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Edition 06/08

8. MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIAL
MEASURES

In case of a break down of your equipment please contact your dealer or the manufacturer of the

unit who will lead a professional repair.

8.1

COMPRESSED AIR SUPPLY UNIT

Type of defect

Appearance of de-
fect

Possible cause

Remedy

No flow through

BINKS airless pump.

Spray material pres-

sure drops.

BINKS airless pump

does not start.

No compressed air.

Nozzle on airless

gun blocked.

Check compressed air

supply.

Clean or replace noz-

zle.

Reduction of area.

Air motor controller

blocked.

Pipeline kinked,

pressure controller

contaminated.

Contaminated com-

pressed air.

Check lines.

Clean pressure control

valve.

Filter compressed air.

8.2

PNEUMATIC DRIVE AND CONTROL SYSTEM UNIT

Type of defect

Appearance of de-
fect

Possible cause

Remedy

Erratic operation,

number of strokes

reduced, pneumatic

drive stops.

Faulty piston valve.

Wear.

Foreign matter in the

control system.

Replace parts.

Remove foreign mat-

ter, replace faulty

parts.

Pneumatic drive

frozen up.

Compressed air too

damp.

Condensation in the

compressed air sup-

ply.

Too many strokes.

Install water separa-

tor.

Check compressor.

Use smaller spray

nozzle.
Modify working condi-

tions.
Install oiler.
Reduce air pressure.

Содержание HP 4/32

Страница 1: ...shing Systems and Products Ringwood Road Bournemouth BH11 9LH England Phone 44 0 1202 571111 Telefax 44 0 1202 581940 Internet www itwifeuro com Correspondance address ITW Oberflächentechnik GmbH Co Justus von Liebig Straße 31 63128 Dietzenbach Deutschland Telefon 49 0 6074 403 1 Telefax 49 0 6074 403 281 Internet www itwifeuro com Correspondance address ITW Surfaces et Finitions 163 171 Avenue de...

Страница 2: ...Edition 06 08 2 ...

Страница 3: ...insing the BINKS airless pump 14 5 4 Preparing and adjusting the spray material 15 5 5 Start up 15 5 6 Work stoppages 16 6 SHUT DOWN 17 7 CLEANING YOUR BINKS UNIT 17 8 MALFUNCTIONS POSSIBLE CAUSES AND REMEDIAL MEASURES 18 8 1 Compressed air supply unit 18 8 2 Pneumatic drive and control system unit 18 8 3 Spray material pump unit 19 8 4 Suction system unit 19 9 INSTRUCTION MANUAL 20 10 COMPULSORY ...

Страница 4: ...s Epoxy and polyurethane paints Oils Liquid synthetic materials Wax based underbody sealant materials Low solvent and solvent free spray material Please observe the working guidelines and safety instructions supplied by the spray material manufacturer You should avoid using abrasive granular spray material Such spray material can cause heavy wear and tear on the valves and packing sets of the mate...

Страница 5: ...r supply connection piece 12 High pressure filter relief valve 4 Spray material pump 13 Return pipe 5 Suction system 14 Grounding terminal 7 Compressed air control valve 15 Spray material outlet connection piece 8 Pressure reducer 16 Grounding terminal if used without HP filter 10 Release agent chamber ...

Страница 6: ...om the airless gun and the BINKS airless pump will start up again The area of the motor piston is greater than the area of the material piston This difference in area causes the pressure to intensify With an area ratio of 60 1 for example a working pressure of 1 bar at the pneumatic drive will be intensified to a working pressure of 60 bar at the spray material pump The lubrication chamber 10 phys...

Страница 7: ...Spray material M 200 less than 0 3 mm colourless lacquer M 150 greater than 0 3 mm surfacer filler red lead M 100 greater than 0 3 mm surfacer filler red lead M 70 greater than 0 5 mm micaceous iron ore red lead M 50 greater than 0 6 mm emulsion loaded spray mate rial Do not use a filter cartridge for fibre loaded spray material HD filter cartridges overview Filter type Order no 01 0114 013525 03 ...

Страница 8: ...014558 Consisting of PTFE packing Packings for high strength and corrosion materials Upper packing Mixed high strength packing for solvent paint materials Part no 0114 016272 Consisting of PTFE high strength Leather packing High strength packing for waterborne paint materials Part no 0114 016262 Consisting of PTFE high strength packing Lower packing Mixed high strength packing for solvent paint ma...

Страница 9: ...3 8 m Air to gun Aircombi only 90 connection for hose 8x6 or 1 4 NPS m Fluid outlet on HP filter 1 4 NPS m Dimensions of bare pump L x W x D in mm 580 x 165 x 120 The nameplate on your outfit is attached to the spray material pump Enter the data from the nameplate into figure 3 Have this information ready when you call customer service Figure 3 ITW Finishing Systems and Products Ringwood Road Bour...

Страница 10: ...d liable for any damage resulting from such use The user alone must bear the risk 4 The manufacturer is not liable for any unauthorised modifications or repairs made to the BINKS airless pump 5 In accordance with the professional association directives governing spray equipment ZH 1 406 paint spraying equipment should be checked by experts on request or at least every 12 months to ensure that ther...

Страница 11: ...ch children and unauthorised persons do not have access Make sure that unauthorised personnel and children in particular cannot start up the BINKS airless pump 9 Store the BINKS airless pump in a dry place 10 Use only original BINKS accessories and original BINKS replacement parts 11 Repair work must only be carried out by authorised specialised companies or by ITW You can obtain the addresses of ...

Страница 12: ...lorinated hydro carbons are used If you use the named solvents or paints which contain these solvents we recommend that you contact the spray material manufacturer or ITW Oberflächentechnik 4 If there are malfunctions or obstructions you must immediately shut off the compressed air supply at the ball valve Disconnect the unit from the compressed air system operate the air less gun and open the hig...

Страница 13: ...e filter The spray material lines in the BINKS supply programme are identified on the screw fitting with the maximum permitted working pressure and the bursting pressure The lesser value the maximum permitted working pressure must be greater than the maximum permitted working pressure of the spray material pump see 3 Technical Data 4 Connect the airless gun designed at least for the maximum permit...

Страница 14: ... the tank of solvent 4 Insert the high pressure filter return pipe into the tank of solvent Open the high pressure filter relief valve 5 Open the ball valve of the air supply and set the compressed air control valve on the pressure regulator to approximately 1 bar The spray material pump or the suction system now draws in the solvent The solvent runs back to the tank through the high pressure filt...

Страница 15: ...ting filler materials 25 to 50 DIN4 sec These figures relating to DIN EN ISO 2431 and have been established at a temperature of 20 C The lacquer and paint manufacturers generally state the best spraying con sistency for each of their products If you use motor driven mixers you must ensure that no air bubbles form in the spray material To take a measurement proceed as follows Immerse the measuring ...

Страница 16: ... valve of the pressure reducer 3 Before carrying out any coating work we recommend a test spray e g on to paper or wood Only if the test gives you the desired result should you start to coat the actual object Make sure that the edges and the fringe areas of the object to be coated are also given an even coating 5 6 WORK STOPPAGES If working with 2 K spray material you must note the given pot life ...

Страница 17: ...the pump and the suction system from the outside Immerse the spray material pump or the suction system in the tank of solvent 2 Clean the fluid tip tip system as described in the service bulletin of the spray gun We recom mend to soak the fluid tip in solvent 3 Unlock the safety lever of the airless gun without fluid tip but with mounted tip system or tip guard Operate the gun Close the high press...

Страница 18: ...on of area Air motor controller blocked Pipeline kinked pressure controller contaminated Contaminated com pressed air Check lines Clean pressure control valve Filter compressed air 8 2 PNEUMATIC DRIVE AND CONTROL SYSTEM UNIT Type of defect Appearance of de fect Possible cause Remedy Erratic operation number of strokes reduced pneumatic drive stops Faulty piston valve Wear Foreign matter in the con...

Страница 19: ...ace parts Careful cleaning nec essary BINKS airless pump does not stop on up stroke Foot valve or plunger valve faulty or stuck Wear Dried material Replace parts Careful cleaning nec essary Spray material es cape at double piston Grooving in the slide faces Wear Replace parts 8 4 SUCTION SYSTEM UNIT Type of defect Appearance of de fect Possible cause Remedy BINKS airless pump works erratically Suc...

Страница 20: ...peration The operator is obliged to regis ter the equipment for testing and to keep written records of the results of such testing An expert is someone whose professional training and experience has given him adequate knowl edge and understanding of jet stream units and who is sufficiently acquainted with the relevant national health and safety and work and accident prevention regulations directiv...

Страница 21: ...it recom mended General condition of system Jet stream unit Equipment name plate Safety valve Pressure gauge fitting Pressure relief valve Jet stream unit with heater Temperature limitation control Temperature display Spraying device Max pressure identification Equipment number identification Efficiency Safety equipment Hoses and fittings Hose identification Fitting identification Grounding Betwee...

Страница 22: ...Edition 06 08 22 TEST DOCUMENTS Test document no Date of test Expert Company Name 12 SPARE PARTS LISTS ...

Страница 23: ...satzteilliste spare parts list Hochdruckpumpe high pressure pump HDP 27 32 0114 014874 Hochdruckpumpe high pressure pump Luftmotor air motor 0114 013441 Materialpumpe material pump 0114 013447 Vorbehaltl Techn Änderungen ...

Страница 24: ...Edition 06 08 24 Ersatzteilliste spare parts list Luftmotor air motor LM 85 75 0114 013441 Luftmotor LM 85 75 air motor LM 85 75 Vorbehaltl Techn Änderungen ...

Страница 25: ...Edition 06 08 25 Ersatzteilliste spare parts list Luftmotor air motor LM 85 75 0114 013441 Luftmotor LM 85 75 air motor LM 85 75 Vorbehaltl Techn Änderungen ...

Страница 26: ...17 0114 014296 Bundbuchse shoulder bush V 1 R 18 0114 014307 Sicherungsring retaining ring 1 R 19 0114 014409 Scheibe spacer 1 20 0114 013956 Nutring u seal V 1 D R 21 0114 014305 Schnepper toggle V 2 22 0114 014340 Schnepperlager toggle bearing V 2 23 0114 014032 Druckfeder spring V 2 24 0114 014297 Lagerbuchse bearing bush 2 25 0114 014466 O Ring o rin V 1 D R 26 0114 014767 Kolbenplatte piston ...

Страница 27: ...Edition 06 08 27 Ersatzteilliste spare parts list 0114 013447 Materialpumpe MP 27 75 material pump MP 27 75 Vorbehaltl Techn Änderungen Materialpumpe material pump MP 27 75 ...

Страница 28: ...lkolben dual piston V 1 13 0114 014508 Kugelanschlag kpl ball stop assembly 1 R 14 0114 014527 Dichtung gasket 1 D R 15 0114 014745 Kugel ball V 1 R 16 0114 014034 Ventilplatte valve seat V 1 17 0114 013863 Schraube screw 1 18 0114 014480 Druckfeder spring 2 19 0114 011284 O ring o ring 2 20 0114 011282 Federgehäuse spring housing 1 21 0114 014512 Packung gemischt kpl unten lower packing mixed cpl...

Страница 29: ... 1x 0114 014307 SI Ring 15x1 1x 0114 014302 Dämpfungscheibe 22x3 1x 0114 014296 Bundbuchse 1x 0114 013956 Nutring DN15 DN7 1x 0114 014468 Führungsbuchse kpl 1x 0114 013953 O Ring 6 5x2 5mm 1x 0114 014765 Führungsring 11 2x7 3mm 1x 0114 014766 U Scheibe 13 7x8 3x1 5mm 1x 0114 014410 Umsteuerachse kpl 4x 0114 014308 O Ring 6 5 1 5mm 1x 0114 014355 Si Ring JK30 0114 014734 1x 0114 014306 Dämmplatte 1...

Страница 30: ...ichtungssatz Luftmotor seal kit air motor LM 85 75 0114 014530 1x 0114 013956 Nutring DN15DN7 1x 0114 014466 O Ring 74 2x5 7mm 1x 0114 013953 O Ring 6 5x2 5mm 2x 0114 014467 O Ring 85x2mm 4x 0114 014308 O Ring 6 5x1 5mm 1x 0114 014355 Si Ring JK30 1x 0114 014468 Führungsbuchse kpl ...

Страница 31: ...6mm 1x 0114 014237 Kugel 15 mm 1x 0114 014739 Dichtung 32x25x1 5 mm 1x 0114 014450 Zyl Stift 3x23 mm 1x 0114 013834 Dichtung 24 5x18x2mm 0114 013448 2x 0114 011284 O Ring 37x1 mm Mansch Leder Mansch Tefl Mansch Tefl Gegenring RF Mansch Tefl Sattelring Packung gem oben 0114 014513 Mansch Tefl Mansch Tefl Mansch Leder Mansch Tefl Sattelring Gegenring RF Packung gem unten 0114 014512 Sattelring Mansc...

Страница 32: ...m 1x 0114 014739 Dichtung 32x25x1 5 mm 1x 0114 014450 Zyl Stift 3x23 mm 1x 0114 013834 Dichtung 24 5x18x2mm 0114 016006 2x 0114 011284 O Ring 37x1 mm Mansch Leder Mansch Tefl Mansch Tefl Gegenring RF Mansch Tefl Sattelring Packung gem oben 0114 014513 Mansch Tefl Mansch Tefl Mansch Leder Mansch Tefl Sattelring Gegenring RF Packung gem unten 0114 014512 Sattelring Manschette PTFE Manschette PTFE Ma...

Страница 33: ...Dichtungssatz Materialpumpe seal kit material pump MP 27 75 0114 018597 1x 0114 014006 O Ring 49x3 mm 1x 0114 013952 Dichtung 24x18x3mm 1x 0114 014527 Profildichtung 14x11 2x1 5mm 1x 0114 014739 Dichtung 32x25x1 5 2x 0114 011284 O Ring 37x1 mm 1x 0114 013834 Dichtung 24 5x18x2mm ...

Страница 34: ... type 02 M 1 0114 014640 Gestell 1 frame 2 0114 014057 Rad 2 wheel 5 11 0114 014806 Wandhalter kpl bestehend aus 1 wall holder cpl 5 0114 019005 Wandhalter 1 wall holder 7 0114 014216 Schraube 4 screw 8 0114 014164 Mutter 4 nut 9 0114 014165 U Scheibe 4 washer 10 o Abb 0114 014179 Zyl Schraube 4 cyl screw 11 o Abb 0114 009743 Federring 4 spring ring Vorbehaltl Techn Änderungen ...

Страница 35: ... Wandhalter spare parts wall bracket Pos Art Nr Bezeichnung Stk Description pcs 0114 014806 Wandhalter Typ 02 M wall bracket assy type 02 M 0114 019005 Wandhalter 1 wall bracket 0114 014179 Schraube 4 screw 0114 009743 Federring 4 ring Vorbehaltl Techn Änderungen ...

Страница 36: ...arts list Ersatzteile Dreibein spare parts triprod Pos Art Nr Bezeichnung Stk Description pcs 0110 011802 Dreibein kpl triprod assy 0114 009743 Federring 4 spring washer ZZ 1892 D Zylinderschraube 4 cylinder screw Vorbehaltl Techn Änderungen ...

Страница 37: ...rt Nr Bezeichnung Stk Description pcs 0114 014613 Behälter kpl container assy 0114 014167 U Scheibe 4 washer 0114 014179 Schraube 4 screw 0114 014445 Behälter 1 container 0114 014447 Deckel kpl 1 cover cpl 0114 014200 Flügelschraube 3 wing screw 0114 014521 Deckel 1 cover Vorbehaltl Techn Änderungen ...

Страница 38: ...or Aircombi Pos Art Nr Bezeichnung Description 1 0114 13531 01 Druckluftregler kpl 2 air pressure regulator cpl 2 0114 009164 Winkel 1 elbow 3 0114 009048 Einstecknippel 1 nipple 4 0114 009049 T Stück 1 T piece 5 0114 014538 Doppelnippel 1 nipple 6 0114 021608 Kugelhahn 1 relief valve 7 0114 014048 Manometer 2 gauge Vorbehaltl Techn Änderungen ...

Страница 39: ...scription 1 0114 13531 01 Druckluftregler kpl 1 air pressure regulator cpl 1 1 0114 014048 Manometer 1 gauge 1 2 0114 020295 Druckreglergehäuse 1 pressure regulator housing 1 3 0114 014597 Knebelschraube mit Mutter 1 t handle with nut 2 0110 009091 Einstecknippel 1 nipple 3 0114 014538 Doppelnippel 1 Doppelnippel 4 0114 021608 Kugelhahn 1 relief pipe Vorbehaltl Techn Änderungen ...

Страница 40: ...30 M blau filter insert small 30 mesh blue 0114 014887 Siebeinsatz klein 50 M orange filter insert small 50 mesh orange 0114 014876 Siebeinsatz klein 70 M gelb filter insert small 70 mesh yellow 0114 014875 Siebeinsatz klein 100 M schwarz 1 filter insert small 100 mesh black 0114 014877 Siebeinsatz klein 150 M rot filter insert small 150 mesh red 0114 014878 Siebeinsatz klein 200 M weiss filter in...

Страница 41: ...0 mesh yellow 0114 014875 HD Sieb 100 M Kunststoff schwarz 1 filler insert 100 mesh black 0114 014877 HD Sieb 150 M Kunststoff rot 1 filler insert 150 mesh red 0114 014878 HD Sieb 200 M Kunststoff weiss 1 filler insert 200 mesh white 5 0114 013597 Anschlußnippel 1 connecting nipple 6 0114 014166 Schraube 1 screw 7 0114 009743 Federring 2 spring ring 8 0114 013730 Doppelnippel 1 male adaptor 9 0114...

Страница 42: ...in suction system DN 20 triprod 1 0114 011515 Ansaugrohr NW 20 suction tube 2 0114 013734 Saugglocke D 70 filter housing 3 0114 014112 Materialsieb D 70 M 20 strainer 20 mesh wahleise optional 0114 014068 Materialsieb D 70 M 50 strainer 50 mesh 0114 014221 Materialsieb D 70 M 70 strainer 70 mesh 4 0114 014080 Sicherungsring safety ring Vorbehaltl Techn Änderungen 1 2 3 4 ...

Страница 43: ...114 016022 Ansaugrohr NW 20 suction tube 2 0114 013734 Saugglocke D 70 filter housing 3 0114 014112 Materialsieb D 70 M 20 strainer 20 mesh wahleise optional 0114 014068 Materialsieb D 70 M 50 strainer 50 mesh 0114 014221 Materialsieb D 70 M 70 strainer 70 mesh 4 0114 014080 Sicherungsring safety ring 0114 014685 Ansaugsieb kpl M 20 Standard suction housing cpl 20 mesh standard Vorbehaltl Techn Än...

Страница 44: ...tem DN 20 flexible 1 0114 013801 Reduziernippel 1 reducing nipple 2 0114 018506 Ansaugleitung NW 20 1 suction hose DN 20 3 0114 013734 Siebgehäuse 1 filter housing 4 0114 014112 Materialsieb D 70 M 20 1 strainer 20 mesh 0114 014068 Materialsieb D 70 M 50 strainer 50 mesh 0114 014221 Materialsieb D 70 M 70 strainer 70 mesh 5 0114 014080 Sicherungsring 1 retaining ring Vorbehaltl Techn Änderungen ...

Страница 45: ...5 250 HP 4 32 Airless Outfit 256 HAP 50 Airless 1 500 420 HP 4 32 Aircombi Outfit 256 AA 4000 DSG 2000 275 250 HP 6 34 Airless Outfit 272 HAP 50 Airless 1 500 420 HP 6 34 Aircombi Outfit 272 AA 4000 275 HP 6 60 Airless Outfit 390 HAP 50 Airless 1 500 420 HP 10 32 Airless Outfit 256 HAP 50 Airless 1 500 420 HP 10 32 Aircombi Outfit 256 AA 4000 275 HP 20 66 Airless Outfit 429 HAP 50 500 HP 25 48 Air...

Страница 46: ...le responsibility that the equipment to which this document relates is in conformity with the following standards or other normative documents EN 13463 1 2009 EN 13463 5 2005 EN 982 1996 A1 2008 and EN 12621 2006 And thereby conform to the protection requirements of Council Directive 98 37 EC relating to Machinery Safety Directive and council Directive 94 9 EC relating to Equipment and Protective ...

Страница 47: ...orrosion negligence accident substitu tion of non ITW parts faulty installation or tampering If ITW inspection discloses no defect in material or workmanship repair or replacement and return will not be covered by the ITW warranty This warranty covers ITW manufactured Piston Pumps manufactured and shipped on or after January 1st 2004 Equipment not covered by this ITW warranty such as accessories o...

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