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Owners Manual
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Warning!
Mortar spraying machines develop high spraying pressures.
Caution – risk of injury!
Never reach into the spray jet with your fingers or hands!
Never aim the spray lance at yourself or other persons!
The materials sprayed cause chemical burns or irritations!
Protect your skin and eyes!
Each time before starting up, follow the procedure below as
specified in the Operating manual:
1. PlastCoat 25
Only connect to the mains supply using a special distributing
point, e.g. using a site distribution system with fault current protection
with INF ≤30 mA.
PlastCoat 35
Only connect to the mains supply using a special distributing
point, e.g. using a site distribution system with fault current protection.
2. Observe the admissible working pressures.
3. Check all connections for leaks.
The instructions for regular cleaning and servicing of the machine
must be strictly adhered to.
Before starting any work on the machine and during breaks, follow
the procedure below:
1. Note the setting time of the material.
2. Relieve the pressure in the spray lance and hose.
3. Switch the machine off.
Be safety-conscious!
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Contents
Page
1 Safety requirements................................... 26
2 Introduction to working with the mortar
spraying machines PlastCoat 25 and 35..... 27
2.1 Operation of the mortar spraying machines
PlastCoat 25 and 35..................................... 27
2.2 What materials can be sprayed?.............. 27
3 Technical data PlastCoat 25 and 35......... 27
4 Equipment overview – mortar spraying
machines PlastCoat 25 and 35.................... 28
4.1 Control unit................................................. 29
4.1.1 Symbols on the changeover switch............. 29
4.2 Drive............................................................ 29
4.3 Receptacle.................................................. 29
Accessories for the receptacle..................... 30
4.3.1 Sliding cover................................................ 30
4.3.2 Sack mangle................................................ 30
4.3.3 Container suction system............................ 30
4.4 Compressor (accessory) .......................... 30
4.5 Mortar hose with electrical remote control 30
4.6 Spray lance with automatic control........... 31
4.7 Spray lance without automatic control.... 31
5 Transport..................................................... 31
5.1 Transport using a crane............................... 31
6 Coating materials equipment table
PlastCoat 25 and 35................................... 32/33
7 Placing into operation................................ 34-36
8 General requirements for application
technology.................................................... 36/37
9 Fitting accessories..................................... 37
9.1 Compressor................................................. 37
9.2 Sack mangle................................................ 37/38
Using coating materials in sacks................. 38
9.3 Container suction system............................ 38
Page
10 Placing out of operation and cleaning..... 38
10.1 Cleaning the mortar hose............................. 38/39
10.2 Cleaning device and changing pump jacket 39
10.3 Cleaning spray lance.................................... 39
11 Malfunction checklist................................. 40/41
12 Servicing..................................................... 41
Electrical equipment..................................... 41
Long-term storage....................................... 41
13 Spare parts list – PlastCoat 25 and 35..... 42
Spare parts illustration –
PlastCoat 25 and 35................................... 96
14 Spare parts list – Spray lances with
automatic control....................................... 43
Spare parts illustration – Spray lances
with automatic control............................... 97
15 Spare parts list – Spray lance without
automatic control....................................... 43
Spare parts illustration – Spray lance
without automatic control......................... 97
16 Spare parts list and spare parts
illustration – Compressor V 400................ 44
17 Spare parts list and spare parts
illustration – Compressor C 350............... 44
18 Spare parts list and spare parts
illustration – Container suction system.... 45
19 Accessories – PlastCoat 25 and 35.......... 46
Accessories illustration –
PlastCoat 25 and 35................................... 98/99
WAGNER-customer service depots.................... 47
Important notes on product liability................... 100
Guarantee declaration.......................................... 100
CE Declaration of conformity.............................. 102
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8. Prevent the socket for the remote control on the
control unit from getting dirty.
Always leave the coupler plug of the remote control
line on the mortar hose screwed complete into the
control unit.
9. Danger of injury from the screw
conveyor.
Never put your hands into the
receptacle when the mortar
spraying machine is running.
Never turn on the mortar spraying machine when
the grating has been removed from the
receptacle, when the receptacle has been
removed or if there is no container connection
plate.
10. Cleaning and servicing
Never uncouple mortar hoses under pressure.
Before uncoupling, check pressure on the pressure
gauge.
Turn off the mortar spraying machine for cleaning
and maintenance work. Pull out mains plug and
ensure that it cannot be plugged back in
unintentionally.
Do not spray the motor or control unit of the mortar
spraying machine with water jet, high-pressure or
steam cleaning equipment. Water could penetrate
the machine and cause a short-circuit.
11. Electrical equipment
Work on the machine’s electrical equipment may be
carried out only by a qualified electrician.
The electrical equipment must be inspected regularly. Defects such as loose connections or
scorched cables must be remedied immediately.
12. Keep the labels on the mortar spraying machine
clean and legible.
13. Positioning on uneven ground
The front of the mortar spraying machine must point
upwards to avoid that the machine slips away.
1 Safety requirements
All local safety regulations in force must be
observed.
For safe operation of the mortar spraying machines,
always comply with the following specific instructions:
1. Use of the mortar spraying machines
The mortar spraying machines PlastCoat 25 and
35 are designed only for the spraying of the
materials described on page 27.
Any other use is not permitted. The manufacturer
cannot be held liable for any damage resulting
from this. In such cases, the risk will be borne
solely by the user.
Intended use also includes compliance with the
Operating manual and compliance with the
inspection and servicing conditions.
Always keep the Operating manual ready at hand
at the machine location.
2. The mortar spraying machines PlastCoat 25 and
35 may only be operated with a pressure gauge.
Only the mortar hose prescribed by the
manufacturer may be used.
3. Only use identified mortar hoses with an
operating pressure of at least 40 bar.
4. Personnel safety
Always wear protective goggles, protective clothing
and gloves and, if necessary, skin barrier cream and
breathing equipment, to protect your eyes, skin and
respiratory system.
Never uncouple mortar hose while it is still under
pressure.
Note pressure gauge!
Wear protective goggles!
Never aim spray lance at any person!
5. Breathing masks
Breathing masks must be provided for the operator
to protect against mineral dust.
6. PlastCoat 25
Only connect to the mains supply using a special
distributing point, e.g. using site distribution
system with fault current protection with
INF ≤ 30 mA.
PlastCoat 35
Only connect to the mains supply using a special
distributing point, e.g. using a site distribution
system with fault current protection.
7. The master switch has an EMERGENCY OFF
function.
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2 Introduction to working
with the mortar spraying machines
PlastCoat 25 and 35
The mortar spraying machines can be combined with
continuous flow, gravitation compulsory or pan mixers
for the processing of mineral coating materials.
The container suction system (accessory) can be used
to suck directly from a container.
2.1 Operation of the mortar spraying machines
PlastCoat 25 and 35
The coating materials are supplied to the machine by
means of the receptacle. The spiral conveyor feeds the
coating material into an eccentric screw pump. This pump
generates the pressure required for the transport through
the mortar hose. The compressed air necessary for the
atomizing of the material is fed into the spray lance.
The mortar spraying machine can be switched on and
off using the electrical remote control.
The continuously adjustable feed rate of the coating
material can be used to create a soft, even spraying
pattern.
2.2 What materials can be sprayed?
• Heat insulating composite system adhesive
(mineral and synthetic resin systems)
• Synthetic resin plasters up to grain size of 5 mm
• Silicate plasters up to grain size 5
• Silicate resin plasters up to grain size 5
• Mineral final coat plaster up to grain size 5
• Light plaster systems up to grain size 5
• Scraped rendering up to grain size 5
• Insulation plaster
• Renovating plaster
• Foam mortar coating
• Quartz plastic
• Roof coatings
• Flameproof coatings
• Mineral sealing slurries
• Bitumen emulsions
• Reinforcing filler
• Liquid wood chip
• Frame sealing mortar
• Synthetic resin rendering base
• Primer
• Filling paints, incl. fiber containing
• Elastic coatings
• Acoustic plaster, synthetic resin bonded
• Filler, synthetic resin bonded
• Concrete trowel
All coating materials should be suitable for applying
using machines. See product data sheet for the coating
material to be used.
Only use other materials after prior consultation with the
manufacturer or WAGNER application technology dept.
3 Technical data
PlastCoat 25 PlastCoat 35
Voltage: 230 V ~, 50 Hz 400 V, 50 Hz, V3 ~
Fuse protection: 16 A slow-blow
Device mains cable
6 m long: 3 x 2.5 mm
2
5 x 1.5 mm
2
Motor output P1: 2.2 kW 3.6 kW
Max. feed rate (water)
Pump yellow: 10 l/min 15 l/min
Pump brown: 15 l/min 20 l/min
Pump green: 20 l/min 25 l/min
Max. operating pressure: 40 bar
Max. grain size: K 5 mm
Measurements L x W x H: 1200 x 520 x 660 mm
Receptacle capacity: 60 l
Weight: 85 kg 87 kg
Tire pressure, max.: 2.5 bar
Protective system: IP 54
Max. sound pressure level: 77 dB (A)*
Atomization air connection: Rapid action coupling
DN 7 mm
Max. atomization air pressure: 10 bar
Required volume of
compressed air, min: 220 l/min
Texture nozzle: 8 mm (standard)
Mortar hose: DN 27 mm, 10 m (standard)
* Measuring point: At a distance of 1m to the side of the
unit and at a height of 1.60 m above floor, reverberant
floor.
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4 Equipment overview – mortar spraying machines PlastCoat 25 and 35
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1 Control unit
2 Receptacle
3 Screw conveyor
4 Pump jacket – pump screw
5 Pressure gauge
6 Outlet unit
7 Compressed air connection
8 Mortar hose, assy.
9 Texture nozzle
10 Spray lance with automatic control
11 Switch sleeve, for switching the mortar spraying
machine on and off using remote control
12 Spray lance without automatic control
13 Remote control switch, for switching of the mortar
spraying machine on and off using remote control
14 Electric motor with transmission
15 Bar for wrapping the mains cable
16 Connection for remote control
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4.1 Control unit
1 Master switch 0 –1
2 Indicator lamp
3 Feed rate regulator 0 –10
4 Changeover switch
5 Mains cable
6 Connection for remote control
The mortar spraying machine can be switched on using
the master switch (1, fig. 3).
The indicator lamp (2) shows that the machine is ready
for operation.
The feed rate can be continuously adjusted by means of
the feed rate switch (3).
4.1.1 Symbols on the changeover switch (fig. 4)
1 Releasing the pressure or removing the pump jacket.
Pump runs in reverse direction.
2 "0" drive is switched off.
3 "AUTO" remote control using the spray lance.
4 Spraying or pulling on the pump jacket.
Pump runs in the forwards direction.
4.2 Drive
If overloading occurs then the mortar spraying machine
switches off. Turn master switch (1, fig. 3) and changeover switch (4, fig. 3) to "0". Wait at least 10 seconds
and then turn the mortar spraying machine back on.
4.3 Receptacle (fig. 5)
1 receptacle made of high-grade steel with grating.
Contents: 60 liter
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Accessories for the receptacle
4.3.1 Sliding cover
Prevents contamination getting into the coating
material. Extends the hardening time of the
coating material, particularly with direct sunlight.
4.3.2 Sack mangle
For using coating material in sacks, a sack mangle
can be placed on the sliding cover.
4.3.3 Container suction system
For sucking up coating material from a container,
an external container can be employed instead of
the receptacle.
4.4 Compressor (accessory)
V 400 suction volume 360 l/min (fig. 6)
1 Compressor holder
2 Compressed air connection
Note: Only operate the compressor according to the
operating manual included.
C 350 suction volume 350 l/min (fig. 7)
1 Compressor holder
2 Compressed air connection
Note: Only operate the compressor according to the
operating manual included.
4.5 Mortar hose with electrical remote
control
(fig. 8)
1 Material connection – mortar spraying machine
2 Remote control connection – mortar spraying
machine
3 Atomization air connection – compressed air supply
4 Material connection – spray lance
5 Mortar hose
6 Atomization air connection – spray lance
7 Remote control connection – spray lance or remote
control switch
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4.6 Spray lance with automatic control (fig. 9)
1 Material connection
2 Switch sleeve, switching the mortar spraying machine
on and off using remote control
3 Texture nozzle
4 Air tap
5 Material tap
6 Remote control connection
7 Atomization air connection
Various different texture nozzles can be fitted to the
spray lance, see accessories page 46, item 1.
The size of the nozzle depends on the grain size of the
coating material and the required spraying pattern.
4.7 Spray lance without automatic
control (fig. 10)
1 Atomization air connection
2 Air tap
3 Texture nozzle
4 Material tap
5 Material connection
Various different texture nozzle can be fitted to the spray
lance, see accessories page 46, item 1.
The size of the nozzle depends on the grain size of the
coating material and the required spraying pattern.
5 Transport
• Moving the mortar spraying machine on its wheels:
Hold the fold-out handles (1, fig. 11), lift and move.
• Carrying the mortar spraying machine:
Hold the fold-out handles (1) and front bar (2) and
lift.
5.1 Transport using a crane
For attaching points for the straps or rope (not wire
cable) see figure 11.
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Tabelle – Teil 1
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Tabelle – Teil 2
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7 Placing into operation
Installation location
Position mortar spraying machine in a level position to
prevent it from sliding away.
Compressor (accessory)
Attach compressor holder to the mortar spraying
machine. Place compressor onto holder and secure with
screws. Connect compressor to power supply.
Connecting mortar hose
• Check that the outlet unit (1, fig. 12) is seated firmly. If
necessary tighten star grips (2) by hand.
• Connect mortar hose (3) and secure with tension
levers (4).
• Screw remote control to connection (5) on the control
unit.
• Connect atomization air connection (6) on mortar hose
to the compressed air supply or compressor
(accessory).
Connecting spray lance with automatic system
• Assemble texture nozzle (1, fig. 13) on the spray lance
with cone in the direction of the spraying head.
The nozzle size should be at least three times the
grain size,
e.g., grain size synthetic resin plaster –> 3 mm
nozzle size –> 10 mm
• Connect spray lance (2) and secure with tension
levers (3).
• Close material tap (4).
• Screw coupling plug (5) for remote control to the
control cable of the mortar hose.
• Connect atomization air connection (6) to the air hose
of the mortar hose.
Connecting spray lance without automatic system
• Fasten remote control switch (1, fig. 14) with the two
O-rings (2) to the mortar hose.
• Screw coupling plug (3) for remote control on the
control cable of the mortar hose.
• Assemble texture nozzle (4) on the spray lance with
cone in the direction of the spraying head.
The nozzle size should be at least three times the
grain size,
e.g., grain size synthetic resin plaster –> 3 mm
nozzle size –> 10 mm
• Connect spray lance (5) and secure with tension
levers (6).
• Close material tap (7).
• Connect atomization air connection (8) to the air
hose of the mortar hose.
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Extension cable PlastCoat 25
The cross section of the cable must be
min. 3 x 2.5 mm2. Unwind extension
cable completely. Make sure that the
couplings and plugs are in complete
working order.
Extension cable PlastCoat 35
The cross section of the cable must be
min. 5 x 2.5 mm2. Unwind extension
cable completely. Make sure that the
couplings and plugs are in complete
working order.
Arrange the mains cable so that there is
no danger of it being tripped over.
Protect against damage, e.g., caused by
it being run over.
• Before connecting to the mains make sure that the
mains voltage is in accordance with the details on the
rating plate.
PlastCoat 25
• Only connect to the mains supply using a special
distributing point, e.g. using a site distribution system
with fault current protection with INF ≤ 30 mA.
PlastCoat 35
• Only connect to the mains supply using a special
distributing point, e.g. using a site distribution system
with fault current protection.
• Connect mortar spraying machine to the mains supply.
Preparing the mortar spraying machine
Recommended lubricant for the mortar hose
Water is not a satisfactory lubricant.
Danger of blockages!
Synthetic resin products –> synthetic resin
dispersion
PCC systems –> cellulose paste
• Fill 2–3 l synthetic resin dispersion or cellulose paste
into the receptacle.
• Caution: set changeover switch (4, fig. 15) to "0"
before turning on the master switch (1, fig. 15).
The pump is switched on, even if the feed
rate regulator is at position "0".
• Turn master switch (1, fig. 15) to "1", the indicator lamp
will show that the machine is ready for operation.
• Set feed rate regulator (3) to "5".
• Turn changeover switch (4) to "AUTO" (remote control
using spray lance).
• Hold spray lance over an empty bucket.
Spray lance with automatic control
• Open material tap (3, fig. 16) on the spray lance. The
mortar spraying machine will switch on.
Spray lance without automatic control
• Open material tap (3, fig. 17) on the spray lance. Press
remote control switch (1, fig. 17). The mortar spraying
machine will switch on.
Spray lance with automatic control
• When the synthetic resin dispersion or cellulose paste
has been pumped into the mortar hose – turn off
device, turn switching sleeve (1, fig. 16) by 90° in a
clockwise direction as far as it will go.
• Close material tap (3, fig. 16).
Spray lance without automatic control
• When the synthetic resin dispersion or cellulose paste
has been pumped into the mortar hose – turn off
device with remote control switch (1, fig. 17).
• Close material tap (3, fig. 17).
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• Check viscosity of the coating material.
• Fill coating material into the receptacle. With mineral
coating materials only fill the receptacle to half full.
Spray lance with automatic control
• Open material tap (3, fig. 16).
• The coating material will be pumped into the mortar
hose.
Spray lance without automatic control
• Open material tap (3, fig. 17).
• Turn on device with remote control switch (1, fig. 17).
• Coating material will be pumped into the mortar hose.
• Pump synthetic resin dispersion or cellulose paste
from the mortar hose into a bucket.
• As soon as coating material starts coming out of the
spray lance – turn off device using remote control and
close material tap on the spray lance.
• Hold spray lance over the receptacle.
• Open material tap (3, fig. 16 and 17) and turn on
device using remote control.
• Set the feed rate regulator (3, fig. 3, page 29) to the
required feed rate.
• Turn off device using remote control and close
material tap (3, fig. 16 and 17).
• Fasten mortar hose using hose holder to the frame
(each connecting hose separately).
Do not kink the mortar hose!
Protect it against damage e.g., resulting
from it being run over or from sharp
objects.
Starting the spraying procedure
• Open air tap (2, fig. 16 and 17) and material tap
(3, fig. 16 and 17) on the spray lance.
Spray lance without automatic control
Turn device on using remote control switch
(1, fig. 17).
End of the spraying procedure
Spray lance with automatic control
• Turn switching sleeve (1, fig. 16) 90° clockwise as far
as it will go.
• Wait 3–5 seconds.
• Close material tap (3, fig. 16).
Noncompliance with the above instructions
will result in additional wear of the material
tap.
• Close air tap (2, fig. 16).
Spray lance without automatic control
• Press remote control switch (1, fig. 17) on mortar
hose.
• Wait 3–5 seconds.
• Close material tap (3, fig. 17).
Noncompliance with the above instructions
will result in additional wear of the material
tap.
• Close air tap (2, fig. 17).
Spray lance with automatic control (fig. 16)
Spray lance without automatic control (fig. 17)
8 General requirements for application
technology
Spraying technique
Guide the spray lance at a uniform distance of
30 – 60 cm from the object when spraying. If you do not
do this, you will not achieve a regular spray pattern.
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The spray pattern is dependent upon the type of
material, material consistency, tip size, material delivery
rate and air delivery rate.
Examples:
fine texture ––> larger air delivery rate
coarse texture ––> low air delivery rateHigher
material delivery rate –> higher air delivery rate
We recommend that you test the required texture on a
sample surface.
To improve the "feathering effect" in order to allow
easier overlap, choose an appropriate distance between
the spray lance and the object surface.
The spray margin should "feather out" to allow easier
overlapping.
Considerably less spray mist is produced if the spray
lance is always guided at 90° parallel to the spray
surface.
Note: Sharp-edged grains and pigments will increase
wear on the pump, hose, material ball valve and
tip.
9 Fitting accessories
9.1 Compressor
V 400 suction volume 360 l/min
• Attach compressor holder (item 1, fig. 18) and
secure with star grip (2).
• Place compressor onto holder. Slide retaining plate
(3) over the compressor base.
• Secure the compressor with star grips (4).
Compressor
C 350 suction volume 350 l/min
• Attach compressor holder (item 1, fig. 19) and
secure with star grip (2).
• Place compressor onto holder, attach retaining
plate (3).
• Secure the compressor with star grips (4).
9.2 Sack mangle
• Use sack mangle together with sliding cover
(accessory item 1, fig. 20).
• Place sliding rails (2) under the sliding cover from the
front.
Turn crank handle and move sack mangle
backwards as far as it go.
• Adjust the pressure force of the roller (4) with the
star grips (3).
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Using coating materials in sacks
• Pull sliding cover back about 15 cm.
• Place sack on the sliding lid.
• Cut sack open.
• Allow the coating material to flow into the receptacle.
• Move sack mangle forwards over the sack by turning
the crank.
Danger of crushing
Do not place hands under the rollers.
9.3 Container suction system
• Turn off device at master switch.
• Pull out mains plug from the socket and ensure
that it cannot be plugged back in unintentionally.
• Unscrew the hexagon nuts (2) on the receptacle
(1, Fig. 21), remove washers.
• Remove receptacle.
• Attach container connection (3) to the base of the receptacle. Mount disks and secure with hexagon nuts (4).
• Connect suction hose (5) to container connection (3).
Alternatively, connect connecting bridge (6) to the
container connection (3) and connect suction hose
to connecting bridge.
• Fill suction hose with water and connect to the
container.
• Turn on mortar spraying machine.
Note:
All connections must be sealed air tight so that a
vacuum can be produced.
Place a small amount of machine lubricant onto the
rubber seals of the connections in order to allow for the
easy opening and closing of the connectors.
10 Placing out of operation and cleaning
Do not spray the motor or control unit of
the mortar spraying machine with water
jet, high-pressure or steam cleaning
equipment. Water could penetrate the
machine and cause a short-circuit.
10.1 Cleaning the mortar hose
• Pump until receptacle is empty.
When operating using the container suction system,
remove suction hose from the container.
Important: Do not let the mortar spray machine
run dry.
• Remove texture nozzle from spray lance and clean.
The mortar hose must be without
pressure. If necessary, turn changeover
switch briefly to (backwards).
Note the pressure gauge ––> 0 bar.
Wear protective goggles.
• Disconnect the mortar hose from the outlet section.
• Insert cleaning ball in the mortar hose.
Re-connect the mortar hose.
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• Fill water into receptacle.
When operating using the container suction system,
immerse suction hose into receptacle with water.
Turn on mortar spraying machine.
• After a few seconds the cleaning ball will come out
of the spray lance.
• Repeat cleaning procedure 3–4 times, depending on
the coating material used.
There is a further possibility for cleaning using the
cleaning adapter.
This cleaning adapter can be connected to a water hose
or tap with a claw coupling.
Place cleaning ball in the mortar hose.
Couple mortar hose to the cleaning adapter and rinse
through with water.
10.2 Cleaning device and changing pump jacket
Pump jacket disassembly
• Lubricate pump
Turn changeover switch to (backwards).
Spray pump antiseize or a little dishwashing liquid
into the outlet unit (2, fig. 22) or place a little
dishwashing liquid into the receptacle and pump
through the pump.
• Turn changeover switch to "0".
• Unscrew star grips (1, fig. 22).
• Remove outlet unit (2) towards the front.
• Set feed rate to "3".
• Turn changeover switch to (forwards).
Danger of crushing
• Pump jacket (3) will disconnect from pump screw.
• Set changeover switch to "0".
• Clean receptacle and receptacle lower section with a
water jet.
When operating using the container suction
system, turn off device using master switch.
Remove the mains plug from the socket and
ensure that it cannot be replaced
unintentionally.
• Unscrew and remove container connection from the
receptacle lower section.
• Clean receptacle lower section, container connection
and suction hose with a water jet and, if necessary,
using a suitable brush.
• Clean pump screw and pump jacket thoroughly with
water.
• Clean outlet unit (2) inside using a bottle brush.
• Keep threads for the star grips clean and grease.
Pump jacket assembly
Important: Spray pump screw and pump jacket with
pump antiseize or wet with dishwashing
liquid.
• Turn changeover switch to (backwards).
Danger of crushing
• Place pump jacket (3) onto pump screw.
• Ensure that the ledge of the pump jacket (3) is
properly slid into the rectangular recess of the pump
trigger (4).
• Pump jacket pulls itself onto the pump screw.
• Set changeover switch to "0".
• Assemble outlet unit.
10.3 Cleaning spray lance
• Clean texture nozzle.
• Clean air holes in the texture nozzle with a cleaning
needle.
• Clean the inside of the spray lance with a bottle
brush
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11 Malfunction checklist
40
Fault
Motar spraying
machine does not
start
Mortar spraying
machine cannot turn
pump screw.
Mortar spraying
machine cannot be
switched on/off by
means of the remote
control.
Mortar spraying
machine builds up
pressure in the mortar
hose. However, no
coating material
comes out of the
spray lance.
The spray jet stops
while spraying,
"spluttering" occurs.
Coating material
suddenly stops
coming out while
spraying.
No clean, even
spraying pattern.
Possible cause
The mortar spraying machine has been
overloaded.
Pump screw is stuck in pump jacket.
Pump was not lubricated with pump
antiseize.
Remote control not on.
Remote control line not connected or
defect.
Coating material "blockages" in mortar
hose. Motor hose not pre-rinsed with
synthetic resin dispersion or cellulose paste.
No coating material in receptacle.
Pump has sucked up air.
Coating material is not sliding down in the
receptacle.
Blockage in texture nozzle due to impurities
in the coating material or too large grain
size.
Air channels in the texture nozzle are
partially blocked with coating material.
Remedy
Set master switch and changeover switch to
„0“.
Turn mortar spraying machine back on after
about 10 sec.
Caution: set changeover switch to „0“
before turning on master switch.
Set delivery rate switch to “0”. Set
changeover switch to (forward).
As soon as the pump screw rotates at a
constant speed, slowly set the delivery rate
switch to the desired delivery rate.
Set changeover switch to "AUTO".
Connect remote control, check
connections, check remote control line for
damage.
Find blockage by feeling the mortar hose.
Remove pressure from mortar hose set
changeover switch to (backwards).
Pump coating material back into receptacle.
Mortar hose must be without pressure.
Observe pressure gauge ––> 0
bar.
Wear protective goggles.
Disconnect mortar hose – bend the blocked
area by hand. Rinse mortar hose with a
water hose. When the blockage has been
removed, fill the mortar hose with synthetic
resin dispersion or cellulose paste. Reconnect mortar hose.
Fill with coating material and pump in
circulation until coating material is free of
bubbles.
Caution:
Do not allow the pump to run dry. The
pump will heat up, thus danger of
"blockage". Refill with coating material.
In all cases turn off mortar spraying machine
(see safety requirements) – then push down
the coating material.
Turn off mortar spraying machine. Close the
material tap on the spray lance. Remove
texture nozzle and clean. If necessary, use
larger texture nozzle.
Rule of thumb:
Grain size x 3 ––> Nozzle size.
Turn off mortar spraying machine.
Close material tap on spray lance.
Remove texture nozzle. Clean air channels
in the texture nozzle.
g
Page 19
Fault
Pressure on the pressure gauge increases
to over 40 bar.
Mortar spraying
machine does not
transport sufficient
coating material.
Mortar spraying
machine does not
start
Possible cause
Viscosity of the coating material too high.
Mortar hose diameter too narrow.
Mortar hose too long.
Flow speed selected too low.
Mortar hose diameter too narrow.
Pump jacket worn.
Viscosity of the coating material too high.
Texture nozzle too small.
The mortar spraying machine has been
overloaded.
41
Remedy
Dilute the coating material.
Use a mortar hose with a larger diameter.
Use shorter mortar hose.
Set feed rate to a higher setting.
Use a mortar hose with a larger diameter.
Install new pump jacket and, if necessary,
new pump screw.
Caution: Spray with pump antiseize.
Dilute coating material.
Select a larger texture nozzle.
Set master switch and changeover switch to
"0".
Turn mortar spraying machine back on after
about 20 sec.
Caution: set changeover switch to "0"
before turning on master switch.
If none of the above-mentioned possible causes was the reason for malfunction, there must be
a defect which will be repaired by the WAGNER after-sales service.
12 Servicing
• Keep the threads for the star grips clean and oiled.
• Spray pump screw and pump jacket with pump
antiseize.
• Geared-motor is maintenance-free.
Electrical equipment
Check lines and plug connections. Rectify faults such as
loose connections, smoldered wires or dirty or damp
plug connections immediately.
Work and repairs on the electrical
equipment may be carried out only
by a qualified electrician even if the
product is accompanied with
operating instructions. We are unable
to assume liability for the consequences of incorrect installation.
Long-term storage
If it is intended to store the machine for a long period, it
must be thoroughly cleaned and protected against
corrosion beforehand.
g
Page 20
42
g
1 0348 363 0348 363 Motor cable
2 9982 820 9982 820 Cable screw connection
3 9982 823 9982 823 Adapter
4 0348 230 ––––––– Transmission motor 230 V앑, 50 Hz
––––––– 0348 231 Transmission motor 400 V, 50 Hz, V3앑
5 9900 204 9900 204 Hexagon screw M 8 x 35 DIN 931 (2)
6 9920 102 9920 102 Washer A 8,4 DIN 125
7 9900 125 9900 125 Hexagon screw M 8 x 50 DIN 933
9 0348 334 0348 334 Supporting ring
10 9972 331 9972 331 Grooved ring 32 x 50 x 10
11 0348 400 0348 400 Intermediate flange
12 9971 171 9971 171 O-Ring 90 x 3,5
14 9930 913 9930 913 Straight pin 8 x 40
15 0348 324 0348 324 Screw
16 9921 518 9921 518 Lock washer B12 DIN 127
17 0348 313 0348 313 Carrier bush
18 9922 746 9922 746 Snap ring A 45
19 0348 314 0348 314 Feed screw
21 0348 329 0348 329 Grating
22 0348 307 0348 307 Receptacle
23 9900 109 9900 109 Hexagon screw M 8 x 25 DIN 933
24 0348 396 ––––––– Type plate PlastCoat 25
––––––– 0348 397 Type plate PlastCoat 35
25 9910 107 9910 107 Hexagon nut M8 DIN 934
26 0348 310 0348 310 Receptacle seal
27 0348 306 0348 306 Receptacle lower part
13 Spare parts list PlastCoat 25 and 35 (Spare parts illustration, see page 96)
30 9910 208 9910 208 Hexagon nut M 8 DIN 985
31 9900 118 9900 118 Hexagon screw M 8 x 30 DIN 933
32 0348 316 0348 316 Pump screw yellow W 10/3 (standard)
33 0348 315 0348 315 Pump jacket yellow W 10/3 (standard)
34 9990 368 9990 368 Star grip M 16
35 0342 321 0342 321 Adapter fix-nipple V 35-M 27
36 0348 233 0348 233 Outlet unit
37 9990 618 9990 618 Coupling
38 9970 109 9970 109 Sealing ring
39 9991 946 9991 946 Pressure gauge
40 9991 947 9991 947 Protective cap
41 0348 349 0348 349 Wheel
42 9994 902 9994 902 Wheel cap
43 0348 419 0348 419 Trolley frame
44 9900 317 9900 317 Cheese head screw M 8 x 50 DIN 912
45 9990 863 9990 863 Pipe end cap
46 0348 318 0348 318 Drawbar tube right
47 9920 103 9920 103 Washer A 6,4 DIN 125
48 9910 204 9910 204 Hexagon nut M 6 DIN 985
49 0348 347 0348 347 Drawbar pipe left
50 0348 422 ––––––– Device mains connection H07 RN-F3G2,5 – 6 m
––––––– 0348 424 Device mains connection H07 RN-F5G1,5 – 6 m
51 9982 822 9982 822 Cable screw connection
52 9951 063 9951 063 Hexagon nut
53 9951 078 9951 078 Hexagon nut
Item Part No. Part No. Designation
PlastCoat 25 PlastCoat 35
Item Part No. Part No. Designation
PlastCoat 25 PlastCoat 35
Page 21
43
g
0348 224 0348 919 Spray lance with automatic control
0348 904 0348 904 Extension kit 500 mm long
(material pipe and air pipe)
0348 923 –––––––– Extension kit 800 mm long
(material pipe and air pipe)
1 9910 204 9910 204 Hexagon nut M6 DIN 985
2 3050 347 3050 347 Washer 6.4 DIN 433
3 0348 225 0348 225 Lever
4 3051 679 3051 679 O-ring 35 x 2
5 0348 354 ––––––– Air pipe 100 mm long
0348 921 0348 921 Air pipe 800 mm long
0348 942 0348 942 Air pipe 500 mm long
6 0348 355 0348 355 Nozzle head
7 0268 779 0268 779 Texture nozzle 4
0348 915 0348 915 Texture nozzle 5
0268 780 0268 780 Texture nozzle 6
0348 916 0348 916 Texture nozzle 7
0268 781 0268 781 Texture nozzle 8 (standard)
0348 917 0348 917 Texture nozzle 9
0268 782 0268 782 Texture nozzle 10
14 Spare parts list – Spray lances with automatic control (Spare parts illustration, see page 97)
Item Part No. Part No. Designation
Spray lance Spray lance
(ceiling spray
lance)
100 mm long 800 mm long
15 Spare parts list – Spray lance without automatic control (Spare parts illustration, see page 97)
Item Part No. Designation
Spray lance
100 mm long
0342 200 Spray lance without automatic control
1 0268 779 Texture nozzle 4
0348 915 Texture nozzle 5
0268 780 Texture nozzle 6
0348 916 Texture nozzle 7
0268 781 Texture nozzle 8 (standard)
0348 917 Texture nozzle 9
0268 782 Texture nozzle 10
0342 327 Texture nozzle 12
2 0342 350 Sealing washer
3 0342 351 Union nut
4 0268 604 Air hose*
5 9991 112 Ball tap*
6 0268 470 Nozzle head
7 0342 469 Material pipe*
8 9991 111 Ball tap
9 9983 237 Double nipple 3/4 in – 1 in
9983 238 Double nipple 3/4 in – round thread 32 x 1/8 in
10 0342 313 Fix nipple connection V 27
* Loctite 222
0342 327 0342 327 Texture nozzle 12
8 0342 350 0342 350 Sealing washer
9 0342 351 0342 351 Union nut
10 0348 346 –––––––– Material pipe 100 mm long
0348 922 0348 922 Material pipe 800 mm long
0348 943 0348 943 Material pipe 500 mm long
11 9902 309 9902 309 Pan head taping screw 4.2 x 16
12 0348 384 0348 384 Cover
13 0348 216 0348 216 Cable
14 0348 226 0348 226 Connection sleeve
15 3105 540 3105 540 O-ring 26 x 2
16 9991 111 9991 111 Ball tap
17 9983 237 9983 237 Double nipple 3/4 in – 1 in
9983 238 9983 238 Double nipple 3/4 in – round
thread 32 x 1/8 in
18 0342 313 0342 313 Fix nipple connectionV 27
19 9991 112 9991 112 Ball tap*
20 0268 604 0268 604 Air hose*
* Loctite 222
Item Part No. Part No. Designation
Spray lance Spray lance
(ceiling spray
lance)
100 mm long 800 mm long
Page 22
44
g
1 0342 231 Compressor V 400, 230 V~, 50 Hz
suction volume 360 l/min
2 9992 823 Rapid action coupling
3 0348 452 Retaining plate
4 0348 442 Compressor holder
5 9990 373 Star grip M 8
6 0348 957 Compressor holder
16 Spare parts list – Compressor V 400
Item Part No. Designation
5
5
2
1
6
3
4
1 0348 955 Compressor C 350, 230 V~, 50 Hz
suction volume 350 l/min
2 9993 040 Rapid action coupling
3 0348 439 Compressor holder
4 0348 440 Retaining plate
5 9990 373 Star grip M 8
6 0348 956 Compressor holder
17 Spare parts list – Compressor C 350
Item Part No. Designation
5
3
1
6
5
4
2
Page 23
g
45
18 Spare parts list – Container suction system
Item Part No. Designation
1 0348 907 Container suction system
2 0097 100 Seal
3 0342 205 Suction hose
4 0097 085 Coupling
5 0348 361 Connecting plate
6 0348 947 Connecting bridge
7 0097 105 Coupling
2
2
4
5
3
2
2
7
7
2
6
1
Page 24
g
46
19 Accessories PlastCoat 25 and 35 (Accessories illustration, see page 98/99)
Item Part No. Designation
1 0268 779 Texture nozzle 4
0348 915 Texture nozzle 5
0268 780 Texture nozzle 6
0348 916 Texture nozzle 7
0268 781 Texture nozzle (standard)
0348 917 Texture nozzle 9
0268 782 Texture nozzle 10
0342 327 Texture nozzle 12
0268 905 Texture nozzle set 4, 6, 8, 10
2 0342 916 Cleaning needle
3 0342 330 Cleaning ball for DN 19 mm
0342 331 Cleaning ball for DN 27 mm
0342 332 Cleaning ball for DN 35 mm
4 0342 329 Bottle brush for cleaning the inside
of the outlet unit and spray lance
5 9992 824 Pump antiseize 500 ml
6 0342 215 Hose holder
7 0342 241 Cleaning adapter M 27 – GK
0348 948 Cleaning adapter M 35 – GK
8 0342 321 Adapter fix-nipple V 35 – M 27
9 0348 946 Mortar hose DN 35 – 13.3 m,
connection V 35 – M 35
0348 912 Mortar hose DN 27 – 10 m,
connection V 27 – M 27
0348 930 Mortar hose DN 19 – 20 m,
connection V 27 – round thread
32 x 1/8 in
0348 909 Mortar hose DN 19 – 10 m,
connection V 27 – round thread
32 x 1/8 in
0342 255 Mortar hose DN 19 – 2 m,
connection V 27 – round thread
32 x 1/8 in
10 9952 672 Plug
11 0342 314 Seal fix-coupling M 27
9971 531 Seal fix-coupling M 35
12 9952 673 Coupling plug
13 0268 216 Pressure switch for remote control of
spray lance without automatic control
14 9983 238 Double nipple 3/4 in – round thread
32 x 1/8 in
15 0342 200 Spray lance 100 mm long
without automatic control
Item Part No. Designation
16 0348 224 Spray lance 100 mm long
with automatic control
17 0348 931 Angled spraying head 70°
for spray lance with automatic control
18 0348 904 Extension kit 500 mm long
material pipe and air pipe) for spray lance
with automatic control
0348 923 Extension kit 800 mm
(material pipe and air pipe)
for spray lance with automatic control
19 0348 919 Spray lance (ceiling spray lance)
800 mm long with automatic control
20 0342 912 Rendering lance 200 U
21 0268 726 Rendering nozzle set 14, 16, 18
22 0342 240 Texture spraying head for application gun
23 0342 246 Application gun, connection V 27
for the application of heat insulation
composite system adhesive
24 0342 231 Compressor V 400, 230 V AC,
50Hz,suction volume 360 l/min
without automatic switch-off
0342 906 Compressor V 400, 230 V~, 50 Hz,
suction volume 360 l/min
with automatic switch-off
25 0348 957 Compressor holder V 400
26 0348 955 Compressor C 350, 230 V~, 50 Hz,
suction volume 350 l/min,
without automatic switch-off
27 0348 956 Compressor holder C 350
28 0348 316 Pump screw yellow (standard)
0348 926 Pump screw brown
0348 928 Pump screw green
29 0348 315 Pump jacket yellow (standard)
0348 925 Pump jacket brown
30 0348 927 Pump jacket green, re-tightenable
31 0348 907 Container suction system
32 0348 908 Sliding cover for receptacle
33 0268 728 Sack mangle
34 0348 958 Accessory box with various accessories
Page 25
47
J. Wagner GmbH
Otto-Lilienthal Str. 18
88677 Markdorf
Fed. Rep. of Germany
Phone 07544 / 5050
Fax 07544 / 505-200
D
Wagner International AG
Industriestr. 22
9450 Altstätten
Switzerland
Phone 071 / 7 57 22 11
Fax 071 / 7 57 22 22
CH
Wagner Spraytech Corp.
P.O. Box 9362
Minneapolis / Minn. 55440
USA
Phone 612 - 553 / 7000
Fax 612 - 553 / 7288
USA
Wagner Spraytech
Japan / Ltd.
2-35, Shinden-Nishimachi
Osaka / Japan
Phone 720 / 743561
Fax 720 / 743426
Japan
J. Wagner GmbH
Oberflächentechnik
Lohnergasse 1
1210 Wien
Austria
Phone 0043/1/2707781-0
Fax 0043/1/2788430
Wagner Spraytech
Australia Pty. Ltd.
POB 286
Mordialloc, 3195
Australia
Phone 03/5872000
Fax 03/5809120
Wagner Spraytech
Belgium SA
Veilinglaan 58
1861 Meise-Wolvertem
Belgium
Phone 02/2694675
Fax 02/2697845
Wagner Spraytech
Scandinavia A/S
Kornmarksvej 26
2605 Brøndby
Denmark
Phone 43632811
Fax 43430528
A
B
Wagner Spraytech
Iberica S.A.
Apartado 132
08750 Molins de Rey
Barcelona / Spain
Phone 93/6800028
Fax 93/6680156
J. Wagner France S.A.R.L
B.P. 75
91122 Palaiseau-Cedex
France
Phone 01/60114050
Fax 01/69817257
Wagner Spraytech (UK) Ltd.
Unit 3 Haslemere Way
Tramway Industrial Estate
Banbury, Oxon OX 16 8TY
Great Britain
Phone 0 12 95 / 265 353
Fax 0 12 95 / 269 861
J. Wagner GmbH (HK)
Room 1801 – 02
Tai Sang Comm. Bldg.
24 – 34 Hennessy Road
Wanchai
Hong Kong
Phone 852 / 865 1802
Fax 852 / 529 1753
E
F
Wagner Colora
Via Ciucani, 3
20060 Ornago (MI)
Italy
Phone 039 / 6010474
Fax 039 / 6010601
Wagner Spraytech
(Nederland) BV
Postbus 1656
3600 BR Maarssen
Netherlands
Phone 030 / 2414155
Fax 030 / 2411787
Wagner Spraytech (NZ) Ltd.
P.O. Box 12629
Penrose, Auckland
New Zealand
Phone 09/641169
Fax 09/642790
Wagner Sverige AB
Muskötgatan 19
254 66 Helsingborg
Sweden
Phone 042/150020
Fax 042/150035
I
S
GB
NZ
MANUFACTURING AND SALES COMPANIES
SALES AND SERVICE COMPANIES
HK
NL
A list of international WAGNER distributors is available on request
AUS
DK
09 / 99
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