Warning! - Italia Star

Original Operating Manual

GB

Warning!

Attention: Danger of injury by injection!

Airless units develop extremely high spraying pressures.

1

Never put your fingers, hands or any other parts of the body into the spray jet!

Never point the spray gun at yourself, other persons or animals.

Never use the spray gun without safety guard.

Do not treat a spraying injury as a harmless cut. In case of injury to the skin through coating materials or solvents, consult a doctor immediately for quick and expert treatment.

Inform the doctor about the coating material or solvent used.

2

The operating instructions state that the following points must always be observed before starting up.

1.

2.

Faulty units must not be used.

Secure Titan spray gun using the safety catch on the trigger.

3. Ensure that the unit is properly earthed. The connection must take place through a correctly earthed two-pole and earth socket outlet.

4. Check allowable operating pressure of high-pressure hose and spray gun.

PE

5. Check all connections for leaks.

3

The instructions regarding regular cleaning and maintenance of the unit must be strictly observed.

Before any work is done on the unit or for every break in work the following rules must be observed:

1. Release the pressure from spray gun and hose.

2. Secure the Titan spray gun using the safety catch on the trigger

0 bar

3. Switch off unit.

Be safety-conscious!

20 Performance Series 1650e

Contents

Page

1.

Safety regulations for Airless spraying .....................22

1.1 Earthing instructions.......................................................23

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2.

General view of application.........................................24

2.1 Application......................................................................24

2.2 Coating materials ...........................................................24

Contents

Page

8.

Cleaning the unit (shutting down) ..............................31

8.1 Cleaning unit from outside .............................................31

8.2 Cleaning the high-pressure filter ....................................32

8.3 Cleaning Airless spray gun ............................................32

8.4 Cleaning the inlet screen................................................32

9.

Remedy in case of faults .............................................33

3.

Description of unit .......................................................24

3.1 Airless process ...............................................................24

3.2 Functioning of the unit ....................................................24

3.3 Legend for explanatory diagram

Performance Series 1650e ............................................25

3.4 Explanatory diagram Performance Series 1650e ..........25

3.5 Technical data ................................................................26

3.6 Transportation ................................................................26

3.7 Transportation in vehicle ................................................26

3.8 Painting material setup...................................................26

3.9 Textured material setup .................................................26

10. Servicing .......................................................................34

10.1 General servicing ...........................................................34

10.2 High-pressure hose ........................................................34

11. Repairs at the unit ........................................................34

11.1 Relief valve.....................................................................34

11.2 Replacing the motor assembly .......................................34

11.3 Replacing the gears .......................................................35

11.4 Replacing the transducer ...............................................35

11.5 Inlet and outlet valve ......................................................36

11.6 Packings.........................................................................37

11.7 Performance Series 1650e connection diagram ............38

4.

Starting operation ........................................................27

4.1 High-pressure hose, spray gun and separating oil ..................................................................27

4.2 Control panel indicators .................................................27

4.3 Pressure control knob settings .......................................28

4.4 Connection to the mains network ...................................28

4.5 Cleaning preserving agent when starting-up of operation initially ......................................28

4.6 Taking the unit into operation with coating material ......................................................28

4.7 Digital Electronic Spray Control (DESC) ........................29

5.

Spraying technique ......................................................30

6.

Handling the high-pressure hose ...............................31

6.1 High-pressure hose ........................................................31

12. Accessories for Performance Series 1650e ..............39

13. Appendix .......................................................................39

13.1 Selection of tip................................................................39

13.2 Servicing and cleaning of Airless hard-metal tips ...............................................................39

Spare parts list for main assembly .......................................80

Spare parts list for fluid section............................................82

Spare parts list for drive assembly .......................................84

Spare parts list of filter assembly .........................................85

Spare parts list for upright cart .............................................86

Warranty ..................................................................................88

7.

Interruption of work .....................................................31

Performance Series 1650e 21

Safety Regulations

1. Safety regulations for Airless spraying

This manual contains information that must be read and understood before using the equipment. When you come to an area that has one of the following symbols, pay particular attention and make certain to heed the safeguard.

GB

Attention

This symbol indicates a potential hazard that may cause serious injury or loss of life. Important safety information will follow.

This symbol indicates a potential hazard to you or to the equipment. Important information that tells how to prevent damage to the equipment or how to avoid causes of minor injuries will follow.

A hazard symbol such as this one refers to a specific, task-related risk. Be sure to heed the safeguard. i

Notes give important information which should be given special attention.

0 bar

HAZARD: INJECTION INJURY

A high pressure stream produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation.

DO NOT TREAT AN INJECTION INJURY AS A

SIMPLE CUT! Injection can lead to amputation. See a physician immediately.

The maximum operating range of the unit is 221 bar

(22.1 MPa, 3200 PSI) fluid pressure.

PREVENTION:

• NEVER aim the gun at any part of the body.

• NEVER allow any part of the body to touch the fluid stream. DO NOT allow body to touch a leak in the fluid hose.

• NEVER put your hand in front of the gun. Gloves will not provide protection against an injection injury.

• ALWAYS lock the gun trigger, shut the fluid pump off and release all pressure before servicing, cleaning the tip guard, changing tips, or leaving unattended.

Pressure will not be released by turning off the engine.

The PRIME/SPRAY valve or pressure bleed valve must be turned to their appropriate positions to relieve system pressure.

• ALWAYS keep tip guard in place while spraying. The tip guard provides some protection but is mainly a warning device.

• NEVER use a spray gun without a working trigger lock and trigger guard in place.

• ALWAYS remove the spray tip before flushing or cleaning the system.

• The paint hose can develop leaks from wear, kinking and abuse. A leak can inject material into the skin.

Inspect the hose before each use.

• All accessories must be rated at or above the maximum operating pressure range of the sprayer.

This includes spray tips, guns, extensions, and hose.

NOTE TO PHYSICIAN:

Injection into the skin is a traumatic injury. It is important to treat the injury as soon as possible. DO

NOT delay treatment to research toxicity. Toxicity is a concern with some coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

HAZARD: EXPLOSION OR FIRE

Solvent and paint fumes can explode or ignite. Severe injury and/or property damage can occur.

PREVENTION:

• Provide extensive exhaust and fresh air introduction to keep the air within the spray area free from accumulation of flammable vapors.

• Avoid all ignition sources such as static electricity sparks, electrical appliances, flames, pilot lights, hot objects, and sparks from connecting and disconnecting power cords or working light switches.

• Plastic can cause static sparks. Never hang plastic to enclose spray area. Do not use plastic drop cloths when spraying flammable materials.

• Always flush unit into separate metal container, at low pump pressure, with spray tip removed. Hold gun firmly against side of container to ground container and prevent static sparks.

• Do not smoke in spray area.

• Fire extinguisher must be present and in good working order.

• Place sprayer at least 6.1 m (20 feet) from the spray object in a well ventilated area (add more hose if necessary). Flammable vapors are often heavier than air. Floor area must be extremely well ventilated. The pump contains arcing parts that emit sparks and can ignite vapors.

PE

• The equipment and objects in and around the spray area must be properly grounded to prevent static sparks.

• Use only conductive or earthed high pressure fluid hose. Gun must be earthed through hose connections.

• Power cord must be connected to a grounded circuit

(electric units only).

• The unit must be connected to an earthed object. Use the green earthing wire to connect the unit to a water pipe, steel beam, or other electrically earthed surface.

• Follow material and solvent manufacturer’s warnings and instructions. Be familiar with the coating material’s

MSDS sheet and technical information to ensure safe use.

• Do not use materials with a flashpoint below 21° C

(70° F). Flashpoint is the temperature at which a fluid can produce enough vapors to ignite.

• Use lowest possible pressure to flush equipment.

22 Performance Series 1650e

GB

HAZARD: EXPLOSION HAZARD DUE TO

INCOMPATIBLE MATERIALS

Will cause severe injury or property damage.

PREVENTION:

• Do not use materials containing bleach or chlorine.

• Do not use halogenated hydrocarbon solvents such as methylene chloride and 1,1,1 - trichloroethane.

They are not compatible with aluminum and may cause an explosion. If you are unsure of a material’s compatibility with aluminum, contact your coating’s supplier.

Safety regulations

HAZARD: HAZARDOUS VAPORS

Paints, solvents, insecticides, and other materials can be harmful if inhaled or come in contact with body. Vapors can cause severe nausea, fainting, or poisoning.

PREVENTION:

• Use a respirator or mask if vapors can be inhaled.

Read all instructions supplied with the mask to be sure it will provide the necessary protection.

• Wear protective eyewear.

HAZARD: GENERAL

This product can cause severe injury or property damage.

PREVENTION:

• Read all instructions and safety precautions before operating equipment.

• Follow all appropriate local, state, and national codes governing ventilation, fire prevention, and operation.

• Pulling the trigger causes a recoil force to the hand that is holding the spray gun. The recoil force of the spray gun is particularly powerful when the tip has been removed and a high pressure has been set on the airless pump. When cleaning without a spray tip, set the pressure control knob to the lowest pressure.

• Use only manufacturer authorized parts. User assumes all risks and liabilities when using parts that do not meet the minimum specifications and safety devices of the pump manufacturer.

• Before each use, check all hoses for cuts, leaks, abrasion or bulging of cover. Check for damage or movement of couplings. Immediately replace the hose if any of these conditions exist. Never repair a paint hose. Replace it with another earthed high-pressure hose.

• Make sure power cord, air hose and spray hoses are routed in such a manner to minimize slip, trip and fall hazard.

• Clean up all material and solvent spills immediately to prevent slip hazard.

• ALWAYS follow the material manufacturer’s instructions for safe handling of paint and solvents.

• Do not use this unit in workshops that are covered under the explosion prevention regulations.

• Always unplug cord from outlet before working on equipment (electric units only).

• Always keep the power cord plug in sight during usage to prevent any accidental shutdown or startup.

• If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.

• Wear ear protection. This unit can produce noise levels above 85 dB(A).

• This equipment is designed to operate at high pressures and recoil forces may occur. Under certain circumstances, such forces could result in repetitive strain injury.

• Device weighs in excess of 36 kg. Three-person lift is required.

• Never leave this equipment unattended. Keep away from children or anyone not familiar with the operation of airless equipment.

• Do not move unit while unit is running.

• Do not spray on windy days.

Performance Series 1650e 23

• Wear protective clothing as required by coating manufacturer.

1.1 Earthing Instructions

PE

Electric models must be earthed. In the event of an electrical short circuit, earthing reduces the risk of electric shock by providing an escape wire for the electric current.

This product is equipped with a cord having an earthing wire with an appropriate earthing plug. The plug must be plugged into an outlet that is properly installed and earthed in accordance with all local codes and ordinances.

DANGER — Improper installation of the earthing plug can result in a risk of electric shock. If repair or replacement of the cord or plug is necessary, do not connect the green earthing wire to either blade terminal. The wire with insulation having a green outer surface with or without yellow stripes is the earthing wire and must be connected to the earthing pin.

Check with a qualified electrician or serviceman if the earthing instructions are not completely understood, or if you are in doubt as to whether the product is properly earthed. Do not modify the plug provided.

If the plug will not fit the outlet, have the proper outlet installed by a qualified electrician.

Caution – The power cord for this equipment acts as an emergency stop/emergency switching off device. The power cord must be placed near an easily accessible, unobstructed socket-outlet.

Work or repairs at the electrical equipment:

These may only be carried out by a skilled electrician. No liability is assumed for incorrect installation.

A list of the materials used in the construction of the equipment will be made available on request to validate compatibility with the coating materials to be used.

Operating Temperature

This equipment will operate correctly in its intended ambient, at a minimum between +10°C and +40°C.

Relative Humidity

The equipment will operate correctly within an environment at 50% RH,

+40°C. Higher RH may be allowed at lower temperatures.

Measures shall be taken by the Purchaser to avoid the harmful effects of occasional condensation.

Altitude

This equipment will operate correctly up to 2100 m above mean sea level.

Transportation and Storage

This equipment will withstand, or has been protected against, transportation and storage temperatures of -25°C to +55°C and for short periods up to +70°C.

It has been packaged to prevent damage from the effects of normal humidity, vibration and shock.

General view of application

2. General view of application

2.1 Application

All painting jobs in the workshop and on the building site, small dispersion work with the spray gun or inter nally fed Airless roller.

Examples of objects of spraying

Doors, door frames, balustrades, furniture, wooden cladding,

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Description of unit

3. Description of unit

3.1 Airless process

The main areas of application are thick layers of highly viscous coating material for large areas and a high consumption of material.

A piston pump takes in the coating material by suction and conveys it to the tip. Pressed through the tip at a pressure of up to a maximum of 221 bar (22.1 MPa), the coating material is atomised. This high pressure has the effect of micro fine atomisation of the coating material.

2.2 Coating materials

Processible coating materials i

Pay attention to the Airless quality of the coating

process.

This method of spraying has the advantages of finest surface. As well as these, the advantages of the speed of work and convenience must be mentioned.

3.2 Functioning of the unit

component coating materials, dispersions, latex paints.

No other materials should be used for spraying without Titan’s approval.

Filtering

Despite suction filter and insertion filter in the spray gun, filtering of the coating material is generally advisable.

Stir coating material before commencement of work.

i

Attention: Make sure, when stirring up with motor-driven agitators that no air bubbles are stirred in. Air bubbles disturb when spraying and can, in fact, lead to interruption of operation.

construction for better understanding of the function.

Titan Performance Series units are electrically driven highpressure spraying units.

A gear unit transfers the driving force to a crankshaft. The crankshaft moves the pistons of the material feed pump up and down.

The inlet valve is opened automatically by the upwards movement of the piston. The outlet valve is opened when the piston moves downward.

The coating material flows under high pressure through the highfrom the tip it atomizes.

The pressure regulator controls the volume and the operating pressure of the coating material.

Viscosity

With this unit it is possible to process highly viscous coating materials of up to around 30.000 MPa·s.

If highly viscous coating materials cannot be taken in by suction,

Two-component coating material

The appropriate processing time must be adhered to exactly.

Within this time rinse through and clean the unit meticulously with the appropriate cleaning materials.

Coating materials with sharp-edged additional materials

These have a strong wear and tear effect on valves, highpressure hose, spray gun and tip. The durability of these parts cane be reduced appreciably through this.

24 Performance Series 1650e

GB

3.3 Legend for explanatory diagram Performance Series 1650e

1 Spray gun

2 High-pressure hose

3 Oil cup for Piston Lube (Piston Lube prevents

increased wear of the packings)

4 Oil level gauge

5 Pail hook

6 Oil button

7 Suction tube

8 Return hose

Description of unit

9 Cart

10 Relief valve

Lever position vertical – PRIME ( k circulation)

Lever position horizontal – SPRAY ( p)

11 Digital Electronic Spray Control (DESC)

12 Control panel indicators

13 Pressure control knob

14 ON/OFF switch

3.4 Explanatory diagram Performance Series 1650e

9

10

Performance Series 1650e

1

7

8

2

3

4

5

6

11

12

13

14

25

Description of unit

3.5 Technical data

Voltage: 220-240 Volt AC, 50/60 Hz

Max. current consumption: 9.5 A @ 230VAC

Power cord:

Acceptance capacity:

3 x 1.5 mm

2

– 6 m

1650 Watt

221 bar (22,1 MPa) Max. operating pressure:

Volume flow at 12 MPa

(120 bar) with water:

Max tip size:

Max. temperature of the

coating material:

Max viscosity:

Weight:

5.0 l/min

0.039 inch – 0.99 mm

43°C

30.000 MPa·s

50 kg

Special high-pressure hose: DN 6 mm, 15 m, connection

Dimensions (L X W X H):

thread M 16 x 1.5

632 x 568 x 743 mm

Max sound pressure level: 80 dB (A) *

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3.8 Paint material setup

i

3.9 Textured material setup

i

This sprayer comes with a filter assembly painting materials, leave the filter installed.

The filter plug should be hand-tightened, but

* Place of measuring: 1 m in distance from the unit and 1.6 reverberant floor.

i This sprayer comes with a filter plug that should be put in place of the filter whenever spraying textured materials. Follow these steps to remove the filter and install the plug.

1. Loosen and remove the filter housing (1) by hand.

2. Remove the adapter spring (2), filter (3), bearing ring (4) and spring (5) from the housing (7).

3. Make sure the O-ring (6) is still in place. Thread the filter plug (8) into the housing until secure.

3.6 Transportation

Pushing or pulling the unit

Pull out the handle (Fig. 2, Item 1) until it will come no further.

1

2

3

4

5

8

6

1

2

7

2

3.7 Transportation in vehicle

Secure the unit with a suitable fastening.

i i

If using this sprayer with textured materials, it is be removed. See section 8.3.

If the sprayer will be used for spraying textured products, removal of the inlet screen in the foot valve may be necessary. This will allow proper section 8.4.

26 Performance Series 1650e

4. Starting operation

4.1 High-pressure hose, spray gun and separating oil

1. Screw the high-pressure hose (2) to the coating material outlet (Fig. 4, Item 1).

high-pressure hose.

so that coating material does not leak.

GB

Starting operation

4

3

4.2 Control Panel Indicators

The following is a description of the control panel indicators.

Service

Indicator

Pressure

Indicator

1

2

4. Remove the oil cup cap with a straight-slot screwdriver.

(4) is showing that it is full.

Attention

6. Replace oil cup cap.

7. Press oil button 2-5 times to prime the oiler. Press once for every eight hours of usage to lubricate the fluid section.

Pressure Indicator

the sprayer. It has three different indications: blinking yellow, solid yellow, and solid green.

Blinking Yellow

When the pressure indicator is blinking yellow, the sprayer is pressure indicator means:

• The sprayer is plugged in and turned “ON”

• The sprayer is at priming pressure (little or no pressure)

• It is safe to move the relief valve between positions

• It is safe to change or replace the spray tip

i

If the pressure indicator begins blinking yellow when the pressure control knob is set at a higher pressure and the relief valve is in the SPRAY position, either the spray tip is worn or the sprayer is in need of service/repair.

Solid Yellow

When the pressure indicator is solid yellow, the sprayer is solid yellow pressure indicator means: stain, lacquer, varnish, and multi-colors

Performance Series 1650e 27

Starting operation

Solid Green

When the pressure indicator is solid green, the sprayer is solid green pressure indicator means:

• The sprayer is at the proper pressure setting for spraying oil-based and latex house paints

• The sprayer is operating at peak performance at a high pressure setting

• If the pressure indicator goes to solid yellow when the pressure is set so that it starts at solid green, it indicates one of the following: high pressure the solid yellow appears. This means the tip is worn and needs to be replaced.

b. Tip Too Large — when a tip that is too large for the sprayer is put in the gun, the pressure indicator will turn from solid green to solid yellow.

c. Fluid Section Wear — if a solid yellow pressure pressure is set at maximum, service may be required

(worn packings, worn piston, stuck valve, etc...).

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4.5 Cleaning preserving agent when startingup of operation initially

(2) into a container with a suitable cleaning agent.

2. Turn the pressure control knob counterclockwise (3) to minimum pressure.

3. Open the relief valve (4), valve position PRIME

(k circulation).

4. Switch the unit (5) ON.

5. Wait until the cleaning agent exudes from the return hose.

6. Close the relief valve, valve position SPRAY (p spray).

7. Pull the trigger of the spray gun.

8. Spray the cleaning agent from the unit into an open collecting container.

4

5 3

Service Indicator

This indicator is used by service centers to troubleshoot motor problems.

4.3 Pressure control knob settings (Fig. 7)

1. Minimum pressure setting

2. Black zone – no pressure generation

3. Blue zone – pulsating pressure for cleaning

1

2

3

4.4 Connection to the mains network

Attention

line voltage matches that specified on the unit’s rating plate.

The connection must be equipped with a residual current protective device with INF ≤ 30 mA.

i a mobile operator protection device for the other electronical equipment.

28

1

2

4.6 Taking the unit into operation with coating material

(2) into the coating material container.

2. Turn the pressure control knob counterclockwise (3) to minimum pressure.

3. Open the relief valve (4), valve position PRIME

(k circulation).

4. Switch the unit (5) ON.

hose.

6. Close the relief valve, valve position SPRAY (p spray).

collecting container until the coating material exits the spray gun without interruption.

control knob.

Check the spray pattern and increase the pressure until the atomization is correct.

Always turn the pressure control knob to the lowest setting with good atomization.

9. The unit is ready to spray.

Performance Series 1650e

4.7 Digital Electronic Spray Control (DESC)

functionality of the sprayer. It is installed directly below the pressure control knob on the control panel. It consists of a display and four function keys. The display shows various menu operation using the function keys.

GB

Starting operation

Volume Pumped Screen

The Volume Pumped screen shows the total number of gallons or liters sprayed by the sprayer.

To select the Volume Pumped screen, press the #4 key.

MENU-1

MENU-1

LITRES-2

GALLONS-2

Display

Job Volume Screen

The Job Volume screen allows the user to reset a liter counter to track usage on specific jobs.

To select the Job Volume screen, press the #4 key.

i

Electronic Spray Control (DESC) settings. sprayer pressure will change accordingly.

Unit Serial # Screen

The Unit Serial # screen shows the sprayers serial number.

To select the Unit Serial # screen, press the #4 key.

Function Keys

The function keys are numbered 1–4. Each key is labeled with an additional function as well.

#1/Menu Key

Pressing the #1 key scrolls through the available menu screens or performs a function described on the active menu screen.

#2/g Key

Timers Screen

The Timers screen shows the total time the sprayer has been turned on as well

MENU-1 as the total time the sprayer has been running (pumping).

To select the Timers screen, press the

#4 key.

#3/h Key

Pressing the #3 key performs a function described on the active menu screen or decrease a value.

#4/Select Key

Pressing the #4 key selects the active menu screen or performs a function described on the active menu screen.

Menu Screens

and monitor sprayer operation. They include Main Screen,

Service Time, Security Code, Prime, and Rapid Clean.

Main Screen

The Main Screen is the default screen for the control system at sprayer startup. Pressing the #2 key switches between PSI, Bar and

MPa units of measure. Press the #1 key to scroll through the remaining menu screens.

i

Digital Electronic Spray Control (DESC):

Pressing the #2 key at the Main Screen switches between PSI, Bar and MPa units of measure.

Pressing the #3 key at the Main Screen changes a total of nine languages available. Each time the #1 key is pressed, a different language will appear. The languages, in order of appearance,

German, French, Italian, and Portuguese.

Job Timers Screen

The Job Timers screen allows the user to reset the “ON TIME” and “RUN TIME” to track time on specific jobs.

the #4 key. “JOB ON” screen will appear. Press #3 to reset. Press #1 to continue to “JOB RUN” screen. Press the remaining menu screens.

Service Time Screen

The Service Time screen allows the user

Below the set time, the screens shows the current amount of hours on the sprayer since the last activation of the service timer.

To select the Service Timer screen, press the #4 key.

To set the service time, press the #2

(up) and/or the #3 (down) keys to the desired time (run hours will increase/decrease in increments of

25 for each time you press a key).

When the service time interval is set and met by the run hours, will remain functional. To return to the Main Screen, press the displayed on the Service Screen back to 0.

Performance Series 1650e 29

Starting operation

Security Code Screen

The Security Code screen allows the user to set a four digit security code to prevent unauthorized use of the sprayer. If a security code has been set, the control system display will ask for the code at startup. If the correct code is entered, the display will show the

Main Screen and the sprayer will operate. If the wrong code is entered, the display will continue to ask for the correct code and the sprayer will be disabled. To set or change the security code, press the #2 key.

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5. Spraying technique

Spraying technique

Injection hazard. Do not spray without the tip guard in place. NEVER trigger the gun unless the tip is completely turned to either the spray or the unclog position. ALWAYS engage the gun trigger lock before removing, replacing or cleaning tip.

i the Main Screen will appear at startup. When setting a security code for the first time, the

“Enter Old Code Number” screen will appear, and you will need to enter “1111”.

surface. Keep your arm moving at a constant speed and keep the spray gun at a constant distance from the surface. The best spraying distance is 25 to 30 cm between the spray tip and the surface. access the screen that allows the code change. If the wrong code is entered, the display will continue to ask for the correct code and the security code cannot be changed.

Enter the new security code. Once the new code is entered, the display will automatically ask that the new code be re-entered for verification. If the same new code is re-entered, the display will confirm that the new code has been accepted and return to the Main Screen.

If the new code is re-entered incorrectly, the display will return to the “Enter New Code Number” screen and the process will repeat.

If you forget or misplace your security code, you can contact

Titan customer service for assistance.

i the “Enter New Code Number” screen (this is the default code that leaves the sprayer unlocked).

As a result, the Main Screen will appear at sprayer startup.

25 - 30 cm

Keep the spray gun at right angles to the surface. This means your wrist.

Prime Screen

The Prime screen appears when the pressure control knob is set at the “MIN” setting.

PRIME

Rapid Clean Screen

The Rapid Clean screen appears when the pressure control knob is set at the

RAPID CLEAN

RAPID CLEAN position and the PRIME/SPRAY valve is in the

PRIME position.

i seconds, the display will go back to the Main

Screen.

end of the pattern will be thicker than the other.

Trigger gun after starting the stroke. Release the trigger before ending the stroke. The spray gun should be moving when the

30%. This will ensure an even coating.

25 - 30 cm 25 - 30 cm

30

i in the spray jet – increase the operating pressure or dilute the coating material.

Performance Series 1650e

Handling the high-pressure hose

6. Handling the high-pressure hose

smallest bending radius amounts to about 20 cm.

Do not drive over the high-pressure hose. Protect against sharp objects and edges.

i hose. Replace any damaged high-pressure hose immediately.

6.1 High-pressure hose

The unit is equipped with a high-pressure hose specially suited for piston pumps.

in order to ensure functionality, safety and durability.

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Cleaning the unit (shutting down)

8. Cleaning the unit (shutting down)

problems. After you have finished spraying, clean the unit. Under no circumstances may any remaining coating material dry and harden in the unit.

The cleaning agent used for cleaning (only with an igni tion point above 21 °C) must be suitable for the coating material used.

Secure the spray gun, refer to the operating manual of the spray gun.

Clean and remove tip.

For a standard tip, refer to Page 39, Section 13.2.

If a non-standard tip is installed, proceed according to the relevant operating manual.

1. Remove suction hose from the coating material.

2. Close the relief valve, valve position SPRAY (p spray).

3. Switch the unit ON.

4. Pull the trigger of the spray gun in order to pump the pressure hose and the spray gun into an open container.

The container must be earthed in case of coating materials which contain solvents.

7. Interruption of work

1. Open the relief valve, valve position PRIME

(k circulation).

2. Switch the unit OFF.

3. Turn the pressure control knob counterclockwise to minimum pressure.

4. Pull the trigger of the spray gun in order to release the pressure from the high-pressure hose and spray gun.

5. Secure the spray gun, refer to the operating manual of the spray gun.

6. If a standard tip is to be cleaned, see Page 39, Section

13.2.

If a non-standard tip is installed, proceed according to the relevant operating manual.

7. Depending on the model, leave the suction tube or the material or swivel or immerse it into a corresponding cleaning agent.

Attention with a small opening (bunghole)!

Refer to the safety regulations.

5. Immerse suction hose with return hose into a container with a suitable cleaning agent.

pulsating pressure for unit cleaning.

7. Open the relief valve, valve position PRIME

(k circulation).

8. Pump a suitable cleaning agent in the circuit for a few minutes.

9. Close the relief valve, valve position SPRAY (p spray).

10. Pull the trigger of the spray gun.

11. Pump the remaining cleaning agent into an open container until the unit is empty.

12. Switch the unit OFF.

Attention

If fast-drying or two-component coating material is used, ensure that the unit is rinsed with a suitable cleaning agent within the processing time.

8.1 Cleaning unit from outside

First of all pull out mains plug from socket.

Danger of short circult through panetrating water!

Attention

Wipe down unit externally with a cloth which has been immersed in a suitable cleaning agent.

Performance Series 1650e 31

Cleaning the unit (shutting down)

8.2 Cleaning the high-pressure filter

Clean the filter cartridge regularly.

A soiled or clogged high-pressure filter can cause a poor spray pattern or a clogged tip.

1. Turn the pressure regulator knob into the black zone until it stops (no pressure).

2. Open the relief valve, valve position PRIME

(k circulation).

3. Switch the unit OFF.

GB

Remedy in case of faults into the gun body.

5. Make sure all the parts are clean and the handle seal (3) is in position inside the gun head.

6. Thread the handle assembly (5) into the gun head (2) until secure.

(5).

Unplug the power plug from the outlet.

2

wrench.

5. Pull the filter cartridge (2) from the bearing spring (3).

If necessary, replace the filter cartridge.

7. Check the O-ring (4), replace it if necessary.

Slide the filter cartridge (2) over the bearing spring.

9. Screw in filter housing (1) and tighten it as far as possible with the strap wrench.

1

4

3

5

1

2

5

3

4

8.4 Cleaning the inlet screen

day.

1. Remove the retaining ring (3) from the foot valve (1) housing.

2. Remove the inlet screen (2) from the foot valve housing

(1).

3. Clean thoroughly with the appropriate solvent.

1

2

3

8.3 Cleaning the Airless spray gun

agent.

2. Clean tip thoroughly with appropriate cleaning agent so that no coating material residue remains.

3. Thoroughly clean the outside of the Airless spray gun.

Intake filter in Airless spray gun (fig. 11)

1. Pull the bottom of the trigger guard forward (1) so that it comes loose from the handle assembly (5).

2. Loosen and remove the handle assembly (5) from the gun head (2).

3. Turning clockwise, unscrew the filter (4) from the gun body

(2).

i

Left-handed threads require turning the filter

32 Performance Series 1650e

9. Remedy in case of faults

Type of malfunction

A. Unit does not start

Possible cause

GB

1. No voltage applied.

2. Pressure setting too low.

3. ON/OFF switch defective.

Remedy in case of faults

Measures for eliminating the malfunction

1. Check voltage supply.

2. Turn up pressure control knob.

3. Replace.

B. Unit does not draw in material

C. Unit draws in material, but the pressure does not build up

D. Coating material exits at the top of the fluid section

E. Increased pulsation at the spray gun

1. Upper packing is worn.

2. Piston is worn.

1. Incorrect high-pressure hose type.

2. Tip worn or too large.

3. Pressure too high.

F. Poor spray pattern

G. Unit loses power

1. Relief valve is set to SPRAY (p spray).

2. Filter projects over the fluid level and sucks air.

3. Filter clogged.

4. Suction hose/suction tube is loose, i.e. the unit is sucking in outside air.

1. Set relief valve to PRIME (k circulation).

2. Refill the coating material.

3. Clean or replace the filter.

4. Clean connecting points. Tighten suction tube.

1. Tip heavily worn.

2. Tip too large.

3. Pressure setting too low.

4. Filter clogged.

5. Coating material flows through the return hose when the relief valve is in the SPRAY (p spray) position.

6. Packings sticky or worn.

7. Valve balls worn.

8. Valve seats worn.

1. Replace.

2. Replace tip.

3. Turn pressure control knob clockwise to increase.

4. Clean or replace the filter.

5. Remove and clean or replace relief valve.

6. Remove and clean or replace packings.

7. Remove and replace valve balls.

8. Remove and replace valve seats.

1. Tip is too large for the coating material which is to be sprayed.

2. Pressure setting incorrect.

3. Volume too low.

4. Coating material viscosity too high.

1. Pressure setting too low.

1. Remove and replace packing.

2. Remove and replace piston.

1. Only use TITAN original-high-pressure hoses in order to ensure functionality, safety and durability.

2. Replace tip.

3. Turn pressure control knob to a lower number.

1. Replace tip.

2. Turn pressure control knob until a satisfactory spraying pattern is achieved.

3. Clean or replace all filters.

4. Thin out according to the manufacturer’s instructions.

1. Turn pressure control knob clockwise to increase.

Digital Electronic Spray Control (DESC) Error Messages

The following error message screens appear whenever the Digital

Electronic Spray Control (DESC) detects a problem with the sprayer.

Once a problem occurs and the error message appears, the sprayer will shut down.

Before proceeding, relieve any pressure remaining in

the system (valve position PRIME k). Additionally,

follow all other warnings to reduce the risk of an injection injury, injury from moving parts or electric shock. Always unplug the sprayer before servicing!

Check Transducer Screen

The Check Transducer screen appears when the transducer has become disconnected or is defective. Take the sprayer to a Titan authorized service center for repair.

Check Motor Screen

The Check Motor screen appears when the motor or motor sensor is defective. Take the sprayer to a Titan authorized service center for repair.

Low Voltage Screen

The Low Voltage screen appears when the sprayer shuts down because of low input voltage. Check the power supply and correct the problem. Restart the sprayer.

High Motor Temperature Screen

The High Motor Temperature screen appears when the temperature of the motor has risen too high. Take the sprayer to a Titan authorized service center for repair.

High Control Temperature Screen

The High Control Temperature screen appears when the temperature of the Digital

Electronic Spray Control (DESC) has risen too high. Take the sprayer to a Titan authorized service center for repair.

High Mechanical Load

The High Mechanical Load screen appears when the sprayer shuts down because of high current or when the sprayer goes into current fold back mode. Take the sprayer to a Titan authorized service center for repair.

Performance Series 1650e 33

Servicing

10. Servicing

10.1 General servicing

Servicing of the unit should be carried out once annually by the

TITAN service.

plug for damage.

2. Check the inlet valve, outlet valve and filter for wear.

10.2 High-pressure hose

bulges, in particular at the transition in the fittings. It must be possible to turn the union nuts freely.

11. Repairs at the unit

Switch the unit OFF.

Before all repair work: Unplug the power plug from the outlet.

11.1 Relief valve

13, Item 1) from the relief valve handle (2).

2. Remove the relief valve handle (2) and cam base (3).

3. Using a wrench, remove the valve housing (4).

4. Ensure that the seal (5) is seated correctly, then screw the new valve housing (4) completely into the filter block (6).

Tighten securely with a wrench.

Lubricate the cam base with grease and slide on the cam base.

6. Bring the hole in the valve shaft (7) and in the relief valve handle (2) into alignment.

GB

Repairs at the unit

11.2 Replacing the Motor Assembly

1. Unplug the unit.

2. Loosen and remove the two motor shroud screws (Fig 14,

Item 1). Remove the motor shroud (2).

3. Loosen and remove the three belly pan screws (3).

Remove the belly pan (4).

4. Loosen and remove the two motor cover screws (5).

Remove the motor cover (6).

5. Disconnect all wires between the motor (7) and the sprayer.

6. Loosen and remove the four control panel screws (8).

Remove the control panel (9).

7. Disconnect the wires between the motor (7) and the control panel (9).

8. Loosen and remove the two motor controller screws (10).

Remove the motor controller (11).

9. Loosen and remove the four motor baffle screws (12).

Remove the motor baffle (13).

10. Loosen and remove the three motor mounting screws

(14).

11. Pull the motor (7) out of the gearbox housing (15).

12. With the motor removed, inspect the gears in the gearbox housing for damage or excessive wear. Replace the gears, if necessary.

13. Install the new motor (7) into the gearbox housing (15).

14. Secure the motor (7) with the three motor mounting screws (14).

15. Reconnect the wires between the sprayer and the new motor (refer to the Connection Diagram, section 11.7).

(7). Secure with the four motor baffle screws (12).

17. Place motor controller (11) back into place behind the screws (10).

18. Reconnect all wires between the motor (7) and sprayer.

control panel (9).

20. Replace control panel (9) and secure with four control panel screws (8).

21. Place the motor cover (6) back over the motor controller

(11). Secure with the two motor cover screws (5).

22. Put the belly pan (4) back in place and secure with the three belly pan screws (3).

23. Slide the motor shroud (2) over the motor assembly (7).

15

4

5

6

8

14

7

2

3

9

2

1

7

3

4

1

13

12

11

10

6

5

34 Performance Series 1650e

11.3 Replacing the Gears

(section 11.2) to remove the motor and control panel.

2. Inspect the armature gear (Fig. 15, Item 1) on the end of the motor for damage or excessive wear. If the gear is completely worn out, replace the motor assembly.

stage gear (3) assemblies for damage or excessive wear.

Replace, if necessary.

excessive wear. If damaged or worn, replace the front gear box assembly.

i

Clean and refill the gear box cavity up to the rear face of each gear with Lubriplate (P/N 314-171).

5. Reinstall the motor into the gearbox housing (4).

6. Follow steps 13-24 in Replacing the Motor Assembly

(section 11.2) to replace the motor and control panel.

GB

Repairs at the unit

3. Loosen and remove the two motor shroud screws (Fig. 17,

Item 1). Remove the motor shroud (2).

4. Loosen and remove the two motor cover screws (3).

Remove the motor cover (4).

(5).

6. Pull the grommet (6) out of the mounting plate and slide mounting plate.

7. Using a wrench, loosen and remove the transducer (7) from the filter housing (8). Carefully thread the transducer wire out through the mounting plate.

onto the new transducer.

9. Thread the new transducer wire through the mounting plate and back to the motor controller (5).

10. Thread the new transducer (7) into the filter housing (8) and tighten securely with a wrench.

4

3

1

i place before threading the transducer into the filter housing.

11. Push the grommet (6) into the mounting plate.

12. Connect the transducer wire to the motor controller (refer to the Connection Diagram, section 11.7).

13. Place the motor cover (4) back over the motor controller

(5). Secure with the two motor cover screws (3).

14. Slide the motor shroud (2) over the motor assembly.

2

screws (1).

16. Replace filter assembly to the cart.

2

11.4 Replacing the Transducer

1. Unplug the unit.

2. Loosen and remove the two filter assembly bolts (Fig. 16,

Item 1). Slide the filter assembly from the cart.

3

4

1

1

8

7

6

5

Performance Series 1650e 35

Repairs at the unit

11.5 Inlet and outlet valve

Danger of crushing - do not reach with the fingers or tool between the moving parts.

Digi-Trac™ screen should say “PRIME”.

3. Press the #1 key on the Digi-Trac™ control panel. The

“CREEP MODE” screen will now appear.

4. Slowly turn the pressure control knob clockwise to begin to move very slowly.

5. When it reaches the bottom, dead-center of its stroke, turn crankshaft/slider assembly should stop.

6. Unplug the power plug from the outlet.

7. Pull off clamp on suction tube and remove return hose.

8. Unscrew the connection hose (Fig. 18, item 1) from the high-pressure filter.

9. Turn the knob on the side of the cart clockwise to unlock the cart. Tilt the cart backwards until it locks into place.

10. Loosen and remove the inlet valve housing (2) from the upper housing.

11. Remove bearing ring (3), O-ring (4), O-ring (5), inlet valve seat (6), inlet valve ball (7) and upper ball guide (8).

12. Clean all the parts with the corresponding cleaning agent.

Check the inlet valve housing (2), inlet valve seat (6) necessary. If the worn inlet valve seat (6) is unused on one side, install it the other way around.

GB

15. Clean all the parts with the corresponding cleaning agent.

Check outlet valve housing (9), outlet valve seat (15), outlet valve ball (13) and upper ball guide (12) for wear and replace parts if necessary. If the worn outlet valve seat (15) is unused on one side, install it the other way around.

16. Carry out installation in the reverse order.

17. If you plan to replace the fluid section packings, move

11

12

13

14

15

9

10

11.6 Packings

1. Remove inlet valve housing in accordance with the steps in Chapter 11.5.

2. It is not necessary to remove the outlet valve.

3. Pull the lever on the underside of the sprayer toward the front of the sprayer. This will un-clamp the entire fluid section.

4. Slide the fluid section forward to remove it from the gear housing.

5. Place the fluid section cylinder upright in a vise by clamping on the wrench flats (Fig. 20, Item 1).

1

8

5

4

7

6

3

6. Turn the upper housing (2) counterclockwise to loosen it from the cylinder (3).

expose the extension slider (4) and the connecting pin (5) that connects the piston rod (6) to the extension slider (4).

8. Push the connecting pin out of the extension slider and piston rod and remove the piston rod and upper housing.

2

Do not over-tighten the vise. Damage to the upper housing may occur.

13. Screw out outlet valve housing (Fig 19, item 9) from the piston (10) with 3/8 inch hexagon socket head wrench.

14. Remove the upper seal (11), upper ball guide (12), outlet valve ball (13), washer (14) and outlet valve seating (15).

36

Item 8).

11. Slide the piston rod (6) out through the bottom of the upper housing (2).

12. Inspect the piston rod (6) for wear and replace if necessary.

Performance Series 1650e

13. Remove the upper support ring (9) and upper packing assembly (10) from the top of the upper housing (2).

14. Remove the adapter (11) and lower packing assembly

(12) from the bottom of the upper housing.

Be careful not to scratch, score, or otherwise packings.

GB

Repairs at the unit

18. Lubricate upper packing (10) and lower packing (12) with machine grease.

19. Insert upper packing (Fig. 21) with O-ring (1) and protruding lip (2) downward.

1

2

14

13

20. Insert upper support ring (9) on top of the upper packing

(10)

(2).

22. Rotate the upper housing in the vise so that the bottom end is facing up.

23. Insert the lower packing (Fig. 22) partially into the bottom toward the cylinder (beveled edge will be facing up when the cylinder is upright).

1

8

9

10

2

12

11

6

7

1

3

4

5

the upper housing and cylinder for damage and replace if necessary.

on the wrench flats (7).

17. Locate the new upper and lower packings and remove the pre-form tools. Save the upper packing pre-form tool for use as the piston insertion tool later in this procedure.

i and lower packings until immediately before they are installed into the upper housing.

Performance Series 1650e 37

24. Push the lower packing assembly (Fig. 20, Item 12) into position using the lower packing insertion tool (see Fluid

Section Assembly parts list for lower packing insertion tool

P/N).

i pre-form tool) and the piston rod with grease before inserting them into the upper housing.

25. Place the piston insertion tool over the top of the piston rod (6).

housing (2), through the lower packing assembly (12), the upper seal retainer (8).

i

Make sure the raised lip on the bottom of the the piston rod after insertion of the piston rod.

rod (6).

28. Lubricate the threads on the upper housing with anti-seize compound. Remove the upper housing from the vise.

29. Insert the piston rod into the extension slider. When the connecting pin hole on the piston rod lines up with the hole in the extension slider, insert the connecting pin.

30. Thread the upper housing into the cylinder, turning clockwise.

flush against the cylinder.

32. Replace the cylinder (3) back into the fluid section clamp on the gear housing. Make sure to slide the top of the piston rod extension into the T-slot (13) on the slider assembly (14).

33. Push the lever on the underside of the unit toward the rear of the sprayer to lock the fluid section back into place.

34. Insert the adapter (Fig. 20, item 11) into the bottom of the upper housing.

Repairs at the unit

35. Making sure that the bearing ring (Fig. 18, item 3) and

O-rings (Fig. 18, items 4-5) are lubricated and in place, reassemble the inlet valve assembly and and thread it into the upper housing. Tighten the inlet valve housing until the o-ring engages, then continue to tighten until snug.

Once snug, tighten an additional 1/8–1/4 turn.

36. Replace the connection hose to the fitting on the highpressure filter.

37. Replace the return hose into the clamp on the siphon tube.

38. Install front cover.

GB

11.7 Performance Series 1650e connection diagram

Blue

EMI Filter

Switch

Blue

P/N 0522053

Ground

Brown

Brown

Ground

P/N 0522052

Ground

Black

Fuse block

Fuse

Black

Blue White

White

Red

Black

Motor

Power Cord

Capacitor

Black

Red

Red (+)

Black (-)

Motor controller

L.E.D.

Hall sensor

Potentiometer

Pressure sensor

38 Performance Series 1650e

GB

Accessories and spare parts

12. Accessories for Performance Series 1650e

Airless Tip Selection

selection is determined by the fan width required for a specific job and by the orifice size that will supply the desired amount of fluid and accomplish proper atomization.

For light viscosity fluids, smaller orifice tips generally are desired.

i

Do not exceed the sprayer’s recommended tip

Tip Size Spray Material

.011 – .013 Lacquers and stains

.015 – .019 Oil and latex

.021 – .026 Heavy bodied latex and blockfillers

Filter Type

100 mesh filter

60 mesh filter

30 mesh filter because they offer more control while spraying and are less likely to plug.

Liquid Shield Plus

Cleans and protects spray systems against rust, corrosion and premature wear. Now with

-25º anti-freeze protection.

Part #

314-483

314-482

Description

4 ounce (112 ml) bottle

1 liter bottle

Piston Lube

adhering to the piston rod, which becomes abrasive to the upper seals. Piston Lube will break down any material that may accumulate in the oil cup and keep it from drying.

Part #

314-481

314-480

Description

4 ounce (112 ml) bottle

8 ounce (240 ml) bottle

Miscellaneous

Part #

490-012

730-397

314-171

314-172

Description

Hose Coupling, 1/4” x 1/4”

High Pressure Fl. Gauge

Lubriplate, 14 ounce individual

Lubriplate, 6 lb. can

Appendix

13. Appendix

13.1 Selection of tip

To achieve faultless and rational working, the selection of the tip is of the greatest importance.

In many cases the correct tip can only be determined by means of a spraying test.

Some rules for this:

The spray jet must be even.

If streaks appear in the spray jet the spraying pressure is either too low or the viscosity of the coating material to high.

Remedy: Increase pressure or dilute coating material. Each pump conveys a certain quantity in proportion to the size of the tip:

The following principle is valid: large tip = small tip = low pressure high pressure

There is a large range of tips with various spraying angles.

13.2 Servicing and cleaning of Airless hard-metal tips

Standard tips

If a different tip type has been fitted, then clean it according to manufacturer’s instructions.

The tip has a bore processed with the greatest precision. Careful handling is necessary to achieve long durability. Do not forget the fact that the hard-metal insert is brittle! Never throw the tip or handle with sharp metal objects.

The following points must be observed to keep the tip clean and ready for use:

1. Turn the relief valve handle fully counterclockwise (k Circulation).

2. Switch off the gasoline engine.

3. Dismount the tip from the spray gun.

4. Place tip in an appropriate cleaning agent until all coating material residue is dissolved.

5. If there is pressure air, blow out tip.

6. Remove any residue by means of a sharp wooden rod (toothpick).

7. Check the tip with the help of a magnifying glass and, if necessary, repeat points 4 to 6.

Performance Series 1650e 39

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