COSMOSTAR A0118 User manual

COSMOSTAR
Instruction Manual
COSMOSTAR -Handle With Care
Fluid Handling Equipment Manufacturer
COSMOSTAR A0118 80:1 Airless Sprayer
M010 Hulk Air Motor
L0118CS & L0118SUS Lower
CHING-YEA MECHANICAL INDUSTRY CO.,LTD.
No. 8, Alley 6, Lane 15, Sec. 2, Jiayuan Rd., Shulin District, New Taipei City 238, Taiwan
TEL: [phone] FAX: [phone]
http://www.cosmostar.net e-mail: [e-mail]

01
WARNING
EQUIPMENT MISUSE HAZARD
•Equipment misuse can cause the equipment to rupture or malfunction and
result in serious injury.
•This equipment is for professional use only.
•Read all instruction manuals, tags, and labels before operating the
equipment.
•Use the equipment only for its intended purpose.
•Do not alter or modify this equipment.
•Check equipment daily. Repair or replace worn or damaged parts
immediately.
•Do not exceed the maximum working pressure of the lowest rated
component in your system.
•Use fluid sand solvents which are compatible with the equipment wetted
parts.
•Do not use hose stop all equipment.
•Route hoses away from traffic areas, sharp edges, moving parts, and hot
surfaces.
•Do not expose hose to temperatures above 82C(180F) or below–4C(–40F).
•Do not lift pressurized equipment.
•Wear hearing protection when operating this equipment.
•
Comply with all applicable local, state, and national fire, electrical, and safety
regulations.
SKIN INJECTION HAZARD
•Hazard out fluid or toxic fumes can cause serious injury or death if splashed
in the eyes, on the skin, inhaled, or swallowed.
•Know the specific hazards of the fluid you are using.
•Store hazard out fluid in an approved container. Dispose of hazard out fluid
according to all local, state and national guide lines.
•Always wear protective eyewear, gloves, clothing and respirator as
recommended by the fluid and solvent manufacturer.
•Pipe and dispose of the exhaust air safely, away from people, animals, and
food handling areas. If the diaphragm fails, the fluid is exhausted along with
the air.
WARNINGS
The following are general warnings related to the setup, use, grounding,
maintenance and repair of this equipment. Additional, more specific warnings
may be found throughout the body of this manual where applicable. Symbols
appearing in the body of the manual refer to these general warnings. When
these symbols appear throughout the manual, refer back to these pages for a
description of the specific hazard.
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WARNING
FIRE AND EXPLOSION HAZARD
•Improper grounding, poor ventilation, open flames or spark scan cause a
hazardous condition and result in a fire or explosion and serious injury.
•Ground the equipment.
•Consult your fluid supplier to determine the conductivity or resistivity of
your fluid.
•If there is any static sparking or you feel an electric shock while using this
equipment, stop pumping immediately. Do not use the equipment until you
identify and correct the problem.
•Provide fresh air ventilation to avoid the build up of flammable fumes from
solvents or the fluid being sprayed, dispensed, or transferred.
•Pipe and dispose of the exhaust air safely, away from all sources of ignition.
If the diaphragm fails, the fluid is exhausted along with the air.
•Keep the work area free of debris, including solvent, rags, and gasoline.
•Electrically disconnect all equipment in the work area.
•Extinguish all open flames or pilot lights in the work area.
•Do not smoke in the work area.
•Do not turn on or off any lights witch in the work area while operating or if
fumes are present.
•Do not operate a gasoline engine in the work area.
02
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COSMOSTAR Airless Sprayer Overview
Part No.
Description
Qty Part No.
Description
Qty
1
Nut
2 18
Hose, air
1
2
Washer
2 19
Frame, cart
1
3
Nut
4 20
Axle
1
4
Washer
4 21
Washer
2
5
Washer
6 22
Wheel, flat
2
6
Nut
6 23
Pin
2
7
Screw, frame
10 24
Ring
2
8
Union, hose
1 25
Suction
tube 1
9
Tube, drain
1 26
Suction
cap 1
10
Nipple
1 27
Regulator
1
11
Coupling, hose
1 28
Housing, lock
1
12
Hose, suction
1 29
Valve
1
13
Hose, fluid
1 30
Filter
2
14
Nut
4 31
Screw, regulator
2
15
Washer, lock
4 32
U Lock
1
16
Screw, cap
4 33
Cart, portable
1
17
Airless
spray gun 1 34
Nut
2
35
Washer
2
03
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Hulk 10'‘ Air Motor Inner Schematic Parts Drawing
04
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05
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M010 Hulk Air Motor Parts Drawing

M010 Hulk Air Motor Parts List
Item
Part
No.
Description
Qty
01
M01001
Shield, motor
1
02
M01002
Screw, cap 7/16"
4
03
WS07CZ
Spring Washer, 7/16"
4
04
M01004
Retainer
2
05
M01005
Spring, compression
2
06
M01006
Guide, spring
2
07
M01007
Plunger, detent
2
08
M01008
Roller, axle
2
09
M01009
Axle, detent
2
10
M01010
Ring, lift
1
11
M01011
Housing, detent
1
12
M01012
Pad, rubber
2
13
M01013
Washer, flat
2
14
M01014
Nut, trip rod
1
15
SF0306CZ
Screw (flat) 3/16" x
3/8"
8
16
M01016
Housing
1
17
M01017
Hub, valve housing
1
18
M01018
Bearing
1
*19
M01019
Washer, backup
1
*20
M01020
Packing, V
-block 1
21
M01021
Spring
2
*22
M01022
O
-Ring, packing 2
23
M01023
Valve, air director
2
24
M01024
Plate, valve
2
*25
M01025
Seal, valve plate
2
Item
Part
No.
Description
Qty
26
SH0616CZ
Screw 3/8" x 1
4
27
M01027
Screw, cap 3/8''
4
28
M01028
Manifold
2
*29
M01029
Gasket, air manifold
2
*30
M01030
Packing, V
-block 2
*31
M01031
Washer
2
32
M01032
Cylinder, motor
1
*33
M01033
O
-Ring, rubber 1
34
M01034
Piston
Assy Set
35
M01035
Trip, Rod
1
36
M01036
Spring
1
37
M01037
Bushing, spring
2
38
M01038
Screw
2
39
M01039
Stud, connecting rod
1
*40
M01040
Gasket
, cylinder 1
41
-
-
-
42
M01042
Base, air motor
1
43
-
-
-
44
M01044
Locker
1
45
SH0824CZ
Screw 1/2" x 1
-1/2"
12
46
M01046
Union, 90 adapter, 3/4"
1
47
M0047
Screw, shield
8
48
M01048
Washer 1/4''
8
49
SP1209CZ
Plug 3/4"
1
50
M01050
O
-ring 1
51
WS08CZ
Spring Washer 1/2"
12
06
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The items marked with stars (*)have limited life time. Please run aregular
checking in order to maintain high performance.

DISPLACEMENT PUMP DISASSEMBLY
PROCEDURE
To reduce the risk of serious injury
whenever you are instructed to relieve
pressure, always follow the Pressure
Relief Procedure.
1. Disconnect the air and fluid hoses and
relieve the remaining pressure by
opening the drain valve.
2. Carefully screw the coupling nut (2)
off of the air motor piston rod.
Unfasten the tie rod locknuts (7) from
the tie rods (5). Carefully pull the
displacement pump away from the air
motor.
3. Please remind to execute the above
procedure carefully
Part
No.
Description
Qty
2
Nut,
coupling 1
3
Rod,
connecting 1
5
Rod, shoulder to
shoulder
3
6
Washer, spring
3
7
Nut,
lock 3
26
Nut,
jam 1
27
Pin,
cotter 1
07
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M010 Hulk Air Motor Parts List

The items marked with stars (*)have limited life time. Please run aregular
checking in order to maintain high performance.
COSMOSTAR Fluid Handling Equipment www.cosmostar.net e-mail: [email protected]
08
L0118CS Displacement Pump Parts Drawing

The items marked with stars (*)have limited life time. Please run aregular
checking in order to maintain high performance.
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09
L0118CS Displacement Pump Parts List
Item
Part No.
Description
Qty
01
C11801
Intake, valve
1
02
011502
Nut, coupling
1
03
011503
Rod, jam
1
04
C11804
Nut, packing
1
05
011505
Rod, tie
3
06
011506
Washer
3
07
011507
Nut
3
08
C11808
Housing, pump
1
*09
11809C
Gland, female CS
2
*10
011810
V
-Packing, teflon 6
*11
011811
V
-Packing, leather 4
*12
11812C
Gland, male, CS
2
13
011513
Gasket
1
14
C11814
Sleeve
1
15
C11815
Rod, displacement
1
16
011516
Pin, cotter
2
17
011517
Pin, ball stop
1
*18
BC0304
3/4” Ball
, SUS 1
*19
011819
Retainer, SUS
1
20
C11820
Stud, piston
1
21
011521
Guide, ball
1
22
011522
Pin, ball stop
1
*23
011523
O
-Ring, teflon 1
*24
BC1104
1
-1/4” Ball, SUS 1
26
011526
Nut, jam
1
27
011527
Pin, cotter
1

Operation
Before operating the equipment, be
sure the drain valve is closed. Flush
the equipment with acompatible
solvent to remove oil used for factory
testing and rust prevention. If you
notice excessive surging at the spray
gun, shut off the pump, trigger the
gun to relieve fluid pressure, and
open the drain valve (D) at the
bottom of the surge tank. See the left
figure, after the tank is drained,
close the drain valve and resume
operation. Be sure the drain valve is
fully closed when spraying and fully
open when draining or circulating
fluid to get the best results and
reduce wears on the valve.
Service Notes
Clean all parts thoroughly when
disassembling. Check parts carefully
for damage or wear, replace as
needed. Numbers in parentheses in
the text refer to the parts drawings.
Check periodically for leakage from
the small holes near the top and
bottom of the fluid filter. If you find
leakage at the holes or anywhere else,
replace the seals promptly.
Inspect the sealing surfaces for
nicks or scratches that might cause
leakage. Do not damage the sealing
surfaces. When reassembling filters
after cleaning or servicing, be sure to
install the filter support as shown in
the parts drawings. Do not install it
upside down.
Pressure Relief Illustration
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10
Fluid Outlet Filter

The items marked with stars (*)have limited life time. Please run aregular
checking in order to maintain high performance.
COSMOSTAR Fluid Handling Equipment www.cosmostar.net e-mail: [email protected]
Item
Part No.
Description
Qty
1
092801
Bowl
1
2
092802
Spring
1
*3
092803
Strainer
1
4
092804
Support
1
*5
092805
Gasket;
PTFE 1
*6
092806
O
-Ring; PTFE 1
7
092807
Manifold
1
8
092808
Plug
1
9
092809
Elbow, outlet
1
10
092810
Union, adapter
1
11
092811
Nipple, adapter
1
12
092812
Plug
1
11
R0928 Fluid Outlet Filter Part Drawing

R2006 Airless Spray Gun Parts Drawing
Item
Part No.
Description
Qty
A
1
2006A1
Gasket; copper
1
2
2006A2
Housing, tip guard
1
3
2006A3
Filter
1
4
2006A4
Tip
1
5
2006A5
Tip
guard 1
B
1
2006B1
Gasket; tip
1
2
2006B2
Tip
1
3
2006B3
Tip
guard 1
C
1
2006C1
Gasket; tip
1
2
2006C2
Tip
guard 1
Item
Part
No.
Description
Qty
1
200601
Body, gun
1
2
200602
Pin, pivot
1
3
200603
Screw, lock
1
4
200604
Setscrew
1
5
200605
Trigger, gun
1
6
200606
Housing, fluid
1
7
200607
Screw, housing
1
8
200608
Needle assembly
1
9
200609
Gasket
1
10
200610
Scre, lock
1
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12

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436
Be sure that all operators read and understand
this entire manual and separate manuals
supplied with components and accessories
before using this equipment.
Reference numbers and letters in parentheses
refer to the figures and the parts.
For assistance in designing asystem to meet
your particular needs, contact us.
Supplied Components
The air filter/ regulator/ lubricator (2)
removes harmful dirt and moisture from
the compressed air supply, controls pump
speed and outlet pressure by adjusting the
air pressure to the pump, and provides
automatic lubrication of the air motor.
Hose and Gun Connections
Connect agrounded fluid hose to the 3/8
npsm(f) outlet union(6)of the fluid filter(5).
Connect the spray gun to the fluid hose.
Connect agrounded air supply hose to the
air line fitting (3).
3
45
1
3
4
5
2
3
13
OPERATION

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PRESSURE RELIEF PROCEDURE
1. Close the fluid supply inlet; make the pump circulates out all of the internal
fluid.
2. Close the bleed-type air valve first, and open the fluid outlet valve or trigger the
gun to relieve pressure and open the drain valve
3. After above steps, the pump would operate slowly until the pressure relief
completely.
4. Close the fluid outlet valve.
Leave the fluid drain valve open until you are ready to pump the fluid again. If the
hose is completely clogged, or pressure has not been fully relieved after following
the steps above, very slowly loosen the hose and coupling and relieve pressure
gradually, then loosen completely. Then clear the hose.
FLUSH THE PUMP BEFORE FIRST USE
The pump is tested with lightweight oil, which is left in to protect the pump
parts. If the fluid you are using may be contaminated by the oil, flush it out with a
compatible solvent.
To clean any settled particles out of the system, flush the entire system after a
period of time. (Recommended 90 days or less).
CONNECT THE HOSES AND GUN TO THE SYSTEM
1. Connect the fluid hose between the fluid outlet valve and the fluid inlet of the
air assistant spray gun.
2. Connect the air hose between the gun air regulator and the air inlet of the air
assistant spray gun.
3. Verify that all fittings throughout the system are tightened securely.
14

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Shutdown and Care of the Pump
To reduce the risk of serious injury
whenever you are instructed to relieve
pressure, always follow the Pressure
Relief Procedure.
Check the oil in the cup of pump;
please add the appropriate
lubricated oil, and it should be over a
half of cup in order to prolong the life
of O-ring and packing.
After a period of time using the pump,
the packing and the O-ring below
the cup could be loosen by wearing.
Meanwhile, please using the tools
that COSMOSTAR provided (or using
the compatible one) to fix the hole of
the cup and turn it by clockwise. The
cup would be tighten with packing
and O-ring, and the material would be
stop leaking.
Set Air and Fluid Pressure with the
Air Regulator
To set the air and fluid pressure with
the air regulator, slowly increase the
air pressure, and use the regulator
setting to control the pump speed
and fluid pressure. Always use the
lowest air pressure necessary to get
desired results. Higher pressures
cause premature tip and pump wear.
To increase air pressure, turn T-
handle clockwise. To decrease air
pressure, turn T-handle
counterclockwise. To lock regulator
setting, tighten jam nut.
With the pump and lines primed, and
with adequate air pressure and
volume supplied, the pump will start
and stop as you open and close the
gun.
15
For overnight shutdown,
stop the pump at the
bottom of its stroke to
prevent fluid from
drying on the exposed
displacement rod and
damaging the throat
packing. Relieve the
pressure. Always flush
the pump before the
fluid dries on the
displacement rod. See
Flushing below.

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3. Connect agun to the hose, and
use wrench to fix it tighten
4. Add alubrication oil before
connect an air supply to the pump.
5. Rotate the oil cup clockwise to open it.
2. Connect aswivel with aairless
spray gun.
Prime the Pump
1. Connect afluid hose to the
high pressure filter as following
picture, and use wrench to fix it
tighten.
16
OPERATION

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9. Adjust the air regulator to close, Zero
bar.
•Pull the air regulator cap up as below
picture, rotate the cap clockwise to
increase air inlet pressure. Rotate the
cap counterclockwise to decrease air
inlet pressure.
•Press the cap down after adjustment
has been finished.
10. Place suction tube into fluid supply
container.
11. Hold metal part of the airless gun
firmly to side of apail and hold trigger
open.
8. Connect air supply line to air
inlet connector.
6. Add acompatible lubrication oil
into the cup.
7. Rotate the oil cup counter
clockwise to tight it.
19
OPERATION

Flush the pump:
•Before the first use.
•When changing colors or fluids.
•Before storing the pump.
Flush with afluid that is compatible
with the fluid you are pumping and with
the wetted parts in your system. Check
with your fluid manufacturer or supplier
for recommended flushing fluids and
flushing frequency.
Never leave water or water-base fluid in
the pump overnight.
To reduce the risk of serious injury
whenever you are instructed to relieve
pressure, always follow the Pressure
Relief Procedure.
1. Use the lowest operating pressure (1-
1.5 bar) to trigger the gun to spray out
all of material in the hose.
2. Close the master air inlet valve.
12. Open bleed-type air valve.
13. Slowly open air regulator until
pump starts, and cycle pump
slowly until all air is pushed out
and pump and hoses are fully
primed.
14. Release gun trigger, and finish
prime the pump.
15. Adjust the air regulator to your
requirement pressure, from 2-5
bars.
Use the lowest pressure to reach
your need possible.
16. Trigger the airless gun to start
spraying.
17. If pump fails to prime, open
drain valve and use drain valve as
apriming valve until fluid flows
from valve. Then close drain valve.
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18
OPERATION

6. Remove the suction tube to spray all of solvent until no fluid goes out, then
close the master air valve.
7. Relieve the pressure.
4. Start the pump. Always use the lowest operating pressure when flushing,
recommend 1-1.5 bar.
5. Flush the pump until clear solvent flow from the fluid outlet.
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19
OPERATION
3. Prepare the compatible flushing fluid in order to clean up pump.