Translation of the Original
Operating Manual
Version 12/2015
Piston Pump
Flow Rate 15
cm
3
II 2G IIB c T3/T4 X
B_04119
VERSION 12/2015
ORDER NUMBER DOC2333558
OPERATING MANUAL
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations in the Text 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Types 9
2.2 Type of Use 9
2.3 Use in an Explosion Hazard Area 9
2.4 Safety Parameters 9
2.5 Processible Working Materials 10
2.6 Reasonably Foreseeable Misuse 11
2.7 Residual Risks 11
3 IDENTIFICATION 12
3.1 Explosion Protection Identi cation 12
3.2 Identi cation X 12
3.3 Type Plate 13
4 GENERAL SAFETY INSTRUCTIONS 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Equipment 14
4.1.2 Personnel Quali cations 14
4.1.3 Safe Work Environment 14
4.2 Safety Instructions for Sta 15
4.2.1 Safe Handling of WAGNER Spray Devices 15
4.2.2 Grounding the Device 16
4.2.3 Product Hoses 16
4.2.4 Cleaning and Flushing 17
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 18
4.2.6 Touching Hot Surfaces 18
5 DESCRIPTION 19
5.1 Components 19
5.2 Mode of Operation 19
5.3 Protective and Monitoring Equipment 20
5.4 Scope of Delivery 20
5.5 Data 21
5.5.1 Materials of Paint-wetted Parts 21
5.5.2 Technical Data 21
5.5.2.1 Technical Data 22
5.5.2.2 Measurements and Connections 23
5.5.3 Performance Diagrams 24
5.6 Pressure Regulator Unit 25
5.6.1 Safety and Motor Pressure Relief Valve 26
5.6.2 Return Valve 26
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6 ASSEMBLY AND COMMISSIONING 27
6.1 Training Assembly/Commissioning Sta 27
6.2 Storage and Installation Conditions 27
6.3 Transportation 27
6.4 Assembly and Installation 28
6.4.1 Ventilation of the Spray Booth 28
6.5 Grounding 29
6.6 Commissioning 31
7 OPERATION 33
7.1 Training the Operating Sta 33
7.2 Safety Instructions 33
7.2.1 General Rules for Making Adjustments to the Spray Gun 34
7.3 Emergency Stop 35
7.4 Spraying 36
7.5 Pressure Relief/Work Interruption 37
7.6 Basic Flushing 38
7.6.1 Filling with Working Material 39
8 CLEANING AND MAINTENANCE 40
8.1 Cleaning 40
8.1.1 Cleaning Sta 40
8.1.2 Safety Instructions 40
8.1.3 Decommissioning and Cleaning 41
8.1.4 Long-term Storage 41
8.2 Maintenance 42
8.2.1 Maintenance Sta 42
8.2.2 Safety Instructions 42
8.2.3 Regular Maintenance Work 43
8.2.4 Filling Separating Agent 43
8.2.5 Emptying the Pump 44
8.2.6 Filling the Empty Pump 46
8.2.7 Product Hoses, Tubes and Couplings 48
9 TROUBLESHOOTING AND RECTIFICATION 49
10 REPAIR 50
10.1 Repair Personnel 50
10.2 Mounting Materials 50
11 DISPOSAL 51
12 ACCESSORIES 52
12.1 EvoMotion 40-15 accessories 52
12.2 Accessories for Product Outlet 52
12.3 Accessories for Product Inlet 52
12.4 Wall Mount and Trolley 55
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13 SPARE PARTS 56
13.1 How Can Spare Parts Be Ordered? 56
13.2 Overview of the Components 57
13.3 Air Motor 58
13.3.1 Reversing Valve 61
13.4 Fluid Section 15 62
13.5 Air Regulator Set for EvoMotion 40-15 65
13.6 Air Regulator Set for AirCoat Air 66
13.7 Trolley 4" 67
13.8 4-Wheel Trolley 68
14 WARRANTY AND CONFORMITY DECLARATIONS 69
14.1 Important Notes Regarding Product Liability 69
14.2 Warranty Claim 69
14.3 CE Declaration of Conformity 70
14.4 Notes on German Regulations and Guidelines 70
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1 ABOUT THESE INSTRUCTIONS
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
sta .
Operating and service personnel 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 THESE INSTRUCTIONS
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
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
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 measures for preventing the danger and its
consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the danger and its consequences.
NOTICE
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 Order No. Language Order No.
German 2333557 English 2333558
French 2333559 Spanish 2333561
Italian 2333560 Hungarian 2352156
Russian 2367138
Additional languages on request or at:
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Double stroke
DN Nominal diameter
PN Nominal pressure
Two components
Materials
Stainless steel
Polyethylene
Ultra-high molecular weight
polyethylene
Polytetra uorethylene
PTFE with graphite
PTFE
Leather
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta quali cations
Trained person Is instructed in the tasks assigned to him/her, the potential
risks associated with improper behavior as well as the
necessary protective devices and measures.
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person A person who, based on his/her technical training, experience
In the context of
TRBS1203 (2010 /
Revision 2012)
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
and recent vocational experience, has su cient technical
knowledge and is familiar with the relevant and generally
accepted rules of technology so that he/she can inspect and
assess the status of devices and coating systems based on
workplace safety.
Additional requirements for skilled persons are given in
the TRBS1203(2010/Revision 2012): Expert knowledge in
the areas of protection against excessive pressure, electrical
hazards, and explosion protection (where applicable).
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2 CORRECT USE
2.1 DEVICE TYPES
Pneumatic pump with spraypack:
40-15
2.2 TYPE OF USE
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classi cation 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).
See Chapter 3.
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The pneumatic pump may only be operated under the following conditions:
The operating sta 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 WORKING MATERIALS
Application
Water-based products
Solvent-based products
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 products
Shear sensitive products
Humidity sensitive products
Legend
recommended limited suitability less suitable
NOTICE
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Do not use any grainy and abrasive working materials with large, sharp-edged
pigments.
Use the application-related model ( ow rate/cycle, material packaging, valve seat,
etc.), as speci ed in Chapter 5.5.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.5.1.
Wear caused by abrasive working materials is not covered by the warranty.
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2.6 REASONABLY FORESEEABLE MISUSE
The forms of misuse listed below may result in physical injury or property damage:
coating work pieces which are not grounded;
unauthorized conversions or modi cations to the pneumatic pump;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out 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 Speci c measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Lacquer in air
outside the de ned
working area
Handling of
lacquers and
cleaning agents
Lacquering outside
the de ned
working area
Skin irritation,
allergies
Inhalation of
substances
hazardous to
health
Use personal safety
equipment.
Observe safety data
sheets
Observe work and
operation instructions.
Use personal safety
equipment
Operation,
maintenance,
disassembly
Operation,
maintenance
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As de ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially
explosive areas.
CE CE mark (European Communities)
Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device (suitable for zone 1)
G Ex-atmosphere gas
c Constructional security
IIB Device class (Gas) IIB
T3 Temperature class T3: maximum surface temperature 200 °C; 392 °F
T4 Temperature class T4: maximum surface temperature 135 °C; 275 °F
X Special instructions exist for safe operation.
Chapter "Identi cation X".
See the following
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 lled with su cient working or ushing agent.
Ensure that the separating agent tank is lled with su cient separating agent.
Temperature class T3: No dry running protection
Temperature class T4: With dry running protection
Ignition temperature
Ensure that the ignition temperature of the surrounding gases (pumping product,
cleaning agents) is higher than the maximum permitted surface temperature of the
device.
Ambient temperature
The permissible ambient temperature is: +5 °C to +50 °C; +41 °F to +122 °F.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
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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 device against steel or rusty iron.
Do not drop the device.
Use only tools that are made of a permitted material.
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.
Use only a damp cloth to clean the device.
National regulations
Ensure that the national explosion prevention rules and regulations are observed when
setting up the device.
Air in the pump uid
Flammable gas mixtures can form if air reaches the pump uid.
Prevent the pump from taking in air and running dry.
If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until the
air has escaped.
Air in the pumped uid can be caused by damaged packings.
Avoid operating the pump with damaged packing.
Ensure that the separating uid tank is lled with su cient separating uid.
Periodically check that the pump is working smoothly, paying special attention to the
presence of air in the pumped uid.
Filling and emptying
Flammable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
3.3 TYPE PLATE
1 Manufacturer and CE
J. WAGNER AG
1
Pumpentyp / Pump type
2
Max. Materialdruck / Fluid pressure
3
Übersetzungsverhältnis / Ratio
4
Fördermenge DH / Delivery DS
5
Max. Luftdruck / Air pressure
6
Max. Temp. Material / Fluid
7
Baujahr - Serie Nr. / Year of manufacture - Serial No.
8
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
9
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
II 2 G c IIB T3/T4 X
Identi cation
2 Pump type
3 Maximum product pressure
4 Pump ratio
5 Flow rate per double stroke
6 Maximum air inlet pressure
7 Maximum product temperature
8 Model year - serial number
9 Read operating manual before use!
B_05439
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device 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 in uences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
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 or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground wire
connection.
Keep liquids away from electrical devices.
4.1.2 PERSONNEL QUALIFICATIONS
Ensure that the device is only operated, maintained and repaired by trained persons.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment is available and is used.
Ensure that all persons within the working area wear static dissipative shoes. Footwear
must comply with EN 20344. The measured insulation resistance must not exceed
100megohms.
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Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 megohms.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking tightness
strength and connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
Grounding
Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical
stress, corrosion).
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics application: Anyone tted with a pacemaker must not enter the high-
voltage area!
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 ushing 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:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
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If necessary or at least every 12 months, the liquid ejection devices should be checked for
safe working conditions by an expert (e.g., WAGNER Service Technician) in accordance
with the guidelines for liquid ejection devices (DGUV regulation 100-500).
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" 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 ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun brie y in a position.
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See chapter "Grounding".
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are wearing
static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the spray
gun handle.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
Ensure that the product hose is suitable for the pressure generated.
Ensure that the following information can be seen on the high-pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
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Make sure that the hoses are laid only in suitable places. Do not lay hoses:
- in high-traffic areas,
- on sharp edges,
- on moving parts or
- on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses are
never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coe cient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non- ammable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure that all
equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or
static dissipative and grounded.
Observe the speci cations of the paint manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.
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Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects and
never spray cleaning agents with a gun. Cleaning the device must not damage it in any
way.
Ensure that no electric component is cleaned with or immersed into solvent.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take the speci ed protective measures. In particular, use personal protective equipment:
safety goggles, protective clothing and gloves, as well as respiratory protection and
skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For su cient 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 products.
4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F: identify the unit with a warning label that says "Warning - Hot Surface".
- Instruction label Order no. 9998910
- Protection label Order no. 9998911
Note: Order the two stickers together.
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5 DESCRIPTION
5.1 COMPONENTS
1 Air motor
2 Air inlet
3 Mounting ange
4 Separating uid tank
5 Product outlet
6 Fluid section
7 Product inlet
8 Grounding connection
9 Reversing valve
10 Safety valve (air motor
vent)
11 Air pressure regulator
12 Ball valve
13 Air outlet to the
reversing valve
14 Air inlet into the
reversing valve
ORDER NUMBER DOC2333558
1
8
4
10
13
6
B_04121
7
5
11
2
3
9
8
12
14
7
5.2 MODE OF OPERATION
The piston pump is driven with compressed air (11). The compressed air moves the air
piston in the air motor (1) and the associated pump pistons in the uid section(6) up and
down. 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 product outlet (5) in both stroke directions.
Air motor (1)
The air motor 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 must 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.
Fluid section (9)
The uid section has been designed as a piston pump with exchangeable ball valves. The
hard chrome-plated pump piston runs in two xed packings which are self-adjusting by
means of a pressure spring, thus resulting in a long service life.
Between the air motor and the uid section there is a separating agent cup (4) for separating
the separating agent.
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5.3 PROTECTIVE AND MONITORING EQUIPMENT
Safety valve
The air motor is tted with a safety valve. The safety valve 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.
5.4 SCOPE OF DELIVERY
Pneumatic piston pump
Consists of:
- Fluid section
- Air motor
- Connection set for air motor - uid section
- Air pressure regulator for air motor
The scope of delivery also includes:
Separating agent 250 ml; 250 cc order no.: 9992504
Declaration of conformity see Chapter 14.3
Operating manual, German order no.: 2333537
Operating manual in the local language see Chapter 1.3
The delivery note shows the exact scope of delivery. Accessories: see Chapter 12.
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5.5 DATA
5.5.1 MATERIALS OF PAINTWETTED PARTS
Pump housing Stainless steel
Piston Stainless steel
Valve balls Stainless steel
Valve seats Stainless steel
Static seals PTFE
Packings
= Ultra high molecular weight polyethylene
PTFE (Polytetra uorethylene)
5.5.2 TECHNICAL DATA
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Air motor switching problems.
Provide water-free and oil-free compressed air
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5.5.2.1 TECHNICAL DATA
Description Units
Pump ratio 40:1
Volume ow per double stroke cm/cc 15
Maximum operating overpressure MPa 25.0
bar 250
psi 3626
Maximum possible strokes in operation /min. 60
Minimum/maximum air inlet pressure MPa 0.2-0.8
bar 2-8
psi 28-116
Quality standard 7.5.4 according to ISO 8573.1, 2010
Compressed air quality: free from oil and water
Ø air inlet connection (inside thread) mm; inch 8.0; 0.1
Minimum Ø of the compressed air supply line mm; inch 9.0; 0.35
Air consumption at 0.6 MPa; 6 bar; 87 psi per
double stroke
Air motor piston diameter mm; inch 80; 3.15
Air motor piston stroke mm; inch 60; 2.4
Sound pressure level at maximum permissible
air pressure*
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*
Product inlet (outside thread) mm M36x2
Product outlet (outside thread) inch NPS 1/4"
Weight kg 9
Product pH value pH 3.5 ÷ 9
Maximum product pressure at pump inlet
Product temperature °C; °F +5...+80; +41...+176
Ambient temperature °C; °F +5...+60; +41...+140
Relative humidity % 10–95 (without condensation)
Allowable inclination for operation
nl 3.9
scf 0.14
dB(A) 72
dB(A) 69
dB(A) 65
lb 19.8
MPa 2
bar 20
psi 90
7: Particle concentration 5–10mg/m
5: Humidity: pressure dew point ≤ +7 °C
4: Oil content ≤ 5mg/m
± 10
A rated sound pressure level measured at 1 m distance, LpA1m according to DIN EN 14462: 2005.
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OPERATING MANUAL
5.5.2.2 MEASUREMENTS AND CONNECTIONS
H1
L
A 104 4.09
B 108.5 4.27
C 621 24.45
D 276.5 10.89
E 134 5.28
F1 G 1/4"
F2 NPS 1/4"
G M36x2
H1 G 1/4"
H2 8 0.31
I 210 8.27
J 207 8.15
K 86 3.39
A
L 7 0.28
M 182 7.17
N 80 3.15
O 106 4.17
P 96.5 3.8
Q ø 9 ø 0.35
B
H2
R ø 7 ø 0.28
S 149 5.87
T ø 25 ø 1
K
J
I
E
F1
F2
Wall mount
S
N
C
T
R
D
Q
O
G
B_04120
M
M/2
P
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5.5.3 PERFORMANCE DIAGRAMS
Example
Product pressure bar (MPa) psi
"?
Water ow rate l/min <gpm>
Diagram EvoMotion 40-15
Stroke frequency /min
BAR
BAR
BAR
BAR
BAR
BAR
Air consumption nl/min <scfm>
bar (MPa)
<psi>
300 (30)
<4350>
240 (24)
<3480>
180 (18)
<2610>
120 (12)
<1740>
60 (6)
<870>
Product pressure
C_00054
Stroke frequency /min
10 20 30 40 50 60
0
A
B
C
0
0.60
0.45
0.30
0.15
0
<0.04>
<0.08>
<0.12>
<0.16>
Product ow - 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
0.75
<0.20>
A
B
C
0.90
<0.24>
nl/min
<scfm>
300
<11>
240
<8>
180
<6>
120
<4>
60
<2>
0
l/min
<gpm>
Air consumption
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5.6 PRESSURE REGULATOR UNIT
1 Pressure regulator
2 Ball valve
3 Pressure gauge (air inlet pressure)
4 Pressure gauge for AirCoat air (option)
5 Compressed air inlet
6 Pressure regulator AirCoat (option)
7 Safety and motor pressure relief valve
2
1
3
4
6
7
5
B_04122
Ball valve positions:
1 Open: working position
2 Closed: the air motor may still be under
pressure.
2
7
1
3
5
open
1
2
closed
B_04123
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5.6.1 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.
WARNING
Overpressure!
Risk of injury from bursting components.
Never change the safety valve setting.
10
Pressure relief of the air motor:
1 Close ball valve (2).
2 Pull back the ring on the safety
valve (10) and hold it there until the
pressure in the air motor has been
equalized.
5.6.2 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.
1 Product outlet
2 Return valve
3 Material return line
10
B_04124
2
2
1
B_04075
3
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6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF
The assembly and commissioning sta must have the technical skills to safely
commission the device.
When assembling, commissioning and carrying out all work, read and follow the
operating manuals and safety regulations for the additionally required system
components.
A skilled person must check to ensure that the device is in a reliable state after it is installed
and before commissioning.
6.2 STORAGE AND INSTALLATION CONDITIONS
Until the point of assembly, the device must be stored in a dry location, free from vibrations
and with a minimum of dust. The device must be stored in closed rooms. For speci cations
on temperatures and relative humidity, see Technical Data.
Long-term storage: Thoroughly clean the pump, if a long-term decommissioning is
planned. See Chapter "Cleaning". For recommissioning, proceed according to following
chapters.
6.3 TRANSPORTATION
The pump can be moved on a trolley or manually without lifting
equipment.
B_04065
WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
Position the trolley with the piston pump horizontally.
If the surface is inclined, position the feet of the trolley towards
the gradient.
Secure the trolley.
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6.4 ASSEMBLY AND INSTALLATION
Note:
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 Con gurator. The nozzles must be selected according to the gun instructions. In the case of
spraypack orders, the pump (1) is already pre-mounted on a trolley (6) or on a frame at the factory.
Procedure:
1 Mount pump (1) on frame, trolley (6) or wall mount.
2 Mount an AirCoat system with the pressure regulator (7) and secure the thread at the air inlet to the
pump (1) with Loctite 270.
3 Mount suction system (5).
4 Mount the return valve (8) for pressure relief or product circulation.
5 Mount return tube (4) or return hose.
6 Connect the high-pressure hose (2) and gun (3) in accordance with the gun operating manual.
Example:
Airless system
3
6
2
1
8
4
5
B_04076
6.4.1 VENTILATION OF THE SPRAY BOOTH
Example:
AirCoat system
3
2
5
7
1
8
4
6
B_04077
Observe the safety instructions in Chapter 4.1.3.
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 exhaust air speed.
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6.5 GROUNDING
Discharge of electrostatically charged components in
atmospheres containing solvents!
Explosion hazard from electrostatic sparks.
Clean the piston pump only with a damp cloth.
Ground all device components.
Ground the work pieces to be coated.
Heavy paint mist if grounding is insu cient!
Danger of poisoning.
Insu cient paint application quality.
ORDER NUMBER DOC2333558
WARNING
WARNING
Ground all device components.
Ground the work pieces to be coated.
Grounding scheme (example)
Paint tank
B_00304
Floor, static dissipative
Conveyor
Work piece
Spraying stand
R max < 1 M:
Cable cross sections
Pump 4 mm; Conveyor 16 mm;
Product tank 6 mm; Booth 16 mm;
Spraying stand 16 mm;
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Safe operation of the EvoMotion pump is only guaranteed with a ground
connection.
Connect all ground cables using a short and direct route.
Procedure:
1. Ground the pump, connect the grounding cable to
potential equalization on-site.
2. Ground the product tank.
3. Ground the other parts of the system to an on-site
grounding connection. 16 mm;
Ex zone
All devices and equipment must be suitable for use in
potentially explosive areas.
Tank
All paints, ushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
Grounding cable
B_04127
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6.6 COMMISSIONING
Observe all safety regulations in accordance with Chapter 4 and Chapter 7.2.
Emergency stop, see Chapter7.3.
Preparation
Before every start-up, the following points should be observed as laid down in the
operating manual:
- Secure gun with safety clip.
- Check the permissible pressures.
- Check all connections for leaks.
- Check hoses for damage in accordance with Chapter 8.2.9.
Fill the pump with ushing agent
The devices are tested during manufacturing with emulsifying oil, pure oil or solvent.
Possible residues must be ushed out of the circuits with a solvent ( ushing agent) before
commissioning.
- Fill the separating agent in accordance with Chapter 8.2.4.
- Fill the empty device with ushing agent in accordance with Chapter 8.2.7.
Pressure tightness test
- Gradually increase the pressure in pump with the pressure regulator until maximum
pressure is reached. Maintain the pressure for 3 minutes and check all connection
points for leaks.
- Depressurization in accordance with Chapter 7.5.
Filling with working material
- In accordance with Chapter 7.6.1.
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Before every start-up, the following points should be observed as laid down in the operating manual:
- Check the permissible pressures.
- Check all connections 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 uid section.
10
closed
10
2
open
B_04124
C_00157
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OPERATING MANUAL
7 OPERATION
7.1 TRAINING THE OPERATING STAFF
The operating sta must be quali ed and t to operate the entire system.
The operating sta must be familiar with the potential risks associated with improper
behavior as well as the necessary protective devices and measures.
Before work commences, the operating sta must receive appropriate system training.
7.2 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 in accordance with Chapter 6.6.
WARNING
Incorrect operation!
Risk of injury and damage to the device.
If contact with lacquers or cleaning agents causes skin irritation,
appropriate precautionary measures must be taken, e.g.,
wearing protective clothing.
The footwear worn by operating sta must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100 megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
WARNING
Unintentional putting into operation!
Risk of injury
Before any work on the device, in the event of work interruptions
and malfunctions:
Relieve the pressure from the spray gun and unit.
Secure the spray gun against actuation.
Switch o the energy/compressed air supply.
Disconnect the control unit form the network.
In the event of functional faults: remedy the fault as described in
the "Troubleshooting" chapter.
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WARNING
Gas mixtures can explode if there is an incompletely filled
pump!
Danger to life from ying parts.
Ensure that the pump and suction system are always completely
filled with ushing agent or working material.
Do not spray the device empty after cleaning.
7.2.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN
Observe the operating manual of the spray gun.
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 immediately.
Use personal protective equipment (protective clothing, gloves,
eyewear and respiratory protection).
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7.3 EMERGENCY STOP
ORDER NUMBER DOC2333558
In the case of unexpected processes, close the ball
valve (2) immediately, open safety valve (10) and
depressurize the parts carrying the product via the
return valve (3).
2
3
B_04078
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OPERATING MANUAL
7.4 SPRAYING
1 Secure the gun and insert the nozzle into the gun.
2 Close return valve (3).
3 Slowly open the ball valve (2).
4 Set required working pressure on the pressure regulator (1).
5 Optimize the spraying results according to the data in the gun operating manual.
6 Start work process.
System example
EvoMotion 40-15 for
AirCoat procedure
closed
open
8
1
2
9
7
3
4
6
5
B_04080
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OPERATING MANUAL
7.5 PRESSURE RELIEF/WORK INTERRUPTION
Pressure relief of the product
1 Close the spray gun.
2 Close ball valve (2).
3 Relieve the system pressure, either by opening the gun or by opening the return
valve (3).
4 Close and secure gun.
5 Open and close the return valve (3) to completely depressurize the system.
Pressure relief of the air (in case of longer work interruptions)
1 Carry out pressure relief of the product (as mentioned above).
2 Ensure that the ball valve (2) is closed.
3 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
B_04124
If the system has been used with 2K products:
2
NOTICE
Hardened working material in the spraying system when 2K product 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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7.6 BASIC FLUSHING
Before each basic ushing, the nozzle must be removed from the gun. The data in the gun's operating manual
are to be observed.
With AirCoat systems, carry out the basic ushing of the system without atomizing air (8).
1. Visual check: personal safety equipment, grounding and all devices ready to use.
2. Place empty tank (5) under return tube (4).
3. Place suction hose (7) in the tank with ushing agent (6).
4. Open return valve (3).
5. Slowly open the ball valve (2).
6. Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly.
7. Flush the system until clean ushing agent ows into the tank (5).
8. Close ball valve (2).
9. Close return valve (3).
10. Point the gun (9), without nozzle, into tank (5) and open it.
11. Slowly open the ball valve (2).
12. Rinse until clean ushing agent ows from the gun.
13. Close ball valve (2).
14. Relieve the system pressure, either by opening the return valve (3) or via the trigger on the gun (9).
15. When there is no pressure remaining in the system, close the gun (9) or the return valve (3).
16. Secure the gun.
17. Dispose of the contents of the tank (5) according to the local regulations.
closed
open
1
8
2
Flush regularly
Regular ushing, cleaning and
maintenance ensures the pumps' high
pumping and suction capacity.
7
Hardener pumps in 2K systems
Do not ush hardener pumps with
water, rather only using suitable
3
ushing agents (solvents).
4
6
9
5
B_04079
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7.6.1 FILLING WITH WORKING MATERIAL
After basic ushing, the system can be lled with working material.
Proceed according to Chapter 7.6, but use working material instead of ushing agent.
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8 CLEANING AND MAINTENANCE
8.1 CLEANING
8.1.1 CLEANING STAFF
Cleaning work should be undertaken regularly and carefully by quali ed and trained sta .
They should be informed of speci c hazards during their training.
The following hazards may arise during cleaning work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable cleaning tools and aids
8.1.2 SAFETY INSTRUCTIONS
Clean the piston pump only with a damp cloth.
Observe safety instructions in Chapter 4.
DANGER
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 unit.
Before all work on the device and in the event of work
interruptions:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
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OPERATING MANUAL
8.1.3 DECOMMISSIONING AND CLEANING
The device should be cleaned for maintenance purposes. Ensure that no remaining
product dries on and sticks to the device.
1. Carry out work interruption Chapter 7.5.
2. Carry out basic ushing in accordance with Chapter 7.6.
3. Empty the pump in a controlled manner in accordance with Chapter 8.2.6.
4. Maintain the gun according to the operating manual.
5. Clean and check the suction system and the suction lter.
6. When using a material lter, check lter insert and lter housing and clean or replace
them. Chapter 8.2.8.
7. Clean the outside of the system.
WARNING
Brittle lter pressure regulator!
The tank on the lter pressure regulator becomes brittle through
contact with solvents and can burst.
Flying parts can cause injury.
Do not clean the tank on the lter pressure regulator with
solvents.
8. Fully assemble the system.
9. Check ll level of the separating agent Chapter 8.2.4.
10. Fill the system with ushing agent in accordance with Chapter 8.2.7.
WARNING
Gas mixtures can explode if there is an incompletely filled
pump!
Danger to life from ying parts.
Ignition of potentially explosive surrounding atmosphere.
Ensure that the pump and suction system are always completely
filled with ushing agent or working material.
Do not spray the device empty after cleaning.
8.1.4 LONGTERM STORAGE
When storing the device for longer periods of time, it is necessary to thoroughly clean it
and protect it from corrosion. Replace the water or solvent in the product pump with a
suitable preservative, ll separating agent cup with separating agent.
Procedure:
1. Carry out points 1 to 9 of Chapter 8.1.3 "Decommission and clean".
2. Fill the system with preservative in accordance with Chapter 8.2.7.
3. Empty the pump in a controlled manner in accordance with Chapter 8.2.6 and seal the
openings.
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8.2 MAINTENANCE
8.2.1 MAINTENANCE STAFF
Maintenance work should be undertaken regularly and carefully by quali ed and trained
sta . They should be informed of speci c hazards during their training.
The following hazards may arise during maintenance work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable tools and aids
An authorized person must ensure that the device is checked for being in a reliable state
after maintenance work is completed.
8.2.2 SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 8.1.2.
Prior to maintenance
It should be ensured that the device is in the following state before carrying out any work
on it:
- Release pressure from the pump, high-pressure hose and gun.
- The gun should be secured with the safety clip.
- The air supply should be interrupted.
After maintenance
- Commissioning in accordance with Chapter 6.6.
In accordance with DGUV regulation 100-500 (BGR 500 Chapter 2.29 and 2.36):
- The liquid ejection devices should be checked by an expert (e.g., WAGNER service
technician) for their safe working conditions as required and at least every
12months.
- For shut down devices, the examination can be suspended until the next start-up.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Repair or replacement of devices or parts of devices are only
allowed to be performed outside the hazard area by quali ed
personnel.
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OPERATING MANUAL
8.2.3 REGULAR MAINTENANCE WORK
1. Check the level of separating agent in the separating agent cup every day, and top
up if necessary.
2. Check and clean the high-pressure lter every day or as required (see Chapter 8.2.8.).
3. Every shut down should be carried out as laid down in Chapter 8.1.3!
4. Check hoses, pipes, and couplings every day and replace if necessary.
If the pump has to be emptied for maintenance work, proceed according to
Chapter8.2.6.
The service manual is available in German and English.
For order number see Chapter 1.3.
8.2.4 FILLING SEPARATING AGENT
NOTICE
Piston pump dry run!
High wear/damage to the packings.
Paint or solvent can escape if the seals are dry.
Ensure that the separating uid tank is lled with su cient separating uid. Filling
level 1 cm; 0.4 inch under the cup edge.
Place the supplied separating agent into the separating agent cup.
Filling level: 1 cm; 0.4 inch under the cup edge.
Separating agent: Order no. 9992504
Inclination angle of the pump
Maximum permissible inclination of pump for moving, transportation,
etc. after lling it with separating agent ±30°.
The pump must be vertical during operation.
B_03918
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OPERATING MANUAL
8.2.5 EMPTYING THE PUMP
WARNING
Gas mixtures can explode if there is an incompletely filled
pump!
Danger to life from ying parts.
Ignition of potentially explosive surrounding atmosphere.
Empty the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
If the pumping product becomes heated, switch o all heaters and let the product
cool o .
1. Visual check: personal safety equipment, grounding and all devices ready to use.
2. Carry out basic ushing in accordance with Chapter 7.6.
3. Place grounded collection tank (5) under the return tube (4).
4. Place the suction hose (7) in an empty, grounded tank (6).
5. Close pressure regulator (1) (0MPa; 0bar; 0psi).
Empty using return line
6. Open return valve (3).
7. Slowly open the ball valve (2).
8. Slowly turn air pressure up on the pressure regulator (1) and only until the pump is
running normally (approx. 0.05 MPa; 0.5 bar; 7.25 psi).
9. Be ready for the switch from working material to air. Turn down pressure regulator
(1) far enough that the pump is still running normally (approx. 0–0.05MPa; 0–0.5bar;
0–7.25psi).
10. As soon as working material is no longer owing from the return tube (4), close ball
valve (2).
11. Close return valve (3).
Empty up to the gun
12. Point the gun, without nozzle, into tank (5) and open it.
13. Slowly open the ball valve (2). Be ready for the switch from working material to air.
14. As soon as working material is no longer owing from the return tube, close the ball
valve (2).
15. Close and secure gun.
16. Depressurization in accordance with Chapter 7.5.
17. Dispose of the contents of the tank (5) according to the local regulations.
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closed
open
7
ORDER NUMBER DOC2333558
1
8
2
System example
EvoMotion 40-15 for the
AirCoat procedure.
3
4
6
9
5
B_04079
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OPERATING MANUAL
8.2.6 FILLING THE EMPTY PUMP
Note:
Before each lling, the nozzle must be removed from the gun. The data in the gun's
operating manual are to be observed.
In case of AirCoat systems, carry out the lling of the system without atomizing air (8).
1. Place empty tank (5) under return tube (4).
2. Place suction hose (7) in the tank with working material (6).
3. Open return valve (3).
4. Slowly open the ball valve (2).
5. Adjust the air pressure on the pressure regulator (1) so that the pump runs
smoothly.
6. Spray until clean working material ows into the tank (5).
7. Close ball valve (2).
8. Close return valve (3).
9. Point the gun (9), without nozzle, into tank (5) and open it.
10. Slowly open the ball valve (2).
11. Spray until clean working material ows 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 tank (5) according to the local regulations.
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closed
open
7
ORDER NUMBER DOC2333558
1
8
2
System example
EvoMotion 40-15 for the
AirCoat procedure.
3
4
6
9
5
B_04079
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OPERATING MANUAL
8.2.7 PRODUCT HOSES, TUBES AND COUPLINGS
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of product and from ying parts.
Ensure that the hose material is chemically resistant to the
sprayed products and the used ushing agents.
Ensure that the spray gun, threaded joints, and product hose
between the device and the spray gun are suitable for the
generated pressure.
Ensure that the following information can be seen on the hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
The service life of the complete hoses between product pressure generator and application
device is reduced due to environmental in uences even when handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
Before every commissioning, check all connections for leaks.
Additionally, the operator must regularly check the complete hoses for wear and tear
as well as for damage at intervals that he/she has set. Records of these checks must
be kept.
Undamaged complete hoses are to be replaced when one of the two following
intervals has been exceeded:
– 6 years from the date of the hose crimping (see tting embossing).
– 10 years from the date of the hose imprinting.
Fitting
embossing
(if present)
xxx bar Pressure
yymm
XX Internal code
Meaning
Crimping date
(year/month)
Hose imprinting Meaning
WAGNER
yymm
xxx bar (xx MPa)
e.g., 270 bar (27
MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
Name /
Manufacturer
Date of
manufacture (year/
month)
Pressure
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9 TROUBLESHOOTING AND RECTIFICATION
Problem Cause Remedy
The pump does not
work
Poor spray pattern See the gun instructions.
Irregular operation of
the pump: spray jet
collapses (pulsation)
The pump runs
smoothly but does not
suck up any product
Pump runs when the
gun is closed
The air motor is iced upThere is a lot of condensation water
Air motor does not work or stops. Open and close ball valve on the pressure
regulator unit or brie y disconnect
compressed air supply.
No pressure indication on the
pressure gauge (air pressure
regulator defective).
Spray nozzle is clogged. Clean the nozzle according to the
Insu cient compressed air supply. Check compressed air supply.
Filter insert in spray gun is clogged. Clean the parts and use a suitable working
Fluid section or high-pressure
hose are blocked (e.g., 2K product
hardened).
Sometimes, the pump stops at a
switching point.
Viscosity is too high. Thin spraying product.
Spraying pressure is too low. Increase incoming air pressure.
Valves are clogged. Clean pump, if necessary leave it to soak in
Foreign body in suction valve. Dismantle suction valve housing, clean and
Diameter of compressed air line too
small.
Valves, packings, or pistons are worn
out.
Pressure regulator lter is clogged. Check lter and clean it if necessary.
The suction system's union nut is
loose; the pump is taking in air.
Suction lter is clogged. Clean lter.
Ball in suction or piston valve is stuck. Clean balls and valve seats.
Packings, valves, or pistons are worn
out.
in the air supply.
Disconnect compressed air supply brie y or
repair or change pressure regulator.
instructions.
material.
Dismount and clean uid section, replace
high-pressure hose.
Press the starter on the reverse valve and
restart the pump.
Clean the slide on the reversing valve
carefully and if necessary lubricate it with a
light layer of oil.
Use a smaller nozzle.
solvent.
check valve seat.
Assemble a larger incoming line
-> Technical Data, Chapter 5.3.2.
Replace the parts.
Tighten union nut.
Replace the parts.
Install a water separator.
If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service
Center.
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OPERATING MANUAL
10 REPAIR
10.1 REPAIR PERSONNEL
Repair work should be undertaken carefully by quali ed and trained personnel. They
should be informed of speci c hazards during their training. The repairs must be carried
out in accordance with the corresponding service manual.
The following hazards may arise during repair work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable tools and aids
A skilled person must check to ensure that the device is in a reliable state after it is repaired.
10.2 MOUNTING MATERIALS
In Chapter 13 the order numbers for device spare parts can be found, as well as for wearing
parts such as seals.
Use torques, greases and glues in accordance with Chapter 13.
Mounting materials
Order No. Quantity Designation Smaller tanks
9992590 1 pc ≙ 50 ml Loctite 222
9992511 1 pc ≙ 50 ml Loctite 243
9992528 1 pc ≙ 50 ml Loctite® 270
9992831 1 pc ≙ 50 ml Loctite 542
9998808 1 pc ≙ 18 kg ! Mobilux EP 2 grease 400 g tube ≙ Order no. 2355418
9992616 1 pc ≙ 1 kg can Molykote DX grease 50 g tube ≙ Order no. 2355419
9992609 1 pc ≙ 100 g Anti-seize paste
9992816 1 pc ≙ 70 g Miranit contact adhesive
Brand notice
The brands speci ed in this document are property of the respective owners. Loctite , for
example, is a registered brand of Henkel.
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OPERATING MANUAL
11 DISPOSAL
When the equipment must be scrapped, please di erentiate the disposal of the waste
materials.
The following materials have been used:
Steel Aluminum Plastics Carbide
Consumable products
Consumable products (lacquers, adhesives, ushing and cleaning agents) must be
disposed of in accordance with all applicable legal requirements.
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12 ACCESSORIES
12.1 EVOMOTION 4015 ACCESSORIES
Order No. Designation
1 2329450 EvoMotion 40-15 PE/T
2 T6145.00A AirCoat regulator set
3 236219 Grounding cable, complete 3 m; 9.8 ft
4 9992504 Separating agent 250 ml
5 9992505 Separating agent 500 ml
= Wearing part
12.2 ACCESSORIES FOR PRODUCT OUTLET
Order No. Designation
11 2334488 Ball valve R1/4"-G1/4"-PN350-SSt
12 2334472 Ball valve R1/4"-G1/4"-PN350-CS
13 2331752 Return tube DN6-G1/4"-100mm-PA
14 2329046 Return hose DN6-PN310-G1/4"-PA
= Wearing part
12.3 ACCESSORIES FOR PRODUCT INLET
Order No. Designation
15 2324158 Suction tube DN16-SSt, complete
16 2324110 Suction hose DN16-SSt, complete
17 2323225 Suction elbow for top reservoir SSt
18 2332169 Top reservoir set, 5 l for piston pump
19 2323396 Suction lter DN16-18mesh-SSt
Wearing part
52
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ORDER NUMBER DOC2333558
3
14
11
x
1
12
13
x
4/5
2
15
18
16
17
19
B_04081
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ORDER NUMBER DOC2333558
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OPERATING MANUAL
12.4 WALL MOUNT AND TROLLEY
Order No. Designation
21 2332143 Wall mount 4", complete
22 2332374 4-leg stand
23 T6196.00 Trolley, 4 wheels
24 2325901 Trolley 4", complete
22
21
23
24
B_04113
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13 SPARE PARTS
Observe "Repair" chapter: Repair personnel and mounting materials.
DANGER
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 unit.
Before all work on the device and in the event of work
interruptions:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
13.1 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 list. 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:
- Address for the invoice
- Address for delivery
- Name of the person to be contacted in the event of any queries
- Type of delivery (normal mail, express delivery, air freight, courier, etc.)
Identi cation in spare parts lists.
Explanation of column "
Wearing parts
Note: These parts are not covered by warranty terms.
Not part of standard equipment, available, however, as additional extra.
" (labeling) in the following spare parts lists:
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13.2 OVERVIEW OF THE COMPONENTS
Order No. Designation
1 1 2329450 EvoMotion 40-15 PE/T
2 1 2329635 Fluid section 15 PE/T EM
3 1 U3B08018060 Air motor M80 EM
4 1 A359.71A Spacer
5 1 E516.71A Safety xture spacer
6 2 9900353 Hexagon socket cylinder head screw
7 1 2332394 Holder plate
8 4 9920106 Washer
9 4 9900330 Hexagon socket cylinder head screw
10 3 3055157 Hexagon nut with clamp
11 3 H115.62 Tie rod
12 1 T6140.00A Pump air regulator set
13 1 9998253 Male stud elbow 8-1/4
13
12
3
7
8
20 Nm; 14.7 lbft
1
9
4
6
5
11
2
10
30 Nm; 22.1 lbft
B_04135
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13.3 AIR MOTOR
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may
Only repair and replace parts that are listed in the "Spare parts"
Before all work on the device and in the event of work
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
ORDER NUMBER DOC2333558
DANGER
carry out repairs and replace parts.
chapter and that are assigned to the unit.
interruptions:
Air motor spare parts list EM M80
Order No. Designation
1 1 U3B08018060 Air motor EM M80
2 1 F132.91C Motor ange, upper, M50 EM
3 2 L108.06 O-ring
4 1 D608.81 Cylinder motor
5 1 3055157 Hexagon nut with clamp
6 1 9920106 Washer
7
8 1 L413.06 Gasket DE 80
9 1 A164.01 Motor piston
10 1 L802.08 Sliding ring
11 1 L110.06 O-ring
12 1 D404.12 Piston rod, M80 EM
13
14 1 A408.12 Air tube, M80 EM
15 1 T616.00C Motor ange, complete M80 EM, at bottom
16
17 1 367258 Grounding, complete
18
19
20 2 K606.02 Lock washer for shaft
21 1 A160.01A Washer
= Wearing parts
= Included in service set.
= Not part of the standard equipment but available as an accessory.
2 G903.06 Steamer
2 L109.06 O-ring
1 P498.00KNE Reversing valve ISO N/1 (spare parts list see
Chapter 11.3.1.)
1 L403.06 Rod seal
1 2339340 Sensor below, M80
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ORDER NUMBER DOC2333558
30 Nm; 22 lbft
28
2
3
29
4
5
6
7
35 Nm; 25.8 lbft
30
29
8
9
29
13
30
7
29
1
10
11
13
4.5 Nm; 3.3 lbft
14
29
3
29
17
B_03431
27
20 Nm; 14.7 lbft
29
18
15
22
12
20
16
24
19
27
25
23
Installation instructions:
Mount piston rod (12) always
from bottom to top by the
assigned rod seal (18).
21
20
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OPERATING MANUAL
Air motor spare parts list EM M80
Order No. Designation
22 1 2341115 Pilot valve
23 1 9992757 Threaded elbow tting
24 2 H505.07 Silencer
25 1 M432.00 Reducing tting
27 1 9992831 Loctite® 542
28 4 9907241 Hexagon socket cylinder head screw
29 1 9998808 Mobilux® EP 2 grease
30 1 9998157 Loctite® 480
1 T910.00 Service set EM Air motor M80
= Wearing parts
= Included in service set.
= Not part of the standard equipment but available as an accessory.
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13.3.1 REVERSING VALVE
1
ORDER NUMBER DOC2333558
4
2
3
B_03139
Spare parts list for the reversing valve, 40-15
Order No. Designation
1 1 G498.00 Reversing valve
2 6 9971123 O-ring
3 1 G521.00 Reversing valve gasket
4 2 G520.00 Steamer
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13.4 FLUID SECTION 15
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 unit.
Before all work on the device and in the event of work
interruptions:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
ORDER NUMBER DOC2333558
DANGER
Spare parts list for uid section 15
No. Designation
1 1 2329635 Fluid section 15 SS PE/T EM
2 1 A661.12 Connecting ange 15
3 1 K617.03 Snap ring
4 1 A662.12 Snap ring ange 15
5
6 1 H204.03 Spring, upper
7 1 A658.03 Tube 15
8 1 H203.03 Spring
9
10 2 L107.06 O-ring
11 1 B534.03 Cylinder 15
12 1 T6157.00I Piston 15 SS
13 1 A170.03 Support spring
14 1 K801.03 Ball
15 1 A169.03 Valve screw 15
16 1 K803.03 Ball
17 1 K601.03 Securing ring
18 1 2323838 Inlet housing 15
19 1 9992831 Loctite 542
20 1 A171.03 Support ring, outside
21 1 A172.03 Support ring, inside
22 1 A411.03 Support ring, inside
23 1 A410.03 Support ring, outside
= Wearing parts
= Included in service set.
= Not part of the standard equipment but available as an accessory.
1 T9037.00E Packing PE/T 13/25
1 T9038.00E Packing PE/T 18/29
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ORDER NUMBER DOC2333558
24
30 Nm; 22.1 lbft
25
25
22
8
26
26
9
29
36
2.5 Nm; 1.84 lbft
2
30
3
30
4
23
20
27
28
27
28
30
1
27
27
27
27
28
28
28
5
30
10
31
11
21
12
6
33
34
B_03445
35
35
7
14
19
15
13
30
10
17
16
31
18
32
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OPERATING MANUAL
Spare parts list for uid section 15
No. Designation
24 1 T6158.00 Connector
25 2 G101.05 Sealing collar T 18/29
26 2 G101.08E Sealing collar PE 18/29
27 6 G104.05 Sealing collar T 13/25
28 5 G104.08E Sealing collar PE 13/25
29 1 9900136 Hexagon screw without shaft
30 1 9998808 Mobilux® EP 2 grease
31
32 1 2329898 Sealing sleeve
33 1 B0461.03A Fitting-DF-MM-R1/4"-1/4"NPS-PN350
34 1 2323718 Hexagon plug
35 1 9992528 Loctite® 270
36 1 9992590 Loctite® 222
= Wearing parts
= Included in service set.
= Not part of the standard equipment but available as an accessory.
1 9992609 Anti-seize paste
1 T9039.00E Service set EM 15 PE/T
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13.5 AIR REGULATOR SET FOR EVOMOTION 4015
14
14
14
14
8
9
4
5
1
13
14
2
10
3
11
B_04117
1 1 T6140.00A Pump air regulator set
2 2 9906026 Hexagon socket cylinder head screw
3
4 1 9985682 Reducer
5 1 9998039 Screw-in connection's elbow
8
9 1 P484.00C1 Safety valve 1/4"
10 1 M297.00 T-connection
11 1 9992743 Straight threaded tting
12 0.32 m 9982078 Hose, black AD8 x 1,25 (0.32 m; 1.05 ft long)
13
14 1 9992831 Loctite® 542
= Wearing parts
1 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi (d40)
1 M101.00 Ball valve, FM
1 P124.00M Filter regulator, CZ 1/4
12
Order No. Designation
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OPERATING MANUAL
13.6 AIR REGULATOR SET FOR AIRCOAT AIR
7
4
5
1
7
B_03436
Order No. Designation
1 1 T6145.00A AirCoat regulator set
2 1 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi (d40)
3 1 9992129 Elbow with taper
4 1 9998719 Detachable double tting
5 1 9985694 T-piece
6 1 G123.00 Air pressure regulator, 1/4”
7 1 9992528 Loctite® 270
= Wearing parts
2
6
7
3
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13.7 TROLLEY 4"
ORDER NUMBER DOC2333558
15
2
Distance
13
14
5
17
10
4
9
5
16
6
1
3
A
11
12
B_04074
7
8
Designation Order No.
1 1 Trolley, complete 2325901
2 1 Frame left 4" (welded) -3 1 Frame right 4“ (welded) -4 4 Hexagon screw DIN931 M6x75 9907140
5 6 Self-locking hexagon nut, M6 9910204
6
2 Wheel, D250 2304440
7 4 Washer 340372
8 4 Cotter pin 9995302
9 1 Wheel axle 4“ --
10
2 Connecting part 4“ 367943
11 2 Tube plug, ribbed -12 2 Saddle feet for round tubes -13 2 Plug -14 4 Hexagon screw 9900218
15 1 Wall mount 2332143
16 2 Hexagon screw without shaft M6x55 3061695
17
2 Handle 9998747
= Wearing parts
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13.8 4WHEEL TROLLEY
12
2
13
1
10
ORDER NUMBER DOC2333558
4
3
8
5
6
9
11
7
B_03439
14
Order No. Designation
1 1 T6196.00 Trolley, 4 wheels
2 5 9910204 Hexagon nut with clamp
3 1 E3107.92B Frame, right
4 1 E3107.92C Frame, left
5 1 H009.62 Spray gun hook
6 1 H1156.62 Frame pin
7 4 R204.07 Plug
8 4 3155404 Contact washer, M08
9 4 9920106 Washer
10 4 R120.00F Wheel
11 4 9900311 Hexagon socket cylinder head screw
12 4 9900389 Hexagon socket cylinder head screw
13 2 9900309 Hexagon socket cylinder head screw
14 4 3055157 Hexagon nut with clamp
= Wearing parts
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14 WARRANTY AND CONFORMITY DECLARATIONS
14.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY
As a result of an EC regulation e ective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
The manufacturer will not be held liable or will only be held partially liable if third-party
accessories or spare parts have been used.
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety
regulations are complied with.
14.2 WARRANTY CLAIM
Full warranty is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 36 months
in single-shift, 18 months in double-shift or 9 months in triple-shift operation from date
of receipt by the purchaser are found to be wholly or substantially unusable due to causes
prior to the sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see t. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the device to a location other
than the address of the purchaser.
We do not provide warranty for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute products and the in uence of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust
paints and so forth reduce the service life of valves, packings, spray guns, nozzles, cylinders,
pistons etc. Wear and tear due to such causes are not covered by this warranty.
Components that have not been manufactured by WAGNER are subject to the original
warranty of the manufacturer.
Replacement of a component does not extend the period of warranty of the device.
The device should be inspected immediately upon receipt. To avoid losing the warranty,
we or the supplier company are to be informed in writing about obvious faults within
14days upon receipt of the device.
We reserve the right to have the warranty compliance met by a contracting company.
The services provided by this warranty are dependent on evidence being provided in the
form of an invoice or delivery note. If the examination discovers that no warranty claim
exists, the costs of repairs are charged to the purchaser.
It is clearly stipulated that this warranty claim does not represent any constraint on statutory
regulations or regulations agreed to contractually in our general terms and conditions.
J. Wagner AG
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14.3 CE DECLARATION OF CONFORMITY
Herewith we declare that the supplied version of pneumatic pumps and their spraypacks
complies with the following guidelines:
2006/42/EC 94/9/EC
Applied standards, in particular:
Applied national technical standards and speci cations, in particular:
Part 2 Chapter 2.29 and Chapter 2.36
Identi cation:
EC Certi cate of Conformity
The CE certi cate 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
II 2G IIB c T3/T4 X
T3: Without dry running protection.
T4: With dry running protection.
14.4 NOTES ON GERMAN REGULATIONS AND GUIDELINES
Part 2, Chapter 2.36 Working with Liquid Ejection Devices
Part 2, Chapter 2.29 Working with Coating Products
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.
70
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E
R
T
I
F
I
E
D
Order No. 2333558
Edition 12/2015
Germany
Phone
Telefax
E-mail
Switzerland
Phone
Telefax
More contact addresses on the internet at:
Document No. 11147042
Version A
Company/Locations/WAGNER worldwide
Subject to changes without notice
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