Performance Series 1650e

Transcripción

1 GB E Operatng manual Instruccones de uso... p. Performance Seres 650e Arless hgh-pressure sprayng unt Arless Equpo de alta presón para pulverzar Model: Orgnal operatng manual Performance Seres 650e Edton 5 / F

2 GB Warnng! Attenton: Danger of njury by njecton! Arless unts develop extremely hgh sprayng pressures. Never put your fngers, hands or any other parts of the body nto the spray jet! Never pont the spray gun at yourself, other persons or anmals. Never use the spray gun wthout safety guard. Do not treat a sprayng njury as a harmless cut. In case of njury to the skn through coatng materals or solvents, consult a doctor mmedately for quck and expert treatment. Inform the doctor about the coatng materal or solvent used. The operatng nstructons state that the followng ponts must always be observed before startng up... Faulty unts must not be used. Secure Ttan spray gun usng the safety catch on the trgger.. Ensure that the unt s properly earthed. The connecton must take place through a correctly earthed two-pole and earth socket outlet. PE. Check allowable operatng pressure of hgh-pressure hose and spray gun. 5. Check all connectons for leaks. The nstructons regardng regular cleanng and mantenance of the unt must be strctly observed. Before any work s done on the unt or for every break n work the followng rules must be observed:. Release the pressure from spray gun and hose.. Secure the Ttan spray gun usng the safety catch on the trgger 0 bar. Swtch off unt. Be safety-conscous! Performance Seres 650e

3 Contents Page. Safety regulatons for Arless sprayng.... Earthng nstructons...5. General vew of applcaton...6. Applcaton...6. Coatng materals...6. Descrpton of unt...6. Arless process...6. Functonng of the unt...6. Legend for explanatory dagram Performance Seres 650e...7. Explanatory dagram Performance Seres 650e Techncal data Transportaton Transportaton n vehcle Pantng materal setup Textured materal setup...8. Startng operaton...9. Hgh-pressure hose, spray gun and separatng ol...9. Control panel ndcators...9. Pressure control knob settngs...0. Connecton to the mans network Cleanng preservng agent when startng-up of operaton ntally Takng the unt nto operaton wth coatng materal Dgtal Electronc Spray Control (DESC) Sprayng technque Handlng the hgh-pressure hose Hgh-pressure hose Interrupton of work... GB Contents Page 8. Cleanng the unt (shuttng down) Cleanng unt from outsde Cleanng the hgh-pressure flter Cleanng Arless spray gun Cleanng the nlet screen Remedy n case of faults Servcng General servcng Hgh-pressure hose...6. Repars at the unt...6. Relef valve...6. Replacng the motor assembly...6. Replacng the gears...7. Replacng the transducer...7. Inlet and outlet valve...8. Packngs...8. Performance Seres 650e connecton dagram...0. Accessores for Performance Seres 650e.... Appendx.... Selecton of tp.... Servcng and cleanng of Arless hard-metal tps... Spare parts lst for man assembly... Spare parts lst for flud secton... Spare parts lst for drve assembly...6 Spare parts lst of flter assembly...7 Spare parts lst for uprght cart...8 Warranty...50 Performance Seres 650e

4 Safety Regulatons. Safety regulatons for Arless sprayng Ths manual contans nformaton that must be read and understood before usng the equpment. When you come to an area that has one of the followng symbols, pay partcular attenton and make certan to heed the safeguard. GB Attenton Ths symbol ndcates a potental hazard that may cause serous njury or loss of lfe. Important safety nformaton wll follow. Ths symbol ndcates a potental hazard to you or to the equpment. Important nformaton that tells how to prevent damage to the equpment or how to avod causes of mnor njures wll follow. NOTE TO PHYSICIAN: Injecton nto the skn s a traumatc njury. It s mportant to treat the njury as soon as possble. DO NOT delay treatment to research toxcty. Toxcty s a concern wth some coatngs njected drectly nto the blood stream. Consultaton wth a plastc surgeon or reconstructve hand surgeon may be advsable. A hazard symbol such as ths one refers to a specfc, task-related rsk. Be sure to heed the safeguard. HAZARD: EXPLOSION OR FIRE Solvent and pant fumes can explode or gnte. Severe njury and/or property damage can occur. PREVENTION: Provde extensve exhaust and fresh ar ntroducton to keep the ar wthn the spray area free from accumulaton of flammable vapors. Notes gve mportant nformaton whch should be gven specal attenton. 0 bar HAZARD: Injecton njury A hgh pressure stream produced by ths equpment can perce the skn and underlyng tssues, leadng to serous njury and possble amputaton. DO NOT TREAT AN INJECTION INJURY AS A SIMPLE CUT! Injecton can lead to amputaton. See a physcan mmedately. The maxmum operatng range of the unt s bar (. MPa, 00 PSI) flud pressure. PREVENTION: NEVER am the gun at any part of the body. NEVER allow any part of the body to touch the flud stream. DO NOT allow body to touch a leak n the flud hose. NEVER put your hand n front of the gun. Gloves wll not provde protecton aganst an njecton njury. ALWAYS lock the gun trgger, shut the flud pump off and release all pressure before servcng, cleanng the tp guard, changng tps, or leavng unattended. Pressure wll not be released by turnng off the engne. The PRIME/SPRAY valve or pressure bleed valve must be turned to ther approprate postons to releve system pressure. ALWAYS keep tp guard n place whle sprayng. The tp guard provdes some protecton but s manly a warnng devce. NEVER use a spray gun wthout a workng trgger lock and trgger guard n place. ALWAYS remove the spray tp before flushng or cleanng the system. The pant hose can develop leaks from wear, knkng and abuse. A leak can nject materal nto the skn. Inspect the hose before each use. All accessores must be rated at or above the maxmum operatng pressure range of the sprayer. Ths ncludes spray tps, guns, extensons, and hose. PE Avod all gnton sources such as statc electrcty sparks, electrcal applances, flames, plot lghts, hot objects, and sparks from connectng and dsconnectng power cords or workng lght swtches. Plastc can cause statc sparks. Never hang plastc to enclose spray area. Do not use plastc drop cloths when sprayng flammable materals. Always flush unt nto separate metal contaner, at low pump pressure, wth spray tp removed. Hold gun frmly aganst sde of contaner to ground contaner and prevent statc sparks. Do not smoke n spray area. Fre extngusher must be present and n good workng order. Place sprayer at least 6. m (0 feet) from the spray object n a well ventlated area (add more hose f necessary). Flammable vapors are often heaver than ar. Floor area must be extremely well ventlated. The pump contans arcng parts that emt sparks and can gnte vapors. The equpment and objects n and around the spray area must be properly grounded to prevent statc sparks. Use only conductve or earthed hgh pressure flud hose. Gun must be earthed through hose connectons. Power cord must be connected to a grounded crcut (electrc unts only). The unt must be connected to an earthed object. Use the green earthng wre to connect the unt to a water ppe, steel beam, or other electrcally earthed surface. Follow materal and solvent manufacturer s warnngs and nstructons. Be famlar wth the coatng materal s MSDS sheet and techncal nformaton to ensure safe use. Do not use materals wth a flashpont below C (70 F). Flashpont s the temperature at whch a flud can produce enough vapors to gnte. Use lowest possble pressure to flush equpment. Performance Seres 650e

5 GB Safety regulatons HAZARD: EXPLOSION HAZARD DUE TO INCOMPATIBLE MATERIALS Wll cause severe njury or property damage. PREVENTION: Do not use materals contanng bleach or chlorne. Do not use halogenated hydrocarbon solvents such as methylene chlorde and,, - trchloroethane. They are not compatble wth alumnum and may cause an exploson. If you are unsure of a materal s compatblty wth alumnum, contact your coatng s suppler. HAZARD: HAZARDOUS VAPORS Pants, solvents, nsectcdes, and other materals can be harmful f nhaled or come n contact wth body. Vapors can cause severe nausea, fantng, or posonng. PREVENTION: Use a resprator or mask f vapors can be nhaled. Read all nstructons suppled wth the mask to be sure t wll provde the necessary protecton. Wear protectve eyewear. HAZARD: GENERAL Ths product can cause severe njury or property damage. PREVENTION: Read all nstructons and safety precautons before operatng equpment. Follow all approprate local, state, and natonal codes governng ventlaton, fre preventon, and operaton. Pullng the trgger causes a recol force to the hand that s holdng the spray gun. The recol force of the spray gun s partcularly powerful when the tp has been removed and a hgh pressure has been set on the arless pump. When cleanng wthout a spray tp, set the pressure control knob to the lowest pressure. Use only manufacturer authorzed parts. User assumes all rsks and labltes when usng parts that do not meet the mnmum specfcatons and safety devces of the pump manufacturer. Before each use, check all hoses for cuts, leaks, abrason or bulgng of cover. Check for damage or movement of couplngs. Immedately replace the hose f any of these condtons exst. Never repar a pant hose. Replace t wth another earthed hgh-pressure hose. Make sure power cord, ar hose and spray hoses are routed n such a manner to mnmze slp, trp and fall hazard. Clean up all materal and solvent splls mmedately to prevent slp hazard. ALWAYS follow the materal manufacturer s nstructons for safe handlng of pant and solvents. Do not use ths unt n workshops that are covered under the exploson preventon regulatons. Always unplug cord from outlet before workng on equpment (electrc unts only). Always keep the power cord plug n sght durng usage to prevent any accdental shutdown or startup. If the supply cord s damaged, t must be replaced by the manufacturer, ts servce agent or smlarly qualfed persons n order to avod a hazard. Wear ear protecton. Ths unt can produce nose levels above 85 db(a). Ths equpment s desgned to operate at hgh pressures and recol forces may occur. Under certan crcumstances, such forces could result n repettve stran njury. Devce weghs n excess of 6 kg. Three-person lft s requred. Never leave ths equpment unattended. Keep away from chldren or anyone not famlar wth the operaton of arless equpment. Do not move unt whle unt s runnng. Do not spray on wndy days. Wear protectve clothng as requred by coatng manufacturer.. Earthng Instructons PE Electrc models must be earthed. In the event of an electrcal short crcut, earthng reduces the rsk of electrc shock by provdng an escape wre for the electrc current. Ths product s equpped wth a cord havng an earthng wre wth an approprate earthng plug. The plug must be plugged nto an outlet that s properly nstalled and earthed n accordance wth all local codes and ordnances. DANGER Improper nstallaton of the earthng plug can result n a rsk of electrc shock. If repar or replacement of the cord or plug s necessary, do not connect the green earthng wre to ether blade termnal. The wre wth nsulaton havng a green outer surface wth or wthout yellow strpes s the earthng wre and must be connected to the earthng pn. Check wth a qualfed electrcan or servceman f the earthng nstructons are not completely understood, or f you are n doubt as to whether the product s properly earthed. Do not modfy the plug provded. If the plug wll not ft the outlet, have the proper outlet nstalled by a qualfed electrcan. Cauton The power cord for ths equpment acts as an emergency stop/emergency swtchng off devce. The power cord must be placed near an easly accessble, unobstructed socket-outlet. Work or repars at the electrcal equpment: These may only be carred out by a sklled electrcan. No lablty s assumed for ncorrect nstallaton. A lst of the materals used n the constructon of the equpment wll be made avalable on request to valdate compatblty wth the coatng materals to be used. Operatng Temperature Ths equpment wll operate correctly n ts ntended ambent, at a mnmum between +0 C and +0 C. Relatve Humdty The equpment wll operate correctly wthn an envronment at 50% RH, +0 C. Hgher RH may be allowed at lower temperatures. Measures shall be taken by the Purchaser to avod the harmful effects of occasonal condensaton. Alttude Ths equpment wll operate correctly up to 00 m above mean sea level. Transportaton and Storage Ths equpment wll wthstand, or has been protected aganst, transportaton and storage temperatures of -5 C to +55 C and for short perods up to +70 C. It has been packaged to prevent damage from the effects of normal humdty, vbraton and shock. Performance Seres 650e 5

6 General vew of applcaton. General vew of applcaton. Applcaton All pantng jobs n the workshop and on the buldng ste, small dsperson work wth the spray gun or nter nally fed Arless roller. Examples of objects of sprayng Doors, door frames, balustrades, furnture, wooden claddng, fences radators (heatng) and steel parts, nternal celngs and walls.. Coatng materals Processble coatng materals Pay attenton to the Arless qualty of the coatng materals to be processed. Dlutable lacquers and pants or those contanng solvents, twocomponent coatng materals, dspersons, latex pants. No other materals should be used for sprayng wthout Ttan s approval. Flterng Despte sucton flter and nserton flter n the spray gun, flterng of the coatng materal s generally advsable. Str coatng materal before commencement of work. Attenton: Make sure, when strrng up wth motor-drven agtators that no ar bubbles are strred n. Ar bubbles dsturb when sprayng and can, n fact, lead to nterrupton of operaton. Vscosty Wth ths unt t s possble to process hghly vscous coatng materals of up to around MPa s. If hghly vscous coatng materals cannot be taken n by sucton, they must be dluted n accordance wth the manufacturer s nstructons. Two-component coatng materal The approprate processng tme must be adhered to exactly. Wthn ths tme rnse through and clean the unt metculously wth the approprate cleanng materals. Coatng materals wth sharp-edged addtonal materals These have a strong wear and tear effect on valves, hghpressure hose, spray gun and tp. The durablty of these parts cane be reduced apprecably through ths. GB. Descrpton of unt. Arless process Descrpton of unt The man areas of applcaton are thck layers of hghly vscous coatng materal for large areas and a hgh consumpton of materal. A pston pump takes n the coatng materal by sucton and conveys t to the tp. Pressed through the tp at a pressure of up to a maxmum of bar (. MPa), the coatng materal s atomsed. Ths hgh pressure has the effect of mcro fne atomsaton of the coatng materal. As no ar s used n ths process, t s descrbed as an AIRLESS process. Ths method of sprayng has the advantages of fnest atomsaton, cloudless operaton and a smooth, bubble-free surface. As well as these, the advantages of the speed of work and convenence must be mentoned.. Functonng of the unt In the followng there s a short descrpton of the techncal constructon for better understandng of the functon. Ttan Performance Seres unts are electrcally drven hghpressure sprayng unts. A gear unt transfers the drvng force to a crankshaft. The crankshaft moves the pstons of the materal feed pump up and down. The nlet valve s opened automatcally by the upwards movement of the pston. The outlet valve s opened when the pston moves downward. The coatng materal flows under hgh pressure through the hghpressure hose to the spray gun. When the coatng materal exts from the tp t atomzes. The pressure regulator controls the volume and the operatng pressure of the coatng materal. 6 Performance Seres 650e

7 GB. Legend for explanatory dagram Performance Seres 650e Descrpton of unt Spray gun Hgh-pressure hose Ol cup for Pston Lube (Pston Lube prevents ncreased wear of the packngs) Ol level gauge 5 Pal hook 6 Ol button 7 Sucton tube 8 Return hose 9 Cart 0 Relef valve Lever poston vertcal PRIME ( k crculaton) Lever poston horzontal SPRAY ( p) Dgtal Electronc Spray Control (DESC) Control panel ndcators Pressure control knob ON/OFF swtch. Explanatory dagram Performance Seres 650e Performance Seres 650e 7

8 Descrpton of unt GB.5 Techncal data Voltage: Max. current consumpton: Power cord: Acceptance capacty: Max. operatng pressure: 00-0 Volt AC, 50 Hz 5 A / 0 A x.5 mm 6 m or.6 m 000 Watt bar (, MPa) Volume flow at MPa (0 bar) wth water: 5.0 l/mn Max tp sze: 0.09 nch 0.99 mm Max. temperature of the coatng materal: C Max vscosty: MPa s Weght: 50 kg Specal hgh-pressure hose: DN 6 mm, 5 m, connecton thread M 6 x.5 Dmensons (L X W X H): 6 x 568 x 7 mm Max sound pressure level: 80 db (A) * * Place of measurng: m n dstance from the unt and.6 m above the floor, MPa (0 bar) operatng pressure, reverberant floor..8 Pant materal setup Ths sprayer comes wth a flter assembly nstalled. If you plan to spray wth untextured pantng materals, leave the flter nstalled..9 Textured materal setup Ths sprayer comes wth a flter plug that should be put n place of the flter whenever sprayng textured materals. Follow these steps to remove the flter and nstall the plug.. Loosen and remove the flter housng () by hand.. Remove the adapter sprng (), flter (), bearng rng () and sprng (5) from the housng (7).. Make sure the O-rng (6) s stll n place. Thread the flter plug (8) nto the housng untl secure. The flter plug should be hand-tghtened, but make sure t s seated fully nto the flter housng..6 Transportaton Pushng or pullng the unt Pull out the handle (Fg., Item ) untl t wll come no further. Insert the handle push the buttons () on the spars, and then push n the handle Transportaton n vehcle Secure the unt wth a sutable fastenng. If If usng ths sprayer wth textured materals, t s mportant that the flter nsde of the spray gun be removed. See secton 8.. the sprayer wll be used for sprayng textured products, removal of the nlet screen n the foot valve may be necessary. Ths wll allow proper prmng and flow of the textured product. See secton Performance Seres 650e

9 GB Startng operaton. Startng operaton. Hgh-pressure hose, spray gun and separatng ol. Screw the hgh-pressure hose () to the coatng materal outlet (Fg., Item ).. Screw the spray gun () wth the selected tp onto the hgh-pressure hose.. Tghten the unon nuts at the hgh-pressure hoses frmly so that coatng materal does not leak.. Control Panel Indcators The followng s a descrpton of the control panel ndcators. Servce Indcator Pressure Indcator. Remove the ol cup cap wth a straght-slot screwdrver. 5. Fll the ol cup wth Pston Lube (Fg. 5) untl the ol gauge () s showng that t s full. Attenton Pston Lube prevents ncreased wear and tear to the packngs. 6. Replace ol cup cap. 7. Press ol button -5 tmes to prme the oler. Press once for every eght hours of usage to lubrcate the flud secton. Pressure Indcator The pressure ndcator shows the current operatng pressure of the sprayer. It has three dfferent ndcatons: blnkng yellow, sold yellow, and sold green. Blnkng Yellow When the pressure ndcator s blnkng yellow, the sprayer s operatng between 0 and. MPa ( bar). A blnkng yellow pressure ndcator means: The sprayer s plugged n and turned ON The sprayer s at prmng pressure (lttle or no pressure) It s safe to move the relef valve between postons It s safe to change or replace the spray tp If the pressure ndcator begns blnkng yellow when the pressure control knob s set at a hgher pressure and the relef valve s n the SPRAY poston, ether the spray tp s worn or the sprayer s n need of servce/repar. Sold Yellow When the pressure ndcator s sold yellow, the sprayer s operatng between. MPa ( bar) and MPa (0 bar). A sold yellow pressure ndcator means: The sprayer s at the proper pressure settng for sprayng stan, lacquer, varnsh, and mult-colors Performance Seres 650e 9

10 Startng operaton GB Sold Green When the pressure ndcator s sold green, the sprayer s operatng between MPa (0 bar) and MPa (0 bar). A sold green pressure ndcator means: The sprayer s at the proper pressure settng for sprayng ol-based and latex house pants The sprayer s operatng at peak performance at a hgh pressure settng If the pressure ndcator goes to sold yellow when the pressure s set so that t starts at sold green, t ndcates one of the followng: a. Tp Wear Indcator when sprayng wth latex or at hgh pressure the sold yellow appears. Ths means the tp s worn and needs to be replaced. b. Tp Too Large when a tp that s too large for the sprayer s put n the gun, the pressure ndcator wll turn from sold green to sold yellow. c. Flud Secton Wear f a sold yellow pressure ndcator appears when usng a new tp and the pressure s set at maxmum, servce may be requred (worn packngs, worn pston, stuck valve, etc...). Servce Indcator The Servce ndcator s on when the motor s commanded to run. Ths ndcator s used by servce centers to troubleshoot motor problems.. Pressure control knob settngs (Fg. 7). Mnmum pressure settng. Black zone no pressure generaton. Blue zone pulsatng pressure for cleanng.5 Cleanng preservng agent when startngup of operaton ntally. Immerse the sucton tube (Fg. 8, Item ) and return hose () nto a contaner wth a sutable cleanng agent.. Turn the pressure control knob counterclockwse () to mnmum pressure.. Open the relef valve (), valve poston PRIME (k crculaton).. Swtch the unt (5) ON. 5. Wat untl the cleanng agent exudes from the return hose. 6. Close the relef valve, valve poston SPRAY (p spray). 7. Pull the trgger of the spray gun. 8. Spray the cleanng agent from the unt nto an open collectng contaner. 5. Connecton to the mans network Attenton The unt must be connected to an appropratelygrounded safety outlet. Before connectng the unt to the mans supply, ensure that the lne voltage matches that specfed on the unt s ratng plate. The connecton must be equpped wth a resdual current protectve devce wth INF 0 ma..6 Takng the unt nto operaton wth coatng materal. Immerse the sucton tube (Fg. 8, Item ) and return hose () nto the coatng materal contaner.. Turn the pressure control knob counterclockwse () to mnmum pressure.. Open the relef valve (), valve poston PRIME (k crculaton).. Swtch the unt (5) ON. 5. Wat untl the coatng materal exudes from the return hose. 6. Close the relef valve, valve poston SPRAY (p spray). 7. Trgger the spray gun several tmes and spray nto a collectng contaner untl the coatng materal exts the spray gun wthout nterrupton. 8. Increase the pressure by slowly turnng up the pressure control knob. Check the spray pattern and ncrease the pressure untl the atomzaton s correct. Always turn the pressure control knob to the lowest settng wth good atomzaton. 9. The unt s ready to spray. 0 Performance Seres 650e

11 GB Startng operaton.7 Dgtal Electronc Spray Control (DESC) The Dgtal Electronc Spray Control (DESC) ncreases the functonalty of the sprayer. It s nstalled drectly below the pressure control knob on the control panel. It conssts of a dsplay and four functon keys. The dsplay shows varous menu screens that allow the user to customze and montor sprayer operaton usng the functon keys. The Dsplay Functon Keys SET MPa.0 ACTUAL MPa.5 pressure control knob overrdes the Dgtal Electronc Spray Control (DESC) settngs. Anytme the pressure control knob s turned, the sprayer pressure wll change accordngly. Functon Keys The functon keys are numbered. Each key s labeled wth an addtonal functon as well. #/Menu Key Pressng the # key scrolls through the avalable menu screens or performs a functon descrbed on the actve menu screen. #/g Key Pressng the # key performs a functon descrbed on the actve menu screen or ncreases a value. #/h Key Pressng the # key performs a functon descrbed on the actve menu screen or decrease a value. #/Select Key Pressng the # key selects the actve menu screen or performs a functon descrbed on the actve menu screen. Menu Screens Several menu screens are avalable for the user to customze and montor sprayer operaton. They nclude Man Screen, Volume Pumped, Job Volume, Unt Seral #, Tmers, Job Tmers, Servce Tme, Securty Code, Prme, and Rapd Clean. Man Screen The Man Screen s the default screen SET MPa.0 for the control system at sprayer ACTUAL MPa.5 startup. Pressng the # key swtches between PSI, Bar and MPa unts of measure. Press the # key to scroll through the remanng menu screens. For sprayers equpped wth an nne-language Dgtal Electronc Spray Control (DESC): Pressng the # key at the Man Screen swtches between PSI, Bar and MPa unts of measure. Current Select Screen The Current Select screen allows you to toggle between operatng n 5 Amp or 0 Amp mode. CURRENT SELECT MENU- SELECT- To select the Current Select screen, press the # key. Pressng the # or # allows you to choose the desred mode. When the screen dsplays the desred mode, press the # key to save and return to the remanng menu screens. Volume Pumped Screen The Volume Pumped screen shows the total number of gallons or lters sprayed by the sprayer. To select the Volume Pumped screen, press the # key. Job Volume Screen The Job Volume screen allows the user to reset a lter counter to track usage on specfc jobs. To select the Job Volume screen, press the # key. Unt Seral # Screen The Unt Seral # screen shows the sprayers seral number. To select the Unt Seral # screen, press the # key. VOLUME PUMPED MENU- SELECT- GALLONS MENU- X LITRES- LITRES MENU- X GALLONS- JOB VOLUME MENU- SELECT- GALLONS MENU- XXXX RESET- UNIT SERIAL # MENU- SELECT- SER # XXXXXXXXXX MENU- Tmers Screen The Tmers screen shows the total tme TIMERS the sprayer has been turned on as well MENU- SELECT- as the total tme the sprayer has been runnng (pumpng). To select the Tmers screen, press the ON TIME XXXX RUN TIME XXXX # key. Job Tmers Screen The Job Tmers screen allows the user to reset the ON TIME and RUN TIME to track tme on specfc jobs. To select the Job Tmers screen, press the # key. JOB ON screen wll appear. Press # to reset. Press # to contnue to JOB RUN screen. Press # to reset. Press # to scroll through the remanng menu screens. JOB TIMERS MENU- SELECT- JOB ON MENU- JOB RUN MENU- X RESET- X RESET- Servce Tme Screen The Servce Tme screen allows the user SERVICE TIME to set a servce tme nterval (n hours). MENU- SELECT- Below the set tme, the screens shows the current amount of hours on the sprayer snce the last actvaton of the servce tmer. To select the Servce Tmer screen, press the # key. To set the servce tme, press the # XX (up) and/or the # (down) keys to the RUN HOURS XX desred tme (run hours wll ncrease/decrease n ncrements of 5 for each tme you press a key). When the servce tme nterval s set and met by the run hours, the dsplay wll show a Servce Requred screen. The pump wll reman functonal. To return to the Man Screen, press the # key. Dong so wll reset the and Run Hours dsplayed on the Servce Screen back to 0. Performance Seres 650e

12 Startng operaton Securty Code Screen The Securty Code screen allows the user to set a four dgt securty code SECURITY CODE MENU- CHANGE- to prevent unauthorzed use of the sprayer. If a securty code has been set, the control system dsplay wll ask for the code at startup. If the correct code s entered, the dsplay wll show the Man Screen and the sprayer wll operate. If the wrong code s entered, the dsplay wll contnue to ask for the correct code and the sprayer wll be dsabled. To set or change the securty code, press the # key. If the sprayer s new, no securty code s set and the Man Screen wll appear at startup. When settng a securty code for the frst tme, the Enter Old Code Number screen wll appear, and you wll need to enter. Enter the old securty code number to access the screen that allows the code ENTER OLD CODE NUMBER change. If the wrong code s entered, the dsplay wll contnue to ask for the correct code and the securty code cannot be changed. Enter the new securty code. Once the new code s entered, the dsplay wll automatcally ask that the new code be re-entered for verfcaton. If the same new code s re-entered, the dsplay wll confrm that the new code has been accepted and return to the Man Screen. ENTER NEW CODE NUMBER XXXX RE-ENTER NEW NUMBER XXXX NEW CODE NUMBER ACCEPTED If the new code s re-entered ncorrectly, the dsplay wll return to the Enter New Code Number screen and the process wll repeat. If you forget or msplace your securty code, you can contact Ttancustomer servce for assstance. GB 5. Sprayng technque Sprayng technque Injecton hazard. Do not spray wthout the tp guard n place. NEVER trgger the gun unless the tp s completely turned to ether the spray or the unclog poston. ALWAYS engage the gun trgger lock before removng, replacng or cleanng tp. The key to a good pant job s an even coatng over the entre surface. Keep your arm movng at a constant speed and keep the spray gun at a constant dstance from the surface. The best sprayng dstance s 5 to 0 cm between the spray tp and the surface. 5-0 cm Keep the spray gun at rght angles to the surface. Ths means movng your entre arm back and forth rather than just flexng your wrst. To nactvate the securty functon, enter at the Enter New Code Number screen (ths s the default code that leaves the sprayer unlocked). As a result, the Man Screen wll appear at sprayer startup. Prme Screen The Prme screen appears when the pressure control knob s set at the MIN settng. PRIME Rapd Clean Screen The Rapd Clean screen appears when RAPID CLEAN the pressure control knob s set at the RAPID CLEAN poston and the PRIME/SPRAY valve s n the PRIME poston. If there s no acton at any menu screen for 0 seconds, the dsplay wll go back to the Man Screen. Keep the spray gun perpendcular to the surface, otherwse one end of the pattern wll be thcker than the other. Trgger gun after startng the stroke. Release the trgger before endng the stroke. The spray gun should be movng when the trgger s pulled and released. Overlap each stroke by about 0%. Ths wll ensure an even coatng. 5-0 cm 5-0 cm If very sharp edges result or f there are streaks n the spray jet ncrease the operatng pressure or dlute the coatng materal. Performance Seres 650e

13 Handlng the hgh-pressure hose 6. Handlng the hgh-pressure hose Avod sharp bendng or knkng of the hgh-pressure hose. The smallest bendng radus amounts to about 0 cm. Do not drve over the hgh-pressure hose. Protect aganst sharp objects and edges. Danger of njury through leakng hgh-pressure hose. Replace any damaged hgh-pressure hose mmedately. Never repar defectve hgh-pressure hoses yourself! 6. Hgh-pressure hose The unt s equpped wth a hgh-pressure hose specally suted for pston pumps. Only use WAGNER orgnal-hgh-pressure hoses n order to ensure functonalty, safety and durablty. 7. Interrupton of work. Open the relef valve, valve poston PRIME (k crculaton).. Swtch the unt OFF.. Turn the pressure control knob counterclockwse to mnmum pressure.. Pull the trgger of the spray gun n order to release the pressure from the hgh-pressure hose and spray gun. 5. Secure the spray gun, refer to the operatng manual of the spray gun. 6. If a standard tp s to be cleaned, see Page 9, Secton.. If a non-standard tp s nstalled, proceed accordng to the relevant operatng manual. 7. Dependng on the model, leave the sucton tube or the sucton hose and return hose mmersed n the coatng materal or swvel or mmerse t nto a correspondng cleanng agent. Attenton If fast-dryng or two-component coatng materal s used, ensure that the unt s rnsed wth a sutable cleanng agent wthn the processng tme. GB Cleanng the unt (shuttng down) 8. Cleanng the unt (shuttng down) A clean state s the best method of ensurng operaton wthout problems. After you have fnshed sprayng, clean the unt. Under no crcumstances may any remanng coatng materal dry and harden n the unt. The cleanng agent used for cleanng (only wth an gn ton pont above C) must be sutable for the coatng materal used. Secure the spray gun, refer to the operatng manual of the spray gun. Clean and remove tp. For a standard tp, refer to Page, Secton.. If a non-standard tp s nstalled, proceed accordng to the relevant operatng manual.. Remove sucton hose from the coatng materal.. Close the relef valve, valve poston SPRAY (p spray).. Swtch the unt ON.. Pull the trgger of the spray gun n order to pump the remanng coatng materal from the sucton hose, hghpressure hose and the spray gun nto an open contaner. Attenton The contaner must be earthed n case of coatng materals whch contan solvents. Cauton! Do not pump or spray nto a contaner wth a small openng (bunghole)! Refer to the safety regulatons. 5. Immerse sucton hose wth return hose nto a contaner wth a sutable cleanng agent. 6. Turn the pressure control knob nto the blue zone - pulsatng pressure for unt cleanng. 7. Open the relef valve, valve poston PRIME (k crculaton). 8. Pump a sutable cleanng agent n the crcut for a few mnutes. 9. Close the relef valve, valve poston SPRAY (p spray). 0. Pull the trgger of the spray gun.. Pump the remanng cleanng agent nto an open contaner untl the unt s empty.. Swtch the unt OFF. 8. Cleanng unt from outsde Frst of all pull out mans plug from socket. Attenton Danger of short crcult through panetratng water! Never spray down the unt wth hgh-pressure or hgh-pressure steam cleaners. Wpe down unt externally wth a cloth whch has been mmersed n a sutable cleanng agent. Performance Seres 650e

14 Cleanng the unt (shuttng down) 8. Cleanng the hgh-pressure flter Clean the flter cartrdge regularly. A soled or clogged hgh-pressure flter can cause a poor spray pattern or a clogged tp.. Turn the pressure regulator knob nto the black zone untl t stops (no pressure).. Open the relef valve, valve poston PRIME (k crculaton).. Swtch the unt OFF. GB 5. Make sure all the parts are clean and the handle seal () s n poston nsde the gun head. 6. Thread the handle assembly (5) nto the gun head () untl secure. 7. Snap the trgger guard () back onto the handle assembly (5). Unplug the power plug from the outlet.. Unscrew the flter housng (Fg. 0, Item ). wth a strap wrench. 5. Pull the flter cartrdge () from the bearng sprng (). 6. Clean all the parts wth the correspondng cleanng agent. If necessary, replace the flter cartrdge. 7. Check the O-rng (), replace t f necessary. 8. Place the bearng rng (5) aganst the bearng sprng (). Slde the flter cartrdge () over the bearng sprng. 9. Screw n flter housng () and tghten t as far as possble wth the strap wrench Cleanng the nlet screen The nlet screen wll clog and must be cleaned at least once a day.. Remove the retanng rng () from the foot valve () housng.. Remove the nlet screen () from the foot valve housng ().. Clean thoroughly wth the approprate solvent. 8. Cleanng the Arless spray gun. Rnse Arless spray gun wth an approprate cleanng agent.. Clean tp thoroughly wth approprate cleanng agent so that no coatng materal resdue remans.. Thoroughly clean the outsde of the Arless spray gun. Intake flter n Arless spray gun (fg. ). Pull the bottom of the trgger guard forward () so that t comes loose from the handle assembly (5).. Loosen and remove the handle assembly (5) from the gun head ().. Turnng clockwse, unscrew the flter () from the gun body (). Left-handed threads requre turnng the flter clockwse to remove.. Turnng counterclockwse, screw the new or cleaned flter nto the gun body. Performance Seres 650e

15 9. Remedy n case of faults GB Remedy n case of faults Type of malfuncton A. Unt does not start Possble cause. No voltage appled.. Pressure settng too low.. ON/OFF swtch defectve. Measures for elmnatng the malfuncton. Check voltage supply.. Turn up pressure control knob.. Replace. B. Unt does not draw n materal. Relef valve s set to SPRAY (p spray).. Flter projects over the flud level and sucks ar.. Flter clogged.. Sucton hose/sucton tube s loose,.e. the unt s suckng n outsde ar.. Set relef valve to PRIME (k crculaton).. Refll the coatng materal.. Clean or replace the flter.. Clean connectng ponts. Tghten sucton tube. C. Unt draws n materal, but the pressure does not buld up. Tp heavly worn.. Tp too large.. Pressure settng too low.. Flter clogged. 5. Coatng materal flows through the return hose when the relef valve s n the SPRAY (p spray) poston. 6. Packngs stcky or worn. 7. Valve balls worn. 8. Valve seats worn.. Replace. For selecton of a smaller tp.. Turn pressure control knob clockwse to ncrease.. Clean or replace the flter. 5. Remove and clean or replace relef valve. 6. Remove and clean or replace packngs. 7. Remove and replace valve balls. 8. Remove and replace valve seats. D. Coatng materal exts at the top of the flud secton. Upper packng s worn.. Pston s worn.. Remove and replace packng.. Remove and replace pston. E. Increased pulsaton at the spray gun. Incorrect hgh-pressure hose type.. Tp worn or too large.. Pressure too hgh.. Only use WAGNER orgnal-hgh-pressure hoses n order to ensure functonalty, safety and durablty.. Replace tp.. Turn pressure control knob to a lower number. F. Poor spray pattern. Tp s too large for the coatng materal whch s to be sprayed.. Pressure settng ncorrect.. Volume too low.. Coatng materal vscosty too hgh.. Replace tp.. Turn pressure control knob untl a satsfactory sprayng pattern s acheved.. Clean or replace all flters.. Thn out accordng to the manufacturer s nstructons. G. Unt loses power. Pressure settng too low.. Turn pressure control knob clockwse to ncrease. Dgtal Electronc Spray Control (DESC) Error Messages The followng error message screens appear whenever the Dgtal Electronc Spray Control (DESC) detects a problem wth the sprayer. Once a problem occurs and the error message appears, the sprayer wll shut down. Before proceedng, releve any pressure remanng n the system (valve poston PRIME k). Addtonally, follow all other warnngs to reduce the rsk of an njecton njury, njury from movng parts or electrc shock. Always unplug the sprayer before servcng! Check Transducer Screen The Check Transducer screen appears when the transducer has become dsconnected or s defectve. Take the sprayer to a Ttanauthorzed servce center for repar. Check Motor Screen The Check Motor screen appears when the motor or motor sensor s defectve. Take the sprayer to a Ttanauthorzed servce center for repar. CHECK TRANSDUCER CHECK MOTOR Low Voltage Screen The Low Voltage screen appears when the sprayer shuts down because of low nput voltage. Check the power supply and correct the problem. Restart the sprayer. Hgh Motor Temperature Screen The Hgh Motor Temperature screen appears when the temperature of the motor has rsen too hgh. Take the sprayer to a Ttanauthorzed servce center for repar. LOW VOLTAGE HIGH MOTOR TEMPERATURE Hgh Control Temperature Screen The Hgh Control Temperature screen HIGH CONTROL appears when the temperature of the Dgtal TEMPERATURE Electronc Spray Control (DESC) has rsen too hgh. Take the sprayer to a Ttanauthorzed servce center for repar. Hgh Mechancal Load The Hgh Mechancal Load screen appears when the sprayer shuts down because of hgh current or when the sprayer goes nto current HIGH MECHANICAL LOAD fold back mode. Take the sprayer to a Ttanauthorzed servce center for repar. Performance Seres 650e 5

16 Servcng 0. Servcng 0. General servcng Servcng of the unt should be carred out once annually by the WAGNER servce.. Check hgh-pressure hoses, devce connectng lne and plug for damage.. Check the nlet valve, outlet valve and flter for wear. 0. Hgh-pressure hose Inspect the hgh-pressure hose vsually for any notches or bulges, n partcular at the transton n the fttngs. It must be possble to turn the unon nuts freely.. Repars at the unt Swtch the unt OFF. Before all repar work: Unplug the power plug from the outlet.. Relef valve. Use a drft punch of mm to remove the grooved pn (Fg., Item ) from the relef valve handle ().. Remove the relef valve handle () and cam base ().. Usng a wrench, remove the valve housng ().. Ensure that the seal (5) s seated correctly, then screw the new valve housng () completely nto the flter block (6). Tghten securely wth a wrench. 5. Algn the cam base () wth the hole n the flter block (6). Lubrcate the cam base wth grease and slde on the cam base. 6. Brng the hole n the valve shaft (7) and n the relef valve handle () nto algnment. 7. Insert the grooved pn () to secure the relef valve handle n poston. GB Repars at the unt. Replacng the Motor Assembly. Unplug the unt.. Loosen and remove the two motor shroud screws (Fg, Item ). Remove the motor shroud ().. Loosen and remove the three belly pan screws (). Remove the belly pan ().. Loosen and remove the two motor cover screws (5). Remove the motor cover (6). 5. Dsconnect all wres between the motor (7) and the sprayer. 6. Loosen and remove the four control panel screws (8). Remove the control panel (9). 7. Dsconnect the wres between the motor (7) and the control panel (9). 8. Loosen and remove the two motor controller screws (0). Remove the motor controller (). 9. Loosen and remove the four motor baffle screws (). Remove the motor baffle (). 0. Loosen and remove the three motor mountng screws ().. Pull the motor (7) out of the gearbox housng (5).. Wth the motor removed, nspect the gears n the gearbox housng for damage or excessve wear. Replace the gears, f necessary.. Install the new motor (7) nto the gearbox housng (5).. Secure the motor (7) wth the three motor mountng screws (). 5. Reconnect the wres between the sprayer and the new motor (refer to the Connecton Dagram, secton.7). 6. Place the baffle () over the end of the motor assembly (7). Secure wth the four motor baffle screws (). 7. Place motor controller () back nto place behnd the motor baffle (). Secure wth the two motor controller screws (0). 8. Reconnect all wres between the motor (7) and sprayer. 9. Reconnect the wres between the motor (7) and the control panel (9). 0. Replace control panel (9) and secure wth four control panel screws (8).. Place the motor cover (6) back over the motor controller (). Secure wth the two motor cover screws (5).. Put the belly pan () back n place and secure wth the three belly pan screws ().. Slde the motor shroud () over the motor assembly (7).. Secure the motor shroud () wth the two motor shroud screws () Performance Seres 650e

17 GB Repars at the unt. Replacng the Gears. Follow steps - n Replacng the Motor Assembly (secton.) to remove the motor and control panel.. Inspect the armature gear (Fg. 5, Item ) on the end of the motor for damage or excessve wear. If the gear s completely worn out, replace the motor assembly.. Remove and nspect the st stage gear () and nd stage gear () assembles for damage or excessve wear. Replace, f necessary.. Inspect the front gear box () assembly for damage or excessve wear. If damaged or worn, replace the front gear box assembly. Clean and refll the gear box cavty up to the rear face of each gear wth Lubrplate (P/N -7). 5. Renstall the motor nto the gearbox housng (). 6. Follow steps - n Replacng the Motor Assembly (secton.) to replace the motor and control panel.. Loosen and remove the two motor shroud screws (Fg. 7, Item ). Remove the motor shroud ().. Loosen and remove the two motor cover screws (). Remove the motor cover (). 5. Dsconnect the transducer wre from the motor controller (5). 6. Pull the grommet (6) out of the mountng plate and slde t up the shaft of the transducer (7) untl t s clear of the mountng plate. 7. Usng a wrench, loosen and remove the transducer (7) from the flter housng (8). Carefully thread the transducer wre out through the mountng plate. 8. Slde the grommet (6) off of the old transducer (7) and onto the new transducer. 9. Thread the new transducer wre through the mountng plate and back to the motor controller (5). 0. Thread the new transducer (7) nto the flter housng (8) and tghten securely wth a wrench. Make sure the o-rng on the transducer s n place before threadng the transducer nto the flter housng.. Push the grommet (6) nto the mountng plate.. Connect the transducer wre to the motor controller (refer to the Connecton Dagram, secton.7).. Place the motor cover () back over the motor controller (5). Secure wth the two motor cover screws ().. Slde the motor shroud () over the motor assembly. 5. Secure the motor shroud () wth the two motor shroud screws (). 6. Replace flter assembly to the cart.. Replacng the Transducer. Unplug the unt.. Loosen and remove the two flter assembly bolts (Fg. 6, Item ). Slde the flter assembly from the cart Performance Seres 650e 7

18 Repars at the unt GB.5 Inlet and outlet valve. Remove the four screws n the front cover and then remove the front cover. Danger of crushng - do not reach wth the fngers or tool between the movng parts.. Turn the pressure control knob to mnmum pressure. The Dg-Trac screen should say PRIME.. Press the # key on the Dg-Trac control panel. The CREEP MODE screen wll now appear.. Slowly turn the pressure control knob clockwse to ncrease the pressure. The crankshaft/slder assembly wll begn to move very slowly. 5. When t reaches the bottom, dead-center of ts stroke, turn the pressure control knob back to mnmum pressure. The crankshaft/slder assembly should stop. 6. Unplug the power plug from the outlet. 7. Pull off clamp on sucton tube and remove return hose. 8. Unscrew the connecton hose (Fg. 8, tem ) from the hgh-pressure flter. 9. Turn the knob on the sde of the cart clockwse to unlock the cart. Tlt the cart backwards untl t locks nto place. 0. Loosen and remove the nlet valve housng () from the upper housng.. Remove bearng rng (), O-rng (), O-rng (5), nlet valve seat (6), nlet valve ball (7) and upper ball gude (8).. Clean all the parts wth the correspondng cleanng agent. Check the nlet valve housng (), nlet valve seat (6) and nlet valve ball (7) for wear and replace the parts f necessary. If the worn nlet valve seat (6) s unused on one sde, nstall t the other way around. 5. Clean all the parts wth the correspondng cleanng agent. Check outlet valve housng (9), outlet valve seat (5), outlet valve ball () and upper ball gude () for wear and replace parts f necessary. If the worn outlet valve seat (5) s unused on one sde, nstall t the other way around. 6. Carry out nstallaton n the reverse order. 7. If you plan to replace the flud secton packngs, move on to secton.6. If not, reassemble flud secton n the reverse order of how t was dsassembled Packngs. Remove nlet valve housng n accordance wth the steps n Chapter.5.. It s not necessary to remove the outlet valve.. Pull the lever on the undersde of the sprayer toward the front of the sprayer. Ths wll un-clamp the entre flud secton.. Slde the flud secton forward to remove t from the gear housng. 5. Place the flud secton cylnder uprght n a vse by clampng on the wrench flats (Fg. 0, Item ) Do not over-tghten the vse. Damage to the cylnder may occur. 6. Turn the upper housng () counterclockwse to loosen t from the cylnder (). 7. Slowly pull down the upper housng () just far enough to expose the extenson slder () and the connectng pn (5) that connects the pston rod (6) to the extenson slder (). 8. Push the connectng pn out of the extenson slder and pston rod and remove the pston rod and upper housng. 9. Place the upper housng uprght n a vse by clampng on the wrench flats (7). Do not over-tghten the vse. Damage to the upper housng may occur.. Screw out outlet valve housng (Fg 9, tem 9) from the pston (0) wth /8 nch hexagon socket head wrench.. Remove the upper seal (), upper ball gude (), outlet valve ball (), washer () and outlet valve seatng (5). 0. Usng a wrench, remove the upper seal retaner (Fg. 0, Item 8).. Slde the pston rod (6) out through the bottom of the upper housng ().. Inspect the pston rod (6) for wear and replace f necessary. 8 Performance Seres 650e

19 GB Repars at the unt. Remove the upper support rng (9) and upper packng assembly (0) from the top of the upper housng ().. Remove the adapter () and lower packng assembly () from the bottom of the upper housng. 8. Lubrcate upper packng (0) and lower packng () wth machne grease. 9. Insert upper packng (Fg. ) wth O-rng () and protrudng lp () downward. Be careful not to scratch, score, or otherwse damage the upper housng durng removal of the packngs. 0. Insert upper support rng (9) on top of the upper packng (0). Thread the upper seal retaner (8) nto the upper housng ().. Rotate the upper housng n the vse so that the bottom end s facng up.. Insert the lower packng (Fg. ) partally nto the bottom of the cylnder wth the large beveled edge () facng toward the cylnder (beveled edge wll be facng up when the cylnder s uprght) Push the lower packng assembly (Fg. 0, Item ) nto poston usng the lower packng nserton tool (see Flud Secton Assembly parts lst for lower packng nserton tool P/N). 5 Coat the pston nserton tool (.e. upper packng pre-form tool) and the pston rod wth grease before nsertng them nto the upper housng. 5. Place the pston nserton tool over the top of the pston rod (6). 6. Insert the pston rod (6) nto the bottom of the upper housng (), through the lower packng assembly (), through the upper packng assembly (0), and out through the upper seal retaner (8). Make sure the rased lp on the bottom of the lower packng s fully outsde the packng around the pston rod after nserton of the pston rod Clean the upper housng () and cylnder (-5). Inspect the upper housng and cylnder for damage and replace f necessary. 6. Place the upper housng uprght () n a vse by clampng on the wrench flats (7). 7. Locate the new upper and lower packngs and remove the pre-form tools. Save the upper packng pre-form tool for use as the pston nserton tool later n ths procedure. Do not remove the pre-form tools from the upper and lower packngs untl mmedately before they are nstalled nto the upper housng. 7. Remove the pston nserton tool from the top of the pston rod (6). 8. Lubrcate the threads on the upper housng wth ant-seze compound. Remove the upper housng from the vse. 9. Insert the pston rod nto the extenson slder. When the connectng pn hole on the pston rod lnes up wth the hole n the extenson slder, nsert the connectng pn. 0. Thread the upper housng nto the cylnder, turnng clockwse.. Contnue to turn the upper housng clockwse untl t s flush aganst the cylnder.. Replace the cylnder () back nto the flud secton clamp on the gear housng. Make sure to slde the top of the pston rod extenson nto the T-slot () on the slder assembly ().. Push the lever on the undersde of the unt toward the rear of the sprayer to lock the flud secton back nto place.. Insert the adapter (Fg. 0, tem ) nto the bottom of the upper housng. Performance Seres 650e 9

20 Repars at the unt GB 5. Makng sure that the bearng rng (Fg. 8, tem ) and O-rngs (Fg. 8, tems -5) are lubrcated and n place, reassemble the nlet valve assembly and and thread t nto the upper housng. Tghten the nlet valve housng untl the o-rng engages, then contnue to tghten untl snug. Once snug, tghten an addtonal /8 / turn. 6. Replace the connecton hose to the fttng on the hghpressure flter. 7. Replace the return hose nto the clamp on the sphon tube. 8. Install front cover..7 Performance Seres 650e connecton dagram Swtch Blue / Whte Black / Brown Ground EMI Flter Blue / Whte Black / Brown Power Cord P/N 0505 P/N 0505 Ground Green / Yellow Blue Whte Blue / Whte Black / Brown Brown Black Green / Yellow Ground Green / Yellow Black Fuse block Red Fuse Black Red (+) Black (-) Capactor Motor controller L.E.D. Fan Blue / Whte Surge suppressor P/N Whte Whte Red Black Motor Hall sensor Potentometer Dsplay wre assembly (P/N 050) Pressure sensor 0 Performance Seres 650e