WAGNER Cobra 40-10, Cobra 40-25 Translation Of The Original Operating Manual

Download

B_04233

B_04234

High-pressure Double Diaphragm Pumps

Version 07/2014

Translation of the Original Operating Manual

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Table of Contents

1 ABOUT THIS MANUAL 6

1.1 Preface 6

1.2 Warnings, Notices, and Symbols in this Operating Manual 6

1.3 Languages 7

1.4 Abbreviations in the Text 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 Use in Potentially Explosive Areas 8

2.4 Safety Parameters 8

2.5 Processible Working Materials 9

2.5.1 Recommended Application Areas 9

2.6 Reasonably Foreseeable Misuse 10

2.7 Residual Risks 10

3 IDENTIFICATION 11

3.1 Explosion Protection Identi cation 11

3.2 Identi cation X 11

3.3 Type Plates 12

4 GENERAL SAFETY INSTRUCTIONS 13

4.1 Safety Instructions for the Operator 13

4.1.1 Electrical Equipment 13

4.1.2 Sta Quali cations 13

4.1.3 Safe Work Environment 13

4.2 Safety Instructions for Sta 14

4.2.1 Safe Handling of WAGNER Spray Devices 14

4.2.2 Grounding the Device 15

4.2.3 Product Hoses 15

4.2.4 Cleaning and Rinsing 16

4.2.5 Handling Hazardous Liquids, Lacquers and Paints 16

4.2.6 Touching Hot Surfaces 17

5 DESCRIPTION 18

5.1 Design 18

5.2 Mode of Operation 18

5.2.1 General Information 18

5.2.2 Air Motor (4) 18

5.2.3 Protective and Monitoring Equipment 18

5.2.4 Fluid Section (9) 19

5.2.5 Positioning 19

5.3 Scope of Delivery 20

5.4 Data 20

5.4.1 Materials of Paint-wetted Parts 20

5.4.2 Technical Data 20

5.4.3 Measurements and Connections 22

5.4.4 Volume Flow 23

5.4.5 Performance Diagrams 23

5.5 Pressure Regulator Unit for Cobra 25

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6 ASSEMBLY AND COMMISSIONING 26

6.1 Training Assembly/Commissioning Sta 26

6.2 Storage Conditions 26

6.3 Installation Conditions 26

6.4 Transportation 26

6.5 Assembly and Installation 27

6.5.1 Ventilation of the Spray Booth 28

6.5.2 Air Supply 28

6.5.3 Product Supply 28

6.6 Grounding 29

6.7 Safety Checks 30

6.8 Commissioning 31

6.8.1 Safety Instructions 31

6.8.2 Preparation for Commissioning 32

6.8.3 Basic Flushing 32

6.8.4 Filling with Working Material 33

7 OPERATION 34

7.1 Training the Operating Sta 34

7.2 Safety Instructions 34

7.3 Emergency Deactivation 35

7.4 Work 36

7.5 Pressure Relief/Work Interruption 36

7.5.1 Pressure Relief/Work Interruption 36

8 CLEANING AND MAINTENANCE 38

8.1 Cleaning 38

8.1.1 Cleaning Sta 38

8.1.2 Safety Instructions 38

8.1.3 Cleaning and Flushing Device 39

8.1.4 Long-term Storage 39

8.2 Maintenance 40

8.2.1 Maintenance Sta 40

8.2.2 Safety Instructions 40

8.2.3 Safety Checks 41

8.2.3.1 Grounding check 41

8.2.3.2 High-Pressure Filter 41

8.2.3.3 Product Hoses, Tubes and Couplings 42

8.2.4 Hydraulic Stage Maintenance 43

8.2.5 Checking the Oil Level 43

8.2.6 Changing the Oil 44

9 TROUBLESHOOTING, MAINTENANCE, AND REPAIR 47

9.1 Troubleshooting and recti cation 47

10 REPAIR WORK 49

10.1 Repair Sta 49

10.2 Safety Instructions 49

10.3 Cleaning the Parts after Disassembly 50

11 FUNCTIONAL CHECK AFTER REPAIR 51

Table of Contents

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

12 DISPOSAL 53

13 ACCESSORIES 54

13.1 Cobra 40-10 Accessories 54

13.2 Cobra 40-25 Accessories 56

14 SPARE PARTS 58

14.1 How Can Spare Parts Be Ordered? 58

14.2 Overview of the Cobra 40-10 Components 59

14.3 Cobra 40-10 Air Motor 60

14.4 Cobra 40-10 Fluid Section 63

14.5 Overview of the Cobra 40-25 Components 67

14.6 Cobra 40-25 Air Motor 68

14.7 Cobra 40-25 71

14.8 Cobra 40-10 Inlet Valve 75

14.9 Inlet Valve Depressor 75

14.10 Cobra 40-25 Inlet Valve 76

14.11 Relief Valve 77

14.12 High-pressure Filter (up to 530 bar; 7687 psi) 78

14.13 Inline Filter 90° (up to 270 bar; 3,916 psi) 80

14.14 Straight Inline Filter (up to 270 bar; 3,916 psi) 81

14.15 Cobra 40-10 Frame, Complete 82

14.16 Cobra 40-25 Frame, Complete 82

14.17 Trolley 83

14.18 Cobra Trolley Horizontal 84

14.19 Hopper, Complete 86

14.20 Small Quantity Cup 87

14.21 2L Tank 88

15 WARRANTY AND CONFORMITY DECLARATIONS 89

15.1 Important Notes Regarding Product Liability 89

15.2 Warranty Claim 89

15.3 CE Declaration of Conformity 90

15.4 Notes on German Regulations and Guidelines 90

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

1 ABOUT THIS MANUAL

1.1 PREFACE

1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL

Warning instructions in this operating manual highlight particular dangers to users and to the device and state measures for avoiding the hazard. These warning instructions fall into the following categories:

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

Warning - possible imminent danger. Non-observance may result in death or serious injury.

Caution - a possibly hazardous situation. Non-observance may result in minor injury.

Notice - a possibly hazardous situation. Non-observance may result in damage to property.

Note - provides information about particular characteristics and how to proceed.

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

DANGER

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

WARNING

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

CAUTION

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

NOTICE

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 operating and service sta . The device may only be operated by trained sta and in compliance with this operating manual. Operating and service sta 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.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

1.3 LANGUAGES

The operating manual is available in the following languages:

Language Order No. Language Order No.

German 2340850 English 2340851 French 2340852 Italian 2340853 Spanish 2340854 Russian 2345830 Japanese 2346196

1.4 ABBREVIATIONS IN THE TEXT

Number of pieces Position Marking in the spare parts lists

Order No. Order number

Double stroke Stainless steel Two components

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning Manual cleaning of devices and device parts with cleaning

agent Flushing Internal  ushing of ink-guiding parts with  ushing agent Product pressure

generator

Pump or pressure tank

Sta quali cations

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

risks associated with improper behavior as well as the

necessary protective devices and measures. Electrically trained

person

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

hazards based on his/her technical training, knowledge and

experience in relevant provisions. Skilled person 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.

In accordance with TRBS 1203 (2010)

Additional languages on request or at:

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

2 CORRECT USE

2.1 DEVICE TYPES

Double diaphragm pump and spray pack:

2.2 TYPE OF USE

2.3 USE IN POTENTIALLY EXPLOSIVE AREAS

The device is suitable for processing liquid materials like paints and lacquers in accordance with the classi cation into explosion classes IIA or IIB.

The double diaphragm pump can be employed in explosion hazard areas (Zone 1).

2.4 SAFETY PARAMETERS

WAGNER accepts no liability for any damage arising from non-intended use.

Use the device only to work with the products recommended by WAGNER. Operate only the device as a whole. Do not deactivate safety  xtures. Use only WAGNER original spare parts and accessories.

The double diaphragm pump may only be operated under the following conditions:

The operating sta must be trained based on this operating manual. The safety regulations listed in this operating manual must be observed. The operating, maintenance and repair information in this operating manual must

be observed. The statutory requirements and accident prevention regulation standards in the

country of use must be observed.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Application

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

2.5.1 RECOMMENDED APPLICATION AREAS

Application

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

Legend

recommended limited suitability less suitable

Legend

recommended limited suitability less suitable

2.5 PROCESSIBLE WORKING MATERIALS

Fluid products such as paints and lacquers.

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 5.4.2.

Check if the  uids and solvents used are compatible with the pump construction

materials as indicated in Chapter 5.4.1.

NOTICE

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

2.6 REASONABLY FORESEEABLE MISUSE

The following is prohibited:

coating work pieces which are not grounded, unauthorized conversions and modi cations to the double diaphragm pump, processing dry or similar coating products, and using defective components, spare parts, or accessories other than those described

in Chapter 13 of this operating manual.

The forms of misuse listed below may result in physical injury or property damage:

use of powder as coating product and incorrectly set values for processing.

Wagner double diaphragm pumps are not designed for pumping food.

2.7 RESIDUAL RISKS

Residual risks are risks which cannot be excluded even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks.

Residual risk Source Consequences Speci c measures Lifecycle phase

Skin contact with lacquers and cleaning agents

Handling of lacquers and cleaning agents

Skin irritations, wear protective

clothing,

operation,

allergies observe safety data

sheets

maintenance,

disassembly

Lacquer in air outside the de ned working area

Lacquering outside the de ned working area

Inhalation of substances which are hazardous to health

Observe working and operating manuals

operation,

maintenance

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

3.1 EXPLOSION PROTECTION IDENTIFICATION

As de ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially explosive areas.

European Communities Symbol for explosion protection Device class II Category 2 (Zone 1) Ex-atmosphere gas Explosion group Constructional safety Special Notes (see Chapter 3.2)

3 IDENTIFICATION

3.2 IDENTIFICATION X

X The maximum surface temperature corresponds to the permissible product

temperature. This and the permissible ambient temperature can be found in the "Technical Data" chapter.

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 is: +10 °C to +60 °C; +50 °C to 140 °F.

Medium supporting atomizing

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

Safe handling of WAGNER spray devices

Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere:

Do not knock or push the device against steel or rusty iron. Do not drop the device. Only use tools that are made of a permitted material.

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 Serie Nr. / Serie No. / N. serie

Vor Gebrauch Betriebsanleitung beachten / Check manual before use!

J. WAGNER AG

MADE IN SWITZERLAND

CH-9450 ALTSTÄTTEN

II 2G IIB c X

B_05038

40-10

25 MPa

40:1

10 ccm

0.6 MPa 80°C

SOM3001

Vor Gebrauch Betriebsanleitung beachten / Check manual before use!

J. WAGNER AG

MADE IN SWITZERLAND

CH-9450 ALTSTÄTTEN

II 2G IIB c X

B_05039

40-25

25 MPa

40:1

25 ccm

0.63 MPa 80°C

SOM3001

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

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. Only use a damp cloth to clean the device.

Operation without Fluid

Avoid running the pump so that it sucks in air (without  uid inside). The air, combined with the vapor of  ammable  uids, can generate internal areas with an explosion hazard. Periodically check that the pump is working, paying special attention to the presence of air in the pumped  uid, which may be caused by damaged diaphragms.

Avoid operating the pump with damaged diaphragms.

3.3 TYPE PLATES

Example for Cobra 40-10

1 2 3 4 5 6 7

Example for Cobra 40-25

1 2 3 4 5 6 7

1 Pump type 2 Max. product pressure 3 Pump ratio 4 Delivery rate 5 Max. air pressure 6 Max. temp. material/  uid 7 Serial No. 8 Read instruction manual

before use

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

4 GENERAL SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

4.1.1 ELECTRICAL EQUIPMENT

4.1.2 STAFF QUALIFICATIONS

4.1.3 SAFE WORK ENVIRONMENT

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

prevention.

Electrical devices and equipment

To be provided 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. Must be operated in accordance with the safety regulations and electrotechnical

regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Inform sta about

planned work. Observe electrical safety regulations.

Ensure that the device is operated, maintained and repaired only by trained sta .

Ensure that the  oor in the working area is static dissipative in accordance with

EN61340-4-1 (resistance must not exceed 100 megohms). 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megohms. Ensure that during spraying, persons wear static dissipative gloves. Grounding takes

place via the spray gun handle. If protective clothing is worn, including gloves, it has to comply with EN1149-5. The

measured insulation resistance must not exceed 100 megohms. Paint mist extraction systems/ventilation systems must be  tted on site according to

local regulations. Ensure that the following components of a safe working environment are available:

– Product/air hoses adapted to the working pressure. – Personal safety equipment (breathing and skin protection).

Ensure that there are no ignition sources such as naked  ames, sparks, glowing wires,

or hot surfaces in the vicinity. Do not smoke.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES

4.2 SAFETY INSTRUCTIONS FOR STAFF

Always follow the information in these instructions, particularly the general safety

instructions and the warning instructions. Always follow local regulations concerning occupational safety and accident

prevention.

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 all work on the device, in the event of work interruptions and functional faults:

- Switch o the energy/compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun to prevent actuation.

- 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 should 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 BGR500 Part2 Chapter2.29 and 2.36).

- If devices have been decommissioned, the examination can be suspended until the

next start-up.

Follow the "Pressure Relief Procedure":

- If pressure relief is required.

- If the spraying work is interrupted or stopped.

- Before the device is cleaned on the outside, checked or serviced.

- Before the spray nozzle is installed or cleaned.

In the event of skin injuries caused by paint or  ushing agents:

Note the paint or  ushing agent that you have been using. Consult a doctor immediately.

Avoid risk of injury from recoil forces:

Ensure that you have ﬁrm footing when operating the spray gun. Only hold the spray gun brie y in a position.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

4.2.3 PRODUCT HOSES

4.2.2 GROUNDING THE DEVICE

In order to avoid electrostatic charging of the device, the device must be grounded. Friction,  owing liquids, and air or electrostatic coating processes create charges. Flames or sparks can form during discharge.

Ensure that the device is grounded for every spraying operation. 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.

Ensure that the hose material is chemically resistant to the sprayed products and the

used  ushing agents.

Ensure that the product hose is 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

- At sharp edges

- On moving parts

- On hot surfaces

Ensure that the hoses are never run over by vehicles (e.g., fork lifts), 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. Make sure that the hoses are never used to pull or move the device. The electrical resistance of the product hose, measured at both valves, must be less

than 1 megohm.

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 tubes,  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.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

4.2.5 HANDLING HAZARDOUS LIQUIDS, LACQUERS AND PAINTS

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, make sure that you wear safety

goggles, protective clothing, and gloves, as well as skin protection cream if necessary.

Use a mask or a 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.

4.2.4 CLEANING AND RINSING

Relieve the pressure from the device. De-energize the device electrically. Preference should be given to non- ammable cleaning and  ushing agents. Observe the speci cations of the paint 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.

Take measures for workplace safety (see Chapter 4.1.3). When commissioning or emptying the device, please note that an explosive mixture

may temporarily exist inside the lines and components of equipment:

- depending on the coating product used,

- 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:

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 gun. Cleaning the device must not damage it in any way.

Ensure that no electrical component is cleaned with nor even immersed into solvent.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

4.2.6 TOUCHING HOT SURFACES

Only touch hot surfaces if you are wearing protective gloves. When operating the device with a coating product with a temperature of > 43 °C;

109.4°F:

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

Order No.

9998910 Instruction label 9998911 Protection label Note: Order the two labels together.

11 12 15

B_04237

Cobra 40-10

B_04238

Cobra 40-25

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

5 DESCRIPTION

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 the 2 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.

5.1 DESIGN

1 Control housing with integrated silencer 2 Air pressure regulator 3 Ball valve 4 Air motor 5 Compressed air inlet 6 Mounting  ange 7 Relief valve 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

5.2 MODE OF OPERATION

5.2.1 GENERAL INFORMATION

5.2.2 AIR MOTOR 4

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).

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.

5.2.3 PROTECTIVE AND MONITORING EQUIPMENT

B_01205

"?

B_01207

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

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

Vertical positioning Horizontal positioning

Overhead positioning

Overpressure!

Risk of injury from bursting components.

Never change the safety valve setting.

WARNING

Overhead operation or storage (air motor with pressure regulator below)

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

Avoid overhead operation or storage at all costs. Venting, see chapter 8.2.6 Oil change

NOTICE

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).

5.2.4 FLUID SECTION 9

5.2.5 POSITIONING

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

5.3 SCOPE OF DELIVERY

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

Description Devices

Pump ratio 40:1 40:1 Volume  ow per double stroke cm 10 25

cu inch 0.6 1.5

Maximum operating overpressure MPa 25 25

bar 250 250

psi 3626 3626 Maximum possible strokes in operation /min 200 200 Minimum/maximum air inlet pressure MPa 0.25-0.6 0.25-0.6

bar 2.5-6 2.5-6

psi 36.3-87 36.3-87

Order No. Designation

2329519 1 Diaphragm pump Cobra 40-10 consisting of:

Fluid section, air motor, connection elements

2329521 1 Frame-mounted diaphragm pump Cobra 40-10 consisting of:

Fluid section, air motor, connection elements

2329523 1 Diaphragm pump Cobra 40-25 consisting of:

Fluid section, air motor, connection elements

2329525 1 Frame-mounted diaphragm pump Cobra 40-25 consisting of:

Fluid section, air motor, connection elements

The standard equipment includes:

322981 1 Sign 236219 1 Grounding cable, complete 341434 1 Double open-end wrench

see Chapter 15.3 1 Declaration of Conformity

2340850 1 Operating manual, German

see Chapter 1.3 1 Operating manual in the local language

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

5.4 DATA

5.4.1 MATERIALS OF PAINTWETTED PARTS

5.4.2 TECHNICAL DATA

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with

DINEN 14462: 2005.

Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).

Description Devices

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

Minimum Ø of the compressed air supply line

mm 13 19 inch 0.51 0.75

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 80 100

inch 3.15 4 Product inlet (outside thread) mm M36x2 M36x2 Product outlet connection (inside

thread)

inch G 3/8" G 3/8"

Product outlet (outside thread) inch G 3/8" G 3/8" 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 2 2

bar 20 20

psi 290 290

Product temperature °C 10 – 80 10 – 80

°F 50 – 176 50 – 176

Ambient temperature °C 10 – 60 10 – 60

°F 50 – 140 50 – 140

Allowable inclination for operation

±10 ±10

Hydraulic oil  lling amount (approximate)

L 0.11 0.13

cu inch 6.71 7.93

Outgoing air containing oil!

Risk of poisoning if inhaled.

Provide water-free and oil-free compressed air

WARNING

Quality standard 7.5.4 according to ISO 8573.1: 2010 7: Solid particles with mass concentration of 5-10 mg/m³ 5: Air humidity: pressure dew point ≤ +7 °C 4: Oil content: ≤ 5 mg/m³

B_02943

B_04235

Cobra 40-10

B_04236

Cobra 40-25

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

5.4.3 MEASUREMENTS AND CONNECTIONS

Measurement

mm; inch 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; 5.28 134; 5.28 E 55; 2.16 55; 2.16 F 182; 7.16 182; 7.16 G 80; 3.15 80; 3.15 HM6M6

25; 0.98 25; 0.98 K G1/4" G1/4" L M36x2 M36x2

M G 3/8"A G 3/8"A

N 149; 5.87 149; 5.87

O 91; 3.58 91; 3.58

P 107; 4.21 107; 4.21

Q 175; 6.89 175; 6.89

7; 0.28 7; 0.28

BAR

BAR

BAR

BAR

BAR

BAR

"?

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

5.4.4 VOLUME FLOW

5.4.5 PERFORMANCE DIAGRAMS

Stroke frequency (

/min)

Product pressure (bar)

Air consumption (nl/min)

Water  ow rate (nl/min)

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

inch mm Spray angle at at at

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

1015 psi 1450 psi 2175 psi

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 /min.

Example

NL/mi

L/mi

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

B_02947

nl/min

<scfm>

bar (MPa)

<psi>

250 (25)

<3625>

200 (20)

<2900>

150 (15)

<2175>

100 (10)

<1450>

50 (5)

<725>

<0.26>

<0.53>

<0.79>

<1.06>

<1.32>

<1.59>

l/min

<USgpm>

1500

<53>

1200

<42>

900

<32>

600

<21>

300

<11>

120

160

200 240

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Diagram for Cobra 40-10

Stroke frequency ( /min)

Product pressure

Air consumption

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

Diagram for Cobra 40-25

Stroke frequency ( /min)

Product pressure

Air consumption

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

B_04300

B_04301

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

5.5 PRESSURE REGULATOR UNIT FOR COBRA

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).

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).

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF

Incorrect installation/operation!

Risk of injury and damage to the device.

The assembly and commissioning sta must have the technical

skills to safely undertake commissioning.

When assembling, commissioning and carrying out all work,

read and follow the operating manuals and safety regulations for the additionally required system components.

WARNING

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 of vibrations and with a minimum amount of dust. The device must be stored in enclosed 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).

6.3 INSTALLATION CONDITIONS

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

B_04239

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6.5 ASSEMBLY AND INSTALLATION

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) as described in the operating

manual.

Note:

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 gun instructions.

Inclined ground!

Risk of accidents if the device rolls away/falls.

Position the trolley with the piston pump horizontally. If the surface is inclined, position the feet of the trolley towards

the gradient.

Secure the trolley.

WARNING

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6.5.1 VENTILATION OF THE SPRAY BOOTH

Toxic and/or  ammable vapor mixtures!

Risk of poisoning and burns

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 outgoing air

speed.

WARNING

6.5.2 AIR SUPPLY

You must 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 spraying pattern.

Hose connections

Risk of injury and damage to the device.

Do not exchange hose connections of product hose and air

hose.

WARNING

6.5.3 PRODUCT SUPPLY

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, threaded joints, 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.

DANGER

"?

2MAX-7

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6.6 GROUNDING

Grounding scheme (example)

Pump

Paint tank

Work piece

Conveyor

Spraying stand

Floor, static dissipative

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic sparks.

Only use a damp cloth to clean the piston pump.

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.

WARNING

"?

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Cable cross sections

Pump 4 mm; Paint tank 6 mm; Conveyor 16 mm; Booth 16 mm; Spraying stand 16 mm;

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.

Carry out safety checks in accordance with Chapter 8.2.3.

6.7 SAFETY CHECKS

Before every start-up, the following points should be observed:

- Secure gun with safety clip.

- Check the permissible pressures.

- Check all connecting parts for leaks.

- Check hoses for damage.

It should be ensured that the device is in the following state before carrying out any work on it:

- The pressure should be released from the pump and high-pressure hose with gun.

- The gun should be secured with the safety clip.

- The air supply should be interrupted.

Overpressure!

Risk of injury from bursting components.

The operating pressure must not exceed the value shown on

the type plate.

WARNING

Pressure tightness test

For pressure tightness control of the entire installation, the  ushing agent product

pressure is slowly increased step by step until the product pressure of the pump indicated on the type plate is reached.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6.8.1 SAFETY INSTRUCTIONS

6.8 COMMISSIONING

Every time before starting up, the following points should be observed as laid down in the operating manual:

- Observe all safety regulations in accordance with Chapter 4.

- Carry out commissioning properly.

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused

by paint or solvent. Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the

pressure from them and replace them.

WARNING

Toxic and/or  ammable vapor mixtures!

Risk of poisoning and burns.

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 outgoing air

speed.

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 cleaning agent or working medium.

Do not spray the device empty after cleaning.

WARNING

"?

B_04240

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6.8.2 PREPARATION FOR COMMISSIONING

Impurities in the spraying system!

Clogging of the spray gun

Flush the spray gun and paint supply with a suitable  ushing agent before

commissioning.

NOTICE

6.8.3 BASIC FLUSHING

Note:

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

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

2 Place suction hose (7) in a tank with cleaning

agent(6).

3 Adjust the pressure regulator (1) to approx.

0.05MPa; 0.5 bar; 7.25 psi.

4 Open relief valve (3). 5 Slowly open the ball valve (2).

6 Adjust the air pressure on the pressure regulator(1)

so that the pump runs smoothly.

7 Rinse the system until the cleaning agent that

 ows into the tank (5) is clean.

8 Close ball valve (2). 9 Reverse the relief valve (3).

10 Point the gun, without nozzle, into tank (5) and

open it.

11 Slowly open the ball valve (2).

12 Flush until clean  ushing agent  ows from the gun. 13 Close ball valve (2). 14 When there is no pressure remaining in the system, close the gun. 15 Secure the gun. 16 Dispose of the contents of the tank (5) according to the local regulations.

B_04301

B_04303

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

6.8.4 FILLING WITH WORKING MATERIAL

Relief valve

Circulation mode

Spraying mode

1 Place suction hose (7) and return tube (4) into

the tank with the working material (6).

2 Adjust the pressure regulator (1) to approx.

0.05MPa; 0.5 bar; 7.25 psi. 3 Open relief valve (3). 4 Slowly open the ball valve (2). 5 Adjust the air pressure on the pressure

regulator(1) so that the pump runs smoothly.

6 Close ball valve (2) as soon as pure working

material starts coming from the return tube (4). 7 Set relief valve (3) to "spray". 8 Point the gun, without nozzle, into tank (5) and

open it. 9 Slowly open the ball valve (2).

10 Close ball valve (2) as soon as pure working

material starts coming from the gun.

11 When there is no pressure remaining in the

system, close the gun.

12 Secure the gun.

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).

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

7 OPERATION

7.1 TRAINING THE OPERATING STAFF

Incorrect operation!

Risk of injury and damage to the device.

The operating sta must be quali ed and  t 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.

WARNING

7.2 SAFETY INSTRUCTIONS

Incorrect operation!

Risk of injury and damage to the device.

If contact with solvent-based paints or cleaning agents causes

skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing.

The footwear worn by operating sta must comply with

EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.

The protective clothing, including gloves, must comply with

EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

WARNING

Observe safety instructions in Chapter 4.

Unintentional putting into operation!

Risk of injury

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 unit. Secure the spray gun against actuation. In the event of functional faults: remedy the fault as described in

the "Troubleshooting" chapter.

WARNING

B_04302

B_04303

B_04099

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

➁

➀

EMERGENCY STOP

In the event of unforeseen occurrences, the ball valve (1) should be vented immediately and the relief valve (2) opened.

vent

Open

Switch position Circulation

7.3 EMERGENCY DEACTIVATION

B_04301

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

7.4 WORK

1 Secure gun and place nozzle in the gun. 2 Slowly open the ball valve.

3 Set the required working pressure on the pressure

regulator.

4 Optimize the spraying results as laid down in the gun instructions. 5 Start work process. Note: Depending on the function, the pump may continue running for 1 - 6

/min. after

the spray gun is closed.

7.5 PRESSURE RELIEF/WORK INTERRUPTION

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).

7.5.1 PRESSURE RELIEF/WORK INTERRUPTION

The pressure must always be relieved when:

- the spraying tasks are  nished,

- servicing the system,

- carrying out cleaning tasks on the system,

- moving the system to another location,

- something needs to be checked on the system or

- the nozzle is removed from the gun.

Observe general safety instructions in Chapter 4.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Process for relieving pressure

1 Close gun. 2 Close ball valve. 3 Vent air motor. 4 Release the system by opening the gun. 5 Close and secure gun.

If the system has been used with 2K products:

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.

NOTICE

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused

by paint or solvent. Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the

pressure from them and replace them.

Wear the appropriate protective clothing, gloves, eyewear and

respiratory protection.

WARNING

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

8 CLEANING AND MAINTENANCE

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 CLEANING

8.1.1 CLEANING STAFF

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.

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 cleaning agent or working medium.

Do not spray the device empty after cleaning.

WARNING

8.1.2 SAFETY INSTRUCTIONS

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

8.1.4 LONGTERM STORAGE

Note:

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

Procedure:

1 Carry out work interruption -> Chapter 7.5. 2 Carry out the basic  ushing -> Chapter 6.8.3. 3 Maintain the gun according to the operating manual. 4 Clean and check the suction system and the suction  lter. 5 Clean the outside of the system. 6 Put the whole system back together. 7 Fill the system with cleaning agent according to Chapter 6.8.4 "Filling with Working

Material".

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

Procedure:

1 Carry out points 1 to 7 in Chapter 8.1.3 "Flushing and Cleaning Device". 2 Flushing with preserving  uid according to Chapter 6.8.3.

8.1.3 CLEANING AND FLUSHING DEVICE

DANGER

Incorrect maintenance/repair!

Danger to life and damage to the device.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare Parts"

chapter and that are assigned to the device.

Before all work on the device and in the event of work

interruptions:

- Switch o the energy/compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun to prevent actuation. Observe the operating manual and service manuals at all times

when carrying out work.

Observe safety instructions in Chapter 4.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

8.2 MAINTENANCE

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.

8.2.1 MAINTENANCE STAFF

8.2.2 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Prior to maintenance

- Flush and clean the system. Chapter 8.1.3.

After maintenance

- Carry out a safety check in accordance with Chapter 8.2.3.

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

- Carry out a function test, if required, in accordance with Chapter 11.

In accordance with the guideline for liquid ejection devices (ZH1/406 and BGR500

Part2 Chapter 2.29 and Chapter 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.

- If devices have been decommissioned, the examination can be suspended until the next start-up.

DANGER

Incorrect maintenance/repair!

Danger to life and damage to the device.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare Parts"

chapter and that are assigned to the device.

Before all work on the device and in the event of work

interruptions:

- Switch o the energy/compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun to prevent actuation. Observe the operating manual and service manuals at all times

when carrying out work.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

8.2.3.1 GROUNDING CHECK

Every day

Before starting work, carry out a visual check to ensure that the earthing connection is present in the device and in all relevant components.

8.2.3 SAFETY CHECKS

WAGNER recommends having all spraying devices checked annually by a technical expert (e.g., WAGNER service technician) for safety reasons.

8.2.3.2 HIGHPRESSURE FILTER

Check and clean the high-pressure  lter every day or as required.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Bursting hose, bursting threaded joints!

Danger to life from injection of product and from  ying parts.

Ensure that the hose material is chemically resistant to the

sprayed products and the used  ushing agents.

Ensure that the spray gun, threaded joints, and product hose

between the device and the spray gun are suitable for the generated pressure.

Ensure that the following information can be seen on the hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture.

DANGER

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)

Pressure

e.g., 270 bar (27MPa) XX Internal code DNxx (e.g., DN10) Nominal diameter

8.2.3.3 PRODUCT HOSES, TUBES AND COUPLINGS

B_04241

B_04242

B_04243

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

8.2.4 HYDRAULIC STAGE MAINTENANCE

8.2.5 CHECKING THE OIL LEVEL

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.

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.

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).

NOTICE

max.

min.

B_04241

B_04244

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Discharging oil

Procedure:

1 Decommission and clean the device -> Chapter 8.1.3 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 oil  ows out of the oil suction  tting. 8 Screw in clean oil tank (3) and seal.

8.2.6 CHANGING THE OIL

The oil should be changed after 500 service hours or once a year.

Necessary accessories: Order No. 322911 Oil  lling set

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).

NOTICE

B_04245

B_04246

17 mm; 0.67in

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Filling hydraulic stage with oil

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 suction  tting 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 suction  tting 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).

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 when purchasing hydraulic oil.

CAUTION

B_04243

B_04247

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Vent

Procedure:

1 Turn the pump upside down. Remove the threaded plug (5). 2 Slowly start up (vent) the pump until no air bubbles appear from the oil suction

 tting. 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 The device is ready for operation again.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

9 TROUBLESHOOTING, MAINTENANCE, AND REPAIR

Problem Cause Remedy Pump does not work. Air motor does not work or stops. Open and close ball valve on the

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

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

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

Spray nozzle is clogged. Clean the nozzle according to the

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

pressure  lter is clogged.

Clean the parts and use a suitable

working material. Fluid section or high-pressure

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

Dismount and clean  uid section,

replace high-pressure hose.

Grease in spool and sleeve assembly.

Degrease spool and sleeve assembly.

Pump stops at the stroke end occasionally.

Check detent body.

Poor spray pattern. See the gun instructions. Irregular operation of product

pump: spray jet collapses (pulsation)

Viscosity is too high. Thin spraying product. Spraying pressure is too low. Increase air inlet pressure.

Use a smaller nozzle. Valves are clogged. Press valve depressor.

Clean product pump and leave to

soak in cleaning agent if necessary. Foreign body in suction valve. Dismount suction valve housing,

clean, and check valve seat. Diameter of compressed air line

too small.

Assemble a larger supply line

->Technical data, see Chapter 5.4.2.

Valves, packings, or pistons are worn out.

Replace the parts.

Control air  lter or work air  lter is clogged.

Check  lter and clean it if necessary.

Strongly irregular operation of material pump.

Diaphragms "blocked" because suction is too fast.

Operate pump with ball valve

opened a minimal amount for a

while.

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

The suction system's union nut is loose; the pump is taking in air.

Tighten.

Suction  lter is clogged. Clean  lter. Valves are clogged. Press valve depressor.

Clean product pump and leave to

soak in cleaning agent if necessary.

9.1 TROUBLESHOOTING AND RECTIFICATION

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Problem Cause Remedy Pump runs fast when the

spray gun is closed.

Valves worn. Replace the parts.

Loss of power due to severe icing.

There is a lot of condensation water in the air supply.

Install a water separator.

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

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

10 REPAIR WORK

10.1 REPAIR STAFF

Repair work must be carried out carefully by quali ed and trained sta . 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 ensure that the device is checked for being in a reliable state after repair work is completed. Carry out function test in accordance with Chapter 11.

10.2 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Before repair work

- Flush and clean the system. Chapter 8.1.3.

After repair work

- Carry out a safety check in accordance with Chapter 8.2.3.

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

- Function test in accordance with Chapter 11.

In accordance with the guideline for liquid ejection devices (ZH1/406 and BGR500

Part2 Chapter 2.29 and Chapter 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.

- If devices have been decommissioned, the examination can be suspended until the next start-up.

DANGER

Incorrect maintenance/repair!

Danger to life and damage to the device.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare Parts"

chapter and that are assigned to the device.

Before all work on the device and in the event of work

interruptions:

- Switch o the energy/compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun to prevent actuation. Observe the operating manual and service manuals at all times

when carrying out work.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

10.3 CLEANING THE PARTS AFTER DISASSEMBLY

In Chapter 14 the order numbers for device spare parts can be found, as well as for wearing parts such as seals.

Please note:

All reusable parts (except for the electrical components) should be cleaned

thoroughly using a suitable cleaning agent. Spare parts may have safety-relevant properties. Defective parts, O-rings and seal sets must always be re-placed.

ATTENTION

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.

WARNING

Use torques, greases and glues in accordance with Chapter 14.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

11 FUNCTIONAL CHECK AFTER 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

1.1 Piston Travel

- It must be possible to move the piston rod on both sides until the button stop with a pre-assembled pressure stage. Balancing bore must be complet3ely open in the respective end position (visual inspection). (see Chapter 14.4 or14.7)

Manual inspection

1.2 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 container. Push piston into the opposite end position.

Fill pump further

with oil until just below end of oil container inspection window (see Chapter 8.2.6).

Oil  lling unit

1.3 EX-relevant inspections

- Check mass connection between earthing 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 earthing connection: <100k

!! These inspections are

- relevant!!

Ohmmeter

1.4 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

Air motor: Test medium compressed

air Leak spray

Fluid section: Test medium: suitable  ushing agent

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Activities

Aid tools

1.5 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 device completely and relieve pressure

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

Torque wrench Visual check

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

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

- Elastomers

- Plastics

- Carbide

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

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Accessories list for Cobra 40-10

Order No. Designation

A 2329519 Diaphragm pump Cobra 40-10 1

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

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-G1/4-530bar-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 Suction hose DN25 14 2333163 Return tube for item 15 15 2344505 5-liter hopper set for Cobra 16 2321424 Small quantity cup 17 2324110 Suction hose DN16 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

322916 Air coupling set DN 10 mm; 0.39 inch

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-G3/8-530bar-SSt 58 9974112 Sealing ring for G3/8 thread

= Wearing part

13 ACCESSORIES

13.1 COBRA 4010 ACCESSORIES

Regarding position 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.

B_04234

B_04248

Cobra 40-10

AirCoat

30,31

10,19

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Note:

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

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

13.2 COBRA 4025 ACCESSORIES

Accessories list for Cobra 40-25

Order No. Designation

A 2329523 Diaphragm pump Cobra 40-25 1

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

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-G1/4-530bar-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 Suction hose DN25 17 2324110 Suction hose DN16 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

322916 Air coupling set DN 10 mm; 0.39 inch

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-G3/8-530bar-SSt 58 2330780 Fitting-DF-MM-G1/2-G3/8-530bar-SSt 59 2333058 Fitting-SF-FM-G3/8-G1/2-530bar-SSt 60

9974112 Sealing ring for G3/8 thread 61

3051041 Sealing ring for G1/2 thread

= Wearing part

Regarding position 7:

Note: When using the HP  lter (item 56), the respective appropriate  tting must be used (for  uid sections material outlet1/2", the two  ttings pos. 55 and 59 are required; for  uid sections material outlet 3/8", only  tting item 55 is required). The suitable sealing ring (item 60/61) must also be used.

30,31

B_04249

Cobra 40-25

AirCoat

10,19

57/58

60/61

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Note:

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

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14 SPARE PARTS

14.1 HOW CAN SPARE PARTS BE ORDERED?

Incorrect maintenance/repair!

Risk of injury and damage to the device.

Have repairs and part replacements carried out only by specially

trained sta or a WAGNER service center.

Before all work on the device and in the event of work

interruptions:

- Switch o the energy/compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun to prevent actuation. Observe the operating manual and service manuals at all times

when carrying out work.

WARNING

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 lists. 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:

- Billing address

- Delivery address

- 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

Note: These parts are not covered by warranty terms.

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

25 Nm; 18 lbft

B_04250

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.2 OVERVIEW OF THE COBRA 4010 COMPONENTS

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 head cap 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 16 1 9992699 Loctite 406

= Wearing part

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.3 COBRA 4010 AIR MOTOR

Order No. Designation

1 1 9998718 Drive fastener 2 1 367318 Shoulder screw 4 3 1 9925033 Washer 4 1 367311 Hood 4 5 1 367319 Sound absorbing mat 4 6 1 9999152 Velcro fastener coating part 7 1 9999151 Velcro fastener adhesive part 8 1 367318 Shoulder screw 4

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 367315 Control housing 4 21

1 367313 Compressed air  lter 4/6 22 1 2328606 Pressure regulator unit 4 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 2310635 Edge ball valve mini 4

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

Cobra 40-10

1 2

31*

46*

11* 12*

36*

37*

40 41*

43*

50*

46*

27*

10-15 Nm; 7-11 lbft

20-25 Nm; 15-18 lbft

2-3 Nm; 1.5-2.2 lbft

B_04251

50*

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Do not dismount the piston

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Order No. Designation

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 - Distributor piece mini 4 50 2 9974166 O-ring 51 1 9904407 Locking screw R1/4 52 1 9974217 Rod seal 53 1 9992816 Adhesive 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

2341627 Cobra 40-10 air motor service set = Wearing part = Included in service set = Not part of the standard equipment but available as a special accessory.

108

B_04252

109

111

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.4 COBRA 4010 FLUID SECTION

Cobra 40-10  uid section

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

= Wearing part = Included in the service set for Cobra 40-10  uid section.

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

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.

100

110

101

102

16 91

67 26

102

89 90

110

112

105

70 Nm; 52 lbft

90 Nm; 66 lbft

30 Nm; 22 lbft

50 Nm; 37 lbft

2 Nm; 1.5 lbft

103

20 Nm; 15 lbft

20 Nm;14.8 lbft

40 Nm; 29.5 lbft

110

B_04253

Cobra 40-10

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Cobra 40-10  uid section

Order No. Designation

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-G3/8-530bar-SSt 20 1 322913 Complete diaphragm set with insert (comprising 2

diaphragms) 21 2 9904306 Screw plug 22

2 9970127 Sealing ring 23 1 322401 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 36 1 2339250 Oil suction  tting 37

1 115944 O-ring 38 1 2333498 Oil tank, complete 40 1 9998274 Threaded plug M7x1 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 1 9910101 Hexagon nut 53 2 322427 Damping washer

= Wearing part = Included in the service set for Cobra 40-10  uid section.

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

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Cobra 40-10  uid section

Order No. Designation

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 322425 Air motor  ange 61 1 367258 Grounding, complete 62

1 369290 Pilot valve 63 1 9998675 Threaded plug 66 1 9998780 Compression 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 91 1 9974112 Sealing ring für G3/8 thread 92 3 9920106 Washer 93 2 341325 Valve guide 94 2 341328 Clasp 95

2 9971470 O-ring 96 2 341326 Compression 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 Compression 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 109 1 9992511 Loctite 243 50 ml; 50 cc 110 1 9992616 Molykote DX grease 111 1 9998808 Mobilux EP 2 grease 112 1 9992528 Loctite 270 50 ml; 50 cc

= Wearing part = Included in the service set for Cobra 40-10  uid section.

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

B_04254

25 Nm; 18 lbft

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.5 OVERVIEW OF THE COBRA 4025 COMPONENTS

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 head cap 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 22 1 9992699 Loctite 406

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.6 COBRA 4025 AIR MOTOR

Order No. Designation

1 1 9998718 Drive fastener

2 1 367318 Shoulder screw 4

3 1 9925033 Washer

4 1 367311 Hood 4

5 1 367319 Sound absorbing mat 4

6 1 9999152 Velcro fastener coating part

7 1 9999151 Velcro fastener adhesive part

8 1 367318 Shoulder screw 4

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 367315 Control housing 4 21

1 367313 Compressed air  lter 4/6 24 1 2328608 Cobra pressure regulator unit 25 4 9906036 Hexagon socket head cap screw M6x55 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 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 2311016 Edge ball valve midi to size 4

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

48*

61*

62*

49*

Cobra 40-25

1 2

31*

11* 12*

36*

37* 38

40 41*

27*

10-15 Nm; 7-11 lbft

20-25 Nm; 15-18 lbft

2-3 Nm; 1.5-2.2 lbft

B_04255

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Do not dismount the piston

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Order No. Designation

43 1 2309973 Pressure regulator valve LR-1/2-D-O-Midi 44 1 2341176 Manometer with air regulator 0-10 bar, G1/4" 47 1 M262.00 Elbow screw-in connection 48 1 3105540 O-ring 49 1 9971018 O-ring 50 2 M396.00 Reducing  tting 52 1 9974217 Rod seal 53 1 9992816 Adhesive (70 g tube) 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 - 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

2341628 Cobra 40-25 air motor service set = Wearing part = Included in service set. = Not part of the standard equipment but available as a special accessory.

105

106

109

B_04256

40 Nm; 29.5 lbft

111

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.7 COBRA 4025

Cobra 40-25  uid section

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 2330795 Inlet housing 6 8 2306195 Hexagon screw 7 8 9925011 Washer

= Wearing part = Included in the service set for Cobra 40-25  uid section. = Not part of the standard equipment but available as a special accessory.

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.

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

Cobra 40-25

81 80

104

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Cobra 40-25  uid section

Order No. Designation

8 2 2306183 O-ring

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-G3/8-530bar-SSt 19* 1 2330780 Fitting-DF-MM-G1/2-G3/8-530bar-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 2306134 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 36 1 322406 Oil suction  tting 37 1 115944 O-ring 38 1 2333498 Oil tank, complete 40 1 9998274 Threaded plug M7x1 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 1 9910101 Hexagon nut 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

= Wearing part = Included in the service set for Cobra 40-25  uid section. = Not part of the standard equipment but available as a special accessory.

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Cobra 40-25  uid section

Order No. Designation

58 2 9920107 Washer 59

1 9974090 Seal wiper ring, pro le EM 60 1 2306202 Air motor  ange 61 1 367258 Grounding, complete 62

1 369290 Pilot valve 63 2 9998675 Threaded plug 66 1 9998780 Compression 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 81 1 9904311 Locking screws with collar/hexagon socket

91* 1 9974111 Sealing ring für 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 Compression 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 Compression 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 106 1 9992511 Loctite 243 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 EP 2 grease

= Wearing part = Included in the service set for Cobra 40-25  uid section. = Not part of the standard equipment but available as a special accessory.

* The internal thread at the material 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).

1.9 ±0.1

B_01230

B_01232

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.8 COBRA 4010 INLET VALVE

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 Compression 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

Note:

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

14.9 INLET VALVE DEPRESSOR

Grease with Vaseline

Order

No.

Designation

1 1 341241 Inlet valve depressor, complete 2 1 9922724 Lock washer 3.2 3 1 341377 Sleeve 4 1 9994275 Compression spring 5 1 9971486 O-ring 4x2 6 1 341316 Scraper 7 1 341375 Screw plug

= Wearing part

B_02942

2.3

-0.1

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Order

No.

Designation

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 Compression 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

Note:

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

14.10 COBRA 4025 INLET VALVE

1.5

B_01231

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.11 RELIEF VALVE

Order No. Designation

1 1 169248 Relief valve, complete 2 1 9920602 Adjusting washer 3 1 169346 Compression spring 4 1 9920202 Washer 5 1 9971395 O-ring, 10x1.25 6 1 9971486 O-ring 4x2 7 1 9992528 Loctite 270, 50 ml; 50 cc 8 1 9971367 Spiral baking ring 4.78x1.78

= Wearing part

Thread: Pretreated with fast cleaner Loctite type 7063.

90 Nm; 66 lbft

140 Nm 103 lbft

B_05065

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.12 HIGHPRESSURE FILTER UP TO 530 BAR; 7687 PSI

Identi cation of the  lter

Tighten pos. 3 by hand

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Ball valve version in: Carbon steel

Designation Order No.

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

7 1 Distribution housing for ball valve 2324670 10 1 Filter support 9894245 11 1 Filter sieve *

* Filter sieve 200 295721 * Filter sieve 100 3514068 * Filter sieve 50 3514069

* Filter sieve 20 291564 12 1 Cone spring 3514058 20 1 Ball valve 9998679 21 1 Pressure ring d45 2325562 23 1 Hexagon plug 2323718 33 1 Double connector 2325826 34 1 Loctite 542 50 ml; 50 cc 9992831 35 1 Mobilux EP 2 grease 9998808 36 1 Anti-seize paste tube 9992609

= Wearing parts

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

B_05066

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.13 INLINE FILTER 90° UP TO 270 BAR; 3,916 PSI

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*

1 2315723 *Filter insert, red ( ne), 200 mesh per inch, 10 pieces 1 2315724 *Filter insert, blue (middle), 150 mesh per inch, 10 pieces 1 2315725 *Filter insert, yellow (middle), 100 mesh per inch, 10 pieces

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 parts

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

B_05085

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.14 STRAIGHT INLINE FILTER UP TO 270 BAR; 3,916 PSI

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*

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 parts

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

B_02292

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Order

No.

Designation

1 1 322052 Cobra 40-10 frame 2 1 322442 Frame pressed 3 1 322443 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

14.15 COBRA 4010 FRAME, COMPLETE

Order

No.

Designation

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

14.16 COBRA 4025 FRAME, COMPLETE

B_03932

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.17 TROLLEY

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 parts

B_05001

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.18 COBRA TROLLEY HORIZONTAL

Axle setting

Cobra trolley

B_05002

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

Name Order No.

1 1 Cobra trolley complete 2341375 2 1 Frame, left 4"-6" 3 1 Frame, right 4"-6" 4 4 Hexagon screw 9907140 5 6 Self-locking hexagon nut, M6 9910204 6 2 Wheel, D250 2304440 7 4 Washer 340372 8 4 Cotter pin 9995302

9 1 Wheel axle 4"-6" complete 10 2 Connecting part 4"-6" 367943 11 2 Tube plug, ribbed 12 4 Saddle feet for round tubes 9998685 13 2 Plug 14 1 Frame pipe long 15 2 Hexagon screw without shaft 3061695 16

2 Handle 9998747 17 4 Hexagon screw M6x40 3051666 18 4 Serrated lock washer, externally toothed 9922017 19 1 Assembly manual of Cobra trolley horizontal 2341412 = Wearing parts

Trolley and pump  tted

B_04258

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

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

14.19 HOPPER, COMPLETE

B_03642

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.20 SMALL QUANTITY CUP

Order No. Designation

1 2321424 Small quantity cup 1 1 2320844 Union nut with bayonet 2 1 2321426 Low-pressure mini ball valve G1/2 3 1 2320841 Gravity feed cup adapter HSM 4 2 2321427 Gravity feed cup SPA easy line TA 5 2 2321676 Sieve insert SPA easy line 6 1 2320888 Cone connector preassembled 7 1 2320870 Sealing washer 8

1 2320922 Sealing sleeve 9

1 2322857 Relief tube 0.5 L, complete

10 1 2322671 Assembly Manual 11 1

2330810 Connection piece

= Wearing part

Sealing plug

Replace for the following pumps:

• Cobra 40-10 with date of product before November 2013

• Cobra 40-25 with date of product before January 2014

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

14.21 2L TANK

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

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

15.2 WARRANTY CLAIM

15.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY

15 WARRANTY AND CONFORMITY DECLARATIONS

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.

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. Signs of wear traced back to these products 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.

J. Wagner AG

OPERATING MANUAL

VERSION 07/2014

ORDER NUMBER DOC2340851

15.3 CE DECLARATION OF CONFORMITY

Cobra 40-10 Cobra 40-25

complies with the following guidelines:

2006/42/EC 94/9/EC (ATEX Directive)

Applied standards, in particular:

DIN EN ISO 12100: 2011 DIN EN 1127-1: 2011 DIN EN ISO 4413: 2011 DIN EN 13463-1: 2009 DIN EN ISO 4414: 2011 DIN EN 13463-5: 2011 DIN EN 809: 2012 DIN EN ISO 13732-1: 2008 DIN EN 12621: 2011 DIN EN 14462: 2010

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

Part 2 Chapter 2.29 and Chapter 2.36

Identi cation:

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

CE Certi cate of Conformity

The CE certi cate 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

15.4 NOTES ON GERMAN REGULATIONS AND GUIDELINES

Part 2, Chapter 2.36 "Working with Liquid Ejection Devices" Part 2, Chapter 2.29 "Working with Coating Products" Explosion protection rules Avoiding ignition risks Painting rooms and equipment Guidelines for liquid ejection devices

Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they can be found on the Internet.

Order No. 2340851 Edition 07/2014

Germany

Phone Fax E-mail

Switzerland

Phone Fax

More contact addresses on the internet at:

Company/Locations/WAGNER worldwide

Subject to changes without notice

Document No. 11156044

Version A

WAGNER Cobra 40-10, Cobra 40-25 Translation Of The Original Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual