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Cobra 40-10

1. Pos K Stk Order Designation 54 1 9974181 Piston sealing profile Z5 55 1 322426 Piston air motor 3 57 1 9974115 O ring 59 e 2 9974185 Seal wiper ring profile EM 60 1 322425 Air motor flange 61 1 367258 Grounding complete 62 1 369290 Pilot valve 63 1 9998675 Threaded plug 66 1 9998780 Pressure spring 67 2 322407 Oil valve screw 68 e 3 9971162 O ring 69 2 322415 70 1 9974217 Rod seal 78 4 341331 Sealing ring 89 e 2 9971486 O ring solvent resistant 90 e 2 341316 5 91 1 9974112 Sealing ring 92 3 9920106 Washer 93 2 341325 guide 94 2 341328 Clasp 95 e 2 9971470 O ring 96 2 341326 Pressure spring 97 2 253405 Spring support ring 98 2 9941501 Ball 11 HM 99 2 341327 Outlet valve seat 100 2 341347 Sealing ring 101 1 9994237 Pressure spring 102 2 322408 Oil valve pressure ring 103 1 9992590 Loctite 222 50 ml 50 cc 104 1 9992831 Loctite 542 50 ml 50 cc 105 e 1 9971395 O ring 10x1 25 106 1 2312288 5 set for Cobra 40 10 fluid 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 5
2. 9 gt European Communities Ex Symbol for explosion protection Il Device class Il 2 Category 2 Zone 1 G Ex atmosphere gas IIB Explosion group Constructional safety Special Notes see Chapter 3 2 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 tem perature 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 10 VERSION 10 2013 OPERATING MANUAL 4 GENERAL SAFETY INSTRUCTIONS ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER 4 1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual to hand near the device at all times Always follow local regulations concerning occupational safety and accident prevention 4 1 1 ELECTRICAL EQUIPMENT Electrical devices and equipment be provided in accordance with the local safety requ
3. Switch position Circulation 30 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 6 2 2 BASIC FLUSHING 1 Place empty tank 5 under return tube 4 2 Place suction hose 7 in a tank with cleaning agent 6 3 Adjustthe pressure regulator 1 to approx 0 05 MPa 0 5 bar 7 25 psi 4 Openrelief 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 Rinsethe system until the cleaning agent that flows into the tank 5 is clean 8 Close ball valve 2 9 Reverse the relief valve 3 and open it 11 Slowly open the ball valve 2 B 04240 12 Flush until clean flushing agent flows 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 V Note During the flushing procedure briefly press both valve depressors V 31 VERSION 10 2013 OPERATING MANUAL 6 2 3 FILLING WITH WORKING MATERIAL Positions of the ball valve 1 2 3 Open working position Closed The air motor can still be under pressure Vent Operating pressure in the air motor is vented control pressure is still present Place suction hose 7 and return tube 4 into the tank with the working material 6 Adjust the pressure regulator 1 to approx 0 0
4. 7 1 9999151 Velcro fastener adhesive part 8 1 367318 Shoulder screw 4 9 1 9925033 Washer 10 1 367310 Silencer 4 11 x 1 9974098 O ring 1 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 filter 4 6 22 1 2328606 Pressure regulator unit 4 25 1 9999228 Threaded connector L 26 2 367307 Sealing plug 4 6 27 2 9974085 O ring 28 1 367324 Filter holder 29 1 367314 Control air filter 30 x 1 322910 Cobra outlet seal set consisting of 2 seals 31 2 9974095 O ring 32 1 368285 Safety valve 0 63 6 3 bar 91 psi 33 e 1 9943080 Spool and sleeve assembly complete 34 e 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 parts Included in service set Not part of the standard equipment but available as a special accessory 46 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER Cobra 40 10 60 2 3 Nm 1 5 2 2 Ibft Do not dismount the
5. Adjusting washer 3 1 169346 Pressure 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 parts Thread Pretreated with fast cleaner Loctite type 7063 B 01231 WAGNER 55 VERSION 10 2013 OPERATING MANUAL ORDER NUMBER DOC 2303675 Cobra 40 10 11 12 COBRA 40 10 FRAME COMPLETE Pos K Stk Order No Designation 322052 Base frame Cobra 40 10 322442 Base frame pressed 322443 Frame pipe 9990861 9999209 Plug Saddle feet for round tubes 9910204 Self locking hexagon nut M6 NIN 1 1 1 3 9900202 Hexagon screw M6x40 o n 4 9900126 Hexagon screw M6x45 Wearing parts 5 1 11 13 HOPPER COMPLETE Pos K Stk Order No Designation 1 1 341267 Hopper set Ex 5 L 1 3 gal 2 2 9902306 Combination tapping screw 3 1 3756 Filter disk mesh 0 4 mm 0 02 inch 1 37607 Filter disk mesh 0 8 mm 0 03 inch 1 340265 Hopper Ex 5 1 2333163 Relief tube 5 L complete 6 1 340429 Cover 5 Wearing parts 04258 4 WAGNER 56 VERSION 10 2013 OPERATING MANUAL 11 14 TROLLEY Distance A Cobra 40 10 B Cobra 40 25
6. Professional Finishing Division Otto Lilienthal Strasse 18 88677 Markdorf Germany Wagner professional guarantee As of 2009 02 01 60 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 12 3 CE DECLARATION OF CONFORMITY We hereby declare that the supplied version of diaphragm pumps and spray packs Cobra 40 10 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 specifications in particular BGR 500 Part 2 Chapter 2 29 and Chapter 2 36 TRBS 2153 Identification CE II 2G IIB c X CE Certificate of Conformity The CE certificate 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 61 VERSION 10 2013 OPERATING MANUAL ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER Service Network in Germany Berlin J Wagner GmbH Service Stutzpunkt Flottenstra e 28 42 13407 Berlin Tel 0 30 41 10 93 86 Fax 0 30 41 10 93 87 Gr nstadt J Wagner GmbH Service St tzpunkt Diesels
7. 1 B 04243 B 04247 41 VERSION 10 2013 OPERATING MANUAL WAGNER ORDER NUMBER DOC 2303675 Cobra 40 10 10 ACCESSORIES 10 1 COBRA 40 10 ACCESSORIES Accessories list for Cobra 40 10 Pos Order No Designation A 2301858 Diaphragm pump Cobra 40 10 1 322912 oil for pressure stage 250 ml 250 cc 2 236219 Grounding cable 3 m 9 8 ft 3 2333479 AirCoat filter pressure regulator 4 341434 Double open end wrench 7 2325343 Fitting DF MM R1 4 M12 PN270 SSt 11 2323325 Air suction filter DN25 12 2329046 Return hose DN6 PN310 G1 4 PA 13 2324116 Suction hose DN25 14 2333163 Return tube for item 15 15 2344505 Hopper set 5L Cobra 16 2321424 Small quantity cup 17 2324110 Suction hose DN16 20 322052 Frame complete 21 2332143 Wall mount 4 complete 24 2323396 Air suction filter DN16 25 2325901 Trolley 4 complete 51 e 322911 Oilfilling set with 100 ml 100 cc syringe 52 322916 Aircoupling set DN 10 mm 0 39 inch 53 9985619 Hose connector with sealing ring Wearing parts 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 42 Cobra 40 10 ORDER NUMBER DOC 2303675 VERSION 10 2013 WAGNER OPERATING
8. 14 1 322410 Fluid section 15 2 322412 Plug 16 2 9904311 Screw plug 17 1 169248 Relief valve complete see Chapter 11 11 18 ki 1 322915 Outlet valve set complete spare parts for 2 valves 19 1 2330776 Fitting DF MM G3 8 3 8NPSM 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 019 53 24 3 9907041 screw 25 1 322402 Piston 019 53 26 2 9941502 Ball 27 2 9971189 O ring 29 1 9962028 Permaglide bushing 30 1 322403 Pressure stage flange 31 2 9974182 Rod sealing profile BS 32 2 9974183 Rod sealing set 33 e 2 9974186 O ring 34 e 2 9971446 O ring 35 2 322405 Pressure disk 36 1 2339250 Oil suction fitting 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 parts Included in the service set for Cobra 40 10 fluid section e Not part of the standard equipment but available as a special accessory WAGNER 52 VERSION 10 2013 OPERATING MANUAL Cobra 40 10 fluid section ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER
9. 23 Measurements and Connections 19 5 24 Volume Flow 20 5 25 Performance Diagrams 20 5 3 Function 22 5 3 1 Pump 22 5 3 2 Pressure Regulator Unit for Cobra 24 VERSION 10 2013 OPERATING MANUAL Table of Contents 6 1 6 1 1 6 1 2 6 2 6 2 1 6 2 2 6 2 3 7 1 7 2 7 3 7 4 8 1 9 3 9 3 1 9 3 2 10 10 1 11 11 1 11 2 11 3 114 11 9 11 10 11 11 11 12 11 13 11 14 11 16 12 12 1 12 2 12 3 12 4 12 5 12 3 ASSEMBLY AND COMMISSIONING Installation and Connection Installing the Pump Grounding Commissioning Safety Instructions Basic Flushing Filling with Working Material OPERATION Spraying Work Interruption Decommissioning and Cleaning Long term Storage TROUBLESHOOTING MAINTENANCE AND REPAIR Troubleshooting and Rectification MAINTENANCE Hydraulic Stage Maintenance Checking the Oil Level Changing the Oil ACCESSORIES Cobra 40 10 Accessories SPARE PARTS How Can Spare Parts Be Ordered Overview of the Cobra 40 10 Components Cobra 40 10 Air Motor Cobra 40 10 Fluid Section Cobra 40 10 Inlet Valve Inlet Valve Depressor Relief Valve Cobra 40 10 Frame Complete Hopper Complete Trolley Small Quantity Cup 3 2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING Scope of Guarantee Guarantee Period and Registration Handling Exclusion of Guarantee Additional Regulations CE Declaration of Conformity 25 25 25 26 28 28 31 32 33 33 33 34 34 35 35 37 38 38 39
10. 42 42 44 44 45 46 50 54 54 55 56 56 57 58 59 59 59 59 60 60 61 ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER VERSION 10 2013 OPERATING MANUAL Cobra 40 10 ORDER NUMBER DOC 2303675 WAGNER 1 ABOUTTHIS OPERATING MANUAL 1 1 PREFACE The operating manual contains information about safely operating maintaining cleaning and repairing the device The operating manual is part of the device and must be available to operating and service staff Operating and service staff should be instructed according to the safety instructions The device may only be operated in compliance with this operating manual This equipment can be dangerous if it is not operated according to the instructions in this operating manual 1 2 WARNINGS NOTICES AND SYMBOLS IN 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 material damage This notice warns you of a hazard Possible consequenc
11. Limited The Coach House 2 Main Road Middleton Cheney 17 2ND Great Britain UK Helpline 01295 714200 Fax 01295 710100 enquiries wagnerspraytech co uk Wagner Colora S r l Via Italia 34 20060 Gessate Italia Tel 39 02 959292 1 Fax 39 02 95780187 info wagnercolora com Wagner Spraytech Benelux b v De Heldinnenlaan 200 3543 MB Utrecht Netherlands Tel 31 30 241 41 55 Fax 31 30 241 17 87 info wagner wsb nl Wagner Spraytech Scandinavia A S Helgeshgj All 28 2630 Taastrup Denmark Tel 45 43 21 18 18 Fax 45 43 43 05 28 wagner wagner group dk Subject to changes and errors
12. ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER Na Pos K Stk Order No Designation 1 1 2325901 Trolley complete 2 1 Stand left 4 6 welded 3 1 Stand right 4 6 welded 4 4 9907140 Hexagon screw DIN931 M6x75 5 6 9910204 Self locking hexagon nut M6 6 2 2304440 Wheel 0250 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 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 Wearing parts 57 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 11 16 SMALL QUANTITY CUP Pos Stk Order No Designation 2321424 Small quantity cup 2320844 Union nut with bayonet 2321426 Low pressure mini ball valve G1 2 2320841 Gravity feed cup adapter HSM 2321427 Gravity feed cup SPA easy line TA 2321676 Sieve insert SPA easy line 2320888 Cone connector preassembled K3 2320870 Sealing washer 2320922 Sealing sleeve 2322857 Relief tube 0 5 L complete 5 p lu N 2322671 Assembly manual Wearing parts Sealing plug 03642 58 VERSION 10 2013 ORDER NUMBER DOC 23
13. cents min WAGNER CONTACT NETWORK GERMANY AVAILABLE ON THE INTERNET AT WWW WAGNER GROUP COM PROFI 62 CH J Wagner Ges m b H DK Ottogasse 2 20 2333 Leopoldsdorf sterreich Tel 43 2235 44 158 Fax 43 2235 44 163 office wagner group at Wagner Spraytech Beneluxb v E Veilinglaan 56 58 1861 Meise Wolvertem Belgium Tel 32 2 269 46 75 Fax 32 2 269 78 45 info wagner wsb nl J Wagner AG F Industriestrasse 22 9450 Altst tten Schweiz Tel 41 71 7 57 22 11 Fax 441 71 7 57 22 22 wagner wagner group ch J Wagner GmbH cz Otto Lilienthal Stra e 18 D 88677 Markdorf Postfach 11 20 D 88669 Markdorf Deutschland Tel 49 0 75 44 505 1664 Fax 49 75 44 505 1155 wagner wagner group com www wagner group com Wagner Spraytech Scandinavia A S Helgeshgj All 28 2630 Taastrup Denmark Tel 45 43 27 18 18 Fax 45 43 43 05 28 wagner wagner group dk Wagner Spraytech Iberica S A P O Box 132 Crta N 340 08750 Molins de Rey Barcelona Espania Tel 34 93 6800028 Fax 34 93 66800555 info wagnerspain com Wagner France S a r l 12 Avenue des Tropiques Z A de Courtaboeuf 91978 Les Ulis Cedex France Tel 0 825 011 111 Fax 433 0 16981 7257 division batiment wagner france fr Wagner spol s r o Nedasovska str 345 155 21 Praha 5 Zlicin Czechia Tel 42 2 579 50 412 Fax 42 2 579 51 052 info wagner cz www wagner group com Wagner Spraytech UK
14. piston B_04251 47 VERSION 10 2013 OPERATING MANUAL ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER Pos K Stk Order No Designation 43 x 1 9971137 O ring 44 4 9900316 Hexagon socket head cap screw M6x50 45 2 9907039 Hexagon socket head cap screw M6x80 46 x 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 1502 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 parts Included in service set Not part of the standard equipment but available as a special accessory 48 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL I WAGNER 49 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 11 4 COBRA 40 10 FLUID SECTION 109 B 04252 Notes The piston rod 25 may only be mounted with the screwed
15. protection Ensure that there are no ignition sources such as naked flames sparks glowing wires or hot surfaces in the vicinity Do not smoke 11 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL 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 4 2 1 SAFEHANDLING OF WAGNER SPRAY DEVICES The spray jet is under pressure and can cause dangerous injuries Avoid injection of paint or cleaning agents Never point the spray gun at people Never reach into the spray jet Before all work on the device in the event of work interruptions and functional faults Switch off the energy compressed air supply Relieve the pressure from the spray gun and device Secure the spray gun against actuation In the event of functional faults remedy the fault as described in the Troubleshooting chapter The liquid ejection devices are to be checked for safe working conditions by an expert e g Wagner Service Technician as often as necessary or at least every 12 months in accordance with the guidelines for liquid emitters ZH 1 406 and BGR 500 Part 2 Chapter 2 36 For devices that have been shut down the inspection can be postponed until the next commissioning Carry out t
16. quality standard 5 5 4 according to ISO 8573 1 5 5 4 40 um 7 5 mg m ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER 18 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 1 0 OPERATING MANUAL I I I I I WASNER 5 2 3 MEASUREMENTS AND CONNECTIONS Cobra 40 10 B_02943 Measurement Cobra 40 10 mm inch 505 19 88 313 12 32 322 12 68 134 5 28 55 2 16 182 7 16 80 3 15 M6 025 00 98 G1 4 M36x2 5 1 4 18 149 5 87 91 3 58 107 4 21 175 6 89 97 20 28 zmiorvjoziErix Iraimimiginonj o 19 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 5 2 4 VOLUME FLOW Wagner AL nozzles Volume flow in l min ginch 5 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 20 40 50 60 80 1 6200 1 9100 0 027 0 69 20
17. 0 ml 50 Wearing parts Included in the service set for Cobra 40 10 fluid section e Not part of the standard equipment but available as a special accessory 53 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 11 9 COBRA 40 10 INLET VALVE Pos K Stk Order No Designation 1 e 1 322914 Complete Cobra 40 10 inlet valve set 2 2 9912100 Hexagon nut with clamp 3 2 344334 Spring guide 4 2 190304 Pressure spring 5 2 158333 Guide 6 4 341331 Sealing ring 7 2 344322 Valve housing 8 2 340346 Valve seat 10 1 9992528 Loctite 270 50 ml 50 cc 11 2 340342 Valve cone 2 3 4 5 6 1 7 Note 8 S Item 8 gt adhesive area BEES Pretreated with fast cleaner 11 Loctite type 7063 B_01230 11 10 INLET VALVE DEPRESSOR Pos Stk Order No Designation 341241 Inlet valve depressor complete 9922724 Lock washer 3 2 341377 Sleeve 9994275 Pressure spring 9971486 O ring 4x2 341316 Scraper 341375 Screw plug Wearing parts Grease with Vaseline OT 4344 N02 B_01232 54 VERSION 10 2013 OPERATING MANUAL 11 11 RELIEF VALVE ORDER NUMBER DOC 2303675 Cobra 40 10 Pos K Stk Order No Designation 1 1 169248 Relief valve complete 2 1 9920602
18. 03675 Cobra 40 10 OPERATINGMANUAL WAGNER 12 3 2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING 12 1 SCOPE OF GUARANTEE All Wagner professional colour application devices hereafter referred to as products are carefully inspected tested and subject to strict checks under Wagner quality assurance Wagner exclusively issues extended guarantees to commercial or professional users hereafter referred to as customer who have purchased the product in an authorized specialist shop and which relate to the products listed on the Internet at www wagner group com profi guarantee The buyer s claim for liability for defects from the purchase agreement with the seller and statutory rights are not impaired by this guarantee We provide a guarantee in that we decide whether to replace or repair the product or individual parts or take the device back and reimburse the purchase price The costs for products and working hours are our responsibility Replaced products or parts become our property 12 2 GUARANTEE PERIOD AND REGISTRATION The guarantee period amounts to 36 months For industrial use or equal wear such as shift operations in particular or in the event of rentals it amounts to 12 months Systems driven by petrol or air are also guaranteed for a 12 month period The guarantee period begins with the day of delivery by the authorized specialist shop The date on the original purchase document is authoritative For all products bought i
19. 40 50 60 80 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 0 043 1 10 20 50 5 0700 6 0400 7 4600 0 052 1 30 50 5 1200 6 5000 7 5200 Volume flow refers to water Maximum ranges for continuous operation at 200 DH min 5 2 5 PERFORMANCE DIAGRAMS Stroke frequency DH min Example 8 bar Product pressure bar Air consumption nl min B 00301 Water flow rate nl min 20 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER Diagram for Cobra 40 10 Stroke frequency DH min bar MPa nl min lt psi gt lt scfm gt 25005 0 40 80 120 160 200 240 lt 3625 gt 1000 lt 35 gt 200 20 4 2900 pod 150 15 600 2175 26 c 3 100 10 m 5 4 lt 1450 gt a Z a L 200 Z lt 725 gt p 8 9 g 0 z 0 0 4 0 8 1 2 1 6 2 24 l min B 01203 01 02 03 04 05 06 Water flow rate 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 21 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 5 3 FUNCTION 5 3 1 PUMP Cobra 40 10 Control housing with integrated silencer Air pressure regulator Ball valve Air motor Comp
20. 5 MPa 0 5 bar 7 25 psi Open relief valve 3 Slowly open the ball valve 2 Adjust the air pressure on the pressure regulator 1 so that the pump runs smoothly Close ball valve 2 as soon as pure working material starts coming from the return tube 4 Set relief valve 3 to spray Point the gun without nozzle into tank 5 and open it Slowly open the ball valve 2 Close ball valve 2 as soon as pure working material starts coming from the gun When there is no pressure remaining in the system close the gun Secure the gun ORDER NUMBER DOC 2303675 Cobra 40 10 POSTA SIRA A WAGNER B 04301 KA Circulation mode Relief valve Spraying mode 32 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 7 OPERATION 7 1 SPRAYING 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 Secure gun and place nozzle in the gun 2 Slowly open the ball valve 04301 3 Setthe 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 DH min after the spray gun is closed 7 2 WORK INTERRUPTION Close gun Close ball valve Release t
21. 75 Cobra 40 10 OPERATING MANUAL WAGNER 2 5 PROCESSIBLE WORKING MATERIALS Fluid products such as paints and lacquers Application Cobra 40 10 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 YI AA AAA Legend recommended gt limited suitability s less suitable NOTICE Abrasive working materials and pigments Greater wear of parts carrying the product Use the application oriented model flow rate cycle product valves etc as indicated in Chapter 5 2 2 Check if the fluids and solvents used are compatible with the pump construction materials as indicated in Chapter 5 2 1 2 5 1 RECOMMENDED APPLICATION AREAS Application Cobra 40 10 Furniture industry Kitchen manufacturers Joinery Window factories Steel processing industry Construction of vehicles Shipbuilding NI IINININ Legend recommended gt limited suitability x less suitable VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL 2 6 REASONABLY FORESEEABLE MISUSE The following is prohibited coating work pieces which are not grounded unauthorized conversions and modifications to the double diaph
22. 75 Cobra 40 10 OPERATING MANUAL 6 ASSEMBLY AND COMMISSIONING WAGNER 6 1 INSTALLATION AND CONNECTION 6 1 1 INSTALLING THE PUMP 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 Procedure 1 Mountthe pump on a base frame trolley 6 or wall mount 2 ForAirCoat systems Mount the additional filter pressure regulator 7 optional 3 Mount suction system 5 4 Mount return hose 4 optional 5 Connecthigh pressure hose and spray gun 2 as described in the operating manual WARNING 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 25 VERSION 10 2013 OPERATING MANUAL 6 1 2 GROUNDING WARNING 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 insufficient Danger of poisoning Insufficient paint application quality Ground all device components Ground the wor
23. MANUAL Cobra 40 10 B 04285 43 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 11 SPARE PARTS 11 1 HOW CAN SPARE PARTS BE ORDERED Always supply the following information to ensure delivery of the right spare part Order number designation and quantity The quantity need not be the same as the number given in the Stk column in 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 of the person to be contacted in the event of any queries Type of delivery normal mail express delivery air freight courier etc Identification in spare parts lists Explanation of column K labeling in the following spare parts lists Wearing parts Note No liability is assumed for wearing parts Not part of the standard equipment but available as a special accessory A WARNING Incorrect maintenance repair Risk of injury and damage to the device Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center Before all workon the device and in the event of work interruptions Switch off the energy compressed air supply Relieve the pressure from the spray gun and device Secure the spray gun against actuation Observe the operatin
24. ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 4 3 USEIN AREAS SUBJECT TO EXPLOSION HAZARDS The pneumatic pump may be used in potentially explosive areas The following safety regulations must be observed and followed 4 3 1 SAFETY REGULATIONS 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 Ignition temperature of the pumped product Check that the ignition temperature of the pumped product is higher than the max allowable surface temperature Medium supporting atomizing To atomize the product use only weakly oxidizing gases e g air Surface spraying electrostatics Do not spray device parts using electrostatic equipment Cleaning If there are deposits on the surfaces the device may form electrostatic charges Flames or sparks can form during discharge Remove deposits from the surfaces to maintain conductivity Only use a damp cloth to clean the device e VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 4 3 2 OPERATION WITHOUT FLUID Avoid running the pump so that it sucks in air without fluid inside The air combined with the vapor of flammable fluids can generate internal areas with an explosi
25. Translation of the Original Operating Manual w 2 U Version 10 2013 High pressure Double Diaphragm Pumps B_04234 II 2G IIB c X Cobra 40 10 VERSION 10 2013 ORDER NUMBER DOC 2303675 OPERATING MANUAL WAGNER Table of Contents 1 ABOUT THIS OPERATING MANUAL 5 1 1 Preface 5 1 2 Warnings Notices and Symbols in this Operating Manual 5 1 3 Languages 6 1 4 Abbreviations in the Text 6 2 CORRECT USE 7 2 1 Device Types 7 2 2 Type of Use 7 2 3 Use in an Explosion Hazard Area 7 2 4 Safety Parameters 7 2 5 Processible Working Materials 8 2 5 1 Recommended Application Areas 8 2 6 Reasonably Foreseeable Misuse 9 2 7 Residual Risks 9 3 IDENTIFICATION 10 3 1 Explosion Protection Identification 10 3 2 Identification X 10 4 GENERAL SAFETY INSTRUCTIONS 11 4 1 Safety Instructions for the Operator 11 4 1 1 Electrical Equipment 11 4 1 2 Staff Qualifications 11 4 1 3 Safe Work Environment 11 4 2 Safety Instructions for Staff 12 4 2 1 Safe Handling of WAGNER Spray Devices 12 4 2 2 Grounding the Device 13 4 2 3 Product Hoses 13 4 24 Cleaning 14 4 25 Handling Hazardous Liquids Lacquers and Paints 14 4 2 6 Touching Hot Surfaces 14 4 3 Use in Areas Subject to Explosion Hazards 15 4 3 1 Safety Regulations 15 4 3 2 Operation without Fluid 16 5 DESCRIPTION 17 5 1 Scope of Delivery 17 5 2 Data 17 5 2 1 Materials of Paint wetted Parts 17 5 2 2 Technical Data 17 5
26. ble strokes in operation DH min 200 Minimum maximum air inlet pressure MPa 0 25 0 6 bar 2 5 6 psi 36 3 87 17 VERSION 10 2013 OPERATING MANUAL Description Devices Cobra 40 10 Air inlet inside thread inch G 1 2 Minimum of the compressed air supply line mm 13 inch 0 51 Air consumption at 0 6 MPa 6 bar 87 psi per double stroke NL 3 5 Sound pressure level at maximum permissible air pressure dB A 74 Sound pressure level at 0 45 MPa 4 5 bar 65 27 psi dB A 72 air pressure Sound pressure level at 0 3 MPa 3 bar 43 5 psi dB A 69 air pressure Air motor piston diameter mm 80 inch 3 15 Product inlet outside thread mm M36x2 Product outlet connection inside thread inch G 3 8 Product outlet outside thread inch G 1 4 Weight kg Ib 19 41 9 Product pH value pH 3 5 9 Maximum product pressure at pump inlet MPa 2 bar 20 psi 290 Product temperature 1e 10 80 F 50 176 Ambient temperature 10 60 SE 50 4140 Allowable inclination for operation Z 10 Hydraulic oil filling amount approximate L 0 110 cu inch 6 71 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 A WARNING Outgoing air containing oil Risk of poisoning if inhaled Provide compressed air free from oil and water
27. ce if necessary WAGNER recommends having all spraying devices checked annually by a technical expert e g WAGNER service technician for safety reasons 37 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 9 3 HYDRAULIC STAGE MAINTENANCE Dismount the device onto a stand as shown in the picture and turn it upside down Observe the fill level marking X on the oil tank B 04241 B 04242 9 3 1 CHECKING THE OIL LEVEL 1 Startup the pump for a short time without any product 2 Thenreadoil level A Dismount the device onto a stand as shown in the picture and turn it upside down Observe the fill level marking X on the oil tank Oil level A in the oil tank 1 has to be within the specified markings X min If the level deviates from these markings the hydraulic oil must be topped up Procedure 1 Unscrew and remove threaded plug 5 m 2 Topupoilto level A 2 middle of marking X 3 Startup 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 Ibft NOTICE Using hydraulic oil Using the wrong hydraulic oil can cause a malfunction Use only original hydraulic oil Wagner Order No 322912 250 ml or 15 cu inch 38 VERSION 10 2013 OPERATING MANUAL 9 3 2 CHANGING THE OIL ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER The oil should be changed a
28. es of not observing the warning instructions The signal word indicates the hazard level The following are measures which can be taken to prevent the hazard and its consequences A WARNING This notice warns you of a hazard Possible consequences of not observing the warning instructions The signal word indicates the hazard level The following are measures which can be taken to prevent the hazard 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 22 The following are measures which can be taken to prevent the hazard and its consequences NOTICE This notice warns you of a hazard Possible consequences of not observing the warning instructions The signal word indicates the hazard level The following are measures which can be taken to prevent the hazard and its consequences Note provides information about particular characteristics and how to proceed VERSION 10 2013 OPERATING MANUAL 1 3 LANGUAGES The operating manual is available in the following languages Language Order No Language Order No German 2303152 English 2303675 French 2303676 Dutch 2303677 Italian 2303678 Spanish 2303679 Danish 2303680 Swedish 2303682 Portuguese 2343519 1 4 ABBREVIATIONS IN THE TEXT Stk Number of pieces P
29. fter 500 service hours or once a year Necessary accessories Order No 322911 Oil filling set NOTICE Using hydraulic oil Discharging oil Procedure Using the wrong hydraulic oil can cause a malfunction Use only original hydraulic oil Wagner Order No 322912 250 ml or 15 cu inch 1 Decommission and clean the device gt follow Chapter 7 3 up to and including point 6 Unscrew piston cover 1 2 3 4 5 6 7 8 Q 04241 Position device as shown in the picture dismount the hood casing Place empty oil collector 2 under the oil tank Unscrew oil tank 3 and drain contents Unscrew and remove locking screws 4 and seals Slowly start up the pump until no oil flows out of the oil suction fitting Screw in clean oil tank 3 and seal 524 Y iy DLL c f 39 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER N CAUTION Environmental pollution caused by waste oil Waste oil in the sewage network or spilled on the ground causes severe environmental damage Groundwater pollution is liable to prosecution Collect waste oil and bring it to a collection point Waste oil is taken back by the seller when purchasing hydraulic oil Filling hydraulic stage with oil Procedure 1 2 3 4 5 6 B_04245 Turn pump mounted on the base frame upside down Unscrew and remove threaded p
30. g manual and service instructions at all times when carrying out work 44 VERSION 10 2013 OPERATING MANUAL ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER 11 2 OVERVIEW OF THE COBRA 40 10 COMPONENTS Pos Stk Order Designation 1 1 Air motor 3 53 2 1 Preassembled Cobra 40 10 fluid 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 profile 30 mm 1 18 inch 11 2 9999211 Edge protection profile 164 mm 6 46 inch 12 1 2332082 Fluid warning label 13 1 322438 Cylinder noise insulation 14 e 1 9974112 Sealing ring 15 1 367913 Fitting DF MM G3 8 M16x1 5 PN530 SSt 16 1 9992616 Molykote DX grease 17 1 9992699 Loctite 406 Wearing parts 25 Nm 18 Ibft 04250 45 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 11 3 COBRA 40 10 AIR MOTOR Pos K Stk 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
31. he system by opening the gun Close and secure gun Q N If the system has been used with 2K products NOTICE Hardened working material in the spraying system when 2K product is processed Destruction of pump and injection system Follow the manufacturer s processing rules particularly regarding the pot life Flush thoroughly before the end of the pot life 33 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 7 3 DECOMMISSIONING AND CLEANING Note The device should be cleaned for maintenance purposes etc Ensure that no remaining product dries on and sticks to the device Procedure Carry out work interruption gt refer to Chapter 7 2 Carry out basic flushing gt refer to Chapter 6 2 2 Maintain the gun according to the operating manual Clean and check the suction system and the suction filter Clean the outside of the system Putthe whole system back together Fill the system with cleaning agent as described in Chapter 6 2 3 Filling with working material Q N N WARNING Brittle filter pressure regulator The tank on the filter pressure regulator becomes brittle through contact BB I I Wea with solvents burst Flying parts can cause injury Donotclean the tank on the filter pressure regulator with solvent A WARNING Gas mixtures explode if there is an incompletely filled pump Da
32. he work steps as described in the Pressure Relief Work Interruptions chapter 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 cleaning agents Note down the paint or cleaning agent that you have been using Consult a doctor immediately Avoid danger of injury through recoil forces Ensure that you have firm footing when operating the spray gun Only hold the spray gun briefly in a position WAGNER 12 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 4 2 22 GROUNDING THE DEVICE In order to avoid electrostatic charging of the device the device must be grounded Friction flowing 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 dissipative gloves when spraying The grounding takes place via the spray gun handle 4 2 3 PRODUCT HOSES Ensure that the hose material is chemically resistant to the sprayed products Ensure that the product hose is suitable for the p
33. irements with to the operating mode and ambient influences 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 staff about planned work Observe electrical safety regulations 4 1 2 STAFF QUALIFICATIONS Ensure that the device is operated and repaired only by trained persons 4 1 3 SAFEWORKENVIRONMENT Ensure that the floor in the working area is static dissipative in accordance with EN 61340 4 1 resistance must not exceed 100 MOhm 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 Mohm Ensure that during spraying persons wear static dissipative gloves The 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 Mohm Paint mist extraction systems must be fitted 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
34. ith solvent Never use hard objects or spray on cleaning agents with a gun Preferably non combustible cleaning agents should be used 1114 1 An explosive gas air mixture forms in closed tanks When cleaning devices with solvents never spray into a closed tank Onlyuse electrically conductive tanks for cleaning liquids The tanks must be grounded 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 specified 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 sufficient 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 14 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 gt 43 C 109 4 F Identify the device with a warning label Warning hot surface Order No 9998910 Instruction label 9998911 Protection sticker Note Order the two stickers together 14 VERSION 10 2013
35. k pieces to be coated Grounding scheme example Conveyor Work piece R max lt 1 MQ Spraying stand Floor static dissipative ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER 26 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER Cable cross sections Pump 4 mm AWG11 Paint tank 6 mm AWG10 Conveyor 16 mm AWG5 Booth 16 mm AWG5 Spraying stand 16 mm AWG5 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 27 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 6 2 COMMISSIONING 6 2 1 SAFETY INSTRUCTIONS 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 N WARNING 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
36. lean product pump and leave to soak in cleaning agent if necessary 35 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER Problem Cause Remedy Pump runs fast when the Valves worn Replace the parts spray gun is closed Loss of power due to severe There is a lot of condensation water Install a water separator icing in the air supply If none ofthe causes of malfunction mentioned are present the defect can be remedied by a WAGNER Service Center 36 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 9 MAINTENANCE A WARNING 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 Catalogue chapter and that are assigned to the device Before all workon the device and in the event of work interruptions Disconnect the control unit from the mains Relieve the pressure from the spray gun and device Secure the spray gun against actuation Observe the operating manual and service instructions at all times when carrying out work 1 Check and clean the high pressure filter every day or as required 2 Each decommissioning procedure should be carried out as described in Chapter 7 3 3 Check hoses pipes and couplings every day and repla
37. lug 5 Unscrew 2 locking screws 4 and replace with 2 screw fittings 6 from the oil filling set Connect hoses with Y pieces 7 Fill syringe 8 with hydraulic oil and insert into hose Move piston 9 into front end position Use the syringe to fill the hydraulic stage until the oil flows out of the suction fitting into the oil tank 3 with no air bubbles Move piston 9 into rear end position Use the syringe to fill the hydraulic stage until the oil flows out of the suction fitting into the oil tank 3 with no air bubbles 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 Screw in threaded plug 5 and tighten gently Put pump on its side and dismount oil filling set Seal the filler openings tightly with 2 locking screws 4 17 mm 0 67in in m 4 B 04246 zm 40 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 1 au W N OPERATING MANUAL 4 Vent Procedure Turn the pump upside down Remove the threaded plug 5 Slowly start up vent the pump until no air bubbles appear from the oil suction fitting Cil level A in the oil tank has to be within the specified markings X Screw in threaded plug 5 and tighten with 2 Nm 1 5 Ibft Mount piston cover 1 and hood with casing The device is ready for operation again 2 pedi
38. n authorized specialist shops from 2009 02 01 the guarantee period is extended to 24 months providing the buyer of these devices registers in accordance with the following conditions within 4 weeks of the day of delivery by the authorized specialist shop Registration can be completed on the Internet at www wagner group com profi guarantee The guarantee certificate is valid as confirmation as is the original purchase document that carries the date of the purchase Registration is only possible if the buyer agrees to the data that is entered during registration being stored When services are carried out under guarantee the guarantee period for the product is neither extended nor renewed Once the guarantee period has expired claims made against the guarantee or from the guarantee can no longer be enforced 12 3 HANDLING If defects can be seen in the materials processing or performance of the device during the guarantee period guarantee claims must be made immediately or at the latest within a period of 2 weeks The authorized specialist shop that delivered the device is entitled to accept guarantee claims Guarantee claims may also be made to the service centers named in the operating manual The product has to be sent without charge or presented together with the original purchase document that includes details of the purchase date and the name of the product In order to claim for an extension to the guarantee the guarantee certificate mu
39. nger to life from flying 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 7 4 LONG TERM STORAGE If storing the system for a prolonged period of time thorough cleaning and corrosion protection are necessary Replace the water or solvent in the material pump with a suitable preserving oil and fill the separating agent cup with separating agent Procedure 1 Carry out points 1 through 7 in Chapter 7 3 Decommissioning and Cleaning 2 Flush with preservative according Chapter 6 2 2 34 VERSION 10 2013 OPERATING MANUAL ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER 8 TROUBLESHOOTING MAINTENANCE AND REPAIR 8 1 TROUBLESHOOTING AND RECTIFICATION 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 briefly disconnect compressed air supply No pressure indication on the pressure gage air pressure regulator defective Disconnect compressed air supply briefly or repair or change pressure regulator Spray nozzle is clogged Clean the nozzle according to the instructions Insufficient compressed air supply Check compressed air supply Filter insert in spray gun or high pressure filter is clogged Clean the parts and use a suitable working material Fluid sec
40. on assembly pin 108 Grease all o rings and seals lightly with grease 111 before mounting them Cobra 40 10 fluid section Pos K Stk Order No Designation 2329898 Sealing sleeve 9900204 Hexagon screw 9920102 Washer 341241 lnlet valve depressor complete see Chapter 11 10 1 2330764 Inlet housing Wearing parts Included in the service set for Cobra 40 10 fluid section e Not part of the standard equipment but available as a special accessory N 50 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL I WAGNER Cobra 40 10 n Hi 1 Os 50 Nm 37 Ibft yo lt gt 3 Q L SS gt O Ah 0 cs 20 Nm 14 8 Ibft B 04253 51 VERSION 10 2013 OPERATING MANUAL Cobra 40 10 fluid section ORDER NUMBER DOC 2303675 Cobra 40 10 Pos K Stk Order Designation 6 8 9907234 Hexagon screw 7 10 9920107 Washer 8 ex 2 9974184 O ring 9 2 322411 Valve fitting 10 2 341336 Clasp 11 ex 1 322914 _ Inlet valve set complete comprising 2 valves see Chapter 11 9 13 1 2330810 Connection piece
41. on hazard Periodically check that the pump is working smoothly paying special attention to the presence of air in the pumped fluid which may be caused by damaged packings Avoid operating the pump with damaged packings Ensure that the separating agent tank is filled with sufficient separating agent 16 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 5 DESCRIPTION 5 1 SCOPE OF DELIVERY Order No Stk Designation 2301858 1 Frame mounted diaphragm pump Cobra 40 10 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 12 3 1 Conformity certificate GM2000W 2303152 1 Operating manual German 1 see Chapter 1 Operating manual in the local language The delivery note shows the exact scope of delivery Accessories see Chapter 10 5 2 DATA 5 2 1 MATERIALS OF PAINT WETTED PARTS Inlet housing Consital aluminum alloy Fluid section Consital aluminum alloy Valve balls Stainless steel Valve seats valve cone Carbide Diaphragms Resistant PA Valve fitting 1 4104 5 2 2 TECHNICAL DATA Description Devices Cobra 40 10 Pump ratio 40 1 Volume flow per double stroke DH cm 10 cu inch 0 6 Maximum operating overpressure MPa 25 bar 250 psi 3626 Maximum possi
42. os Position K Marking in the spare parts lists Order No Order number DH Double stroke SSt Stainless steel 2K Two components ORDER NUMBER DOC 2303675 Cobra 40 10 WAGNER VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 2 CORRECT USE 2 1 DEVICETYPES Double diaphragm pump and spray pack Cobra 40 10 2 2 TYPEOF USE The device is suitable for processing liquid materials like paints and lacquers in accordance with the classification into explosion classes or IIB 2 3 USEIN AN EXPLOSION HAZARD AREA 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 incorrect use Use the device only to work with the products recommended by WAGNER Only operate the device as a whole Do not deactivate safety fixtures Use only WAGNER original spare parts and accessories The double diaphragm pump may only be operated under the following conditions The operating staff must be trained on the basis of 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 statutory requirements and accident prevention regulation standards in the country of use must be observed VERSION 10 2013 ORDER NUMBER DOC 23036
43. ponents Never change the safety valve setting Fluid section 9 The fluid 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 Positioning The Cobra pump may only be operated in a horizontal or vertical position as shown in the diagrams Overhead operation is not permitted Vertical positioning Horizontal positioning B 01207 Overhead positioning NOTICE 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 Vent see service manual 23 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 5 3 2 PRESSURE REGULATOR UNIT FOR COBRA Pressure regulator Ball valve Pressure gauge Compressed air inlet AirCoat filter regulator Cobra accessories Q N AirCoat filter regulator must be mounted vertically in all installation positions for the diaphragm pump see assembly manual for Filter Regulator order number 2328614 Positions of the ball valve 1 Open working position 2 Closed The air motor can still be under pressure 3 Vent Operating pressure in the air motor is vented 2 control pressure is still present B_04301 24 VERSION 10 2013 ORDER NUMBER DOC 23036
44. ragm pump processing dry or similar coating products and using defective components spare parts or accessories other than those described in Chapter 10 of this operating manual The forms of misuse listed below may result in health issues and or material 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 WAGNER Residual risk Source Consequences Specific 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 maintenance sheets disassembly Paint in air outside Painting outside the Inhalation of Observe working Operation the defined working area defined working area substances which are hazardous to health and operating instructions maintenance VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 3 IDENTIFICATION 3 1 EXPLOSION PROTECTION IDENTIFICATION Asdefinedin Directive 94 9 EC ATEX 95 the device is suitable for use in potentially explosive areas
45. replace them AN WARNING Toxic and or flammable 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 flying parts gt 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 28 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL 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 Thegun should be secured with the safety clip Theair supply should be interrupted 29 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER Cobra EMERGENCY STOP In the event of unforeseen occurrences the ball valve 1 should be vented immediately and the relief valve 2 opened B_04099
46. ressed air inlet Mounting flange Relief valve 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 OANA W N B_04237 General information 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 fluid 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 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 fitted 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 22 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL N WARNING Overpressure Risk of injury from bursting com
47. ressure generated in the device Ensure that the following information can be seen on the high pressure hose Manufacturer Permissible operating overpressure Date of manufacture Make sure that the hoses are laid only in suitable places In no case should hoses be laid in the following places in high traffic areas on sharp edges on moving parts or on hot surfaces Make sure that the hoses are never used to pull or move the device The electrical resistance of the complete high pressure hose must be less than 1 Mohm Several liquids have a high expansion coefficient In some cases their volume can rise with consequent damage to pipes fittings etc and cause fluid leakage When the pump sucks liquid from a closed tank ensure that air or suitable gas can enter the tank to avoid a vacuum being generated in the tank itself 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 flow out The pressure created by the pump is a multiplication of the inlet air pressure 13 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATING MANUAL WAGNER 4 2 4 CLEANING De energize the device electrically Disconnect the pneumatic supply line Relieve the pressure from the device Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature To clean use cloths and brushes moistened w
48. st be included The costs as well as the risk of loss or damage to the product in transit or by the center that accepts the guarantee claims or who delivers the repaired product are the responsibility of the customer 59 VERSION 10 2013 ORDER NUMBER DOC 2303675 Cobra 40 10 OPERATINGMANUAL WAGNER 12 4 EXCLUSION OF GUARANTEE Guarantee claims cannot be considered for parts that are subject to wear and tear due to use or other natural wear and tear as well as defects in the product that are a result of natural wear and tear or wear and tear dueto use This includes in particular cables valves packings nozzles cylinders pistons means carrying housing components filters pipes seals rotors stators etc Damage due to wear and tear that is caused in particular by sanded coating products such as dispersions plasters putties adhesives glazes quartz foundation in the event of errors in devices that due to non compliance with the operating instructions unsuitable or unprofessional use incorrect assembling and or commissioning by the buyer or by a third party utilization other than is intended abnormal ambient conditions unsuitable coating products the influence of chemical electrochemical or electrical agents unsuitable operating conditions operation with the incorrect mains voltage supply frequency overload or defective servicing or care and or cleaning for errors in the device that have been caused by
49. tion or high pressure hose is blocked e g 2K product hardened Dismount and clean fluid section replace high pressure hose Grease in spool and sleeve assembly Pump stops at the stroke end occasionally Degrease spool and sleeve assembly Check detent body Poor spray pattern Irregular operation of product pump spray jet collapses pulsation See gun instructions 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 2 2 Valves packings or pistons are worn out Control air filter or work air filter is clogged Replace the parts Check filter 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 filter is clogged Clean filter Valves are clogged Press valve depressor C
50. tra e 1 67269 Gr nstadt Tel 49 0 63 59 87 27 550 Fax 49 0 63 59 80 74 80 Ratingen J Wagner GmbH Service St tzpunkt Siemensstra e 6 10 40885 Ratingen Tel 49 0 21 02 3 1037 Fax 49 0 21 02 3 43 95 Heidersdorf in Sachsen J Wagner GmbH Service St tzpunkt Olbernhauer 5 11 09526 Heidersdorf Tel 49 0 3 73 61 157 07 Fax 49 0 3 73 61 1 57 08 Stuttgart J Wagner GmbH Service St tzpunkt In der Steige 6 1 72564 Neckartenzlingen Tel 0 7127 3074 Fax 0 71 27 30 75 Munich Jahnke GmbH Hochstra e 7 82024 Taufkirchen Tel 49 0 89 6 14 00 22 Fax 49 0 89 6 14 04 33 email info airless de www airless de Nuremberg Grimmer GmbH Starenweg 28 91126 Schwabach Tel 49 0 91 22 7 94 73 Fax 49 0 91 22 7 94750 email info grimmer sc de www grimmer sc de Hannover J Wagner GmbH Service St tzpunkt Kornstra e 20 31535 Neustadt Tel 49 0 50 32 8 00 06 23 Fax 49 0 50 32 8 00 06 24 Markdorf Headquarters J WAGNER GmbH Otto Lilienthal Stra e 18 88677 Markdorf Postfach 11 20 88669 Markdorf Tel 49 0 75 44 505 0 Fax 49 0 75 44 505 1200 www wagner group com Customer Center Tel 49 0 75 44 505 1664 Fax 49 0 75 44 505 1155 E mail kundenzentrum wagner group com Technical Service Tel 49 0 180 5 59 24 637 14 cents minute when calling from the German landline network mobile charge no more than 42
51. using accessory parts additional components or spare parts that are not original Wagner parts for products to which modifications or additions have been carried out for products where the serial number has been removed is illegible for products to which attempts at repairs have been carried out by unauthorized persons for products with slight deviations from the target properties which are negligible with regard to the value and usability of the device for products that have been partially or fully taken apart 12 5 ADDITIONAL REGULATIONS Theabove guarantees apply exclusively to products that have been bought from authorized specialist shops in the EU CIS Australia and are used within the reference country If an inspection finds damage not covered by the present guarantee repairs are carried out atthe expense of the buyer The above regulations manage the legal relationship to us concludingly Additional claims in particular for damages and losses of any type which occur as a result of the product or its use are excluded from the product liability act except with regard to the area of application Claims for liability for defects to the specialist trader remain unaffected German law applies to this guarantee The contractual language is German In the event that the meaning of the German and a foreign text of this guarantee deviate from one another the meaning of the German text has priority J Wagner GmbH

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