Krautzberger KS 5D User manual

T-Dok-660-GB-Rev.1
GB Hand-held Spray Gun KS 5D
Operating instructions
■ 200-0378
Translation of the original 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 and must always be kept in the immediate proximity of the device
so that it is accessible 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 that.
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 an 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 currently 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 Using this operating manual............................................................................................. 7
2.1 Symbols in this manual................................................................................................ 7
2.2 Personnel requirements............................................................................................... 8
2.3 Personal protective equipment.................................................................................... 9
3 Safety and responsibility................................................................................................. 12
3.1 Responsibility of the owner........................................................................................ 12
3.2 Intended use.............................................................................................................. 12
3.3 Predictable misuse.................................................................................................... 12
3.4 General safety instructions........................................................................................ 13
3.5 Residual risks............................................................................................................ 15
3.6 Course of action in an emergency............................................................................. 15
4 Transport, storage, and packaging................................................................................. 16
4.1 Transport................................................................................................................... 16
4.2 Storage...................................................................................................................... 16
4.3 Packaging.................................................................................................................. 16
5 Overview............................................................................................................................ 17
6 Operation........................................................................................................................... 18
6.1 Safety......................................................................................................................... 18
6.2 General information about start-up/commissioning................................................... 19
6.3 Function test and start-up.......................................................................................... 20
6.4 Shutting down............................................................................................................ 22
6.4.1 Temporary shut-down............................................................................................. 22
6.4.2 Long-term shut-down.............................................................................................. 22
7 Maintenance...................................................................................................................... 24
7.1 Safety......................................................................................................................... 24
7.2 General maintenance information.............................................................................. 24
7.3 Maintenance schedule............................................................................................... 24
7.4 Clean hand-held spray gun........................................................................................ 25
7.5 Replace threaded needle and needle pack............................................................... 25
7.6 Replace valve seat screw and fluid nozzle................................................................ 38
8 Troubleshooting............................................................................................................... 40
8.1 Customer Care.......................................................................................................... 40
9 Spare parts........................................................................................................................ 41
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10 Accessories...................................................................................................................... 42
11 Disassembly and disposal............................................................................................... 43
11.1 Safety....................................................................................................................... 43
11.2 Disassembly............................................................................................................ 43
11.3 Disposal................................................................................................................... 43
12 Technical data................................................................................................................... 44
12.1 Dimensions and weight............................................................................................ 44
12.2 General specifications............................................................................................. 44
12.3 Dimensions.............................................................................................................. 45
13 Declaration of conformity................................................................................................ 46
14 Notes.................................................................................................................................. 47
15 Index.................................................................................................................................. 50
Operating instructions T-Dok-660-GB-Rev.1
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1 Function and identification
1.1 Function
The airless spray gun KS 5D is fitted with material passages with enlarged cross-section and is
used to coat surfaces with highly viscous materials (viscose material processing). The coating
material is fed to the spray gun in liquid form under high fluid pressure. 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 fluid pressure, which presses the fluid 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 pull lever. The coating
material is fed to the hand-held spray gun in liquid form under high fluid 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 fluid pressure!
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 pivotable fluid connection enables the material supply from above or below.
The use is particularly suitable where comparatively large volumes of material need to be pro-
cessed per unit of time.
The hand-held spray gun features a locking lever and a protection hoop for safe operation.
Hand-held Spray Gun KS 5D ENGLISH
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1.2 Identification
Scope of delivery Model Product number
Hand-held spray gun KS 5D 200-0378
Operating manual T-Dok-660
Serial number
The serial number of the hand-held spray gun is located on the main element. It serves as a
unique identifier.
Operating instructions T-Dok-660-GB-Rev.1
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2 Using this operating manual
2.1 Symbols in this manual
Safety instructions
This manual uses symbols to identify safety instructions. The safety instructions are 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 dangers to the environment.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and trouble-free operation.
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Example for safety instructions in operating instructions
Safety instructions can refer to specific, individual operating instructions. Such safety instructions
are embedded in the operating instructions so that they do not disrupt the reading flow during the
execution of the action. The signal words described above are used.
1. Unfasten 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 specific hazards:
Warning signs Type of danger
Warning – danger zone.
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 instructions
ðResults of procedural steps
References to sections in this manual and other applicable docu-
ments
Lists without specified order
[Pushbuttons] Operating elements (e.g. pushbuttons, switches), display ele-
ments (e.g. signal lights)
‘Display’ Screen elements (e.g. pushbuttons, assignment of function keys)
2.2 Personnel requirements
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.
Operating instructions T-Dok-660-GB-Rev.1
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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.
Specialised 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 hazards on their own.
User
The user is familiar with the basic regulations on occupational safety and accident prevention.
2.3 Personal protective equipment
Personal protective equipment is used to protect persons against adverse impacts on their occupa-
tional health and safety.
The personnel must wear personal protective equipment while carrying out the different tasks and
while working with the device.
The selection of the protective equipment depends on the environmental conditions at the site
of the system owner and the utilised coating material. To ensure the proper selection of per-
sonal protective equipment, the information provided by the spray material manufacturer indi-
cated on the safety data sheet must be adhered to.
Description of the personal protective equipment recommended by Krautzberger
The personal protective equipment is described below:
Protective work clothing
Protective work clothing are tight fitting work clothes with low tear resistance, with tight sleeves,
and without any protruding parts.
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Ear protection
Ear protection provides protection against hearing damage.
Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
Safety goggles
Safety goggles are used to protect the eyes from flying parts and splashes of liquid.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as
well as from contact with hot surfaces.
Safety shoes
Operating instructions T-Dok-660-GB-Rev.1
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Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
Safety helmet
The helmet protects the head against injuries from falling parts and oscillating loads as well as in
tight spaces.
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3 Safety and responsibility
3.1 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.
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.
3.2 Intended use
The hand-held spray gun KS 5D is used for the coating of various surfaces.
The intended use also includes the compliance with all the information in this operating manual.
3.3 Predictable misuse
Any use beyond the intended use or any other use constitutes misuse.
nOnly carry out the installation, start-up, and use in accordance with the steps described in
these operating instructions.
nEnsure that the utilised hose lines fulfil the requirements with respect to pressure, chemical,
and mechanical loads.
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.
nThe chemical resistance of the materials which we use cannot always be assessed with
authority due to the large number of fluids, concentrations, temperatures and impurities used.
For this reason, the suitability must be checked because we cannot extend any respective
guarantees.
nOnly use the manufacturer's OEM parts.
nOnly operate the hand-held spray gun in compliance with the values specified in (
Ä Chapter
12 ‘Technical data’ on page 44).
nWhen using solvent-containing paints, avoid open flames, red-hot parts, and equipment, tools,
and parts that can create flammable sparks in the work area.
nWhen using solvent-containing paints, provide a sufficient fresh air supply.
nNever point the hand-held spray gun at living beings.
nThe conformity of the product is voided in case of structural modifications of the hand-held
spray gun.
Operating instructions T-Dok-660-GB-Rev.1
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nUnauthorized persons must be prevented from entering the hazard zone.
nAlways securely store the hand-held spray gun away from children. Especially during work
breaks and in particular during the processing of hazardous materials, preventative measures
must be taken against the improper use through unauthorised persons! Clean thoroughly prior
to storage and/or transport.
nTake preventative measures against unintended operation or triggering of the pull lever!
nNever remove the protection hoop.
WARNING!
Misuse of the hand-held spray gun can cause dangerous situations.
No claims of any kind can be asserted due to damage resulting from misuse!
3.4 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.
– 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.
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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.
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.
– Carefully handle open, sharp-edged components.
– Maintain order and cleanliness at the installation site. Components that are loosely
stacked or are scattered 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.
WARNING!
Risk of injury due to improper operation!
Improper operation can lead to serious personal injuries or property damage.
Note:
– Never point the fluid outlet opening or the spray jet toward people.
– Check the material hose lines for damage and to make sure that they are firmly in place
before each operation.
– Adhere to the spray media manufacturer's specifications in the safety data sheet.
Operating instructions T-Dok-660-GB-Rev.1
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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.
3.5 Residual risks
The hand-held spray gun made by Krautzberger GmbH has been manufactured based on state-of-
the-art technology and generally accepted 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.
3.6 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.
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4 Transport, storage, and packaging
4.1 Transport
nThe hand-held spray gun is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
4.2 Storage
Store the hand-held spray gun under the following conditions:
nStore 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%.
4.3 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.
nRemove packaging material.
nRemove potentially present transport safety restraints.
Operating instructions T-Dok-660-GB-Rev.1
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5 Overview
Fig. 1: Overview KS 5D
1 Protection hoop
2 Pull lever
3 pivotable / rigid fluid connection
4 Material outlet
5 Main element
6 Locking lever
7 Plastic grip
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6 Operation
6.1 Safety
Personnel:
nUser
nSpecialised personnel
Protective equipment:
The selection of the personal protective equipment depends on the utilised medium of the system
owner. The information provided by the medium manufacturer indicated on the safety data sheet
must be adhered to in order to ensure the proper selection of personal protective equipment.
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.
– 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 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 lessons learned, the safety data sheet must be checked regularly
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.
Operating instructions T-Dok-660-GB-Rev.1
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WARNING!
Risk of fatal injury, risk of injury or property damage due to damaged or disconnected
lines!
Damaged or disconnected lines can cause death, serious injuries or property damage due to
whip-like movements and the spraying of fluids.
Note:
– Check the fluid pressure lines for damage and a tight fit prior to every work process.
6.2 General information about start-up/commissioning
Adhere to the following general start-up/commissioning information:
nOnly carry out the start-up and commissioning of the hand-held spray gun in accordance with
the steps described in these operating instructions.
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.
nOnly operate the hand-held spray gun in compliance with the values specified in (
Ä Chapter
12 ‘Technical data’ on page 44).
nOnly use accessories from Krautzberger GmbH!
nOnly use sufficiently sturdy hoses! Check and, if necessary, replace older hoses before
starting up the hand-held spray gun.
nOnly use hoses that match the hose connections and check them for their proper seat and
ensure that they are leak-proof.
nIt is recommended to flush the hand-held spray gun prior to start-up using a suitable cleaning
product (spraying process with cleaning product, until it runs clear when exiting).
nTo ensure that there are no particles clogging the nozzles, we recommend to clean the
coating material with a material filter positioned in front of the fluid connection (high pressure
material filters can be purchased from Krautzberger GmbH).
nTo achieve a unified coating thickness and spray pattern for high-quality coatings, a cross-
coating process is recommended, which means that the area is first coated in horizontal lines
and then in vertical lines.
In contrast to compressed air-operated hand-held spray guns, the spray pattern of airless
devices can by default not be changed through settings on the nozzle. If a different spray pat-
tern is desired, the airless-nozzle must be exchanged. When adjustable fluid nozzles are
used, the spray angle can be adjusted.
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Among other factors, the spray pattern depends on the viscosity of the coating material. It can
be modified through the fluid pressure. If the optimal application cannot be achieved through
fluid pressure changes, it is recommended to try again with a different fluid nozzle.
6.3 Function test and start-up
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.
– The pull lever must be locked with the locking lever every time the spray gun is put down!
Operating instructions T-Dok-660-GB-Rev.1
[email protected], www.krautzberger.com GB–20