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Translation of the original Operating manual Cobra 40-10 Cobra 40-25 Edition 01/ 2012 High pressure Double diaphragm pump B_02999 II 2G IIB c X...
Safety instructions for the operator 2.1.1 Electrical equipment 2.1.2 Personnel qualifi cations 2.1.3 A safe work environment Safety instructions for personnel 2.2.1 Safe handling of WAGNER spray units 2.2.2 Earth the unit 2.2.3 Material hoses 2.2.4 Cleaning 2.2.5 Handling hazardous liquids, varnishes and paints 2.2.6...
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Relief valve 8.13 Cobra 40-10 Base frame assy 8.14 Cobra 40-25 Base frame assy. 8.15 Trolley 8.16 Cobra 40-10 and 40-25 Suction system 8.17 Upper hopper assy. 8.18 Cobra 40-10 High pressure fi lter 8.19 Cobra 40-25 High pressure fi lter...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 322850 322851 322852 322853 322854 322855 322857 322856 322858 2327863 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences.
PART NUMBER DOC322851 EDITION 01/2012 OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS 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.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 2.2.4 CLEANING De-energize the unit electrically. Disconnect the pneumatic supply line. Relieve the pressure from the unit. Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL USE IN AN EXPLOSION HAZARD AREA 2.4.1 CORRECT USE 2.4.2 EXPLOSION PROTECTION IDENTIFICATION As defined in the Directive 94/9/EC (ATEX 95), the unit is suitable for use in areas where there is an explosion hazard. II 2G IIB c X Communautés Européennes Symbol for explosion protection...
fitted , operated and maintained. If other makes of accessory and spare parts are used, the manufacturer‘s liability could be fully or partially null and void. The usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed. GUARANTEE CLAIM...
TRBS 2153 Marking: II 2G IIB c X CE Certificate of Conformity The certificate is enclosed with this product. The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number : 2302350...
USING IN ACCORDANCE WITH THE INSTRUCTIONS The pneumatic piston pump is suitable for process liquid materials according chapter 4.1.2. 4.1.2 SUITABLE SPRAY MATERIALS Application Cobra 40-10 Cobra 40-25 ➚ ➚ Water based lacquers and paints ➚ ➚ Solvent based lacquers and paints ➚...
322040 Diaphragm pump Cobra 40-10 consisting of: Material pump, air motor, connection elements 322102 Diaphragm pump Cobra 40-10 on frame consisting of: Material pump, air motor, connection elements 2308721 Diaphragm pump Cobra 40-25 consisting of: Material pump, air motor, connection elements...
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Cobra. PART NUMBER DOC322851 EDITION 01/2012 OPERATING MANUAL Description Units Cobra 40-10 Cobra 40-25 Ø air inlet connection (female) Zoll G 1/2 G 1/2 inch Min. Ø compressed air hose inch 0.51 0.75 Air consumption at 0.6 MPa; 6 bar; 87 psi per DS Sound pressure level at maxi.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 4.3.4 VOLUME FLOW Wagner Airless nozzle Volume fl ow in l/ min.* 7 MPa 10 MPa 15 MPa 70 bar 100 bar 150 bar ø inch ø mm Spray angle 1015 psi...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL FUNCTIONS 4.4.1 PUMP Cobra 40-10 Control housing with integrated silencer Air regulator Ball valve Air motor Compressed air connection Mounting fl ange Return valve Material outlet B_01204 Material pump Material inlet Cobra 40-25...
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL WARNING Overpressure! Risk of injury from bursting components Never change the safety valve setting. SIHI_0026_GB Material pump (9) The material pump has been designed as a double diaphragm pump with exchangeable inlet valves and outlet valves. Change between spraying mode and circulation mode with the return valve (7).
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 4.4.2 PRESSURE REGULATOR UNIT COBRA 40-10 1 Air pressure regulator 2 Ball valve 3 Pressure gauge 4 Compressed air connection 5 Filter pressure regulator AirCoat (Option) The AirCoat regulator (5) must mounted in all mounting variants of diaphragm pump in vertical position.
HIGH PRESSURE FILTER (OPTION) To ensure problem free operation it is recommended that a WAGNER high-pressure fi lter is used. These have been de- veloped especially for the respective pumps. The fi lter inserts can be exchanged depending on the ma- terial to be used.
Cobra. PART NUMBER DOC322851 EDITION 01/2012 OPERATING MANUAL STARTING UP AND OPERATION SET UP AND CONNECT 5.1.1 SET UP 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 spraypack.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 5.1.2 EARTHING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks Clean the piston pump only with a damp cloth. SIHI_0041_GB WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning Insufficient paint application quality Earth all unit components.
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Cobra. PART NUMBER DOC322851 EDITION 01/2012 OPERATING MANUAL Cable cross sections Pump 4 mm²; AWG11 Paint container 6 mm²; AWG10 Conveyor 16 mm²; AWG5 Spraying booth 16 mm²; AWG5 Spraying stand 16 mm²; AWG5 Procedure: 1. Screw on earthing cable with eye. 2.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL STARTING UP 5.2.1 SAFETY NOTES Every time before starting up the following points should be observed as laid down in the operating instructions: - That it is possible to observe the safety regulations in chap. 2. - The starting up procedure, has been carried out properly.
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- The pressure should be released from the pump and high-pressure hose with gun. - The gun should be secured with safety catch. - The air supply should be interrupted. Emergency off Cobra 40-10 In the case of unforeseen occurrences the ball valve (1) should be closed immediately and the return valve (2) opened.
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Cobra. PART NUMBER DOC322851 EDITION 01/2012 OPERATING MANUAL Emergency off Cobra 40-25 In the case of unforeseen occurrences the ball valve (1) should be closed immediately, relieve the pressure in the pneumatic motor over the safety valve (2) and the return valve (3) opened. ➁...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 5.2.2 BASIC CLEANING 1. Place empty container (5) under return tube (4). 2. Place suction hose (7) in a container with solvent (6). 3. Set pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.25 psi 4.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 5.2.3 FILLING WITH WORKING MATERIAL Ball valve closed 1. Place suction hose (7) with return tube (4) in the container with working material (6). 2. Set pressure regulator (1) to approx. 0.05 MPa; 0.5 bar;...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 5.3.3 SHUTTING DOWN AND CLEANING Note The device should be cleaned for maintenance purposes, etc. Ensure that no remaining material dries and sticks. Procedure: 1. Working break -> carry out Paragraph 5.3.2. 2.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL TROUBLESHOOTING AND MAINTENANCE ELIMINATING FAULTS Problem Cause Remedy The pump does not work Air motor does not work or stops Open and close ball valve on the pressure regulator unit or disconnect compressed air supply shortly No pressure indication (pressure Disconnect compressed air...
2. Every shut down should be carried out as laid down in paragraph 5.3.3 ! 3. Check and replace if necessary hoses, tubes, couplings every days. WAGNER recommends to check the whole spray system every year from a technical expert (e.g. WAGNER service technician).
4. Mount threaded plug (5) and tighten it with 3-4 Nm; 2.7-3 lbft. B_01224 CAUTION Using of hydraulic oil Malfunction by using of wrong hydraulic oil Take only original hydraulic oil - Wagner Order No. 322912 (250 ml; 15 cu inch) SIHI_0072_GB...
Necessary accessories: Order number 322911 kit oil fi lling. CAUTION Using of hydraulic oil Malfunction by using of wrong hydraulic oil Take only original hydraulic oil - Wagner Order No. 322912 (250 ml; 15 cu inch) SIHI_0072_GB Discharge oil Procedure 1.
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL CAUTION Environmental pollution by waste oil! Waste oil in the duct system or buried in the soil leads to heavy environmental damage Groundwater contamination is punishable Collect waste oil and return it at punblic collecting point . Waste oil is taken back with the purchase of hydraulic oil by the salesman .
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL Bleeding Procedure 1. Place the pump on the head and unscrew threaded plug (5). 2. Slowly start up the pump and check the oil suction nipple until no more air-bubbles withdraw. 3. The oil level A in the oil reservoir has to be within the specifi ed limit values. 4.
Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.
Cobra. PART NUMBER DOC322851 EDITION 01/2012 OPERATING MANUAL COBRA 40-10 - OVERVIEW MODULES Pos Qty Part No. Description Air motor 3/53 Pump preassembled 322436 Shuttering air motor 322437 Shuttering Pressure stage 322235 Cap 4 with air-outlet 9907224 Hexagon socket head cap screw...
Cobra. PART NUMBER DOC322851 EDITION 01/2012 OPERATING MANUAL COBRA 40-10 MATERIAL PUMP 29 59 30 31 B_01228 Note: The assembly of the piston rod (25) may be accomplished only with screwed on assembly arbor (108). Grease all the o-rings and seal slightly using grease (111) before mounting them.
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL Cobra Material pump 40-10 Part No. Description ◆ ★ 9974184 O-ring 322411 Valve fi tting 341336 Clasp ◆ ★ 322914 Set Inlet valve assy. (consisting of 2 valves) see chapt. 8.10 322413 Connection piece 322410 Material pump...
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL Cobra Material pump 40-10 Part No. Description 322426 Piston air motor 3 ◆ 9974115 O-ring ◆ 9974185 Sealing-wiper ring profi le EM 322425 Flange air motor 367258 Earthing assy. ◆ 369290 Pilot valve 9998675 Threaded plug 9998780 Compression spring 322407...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL COBRA 40-25 - OVERVIEW MODULES Part No. Description Air motor Cobra 40-25 Cobra 40-25 preassembled 9920106 Washer 322235 Cap 4 with air-outlet 2308693 Cheese head screw with hexagon 9900107 Hexagon screw without shaft 367807 Warning plate 377887...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL COBRA 40-25 MATERIAL PUMP 40 Nm; 29.5 lbft Note: The assembly of the piston rod (25) may be accomplished only with screwed on assembly arbor (109). Grease all the o-rings and seal slightly B_02941 using grease (111) before mounting them.
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL Cobra Material pump 40-25 Part No. Description 2306164 Valve fi tting 341336 Clasp ◆ ★ 2308753 Set Inlet valve assy. (consisting of 2 valves) see chapt. 8.9 322413 Connection piece 2306165 Material pump 2308868 Flange connection 2308886...
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL Cobra Material pump 40-25 Part No. Description ◆ 2306204 Piston sealing profi le Z5 2306205 Piston air motor 4 ◆ 9974084 O-ring 9920107 Washer ◆ 9974090 Sealing-wiper ring profi le EM 2306202 Flange air motor 367258 Earthing assy.
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 8.10 COBRA 40-10 INLET VALVE Part No. Description 322914 Set inlet valves assy. Cobra 40-10 9912100 Hexagon nut with clamp 344334 Spring guide 190304 Compression spring 158333 Guide 341331 Sealing ring 344322...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 8.16 COBRA 40-10 AND 40-25 SUCTION SYSTEM Pos K Part No. Description 2311832 Suction system assy. 2311833 Return pipe 2311834 Suction fi lter B_03114 8.17 UPPER HOPPER ASSY. Pos K Qty Part No. Description 341267 Upper hopper set Ex, 5 L;...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 8.18 COBRA 40-10 HIGH PRESSURE FILTER Pos K Part No. Description 322053 High pressure fi lter 3/8” (no ball valve) 367911 Filter housing 367912 Union nut 367555 Double connector NPSM1/4”-G3/8” ◆ 367914...
Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL 8.19 COBRA 40-25 HIGH PRESSURE FILTER 90 Nm; 66 lbft Identifi cation of the fi lter 12, 13 90 Nm; 66 lbft B_03107...
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Cobra. EDITION 01/2012 PART NUMBER DOC322851 OPERATING MANUAL Pos K Part No. Description 2311185 High pressure fi lter set HPF-3 3/8“ NPS 367911 Filter housing 367912 Union nut 367556 Double fi tting DF MM G3/8“-3/8“ NPS PN530-SSt ◆ 367914 O-ring 367910 Distribution housing 9894245 Filter support ◆...
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DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 70 200 245 Telefax: +32 (0)2 269 7845 Telefax: +45 86 856 027 E-Mail: info@wsb-wagner.be / HP www.wsb-wagner.eu E-Mail info@wagner-industri.com United Kingdom France WAGNER Spraytech (UK) Ltd. J. WAGNER France S.A.R.L.
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