Anest Iwata ALS 333 C Instruction And Maintenance Manual Download Page 3

Page: 3 / 48

USE OF THE MANUAL ............................................................................................................................. 4

SYMBOLS USED ...................................................................................................................................... 4

INFORMATIVE LETTER ............................................................................................................................ 5

WARRANTY ............................................................................................................................................ 7

TRANSPORT AND HANDLING ....................................................................................................... 8

1.1 TRANSPORT ................................................................................................................................... 8

1.2 TRANSPORT WITH CARDBOARD PACKING ................................................................................ 8

1.3 HANDLING ...................................................................................................................................... 9

1.4 TEMPORARY STORAGE ................................................................................................................ 9

PRODUCT IDENTIFICATION ........................................................................................................ 10

2.1 PLATE DATA ................................................................................................................................. 10

2.2 THE DIFFERENT MODELS ........................................................................................................... 10

2.3 TECHNICAL SPECIFICATIONS .................................................................................................... 11

2.4 SAFETY SYSTEMS ....................................................................................................................... 15

2.5 WORKABLE PRODUCTS .............................................................................................................. 16

3. OPERATION .................................................................................................................................. 17

3.1 OPERATION DESCRIPTION ......................................................................................................... 17

INSTALLATION AND STARTING-UP ............................................................................................ 18

4.1 CHECK ON THE PURCHASED PRODUCT .................................................................................. 18

4.2 CONDITIONS FOR INSTALLATION .............................................................................................. 18

4.3 INSTALLATION ............................................................................................................................. 18

4.4 CAUTIONS .................................................................................................................................... 19

5. USE .......................................................................................................................................... 20

5.1 USE .......................................................................................................................................... 20

5.2 SAFETY RULES DURING USE ..................................................................................................... 20

5.3 CLOTHES ...................................................................................................................................... 20

5.4 UPPER GASKETS PREWASH AND ADJUSTMENT ..................................................................... 21

5.5 STARTING-UP .............................................................................................................................. 21

5.6 DAILY INTERRUPTIONS ............................................................................................................... 22

5.7 WRONG AND DANGEROUS USES .............................................................................................. 23

5.8 PRESSURE RELEASE PROCESS ................................................................................................ 24

MAINTENANCE AND INSPECTION .............................................................................................. 25

6.1 GENERAL NOTES ......................................................................................................................... 25

6.2 SAFETY RULES DURING MAINTENANCE ................................................................................... 25

6.3 RECOMMENDED SCHEDULED OPERATIONS ........................................................................... 25

6.4 DISASSEMBLY AND RE-ASSEMBLY PROCEDURE ................................................................... 26

6.5 MOTOR GROUP DISASSEMBLY ................................................................................................. 26

6.6 MOTOR GROUP MAINTENANCE ................................................................................................. 26

6.7 MOTOR GROUP RE-ASSEMBLY ................................................................................................. 27

6.8 PNEUMATIC MOTOR DISASSEMBLY FROM THE PUMP ROD .................................................. 27

6.9 PUMP ROD DISASSEMBLY ......................................................................................................... 28

6.10 PUMP ROD MAINTENANCE ........................................................................................................ 28

6.11 PUMP ROD RE-ASSEMBLY ......................................................................................................... 29

6.12 MOTOR GROUP RE-ASSEMBLY TO THE PUMP ROD ............................................................... 29

6.13 TESTS TO BE CARRIED OUT AFTER RE-ASSEMBLY ................................................................ 29

6.14 PAINT FILTER MAINTENANCE ..................................................................................................... 29

7. TROUBLESHOOTING ................................................................................................................... 30

EXPLODED VIEWS WITH SPARE PART LISTS ............................................................................ 32

8.1 AIRLESS UNIT ALS 333 C ............................................................................................................ 32

8.2 AIRLESS UNIT ALS 433 C ............................................................................................................ 34

8.3 AIRLESS UNIT ALS 433 TX .......................................................................................................... 36

8.4 AIRLESS UNIT ALS 453 C ............................................................................................................ 38

8.5 AIRLESS UNIT ALS 423 TX .......................................................................................................... 40

9. ACCESSORIES ............................................................................................................................. 42

9.1 / 9.2 / 9.3 / 9.4 - ALS ACCESSORIES ............................................................................................. 43

9.5 DELIVERY FILTER TF-8 ................................................................................................................ 44

9.6 DELIVERY FILTER TF-8N ............................................................................................................. 44

9.7 DELIVERY FILTER TF 9 ................................................................................................................ 45

9.8 / 9.9 AIR REGULATION UNITS ......................................................................................................... 46

9.10 DIP TUBE WITH FILTER ............................................................................................................... 47

10. DISMANTLING .............................................................................................................................. 57

CONTENTS

Summary of Contents for ALS 333 C

Page 1: ...el II 2 GX Suitable for use in Zones 1 and 2 X marking Any static electricity discharge from the pump is to be diverted to the ground through the grounding wire which is included in this product Instruction Use and Maintenance Manual ME0004ENRev 15 ALS 423 TX ALS 333 C ALS 433 C ALS 433 TX ALS 453 C ...

Page 2: ...bers use their knowledge and skills to provide their customers with an excellent service to satisfy them with high quality and reliability and with continuous innovation Our activities as those of many other companies are in compliance with several European Directives Safety and Environment and International Standards ISO Quality and Environment As to SAFETY the standards our products refer to are...

Page 3: ...D INSPECTION 25 6 1 GENERAL NOTES 25 6 2 SAFETY RULES DURING MAINTENANCE 25 6 3 RECOMMENDED SCHEDULED OPERATIONS 25 6 4 DISASSEMBLY AND RE ASSEMBLY PROCEDURE 26 6 5 MOTOR GROUP DISASSEMBLY 26 6 6 MOTOR GROUP MAINTENANCE 26 6 7 MOTOR GROUP RE ASSEMBLY 27 6 8 PNEUMATIC MOTOR DISASSEMBLY FROM THE PUMP ROD 27 6 9 PUMP ROD DISASSEMBLY 28 6 10 PUMP ROD MAINTENANCE 28 6 11 PUMP ROD RE ASSEMBLY 29 6 12 MO...

Page 4: ...ation SECTION 4 Equipment installation SECTION 5 Ordinary and extraordinary maintenance ENCLOSURES Exploded view and list of components Symbols used The operations which can be dangerous if they are not carried out correctly are indicated with the symbol The prescriptions given by these symbols refer exclusively to the equipment in compliance with Directive ATEX 94 9 EC The operations described by...

Page 5: ...pdating this manual immediately COMPLIANCE WITH THE STANDARD All the units are conceived in compliance with the applicable Essential Safety Requirements of the Machinery Directive 98 37 EC The units are also designed and manufactured in compliance with the Essential Safety Requirements ESR of Annex II of Directive ATEX 94 9 EC and they comply with the following classification Equipment group II Ca...

Page 6: ...GINAL CONFIGURATION OF THE EQUIPMENT MUST NOT BE CHANGED AT ALL On receiving the equipment check that The supply corresponds to the order specifications In case of non compliance inform immediately our Technical Services CUSTOMER SERVICE ANEST IWATA EUROPE s r l C so Vigevano 46 10155 Torino Telephone 39 011 24 80 868 Telefax 39 011 85 19 44 E mail info anest iwataeu com ...

Page 7: ...covers no repair operations carried out by the customer or by a third party either THE WARRANTY DOES NOT COVER Damage or breakdown caused by improper use or assembly Damage or breakdown caused by the use of spare parts that are different from the original or recommended ones Damage or breakdown caused by a bad preservation Components subject to wear described in the spare part list WARRANTY FORFEI...

Page 8: ... IS ADVISABLE THAT THE STAFF IN CHARGE OF HANDLING THE EQUIPMENT WEAR PROTEC TIVE GLOVES AND SAFETY SHOES WARNING WHILE LIFTING OR HANDLING THE EQUIPMENT OR ANY OF ITS COMPONENTS CLEAR THE WORKING AREA LEAVE ALSO A SUFFICIENT SAFETY AREA AROUND THE EQUIPMENT TO AVOID DAMAGING PEOPLE OR OBJECTS WHICH COULD BE THERE 1 2 Transport with cardboard packaging The equipment is put inside a cardboard packa...

Page 9: ...OLLOW THE INSTRUCTIONS ON THE PACKAGING BEFORE HANDLING AND OPENING IT HANDLING BY MEANS OF HANDLE HANDLING BY MEANS OF TROLLEY 1 4 Temporary storage During transport and storage make sure the temperatures between 0 and 40 C are not exceeded In case of storage make sure the equipment is not put in places with an excessive humidity ...

Page 10: ... Pump type PP 4301 C on trolley with air adjustment suction pipe delivery and suction paint filter fluid recirculation ALS 453 C ALS 453 C AIRLESS UNIT Pump type PP 4531 C on trolley with air adjustment suction pipe delivery and suction paint filter fluid recirculation MODELS FOR WATER BASED PAINT ALS 433 TX ALS 433 TX AIRLESS UNIT Pump type PP 4301 CNE on trolley with air adjustment suction pipe ...

Page 11: ...suction filter 50 Mesh Max air working pressure 6 8 bar Compression ratio 25 1 Max fluid delivery 2 5 l min Delivery cycle 26 ml cycle Max No of cycles per minute 90 cycles min Cycle stroke 58 mm Compressor required power di 0 75 Kw Working temperature 5 40 C Noise level 84 1 dB A This noise level has been measured in compliance with Machinery Directive 89 392 and with ISO 3744 standards ...

Page 12: ...0 Mesh Max air working pressure 6 8 bar 6 8 bar Compression ratio 30 1 30 1 Max fluid delivery 5 0 l min 5 0 l min Delivery cycle 59 ml cycle 59 ml cycle Max No of cycle per minute 80 cycles min 80 cycles min Cycle stroke 93 mm 93 mm Compressor required power di 1 5 Kw di 1 5 Kw Working temperature 5 40 C 5 40 C Noise level 78 1 dB A 78 1 dB A This noise level has been measured in compliance with ...

Page 13: ... 50 Mesh Max air working pressure 6 8 bar Compression ratio 53 1 Max fluid delivery 2 8 l min Delivery cycle 35 ml cycle Max No of cycles per minute 80 cycles min Cycle stroke 93 mm Compressor required power di 1 5 Kw Working temperature 5 40 C Noise level 78 6 dB A This noise level has been measured in compliance with Machinery Directive 89 392 and with ISO 3744 standards ...

Page 14: ...er 30 Mesh Max air working pressure 6 8 bar Compression ratio 23 1 Max fluid delivery 8 0 l min Delivery cycle 80 ml cycle Max No of cycles per minute 100 cycles min Cycle stroke 93 mm Compressor required power di 1 5 Kw Working temperature 5 40 C Noise Level 78 1 dB A This noise level has been measured in compliance with Machinery Directive 89 392 and with ISO 3744 standards ...

Page 15: ...her necessary environmental safety measures must be adopted such as the elimination of gas or residual dusts etc SAFETY VALVE A 8 bar calibrated safety valve is installed to ensure the pump working pressure does not exceed the limits inside the feeding circuit If the calibration pressure is exceeded the valve opens by releasing the excess of air WARNING DO NOT REMOVE THE VALVE PLASTIC PROTECTION A...

Page 16: ...nts with a maximum viscosity of 85 sec Ford 4 100 sec NK 2 Models ALS 423 TX and ALS 433 TX are intended for high viscosity thixotropic water based paints To use the equipment with special products ask for the approval of the manufacturer Moreover the technical features of the unit must be adapted for processing such products ANEST IWATA is not liable for any accident due to UNAUTHORISED and non q...

Page 17: ...askets can be adjusted The motor straight and alternate movement produces an equivalent movement in the pumping unit A system of valves allows the simultaneous suction and pressurisation of the product to be spra yed in the two chambers of the suction body therefore guaranteeing the utmost uniformity during the application 17 3 OPERATION MOTOR PUMP Air cylinder Change over valve Pneumatic piston A...

Page 18: ...uction devi ce Do not use the unit if the suction device is off WARNING IF PAINTING IS CARRIED OUT OUTSIDE THE SPRAY BOOTH ALWAYS OPERATE IN A PLACE WITH A RIGHT VENTILATION TO AVOID CONCENTRATING INFLAMMABLE VAPOURS COMING FROM SOLVENTS OR PAINTS 4 3 Installation Place the equipment on the floor on a horizontal surface Secure it firmly to the ground by means of the trolley fastening bracket pic 2...

Page 19: ... Do not run the pump idle 3 Do not spray paint or solvents towards the pump 4 Do not place the pump close to heat sources or exposed to the sun Locate it in a place shel tered from water sprinkles PAINT OUTLET RECIRCULATION VALVE C UPPER GASKETS ADJUSTING CUP D MATERIAL RECIR CULATION PIPE B TROLLEY FASTENING BRACKET AIR INLET PAINT INLET GROUND CABLE SUCTION PIPE SAFETY SPRING PICTURE 2 ...

Page 20: ...omply with them It is not to be held responsible for any carelessness during the pump use either If the system is used improperly it could be broken by causing serious damage Use the airless unit for professional purposes only Do not change the system use only Anest Iwata original spare parts Check the system daily repair or replace immediately all worn or damaged parts Never exceed the maximum wo...

Page 21: ... bar and let the cleaning liquid flow in the recirculation pipe for a few minutes 9 Close the recirculation valve pos C in pic 2 on page 19 clean the paint pipe and the gun by keeping its trigger pulled 10 Once you are sure the cleaning has been properly carried out lift the dip tube from the vessel containing the cleaning liquid and let the residual liquid flow out of the gun first and then from ...

Page 22: ...gger safety catch c Never exceed the maximum working pressure 6 8 bar d Always use a airless ANEST IWATA gun which is provided with various safety devices e During functioning never touch the moving parts Before carrying out any maintenance opera tion disconnect the air supply and discharge the residual pressure 5 6 Daily interruptions 1 Upon suspending the use of the pump It is not necessary to d...

Page 23: ... soa ked rags or clothes Before starting the system disconnect all the electrical connections inside the working area Before using the system switch off all the naked flames and pilot lights inside the working area Do not smoke inside the working area During painting operations or if there are some vapours in the air do not switch on or off the lights inside the working area Do not use any petrol ...

Page 24: ...Hold the gun tightly and lean it against the metal vessel with the paint Remove the safety catch of the airless gun trigger and gently pull the trigger to release the pressure inside the airless pipe and inside the gun 5 Block the airless gun trigger once more by means of the safety catch 6 If you believe the pressure has not been fully released by following the instructions provided in point 4 lo...

Page 25: ...2 6 2 Safety rules during maintenance The main rules to follow during maintenance interventions on the unit are 1 Disconnect the pneumatic supply before replacing any component 2 Remove safety spring 3 Do not wear rings watches chains bracelets etc during maintenance operations 4 Always use the individual protections gloves safety shoes etc 5 Do not use naked flames points or pins for cleaning 6 D...

Page 26: ...lves adjusting nuts 13 During this ope ration keep the adjusting valves 23 blocked by means of a slotted screwdriver 4 Unscrew the two valves 23 from the change over bar 12 and slip them out 5 Lifting the change over rod 15 it is possible to remove the two pins 8 the change over pivot 9 the change over body 7 the springs 10 and the change over bar 12 6 6 Motor group maintenance Any time the motor ...

Page 27: ... thread brake to prevent subsequent unscrewing 3 After carrying out the operations provided in point 2 of chapter 6 6 check the clearance 2 mm once more 4 Grease all components with lithium based grease caring not to obstruct the air passages 5 Re assemble the cylinder 6 and fasten it with the proper screws 31 6 Lock the change over rod 15 by means of the two nuts 3 as shown in the picture 6 8 Pne...

Page 28: ...d If they show deep scratches in the sliding areas replace them 3 Make sure the upper valve 56 and the lower valve 61 are not damaged especially in the area in touch with the ball If any anomaly is found replace them 4 Whenever the pumping unit is completely disassembled it is advisable to replace the following compo nents 46 UPPER GASKETS SET 54 LOWER GASKETS SET 55 BALL 60 BALL Moreover check th...

Page 29: ...od in the best position it is advisable to tighten the three nuts 49 and the liner 58 completely with the pump running Air pressure 0 5 bar This procedure allows a further reduction of the adjustable gaskets wear 6 13 Tests to be carried out after re assembly 1 The pump must start with a supply pressure equal to at least 1 5 bar 2 Check for possible air and paint spillage If necessary tighten the ...

Page 30: ...n valve b The paint course from the gun the paint flows out regularly but not nozzle to the fluid pipe fitting when pulling the gun trigger is blocked Check for the obstructed point and remove the clogging this inconvenience is usually caused by the obstruction of the gun filter b Clogged nozzle b Remove the nozzle and pull b If the paint flows out it means that the trigger of the gun the nozzle i...

Page 31: ... lower lip seals d Disassemble the liner and check d If it is enough adjust them inside the liner are their wear conditions Otherwise if they are irreparably not tight worn out replace them e Leakage from the paint e Inspect all the paint ducts e If any leakage is found see ducts to its fixing f The recirculation valve is f Close the recirculation valve not closed 5 The spray fan size a Worn out l...

Page 32: ...7 INNER VALVE 18 AIR PISTON 19 SCREW 19 1 SPRING WASHER 20 SILENCER FILTER 21 BAR SEAT 22 REINFORCEMENT PLATE 23 OUTER VALVE 24 MOTOR ROD 25 SPLIT PIN 26 O RING 27 O RING 28 RETAINER 30 BOLT SPRING WASHERS 32 MOTOR BASE 33 PLATE 34 SCREW 35 LID 36 BUSHING 37 RETAINER 38 JOINT 39 ROD 40 ADJUSTMENT CUP 41 BUSHING 42 UPPER FEMALE ADAPTER 43 UPPER SPACER 44 LOWER MALE ADAPTER 45 CONNECTION SHAFT 46 UP...

Page 33: ...33 PUMP TYPE PP1251 C ...

Page 34: ... AIR PISTON 19 SCREW 19 1 SPRING WASHER 20 SILENCER FILTER 21 BAR SEAT 22 REINFORCEMENT PLATE 23 OUTER VALVE 24 MOTOR ROD 25 SPLIT PIN 26 O RING 27 O RING 28 RETAINER 30 BOLT SPRING WASHERS 32 MOTOR BASE 33 PLATE 34 SCREW 35 LID 36 BUSHING 37 RETAINER 38 JOINT 39 ROD 40 ADJUSTMENT CUP 41 BUSHING 42 UPPER FEMALE ADAPTER 43 UPPER SPACER 44 LOWER MALE ADAPTER 45 CONNECTION SHAFT 46 UPPER GASKETS SET ...

Page 35: ...35 PUMP TYPE PP4301C ...

Page 36: ...G 17 INNER VALVE 18 AIR PISTON 19 SCREW 19 1 SPRING WASHER 20 SILENCER FILTER 21 BAR SEAT 22 REINFORCEMENT PLATE 23 OUTER VALVE 24 MOTOR ROD 25 SPLIT PIN 26 O RING 27 O RING 28 RETAINER 30 BOLT SPRING WASHERS 32 MOTOR BASE 33 PLATE 34 SCREW 35 LID 36 BUSHING 37 RETAINER 38 JOINT 39 ROD 40 ADJUSTMENT CUP 41 BUSHING 42 UPPER FEMALE ADAPTER 43 UPPER SPACER 44 LOWER MALE ADAPTER 45 CONNECTION SHAFT 46...

Page 37: ...37 POMPA TIPO PP4301 CNE ...

Page 38: ...N O RING 17 INNER VALVE 18 AIR PISTON 19 SCREW 19 1 SPRING WASHER 21 BAR SEAT 22 REINFORCEMENT PLATE 23 OUTER VALVE 24 MOTOR ROD 25 SPLIT PIN 26 O RING 27 O RING 28 RETAINER 30 BOLT SPRING WASHERS 32 MOTOR BASE 33 PLATE 34 SCREW 35 LID 36 BUSHING 37 RETAINER 38 JOINT 39 ROD 40 ADJUSTMENT CUP 41 BUSHING 42 UPPER FEMALE ADAPTER 44 LOWER MALE ADAPTER 45 CONNECTION SHAFT 46 UPPER GASKETS SET 47 SUCTIO...

Page 39: ...39 PUMP TYPE PP4531 C ...

Page 40: ... RING 17 INNER VALVE 18 AIR PISTON 19 SCREW 19 1 SPRING WASHER 20 SILENCER FILTER 21 BAR SEAT 22 REINFORCEMENT PLATE 23 OUTER VALVE 24 MOTOR ROD 25 SPLIT PIN 26 O RING 27 O RING 28 RETAINER 30 BOLT SPRING WASHERS 32 MOTOR BASE 33 PLATE 34 SCREW 35 LID 36 BUSHING 37 RETAINER 38 JOINT 39 ROD 40 ADJUSTMENT CUP 41 BUSHING 42 UPPER FEMALE ADAPTER 43 UPPER SPACER 44 LOWER MALE ADAPTER 45 CONNECTION SHAF...

Page 41: ...41 PUMP TYPE PP4231 NE ...

Page 42: ...42 9 ACCESSORIES PICTURE 7 ...

Page 43: ...VANISED STEEL CONNECTION 50 MESH 6 AIR REGULATOR GROUP 3 8 ALS 433 TX Posit Description 4 TF 8N PAINT FILTER 5 DIP TUBE WITH STAINLESS STEEL CONNECTION 30 MESH 6 AIR REGULATOR GROUP 3 8 9 3 ALS 453 C Posit Description 4 TF 9 PAINT FILTER 5 DIP TUBE WITH GALVANISED STEEL CONNECTION 50 MESH 6 AIR REGULATOR GROUP 3 8 9 4 ALS 423 TX Posit Description 4 TF 8N PAINT FILTER 5 DIP TUBE WITH STAINLESS STEE...

Page 44: ...N VALVE 1 4 FF F 9 JOINT R 1 4 M8x6 F 10 JOINT RC 1 4 F 11 JOINT AP 1 4 1 4 MM F 12 PLUG R 1 4 9 6 DELIVERY FILTER TF 8N For ALS 423 TX and ALS 433 TX Posit Description Pic D D 1 BODY D 2 CYLINDER D 3 SCREW D 4 NUT D 5 O RING D 6 FILTER 100 MESH D 7 JOINT R 1 4 R3 8 D 8 DRAIN VALVE G 1 4 FF D 9 JOINT R1 4 M M8x6 D 10 JOINT R 3 8 MF D 11 ADAPTOR JOINT 3 8 1 4 44 Fig D Fig A ...

Page 45: ...S 453 C Posit Description Fig E E 1 BODY E 2 CYLINDER E 3 SCREW E 4 NUT E 5 O RING E 6 FILTER E 7 JOINT AP 3 8 GC_1 4 MM E 8 DRAIN VALVE A P 1 4 E 9 JOINT 1 4 M8x6 E 10 JOINT RC 1 4 E 11 JOINT AP 1 4 GC_1 4 MM E 12 PLUG 45 Fig E ...

Page 46: ... 1 4 FMF 3 9 NIPPLE G 1 4 MM 3 12 QUICK JOINT 1 4 M 3 14 PRESSURE GAUGE OPTIONAL 9 9 AIR REGULATION GROUP FOR ALS 433 C ALS 433 TX ALS 423 TX ALS 453 C Posit Description 3 1 PRESSURE GAUGE OPTIONAL 3 2 AIR REGULATOR 3 8 3 3 SCREW 3 4 JOINT 3 5 PLATE 3 6 NUT 3 7 NIPPLE R 3 8 3 8 BALL VALVE 3 8 3 9 REDUCTION 3 10 SAFETY VALVE 3 11 T JOINT FMF 3 8 3 12 QUICK JOINT 3 8 46 ...

Page 47: ...3 FILTER STOPPER 2 1 2 FILTER SET FOR G3 4 DIP TUBES 4 1 2 COMPLETE FILTER SET 4 1 1 2 FILTER COVER 4 2 30 MESH FILTER 4 3 FILTER STOPPER 10 DISMANTLING 10 1 Equipment storage If the airless unit is to be stored for a certain period the following operations are recommended Disconnect the equipment from the energy sources Remove all residues and deposits from the pump Cover the equipment with a wat...

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