Krautzberger KS 5 User manual

■ 200-0368
Translation of the original operating instructions
T-Dok-653-GB-Rev.0
GB Hand-held Spray Gun KS 5
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.
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GB–2

Table of contents
1 Function and identification................................................................................................ 5
1.1 Function....................................................................................................................... 5
1.2 Identification................................................................................................................. 6
2 Safety and responsibility................................................................................................... 7
2.1 Symbols in this manual................................................................................................ 7
2.2 Personnel requirements............................................................................................... 8
2.3 Personal safety equipment and clothing...................................................................... 9
2.4 Responsibility of the owner........................................................................................ 10
2.5 Intended use.............................................................................................................. 11
2.6 General safety instructions........................................................................................ 13
2.7 Residual risks............................................................................................................ 13
2.8 Course of action in an emergency............................................................................. 14
3 Transport, delivery condition, storage and packaging................................................. 15
3.1 Transport................................................................................................................... 15
3.2 Delivery condition...................................................................................................... 15
3.3 Storage...................................................................................................................... 15
3.4 Packaging.................................................................................................................. 15
4 Menu.................................................................................................................................. 17
4.1 Dimensions................................................................................................................ 18
5 Operation........................................................................................................................... 19
5.1 Safety......................................................................................................................... 19
5.2 General information about commissioning/start-up................................................... 20
5.3 Start-up...................................................................................................................... 21
5.3.1 Preparation............................................................................................................. 21
5.3.2 Function test and start-up....................................................................................... 22
5.4 Shut-down.................................................................................................................. 22
5.4.1 Temporary shut-down............................................................................................. 22
5.4.2 Long-term shut-down.............................................................................................. 23
6 Maintenance...................................................................................................................... 24
6.1 Safety......................................................................................................................... 24
6.2 General maintenance information.............................................................................. 25
6.3 Maintenance schedule............................................................................................... 26
6.4 Clean hand-held spray gun........................................................................................ 26
6.5 Replace valve needle and needle pack..................................................................... 27
6.6 Replace valve seat screw and fluid nozzle................................................................ 37
7 Troubleshooting............................................................................................................... 39
7.1 Customer care........................................................................................................... 39
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8 Spare parts........................................................................................................................ 40
8.1 Spare parts................................................................................................................ 40
9 Accessories...................................................................................................................... 41
10 Disassembly and disposal............................................................................................... 42
10.1 Safety instructions................................................................................................... 42
10.2 Disassembly............................................................................................................ 42
10.3 Disposal................................................................................................................... 42
11 Technical data................................................................................................................... 44
11.1 Dimensions and weight............................................................................................ 44
11.2 General specifications............................................................................................. 44
12 Declaration of conformity................................................................................................ 45
13 Index.................................................................................................................................. 46
Operating instructions T-Dok-653-GB-Rev.0
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1 Function and identification
1.1 Function
The hand-held spray gun, type KS 5, is used to coat surfaces such as metal, plastic, ceramics,
wood and similar materials as well as other suitable surfaces. Typical coating materials include
paints, dyes, water-soluble paints, adhesives, oils, and anti-adhesives.
The hand-held spray gun operates based on the airless principle, which means the spray jet is
exclusively generated by the material pressure, which presses the material through a nozzle. After
exiting the nozzle, the spray jet takes the shape specified by the nozzle. It is directed towards the
work piece. The effective spray jet is not quite as wide as theoretically possible.
The coating material that is to be processed is applied to the surface by a person who is manually
guiding the hand-held spray gun over the surface that needs to be coated and who is starting the
spraying process at the respectively intended location by operating the trigger. The coating mate-
rial is fed to the hand-held spray gun in liquid form under high material pressure.
Pulling the pull lever towards the handle of the main element moves the valve needle back against
the resetting force of the valve spring. The valve needle slides out of the valve seat of the valve
seat screw and thereby releases the material flow to the fluid nozzle. It sprays the material as an
elliptical cone jet.
The volume of the exiting material depends exclusively on the nozzle size and the material pres-
sure!
The volume and shape of the jet can only be modified by changing the nozzle. The diameter of the
nozzle bore determines the material flow volume, while the size and geometry of the always ellipti-
cally shaped nozzle opening determine the height and width of the jet.
A large number of airless nozzles are available. They can only be purchased from Krautzberger
GmbH.
The nozzle can be seamlessly turned in the axis of the spray jet by 360° and locked into place in
any position. This allows an optimal adjustment of the angle with which the jet hits the work piece
to the respective conditions.
The KS model is particularly suitable for use where comparatively large volumes of material need
to be processed per unit of time.
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1.2 Identification
Scope of delivery Model Product number
Hand-held spray gun KS 5 200-0368
Operating instructions T-Dok-653
Serial number
The serial number of the hand-held spray gun is located on the main element. It serves as a
unique identifier.
Additional information can be found in ( Ä Chapter 11 ‘Technical data’ on page 44).
Operating instructions T-Dok-653-GB-Rev.0
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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.
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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)
2.2 Personnel requirements
Operating instructions T-Dok-653-GB-Rev.0
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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.
User
The user is familiar with the basic regulations on occupational safety and accident prevention.
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.
The selection of the personal safety equipment depends on the coating material that is used.
To ensure the proper selection of personal safety equipment, the information provided by the
spray material manufacturer indicated on the safety data sheet must be adhered to.
Description of the personal safety equipment recommended by Krautzberger
The personal safety equipment and clothing is described below:
Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
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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.
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.
Operating instructions T-Dok-653-GB-Rev.0
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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.
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 KS 5 is used for the coating of various surfaces.
The intended use also includes the compliance with all the information in this manual.
Any use beyond the intended use or any other use constitutes misuse.
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WARNING!
Danger due to misuse!
Misuse of the hand-held spray gun can cause dangerous situations.
– Only carry out the installation, start-up, and use in accordance with the steps described
in this operating manual.
– Ensure that the utilised hose lines fulfil the requirements with respect to pressure, chem-
ical, 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 hand-held
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. For this reason, the suitability must be checked because we cannot extend
any respective guarantees.
– Only use the manufacturer's OEM parts.
– Only operate the hand-held spray gun in compliance with the values specified in the (
Ä Chapter 11 ‘Technical data’ on page 44).
– When using solvent-containing paints, avoid open flames, red-hot parts, and equipment,
tools, and parts that can create flammable sparks in the work area.
– When using solvent-containing paints, provide a sufficient fresh air supply.
– Never point the hand-held spray gun at living beings.
– The conformity of the product is voided in case of structural modifications of the hand-
held spray gun.
– Unauthorized persons, especially children and youth, must be prevented from entering
the hazard zone.
– Always securely store the hand-held spray gun away from children. Especially during
work breaks and in particular during the processing of hazardous materials, preventive
measures must be taken against the improper use through unauthorised persons! Clean
thoroughly prior to storage and/or transport.
– Take preventative measures against unintended operation or triggering of the pull lever!
No claims of any kind can be asserted due to damage resulting from misuse.
Operating instructions T-Dok-653-GB-Rev.0
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2.6 General safety instructions
WARNING!
Risk of death, risk of injury or property damage due to hazardous media!
Potential consequences: The application of hazardous media can lead to death, severe inju-
ries or property damage.
When handling hazardous substances, ensure that the current safety data sheets of the haz-
ardous substance manufacturer are available. The necessary measures can be derived from
the content of the safety data sheet. Since the hazardous potential of a material can be reas-
sessed at any time due to new lessons learned, the safety data sheet must be checked regu-
larly and replaced if necessary.
The system owner is responsible for the presence and the up-to-date status of the safety data
sheet and the associated generation of the risk assessment of the effected workstations.
DANGER!
Risk of death due to high pressure!
The material jet exits the front opening of the fluid nozzle with high speed. The material jet
may penetrate skin, enter the body and forcefully inject air.
This presents the risk of causing a fatal embolism.
In addition, there is a risk of poisoning in case of toxic coating or cleaning material.
– Avoid unintended triggering of the pull lever.
– Concentration at the work station is imperative.
– When unauthorized persons are present, alert them to keep at a distance from the oper-
ator while he is performing his work.
– Before starting any cleaning or maintenance work, it is imperative to close the material
supply and to discharge the stored residual energy by operating the pull lever. Always
wait until the pressure is released.
– Never point the hand-held spray gun at living beings.
– Only trained personnel is permitted to perform cleaning and maintenance work.
2.7 Residual risks
The hand-held spray gun made by Krautzberger GmbH has been manufactured based on state-of-
the-art technology and recognised technical safety regulations.
Nonetheless, its use can pose a threat to the life or health of users or third parties, damage the
hand-held spray gun itself or cause other property damage.
nThe hand-held spray gun must only be used as intended.
nThe hand-held spray gun may only be operated in a defect-free condition.
nAny faults impacting the safety must be remedied immediately.
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2.8 Course of action in an emergency
In principle, the applicable national, regional and internal company regulations concerning the
course of action in case of an emergency must be adhered to and if necessary respective
safety measures must be taken on the system owner's side.
Operating instructions T-Dok-653-GB-Rev.0
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3 Transport, delivery condition, storage and packaging
3.1 Transport
nThe hand-held spray gun is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
3.2 Delivery condition
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.
3.3 Storage
Store the hand-held spray gun under the following conditions:
nIf possible, store the hand-held spray gun in the original packaging.
nDo not store outside.
nStore in a dry and dust-free environment.
nKeep away from any aggressive media.
nProtect from UV radiation.
nAvoid mechanical shocks.
nStorage temperature: 15 to 40 °C.
nRelative atmospheric humidity: max. 60%.
nWhen storing for longer than three months, check the general condition of all parts of the
packaging on a regular basis.
It is possible that there are notes on the packaged units concerning the storage that extend
beyond the requirements listed here. Those must be adhered to accordingly.
DANGER!
Risk of fatal injury due to toxic, flammable or explosive material
High risk potential during the storage and transport of the hand-held spray gun still containing
toxic, flammable or explosive material or cleaning products.
– Properly clean the hand-held spray gun before storage and transport so that there is no
toxic, flammable or explosive products inside.
3.4 Packaging
The hand-held spray gun is packaged in accordance with the anticipated transport conditions and
the packaging needs to protect it against transport damage, corrosion, and other damage.
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nRemove packaging material.
nRemove potentially present transport safety restraints.
Disposal of packaging
Dispose of the packaging material in accordance with the respectively applicable statutory regula-
tions and ordinances.
Operating instructions T-Dok-653-GB-Rev.0
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4 Menu
Menu
Fig. 1: Overview KS 5 with long pull lever
1 Pull lever, long
2 Material input
3 Material outlet
4 Main element
5 Plastic grip
Fig. 2: Overview KS 5 with short pull lever
1 Pull lever, short
2 Material input
3 Material outlet
4 Main element
5 Plastic handle with grip support
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4.1 Dimensions
Fig. 3: Dimensions
Operating instructions T-Dok-653-GB-Rev.0
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5 Operation
5.1 Safety
Personnel:
nUser
Protective equipment:
nLight respiratory protection
nSafety goggles
DANGER!
Risk of death due to high pressure!
The material jet exits the front opening of the fluid nozzle with high speed. The material jet
may penetrate skin, enter the body and forcefully inject air.
This presents the risk of causing a fatal embolism.
In addition, there is a risk of poisoning in case of toxic coating or cleaning material.
– Avoid unintended triggering of the pull lever.
– Concentration at the work station is imperative.
– When unauthorized persons are present, alert them to keep at a distance from the oper-
ator while he is performing his work.
– Before starting any cleaning or maintenance work, it is imperative to close the material
supply and to discharge the stored residual energy by operating the pull lever. Always
wait until the pressure is released.
– Never point the hand-held spray gun at living beings.
– Only trained personnel is permitted to perform cleaning and maintenance work.
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.
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WARNING!
Risk of injury due to improper operation!
Improper operation can lead to serious personal injuries or property damage.
Note:
– Never point compressed air at people.
– Check the material and compressed air hose lines before each use for damage and tight
fit.
– Adhere to the spray media manufacturer's specifications in the safety data sheet.
– Make sure that the connected compressed air is oil-free and free of solid matter.
WARNING!
Life threatening risk of injury or property damage through the application of hazardous
media!
The application of hazardous media can lead to death, severe injuries or property damage.
Note:
– Ensure the resistance of the device/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 generation of the risk assessment of the effected workstations.
WARNING!
Risk of injury due to recoil forces during the activation of the spray gun!
During long-term use, the recoil forces created when the spraying process is activated can
damage the central nervous system.
Note:
– Take breaks between spray processes.
5.2 General information about commissioning/start-up
Adhere to the following general commissioning/start-up information:
nOnly carry out the commissioning and start-up of the hand-held spray gun in accordance with
the steps described in this operating manual.
nAlways observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations for the area of use for the hand-held spray
gun.
nAdhere to the spray media manufacturer's safety data sheets.
Operating instructions T-Dok-653-GB-Rev.0
[email protected], www.krautzberger.com GB–20