MASPRA EP-45G User manual

User manual
EP-45G

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Table of contents
1. Safety regulations
1.1. Explanation of symbols used
1.2. Electrical safety
1.3. Electrostatic charge
(spark or flame formation)
2. Summary of Application
2.1. Area of operations
2.2. Coating materials
3. Device description
3.1. Airless procedure
3.2. Function of the device
3.3. Transport in the vehicle
4. Commissioning
4.1. Cleaning of preservatives
4.2. Preparation for commissioning
4.3. Commissioning
5. Spray technology
6. Handling of the high-pressure hose

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7. Work interruptions/pressure drain method
8. Clean Up
8.1. General and equipment cleaning from the outside
8.2. Intake filter
8.3. Clean high-pressure filters
8.4. Airless gun clean
Quick Start Manual page 36
9. Help with faults
10. Maintenance
10.1. Clean high-pressure filters
10.2. High pressure hose
11. Repairs to the device
11.1. Relief valve
11.2. Inlet / outlet valve
12. Attachments
12.1. Nozzle selection
12.2. Maintenance and cleaning of airless reversing nozzles
Warranty

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Attention
1. Safety regulations for airless spraying
1.1. Explanation of the symbols used
This user manual contains information that the user must thoroughly
work through before using the device. In areas marked with the
following symbols, work extra carefully and observe all safety
instructions.
This symbol indicates a potential danger that
can lead to death or serious injury. Here you
will find important security information.
This icon indicates a potential danger for you
or the device. Under this icon you will find
important information on how to avoid
damage to the device and risk of injury.
Danger of skin injection

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DANGER: Injury by liquids under
pressure
A high-pressure liquid, such as that
produced by this device, can penetrate the
skin and penetrate into the underlying
connective tissue, leading to serious injuries
and even amputation. Do not treat a splash
injury as a harmless cut. In the event of a
skin injury caused by coating material or
solvent, consult a doctor immediately. For
fast, expert treatment, inform the doctor
about the coating material or solvent used.
Fire hazard due to solvents and paint va-
pors
Risk of explosion due to solvents, paint va-
pors and unsuitable materials
Inhalation of harmful vapors
Notes contain important information that
should be noted.
,

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Precautions:
•NEVER hold the spray gun on body parts.
•NEVER touch the liquid jet with body parts.
•NEVER touch a leak in the pressure hose with the body.
•NEVER hold your hand in front of thenozzle of the spray
gun. Gloves do not provide safe protection against injury
from injected liquids.
ALWAYS lock the spray gun trigger, turn off the pump
and completely relax the pressure before performing
maintenance and cleaning, inspections, nozzle
changes or similar work or leaving the device
unattended. Even after switching off the engine, the
device is still under pressure. The valve PRIME /
SPRAY (relief/bypass/pre-fill / spray valve) must stand
in its relief /target positions to relax the system
pressure.
•ALWAYS put on the nozzle guard when spraying work
is carried out. The nozzle protection represents a cer-
tain protection, but is primarily intended as a warning
device.
•ALWAYS remove the spray nozzle before cleaning or
rinsing the system.
•NEVER use a spray gun without a functional trigger
lock and without a protective bar.
•All accessories must be approved for at least the max-
imum operating pressure range of the sprayer. These
include spray nozzles, spray guns, extensions and
hoses.

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Danger: High pressure hose
Due to wear, buckling and inappropriate use, leaks
can form in thepaint hose. Through a leak, fluid can
be injected into the skin. Thoroughly check the hose
before use.
Precautions:
•Avoid sharp bending or bending of the high-pressure hose,
smallest bending radius about 20 cm.
•Do not run over the high-pressure hose, as well as protect
against sharp objects and edges.
•Replace the damaged high-pressure hose immediately.
•Never repair a defective high-pressure hose yourself!
•Electrostatic charging of the spray gun and high-pressure
hose is discharged via the high-pressure hose. Therefore,
the electrical resistance between the connections of the
high-pressure hose must be equal to or less than one
megaohm.
•For reasons of function, safety and service life, use only
MASPRA-Original-replacement high pressure hoses.
•Before each use, check all hoses for incisions, leaks, chafing
points or curved surfaces. Check the clutches for integrity and
firm fit. Replace hoses immediately if any of the above faults
are detected. Never repair a paint hose. Replacea defective
hose with a grounded high-pressure hose.
•Be sure to lay spray hoses in such a way that the risk of
slipping, tripping and falling over is minimized
Warning!

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Attention: Risk of injury due to injection!
Airless devices develop extremely high spray
pressures.
Never bring fingers, hands or other body parts into
contact with the spray jet!
Never point the spray gun at yourself, people and
animals.
Never use the spray gun without spray jet contact
protection.
Do not treat a splash injury as a harmless cut.
In the event of a skin injury caused by coating
material or solvent, consult a doctor immediately for
fast, expert treatment.
Tell the doctor about the coating material or solvent
used.
1

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According to the operating instructions, the following
points must be observed before each commissioning:
1. Faulty devices must not be used.
2. Securing the spray gun with a safety lever on the trigger
guard.
3. Ensure grounding.
4. Check the permissible operating
pressure of the high-pressure hose
and spray gun.
5. Check all connecting parts for tightness.
Instructions for regular cleaning and maintenance of
the device must be strictly adhered to.
Before all work on the device and at every break from
work, observe the following rules:
1. Spray gun and high-pressure hose pressure relief.
2. Securing the spray gun with a safety lever on the trigger
guard.
3. Turn off the device.
Pay attention to
safety!

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Hazard: Explosion and fire hazard
Flammable vapors, such as Fumes from solvents and
paints can ignite or explode in the work areas.
Precautions:
•Do not process materials with a flash point below 38 °C (100 °F).
The flash point is the temperature at which aliquid develops so
many vapors that they can ignite.
•Do not use the device in production facilities that are covered by
the Explosion Protection Ordinance.
•Ensure good extraction and supply of fresh air so that no flamma-
ble fumes accumulate in the spray area.
•Exclude all ignition sources such as sparks from electrostatic dis-
charge, electrical appliances, open flames, ignition flames, hot ob-
jects and sparks by closing and disconnecting power cords or actu-
ating work light switches.
•Do not smoke in the spray area.
•Place the sprayer at a sufficient distance from the object to be
sprayed in a well-ventilated area (use an extension hose if neces-
sary). Flammable fumes are often heavier than air. The area above
the ground must be particularly well ventilated. The pump contains
parts in which arc formation cannot be ruled out and which ignite
vapours through sparks.
•The objects to be sprayed and the equipment in the spray area
must be carefully grounded to avoid sparks caused by electrostatic
discharges.
•Use only conductive or grounded high-pressure liquid hoses. The
spray gun must be grounded via the hose connections.
•The power cord must be connected to aprotective contact
circuit (for electrical appliances only).
•To flush the device, always spray into a separate metal con-
tainer with low pump pressure and removed spray nozzle.

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Hold the spray gun firmly against the wall of the container to
ground the container and prevent sparks from electrostatic
discharges.
•Comply with the warnings and regulations of the manufac-
turer of the solvents and materials. For safe use, please re-
fer to the safety data sheet and the technical specifications
of the painting material.
•To rinse the device, always work with the lowest possible
pressure setting.
•When cleaning equipment with solvent, it must not be in-
jected or pumped into a container with a small opening
(sheet pile hole). Hazard due to the formation of an explo-
sive gas/air mixture. The container must be grounded.
•Do not use any colors or colors. Solvents containing halo-
genated hydrocarbons, such as chlorine, bleach, anti-mold
agents, methylene chloride and trichloroethane. They are
not compatible with aluminium. Contact the supplier of the
coating regarding the compatibility of the material with alu-
minum.
Hazard: Dangerous fumes
Paints, solvents and other materials can be harmful to
health when inhaled or in contact with the body. The
fumes can cause severe nausea, fainting and poisoning.

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Precautions:
•Wear respiratory protection during spraying work. Work through all
the instructions supplied with the face mask so that the face mask
also offers the desired protection.
•A respirator must be provided to the user (professional and cooper-
ative rules "Rules for the use of respiratory protective devices"
(BGR 190).
•Wear safety goggles.
•To protect the skin, protective clothing, gloves and possibly skin protec-
tion cream are required(BGR 197 "Useofskin protection"). The regula-
tionsofthemanufacturers areobserved with regard to the treatment
materials,solventsand cleaning agentsduring preparation, processing
and equipment cleaning.
Danger: General
Can cause serious personal or property damage.
Precautions:
•Comply with all local and state regulations on fire protec-
tion, operation and ventilation.
•When the shutter release is pressed, the spray gun pulls
to the side. This force effect of the spray gun is particu-
larly strong when the nozzle has been removed and high
pressure has been set at the pump. When cleaning
with the nozzle unscrewed, therefore set the pressure
regulator to the lowest pressure.
•Use only manufacturer-approved parts. When using
parts that do not meet the minimum technical require-
ments, the user bears all risks and all liability. This also
applies to the safety devices of the pump.
•ALWAYS follow the manufacturer's instructions for the

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safe handling of paints and solvents.
•Wipe up spilled materials and solvents immediately to
avoid slipping.
•Wear hearing protection. This device can produce a
sound pressure above 85 dB(A).
•Never leave the device unattended. Keep children or
other persons who are not familiar with the operation of
the compressed airless sprayer away from the device.
•Do not splash outdoors on windy days.
•The device including all liquids (e.B. Hydraulic oil) must
be disposed of in an environmentally friendly manner.
1.2. Electrical safety
Electrical appliances must be grounded. In the case of an electrical
short circuit, grounding reduces the risk of electric shock because
the residual current is dissipated via the protective conductor. This
device is equipped with a power cord that has a safety plug. Con-
nection to the power grid only via a special supply point, e.B. via a
residual current protection device with INF≤ 30 mA.
HAZARD —Have work or repairs to the electrical
equipment carried out only by an electrician. No li-
ability is assumedfor improper installation. Turn off
the device.
Before all repairs –unplug from the socket.
Appliance cleaning: Risk of short circuits due to water penetrating
into the electrical equipment. Never spray the device with a high-
pressure or steam high-pressure cleaner.

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Work or repairs on electrical equipment:
These are only carried out by an electrician. No liability is assumed
for improper installation.
1.3. Electrostatic charge
(spark or flame formation)
Due to the flow velocity of the coating material during
spraying, electrostatic charges may occuronthe device.
These can cause sparks or flames to form when dis-
charged. Therefore, itis necessary that the device is al-
ways grounded via the electrical installation. The con-
nection must be made via a properly grounded protec-
tive contact socket.
Electrostatic charging of the spray gun and high-pressure hose
is discharged via the high-pressure hose. Therefore, the
electrical resistance between the connections of the high-
pressure hose must be equal to or less than one megaohm.

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2. Overview
2.1. Applications
The device performance of the respective MASPRA airless system is
designed in a way that the processing of every material that is
intended for the system is possible.
Spray Object Examples
In the painting sector, all devices are suitable for all common work,
such as: doors, door frames, railings, furniture, wood paneling,
fences, radiators and steel parts.
For dispersion and façade paint, high-performance airless devices
with a flow rate of at least 2.5 l/min. are recommended.
For spray spatulas, devices with a flow rate of at least 4.5 –5.0 l/min
are suitable.
2.2. Coatings and paint
Usable coatings and paint
Water-soluble and solvent-based paints and varnishes, two-
componentcoating materials, dispersions, latex paints, release
agents, oils, precoats, primers and fillers. Fire protection materials
and airless spray spatulas.
The processing of other coating materials only with the
consent of MASPRA.
Pay attention to airless quality in the coating materials to be
processed.

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Filtering
Despite the suction filter and plug-in filter in the spray gun,
filtering of the coating material is generally recommended.
Stir the coating material well before starting work.
Viscosity
With these devices it is possible to process highly viscous
coating materials.
If highly viscous coating materials cannot be sucked in,
dilute according to the manufacturer's instructions.
2 K materials
The corresponding processing time must be strictly adhered
to. Within this time, rinse and clean the device carefully with
the appropriate detergent.
Coating materials with sharp-edged
Additives
These exert a strong wearing effect on all material-carrying
parts (valves, pistons, sealing packs, high-pressure hose,
spray gun and nozzle). As a result, the service life of these
parts can be significantly shortened.
Attention: When stirring with motor-driven agitators, make
sure that No air bubbles are stirred in. Air bubbles interfere
with spraying, can even lead to interruption of operation.

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3. Device description
3.1. Airless
The main areas of application are the coating of large areas with a
high use of materials.
An airless pump sucks in the coating material and conveys it to the
nozzle under pressure. At a pressure up to max. approx. 230 bar (23
MPa) pressed through the nozzle, the coating material atomizes.
This high pressure causes microfine atomization of the coating
material. Since no air is used in this system, this method is called
AIRLESS (airless).
This type of spraying has the advantage of the finest atomization,
low-fog operation and smooth, bubble-free surfaces. In addition to
these advantages, the working speed and the great handiness are to
be mentioned.
3.2. Function of the device
For a better understanding of the function, briefly the
technical structure;
MASPRA piston airless units are high-pressure piston
sprayers driven by electric or petrol motors.
A gear transmission transmits the driving force to a
crankshaft. The crankshaft moves the piston of the material
feed pump up and down.
Due to the upward movement of the piston, theinlet valve
opens independently. When the piston moves downwards,
the exhaust valve opens.

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The coating material flows under high pressure through the
high-pressure hose to the spray gun.
When leaving the nozzle, the layering material atomizes.
The pressure regulator regulates the flow rate and the
operating pressure of the coating material.
MASPRA compact hydraulic airless devices are electrically driven
diaphragm high-pressure sprayers. The hydraulic pump is driven by
a gearbox. A piston is moved up and down, thus requiring hydraulic
oil under the diaphragm, which then moves. Due to the downward
movement of the diaphragm, the disc inlet valve opens automatically
and the coating material is sucked in. During the upward movement
of the diaphragm, the coating material is displaced and the ball-ex-
haust valve opens while the intake valve is closed.
The coating material flows under high pressure through the
High-pressure hose to spray gun and becomes at exit
atomized at the Duse. The pressure control valve limits the set pres-
sure in the hydraulic oil circuit and thus also the pressure of the coat-
ing material.
A change in print when using the same Duse also leads to a change
in the amount of atomized ink.
3.3. Transport in the vehicle
Secure the device with a suitable fastener.
NEVER transport a pressurized device!

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4. Commissioning
4.1. How to start the first time:
Cleaning of preservatives
1. Suction hose or intake pipe and return hose
immerse in a container with suitable detergent.
2. Rotate the pressure regulator to minimum pressure.

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3. Open bypass valve.
Valve position PRIME ( cir-
culation). Counterclock-
wise rotary knobs
4. Turn on the device.
5. Wait until detergent comes out of the return hose.
6. Close the relief valve.
Valve position SPRAY
(spraying). Turn the
lever in transverse posi-
tion.
7. Pull the trigger guard of the spray gun.
8. Inject detergent from the device into an open collection con-
tainer.
ON = An / OFF = Aus