WAGNER Cobra 40-10/2K Operating Manual

Translation of the Original Operating Manual

For professional use. Always follow the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place.

Cobra 40-10 / 2K

High Pressure Double Diaphragm Pump for 2-Component Products with Mixing Ratio 1:1

Version 04/2018

B_5076

VERSION 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

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 plate 11

Cobra 40-10 / 2K

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 the Personnel 13

4.2.1 Personal Safety Equipment 13

4.2.2 Safe Handling of WAGNER Spray Devices 14

4.2.3 Grounding 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 Flow 22

5.5.5 Performance diagrams 22

5.6 Pressure Regulator Unit 23

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6 ASSEMBLY AND COMMISSIONING 24

6.1 Training of Assembly/Commissioning Personnel 24

6.2 Storage Conditions 24

6.3 Installation Conditions 24

6.4 Transportation 24

6.5 Assembly and Installation 25

6.5.1 Ventilation of the Spray Booth 26

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 Personnel 30

7.2 Emergency Stop 30

7.3 Tasks 31

7.4 Pressure Relief/Work Interruption 31

7.5 Basic Flushing 32

7.5.1 Filling with Working Material 33

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Cobra 40-10 / 2K

8 CLEANING AND MAINTENANCE 34

8.1 Cleaning 34

8.1.1 Cleaning Personnel 34

8.1.2 Decommissioning and Cleaning 34

8.1.3 Long-term Storage 34

8.2 Maintenance 35

8.2.1 Maintenance Personnel 35

8.2.2 Maintenance Instructions 35

8.2.3 Safety Checks and Maintenance Intervals 36

8.2.4 Emptying Pump 38

8.2.5 Filling the Empty Pump 40

8.2.6 Hydraulic Stage Maintenance 41

8.2.7 Checking the Oil Level 42

8.2.8 Oil Change 42

9 TROUBLESHOOTING AND RECTIFICATION 46

10 REPAIR WORK 47

10.1 Repair Personnel 47

10.2 Repair Notes 47

10.3 Tools 47

10.4 Cleaning the Parts After Disassembly 48

10.5 Assembly of the Device 48

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11 FUNCTION TEST AFTER REPAIR WORK 49

12 DISPOSAL 50

13 ACCESSORIES 50

14 SPARE PARTS 52

14.1 How can spare parts be ordered? 52

14.2 Overview of the Components 53

14.3 Air motor 54

14.4 Fluid section 56

14.5 Inlet Valve 59

14.6 Inlet Valve Depressor 59

14.7 Complete Vertical Mixer 60

14.8 Complete Horizontal Mixer 61

14.9 AirCoat Regulator and AirCoat Filter Regulator 62

14.10 Complete Frame 63

14.11 Sliding tables 64

14.12 Horizontal Trolley 65

14.13 Suction system 66

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Cobra 40-10 / 2K

15 EU DECLARATION OF CONFORMITY 67

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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 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 / 2K

DANGER

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

WARNING

CAUTION

NOTICE

Notice

Explanation of warning notice:

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 notice.

The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 2349649

Translation of the original operating manual

Language Order no.

English 2349980 Italian 2349981 Lithuanian 2373423

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

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Cobra 40-10 / 2K

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

Personnel 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.

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2 CORRECT USE

2.1 DEVICE TYPES

Double diaphragm pump and spray pack:

Cobra 40-10 / 2K

2.2 TYPE OF USE

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

– Non-ignitable products – Products in accordance with their classication into explosion class 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 / 2K

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 lacquers.

Application Cobra 40-10 / 2K

Water-dilutable products Solvent-based lacquers and paints 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 product-wetted parts.

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.

Cobra 40-10 / 2K

Typical applications

Application Cobra 40-10 / 2K

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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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: Cobra 40-10 / 2K double diaphragm pumps 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 / 2K

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

The permissible ambient temperature range is: 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.

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Air in the pump uid

Ignitable gas mixtures can form if air enters 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

Ignitable gas mixtures can form in the uid section or product hoses if the pump must be emptied for maintenance and/or repair purposes.

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

3.3 TYPE PLATE

Cobra 40-10 / 2K

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

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_06984

II 2G Ex h IIB T6 Gb X

Designation

1 Pump type 2 Max. product pressure 3 Pump ratio 4 Flow rate 5 Max. air pressure 6 Max. temp. product/uid 7 Model year - serial number 8 Check manual before use!

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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, the mains voltage poses a danger.

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 personnel 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 / 2K

4.1.2 A SAFE WORK ENVIRONMENT

Hazard due to dangerous uids or vapors!

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 area is static dissipative in accordance with EN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 hoses / 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.

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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.

Cobra 40-10 / 2K

4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL

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 vapors!

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

When preparing or working with lacquer 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 lacquer 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 when falling.

Avoid risk of injury from recoil forces:

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

Cobra 40-10 / 2K

4.2.3 GROUNDING 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

− 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. 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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Cobra 40-10 / 2K

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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-ignitable 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:

−depending upon the coating product used,

−depending on the ushing agent (solvent) used. an explosive mixture may temporarily exist inside the lines and components 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.

Cobra 40-10 / 2K

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".

Part no.

9998910 instruction label 9998911 protection label

Note: Order the two stickers together.

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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 Chapter 13 and Chapter 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.

Cobra 40-10 / 2K

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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5 DESCRIPTION

5.1 COMPONENTS

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

Cobra 40-10/2K

13 11

B_05078

12 14

10 (A)

10 (B)

Designation

1 Control housing with integrated silencer 2 Air pressure regulator 3 Ball valve 4 Air motor 5 Compressed air inlet 6 Fastening ange 7 AirCoat pressure regulator (option) 8 Product outlet (A, B) 9 Fluid section

8 (A)

8 (B)

15 (A)

A + B

15 (B)

Designation

10 Suction system product inlet (A, B) 11 Grounding connection 12 Fluid section casing 13 Valve depressor (A, B) 14 Exhaust air opening 15 Relief valve (A, B) 16 Mixing block holder 17 Mixing block 18 Mixing tube

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 uid section (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 in the uid section is produced by hydraulic oil, which is moved by the piston rod in the uid section. With every stroke of the piston rod, working product is sucked in and delivered to the spray gun at the same time.

5.2.1 AIR MOTOR

The air motor (4) 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 (9) has been designed as a double diaphragm pump with exchangeable inlet and outlet valves. With the mixing block (17), upstream relief valves (15) can be switched from "Spraying mode" to "Product circulation mode".

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5.3 PROTECTIVE AND MONITORING EQUIPMENT

WARNING

Overpressure!

Danger to life from bursting device 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

Cobra 40-10/2K double diaphragm pump comprising:

1 U850.00CA

1 U850.00MA

1 U850.00SA

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 Declaration of Conformity 1 2349649 Operating manual, in 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.

uid section, air motor and connection elements mounted on trolley (vertical).

Cobra 40-10/2K double diaphragm pump comprising: uid section, air motor, connection elements and mounting brackets for wall mounting (vertical).

Cobra 40-10/2K double diaphragm pump comprising: uid section, air motor, connection elements and mounted on a special frame (horizontal).

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

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 Diaphragm PA-resistant Valve tting 1.4104

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5.5.2 TECHNICAL DATA

Description Units Cobra 40-10 / 2K

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

Maximum operating overpressure MPa

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

Compressed air quality: free from oil and water

Air inlet (inside thread) inch 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 Sound pressure level at maximum permissible air pressure* dB(A) 74 Sound pressure level at 0.45 MPa; 4.5 bar; 65.27 psi air pressure* Sound pressure level at 0.3 MPa; 3 bar; 43.5 psi air pressure* dB(A) 69 Air motor piston diameter mm

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

Product temperature °C

Ambient temperature °C

Allowable inclination for operation ±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 2349980

cu inch

Quality standard 7.5.4 according to ISO 8573.1, 2010 7: Particle concentration 5–10mg/m³ 5: Humidity: pressure dew point ≤ 7 °C 4: Oil content ≤ 5mg/m3

cu inch

0.6 25

bar

psi

bar

psi

inch

dB(A) 72

inch mm inch inch

bar

psi

°F

250

3626

0.25–0.6

2.5–6

36.3–87

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

Cobra 40-10 / 2K

WARNING

Exhaust air containing oil!

Risk of poisoning if inhaled.

Provide compressed air free from oil and water.

VERSION 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

5.5.3 DIMENSIONS AND CONNECTIONS

Cobra 40-10 / 2K

mm; inch

A 505; 19.88 B 313; 12.32 C 313; 12.32 D 134; 5.28 E 55; 2.16

F 182; 7.16 G 80; 3.15 H M6

25; 0.98

K G3/8

L M36×2

mm; inch

M G3/8

N 149; 5.87

O 91; 3.58

P 107; 4.21

Q 175; 6.89

S 65; 2.56 T 725

7; 0.28

U 318 V 262

-- --

Cobra 40-10/2K

B_03111

B_06991

VERSION 04/2018

NL/min

L/min

B_01203

nl/min

<scfm>

bar (MPa)

<psi>

250 (25)

<3625>

200 (20)

<2900>

150 (15)

<2175>

100 (10)

<1450>

50 (5)

<725>

0.4

<0.1>

0.8

<0.2>

1.2

<0.3>

1.6

<0.4>

<0.5>

2.4

<0.6>

l/min

<gpm>

1000

<35>

800

<28>

600

<21>

400

<14>

200

<7>

120

160

200 240

OPERATING MANUAL

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 / 2K

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

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

Volume ow refers to water.

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

ORDER NUMBER DOC 2349980

7 MPa 10 MPa 15 MPa

70 bar 100 bar 150 bar

1015 psi 1450 psi 2175 psi

Cobra 40-10 / 2K

5.5.5 PERFORMANCE DIAGRAMS

Example

Product pressure (bar)

B_00301

Stroke frequency (DH/min)

8 bar

6 bar

4 bar

Water ow rate (nl/min)

8 bar

6 bar

4 bar

Cobra 40-10/2K

Air consumption (nl/min)

Product pressure

Water ow rate

Stroke frequency (

/min)

Air consumption

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

VERSION 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

5.6 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 lter regulator, order number2328614).

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).

Cobra 40-10 / 2K

B_04300

B_04301

VERSION 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL

The assembly and commissioning personnel 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 / 2K

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 104 °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 04/2018

B_06989

OPERATING MANUAL

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 oor 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 40-10 / 2K diaphragm pump may only be operated in the positions shown in the diagrams. Upside down operation is not permitted.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_05063

B_05061

Vertical position on wall mount

NOTICE

Upside down operation or storage (air motor with pressure regulator below):

Air could get into the hydraulic circuit, causing a malfunction.

Avoid upside down operation or upside down storage at all costs. Venting, see chapter 8.2.8 Oil change

Vertical position on trolley

B_06988

Horizontal position on frame

VERSION 04/2018

OPERATING MANUAL

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.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_05079

Procedure

1. Mount pump (1) on trolley (6) or wall mount.

2. For AirCoat systems (picture above): mount the additional lter pressure regulator (7 - option).

3. Mount suction systems (5).

4. Connect the suction system's return hoses (4) to the return valves (3).

5. Connect the spray gun's high-pressure hose (2) to the static mixer (8) and, when

using the AirCoat process, connect air hose to lter pressure regulator (7).

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 stand with the ventilation (extraction) switched on.

Observe national and local regulations for the exhaust air speed.

VERSION 04/2018

OPERATING MANUAL

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

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.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

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 04/2018

B_01214

OPERATING MANUAL

Grounding scheme (example)

Designation

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

ORDER NUMBER DOC 2349980

EX zone

Cobra 40-10 / 2K

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 grounding cables using a short and direct route.

Procedure

1. Screw on grounding cable with eyelet.

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

3. Ground the product 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 04/2018

OPERATING MANUAL

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 2349980

Cobra 40-10 / 2K

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 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

7 OPERATION

7.1 TRAINING THE OPERATING PERSONNEL

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

The operating personnel 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 personnel must receive appropriate system training.

7.2 EMERGENCY STOP

In the case of unforeseen occurrences:

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

Cobra 40-10 / 2K

Set the valves (A, B) to circulation (rotate clockwise)

B_05077

VERSION 04/2018

OPERATING MANUAL

7.3 TASKS

Ensure that:

commissioning is carried out in accordance with Chapter 6.7.

Ball valve position

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).

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

2. Secure spray gun and insert nozzle 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 2349980

Cobra 40-10 / 2K

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 will process 2K products:

NOTICE

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

Destruction of pump and injection system.

Observe the manufacturer's processing rules, particularly in regards to the pot life. Flush thoroughly before the end of the pot life. The pot life is decreased by warmth.

VERSION 04/2018

OPERATING MANUAL

7.5 BASIC FLUSHING

Regular ushing

Regular ushing, cleaning and maintenance ensures the pump's high pumping and extraction 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, grounded tank (5a and 5b) under the return tubes (4a and 4b).

3. Place suction hoses (7a and 7b) in tanks with cleaning agent (6a and 6b).

4. Adjust the pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.25 psi.

Flushing via return tube

5. Open return valves (3a and 3b).

6. Slowly open the ball valve (2).

7. Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly.

8. Flush the system until the cleaning agent that ows into the tanks (5a and 5b) is clean.

9. Close ball valve (2).

Flushing via spray gun

10. Switch over return valves (3a and 3b).

11. Point the spray gun (8), without nozzle, into the tanks (5a or 5b) and pull the trigger.

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.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

VERSION 04/2018

OPERATING MANUAL

17. Dispose of the contents of the tanks (5 and 5b) according to the local regulations.

ORDER NUMBER DOC 2349980

Note:

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

B_05081

Cobra 40-10 / 2K

B_05080

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 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING PERSONNEL

Cleaning work should be undertaken regularly and carefully by qualied and trained personnel. 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. Clean the outside of the system.

7. Fully assemble the system.

8. Fill the system with ushing agent in accordance with Chapter 8.2.5.

Cobra 40-10 / 2K

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. Fill separating agent cup with separating agent.

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 04/2018

OPERATING MANUAL

8.2 MAINTENANCE

8.2.1 MAINTENANCE PERSONNEL

Maintenance work should be undertaken regularly and carefully by qualied and trained personnel. 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. Chapter 8.1.2

− Interrupt the air supply.

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 Chapter 11.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

VERSION 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

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

The oil change is to be performed as necessary, at least however, every 12 months in accordance with Chapter 8.2.8. 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.

Cobra 40-10 / 2K

VERSION 04/2018

OPERATING MANUAL

8.2.3.1 PRODUCT HOSES, PIPES 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

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

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

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.

Pressure

VERSION 04/2018

OPERATING MANUAL

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 empty, grounded tank (5a and 5b) under the return tubes (4a and 4b).

3. Place suction hoses (7a and 7b) in tanks with cleaning agent (6a and 6b).

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

Emptying via return line

5. Open return valves (3a and 3b).

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. Close ball valve (2) as soon as no more working product comes out of the return hoses (4a and 4b).

10. Close return valves (3a and 3b).

Emptying up to the spray gun

11. Point the spray gun without nozzle in an empty, grounded residual product container and pull the trigger.

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 the spray gun.

15. Depressurization in accordance with Chapter 7.4.

16. Dispose of the contents of the tanks (5 and 5b) and the residual product container according to the local regulations.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

VERSION 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_05080

VERSION 04/2018

OPERATING MANUAL

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.

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

Procedure

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

2. Place empty, grounded tank (5a and 5b) under the return tubes (4a and 4b).

3. Place suction hoses (7a and 7b) in the tanks with working material (6a) and hardener (6b).

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

5. Open relief valves (3a and 3b).

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 air to working material and prevent back spray.

8. Close ball valve (2) as soon as pure working material starts coming from the return hoses (4a and 4b)

9. Open relief valves (3a and 3b) (turn counterclockwise).

10. Point the spray gun (8) without nozzle, into empty tank (5a) and pull the trigger.

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

12. As soon as pure working material without air bubbles is owing, close the 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 tanks (5a and 5b) according to the local regulations.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

VERSION 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_05080

8.2.6 HYDRAULIC STAGE MAINTENANCE

Dismount the pump and place it upside down on a suitable underlay and position it horizontally. Observe the ll level marking X on the oil tank.

B_05067

B_05068

VERSION 04/2018

OPERATING MANUAL

8.2.7 CHECKING THE OIL LEVEL

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

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

2. Then read oil level A.

Dismount the pump and place it upside down on a suitable underlay and position it horizontally. Observe the ll level marking X on the oil tank. Oil level A in the oil tank (3) has to be within the specied markings (X). If the level deviates from these markings, the hydraulic oil must be topped up or removed by extraction.

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).

8.2.8 OIL CHANGE

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

Necessary accessories:

Order no. 322911 - Oil lling set

max.

min.

B_05069

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).

VERSION 04/2018

OPERATING MANUAL

8.2.8.1 DRAINING OIL

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_05070

B_05067

Procedure

1. Decommission and clean Chapter 8.1.2 points 1 to 7.

2. Dismount the pump and place it upside down on a suitable underlay and position it horizontally.

3. Unscrew piston cover (1).

4. Place 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 suction tube.

8. Screw in clean oil tank (3) together with seal.

VERSION 04/2018

OPERATING MANUAL

8.2.8.2 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 2349980

Cobra 40-10 / 2K

B_05071

17 mm; 0.67in

Procedure

1. Dismount the pump and place it upside down on a suitable underlay and position it horizontally.

2. Unscrew and remove threaded plug (5).

3. Unscrew 2 locking screws (4) and replace with 2 threaded 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 the rst end position. Use the syringe to ll the hydraulic stage until the oil ows out of the suction tube into the oil tank (3) with no air bubbles.

7. Move piston (9) into the second end position. Use the syringe to ll the hydraulic stage until the oil ows out of the suction 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).

B_04246

VERSION 04/2018

OPERATING MANUAL

8.2.8.3 VENT

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_04243

B_05072

Procedure

1. The dismounted pump is to be place upside down on a suitable underlay and positioned horizontally. Remove the threaded plug (5).

2. Slowly start up the pump (vent), until no more air bubbles rise from the oil suction 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 pump to correct setup position.

7. Pump is ready for use again.

VERSION 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

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 / 2K

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. Occasionally, the pump stops at the

reversal point. Poor spray pattern. See spray gun instructions. Irregular pump operation:

spray jet collapses (pulsation).

Highly irregular operation of the 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 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 suitable product.

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

Check detent body.

Use a smaller nozzle.

Clean pump. If necessary, leave it to soak in cleaning agent.

and check valve seat. Assemble a larger supply line

Technical data, see Chapter 5.5.2. Replace the parts.

Check and clean it if necessary.

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

Tighten.

Clean pump. If necessary, leave it to soak in cleaning agent.

Install a water separator.

VERSION 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

10 REPAIR WORK

10.1 REPAIR PERSONNEL

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 Repair Work

− Flush and clean the system. Chapter 8.1.2

− Interrupt the air supply.

After Repair Work

− 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 Chapter 11.

Cobra 40-10 / 2K

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 04/2018

OPERATING MANUAL

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 dismantled 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). Perform cleaning and mounting tasks 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 2349980

Cobra 40-10 / 2K

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

Assembly Aids

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 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

11 FUNCTION TEST AFTER REPAIR WORK

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 personnel.

Activity Means

1. Piston travel

Cobra 40-10 / 2K

− 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 8.2.8).

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. When the air supply is turned o, a drop in pressure must be watched for. Check seal of following modules:

− ange seal

− ball valve (in all positions)

− pressure stage

− uid section

5. General inspections

− Check tightening torque of various screws. Tighten hexagon screws M12x65 and input valve housing with the prescribed torque (see Chapter 14).

− Check all ttings.

− 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 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

12 DISPOSAL

Cobra 40-10 / 2K

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

The following materials have been used:

Stainless steel Aluminum Elastomers Plastics Carbide

Consumable products

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

13 ACCESSORIES

Cobra 40-10/2K

AirCoat

B_03130

VERSION 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

Order no. Designation

A 2341579 Diaphragm pump Cobra 40-10/2K

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

5 2328611 AirCoat regulator set 11 R033.00 Suction hose cup GR, complete 12 367141 Return hose DN 13; ID 0.51 inch, M20x2 16 322052 Frame, complete 17 T423.00FA Flexible suction hose, lacquer F36x2 18 367527 O-ring, PTFE 19 9974127 O-ring FEP 20 367959 Washer PTFE 21 2332143 Wall mount 22

23 25 2325901 Trolley, complete

26 369657 Connector A=G3/4" -A=NPSM3/8" 27 367563 Fitting RF FM 3/8" NPS M16x1.5 PN530-SSt 28 97073 Suction hose complete, lacquer Niro, DN 13; ID 0.98 inch 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 tting with sealing ring

= Wearing parts

2349756 Wall mounting, long 2341375 Cobra trolley, complete

Cobra 40-10 / 2K

VERSION 04/2018

OPERATING MANUAL

ORDER NUMBER DOC 2349980

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

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 / 2K

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 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

14.2 OVERVIEW OF THE COMPONENTS

Cobra 40-10 / 2K

Part no. Designation

1 1 -- Air motor 3/53 2 1 -- Cobra 40-10 uid section, preassembled 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 13 1 322438 Cylinder noise insulation 14 1 9974112 Sealing ring 15 1 9992616 Molykote® DX grease

= Wearing part

25 Nm; 18 lbft

B_05073

VERSION 04/2018

OPERATING MANUAL

14.3 AIR MOTOR

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

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

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 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

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 Fitting 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 9998677 Pressure gauge 0-10 bar RF40 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.

Cobra 40-10 / 2K

VERSION 04/2018

OPERATING MANUAL

14.4 FLUID SECTION

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

110

50 Nm (37 lbft)

110

100

90 Nm (66 lbft)

70 Nm (52 lbft)

110

102

2 Nm; 1.5 lbft

110

40 Nm; 29.5 lbft

101 102

20 Nm;14.8 lbft

67 26

110

B_05074

VERSION 04/2018

OPERATING MANUAL

Order no. Designation

1 2 340339 Inlet 4 2 341241 Inlet valve depressor, complete 6 8 9907234 Hexagon screw 7 10 9920107 Washer 9 2 341335 Depressor housing

10 2 341336 Clasp 11 1 322914 Inlet valve set, complete (consisting of 2 valves) 14 1 322460 Cobra 40-10/2K uid section 18 1 322915 Outlet valve set, complete (consisting of spare parts for 2 valves) 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 2333498 Oil tank, complete 40 1 9998274 Threaded plug M7x1 41 1 322435 Piston cover 42 2 2334842 Check valve assy. 46 1 322404 Pressure stage cover disk 47 1 9974074 O-ring 49 4 9907233 Hexagon screw 50 4 9920102 Washer

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 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

1 2386160 Hexagon nut (self-locking, new) 1 9910101 Hexagon nut (secure with Loctite® 243, old)

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

VERSION 04/2018

108

B_04252

111

40 Nm; 29.5 lbft

OPERATING MANUAL

Order no. Designation

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 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 109 1 9992511 Loctite® 243 50 ml; 50 cc 110 1 9992616 Molykote® DX grease 111 1 9998808 Mobilux® EP2 grease

= Wearing part = Included in service set. = Not part of the standard equipment but available as a special accessory.

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

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 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

14.5 INLET VALVE

B_01230

Order no. Designation

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

1.9 ±0.1

Cobra 40-10 / 2K

Note:

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

14.6 INLET VALVE DEPRESSOR

Order no. Designation

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 04/2018

B_05082

A+B

B_05075

ORDER NUMBER DOC 2349980

OPERATING MANUAL

14.7 COMPLETE VERTICAL MIXER

Cobra 40-10 / 2K

Order no. Designation

1 1 T678.00 Mixing tube, complete D6 2 2 M604.12 Fitting D 1/4x10 3 2 A194.22 Valve body 4 1 B0284.03 Mixing block 5 1 B0285.71 Mixing block support 6 2 K118.62 Screw, M5x40 7 2 K151.62 Screw, M6x60 8 2 M116.00A Ball valve pin A 1/4 C/R

9 2 M6014.00 Fitting 1/4", adjustable 10 2 M614.62 Fitting, 1/4" 11 1 M623.12 Plug EI 1/4" 12 2 T701.00 Lock valve lacquer mix 13 1 S521.00 Hose AP 1/4 MT.0,500 14 1 S516.00 Hose AP 1/4 MT.0.65 15 2 M6029.00 Connection 90° M1/4xFG1/4 16 2 M618.62 Fitting 3/8-1/4 17 2 S401.00 Return hose BP MT 2 D 8

VERSION 04/2018

ORDER NUMBER DOC 2349980

OPERATING MANUAL

14.8 COMPLETE HORIZONTAL MIXER

Cobra 40-10 / 2K

B_06990

Order no. Designation

1 1 T678.00 Mixing tube, complete D6

2 2 M604.12 Fitting D 1/4x10

3 2 A194.22 Valve body

4 1 B0284.03 Mixing block

6 2 K1003.62 Screw, M5x50

7 2 K1003.62 Screw, M8x50

8 2 M116.00A Ball valve pin A 1/4 C/R

9 2 M6014.00 Fitting 1/4", adjustable 10 2 M614.62 Fitting, 1/4" 11 1 M623.12 Plug EI 1/4" 12 2 T701.00 Lock valve lacquer mix 13 1 S501.00 Hose AP 1/4 X MT 0.420 14 1 S506.00 Hose AP 1/4 MT.0.65 15 2 M6029.00 Connection 90° M1/4xFG1/4 16 2 M618.62 Fitting 3/8-1/4 17 2 H188.62C Spacer 18 1 E0080.01 Mounting plate 19 4 K515.62 Plain washer ø 5 20 2 K323.62 Self-locking nut M5 21 4 K509.62 Plain washer ø 8 22 2 K312.62 Self-locking nut M8 23 1 M6014.00 Extension MF 1/4" 24 1 M6008.00 Fitting L1/4 MF 25 2 S401.00 Return hose BP MT 2 D 8

VERSION 04/2018

B_06938

ORDER NUMBER DOC 2349980

OPERATING MANUAL

14.9 AIRCOAT REGULATOR AND AIRCOAT FILTER REGULATOR

Cobra 40-10 / 2K

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 on 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 valve LR-1/4-D-O-I-Mini

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 04/2018

OPERATING MANUAL

14.10 COMPLETE FRAME

B_06841

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

Order no. Designation

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

VERSION 04/2018

OPERATING MANUAL

14.11 SLIDING TABLES

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

Distance:

/ 2K

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 04/2018

OPERATING MANUAL

14.12 HORIZONTAL TROLLEY

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_06992

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 for Cobra horizontal trolley

= Wearing part

VERSION 04/2018

OPERATING MANUAL

14.13 SUCTION SYSTEM

ORDER NUMBER DOC 2349980

Cobra 40-10 / 2K

B_03134

Part no. Designation

1 1 T423.00FA Suction system exible, complete

2 1 T423.00F Suction tube

3 1 R033.00A Filter housing

4 1 T468.00 Filter sieve

5 1 H220.03 Retaining spring

6 1 R033.00 Filter housing, complete

15 EU DECLARATION OF CONFORMITY

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

Cobra 40-10 / 2K

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

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

Document No. 11180373

Version A

Order no. 2349980 Edition 04/2018

Germany

88677

Phone Telefax E-mail ts-liquid@wagner-group.com

Italy

WAGNER S.p.A. Via Santa Vecchia, 109 23868 Valmadrera (LC) Phone +39 0341 210100 Telefax +39 0341 210200 E-mail wagner_it_va@wagner-group.com

More contact addresses:

www.wagner-group.com

Subject to changes without notice

WAGNER Cobra 40-10/2K Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual