Krautzberger HS 25 Series User manual

HS 25, HS 25 HV1, HS 25 HV3
Translation of the original operating instructions
T-Dok-009-GB-Rev.3
GB Hand-held Spray Gun HS 25
Operating instructions

Thank you for selecting a Krautzberger product.
This product has been manufactured following state-of-the-art manufacturing procedures and
extensive quality assurance measures. We promise you a product of the highest quality.
If you have questions, requests or suggestions, please contact us. We are always glad to assist
you.
Information about the operating manual
This manual provides important information on how to work with the device safely and efficiently.
The manual is part of the device, must always be kept in the device's direct proximity and should
be available to the personnel at all times.
The personnel must have read and understood this manual before starting any work. Compliance
with all specified safety information and instructions is a basic requirement for safe working condi-
tions.
In addition, the local occupational safety regulations and general safety rules apply for the area of
application of the device.
Due to optional finishing variants, it is possible that the figures shown in this operating manual
deviate from your device.
Information about explosion protection
Many of our competitors have been marking their products with the Ex symbol as a matter of prin-
ciple for some time now.
At Krautzberger we do not do this.
We engineer and manufacture our products in line with currently applicable directives.
If the labelling on the product is required, it is affixed to the product as the result of the necessary
analysis of ignition sources. If no labelling is affixed, the analysis of ignition sources and previous
experience with the assessment of the suitability of products for use in a potentially explosive area
have shown that the product described in this operating manual does not represent a potential
source of ignition, with the exception of electrostatic charge.
Taking into account the potential equalisation (provided by proper earth connection), the use in an
area at risk for explosions is permitted in accordance with the current valid directives.
[email protected], www.krautzberger.com
GB–2

Table of contents
1 Function and identification................................................................................................ 5
1.1 Function....................................................................................................................... 5
1.2 Identification................................................................................................................. 5
2 Safety and responsibility................................................................................................... 7
2.1 Symbols in this manual................................................................................................ 7
2.2 Personnel requirements............................................................................................... 9
2.3 Personal safety equipment and clothing.................................................................... 10
2.4 Responsibility of the owner........................................................................................ 11
2.5 Intended use.............................................................................................................. 12
2.6 General safety information......................................................................................... 13
2.7 Residual risks............................................................................................................ 13
2.8 Course of action in a hazardous situation.................................................................. 13
3 Transport and storage..................................................................................................... 15
3.1 Transport................................................................................................................... 15
3.2 Storage of packaged units......................................................................................... 15
3.3 Unpacking.................................................................................................................. 15
3.4 Packaging.................................................................................................................. 15
4 Overview............................................................................................................................ 17
5 Installation......................................................................................................................... 18
5.1 Safety......................................................................................................................... 18
5.2 General information about the installation................................................................. 19
5.3 Dimensions................................................................................................................ 20
5.4 Connections............................................................................................................... 20
6 Commissioning................................................................................................................. 21
6.1 Safety......................................................................................................................... 21
6.2 General information about the operation................................................................... 22
6.3 Commissioning.......................................................................................................... 23
6.4 Adjusting the spray pattern........................................................................................ 23
6.5 Shutting down............................................................................................................ 24
7 Maintenance...................................................................................................................... 26
7.1 Safety......................................................................................................................... 26
7.2 General information about the maintenance.............................................................. 26
7.3 Maintenance schedule............................................................................................... 27
7.4 Work after completed maintenance........................................................................... 27
7.5 Clean hand-held spray gun........................................................................................ 27
7.6 Change air and fluid nozzles..................................................................................... 29
7.7 Change fluid needle................................................................................................... 30
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–3

7.8 Change seals............................................................................................................. 32
8 Trouble shooting.............................................................................................................. 38
8.1 Safety......................................................................................................................... 38
8.2 Troubleshooting table................................................................................................ 39
9 Spare parts........................................................................................................................ 41
9.1 Safety......................................................................................................................... 41
9.2 General information................................................................................................... 41
9.3 Spare parts................................................................................................................ 42
10 Accessories...................................................................................................................... 45
11 Dismantling....................................................................................................................... 47
11.1 Safety....................................................................................................................... 47
11.2 Dismantling.............................................................................................................. 48
12 Disposal and recycling.................................................................................................... 49
12.1 Safety....................................................................................................................... 49
12.2 Disposal and recycling............................................................................................. 49
13 Technical data................................................................................................................... 51
13.1 Dimensions and weight............................................................................................ 51
13.2 General specifications............................................................................................. 51
14 Declaration of conformity................................................................................................ 52
15 Notes.................................................................................................................................. 53
16 Index.................................................................................................................................. 55
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–4

1 Function and identification
1.1 Function
Hand-held spray guns are used for the
nCoating/marking of surfaces
nDosing of fluids
nPlacement of adhesive or marking points
The fluid medium is fed into the hand-held spray gun via
nPumps, pressure or pressure-drop containers
nScrewed-on fluid or suction container
If small quantities of a fluid are processed, the use of fluid or suction containers is recom-
mended. Suction containers should only be used with low-viscosity fluids. For suction opera-
tion, the air consumption of the hand-held spray gun is higher since the fluid is conveyed
against the force of gravity.
Depending on the customer configuration, the hand-held spray gun HS25 can be fitted with the
HV1 or HV3 nozzle system. Both systems are HVLP systems (hvlp = high volume, low pressure)
for low-mist coating.
The spray fluid is atomised using compressed air. The geometry of the spray jet and the sprayed
quantity of the spray fluid can be adjusted with the following measures:
nSelection of the air and fluid nozzle
nChanging the atomisation air pressure on the external regulator
nChanging of the spray fluid pressure
nAdjustment of the needle stroke on the regulator of the hand-held spray gun
nAdjustment of the flat jet regulator on the hand-held spray gun.
1.2 Identification
Type Max. working
pressure spray
agent
Max. working
pressure atom-
iser air
Design Product number
HS 25 6 bar 12 bar Suction connection -
short lever
200-0100
Suction connection -
long lever
200-0101
Flow connection -
short lever
200-0110
Flow connection -
long lever
200-0111
HS 25 HV1 * 4 bar 4 bar Suction connection -
short lever
200-0106
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–5

Suction connection -
long lever
200-0107
Flow connection -
short lever
200-0112
Flow connection -
long lever
200-0113
HS 25 HV3 * 4 bar 4 bar Suction connection -
short lever
200-0108
Suction connection -
long lever
200-0109
Flow connection -
short lever
200-0114
Flow connection -
long lever
200-0115
* HV = High Volume
Additional information can be found in ( Ä Chapter 13 ‘Technical data’ on page 51)
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–6

2 Safety and responsibility
2.1 Symbols in this manual
Safety information
This manual uses symbols to identify safety information. The safety information is preceded by
signal words that indicate the severity of the hazard.
DANGER!
This combination of symbol and signal word indicates an immediate dangerous situation,
which will cause death or severe injuries if it is not averted.
WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause property and environmental damage if it is not averted.
ENVIRONMENT!
This combination of symbol and signal word indicates potential environmental hazards.
Safety information in operating instructions
Safety information can refer to specific, individual operating instructions. Such safety information is
embedded in the operating instructions so that it does not disrupt the reading flow during the exe-
cution of the action. The signal words described above are used.
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–7

Example:
1. Loosen screw.
2.
CAUTION!
Pinching hazard at the cover!
Carefully close cover.
3. Tighten screw.
Special safety instructions
The following symbols are used in safety instructions to draw the attention to special hazards:
Warning signs Type of danger
Warning – danger zone.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and fault-free operation.
Additional identifications
The following symbols are used in this manual to highlight operating instructions, results, lists, ref-
erences, and other elements:
Identification Explanation
Step-by-step operating instructions
ðResults of procedural steps
References to sections in this manual and other applicable docu-
ments
Lists without specified sequence
[Pushbutton] Operating elements (e.g. buttons, switches), display elements
(e.g. signal lights)
‘Display’ Screen elements (e.g. buttons, assignment of function keys)
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–8

2.2 Personnel requirements
WARNING!
Risk of injury in case of insufficient qualification of the personnel!
The owner of the system/device is responsible for adhering to the qualifications.
If unqualified personnel carries out work on the device or steps into the danger zone of the
device, hazards arise which may cause severe injuries and significant material damage.
– All work must only be carried out by respectively qualified personnel.
– Unqualified personnel must be kept away from the hazard areas.
This manual identifies the qualifications of the personnel for the different scopes of work as listed
below:
Operator
The operator has been instructed by the system owner in an orientation session on the assigned
tasks and possible dangers in case of improper behaviour. Tasks that go beyond the operation in
standard mode must only be carried out by the operator if such is indicated in this manual and the
operate has explicitly been tasked to do so.
Qualified personnel
Due to their specialised professional training, knowledge, and experience as well as knowledge of
the industry-specific standards and regulations, qualified personnel are in a position to perform
assigned tasks and to identify and avert potential risks on their own.
Only persons who can be expected to perform their tasks reliably are permitted as personnel. Per-
sons whose reaction capability is impaired, e.g. through drugs, alcohol or medication are not per-
mitted.
When selecting the personnel, the stipulations regarding age and occupation that apply at the site
of implementation must be observed.
Unauthorized persons
WARNING!
Risk of fatal injury for unauthorized person through hazards in the hazard zone and
work area!
Unauthorized persons, who do not fulfil the requirements described herein do not know the
dangers in the work area. Unauthorized persons are therefore subject to a risk of serious
injury including death.
– Keep unauthorized persons away from hazard zone and work area.
– If in doubt, address persons and tell them to leave the hazard zone and work area.
– Discontinue the work as long as unauthorized persons are present in the hazard zone
and the work area.
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–9

2.3 Personal safety equipment and clothing
Personal safety equipment is used to protect persons from impacts on safety and health at work.
The personnel must wear personal safety equipment while carrying out the various tasks and while
working with the device. The individual sections of this manual will indicate the personal safety
equipment separately.
Description of the personal safety equipment and clothing
The personal safety equipment and clothing is described below:
Ear protection
Ear protection provides protection against hearing damage.
Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
Protective clothing
Protective clothing are tight fitting work clothes with low tear resistance, with tight sleeves, and
without any protruding parts.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as
well as from contact with hot surfaces.
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–10

Safety goggles
Safety goggles are used to protect the eyes from flying components and splashes of liquid.
Safety shoes
Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
2.4 Responsibility of the owner
Owner
The owner is the person, who directly operates the machine for commercial or economical pur-
poses or who allows a third-party to use/apply it and who is responsible for the legal product stew-
ardship for the protection of the user, the personnel or third parties.
Owner responsibilities
The machine is used in an industrial environment. The owner of the machine is therefore subject to
the obligations as stipulated by the Occupational Health and Safety Act.
In addition to the safety information in this manual, the country-specific safety, accident prevention
guidelines and environmental protection regulations, applicable at the site of implementation of the
machine must be adhered to.
The following shall apply in particular:
nThe owner must familiarise himself with the applicable occupational safety regulations and
also conduct a risk assessment to determine additional risks that may arise due to the specific
working conditions at the place of use of the machine. These must be implemented in the
form of operating instructions for the operation of the machine.
nDuring the entire operating time of the machine, the owner must check whether the operating
instructions that were established by the owner correspond with the respective current appli-
cable rules and standards and must adjust them if necessary.
nThe owner must clearly regulate and specify the responsibilities for installation, operation,
repair of malfunctions, maintenance, and cleaning.
nThe owner must ensure that all persons working with the machine have read and understood
these instructions. In addition, the owner must train personnel at regular intervals and inform
the personnel of the hazards.
nThe owner must provide the personnel with the necessary protective gear and make the
wearing of the necessary protective gear mandatory.
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–11

Furthermore, the owner is responsible for making sure that the machine is always in perfect tech-
nical condition. Therefore, the following applies:
nThe owner must ensure that the maintenance intervals described in this operating manual are
adhered to.
nThe owner must have all safety equipment checked regularly for functionality and complete-
ness.
2.5 Intended use
The hand-held spray gun manually coats surfaces with liquid and low-viscosity spray fluids. Typ-
ical spray fluids are paints, dyes, adhesives, glazes, enamels, debonding agents, etc.
The intended use also includes adherence to all the specifications in this manual.
Any use beyond the intended use or any other use constitutes improper use.
WARNING!
Danger due to improper use!
Misuse of the hand-held spray gun can cause dangerous situations.
– Only carry out the installation and start-up according to the steps described in this oper-
ating manual.
– Make sure that the utilised hose lines fulfil the requirements with respect to pressure,
chemical, and mechanical loads.
– Always observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations for the area of use for the spray gun.
– The chemical consistency of the materials used by us cannot always be reliably
assessed due to the large variety of utilised fluids, concentrations, temperatures, and
impurities. Note, please test the suitability because we cannot extend any guarantees for
that.
– Adhere to the spray media manufacturer's safety data sheets.
– Only use the manufacturer's original spare parts.
– Only operate the hand-held spray gun in compliance with the values specified in the (
Ä Chapter 13 ‘Technical data’ on page 51).
– The conformity of the product is voided in case of structural modifications.
– Make sure that the connected compressed air is oil-free and free of solid matter.
– Operate the hand-held spray gun with processed, dried compressed air (air quality pur-
suant to DIN ISO 8573-1: grade 4).
– Never point the compressed air and the spray jet towards living beings.
No claims of any kind can be asserted due to damage resulting from improper use.
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–12

2.6 General safety information
WARNING!
Life threatening risk of injury or property damage through the application of hazardous
media!
The application of hazardous media can lead to death, most severe injuries or property
damage.
Note:
– Ensure the resistance of the machine against the medium that is to be applied.
– Always adhere to the safety data sheet of the medium that is to be applied.
The owner is responsible for the presence and the up-to-date status of the safety data
sheet and the associated creation of the risk assessment of the effected workstations.
CAUTION!
Risk of injury through compressed air!
Uncontrolled leaks of compressed air can lead to serious injuries!
Note:
– Prior to any work on the device/machine, all compressed-air lines must be closed and
disconnected.
– Never point compressed air at living beings.
2.7 Residual risks
Hand-held spray guns made by Krautzberger GmbH have been manufactured according to the
state of the art and recognized technical safety regulations.
Nonetheless, their use may pose a threat to the life or health of users or third parties, or harm the
device itself or other material assets.
nThe hand-held spray gun must only be used as intended.
nThe manual spray gun may only be transported in a defect-free condition.
nAny malfunctions impacting the safety must be remedied immediately.
2.8 Course of action in a hazardous situation
In principle, the applicable country-specific and regional regulations concerning the course of
action in case of an emergency must be adhered to and if necessary respective safety meas-
ures must be taken on the system owner side.
The following scenarios constitute an emergency:
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–13

nHuman life is at risk
nThe machine and/or the work piece are being damaged.
In these cases, the emergency stop system of the machine must be activated immediately and
countermeasures must be initiated if necessary.
Course of action in case of an accident / fire
The following measures must be initiated in case of an accident / fire:
nImmediate measures must be taken at the accident site / location of the fire
nReport accident / fire
The following information must be provided when reporting an accident:
nAdminister first aid
nIn case of a fire: Fight fire
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–14

3 Transport and storage
3.1 Transport
nThe hand-held spray gun is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
3.2 Storage of packaged units
Storage of packaged units
Store packaged units subject to following conditions:
nDo not store outside.
nDry and dust-free storage.
nKeep away from any aggressive media.
nProtect from UV radiation.
nAvoid mechanical shocks.
nStorage temperature: 15 to 35 °C.
nRelative atmospheric humidity: max. 60%.
nFor storage for longer than 3 months, check the general condition of all parts and the pack-
aging on a regular basis. If necessary, refresh or renew the conservation.
It is possible that there are notes on the packaged units concerning the storage that extend
beyond the requirements listed here. Follow those accordingly.
3.3 Unpacking
Transport inspection
Immediately upon receipt check the delivery for completeness and damage from transport.
In the event of visible exterior transport damage, proceed as follows:
nDo not accept delivery or only do so with reservations.
nRecord scope of damage on the transport documents or on the bill of delivery of the shipping
company.
nInitiate complaint.
Report any damage as soon as it has been detected. Damage claims can only be asserted
within the applicable complaint period.
3.4 Packaging
The individual packaged pieces are packaged in accordance with the anticipated transport condi-
tions and need to protect the packaged piece against transport damage, corrosion, and other
damage until installation.
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–15

nRemove packaging material.
nRemove potentially present transport safety restraints.
Disposal of packaging
Dispose of the packaging material in accordance with the respectively valid legal regulations and
ordinances.
NOTICE!
Environmental damage due to incorrect disposal of the packaging material!
Packaging materials are valuable raw materials and in many cases they can be reused or
sensibly recycled.
Note:
Dispose of packaging materials in an environmentally and proper manner.
Adhere to the respectively applicable statutory regulations and ordinances and commission a
specialized company with the disposal if necessary.
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–16

4 Overview
Fig. 1: Overview
1 Air nozzle
2 Fluid connection, flow
3 Main element
4 Air regulator
5 Connector with needle stroke adjusting screw
6 Jet regulator
7 Knurl nut
8 Pull lever, short
9 Plastic grip
10 Hose nozzle, compressed air connection
11 Fluid connection, suction
12 Pull lever, long
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–17

5 Installation
5.1 Safety
Personnel:
nQualified personnel
WARNING!
Risk of injury due to improper installation!
Improper installation may cause serious personal injury or material damage.
Note:
– Ensure ample of space for the installation prior to starting any work.
– Handle open, sharp-edged components with care.
– Maintain order and cleanliness at the installation site. Components that are loosely
stacked or lying around can cause accidents.
– Assemble components properly. Adhere to specified screw tightening torque.
– Secure components against tipping or falling.
– Ensure that the utilised hose lines meet the requirements for pressure, chemical and
mechanical loads. At the same time, adhere to the spray media manufacturer's specifica-
tions in the safety data sheet.
CAUTION!
Risk of injury through compressed air!
Uncontrolled leaks of compressed air can lead to serious injuries!
Note:
– Prior to any work on the device/machine, all compressed-air lines must be closed and
bled if necessary.
– Never point compressed air at living beings.
– Check the compressed-air hoses for damage and tight fit before the start-up.
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–18

WARNING!
Vibrations caused by pulsation-generating compressor units!
Vibrations caused by pulsation-generating compressor units (pumps, compressors) can be
transferred to the spray gun via hose lines and lead to neurological or vascular disorders.
Note:
– Take breaks between spray processes.
– Use pulsation-dampening devices (pressure compensation container, etc.).
CAUTION!
Risk of injury through tripping over hoses and cables!
Hoses and cables are slipping and tripping hazards. A fall can cause injuries.
Note:
– Always pay attention to hoses and cables in the working environment.
– Install cables outside of the work area in a designated cable conduit.
– Mark tripping hazards with black-yellow marking tape.
5.2 General information about the installation
Adhere to the following general information for the installation:
nOnly carry out the installation and start-up according to the steps described in this operating
manual.
nEnsure that the utilised hose lines meet the requirements for pressure, chemical and mechan-
ical loads.
nDepending on the model of the hand-held spray gun, reduce the supply air to max. 4 (HV1 or
HV3) or max. 12 bar through the installation of a pressure regulator.
nMake sure that the connected compressed air is oil-free and free of solid matter.
nOperate the spray gun with processed, dried compressed air (air quality pursuant to DIN ISO
8573-1: grade 4).
Hand-held Spray Gun HS 25 ENGLISH
HS 25, HS 25 HV1, HS 25 HV3 GB–19

5.3 Dimensions
Fig. 2: Dimensions
5.4 Connections
Fig. 3: Connections
1. Connect the compressed air line to the compressed air connection ( Fig. 3/2 ) of the hand-
held spray gun.
2. Establish material supply, depending on the design, through gravity feed cup ( Fig. 3/1),
suction cup ( Fig. 3/3).
Operating instructions T-Dok-009-GB-Rev.3
[email protected], www.krautzberger.com GB–20