Durr EcoGun AS MAN 1AF User manual

EcoGun AS MAN 1AF
Manual Spray Gun with Pressure Support
Gravity Cup
MSG00020EN, V02
N36320001V
www.durr.com
Operation manual

Information about the document
This document describes the correct han-
dling of the product.
Read the document prior to every activity.
Prepare the document for the application.
Pass on the product only together with
the complete documentation.
Always follow safety instructions, han-
dling instructions and specifications of
every kind.
Illustrations can deviate from the tech-
nical construction.
Validity range of the document
This document describes the following prod-
ucts:
N36320001V
EcoGun AS MAN 1AF
Hotline and Contact
If you have queries or would like technical
information, please contact your dealer or
sales partner.
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TABLE OF CONTENTS
1 Product overview.......................... 4
1.1 Overview................................ 4
1.2 Short description.................... 4
2 Safety............................................. 4
2.1 Presentation of Notes............ 4
2.2 Intended Use.......................... 5
2.3 Staff qualification.................... 5
2.4 Personal protective equip-
ment....................................... 6
2.5 Residual risks......................... 6
3 Transport, scope of supply and
storage........................................... 7
3.1 Scope of delivery................... 7
3.2 Handling of
packaging material................. 7
3.3 Storage.................................. 7
4 Assembly....................................... 7
4.1 Requirements for the
Installation point..................... 7
4.2 Assembly............................... 7
5 Commissioning............................. 8
6 Operation..................................... 10
6.1 Safety recommendations..... 10
6.2 Checks................................. 10
6.3 Changing the air cap............ 11
6.4 Alignment of the air cap....... 11
6.5 Guiding the spray gun.......... 12
6.6 Rinsing................................. 12
6.6.1 Safety recommendations.. 12
6.6.2 General notes................... 12
6.6.3 Rinsing spray gun............. 12
7 Cleaning and maintenance........ 14
7.1 Safety recommendations..... 14
7.2 Cleaning............................... 15
7.3 Maintenance........................ 17
7.3.1 Maintenance schedule...... 17
7.3.2 Lubrication........................ 17
8 Faults........................................... 17
8.1 Safety recommendations .... 17
8.2 Defects table........................ 19
8.3 Troubleshooting................... 20
8.3.1 Replace needle and
nozzle................................ 20
8.3.2 Replacing valve seal......... 21
8.3.3 Replace needle gland....... 23
9 Disassembly and Disposal........ 24
9.1 Safety recommendations..... 24
9.2 Disassembly......................... 24
9.3 Disposal .............................. 24
10 Technical data............................. 24
10.1 Dimensions and weight...... 24
10.2 Connections....................... 24
10.3 Operating conditions.......... 25
10.4 Emissions........................... 25
10.5 Operating values................ 25
10.6 Type plate.......................... 25
10.7 Materials used.................... 25
10.8 Operating and auxiliary
materials............................ 25
10.9 Material specification......... 25
11 Replacement parts, tools and
accessories................................. 26
11.1 Replacement parts............. 26
11.2 Tools.................................. 31
11.3 Accessories........................ 32
11.4 Order.................................. 33
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1 Product overview
1.1 Overview
Fig. 1: Overview
1 Air cap
2 Cap nut
3 Cup air hose
4 Overpressure valve (factory fitted)
5 Flow cup with air support
6 Throttle check valve (factory fitted)
7 Locknut
8 Material flow control
9 Air connection
10 Air control
11 Trigger
12 Flat jet control
1.2 Short description
The spray gun is intended for surface
coating. Compressed air is used to apply
material. The material to be atomized is fed
through a flow cup with air support. The
spray gun is handheld.
The spray gun is operated with the air cap
LC. The air cap LC is used for solvent-based
flammable and non-flammable fluid coating
materials (1-component paints and 2-compo-
nent paints) and water-based ones. It is
used for application of fillers, basecoats and
topcoats. If used with a hardened nozzle,
coating materials with abrasive additives
(coating materials containing zinc and alu-
minum) can be applied.
The following factors influence the spray jet
and therefore the result
Alignment of the air cap Ä 6.4 “Alignment
of the air cap”
Material quantity Ä 5 “Commissioning”
Air pressure Ä 5 “Commissioning”
Horn air pressure Ä 5 “Commissioning”
The spray gun uses a self-adjusting needle
package. The needle gland automatically
regulates the material-related wear of the
needle gland seal.
2 Safety
2.1 Presentation of Notes
The following notes can appear in this
instructions manual.
DANGER!
High risk situation that can lead to serious
injuries or death.
WARNING!
Medium risk situation that can lead to
serious injuries or death.
Product overview
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CAUTION!
Low risk situations that can lead to minor
injuries.
NOTICE!
Situations that can lead to material
damage.
ENVIRONMENT!
Situations that can lead to environmental
damage.
Contains additional information and
recommendations.
2.2 Intended Use
The spray gun EcoGun AS MAN 1AF is
used exclusively for hand guided spraying
coating of surfaces. Compressed air is used
to apply material.
The material is fed through a flow cup with
air support.
The use is only permitted in the industrial
area within the specified technical data Ä 10
“Technical data”.
The spray gun is approved for use in explo-
sive areas of Ex zones 1 and 2.
Wrong use
Wrong use of the spray gun entails a risk of
death.
Do not aim the spray gun at people or
animals.
Do not atomize liquid nitrogen.
Combine the spray gun only with compo-
nents approved by Dürr Systems for
operation.
Only use approved materials. Follow
safety data sheets of the materials.
Do not attempt to make conversions or
changes on your own.
Do not use spray gun in areas with Ex
zone 0.
EX labeling
II 2G T60°C X
II - Device group II: all areas except
mining
2G - Device category 2 for gas
T60 °C - Surface temperature max. 60 °C
X - Specific operating conditions for
safe operation
The following conditions must be observed
for safe operation:
Ground spray gun and work piece.
Only use conductive air hoses.
Ensure that static electricity can be dis-
charged.
Use compressed air quick couplings
exclusively for water-based materials.
2.3 Staff qualification
WARNING!
Inadequate qualification
If you do not assess risks properly,
serious injury or death may result.
– All activities must be conducted exclu-
sively by people who possess the
proper qualifications.
This instructions manual is intended for
qualified personnel in the industry pos-
sessing at least the following knowledge:
Safe operation of application stations
Fundamentals of electrical engineering,
hydraulics and pneumatics:
Safe handling of the used material, oper-
ating and auxiliary materials
Training for operation, maintenance and
troubleshooting
Dürr Systems offers special product training
Ä “Hotline and Contact”.
Safety
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2.4 Personal protective equipment
When working in explosive areas, the pro-
tective clothing, including gloves, must meet
the requirements of DIN EN 1149-5. The
insulation resistor must not exceed 100 MΩ.
Footwear must meet the requirements of EN
ISO 20344. The insulation resistor must not
exceed 100 MΩ.
Wear the specified personal protective
equipment when working. Provide the fol-
lowing personal protective equipment:
2.5 Residual risks
Explosion
Sparks, open flames and hot surfaces can
cause explosions in explosive atmospheres.
Serious injuries and death can be the conse-
quence.
Perform all maintenance away from
explosive atmospheres.
Do not use any sources of ignition and
open light.
Do not smoke.
Ground the product.
Ground the work piece.
Only use conductive lines.
Use compressed air quick couplings
exclusively for water-based materials.
Flammable materials can cause a fire or an
explosion.
Ensure that the flashpoint of the cleaning
agent is at least 5 K above the ambient
temperature.
Pay attention to the explosion group of
the material, cleaning agent and rinsing
agent.
Ensure that forced ventilation and fire
protection equipment are in operation.
Do not use any sources of ignition and
open light.
Do not smoke.
Follow safety data sheets.
Danger from harmful or irritant sub-
stances
If you come in contact with hazardous sub-
stances or vapors, it can cause serious
injury or death can result.
Ensure that the forced ventilation is
operational.
Follow safety data sheets.
Wear specified protective equipment.
Pressure
Material can escape with high pressure and
penetrate the body. Death or serious injuries
may result.
Before working on the product:
Disconnect the system with the product
from compressed air and material supply.
Secure the system against being
switched on again.
Relieve the lines.
Noise
The noise during normal operation may
cause severe hearing damage.
Wear hearing protection.
Do not spend more time then necessary
in the work area.
Hot surfaces
During normal operation the surfaces of
components can get extremely hot. Contact
with it can cause burns.
Before carrying out any work:
Check the temperature.
Do not touch hot surfaces.
Let components cool down.
Wear protective gloves.
Safety
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3 Transport, scope of supply
and storage
3.1 Scope of delivery
The scope of supply includes the following
components:
Spray gun
Tool kit Ä 11.2 “Tools”
Inspect delivery on receipt for completeness
and integrity.
Report defects immediately Ä “Hotline and
Contact”.
3.2 Handling of packaging material
ENVIRONMENT!
Environmental damage due to wrong
disposal
Wrongly disposed packaging material may
not be re-used or recycled. It harms the
environment.
– Dispose of material no longer required
in an environment-friendly manner.
– Observe local disposal specifications.
3.3 Storage
Requirements for the warehouse:
Do not store outdoors.
Store in a dry and dust-free place.
Do not expose to aggressive media.
Protect from solar radiation.
Avoid mechanical vibrations.
Temperature: 10°C to 40°C
Relative humidity: 35% to 90%
4 Assembly
4.1 Requirements for the
Installation point.
It must be possible to disconnect the
compressed air supply to the spray gun
and secure it against reconnection.
The compressed air supply must be
adjustable.
Lines, seals and screw connections must
be designed to conform to the spray gun
requirements Ä 10 “Technical data”.
The workplace must have technical venti-
lation.
Working environment and grounding
Flooring of the working areas must be anti-
static, according to DIN EN
50050-1:2014-03, measurement according
to DIN EN 1081:1998-04.
4.2 Assembly
Protective equipment:
Protective workwear
Protective gloves
1. WARNING!
Sources of ignition may cause explo-
sions!
Ensure a non-explosive atmosphere.
2. Insert filter, if necessary.
Transport, scope of supply and storage
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Fig. 2: Assembly
3. Screw flow cup with air support (3) on the
thread of the material connection.
4. Connect cup air hose (1) to the overpres-
sure valve (2) and throttle check valve
(4).
Do not disturb the overpressure
valve (2) and throttle check valve
(4). Valves are already factory-
set.
5. Connect air hose to the air connection
(5).
For water-based materials, you
can also use compressed air
quick couplings.
6. Check air hose for correct seating.
5 Commissioning
Protective equipment:
Protective gloves
Safety boots
Protective workwear
Eye protection
Respiratory protection device
Use ear protection
Requirements:
Flow cup with air support and cup air sup-
port have been assembled Ä 4.2
“Assembly”.
1. Rinse the spray gun before filling it with
paint Ä 6.6.3 “Rinsing spray gun”:
Using solvent for solvent-based paints
Use water for water-based paints
2. NOTICE!
Maintain a distance of 20 mm between
upper paint border and cup edge.
Fill paint in the flow cup.
3. Create a trial spray pattern on a test work
piece.
Commissioning
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Setting the spray pattern
Setting the material flow
Fig. 3: Setting the material flow
1. Set the material flow.
Loosen locknut (1).
Turn set screw (2) in required direc-
tion.
Right turn: less material
Left turn: more material
Tighten the locknut (1).
Do not turn the set screw up to
the mechanical stop. The needle
can then no longer move prop-
erly.
Set total air pressure
Fig. 4: Setting the total air and horn air pres-
sure
2. Set the total air pressure by turning the
total air control (2).
Right turn: Lower total air pressure
Left turn: higher total air pressure
Observe the following character-
istic curve.
Do not adjust total air pressure
higher than needed for atomiza-
tion of the material and to achieve
the desired coating quality.
Excess air pressure causes
increased spray mist and lower
transfer power.
Setting the horn air pressure
3. Set the horn air pressure by turning the
flat jet control (1).
Commissioning
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Right turn: Flat jet minimum (rounder
spray pattern)
Left turn: Flat jet maximum (flatter
spray pattern)
You can turn the flat jet control
continuously and adjust the spray
pattern from flat to round jet.
Characteristic curves
The characteristic curves show the air flow
rate for various nozzle sets and air caps for
different air pressures.
Fig. 5: Characteristic curve
1 Flat jet
2 Circular jet
X axis Atomizer air pressure and control air
pressure (psi)]
Y axis Flow rate [Nl/min (CFM)]
6 Operation
6.1 Safety recommendations
WARNING!
Danger of explosion due to chemical
reactions
Material, halogenated hydrocarbon-based
rinsing agent or cleaning agent can chemi-
cally react with aluminum components of
the product. Chemical reactions can
cause explosions. Serious injuries and
death can be the consequence.
– Only use rinsing agents and cleaning
agents that do not contain any halo-
genated hydrocarbons.
NOTICE!
Material damage due to dried material
residues
If material residues dry in the product, that
can harm components.
– Rinse product immediately after each
use.
6.2 Checks
1. Perform the following checks during oper-
ation:
Check air connection for correct seat
and leaks.
Check air car for cleanliness.
Check nozzle for cleanliness.
Operation
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6.3 Changing the air cap
Protective equipment:
Protective workwear
Protective gloves
Removing the air cap
Fig. 6: Changing the air cap
1. Loosen the cap nut (2).
2. Remove the air cap (1).
Assembling air cap
3. Place the air cap (1).
4. Align the air cap (1) as required Ä 6.4
“Alignment of the air cap”.
5. Tighten cap nut (2).
6.4 Alignment of the air cap
Protective equipment:
Protective workwear
Protective gloves
The position of the air cap determines the
alignment of the spray pattern.
Fig. 7: Air cap alignment
1. Lightly loosen cap nut (2).
2. Turn the air cap (1) as required for the
desired spray pattern.
3. Tighten cap nut (2) by hand.
Operation
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6.5 Guiding the spray gun
Protective equipment:
Protective gloves
Safety boots
Protective workwear
Eye protection
Respiratory protection device
Use ear protection
Fig. 8: Guiding the paint gun
1. Guide the spray gun as follows:
Guide spray gun at 90 degrees to the
surface.
Maintain a distance of 15 to max.
25 cm to the surface.
The distance can vary for effect
coatings.
6.6 Rinsing
6.6.1 Safety recommendations
NOTICE!
Material damage due to unsuitable
rinsing agent
If the rinsing agent reacts chemically with
the components or the material, compo-
nents get damaged.
– Use only the rinsing agents that are
compatible with the components and
the material.
–Refer to safety data sheet of material
manufacturer.
6.6.2 General notes
When rinsing, use fluid to remove inner
soiling from components.
6.6.3 Rinsing spray gun
Protective equipment:
Use ear protection
Eye protection
Respiratory protection device
Protective workwear
Protective gloves
Rinsing spray gun:
After end of work
Before every change of material
Prior to cleaning
Prior to dismantling
Before a long time of non-use
Before placing in storage
From the end of the processing time of 2-
component paints
Operation
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Additional rinsing intervals depend
on the material used.
Preparation for rinsing
1. Disconnect air hose from the air connec-
tion.
Fig. 9: Removing the air cap
2. Screw flow cup with air support from the
threads of the material connection (2).
NOTICE!
Material residues in the overpres-
sure valve
Remains of the application materials or
cleaning materials can enter the over-
pressure valve during cleaning of the
flow cup lid.
– Clean flow cup lid carefully.
3. Remove cup air hose from the throttle
check valve (1).
4. Loosen cap nut (3).
5. Remove air cap (4).
Purging
6. Keep collecting tray ready.
Fig. 10: Rinsing spray gun
7. Hold the spray gun slightly at an angle
above the collecting tray, nozzle pointing
towards the ground.
8. Rinse the spray gun with an appropriate
rinsing agent through the material con-
nection (2), until the rinsing agent runs
clean without any material residue. Use a
brush to carefully clean the nozzle holes
(5).
9. Ensure proper disposal of the exiting
material and rinsing agent.
10. Connect the compressed air hose to the
spray gun.
11. Operate trigger lever until no more
rinsing agent flows out.
Final work
12. Place air cap (4).
13. Tighten cap nut (3).
Operation
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7 Cleaning and maintenance
7.1 Safety recommendations
WARNING!
Danger of fire and explosion
Flammable materials can cause a fire or
an explosion.
– Ensure that the flashpoint of the
cleaning agent is at least 5K above the
ambient temperature.
– Only electrically conductive containers
may be used for the cleaning fluid.
Containers must be grounded.
–Pay attention to the explosion group of
the material, cleaning and rinsing
agent.
– Ensure that forced ventilation and fire
protection equipment are in operation.
– Do not use any sources of ignition and
no open light.
– Do not smoke.
– Follow safety data sheets.
WARNING!
Risk of injury from unsuitable replace-
ment parts in explosive areas.
Replacement parts not compliant with the
specifications of the ATEX guidelines can
cause explosions in an explosive atmos-
phere. Serious injuries and death can be
the consequence.
– Use exclusively original replacement
parts.
WARNING!
Danger to health from harmful or irri-
tant substances
Contact with hazardous liquids or vapors,
can result in serious injury or death.
– Ensure that the forced ventilation is
operational.
– Follow safety data sheets.
–Wear specified protective clothing.
WARNING!
Risk of injury due to escaping material
and compressed air
Escaping compressed material can cause
serious injury.
Before working on the product:
– Disconnect the system with the product
from compressed air and material
supply.
–Secure the system against reconnec-
tion.
– Relieve the lines.
WARNING!
Danger of explosion due to chemical
reactions
Material, halogenated hydrocarbon-based
rinsing agent or cleaning agent can chemi-
cally react with aluminum components of
the product. Chemical reactions can
cause explosions. Serious injuries and
death can be the consequence.
– Only use rinsing agents and cleaning
agents that do not contain any halo-
genated hydrocarbons.
Cleaning and maintenance
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NOTICE!
Unsuitable cleaning agents
Unsuitable cleaning agents can damage
the product.
– Only use cleaning agents approved by
the material manufacturer.
–Follow safety data sheets.
–Place heavily soiled components in a
cleaning bath.
– Only place those parts in the
cleaning bath, which are suitable for
the cleaning bath.
– Use only electrically conductive
containers.
– Ground the container.
– Do not use ultrasound baths.
Use alcohols (isopropanol, butanol) for
water-based paint.
Remove dried water-based paint residue
using a manufacturer approved thinner.
When cleaning with solvent, do not spray
into a closed container. An explosive gas-
air mixture can form inside closed con-
tainers.
NOTICE!
Damage due to unsuitable cleaning
tools
Unsuitable cleaning tools can damage the
product.
– Only use cloths, soft brushes and
paintbrushes.
– Do not use abrasive cleaning tools.
–Do not poke blocked nozzles with met-
allic objects.
– Do not use compressed air for
cleaning.
– Do not use any thinner spray guns.
– Do not use high pressure for cleaning
agents.
7.2 Cleaning
Protective equipment:
Use ear protection
Eye protection
Respiratory protection device
Protective workwear
Protective gloves
1. Rinse the spray gun Ä 6.6 “Rinsing”.
2. Remove material residues with a cloth or
a soft brush.
3. Clean the spray gun carefully and dry it
with a soft cloth.
Cleaning and maintenance
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Clean filter of the flow cup.
Protective equipment:
Protective workwear
Protective gloves
For a thorough cleaning, you need to
remove the filter screen.
Disassembly
Fig. 11: Clean filter screen
1. Pull out filter screen (1) by the holding pin
from the connector.
2. Clean the filter screen (1) in the cleaning
bath.
3. Insert filter screen (1) in the connector
and push down until it sits firmly.
Clean air cap, nozzle and needle.
Protective equipment:
Protective workwear
Protective gloves
For a thorough cleaning you need to remove
the air cap, nozzle and needle.
Disassembly
Fig. 12: Disassemble air cap, nozzle and
needle
1. Loosen the cap nut (2).
2. Remove the air cap (1).
3. Push trigger (5) through. Keep it pressed.
ðThe needle (4) is pushed backwards
so that it will not be damaged during
disassembly of the nozzle (3).
4. Unscrew and remove nozzle (3) using
monkey wrench.
5. Release trigger lever (5).
6. Unscrew and remove set screw (7) and
locknut (6). Remove with needle spring
and bearing.
7. Clean air cap (1) using cleaning agent
and cleaning brush.
8. Dry cleaned air cap (1) using compressed
air (at max. 2 bar).
9. Clean the nozzle in the cleaning bath
using a soft brush.
Cleaning and maintenance
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10. Remove needle (4). Remove the appli-
cation material with detergent and a soft
cloth.
Assembly
11. Insert and tighten nozzle (3).
Tightening torque: 10 Nm
12. Place the air cap (1).
13. Tighten cap nut (2).
14. Push in needle (4) into the gun housing
from the back.
15. Set needle spring with bearing on
needle (4). Unscrew and remove set
screw (7) and locknut (6).
16. Lubricate needle (4) in the area of the
gland bolt and the trigger lever (5).
7.3 Maintenance
7.3.1 Maintenance schedule
The maintenance intervals given below are based on experiential values. Adjust maintenance
intervals individually to increased requirements.
Interval Maintenance work
After each use Cleaning Ä 7.2 “Cleaning”.
Daily Check condition and tightness of the spray gun and of the connections
and lines.
Weekly Lubricate lever bearing Ä 7.3.2 “Lubrication”.
7.3.2 Lubrication
The following components must be lubri-
cated with a silicone-free grease:
O-rings and seals
Bearing
Set screw and threads
Needle gland
Lever bearing
Lubricate internal components at the
time of maintenance work, which
include disassembly of the con-
cerned components any way.
Recommended lubricant: SYN-
THESO GLEP 1 Ä 10.8 “Operating
and auxiliary materials”
8 Faults
8.1 Safety recommendations
NOTICE!
Property damage due to improper
replacement of needle and nozzle
Replacing only the needle or only the
nozzle could damage spray gun compo-
nents. This can compromise the tightness
of the spray gun. The spray pattern deteri-
orates.
– Observe order of replacement steps
(needle – nozzle).
– Observe order of assembly steps
(nozzle – needle).
–Always replace nozzle and needle at
the same time.
Faults
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NOTICE!
Property damage due to improper han-
dling
Mechanical load can damage needle and
nozzle.
– Handle with care during installation
and dismantling.
– Do not subject the needle to any
mechanical pressure.
– Avoid collisions of components to be
assembled and disassembled with the
needle.
–Do not excessively tighten compo-
nents.
Faults
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8.2 Defects table
Visualizer of typical spray pattern problems
Spray pattern Fault identification
Spray jet is distorted.
Spray jet is bent or tapered.
Spray jet is too thick in the middle.
Spray jet is split.
Spray jet is uneven (pulsating).
Fault description Cause Remedy
No material Flow cup empty Check flow cup. Top up, if necessary.
Material escapes at the
needle gland.
Needle gland worn
out
Replace needle gland Ä 8.3.3
“Replace needle gland”.
Needle gland loose Tighten needle gland sensitively.
Air escapes between valve
pin and housing.
Valve seal worn out. Replace valve seal Ä 8.3.2 “Replacing
valve seal”.
Spray jet is distorted. Air cap is misaligned. Rotate air cap into the required posi-
tion. Ä 6.4 “Alignment of the air cap”
Spray jet is bent or tapered. Bores in air cap are
soiled.
Clean and check air cap. Replace air
cap if defective Ä 7.2 “Cleaning”.
Faults
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Fault description Cause Remedy
Nozzle seat soiled. Cleaning the nozzle seat Ä 7.2
“Cleaning”.
Nozzle soiled or
defective.
Clean and check the nozzle. If nozzle
is defective, replace it along with the
needle Ä 8.3.1 “Replace needle and
nozzle.”.
Spray jet is too thick in the
middle.
Material too viscous. Change material consistency.
Horn air pressure too
low
Increase horn air pressure via the flat
jet control Ä 5 “Commissioning”.
Air pressure too low Increase the air pressure via the total
air control Ä 5 “Commissioning”.
Spray jet is split. Material too thin. Change material consistency.
Horn air pressure too
high
Decrease the horn air pressure via the
flat jet control Ä 5 “Commissioning”.
Air pressure too high Decrease the air pressure via the total
air control Ä 5 “Commissioning”.
Spray jet is uneven (pul-
sating). The spray pattern
quality is bad.
Nozzle soiled or
defective.
Clean and check the nozzle. If nozzle
is defective, replace it along with the
needle Ä 8.3.1 “Replace needle and
nozzle.”.
Cap nut or nozzle is
not properly tight-
ened.
Tighten cap nut and nozzle Ä 7.2
“Cleaning”.
Damaged O-ring Replace O-ring Ä 8.3.1 “Replace
needle and nozzle.”
8.3 Troubleshooting
8.3.1 Replace needle and nozzle.
Protective equipment:
Protective workwear
Protective gloves
Requirements:
Spray gun was disassembled Ä 9.2 “Dis-
assembly”.
Disassembly
Faults
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