WAGNER Leopard 48-110, Leopard 35-150, Leopard 35-70, Wildcat 10-70, Tiger 72-300 Service Manual
...
II 2G IIB c T3 X
B_00343
"?
B_00365
Wildcat Puma
10-70 28-40
18-40 15-70
Leopard 21-110
35-70 15-150
35-150 Jaguar
48-110 75-150
Tiger
72-300
IceBreaker Pumps
Feed volume 40 ccm - 300 ccm
Edition 01/2012
Translation of the original
Service manual
3
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Languages 5
1.2 Warnings, notes and symbols in these instructions 6
2 GENERAL SAFETY INSTRUCTIONS 7
2.1 Safety instructions for the operator 7
2.1.1 Electrical equipment 7
2.1.2 Personnel qualifi cations 7
2.1.3 A safe work environment 7
2.2 Safety instructions for staff 7
2.2.1 Safe handling of WAGNER spray units 8
2.2.2 Earth the unit 8
2.2.3 Paint hoses 8
2.2.4 Cleaning 9
2.2.5 Handling hazardous liquids, varnishes and paints 9
2.2.6 Touching hot surfaces 9
2.3 Correct use 9
2.4 Use in an explosion hazard area 10
2.4.1 Correct use 10
2.4.2 Explosion protection identifi cation 10
2.4.3 Identifi cation X 10
2.4.4 German regulations and guidelines 11
3 GUARANTEE AND CONFORMITY DECLARATIONS 12
3.1 Important notes on product liability 12
3.2 Guarantee claim 12
3.3 CE-conformity 13
4 PRODUCT DESCRIPTION 14
4.1 Modular structure 14
4.2 Date 15
4.2.1 Materials of the parts transporting paint 15
4.2.2 Recommended V-packings 15
4.2.3 Technical data 16
4.2.3.1 Technical Data for Wildcat, Puma 16
4.2.3.2 Technical data for Leopard, Jaguar and Tiger 17
5 REPAIRS 18
5.1 Tools, test devices and assembly aids 18
5.2 Dismantling / mounting 19
6 FUNCTIONAL TEST 20
6.1 Field-test preparation 20
6.2 Dead point test 20
6.3 Pump running-in 20
6.4 Testing air motor for air leaks 21
6.5 Testing pump for fl uid leaks 21
6.6 Function test 22
6.7 Test data table 23
4
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Contents
7 SPARE PARTS 24
7.1 How to order spare parts? 24
7.2 Over views modules 25
7.2.1 Wildcat, Puma, Leopard and Jaguar 25
7.2.2 Tiger 29
7.3 Air motors 30
7.3.1 Air motors Wildcat, Puma, Leopard 30
7.3.2 Air regulator for air motors Wildcat, Puma and Leopard 34
7.3.3 Air motor Jaguar 35
7.3.4 Regulator for Jaguar 40
7.3.5 Air motor Tiger 41
7.3.6 Regulator for air motor Tiger 46
7.4 Material pumps 47
7.4.1 Material pumps 40 ccm 47
7.4.2 Material pumps 70 ccm 50
7.4.3 Material pump 110 ccm 53
7.4.4 Material pumps 150 ccm 56
7.4.5 Material pumps 300 ccm 59
7.5 High-pressure fi lter 62
7.5.1 High-pressure fi lter Wildcat, Puma, Leopard, Jaguar 62
7.5.2 High-pressure fi lter Tiger 64
7.6 Filter-relief combination 66
7.7 Distributor 67
7.8 Trolley 68
7.9 Trolley „Heavy Duty“ 69
7.10 Lifting trolley pneumatic 70
7.11 Lifting trolley 74
7.12 Wall lifting gear pneumatic 76
7.13 Wall lifting gear 80
8 ACCESSORIES 82
8.1 Accessories for Wildcat and Puma pumps 82
8.2 Accessories for Leopard and Jaguar pumps 89
8.3 Accessories for Tiger 95
5
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
367865 367866
These service instructions contain information on the maintenance and repair of the units.
For further information on technical data and accessories, please see the respective operating instructions.
The manuals respective are available in the following languages:
WILDCAT, PUMA, LEOPARD, JAGUAR
Language Part No. Language Part No.
German 367850 English 367851
French 367852 Dutch 367853
Italian 367854 Spanish 367855
Danish 367857 Swedish 367856
Portuguese 367859 Turkish 367858
Polish 367864 Greek 2309490
TIGER
Language Part No. Language Part No.
German 370850 English 370851
French 370852 Dutch 370853
Italian 370854 Spanish 370855
Danish 370857 Swedish 370856
The service instructions are available under the following order numbers:
Language: Part No. Language: Part No.
German English
6
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual point out particular dangers to users and equipment
and state measures for avoiding the hazard.
These warning instructions fall into the following categories:
Danger - imminent danger. Non-observance will result
in death, serious injury and serious material damage.
Warning - possible danger. Non-observance can result
in death, serious injury and serious material damage.
Caution - a possibly hazardous situation.
Non-observance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation.
Non-observance can cause material damage.
SIHI_0100_GB
DANGER
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0103_GB
WARNING
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0101_GB
C AUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0102_GB
CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions . The signal word
points out the hazard level.
The measures for preventing the hazard and its consequences.
7
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL EQUIPMENT
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 A SAFE WORK ENVIRONMENT
2.2 SAFETY INSTRUCTIONS FOR STAFF
Keep these operating instructions to hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Electrical plant and unit
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform staff about
planned work, observe electrical safety regulations.
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
Make sure that the floor in the area where you are working is derivable in accordance
with EN 61340-4-1.
Ensure that all persons within the working area wear derivable shoes.
Ensure that during spraying, persons wear derivable gloves so that they are earthed via
the handle of the spray gun.
Customer to provide paint mist extraction units conforming to local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure
– Personal safety equipment (breathing and skin protection)
Ensure that there are no ignition sources such as naked flame, glowing wires or hot
surfaces in the vicinity. Do not smoke.
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
8
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
2.2.2 EARTH THE UNIT
2.2.3 PAINT HOSES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the unit, in the event of work interruptions and functional faults:
– Switch off the energy/compressed air supply.
– Secure the spray gun against actuation.
– Relieve the pressure from the spray gun and unit.
– By functional faults: Identify and correct the problem, proceed as described in
chapter „Trouble shooting“.
In the event of skin injuries caused by paint or cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
Depending on the electrostatic charge and the flow speed of the spray, an electrostatic
charge may occur in the equipment. This could cause a spark or flame on discharging.
Ensure that the unit is earthed for every spraying operation.
Earth the work pieces being painted.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing
derivable shoes.
When spraying, wear derivable gloves to earth yourself via the spray gun handle.
Ensure that the hose material is chemically resistant to the sprayed materials.
Ensure that the material hose is suitable for the pressure generated in the unit.
Ensure that the following information is visible on the high pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture.
The electrical resistance of the complete high pressure hose must be less than 1 MOhm.
9
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2.2.4 CLEANING
2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
2.2.6 TOUCHING HOT SURFACES
2.3 CORRECT USE
De-energize the unit electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the unit.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient
temperature.
To clean, use only solvent-free cloths and brushes. Never use hard objects or spray on
cleaning agents with a gun.
An explosive gas/air mixture forms in closed containers.
When cleaning units with solvents, never spray into a closed container.
Earth the container.
When preparing or working with paint and when cleaning the unit, follow the working
instructions of the manufacturer of the paints, solvents and cleaning agents being
used.
Take the specified protective measures, in particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sufficient health and environmental safety: Operate the unit in a spray booth or on
a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot materials.
➞ Touch hot surfaces only if you are wearing protective gloves.
➞ When operating the unit with a coating material with a temperature of > 43 °C; 109.4 °F:
- Identify the unit with a warning label that says „Warning - hot surface“.
Order No.
9998910 Information label
9998911 Safety label
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
10
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2.4.1 CORRECT USE
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
2.4.3 IDENTIFICATION X
2.4 USE IN AN EXPLOSION HAZARD AREA
4HEUNITISSUITABLEFORWORKINGLIQUIDMATERIALSINACCORDANCEWITHTHECLASSIlCATIONINTO
EXPLOSIONCLASSES
As defined in the Directive 94/9/EC (ATEX 95), the unit is suitable for use in areas where
there is an explosion hazard.
II 2G IIB c T3 X
CE: Communautés Européennes
Ex: Symbol for explosion protection
II: Unit class II
2: Category 2 (Zone 1)
G: Ex-atmosphere gas
IIB: Explosion group
c: Constructional security
T3: Temperature class: maximum surface temperature < 200 °C; 392 °F.
X: Special Notes (see chapter 2.4.3)
Maximum surface temperature
The maximum surface temperature of the piston pump can be reached if it runs dry.
Ensure that the piston pump is filled with sufficient working or cleaning medium.
Ensure that the separating fluid container is filled with sufficient separating fluid.
Ignition temperature of the coating material
Ensure that the ignition temperature of the coating material is above the maximum
surface temperature.
Ambient temperature
The permissible ambient temperature is +5 °C to +60 °C; +41 °C to 140 °F
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.
Mechanical sparks can form if the unit comes into contact with metal
In an explosive atmosphere:
Do not knock or push the unit against steel or rusty iron.
Do not drop the unit.
Use only tools that are made of a permitted material.
11
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Cleaning
If there are deposits on the surfaces, the unit may form electrostatic charges. Flames or
sparks can form if there is a discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the unit.
Surface spraying, electrostatic
Do not spray unit parts with electrostatic (e.g. electrostatic spray gun).
2.4.4 GERMAN REGULATIONS AND GUIDELINES
a) BGR 500 Part 2, Chap. 2.36 Working with liquid ejection devices
b) BGR 500 Part 2, Chap. 2.29 Using coating materials
c) BGR 104 Explosion protection rules
d) TRBS 2153 Avoiding ignition risks
e) BGR 180 Setting up for cleaning with solvents for cleaning workpieces with
solvents
f) ZH 1/406 Guidelines for liquid ejection devices
g) BGI 740 Painting rooms and equipment
h) Betr.Sich.V. Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne,or they are
to be found in the Internet.
12
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
3 GUARANTEE AND CONFORMITY DECLARATIONS
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 GUARANTEE CLAIM
As a result of an EC regulation, effective as from January 1, 1990, the manufacturer shall
only be liable for his product if all parts come from him or are approved by him, and if the
devices are properly fitted , operated and maintained.
If other makes of accessory and spare parts are used, the manufacturer‘s liability could be
fully or partially null and void.
The usage of original WAGNER accessories and spare parts guarantees that all safety
regulations are observed.
Full guarantee is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the Purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of guarantee provided is such that the device or individual components of the
device are either replaced or repaired as we think fit. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the unit to a location other
than the address of the purchaser.
We do not provide guarantee for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electro chemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust
paints and similar reduce the service life of valves, packings, spray guns, tips, cylinders,
pistons etc. Signs of wear and tear due to such causes are not covered by this guarantee.
Components that have not been manufactured by WAGNER are subject to the original
guarantee of the manufacturer.
Replacement of a component does not extend the period of guarantee of the device.
The unit should be inspected immediately upon receipt. To avoid losing the guarantee, we
or the supplier company are to be informed in writing about obvious faults within 14 days
upon receipt of the device.
We reserve the right to have the guarantee compliance met by a contracting company.
The services provided by this guarantee depend on evidence being provided in the form
of an invoice or delivery note. If an examination discovers that no guarantee claim exists,
the costs of repairs are charged to the purchaser.
It is clearly stipulated that this guarantee claim does not represent any constraint to statutory
regulations or regulations agreed contractually in our general terms and conditions.
J. Wagner AG
13
40 ccm - 300 ccm.
Wildcat Puma Leopard Jaguar Tiger
10-70 28-40 35-70 75-150 72-300
18-40 15-70 35-150 38-300 17-1200
21-110 48-110 9-1200
15-150 18-300
8-300 8-600
3-600 4-1200
II 2G IIB c T3 X
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
3.3 CE-CONFORMITY
CE Certificate of Conformity
The certificate is enclosed with this product. The certificate of conformity can be reordered
from your WAGNER representative, quoting the product and serial number.
Part number :
Herewith we declare that the supplied version of
Pneumatic pumps and spraypacks
Complies with the following guidelines;
2006/42/EG 94/9/EG Atex-directives
Applied standards, in particular:
DIN EN ISO 12100-1: 2004 DIN EN 809: 2011 DIN EN 12621/A1: 2010
DIN EN ISO 12100-1/A1: 2009 DIN EN 14462: 2005 DIN EN 13463-1: 2009
DIN EN ISO 12100-2: 2004 DIN EN ISO 14121-1: 2007 DIN EN 13463-5: 2004
DIN EN ISO 12100-2/A1: 2009 DIN EN 1127-1: 2008
DIN EN ISO 13732-1: 2008 DIN EN 12621: 2006
Applied national technical standards and specifi cations, in particular:
BGR 500 Part 2 Chap. 2.29 and Chap. 2.36 BGR 104 TRBS 2153
Marking:
2302304
14
40 ccm - 300 ccm.
B_02326
WILDCAT
Ø 80 mm
H 75 mm
Ø 3 inch
S 3 inch
PUMA
Ø 100 mm
H 75 mm
Ø 4 inch
S 3 inch
WILDCAT
Ø 80 mm
H 75 mm
Ø 3 inch
S 3 inch
PUMA
Ø 100 mm
H 75 mm
Ø 4 inch
S 3 inch
LEOPARD
Ø 150 mm
H 75 mm
Ø 6 inch
S 3 inch
WILDCAT 18-40
PUMA 28-40
WILDCAT 10-70
PUMA 15-70
LEOPARD 35-70
PUMA
Ø 100 mm
H 150 mm
Ø 4 inch
S 6 inch
LEOPARD
Ø 150 mm
H 150 mm
Ø 6 inch
S 6 inch
LEOPARD
Ø 150 mm
H 150 mm
Ø 6 inch
S 6 inch
JAGUAR
Ø 220 mm
H 150 mm
Ø 9 inch
S 6 inch
TIGER
Ø 300 mm
H 150 mm
Ø 13 inch
S 6 inch
PUMA 15-150
LEOPARD 35-150
JAGUAR 75-150
TIGER 72-300
LEOPARD 48-110
PUMA 21-110
40 cm
3
300 cm
3
150 cm
3
70 cm
3
110 cm
3
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4 PRODUCT DESCRIPTION
4.1 MODULAR STRUCTURE
15
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4.2 DATE
4.2.1 MATERIALS OF THE PARTS TRANSPORTING PAINT
Housing Stainless steel
Piston Stainless steel and hard chrome
Valve balls Stainless steel
Valves seats Hard chrome (without Type ESS -> Stainless steel)
O-rings Tefl on
V-packings Standard PE/ TG
PE = Polyethylen UHMW
TG = Tefl on (PTFE) with graphite
4.2.2 RECOMMENDED V-PACKINGS
Wagner V-packings are manufactured in four different materials:
Code Material Colour
L Leather dark brown
TG Tefl on with graphite black
PE Polyethylen UHMW transparent
T Tefl on white
Each material has the following properties, which infl uence the packings:
LTGPET
Mechanical stability low good good low
Coeffi cient of friction low very good good very good
Sealing capacity good* good good good
Chemical resistance or
reactivity
low good very good very good
Temperature stability good low - good very good low
* for abrasive materials
Standard combinations
Standard pneumatic pumps PE/TG
Heavy duty (HD) pumps PE/L
Hardener pump in 2C-Systems PE/T
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SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4.2.3 TECHNICAL DATA
4.2.3.1 TECHNICAL DATA FOR WILDCAT, PUMA
Description
Units WILDCAT
10-70
WILDCAT
18-40
PUMA
28-40
PUMA
15-70
PUMA
21-110
PUMA
15-150
Transmission ratio 10 :1 18 :1 28 : 1 15 :1 21:1 15 :1
Flow volume per double stroke (DS) cm³; cc 70 40 40 70 110 150
Maxi. operating over pressure MPa
bar
psi
8
80
1160
14.4
144
2089
22.4
224
3249
12
120
1740
16.8
168
2436
12
120
1740
Maxi. possible strokes in operation DH/min
DS/min
60 60 60 60 60 60
Min. Maxi. incoming air pressure MPa
bar
psi
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
Ø Incoming air (inside threads) Zoll Inch G 1/2“ G 1/2“ G 1/2“ G 1/2“ G 1/2“ G 1/2“
Min. Ø compressed air hose mm; Inch 9; 0.354 9; 0.354 9; 0.354 9; 0.354 9; 0.354 9; 0.354
Air consumption at 0.6 MPa; 6 bar; 87
psi per DS
nl
scf
5.3
0.19
5.3
0.19
8.3
0.29
8.3
0.29
16.5
0.58
16.5
0.58
Sound pressure level at maxi.
permissible air pressure*.
dB(A) 77 77 78 77 78 78
Sound pressure level at 0.6 MPa; 6
bar; 87 psi air pressure*
dB(A) 74 74 74 74 74 74
Sound pressure level at 0.4 MPa; 4
bar; 58.01 psi air pressure*
dB(A) 69 69 69 69 69 69
Ø piston of air motor mm; Inch 80; 3.2 80; 3.2 100; 4 100; 4 100; 4 100; 4
Mat. inlet connection (inside threads) Zoll Inch G 1“ G 3/4“ G 3/4“ G 1“ G 1“ G 1“
Material outlet connection (inside
threads)
Zoll Inch G 3/8“ G 3/8“ G 3/8“ G 3/8“ G 3/8“ G 3/8“
Weight kg; lb 17; 38 15; 33 16; 35 18; 40 28; 62 28; 62
Material pH value pH 3.5 ÷ 9
Maxi. material pressure at pump inlet MPa;bar; psi 2; 20; 290
Material temperature °C; °F +5° ÷ +80°; +41 ÷ +176
Ambient temperature °C; °F +5° ÷ +60° +41 ÷ +140
Allowable sloping position at work <) ° ± 10
* A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005.
Reference measurements have been made by SUVA (Swiss accident insurance institute).
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled
Function problem airmotor
Provide water-free and oil-free compressed air (quality standard
5.5.4 as per ISO 8573.1) 5.5.4 = 40 μm / +7 / 5 mg/m³.
SIHI_0068_GB
17
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4.2.3.2 TECHNICAL DATA FOR LEOPARD, JAGUAR AND TIGER
Description Units LEOPARD
35-70
LEOPARD
48-110
LEOPARD
35-150
JAGUAR
75-150
Tiger
72-300
Transmission ratio 35 : 1 48 :1 35 : 1 75:1 72 :1
Flow volume per double stroke (DS) cm³; cc 70 110 150 150 300
Maxi. operating over pressure MPa
bar
psi
25
250
3626
37
370
5366
27
270
3916
53
530
7687
53
530
7687
Maxi. possible strokes in operation DH/min
DS/min
60 60 60 60 40
Min. - Maxi. air inlet pressure MPa
bar
psi
0.25-0.71
2.5-7.1
36-103
0.25-0.8
2.5-8
36-116
0.25-0.77
2.5-7.7
36-112
0.25-0.71
2.5-7.1
36-103
0.25-0.74
2.5-7.4
36-107
Ø air inlet (inside threads) Zoll Inch G 1/2“ G 1/2“ G 1/2“ G 1“ G 1“
Min. Ø compressed air hose mm; Inch 13; 0.512 13; 0.512 13; 0.512 25; 0.984 25; 0.984
Air consumption at 0.6 MPa; 6 bar; 87 psi
per DS
nl; scf 18.6; 0.66 37.3; 1.32 37.3; 1.32 79.9; 2.82 170; 6
Sound pressure level at maxi.
permissible air pressure*
dB(A) 77 78 80 83 82
Sound pressure level at 0.6 MPa; 6 bar;
87 psi air pressure*
dB(A) 74 74 78 81 80
Sound pressure level at 0.4 MPa; 4 bar;
58 psi air pressure*
dB(A) 71 69 74 74 75
Ø piston of air motor mm; Inch 150; 6 150; 6 150; 6 220; 8.7 320; 12.6
Mat. inlet connection (inside threads) Zoll Inch G 1“ G 1“ G 1“ G 1“ G 1 1/2“
Mat. outlet connection (inside threads) Zoll Inch G 3/8“ G 3/8“ G 3/8“ G 3/8“ G 3/4“
Weight kg; lb 26; 57 36; 79 36; 79 53; 117 80; 176
Material pH value pH 3.5 ÷ 9
Maxi. material pressure at pump inlet MPa; bar; psi 2; 20; 290
Material temperature °C; °F +5° ÷ +80°; +41 ÷ +176
Ambient temperature °C; °F +5° ÷ +60°; +41 ÷ +140
Allowable sloping position at work <) ° ± 10
* A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005.
Reference measurements have been made by SUVA (Swiss accident insurance institute).
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled
Function problem airmotor
Provide water-free and oil-free compressed air (quality standard
5.5.4 as per ISO 8573.1) 5.5.4 = 40 μm / +7 / 5 mg/m³.
SIHI_0068_GB
18
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SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
5 REPAIRS
5.1 TOOLS, TEST DEVICES AND ASSEMBLY AIDS
Standard tools:
Single-head engineers jaw wrench SW13; size 0.51 inch
Single-head engineers jaw wrench SW17; size 0.67 inch
Single-head engineers jaw wrench SW19; size 0.75 inch
Single-head engineers jaw wrench SW22; size 0.87 inch
Hexagon key SW5; size 0.2 inch
Hexagon key SW6; size 0.24 inch
Hexagon key SW13; size 0.51 inch
Screwdriver size 1
Screwdriver size 5
Screwdriver Torx T25
Circlip pliers
Other tools:
Mandrel for removing inlet valve seat ø 18.3 mm; 0.72 inch
Assembly arbor ø 15.4 mm; 0.60 inch for spool and sleeve assembly
Torque wrench
Assembly aids:
Lubricant Beacon EP 2
Anti-sieze paste
Loctite 243 / 542
Separating fl uid (Mesamol)
Vaseline
Test devices
Container for testing fl uid (approx. 20 l; 0.70 cf)
Earth cable
Suction system
High-pressure hose
Pressure gauge
Gun and nozzle
19
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
5.2 DISMANTLING / MOUNTING
See safety regulations in chapter 2!
After disassembly:
Treat all parts with a suitable cleaning agent.
Inspect all parts for traces of wear and replace if necessary.
Change all parts contained in the service set.
SIHI_0004_GB
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the equipment
Repairs and part replacement may only be carried out by specially
trained staff or a WAGNER service center.
Before all work on the unit and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
WARNING
Overpressure!
Risk of injury from bursting components
Never change the safety valve setting.
SIHI_0026_GB
SIHI_0134_ENG
WARNING
Flying parts!
Risk of injury
➞ Before dismounting a part from the fan motor, this must be
disconnected from the compressed air system:
1. Remove air hose.
2. Set spherical valve to vent position.
20
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
6 FUNCTIONAL TEST
6.1 FIELD-TEST PREPARATION
Re-assemble pump and other components on trolley or wall-support. Connect suction and
HP hoses, test gauge, spray gun with suitable nozzle.
SIHI_0117_GB
WARNING
Overpressure!
Risk of injury bursting components
➞ Ensure that the pressure range of all the test components used
lies above the maximum operating pressure of the pump.
6.2 DEAD POINT TEST
Fill pump, hose, gun with test fl uid:
Use 0.6 MPa; 6 bar; 87 psi input air, allow pump to cycle slowly (hold gun open with nozzle
under fl uid level).
Stop pump at change-over points, check for pressure drop. There should be no signifi cant
less of pressure after change-over
Pilot valves may blow at change over.
Aids:
Flow controller
6.3 PUMP RUNNING-IN
Allow pump 0.7-0.8 MPa; 7-8 bar; 101.5-116 psi to cycle with gun open (Raise operating
pressure to maximum).
So pump cycles around 15-20 cycles/min (DS) / min
For 10 minutes
Control cycle rate with tip size. After test, check tightness of fi ttings see chapter 7.2.
Test conductivity between piston and pump housing: <100 k
Attention, this test is
-relevant.
Aids:
Test stand with adjustable fl ow
Test medium oil
Torque wrench
Ohmmeter
21
40 ccm - 300 ccm.
B_02327
35
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
6.4 TESTING AIR MOTOR FOR AIR LEAKS
Allow pump to cycle slowly, and stop pump by closing gun at various points in up and
down stroke. Check for any air leaks. Close air-supply ball-valve without relieving and check
for pressure-loss.
1. Check for leaks at air piston by listening for leaking at exhausts with gun closed in both
upwards and downwards directions.
2. Check for leaks at air piston by listening for leaking at exhausts with gun closed in both
upwards and downwards directions.
3. Check fl ange seals.
4. Check air connections to pilot valve.
5. Check ball-valve for leaks in all positions.
6. Check switching point of installed over pressure valve (35) and correct if necessary.
(See chapter 6.7, table columns 1 and 2)
7. Tightness of sliding case combination: Stop pump once in upwards and downwards
stroke respectively and close air supply. The air pressure must not fall below 0.6 MPa, 6
bar; 87 psi within 25 seconds, starting at 0.7 MPa; 7 bar; 101.5 psi.
The test data must be documented and should match the values from the test data table
in chapter 6.7.
Aids:
Test stand
Test medium air
Leakage spray
Stopwatch
Checklist C-367000
6.5 TESTING PUMP FOR FLUID LEAKS
Allow pump to cycle slowly:
Close gun and raise operating air to maxi. pressure. Close gun. Check visnally for leaks at all
joints. The pump piston must not „creep“. Repeat test in opposite cycle direction, e.g.
1. Lower / upper packings and outlet (piston) valve in upwards stroke.
2. Lower packing / inlet valve in downwards stroke.
3. Check complete pump section for leaks.
4. Check all fi ttings / connections for leaks
Aids:
Test stand with HD hose (min. NW6), 53 MPa; 530 bar; 7687 psi; 10 m; 32.8 ft.
Pressure gauge
Test medium oil or water
22
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
The function test should be carried out according to the pressure shown in column 3 of the
table of „test data“ chapter 6.7.
1. For fi nal pressure, see test data table column 4. Pressure difference between upward
stroke and downward stroke must not exceed that in the table column 5.
2. For start-up at mains pressure, see table column 8.
(The pressure before the pump pressure controller is relevant).
3. Suction head >= 8.2 m; 26.9 ft.
4. Pulsation: The pressure drop at the upper and lower switch-over point must not
exceed the value in column 7 for the dynamic spray pressure (column 6) of the test
data table in chapter 6.7.
Attention:
Depending on the nozzle size.
5. Check idler frequency without gun.
Aim: high frequency (>30 DH/Min), no erratic running.
6.6 FUNCTION TEST
23
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Column 1 2 3 4 5 6 7 8
Maxi. air pressure
Maxi. material
pressure
Test pressure air
Test pressure ma-
terial
Differential
pressure upward /
downward stroke
Fluid pressure
(Run-in)
Pulsation
Start-up mains
pressure
WILDCAT
10-70
MPa
bar
psi
0.8
8
116.0
7.4±0.5
74±5
1073±72.5
0.7
7
101.5
6.5±0.5
65±5
943±72.5
0.5
5
72.5
4.0±0.5
40±5
580±72.5
0.7
7
72.5
0.25
2.5
36.3
WILDCAT
18-40
MPa
bar
psi
0.8
8
116.0
14.4±1
144±10
2089±145
0.7
7
101.5
12.6±1
126±10
1827±145
1
10
145
10±1
100±10
1450±145
1.5
15
217.5
0.25
2.5
36.3
PUMA
15-70
MPa
bar
psi
0.8
8
116.0
12±1
120±10
1741±145
0.7
7
101.5
10±1
100±10
1450±145
1
10
145
7±1
70±10
1015±145
2
20
290
0.25
2.5
36.3
PUMA
28-40
MPa
bar
psi
0.8
8
116.0
22±1
220±10
3191±145
0.7
7
101.5
19±1
190±10
2756±145
1
10
145
16±1
160±10
2321±145
1
10
145
0.25
2.5
36.3
PUMA
21-110
MPa
bar
psi
0.8
8
116.0
16±1
160±10
2320±145
0.7
7
101.5
14±1
140±10
2030±145
1
10
145
10±1
100±10
1450±145
1
10
145
0.25
2.5
36.3
PUMA
15-150
MPa
bar
psi
0.8
8
116.0
12±1
120±10
1741±145
0.7
7
101.5
10±1
100±10
1450±145
1
10
145
7±1
70±10
1015±145
2
20
290
0.25
2.5
36.3
LEOPARD
35-70
MPa
bar
psi
0.71
7.1
103
24±1
240±10
3481±145
0.7
7
101.5
23.1±1
231±10
3350±145
1
10
145
20±1
200±10
2901±145
2
20
290
0.25
2.5
36.3
LEOPARD
48-110
MPa
bar
psi
0.8
8
116
35±1
350±10
5076±145
0.7
7
101.5
30.6±1
308±10
4467±145
1
10
145
30±1
300±10
4351±145
2
20
290
0.25
2.5
36.3
LEOPARD
35-150
MPa
bar
psi
0.77
7.7
112
24±1
240±10
3481±145
0.7
7
101.5
23.2±1
232±10
3365±145
1
10
145
20±1
200±10
2901±145
2
20
290
0.25
2.5
36.3
JAGUAR
75-150
MPa
bar
psi
0.71
7.1
103
52±1
520±10
7542±145
0.7
7
101.5
50±1
500±10
7252±145
2
20
290
45±1
450±10
6527±145
2.5
25
362.6
0.25
2.5
36.3
TIGER
72-300
MPa
bar
psi
0.74
7.4
107.3
52±1
520±10
7542±145
0.74
7.4
107.3
52±1
520±10
7542±145
2
20
290
42±1
420±10
6092±145
5
50
72.5
0.25
2.5
36.3
Tolerance MPa
bar
psi
±0.01
±0.1
±1.45
- ±0.01
±0.1
±1.45
- Maxi. - Maxi. Maxi.
6.7 TEST DATA TABLE
24
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Always supply the following information to ensure delivery of the right spare part:
Part Number, description and quantity
The quantity need not be the same as the number given in the „Quantity“ column.
This number merely indicates how many of the respective parts are used in each sub
assembly.
The following information is also required to ensure smooth processing of your order:
- Address for the invoice
- Address for delivery
- Name of the person to be contacted in the event of any queries
- Type of delivery required (air freight or mail, sea route or overland route, etc.)
Marks in spare parts lists
Note to column „K“ in the following spare parts lists.
U = Wearing parts
Note: No liability is assumed for wearing parts
L = Not part of standard equipment, available, however, as additional extra.
7 SPARE PARTS
7.1 HOW TO ORDER SPARE PARTS?
SIHI_0004_GB
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the equipment
Repairs and part replacement may only be carried out by specially
trained staff or a WAGNER service center.
Before all work on the unit and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
25
40 ccm - 300 ccm.
B_00336
3
2
7
6
4
5
8
9
10
11
13
12
1
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
7.2 OVER VIEWS MODULES
7.2.1 WILDCAT, PUMA, LEOPARD AND JAGUAR
WILDCAT
10-70
PE/TG
WILDCAT
10-70
PE/T
WILDCAT
18-40
PE/TG
WILDCAT
18-40
PE/T
WILDCAT
18-40
PE/TG
Valve tappet
WILDCAT
18-40
PE/T
Valve tappet
Item Description No. No. No. No. No. No.
1 Piston pump 366112 366113 366110 366111 366105 366106
2 Material pump 368070 368076 367070 367072 367074 2302057
3 Air motor 366080 366080 366080 366080 366080 366080
4 Spring 367530
5 Coupling 367579 367529
6 Double nipple 368958 (M36x2- G 1“) 367958 (M36x2- G 3/4“)
7 Sealing ring 9974110 9974109
8 Sealing ring 9925024
9 Double nipple
(G 3/8“ -NPSM 3/8“)
367556
10 Adapter (NPSM 3/8“ -NPSM1/4“) 367562
11 Adapter (NPSM 3/8“ -M16x1.5) 367563
12 Earthing cable compl. 236219
13 Molykote DX grease 9992616
Tightening torque
Air motor/ Material pump
25 Nm; 18 lbft
Tightening torque pos. 6 160 Nm; 118 lbft
Tightening torque pos. 9 100 Nm; 74 lbft
Tightening torque pos. 2 with 3
26
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
PUMA
28-40
PE/TG
PUMA
28-40
PE/T
PUMA
28-40
PE/TG
ESS
PUMA
15-70
PE/TG
PUMA
15-70
PE/T
Item Description No. No. No. No. No.
1 Piston pump 367103 367105 367119 367106 367107
2 Material pump 367070 367072 367073 368070 368076
3 Air motor 367080
4 Spring 367530
5 Coupling 367529 367579
6 Double nipple 367958 (M 36x2-G 3/4“) 368958 (M 36x2-G 1“)
7 Sealing ring 9974109 9974110
8 Sealing ring 9925024
9 Double nipple (G 3/8“ -NPSM 3/8“) 367556
10 Adapter (NPSM 3/8“ -NPSM1/4“) 367562
11 Adapter (NPSM 3/8“ -M16x1.5) 367563
12 Earthing cable compl. 236219
13 Molykote DX grease 9992616
Tightening torque Air motor/ Material pump 25 Nm; 18 lbft
Tightening torque pos. 6 160 Nm; 118 lbft 200 Nm; 148 lbft
Tightening torque pos. 9 100 Nm; 74 lbft
PUMA
15-150
PE/TG
PUMA
15-150
PE/T
PUMA
21-110
PE/TG
PUMA
21-110
PE/L
Item Description No. No. No. No.
1 Piston pump 368114 368115 2319960 2319953
2 Material pump 368071 368073 368077 368079
3 Air motor 367083
4 Spring 367530
5 Coupling 367579
6 Double nipple (M36x2 -G 1“) 368958
7 Sealing ring 9974110
8 Sealing ring 9925024
9 Double nipple (G 3/8“ -NPSM 3/8“) 367556
10 Adapter (NPSM 3/8“ -NPSM1/4“) 367562
11 Adapter (NPSM 3/8“ -M16x1.5) 367563
12 Earthing cable compl. 236219
13 Molykote DX grease 9992616
Tightening torque Air motor/ Material pump 50 Nm; 37 lbft
Tightening torque pos. 6 200 Nm; 148 lbft
Tightening torque pos. 9 100 Nm; 74 lbft
27
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
LEOPARD
35-70
PE/TG
LEOPARD
35-70
PE/T
LEOPARD
35-150
PE/TG
LEOPARD
35-150
PE/T
LEOPARD
35-150
PE/L
Item Description No. No. No. No. No.
1 Piston pump 368103 368105 368106 368107 368109
2 Material pump 368070 368076 368071 368073 368072
3 Air motor 368080 368081
4 Spring 368530
5 Coupling 368529
6 Double nipple (M36x2 -G 1“) 368958
7 Sealing ring 9974110
8 Sealing ring 9925024
9 Double nipple (G 3/8“ -NPSM 3/8“) 367556
10 Adapter (NPSM 3/8“ -NPSM1/4“) 367562
11 Adapter (NPSM 3/8“ -M16x1.5) 367563
12 Earthing cable compl. 236219
13 Molykote DX grease 9992616
Tightening torque
Air motor/ Material pump
25 Nm; 18 lbft 50 Nm; 37 lbft
Tightening torque pos. 6 200 Nm; 148 lbft
Tightening torque pos. 9 100 Nm; 74 lbft
LEOPARD
48-110
PE/TG
LEOPARD
48-110
PE/T
LEOPARD
48-110
PE/L
Item Description No. No. No.
1 Piston pump (NPSM) 368023 368024 368025
2 Material pump 368077 368078 368079
3 Air motor 368081
4 Spring 368530
5 Coupling 368529
6 Double nipple (M36x2 -G 1“) 368958
7 Sealing ring 9974110
8 Sealing ring 9925024
9 Double nipple (G 3/8“ -NPSM 3/8“) 367556
10 Adapter (NPSM 3/8“ -NPSM1/4“) 367562
11 Adapter (NPSM 3/8“ -M16x1.5) 367563
12 Earthing cable compl. 236219
13 Molykote DX grease 9992616
Tightening torque Air motor/ Material pump 50 Nm; 37 lbft
Tightening torque pos. 6 200 Nm; 148 lbft
Tightening torque pos. 9 100 Nm; 74 lbft
28
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
JAGUAR
75-150
PE/TG
JAGUAR
75-150
PE/T
JAGUAR
75-150
PE/L
Item Description No. No. No.
1 Piston pump (NPSM) 369121 369123 369122
2 Material pump 368071 368073 368072
3 Air motor 369080 369080 369080
4 Spring 368530
5 Coupling 368529
6 Double nipple 368958
7 Sealing ring 9974110
8 Sealing ring 9925024
9 Double nipple (NPSM) 367556
10 Adapter (NPSM 3/8“ -NPSM1/4“) 367562
11 Adapter (NPSM 3/8“ -M16x1.5) 367563
12 Earthing cable compl. 236219
13 Molykote DX grease 9992616
Tightening torque Air motor/ Material pump 50 Nm; 37 lbft
Tightening torque pos. 6 200 Nm; 148 lbft
Tightening torque pos. 9 100 Nm; 74 lbft
29
40 ccm - 300 ccm.
2
9
8
7
3
4
5
1
6
B_00350
11
10
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Tightening torque
Tiger
72-300
PE/L
Tiger
72-300
PE/TG
Tiger
72-300
PE/T
Item Description No. No.
No.
1
Piston pump (NPSM)
370102 370104 370103
2
Material pump
370070 2302211 370071
3
Air motor
370080
4
Spring
370530
5
Coupling
370529
6
Double nipple
369958
7 Sealing ring 9974126
8 Reducing nipple 2 x 60
0
; A=G3/4“- A=NPSM3/8“ 369657
9 Adapter I=NPSM3/8“- A=M16x1.5 367563
10 Earthing cable compl. 236219
11 Molykote DX grease 9992616
Tightening torque Air motor/ Material pump 70 Nm; 52 lbft
Tightening torque pos. 6 300 Nm; 222 lbft
7.2.2 TIGER
30
40 ccm - 300 ccm.
14
23
37
8
25
54
48
35
57
8
37
74
75
75
47
31
81
40
30
9
45
44
13
62
18
69
16
49
12
46
17
16
49
11
42
55
56
10
43
52
50
60
59
61
34
41
5
41
71
6
39
32
2
3
53
33
53
36
51
36
4
47
15
72
58
2-3 Nm; appr. 2 lbft
40 Nm; 30 lbft
10-15 Nm;
7-11 lbft
20-25 Nm; 15-19 lbft
28
25 Nm; 19 lbft
29
B_00258
29
30
110
1
110
106
109
106
108
110
110
107
110
108
109
109
100
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
7.3 AIR MOTORS
7.3.1 AIR MOTORS WILDCAT, PUMA, LEOPARD
Do not dismount the piston (Pos. 81)
Pressure regulator (pos. 100)
Detail see paragraph 7.3.2
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