Translation of the Original
Operating Manual
Version 03/2013
Piston Pumps
Flow Rate 15 cm3 - 30 cm3
B_04119
II 2G IIB c T3 X
VERSION 03/2013
ORDER NUMBER DOC 2310799
OPERATING MANUAL
Contents
1
ABOUT THIS OPERATING MANUAL
Preface
Warnings, Notices, and Symbols in this Operating Manual
Languages
5
5
5
6
6
1.1
1.2
1.3
1.4
Abbreviations in the Text
2
CORRECT USE
Device Types
Type of Use
Use in an Explosion Hazard Area
Safety Parameters
Processible Materials
Reasonably Foreseeable Misuse
Residual Risks
7
7
7
7
7
8
8
9
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3
3.1
3.2
IDENTIFICATION
Explosion Protection Identification
Identification X
10
10
10
4
4.1
GENERAL SAFETY INSTRUCTIONS
Safety Instructions for the Operator
11
11
11
11
11
12
12
13
13
14
14
14
15
15
15
4.1.1 Electrical Equipment
4.1.2 Staff Qualifications
4.1.3 Safe Work Environment
4.2
Safety Instructions for Staff
4.2.1 Safe Handling of WAGNER Spray Devices
4.2.2 Grounding the Device
4.2.3 Material Hoses
4.2.4 Cleaning
4.2.5 Handling Hazardous Liquids, Varnishes, and Paints
4.2.6 Touching Hot Surfaces
4.3
Use in Areas Subject to Explosion Hazards
4.3.1 Safety Regulations
4.3.2 Operation without Fluid
5
5.1
DESCRIPTION
Field of Application
16
16
16
16
17
17
17
18
20
21
22
25
25
26
27
27
5.1.1 Correct Use
5.1.2 Processible Materials
5.2
5.3
5.3.1 Materials of Paint-wetted Parts
5.3.2 Technical Data
5.3.3 Measurements and Connections for FineFinish 40-15
5.3.4 Measurements and Connections for FineFinish 20-30
5.3.5 Performance Diagrams
Scope of Delivery
Data
5.4
Function
5.4.1 Pump
5.4.2 Pressure Regulator Unit
5.4.3 Safety and Motor Pressure Relief Valve
5.4.4 Return Valve
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OPERATING MANUAL
Contents
6
ASSEMBLY AND COMMISSIONING
Transportation
Storage
Assembling the Pump
Grounding
Commissioning
28
28
28
29
30
32
32
34
35
6.1
6.2
6.3
6.4
6.5
6.5.1 Safety Instructions
6.5.2 Filling with Separating Agent
6.5.3 Basic Flushing
7
7.1
7.2
OPERATION
Filling with Working Material
Work
36
36
37
37
38
39
40
7.2.1 Spraying
7.2.2 Pressure Relief/Work Interruption
7.2.3 Decommissioning and Cleaning
7.3
Long-term Storage
8
TROUBLESHOOTING AND RECTIFICATION
41
9
9.1
9.2
MAINTENANCE
High-pressure Hoses
Decommissioning
42
43
43
10
ACCESSORIES
44
11
11.1
11.2
SPARE PARTS
How Can Spare Parts Be Ordered?
Overview of the Components
47
47
48
48
49
50
53
54
54
56
58
59
60
61
11.2.1 Components for FineFinish 40-15
11.2.2 Components for FineFinish 20-30
11.3
11.3.1 Reversing Valve
11.4 Fluid sections
11.4.1 Fluid Section 15
11.4.2 Fluid Section 30
11.5
11.6
11.7
11.8
Air Motor
Air Regulator Set
Air Regulator Set for AirCoat Air
Trolley, 4"
4-Wheel Trolley
12
3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING
Scope of Guarantee
Guarantee Period and Registration
Handling
Exclusion of Guarantee
Additional Regulations
62
62
62
62
63
63
65
65
12.1
12.2
12.3
12.4
12.5
12.6
12.7
CE Declaration of Conformity
Reference to German Regulations and Guidelines
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OPERATING MANUAL
1 ABOUT THIS OPERATING MANUAL
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to operating and service
staff.
Operating and service staff should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
Warning instructions in this operating manual highlight particular dangers to users and
to the device and state measures for avoiding the hazard. These warning instructions fall
into the following categories:
DANGER
This notice warns you of a hazard!
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
WARNING
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
CAUTION
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
NOTICE
Notice - a possibly hazardous situation.
Non-observance may result in material damage.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The following are measures which can be taken to prevent the hazard and its
consequences.
Note - provides information about particular characteristics and how to proceed.
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1.3 LANGUAGES
The operating manual is available in the following languages:
Language
German
French
Italian
Portuguese
Danish
Order No.
2310798
2310800
2310802
2310804
2310805
Language
English
Spanish
Dutch
Order No.
2310799
2310803
2310801
2310806
Swedish
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order No.
No.
Number
Double stroke
Stainless steel
Two components
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2 CORRECT USE
2.1 DEVICE TYPES
Pneumatic pump with spraypack:
2.2 TYPE OF USE
The device is suitable for processing liquid materials such as paints and varnishes in
accordance with their classification into explosion classes IIA or IIB.
2.3 USE IN AN EXPLOSION HAZARD AREA
The pneumatic pump can be employed in explosion hazard zones (Zone 1).
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the materials recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety fixtures.
Use only WAGNER original spare parts and accessories.
The pneumatic pump may only be operated under the following conditions:
The operating staff must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance, and repair information in this operating manual must
be observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.
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2.5 PROCESSIBLE MATERIALS
Fluid materials such as paints and varnishes.
NOTICE
Abrasive materials and pigments!
Greater wear of parts carrying the material.
Use the application-oriented model (flow rate/cycle, material, valves, etc.) as
indicated in Chapter 5.3.2.
Check if the fluids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.3.1.
2.6 REASONABLY FORESEEABLE MISUSE
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modifications to the pneumatic pump,
processing powder or similar coating materials, and
using defective components, spare parts, or accessories other than those described
in Chapter 10 of this operating manual.
The forms of misuse listed below may result in health issues and/or material damage:
use of powder as coating material and
incorrectly set values for processing.
Wagner pneumatic pumps are not designed for pumping food.
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2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk
Source
Consequences
Specific measures Lifecycle phase
Skin contact with
paints and cleaning and cleaning agents
agents
Handling of paints Skin irritations,
Wear protective
clothing,
Observe safety data maintenance,
Operation,
allergies
sheets
disassembly
Paint in air outside Painting outside the Inhalation of
the defined working defined working substances which are
area area hazardous to health
Observe working
and operating
instructions
Operation,
maintenance
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As defined in Directive 94/9/EC (ATEX 95), the device is suitable for use in areas where there
is an explosion hazard.
European Communities
Symbol for explosion protection
Device class II
Category 2 (Zone 1)
Ex-atmosphere gas
Explosion group
Constructional safety
Temperature class: maximum surface temperature < 200 °C; 392 °F
Special Notes (see Chapter 3.2)
3.2 IDENTIFICATION X
Maximum surface temperature
The maximum surface temperature of the piston pump can be reached if it runs dry.
Ensure that the piston pump is filled with sufficient working or flushing agent.
Ensure that the separating agent container is filled with sufficient separating agent.
Ignition temperature of the coating material
Ensure that the ignition temperature of the coating material is above the maximum
surface temperature.
Ambient temperature
The permissible ambient temperature is: +5 °C to +60 °C; +41 °C to 140 °F.
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
4.1.1 ELECTRICAL EQUIPMENT
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform staff about
planned work. Observe electrical safety regulations.
4.1.2 STAFF QUALIFICATIONS
Ensure that the device is operated and repaired only by trained persons.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the floor in the working area is electrically conductive in accordance with
EN 61340-4-1 (resistance must not exceed 100 Mohm).
Ensure that all persons within the working area wear electrostatically conductive shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 Mohm.
Ensure that during spraying, persons wear electrically conductive gloves.The grounding
takes place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5. The
measured insulation resistance must not exceed 100 Mohm.
Paint mist extraction systems must be fitted on site according to local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked flames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
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4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
– Switch off the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– In the event of functional faults: remedy the fault as described in the "Troubleshooting"
chapter.
The liquid emitters are to be checked for safe working conditions by an expert
(e.g. Wagner Service Technician) as often as necessary or at least every 12 months,
in accordance with the guidelines for liquid emitters (ZH 1/406 and BGR 500 Part 2
Chapter 2.36).
– For shut down devices, the examination can be suspended until the next commissioning.
Carry out the work steps as described in the "Pressure Relief/Work Interruptions"
chapter:
– if pressure relief is required.
– if the spraying work is interrupted or stopped.
– before the device is cleaned on the outside, checked, or serviced.
– before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briefly in a position.
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4.2.2 GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, flowing liquids, and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. that they are wearing
electrostatically conductive shoes.
Wear electrostatically conductive gloves when spraying. The grounding takes place via
the spray gun handle.
4.2.3 MATERIAL HOSES
Ensure that the hose material is chemically resistant to the sprayed materials.
Ensure that the material hose is suitable for the pressure generated in the device.
Ensure that the following information can be seen on the high-pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture
Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid
in the following places:
– in high-traffic areas,
– on sharp edges,
– on moving parts, or
– on hot surfaces
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the complete high-pressure hose must be less than 1 Mohm.
Several liquids have a high expansion coefficient. In some cases their volume can rise with
consequent damage to pipes, fittings, etc. and cause fluid leakage.
When the pump sucks liquid from a closed container, ensure that air or suitable gas can
enter the container to avoid a vacuum being generated in the container itself. Thus a
negative pressure is avoided. The vacuum could implode the container (squeeze) and can
cause it to break. The container would leak and the liquid would flow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
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4.2.4 CLEANING
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient
temperature.
To clean, use cloths and brushes moistened with solvent. Never use hard objects or
spray on cleaning agents with a gun.
Preferably, non-combustible cleaning agents should be used.
An explosive gas/air mixture forms in closed containers.
When cleaning devices with solvents, never spray into a closed container.
Only use electrically conductive containers for cleaning liquids.
The containers must be grounded.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES, AND PAINTS
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the paints, solvents, and cleaning agents
being used.
Take the specified protective measures. In particular, wear safety goggles, protective
clothing, and gloves, as well as hand protection cream if necessary.
Use a mask or a breathing apparatus if necessary.
For sufficient health and environmental safety: operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot materials.
4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating material with a temperature of > 43 °C; 109 °F:
- Identify the device with a warning label "Warning - hot surface".
Order No.
9998910
9998911
Instruction label
Protection sticker
Note: Order the two stickers together.
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4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
The pneumatic pump may be used in areas subject to explosion hazards. The following
safety regulations must be observed and followed.
4.3.1 SAFETY REGULATIONS
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the unit against steel or rusty iron.
Do not drop the device.
Only use tools that are made of a permitted material.
Ignition temperature of the pumped material
Check that the ignition temperature of the pumped material is higher than the max.
allowable surface temperature.
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Only use a damp cloth to clean the device.
4.3.2 OPERATION WITHOUT FLUID
Avoid running the pump so that it sucks in air (without fluid inside). The air, combined with
the vapor of flammable fluids, can generate internal areas with an explosion hazard.
Periodically check that the pump is working smoothly, paying special attention to the
presence of air in the pumped fluid, which may be caused by damaged packings.
Avoid operating the pump with damaged packings.
Ensure that the separating agent container is filled with sufficient separating agent.
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5 DESCRIPTION
5.1 FIELD OF APPLICATION
5.1.1 CORRECT USE
The pneumatic piston pump is suitable for conveying and processing (AirCoat technique)
liquid materials in accordance with Chapter 5.1.2.
5.1.2 PROCESSIBLE MATERIALS
Application
Water-based materials
Solvent-based materials
Low viscosity (<40 sec. DIN No. 4)
Medium viscosity (40 to 60 sec. DIN No. 4)
High viscosity ( >60 sec. DIN No. 4)
UV - sensitive materials
Shear sensitive materials
Humidity sensitive materials
Legend
recommended
limited suitability
less suitable
NOTICE
Abrasive materials and pigments!
Greater wear of parts carrying the material.
Use suitable combinations of devices (packings, valves, etc.)
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5.2 SCOPE OF DELIVERY
Pneumatic piston pump consisting of:
-
-
-
Fluid section
Air motor
Connection elements
Separating agent 250 ml
Conformity certificate GM2000W
Operating manual, German
Order No.: 9992504
see Chapter 12
Order No.: 2310798
see Chapter 1
Operating manual in the local language
The delivery note shows the exact scope of delivery.
Accessories: see Chapter 10.
5.3 DATA
5.3.1 MATERIALS OF PAINT-WETTED PARTS
Pump housing
Piston
Valve balls
Valve seats
Static seals
Packings
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Ultra high molecular weight polyethylene
PTFE
=
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5.3.2 TECHNICAL DATA
Description
Units
20:1
Pump ratio
40:1
Volume flow per double stroke
Maximum operating overpressure
cm3; cc
MPa
bar
15
25.0
250
3626
60
30
16.0
160
2320
60
psi
Maximum possible strokes in operation
Minimum/maximum air inlet pressure
/min
MPa
bar
0.2-0.8
2-8
psi
28-116
8.0
0.31
9.0
0.35
3.9
Ø air inlet connection (inside thread)
Minimum Ø of the compressed air supply line
Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke
Air motor piston diameter
mm
inch
mm
inch
nl
scf
0.14
80
3.15
60
mm
inch
mm
inch
Air motor piston stroke
2.4
Sound pressure level at maximum permissible air pressure* dB(A)
72
Sound pressure level at 0.6 MPa; 6 bar; 87 psi air pressure*
Sound pressure level at 0.4 MPa; 4 bar; 58 psi air pressure*
Material inlet (outside thread)
dB(A)
dB(A)
mm
69
65
M36x2
Material outlet (outside thread)
Weight
inch
kg
NPS 1/4"
9
11
lb
19.8
24.7
Material pH value
Maximum material pressure at pump inlet
pH
MPa
bar
psi
3.5 ÷ 9
2
20
90
Material temperature
+5 ÷ +80
+41 ÷ +176
+5 ÷ +60
+41 ÷ +140
10
Ambient temperature
Allowable inclination for operation
*
A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.
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WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Air motor switching problems.
Provide compressed air free from oil and water
(Quality Standard 5.5.4 in accordance with ISO 8573.1)
5.5.4 = 40 μm / +7 / 5 mg/m³.
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5.3.3 MEASUREMENTS AND CONNECTIONS FOR FINEFINISH 40-15
mm
104
108.5
621
276.5
134
inch
4.09
4.27
24.45
10.89
5.28
A
B
C
D
E
F1
F2
G
H1
H2
I
J
K
L
M
N
O
P
Q
R
G 1/4"
NPS 1/4"
M36x2
G 1/4"
8
210
207
86
7
182
80
106
96.5
ø 9
ø 7
149
ø 25
0.31
8.27
8.15
3.39
0.28
7.17
3.15
4.17
3.8
A
H1
ø 0.35
ø 0.28
5.87
B
L
H2
S
T
ø 1
K
I
J
F1
F2
Wall mount
S
N
R
Q
G
M/2
M
B_04120
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5.3.4 MEASUREMENTS AND CONNECTIONS FOR FINEFINISH 20-30
mm
104
108.5
643
201
134.5
inch
4.09
4.27
25.3
7.91
5.3
A
B
C
D
E
F1
F2
G
H1
H2
I
J
K
L
M
N
O
P
Q
R
G 3/8"
NPS 1/4"
M36x2
G 1/4"
8
210
207
80
7
182
80
106
96.5
ø 9
ø 7
149
ø 25
0.31
8.27
8.15
3.15
0.28
7.17
3.15
4.17
3.8
A
H1
B
ø 0.35
ø 0.28
5.87
L
H2
S
T
ø 0.98
J
K
I
F1
F2
S
Wall mount
N
R
Q
G
M/2
M
B_04100
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5.3.5 PERFORMANCE DIAGRAMS
Example
Stroke frequency /min
ꢀ BAR
ꢁ BAR
ꢂ BAR
"?ꢃꢃꢄꢃꢅ
Water delivery rate l/min <gpm>
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Diagram of FineFinish 40-15
Stroke frequency /min
bar (MPa)
<psi>
nl/min
<scfm>
0
10
20
30
40
50
60
300
<11>
300 (30)
<4350>
A
B
A
240
240 (24)
<8>
<3480>
B
180
<6>
180 (18)
<2610>
C
C
120
<4>
120 (12)
<1740>
60
<2>
60 (6)
<870>
0
0
0
0.15 0.30 0.45 0.60 0.75 0.90 l/min
<0.04> <0.08> <0.12> <0.16> <0.20> <0.24> <gpm>
C_00054
Material flow - water
A = 8 bar; 0.8 MPa; 116 psi air pressure
B = 6 bar; 0.6 MPa; 87 psi air pressure
C = 4 bar; 0.4 MPa; 58 psi air pressure
Diagram of FineFinish 20-30
Stroke frequency /min
bar (MPa)
<psi>
nl/min
<scfm>
0
10
20
30
40
50
60
150 (15)
<2176>
350
<12.5>
A
B
A
120 (12)
<1740>
280
<10>
B
90 (9)
<1305>
210
<7.5>
C
C
60 (6)
<870>
140
<5>
30 (3)
<435>
70
<2.5>
0
0
0
0.30
0.60 0.90 1.20 1.50 1.80 l/min
C_00142
<0.08> <0.16> <0.23> <0.31> <0.39> <0.47> <gpm>
Material flow - water
A = 8 bar; 0.8 MPa; 116 psi air pressure
B = 6 bar; 0.6 MPa; 87 psi air pressure
C = 4 bar; 0.4 MPa; 58 psi air pressure
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OPERATING MANUAL
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OPERATING MANUAL
5.4 FUNCTION
5.4.1 PUMP
11
1
8
2
9
1
2
3
4
Air motor
Air inlet
Mounting flange
Separating fluid
container
3
5
6
7
8
9
Material outlet
Fluid section
Material inlet
Grounding connection
Reversing valve
4
8
10
13
12
6
5
10 Safety valve
(air motor ventilation)
14
11 Air pressure regulator
12 Ball valve
B_04121
13 Air outlet to the
reversing valve
14 Air inlet into the
reversing valve
7
7
Function principle
The piston pump is driven with compressed air (11). This compressed air moves the air piston up and down in
the air motor (1) and it also moves the associated pump piston up and down in the fluid section (6). At the end
of each stroke, the compressed air is redirected by a reversing valve (9).
The working material is sucked up during the upwards stroke and is continuously conveyed towards the
material outlet (5) in both stroke directions.
Air motor
The air motor (1) with its pneumatic reverse (9) does not require pneumatic oil.
The compressed air is fed to the motor via an air regulator (11) and the ball valve (12).
The air motor is to be equipped with a safety valve (10) in accordance with Chapter 5.4.3. The safety valve (10)
has been set and sealed at the factory. In case of pressures over and above the permissible operating pressure,
the valve, which is held with a spring, automatically opens and releases the excess pressure.
WARNING
Overpressure!
Risk of injury from bursting components.
Never change the safety valve setting.
Fluid section (6)
The fluid section has been designed as a piston pump with exchangeable ball valves. The
pump piston runs in two fixed packings which are self-adjusting by means of a pressure
spring, thus resulting in a long service life.
Between the air motor and the fluid section there is a separating agent cup (4) for holding
the separating agent.
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OPERATING MANUAL
5.4.2 PRESSURE REGULATOR UNIT
1
2
3
4
5
6
7
Pressure regulator
Ball valve
Pressure gage (air inlet pressure)
Pressure gage for AirCoat air (option)
Compressed air inlet
Pressure regulator AirCoat (option)
Safety and motor pressure relief valve
1
2
3
1
2
3
4
6
5
7
7
5
B_04122
Ball valve positions:
open
1
2
Open: working position
Closed: the air motor may still be
under pressure.
1
2
closed
B_04123
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OPERATING MANUAL
5.4.3 SAFETY AND MOTOR PRESSURE RELIEF VALVE
Safety valve
The safety valve (10) has been factory adjusted so as to ensure that if pressure exceeds the
permitted operating pressure, the valve, which is held with a spring, automatically opens
and releases the excess pressure.
As well as handling pressure limits, the valve is also used as a pressure relief valve for the
air motor.
10
Pressure relief of the air motor:
10
2
1
2
Close ball valve (2).
Pull back the ring on the safety
valve (10) and hold it there until
the pressure in the air motor has
been equalized.
B_04124
WARNING
Overpressure!
Risk of injury from bursting components.
Never change the safety valve setting.
5.4.4 RETURN VALVE
So that the complete pressure relief of the pump can be
performed (see Chapter 7.2.2), the installation of a return
valve is mandatory.
The suitable return valves (ball valves), return pipes and hoses
for the device can be found in the accessories list.
2
1
2
3
Material outlet
Return valve
Material return line
1
B_04075
3
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OPERATING MANUAL
6 ASSEMBLY AND COMMISSIONING
6.1 TRANSPORTATION
The pump can be moved on a trolley or manually without lifting equipment.
6.2 STORAGE
Store the pump in a closed and dry environment.
Thoroughly clean the pump, if a long-term decommissioning is planned.
When resuming pump operation, proceed as described in the following sections.
WARNING
Discharge of electrostatically charged components in atmospheres
containing solvents!
Explosion hazard from electrostatic sparks.
Only use a damp cloth to clean the pump.
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6.3 ASSEMBLING THE PUMP
Notice
This pump can be used as part of a spraying system for Airless
or AirCoat applications. Individual supplement components
for this pump can be found in the Wagner Accessories
Catalogue, or can be put together with the Spraypack
Configurator. The nozzles must be selected according to the
gun instructions. In the case of spraypack orders, the pumps
(1) are already pre-mounted on a trolley (6) or on a stand at
the factory.
Example:
Airless system
3
6
1
2
8
4
Procedure:
5
1
2
Mount pump (1) on stand, trolley (6), or wall mount.
Mount an AirCoat system with the pressure regulator
(7) and secure the thread at the air inlet to the pump
(1) with Loctite 270.
B_04076
3
4
Mount suction system (5).
Mount the return valve (8) for pressure relief or
material circulation.
5
6
Mount return tube (4) or return hose.
Connect the high pressure hose (2) and gun (3) in
accordance with the gun operating manual.
Example:
AirCoat system
7
3
1
8
6
2
4
5
B_04077
WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
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OPERATING MANUAL
6.4
GROUNDING
WARNING
Discharge of electrostatically charged components in atmospheres
containing solvents!
Explosion hazard from electrostatic sparks.
Only use a damp cloth to clean the piston pump.
WARNING
Heavy paint mist if grounding is insufficient!
Danger of poisoning.
Insufficient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
Grounding scheme (example)
Conveyor
Note for the sprayer
Safety shoes and gloves, if
used, must be electrostatically
conductive.
Work piece
Spraying stand
R max < 1 MΩ
Paint container
B_00304
Floor, electrostatically conductive
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OPERATING MANUAL
Cable cross sections
Pump
4 mm2;
Paint container
Conveyor
Spray booth
Spraying stand
6 mm2;
16 mm2;
16 mm2;
16 mm2;
Procedure:
1
2
3
4
Screw on grounding cable with eye.
Clamp the grounding cable clip to a grounding connection on site.
Ground the material (paint) container to an on-site grounding connection.
Ground the other parts of the system to an on-site grounding connection.
Grounding cable
B_04127
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OPERATING MANUAL
6.5 COMMISSIONING
6.5.1 SAFETY INSTRUCTIONS
Before carrying out any work, the following points must be observed in accordance with
the operating manual:
- Observe all safety regulations in accordance with Chapter 4.
- Carry out commissioning properly.
WARNING
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused
by paint or solvent. Inform the doctor about the paint or solvent
used.
Never seal defective high-pressure parts; instead relieve the
pressure from them and replace them.
WARNING
Toxic and/or flammable vapor mixtures!
Risk of poisoning and burns.
Operate the device in a spray booth approved for the working
materials.
-or-
Operate the device on an appropriate spraying wall with the
ventilation (extraction) switched on.
Observe national and local regulations for the outgoing air
speed.
WARNING
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from flying parts.
Ensure that the pump and suction system are always completely
filled with flushing agent or working medium.
Do not spray the device empty after cleaning.
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OPERATING MANUAL
Before every start-up, the following points should be observed as laid down in the
operating manual:
-
-
-
Check the permissible pressures.
Check all connecting parts for leaks.
Check hoses for damage.
It should be ensured that the device is in the following state before carrying out any work
on it:
-
-
-
Interrupt the air supply (2).
Depressurize the air motor (pull the ring on the safety valve (10)).
Relieve the pressure from the fluid section.
10
closed
open
10
2
C_00157
B_04124
EMERGENCY STOP
2
In the case of unforeseen occurrences
the ball valve (2) should be closed
immediately.
Open the safety valve (10) and relieve the
material-conveying parts completely of
pressure via the return valve (3).
B_04078
3
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OPERATING MANUAL
6.5.2 FILLING WITH SEPARATING AGENT
NOTICE
Piston pump runs dry!
High wear/damage to the packings.
Paint or solvent can escape if the seals are dry.
Ensure that the separating agent container is filled with sufficient separating agent.
Filling level 2 cm; 0.8 inch under the cup edge.
Pour the supplied separating agent into the intended opening.
Filling level:
2 cm; 0.8 inch under the cup edge
Separating agent: See accessories.
Notice
Maximum permissible inclination of pump for moving, transportation
etc. after filling it with separating agent 30°.
The pump must be vertical during operation.
B_04130
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OPERATING MANUAL
6.5.3 BASIC FLUSHING
Before each basic flushing, the nozzle must be removed from the pistol. The data in the
gun's operating manual are to be observed.
With AirCoat systems, carry out the basic flushing of the system without atomizing air (8)
.
1
2
3
4
5
6
7
8
9
Place empty container (5) under return tube (4).
Place suction hose (7) in the container with flushing agent (6).
Open return valve (3).
Slowly open the ball valve (2).
Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly.
Flush the system until clean flushing agent flows into the container (5).
Close ball valve (2).
Close return valve (3).
Point the gun (9), without nozzle, into container (5) and open it.
10 Slowly open the ball valve (2).
11 Rinse until clean flushing agent flows from the gun.
12 Close ball valve (2).
13 Relieve the system pressure, either by opening the return valve (3) or via the trigger
on the gun (9).
14 When there is no pressure remaining in the system, close the gun (9) or the return
valve (3).
15 Secure the gun.
16 Dispose of the contents of the container (5) according to the local regulations.
closed
1
8
2
open
7
3
4
6
9
5
B_04079
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OPERATING MANUAL
7 OPERATION
7.1
FILLING WITH WORKING MATERIAL
Note:
Before each filling, the nozzle must be removed from the pistol. The data in the gun's
operating manual are to be observed.
In case of AirCoat systems, carry out the filling of the system without atomizing air (8).
1
2
3
4
5
6
7
8
9
Place empty container (5) under return tube (4).
Place suction hose (7) in the container with working material (6).
Open return valve (3).
Slowly open the ball valve (2).
Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly.
Spray until clean working material flows into the container (5).
Close ball valve (2).
Close return valve (3).
Point the gun (9), without nozzle, into container (5) and open it.
10 Slowly open the ball valve (2).
11 Spray until clean working material flows from the gun (9).
12 Close ball valve (2).
13 Relieve the system pressure, either by opening the return valve (3) or via the trigger
on the gun (9).
14 When there is no pressure remaining in the system, close the gun (9) or the return
valve (3).
15 Secure the gun.
16 Dispose of the contents of the container (5) according to the local regulations.
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OPERATING MANUAL
7.2 WORK
7.2.1 SPRAYING
System example for
the AirCoat procedure
closed
open
1
8
2
9
7
3
4
6
5
B_04080
1
2
3
4
5
6
Secure the gun and insert the nozzle into the gun.
Close return valve (3).
Slowly open the ball valve (2).
Set required working pressure on the pressure regulator (1).
Optimize the spraying results according to the data in the gun operating manual.
Start work process.
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OPERATING MANUAL
7.2.2 PRESSURE RELIEF/WORK INTERRUPTION
Pressure relief of the material
1
2
3
Close the spray gun.
Close ball valve (2).
Relieve the system pressure, either by opening the gun or by opening the return
valve (3).
4
5
Close and secure gun.
Open and close the return valve (3) to completely depressurize the system.
Pressure relief of the air (in case of longer work interruptions)
1
2
3
Carry out pressure relief of the material (as mentioned above).
Ensure that the ball valve (2) is closed.
Pull back the ring on the safety valve (10) and hold it there until the pressure in the
air motor has been equalized.
10
10
2
B_04124
If the system has been used with 2-component materials:
NOTICE
Hardened working material in the spraying system when two-component material
is processed!
Destruction of pump and injection system.
Follow the manufacturer‘s processing rules, particularly regarding the pot life.
Flush thoroughly before the end of the pot life.
The pot life is decreased by warmth.
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OPERATING MANUAL
7.2.3 DECOMMISSIONING AND CLEANING
Notice
The device should be cleaned for maintenance purposes. Ensure that no remaining
material dries and sticks.
Procedure:
1
2
3
4
5
Carry out pressure relief of the material and air -> Chapter 7.2.2.
Basic cleaning -> carry out the steps in Chapter 6.5.3.
Maintain the gun according to the operating manual.
Clean and check the suction system and the suction filter.
Clean the outside of the system.
WARNING
Brittle filter pressure regulator!
The container on the filter pressure regulator becomes brittle
through contact with solvents and can burst.
Flying parts can cause injury.
Do not clean the container on the filter pressure regulator with
solvent.
6
7
8
Put the whole system back together.
Check the level of the separating agent -> Chapter 6.5.2.
Fill the system with flushing agent as laid down in Chapter 7.1 "Filling with Working
Material".
WARNING
Gas mixtures can explode if there is an incompletely filled
pump!
Danger to life from flying parts.
Ensure that the pump and suction system are always completely
filled with flushing agent or working medium.
Do not spray the device empty after cleaning.
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OPERATING MANUAL
7.3 LONG-TERM STORAGE
When storing the device for longer periods of time, it is necessary to thoroughly clean it
and protect it from corrosion. For the last rinse, replace the water or solvent in the material
pump with a suitable preservative. Fill separating agent cup with separating agent. Store
pump vertically.
Procedure:
1
2
3
4
Chapter 7.2.3 "Decommissioning and Cleaning", perform points 1 to 7.
Flush with preservative according to Chapter 6.5.3 and paint supplier's instructions.
If the discharge duct is to be removed, seal material outlet with plug.
If the suction system is to be removed, seal material inlet with plug.
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VERSION 03/2013
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OPERATING MANUAL
8 TROUBLESHOOTING AND RECTIFICATION
Problem
Cause
Remedy
Pump does not work. Air motor does not work or stops.
Open and close ball valve on the pressure
regulator unit or briefly disconnect
compressed air supply.
No pressure indication on the
pressure gage
Disconnect compressed air supply briefly or
repair or change pressure regulator.
(air pressure regulator defective).
Spray nozzle is clogged.
Insufficient compressed air supply.
Filter insert in spray gun is clogged.
Clean the nozzle according to the instructions.
Check compressed air supply.
Clean the parts and use a suitable working
material.
Fluid section or high pressure hose
are blocked (e.g., two-component
material hardened).
Dismount and clean fluid section, replace
high-pressure hose.
Sometimes, the pump stops at a
switching point.
Press the starter on the reversing valve and
restart the pump.
Clean the slide on the reverse valve carefully
and if necessary lubricate it with a light
layer of oil.
Poor spray pattern
Irregular pump
See gun instructions.
Viscosity is too high.
Thin spraying material.
operation: spray jet
collapses (pulsation).
Spraying pressure is too low.
Increase air inlet pressure.
Use a smaller nozzle.
Valves are clogged.
Clean pump, if necessary leave it to soak in
solvent.
Foreign body in suction valve.
Dismount suction valve housing, clean, and
check valve seat.
Diameter of compressed air line too Assemble a larger incoming line
small. -> Technical Data, Chapter 5.3.2.
Valves, packings, or pistons are worn Replace the parts.
out.
Pressure regulator filter is clogged.
Check filter and clean it if necessary.
The pump runs evenly, The suction system's union nut is
Tighten union nut.
does not however,
suck up material.
loose; the pump is taking in air.
Suction filter is clogged.
Clean filter.
Ball in suction or piston valve is stuck. Clean balls and valve seats.
Packings, valves, or pistons are worn Replace the parts.
out.
Pump runs when the
gun is closed.
Air motor is iced up.
There is a lot of condensation water Install a water separator.
in the air supply.
If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service
Center.
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VERSION 03/2013
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OPERATING MANUAL
9 MAINTENANCE
WARNING
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may
carry out repairs and replace parts.
Only repair and replace parts that are listed in the "Spare Parts"
chapter and that are assigned to the device.
Before all work on the device and in the event of work
interruptions:
- Disconnect the control unit from the mains.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
1
Check the level of separating agent in the separating agent cup every day, and top
up if necessary.
2
3
4
Check and clean the high pressure filter every day or as required (if available).
Every decommissioning should be carried out as laid down in Chapter 7.2.3!
Check hoses, pipes, and couplings every day and replace if necessary.
In accordance with the guideline for liquid emitters (ZH 1/406 and BGR 500 Part 2
Chapter 2.36):
- The liquid emitters should be checked by an expert (e.g.Wagner service technician)
for their safe working conditions as required and at least every 12 months.
- If devices have been decommissioned, the examination can be suspended until
the next start-up.
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VERSION 03/2013
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OPERATING MANUAL
9.1 HIGH-PRESSURE HOSES
The service life of the fluid hoses is reduced due to environmental influences even when
handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
As a precaution, fluid hoses should be replaced after a period specified by the
operator.
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of material.
Ensure that the hose material is chemically resistant to the
sprayed materials.
Ensure that the spray gun, threaded joints, and material hose
between the device and the spray gun are suitable for the
pressure generated in the device.
Ensure that the following information can be seen on the high-
pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
9.2 DECOMMISSIONING
When the equipment must be scrapped, please differentiate the disposal of the waste
materials.
The following materials have been used:
Steel
Aluminum
Elastomers
Plastics
Carbide
The consumable materials (paints, adhesives, sealers, solvents) must be disposed of
according to the valid specific standards.
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VERSION 03/2013
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OPERATING MANUAL
10 ACCESSORIES
Accessories
Designation
Order No.
2329450
Order No.
2329452
1
2
3
4
5
Pump PE/T
AirCoat regulator set
Grounding cable, complete 3 m; 9.8 ft
Separating agent 250 ml
Separating agent 500 ml
T6145.00A
236219
9992504
9992505
Material outlet accessories
Designation
Order No.
2334488
2334472
2331752
2329046
11
12
13
14
Ball valve R1/4"-G1/4"-PN350-SSt
Ball valve R1/4"-G1/4"-PN350-CS
Return tube DN6-G1/4"-100mm-PA
Return hose DN6-PN310-G1/4"-PA
Material inlet accessories
Designation
Order No.
2324158
2324110
2323225
2332169
2323396
15
16
17
18
19
Suction pipe DN16-SSt, complete
Suction hose DN16-SSt, complete
Suction elbow for top reservoir SSt
Top reservoir set, 5 l for piston pump
Suction filter DN16-18mesh-SSt
Wearing part
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VERSION 03/2013
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OPERATING MANUAL
3
2
x
x
1
11
4/5
12
13
14
18
15
16
17
19
B_04081
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VERSION 03/2013
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OPERATING MANUAL
Trolley, rack and wall bracket accessories
Designation
Order No.
2332143
2332374
T6196.00
2325901
21
22
23
24
Wall mount 4", complete
4-leg stand
Trolley, 4 wheels
Trolley 4", complete
21
22
23
24
B_04113
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VERSION 03/2013
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OPERATING MANUAL
11 SPARE PARTS
11.1 HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
Order number, designation, and quantity
The quantity need not be the same as the number given in the quantity column " " on
the lists. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
-
-
-
-
Billing address
Delivery address
Name of the person to be contacted in the event of any queries
Type of delivery (normal mail, express delivery, air freight, courier, etc.)
Identification in spare parts lists
Explanation of column " " (labeling) in the following spare parts lists:
Wearing parts
Note: No liability is assumed for wearing parts.
Not part of the standard equipment but available as a special accessory.
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements carried out only by specially
trained staff or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
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OPERATING MANUAL
11.2 OVERVIEW OF THE COMPONENTS
11.2.1 COMPONENTS FOR FINEFINISH 40-15
Designation
Order No.
2329450
2329635
U3B08018060
A359.71A
E516.71A
9900353
2332394
9920106
9900330
3055157
H115.62
1
1
1
1
1
1
2
1
4
4
3
3
1
1
2
3
4
5
6
7
8
9
Fluid section 15 PE/T EM
Air motor M80 EM
D 25 X 160 Spacer
Safety fixture spacer
Hexagon socket head cap screw
Holder plate
Washer
Hexagon socket head cap screw
10 Hexagon nut with clamp
11 Tie rod
12 Pump air regulator set
13 Screwing in angle
T6140.00A
9998253
13
3
12
7
8
9
20 Nm; 14.7 lbft
4
1
6
5
11
2
10
30 Nm; 22.1 lbft
B_04135
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VERSION 03/2013
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OPERATING MANUAL
11.2.2 COMPONENTS FOR FINEFINISH 20-30
Designation
Order No.
2329452
2329639
U3B08018060
A359.71A
E516.71A
9900353
2332394
9901115
9920106
2332990
9906024
T6140.00
9998253
9992590
1
1
1
1
1
1
2
1
4
4
4
4
1
1
1
2
3
4
5
6
7
8
9
Fluid section 30 PE/T EM
Air motor M80 EM
D 25 X 160 Spacer
Safety fixture spacer
Hexagon socket head cap screw
Holder plate
Threaded bolt
Washer
10 Hexagon extension nut
11 Hexagon socket head cap screw
12 Pump air regulator set
13 Screwing in angle
14 Loctite 222 50ml; 50cc
13
3
12
7
8
9
14
1
10
30 Nm; 22.1 lbft
4
6
5
7
2
11
B_04115
30 Nm; 22.1 lbft
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VERSION 03/2013
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OPERATING MANUAL
11.3 AIR MOTOR
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements carried out only by specially
trained staff or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
Air motor spare parts list EM M80
Designation
Order No.
U3B08018060
F132.91C
L108.06
D608.81
3055157
9920106
G903.06
L413.06
A164.01
L802.08
L110.06
D404.12
L109.06
A408.12
T616.00C
--
1
2
3
4
5
6
7
8
Air motor EM M80
Motor flange, upper, M50 EM
O-ring
Cylinder motor
Hexagon nut with clamp
Washer
Steamer
Gasket DE 80
Motor piston
Sliding ring
O-ring
Piston rod, M80 EM
O-ring
Air tube, M80 EM
Motor flange, complete M80 EM, at bottom
Type plate
Grounding, complete
Rod seal
Sensor below, M80
Lock washer for shaft
Washer
Pilot valve
Threaded elbow fitting
Silencer
1
1
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
2
1
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
367258
L403.06
T703.00
K606.02
A160.01A
369290
9992757
H505.07
M432.00
Reducing nipple
= Wearing part
= Included in service set
= Not part of the standard equipment but available as an accessory.
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OPERATING MANUAL
30 Nm; 22 lbft
28
2
3
29
4
16
35 Nm; 25.8 lbft
30
5
6
7
29
29
29
9
13
30
29
4.5 Nm;
3.3 lbf
t
7
14
11
1
10
13
3
36
29
35
31
17
32
33
15
34
24
19
22
27
20 Nm; 14.7 lbft
27
29
25
23
18
Installation instructions:
Mount piston rod (12) always
from bottom to top by the
assigned rod seal (18).
12
20
21
20
B_04347
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OPERATING MANUAL
Air motor spare parts list EM M80
Designation
Order No.
9992831
9907241
9998808
9998157
27
28
29
30
31
Loctite 542
1
4
1
1
1
Hexagon socket head cap screw
Mobilux EP 2 grease
Loctite 480
Reversing valve ISO N/1
(consisting of items 32 to 36)
Reversing valve
P498.00KNE
32
1
P498.00
(spare parts list, see Chapter 11.3.1)
33
34
35
36
Valve plate
Valve sealing
Washer, A4.3
Hexagon socket head cap screw
1
1
4
4
A818.71B
G735.06AB
9920104
9900386
Service set EM Air motor M80
1
T910.00
= Wearing part
= Included in service set
= Not part of the standard equipment but available as an accessory.
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements carried out only by specially
trained staff or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
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OPERATING MANUAL
11.3.1 REVERSING VALVE
4
1
2
3
B_03139
Spare parts list for the reversing valve
Designation
Order No.
P498.00
9971123
P521.00
P520.00
1
2
3
4
Reversing valve
O-ring
Reversing valve gasket
Steamer
1
6
1
2
= Wearing part
53
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OPERATING MANUAL
11.4 FLUID SECTIONS
11.4.1 FLUID SECTION 15
30 Nm; 22.1 lbft
24
8
29
36
22
2.5 Nm; 1.84 lbft
2
25
25
30
26
9
3
4
30
26
23
20
30
10
27
28
31
27
28
11
30
27
28
28
28
5
27
27
27
1
21
12
6
35
33
13
7
14
19
30
15
10
17
16
34
35
31
18
32
B_03445
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OPERATING MANUAL
Spare parts list for fluid section 15
Designation
Order No.
2329635
A661.12
K617.03
A662.12
T9037.00E
H204.03
A658.03
H203.03
T9038.00E
L107.06
B534.03
T6157.00I
A170.03
K801.03
A169.03
K803.03
K601.03
2323838
9992831
A171.03
A172.03
A411.03
A410.03
T6158.00
G101.05
G101.08E
G104.05
G104.08E
9900136
9998808
9992609
2329898
B0461.03A
2323718
9992528
9992590
1
2
3
Fluid section 15 SS PE/T EM
Connecting flange 15
Snap ring
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
6
5
1
1
1
1
1
1
1
1
4
5
6
Snap ring flange 15
Packing PE/T 13/25
Spring, upper
7
Tube 15
8
Spring
9
Packing PE/T 18/29
O-ring
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Cylinder 15
Piston 15 SS
Support spring
Ball
Valve screw 15
Ball
Securing ring
Inlet housing 15
Loctite 542
Support ring, outside
Support ring, inside
Support ring, inside
Support ring, outside
Connector
Sealing collar T 18/29
Sealing collar PE 18/29
Sealing collar T 13/25
Sealing collar PE 13/25
Hexagon screw without shaft
Mobilux EP 2 grease
Anti-seize paste
Sealing sleeve
Fitting-DF-MM-R1/4"-1/4"NPS-PN350
Hexagon plug
Loctite 270
Loctite 222
Service set EM 15 PE/T
1
T9039.00E
= Wearing part
= Included in service set
= Not part of the standard equipment but available as an accessory.
55
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11.4.2 FLUID SECTION 30
30 Nm; 22.1 lbft
41
3
2
21
22
4
42
5
6
7
8
7
23
24
42
8
10
7
8
25
7
26
26
28
8
42
9
27
27
29
11
12
45
1
42
14
30
15
42
13
16
31
45
44
32
33
34
17
35
18
36
37
19
20
43
B_04116
56
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OPERATING MANUAL
Spare parts list for fluid section 30
Designation
Order No.
2329639
T6158.00
9900136
B0388.62
L112.06
G119.08
G101.08E
G101.05
G120.08
T920.00D
A114.03
H203.03
L170.06
B0391.03
B0461.03
2323718
T6181.00
A156.03
K802.03
A155.03
B0387.62
9907087
H222.03
B0099.03
G185.05
G152.05
G152.08E
G184.05
T941.00G
K640.02
B0392.03
A961.03B
K803.03
L170.06
1
2
Fluid section 30 PE/T, complete
Connector
1
1
1
1
1
1
4
4
1
1
1
1
2
1
1
1
1
1
1
1
1
3
1
1
1
2
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
3
4
5
Hexagon screw without shaft
Connecting flange 30
O-ring
6
7
8
9
Support ring, outside
Sealing collar PE 18/29
Sealing collar T 18/29
Support ring, inside
Packing PE/T, complete 18/29
Support ring plate
Spring
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
41
42
43
44
45
O-ring
Tube 30
Fitting-DF-MM-R3/8"-1/4"NPS-PN350
Hexagon plug
Piston 30
Support spring
Ball
Valve screw 30
Lower pump flange
Hexagon socket head cap screw
Pressure spring
Ring
Support ring, inside
Sealing collar T 25/36
Sealing collar PE 25/36
Support ring, outside
Packing PE/T, complete 25/36
Round wire snap ring for waves
Cylinder 30
Ball stopper
Ball
O-ring
Inlet fitting
Sealing sleeve
Valve screw 30
Loctite 222
Mobilux EP 1 grease
Loctite 542
2323833
2329898
B0389.03
9992590
9998008
9992831
9992609
9992528
Anti-seize paste
Loctite 270
Service set EM 20 PE/T
1
T940.00G
= Wearing part
= Included in service set
= Not part of the standard equipment but available as an accessory.
57
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OPERATING MANUAL
11.5 AIR REGULATOR SET
14
14
14
9
5
4
14
8
1
13
2
3
10
14
11
12
B_04117
Spare parts list for air regulator set
Designation
Order No. Order No.
T6140.00A T6140.00
9906026
1
2
Pump air regulator set
Hexagon socket head cap screw
Pressure gage 0-1 MPa; 0-10 bar; 0-145 psi (d40)
Reducer
1
2
1
1
3
4
9998677
9985682
5
8
Screw-in connection's elbow
Ball valve, FM
1
1
9998039
M101.00
9
Safety valve 1/4"
T-connection
Straight threaded fitting
Hose, black AD8 x 1.25 (0.32 m; 1.05 ft long)
Filter regulator, CZ 1/4
Loctite 542
1
1
1
P484.00C1 P484.00C0
M297.00
10
11
12
13
14
9992743
9982078
P124.00M
9992831
0.32 m
1
1
= Wearing part
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VERSION 03/2013
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OPERATING MANUAL
11.6 AIR REGULATOR SET FOR AIRCOAT AIR
7
6
4
7
5
1
3
7
2
B_03436
Spare parts list for air regulator set for AirCoat Air
Designation
Order No.
T6145.00A
9998677
9992129
9998719
9985694
P123.00
1
2
3
4
5
6
7
AirCoat regulator set
Pressure gage 0-1 MPa; 0-10 bar; 0-145 psi (d40)
Elbow with taper
Detachable double nipple
T-piece
1
1
1
1
1
1
1
Air pressure regulator, 1/4"
Loctite 270
9992528
= Wearing part
59
VERSION 03/2013
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OPERATING MANUAL
11.7 TROLLEY, 4"
15
5
17
10
13
14
4
2
9
5
16
6
1
3
7
A
8
Distance
11
12
B_04074
Spare parts list for trolley, 4"
Designation
Trolley, complete
Order No.
2325901
--
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
1
1
4
6
2
4
4
1
2
2
2
2
4
1
2
2
Stand left 4" (welded)
Stand right 4" (welded)
Hexagon screw DIN931 M6x75
Self-locking hexagon nut, M6
Wheel, D250
Washer
Cotter pin
Wheel axle 4"
Connecting part 4"
Tube plug, ribbed
Saddle feet for round tubes
Plug
Hexagon screw
Wall mount
--
9907140
9910204
2304440
340372
9995302
--
367943
--
--
--
9900218
2332143
3061695
9998747
Hexagon screw without shaft M6x55
Handle
= Wearing parts
60
VERSION 03/2013
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OPERATING MANUAL
11.8 4-WHEEL TROLLEY
4
12
3
2
8
13
5
1
6
10
9
11
7
B_03439
14
Designation
Trolley, 4 wheels
Hexagon nut with clamp
Stand, right
Stand, left
Spray gun hook
Stand pin
Plug
Contact washer, M08
Washer
Wheel
Hexagon socket head cap screw
Hexagon socket head cap screw
Hexagon socket head cap screw
Hexagon nut with clamp
Order No.
T6196.00
9910204
E3107.92B
E3107.92C
H009.62
H1156.62
R204.07
3155404
9920106
R120.00F
9900311
9900389
9900309
3055157
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
5
1
1
1
1
4
4
4
4
4
4
2
4
= Wearing part
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OPERATING MANUAL
12 3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING
12.1 SCOPE OF GUARANTEE
All Wagner professional colour application devices (hereafter referred to as products)
are carefully inspected, tested, and subject to strict checks under Wagner quality
assurance. Wagner exclusively issues extended guarantees to commercial or professional
users (hereafter referred to as "customer") who have purchased the product in an
authorized specialist shop, and which relate to the products listed on the Internet at
.
The buyer’s claim for liability for defects from the purchase agreement with the seller and
statutory rights are not impaired by this guarantee.
We provide a guarantee in that we decide whether to replace or repair the product or
individual parts, or take the device back and reimburse the purchase price. The costs for
materials and working hours are our responsibility. Replaced products or parts become
our property.
12.2 GUARANTEE PERIOD AND REGISTRATION
The guarantee period amounts to 36 months. For industrial use or equal wear, such as shift
operations in particular, or in the event of rentals, it amounts to 12 months.
Systems driven by petrol or air are also guaranteed for a 12 month period.
The guarantee period begins with the day of delivery by the authorized specialist shop.
The date on the original purchase document is authoritative.
For all products bought in authorized specialist shops from 2009-02-01 the guarantee
period is extended to 24 months providing the buyer of these devices registers in
accordance with the following conditions within 4 weeks of the day of delivery by the
authorized specialist shop.
Registration can be completed on the Internet at
The guarantee certificate is valid as confirmation, as is the original purchase document
that carries the date of the purchase. Registration is only possible if the buyer agrees to the
data that is entered during registration being stored.
When services are carried out under guarantee the guarantee period for the product is
neither extended nor renewed.
Once the guarantee period has expired, claims made against the guarantee or from the
guarantee can no longer be enforced.
12.3 HANDLING
If defects can be seen in the materials, processing, or performance of the device during the
guarantee period, guarantee claims must be made immediately, or at the latest within a
period of 2 weeks.
The authorized specialist shop that delivered the device is entitled to accept guarantee
claims. Guarantee claims may also be made to the service centers named in the operating
manual. The product has to be sent without charge or presented together with the
original purchase document that includes details of the purchase date and the name of
the product. In order to claim for an extension to the guarantee, the guarantee certificate
must be included.
The costs as well as the risk of loss or damage to the product in transit or by the center that
accepts the guarantee claims or who delivers the repaired product, are the responsibility
of the customer.
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12.4 EXCLUSION OF GUARANTEE
Guarantee claims cannot be considered
- for parts that are subject to wear and tear due to use or other natural wear and tear, as
well as defects in the product that are a result of natural wear and tear, or wear and tear
due to use. This includes in particular cables, valves, packings, nozzles, cylinders, pistons,
means-carrying housing components, filters, pipes, seals, rotors, stators, etc. Damage
due to wear and tear that is caused in particular by sanded coating materials, such as
dispersions, plasters, putties, adhesives, glazes, quartz foundation.
- in the event of errors in devices that are due to non-compliance with the operating
instructions, unsuitable or unprofessional use, incorrect assembly and/or commissioning
by the buyer or by a third party, utilization other than is intended, abnormal ambient
conditions, unsuitable coating materials, the influence of chemical, electrochemical, or
electrical agents, unsuitable operating conditions, operation with the incorrect mains
voltage supply/frequency, overload, or defective servicing or care and/or cleaning.
- for errors in the device that have been caused by using accessory parts, additional
components, or spare parts that are not original Wagner parts.
- for products to which modifications or additions have been carried out.
- for products where the serial number has been removed or is illegible.
- for products to which attempts at repairs have been carried out by unauthorized persons.
- for products with slight deviations from the target properties, which are negligible with
regard to the value and usability of the device.
- for products that have been partially or fully taken apart.
12.5 ADDITIONAL REGULATIONS
Theaboveguaranteesapplyexclusivelytoproductsthathavebeenboughtfromauthorized
specialist shops in the EU, CIS, Australia and are used within the reference country.
If an inspection finds damage not covered by the present guarantee, repairs are carried out
at the expense of the buyer.
The above regulations manage the legal relationship to us concludingly. Additional claims,
in particular for damages and losses of any type, which occur as a result of the product
or its use, are excluded from the product liability act except with regard to the area of
application.
Claims for liability for defects to the specialist trader remain unaffected.
German law applies to this guarantee. The contractual language is German. In the event
that the meaning of the German and a foreign text of this guarantee deviate from one
another, the meaning of the German text has priority.
Germany
Wagner professional guarantee
(As of 2009-02-01)
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OPERATING MANUAL
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12.6 CE DECLARATION OF CONFORMITY
Herewith we declare that the supplied version of pneumatic pumps and their spraypacks
FineFinish
comply with the following guidelines:
2006/42/EC
94/9/EC
Applied standards, in particular:
Applied national technical standards and specifications, in particular:
Part 2 Chapter 2.29 and Chapter 2.36
Identification:
II 2G IIB c T3 X
EC Certificate of Conformity
The CE certificate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number:
2312813
12.7 REFERENCE TO GERMAN REGULATIONS AND GUIDELINES
Part 2, Chapter 2.36 Working with Liquid Ejection Devices
Part 2, Chapter 2.29 Working with Coating Materials
Explosion protection rules
Avoiding ignition risks
Equipment for cleaning work pieces with solvents
Guidelines for liquid ejection devices
Painting rooms and equipment
Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they can
be found on the Internet.
65
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OPERATING MANUAL
66
A
DK
GB
Tel.
Fax
Tel.
Fax
Fax
B
E
F
I
Tel.
Fax
Tel.
Fax
Tel.
Fax
CH
NL
Tel.
Fax
Tel.
Fax
Tel.
Fax
D
CZ
S
Tel.
Fax
Tel.
Fax
Tel. +49 / 75 44 / 505 -1664
Fax
Subject to changes and errors.
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