Anest Iwata TOF-5 User manual

IMPORTANT
This automatic spray gun should be operated only by an adequately trained operator for safe use and maintenance of the equip-
ment. Any misuse or handling other than those indicated in this Instruction Manual is not covered by guarantee.
ANEST IWATA disclaims all responsibility for any accident or damage caused by failure observing the operational and safety pro-
cedures as from this manual. In the interest of user friendliness, this manual contains information in a brief and concise form.
For any additional information you may require regarding the automatic spray gun operations, or if any missing parts or any dam-
age during transportation is found, or details of training courses, please contact your nearest ANEST IWATA Company (see last
cover page).
Manufactured by: ANEST IWATA Corporation 3176,Shinyoshida-cho, Kohoku-ku, Yokohama, 223-8501 Japan
Instruction Manual
This ANEST IWATA spray guns kit complies to ATEX regulations 94/9/EC
Protection level: II 2 G X Suitable for using in Zones 1 and 2.
X marking: Any static electricity discharge from the spray gun is to be diverted to the ground via the conductive air hose as stipulated.
TOF-5 / TOF-6 AUTOMATIC SPRAY GUN
TOF-5R / TOF-6R (round pattern) AUTOMATIC SPRAY GUN
Before use, adjustment or maintenance, it is important to read
this instruction manual very carefully. This manual must be
stored in a safe place for any future reference that may be necessary.
GB
T013-02EREV.02
IMPORTANT SPECIFICATIONS
Max. Pressure: 6.8 bar (98 PSI) Max. Temperature:
Noise Level (LAeqT) 69.4 dB(A)* Atmosphere 5 ~ 40 °C
Air connection: G 1/8” Air and fluid 5 ~ 43 °C
Fluid connection: G 1/8”
TECHNICAL SPECIFICATIONS
Be sure to observe warnings and cautions in this instruction manual.
If not, it can cause paint ejection and serious bodily injury by drawing organic solvent.
Be sure to observe following marked items which are especially important.
WARNING Indicates a potentially hazardous situation which, if not avoided, may result in serious injury or loss of life.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or pro-
perty damage.
IMPORTANT Indicates notes which we ask you to observe. The safety precautions in this instruction manual are the mini-
mum necessary conditions. Follow national and local regulations regarding fire prevention, electricity and
safety as well as your own company regulations.
Model Nozzle orifice Air cap Fluid output Air consumption *Pattern width Mass
ø mm (in) set ml/min l/min (cfm) mm (in) g (lbs)
TOF-6 / TOF-5 / TOF-6R / TOF-5R Pressure feed Fan Round Fan Round
TOF-5/5R - 05
TOF-6/6R - 05
TOF-5/5R - 10
TOF-6/6R - 10
TOF-5/5R - 13
TOF-6/6R - 13
TOF-5/5R - 20
TOF-6/6R - 20
0.5 (0.02)
1.0 (0.04)
1.3 (0.05)
2.0 (0.08)
05 60 60 (2.1) 40 (1.4)
50 (1.8)
55 (1.9)
85 (3.0)
250 (9.8)
350 (13.8)
400 (15.7)
200 (7.9)
70 (2.8)
80 (3.1)
90 (3.5)
50 (2.0)
80 (2.8)
100 (3.5)
140 (4.9)
250
360
600
10
13
20
350
(0.77)
Measuring conditions: Tested with water at 3.0 bar.
* Spray distance 300 mm
ANEST IWATA Italia S.r.l.
46, Corso Vigevano 10155, Torino (Italy)
Tel. diretto +39 011 - 24 80 868 - Fax: +39 011 - 85 19 44
[email protected] www.anest-iwata.it
ANEST IWATA Iberica
Calle de Les Teixidores, 3-5
08918 - Badalona (Barcelona)
Tel.:[phone] - Fax.:[phone]
[email protected] www.anest-iwata.es
ANEST IWATA Europe S.r.l.
NIEDERLASSUNG DEUTSCHLAND
Dorfäckerstr. 23/1, 74248 Ellhofen
Telefon: [phone] - Fax: [phone] - 917378
Handy: +49 (0) 172 - 62 74 542
[email protected] www.anest-iwata.de
ANEST IWATA Europe S.r.l.
46, Corso Vigevano 10155, Torino Italy
Direct Tel. +39 011 - 22 74 402
Fax +39 011 - 22 74 406
[email protected]
www.anest-iwataeu.com
ANEST IWATA Scandinavia
Ögärdesvägen 6C, 433 30 PARTILLE - Sweden
Tel. +46 (0)31 - 340 28 60 - Fax +46 (0)31 - 340 28 69
[email protected] www.anest-iwata.se
ANEST IWATA France
25 rue de Madrid - 38070 St Quentin Fallavier - France
Tél. +33 (0)4 - 74 94 59 69 - Fax +33 (0)4 - 74 94 34 39
[email protected] www.anest-iwata.fr
ANEST IWATA U.K.
Unit 10 Little End Road - Eaton Socon
St. Neots - CAMBRIDGESHIRE
PE19 8JH
Tel.: [phone] Fax: [phone]
[email protected] www.anest-iwata.co.uk
European Sales Branches:
*Measuring point: 1m backwards from gun, 1,6 m height

72
SAFETY WARNINGS
1. Spark and open flames are strictly prohibited.
Flammable liquids can cause fire. Avoid any ignition sources such as smoking, open
flames, electrical goods, etc.
2. Ground spray gun securely.
Use grounded gun stay. Ground resistance : Less than 1MΩ
Check the earth stability periodically. If not, insufficient grounding can cause fire and
explosion due to static electric sparking.
1. Never point gun towards people or animals.
If done, it can cause inflammation of eyes and skin or bodily injury.
2. Never exceed maximum operating pressure and maximum operating Temperature.
3. Be sure to release both air and fluid pressure before cleaning, disassembling, servicing or job
interruption.
If not, remaining pressure can cause bodily injury due to improper operation or scattering of cleaning liq-
uid. In order to release pressure, first stop supply of compressed air to pressure feed tank, operate piston of gun to release
pressure in fluid hose and stop compressed air to gun.
4. Tip of fluid needle set has a sharp point.
Do not touch the tip of fluid needle during maintenance for the protection of the human body.
1. Use in a well-ventilated site by using spray booth.
If not, poor ventilation can cause organic solvent poisoning and start a
fire.
2. Always wear protective gear (safety glasses, mask, gloves).
If not, cleaning liquid, etc., can cause inflammation of eyes and skin.
If you feel something wrong with eyes or skin, immediately see a doctor.
3. Wear earplugs if necessary. Noise level can exceed 85dB(A), depending on operating conditions and painting site.
1. Never alter this spray gun.
If done, it can cause insufficient performance or failure.
2. Enter working areas of other equipment (robots, reciprocators, etc.) after machines are turned off.
If not, contact with them can cause injury.
3. Do not use corrosive liquid (acid and alkali, etc.).
Before using corrosive liquids, make sure that they are compatible with the gun components. We can provide you with a list of
materials used in the product.
4. Never spray food, medicines or chemicals through this gun.
If done, it can cause accidents due to corrosion inside fluid passages and health problems by drawing foreign matter.
5. Do not spray products which could directly affect the health and growth of people, animals or plants causing envi-
ronmental pollution and could also cause damage to the paint passages.
6. If something goes wrong, immediately stop operation and determine the cause. Do not use again until you have
resolved the problem.
FIRE OR EXPLOSION HAZARD
IMPROPER USE OF EQUIPMENT
PROTECTION OF HUMAN BODY
OTHER PRECAUTIONS
COMMENTS

PROBLEMS AND REMEDIES
Problem Where it Parts to be Cause Remedy
occurred checked Retighten Adjust Clean Replace
Fluid leaks Fluid nozzle - * Dirt, damage, wear on X X
Piston seat surface
* Wear on piston spring X
Tip of gun Fluid nozzle - * Insufficient tightening X
Gun body * Dirt or damage on seat X X
Piston - * Piston does not return
O-ring (P-3) due to fluid buildup on X
it.
* Wear X
Paint does Tip of gun Fluid adj. knob * Insufficient opening X
not flow Hole of nozzle * Clogged X
HOW TO CONNECT
- Job 1. Fit the gun to fitting stay, aim at spraying direction and fix it with fitting bolts.
- Job 2. Connect atomizing air hose to atomizing air side (AIR marked side) and operating air hose to operating air side
(CYL marked side) tightly.
- Job 3. Connect fluid hose to fluid inlet (FLUID marked side) tightly.
- Job 4. Pour compatible cleaning liquid into container, spray to clean fluid passages.
- Job 5. Supply paint to container, test spray and adjust fluid output, air volume and pattern width.
Connecting example of air hose and fluid hose:
-TOF-5/5R:
Operating three-way valve, both atomizing air and piston operating air will flow and spray will start.
-T
OF-6/6R:
1. Operate two-way valve to let atomizing air flow.
2. Operate three-way valve, to let piston operating air flow and spray paint.
3. In order to stop spraying, first stop three-way valve. Next stop two-way valve and then stop atomizing air.
36
TROUBLESHOOTING
Spray Pattern Problems Remedies
1.Air enters between fluid nozzle and 1. Remove fluid nozzle to clean seat.
Fluttering tapered seat of gun body. If it is damaged, replace nozzle.
2.Air enters from fluid hose connection. 2. Retighten it.
3.Air enters fluid passage because O-ring (P-3) 3. Replace O-ring.
is worn out.
1.Paint buildup on air cap partially 1. Remove obstructions from hole with a brush.
*Crescent clogs horn holes. Air pressure from But do not use metal objects to clean
both horns differs. horn holes.
1.Paint buildup or damage on fluid nozzle cir- 1. Remove obstructions.
*Inclined cumference and air cap center. Replace if damaged.
2. Fluid nozzle is not properly fitted. 2. Remove fluid nozzle, clean seated section.
1.Paint viscosity too low. 1. Add paint to increase viscosity.
*Split 2.Fluid output too high. 2. Tighten fluid adj. knob to reduce fluid output
or turn pattern adj. knob clockwise.
*Heavy 1.Paint viscosity is too high. 1. Add thinner to reduce viscosity.
Center 2.Fluid output is too low. 2. Turn fluid adj. knob counter-clockwise to
increase fluid output. Or increase air pres-
sure for atomizing air.
* Round pattern specifications are excluded.
IMPORTANT
- This gun should be operated by adequately trained operators only.
- Ensure that the gun has not been damaged during transportation.
CAUTION
- Use clean air filtered through air dryer and air filter. If not, dirty air can cause coating failure.
- When you use this gun for the first time after purchasing, clean fluid passages spraying thinner to
remove rust preventive oil.
If not, remaining preventive oil can cause painting failure such as fish eyes.
- Use three-way solenoid valve of more than ø 4 mm inner cross-sectional area and air hose of over
ø 4 mm inner diameter and less than 10m length. If not, small diameter of solenoid valve and longer
air hose between three-way solenoid valve and gun can cause delay in operation.
- Firmly fix hose to spray gun. If not, disconnection of hose can cause bodily injury.
Gun Stay (ø10)
Gun Stay (ø10)
Three-way solenoid valve
Three-way solenoid valve
Two-way solenoid valve
Air regulator
Air regulator
Air regulator
Air compressor
Air compressor
Air dryer
Air dryer
Air filter Air filter
Air filter Air filter
Pressure
feed
tank
Pressure
feed
tank
Atomizing air
(To AIR)
Atomizing air
(To AIR)
Operating air
(To CYL)
Fluid line
(To FLUID)
Fluid line
(To FLUID)
Grounded
Grounded

HOW TO ADJUST
1. Adjust atomizing air pressure varies according to viscosity and paint property. Recommended air pressure is between 2.5-
4.0 bar. (Use higher air pressure to spray fine mist and lower air pressure to spray coarse mist).
2. For TOF-6/6R, set piston operating air pressure to 2.5 bar or more (CYL marked side).
3. When using the pressure feed tank, set its pressure to 2.0 bar or less.
There are two methods to adjust fluid output:
1) Adjust compressed air pressure to the pressure feed tank.
2) Open and close fluid adjustment knob of gun. Fluid output becomes zero when fluid adjustment knob of gun is turned fully
clockwise. Fluid output gradually starts increasing when fluid adjustment knob is turned 0.5 turn counterclockwise from
zero point and fluid output stops increasing when fluid adjustment knob is 4 full turns counterclockwise.
MAINTENANCE AND INSPECTION
54
Step-by-step procedure Important
1. Clean fluid passages and air cap set. 1. Incomplete cleaning can fail pattern shape and uniform particles.
Spray a small amount of thinner to clean fluid passages.
2. Clean each section with brush soaked with thinner and wipe out with waste cloth. 2. Do not immerse the whole gun in thinner. If done, it can damage parts.
When cleaning, never scratch any holes of air cap set, fluid nozzle,
fluid needle set or piston set.
3. Before disassembly, fully clean fluid passages. 3. During disassembly, do not scratch seat section.
(1) Disassemble piston set.
First remove fluid adjustment knob and pull it by holding end of piston. (1) Ensure that piston spring does not suddenly fly out because fluid adjust-
ent knob is strongly pushed by piston spring.
(2) Disassemble fluid nozzle (2) Remove fluid nozzle while piston set is kept pulled backwards,
Use ring spanner and box wrench. in order to protect seated section of fluid nozzle and fluid needle.
(3) Assemble pattern adj. set (3) If pattern adj. set is not fully opened, tip of pattern adj. set can strike
First turn fluid adjustment knob counterclockwise and fully open it, and then gun body and the point of the pattern adjustiment set will collide
insert pattern adj. set into gun body. with gun body, causing damage to both parts.
Where to inspect Parts replacement standard
1. Each hole passage of air cap and fluid nozzle. Replace if it is crushed or deformed.
2. Packings and O rings. Replace if it is deformed or worn out.
3. Leakage from seat section between fluid nozzle and piston. Replace nozzle - piston set if there is any leakage even after cleaning fluid
nozzle and piston.
WARNING
- First fully release air and fluid pressure according to item No. 3 of “Improper use of equipment”
of WARNING on page 2.
- Tip of fluid needle set has a sharp point. Do not touch the tip of needle during maintenance for pro-
tection of the human body.
- Be careful not to damage the tip of the fluid nozzle or put your hand on it.
- Only an experienced person who is fully conversant with the equipment can do maintenance and
inspection.
CAUTION
- Never use commercial or other parts instead of ANEST IWATA original spare parts.
- Never immerse the whole gun into liquid such as thinner.
- Never soak air cap set in solvent for extended period even if cleaning. It can cause defective pattern.
- Never damage holes of air cap, fluid nozzle or fluid needle.
SPARE PARTS LIST
DESCRIPTION REF. PART
AIR CAP SET 1-1
AIR CAP SET (TOF-5R/6R) 1-2
NOZZLE PISTON SET 2
NOZZLE 2-1
PISTON SET 2-2
GUN BODY 3
O-RING SEAT 4
PISTON SPRING 5
PATTERN ADJ. SET 6-1
PLUG (TOF-5R/6R) 6-2
HOLDER 7
JAM NUT 8
BOLT 9
NIPPLE 10
O-RING (P-3) 11
NUT 12
FLUID ADJ. KNOB 13
NUT 14
JOINT 15
Marked parts are wearable parts.
- When ordering parts, specify gun model, part name with
ref. No. and marked No. of air cap set and nozzle
piston set.
- When replacing nozzle or piston, replace it with nozzle-
piston set.
- Before use, be sure to confirm that there is no damage
or missing parts.
- If there is some damage or something is lost during
transportation, do not use the product and contact the
shop which sold it to you.
IMPORTANT
1. One air supply line is used as both atomizing air and piston operating air. So if supply air setting is
not appropriate, it can cause failure of piston operation.
2. Securely lock fluid adjustment knob with jam nut when fluid output has been decided, so that the
the fluid output is not changed by vibrations caused by piston operation and the piston and the pis-
ton spring do not suddenly fly out unexpectedly due to loosening of adjustment knob.