WEBAC IP 1 WEBAC IP 2 WEBAC IP 3. Operating Instructions Product Description Safety Notes User Information Spare Parts List

Transcription

1 Operating Instructions Product Description Safety Notes User Information Spare Parts List WEBAC IP 1 WEBAC IP 2 WEBAC IP 3 Sales and Service WEBAC Chemie GmbH Fahrenberg 22, D Barsbüttel Phone: +49(0) Fax: +49(0)

2 Table of Contents Contents Page Safety Notes 3 Intended Use 3 Description of the Pumps 4 Technical Data 4 Suitable Materials 4 Nameplates 5 Safety Instructions 6 Operational Safety 6 Particular Danger Spots 7 Start-up and Operation 9 General Information 10 Start-up of the Pumps 10 Stops and Pauses 11 Placing the Pumps Out of Service 12 Detail Drawing of Hopper and Suction System 13 Maintenance and Care 14 Oil Change, Checking Oil Level 14 Repair and Assembly Diaphragm Paint Step Suction Valve Outlet Valve Pressure Regulating Valve Malfunctions and Remedies 20 Spare Parts Lists 21 HAP 35 HP Injection Gun 33 Service / Testing Warranty Point of Service Any non-compliance with this sign may endanger the safety of humans or cause damage to the electric HP injection pumps. This sign refers to recommendations or particularities. This sign suggests an environmentally-friendly behavior. Page 2

3 It is absolutely necessary to read these instructions carefully before, and to observe the safety instructions while operating the electric WEBAC Injection Pumps. Put the injection gun on safe and check all connecting parts for tightness! Maximum working overpressure: 250 bars. INTENDED USE WEBAC HP diaphragm-operated pumps must not be used for applications other than the injection of materials under high pressure (not exceeding 250 bars). Only those materials shall be used with the devices which are described in the technical data sheets of the respective devices. No other materials shall be used with the devices, unless WEBAC has given its explicit prior consent therefore. Depending on the manufacturer's technical data sheets, WEBAC HP diaphragm-operated pumps are recommended for the following applications: 1. Draining and drying of building constructions 2. Preservation of building constructions 3. Concrete repair 4. Wood preservation or impregnation 5. Facade protection or decoration 6. Rust prevention 7. Sealing 8. Undercoating and coating 9. Interior renovation The instructions for use and safety instructions provided by each manufacturer of materials to be injected must be observed. Page 3

4 DESCRIPTION OF THE PUMPS WEBAC pumps, model IP1, IP2 and IP3, are airless, electrohydraulic diaphragm-operated piston pumps of similar design. The shaft of the electric motor is provided with an eccentric bearing which is connected to a hydraulic piston by means of a recuperating spring in a non-positive manner. The hydraulic piston is forced into an up-and-down movement by the rotation of the eccentric bearing. As soon as the hydraulic piston moves downwards, a negative pressure is created in the space below the diaphragm. The diaphragm arches downwards thus forcing the suction valve in the pump head open, with the injection material being drawn into the material chamber of the pump head as a result thereof. After the suction circle, the hydraulic piston is forced into an upward movement so that the diaphragm arches into the material chamber of the pump head. The outlet valve opens thus allowing the injection material to be fed into the high pressure hose. The material pressure can be continuously adjusted to bars by means of the pressure regulating valve. The diaphragm-operated pump can draw in the material in two different ways: Direct suction: A feed container (hopper) receiving the injection material is installed directly on the suction valve. Suction through a flexible suction system (optional): A flexible suction system is mounted on the suction valve, with the free end of the suction system being inserted into the container in which the injection material is supplied. TECHNICAL DATA: Operating pressure WEBAC IP 1 WEBAC IP 2 WEBAC IP bars Mat. volumetric flow at 120 bar 1.6 l/min 2.5 l/min 5.5 l/min Time-lag fuse 10 A tr. 10 A tr. 16 A tr. Voltage 110V or 230 V /50 Hz ~ Output power 0.55 kw 0.75 kw 1.8 kw Cable length 3 m 6 m 6 m Sound level 78 db (A) 78 db (A) 83 db (A) Feed container (hopper) Weight (approx.) 18 kg 24 kg 54 kg 6 l Inflammable materials having a flash point below 21 C must not be used with this type of device. Water-dilutable materials must only be applied by means of appropriate devices in order to avoid undesired reactions with nonferrous metals and steel. Page 4

5 Nameplates A nameplate is fastened to the device as shown in the following illustration. The data of the nameplate shall be transcribed to the respective illustration. Have this information ready if you call our customer service. WEBAC Chemie GmbH WEBAC Chemie GmH Page 5

6 SAFETY Besides the operating instructions and the applicable legal and other mandatory regulations relevant to the prevention of accidents in the country of use and at the place of use, you must also observe the recognized special engineering regulations governing safe and professional working practices. Principle of operation; intended use 1. All WEBAC IP HP diaphragm-operated pumps have been built to comply with state-of-the-art standards and recognized safety regulations. Nevertheless, their use may constitute a risk to life and limb for the user or for third parties, or cause damage to the device and other assets. 2. WEBAC IP HP diaphragm-operated pumps must only be used in technically perfect condition in accordance with the regulations and the instructions set out in the operating instructions and only by safety-conscious persons fully aware of the risks involved. Any malfunctions, especially those affecting safety, must be rectified immediately! HP material lines must not be pulled across sharpedged objects and must always be checked before use to ensure that they are in perfect condition. 3. WEBAC IP HP diaphragm-operated pumps are designed exclusively for the intended use stated in the section above. Any use for other purposes that those mentioned is considered contrary to the intended use. The manufacturer/supplier cannot be held liable for any damage resulting from such use. The user alone must bear the risk. 4. The manufacturer is not liable for any unauthorized modifications or repairs made to the devices. 5. In accordance with the trade associations' directives governing liquid jet pumps, ZH 1/406, injection devices must be checked by experts on request, or at least every 12 months, to ensure that there is no risk involved in its continued operation. If the units are idle, the examination can be delayed until the next period of operation. The operator is obliged to register the equipment for testing and to keep written records of the results of such testing. OPERATIONAL SAFETY 1. The following safety instructions must be observed when working with HP devices: Regulation for the prevention of accidents VBG 23 - Application of Coating Materials Regulation for the prevention of accidents VBG 87 - Working with Liquid Jet Pumps Guidelines for Liquid Jet Pumps ZH 1/406 of the trade associations. 2. Each person using a WEBAC IP HP diaphragm-operated pump must have read and understood the operating instructions, in particular the chapter on "Safety". 3. When working in closed rooms, provide for sufficient ventilation. 4. Only use injection material lines and devices designed to perfectly withstand the maximum operating overpressure of the pump. 5. Keep away all sources of ignition, e.g. open fires, sparks, glowing wires, burning cigarettes, from the vicinity of the pump. There must be a distance of at least 5 m between the spray jet outlet and any possible source of ignition. Inflammable injection materials having a flash point below 21 C must not be used with this type of device. The injection material is ejected under very high pressure (up to 250 bars) from the spray nozzle. Therefore, never direct the spray jet towards humans or animals in order to avoid the acute risk of injury (strong cutting effect). In case of skin injuries, there is a risk of infection. Seek medical advise immediately; take along the safety data sheet of the injection material used. Page 6

7 Always take the safety data sheets along to the building site. 6. Water-dilutable materials must only be applied by means of appropriate devices. Upon contact with water, the nonferrous components of the device may react with those made of steel. 7. The work may generate vapors damaging your health. Observe the manufacturers' guidelines in the technical data sheets. Use personal breathing equipment, if necessary. Keep children right away from the work area. 8. Keep WEBAC IP HP diaphragm-operated pumps in a safe place inaccessible to children and unauthorized persons. Make sure that unauthorized personnel (and children in particular) cannot start up the pump. 9. Store WEBAC IP HP diaphragm-operated pumps in a dry place. 10. Use only original equipment and spare parts. 11. Maintenance work must only be carried out by authorized specialized companies or by the manufacturer. For addresses of authorized companies, contact the manufacturer or your dealer. 12. Do not direct the jet stream towards the device. Do not allow any paint or solvent residue to enter the soil or sewage system. Dispose of cleaning agents and injection materials in accordance with the manufacturer's instructions. 13. When interrupting work, e.g. during breaks or while replacing components, please proceed as follows: A Switch off the system. B Keep open the ball valve /injection gun until no more materials emerges (to decrease residual pressure). C Put on safe, then lock the ball valve / injection gun. PARTICULAR DANGER SPOTS 1. The emerging injection material generates a certain power of recoil. This power is increased considerably when using nozzle extensions and in the case of large outlet diameters. Therefore a firm grip of the ball valve /injection gun and a safe distance are of utmost importance. 2. In closed or pressurized systems, where aluminum or galvanized components come into contact with the injection material, dangerous chemical reactions can be the result when using trichloroethane, metylane chloride or other solvents containing halogenated chlorinated hydrocarbons. We strongly recommend to contact your customer service or the manufacturer if theses solvents shall be used. 3. To prevent static charging causing fires or explosions, the system must be properly grounded. Connect WEBAC IP HP diaphragm-operated pumps to shockproof sockets only which on their part must be connected to an earth conductor. Page 7

8 4. Any equipment that is not explosion-proof must not be used in premises subject to the regulations on explosion protection. Only injection materials and solvents having a flash point above 21 C (group A II and A III) may be used without additional heating. 5. HP hoses and hose couplers used must be electrically conductive and withstand the pressure generated by the equipment. Only use original parts. 6. Never spray back material into a closed container since inflammable gas or air mixtures will form. 7. As the working areas are not defined and cannot be defined, the maximum noise level is indicated. 8. Local conditions may generate a higher sound level causing noise deafness. In this case, the operating personnel must be provided with suitable protective equipment or safety measures. 9. When using materials containing solvents, the forming solvent vapors must be evacuated by means of an extraction system or the room must be sufficiently ventilated. 10. The use of injection gun extensions may generate a very strong power of recoil. Hold the injection gun firmly with both hands. 11. The use of ball valves with injection hoses or injection guns without female zerk couplers is strongly prohibited. Page 8

9 START-UP AND OPERATION Valve lifter (tapper) 2 Suction valve 3 Motor switch ON/OFF 4 Oil control glass 5 Pressure regulator 6 Pressure gauge 7 Pressure joint 8 Oil filler screw Page 9

10 GENERAL INFORMATION Initial start-up of the pump following its purchase: Injection material reacts with water. Rinse the pump with the type of cleaning agent indicated by the manufacturer of the injection material. After the very first injection job, re-tighten the cylinder head studs of the pump head crosswise with a torque wrench (IP 2: 60 Nm, IP3: 83 Nm). Install the device in a stable and horizontal position. Protect the device against falling objects. The shockproof socket must at least be protected by a 16 A fuse. Replace the locking screw mounted for transportation purposes only with the provided oil filler screw. Select the injection pressure in such a way that the equipment can be operated without wear and tear. PUMP WITH HOPPER (A), WITH (OPTIONAL) SUCTION SYSTEM (B) 1. Install the pump in a stable and horizontal position. 2. Remove the sealing cap from the suction valve. 3. Check the hydraulic oil level of the pumps regularly. On pump models IP2 and IP3, the oil level is correct if it is just about visible through the oil control glass (4). On model IP1, check the oil level by means of the notch in the casing which must be just about covered with oil. 4. A: Place the hopper on the suction fitting (2) and screw it in tightly. B: Place the suction system on the suction fitting (2) and screw it in tightly. 5. Screw the entire hose system onto the pressure joint (7). Prior to the first start-up of the device, check all screw fittings for firm fit and re-tighten, if necessary. 6. A: Fill the hopper with cleaning agent. Place the nozzle (female zerk coupler /injection gun with female zerk coupler) into the hopper. B: Insert the suction system with filtering basket into the container filled with cleaning agent. Place the nozzle (female zerk coupler /injection gun with female zerk coupler) into the container. 7. Close all valves. Turn the pressure regulator to the left (minimum). 8. Plug the device into a 230V/50 Hz shockproof socket. 9. Activate the ON/OFF motor switch (3) to start the device. 10. Open the ball valve /gun, slightly increase the pressure via the pressure regulator (5) (turn to the right) until cleaning agent is transported evenly and emerges at the female zerk coupler. 11. Let the equipment rotate idle for several minutes. 12. Then close the ball valve/ gun. 13. A: Drain the cleaning agent from the hopper, fill in and mix the injection material in accordance with the manufacturer's technical data sheets. B: Remove the container with cleaning agent, fill the injection material into the container to be used for the injection, mix it, and insert the suction system with filtering basket into the container. Page 10

11 When using WEBAC Injection Foam Resins (e.g. WEBAC 151), first fill only component A into the hopper and feed it through the pump system. Injection foam resins are water reactive and may react upon contact with residual dampness in the device causing the pump to clog. Then add component B, observing the material's mixing ratio. 14. Turn the pressure regulator (5) to the right to obtain the desired injection pressure. The actual injection pressure can be read on the pressure gauge. 15. The equipment is now ready for use and work can be taken up. OPERATION NOTES Carry out the application swiftly and evenly. Ensure firm, event contact between the female zerk coupler and the injection fitting. Do not jam the nozzle to avoid dripping, leakage or even lateral injection of the material. Do not allow any paint or solvent residue to enter the soil or the sewage system. Dispose of cleaning agents and injection materials in accordance with the manufacturer's instructions. We recommend to use the manufacturer's HP pressure hoses of at least 5 mm inside diameter. The HP hoses used can be extended up to 90 m without any decrease in pressure. Do not bend the HP hoses sharply. Do not bend the hoses below a bending radius of 20. HP hoses must not be pulled across sharp edges or objects. Do not drive across the HP hoses. Clean the HP hoses after use. Check all screw fittings for firm fit regularly and re-tighten, if necessary. Replace all defective HP hoses, female zerk couplers and pressure gauges immediately. Repair or replace all defective pump components immediately. All these measures serve your own safety. SHORT STOPS / PAUSES 1. Close the ball valve /injection gun. 2. Turn the pressure regulator (5) to the left (minimum). 3. Activate the ON/OFF switch (3) to switch off the equipment. 4. Place the ball valve /injection gun into the waste container and open it until the whole injection system is depressurized and no more material emerges from the female zerk coupler. 5. Close the ball valve /injection gun. 6. Deposit the entire hose system in a safe place. Page 11

12 LONG STOPS / PLACING THE PUMPS OUT OF SERVICE When using quick-action injection materials (e.g. WEBAC 1403 or WEBAC 4110) clean the whole system immediately. Do not allow any material residue to dry up in the hopper or device. The cleaning agent used must be suitable for the respective injection material. Observe the manufacturer's technical data sheets. Cleanliness is an indispensable prerequisite for a trouble-free and reliable operation of the equipment. Upon completion of the injection procedure, proceed as follows: 1. Close the ball valve/ injection gun. 2. Put the nozzle into an open, empty container. Open the ball valve /injection gun and feed all residual injection material from the hopper into the waste container until the screen in the hopper is only slightly covered. Then close the ball valve /injection gun. 3. Fill the hopper with approx. 2-3 l of suitable cleaning agent. Then feed the residual material in the system into the waste container. Close the ball valve /injection gun. 4. Place the nozzle in the cleaning agent. 5. Open the ball valve /injection gun and clean the pump for approx. 5 minutes in rotating mode. 6. Repeat step Turn the pressure regulator (5) to the right to maximum. 8. Open and close the ball valve /injection gun several times at short intervals. 9. Repeat step The cleaning agent used can be collected in a separate container and be reused for the next cleaning procedure. 10.Turn the pressure regulator (5) to the left to minimum. Open the ball valve /injection gun to depressurize the system. 11.Actuate the ON/OFF switch (3) to switch off the pump. 12.Clean the whole system from outside. If the equipment shall be placed out of service for a longer period of time, it must first be cleaned thoroughly as described above and then rinsed with a preservative oil (or hydraulic oil). When using a suction system (optional), clean the system as described above. Instead of using a hopper, separate containers shall be used into which the suction system shall be inserted. Page 12

13 Drawing of Hopper, Suction System Clamp 2 Screen 3 Cover 4 Hopper 1 2-binaural clamp 2 Plastic snap-on connector 3 Filtering basket Page 13

14 MAINTENANCE AND CARE (Notes) Hopper and Suction System, Replacing the Filter Screen Use a solvent or cleaning agent to clean the hopper and the suction system. A brush for sweeping pipes is suitable for cleaning the suction pipes without leaving any deposit. Use a brush and a solvent (e.g. WEBAC Cleaner A) to clean the filter screen (2) and the clamp for the filter screen (1) after dismounting these from the hopper (4). Proceed as follows to clean and replace the screen in the hopper: 1. Squeeze the clamp (1) to remove it. 2. Grab the screen (2) by the center journal and remove it. 3. Carry out the assembly in opposite sequence. Ensure that the center journal points upwards; otherwise problems will arise during the next replacement. Hydraulic System The diaphragm is responsible for the transfer of the injection material and is driven hydraulically. Check the oil level of the hydraulic system at regular intervals. To do so, undo the oil filler screw. Below the thread for the oil filler screw, you will see a notch in the casing which marks the oil level. Oil Change: All hydraulic oil is subject to aging and should be changed not later than 400 service hours or once every year maximum. The first oil change shall take place after 100 service hours at the latest. The manufacturer recommends the following hydraulic oils: - ESSO Nuto H22 - Shell Tellus 22 - ARAL Vitan GF 22 - Valvoline ETC /22 Amount of oil WEBAC IP1 Amount of oil WEBAC IP2 Amount of oil WEBAC IP3 750 ml 950 ml 1,200 ml Do not mix hydraulic oils with each other. Checking the Oil Level on Pump IP1 1. Place a collection pan underneath the oil filler screw (8). 2. Undo the oil filler screw. 3. The hydraulic oil must be visible at the notch of the oil filler neck. 4. If necessary, top up with hydraulic oil. 5. Screw the oil filler screw back into the oil filler neck and tighten by hand. Page 14

15 Checking the Oil Level on Pumps IP2 and IP3 1. The hydraulic oil must be visible through the oil control glass (4). 2. If necessary, undo the oil filler screw (8) and top up with hydraulic oil. 3. Screw the oil filler screw back into the oil filler neck and firmly tighten by hand. Oil Change First oil change after 100 service hours from the first start-up. Subsequent oil changes at intervals of 400 service hours or at least once every year. Change the oil while the pump is still warm. Always place a collection pan underneath the pump. Dispose of waste oil in a manner compatible with the environment. Oil Change on WEBAC Pump IP1 1. Place a collection pan underneath the waste oil screw (8). 2. Undo the oil filler screw in the filler neck. 3. Tilt the pump to drain all hydraulic oil into the collection pan. 4. Drain the oil completely. 5. Top up with (approx l) hydraulic oil via the oil filler screw. 6. Screw the oil filler screw (8) back into the filler neck and firmly tighten by hand. Oil Change on WEBAC Pumps IP2 and IP3 1. Place a collection pan underneath the waste oil screw (8). 2. Undo the oil filler screw in the filler neck. 3. Use a NW 8 Allan key to undo the oil filler screw in the oil outlet drilling. 4. Drain the oil. 5. Screw the oil filler screw back into the oil outlet drilling and firmly tighten by hand. 6. Top up with hydraulic oil via the filler neck. 7. Screw the oil filler screw (8) back into the filler neck and firmly tighten by hand. Page 15

16 Diaphragm and Paint Step (Pump Head) The paint step shall be replaced, if and when: the paint element is eroded, or the packing grooves are damaged. Replacing the Paint Step and the Diaphragm of WEBAC Pump IP1 1. Use a size 6 Allan key to undo the fillister head screws of the paint step crosswise. 2. Remove the paint step upward. 3. Pull out the diaphragm upward. 4. Carry out the assembly in reverse order. The tightening torque for the fillister head screws is 40 Nm. The diaphragm fitting edge (batching) inside the pump chamber must be mounted. Replacing the Paint Step and the Diaphragm of WEBAC Pumps IP2 and IP3 1. Use a size 36 open-jawed wrench to unscrew the suction valve. 2. Unscrew the Phillips screws of the cover. 3. Use a size 10 Allan key to unscrew the fillister head screws of the paint step crosswise. 4. Remove the paint step upward. 5. Pull out the diaphragm upward. 6. Carry out the assembly in reverse order. The tightening torque for the fillister head screws is 60 Nm for the IP2 and 82 Nm for the IP3. The diaphragm fitting edge (batching) inside the pump chamber must be mounted. Retighten the fillister head screws crosswise after the first use while the device is cold. Page 16

17 Suction Valve The suction valve, which is a plug-type valve, must be changed as a whole. The slanted tapping valve serves to remove clotted deposits in the suction valve. 1. Use a NW 36 (IP2 and IP3) or a size 27 (IP1) open-jawed wrench to unscrew the suction valve. 2. Use a suitable cleaning agent (e.g. WEBAC Cleaner A) to remove any residual material from the conical surface of the suction valve. 3. Insert a new sealing ring (IP2 and IP3) each time the valve is replaced. 4. Screw in the cleaned or the new suction valve and tighten. Outlet Valve (OV): Disassembly of WEBAC Pump IP1 Outlet Valve IP 1 1 OV screw plug 5 OV pin 2 OV Cu-sealing ring 6 OV ball 3 OV damper 7 OV face screw 4 OV spring 8 OV valve face 1. Use a size 8 Allan key to undo and remove the OV screw plug (1). 2. Remove the OV Cu-sealing ring (2), the OV damper (3), the OV spring (4), the OV pin (5) and the OV ball (6). The ball (6) can be checked with a micrometer gauge. Check the ball for traces of grinding and ovalness. Replace the ball in cases of doubt, since even a minor ovalness of 0.01 mm can cause severe pressure fluctuations. 3. Use a SW 8 Allan key to undo the OV face screw (7) and remove it together with the embedded hard-metal OV valve face (8). The OV valve face and the OV pin must not be dome-shaped. Should this be the case, replace the entire valve face (8). Page 17

18 Carry out the Assembly as Follows: 1. Grease the thread of the OV face screw (7) with Cu-sliding paste. 2. Screw the OV face screw (7), together with the embedded OV hard-metal valve face (8), into the OV drilling and tighten it with a size 8 Allan key. 3. Place the OV damper (3), the OV spring (4), the OV pin (5) and the OV ball (6) into the valve drilling. 4. Place a new OV Cu-sealing ring (2) onto the thread of the OV screw plug (1). 5. Use a size 8 Allan key to tightly screw the OV screw plug (1) into the valve drilling. In so doing, use Loctite special thread glue. Disassembly of WEBAC Pumps IP2 and IP 3 Outlet Valve WEBAC IP2 and IP3 1 Pressure joint 5 Spring bolt 2 Sealing ring 6 Ball 3 Threaded ring 7 Valve face 4 Spring 8 Sealing washer 1. Unscrew and remove the pressure joint (1). 2. Remove the sealing ring (2), the threaded ring (3), the spring (4), the spring bolt (5) and the ball (6). The ball (6) can be checked with a micrometer gauge. Check the ball for traces of grinding and ovalness. Replace the ball in cases of doubt, since even a minor ovalness of 0.01 mm can cause severe pressure fluctuations. 3. Use a size 12 Allan key to unscrew the valve face (7). The valve face in the drilling base must not be dome-shaped. Should this be the case, replace the entire valve face (7). 4. Remove the sealing washer (8). Page 18

19 Carry out the Assembly as Follows: 1. Place the OV sealing washer (8), with the step side up, into the drilling base. 2. Insert the entire valve face (7), with the hard-metal part first, into the drilling base. 3. Use a size 12 Allan key to tightly screw in the OV threaded ring (3). It is absolutely necessary to grease the thread with Cu-sliding paste. 4. Place the ball (6) and the OV spring bolt (5) with OV spring (4) into the valve seat. 5. Put the new OV sealing ring (2) onto the thread of the OV pressure joint (1). 6. Use a size 27 ring wrench to tightly screw the OV pressure joint (1) into the paint step. In so doing, use silicone-free grease. Pressure Regulating Valve The factory settings of the pressure regulating valve must not be changed (safety valve). The valve is supplied as a complete unit and must not be changed but as a whole. Page 19

20 MALFUNCTIONS AND REMEDIES Malfunction Possible reason Remedy Device does nor start No electric voltage Wrong voltage Main supply insufficiently fused Defective or weak extension cable Check voltage Check type of voltage Install correct fusing Extension cable must have a min. cross section of 3 x 1.5 mm² Wrong hydraulic oil Running capacitor defective Use recommended hydraulic oil (see p. 9) Have an electrician replace defective capacitor No suction Model with hopper: Suction filter clogged Oil level too low Suction valve sticky (the valve in the suction fitting must readily yield under pressure) Clean or replace suction filter Top up with oil Use appropriate cleaning agent and hard brush to clean the suction valve. Start equipment. Pour detergent into the suction fitting. Simultaneously, push down valve until you can hear the suction valve open and close. Suction valve defective (injection material is sucked in and ejected through the suction valve) Replace according to instructions Outlet valve sticky Suction filter clogged Dismount the valve according to instructions. Clean all parts in case of doubt, replace valve ball and spring Clean/Replace Device sucks in material, but does not build up pressure Oil level too low Air in hydraulic system Outlet valve defective Top up with oil Ventilate without injection material Dismount valve according to instructions Loss of pressure as soon as ball valve /injection gun opens Suction filter clogged Injection medium too thick or too coarse Clean or replace suction filter Contact manufacturer Page 20

21 IP 1 Spare Parts List Ersatzteile / Spare Parts for IP 1 Pos. Bestell-Nr. / Order No. Bezeichnung Designation Senkschraube countersunk screw Gehäusedeckel cover O-Ring 80x2, bis 8/94 o-ring, until 08/ O-Ring 85x2, ab 8/94 o-ring, since 08/ Sicherungsring safety ring Stützrolle support roller Scheibe washer Einfüllschraube oil filler screw Gehäusedeckel cover Stopfen stopper Sicherungsring safety ring Hauptlager main bearing Wellendichtring shaft sealing O-Ring 11x1,5 o-ring, 11x Druckregler komp. pressure regulator cpl Druckfeder (Hydr.) spring (hydr.) Federauflage spring base Hydraulikkolben (k. Ersatzt.) hydraulic piston** Sicherungsring safety ring Filter Hydraulik filter, hydraulic Ansaugrohr Hydr. suction pipe, hydr. 1 ** = no spare part Page 21

22 IP 1 Spare Parts List Ersatzteile / Spare Parts for IP 1 Pos. Bestell-Nr. / Order No. Bezeichnung Designation Entlastungshahn relief pipe Dichtring sealing ring Druckstutzen pressure joint AV-Sitz mit Schr. Pos 5 OV 2 face + screw AV-Sitzschraube OV face screw AV-Kugel OV ball AV-Pilz OV pin AV-Feder OV spring AV-Federführung OV spring guide Cu-Dichtungsring Cu-sealing ring AV-Verschluß OV screw plug Abdeckung GPN cap Einlaßventil kpl. intake valve cpl Einlaßventil kpl. mit Tupfer IV 3 cpl. with tapper Käppi cap Zylinderschraube fillister head screw Federring spring ring Tragbügel handle 2 OV = outlet valve 3 IV = inlet valve Page 22

23 Ersatzteile / Spare Parts for IP 1 continued Federring spring ring Zylinderschraube fillister head screw Pumpenkopf, Gehäuse pump head casing Zylinderfüllung cylinder insert Membran kpl. D39 diaphragm cpl. D Kreuzringdichtung crossring sealing Manometer pressure gauge IP 1 Spare Parts List - Rahmen/Frame Ersatzteile / Spare Parts for IP 1 - Rahmen/Frame Pos. Bestell-Nr. / Order No. Bezeichnung Designation Apparatepuffer stopper Scheibe washer Linsenschraube oval head screw Zylinderschraube fillister head screw Federring spring ring T-Gestell T-frame Gummipuffer rubber buffer Distanzstück spacer piece 9 Abdeckung cap Page 23

24 IP 1 Spare Parts List - Motor Ersatzteile / Spare Parts for IP 1 - Motor Pos. Bestell-Nr. / Order No. Bezeichnung Designation Exzenterwelle kpl. eccentric shaft cpl Wasserschutzkappe water protection cap Schutzschalter 7A safety switch 7A Motor 0,55 kw, 220V 0.55 kw, 220V motor Kabel mit Stecker cable with plug Kabeleinführung cable entry Senkschraube M4x10 M4x10 countersunk Ein-/Ausschalter on-off switch Zylinderschraube M5x12 M5x12 fillister head Kugellager ball bearing Ausgleichsscheibe balance washer Abdeckscheibe washer B-Lagerschild end shield Lüfterrad fan Lüfterhaube fan cap Zuganker tie rod Federring spring ring Kondensator 16MF 16 MF capacitor Befestigungsband holding strap Page 24

25 IP2 Spare Parts List - Motor Ersatzteile / IP 2 Spare Parts Pos. Bestell-Nr. / Order No. Bezeichnung Designation Exzenterwelle kpl. eccentric shaft cpl Kondensator 240V 25µF capacitor Stator 240V/50Hz, 0.75 kw stato 4 Schiene (kein ET) rail** 5 Federring (kein ET) spring ring** Zyl. Schraube fillister head screw Wasserschutzhaube water protection cap Schutzschalter 8A 8A safety switch Abdeckblech hinten rear cover plate Käppi cap Kreuzschlitzschraube Phillips screw Fächerscheibe washer Sechskantmutter M8 M8 hexagon nut Kugellager ball bearing Ausgleichsscheibe balance washer Lagerschild end shield Federring A5 A5 spring ring Zuganker tie rod Lüfterrad fan Motorhaube A2 A2 motor cap Zugentlastung tension relief Netzkabel m. Eurostecker mains cable with Euro plu Zyl. Schraube fillister head screw 26/27 Typenschild, Nieten nameplate, rivets Dichtungsgummisatz rubber sealing set Page 25

26 IP2 Spare Parts List Ersatzteile / Spare Parts for IP 2 Pos. Bestell-Nr. / Order No. Bezeichnung Designation Hydraulikgehäuse hydraulic casing Dichtung sealing ring Verschlußschraube screw plug Stützrolle support roller Sicherungsring safety ring O-Ring 120x2 o-ring Getriebedeckel IP2 IP2 gear cover Federring A6 A6 spring ring Zyl. Schraube M6x40 fillister head screw Ölschauglas oil control glass Zyl. Schraube M6x16 fillister head screw Federring A6 A6 spring ring Öleinfüllschraube oil filler screw Druckregler kpl. (inkl. 15) pressure regulator O-Ring 11x1,5 11x1.5 o-ring Hydraulikeinsatz kpl. hydr. insert cpl Zylinderstift M6 M6 straight pin Federring spring ring O-Ring 51x2 51x2 o-ring Zylinderstift M4 M4 straight pin Hydraulikkolben hydraulic piston Druckfeder Hydraulik spring, hydr Federauflage spring base Sicherungsring safety ring O-Ring 6x2 6x2 o-ring Sicherungsring safety ring Motorlager motor bearing Wellendichtring shaft sealing Page 26

27 Spare Parts List for IP2 (Drucktechnik/Pressure Technique) Ersatzteile / Spare Parts for IP 2 Pos. Bestell-Nr. / Order No. Bezeichnung Designation Fronthaube front cap Dichtscheibe sealing washer O-Ring 12x1,5 12x1.5 o-ring Entlastungsventil kpl. relief valve cpl Kreuzringdichtung crossring sealing Manometer pressure gauge Linsenschraube M5x6 oval head screw Zahnscheibe toothed washer Druckstutzen M16x1,5 pressure joint Cu-Scheibe Cu-washer AV-Federaufnahme OV spring retainer AV-Feder OV spring AV-Federführung OV spring guide AV-Kugel OV ball AV-Sitz kpl. vorm. OV face cpl Dichtscheibe PA sealing washer Käppi cap Kreuzschlitzschraube Phillips screw EV-Dichtring IV sealing ring Einlaßventil kpl. IV cpl EV-Dichtring IV sealing ring EV kpl. mit Tupfer IV cpl. with tapper Abdeckblech vorn front cover plate Page 27

28 Ersatzteile / Spare Parts for IP 2 continued Zyl. Schraube M10x40 fillister head screw Federring A10 A10 spring ring Pumpenkopf kpl. pump head cpl Rücklaufstutzen (optional) return flow pipe Cu-Dichtung Cu-washer Zylinderfüllung cylinder insert Membrane kpl. diaphragm cpl. IP3 Spare Parts List Ersatzteile / Spare Parts for IP 3 Pos. Bestell-Nr. / Order No. Bezeichnung Designation Stator 240V/50Hz, 0,75 kw 240V/50Hz, 0.75 kw stato Kondensator 240V 25µF 240V 25µF capacitor Exzenterwelle kpl. eccentric shaft cpl. 4 Schiene (kein ET) rail** 5 Federring (kein ET) spring ring** Zyl. Schraube fillister head screw Wasserschutzhaube water protection cap Schutzschalter 16A 16A safety switch Abdeckblech hinten rear cover plate Käppi cap Kreuzschlitzschraube Phillips screw Fächerscheibe 8,3 8.3 washer Sechskantmutter M8 M8 hexagon nut Page 28

29 Ersatzteile / Spare Parts for IP 3 continued Motorlager motor bearing Ausgleichsscheibe balance washer Lagerschild end shield Federring A5 A5 spring ring Zuganker tie rod Lüfterrad fan Motorhaube IP3 IP3 motor cap Zugentlastung tension relief Netzkabel m. Eurostecker mains cable with Euro plug Zyl. Schraube fillister head screw 26 Typenschild nameplate 27 Nieten rivets Dichtungsgummisatz rubber sealing set IP3 Spare Parts List Ersatzteile / Spare Parts for IP 3 Pos. Bestell-Nr. / Order No. Bezeichnung Designation Hydraulikgehäuse casing, hydraulic Verschlußschraube screw plug Dichtung sealing ring Stützrolle support roller Sicherungsring safety ring O-Ring 146x2 146x2 o-ring Getriebedeckel IP3 IP3 gear cover Abdeckblech vorn front cover plate Page 29

30 Ersatzteile / Spare Parts for IP 3 continued Zyl. Schraube M6x40 fillister head screw Ölschauglas oil control glass Federring A6 A6 spring ring Zyl. Schraube M6x16 fillister head screw Öleinfüllschraube oil filler screw Druckregler kpl. (inkl. 15) pressure regulator O-Ring 11x1,5 11x1.5 o-ring Hydraulikeinsatz kpl. hydr. insert cpl Zylinderstift M6 M6 straight pin Zyl. Schraube fillister head screw Federring spring ring O-Ring 64x3 64x3 o-ring Halbrundschraube M5x60 half-round screw Hydraulikkolben hydraulic piston Druckfeder Hydraulik spring, hydr Federauflage spring base Sicherungsring safety ring Sicherungsring safety ring Motorlager motor bearing Wellendichtring shaft sealing O-Ring 6x2 6x2 o-ring IP3 Spare Parts List (Drucktechnik/Pressure Technique) Page 30

31 Ersatzteile / Spare Parts for IP 3 Pos. Bestell-Nr. / Order No. Bezeichnung Designation Fronthaube front cap Dichtscheibe sealing washer O-Ring 12x1,5 12x1.5 o-ring Entlastungsventil kpl. relief valve cpl Kreuzringdichtung crossring sealing Manometer pressure gauge Linsenschraube M5x6 oval head screw Zahnscheibe toothed washer Druckstutzen M16x1,5 pressure joint Cu-Scheibe Cu-washer AV-Federaufnahme OV spring retainer AV-Feder OV spring AV-Federführung OV spring guide AV-Kugel OV ball AV-Sitz kpl. vorm. OV face cpl Dichtscheibe PA sealing washer Käppi cap Kreuzschlitzschraube Phillips screw EV-Dichtring IV sealing ring Einlaßventil kpl. intake valve cpl EV-Dichtring IV sealing ring EV kpl. mit Tupfer IV cpl. with tapper Abdeckblech vorn front cover plate Zyl. Schraube M10x40 fillister head screw Federring A10 A10 spring ring Pumpenkopf kpl. pump head cpl Rücklaufstutzen (optional) return flow pipe Cu-Dichtung Cu-washer Zylinderfüllung cylinder insert Membrane kpl. diaphragm cpl. Page 31

32 Ersatzteile / Spare Parts for IP 3 - Fahrwagen/Cart Pos. Bestell-Nr. / Order No. Bezeichnung Designation Lamellenstopfen D30 stopper D Lamellenstopfen D25 stopper D Dose container Bügel handle Rohrklappstecker clamp Rad 260x105x25 mm wheel Scheibe 26x44x4 26x44x4 washer Radkappe wheel cap Wagen Schwt. cart Unterlegteil washer Federring A8 A8 spring ring Zylinderschraube M8x20 fillister head screw Fahrwagen IP 2, IP3 kpl. IP2, IP3 cart cpl. Page 32

33 HP Injection Gun HAP 35 The injection gun HAP 35 is suitable for a max. injection pressure up to 250 bars. It is standardequipped with a swivel (20) for easier operation and can be connected to all common injection system. How to Clean the HAP 35 Clean the injection gun with a suitable cleaner immediately after use. To avoid clogging of packings, rinse the gun with a cleaning agent recommended by the manufacturer of the injection material used. HAP 35 Spare Parts List Page 33

34 Ersatzteile / Spare Parts for HAP 35 Pos. Bestell-Nr. /Order No. Bezeichnung Designation Überwurfmutter union nut 2 Düse nozzle Düsendichtung nozzle sealing Schraubstück m. HM screw piece Schutzbügel protective handle Kugelkopf mit Kugel ball head with ball Druckstück pressure piece Stützscheibe supporting washer Packung packing Gehäuse casing Nadelhalter needle holder Sechskantmutter hexagon nut Schleißfeder closing screw Verschluß screw plug Dichtung sealing Griff handle Einsteckfilter, gelb 100 M filter insert, 100 m, yellow Einsteckfilter, rot 200 M filter insert, 200 m, red Einsteckfilter, weiß 50 M filter insert, 50 m, white Feder spring Dichtscheibe sealing washer Drehgelenk NPS ¼ NPS ¼ swivel Drehgelenk M 16x1,5 M 16x1.5 swivel Abzugsgriff trigger Abzugsstift trigger pin Remove filter insert (17) if injection materials are used. Page 34

35 Service / Testing According to the safety requirements for injection and spray devices, these devices must be checked on request, or at least every 12 months, to ensure that there is no risk involved in its continued operation. If the units are idle, the examination can be delayed until the next period of operation. The operator is obliged to keep written records of the results of such testing. The examinations may be carried out by anyone whose professional training and experience has given him adequate knowledge and understanding in the special field of injection and spray devices including all the relevant national health, safety, work and accident prevention regulations, directives and generally recognized technical regulations, i.e. he is able to assess whether or not injection and spray devices are safe to operate. The operator must ensure that the test results of each device are recorded in writing and kept in safe custody until the next testing. Test Documents Date of test Examiner Result Page 35

36 Test Report Manufacturer: Examiner: Date of commission: Deadline: Type of pump: Pump received on: Pump. No.: Work to be carried out (tick where applicable) Repair: Examination Other Examined components: Result Replaced Spare Parts: WEBAC Art. No.: General condition Frame/cart Switches/operating levers Designation/classification Intake valve Diaphragm Outlet valve Pressure regulating valve, classification Electronic switches Electronic cables, grounding Motor HP hose Pressure gauge fittings, pressure gauge Ball valve /gun Injection hose and coupler Oil level Hopper Operating instructions Function of pump tested: Function: OK: To Manufacturer* Date, signature (examiner) *Tests and Repair executed by the manufacturer will be invoiced Page 36

37 Warranty All warranty is subject to the relevant legal regulations, i.e. claims for damages in the case of defects must be asserted immediately, or within 6 months at the latest in the case of claims for conversion, reduction and damages, from the date of delivery. The device shall be checked immediately upon receipt. Apparent defects shall be reported to us in writing within 7 days from the date of receipt of the device. Any non-compliance with this clause will result in the loss of the purchaser s rights in respect of the defects. No warranty is granted for damages attributable, among others, to either or several of the following causes. Unsuited or inexpert use; faulty assembly or start-up by the purchaser or any third party; natural wear, faulty handling or maintenance; use of unsuited materials or substitute materials; chemical, electrochemical, or electrical influences, unless the damages are attributable to our own fault. Wear and tear attributable to the use of abrasive materials reducing the service life of valves, sealings, nozzles and pistons shall not be covered by the present warranty. The present warranty shall be null and void, unless the Certificate of Warranty with the date of sale filled in and duly undersigned by the seller were returned to us together with the defective device. If it is established by inspection that the damage is not covered by the present warranty, the costs of repair shall be borne by the purchaser. Besides, our "General Standard Terms and Conditions" are applicable. WEBAC Chemie GmbH Notes on Product Liability According to the relevant EC Regulation, in force since 1 January 1990, the manufacturer shall be liable for his product only if all parts and components were furnished by himself or released by him and that the device was assembled and operated in an expert manner. The manufacturer s liability may not, or not fully, apply in case any third-party accessories or spare parts were used. In some extreme cases (e.g. HP hoses which are unfit to withstand the max. operating overpressure of the device), the competent authorities (trade associations and trade board) may prohibit the purchaser or user from putting the device into operation at all. Production and Service Point WEBAC Chemie GmbH Fahrenberg 22 D Barsbüttel Tel.: +49(0) Technical Innovations The above information on pumps is subject to alterations due to technical innovations. Page 37