WAGNER Leopard 48-110, Wildcat 10-70, Leopard 35-150, Puma 28-40, Jaguar 75-150 Translation Of The Original Operating Manual
...
Wildcat 10-70 / 18-40
Puma 28-40 / 15-70
Puma 21-110 / 15-150
Leopard 35-70
Leopard 35-150 / 48-110
Jaguar 75-150
IceBreaker Piston Pumps
3
Flow rate 40 cm3 – 150 cm
Version 08/2018
B_06985
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 6
1.4 Service Manual 7
1.5 Abbreviations 7
1.6 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Types 8
2.1.1 Pneumatic Pumps and Their Spraypacks 8
2.1.2 Special Versions for Acidic Hardeners and Their Spraypacks 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 8
2.4.1 Special Versions for Acidic Hardeners 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Identication "X" 10
3.3 Type plates 11
4 BASIC SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 13
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Spray Devices 14
4.2.3 Grounding the Unit 14
4.2.4 Product hose 15
4.2.5 Cleaning and Flushing 16
4.2.6 Touching Hot Surfaces 16
4.2.7 Maintenance and Repair 17
4.2.8 Protective and Monitoring Equipment 17
5 DESCRIPTION 18
5.1 Components 18
5.2 Mode of Operation 18
5.2.1 Air motor 18
5.2.2 Fluid section 18
5.3 Protective and monitoring equipment 19
5.4 Included Items 19
5.5 Data 19
5.5.1 Materials of Paint-wetted Parts 19
5.5.2 Recommended Packings 20
5.5.3 Technical Data for Wildcat and Puma 21
5.5.4 Measurements and Connections for Wildcat and Puma 22
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5.5.5 Technical Data for Leopard and Jaguar 23
5.5.6 Measurements and Connections for Leopard and Jaguar 24
5.5.7 Volume Flow 25
5.5.8 Performance diagrams 25
5.6 Operating elements 28
5.6.1 Pressure Regulator Unit 28
5.7 Product Filter and Return Line 28
5.7.1 High-pressure Filter (Option) 28
5.7.2 Relief Combination and Inline Filter up to 270 Bar (Option) 29
5.8 Stroke Count (Option) 29
5.9 Feed Pump (Option) 30
6 ASSEMBLY AND COMMISSIONING 31
6.1 Training of Assembly/Commissioning Personnel 31
6.2 Storage Conditions 31
6.3 Installation Conditions 31
6.4 Transportation 31
6.5 Assembly and Installation 32
6.5.1 Ventilation of the Spray Booth 33
6.5.2 Air Supply Lines 33
6.5.3 Product supply lines 33
6.6 Grounding 33
6.7 Commissioning 35
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
7 OPERATION 36
7.1 Training the Operating Personnel 36
7.2 Emergency Stop 36
7.3 Tasks 36
7.4 Pressure Relief/Work Interruption 37
7.5 Basic Flushing 38
7.6 Filling with Working Material 38
8 CLEANING AND MAINTENANCE 39
8.1 Cleaning 39
8.1.1 Cleaning Personnel 39
8.1.2 Decommissioning and Cleaning 39
8.1.3 Long-term Storage 39
8.2 Maintenance 40
8.2.1 Maintenance Personnel 40
8.2.2 Maintenance Instructions 40
8.2.3 Safety Checks and Maintenance Intervals 41
8.2.4 Emptying Pump 43
8.2.5 Filling the Empty Pump 44
8.2.6 Cleaning and Replacing the Filter 45
9 TROUBLESHOOTING AND RECTIFICATION 47
10 REPAIR WORK 48
10.1 Repair Personnel 48
10.2 Repair Notes 48
10.3 Tools 48
10.4 Cleaning the Parts After Disassembly 49
10.5 Assembly of the Device 49
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IceBreaker 40-150 cm3
11 FUNCTION TEST AFTER REPAIR WORK 50
12 DISPOSAL 50
13 ACCESSORIES 52
13.1 Wildcat and Puma Pumps 52
13.1.1 Product Outlet and Miscellaneous 52
13.1.2 Product inlet 54
13.1.3 Trolley, Frame and Wall Mount Accessories 56
13.2 Leopard and Jaguar Pumps 58
13.2.1 Product Outlet and Miscellaneous 58
13.2.2 Product inlet 60
13.2.3 Trolley and Wall Mount 62
14 SPARE PARTS 63
14.1 How can spare parts be ordered? 63
14.2 Overview of the Components 64
14.3 Air Motors 68
14.3.1 Wildcat, Puma and Leopard Air Motors 68
14.3.2 Wildcat and Puma Air Motor Regulators 71
14.3.3 Leopard Air Motor Regulator 72
14.3.4 Jaguar Air Motor 73
14.3.5 Jaguar Air Motor Regulator 76
14.4 Connection Sets 77
14.4.1 Connection Sets for 40–70 cm3 77
14.4.2 Connection Sets for 110–150 cm3 78
14.5 Fluid Sections 80
14.5.1 Fluid Sections 40 cm
14.5.2 Fluid Sections 70 cm
14.5.3 Fluid Sections 110 cm
3 80
3 82
3 84
14.5.4 Fluid Sections 150 cm3 86
14.6 Inlet Valve with Valve Depressor 88
14.7 Relief Combination 270 Bar 88
14.8 Straight Inline Filter, 270 bar 89
14.9 Angled Inline Filter, 530 Bar 89
14.10 High-pressure Filter, 270 Bar 90
14.11 High-pressure Filter, 530 Bar 92
14.12 AirCoat Regulator and AirCoat Filter Regulator 94
14.13 Trolley for Wildcat, Puma and Leopard 95
14.14 Trolley for Leopard 48-110 and Jaguar 96
15 EU DECLARATION OF CONFORMITY 97
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IceBreaker 40-150 cm3
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 the
operating and service personnel. The device may only be operated by trained personnel and in
compliance with this operating manual.
Operating and service personnel should be instructed according to the safety instructions.
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 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
WARNING
CAUTION
NOTICE
Notice
Explanation of warning notice:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance can result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and how to
proceed.
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.
1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order No.
German 2333537
Translation of the original operating manual
Language Order No. Language Order No.
French 2333539 English 2333538
Spanish 2333541 Italian 2333540
Japanese 2338088 Russian 2351629
Dutch 2367552 Hungarian 2352104
Additional languages on request or at: www.wagner-group.com
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1.4 SERVICE MANUAL
The service manual is available in the following languages:
Language Order No. Language Order No.
German 2335993 English 2335994
Additional languages on request or at: www.wagner-group.com
1.5 ABBREVIATIONS
Number of pieces Stainless steel
Position Polyethylene
Marking in the spare parts lists Ultra-high molecular weight polyethylene
Order No. Order number Polytetrauorethylene
Double stroke PTFE with graphite
DN Nominal diameter PTFE
PN Nominal pressure Leather
Two components -- --
1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Product pressure
generator
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
Pump or pressure tank.
associated with improper behavior as well as the necessary
protective devices and measures.
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,
experience and knowledge of the relevant provisions.
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) 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.
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IceBreaker 40-150 cm3
2 CORRECT USE
2.1 DEVICE TYPES
2.1.1 PNEUMATIC PUMPS AND THEIR SPRAYPACKS
Wildcat Puma Leopard Jaguar
10-70 28-40 35-70 75-150
18-40 15-70 35-150 --
-- 21-110 48-110 --
-- 15-150 -- --
2.1.2 SPECIAL VERSIONS FOR ACIDIC HARDENERS AND THEIR SPRAYPACKS
Wildcat Leopard
10-70 (TC 1.4404) 35-70 (TC 1.4404)
2.2 TYPE OF USE
The device is suitable for processing liquid products like paints and lacquers:
– Non-ignitable products.
– Products in accordance with their classication in explosion class IIB.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).
2.4 PROCESSIBLE WORKING MATERIALS
Fluid materials like paints and lacquers.
Application
Water-dilutable products
Solvent-based lacquers and paints
Primers
Epoxy and polyurethane lacquers, phenolic
lacquers
Liquid plastics
Wax-based underside protection
Chemically aggressive products that attack
carbide seats
Special versions for 2K products:
Wildcat 10-70 TC and Leopard 35-70 TC
recommended limited suitability not suitable -- not compatible with 2K products
-- -- -- --
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IceBreaker 40-150 cm3
NOTICE
Abrasive working materials and pigments!
Greater wear of product-wetted parts.
Use the application-oriented model (ow rate/cycle, product, valves, etc.) as
indicated 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.
Use suitable combinations of devices (packings, valves etc.)
Wear caused by abrasive working materials is not covered by the warranty.
Typical applications
Fields of application
Furniture industry
Kitchen manufacturers
Joinery
Window factories
Steel-processing industry
Construction of vehicles
Shipbuilding
recommended limited suitability not suitable
2.4.1 SPECIAL VERSIONS FOR ACIDIC HARDENERS
WARNING
Acidic hardeners!
Risk of burns and injury for skin, tissue and organs.
Observe the lacquer manufacturer's safety data sheets and take prescribed safety
measures.
Special versions:
Wildcat 10-70 TC and Leopard 35-70 TC
Check products for compatibility: see Chapter 5.5.1.
Parts made of stainless steel 1.4404 are labeled with
"1.4404" (see example).
Further information about operation with acidic
hardeners can be found in the operating manual for the
entire system.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g., powder are processed.
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.
Example of hardener pump
1.4404
B_06427
Maximum pressure
for the uid
section's output
Designation "1.4404"
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ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device types: IceBreaker Piston Pump
Wildcat 10-70, Wildcat 18-40
Puma 28-40, Puma 15-70, Puma 21-110, Puma 15-150
Leopard 35-70, Leopard 35-150, Leopard 48-110
Jaguar 75-150
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
European Communities
Symbol for explosion protection
Device class II
Category 2 (zone 1)
Ex-atmosphere gas
Explosion protection
Ignition protection for non-electrical devices
Explosion group
Maximum surface temperature < 200 °C; 392 °F (without drying protection
active)
Maximum surface temperature < 135 °C; 275 °F (with drying protection
active)
High safety level
There are special instructions to ensure safe operation.
See the following Chapter "Identication X".
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.5.3 and 5.5.5
(technical data regarding the Wildcat, Puma, Leopard and Jaguar pumps).
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
Do not drop the device or components.
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 sucient working or ushing agent.
Ensure that the separating agent tank is lled with sucient separating agent.
Ignition temperature of the coating product
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 range is: 5 °C to 50 °C; 41 °F to 122 °F.
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1
2
4
5
6
7
8
9
3
B_06856
Pumpentyp / Pump type
Max. Materialdruck / Fluid pressure
Übersetzungsverhältnis / Ratio
Fördermenge DH / Delivery DS
Max. Luftdruck / Air pressure
Max. Temp. Material / Fluid
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
Wagner International AG
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN
II 2 G Ex h IIB T3/T4 Gb X
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
Medium supporting atomizing
To atomize the product, 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.
Use only a damp cloth to clean the device.
Air in the pump uid
Ignitable gas mixtures can form if air enters 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 agent tank is lled with sucient separating agent.
Periodically check that the pump is working smoothly, paying special attention to
the presence of air in the pumped uid.
Filling and emptying
Ignitable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance and/or repair purposes.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
3.3 TYPE PLATES
Designation
1 Manufacturer and CE Identication
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 the operating manual before use
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ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
4 BASIC 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 DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform personnel 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 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or vapors!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 M).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product hoses / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) 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 100 M.
Ensure that during spraying, persons wear electrically conductive gloves. The
grounding takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M.
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. No smoking.
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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 of the 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.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics applications: anyone who belongs to a risk group according to EMF
Directive 2013/35/EU (e.g. those with active implants), must not enter the highvoltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
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 specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient 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.
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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
− Disconnect the control unit from the mains.
– In the event of functional faults, remedy the fault as described in the
"Troubleshooting" chapter.
If necessary or at least every 12 months, the liquid ejection devices must be
checked for safe working conditions by an expert (e.g. WAGNER Service Technician)
in accordance with the guidelines for liquid ejection devices (ZH 1/406 and DGUV
100-500 Chapters 2.29 and 2.36).
− For shut-down devices, the check can be postponed until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby, the user can lose his
balance and injure himself when falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
4.2.3 GROUNDING THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
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 or the trigger.
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4.2.4 PRODUCT HOSE
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are 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
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
− in high-traffic areas
− on sharp edges
− on moving parts
− on hot surfaces
Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), 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.
Ensure that no work is ever performed with a damaged hose.
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 M.
Suction hoses may not be subjected to pressure.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
Several liquids have a high expansion coecient. 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.
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4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable 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 specications of the lacquer 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.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with units containing aluminium or galvanized and zinc-plated parts. They
may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
−depending upon the coating product used,
−depending on the ushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of
equipment.
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:
Relieve the pressure from the device.
De-energize the device electrically.
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 spray gun. Cleaning the device must not
damage it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
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 device with a warning label "Warning – hot surface".
Part no.
9998910 instruction label
9998911 protection label
Note: Order the two stickers together.
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4.2.7 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are
assigned to the unit.
Do not use any defective components.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
- Relieve the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
- Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
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ORDER NUMBER DOC 2333538
5 DESCRIPTION
5.1 COMPONENTS
Designation
1 Control housing with integrated silencer
2 Air pressure regulator
3 Ball valve
4 Air motor
5 Compressed air inlet
6 Mounting ange
7 Separating agent cup
8 Product outlet
9 Fluid section
10 Product inlet
11 Grounding connection
IceBreaker 40-150 cm3
1
2
3
5
7
8
4
11
6
9
B_06986
10
5.2 MODE OF OPERATION
The piston pump is driven with compressed air (2). This compressed air moves the air
piston up and down in the air motor (4) and it also moves the associated pump piston up
and down in the uid section (9).
In the control housing (1), the air pressure is redirected at the end of each stroke with the
help of the reversing valve. The working material is sucked up during the upwards stroke
and is continuously conveyed towards the product outlet (8) in both stroke directions.
5.2.1 AIR MOTOR
The air motor (4) with its pneumatic reverse (1) does not require pneumatic oil.
The compressed air is fed to the motor via the air regulator (2) and the ball valve (3).
The air motor (4) is tted with a safety valve in accordance with Chapter 5.3.
5.2.2 FLUID SECTION
The uid section (9) 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 (4) and the uid section (9) there is a separating agent cup (7) for
holding the separating agent.
18
VERSION 08/2018
5.3 PROTECTIVE AND MONITORING EQUIPMENT
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
WARNING
Overpressure!
Danger to life from bursting device components.
Never change the safety valve setting.
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 springloaded valve, automatically opens and releases the excess pressure.
The control housing is equipped with noise insulation. Never operate the device without
noise insulation.
The connection set is equipped with a coupling cover. Never operate the device without
a coupling cover.
5.4 INCLUDED ITEMS
Pneumatic piston pump
– Fluid section
– Air motor
– Connection set for air motor - uid section
– Air pressure regulator for air motor
The standard equipment includes:
Order No. Designation
1 9992504 Separating agent 250 ml; 250 cc
1 2333537 Operating manual, in German
1 see Chapter 15 Declaration of Conformity
1 see Chapter 1.3 Operating manual in the local language
The delivery note shows the exact scope of delivery. Accessories: see Chapter 13.
5.5 DATA
5.5.1 MATERIALS OF PAINTWETTED PARTS
Paint-wetted part Product
Housing Stainless steel
Piston Stainless steel and hard chrome
Valve balls Stainless steel
Valve seats Carbide
O-rings PTFE
Packings Standard
= PTFE with graphite = Ultra high molecular weight polyethylene
5.5.1.1 MATERIALS OF THE PAINTWETTED PARTS FOR ACIDIC HARDENERS
Special versions for working with acidic hardeners
Pumps Product
Wildcat 10-70 TC 1.4404
Leopard 35-70 TC 1.4404
1.4301, 1.4404, 1.4408, 1.4571
Fluoroelastomer, carbide, Polyethylene, Polytetrauorethylene
19
VERSION 08/2018
5.5.2 RECOMMENDED PACKINGS
WAGNER packings for this device:
Product Color
Leather dark brown
PTFE with graphite black
Ultra high molecular weight
polyethylene
PTFE white
Each product has the following properties, which inuence the packings:
Designation L TG PE T
Mechanical stability poor good good poor
Friction coecient poor very good good very good
Sealing force good* good good good
Chemical resistance poor good very good very good
Temperature resistance good poor - good very good poor
* for abrasive products
ORDER NUMBER DOC 2333538
transparent
IceBreaker 40-150 cm3
Standard combinations
Standard pumps PE / TG
Heavy duty (high-pressure) pumps PE/L
Hardener pumps in 2K systems: PE/T
20
VERSION 08/2018
5.5.3 TECHNICAL DATA FOR WILDCAT AND PUMA
Description Units
Pump ratio 10:1 18:1 28:1 15:1 21:1 15:1
Volume ow per double stroke cm; cc 70 40 40 70 110 150
Maximum operating overpressure
Maximum possible strokes in operation /min. 60
Maximum recommended strokes per
minute in continuous operation
Minimum/maximum air inlet pressure
Compressed air quality: free from oil and
water
ø air inlet (inside thread) inch G 1/2"
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 80; 3.2 100; 4
Air motor piston stroke mm; Inch 75; 3 75; 3 150; 6
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 M 36×2
Product outlet (outside thread) mm M 24×1.5
Weight kg; lb 17; 38 15; 33 16; 35 18; 40 28; 62
Product pH value pH 3.5–9
Product pH value with acidic hardeners pH ** --
Maximum product pressure at pump
inlet
Product temperature 5–80; 41–176
Construction
Ambient temperature
Relative humidity % 10–95 (without condensation)
Allowable inclination for operation ± 10
** Check products for compatibility (Chapter 5.5.1.1).
A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2005.
Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).
and assembly
Storage -20–60; -4–140
ORDER NUMBER DOC 2333538
MPa
bar
psi
/min. 40
MPa
bar
psi
Quality standard 7.5.4 according to ISO 8573.1, 2010
mm; Inch 9; 0.35
nl
scf
dB(A) 77 77 78 77 78 78
dB(A) 74 74 74 74 74 74
dB(A) 69 69 69 69 69 69
MPa
bar
psi
8
80
1160
7: Particle concentration 5–10mg/m³
5: Humidity: pressure dew point ≤ 7 °C
4: Oil content ≤ 5mg/m3
5.3
0.19
IceBreaker 40-150 cm3
14.4
144
2089
22.4
224
3249
0.25–0.8
36–116
5–50; 41–122
1740
2.5–8
8.3
0.29
2
20
290
12
120
16.8
2436
168
12
120
1740
16.5
0.58
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water.
21
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
5.5.4 MEASUREMENTS AND CONNECTIONS FOR WILDCAT AND PUMA
mm; Inch
mm; Inch
mm; Inch
mm; Inch
mm; Inch
A 736; 29 722; 28.4 736; 29 1034; 40.7
B 169; 6.7
C ~ 321; 12.6
D 261.5; 10.3 336; 13.2
E 474.5; 18.7 460.5; 18.1 474.5; 18.7 698; 27.5
F 134; 5.3
G 182; 7.2
H 80; 3.2
I ø 25; ø 1
J M6
K M36×2
L1 M24×1.5
L2 G3/8"
M G1/2"
N G1/4"
O 106; 4.2
P 96.5; 3.8
Q ø 9; ø 0.35
R ø 7; ø 0.28
S 149; 5.9
T 55; 2.2
Wall mount
C
B
F
T
H
I
N
S
R
mm; Inch
Q
G/2
D
A
(E)
M
G
J
L1
L2
K
H
B_03901
G
B_03902
O
P
22
VERSION 08/2018
5.5.5 TECHNICAL DATA FOR LEOPARD AND JAGUAR
Description Units
Pump ratio 35:1 48:1 35:1 75:1
Volume flow per double stroke (DH) cm; cc 70 110 150 150
Maximum operating overpressure MPa 25 38 27 53
Maximum possible strokes in operation DH/min 60
Maximum recommended strokes per minute in
continuous operation
Minimum/maximum air inlet pressure MPa 0.25–0.71 0.25–0.8 0.25–0.77 0.25–0.71
Compressed air quality: free from oil and water
ø air inlet (inside thread) inch G1/2" G1"
Minimum ø of the compressed air supply line mm; Inch 13; 0.51 25; 0.98
Air consumption at 0.6 MPa; 6 bar; 87 psi per double
stroke
Air motor piston diameter mm; Inch 150; 6 220; 8.7
Air motor piston stroke mm; Inch 75; 3 150; 6
Sound pressure level at maximum permissible air
pressure*
Sound pressure level at 0.6 MPa; 6bar; 87psi air pressure* dB(A) 74 78 81
Sound pressure level at 0.4 MPa; 4bar; 58psi air pressure* dB(A) 71 69 74
Product inlet (outside thread) mm M36×2
Product outlet (outside thread) mm M24×1.5
Weight kg; lb 26; 57 36; 79 53; 117
Product pH value pH 3.5–9
Product pH value with acidic hardeners pH ** -Maximum product pressure at pump inlet MPa 2
Product temperature 5–80; 41–176
Construction and
Ambient temperature
Relative humidity % 10–95 (without condensation)
Allowable inclination for operation ± 10
** Check products for compatibility (Chapter 5.5.1.1).
A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2005.
Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).
assembly
Storage -20–60; -4–140
ORDER NUMBER DOC 2333538
bar 250 380 270 530
psi 3626 5511 3916 7687
DH/min 40
bar 2.5–7.1 2.5–8 2.5–7.7 2.5–7.1
psi 36–103 36–116 36–112 36–103
Quality standard 7.5.4 according to ISO 8573.1, 2010
7: Particle concentration 5–10mg/m³
5: Humidity: pressure dew point ≤ 7 °C
4: Oil content ≤ 5mg/m3
nl 18.6 37.3 79.9
scf 0.66 1.32 2.82
dB(A)
bar 20
psi 290
IceBreaker 40-150 cm3
77 78 80 83
5–50; 41–122
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water.
23
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
5.5.6 MEASUREMENTS AND CONNECTIONS FOR LEOPARD AND JAGUAR
mm; inch
mm; inch
mm; inch
mm; inch
A 799; 31.5 1080; 42.5 1200; 47.2
B 240; 9.4 304; 12
C ~ 434; 17.1 ~ 595; 23.4
D 305; 12 380; 15 516; 20.3
E 490; 19.3 705; 27.6 684; 26.9
F 192; 7.6 244; 9.6
G 230; 9.1
H 110; 4.3
I 20×35; 0.8×1.4 20×48; 0.8×1.9
J M6 M8
K M36×2
L1 M24×1.5
L2 G3/8"
M G1/2" G1"
N G1/4" -O 129; 5.1 135.5; 5.3
P 111.5; 4.4 238; 9.4
Q 9; ø 0.35
R 7; 0.28 9; 0.35
S 167; 6.6 206; 8.1
T 30; 1.2 17; 0.67
C
B
T
F
N
Jaguar wall mount
S
H
Ih
I (IbxIh)
Ib
G/2
G
R
O
Q
P
B_03905
D
A
(E)
M
G
L1
L2
K
H
J
B_03903
Leopard wall mount
S
H
Ih
I (IbxIh) Ib
G/2
G
R
Q
B_03904
O
P
24
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
5.5.7 VOLUME FLOW
WAGNER AL nozzles Volume ow* in l/min
ø inch ø mm Spray angle
7 MPa
70 bar
1015 psi
10 MPa
100 bar
1450 psi
15 MPa
150 bar
2175 psi
20 MPa
200 bar
2900 psi
Maximum ranges for
continuous operation
at 40DS/min
0.007 0.18 40° 0.17 0.20 0.21 0.22
0.009 0.23 20-30-40-50-60° 0.21 0.25 0.31 0.36
0.011 0.28 10-20-30-40-50-60° 0.30 0.35 0.43 0.50
0.013 0.33 10-20-30-40-50-60-80° 0.45 0.53 0.62 0.68
0.015 0.38 10-20-30-40-50-60-80° 0.58 0.67 0.81 0.91
0.017 0.43 20-30-40-50-60-70° 0.73 0.79 1.06 1.23 Wildcat 18-40
0.019 0.48 20-30-40-50-60-70-80° 0.93 1.09 1.37 1.47 Puma 28-40
0.021 0.53 20-40-50-60-80° 1.14 1.36 1.69 1.78 Wildcat 10-70
0.023 0.58 20-40-50-60-70-80° 1.37 1.59 2.01 2.24 Puma 15-70
0.025 0.64 20-40-50-60-80° 1.62 1.91 2.40 2.60 Leopard 35-70
0.027 0.69 20-40-50-60-80° 1.83 2.13 2.68 3.12
0.029 0.75 60° 2.19 2.51 3.17 3.63
0.031 0.79 20-40-50-60° 2.40 2.77 3.49 4.00 Puma 21-110
Leopard 48-110
0.035 0.90 20-40-50-60° 3.22 3.74 4.69 5.14 Puma 15-150
Leopard 35-150
Jaguar 75-150
0.043 1.10 20-50° 5.07 6.04 7.46 7.84
0.052 1.30 50° 5.12 6.10 7.52 8.06
Volume ow refers to water.
5.5.8 PERFORMANCE DIAGRAMS
Example
Product pressure bar (MPa) psi
Stroke frequency /min
8 bar
6 bar
4 bar
B_00301
Water ow rate l/min <gpm>
8 bar
6 bar
4 bar
Air consumption nl/min <scfm>
25
VERSION 08/2018
<1.1>
<0.92>
<0.74> <0.55> <0.37>
<0.18>
<gpm>
bar (MPa)
<psi>
bar (MPa)
<psi>
bar (MPa)
<psi>
ORDER NUMBER DOC 2333538
WILDCAT 18-40 WILDCAT 10-70
bar (MPa)
<psi>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
<725>
Product pressure
B_00315
Stroke frequency /min
10 20 30 40 50 60
0
nl/min
<scfm>
600
<21>
A
400
A
B
<14>
B
C
0
0 l/min
0.4
<0.1>
0.8
<0.2>
1.2
<0.3>
1.6
<0.4>
2
<0.5>
C
2.4
<0.6>
200
<7>
0
<gpm>
bar (MPa)
<psi>
80 (8)
<1160>
60 (60)
<870>
40 (4)
<580>
20 (2)
<290>
Air consumption
Product pressure
0
0
0
0.7
PUMA 28-40 PUMA 15-70
bar (MPa)
<psi>
250 (25)
<3625>
200 (20)
<2900>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
<725>
Product pressure
B_00317
Stroke frequency /min
10 20 30 40 50 60
0
A
B
C
0
0.4
0
<0.1>
0.8
<0.2>
1.2
<0.3>
1.6
<0.4>
2
<0.5>
nl/min
<scfm>
750
<26>
600
A
<21>
B
450
<16>
C
300
<11>
150
<3.5>
Air consumption
Product pressure
2.4
<0.6>
0
l/min
<gpm>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
<725>
B_00313
0
0
C
0
IceBreaker 40-150 cm3
Stroke frequency /min
10 20 30 40 50 60
C
3.5
3.5
<0.92>
A
B
4.2
A
B
C
4.2
<1.1>
A
B
C
1.4
2.1
2.8
Stroke frequency /min
10 20 30 40 50 60
A
B
2.8
2.1
1.4
0.7
<0.18>
<0.37>
<0.55>
<0.74>
nl/min
<scfm>
400
<14>
300
<10.5>
200
<7>
100
<3.5>
0
L/min
nl/min
<scfm>
900
<32>
600
<21>
300
<11>
0
l/min
<gpm>
Air consumption
Air consumption
PUMA 21-110 PUMA 15-150
A
B
6.6
<1.7>
nl/min
<scfm>
1200
<42>
900
<32>
600
<21>
300
<11>
0
Air consumption
l/min
<gpm>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
<725>
Product pressure
B_00314
0
0
0
Flow rate (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
Stroke frequency /min
10 20 30 40 50 60
0
200 (20)
<2900>
150 (15)
<2175>
100 (10)
<1450>
A
B
C
500 (5)
<725>
Product pressure
B_03483
0
2.2
1.1
0
<0.3>
<0.6>
3.3
<0.9>
4.4
<1.2>
Flow rate (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
C
5.5
<1.5>
Stroke frequency /min
10 20 30 40 50 60
A
B
C
7.5
6
4.5
3
1.5 l/min
<0.4>
<0.8>
<1.2>
<1.6>
<2>
nl/min
<scfm>
1200
A
<42>
B
800
<28>
C
400
<14>
0
9
<2.4>
Air consumption
<gpm>
26
VERSION 08/2018
<1.7>
<1.5>
<1.2>
<0.9>
<0.6>
<0.3>
bar (MPa)
<psi>
<gpm>
ORDER NUMBER DOC 2333538
LEOPARD 35-70 LEOPARD 48-110
bar (MPa)
<psi>
250 (25)
<3625>
200 (20)
<2900>
150 (15)
<2175>
100 (10)
<1450>
50 (5)
<725>
Product pressure
B_00318
Stroke frequency /min
10 20 30 40 50 60
0
A
B
C
0
0.7
0
<0.18>
1.4
<0.37>
2.1
<0.55>
2.8
<0.74>
3.5
<0.92>
Flow rate (water)
A = 7.1 bar; 0.71 MPa; 103 psi air pressure
B = 6 bar; 0.6 MPa; 87 psi air pressure
C = 4 bar; 0.4 MPa; 58 psi air pressure
nl/min
<scfm>
1500
<53>
A
1200
<43>
B
900
<32>
C
600
<21>
300
<11>
0
4.2
l/min
<1.1>
<gpm>
400 (40)
<5800>
300 (30)
<4350>
200 (20)
<2900>
100 (10)
<1450>
Air consumption
Product pressure
B_02755
10 20 30 40 50 60
0
0
1.1
0
Flow rate (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
IceBreaker 40-150 cm3
Stroke frequency /min
A
B
C
3.3
2.2
4.4
C
5.5
nl/min
<scfm>
3000
<106>
A
2250
<79>
B
1500
<53>
750
<26>
0
6.6
l/min
Air consumption
LEOPARD 35-150 JAGUAR 75-150
bar (MPa)
<psi>
300 (30)
<4350>
Stroke frequency /min
10 20 30 40 50 60
0
A
A
200 (20)
<2900>
100 (10)
<1450>
Product pressure
B_00319
0
0
C
1.5
<0.4>
B
C
7.5
6
4.5
3
<0.8>
<1.2>
<1.6>
<2>
Flow rate (water)
A = 7.7 bar; 0.77 MPa; 112 psi air pressure
B = 6 bar; 0.6 MPa; 87 psi air pressure
C = 4 bar; 0.4 MPa; 58 psi air pressure
B
9
<2.4>
nl/min
<scfm>
3000
<105>
2000
<70>
1000
<35>
0
l/min
<gpm>
bar (MPa)
<psi>
Air consumption
Product pressure
500 (50)
<7250>
400 (40)
<5800>
300 (30)
<4350>
200 (20)
<2900>
100 (10)
<1450>
B_00322
0
0
0
1.5
<0.4>
Flow rate (water)
A = 7.1 bar; 0.71 MPa; 103 psi air pressure
B = 6 bar; 0.6 MPa; 87 psi air pressure
C = 4 bar; 0.4 MPa; 58 psi air pressure
Stroke frequency /min
10 20 30 40 50 60
A
B
C
6
4.5
3
<0.8>
<1.2>
<1.6>
A
7.5
<2>
B
C
9
<2.4>
nl/min
<scfm>
5000
<175>
4000
<140>
3000
<105>
2000
<70>
1000
<35>
0
l/min
<gpm>
Air consumption
27
VERSION 08/2018
B_03909
B_03907
B_05272
ORDER NUMBER DOC 2333538
5.6 OPERATING ELEMENTS
5.6.1 PRESSURE REGULATOR UNIT
Puma 28-40 AirCoat pneumatic pump
Pos Designation
1 Pressure regulator
2 Ball valve
3 Pressure gauge
4 Compressed air inlet
5 AirCoat regulator (option)
Puma 28-40 Airless pneumatic pump
Pos Positions of the ball valve
1 Closed: working pressure in the air motor will be relieved
(control pressure is still present).
2 Closed: The air motor may still be under pressure.
3 Open: working position
IceBreaker 40-150 cm3
1
2
3
1
2
3
5
4
5.7 PRODUCT FILTER AND RETURN LINE
So that complete pressure relief of the pump can be performed (see Chapter 7.4), a highpressure lter with a return line or a relief combination, is mandatory.
5.7.1 HIGHPRESSURE FILTER OPTION
To ensure problem-free operation it is recommended that a
WAGNER high-pressure lter be used.
These have been developed especially for WAGNER pneumatic
pumps.
The lter inserts can be exchanged depending on the product to
be used.
Preferred
lter installation
pos.
The high-pressure lter, which corresponds to the device, can be
found in Chapter 13. The compatible lter inserts can be found in
Chapter 14.
53MPa
530bar
7687psi
Designation
1 Fluid section connection
2 Product outlet
27MPa
270bar
3916psi
3 Return line
1
Open
(Return
B_03908
line)
1
2
Open
3
Closed
(Spraying)
B_04064
3
2
28
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
5.7.2 RELIEF COMBINATION AND INLINE FILTER UP TO 270 BAR OPTION
Instead of the standard high-pressure filter the lower-cost filter-relief
combination and an inline filter can be used if only a small volume of
product will be processed.
27MPa, 270bar, 3916psi
1
Application: in pumps with a maximum product pressure of 270bar;
3916psi.
Relief combination and inline filter (see Chapter 13).
Designation
2
3
1 Fluid section connection
2 Relief combination
3 Return line
B_03911
4 Inline lter
5 Product outlet
5.8 STROKE COUNT OPTION
Each air motor has a 1/8" air connection with which the air pressure in the lower air motor
chamber can be measured. This signal can be used for counting the strokes in an external
controller, for example.
The pressure signal corresponds to the set working air pressure and is available during the
complete upwards stroke of the pump. If both of the signal edges are evaluated, the upper
and lower reversal point can be determined. An air hose (4/2-mm; 0.16/0.08-inch) is used
as an air signal line.
Order No. Designation
1 9998675 Threaded plug
Pneumatic pumps: Wildcat, Puma and Leopard
2
2 9999066 Male stud elbow
3 9982072 Air hose (per meter)
4 9943049 Pneumatic pre-selection counter
4
5
3
1
B_03912
4
B_03703
Pneumatic pumps: Jaguar
1
2
3
B_03913
29
VERSION 08/2018
!
B_05174
!
5.9 FEED PUMP OPTION
A feed pump can be used with high-viscosity products or longer feed lines.
Dimensioning of the feed pump
The IceBreaker piston pumps pump the working product to the product output
with up and down strokes but only draw in new product on the up stroke. The feed
pump therefore has to pump twice the volumetric ow.
Main pump protection
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
The maximum product pressure at the
pump inlet of the IceBreaker pump may
not be exceeded.
Protection of feed pump
If the maximum pressure of the feed pump is lower than the maximum pressure
of the main pump, this could be exceeded if the main pump malfunctions. The
feed pump and connection line must therefore be protected from excessive
overpressure. An overpressure valve must then be installed between the feed pump
and main pump.
Observe the ow direction during installation.
Feed pump
Pressure relief valve
Feed pump
B_05173
Main pump
(Icebreaker)
Main pump
(Icebreaker)
The pressure-relief valve must be cleaned regularly and after each activation: Flush
with solvent.
Installation sets and compatible feed pumps
See assembly manual "Feed pump installation sets", order no. 2357584.
30
VERSION 08/2018
B_04065
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL
The assembly and commissioning personnel 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 commissioned.
6.2 STORAGE 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.
The air temperature at the storage location must be between -20 °C and 60 °C (-4 °F and
140 °F).
The relative air humidity at the storage location must be between 10 and 95% (without
condensation).
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 5 °C and 50 °C; 41
°F and 122 °F.
The relative air humidity at the installation site must be between 10 and 95% (without
condensation).
6.4 TRANSPORTATION
Only the pump, without trolleys, may be lifted by the lifting eye nut or
lifting eye bolt (see accessories) and transported short distances.
Wildcat, Puma and Leopard: The pump can be moved on a trolley
(4"/6" trolley) or manually without lifting equipment or a crane.
Jaguar: The pump must be moved on a trolley (heavy-duty PC trolley)
or with lifting equipment or a crane.
31
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
6.5 ASSEMBLY AND INSTALLATION
WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
Place the device on horizontal oor.
If the oor is inclined, position the feet of the trolley towards the gradient.
Secure the trolley.
National regulations
Ensure that the national explosion prevention rules and regulations are observed
when setting up the device.
This pump can be used as part of a spraying system for Airless or AirCoat applications. The
individual components are shown in the accessories, or can be arranged with a spraypack
congurator. The nozzles must be selected according to the spray gun operating manual.
In the case of spraypack orders, the pumps (1) are already pre-mounted on a trolley (6) or
on a frame at the factory.
1. Mount pump (1) on frame, trolley (6) or wall mount.
2. Mount the AirCoat regulator (7) with an AirCoat system.
3. Mount high-pressure lter (3) or lter relief combination and inline lter.
4. Mount suction system (5).
5. Mount return tube (4) or return hose.
6. Connect high-pressure hose and spray gun (2) according to the operating manual
for the spray gun.
2
1
3
4
AirCoat system
6
7
B_03915
5
Airless system
2
1
3
4
6
5
B_05291
32
VERSION 08/2018
6.5.1 VENTILATION OF THE SPRAY BOOTH
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.
6.5.2 AIR SUPPLY LINES
Ensure that only dry, clean atomizing air is used in the spray gun! Dirt and moisture in the
atomizing air worsens the spraying quality and spray pattern.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
WARNING
Hose connections!
Risk of injury and damage to the device.
Do not mix up hose connections of product hose and air hose.
6.5.3 PRODUCT SUPPLY LINES
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of product.
Ensure that the hose material is chemically resistant to the sprayed products.
Ensure that the spray gun, ttings and product 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
6.6 GROUNDING
WARNING
Discharge of electrostatically charged components in atmospheres containing
solvents!
Explosion hazard from electrostatic sparks.
Clean the pump only with a damp cloth.
WARNING
Heavy paint mist if grounding is insucient!
Danger of poisoning.
Insucient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
33
VERSION 08/2018
B_06960
Grounding scheme (example)
Ex zone
ORDER NUMBER DOC 2333538
Conveyor
Work piece
IceBreaker 40-150 cm3
R max < 1 MΩ
Spraying
stand
B_00304
Product
tank
Floor, static dissipative
Part / workstation Cable cross section
Pump 4 mm; AWG 12
Product tank 6 mm; AWG 10
Conveyor 16 mm; AWG 6
Booth 16 mm; AWG 6
Spraying stand 16 mm; AWG 6
Safe operation of the pump is only guaranteed with a
grounding connection.
Connect all grounding cables using a short and direct
route.
Procedure:
1. Screw on grounding cable with eyelet.
2. Clamp the grounding cable clip to a grounding connection on site.
3. Ground the product tank to an on-site grounding connection.
4. 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.
All paints, ushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
34
VERSION 08/2018
6.7 COMMISSIONING
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
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 medium.
Do not spray the device empty after cleaning.
NOTICE
Impurities in the spraying system!
Spray gun blockage.
Flush the spray gun and paint supply with a suitable ushing agent before
commissioning.
Emergency stop, see Chapter 7.2.
Preparation
Before every start-up, the following points should be observed as laid down in the operating manual:
− Secure spray gun with safety lever.
− Check the permissible pressures.
− Check all connections for leaks.
− Check hoses for damage in accordance with Chapter 8.2.3.3.
− Fill the separating agent in accordance with Chapter 8.2.3.1.
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 empty device with ushing agent in accordance with Chapter 8.2.5.
Pressure tightness test
WARNING
Overpressure!
Risk of injury from bursting components.
The operating pressure must not exceed the value shown on the type plate.
− 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 7.4.
Verifying a Safe Operational Condition
A skilled person must check to ensure that the device is in a reliable state after it is
installed and commissioned.
This includes:
− Carry out safety checks in accordance with Chapter 8.2.3.
Filling with Working Material
− According to Chapter 8.2.5.
35
VERSION 08/2018
B_05269
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
7 OPERATION
7.1 TRAINING THE OPERATING PERSONNEL
The operating personnel must be qualied to operate the entire system.
The operating personnel 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 personnel must receive appropriate system
training.
7.2 EMERGENCY STOP
In the case of unforeseen
occurrences:
High-pressure lter 530 bar
– Close ball valve (2);
– Open return valve (3).
Close
2
7.3 TASKS
Ensure that:
commissioning is carried out in
accordance with Chapter 6.7.
1. Visual check: personal safety
equipment, grounding and all devices
ready to use.
2. Secure spray gun and insert nozzle into
the spray gun.
3. Close return valve (3).
4. Slowly open the ball valve (2).
5. Set required working pressure on the
pressure regulator (1).
6. Optimize spray pattern in accordance
with the spray gun's operating manual.
7. Start work process.
Open
High-pressure lter 270 bar
3
Open:
Relief combination 270 bar
3
Open:
B_05292
B_03917
closed
open
1
2
7
3
4
5
6
3
36
VERSION 08/2018
7.4 PRESSURE RELIEF/WORK INTERRUPTION
The pressure must always be relieved when:
− after the spraying tasks are nished,
− before servicing or repairing the spraying system,
− before carrying out cleaning tasks on the spraying system,
− Before moving the spraying system to another location.
− before something must be checked on the spraying system,
− before the nozzle or the lter is removed from the spray gun.
The components for pressure relief on a CE-compliant spraying system include:
− Air cock with pressure relief hole mounted between compressed air source and
pneumatic pump.
− Outlet equipment (return valve) mounted between pump and spray gun.
Process for relieving pressure
1. Close the spray gun.
2. Close ball valve (2).
3. Release the system of pressure by opening the spray gun.
Attention: If a blocked nozzle is preventing relief, rst carry out the additional steps
4 and 5, then clean the nozzle.
4. Close and secure the spray gun.
5. Open and close the return valve (3) slowly to completely depressurize the system.
If the system will process 2K products:
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
NOTICE
Hardened working material in the spraying system when 2K product is processed!
Destruction of pump and injection system.
Observe the manufacturer's processing rules, particularly in regards to the pot life.
Flush thoroughly before the end of the pot life.
The pot life is decreased by warmth.
37
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
7.5 BASIC FLUSHING
Regular ushing
Regular ushing, cleaning and maintenance ensures the pump's high pumping and
extraction capacity.
The cleaning and ushing agents used must be compatible with the working
material.
Do not ush hardener pumps with water. Only ush them using suitable ushing
agents (solvents).
WARNING
Incompatibility of ushing / cleaning agent with the working medium!
Risk of explosion and danger of poisoning by toxic gases.
Examine the compatibility of the ushing and cleaning agents and working media
on the basis of the safety data sheets.
Flushing procedures
1. Visual check: personal safety equipment, grounding and all devices ready to use.
2. Place an empty, grounded collection tank (5) under the return tube (4).
3. Place the suction hose (7) in the grounded tank with ushing agent (6).
4. Adjust the pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.25 psi.
Flushing via the return valve
5. Open return valve (3).
6. Slowly open the ball valve (2).
7. Adjust the air pressure on the pressure
regulator (1) so that the pump runs smoothly.
8. Flush the system until clean ushing agent
ows into the tank (5).
9. Close ball valve (2).
10. As soon as there is no pressure remaining in
the system, close the return valve (3).
Flushing via spray gun
11. In case of AirCoat systems, carry out the basic
ushing without atomizing air.
12. Point the spray gun, without nozzle, into the
tank (5) and open it.
B_05292
13. Slowly open the ball valve (2).
14. Rinse until clean ushing agent ows from
the spray gun.
15. Close ball valve (2).
16. As soon as there is no pressure remaining in the system, close the spray gun.
17. Secure the spray gun.
18. Dispose of the contents of the tank (5) according to the local regulations.
External Cleaning
19. Clean the outside of the system.
20. Fully assemble the system.
21. Relieve the pump's pressure according to Chapter 7.4.
22. Dispose of the contents of the tank (5) according to the local regulations.
1
closed
2
open
3
4
5
7
6
7.6 FILLING WITH WORKING MATERIAL
After basic ushing, the system can be lled with working product.
Proceed according to Chapter 8.2.5, but use working material instead of ushing agent.
38
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
8 CLEANING AND MAINTENANCE
8.1 CLEANING
8.1.1 CLEANING PERSONNEL
Cleaning work should be undertaken regularly and carefully by qualied and trained
personnel. They should be informed of specic 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 DECOMMISSIONING AND CLEANING
The device should be cleaned for maintenance purposes, etc. Ensure that no remaining
product dries on and sticks to the device.
Procedure
1. Carry out work interruption Chapter 7.4.
2. Carry out the basic ushing Chapter 7.5.
3. Empty system in a controlled manner Chapter 8.2.4.
4. Service spray gun in accordance to its operating instructions.
5. Clean and check the suction system and the suction lter.
6. When using a product lter, check lter insert and lter housing and clean or replace
them. Chapter 8.2.6
7. Clean the outside of the system.
8. Fully assemble the system.
9. Check ll level of the separating agent Chapter 8.2.3.1.
10. Fill the system with ushing agent in accordance with Chapter 8.2.5.
8.1.3 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. Perform points 1 to 8 in Chapter 8.1.2.
2. Fill the system with preservative in accordance with Chapter 8.2.5.
3. Empty the system in a controlled manner in accordance with Chapter 8.2.4 and seal
the openings.
39
VERSION 08/2018
8.2 MAINTENANCE
8.2.1 MAINTENANCE PERSONNEL
Maintenance work should be undertaken regularly and carefully by qualied and trained
personnel. They should be informed of specic 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 MAINTENANCE INSTRUCTIONS
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
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.
Use only WAGNER original spare parts and accessories.
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 the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
- Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
Prior to Maintenance
It should be ensured that the device is in the following state before carrying out any
work on it:
− Flush and clean the system. Chapter 8.1.2
− Interrupt the air supply.
After maintenance
− Carry out safety checks in accordance with Chapter 8.2.3.
− Put the system into operation and check for leaks as described in Chapter 6.7.
− Have the system checked for safe condition by an authorized person.
− Function test in accordance with Chapter 11.
40
VERSION 08/2018
8.2.3 SAFETY CHECKS AND MAINTENANCE INTERVALS
Every day
Check grounding: see Chapter 6.6.
Check hoses, tubes and couplings: see Chapter 8.2.3.3
Check the level of separating agent in the separating agent tank and top up, if
necessary, in accordance with Chapter 8.2.3.1. Check coupling cover.
For each decommissioning, the process according to Chapter 8.1.2 must be followed.
If the pump has to be emptied for maintenance work, proceed according to Chapter
7.5 and Chapter 8.2.4.
Weekly
Check system for damage.
Check that the safety xtures function properly (see Chapter 5.3).
Yearly or as required
In accordance with DGUV regulation 100-500 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 12 months.
– For shut down devices, the examination can be suspended until the next start-
up.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
8.2.3.1 FILLING WITH 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 agent tank is lled with sucient separating agent.
Pour the supplied separating agent into the intended opening.
Separating agent: order no. 9992504
Filling level: 1 cm; 0.4 inch under the cup edge.
Inclination angle of the pump
Maximum permissible tilt of the pump for moving, transporting, etc.
after lling separating agent is±30°.
The pump must be vertical during operation.
8.2.3.2 CONDENSATE DRAIN FROM THE AIRCOAT FILTER REGULATOR
Frequently drain the condensate that may accumulate in the pneumatic lter.
– Make sure the water level in the lter cup never reaches the max. level marked on
the cup.
B_03918
41
VERSION 08/2018
8.2.3.3 PRODUCT HOSES, PIPES AND COUPLINGS
The service life of the complete hoses between product pressure generator and application
device is reduced due to environmental inuences 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.
The complete hose is to be replaced as soon as 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 Meaning
xxx bar Pressure
yymm Crimping date (year/month)
XX Internal code
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
Hose imprinting Meaning
Wagner Name / Manufacturer
yymm Date of manufacture (year/month)
xxx bar (xx MPa)
e.g., 270 bar (27 MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
Pressure
42
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
8.2.4 EMPTYING 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. Place an empty, grounded collection tank (5) under the return tube (4).
2. Place the suction hose (7) in an empty, grounded tank (6).
3. Close pressure regulator (1) (0MPa; 0bar; 0psi).
Emptying via return line
4. Open return valve (3).
5. Slowly open the ball valve (2).
6. 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).
7. 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).
8. As soon as working material is no longer
owing from the return tube (4), close the ball
valve (2).
9. Close return valve (3).
Emptying up to the spray gun
10. Point the spray gun, without nozzle, into the
tank (5) and open it.
11. Slowly open the ball valve (2). Be ready for the
switch from working material to air.
B_05292
1
closed
2
open
3
4
5
7
6
12. As soon as working material is no longer owing from the return tube, close the ball valve (2).
13. Close and secure the spray gun.
14. Depressurization in accordance with Chapter 7.4.
15. Dispose of the contents of the tank (5) according to the local regulations.
43
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
8.2.5 FILLING THE EMPTY 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.
Fill the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
Before each lling, the nozzle must be removed from the spray gun. Here, the specications
in the spray gun operating manual must be followed.
In case of AirCoat systems, carry out the lling of the system without atomizing air (8).
1. Visual check: personal safety equipment, grounding and all devices ready to use.
2. Place an empty, grounded collection tank (5) under the return tube (4).
3. Place the suction hose (7) in a grounded tank with working material (6).
Note:
If the pump is equipped with a rigid suction system, it should only be dipped in into
the working product up to the middle of the inlet housing at the maximum!
4. Close pressure regulator (1) (0MPa;
0bar; 0psi).
5. Open return valve (3).
6. Slowly open the ball valve (2).
7. Slowly turn the air pressure up on the
pressure regulator (1) and only until
the pump is running normally (approx.
0–0.05MPa; 0–0.5 bar; 0–7.25 psi).
Be ready to switch from air to working
material and prevent back spray.
8. Close ball valve (2) as soon as pure
working product starts coming from the
return tube (4).
9. Close return valve (3).
10. Point the spray gun, without nozzle, into
the tank (5) and open it.
11. Slowly open the ball valve (2).
Be ready to switch from air to working
material and prevent back spray.
B_05292
1
closed
2
open
3
4
5
7
6
12. As soon as pure working material without air bubbles is owing, close the ball valve (2).
13. Close and secure the spray gun.
14. Depressurization in accordance with Chapter 7.4.
15. Dispose of the contents of the tank (5) according to the local regulations.
44
VERSION 08/2018
2
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
8.2.6 CLEANING AND REPLACING THE FILTER
8.2.6.1 STRAIGHT INLINE FILTER
1. Flush the pump and inline lter in accordance with
Chapter 7.5. Flush using the spray gun so that the
ushing agent ows through the inline lter. Maximize
the ow (remove the nozzle, open the dosing valve if
necessary).
2. Empty the pump in a controlled manner in accordance
27MPa; 270bar; 3916psi
2
1
with Chapter 8.2.4.
3. Place the grounded collection tank under the inline
lter.
4. If no swivel joint is mounted, remove the hose.
Flow direction
**
5. Unscrew the inlet housing (2) and outlet housing(5)
with two size 19 wrenches.
6. Remove the lter insert (3).
7. If the inline lter has any leaks, replace the seal* (1).
8. Insert the new lter insert* (3). Note the installation position: closed end in direction
of ow.
9. If necessary, coat the thread with anti-seize paste**.
10. Screw together the inlet housing (2) and outlet housing (5) with two size 19 wrenches.
11. If necessary, screw the hose back on.
12. Fill the pump in accordance with Chapter 8.2.5.
* Order no., see Chapter 13.
** Order no., see Chapter 10.5.
3
5
B_05274
8.2.6.2 ANGLED INLINE FILTER
1. Flush the pump and inline lter in accordance with
Chapter 7.5. Flush using the spray gun so that the
53MPa; 530bar; 7687psi
ushing agent ows through the inline lter. Maximize
the ow (remove the nozzle, open the dosing valve if
necessary).
2. Empty the pump in a controlled manner in accordance
with Chapter 8.2.4.
3. Place the grounded collection tank under the inline
lter.
Flow direction
**
4. Unscrew the lter by turning the handle (4).
5. Remove the lter insert (3).
6. If the inline lter has any leaks, replace the seal* (1).
7. Insert the new lter insert* (3). Note the installation
position: closed end in direction of ow.
8. If necessary, coat the thread with anti-seize paste**.
9. Assemble the turning handle (4), inlet housing (2) and outlet housing(5) and tighten
by turning the handle.
10. Fill the pump in accordance with Chapter 8.2.5.
* Order no., see Chapter 13.
** Order no., see Chapter 10.5.
1
3
4
5
B_05273
45
VERSION 08/2018
B_05275
8.2.6.3 HIGHPRESSURE FILTER
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
1. Flush the pump and HP lter in accordance with Chapter 7.5,
and while doing so:
– At the preferred lter installation position: Flush via the
return valve (1). This produces a large ow. As a result, the
ushing agent also ows through the upper part of the
lter cartridge (11). Pressure regulator approx. 0.15MPa;
1.5bar; 22psi.
– With a reversed lter installation position: Flush using
the spray gun. This is required in the case of a reversed
installation position so that the ushing agent ows
through the lter cartridge (11). Maximize the ow
(remove the nozzle, open the dosing valve if necessary).
2. Empty the pump in a controlled manner in accordance with
Chapter 8.2.4.
3. Place the grounded collection tank under the high-pressure
lter.
4. Open ball valve (1).
5. Loosen union nut (3) with a size 70 wrench.
6. Unscrew the union nut (3) and lift slightly so that it does not
get dirty in the next step.
7. Remove the lter housing (2) with the union nut (3). The
cone spring (12) remains in the lter housing (2). If the O-ring
(5) is not damaged, it remains on the lter housing (2).
8. Remove the lter cartridge (11) and lter socket (10) from
the lter housing (2).
9. Clean all parts:
– Place the lter cartridge (11) and lter support (10) in
solvent. Clean using brush.
– Fill the lter housing (2) approx. 1/3 full with solvent.
Close, wearing a glove, and shake well.
– Clean the distribution housing (7) using a brush.
10. If necessary, replace the O-ring (5) and/or lter cartridge (11).
Order No., see Chapter 14.11.
11. Assemble all parts in reverse order. While doing so:
– Coat the thread of the distribution housing (7) with anti-
seize paste**.
– Coat the O-ring (5) and pressure ring (21) with Mobilux
EP2**.
– Observe the installation position of the lter cartridge
(11): Push the closed end with the lter identication
ahead into the lter housing (2).
– Make sure that the cone spring (12) is in the lter housing
(note the installation position). Press on the cone spring
after inserting the lter cartridge (11) and lter support
(10); the spring action must be noticeable.
– Tighten the union nut (3) by hand.
12. Close ball valve (1).
13. Fill the pump in accordance with Chapter 8.2.5.
** Order no., see Chapter 10.5.
Filter installation position
Preferred
Turned over
3
12
Mobilux EP2**
2
21
5
Filter
11
10
identication
Anti-seize paste**
7
1
B_05271
53MPa;
530bar;
7687psi
27MPa;
270bar;
3916psi
46
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
9 TROUBLESHOOTING AND RECTIFICATION
Problem Cause Remedy
The pump does not work Air motor does not work or stops. Open and close ball valve on the
pressure regulator unit or briey
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
Insucient compressed air supply. Check compressed air supply.
Filter insert in spray gun or high-
pressure lter is clogged.
Fluid section or high-pressure
hose are blocked (e.g., 2K product
hardened).
Grease in spool and sleeve
assembly.
Occasionally, the pump stops at the
reversal point.
Poor spray pattern See operating manual of spray gun.
Irregular operation of
product pump: spray jet
collapses (pulsation)
Pump is running uniformly,
but does not take in any
working product
The pump is working with a
closed spray gun.
The air motor is iced up There is a lot of condensation water
If none of the causes of malfunction mentioned are present, the defect can be remedied
by a WAGNER Service Center.
Viscosity is too high. Dilute the working material.
Spraying pressure is too low. Increase incoming air pressure. Use a
Valves are clogged. Clean pump. If necessary, leave it to soak
Foreign body in suction valve. Dismantle suction valve housing, clean
Diameter of compressed air line too
small.
Valves, packings, or pistons are
worn out.
Control air lter or work air lter is
clogged.
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
sticking.
Packings, valves, or pistons are
worn out.
in the air supply.
Disconnect compressed air supply
briey or repair or change pressure
regulator.
instructions.
Clean the parts and use a suitable
working product.
Dismount and clean uid section,
replace high-pressure hose.
Degrease spool and sleeve assembly.
Check detent element (see service
manual).
smaller nozzle.
in cleaning agent.
and check valve seat.
Assemble a larger supply line.
Technical data, Chapter 5.5.
Replace the parts.
Check and clean it if necessary.
Tighten union nut.
Clean ball and valve seats.
Replace the parts.
Install a water separator.
47
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
10 REPAIR WORK
10.1 REPAIR PERSONNEL
Repair work must be carried out carefully and by qualied and trained personnel. They
should be informed of specic hazards during their training.
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.
Carry out function test in accordance with Chapter 11.
10.2 REPAIR NOTES
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.
Use only WAGNER original spare parts and accessories.
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 the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
- Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
Before Repair Work
− Flush and clean the system. Chapter 8.1.2
− Interrupt the air supply.
After Repair Work
− Carry out safety checks in accordance with Chapter 8.2.3.
− Put the system into operation and check for leaks as described in Chapter 6.7.
− Have the system checked for safe condition by an authorized person.
− Function test in accordance with Chapter 11.
10.3 TOOLS
For disassembling and assembling the devices, the following tools are required:
(if possible, always bring entire tool sets with you):
– Torque wrench 2-3 Nm; 2 lbft. – Torque wrench 70 Nm; 52 lbft.
– Torque wrench 8-10 Nm; 6-7 lbft. – Torque wrench 140 Nm; 103 lbft.
– Torque wrench 10-15 Nm; 7-11 lbft. – Allen wrench, wrench size (SW) 4, 5, 6, 8, 10, 14, 17.
– Torque wrench 20-25 Nm; 15-19 lbft. – Allen wrench, wrench size (SW) 6, 12, 13, 17, 19, 22,
32.
– Torque wrench 40 Nm; 30 lbft. – Torx wrench size (SW) 4.5, 5.5.
48
VERSION 08/2018
10.4 CLEANING THE PARTS AFTER DISASSEMBLY
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
WARNING
Incompatibility of cleaning agent and working medium!
Risk of explosion and danger of poisoning by toxic gases.
Examine the compatibility of the cleaning agents and working media on the basis
of the safety data sheets.
Please note:
Thoroughly clean all reusable parts with a suitable cleaning agent.
All dismantled parts have to be clean and dry after cleaning. Care should be taken
that these parts remain free of solvents, grease or sweat from the hands (salt water).
Perform cleaning and mounting tasks wearing gloves.
10.5 ASSEMBLY OF THE DEVICE
In Chapter 14 the order numbers for device spare parts can be found, as well as for wearing
parts such as seals.
Defective parts, O-rings and seal sets must always be replaced.
Use greases and glues in accordance with Chapter 14.
Observe torque specications in Chapter 14.
Assembly Aids
Order No. Quantity Designation Smaller tanks
9992590 1 pc ≙ 50 ml Loctite 222
9992511 1 pc ≙ 50 ml Loctite 243
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 specied in this document are property of the respective owners. Loctite , for example, is a
registered brand of Henkel.
49
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
11 FUNCTION TEST AFTER REPAIR WORK
After all repairs, the device must be checked for safe condition before recommissioning.
The necessary scope of inspection and testing depends on the repair carried out and must
be documented by the repair personnel.
Activity Means
1.1 Filling with separating agent
See Chapter 8.2.3.1.
1.2 EX-relevant inspections
− Check grounding connection between ground connection of the pump and
the frame/trolley and between the individual components of the frame/
trolley: < 1M
− Check conductivity between piston and grounding connection: < 1M
These inspections are - relevant!
1.3 Testing for leaks
− Connect the air motor to the air supply 7 bar. To perform a leak test on the
device, the product pressure with the ushing agent is slowly increased
in increments until the maximum pressure indicated on the type plate
is reached. Close pump outlet. In each position (with upstroke and
downstroke), let sit for 0.5-1 minutes and listen for audible blowing o.
When the air supply is turned o, a drop in pressure must be watched for.
Check seal of following modules:
− uid section
− mounted ttings and regulators
1.4 General inspections
− Check tightening torque of various screws. See Chapter 14.
− Check all ttings.
− Empty device in a controlled manner (Chapter 8.2.4) and depressurize
(Chapter 7.4).
− Check function of frame or transport trolley.
Ωm
(measurement voltage
500...1000 VDC)
Air motor:
Test medium compressed
air
Leak spray
Fluid section:
Test medium: suitable
Flushing agent
Torque wrench
Visual check
12 DISPOSAL
When the equipment must be scrapped, please dierentiate the disposal of the waste
materials.
The following materials have been used:
Stainless steel
Aluminum
Elastomers
Plastics
Carbide
Consumable products
Consumable products (lacquers, adhesives, ushing and cleaning agents and solvents)
must be disposed of in accordance with all legal requirements and provisions.
50
51
VERSION 08/2018
ORDER NUMBER DOC 2333538
13 ACCESSORIES
13.1 WILDCAT AND PUMA PUMPS
13.1.1 PRODUCT OUTLET AND MISCELLANEOUS
IceBreaker 40-150 cm3
28
22
23
30
270 bar
270 bar
20
21
24
19
27
x
270 bar
29
x
50
530 bar
3
A
2
5
4
y
53
52
1
31
54
57
B_05287
55/56
y
26
Mount ttings x and y at the correct position, depending on the system's characteristics.
25
52
VERSION 08/2018
A 2329460 2329456 2329467 2329471 2329517 2329475 Piston pump PE/TG
A 2329462 2329458 2329469 2329473 2330614 2329477 Piston pump PE/T
A 2366704 / / / / / Piston pump PE/T TC 1.4404
1 9992504 Separating agent 250 ml; 250 cc
2 236219 Grounding cable 3 m; 9.8 ft
3 9907133 Lifting eye bolt
4 2328611 AirCoat regulator set (Chapter14.12)
5 2382997 AirCoat lter regulator set (Chapter14.12)
19 9985619 Plug-in tting with hose tting DN13
20 9998813
21 9998812
22 9998810
23 9998811
24 2334956 Regulator lock
25 2335815 Ball valve DN7-PN10-G1/4-R1/4-CB
26 9992831 Loctite 542, 50 ml; 50cc
Product outlet up to 270 bar
27 2329024
28 2329023
29 2324558
30 2329026
31 2332619 Adapter G1/4"-NPS1/4"
Product outlet up to 530 bar
50 2329025
52 2332621 Adapter G3/8"-NPS1/4"
53 2332620 Adapter G3/8“-NPS 3/8“
54 2331752 Return tube, DN6-G1/4"-100mm-PA
55 2331017 Circulation hose DN6-G1/4"-1.8m-PA
56 2331014 Circulation hose DN6-G1/4"-2.8m-PA
57 2329046 Return hose DN6-PN310-G1/4"-PA
= Wearing parts
/ = Item does not exist.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
DesignationOrder No. Order No. Order No.
Plug-in tting with quick-release
coupling DN13
Quick release coupling with hose tting
DN 13
Plug-in tting with quick-release
coupling DN10
Quick release coupling with hose tting
DN 10
HP lter DN10-PN270-SSt, complete
Details and lter cartridges: Chapter
14.10
Relief combination, complete
For details, see Chapter 14.7
Inline lter DN6-PN270-G1/4"-SSt
Details and lter insert: Chapter 14.7
Inline lter HL DN6-PN270-G1/4"-SSt
Details and lter insert: Chapter 14.8
HP lter DN12-PN530-SSt, complete
Details and lter cartridges: Chapter 14.9
53
VERSION 08/2018
13.1.2 PRODUCT INLET
12
ORDER NUMBER DOC 2333538
11
IceBreaker 40-150 cm3
19
13
DN25
30L
DN16
15
16
9
8
5
6
DN16
10
DN25
7
3
4
8
13
5
DN16
DN25
1
200L
14
DN16 DN25
2
B_03921
17 18
For trouble-free suction, use hoses which are as short as possible. The maximum hose
length is dependent upon the viscosity of the product, the suction height, and the nominal
diameter of the hose.
54
VERSION 08/2018
A 2329460 2329456 2329467 2329471 2329517 2329475 Piston pump PE/TG
A 2329462 2329458 2329469 2329473 2330614 2329477 Piston pump PE/T
A 2366704 / / / / / Piston pump PE/T TC 1.4404
1 2332169 -- -- Hopper set, 5 l for piston pump
2 2323225 -- -- Suction elbow for hopper SSt
3 2324110 -- Suction hose DN16-SSt, complete
4 2324116 Suction hose DN25-SSt, complete
5 2325408 LP hose-tting DN25-M36-SSt
6* 2323474
7* 2323595 LP hose DN25-PN10-PE (per meter)
8 2325390 -- LP hose-tting DN16-M36-SSt
9* 2323329 --
10* 2323597 -- LP hose DN16-PN10-PE (per meter)
11 2324158 -- -- Suction tube DN16-SSt, complete
12 2323239 Suction tube DN25-SSt, complete
13 2324247 Suction elbow DN25-SSt
14 2324238
15 2315163 Bung adapter DN25-G2"
16 2324241
17 2323396 -- Suction lter DN16-18mesh-SSt
18 2323325 Suction lter DN25-18mesh-SSt
19 2329688 2329689 2329688 -- --
= Wearing parts
-- = Item not available as spare part.
/ = Item does not exist.
* Pos 6, 7, 9, 10: max. 10 bar:
If a feed pump (>10 bar) is used, do not use downstream of the feed pump.
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
DesignationOrder No. Order No. Order No.
LP hose DN25-PN10-EPDM (per
meter)
LP hose DN16-PN10-EPDM (per
meter)
Suction tube DN25-200L-SSt,
complete
Suction tube DN25-30L-SSt,
complete
Inlet valve with valve depressor
For details, see Chapter 14.6
55
VERSION 08/2018
ORDER NUMBER DOC 2333538
13.1.3 TROLLEY, FRAME AND WALL MOUNT ACCESSORIES
3
1
2
IceBreaker 40-150 cm3
B_03922
DesignationOrder No. Order No. Order No.
A 2329460 2329456 2329467 2329471 2329517 2329475 Piston pump PE/TG
A 2329462 2329458 2329469 2329473 2330614 2329477 Piston pump PE/T
A 2366704 / / / / / Piston pump PE/T TC 1.4404
1 2325901
Trolley 4", complete
For details, see Chapter 14.13
2 2332374 Frame 4", complete
3 2332143 Wall mount 4“, complete
= Wearing parts
/ = Item does not exist.
56
57
VERSION 08/2018
ORDER NUMBER DOC 2333538
13.2 LEOPARD AND JAGUAR PUMPS
13.2.1 PRODUCT OUTLET AND MISCELLANEOUS
24
23
20
22
IceBreaker 40-150 cm3
3
A
2
28
30
270 bar
31
54
21
19
5
27
270 bar
50/51
530 bar
55/56
26
4
1
y
25
y
x
29
x
53
52
57
B_05290
Mount ttings x and y at the correct position, depending on the system's characteristics.
58
VERSION 08/2018
A 2329479 2329484 2329490 2329501 Piston pump PE/TG
A 2329481 2329486 2329493 2329505 Piston pump PE/T
A -- -- 2329495 2329503 Piston pump PE/L
A 2366702 / / / Piston pump PE/T TC 1.4404
1 9992504 Separating agent 250 ml; 250 cc
2 236219 Grounding cable 3 m; 9.8 ft
3 9907133 -- Lifting eye bolt
4 2328611 AirCoat regulator set (see Chapter14.12)
5 2382997 AirCoat lter regulator set (see Chapter14.12)
19 9985619 -- Plug-in tting with hose tting DN13
20 9998813 -- Plug-in tting with quick-release coupling DN13
21 9998812 -- Quick release coupling with hose tting DN 13
22 -- 9985671 Outside thread grommet 1"-DN25
23 -- 9974135 Sealing ring 1"
24 2334957 2334958 Regulator lock
25 2335815 Ball valve DN7-PN10-G1/4-R1/4-CB
26 9992831 Loctite 542, 50 ml; 50cc
Product outlet up to 27MPa; 270bar; 3916psi
27 2329024 --
28 2329023 --
29 2324558 --
30 2329026 --
31 2332619 -- Adapter G1/4"-NPS1/4"
Product outlet up to 53MPa; 530bar; 7687psi
50 2329025
51 -- 2335334
52 2332621 Adapter G3/8"-NPS1/4"
53 2332620 Adapter G3/8“-NPS 3/8“
54 2331752 Return tube DN6-G1/4"-100mm-PE
55 2331017 Circulation hose DN6-G1/4"-1.8m-PA
56 2331014 Circulation hose DN6-G1/4"-2.8m-PA
57 2329046 Return hose DN6-PN310-G1/4"-PA
= Wearing parts
-- = Item not available as spare part.
/ = Item does not exist.
ORDER NUMBER DOC 2333538
Order
No.
DesignationOrder No. Order No. Order No.
HP lter DN10-PN270-SSt, complete
Details and lter cartridges: Chapter 14.10
Relief combination, complete
For details, see Chapter 14.7
Inline lter DN6-PN270-G1/4"-SSt
Details and lter insert: Chapter 14.8
Inline lter HL DN6-PN270-G1/4"-SSt
Details and lter insert: Chapter 14.9
HP lter DN12 PN530-SSt with stainless steel ball
valve
Details and lter cartridges: Chapter 14.11
HP lter DN12 PN530-SSt with carbon steel ball
valve. Details and lter cartridges: Chapter 14.11
IceBreaker 40-150 cm3
59
VERSION 08/2018
13.2.2 PRODUCT INLET
10
ORDER NUMBER DOC 2333538
9
IceBreaker 40-150 cm3
17
11
DN25
30L
DN16
13
14
7
6
3
4
DN16
8
DN25
5
6
11
3
1
2
DN16
DN25
200L
12
DN16 DN25
15 16
For trouble-free suction, use hoses which are as short as possible. The maximum hose
length is dependent upon the viscosity of the product, the suction height, and the nominal
diameter of the hose.
60
VERSION 08/2018
A 2329479 2329484 2329490 2329501 Piston pump PE/TG
A 2329481 2329486 2329493 2329505 Piston pump PE/T
A -- -- 2329495 2329503 Piston pump PE/L
A 2366702 / / / Piston pump PE/T TC 1.4404
1 2324110 -- -- -- Suction hose DN16-SSt, complete
2 2324116 Suction hose DN25-SSt, complete
3 2325408 LP hose-tting DN25-M36-SSt
4* 2323474 LP hose DN25-PN10-EPDM (per meter)
5* 2323595 LP hose DN25-PN10-PE (per meter)
6 2325390 -- -- -- LP hose-tting DN16-M36-SSt
7* 2323329 -- -- -- LP hose DN16-PN10-EPDM (per meter)
8* 2323597 -- -- -- LP hose DN16-PN10-PE (per meter)
9 2324158 -- -- -- Suction tube DN16-SSt, complete
10 2323239 Suction tube DN25-SSt, complete
11 2324247 Suction elbow DN25-SSt
12 2324238 Suction tube DN25-200L-SSt, complete
13 2315163 Bung adapter DN25-G2"
14 2324241 Suction tube DN25-30L-SSt, complete
15 2323396 -- -- -- Suction lter DN16-18mesh-SSt
16 2323325 Suction lter DN25-18mesh-SSt
17 2329688 -- -- --
= Wearing parts
-- = Item not available as spare part.
/ = Item does not exist.
* Pos 4, 5, 7, 8: max. 10 bar.
If a feed pump (>10 bar) is used, do not use downstream of the feed pump.
ORDER NUMBER DOC 2333538
DesignationOrder No. Order No. Order No. Order No.
Inlet valve with valve depressor
For details, see Chapter 14.6
IceBreaker 40-150 cm3
61
VERSION 08/2018
ORDER NUMBER DOC 2333538
13.2.3 TROLLEY AND WALL MOUNT
3
1
IceBreaker 40-150 cm3
4
2
DesignationOrder No. Order No. Order No. Order No.
A 2329479 2329484 2329490 2329501 Piston pump PE/TG
A 2329481 2329486 2329493 2329505 Piston pump PE/T
A -- -- 2329495 2329503 Piston pump PE/L
A 2366702 / / / Piston pump PE/T TC 1.4404
1 2325916 --
2 -- 2339705
Trolley 6", complete
For details, see Chapter 13.13
Heavy-duty PC trolley, complete
For details, see Chapter 14.14
3 2332145 -- Wall mount 6“, complete
4 -- 369020 Wall mount 9“, complete
-- = Item not available as spare part.
/ = Item does not exist.
B_05270
62
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
14 SPARE PARTS
14.1 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:
− billing address
− 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.)
Identication in spare parts lists
Explanation of column " " (labeling) in the following spare parts lists:
Wearing parts/
Included in service set
Notice
These parts are not covered by warranty terms.
Not part of standard equipment, available, however, as additional extra.
Identication in the order no. column.
-- Item not available as spare part.
/ Position does not exist.
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.
Use only WAGNER original spare parts and accessories.
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 the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
- Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
63
VERSION 08/2018
14.2 OVERVIEW OF THE COMPONENTS
ORDER NUMBER DOC 2333538
3
10
1
IceBreaker 40-150 cm3
9
4
2
B_05154
Designation
1 Piston pump 2329460 2329462 2329456 2329458
2 Fluid section 2329645 2329647 2329641 2329643
3 Air motor 3/75 2329613
4 Connection set for air motor - uid section 2350030 2350028
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 25 Nm; 18 lbft
Designation
1 Piston pump 2366704
2 Fluid section 2366710
3 Air motor 3/75 2334375
4 Connection set for air motor - uid section 2350030
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 25 Nm; 18 lbft
Designation
1 Piston pump 2329467 2329469 2329471 2329473
2 Fluid section 2329641 2329643 2329645 2329647
3 Air motor 3/75 2329617
4 Connection set for air motor - uid section 2350028 2350030
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 25 Nm; 18 lbft
Order No. Order No. Order No. Order No.
Order No. Order No. Order No. Order No.
Tightening torque pos. 2 and 3
Order No.
64
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
3
9
1
10
4
2
Tightening torque pos. 2 and 3
B_05261
Designation
1 Piston pump 2329475 2329477 2329517 2330614
2 Fluid section 2329650 2329652 2329654 2329656
3 Air motor 3/75 2329619
4 Connection set for air motor - uid section 2350031
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 50 Nm; 37 lbft
Order No. Order No. Order No. Order No.
65
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
3
9
10
1
4
2
B_05154
Designation
1 Piston pump 2329479 2329481 2329484 2329486
2 Fluid section 2329645 2329647 2329650 2329652
3 Air motor 3/75 2329621 2329623
4 Connection set for air motor - uid section 2350032 2350033
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 25 Nm; 18 lbft 50 Nm; 37 lbft
Designation
1 Piston pump 2366702
2 Fluid section 2366710
3 Air motor 3/75 2334375
4 Connection set for air motor - uid section 2350030
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 25 Nm; 18 lbft
Order No. Order No. Order No.
Tightening torque pos. 2 and 3
Order No.
Order No.
Designation
1 Piston pump 2329490 2329493 2329495
2 Fluid section 2329654 2329656 2329658
3 Air motor 2329623
4 Connection set for air motor - uid section 2350033
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 50 Nm; 37 lbft
Order No. Order No. Order No.
66
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
3
9
1
10
4
2
Tightening torque pos. 2 and 3
B_05261
Designation
1 Piston pump 2329501 2329505 2329503
2 Fluid section 2329650 2329652 2329664
3 Air motor 2329625
4 Connection set for air motor - uid section 2350033
9 Grounding cable, complete 236219
10 Molykote DX grease 9992616
Tightening torque for air motor/uid section 50 Nm; 37 lbft
Order No. Order No. Order No.
67
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.3 AIR MOTORS
14.3.1 WILDCAT, PUMA AND LEOPARD AIR MOTORS
IceBreaker 40-150 cm3
69
49
109
106
1
110
106
110
108
29
16
12
46
17
20-25 Nm; 15-19 lbft
49
16
11
43
42
2-3 Nm; appr. 2 lbft
55
56
10
40
18
30
44
45
13
8
100
25
14
23
37
10-15 Nm;
7-11 lbft
36
110
Pressure regulator (pos. 100):
For details, see Chapter 14.3.2 and/or Chapter 14.3.3
110
45 Nm; 33 lbft
110
9
57
35
47
75
8
37
74
29
30
31
48
47
54
75
28
81
B_03927
Do not dismount the piston (pos. 81).
15
4
71
72
41
5
6
39
36
41
51
53a, 53b
33
53b
3
32
34
60
59
58
109
2
52
50
25 Nm; 19 lbft
108
61
68
VERSION 08/2018
1
2
3 1 367302 367402 368302 368402 Piston rod
4 1 366303 367303 367403 368303 368403 Cylinder pipe
5 1 367304 367404 368304 368404 Compressed air pipe
6 1 367305 367405 367305 367405 Control air pipe
8 2 367307 Plug
9 2 L414.06C L423.06 Outlet seal
10 1 367309 368309 Connecting part
11 1 367310 368310 Silencer
12 1 367311 368311 Hood
13 1 367313 Compressed air lter
14 1 367314 Control air lter
15 1 2332082 Fluid warning label
16 2 367318 368324 Shoulder screw
17 1 367319 368319 Sound deadening pad
18 2 367320 368320 Cotter pin
23 1 367324 Filter holder
25 1 / / / 367325 Throttle
28 6 9971123 9974142 O-ring
29 2 9974217 Rod seal
30 2 369290 Pilot valve
31 1 9943080 9943081
32 1 9962018 9962019 Permaglide bushing
33 1 9998663 9998661 9998662 Complete piston
34 1 9974090 9974091 Seal wiper ring
35
36 2 9974115 9974084 9974087 O-ring
37 2 9974085 O-ring
39 2 9974089 O-ring
40 2 9974095 9974096 O-ring
41 2 9971448 9971137 O-ring
42 1 9974097 9974100 O-ring
43 1 9974098 9974101 O-ring
44 2 9998674 Threaded plug
45 1 9998274 Threaded plug
46 1 2330369 2330370 2330371 Label, WAGNER
1 2329613 2329617 2329619
1 2334375 / / Air motor TC 1.4404
1 2344071 2344075 Flange
1 2349900 / Flange TC 1.4404
1 368288 / Safety valve, 8.4 bar
1 / 368286 Safety valve, 7.5 bar
1 / / Safety valve, 8.1 bar
1 2336178 / / Safety valve, 4.4 bar TC 1.4404
ORDER NUMBER DOC 2333538
2329621
2329623 Air motor
IceBreaker 40-150 cm3
DesignationOrder No. Order No. Order No.
Spool and sleeve assembly,
complete
69
VERSION 08/2018
47 2 9998675 Threaded plug
48
49 2 9925033 9920106 9925026 Washer
50 3 9900225 9907121 9900225 Hexagon screw
51
52 3 9920106 Washer
53a 1 9920107 / Washer
53b 2 / / / 9920110 Washer
54
55 3 9900325 9900313 Socket cap screw, M6x16
56 3 9920103 9920102 Washer
57 1 9970149 Sealing ring
58 1 9952668 Base
59 1 9952667 Clamping bracket
60 1 9900701 Socket cap screw
61 1 9921505 Spring washer
69 1 9998718 Drive fastener
71 1 2330382 IceBreaker label
72 1 2332077 Warning label
74 1 368038 Detent element, complete ISO 1/2
75 2 368313 Damper ISO 1/2
81 1 9943097 9943098
100
106 1 9992590 Loctite 222 50 ml; 50cc
108 1 9992831 Loctite 542, 50 ml; 50cc
109 1 9992616 Molykote DX grease
110 1 9998808 Mobilux EP 2 grease
= Wearing parts
= Included in service set
1 2359165 2359171 Control housing
1 2359170 / Control housing TC 1.4404
1 2386160 (new) 2386161 (new) Self-locking hexagon nut
1 9910101 (old) 9910605 (old)
2 9907126 / SFS screw
3 / / / 9907125 SFS screw
1 2384849 /
1 / 2328607
1 366995 367995 368995 Service set
1 9992511 Loctite 243, 50 ml; 50cc
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
DesignationOrder No. Order No. Order No.
Hexagon nut secured with Loctite
243
Spool and sleeve assembly ISO1 or
ISO2
Pressure regulator unit, 4", complete
For details, see Chapter 14.3.2
Pressure regulator unit 6", complete
For details, see Chapter 14.3.3
70
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.3.2 WILDCAT AND PUMA AIR MOTOR REGULATORS
IceBreaker 40-150 cm3
9
10
16
6
2
16
7
1
8
4
14
7
16
11
3
15
13
6
B_06962
14
12
15
14
5
Pos 3: Screw in the pressure gauge only until the white sealing ring is completely inside the lter control
valve. Thereafter continue turning the pressure gauge only to align the display scale.
/ / /
DesignationOrder No.
1 1 2384849 Pressure regulator unit, 4" complete
2 1 2309972 Pressure regulator valve, 4“
3 1 9998677 Pressure gauge 0-10 bar (d40)
4 1 2309744 Distribution piece, 4"
5 2 9907039 Hexagon socket cylinder head screw
6 4 9900316 Hexagon socket cylinder head screw
7 2 9974166 O-ring
8 1 9971313 O-ring
9 1 9971137 O-ring
10 1 2360756 Edge ball valve, 4“
11 1 9904307 Screw plug
12 1 9990506 Cone plug, GPN 600
13 1 9970154 Sealing ring
14 1 9992616 Molykote DX grease
15 1 9992831 Loctite 542, 50 ml; 50cc
16 1 9998808 Mobilux EP 2 grease
= Wearing parts
71
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.3.3 LEOPARD AIR MOTOR REGULATOR
IceBreaker 40-150 cm3
12
7
11
18
2
18
9
1
10
4
8
17
13
3
B_06963
16
6
17
14
15
16
17
Pos 3: Screw in the pressure gauge only until the white sealing ring is completely inside the lter
control valve. Thereafter continue turning the pressure gauge only to align the display scale.
18
5
/
DesignationOrder No.
1 1 2328607 Pressure regulator unit, 6" complete
2 1 2309973 Pressure regulator valve, 6“
3 1 9998725 Pressure gauge 0-10 bar (d50)
4 1 2309783 Distribution piece, 6"
5 2 3050699 Hexagon socket cylinder head screw
6 2 9907024 Hexagon socket cylinder head screw
7 2 9906020 Hexagon socket cylinder head screw
8 1 9974166 O-ring
9 1 9971018 O-ring
10 1 3105540 O-ring
11 1 9971137 O-ring
12 1 2370107 Edge ball valve, 6“
13 1 9904307 Screw plug
14 1 9990506 Cone plug, GPN 600
15 1 9970154 Sealing ring
16 1 9992831 Loctite 542
17 1 9992616 Molykote DX grease
18 1 9998808 Mobilux EP 2 grease
= Wearing parts
72
VERSION 08/2018
14.3.4 JAGUAR AIR MOTOR
40 Nm / 30 lbft
83
82
81
49
46
ORDER NUMBER DOC 2333538
106
96
IceBreaker 40-150 cm3
15
4
72
12
71
41
109
95
17
70 Nm / 52 lbft
16
54
80
97
110
39
5
6
41
11
108
36
84
33
53
75
51
88
3
32
34
61
58
47
114
60
59
2
140 Nm / 103 lbft
110
55
56
43
8-10 Nm / 6-7 lbft
110
10
93
79
78
94
90
98
77
91
54
36
110
74
106
20 Nm
15 lbft
31
110
92
37
109
52
50
40 Nm /
30 lbft
29
30
103
1
108
30
29
110
89
85
35
40
87
37
87
9
18
57
48
8
28
76
1:2
13
25
14
23
B_03928
105
Pressure regulator (pos. 105):
For details, see Chapter14.3.5
Do not dismount the piston (pos. 94).
73
VERSION 08/2018
1 1 2329625 Air motor
2 1 369316 Flange
3 1 368402 Piston rod
4 1 369403 Cylinder pipe
5 2 368404 Compressed air pipe
6 1 367405 Control air pipe
8 1 369307 Sealing plug
9 2 369312 Outlet seal
10 1 369309 Connecting part
11 1 369310 Silencer
12 1 369905 Hood
13 1 369313 Compressed air lter
14 1 367314 Control air lter
15 1 2332082 Fluid warning label
16 1 369318 Shoulder screw
17 1 369906 Sound absorbing mat
18 2 369320 Cotter pin
23 1 367324 Filter holder
25 1 367325 Throttle
28 6 9974143 O-ring
29 2 9974217 Rod seal
30 2 369290 Pilot valve
31 1 369907 Spool-sleeve combination assembly, ISO3
32 1 9962019 Permaglide bushing
33 1 369385 Piston 9
34 1 9974125 Seal wiper ring
35 1 368286 Safety valve, 7.5 bar
36 2 9974133 O-ring
37 2 9971056 O-ring
39 2 9974089 O-ring
40 2 9974132 O-ring
41 4 9971137 O-ring
43 1 9974165 O-ring
46 1 2330372 Label, WAGNER
47 2 9998675 Threaded plug
48 1 369315 Control housing
49 1 9925034 Washer
50 4 9907137 Hexagon screw
51
52 4 9920106 Washer
53 2 369303 Washer
54 7 9907125 SFS screw
55 3 9900314 Socket cap screw
56 3 9925029 Washer
57 1 9970149 Sealing ring
58 1 9952668 Base
59 1 9952667 Clamping bracket
60 1 9900701 Socket cap screw
1 2386161 Self-locking hexagon nut (new)
1 9910605 Hexagon nut, secured with Loctite® 243 (old version!)
ORDER NUMBER DOC 2333538
DesignationOrder no.
IceBreaker 40-150 cm3
74
VERSION 08/2018
61 1 9921505 Spring washer
71 1 2330382 IceBreaker label
72 1 2332077 Warning label
74 1 369027 Detent body
75 1 9974124 Rod seal prole E5
76 2 9992757 Threaded elbow tting
77 1 9992758 Screw connector T
78 4 9920102 Washer
79 4 9900313 Socket cap screw
80 2 9925031 Washer
81 1 369325 Lifting eye nut
82 1 369324 Shoulder ring
83 1 9900150 Hexagon screw
84 1 9974262 O-ring
85 1 369306 Air pipe
87 3 9971004 O-ring
88 2 369304 Damping washer
89 1 369317 Control ange
90 1 369026 Air hose, rear
91 1 369025 Air hose, front
92 1 369326 Lock space 9
93 2 369329 Damper ISO3
94 1 9943131 Spool & sleeve assembly, ISO3
95 1 9999151 Velcro fastener adhesive part
96 1 9999152 Velcro fastener coating part
97 1 9992816 Miranit contact adhesive
98 1 9971372 Viton B O-ring
103 1 369330 Sound absorbing mat 9/12"
105 1 2328609
106 1 9992590 Loctite 222 50 ml; 50cc
108 1 9992831 Loctite 542 50 ml; 50cc
109 1 9992616 Molykote DX grease
110 1 9998808 Mobilux EP 2 grease
114 1 369971 Piston 9 with SOFT O-ring
1 369987 Service set
1 9992511 Loctite 243 50 ml; 50cc
= Wearing parts
= Included in service set
= Not part of the standard equipment but available as a special accessory
ORDER NUMBER DOC 2333538
DesignationOrder no.
Pressure regulator unit, 9", complete. For details, see Chapter
14.3.3
IceBreaker 40-150 cm3
75
VERSION 08/2018
B_06987
1
7
11
10 2
4
8
6
9
3
5
6
5
7
14
9
12
12
12
13
14
14
ORDER NUMBER DOC 2333538
14.3.5 JAGUAR AIR MOTOR REGULATOR
IceBreaker 40-150 cm3
Pos 4: Screw in the pressure gauge only until the white sealing ring is completely inside
the lter control valve. Thereafter continue turning the pressure gauge only to
align the display scale.
DesignationOrder no.
1 1 2328609 Pressure regulator unit, 9" complete
2 1 2309974 Pressure regulator valve, 9“
3 1 2309963 Distribution piece, 9"
4 1 9998725 Pressure gauge 0-10 bar (d50)
5 2 9900360 Hexagon socket cylinder head screw
6 2 9907087 Hexagon socket cylinder head screw
7 2 9900356 Hexagon socket cylinder head screw
8 1 9974166 O-ring
9 2 3105540 O-ring
10 1 9971405 O-ring
11 1 2371922 Edge ball valve, 9“
12 1 9992616 Molykote DX grease
13 1 9992831 Loctite 542, 50 ml; 50cc
14 1 9998808 Mobilux EP 2 grease
= Wearing parts
76
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.4 CONNECTION SETS
14.4.1 CONNECTION SETS FOR 4070 CM3
2
3
IceBreaker 40-150 cm3
1
4
9
5
8
25 Nm; 18 lbft
Assembly with
11
B_07033
6
LM-FS 1
7
LM-FS 2
air motor and
uid section: see
Chapter 14.5
LM-FS 4
DesignationOrder No. Order No. Order No.
1 1 2350028 2350030 2350032 Connection set LM-FS …
2 2 367532 Coupling cover stroke 75
3 1 367529 367579 368529 Coupling
4 1 367530 368530 Spring
5 1 367531 Separating agent cup, stroke
75
6 1 9974093 O-ring
7 3 9900225 Hexagon screws
8 3 9920106 Washer
9 3 367306 Connecting tube stroke 75
11 1 9998808 Mobilux EP 2 grease
= Wearing parts
= Included in the service set of the uid section PE/TG or PE/T (see Chapter 14.5).
77
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.4.2 CONNECTION SETS FOR 110150 CM3
2
9
3
IceBreaker 40-150 cm3
1
8
4
7
50 Nm; 37 lbft
10
B_05263
5
6
Assembly with air motor
and uid section: see
Chapter 14.5.2
/
/
LM-FS 3
LM-FS 5
DesignationOrder No. Order No.
1 1 2350031 2350033 Connection set LM-FS …
2 2 368532 Coupling cover stroke 150
3 1 367579 368529 Coupling
4 1 367530 368530 Spring
5 3 9920107 Washer, A12, DIN 125-1
6 3 9900157 Hexagon screws
7 1 9974116 O-ring
8 1 368531 Separating agent cup, stroke
150
9 3 368533 Threaded bolt, M12x169
10 1 9998808 Mobilux EP 2 grease
= Wearing parts
=
Included in the service set of the uid section PE/TG or PE/T or PE/L (see Chapter 14.5).
78
79
VERSION 08/2018
14.5 FLUID SECTIONS
14.5.1 FLUID SECTIONS 40 CM
ORDER NUMBER DOC 2333538
3
IceBreaker 40-150 cm3
5
60
8
60
44
16
21
20
1
21
20
100
101
43
28
10
6
25
12
11
61
70 Nm
52 lbft
+10 Nm
+ 7 lbft
28
10
21
60
2
61
17
40
3
13
50
62
111
46
51
40 Nm;
30 lbft
60
27
9
61
70
60
100 Nm
74 lbft
19
23
22
23
22
23
41
103
104
60
25
42
27
9
4
7
18
71
B_05264
Pos. 4 Tighten by hand on block.
Use a standard wrench only if necessary. In this case, use a wrench to counterhold pos. 3.
* Notice regarding pos. 111: Stainless steel valve seat set 40, consisting of: pos. 28, 10, 27, 9, but in stainless
steel version.
80
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
DesignationOrder No. Order No.
1 1 2329641 2329643 Fluid section 40 cm
3
2 1 367502 Pipe
3 1 367503 Cylinder
4 1 2322467 Inlet housing 40
5 1 367505 Piston
6 1 367506 Valve screw
7 1 367507 Ball guide, inlet
8 1 367501 Connecting ange
9 1 367509 Valve seat, inlet
10 1 367510 Valve seat, outlet
11 1 367511 Snap ring ange
12 2 367512 Snap ring half
13 1 367513 Securing ring
16 1 367516 Support ring
17 1 367517 Pressure ring
18 1 367518 Support ring
19 1 367519 Pressure ring
100 1 115805 / Packing PE/TG, complete (small)
101 1 / 123219 Packing PE/T, complete (small)
20 2 123398 / Sealing collar TG (small)
20 2 / 123426 Sealing collar T (small)
21 3 123427 Sealing collar PE (small)
103 1 367991 / Packing PE/TG, complete (large)
104 1 / 367992 Packing PE/T, complete (large)
22 2 367522 / Sealing collar TG (large)
22 2 / 367900 Sealing collar T (large)
23 3 367523 Sealing collar PE (large)
25 2 367525 O-ring
27 1 367527 O-ring
28 1 367528 O-ring
40 1 9998669 Wave spring (small)
41 1 9998670 Wave spring (large)
42 1 9941513 Ball (large)
43 1 9941518 Ball (small)
44 1 9974094 O-ring
46 1 9974106 O-ring
50 3 9907124 Hexagon screw
60 1 9998808 Mobilux EP 2 grease
61 1 9992609 Anti-seize paste tube
62 1 9992616 Molykote DX grease
70 1 2329922 Fitting SF-MM-G3/8"-M24x1.5-PN530-SSt
71 1 2329898 Sealing sleeve
111 1 2331582 Valve seat set 40, stainless steel*
1 367990 / Service set PE/TG
1 / 367994 Service set PE/T
= Wearing parts
= Included in the service set (For more parts, see Chapter 14.4.1.)
= Not part of the standard equipment but available as a special accessory
81
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
14.5.2 FLUID SECTIONS 70 CM
3
Pos. 4 Tighten by hand on block.
Use a standard wrench only if necessary. In
this case, use a wrench to counterhold pos. 3.
* Note on pos. 111:
Stainless steel valve seat set 70, consisting of:
pos. 28, 10, 27, 9, but in stainless steel version.
8
44
1
60
2
61
100 Nm
70
74 lbft
60
B_05266
16
20
17
40
19
22
23
22
23
18
21
20
21
21
41
23
100
101
102
103
104
105
60
60
71
5
28
10
25
12
11
3
46
42
27
9
43
6
13
25
7
4
60
28
+10 Nm
+ 7 lbft
60
62
60
10
111
57
27
9
61
61
70 Nm
52 lbft
a)
50
51
40 Nm;
30 lbft
Order No. Order No. Order No.
1 1 2329645 - 2329647
2 1 368502
3 1 368503
Order No.
2366710
2370141
2370139
Designation
Fluid section
Pipe
Cylinder
4 1 2322465 2370138 Inlet housing 70
5 1 368505 2370129 Piston
6 1 368506 2370137 Valve screw
7 1 368507 2338788 Ball guide, inlet
8 1 368501 Connecting ange
9 1 368509 Valve seat, inlet
10 1 368510 Valve seat, outlet
82
VERSION 08/2018
Order No. Order No. Order No.
11 1 368511 Snap ring ange
12 2 368512 Snap ring half
13 1 368513 Securing ring
16 1 368516 2370142 Support ring
17 1 367519 2366649 Pressure ring
18 1 368518 2370140 Support ring
19 1 368519 2366647 Pressure ring
100 1 367991 / / -- Packing PE/TG, complete (small)
101 1 / / 367992 Packing PE/T, complete (small)
102 1 / 367993 / -- Packing PE/L, complete (small)
2 367522 / / -- Sealing collar TG (small)
20
21 3 367523 -- Sealing collar PE (small)
103 1 368991 / / -- Packing PE/TG, complete (large)
104 1 / / 368992 Packing PE/T, complete (large)
105 1 368993 / -- Packing PE/L, complete (large)
22
23 3 368523 -- Sealing collar PE (large)
25 2 368525 O-ring
27 1 368527 O-ring
28 1 368528 O-ring
40 1 9998670 2366668 Wave spring (small)
41 1 9998671 2366673 Wave spring (large)
42 1 9943082 9943103 Ball (large)
43 1 9941512 9943017 Ball (small)
44 1 9974092 O-ring
46 1 9974107 O-ring
50 3 9907124 Hexagon screw
57 1 369926 / Ball guide for high-viscosity products
60 1 9998808 Mobilux EP 2 grease
61 1 9992609 Anti-seize paste tube
62 1 9992616 Molykote DX grease
70 1 2329922 2370580 Fitting SF-MM-G3/8"-M24x1.5-PN530-SSt
71 1 2329898 2367066 Sealing sleeve
111 1 2331585 / Valve seat set 70, stainless steel*
= Wearing parts
= Included in the service set (For more parts, see Chapter 14.4.1.)
= Special accessories
2 / / 367900 Sealing collar T (small)
2 / 367922 / -- Sealing collar L (small)
2 368522 / / -- Sealing collar TG (large)
2 / / 368900 Sealing collar T (large)
2 / 368922 / -- Sealing collar L (large)
1 368990 / / / Service set PE/TG
1 / / 368994 / Service set PE/T
/ / / 2371972 Service set PE/T TC 1.4404
1 / 2342071 / / Service set PE/L
ORDER NUMBER DOC 2333538
Order No.
IceBreaker 40-150 cm3
Designation
83
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
14.5.3 FLUID SECTIONS 110 CM
Pos. 4 Tighten by hand on block.
Use a standard wrench only if
necessary. In this case, use a wrench to
counterhold pos. 3.
8
1
60
2
61
3
70 Nm
52 lbft
60
61
+10 Nm
+ 7 lbft
60
60
61
57
60
44
16
20
21
20
21
17
40
21
100
101
102
60
28
10
12
11
13
46
5
43
6
25
3
25
7
42
27
9
4
100 Nm
106
60
74 lbft
B_05267
41
19
23
103
22
104
23
105
22
23
18
Order No. Order No. Order No.
107
50
51
Designation
1 1 2329654 2329658 2329656 Fluid section
2 1 368434 Pipe
3 1 368435 Cylinder
4 1 2327888 Inlet housing 150
61
62
160 Nm
118 lbft
84
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
Order No. Order No. Order No.
5 1 368433 Piston
6 1 367506 Valve screw
7 1 368507 Ball guide, inlet
8 1 368551 Connecting ange
9 1 368509 Valve seat, inlet
10 1 367510 Valve seat, outlet
11 1 368561 Snap ring ange
12 2 368512 Snap ring half
13 1 368513 Securing ring
16 1 368428 Support ring
17 1 368425 Pressure ring
18 1 368430 Support ring
19 1 368432 Pressure ring
100 1 368253 / / Packing PE/TG, complete (small)
101 1 / / 368297 Packing PE/T, complete (small)
102 1 / 368295 / Packing PE/L, complete (small)
20 2 368426 / / Sealing collar TG (small)
20 2 / / 368436 Sealing collar T (small)
20 2 / 368437 / Sealing collar L (small)
21 3 368427 Sealing collar PE (small)
103 1 368299 / / Packing PE/TG, complete (large)
104 1 / / 368296 Packing PE/T, complete (large)
105 1 / 368294 / Packing PE/L, complete (large)
22 2 368429 / / Sealing collar TG (large)
22 2 / / 368438 Sealing collar T (large)
22 2 / 368439 / Sealing collar L (large)
23 3 368431 Sealing collar PE (large)
25 2 368525 O-ring
27 1 368527 O-ring
28 1 367528 O-ring
40 1 9998670 Wave spring (small)
41 1 9998671 Wave spring (large)
42 1 9943082 Ball (large)
43 1 9941518 Ball (small)
44 1 9974092 O-ring
46 1 9974107 O-ring
50 3 9907142 Hexagon screw
51 3 9925011 Washer
57 1 369926 Ball guide for high-viscosity products
60 1 9998808 Mobilux EP 2 grease
61 1 9992609 Anti-seize paste tube
62 1 9992616 Molykote DX grease
106 1 2329922 Fitting SF-MM-G3/8"-M24x1.5-PN530-SSt
107 1 2329898 Sealing sleeve
1 368997 / / Service set PE/TG
1 / / 2304930 Service set PE/T
1 / 2319924 / Service set PE/L
Wearing parts
= Included in the service set (For more parts, see Chapter 14.5.1.)
Special accessories
Designation
85
VERSION 08/2018
14.5.4 FLUID SECTIONS 150 CM3
Pos. 4 Tighten by hand on block.
Use a standard wrench only if
necessary. In this case, use a wrench to
counterhold pos. 3.
8
ORDER NUMBER DOC 2333538
5
43
28
10
6
25
12
11
IceBreaker 40-150 cm3
60
60
61
+10 Nm
70 Nm
+ 7 lbft
52 lbft
60
1
60
2
61
100 Nm
106
74 lbft
44
16
20
17
41
21
20
21
21
40
100
101
102
60
46
107
3
13
25
7
42
27
9
4
61
57
60
61
19
60
B_05268
23
18
23
22
23
22
103
104
105
50
51
160 Nm
118 lbft
62
86
VERSION 08/2018
1 1 2329650 2329664 2329652 Fluid section
2 1 368552 Pipe
3 1 368553 Cylinder
4 1 2327888 Inlet housing 150
5 1 368555 Piston
6 1 368506 Valve screw
7 1 368507 Ball guide, inlet
8 1 368551 Connecting ange
9 1 368509 Valve seat, inlet
10 1 368510 Valve seat, outlet
11 1 368561 Snap ring ange
12 2 368512 Snap ring half
13 1 368513 Securing ring
16 1 368516 Support ring
17 1 367519 Pressure ring
18 1 368518 Support ring
19 1 368519 Pressure ring
100 1 367991 / / Packing PE/TG, complete (small)
101 1 / / 367992 Packing PE/T, complete (small)
102 1 / 367993 / Packing PE/L, complete (small)
2 367522 / / Sealing collar TG (small)
20
21 3 367523 Sealing collar PE (small)
103 1 368991 / / Packing PE/TG, complete (large)
104 1 / / 368992 Packing PE/T, complete (large)
105 1 / 368993 / Packing PE/L, complete (large)
22
23 3 368523 Sealing collar PE (large)
25 2 368525 O-ring
27 1 368527 O-ring
28 1 368528 O-ring
40 1 9998670 Wave spring (small)
41 1 9998671 Wave spring (large)
42 1 9943082 Ball (large)
43 1 9941512 Ball (small)
44 1 9974092 O-ring
46 1 9974107 O-ring
50 3 9907142 Hexagon screw
51 3 9925011 Washer
57 1 369926 Ball guide for high-viscosity products
60 1 9998808 Mobilux EP 2 grease
61 1 9992609 Anti-seize paste tube
62 1 9992616 Molykote DX grease
106 1 2329922 Fitting SF-MM-G3/8"-M24x1.5-PN530-SSt
107 1 2329898 Sealing sleeve
Wearing parts
= Included in the service set (For more parts, see Chapter 14.4.2.)
Special accessories
2 / / 367900 Sealing collar T (small)
2 / 367922 / Sealing collar L (small)
2 368522 / / Sealing collar TG (large)
2 / / 368900 Sealing collar T (large)
2 / 368922 / Sealing collar L (large)
1 368990 / / Service set PE/TG
1 ⁄ / 368994 Service set PE/T
1 / 2342071 / Service set PE/L
ORDER NUMBER DOC 2333538
Designation
IceBreaker 40-150 cm3
87
VERSION 08/2018
3
ORDER NUMBER DOC 2333538
14.6 INLET VALVE WITH VALVE DEPRESSOR
2
3
4
5
1
6
7
9
IceBreaker 40-150 cm3
B_04072
8
Fluid section 40 cm3 Fluid section 70 cm3
DesignationOrder No. Order No.
1 1 2329689 2329688 Inlet valve with valve depressor
2 1 367507 368507 Ball guide, inlet
3 1 9941513 9943082 Ball
4 1 367527 368527 O-ring
5 1 367509 368509 Valve seat, inlet
6 1 2329412 2329413 Inlet housing
7 1 368037 Valve tappet, complete
8 1 2329898 Sealing sleeve
9 1 9992528 Loctite 270
Wearing parts
14.7 RELIEF COMBINATION 270 BAR
3
7
1
4
8
5
2
7
7
9
6
100 Nm
74 lbft
27MPa; 270bar; 3916psi
B_04068
Order no. Designation
1 1 2329023 Relief combination, 270 bar
2 1 2324549 Relief housing
3 2 2323718 Hexagon plug
4
5 1 2324552 Outlet pipe
6 1 3204611 Fitting DF-MM-G1/4"-G1/4"-PN530-SSt
1 169248 Relief valve, complete
1 2356467 Ball valve set (option)
7 1 9992831 Loctite 542, 50 ml; 50cc
8 1 9992616 Molykote DX grease
9 1 9992609 Anti-seize paste tube
Wearing parts
Not part of the standard equipment but available as a special accessory.
88
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.8 STRAIGHT INLINE FILTER, 270 BAR
2
3
1
6
B_04070
27MPa; 270bar; 3916psi
4
5
Order no. Designation
1 1 2324558 Inline lter DN6-PN270-G1/4"-SSt
2 1 2324550 Filter inlet housing
3 1 128389 Seal
1 2315723 * Filter insert, red (ne), 200 mesh per inch – 10 pieces
1 2315724 * Filter insert, blue (middle), 150 mesh per inch – 10 pieces
4
1 2315725 * Filter insert, yellow (middle), 100 mesh per inch – 10 pieces
1 2365429 * Filter insert, green (coarse), 30 mesh per inch – 10 pieces
1 2315726 * Filter insert, white (coarse), 50 mesh per inch – 10 pieces
5 1 2324551 Filter outlet housing
6 1 9992609 Anti-seize paste tube
Wearing parts
Not part of the standard equipment but available as a special accessory.
IceBreaker 40-150 cm3
14.9 ANGLED INLINE FILTER, 530 BAR
2
7
1
6
B_04071
53MPa; 530bar; 7687psi
3
4
5
Order no. Designation
1 1 2329026 Inline lter HL DN6-PN530-G1/4"-SSt
2 1 2326045 Filter inlet housing, pre-assembled
1 2315723 * Filter insert, red (ne), 200 mesh per inch – 10 pieces
1 2315724 * Filter insert, blue (middle), 150 mesh per inch – 10 pieces
3
1 2315725 * Filter insert, yellow (middle), 100 mesh per inch – 10 pieces
1 2365429 * Filter insert, green (coarse), 30 mesh per inch – 10 pieces
1 2315726 * Filter insert, white (coarse), 50 mesh per inch – 10 pieces
4 1 2311491 Turning handle
5 1 2325950 Filter outlet housing 90°, pre-assembled
6 1 9992609 Anti-seize paste tube
7 1 128389 Seal
Wearing parts
Not part of the standard equipment but available as a special accessory.
89
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.10 HIGHPRESSURE FILTER, 270 BAR
27MPa; 270bar; 3916psi
IceBreaker 40-150 cm3
90 Nm; 66 lbft
23
34
3
Tighten pos. 3 by hand
2
21
35
5
1
12
Identication of the lter
11
37
8
140 Nm; 103 lbft
4
36
13
10
36
7
34
B_04069
90
VERSION 08/2018
Order no. Designation
1 1 2329024 HP lter DN10-PN270 SSt, complete
2 1 2324542 Filter housing
3 1 2324543 Union nut
4 1 2325826 Reducing double tting with 2x60°
5 1 9955863 O-ring
7 1 2324544 Distribution housing
8
10 1 9894245 Filter support
11 1 -- Filter cartridge *
12 1 3514058 Cone spring
13 1 2324552 Outlet pipe
21 1 2325562 Pressure ring d45
23 1 2323718 Hexagon plug
34 1 9992831 Loctite 542 50 ml; 50 cc
35 1 9998808 Mobilux EP2 grease
36 1 9992609 Anti-seize paste tube
37 1 9992616 Molykote DX grease
Wearing parts
Not part of the standard equipment but available as a special accessory.
1 169248 Relief valve
1 2356467 Ball valve set (option)
295721 * Filter sieve, 200 mesh per inch (ne)
3514068 * Filter sieve, 100 mesh per inch (medium), mesh width 0.16 mm
3514069 * Filter sieve, 50 mesh per inch (rough)
291564 * Filter sieve, 20 mesh per inch (rough)
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
91
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.11 HIGHPRESSURE FILTER, 530 BAR
53MPa; 530bar; 7687psi
IceBreaker 40-150 cm3
90 Nm; 66 lbft
23
34
3
Tighten pos. 3 by hand
2
21
35
5
12
Identication of the lter
1
11
36
140 Nm
103 lbft
B_03934
10
36
7
34
4
13
20
Stainless steel
34
20
Carbon steel
34
33
92
VERSION 08/2018
Stainless
steel Carbon steel
1 1 2329025 2335334 HP lter DN12-PN530, complete
2 1 2324542 Filter housing
3 1 2324543 Union nut
4 1 2330780 Fitting DF-MM-G1/2-G3/8-PN530-SSt
5 1 9955863 O-ring
7 1 2324670 Distribution housing for ball valve
10 1 9894245 Filter support
11 1 Filter cartridge *
12 1 3514058 Cone spring
13 1 2328291 / Fitting-DF-MM-R3/8-R1/4-PN530-SSt
20 1 2330156 9998679 Ball valve
21 1 2325562 Pressure ring d45
23 1 2323718 Hexagon plug
33 1 3204611 2325826 Double connector
34 1 9992831 Loctite 542 50 ml; 50 cc
35 1 9998808 Mobilux EP2 grease
36 1 9992609 Anti-seize paste tube
Wearing parts
Not part of the standard equipment but available as a special accessory.
ORDER NUMBER DOC 2333538
DesignationOrder No. Order No.
295721 * Filter sieve, 200 mesh per inch (ne)
3514068
3514069 * Filter sieve, 50 mesh per inch (rough)
291564 * Filter sieve, 20 mesh per inch (rough)
* Filter sieve, 100 mesh per inch (medium), mesh width 0.16
mm
IceBreaker 40-150 cm3
93
VERSION 08/2018
B_06938
2
5
*
4
15
15
16
17
18
19
20
ORDER NUMBER DOC 2333538
14.12 AIRCOAT REGULATOR AND AIRCOAT FILTER REGULATOR
IceBreaker 40-150 cm3
AirCoat lter regulator
14
AirCoat Regulator
6
3
14
7
5
1
9
11
*
12
B_05400
Pos 3 or 4:
*
Observe the ow direction (direction of arrow on the housing)
10
8
13
Pos 5:
Screw in the pressure gauge only until the white sealing ring is completely inside the lter control
valve. Thereafter continue turning the pressure gauge only to align the display scale.
AirCoat Regulator AirCoat lter regulator
DesignationOrder No. Order No.
1 1 2328611 / AirCoat regulator set
2 1 / 2382997 AirCoat lter regulator set
3 1 2309972 / Pressure regulator LR-1/4-D-O-l-Mini
4 1 / 2331950 Filter control valve (manual drain)
/ 2360259 Option: lter pan (automatic drain)
5 1 9998677 Pressure gauge, 0-10 bar RF40 (d40)
6 1 9974166 / O-ring
7 1 2325527 / Holding plate
8 1 9906021 / Hexagon socket cylinder head screw
9 1 9900320 / Hexagon socket cylinder head screw
10 1 9994627 / Double tting R1/4-R1/4
11 1 9971313 / O-ring
12 1 9992831 / Loctite 542
13 1 9992616 / Molykote DX grease
14 1 9998808 / Mobilux EP 2 grease
15 1 / 9992528 Loctite 270
16 1 / 2366466 Contact plate
17 1 / 2389277 Fitting EF-MM-G1/4-R1/4-530 bar
18 2 / 9900152 Hexagon screw without shaft
19 3 / 9920104 Washer
20 1 / 9998719 Detachable double tting
Wearing parts
94
VERSION 08/2018
ORDER NUMBER DOC 2333538
14.13 TROLLEY FOR WILDCAT, PUMA AND LEOPARD
IceBreaker 40-150 cm3
15
5
10
17
Distance
13
2
14
9
A
B
11
12
4
5
16
6
3
7
8
B_03932
Wildcat Puma Leopard
DesignationOrder No. Order No.
1 1 2325901 2325916 Trolley, complete
2 1 -- Frame, left, 4"-6" (welded)
3 1 -- Frame, right, 4"-6" (welded)
4 4 9907140 Hexagon screw DIN931 M6x75
5 6 9910204 Self-locking hexagon nut, M6
6 2 2304440 Wheel, D250
7 4 340372 Washer
8 4 9995302 Cotter pin
9 1 -- Wheel axle, 4"-6"
10 2 367943 Connecting part, 4"-6"
11 2 -- Tube plug, ribbed
12 2 -- Saddle feet for round tubes
13 2 -- Plug
14 4 9900218 9900126 Hexagon screw
15 1 2332143 2332145 Wall mount
16 2 3061695 Hexagon screw without shaft, M6x55
17 2 9998747 Handle
Wearing parts
1
95
VERSION 08/2018
B_05285
ORDER NUMBER DOC 2333538
14.14 TROLLEY FOR LEOPARD 48110 AND JAGUAR
IceBreaker 40-150 cm3
Assembly
Mount bracket holder (3) above
the crossbar (4).
3
3
5
4
6
1
7
8
9
10
B_05277
Leopard 48-110 (6") Jaguar 75-150 (9")
DesignationOrder No. Order No.
1 1 2339705 PC heavy duty trolley
3 1 -- Bracket holder
5 4 9900246 Hexagon screw
6 4 9920102 Washer, A8.4
7 4 3155404 Contact washer, M8
8 4 9910208 Self-locking hexagon nut, M8
9 4 9925031 9920102 Washer, A6.4 or A8.4
10 4 9900126 9900130 Hexagon screw
3
96
VERSION 08/2018
ORDER NUMBER DOC 2333538
IceBreaker 40-150 cm3
15 EU DECLARATION OF CONFORMITY
Herewith we declare that the supplied version of pneumatic pumps and their spraypacks:
10-70 28-40 21-110 35-70 48-110 75-150
18-40 15-70 15-150 35-150 / /
complies with the following guidelines:
2006/42/EC 2014/34/EU
Applied standards, in particular:
DIN EN ISO 12100: 2010 DIN EN ISO 13732-1: 2008 EN ISO 80079-36:2016
DIN EN809: 1998+A1: 2009+AC: 2010 DIN EN14462:2015 EN ISO 80079-37:2016
DIN EN ISO 4413: 2010 DIN EN12621: 2006+A1: 2010 EN ISO/IEC 80079-34:2011
DIN EN ISO 4414: 2010 DIN EN 1127-1: 2011
Applied national technical standards and specications, in particular:
DGUV regulation 100-500 (Chapter 2.29 and 2.36)
Identication:
T3: without dry running protection.
T4: with dry running protection.
EU Declaration of Conformity
The EU Declaration 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: 2302304
97
98
C
E
R
T
I
F
I
E
D
Order No. 2333538
Edition 08/2018
ts-liquid@wagner-group.com
Document No. 11145601
Version D
www.wagner-group.com
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