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Operation and Maintenance Manual
High Performance Plunger Type Airless Pump
SUPER BEAR
SP2544/54/78(S)
This manual contains important information on warnings and cautions. Read the manual
thoroughly before starting to operate the equipment, and follow the instructions.
Always keep the manual handy until such time as the equipment is no longer being used.
If your manual is lost or worn badly, do not hesitate to contact our agency which is closest to
you, or the Asahi Sunac Corporation, directly, and ask us to send you a new one.
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Table of Contents
Related Manuals for Asahi Sunac SUPER BEAR SP2544
Summary of Contents for Asahi Sunac SUPER BEAR SP2544
- Page 1 Always keep the manual handy until such time as the equipment is no longer being used. If your manual is lost or worn badly, do not hesitate to contact our agency which is closest to you, or the Asahi Sunac Corporation, directly, and ask us to send you a new one.
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Page 2: Table Of Contents
You can reach us at any of the addresses, phone numbers and fax numbers shown on the back cover. Thank you, Asahi Sunac Corporation For Your Safety ................1 Specifications, Dimensions and System Configurations ... 7 Setting Up for Operation ............8 General Set-up Precautions .......... -
Page 3: For Your Safety
For Your Safety Please carefully read this manual and get acquainted with the equipment. Please observe the operating procedures in the manual. Failure to do so may result in personal injury and/or damage to property. This manual covers only minimum safety precautions, and it does not suggest or imply that no other precautions are required. - Page 4 WARNING Injection Hazard <<General Safety Precautions>> ● This is a high-pressure painting equipment and an extreme care should be exercised to prevent serious personal injury. This pump generates very high pressure to feed paint fluid to the airless spray gun. High-pressure spray or ruptured component pieces from point-blank range can inject fluid or fragments into your body, causing skin injury from which no small amount of toxic substances might enter into the body.
- Page 5 WARNING <<Nozzle Safety Precautions>> ● Don’t put your hand or fingers or anything over the spray nozzle. ● Be extra careful when cleaning or replacing the nozzle. If the nozzle gets clogged while spraying, immediately lock the trigger safety lock and relieve the fluid pressure in accordance with the “Pressure Relief Procedure,”...
- Page 6 WARNING <<Paint / Solvent Compatibility>> Check the compatibility of the paint and solvent with the “material of the pump parts they come into contact with” against the parts material specifications provided by the pump manufacturer -- before you introduce the fluid (paint/solvent) into the pump. <<Hose Safety Precautions>>...
- Page 7 WARNING Fire and Explosion Hazard <<Source of Fire>> As liquid flows through the pump and hose, static electricity is generated. If each component of the painting equipment is not properly grounded, sparks may occur due to static electricity. When there are vaporized solvent, sprayed paint particles, floating dust and other flammables in the atmosphere near the painting equipment, these sparks can cause fire or explosion, possibly causing serious injury to the operator and damage to the equipment.
- Page 8 WARNING □ Grounding Fluid Container When your fluid container is made of conductive metal, you can place it on the grounded floor or table. When it is made of something else, you cannot. □ Grounding Cleaning Solvent Can When the cleaning solvet is made of conductive metal, you can place it on the grounded floor or table.
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Page 9: Specifications, Dimensions And System Configurations
Specifications, Dimensions and System Configurations ● Dimensions ● Specifications Model SP2578 SP2554 SP2544 Name SUPER BEAR Fluid flow 1:20 1:45 1:65 8L/min 6L/min 4L/min Maximum fluid working pressure (Max. 30 L/min) (Max. 20 L/min) (Max. 14 L/min) Dimensions 720L x 600W x 1280H (mm) Weight 115 kg 108 kg... -
Page 10: Setting Up For Operation
If your problems still exist after you did all this, don’t try to do anything further but immediately contact our agency near you or Asahi Sunac directly, giving us details about the problems. Please rest assured; we’ll take care of them. -
Page 11: Unpacking And Connections
If you find anything wrong, please get in touch with our agency near you or us directly at Asahi Sunac. (1) Upon unpacking you’ll find that the equipment, high-pressure hose, and spray gun are not assembled yet. -
Page 12: Operation
Operation ① Operation ▲ Flushing the equipment before first use Flush the equipment before first use. Check the fluid passage for leak at the same time. If there is any leak, retighten using two (2) special spanner, putting one on the joint, the other on the base. Remove foreign materials, as well. -
Page 13: Shutdown And Equipment Care
(8) Put the nozzle on the spray gun. WARNING Ensure that spray gun’s trigger is locked. If you fail to do so, trigger could be pulled accidentally, resulting in personal injury. (9) Check to see that there is no leak from the painting equipment or the joint between the painting equipment and hose. -
Page 14: Color Change And Additive Addition Precautions
Follow the procedure described below to relief pressure. <<Pressure Relief Procedure>> ① Lock the trigger. ② Shut off air supply by turning the pressure control dial counter-clockwise, bringing down the pressure all the way. ③ Relive the ball cock, bring down the system pressure to zero. Unlock the trigger and pull it for double-checking. -
Page 15: Maintenance
Maintenance Equipment Maintenance Guidelines (1) When the pump V-packing is worn, replace. (Rule of thumb: Replace every six months under normal operation condition.) (2) When paint is solidified and accumulated in the pump, take it apart and clean. WARNING Before you take parts apart, always drain all paint fluid in the system and completely relieve the pump operating pressure and wrap air pressure down to zero. -
Page 16: Tear Down Inspection And Parts Replacement Procedure
Tear Down Inspection and Parts Replacement Procedure WARNING Before you take parts apart, always drain all paint fluid in the system and completely relieve the pump operating pressure and wrap air pressure down to zero. ① Air Motor ※ For the index number in parentheses ( ), see page 22. When you apply grease to the cylinder interior or replace perishable parts, follow the procedure shown below. - Page 17 ② Material Cylinder ※ For the index number in parentheses ( ), see page 24. Shown below are the replacement procedures for the booster V-packing (23) at the upper end of the piston and the suction V-packing (23) at the lower end of the piston. Suction V-packing Replacement Procedure ①...
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Page 18: Troubleshooting
Troubleshooting ※ For part index numbers, see page 21. Symptom Cause Remedy ① Air regulator not opened. ① Fully open. 1. No fluid pressure ② Defective pressure gauge (Contrary to ② Replace it with a new one. the meter reading, fluid pressure builds up normally.) ③... - Page 19 Symptom Cause Remedy ① ① through ③ per 3 above, apply ① Check ① through ③ per 3 above 4. Fluttering spray and tails ② Fluid viscosity too high ② Adjust viscosity to proper level ③ Clogged or contaminated nozzle ③...
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Page 20: Performance Tips
Performance Tips (1) Always pay attention to pressure Don’t raise output pressure more than required. Always lock the trigger of your gun – each time you stop spraying for a break or interruption. When you found leak from joint, Bring the pressure down, Drain the fluid, Locate the point of leakage,... -
Page 21: Exploded Diagram And Names Of Parts
Exploded Diagram and Names of Parts ● Appearance Duster gun (Option) Gun filter Air regulator Nozzle Spray gun Safety valve High-pressure fluid hose Cart Material filter Accumulator hose (Option) Suction filter By-pass flushing line Suction hose... - Page 22 SP2544 SP2554 SP2578 40381-3 40342 40342-1 SP2544S SP2578S SP2554S 40382-3 40379-7 40379-8 Air motor Material cylinder Material filter SP2578 only Ball cock...
- Page 23 Airless Pump SP2544 (40381-3), SP2554 (40342), SP2578 (40342-1) Part No. Part Name Remarks Part No. Part Name Remarks 4108-001 Stay 305-0012 Pressure gauge 15-12000 Hex. nut 310-0006 Safety valve 41-52000 Spring washer 3208-015 Nipple 242-1010 Barrel nipple 544-1006 Air hose 5607 Suction hose 295-2404...
- Page 24 Air motor 0109-3...
- Page 25 Air motor AM2512 (0109-3) Part No. Part Name Remarks Part No. Part Name Remarks 0109-001 Cylinder 0109-030 Ring 0109-002A Stand 0109-031 Washer 0109-003 Piston 0109-032 0109-004A 0109-199 Stopper 0109-005 Piston rod 0109-334 Nameplate 0109-006 Bushing 101-60125 O-ring 0109-007 Bushing 101-6040 O-ring ※...
- Page 26 Material cylinder SP2544<0295-8>・SP2554<0288>・SP2578<0296-5> Material cylinder (SUS) SP2544S<0285-3>・SP2554S<0275-5>・SP2578S<0276-1>...
- Page 27 Material cylinder (1:65, 1:45, 1:20) SP2544<0295-8>, SP2554<0288>, SP2578<0296-5> The part number on the top is for a 1:65 ratio The part number in the middle is for a 1:45 ratio The part number at the bottom is for a 1:20 ratio Part No.
- Page 28 Suction filter Option Suction filter SF1408 (0502-1) (Option) Part No. Part Name Remarks Part No. Part Name Remarks 0502-101 Filter body 0502-003-04 Screen 1set 40 mesh ※ 0502-002 Snap Items marked with ※ are the parts we recommend you to carry in stock. Suction filter SF1408S (0522) (Option) SUS specification Part No.
- Page 29 Ball cock HPC3T<0901> Ball cock HPC3TS<0911> Ball cock HPC3T (0901) Part No. Part Name Remarks Part No. Part Name Remarks 0901-201 Body 03-50422 Hex. socket bolt 0901-002 Seat housing 146-2001 Gasket ※ 0901-003 Valve ball 145-2001 Ball seat ※ ※ 0901-104 Handle shaft 101-6010...
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Page 30: Maintenance Log
Date of service Portion worked on Description Results Who serviced In-house / Agency / Asahi Sunac In-house / Agency / Asahi Sunac In-house / Agency / Asahi Sunac In-house / Agency / Asahi Sunac In-house / Agency / Asahi Sunac... -
Page 31: Warranty
Warranty ASAHI SUNAC CORPORATION (the “Company”) shall provide the original purchaser (the “Purchaser”) with warranty service for a period of one (1) year from the date of purchase of the product, as follows: Should you find defects in design or workmanship with regard to parts, ship them back to the Company, with freight prepaid. - Page 32 In the rare eventuality of this equipment being used outside Japan, compliance with the safety standards of the relevant countries is of course mandatory. 16th Edition: March 13, 2016 Leading Manufacturer of Coating FA Systems ASAHI SUNAC CORPORATION Head office & Factory: 5050 Asahimae-cho, Owariasahi, Aichi 488-8688 Japan TEL 81-561-52-0717 FAX 81-561-54-8847 e-mail: ctrd01@sunac.co.jp...
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