Incompatibility of cleaning agent and working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the cleaning agents and working media on the basis of the safety data sheets.

Please note:

Thoroughly clean all reusable parts with a suitable cleaning agent. All uninstalled parts have to be clean and dry after cleaning. Care should be taken

that these parts remain free of solvents, grease or sweat from the hands (salt water). Clean and mount wearing gloves.

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.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Defective parts, O-rings and seal sets must always be re-placed. Use greases and glues in accordance with Chapter 14. Observe torque specications in Chapter 14.

Mounting materials

Order No. Quantity Designation Smaller tanks

9992590 1 pc ≙ 50 ml Loctite 222 9992511 1 pc ≙ 50 ml Loctite 243 9992528 1 pc ≙ 150 g Loctite 270 9992831 1 pc ≙ 50 ml Loctite 542 9998808 1 pc ≙ 18 kg! Mobilux EP 2 grease 400 g tube ≙ Order No. 2355418 9992616 1 pc ≙ 1 kg can Molykote DX grease 50 g tube ≙ Order No. 2355419 322912 1 pc ≙ 250 ml Hydraulic oil - Wagner

Brand notice

The brands specied in this document are property of the respective owners. Loctite , for example, is a registered brand of Henkel.

VERSION 01/2018

ORDER NUMBER DOC 2340851

11 FUNCTION TEST AFTER THE REPAIR

After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair sta.

Activities Aid tools

1. Piston travel

Cobra 40-10 / 40-25

− It must be possible to move the piston rod on both sides up to stop with a pre-assembled pressure stage. Balancing bore must be completely open in the respective end position (Visual inspection, see Chapter 14.4).

2. Oil lling

− Mount pressure and uid section on frame. Push piston into air motor-side end position. Fill pre-assembled pump with oil via lling port until oil is visible in the oil tank. Push piston into the opposite end position. Fill pump further with oil until just below end of oil tank inspection window (see Chapter 8.2.9).

3. EX-relevant inspections

− Check mass connection between grounding connection of the pump and the frame/trolley and between the individual components of the frame/ trolley: <100k

− Check conductivity between the piston and the grounding connection: <100k

Manual inspection

Oil lling unit

Ohmmeter

These inspections are − relevant!!

4. Testing for leaks

− Connect the air motor to the air supply 6 bar. To perform a leak test on the device, the product pressure with the ushing agent is slowly increased in increments until the maximum pressure indicated on the type plate is reached. Close pump outlet. Allow to stand in this position for 0.5-1 minute and listen for audible blowing o. Close air-supply ball-valve without relieving and check for pressure-loss. Check seal of following modules:

− Flange seal

− Ball valve (in all positions)

− Pressure stage

− Fluid section

5. General inspections

− Check tightening torque of various screws. Tighten hexagon screws M12x65 (40-10) or M16x80 (40-25) and input valve housing with the prescribed torque (see Chapter 14).

− Check all threaded connections.

− Empty the device completely and relieve pressure.

− Check function of frame or transport trolley. Check whether the pump is mounted horizontally on the frame.

Air motor: Test medium compressed air Leak spray

Fluid section: Test medium: suitable ushing agent

Torque wrench Visual check

VERSION 01/2018

ORDER NUMBER DOC 2340851

12 DISPOSAL

When the equipment must be scrapped, please dierentiate the disposal of the waste materials.

The following materials have been used:

Stainless steel Aluminum Elastomerics Plastics Carbide

Consumable products

Consumable products (lacquers, adhesives, ushing and cleaning agents, solvents) must be disposed of in accordance with all applicable legal requirements.

Cobra 40-10 / 40-25

VERSION 01/2018

B_04234

B_04248

AirCoat

30,31

10,19

13 ACCESSORIES

13.1 COBRA 4010 ACCESSORIES

ORDER NUMBER DOC 2340851

Note:

When the tting at the product outlet is replaced (item 55/57), a new sealing ring (item 58) must also be installed.

Cobra 40-10 / 40-25

VERSION 01/2018

Order No. Designation

A 2329519 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 2382997 AirCoat lter pressure regulator 4 341434 Double open-end wrench 6 2329026 Inline lter, HL DN6-PN270-G1/4"-SSt 7 2325343 Fitting, DF-MM-R1/4"-M12-PN270-SSt 8 2341068 Fitting, SF-FF-G3/8-G1/4-530 bar-SSt

9 2331273 Fitting, EF-FM-G1/4-G1/4-530 bar-SSt 10 2332621 Fitting RF-FM-G3/8-1/4NPSM-530 bar-SSt 11 2323325 Air suction lter DN25 12 2329046 Return hose DN6-PN310-G1/4"-PA 13 2324116 DN25 suction hose 14 2333163 Return tube for item 15 15 2344505 5-liter hopper set for Cobra 16 2328611 AirCoat regulator set 17 2324110 DN16 suction hose 18 2330774 Fitting, DF-MM-G1/4-1/4NPSM-530 bar-SSt 19 2332620 Fitting 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 lter DN16 25 2325901 Trolley 4", complete 26 2344741 2 L tank for Cobra 27 2341278 20 L tank for Cobra 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 lter DN6-PN270-G1/4"-SSt 34 2332619 Fitting RF-FM-G1/4-1/4NPSM-530 bar-SSt 51 322911 Oil lling set with 100 ml; 100 cc syringe 52 322916 Air coupling set DN 10 mm; 0.39 inch 53 9985619 Hose connector with sealing ring 55 2329922 Fitting SF-MM-G3/8"-M24-PN530-SSt 56 2335334 HP lter DN12-PN530-CS, complete 57 2330775 Fitting, DF-MM-G3/8-G3/8-530 bar-SSt 58 9974112 Sealing ring for G3/8 thread

= Wearing parts.

Regarding item 7: Fitting (7) can be screwed in instead of the relief valve. In this case, the required ball valve must be provided by the customer. The return hose can no longer be connected to the "return socket" output.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

30,31

B_04249

10,19

57/58

60/61

AirCoat

VERSION 01/2018

13.2 COBRA 4025 ACCESSORIES

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Note:

When the tting is replaced at the product output (item 55/57/58/59), a new sealing ring (item 60/61) must also be installed.

VERSION 01/2018

Order No. Designation

A 2329523 Diaphragm pump Cobra 40-25

1 322912 Hydraulic oil (for pressure stage) 250 ml; 250 cc

2 236219 Grounding cable 3 m; 9.8 ft

3 2333479 AirCoat lter pressure regulator

4 341434 Double open-end wrench

6 2329026 Inline lter, HL DN6-PN270-G1/4"-SSt

7 2325343 Fitting, DF-MM-R1/4"-M12-PN270-SSt

8 2341068 Fitting, SF-FF-G3/8-G1/4-530 bar-SSt

9 2331273 Fitting, EF-FM-G1/4-G1/4-530 bar-SSt 10 2332621 Fitting RF-FM-G3/8-1/4NPSM-530 bar-SSt 11 2323325 Air suction lter DN25 12 2329046 Return hose DN6-PN310-G1/4"-PA 13 2324116 DN25 suction hose 14 2333163 Return tube for item 15 15 2344505 5-liter hopper set for Cobra 16 2328611 AirCoat regulator set 17 2324110 DN16 suction hose 18 2330774 Fitting, DF-MM-G1/4-1/4NPSM-530 bar-SSt 19 2332620 Fitting RF-FM-G3/8-3/8NPSM-530 bar-SSt 20 2308732 Cobra 40-25 frame 21 2332143 Wall mount 4", complete 22 2349756 Wall mounting long 24 2323396 Air suction lter DN16 25 2325901 Trolley 4", complete 27 2341278 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 lter DN6-PN270-G1/4"-SSt 34 2332619 Fitting RF-FM-G1/4-1/4NPSM-530 bar-SSt 51 322911 Oil lling set with 100 ml; 100 cc syringe 52 322916 Air coupling set DN 10 mm; 0.39 inch 53 9985619 Hose connector with sealing ring 55 2329922 Fitting SF-MM-G3/8"-M24-PN530-SSt 56 2335334 HP lter DN12-PN530-CS, complete 57 2330775 Fitting, DF-MM-G3/8-G3/8-530 bar-SSt 58 2330780 Fitting, DF-MM-G1/2-G3/8-530 bar-SSt 59 2333058 Fitting, SF-FM-G3/8-G1/2-530 bar-SSt 60 9974112 Sealing ring for G3/8 thread 61 3051041 Sealing ring for G1/2 thread

= Wearing parts.

Note: When using the HP lter (item 56), the respective appropriate tting must be used (for product outlet uid sections 1/2", the two ttings pos. 55 and 59 are required; for product outlet uid sections 3/8", only tting item 55 is required). The suitable sealing ring (item 60/61) must also be used. Regarding item 7: Fitting (7) can be screwed in instead of the relief valve. In this case, the required ball valve must be provided by the customer. The return hose can no longer be connected to the "return socket" output.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

VERSION 01/2018

ORDER NUMBER DOC 2340851

14 SPARE PARTS

14.1 HOW CAN SPARE PARTS BE ORDERED?

Always supply the following information to ensure delivery of the right spare part:

Order number, designation and quantity

The quantity need not be the same as the number given in the quantity column " " on the list. This number merely indicates how many of the respective parts are used in each component.

The following information is also required to ensure smooth processing of your order:

− Address for the invoice

− Address for delivery

− Name of the person to be contacted in the event of any queries

− Type of delivery (normal mail, express delivery, air freight, courier etc.)

Identication in spare parts lists

Explanation of column " " (labeling) in the following spare parts 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, however, as additional extra.

Explanation of Order No. column

-- Item not available as spare part. / Position does not exist.

Cobra 40-10 / 40-25

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Use 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 event of work interruptions:

- Relieve the pressure from the spray gun, high-pressure hoses and all devices.

- Secure the spray gun against actuation. – Switch o the energy and compressed air supply.

- Disconnect the control unit from the mains. Observe the operating and service manual for all work.

VERSION 01/2018

ORDER NUMBER DOC 2340851

14.2 OVERVIEW OF THE COBRA 4010 COMPONENTS

Cobra 40-10 / 40-25

25 Nm; 18 lbft

5 7 8

B_04250

Order No. Designation

1 1 -- Air motor 3/53 2 1 -- Preassembled Cobra 40-10 uid section 3 1 322436 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 label 10 4 9999211 Edge protection prole 30 mm; 1.18 inch 11 2 9999211 Edge protection prole 164 mm; 6.46 inch 12 1 2332082 Fluid warning label 13 1 322438 Cylinder noise insulation 14 1 9974112 Sealing ring 15 1 9992616 Molykote DX grease

= Wearing part.

VERSION 01/2018

14.3 COBRA 4010 AIR MOTOR

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

1 2

10-15 Nm; 7-11 lbft

11* 12*

27*

20-25 Nm; 15-18 lbft

2-3 Nm; 1.5-2.2 lbft

Do not dismount the piston

31*

46*

37* 38

35 36*

26 27

43*

4244 47

49 5150*46*

50*

25Nm

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

8 1 367318 Shoulder screw 4

9 1 9925033 Washer

40 41*

B_06851

VERSION 01/2018

Order No. Designation

10 1 367310 Silencer 4 11 1 9974098 O-ring 12 1 9974097 O-ring 13 3 9900325 Socket cap screw 14 3 9920103 Washer A6.4 15 1 367309 Connecting part 4 16 2 367320 Cotter pin 17 1 369290 Pilot valve 18 2 9998674 Threaded plug 19 1 9998274 Threaded plug 20 1 2359165 Control housing 4 21 1 367313 Compressed air lter 4/6 22 1 2328606 Pressure regulator unit 4 24 1 9990506 Cone plug, GPN 600 25 1 9999228 Screw connector L 26 2 367307 Sealing plug, 4/6 27 2 9974085 O-ring 28 1 367324 Filter holder 29 1 367314 Control air lter 30 1 322910 Cobra outlet seal set (consisting of 2 seals) 31 2 9974095 O-ring 32 1 368285 Safety valve 0.63 MPa; 6.3 bar; 91 psi 33 1 9943080 Spool and sleeve assembly, complete 34 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 pipe 41 2 9971448 O-ring 42 1 2360756 Edge ball valve 4, cpl. 43 1 9971137 O-ring 44 4 9900316 Hexagon socket head cap screw M6x50 45 2 9907039 Hexagon socket head cap screw M6x80 46 1 9971313 O-ring 47 1 2341175 Manometer with air regulator 0-10 bar, G1/8" 48 1 2309972 Pressure regulator 49 1 2309744 Distributor LR-D-I Mini 4 50 2 9974166 O-ring 51 1 9904307 Locking screw with collar / hexagon socket 52 1 9974217 Rod seal 53 1 9970154 Sealing ring 54 1 322439 Air motor noise insulation 55 1 9990861 Ribbed plug 56 2 368313 Damper ISO1 and ISO2 57 6 9971123 O-ring 58 1 9992590 Loctite 222 50 ml; 50 cc 59 1 9992831 Loctite 542 50 ml; 50 cc 60 1 9992616 Molykote DX grease 61 1 9992528 Loctite 270 50 ml; 50 cc

2341627 Cobra 40-10 air motor service set = Wearing part. = Included in service set.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

VERSION 01/2018

ORDER NUMBER DOC 2340851

14.4 COBRA 4010 FLUID SECTION

Cobra 40-10

89 90

110

105

Cobra 40-10 / 40-25

70 Nm; 52 lbft

6 7

50 Nm; 37 lbft

1.5 Nm; 1.1 lbft

2 Nm; 1.5 lbft

102

110

90 Nm; 66 lbft

112

20 Nm; 15 lbft

40 Nm; 29.5 lbft

110

30 Nm; 22 lbft

110

101

102

100

110

103

20 Nm;14.8 lbft

B_04253

VERSION 01/2018

Order No. Designation

1 1 2329898 Sealing sleeve 2 4 9900204 Hexagon screw 3 4 9920102 Washer 4 2 341241 Inlet valve depressor, complete, see Chapter 14.10 5 1 2330764 Inlet housing 6 8 9907234 Hexagon screw 7 10 9920107 Washer 8 2 9974184 O-ring

9 2 322411 Valve tting 10 2 341336 Clasp 11 1 322914 Inlet valve set, complete (comprising 2 valves), see Chapter 14.9 13 1 2330810 Connection piece 14 1 322410 Fluid section 15 2 322412 Plug 16 2 9904311 Screw plug 17 1 169248 Relief valve, complete, see Chapter 14.11 18 1 322915 Outlet valve set, complete (spare parts for 2 valves) 19 1 2330775 Fitting, DF-MM-G3/8-G3/8-530 bar-SSt 20 1 322913 Complete diaphragm set with insert (comprising 2 diaphragms) 21 2 9904306 Screw plug 22 2 9970127 Sealing ring 23 1 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 ange 31 2 9974182 Rod sealing prole BS 32 2 9974183 Rod sealing set 33 2 9974186 O-ring 34 2 9971446 O-ring 35 2 322405 Pressure disk

37 1 115944 O-ring 38 1 2352719 Oil tank set 40 1 9998274 Threaded plug G1/4 41 1 322435 Piston cover 42 1 2334842 Pressure relief valve 46 1 322404 Pressure stage cover disk 47 1 9974074 O-ring 49 4 9907233 Hexagon screw 50 4 9920102 Washer

51 53 2 322427 Damping washer

54 1 9974181 Piston sealing prole Z5 55 1 322426 Piston air motor 3 57 1 9974115 O-ring 59 2 9974185 Seal wiper ring, prole EM 60 1 2344068 Air motor ange 61 1 367258 Grounding, complete 62 1 369290 Pilot valve 63 1 9998675 Threaded plug 66 1 9998780 Pressure spring 67 2 322407 Oil valve screw 68 3 9971162 O-ring

1 2386160 Self-locking hexagon nut (new) 1 9910101 Hexagon nut, secured with Loctite® 243 (old version!)

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

VERSION 01/2018

108

B_04252

111

40 Nm; 29.5 lbft

Order No. Designation

69 2 322415 Insert 70 1 9974217 Rod seal 78 4 341331 Sealing ring 89 2 9971486 O-ring (solvent-resistant) 90 2 341316 Scraper 91 1 9974112 Sealing ring for G3/8 thread 92 3 9920106 Washer 93 2 341325 Valve guide 94 2 341328 Clasp 95 2 9971470 O-ring 96 2 341326 Pressure spring 97 2 253405 Spring support ring 98 2 9941501 Ball 11 HM 99 2 341327 Outlet valve seat

100 2 341347 Sealing ring 101 1 9994237 Pressure spring 102 2 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 uid section 107 1 322917 Service set for Cobra 40-10 piston (incl. items 25, 31, 32, 33, 59, and 108) 108 1 322930 Piston rod assembly pin 110 1 9992616 Molykote DX grease 111 1 9998808 Mobilux EP2 grease 112 1 9992528 Loctite 270 50 ml; 50 cc

= Wearing part. = Included in service set.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Notes:

The piston rod (25) may only be mounted with the screwed-on assembly pin (108).

Grease all o-rings and seals lightly with grease (111) before mounting them.

VERSION 01/2018

ORDER NUMBER DOC 2340851

14.5 OVERVIEW OF THE COBRA 4025 COMPONENTS

Cobra 40-10 / 40-25

B_04254

Order No. Designation

1 1 -- Cobra 40-25 air motor 2 1 -- Preassembled Cobra 40-25 uid section 3 4 9920106 Washer 4 1 322235 Hood 4 with 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 screw 12 2 9922107 Lock washer internal teeth 13 1 2308646 Cylinder noise insulation 14 1 2306110 Air motor casing 15 1 2306111 Pressure stage casing 16 2 2306114 Fluid section bulkhead 17 1 2308620 Pressure stage casing 20 1 9999211 Edge protection prole (total length: 0.80 m; 2.62 ft) 21 1 9992616 Molykote DX grease

25 Nm; 18 lbft

4 3

VERSION 01/2018

14.6 COBRA 4025 AIR MOTOR

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

1 2

11*

12*

27*

10-15 Nm; 7-11 lbft

20-25 Nm; 15-18 lbft

2-3 Nm; 1.5-2.2 lbft

Do not dismount the piston

31*

35 36*

37* 38

26 27

42 44 43

48*

6260

25Nm

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

8 1 367318 Shoulder screw 4

41*

B-06852

VERSION 01/2018

Order No. Designation

9 1 9925033 Washer 10 1 367310 Silencer 4 11 1 9974098 O-ring 12 1 9974097 O-ring 13 3 9900325 Socket cap screw 14 3 9920103 Washer A6.4 15 1 367309 Connecting part 4 16 2 367320 Cotter pin 17 1 369290 Pilot valve 18 2 9998674 Threaded plug 19 1 9998274 Threaded plug 20 1 2359165 Control housing 4 21 1 367313 Compressed air lter 4/6 22 1 9970154 Sealing ring 24 1 2328606 Cobra pressure regulator unit 25 1 9904307 Locking screw with collar / hexagon socket 26 2 9990506 Cone plug, GPN 600 27 2 9974085 O-ring 28 1 367324 Filter holder 29 1 367314 Control air lter 30 1 322910 Cobra outlet seal set (consisting of 2 seals) 31 2 9974095 O-ring 32 1 368285 Safety valve 0.63 MPa; 6.3 bar; 91 psi 33 1 9943080 Spool and sleeve assembly, complete 34 1 368038 Detent 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-ring 42 1 2391704 Edge ball valve midi to size 4 43 1 2309973 Pressure regulator valve LR-1/2-D-O-Midi 44 1 2341176 Pressure gauge with air regulator 0-10 bar, G1/4" 47 1 9999228 Elbow screw-in connection R1/2 - G1/2 48 1 3105540 O-ring 49 1 9971018 O-ring 50 1 M396.00 Reducing tting 52 1 9974217 Rod seal 54 1 322439 Air motor noise insulation 55 1 9990861 Ribbed plug 56 2 368313 Damper ISO1 and ISO2 57 6 9971123 O-ring 58 1 9992590 Loctite 222 50 ml; 50 cc 60 1 2311012 Distribution piece midi to size 4 61 1 9971137 O-ring 62 1 9974166 O-ring 63 3 9906020 Hexagon socket head cap screw M6x70 64 1 9907039 Hexagon socket head cap screw M6x80 65 2 9907014 Hexagon socket head cap screw M6x90 66 1 9992616 Molykote DX grease

67 1 9992528 Loctite 270 50 ml; 50 cc

2341628 Cobra 40-25 air motor service set = Wearing part. = Included in service set.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

VERSION 01/2018

B_04257

2 3

10 11

100

101

102

24/92

102

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

81 80

104

1.5 Nm; 1.1 lbft

14.7 COBRA 4025

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

1 1 2329898 Sealing sleeve 2 4 9900204 Hexagon screw 3 4 9920102 Washer 4 2 341241 Inlet valve depressor, complete, see Chapter 14.9 5 1 2330795 Inlet housing 6 8 2306195 Hexagon screw 7 8 9925011 Washer 8 2 2306183 O-ring

VERSION 01/2018

Order No. Designation

9 2 2306164 Valve tting 10 2 341336 Clasp 11 1 2308753 Inlet valve set, complete (comprising 2 valves), see Chapter 14.8 13 1 2330810 Connection piece 14 1 2337668 Fluid section 15 2 2308868 Flange connection 16 2 2308886 O-ring 17 1 169248 Relief valve, complete (for spare parts, see Chapter 14.11) 18 1 2308760 Outlet valve set, complete (spare parts for 2 valves)

19* 1 2330775 Fitting, DF-MM-G3/8-G3/8-530 bar-SSt 19* 1 2330780 Fitting, DF-MM-G1/2-G3/8-530 bar-SSt

20 1 2308754 Complete Cobra 40-25 diaphragm kit with insert (comprising 2 diaphragms) 21 2 9904306 Screw plug 22 2 9970127 Sealing ring 23 1 2337746 Pressure stage 24 3 9907041 Hexagon screw 25 1 2306251 Piston rod D25/70 26 2 9941502 Ball 27 2 9971189 O-ring 28 1 2334842 Pressure relief valve 29 1 2306146 Permaglide bushing 30 1 2308870 Pressure stage ange 31 2 2306143 Rod sealing prole BS 32 2 2306144 Rod sealing set 33 2 2306145 O-ring 34 2 9971446 O-ring 35 2 2306139 Pressure disk 37 1 115944 O-ring 38 1 2352719 Oil tank set 40 1 9998274 Threaded plug G1/4 41 1 2306196 Piston cover 46 1 2308869 Pressure stage cover disk 47 1 2306142 O-ring 49 4 9907124 Hexagon screw 50 4 9920106 Washer

51 53 2 322427 Damping washer

54 1 2306204 Piston sealing prole Z5 55 1 2306205 Piston air motor 4 57 1 9974084 O-ring 58 2 9920107 Washer 59 1 9974090 Seal wiper ring, prole EM 60 1 2344073 Air motor ange 61 1 367258 Grounding, complete 62 1 369290 Pilot valve 63 2 9998675 Threaded plug 66 1 9998780 Pressure spring 67 2 322407 Oil valve screw 68 1 9971162 O-ring 69 2 2306179 Insert 70 1 9974217 Rod seal 71 2 9971486 O-ring (solvent-resistant) 72 2 341316 Scraper 73 1 9971395 O-ring, 10x1.25 80 1 2339251 Plug

1 2386160 Self-locking hexagon nut (new) 1 9910101 Hexagon nut, secured with Loctite® 243 (old version!)

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

VERSION 01/2018

Order No. Designation

81 1 9904311 Locking screws with collar/hexagon socket

91* 1 9974111 Sealing ring for G3/8 thread 91* 1 3051041 Sealing ring for G1/2 thread

92 3 9920106 Washer 93 2 341325 Valve guide 94 2 341328 Clasp 95 2 9971470 O-ring 96 2 341326 Pressure spring 97 2 253405 Spring support ring 98 2 9941501 Ball 11 HM 99 2 2306166 Outlet valve seat

100 2 2306167 Sealing ring 101 1 9994237 Pressure spring 102 2 322408 Oil valve pressure ring 104 1 9992831 Loctite 542 50 ml; 50 cc 105 1 9992528 Loctite 270 50 ml; 50 cc 107 1 2312289 Service set for Cobra 40-25 uid 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 pin 110 1 9992616 Molykote DX grease 111 1 9998808 Mobilux EP2 grease

= Wearing part. = Included in service set.

* The internal thread at the

product output of the uid section (item 14) will be converted as of 2014 from G1/2" to G3/8", please use the corresponding tting and sealing ring (see chapter "Accessories").

ORDER NUMBER DOC 2340851

40 Nm; 29.5 lbft

111

105

Cobra 40-10 / 40-25

Note:

The piston rod (25) may only be mounted with the screwed-on assembly pin (109).

Grease all o-rings and seals lightly with grease (111) before mounting them.

109

B_04256

111

VERSION 01/2018

14.8 COBRA 4010 INLET VALVE

B_01230

ORDER NUMBER DOC 2340851

1.9 ±0.1

Cobra 40-10 / 40-25

Note:

Item 8 adhesive area: Pretreated with fast cleaner Loctite type 7063.

Order

Designation

No.

1 1 322914 Complete Cobra 40-10 inlet valve set 2 2 9912100 Hexagon nut with 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 cone

= Wearing part.

14.9 INLET VALVE DEPRESSOR

Order

Designation

No.

1 1 341241 Inlet valve depressor, complete

2 1 9922724 Lock washer 3.2

3 1 341377 Sleeve

4 1 9994275 Pressure spring

5 1 9971486 O-ring, 4x2

6 1 341316 Scraper

7 1 341375 Screw plug

= Wearing part.

Grease with Vaseline.

B_01232

VERSION 01/2018

B_02942

2.3

-0.1

14.10 COBRA 4025 INLET VALVE

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Note:

Item 8 adhesive area: Pretreated with fast cleaner Loctite type 7063.

Order

Designation

No.

1 1 2308753 Complete Cobra 40-25 inlet valve set

2 2 9912100 Hexagon nut with clamp

3 2 253324 Spring guide

4 2 9994304 Pressure spring

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 RELIEF VALVE

Order

No.

1 169248 Relief valve, complete

2 1 9920602 Adjusting washer

Designation

Thread: Pretreated with fast cleaner Loctite type 7063.

3 1 169346 Pressure spring

4 1 9920202 Washer

7 1 9992528 Loctite 270, 50 ml; 50 cc

= Wearing part.

1 9971395 O-ring, 10x1.25 1 9971486 O-ring, 4x2

1 9971367 Spiral baking ring 4.78x1.78

1.5

B_01231

VERSION 01/2018

ORDER NUMBER DOC 2340851

14.12 HIGHPRESSURE FILTER UP TO 530 BAR; 7687 PSI

Cobra 40-10 / 40-25

90 Nm; 66 lbft

Tighten pos. 3 by hand

Identication of the lter

140 Nm 103 lbft

B_05065

VERSION 01/2018

Ball valve version in carbon steel

Order No. Designation

1 1 2335334 HP lter DN12-PN530, complete 2 1 2324542 Filter housing 3 1 2324543 Union nut 4 1 2330780 Fitting, DF-MM-G1/2-G3/8-PN530-SSt 5 1 9955863 O-ring

7 1 2324670 Distribution 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 9998679 Ball valve 21 1 2325562 Pressure ring d45 23 1 2323718 Hexagon plug 33 1 2325826 Double connector 34 1 9992831 Loctite 542 50 ml; 50 cc 35 1 9998808 Mobilux EP2 grease 36 1 9992609 Anti-seize paste tube

= Wearing part.

= Not part of the standard equipment but available as a special accessory.

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

VERSION 01/2018

ORDER NUMBER DOC 2340851

14.13 INLINE FILTER 90° UP TO 270 BAR; 3916 PSI

Cobra 40-10 / 40-25

B_05066

Order No. Designation

1 1 2329026 Inline lter, HL DN6-PN270-G1/4"-SSt 2 1 2326045 Filter inlet housing, pre-assembled 3 1

-- Filter insert, yellow (middle), 100 mesh per inch* 3 1 2315723 *Filter insert, red (ne), 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 inch, 10 pieces 3 1 2315726 *Filter insert, white (coarse), 50 mesh per inch, 10 pieces 4 1 2311491 Turning handle 5 1 2325950 Filter outlet housing 90°, pre-assembled 6 1 9992609 Anti-seize paste tube

Wearing part.

= Not part of the standard equipment but available as a special accessory.

VERSION 01/2018

ORDER NUMBER DOC 2340851

14.14 STRAIGHT INLINE FILTER UP TO 270 BAR; 3,916 PSI

Cobra 40-10 / 40-25

B_05085

Order No. Designation

1 1 2324558 Inline lter DN6-PN270-G1/4"-SSt 2 1 2324550 Filter inlet housing 3 1 128389 Seal 4 1 -- Filter insert, yellow (middle), 100 mesh per inch* 4 1 2315723 *Filter insert, red (ne), 200 mesh per inch, 10 pieces 4 1 2315724 *Filter insert, blue (middle), 150 mesh per inch, 10 pieces 4 1 2315725 *Filter insert, yellow (middle), 100 mesh per inch, 10 pieces 4 1 2315726 *Filter insert, white (coarse), 50 mesh per inch, 10 pieces 5 1 2324551 Filter outlet housing 6 1 9992609 Anti-seize paste tube

Wearing part.

= Not part of the standard equipment but available as a special accessory.

VERSION 01/2018

B_06938

ORDER NUMBER DOC 2340851

14.15 AIRCOAT REGULATOR AND AIRCOAT FILTER REGULATOR

Cobra 40-10 / 40-25

AirCoat lter regulator

AirCoat regulator

B_05400

Remove protective container. Mount contact plate. Screw on / unscrew protective container three times (provides contact point via container coating)

Pos 3 or 4:

Observe the ow direction (direction of arrow to the housing)

Pos 5:

Screw in the pressure gauge until the white sealing ring is completely in the lter control valve. Thereafter continue turning the pressure gauge only to align the display scale.

Order

No.

Order

No.

Designation

1 1 2328611 / AirCoat regulator set 2 1 / 2382997 AirCoat lter regulator set 3 1 2309972 / Pressure regulator, LR-1/4-D-O-l-Mini 4 1 / 2331950 Filter control valve (manual drain)

/ 2360259 Option: lter pan (automatic drain) 5 1 9998677 Pressure gauge, 0-10 bar RF40 (d40) 6 1 9974166 / O-ring 7 1 2325527 / Holding plate 8 1 9906021 / Hexagon socket cylinder head screw 9 1 9900320 / Hexagon socket cylinder head screw

10 1 9994627 / Double tting R1/4-R1/4 11 1 9971313 / O-ring 12 1 9992831 / Loctite 542 13 1 9992616 / Molykote DX grease 14 1 9998808 / Mobilux EP 2 grease 15 1 / 9992528 Loctite 270 16 1 / 2366466 Contact plate 17 1 / 2389277 Fitting, EF-MM-G1/4-R1/4-530 bar 18 2 / 9900152 Hexagon screw without shaft 19 3 / 9920104 Washer 20 1 / 9998719 Double nipple, detachable

= Wearing part.

VERSION 01/2018

ORDER NUMBER DOC 2340851

14.16 COBRA 4010 FRAME, COMPLETE

B_06841

Cobra 40-10 / 40-25

Order

Designation

No.

1 1 322052 Cobra 40-10 frame 2 1 -- Frame pressed 3 1 -- Frame pipe 4 2 9990861 Plug 5 4 9999209 Saddle 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

Designation

No.

1 1 2308732 Cobra 40-25 frame 2 1 -- Frame pressed 3 1 -- Frame pipe 4 2 9990861 Plug 5 4 9999209 Saddle 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.

VERSION 01/2018

B_05001

ORDER NUMBER DOC 2340851

14.18 HORIZONTAL COBRA TROLLEY

Axle setting

Cobra trolley

Cobra 40-10 / 40-25

VERSION 01/2018

Trolley and pump tted

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

B_05002

Order No. Name

1 1 2341375 Cobra trolley complete 2 1 -- Frame, left 4"-6" 3 1 -- Frame, right 4"-6" 4 4 9907140 Hexagon screw 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" complete 10 2 367943 Connecting part 4"-6" 11 2 -- Tube plug, ribbed 12 4 9998685 Saddle feet for round tubes 13 2 -- Plug 14 1 -- Frame pipe long 15 2 3061695 Hexagon screw without shaft 16 2 9998747 Handle 17 4 3051666 Hexagon screw M6x40 18 4 9922017 Serrated lock washer, externally toothed 19 1 2341412 Assembly manual of Cobra trolley horizontal

= Wearing part.

VERSION 01/2018

14.19 SLIDING TABLES

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Distance:

and

Order No. Designation

1 1 2325901 Trolley, complete

2 1 -- Frame, left, 4"-6" (welded)

3 1 -- Frame, right, 4"-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"-6" 11 2 -- Tube plug, ribbed 12 2 9998685 Saddle feet for round tubes 13 2 -- Plug 14 4 9900218 Hexagon screw 15 1 2332143 Wall mount 16 2 3061695 Hexagon screw without shaft, M6x55 17 2 9998747 Handle 18 1 2329546 Assembly manual of trolley

= Wearing part.

B_03932

VERSION 01/2018

14.20 COMPLETE HOPPER

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

B_04258

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 340265 Hopper Ex

5 1 2333163 Relief tube 5 L, complete

6 1 340429 Cover

7 2 9920314 Washer

= Wearing part.

VERSION 01/2018

14.21 2 LITER TANK

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

B_05018

* Replace for the following pumps:

− Cobra 40-10 with date of product before November 2013.

Order 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 6 1 2320888 Cone connector preassembled 7 1 9990623 Protection plug 8 1 2320922 Sealing sleeve 9 1 2333163 Exhaust pipe 2L / 5L assy.

10 1 2347181 Assembly Manual

11* 1

2330810 Connection piece

= Wearing part.

VERSION 01/2018

ORDER NUMBER DOC 2340851

15 GUARANTEE AND CONFORMITY DECLARATIONS

15.1 IMPORTANT NOTES ON PRODUCT LIABILITY

As a result of an EC regulation eective from January 1, 1990, the manufacturer shall only be liable for his product if all parts originate from him or are approved by him, and if the devices are properly mounted, operated and maintained. The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

15.2 WARRANTY CLAIM

Full warranty is provided for this device: We will at our discretion repair or replace free of charge all parts which within 24 months in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship. The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see t. The resulting costs, in particular shipping charges, road tolls, labor and material costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address 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 purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute products and the inuence of chemical, electrochemical or electrical agents, except when the damage is attributable to us. Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust paints and so forth reduce the service life of valves, packings, spray guns, nozzles, cylinders, pistons etc. Wear and tear due to such causes are not covered by this warranty. Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer. Replacement of a component does not extend the period of warranty of the device. The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14days upon receipt of the device. We reserve the right to have the warranty compliance met by a contracting company. The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions.

Cobra 40-10 / 40-25

Wagner International AG

VERSION 01/2018

15.3 EU DECLARATION OF CONFORMITY

We hereby declare that the supplied version of diaphragm pumps and spray packs:

Cobra 40-10 Cobra 40-25

complies with the following guidelines:

2006/42/EC 2014/34/EU (ATEX Directive)

Applied standards, in particular:

EN ISO 12100:2010 EN 12621: 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

ORDER NUMBER DOC 2340851

Cobra 40-10 / 40-25

Applied national technical standards and specications, in particular:

Chapter 2.29 and Chapter 2.36

Identication:

EU Declaration of Conformity

The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number.

Order number: 2302350

Order No. 2340851 Edition 01/2018

ts-liquid@wagner-group.com

Document No. 11156044

Version B

www.wagner-group.com

WAGNER Cobra 40-10, Cobra 40-25 Original Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual