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WAGNER Cobra 40-10/2K Operating Manual Download Page 1

Translation of the Original 

Operating Manual

For professional use.

Always follow the information in this manual, 

particularly the safety instructions and the warning 

instructions. Store the manual in a safe place.

Cobra 40-10 / 2K

High Pressure Double 

Diaphragm Pump for 

2-Component Products with 

Mixing Ratio 1:1

Version 04/2018

B_5076

Summary of Contents for Cobra 40-10/2K

Page 1: ...Always follow the information in this manual particularly the safety instructions and the warning instructions Store the manual in a safe place Cobra 40 10 2K High Pressure Double Diaphragm Pump for...

Page 2: ......

Page 3: ...rator 12 4 1 1 Electrical Devices and Equipment 12 4 1 2 A Safe Work Environment 12 4 1 3 Personnel Qualifications 13 4 2 Safety Instructions for the Personnel 13 4 2 1 Personal Safety Equipment 13 4...

Page 4: ...sure Relief Work Interruption 31 7 5 Basic Flushing 32 7 5 1 Filling with Working Material 33 8 CLEANING AND MAINTENANCE 34 8 1 Cleaning 34 8 1 1 Cleaning Personnel 34 8 1 2 Decommissioning and Cleani...

Page 5: ...ordered 52 14 2 Overview of the Components 53 14 3 Air motor 54 14 4 Fluid section 56 14 5 Inlet Valve 59 14 6 Inlet Valve Depressor 59 14 7 Complete Vertical Mixer 60 14 8 Complete Horizontal Mixer 6...

Page 6: ...CES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual highlight particular dangers to users and to the device and state measures for avoiding the hazard These warning instructions...

Page 7: ...ions Trained person Is instructed in the tasks assigned to him her the potential risks associated with improper behavior as well as the necessary protective devices and measures Electrically trained p...

Page 8: ...classification into explosion class IIB see Chapter 2 4 WAGNER explicitly prohibits any other use The device may only be operated under the following conditions Use the device only to work with the pr...

Page 9: ...lves etc as indicated in Chapter 5 5 Check if the fluids and solvents used are compatible with the pump construction materials as indicated in Chapter 5 5 1 Use suitable combinations of devices packin...

Page 10: ...5 5 2 Technical Data Safe Handling of WAGNER Spray Devices Mechanical sparks can form if the device comes into contact with metal In an explosive atmosphere knocking or pushing metal against metal is...

Page 11: ...hoses if the pump must be emptied for maintenance and or repair purposes Empty and fill the device slowly and in a controlled manner Avoid potentially explosive atmosphere in the surroundings 3 3 TYP...

Page 12: ...rical devices 4 1 2 A SAFE WORK ENVIRONMENT Hazard due to dangerous fluids or vapors Severe or fatal injuries due to explosion hazard or inhalation swallowing or contact with the skin or eyes Ensure t...

Page 13: ...n about the required personnel qualifications 4 2 SAFETY INSTRUCTIONS FOR THE PERSONNEL Always follow the information in this manual particularly the safety instructions and the warning instructions A...

Page 14: ...100 500 Chapters 2 29 and 2 36 For shut down devices the check can be postponed until the next start up In the event of skin injuries caused by lacquer or flushing agents Note the lacquer or flushing...

Page 15: ...are never run over by vehicles e g fork lift trucks or that the hoses are never put under pressure from the outside in any other way Ensure that the hoses are never kinked Observe maximum bending radi...

Page 16: ...g product used depending on the flushing agent solvent used an explosive mixture may temporarily exist inside the lines and components of equipment Only electrically conductive tanks may be used for c...

Page 17: ...13 and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun high pressure hoses and all devices Secure the spray g...

Page 18: ...ir This compressed air moves the air piston in the air motor 4 and consequently the piston rod in the fluid section 9 up and down At the end of each stroke the compressed air is redirected by a revers...

Page 19: ...10 2K double diaphragm pump comprising fluid section air motor connection elements and mounting brackets for wall mounting vertical 1 U850 00SA Cobra 40 10 2K double diaphragm pump comprising fluid s...

Page 20: ...essure level at maximum permissible air pressure dB A 74 Sound pressure level at 0 45 MPa 4 5 bar 65 27 psi air pressure dB A 72 Sound pressure level at 0 3 MPa 3 bar 43 5 psi air pressure dB A 69 Air...

Page 21: ...ONNECTIONS mm inch A 505 19 88 B 313 12 32 C 313 12 32 D 134 5 28 E 55 2 16 F 182 7 16 G 80 3 15 H M6 I 25 0 98 K G3 8 L M36 2 mm inch M G3 8 N 149 5 87 O 91 3 58 P 107 4 21 Q 175 6 89 R 7 0 28 S 65 2...

Page 22: ...023 0 58 20 40 50 60 70 80 1 3700 1 5900 2 0100 Cobra 40 10 2K 0 025 0 64 20 40 50 60 80 1 6200 1 9100 0 027 0 69 20 40 50 60 80 1 8300 Volume flow refers to water Maximum ranges for continuous opera...

Page 23: ...oat filter regulator Cobra accessories The AirCoat filter regulator must be mounted vertically in all installation positions for the diaphragm pump see assembly manual for filter regulator order numbe...

Page 24: ...nstalled and commissioned 6 2 STORAGE CONDITIONS Until the point of assembly the device must be stored in a dry location free from vibrations and with a minimum of dust The device must be stored in cl...

Page 25: ...losion prevention rules and regulations are observed when setting up the device Positioning The Cobra 40 10 2K diaphragm pump may only be operated in the positions shown in the diagrams Upside down op...

Page 26: ...unt 2 For AirCoat systems picture above mount the additional filter pressure regulator 7 option 3 Mount suction systems 5 4 Connect the suction system s return hoses 4 to the return valves 3 5 Connect...

Page 27: ...se material is chemically resistant to the sprayed products Ensure that the spray gun fittings and product hose between the device and the spray gun are suitable for the pressure generated in the devi...

Page 28: ...e operation of the Cobra pump is only guaranteed with a grounding connection Connect all grounding cables using a short and direct route B_01214 Procedure 1 Screw on grounding cable with eyelet 2 Clam...

Page 29: ...hapter 8 2 3 Fill the pump with flushing agent The devices are tested during manufacturing with emulsifying oil pure oil or solvent Possible residues must be flushed out of the circuits with a solvent...

Page 30: ...ting personnel must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures Before work commences the operating personnel must r...

Page 31: ...r 1 6 DH min after the spray gun is closed 7 4 PRESSURE RELIEF WORK INTERRUPTION The pressure must always be relieved when after the spraying tasks are finished before servicing the system before carr...

Page 32: ...mpty grounded tank 5a and 5b under the return tubes 4a and 4b 3 Place suction hoses 7a and 7b in tanks with cleaning agent 6a and 6b 4 Adjust the pressure regulator 1 to approx 0 05 MPa 0 5 bar 7 25 p...

Page 33: ...the local regulations B_05080 6A 6B 5B 5A 7B 7A 1 2 8 9 3B 3A 4B 4A B_05081 V Note During the flushing procedure briefly press both valve depressors V 7 5 1 FILLING WITH WORKING MATERIAL After basic f...

Page 34: ...ry out the basic flushing Chapter 7 5 3 Empty system in a controlled manner Chapter 8 2 4 4 Service spray gun in accordance to its operating instructions 5 Clean and check the suction system and the s...

Page 35: ...replace parts Use only WAGNER original spare parts and accessories Only repair and replace parts that are listed in the Spare parts chapter and that are assigned to the unit Before all work on the de...

Page 36: ...ter 7 5 and Chapter 8 2 4 Weekly Check spraying system for damage Check that the safety fixtures function properly see Chapter 5 3 Yearly or as required The oil change is to be performed as necessary...

Page 37: ...s set Records of these checks must be kept The complete hose is to be replaced as soon as one of the two following intervals has been exceeded 6 years from the date of the hose crimping see fitting em...

Page 38: ...wly open the ball valve 2 7 Slowly turn air pressure up on the pressure regulator 1 and only until the pump is running normally approx 0 05 MPa 0 5 bar 7 25 psi 8 Be ready for the switch from working...

Page 39: ...39 OPERATING MANUAL VERSION 04 2018 ORDER NUMBER DOC 2349980 Cobra 40 10 2K B_05080 6A 6B 5B 5A 7B 7A 1 2 8 9 3B 3A 4B 4A...

Page 40: ...Open relief valves 3a and 3b 6 Slowly open the ball valve 2 7 Slowly turn the air pressure up on the pressure regulator 1 and only until the pump is running normally approx 0 0 05 MPa 0 0 5 bar 0 7 25...

Page 41: ...0 Cobra 40 10 2K B_05080 6A 6B 5B 5A 7B 7A 1 2 8 9 3B 3A 4B 4A 8 2 6 HYDRAULIC STAGE MAINTENANCE Dismount the pump and place it upside down on a suitable underlay and position it horizontally Observe...

Page 42: ...be topped up or removed by extraction Procedure 1 Unscrew and remove threaded plug 5 2 Top up oil to level A middle of marking X 3 Start up the pump for a short time without any product and check for...

Page 43: ...7 2 Dismount the pump and place it upside down on a suitable underlay and position it horizontally 3 Unscrew piston cover 1 4 Place oil collector 2 under the oil tank 5 Unscrew oil tank 3 and drain c...

Page 44: ...ded plug 5 3 Unscrew 2 locking screws 4 and replace with 2 threaded fittings 6 from the oil filling set 4 Connect hoses with Y pieces 7 5 Fill syringe 8 with hydraulic oil and insert into hose 6 Move...

Page 45: ...rlay and positioned horizontally Remove the threaded plug 5 2 Slowly start up the pump vent until no more air bubbles rise from the oil suction tube 3 Oil level A in the oil tank has to be within the...

Page 46: ...Viscosity is too high Thin product Spraying pressure is too low Increase incoming air pressure Use a smaller nozzle Valves are clogged Press valve depressor Clean pump If necessary leave it to soak in...

Page 47: ...and replace parts that are listed in the Spare parts chapter and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray...

Page 48: ...tasks wearing gloves 10 5 ASSEMBLY OF THE DEVICE In Chapter 14 the order numbers for device spare parts can be found as well as for wearing parts such as seals Defective parts O rings and seal sets m...

Page 49: ...ction of the pump and the frame trolley and between the individual components of the frame trolley 100k Ohmmeter Check conductivity between the piston and the grounding connection 100k These inspectio...

Page 50: ...s The following materials have been used Stainless steel Aluminum Elastomers Plastics Carbide Consumable products Consumable products lacquers adhesives flushing and cleaning agents and solvents must...

Page 51: ...rn hose DN 13 ID 0 51 inch M20x2 16 322052 Frame complete 17 T423 00FA Flexible suction hose lacquer F36x2 18 367527 O ring PTFE 19 9974127 O ring FEP 20 367959 Washer PTFE 21 2332143 Wall mount 22 23...

Page 52: ...are parts lists Wearing parts Wearing parts are not included in the warranty terms Included in service set Notice These parts are not covered by warranty terms Not part of standard equipment available...

Page 53: ...sembled 3 1 322436 Air motor casing 4 1 322437 Pressure stage casing 5 1 322235 Hood 4 with air outlet 6 3 9907224 Hexagon socket cylinder head screw 7 4 9920106 Washer 8 1 9900107 Hexagon screw 9 1 2...

Page 54: ...7 27 33 35 36 37 38 39 40 41 22 25 43 42 44 47 48 45 44 49 51 50 46 26 26 55 28 29 27 10 15 Nm 7 11 lbft 20 25 Nm 15 18 lbft 2 3 Nm 1 5 2 2 lbft 50 25Nm 24 53 B_06851 Do not dismount the piston Order...

Page 55: ...complete 34 1 368038 Detent body complete ISO 1 2 35 2 9907126 Screw SFS Plastite 45 36 2 9974089 O ring 37 2 9974115 O ring 38 1 322432 Control air pipe 39 1 322430 Cylinder pipe 40 1 322431 Compress...

Page 56: ...UID SECTION 35 33 34 32 31 46 47 49 50 41 101 27 102 26 66 67 38 40 21 22 23 92 24 25 67 26 102 27 2 Nm 1 5 lbft 20 Nm 14 8 lbft 40 Nm 29 5 lbft 110 110 42 B_05074 4 1 6 7 9 10 11 14 110 110 100 110 9...

Page 57: ...ange 31 2 9974182 Rod sealing profile BS 32 2 9974183 Rod sealing set 33 2 9974186 O ring 34 2 9971446 O ring 35 2 322405 Pressure disk 37 1 115944 O ring 38 1 2333498 Oil tank complete 40 1 9998274 T...

Page 58: ...ml 50 cc 105 1 2312288 Service set for Cobra 40 10 fluid section 107 1 322917 Service set for Cobra 40 10 piston incl items 25 31 32 33 59 and 108 108 1 322930 Piston rod assembly pin 109 1 9992511 L...

Page 59: ...clamp 3 2 344334 Spring guide 4 2 190304 Pressure spring 5 2 158333 Guide 6 4 341331 Sealing ring 7 2 344322 Valve housing 8 2 340346 Valve seat 10 1 9992528 Loctite 270 50 ml 50 cc 11 2 340342 Valve...

Page 60: ...0 3 2 A194 22 Valve body 4 1 B0284 03 Mixing block 5 1 B0285 71 Mixing block support 6 2 K118 62 Screw M5x40 7 2 K151 62 Screw M6x60 8 2 M116 00A Ball valve pin A 1 4 C R 9 2 M6014 00 Fitting 1 4 adju...

Page 61: ...6 00A Ball valve pin A 1 4 C R 9 2 M6014 00 Fitting 1 4 adjustable 10 2 M614 62 Fitting 1 4 11 1 M623 12 Plug EI 1 4 12 2 T701 00 Lock valve lacquer mix 13 1 S501 00 Hose AP 1 4 X MT 0 420 14 1 S506 0...

Page 62: ...point via container coating Order no Order no Designation 1 1 2328611 AirCoat regulator set 2 1 2382997 AirCoat filter regulator set 3 1 2309972 Pressure regulator valve LR 1 4 D O I Mini 4 1 2331950...

Page 63: ...E FRAME B_06841 1 2 3 4 6 7 8 5 Order no Designation 1 1 322052 Cobra 40 10 frame 2 1 Frame pressed 3 1 Frame pipe 4 2 9990861 Plug 5 4 9999209 Saddle feet for round tubes 6 2 9910204 Self locking hex...

Page 64: ...ght 4 6 welded 4 4 9907140 Hexagon screw DIN931 M6x75 5 6 9910204 Self locking hexagon nut M6 6 2 2304440 Wheel D250 7 4 340372 Washer 8 4 9995302 Cotter pin 9 1 Wheel axle 4 6 10 2 367943 Connecting...

Page 65: ...9910204 Self locking hexagon nut M6 6 2 2304440 Wheel D250 7 4 340372 Washer 8 4 9995302 Cotter pin 9 1 Wheel axle 4 6 complete 10 2 367943 Connecting part 4 6 11 2 Tube plug ribbed 12 4 9998685 Sadd...

Page 66: ...ra 40 10 2K 14 13 SUCTION SYSTEM 2 3 4 5 6 1 B_03134 Part no Designation 1 1 T423 00FA Suction system flexible complete 2 1 T423 00F Suction tube 3 1 R033 00A Filter housing 4 1 T468 00 Filter sieve 5...

Page 67: ...010 EN 1127 1 2011 EN ISO 4413 2010 EN ISO 80079 36 2016 EN ISO 4414 2010 EN ISO 80079 37 2016 EN ISO 13732 1 2008 EN ISO IEC 80079 34 2011 EN 14462 2015 Applied national technical standards and speci...

Page 68: ...y WAGNER S p A Via Santa Vecchia 109 23868 Valmadrera LC Phone 39 0341 210100 Telefax 39 0341 210200 E mail wagner_it_va wagner group com More contact addresses www wagner group com Subject to changes...

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