Metacap D/A User manual

Operating Instructions
METACAP Spray Gun D/A

Operating Instructions
General Information
METACAP Spray Gun D/A
1-2 Version/Edition July 2008
Table of Contents
1 General Information...........................................................................1-3
1.1 Introduction..........................................................................................1-3
1.2 Scope of Supply of the METACAP Spray Gun D/A.............................1-3
2 Description of the METACAP Spray Gun D/A.................................2-4
2.1 Technical Data.....................................................................................2-4
2.2 Identification.........................................................................................2-4
3 Use ......................................................................................................3-5
3.1 Intended Use .......................................................................................3-5
3.2 Incorrect Use .......................................................................................3-5
4 Warranty .............................................................................................4-6
5 General Safety Instructions..............................................................5-7
5.1 Risk of Fire and Explosions.................................................................5-7
5.2 Personal Protection .............................................................................5-8
5.3 Noise Level..........................................................................................5-9
5.4 Instruction of the Personnel.................................................................5-9
6 Description, Structure and Functioning........................................6-10
6.1 Description.........................................................................................6-10
6.2 Structure of the METACAP Spray Gun D/A ......................................6-11
6.3 Spare Parts List for the METACAP Spray Gun D/A..........................6-12
6.4 Functioning ........................................................................................6-13
7 Initial Operation ...............................................................................7-14
8 Operating Instructions ....................................................................8-15
8.1 Default Settings .................................................................................8-15
8.2 Spray Process ...................................................................................8-18
9 Maintenance and Care.....................................................................9-19
9.1 Cleaning.............................................................................................9-19
9.2 Maintenance and Repair....................................................................9-22
9.2.1 Safety Instructions .............................................................................9-22
9.2.2 Check/Replacement of Silencer Ring................................................9-22
9.2.3 Replacement of Nozzle & AKKORD Needle, Adjustment of Initial Air
Input Settings.....................................................................................9-22
9.2.4 (Dis-)Assembly of Nozzle Holder , Replacement of Sealing Ring.....9-24
9.2.5 Air Converter Adjustment...................................................................9-26
10 Troubleshooting Table – METACAP Spray Gun D/A .................10-28
11 Cleaning and Disposal..................................................................11-30
11.1 Cleaning...........................................................................................11-30
11.2 Disposal...........................................................................................11-31
12 ATEX ...............................................................................................12-31
13 EC-Declaration of Conformity ......................................................13-32

Operating Instructions
General Information
METACAP Spray Gun D/A
Version/Edition July 2008
1-3
1 General Information
1.1 Introduction
It is indispensable for the user of this METACAP Spray Gun D/A to carefully
read the complete contents of this operating manual before using the spray
gun to ensure a safe and correct operation. This operating manual includes
important information concerning the safe and economical use of this spray
gun.
Therefore, always keep this operating manual accessible!
Failure to observe the instructions of this operating manual will render the
manufacturer free of any legal liabilities!
1.2 Scope of Supply of the METACAP Spray Gun D/A
1 METACAP Spray Gun D/A Item no. 101115
1 cleaning brush, short (see 9.1 Cleaning, page 9-19) Item no. 30078
1 cleaning brush, long (see 9.1 Cleaning, page 9-19)
Item no. 30077
1 needle cleaning brush (see 9.1 Cleaning, page 9-19)
(only for the AKKORD type) Item no. 30083
1 mounting bolt for nozzle holder
(see 9.2.4 (Dis-)Assembly of Nozzle Holder , page 9-24) Item no. 30084
The above mentioned item numbers refer to the spare parts available by
Metacap upon request.

Operating Instructions
Description of the METACAP Spray Gun D/A
METACAP Spray Gun D/A
2-4 Version/Edition July 2008
2 Description of the METACAP Spray Gun D/A
The METACAP Spray Gun D/A was developed for the combined use with
conveying equipment and circulation systems for coating materials and with
METACAP bottom cup sets.
2.1 Technical Data
Hose couplings Air supply 1/4" outside thread with plug-in nipple
for quick connect coupling NW7, 2 equipped.
Material supply 3/8" outside thread
Maximum working
pressure Air supply PI 10bar max. Material pressure 8bar max.
Weight 680g without cup,
Bottom cup set 0.5L - 305g
Bottom cup set 1.0L - 370g
Accessories Bottom cup sets for 0.5 and 1.0 L
item no. 101115A and 101115B
Recommended air
pressure 3 – 6 bar for at least 300 L/min of efficient air supply
The compressed air must be dry and oil-free.
Minimum inner section of the feed pipe: 9mm
Material pressure The material pressure depends on the coating
material and can be adjusted on the paint delivery
unit (maximum: 8 bar).
When using bottom cup sets, the material
pressure results from the spraying pressure.
2.2 Identification
Note:
The identification was effected according to DIN EN 1953 "Atomising and
Spraying Equipment for Coating Materials– Safety Requirements", section
7.2 "Identification".
The serial number of the spray gun is recorded on the left side of the spray
gun handle, the maximum air pressure and the maximum pressure for the
coating material are indicated on the right side of the spray gun handle.

Operating Instructions
Use
METACAP Spray Gun D/A
Version/Edition July 2008
3-5
3 Use
3.1 Intended Use
The METACAP Spray Gun is exclusively intended for:
— the spraying of coating materials (paint, lacquer, stripping agent, oil,
fatty matters and similar substances).
— the combined use with conveying equipment and circulation systems for
coating materials and with METACAP Bottom Cup Sets.
— Use only conductive tubing. (more information see 5.1 Risk of Fire and
Explosions)
3.2 Incorrect Use
— Never point the spray beam and/or air jet at living things.
There is a risk of injury.
— Never exceed the admissible working pressures of the coating device /
of the spray gun.
— Use accessories or spare parts supplied or recommended by the
manufacturer only.
— Before effecting any maintenance work or cleaning procedures, always
switch off the air and the material supply. Actuate the spray gun to
reduce the pressure of the coating device.
— Never use the METACAP Spray Gun D/A in combination with airless
pumps or with pumps for air-supported airless.
— Do not atomize acids, caustic solutions, removers and similar
substances.
— Do not use non-conductive tubing.

Operating Instructions
Warranty
METACAP Spray Gun D/A
4-6 Version/Edition July 2008
4 Warranty
The warranty period for the METACAP Spray Gun D/A is 24 months. This
period will start from the date of purchase.
It is not possible to make any warranty claims:
— regarding wear parts like gaskets, silencers, nozzles, needles or similar
parts.
— if the user does not observe the instructions of this operating manual.
— if the user modifies the METACAP Spray Gun D/A without prior
authorization of the manufacturer.
— if other than original spare parts are used.
— if the user tries to eliminate warranty deficiencies on his own without
prior written consent of the manufacturer.
The manufacturer must be informed in writing about any warranty claims
immediately after the occurrence of the deficiency. Then, the METACAP
Spray Gun D/A will have to be sent to the manufacturer to check the
warranty claim.
We are of course available for any maintenance or repair work which might
become necessary.
METACAP reserve the right to carry out all modifications which might be
required for an improved functioning of the METACAP Spray Gun D/A.

Operating Instructions
General Safety Instructions
METACAP Spray Gun D/A
Version/Edition July 2008
5-7
5 General Safety Instructions
5.1 Risk of Fire and Explosions
Caution!
Solvents and coating materials may represent a potential risk of fire and
explosions.
— All dangerous zones must be equipped with an efficient ventilation or
suction system to avoid a potentially dangerous accumulation of
inflammable vapors.
Please observe the respective rules for prevention of accidents
"Processing of Coating Materials".
— Open fires and smoking are not allowed within the working areas for
spraying and mixing.
— Appropriate fire extinction devices must be available within the working
areas.
— When using spray guns or when working with coating materials in
general, all legal and official instructions will have to be observed and all
requirements of the employer's liability insurance associations regarding
the protection against fire and explosions must be met.
Caution!
Solvents basing on halogenated hydrocarbon, like trichloroethane and
methylene chloride 1,1,1, for example, may cause chemical reactions in
combination with aluminum and galvanized or hot galvanized components
and will therefore represent a potential risk of explosion.
Please carefully read all labels, safety data sheets and technical data sheets
regarding the materials you want to use.
The METACAP Spray Gun D/A is originally not designed to be used with
halogenated hydrocarbon. The manufacturer is, however, in the position to
modify it accordingly on request. Moreover, the user has to ensure that all
other components of the coating device are suitable for the above mentioned
materials.
Attention!
Never use devices to spray materials containing solvents which are not
authorized accordingly by their manufacturers.

Operating Instructions
General Safety Instructions
METACAP Spray Gun D/A
5-8 Version/Edition July 2008
Caution!
It is possible that static electricity may be produced during the spraying
procedure.
In case of high flow rates, it might be possible that an electrostatic spark is
generated by friction. This spark may then ignite certain types of solvents
and coating materials. To avoid fire and explosions, a continuous grounding
of the spray system and of the object to be sprayed should be ensured.
Make also sure that the compressed air plant is grounded so that eventual
charges can be discharged by the tubing. Use only conductive tubing
(resistance > 10
3
Ω/m and < 10
6
Ω/m according to the German Employers'
Liability Insurance Association guideline 132). Use our anti-static air hoses,
e.g. 10m item no. 30051, or sold by the meter item no. 300531 as
compressed air supply line. For spreaders METASET 2 – 10 L or bigger,
use our conductive twin-hoses, e.g. 5m item no.30058 or for METASET 3 –
2 Liter our conductive twin-hoses for combination, e.g. 1.5m item no.30073.
5.2 Personal Protection
Toxic vapors:
When spraying coating materials, dangerous vapors or clouds (aerosols),
which are detrimental to your health, can escape. Please carefully read all
labels and safety instructions and observe all indicated instructions and
recommendations.
In case of doubt, please ask the material supplier.
— Please use respiratory equipment when spraying. The respiratory
equipment used must be suitable for the material in use and adapted to
the degree of the gas concentration (when spraying paint, please use
respiratory equipment independent of the ambient atmosphere or
equipment with filter combination A1/A2-P2.
— Always wear safety goggles during all spraying and cleaning
procedures.
— When using certain coating materials and solvents, it is indispensable to
wear protective gloves during all spraying, cleaning or maintenance
procedures.
— Ensure a sufficient protection of your skin during all spraying and
cleaning procedures. Either wear appropriate protective clothes or use
suitable protective skin ointments. We recommend expendable suits
and/or our liquid gloves called METACLEAN or similar products.

Operating Instructions
General Safety Instructions
METACAP Spray Gun D/A
Version/Edition July 2008
5-9
5.3 Noise Level
The continuous noise level within the highest performance range of these
spray guns may exceed 85 db(A) depending on the adjusted supply air
pressure and on the nozzle cap settings. The noise levels are measured by
using impulse noise meters under normal operating conditions of the spray
gun.
In case of a continuous noise level of more than 85 db(A), it is
recommended to wear an appropriate ear protection (see the respective
rules for prevention of accidents).
Please contact the manufacturer for more detailed information on the noise
levels.
5.4 Instruction of the Personnel
The personnel has to be made familiar with the correct use and with the
necessary maintenance procedures regarding the METACAP Spray Gun
D/A. The general instructions and the safety instructions of this operating
manual as well as the operating instructions of the coating materials to be
used should be thoroughly read and understood before using the spray gun.

Operating Instructions
Description, Structure and Functioning
METACAP Spray Gun D/A
6-10 Version/Edition July 2008
6 Description, Structure and Functioning
6.1 Description
The METACAP Spray Gun is a low pressure device.
The spray material is atomized with low pressure while at the same time
being encapsulated by a large volume of air; this air jacket presses the
atomized spray material against the surface to be processed and prevents
clouds of atomized spray material from escaping. This process is, however,
only efficient within a distance of max. 20 cm for a wide spray beam and of
approx. 30 cm for a circular spray beam. Please keep these distances during
the spraying procedures and always guide the spray gun in such a way that
the spray beam will vertically hit the surface. Otherwise, clouds of atomized
spray material will escape.
The nozzle and needle are made of stainless special steel and therefore
ensure a high durability. Both components are appropriate for various
coating materials.
This spray gun is equipped with the standard METACAP-AKKORD nozzle
set. This nozzle set is continuously adjustable according to nozzle sizes
between 0.5 and 3.6 mm. Thus, different coating materials can be processed
using only one nozzle set avoiding the annoying nozzle change and the
purchase of further nozzle sets. Furthermore, the AKKORD needle is a pipe
through which an additional atomizing airflow is brought to the coating
material to improve the spraying process.
Apart from the AKKORD nozzle set and nozzle cap, also nozzle sets with
fixed nozzle diameters and standard nozzle caps can be installed in the
spray gun.
For special applications, there are of course nozzle sets with fixed diameters
available upon request.
Important note:
The standard type of this spray gun can only be used to a certain degree in
case of highly corrosive or abrasive coating materials.
If the spray gun is charged with such materials, an increased need of
maintenance and cleaning and of spare parts will be the consequence.
If you are in doubt concerning the possible use of any kind of material with
this spray gun, please contact the manufacturer and exactly indicate the
material to be used and/or send us a sample.
Special designs concerning the whole material guiding system made of
special steel are of course possible. A list of the materials used for the
manufacturing of this spray gun is available upon request.
If necessary, please also check the other components of your coating
device, if they are suitable for the above mentioned coating materials.

Operating Instructions
Description, Structure and Functioning
METACAP Spray Gun D/A
Version/Edition July 2008
6-11
6.2 Structure of the METACAP Spray Gun D/A
Figure 1: Structure of the METACAP Spray Gun D/A

Operating Instructions
Description, Structure and Functioning
METACAP Spray Gun D/A
6-12 Version/Edition July 2008
6.3 Spare Parts List for the METACAP Spray Gun D/A
Pos. Item No. Designation Quantity
1 10266 Nozzle cap adjusting ring 1
2 10252 AKKORD nozzle cap 1
3 10265 Nozzle cap diaphragm, complete 1
4 10251 AKKORD nozzle 1
5 10224 Blocking screw 1
6 10221 Sealing ring 1
7 10218 Nozzle holder 1
8 10211 Gun body 1
10 10248 Needle guide ring 1
11 10247 Guiding spring 1
12 10249 AKKORD needle 1
13 10245 AKKORD needle adjusting screw 1
14 102138 Counternut 1
15 10261 Pressure spring 1
17 10213 Control device 1
18 10212 Articulated axle 1
19 10281 Venturi air converter, complete 1
20 10279 Annular gasket for air converter 1
21 10273 Valve block 1
22 10272 Valve spring 1
23 10270 Valve needle 1
24 10269 Valve support 1
25 10267 Basic body of venturi air converter
1
26 10268 Air supply nozzle 1
27 10271 Valve underpart 1
27-A 10277 O-ring for valve underpart 1
28 10228 Air hose pipe connection piece
Inner Thread M4 1
28-A 10231 Screw plug for
10228 DIN 84 M4x6 VA 1
29 10230 Thread connection piece for paint
3/8" 1
31 10238 Fastening screw for trigger handle 2
33 10236 Trigger handle 1
36 102137 Pressure spring sleeve 1
37 1021391 O-ring for the material fine
adjustment device PTFE 1
38 102136 Knurled nut 1
39 102135 Material fine adjustment device,
complete 1
45 10214 Pressure guide screw 1
46 10215 Guide pin 1
47 10250 AKKORD needle, complete 1
49 10282 Locking screw for air converter 1
50 10274 silencer ring 1
51 10276 O-ring for silencer ring 1
52 30031 Plug-in nipple for quick connect
coupling 1/4" Inner Thread 1

Operating Instructions
Description, Structure and Functioning
METACAP Spray Gun D/A
Version/Edition July 2008
6-13
6.4 Functioning
Note:
The position numbers refer to figure 1, see chapter 6.2 Structure of the
METACAP Spray Gun D/A, page 6-11.
The METACAP Spray Gun D/A generates the necessary low pressure and
the required high air volume from the compressed air produced by the
compressor and from the ambient air.
The air supply nozzle (1/26) supplies the compressed air into the spray gun,
where it is reduced to approx. 0.3 bar to considerably increase the
compressor-driven air volume with a Venturi nozzle (Bernoulli system),
which is located within the Venturi air converter body (1/25) to take in the
ambient air via suction holes. This air now flows through the completely
hollow interior space of the spray gun body (1/8) up to the nozzle cap (1/2),
where, depending on the respective adjustment of the nozzle cap with
regard to the nozzle (1/4), the actual spraying pressure (approx. 0.3 - 0.5
bar) is built up which ensures the spraying of the coating material.
When using bottom cup sets, a part of this air volume will be pressed into
the cupcup via the air tube connection piece (1/28) and ensures the paint
transport to the nozzle.
It is also possible to operate these spray guns using turbines. For such an
operation, it is necessary to dismount the air converter (1/19), which
prepares the compressed air for low pressure according to the process
described above, and to replace it by corresponding blower adapters
(available upon request).
The coating material is transported via the thread connection piece for paint
(1/29) into the nozzle holder (1/7) and then reaches the nozzle (1/4), which
adds the coating material to the atomizing airflow. The AKKORD needle
(1/12) opens and closes the nozzle.
The generated coating material cloud will be encapsulated by an outside air
jacket, which is produced by the special geometry of the nozzle and of the
nozzle cap, and will then be guided to the work piece. Thus, this system is
able to considerably reduce clouds of atomized spray material from
escaping.

Operating Instructions
Initial Operation
METACAP Spray Gun D/A
7-14 Version/Edition July 2008
7 Initial Operation
Note:
The position numbers refer to the figure 1, see chapter 6.2 Structure of the
METACAP Spray Gun D/A, page 6-11.
Important note:
To ensure that no residual matters have a negative effect on the spray
results, use an appropriate solvent to thoroughly rinse the METACAP Spray
Gun D/A before initial operation.
Attention!
Before using the METACAP Spray Gun D/A for the first time, carefully and
thoroughly read the complete content of this operating manual to avoid
possible dangers and damages caused by an incorrect use of your spray
gun.
The same applies to new staff members who have to work for the first time
with a METACAP Spray Gun D/A that has already been in use.
Since the handling and operation of the METACAP Spray Gun D/A are
different compared to other spray gun types, it is recommended to practice
the manipulation and adjustment of this spray gun using water before using
any coating materials.
The same applies to new staff members who have to work for the first time
with a METACAP Spray Gun D/A that has already been in use.
— Ensure the air supply by mounting the quick connect coupling NW 7,2 of
your compressed air tube on the plug-in nipple (1/52) of your spray gun
until it locks and latches audibly and perceptibly. If you are not sure, pull
the air hose to check the firm connection.
— Establish the coating material supply by connecting your material tube
with a union nut (3/8") and the threaded connection piece for paint
(1/29), then use an appropriate wrench to tighten the nut.
If you are using bottom cup sets, please install these cups according to the
corresponding mounting instructions belonging to the scope of supply of
your cup set.

Operating Instructions
Operating Instructions
METACAP Spray Gun D/A
Version/Edition July 2008
8-15
8 Operating Instructions
Note:
The position numbers refer to the figure 1, see chapter 6.2 Structure of the
METACAP Spray Gun D/A, page 6-11.
— Mix, condition and filter the coating material to be sprayed according to
the instructions of the manufacturer.
— Fill the material container with the coating material taking into account
the maximum filling height indicated by the manufacturer.
The maximum filling height for the bottom cups is approx. 10 mm below
the cup shoulder.
8.1 Default Settings
1. Turn the knurled screw (1/38) carefully clockwise to the limit stop to
close the paint supply. Please be careful, if you use too much force, you
may damage the AKKORD needle (1/12) and the nozzle (1/4).
2. Tighten the nozzle cap (1/2) by means of the nozzle cap adjusting ring
(1/1) and then loosen the connection by a half up to a full turn.
The horns of the nozzle cap should be in a horizontal position.
3. Set the compressed air and material hose pipes under pressure. Closely
watch all pipes and connections and pay attention to potential leaks.
Attention!
When using cup sets, it is not required to set the material supply under
pressure. This will be effected automatically by starting the spraying process
by means of the spraying pressure let off by the spray gun. When the spray
process is finished, the cup will de-aerate automatically via the air supply
hose pipes.
The material pressure streams out of spray gun and is also de-aerated here,
so hold the spray gun in a vertical and steady position. In cases where this
is not possible, hold the trigger handle (1/33) at action point to ensure a
continuous initial air input.
The air supply pipes are under pressure and a material return flow into the
spray gun is therefore not possible.
Do not put down, knock over or shake spray guns with filled cups, otherwise
coating materials or solvents may be transported into the spray gun via the
air supply hose pipes.
4. Now, carry out a trial spray operation. Take a piece of cardboard, of
sheet metal or the like.
— Keep the spray gun in a vertical position with a distance of approx. 20
cm to the work piece surface and pull the trigger handle (1/33) until
the limit stop. In this state, there should not be any visible coating
material since the AKKORD needle is still not able to lift off the
nozzle due to the tightened knurled screw (1/38). Now, turn the
knurled screw counterclockwise in a careful and gradual manner and
thus open the material supply.

Operating Instructions
Operating Instructions
METACAP Spray Gun D/A
8-16 Version/Edition July 2008
— Turn the screw as long as the required coating material quantity
becomes visible.
5. Now move the spray gun to and fro in front of the work piece and ensure
a vertical spray beam, if possible (see figure 2).
Figure 2: Guiding of the METACAP Spray Gun D/A
Attention!
Intensive waving will cause the air jacket will become unstable, allowing
clouds of atomized spray material to escape.
6. Now, adjust the required spray beam, as described below:
— Necessary adjustments to modify the spray beam
— The shape (circular or wide) of the spray beam will be directly
adjusted on the nozzle cap (1/2). The nozzle cap is spring-mounted
and engages automatically in the corresponding positions.
— To adjust the shape of the spray beam, engage the nozzle cap in the
required position by means of the horns.
— The horns are horizontal to the gun axis: vertical wide spray beam.
— The horns are vertical to the gun axis: horizontal wide spray beam.
— The horns are transversal to the gun axis: circular spray beam.
See figure 3.

Operating Instructions
Operating Instructions
METACAP Spray Gun D/A
Version/Edition July 2008
8-17
Figure 3: Spray Beam Shape Adjustment
7. Adjust the width of the spray beam by using the nozzle cap adjusting
ring (1/1) to modify the distance between the nozzle cap (1/2) and the
nozzle (1/4).
— turn clockwise – wide spray beam
— turn counterclockwise – narrow spray beam
Attention!
Never tighten the nozzle cap adjusting ring too firmly.
If you tighten the nozzle cap adjusting ring too firmly, the nozzle cap is
directly positioned on the nozzle. Thus, the atomizing airflow is blocked and
the horn air becomes so strong that the air jacket cannot be produced.
The consequence will be a sputtering spray gun producing unwanted
clouds, see figure 4.
Figure 4: Adjustment of the Spray Beam Width
Description of the position according to figure 4:
1 narrow spray beam: larger
droplets 3 wide spray beam: smaller droplets
2a spray beam, narrow 2b spray beam, wide

Operating Instructions
Operating Instructions
METACAP Spray Gun D/A
8-18 Version/Edition July 2008
An infinite number of variants are possible between the indicated settings 1,
2, and 3.
The quantity of coating material coming out of the spray gun can be adjusted
by turning the knurled screw (1/38).
— counterclockwise: more material
— clockwise: less material
Attention!
Please, take into account that you always adjust the material quantity
simultaneously when modifying the width or shape of the spray beam.
Always adjust the spray beam only as wide as required to avoid a nuisance
or possible danger caused by coating material splashes.
Depending on the coating material used, spray beam widths of about 5 mm
up to 200 mm are adjustable.
8.2 Spray Process
The required spray beam has been correctly adjusted by spraying a test
object. This process might not be necessary in case of trained operators.
Such experienced users may adjust the spray beam directly on the work
piece.
— Always keep the spray gun vertical to the work piece surface. If you
move or incline the spray gun in a bow shaped way, the coating material
will be irregularly applied. The spraying distance should not exceed
approx. 200 mm.
— Spray all edges first. Let approx. 50% of each applied spray beam
overlap. Actuate the trigger handle (1/33) only shortly before reaching
the edge of the surface to be sprayed. Move your spray gun with
continuous velocity over the surface and then release the trigger handle.
Repeat all these steps for the application of the following spray beam in
the counter direction.
Attention!
If there are any holes, grids, or the like within the work piece, place a plate
behind these orifices allowing the air jacket to build up for catching misled
coating material overspray.
Avoid an unintentional spraying of coating material by switching off the air
and material pressure and by releasing the residual pressure when the spray
gun is not used.

Operating Instructions
Maintenance and Care
METACAP Spray Gun D/A
Version/Edition July 2008
9-19
9 Maintenance and Care
9.1 Cleaning
Note:
The position numbers refer to the figure 1, see chapter 6.2 Structure of the
METACAP Spray Gun D/A, page 6-11.
1. Switch off the air and material supply and release the residual pressure.
2. Remove the residual coating material from the conveyor according to
the instructions of the manufacturer. Refill the coating material residues
into the container or evacuate them professionally.
3. Clean the conveyor according to the instructions of the manufacturer.
— When using METACAP Bottom Cup Sets, clean the cup (acc. to the
structural drawing of the bottom cup sets 1/78 and 1//81) by means of
a brush. Dismount the gasket sheet (see structural drawing of bottom
cup set 1/77) by pulling it out of the holding device (see structural
drawing of bottom cup set 1/79). Clean both the gasket sheet and the
holding device by means of a brush.
— Fill in the corresponding solvent (filling height: half-full).
4. Adjust the nozzle cap (1/2) to circular spray beam, then use the nozzle
cap adjusting ring to tighten it, so that there is no remaining annular gap
between the nozzle cap and the nozzle.
5. Now spray with the solvent suitable for the coating material to be used.
Never spray directly in the ambient area, because this will cause
needless dangers through the release of solvents.
— Always use the METACAP SRG spray gun cleaning device or the
injection orifice of a spray gun cleaning device. Repeat this
procedure until the spray gun is clean. The number of the rinsing
cycles depends on the coating material and on the corresponding
type of solvent.
6. Switch off the air and material supply and release the residual pressure.
7. Now, clean the outside of the spray gun by means of a cleaning cloth, if
necessary.

Operating Instructions
Maintenance and Care
METACAP Spray Gun D/A
9-20 Version/Edition July 2008
8. Unscrew the nozzle cap adjusting ring and remove the nozzle cap (1/2)
and the nozzle cap diaphragm (1/3) from the spray gun. Clean these
component parts by means of an appropriate solvent. If the drilled holes
of the nozzle cap are clogged, clean them by means of a tooth pick. Do
not use a wire, a drill or similar objects which may damage the nozzle
cap. Such damages may lead to incorrect spraying results.
— Now, the spray gun is clean enough to start working with a new
coating material.
— If the work is interrupted for a longer period of time (e.g. at the end of
the working shift), the following operations will have to be carried out:
— Unscrew the knurled screw (1/38) counterclockwise and remove it.
— Unscrew the pressure spring sleeve (1/36) counterclockwise and
remove it.
9. Pull the complete AKKORD needle (1/47) carefully backwards out of the
spray gun. Push the AKKORD needle guide ring and guiding spring
(1/10 and 1/11) forward down from the AKKORD needle. Do not loosen
the adjustment screw of the AKKORD needle (1/13) and the counternut
(1/14), as they ensure the initial air input settings of the spray gun which
should not be altered.
— Clean the outside of the AKKORD needle with a solvent and the
inner part of the flare needle by means of the brass wire brush
belonging to the scope of supply of your spray gun. Push this brush
completely through the needle before you pull it back, otherwise the
brass wires will wedge with the needle and it will not be possible any
longer to remove the brush without damaging the flare needle.
10. Remount the AKKORD needle guide ring and the guiding spring on the
AKKORD needle.
— Slightly lubricate a length of approx. 10 mm of the AKKORD needle
situated approx. 30 cm behind the tip by means of a non-corrosive, non-
hardening lubricant (for example: Molycote LongTerm W2 or Vaseline)
and then put it aside.
11. Unscrew the nozzle (1/4) counterclockwise by means of a deep offset
wrench, a wrench or a nut (wrench size: 13 mm) and remove it from the
nozzle holder (1/7). Do not use an open-jawed wrench or tongs for
mounting or dismounting the nozzle, because these types of tools may
damage the nozzle or the spray gun body. It is possible that such
damages completely destroy the spray gun. If there are still coating
material residues within the nozzle, clean the nozzle by means of a
solvent. To clean the inside, use the short cleaning brush belonging to
the scope of supply of your spray gun. Afterwards, clean the nozzle and
put it aside as well.