WAGNER Jaguar, Tiger, PROTEC Operating Manual

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PROTEC

B_04259

IceBreaker Piston Pumps

Flow Rate 150 cm3 – 300 cm

Version 05/2015

Translation of the Original Operating Manual

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Table of Contents

1 ABOUT THESE INSTRUCTIONS 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 7

1.3.1 Operating Manuals for the Individual Components 7

1.4 Abbreviations in the Text 7

1.5 Terminology for the Purpose of this Manual 8

2 CORRECT USE 9

2.1 Device Types 9

2.2 Type of Use 9

2.3 Use in an Explosion Hazard Area 9

2.4 Safety Parameters 9

2.5 Processible Working Materials 10

2.6 Recommended Application Areas 10

2.7 Reasonably Foreseeable Misuse 11

2.8 Residual Risks 11

3 IDENTIFICATION 12

3.1 Explosion Protection Identi cation 12

3.2 Identi cation X 12

3.3 Type Plate 13

4 GENERAL SAFETY INSTRUCTIONS 14

4.1 Safety Instructions for the Operator 14

4.1.1 Electrical Equipment 14

4.1.2 Personnel Quali cations 14

4.1.3 Safe Work Environment 14

4.2 Safety Instructions for Sta 15

4.2.1 Safe Handling of WAGNER Spray Devices 15

4.2.2 Grounding the Device 16

4.2.3 Product Hoses 16

4.2.4 Cleaning and Flushing 17

4.2.5 Handling Hazardous Liquids, Varnishes and Paints 18

4.2.6 Touching Hot Surfaces 18

5 DESCRIPTION 19

5.1 Design 19

5.2 Mode of Operation 19

5.3 Protective and Monitoring Equipment 20

5.4 Scope of Delivery 20

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Table of Contents

5.5 Data 21

5.5.1 Materials of Paint-wetted Parts 21

5.5.2 Recommended Packings 21

5.5.3 Technical Data 21

5.5.3.1 Technical Data for Jaguar and PROTEC 22

5.5.3.2 Measurements and Connections for Jaguar and PROTEC 23

5.5.3.3 Technical Data for Tiger 24

5.5.3.4 Measurements and Connections for Tiger 25

5.5.4 Volume Flow 26

5.5.5 Performance Diagrams 26

5.6 Pressure Regulator Unit 28

5.7 Pressure Relief 28

5.7.1 High-Pressure Filter (Option) 28

5.8 Air Filter Set PC (Option) 29

5.9 Heater Set PC (Option) 30

5.10 Feed Pump (Option) 31

6 ASSEMBLY AND COMMISSIONING 32

6.1 Training Assembly/Commissioning Sta 32

6.2 Storage and Installation Conditions 32

6.3 Transportation 32

6.4 Assembling the Pump 33

6.4.1 Ventilation of the Spray Booth 33

6.5 Grounding 34

6.6 Commissioning 35

7 OPERATION 36

7.1 Training the Operating Sta 36

7.2 Safety Instructions 36

7.2.1 General Rules for Making Adjustments to the Spray Gun 37

7.3 Emergency Stop 37

7.4 Spraying 38

7.5 Pressure Relief/Work Interruption 38

7.6 Basic Flushing 39

7.6.1 Filling with Working Material 39

8 CLEANING AND MAINTENANCE 40

8.1 Cleaning 40

8.1.1 Cleaning Sta 40

8.1.2 Safety Instructions 40

8.1.3 Decommissioning and Cleaning 41

8.1.4 Long-term Storage 41

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Table of Contents

8.2 Maintenance 42

8.2.1 Maintenance Sta 42

8.2.2 Safety Instructions 42

8.2.3 Regular Maintenance Work 43

8.2.4 Filling Separating Agent 43

8.2.5 Emptying the Pump 44

8.2.6 Filling the Empty Pump 45

8.2.7 Cleaning and Replacing the High-pressure Filter 46

8.2.8 Product Hoses, Tubes and Couplings 47

9 TROUBLESHOOTING AND RECTIFICATION 48

10 REPAIRS 49

10.1 Repair Sta 49

10.2 Mounting Materials 49

11 DISPOSAL 49

12 ACCESSORIES 50

12.1 Accessories for Product Outlet 50

12.2 Accessories for Product Inlet 52

12.2.1 Suction Hose 52

12.2.2 20 Liter Tank 53

12.3 Accessories for Trolley and Wall Mount 54

13 SPARE PARTS 55

13.1 How Can Spare Parts Be Ordered? 55

13.2 Overview of the Components 56

13.3 Air Motors 58

13.3.1 Jaguar Air Motor 9" 58

13.3.2 Air Motor Regulator for Jaguar and PROTEC 62

13.3.3 PROTEC Air Motor 10" 63

13.3.4 Tiger Air Motor 12" 67

13.3.5 Tiger Air Motor Regulator 71

13.4 Connection Sets 72

13.5 Fluid Sections 73

13.5.1 Fluid Section 150 cm3 73

13.5.2 Fluid Sections 200 cm3 – 240 cm3 76

13.5.3 Fluid Section 300 cm3 79

13.6 High-pressure Filter (up to 530 bar; 7687 psi) 82

13.7 Suction Hose DN38 84

13.8 Suction Tube PC 85

13.9 PC Heavy Duty Trolley 86

13.9.1 Air Filter Set PC 87

13.9.2 Heater Set PC 88

14 WARRANTY AND CONFORMITY DECLARATIONS 89

14.1 Important Notes Regarding Product Liability 89

14.2 Warranty Claim 89

14.3 CE Declaration of Conformity 90

14.4 Notes on National Regulations and Guidelines 90

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1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

1 ABOUT THESE INSTRUCTIONS

Warning instructions in this operating manual highlight particular dangers to users and to the device and state measures for avoiding the hazard. These warning instructions fall into the following categories:

Danger - immediate risk of danger. Non-observance will result in death or serious injury.

Warning - possible imminent danger. Non-observance may result in death or serious injury.

Caution - a possibly hazardous situation. Non-observance may result in minor injury.

Notice - a possibly hazardous situation. Non-observance may result in damage to property.

Note - provides information about particular characteristics and how to proceed.

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

DANGER

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

WARNING

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

CAUTION

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The measures for preventing the danger and its consequences.

NOTICE

1.1 PREFACE

The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to operating and service sta . The device may only be operated by trained sta 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.

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1.3 LANGUAGES

The operating manual is available in the following languages:

Language Order No. Language Order No. Language Order No.

German 2340281 English 2340282 French 2340285 Italian 2340284 Spanish 2340286 Russian 2351798 Japanese 2359824

The corresponding service manuals are available under the following order number:

Language Order No. Language Order No.

German 2335993 English 2335994

1.4 ABBREVIATIONS IN THE TEXT

Continuous- ow heater operating manual:

Language Order No. Language Order No. German 65860 English 65860

French 65860 Italian 65860

1.3.1 OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS

Number of pieces Position Marking in the spare parts lists

Order No. Order number

Double stroke DN Nominal diameter PN Nominal pressure

Two components

: Heavy duty

corrosion protection

Materials

Stainless steel Polyethylene Ultra-high molecular weight

polyethylene Polytetra uorethylene PTFE with graphite PTFE Leather

Additional languages on request or at:

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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning Manual cleaning of devices and device parts with cleaning

agent

Flushing Internal  ushing of paint-wetted parts with  ushing agent

Sta quali cations

Trained person Is instructed in the tasks assigned to him/her, the potential

risks associated with improper behavior as well as the necessary protective devices and measures.

Electrically trained person

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.

Electrician Can assess the work assigned to him/her and detect possible

hazards based on his/her technical training, knowledge and experience in relevant provisions.

Skilled person A person who, based on his/her technical training, experience

and recent vocational experience, has su cient technical knowledge and is familiar with the relevant and generally accepted rules of technology so that he/she can inspect and assess the status of devices and coating systems based on workplace safety.

In the context of TRBS1203 (2010 / Revision 2012)

Additional requirements for skilled persons are given in the TRBS1203(2010/Revision 2012): Expert knowledge in the areas of protection against excessive pressure, electrical hazards, and explosion protection (where applicable).

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2 CORRECT USE

2.1 DEVICE TYPES

2.2 TYPE OF USE

2.3 USE IN AN EXPLOSION HAZARD AREA

Pneumatic pump with spraypack:

The device is suitable for processing liquid materials like paints and lacquers in accordance with the classi cation into explosion classes IIA or IIB.

The pneumatic pump can be employed in explosion hazard zones (Zone 1). See Chapter 3.

2.4 SAFETY PARAMETERS

WAGNER accepts no liability for any damage arising from incorrect use.

Use the device only to work with the products recommended by WAGNER. Only operate the device as a whole. Do not deactivate safety  xtures. Use only WAGNER original spare parts and accessories.

The pneumatic pump may only be operated under the following conditions:

The operating sta must be trained on the basis of this operating manual. The safety regulations listed in this operating manual must be observed. The operating, maintenance and repair information in this operating manual must

be observed. The statutory requirements and accident prevention regulation standards in the

country of use must be observed.

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2.5 PROCESSIBLE WORKING MATERIALS

Abrasive working materials and pigments!

Greater wear of parts carrying the product.

Do not use any grainy and abrasive working materials with large, sharp-edged

pigments.

Use the application-related model ( ow rate/cycle, material packaging, valve seat,

etc.), as speci ed in Chapter 5.5.

Check if the  uids and solvents used are compatible with the pump construction

materials as indicated in Chapter 5.5.1.

NOTICE

Wear caused by abrasive working materials is not covered by the warranty.

Working materials

Water-dilutable products Solvent based materials Primers Epoxy and polyurethane lacquers, phenolic lacquers Underside protection,  re protection materials

Legend

recommended limited suitability less suitable

Application area

Steel-processing industry Rail vehicle Shipbuilding Tank construction Pipeline construction Wind energy

Legend

recommended limited suitability less suitable

2.6 RECOMMENDED APPLICATION AREAS

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2.8 RESIDUAL RISKS

Residual risks are risks which cannot be ruled out even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks.

Residual risk Source Consequences Speci c measures Lifecycle phase

Skin contact with lacquers and cleaning agents

Handling of lacquers and cleaning agents

Skin irritation, allergies

Use personal safety equipment.

Operation,

Observe safety data sheets

maintenance, disassembly

Lacquer in air outside the de ned working area

Lacquering outside the de ned working area

Inhalation of substances hazardous to health

Observe work and operation instructions. Use personal safety equipment

Operation, maintenance

2.7 REASONABLY FORESEEABLE MISUSE

The forms of misuse listed below may result in physical injury or property damage:

coating work pieces which are not grounded; unauthorized conversions or modi cations to the pneumatic pump; processing dry or similar coating products, e.g., powder; using defective components, spare parts or accessories other than those described in

the "Accessories" chapter of this operating manual; continuing work with a defective or kinked product hose; working with incorrectly set values; processing food.

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3.1 EXPLOSION PROTECTION IDENTIFICATION

3.2 IDENTIFICATION X

As de ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially explosive areas.

CE CE mark (European Communities)

Explosion-proof equipment

II Device class II (not mining) 2 Category 2 device (suitable for zone 1)

G Ex-atmosphere gas

c Constructional security IIB Device class (Gas) IIB T3 Temperature class T3: maximum surface temperature 200 °C; 392 °F T4 Temperature class T4: maximum surface temperature 135 °C; 275 °F

X There are special notices for safe operation

See the following Chapter

"Identi cation X".

3 IDENTIFICATION

Maximum surface temperature

The maximum surface temperature T3 of the piston pump can be reached if it runs dry.

Ensure that the piston pump is  lled with su cient working or  ushing agent. Ensure that the separating agent tank is  lled with su cient separating agent.

Temperature class T3: No dry running protection. Temperature class T4: With dry running protection.

Ignition temperature

Ensure that the ignition temperature of the surrounding gases (pumping product,

cleaning agents) is higher than the maximum permitted surface temperature of the device.

Ambient temperature

The permissible ambient temperature is: +5 °C to +50 °C; +41 °C to +122 °F.

Medium supporting atomizing

To atomize the product, use only weakly oxidizing gases, e.g., air.

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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!

J. WAGNER AG

MADE IN SWITZERLAND

CH-9450 ALTSTÄTTEN

II 2 G c IIB T3/T4 X

4 5 6 7 8

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Safe handling of WAGNER spray devices

Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere:

Do not knock or push the device against steel or rusty iron. Do not drop the device. Use only tools that are made of a permitted material.

Surface spraying, electrostatics

Do not spray device parts using electrostatic equipment.

Cleaning

If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge.

Remove deposits from the surfaces to maintain conductivity. Use only a damp cloth to clean the device.

National regulations

Ensure that the national explosion prevention rules and regulations are observed when

setting up the device.

Air in the pump  uid

Flammable gas mixtures can form if air reaches the pump  uid.

Prevent the pump from taking in air and running dry. If air has been taken in,  x the leak. Then,  ll slowly and in a controlled manner until the

air has escaped.

Air in the pumped  uid can be caused by damaged packings.

Avoid operating the pump with damaged packing. Ensure that the separating  uid tank is  lled with su cient separating  uid. Periodically check that the pump is working smoothly, paying special attention to the

presence of air in the pumped  uid.

Filling and emptying

Flammable gas mixtures can form in the  uid section or product hoses if the pump must be emptied for maintenance.

Empty and  ll the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

3.3 TYPE PLATE

1 Manufacturer and CE

Identi cation 2 Pump type 3 Maximum product pressure 4 Pump ratio 5 Flow rate per double stroke 6 Maximum air inlet pressure 7 Maximum product temperature 8 Model year - serial number 9 Read operating manual before

use!

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4 GENERAL SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention.

4.1.1 ELECTRICAL EQUIPMENT

Electrical devices and equipment

To be provided in accordance with the local safety requirements with regard to the

operating mode and ambient in uences.

May only be maintained by skilled electricians or under their supervision. With open

housings, there is a danger from line voltage.

Must be operated in accordance with the safety regulations and electrotechnical

regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard or are damaged. Must be de-energized before work is commenced on active parts. Inform sta about

planned work. Observe electrical safety regulations. Ground all devices to a common grounding point. Only operate the device with a properly installed socket with a protective ground wire

connection. Keep liquids away from electrical devices.

4.1.2 PERSONNEL QUALIFICATIONS

Ensure that the device is only operated, maintained and repaired by trained persons.

4.1.3 SAFE WORK ENVIRONMENT

Ensure that the  oor in the working area is static dissipative in accordance with

EN61340-4-1 (resistance must not exceed 100 megohms). Paint mist extraction systems/ventilation systems must be  tted on site according to

local regulations. Ensure that product / air hoses adapted to the working pressure are used. Ensure that personal protective equipment is available and is used. Ensure that all persons within the working area wear static dissipative shoes. Footwear

must comply with EN 20344. The measured insulation resistance must not exceed

100megohms.

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Always follow the information in this manual, particularly the general safety instructions

and the warning instructions. Always follow local regulations concerning occupational safety and accident

prevention. In electrostatics application: Anyone  tted with a pacemaker must not enter the high-

voltage area!

4.2 SAFETY INSTRUCTIONS FOR STAFF

Ensure that during spraying, persons wear static dissipative gloves. The grounding

takes place via the spray gun handle. Protective clothing, including gloves, must comply with EN 1149-5. The measured

insulation resistance must not exceed 100 megohms. Ensure that there are no ignition sources such as naked  ames, sparks, glowing wires,

or hot surfaces in the vicinity. Do not smoke. Ensure that the pipe joints, hoses, equipment parts and connections are permanently,

technically leak-proof:

- Periodic preventative maintenance and service (replacing hoses, checking tightness strength and connections, etc.)

- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g., daily before commissioning, at the end of work or weekly.

In the event of defects, immediately bring the device or system to a stop and arrange

to have repairs carried out immediately.

Grounding

Make sure that the ground and potential equalization of all system parts are performed

reliably and continuously and can withstand the expected stress (e.g. mechanical stress, corrosion).

The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or  ushing agents:

Never point the spray gun at people. Never reach into the spray jet. Before all work on the device, in the event of work interruptions and functional faults:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains.

- In the event of functional faults, remedy the fault as described in the "Troubleshooting" chapter.

4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES

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4.2.3 PRODUCT HOSES

Ensure that the hose material is chemically resistant to the sprayed products and the

 ushing agents used.

Ensure that the product hose is suitable for the pressure generated. Ensure that the following information can be seen on the high pressure hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture

4.2.2 GROUNDING THE DEVICE

Friction,  owing liquids and air or electrostatic coating processes create charges. Flames or sparks can form during discharge. Grounding prevents electrostatic charging.

Ensure that the device is grounded. See chapter "Grounding". Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g., that they are wearing

static dissipative shoes.

Wear static dissipative gloves when spraying. The grounding takes place via the spray

gun handle.

The spray substance supply (spray substance tank, pump, etc.) must be grounded.

If needed, the liquid ejection devices must be checked by experts (e.g. Wagner service

technician) at least every 12 months for their work-safe condition in accordance with DGUV regulation 100-500.

- For shut down devices, the examination can be suspended until the next start-up.

Carry out the work steps as described in the "Pressure Relief" chapter:

- If pressure relief is required.

- If the spraying work is interrupted or stopped.

- Before the device is cleaned on the outside, checked or serviced.

- Before the spray nozzle is installed or cleaned.

In the event of skin injuries caused by paint or  ushing agents:

Note the paint or  ushing agent that you have been using. Consult a doctor immediately.

Avoid risk of injury from recoil forces:

Ensure that you have ﬁrm footing when operating the spray gun. Only hold the spray gun brie y in a position.

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4.2.4 CLEANING AND FLUSHING

Relieve the pressure from the device. De-energize the device electrically. Preference should be given to non- ammable cleaning and  ushing agents. When carrying out cleaning work with  ammable cleaning agents, make sure that all

equipment and resources (e.g. collection tank, funnel, transport cart) are conductive or static dissipative and grounded.

Observe the speci cations of the paint manufacturer. Ensure that the  ash point of the cleaning agent is at least 15 K above the ambient

temperature or that cleaning is undertaken at a cleaning station with technical ventilation.

Take measures for workplace safety (see Chapter 4.1.3). When commissioning or emptying the device, please note that an explosive mixture

may temporarily exist inside the lines and components of equipment:

- depending on the coating product used,

- depending on the  ushing agent (solvent) used,

explosive mixture inside the lines and items of equipment.

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

- at sharp edges

- on moving parts

- on hot surfaces

Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses are

never put under pressure from the outside in any other way.

Ensure that the hoses are never kinked. Observe maximum bending radii. Make sure that the hoses are never used to pull or move the equipment. The electrical resistance of the product hose, measured at both valves, must be less

than 1 megohm.

Suction hoses may not be subjected to pressure.

Several liquids have a high expansion coe cient. In some cases their volume can rise with consequent damage to pipes,  ttings, etc. and cause  uid leakage. When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank (squeeze) and can cause it to break. The tank would leak and the liquid would  ow out. The pressure created by the pump is a multiplication of the inlet air pressure.

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4.2.6 TOUCHING HOT SURFACES

Only touch hot surfaces if you are wearing protective gloves. When operating the device with a coating product with a temperature of > 43 °C;

109°F: identify the unit with a warning label that says "Warning - Hot Surface".

- Instruction label Order No. 9998910

- Protection label Order No. 9998911 Note: Order the two stickers together.

Only electrically conductive tanks may be used for cleaning and  ushing agents. The containers must be grounded.

An explosive gas/air mixture forms in closed containers.

Never spray into a closed tank when using solvents for  ushing.

External cleaning

When cleaning the exterior of the device or its parts, also observe the following:

Disconnect the pneumatic supply line. Use only moistened cloths and brushes. Never use abrasive agents or hard objects and

never spray cleaning agents with a gun. Cleaning the device must not damage it in any way.

Ensure that no electric component is cleaned with or immersed into solvent.

4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS

When preparing or working with lacquer and when cleaning the device, follow the

working instructions of the manufacturer of the lacquers, solvents and cleaning agents being used.

Take the speci ed protective measures. In particular, use personal protective equipment:

safety goggles, protective clothing and gloves, as well as respiratory protection and skin protection cream if necessary.

Use a mask or breathing apparatus if necessary. For su cient health and environmental safety: Operate the device in a spray booth or

on a spraying wall with the ventilation (extraction) switched on.

Wear suitable protective clothing when working with hot products.

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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.

Air motor (4)

The air motor 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).

Fluid section (9)

The  uid section has been designed as a piston pump with exchangeable ball valves. The hard chrome-plated pump piston runs in two  xed packings which are self-adjusting by means of a pressure spring, thus resulting in a long service life.

Between the air motor and the  uid section there is a separating agent cup (7) for separating the separating agent.

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 Material outlet

9 Fluid section 10 Material inlet 11 Grounding connection

5 DESCRIPTION

5.1 DESIGN

5.2 MODE OF OPERATION

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5.4 SCOPE OF DELIVERY

Pneumatic piston pump

Consists of:

- Fluid section

- Air motor

- Connection elements

- Air pressure regulator for air motor

The scope of delivery also includes: Separating agent 250 ml; 250 cc Order No.: 9992504 Declaration of conformity See Chapter 14 Operating manual, German Order No.: 2340281 Operating manual in the local language See Chapter 1.3

The delivery note shows the exact scope of delivery. Accessories: see Chapter 12.

5.3 PROTECTIVE AND MONITORING EQUIPMENT

Safety valve

The air motor is  tted with a safety valve. The safety valve has been set and sealed at the factory. In case of pressures over and above the permissible operating pressure, the valve, which is held with a spring, automatically opens and releases the excess pressure.

Overpressure!

Risk of injury from bursting components.

Never change the safety valve setting.

WARNING

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5.5.2 RECOMMENDED PACKINGS

5.5 DATA

5.5.1 MATERIALS OF PAINTWETTED PARTS

Housing Stainless steel Piston Stainless steel and hard chrome Valve balls Stainless steel Valve seats Carbide O-rings PTFE Packings Standard

= Ultra high molecular weight polyethylene

= PTFE with graphite

WAGNER packings are manufactured in four di erent materials:

Product Color

Leather dark brown PTFE with graphite black Ultra high molecular weight

polyethylene

transparent

PTFE white

Each product has the following properties, which in uence the packings:

Mechanical stability poor good good poor Friction coe cient 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

Standard combinations

Standard pumps: Heavy-duty (high-pressure) pumps: Hardener pumps in 2K systems:

5.5.3 TECHNICAL DATA

Outgoing air containing oil!

Risk of poisoning if inhaled. Air motor switching problems.

Provide water-free and oil-free compressed air

WARNING

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Description

Measuring

unit

Pump ratio 75:1 55:1 60:1 Volume  ow per double stroke cm; cc 150 200 240

Maximum operating overpressure

MPa 53 44 48

bar 530 440 480

psi 7687 6382 6962

Maximum possible strokes in operation

/min. 60

Maximum recommended strokes per minute in continuous operation

/min. 40

Minimum/maximum air inlet pressure

MPa 0.25–0.71 0.25–0.80

bar 2.5–7.1 2.5–8.0

psi 36–103 36–116

Compressed air quality: free from oil and water

Quality standard 7.5.4 according to ISO 8573.1, 2010

7: Particle concentration 5–10mg/m 5: Humidity: Pressure dew point ≤ +7 °C 4: Oil content ≤ 5mg/m

Air inlet (inside thread) inch G1" Minimum of the compressed air supply line mm; inch 25; 0.98 Air consumption at 0.6 MPa; 6 bar; 87 psi per

double stroke

nl 79.9 103.1

scf 2.82 3.64 Air motor piston diameter mm; inch 220; 8.7 250; 9.8 Air motor piston stroke mm; inch 150; 6 Sound pressure level at maximum permissible air

pressure*

dB(A) 83 83

Sound pressure level at 0.6 MPa; 6 bar; 87 psi air pressure*

dB(A) 81 80

Sound pressure level at 0.4 MPa; 4 bar; 58 psi air pressure*

dB(A) 69 76

Product inlet connection (inside thread) mm G1½" Product outlet (outside thread) mm M24x1.5 Weight kg; lb 53; 117 60.5; 133.5 Product pH value pH 3.5–9

Maximum product pressure at pump inlet

MPa 2

bar 20

psi 290 Material temperature

+5…+80; +41…+176

Ambient temperature

Construction and assembly

+5…+50; +41…+122

Suspension -20…+60 ; -4…+140 Relative humidity % 10–95 (without condensation) Allowable inclination for operation

± 10

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).

5.5.3.1 TECHNICAL DATA FOR JAGUAR AND PROTEC

150 cm3 - 300 cm3

B_03905

G/2

I (IbxIh) Ib

(E)

B_04260

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Jaguar / PROTEC wall mount

5.5.3.2 MEASUREMENTS AND CONNECTIONS FOR JAGUAR AND PROTEC

mm; inch mm; inch mm; inch

A 1145; 45.0 1157; 45.5 1169; 46.0 B 304; 12 C ~582; 22.9 D 470; 18.5 483; 19.0 E 675; 26.6 687; 27.0 F 244; 9.6 G 230; 9.1 H 110; 4.3

I 20x48; 0.8x1.9 J M8

K G1½" (female thread) L1 M24x1.5 (outside thread) L2 G3/8" G1/2"

M G1" O 135.5; 5.3

P 238; 9.4

9; 0.35

R 9; 0.35

S 206; 8.1

T 17; 0.67

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Description

Measuring

Unit

Pump ratio - 72 :1 Volume  ow per double stroke ( ) cm; cc 300 Maximum operating overpressure MPa; bar; psi 53; 530; 7687 Maximum possible strokes in operation

/min. 40

Maximum recommended strokes per minute in continuous operation

/min. 30

Minimum/maximum air inlet pressure MPa; bar; psi 0.25-0.74; 2.5-7.4; 36-107

Compressed air quality: free from oil and water

Quality standard 7.5.4 according to ISO 8573.1, 2010

7: Particle concentration 5–10mg/m 5: Humidity: Pressure dew

point ≤ +7 °C 4: Oil content ≤ 5mg/m

Air inlet (inside thread) inch G 1" Minimum Ø of the compressed air supply line mm; inch 25; 1.0 Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke

nl; scf 170; 6 Air motor piston diameter mm; inch 300; 11.8 Air motor piston stroke mm; inch 150; 5.9 Sound pressure level at maximum permissible air pressure*

82 Sound pressure level at 0.6 MPa; 6 bar; 87 psi air pressure* 80 Sound pressure level at 0.4 MPa; 4 bar; 58 psi air pressure* 75 Product inlet connection (inside thread) mm G1 1/2" Product outlet (outside thread) mm M24x1.5 Weight kg; lb 80; 176 Product pH value pH 3.5–9 Maximum product pressure at pump inlet MPa; bar; psi 2; 20; 290 Material temperature

+5…+80; 41…176

Ambient temperature

Construction and assembly

+5…+50; 41…122

Suspension

-20…+60 ; -4…+140 Relative humidity % 10–95 (without condensation) Allowable inclination for operation

± 10

* A rated sound pressure level measured at 1 m distance, L pA1m, according to DIN EN 14462: 2005. Reference measurements have been made by SUVA (Swiss Accident Insurance Institute).

5.5.3.3 TECHNICAL DATA FOR TIGER

Outgoing air containing oil!

Risk of poisoning if inhaled. Air motor switching problems.

Provide water-free and oil-free compressed air

WARNING

150 cm3 - 300 cm3

B_03905

G/2

I (IbxIh) Ib

(E)

B_04261

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Unit

A 1106 mm

43.5 inch

B 340 mm

13.4 inch

C 562 mm

22.1 inch

D 518 mm

20.4 inch

E 588 mm

23.1 inch

F 244 mm

9.6 inch

G 230 mm

9.1 inch

Wall mount

Unit

H 110 mm

4.3 inch

I 20x48 mm

0.8x1.9 inch

JM8

K G1 1/2" mm L1 M24x1.5 mm L2 G3/4" inch

M G 1" inch O 135 mm

5.3 inch

P 238 mm

9.4 inch

Unit

Q 9mm

0.35 inch

9mm

0.35 inch

S 206 mm

8.1 inch

T32 mm

1.3 inch

5.5.3.4 MEASUREMENTS AND CONNECTIONS FOR TIGER

150 cm3 - 300 cm3

BAR

BAR

BAR

BAR

BAR

BAR

"?

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

5.5.4 VOLUME FLOW

5.5.5 PERFORMANCE DIAGRAMS

Stroke frequency /min

Product pressure bar (MPa) psi

Air consumption nl/min <scfm>

Water  ow rate l/min <gpm>

Example diagram

Wagner AL nozzles Volume  ow* in l/min

at at at at

Maximum ranges for continuous operation at 40 DH/min (Jaguar, PROTEC) or 30 DH/min (Tiger)

7 MPa 10 MPa 15 MPa 20 MPa 70 bar 100 bar 150 bar 200 bar

inch mm Spray angle 1015 psi 1450 psi 2175 psi 2900 psi

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

0.019 0.48 20-30-40-50-60-70-80° 0.93 1.09 1.37 1.47

0.021 0.53 20-40-50-60-80° 1.14 1.36 1.69 1.78

0.023 0.58 20-40-50-60-70-80° 1.37 1.59 2.01 2.24

0.025 0.64 20-40-50-60-80° 1.62 1.91 2.40 2.60

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

0.035 0.90 20-40-50-60° 3.22 3.74 4.69 5.14

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.

150 cm3 - 300 cm3

























     

















































!

"

#

BAR-0A

PSI

NLMIN

SCFM

LMIN

GPM

!

"

#

"?

500 (50)

<7250>

400 (40)

<5800>

300 (30)

<4350>

200 (20)

<2900>

100 (10)

<1450>

10 20 30 40 50 60

5000

<175>

4000

<140>

3000

<105>

2000

<70>

1000

<35>

<3.2>

<2.7>

<2.1>

<1.6>

<1.1>

<0.5>

bar (MPa)

<psi>

nl/min

<scfm>

l/min

<gpm>

B_04262

500 (50)

<7250>

400 (40)

<5800>

300 (30)

<4350>

200 (20)

<2900>

100 (10)

<1450>

10 20 30 40 50 60

5000

<175>

4000

<140>

3000

<105>

2000

<70>

1000

<35>

bar (MPa)

<psi>

nl/min

<scfm>

l/min

<gpm>

14.4

<3.8>

<3.2>

9.6

<2.5>

7.2

<1.9>

4.8

<1.3>

2.4

<0.6>

B_05288

300 (30)

<4350>

200 (20)

<2900>

100 (10)

<1450>

10 20 30 40 50 60

9000

<318>

6000

<212>

3000

<106>

<4.8>

<4>

<3.2>

<2.4>

<1.6>

<0.8>

bar (MPa)

<psi>

nl/min

<scfm>

l/min

<gpm

400 (40)

<5800>

500 (50)

<7250>

12000

<424>

15000

<530>

B_00321

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

PROTEC 60-240

Stroke frequency /min

Product pressure

Air consumption

Water  ow rate

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

Tiger 72-300

Stroke frequency

/min

Product pressure

Air consumption

JAGUAR 75-150

Stroke frequency

/min

Product pressure

Air consumption

JAGUAR 55-200

Stroke frequency /min

Product pressure

Air consumption

Water  ow rate

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

Water  ow rate

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

Water  ow rate

A = 7.4 bar (0.74 MPa; 107 psi) air pressure B = 6 bar (0.6 MPa; 87 psi) air pressure C = 4 bar (0.4 MPa; 58 psi) air pressure

150 cm3 - 300 cm3

B_03907

B_04264

B_04265

B_05295

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

5.6 PRESSURE REGULATOR UNIT

1 Pressure regulator 2 Ball Valve 3 Pressure gauge 4 Compressed air Inlet

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

5.7 PRESSURE RELIEF

5.7.1 HIGHPRESSURE 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. The high-pressure  lter corresponding to the device can be found in the "Accessories" chapter; the compatible  lter inserts can be found in the "Spare parts" chapter.

Closed

Open

Preferred  lter installation position

So that the complete pressure relief of the pump can be performed (see Chapter 7.5), a high-pressure  lter with a return  ow or a relief combination, is mandatory.

1 Fluid section

connection 2 Material outlet 3 Return line

53MPa 530bar

7687psi

150 cm3 - 300 cm3

B_04282

Loctite 638

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

5.8 AIR FILTER SET PC OPTION

The air  lter serves to  lter the inlet's compressed air.

Assembly of the air  lter set PC on the PC heavy duty trolley (1):

1. Mount the air  lter (2).

2. Mount the air  lter (2) on trolley (1).

3. Mount the air connection (3) on the air motor.

4. Mount the air hose between (2) and (3).

If necessary turn the adaptor plate 180° so that the air  lter can be mounted on the trolley. Observe the air  lter's  ow direction.

150 cm3 - 300 cm3

B_04283

Molykote

80 Nm; 59 lbft

Molykote

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

5.9 HEATER SET PC OPTION

The electric, continuous- ow heater with explosion protection is downstream of the pump. The coating product can only be heated to maximum 80 °C. The continuous- ow heater is  tted with a temperature limiter.

The temperature is set using the temperature regulator. The coating product temperature is read o the thermometer on the coating product output.

Heater and thermometer description

see heater operating manual (Order No. 65860).

Assembly of the heater set PC on the PC heavy duty trolley:

1. Mount heater (2).

2. Mount heater (2) on trolley (1).

3. Connect heater in accordance with the operating manual.

4. Mount enclosed  tting (3) on the  uid section's outlet  tting.

150 cm3 - 300 cm3

B_05173

B_05174

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

5.10 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 material 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.

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.

Main pump protection

The maximum product pressure at

the pump inlet of the IceBreaker pump may not be exceeded.

Feed pump

Main pump (IceBreaker)

Feed pump

Main pump (IceBreaker)

Pressure relief valve

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.

150 cm3 - 300 cm3

B_04065

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

6.3 TRANSPORTATION

The pump must be moved on a trolley (PC heavy duty trolley) or with lifting equipment or a crane.

Only the pump without trolleys may be lifted by the ring nut or lifting eye bolt (see accessories) and transported short distances.

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF

6.2 STORAGE AND INSTALLATION CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms. For speci cations on temperatures and relative humidity, see Technical Data.

Long-term storage: Thoroughly clean the pump, if a long-term decommissioning is planned. See Chapter "Cleaning". For recommissioning, proceed according to following chapters.

A skilled person must check to ensure that the device is in a reliable state after it is installed and before commissioning.

The assembly and commissioning sta must have the technical skills to safely undertake

commissioning.

When assembling, commissioning and carrying out all work, read and follow the

operating manuals and safety regulations for the additionally required system components.

Inclined ground!

Risk of accidents if the device rolls away/falls.

Position the trolley with the piston pump horizontally. If the surface is inclined, position the feet of the trolley towards

the gradient.

Secure the trolley.

WARNING

150 cm3 - 300 cm3

B_04266

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

6.4 ASSEMBLING THE PUMP

Note:

This pump can be used as part of a spraying system for Airless applications. The individual components are shown in the accessories, or can be arranged with a spraypack con gurator. The nozzles must be selected according to the gun operating manual.

Procedure:

a) Mount pump (1) on frame, trolley (6), or wall mount. When using a wall mount, the

 uid section must be turned by 180°. b) Mount high pressure  lter (3). c) Mount suction system (5). d) Mount return tube (4) or return hose. e) Connect high-pressure hose and gun (2) as laid down in the operating manual for the

gun.

Airless system

6.4.1 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 outgoing air speed.

Observe the safety instructions in Chapter 4.1.3.

150 cm3 - 300 cm3

B_00304

R max < 1 M:

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

6.5 GROUNDING

Grounding scheme (example)

Paint tank

Work piece

Conveyor

Spraying stand

Floor, static dissipative

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic sparks.

Clean the piston pump only with a damp cloth. Ground all device components. Ground the work pieces to be coated.

WARNING

Heavy paint mist if grounding is insu cient!

Danger of poisoning. Insu cient paint application quality.

Ground all device components. Ground the work pieces to be coated.

WARNING

Ex zone

Cable cross sections

Pump 4 mm;

Conveyor 16 mm;

Product tank 6 mm; Booth 16 mm;

Spraying stand 16 mm;

150 cm3 - 300 cm3

B_05443

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Procedure:

1. Ground the pump, connect the grounding cable to potential equalization on-site.

2. Ground the product tank.

3. Ground the other parts of the system to an on-site grounding connection. 16 mm;

Ex zone

All devices and equipment must be suitable for use in potentially explosive areas.

Safe operation of the IceBreaker pump is only guaranteed with a ground connection.

Connect all ground cables using a short and direct route.

Tank

All paints,  ushing agents and waste containers have to be electrically conductive. All containers must be grounded.

6.6 COMMISSIONING

Observe all safety regulations in accordance with Chapter 4 and Chapter 7.2. Emergency stop, see Chapter7.3.

Preparation

Before every start-up, the following points should be observed as laid down in the operating manual:

- Secure gun with safety clip.

- Check the permissible pressures.

- Check all connections for leaks.

- Check hoses for damage in accordance with Chapter 8.2.8.

Fill the pump with  ushing agent

The devices are tested during manufacturing with emulsifying oil, pure oil or solvent. Possible residues must be  ushed out of the circuits with a solvent ( ushing agent) before commissioning.

- Fill the separating agent in accordance with Chapter 8.2.4.

- Fill the empty device with  ushing agent in accordance with Chapter 8.2.6.

Pressure tightness test

- Gradually increase the pressure in pump with the pressure regulator until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points for leaks.

- Depressurization in accordance with Chapter 7.5.

Filling with working material

- In accordance with Chapter 7.6.1.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

7 OPERATION

7.2 SAFETY INSTRUCTIONS

Incorrect operation!

Risk of injury and damage to the device.

If contact with lacquers or cleaning agents causes skin irritation,

appropriate precautionary measures must be taken, e.g., wearing protective clothing.

The footwear worn by operating sta must comply with

EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.

The protective clothing, including gloves, must comply with

EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

WARNING

Before carrying out any work, the following points must be observed in accordance with the operating manual:

Observe all safety regulations in accordance with Chapter 4. Carry out commissioning in accordance with Chapter 6.6.

7.1 TRAINING THE OPERATING STAFF

The operating sta must be quali ed and  t to operate the entire system. The operating sta must be familiar with the potential risks associated with improper

behavior as well as the necessary protective devices and measures.

Before work commences, the operating sta must receive appropriate system training.

Unintentional putting into operation!

Risk of injury

Before any work on the device, in the event of work interruptions and malfunctions:

Relieve the pressure from the spray gun and unit. Secure the spray gun against actuation. Switch o the energy/compressed air supply. Disconnect the control unit form the network. In the event of functional faults: remedy the fault as described in

the "Troubleshooting" chapter.

WARNING

150 cm3 - 300 cm3

B_04267

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

7.2.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN

High pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused

by paint or solvent. Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the

pressure from them and replace them.

Use personal protective equipment (protective clothing, gloves,

eyewear and respiratory protection).

WARNING

Observe spray gun operating manual.

In the case of unforeseen occurrences, immediately:

- close ball valve (2);

- open return valve (3).

7.3 EMERGENCY STOP

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from  ying parts.

Ensure that the pump and suction system are always completely

ﬁlled with  ushing agent or working material.

Do not spray the device empty after cleaning.

WARNING

Open

Closed

Open

150 cm3 - 300 cm3

B_04268

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

7.5 PRESSURE RELIEF/WORK INTERRUPTION

If the system has been used with 2K products:

1. Close the spray gun.

2. Close ball valve (2).

3. Release the system by opening the 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 gun.

5. Open and close the return valve (3) slowly to completely depressurize the system.

Hardened working material in the spraying system when 2K product is processed!

Destruction of pump and injection system.

Follow the manufacturer‘s processing rules, particularly regarding the pot life. Flush thoroughly before the end of the pot life. The pot life is decreased by warmth.

NOTICE

Closed

Open

7.4 SPRAYING

1. Visual check: personal safety

equipment, grounding and all devices ready to use.

2. Secure the spray gun and

place the nozzle in the gun.

3. Set required working

pressure on the pressure regulator (1).

4. Slowly open the ball valve (2).

5. Optimize the spraying results

as laid down in the gun instructions.

6. Start work process.

150 cm3 - 300 cm3

B_04268

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Closed

Open

7.6 BASIC FLUSHING

Procedure

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.

Flush via the return  ow 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).

Flush using gun

11. Point the spray gun, without nozzle, into the tank (5) and open it.

12. Slowly open the ball valve (2).

13. Rinse until clean  ushing agent  ows from the gun.

14. Close ball valve (2).

15. As soon as there is no pressure in the system, close the gun.

16. Secure the gun.

17. Dispose of the contents of the tank (5) according to the local regulations.

7.6.1 FILLING WITH WORKING MATERIAL

After basic  ushing, the system can be  lled with working material. Proceed according to Chapter 7.6, but use working material instead of  ushing agent.

Flush regularly

Regular  ushing, cleaning and maintenance ensures the pumps' high pumping and suction capacity.

Hardener pumps in 2K systems

Do not  ush hardener pumps with water, rather only using suitable  ushing agents (solvents).

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

8 CLEANING AND MAINTENANCE

Cleaning work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during cleaning work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable cleaning tools and aids

8.1 CLEANING

8.1.2 SAFETY INSTRUCTIONS

8.1.1 CLEANING STAFF

Clean the piston pump only with a damp cloth. Observe safety instructions in Chapter 4.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains. Observe the operating manual and service manuals at all times

when carrying out work.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

8.1.3 DECOMMISSIONING AND CLEANING

8. Fully assemble the system.

9. Check  ll level of the separating agent

Chapter 8.2.4.

10. Fill the system with  ushing agent in accordance with Chapter 8.2.6.

When storing the device for longer periods of time, it is necessary to thoroughly clean it and protect it from corrosion. Replace the water or solvent in the product pump with a suitable preservative,  ll separating agent cup with separating agent.

Procedure:

1. Carry out points 1 to 9 of Chapter 8.1.3 "Decommission and clean".

2. Fill the system with preservative in accordance with Chapter 8.2.6.

3. Empty the pump in a controlled manner in accordance with Chapter 8.2.5 and seal the openings.

8.1.4 LONGTERM STORAGE

The device should be cleaned for maintenance purposes. Ensure that no remaining product dries on and sticks to the device.

1. Carry out work interruption

Chapter 7.5.

2. Carry out basic  ushing in accordance with Chapter 7.6.

3. Empty the pump in a controlled manner

in accordance with Chapter 8.2.5.

4. Maintain the gun according to the operating manual.

5. Clean and check the suction system and the suction  lter.

6. When using a material  lter, check  lter insert and  lter housing and clean or replace

them. Chapter 8.2.7.

7. Clean the outside of the system.

Brittle  lter pressure regulator!

The tank on the  lter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury.

Do not clean the tank on the  lter pressure regulator with

solvents.

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from  ying parts. Ignition of potentially explosive surrounding atmosphere.

Ensure that the pump and suction system are always completely

ﬁlled with  ushing agent or working material.

Do not spray the device empty after cleaning.

WARNING

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

8.2 MAINTENANCE

Maintenance work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during maintenance work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable tools and aids

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

8.2.1 MAINTENANCE STAFF

8.2.2 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Prior to maintenance

It should be ensured that the device is in the following state before carrying out any work on it:

- Release pressure from the pump, high-pressure hose and gun.

- The gun should be secured with the safety clip.

- The air supply should be interrupted.

After maintenance

- Commissioning in accordance with Chapter 6.6.

According DGUV regulation 100-500:

- 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.

Incorrect maintenance/repair!

Danger to life and equipment damage.

Repair or replacement of devices or parts of devices are only

allowed to be performed outside the hazard area by quali ed personnel.

DANGER

150 cm3 - 300 cm3

B_03918

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

1. Check the level of separating agent in the separating agent cup every day, and top up if necessary.

2. Check and clean the high-pressure  lter every day or as required. (See Chapter 8.2.7)

3. Every shut down should be carried out as laid down in Chapter 8.1.3!

4. Check hoses, pipes, and couplings every day and replace if necessary.

If the pump has to be emptied for maintenance work, proceed according to Chapter 8.2.5.

The service manual is available in German and English. For order number see Chapter 1.3.

8.2.3 REGULAR MAINTENANCE WORK

8.2.4 FILLING SEPARATING AGENT

Place the supplied separating agent into the separating agent cup. Filling level: 1 cm; 0.4 inch under the cup edge. Separating agent: Order No. 9992504

Inclination angle of the pump

Maximum permissible inclination of pump for moving, transportation, etc. after  lling it with separating agent ±30°.

The pump must be vertical during operation.

Piston pump dry run!

High wear/damage to the packings. Paint or solvent can escape if the seals are dry.

Ensure that the separating  uid tank is  lled with su cient separating  uid. Filling

level 1 cm; 0.4 inch under the cup edge.

NOTICE

150 cm3 - 300 cm3

B_04268

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

If the pumping product becomes heated, switch o all heaters and let the product cool o .

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Carry out basic  ushing in accordance with Chapter 7.6.

3. Place grounded collection tank (5) under the return tube (4).

4. Place the suction hose (7) in an empty, grounded tank (6).

5. Close pressure regulator (1) (0MPa; 0bar; 0psi).

Empty using return line

6. Open return valve (3).

7. Slowly open the ball valve (2).

8. Slowly turn air pressure up on the pressure regulator (1) and only until the pump is running normally (approx.

0.05 MPa; 0.5 bar; 7.25 psi).

9. Be ready for the switch from working material to air. Turn down pressure regulator (1) far enough that the pump is still running normally (approx. 0–0.05MPa; 0–0.5bar; 0–7.25psi).

10. As soon as working material is no longer  owing from the return tube (4), close ball valve (2).

11. Close return valve (3).

Empty up to the gun

12. Point the gun, without nozzle, into tank (5) and open it.

13. Slowly open the ball valve (2). Be ready for the switch from working material to air.

14. As soon as working material is no longer  owing from the return tube, close the ball valve (2).

15. Close and secure gun.

16. Depressurization in accordance with Chapter 7.5.

17. Dispose of the contents of the tank (5) according to the local regulations.

8.2.5 EMPTYING THE PUMP

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.

WARNING

Closed

Open

150 cm3 - 300 cm3

B_04268

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Place 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 material up to the middle of the inlet housing at the maximum!

4. Close pressure regulator (1) (0MPa; 0bar; 0psi).

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. .0–0.05MPa; 0–0.5 bar; 0–7.25 psi).

Be ready to switch from working material to air and prevent back spray.

8. Close ball valve (2) as soon as pure working material 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 working material to air and prevent back spray.

12. As soon as pure working material without air bubbles is  owing, close ball valve (2).

13. Close and secure the spray gun.

14. Depressurization in accordance with Chapter 7.5.

15. Dispose of the contents of the tank (5) according to the local regulations.

8.2.6 FILLING THE EMPTY PUMP

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from  ying parts. Ignition of potentially explosive surrounding atmosphere.

Empty and  ll the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

WARNING

Closed

Open

150 cm3 - 300 cm3

B_05427

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

8.2.7 CLEANING AND REPLACING THE HIGHPRESSURE FILTER

1. Flush the pump and HP  lter in accordance with Chapter 7.6, and while doing so:

- At the preferred  lter installation position: Flush via the

return  ow 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. 0.15MPa;

1.5bar; 22psi.

- At the reversed  lter installation position: Flush using the

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 8.2.5.

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 support (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, secure

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 13.6.

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 identi cation 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 8.2.6.

** Order No., see Chapter 10.2.

Filter installation position

Preferred Turned over

B_05275

B_05276

Filter identi cation

Mobilux

EP2**

grease

Anti-seize paste**

53MPa 530bar 7687psi

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Bursting hose, bursting threaded joints!

Danger to life from injection of product and from  ying parts.

Ensure that the hose material is chemically resistant to the

sprayed products and the used  ushing agents.

Ensure that the spray gun, threaded joints, and product hose

between the device and the spray gun are suitable for the generated pressure.

Ensure that the following information can be seen on the hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture.

DANGER

8.2.8 PRODUCT HOSES, TUBES AND COUPLINGS

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental in uences even when handled correctly.

Check hoses, pipes, and couplings every day and replace if necessary. Before every commissioning, check all connections for leaks. Additionally, the operator must regularly check the complete hoses for wear and tear

as well as for damage at intervals that he/she has set. Records of these checks must be kept.

Undamaged complete hoses are to be replaced when one of the two following intervals has been exceeded:

– 6 years from the date of the hose crimping (see  tting embossing). – 10 years from the date of the hose imprinting.

Fitting embossing

Meaning

(if present) xxx bar Pressure

yymm

Crimping date (year/month)

XX Internal code

Hose imprinting Meaning

WAGNER

Name / Manufacturer

yymm

Date of manufacture (year/ month)

xxx bar (xx MPa)

Pressure

e.g., 270 bar (27MPa)

XX Internal code DNxx (e.g., DN10) Nominal diameter

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

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 brie y disconnect compressed air supply.

No pressure indication on the pressure gage (air pressure regulator defective).

Disconnect compressed air supply brie y or repair or change pressure regulator.

Spray nozzle is clogged. Clean the nozzle according to the

instructions. Insu cient compressed air supply. Check compressed air supply. Filter insert in spray gun or high-

pressure  lter is clogged.

Clean the parts and use a suitable

working material. Fluid section or high-pressure

hose are blocked (e.g., 2K product hardened).

Dismount and clean  uid section,

replace high pressure hose.

Grease in spool and sleeve assembly.

Degrease spool and sleeve assembly.

Pump stops at the stroke end occasionally.

Check detent element (see service

manual).

Poor spray pattern See the gun instructions. Irregular operation of

product pump: spray jet collapses (pulsation)

Viscosity is too high. Thin spraying product. Spraying pressure is too low. Increase incoming air pressure. Use a

smaller nozzle. Valves are clogged. Clean product pump, if necessary leave

to soak in  ushing agent. Foreign body in suction valve. Dismantle suction valve housing, clean

and check valve seat. Diameter of compressed air line too

small.

Assemble a larger incoming line

-> Technical Data, Chapter 5.5.3.

Valves, packings, or pistons are worn out.

Replace the parts.

Control air  lter or work air  lter is clogged.

Check  lter and clean it if necessary.

The pump runs smoothly but does not suck up any product

The suction system's union nut is loose; the pump is taking in air.

Tighten union nut.

Suction  lter is clogged. Clean  lter. Ball in suction or piston valve is

sticking.

Clean with  ushing agent (if necessary

vent device).

Pump runs when the gun is closed

Packings, valves, or pistons are worn out.

Replace the parts.

The air motor is iced up There is a lot of condensation water

in the air supply.

Install a water separator.

If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

10 REPAIRS

10.1 REPAIR STAFF

Repair work must be carried out carefully by quali ed and trained sta . They should be informed of speci c hazards during their training. The repairs must be carried out in accordance with the corresponding service manual.

The following hazards may arise during repair work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable tools and aids

A skilled person must ensure that the device is checked for being in a reliable state after repair work is completed.

10.2 MOUNTING MATERIALS

In Chapter 13 the order numbers for device spare parts can be found, as well as for wearing parts such as seals. Use torques, greases and glues in accordance with Chapter 13.

Mounting materials

Order No. Quantity Designation Smaller containers

9992590 1 pc ≙ 50 ml Loctite 222 9992511 1 pc ≙ 50 ml Loctite 243 9992528 1 pc ≙ 150 g Loctite

270 9992831 1 pc ≙ 50 ml Loctite 542 9999042 1 pc ≙ 50 ml Loctite 638 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 Z102.00 1 pc ≙ 1000 ml Tecni oil 1000 ml 125 cc ≙ Order No. Z101.00 9992698 1 pc ≙ 200 g can Vaseline white PHHV II

Brand notice

The brands speci ed in this document are property of the respective owners. Loctite

, for

example, is a registered brand of Henkel.

When the equipment must be scrapped, please di erentiate the disposal of the waste materials. The following materials have been used:

Steel Aluminum Plastics Carbide

Consumable products

Consumable products (lacquers, adhesives,  ushing and cleaning agents) must be disposed of in accordance with all applicable legal requirements.

11 DISPOSAL

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

12.1 ACCESSORIES FOR PRODUCT OUTLET

Accessories list

Designation Order No. Order No. Order No. Order No.

A Piston pump PE/TG (Tiger: PE/L) 2339845 2339846 2351205 2339847 1 Separating agent 250 ml; 250 cc 9992504 2 Grounding cable 3 m; 9.8 ft 236219

HP  lter DN12 PN530-SSt with carbon steel ball valve

2339900

9 Y-distributor with 2 gun connections M3/8" NPS 2339850

Return tube DN6-G1/4"-100mm-PE 2331752

Relief combination complete 2347275 22 Outside thread grommet 1"-NW25 9985671 23 Sealing ring 1" 9974135 24 Regulator lock 2334958

= Wearing part

12 ACCESSORIES

150 cm3 - 300 cm3

B_04269

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

150 cm3 - 300 cm3

DN38

B_05289

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

12.2 ACCESSORIES FOR PRODUCT INLET

For trouble-free intake, 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.

Accessories for product inlet

Designation Order No. Order No. Order No. Order No.

A Piston pump PE/TG (Tiger: PE/L) 2339845 2339846 2351205 2339847 1 Suction hose set DN38-PC-G11/2 2352549

Suction hose DN38-PC (including Pos 3, 4). For

details, see Chapter 13.7.

2325815

3 O-ring for suction hose quick coupler 367525 4

Suction  lter DN38-12.8mesh-SSt 2329596

5 Fitting-DF-MM-G1 1/2-Rd55x1/6-PN25-CS 2336489 6 Fitting-EF-FM-G1 1/2-G1 1/2-PN25-TG 2329019 7 Loctite

638 9992833

= Wearing part

Regarding position 2: For the assembly or disassembly of the nut, hit the cam with a

rubber mallet.

Regarding position 6: Before assembling the suction bend, check if the inlet housing is

screwed on  rmly. Set the desired orientation of the suction bend during assembly.

12.2.1 SUCTION HOSE

150 cm3 - 300 cm3

B_05294

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Accessories for product inlet

Designation Order No. Order No. Order No. Order No.

A Piston pump PE/TG (Tiger: PE/L) 2339845 2339846 2351205 2339847 1 20 liter tank 2341278 2 Coarse sieve 2348279

Suction tube PC complete.

2348257

For details, see Chapter 13.8.

= Wearing part

12.2.2 20 LITER TANK

150 cm3 - 300 cm3

B_04271

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

12.3 ACCESSORIES FOR TROLLEY AND WALL MOUNT

Accessories for trolley and wall mount

Designation Order No. Order No. Order No. Order No.

A Piston pump PE/TG (Tiger: PE/L) 2339845 2339846 2351205 2339847

Heavy-duty PC trolley, complete.

2339705

For details, see Chapter 13.9.

2 Wall mount 9", complete 369020 3 Air  lter set PC (for details, see Chapter 13.9.1) 2339851

Filter cartridge 2347890

4 Heater set PC (for details, see Chapter 13.9.2) 2339728

= Wearing part

Regarding position 2: When using a wall mount, the  uid section must be turned by 180°.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13 SPARE PARTS

13.1 HOW CAN SPARE PARTS BE ORDERED?

Always supply the following information to ensure delivery of the right spare part:

Order number, designation and quantity

The quantity need not be the same as the number given in the quantity column "

" on the list. This number merely indicates how many of the respective parts are used in each component.

The following information is also required to ensure smooth processing of your order:

- Address for the invoice

- Address for delivery

- Name of the person to be contacted in the event of any queries

- Type of delivery (normal mail, express delivery, air freight, courier, etc.)

Identi cation in spare parts lists.

Explanation of column "

" (labeling) in the following spare parts lists:

Wearing parts

Note: These parts are not covered by warranty terms.

Not part of standard equipment, available, however, as additional extra.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains. Observe the operating manual and service manuals at all times

when carrying out work.

Observe "Repair" chapter: Repair personnel and mounting materials. The service manuals are available separately. See Chapter 1.3.

150 cm3 - 300 cm3

B_05280

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Designation Order No. Order No. Order No.

1 Piston pump 2339845 2339846 2351205 2 Fluid section 2340007 2340008 2349152 3 Air motor 2329625 2342487 2351208

Connection set for air motor -  uid section

2350033 2350036 2351190

9 Grounding cable, complete 236219

10 Molykote

DX grease 9992616

Tightening torque for air motor/ uid section

50 Nm; 37

lbft

70 Nm; 52

lbft

70 Nm; 52

lbft

Tightening torque pos. 2 and 3

13.2 OVERVIEW OF THE COMPONENTS

150 cm3 - 300 cm3

B_05281

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Designation Order No.

1 Piston pump 2339847 2 Fluid section 2340009 3 Air motor 2329627 4 Connection set for air motor -  uid section 2350037 9 Grounding cable, complete 236219

10 Molykote

DX grease 9992616

Tightening torque for air motor/ uid section 70 Nm; 52 lbft

Tightening torque pos. 2 and 3

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.3.1 JAGUAR AIR MOTOR 9"

Jaguar air motor 9" spare parts list

Designation Order No. Order No.

1 1 Air motor 2329625 2342487 2 1 Flange 369316 3

1 Piston rod 368402 4 1 Cylinder pipe 369403 5 2 Compressed air pipe 368404 6 1 Control air pipe 367405 8 1 Sealing plug 369307 9

2 Outlet seal 369312

10 1 Connecting part 369309 11 1 Silencer 369310 12 1 Hood 369905 13

1 Compressed air  lter 369313

14 1 Control air  lter 367314 15 1 Fluid warning label 2332082 16 1 Shoulder screw 369318 17

1 Sound deadening pad 369906

18 2 Cotter pin 369320 23 1 Filter holder 367324 25 1 Throttle 367325

= Wearing part = Included in service set = Not part of the standard equipment but available as a special accessory

13.3 AIR MOTORS

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains. Observe the operating manual and service manuals at all times

when carrying out work.

150 cm3 - 300 cm3

105

109

110

17 16 54

103

8-10 Nm / 6-7 lbft

140 Nm / 103 lbft

40 Nm / 30 lbft

70 Nm / 52 lbft

106

110

108

40 Nm / 30 lbft

20 Nm 15 lbft

B_03928

109

106

108

107

110

114

1:2

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Do not dismount the piston of the spool and sleeve assembly (pos. 94).

Pressure regulator (pos. 105). Details see Chapter 13.3.2.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Jaguar air motor 9" spare parts list

Designation Order No. Order No.

28 6 O-ring 9974143 29 2 Rod seal 9974217 30 2 Pilot valve 369290 31 1 Spool-sleeve combination assembly, ISO3 369907 32

1 Permaglide bushing 9962019 33 1 Piston 9 369385 34 1 Seal wiper ring 9974125

1 Safety valve 7.5 bar 368286

1 Safety valve 8.4 bar 368288 36

2 O-ring 9974133 37 2 O-ring 9971056 39

2 O-ring 9974089 40 2 O-ring 9974132 41 4 O-ring 9971137 43 1 O-ring 9974165 46 1 WAGNER label 2330372 47 2 Threaded plug 9998675 48 1 Control housing 369315 49 1 Washer 9925034 50 4 Hexagon screw 9907137 51 1 Hexagon nut 9910605 52 4 Washer 9920106 53 2 Washer 369303 54 7 SFS screw 9907125 55 3 Socket cap screw 9900314 56 3 Washer 9925029 57

1 Sealing ring 9970149 58 1 Base 9952668 59 1 Clamping bracket 9952667 60 1 Socket cap screw 9900701 61 1 Spring ring 9921505 71 1 IceBreaker label 2330382 72 1 Warning label 2332077 74

1 Detent body 369027 75

1 Rod seal pro le E5 9974124 76 2 Threaded elbow  tting 9992757 77 1 Screw connector T 9992758 78 4 Washer 9920102 79 4 Socket cap screw 9900313 80 2 Washer 9925031 81 1 Lifting eye nut 369325

= Wearing part = Included in service set = Not part of the standard equipment but available as a special accessory

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Jaguar air motor 9" spare parts list

Designation Order No. Order No.

82 1 Shoulder ring 369324 83 1 Hexagon screw 9900150 84 1 O-ring 9974262 85 1 Air pipe 369306 87

3 O-ring 9971004 88 2 Damping washer 369304 89 1 Control  ange 369317 90 1 Air hose back 369026 91 1 Air hose front 369025 92 1 Lock space 9 369326 93

2 Damper ISO3 369329 94

1 Spool & sleeve assembly ISO3 9943131 95 1 Velcro fastener adhesive part 9999151 96 1 Velcro fastener coating part 9999152 97 1 Miranit contact adhesive 9992816 98

1 Viton B O-ring 9971372

103 1 Sound deadening pad 9/12" 369330

105 1

Pressure regulator unit 9 complete (for details, see Chapter 13.3.2)

2328609

106 1 Loctite 222 50ml; 50cc 9992590 107 1 Loctite

243 50ml; 50cc 9992511 108 1 Loctite 542 50ml; 50cc 9992831 109 1 Molykote DX grease 9992616 110 1 Mobilux

EP 2 grease 9998808

114 1 Piston 9 with SOFT O-ring 369971

1 Service set air motor 9" 369987

= Wearing part = Included in service set = Not part of the standard equipment but available as a special accessory

150 cm3 - 300 cm3

B_03937

711 102

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.3.2 AIR MOTOR REGULATOR FOR JAGUAR AND PROTEC

9" 10"

Jaguar air motor regulator spare parts list

Order No. for

Jaguar

Order No. for

PROTEC

75-150 60-240

Designation 55-200

1 1 Pressure regulator unit, complete 2328609 -2

1 Pressure regulator valve 9" 2309974 3 1 Distribution piece 2309963 2346229 4

1 Pressure gauge 0-10 bar (d50) 9998725 5 2 Hexagon socket cylinder head screw 9900360 6 2 Hexagon socket cylinder head screw 9907087 7 2 Hexagon socket cylinder head screw 9900356 8

1 O-ring 9974166 9

2 O-ring 3105540

10 1 O-ring 9971405 11 1 Edge ball valve 9" 2310637 12 1 Molykote

DX grease 9992616 13 1 Loctite 542, 50ml; 50cc 9992831 14 1 Mobilux EP 2 grease 9998808

= Wearing part

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.3.3 PROTEC AIR MOTOR 10"

PROTEC 10" air motor spare parts list

PROTEC

Designation Order No.

1 1 Air motor 10", complete 2351208 2 1 Hexagon screw without shaft 9900150 3 1 Shoulder ring 369324 4 1 Lifting eye nut 369325 5 1 Washer 9925034 6 1 WAGNER PROTEC 10 label 2353725 7 1 Hood 9 369311 8

2 Velcro fastener adhesive part 9999151

9 2 Velcro fastener coating part 9999152

1 Sound deadening pad 9 369319 11 1 Shoulder screw 9 369318 12 7 Screw SFS Plastite 45 9907125 13 2 Washer 6.4 9925031 14 1 Silencer 9 369310 15

1 O-ring 9974165 16 3 Socket cap screw; hexagon socket M8X35 9900314 17 3 Washer 8.4 9925029 18 1 Connecting part 9 369309 19

1 Sound deadening pad 9/12" 369330 20 2 O-ring 9974132 21 1 Safety valve 8.4 bar 368288 22 1 Angular plug connection 9992718 23 2 Air hose 369026 24 2 Straight screw-in  ttings 9998993 25

2 Pilot valve 369290

25a 2 Rod seal 9974217

26 2 Outlet seal 9 369312 27 1 Y-plug connection 3159464 28 1 Hose 8x1 L=42mm 9982078 29 1 Male stud elbow, 8-1/8 9992757 30 2 Cotter pin 2355809 31 1 Control- ange 10 2345960 33 1 Pressure regulator unit 10": see Chapter 13.3.2 -34 1 Plug 10 2354547 35

2 O-ring 2310252 36 1 Spool-sleeve combination assembly, ISO3 369907 37

1 Spool & sleeve assembly ISO3 9943131 38 6 O-ring 9974143 39 2 Damper ISO3 369329

= Wearing part = Included in service set = Not part of the standard equipment but available as a special accessory

150 cm3 - 300 cm3

B_05279

52 53 66

B_05293

494746

66 57

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

PROTEC 10" air motor spare parts list

PROTEC

Designation Order No.

40 1 Detent element, complete ISO 3 369027 41 1 Lock space 10 2354548 42 1 Cover 2354549 43 1 O-ring 9971375 44 1 Securing ring 9999360 45 1 Threaded plug G1/4" 9998274 46 1 Filter holder 367324 47

1 Control air  lter 367314 48 1 Filter compressed air 9 369313 49 1 Throttle 367325 51 1 Hexagon nut 9913051 52 1 Piston 10 2347028 53

1 O-ring 2347183

= Wearing part = Included in service set = Not part of the standard equipment but available as a special accessory

Pos Assembly instructions

8 Stick the adhesive part to the inside of the hood.

"Miranit" adhesive (pos. 107).

9 Stick velvet label to  eece side of the deadening

pad. "Miranit" adhesive (pos. 107).

10 Insert the deadening pad into the hood (tight-

 tting). Fleece side outwards.

19 Stick deadening pad with  eece side outwards

holohedral to the connecting part. "Miranit" adhesive (pos. 107).

36–44 Before assembling, lightly oil the housing bore of

pos. 31 with Tecni oil (pos. 108).

Do not dismount the piston of the spool and sleeve assembly (pos. 37).

Mount to limit stop.

150 cm3 - 300 cm3

37*

36*

2 3

107

10*

11 12 13

18 19*

10 Nm; 7 lbft

40 Nm; 30 lbft

70 Nm; 52 lbft

103

102

B_05278

101

103

22 23 23

26 27 28

53 54

56 57

64 65 66

84 83

102

≤ 4 Nm; ≤ 3 lbft

102

104

140 Nm; 103 lbft

102

105

101

40 Nm; 30 lbft

≤ 4 Nm; ≤ 3 lbft

106

102

107

102

108

25a

106

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Do not dismount the piston of the spool and

sleeve assembly (pos. 37).

* Observe assembly instructions.

Grease all O-rings with Mobilux EP2 (pos. 102)

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

PROTEC 10" air motor spare parts list

PROTEC

Designation Order No.

54 2 Pistonwasher 12 370303 55 2 Damping washer 12 370304 56

1 Piston rod 10 2348760 57 1 Tube 10 2347029 58

2 O-ring 9971004 59 1 Compressed air tube 10 2347257 60 1 Type plate PP3000 -61 1 Warning label 2332077 62 1 Fluid warning label 2332082 63 1 IceBreaker label 2330382 64

2 O-ring 9974089 65 1 Control air pipe 150 367405 66 2 O-ring 2347178 67 8 Washer 9920106 68 8 Hexagon screws 9907137 70 1 Connection  uid section 2348761 80 1 Flange 10 2345964 81

1 Rod seal 2347218 82 2 Threaded plug G1/8" 9998675 83

1 Scraper ring 2347211 84

1 Permaglide bushing 2347187 85 1 Grounding, complete 367258 86 1 Base -87 1 Clamping bracket 9952667 88 1 Spring washer 9921505 89 1 Socket cap screw with slit 9900701

101 1 Molykote

DX grease 9992616

102 1 Mobilux

EP 2 grease 9998808

103 1 Loctite

222 9992590 104 1 Lock screw Loctite 243 9992511 105 1 Loctite

270 9992528 106 1 Loctite 542 9992831 107 1 Miranit contact adhesive 9992816 108 1 Tecni oil 1000 ml Z102.00

1 Service set air motor 10" 2353088

= Wearing part = Included in service set = Not part of the standard equipment but available as a special accessory

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.3.4 TIGER AIR MOTOR 12"

Tiger air motor 12" spare parts list

Designation Order No.

1 1 Air motor, complete 2329627

2 1 Shoulder ring 369324

3 1 Lifting eye nut 369325

1 Pressure regulator unit 12 (incl. Pos. 40) 2328610 5 2 Control air pipe 150 367405 6 1 Pistonwasher 12 370303 7 2 Damping washer 12 370304 8 1 Piston 12 370385 9

1 Piston rod 12/150 370402

10 1 Hexagon nut 9913051 11

1 O-ring 9974261

13 1 Base 9952668 14 1 Clamping bracket 9952667 15 1 Spring washer 9921505 16 1 Socket cap screw with slit 9900701 17 1 Gauging pin 370307 18 2 Valve cover 370309 19 2 Spiral spring 370310 20 2 Screw plug 370311 21

2 Valve body 370312

22 2 Lock washer 9922724 = Wearing part = Included in service set

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains. Observe the operating manual and service manuals at all times

when carrying out work.

150 cm3 - 300 cm3

107

16 15

118

3 / 2

112

116

77 52 63

116

114

116

62 55

75 a)

108

115

116

109

111

8-10 Nm / 6-7 lbft

200 Nm / 148 lbft

40 Nm / 30 lbft

70 Nm / 51 lbft

20 Nm / 15 lbft

60 Nm / 44 lbft

B_03954

112

116

113

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Do not dismount the piston of the spool and sleeve assembly (pos. 87).

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Tiger air motor 12" spare parts list

Designation Order No.

2 O-ring 9974102 24 1 Flange 12 370316 25 1 Permaglide bushing 9962026 26 1 O-ring 9971446 27 1 Scraper ring d35 9974158 28

1 Rod seal d35 9974159 29 1 Threaded plug 9998675 30 2 Threaded plug 9998274 31 1 Air tube 12 370306 32 1 Cylinder tube 12/150 370403 33

1 O-ring 9971129 35 4 O-ring 9974089 36 1 Hood 9 369311 37

1 Sound absorbing mat 9 369319 38 1 WAGNER 12 Tiger label 2330374 39 1 Hexagon screw 9900150 41 8 Hexagon screw 9907208 42 5 Screw 9907125 43 8 Washer 9920107 44 1 Washer 9925034 45 1 Silencer 9 369310 46 1 Shoulder screw 9 369318 47

1 Control air  lter 367314 48 1 Filter holder 367324 49 1 Throttle 367325 50 1 Connecting part 9 369309 51

1 Filter compressed air 9 369313 52

2 Discharger Gasket DE 50 369312 53 1 Stop plate 12 370313 54 1 Sealing plug 12 370314 55 1 Control housing 12 370315 56 2 Securing ring 370330 57

1 Spool and sleeve assembly 9943121 58 6 O-ring 9974160 59 1 Safety valve 7.8 bar 2302480 60

1 Sealing ring 9970149 61 2 O-ring 9974092 62 2 Threaded elbow  tting, 8-1/4" 9998253 63 2 Threaded elbow  tting, 8-1/8" 9992757 64 1 Air hose front 370233 65 1 Air hose back 370234 66 2 Air hose down 370235 67 1 Gauging pin 370308 = Wearing part

= Included in service set

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Tiger air motor 12" spare parts list

Designation Order No.

68 1 Control- ange 12 370317 69 1 Compressed air tube 12 370404 70 4 Socket cap screw 9900313 71 3 Socket cap screw 9900314 72 4 Washer 9920102 73 3 Washer 9925029 74

5 O-ring 9971004 75

1 O-ring 9971129 76

1 O-ring 9971372 77

2 O-ring 9974132 78 1 Threaded elbow  tting, 8-1/8" 9992757 79 1 Screw connector L 9998613 80 1 IceBreaker label 2330382 81 2 Pin for control  ange 370318 82 1 Straight threaded  tting 9992744 83 1 Straight threaded  tting 9992743 84 2 Screw SFS Plastite 45 9907125 85 2 Washer 9925031 86

1 O-ring 9974165 90 1 Elbow ball valve housing 12 370323

107 1 Warning label 2332077 108

1 Velcro fastener adhesive part 9999151

109 1 Velcro fastener coating part 9999152 111 1 Miranit contact adhesive 9992816 112 1 Loctite

222 50 ml; 50 cc 9992590 113 1 Loctite 243 50 ml; 50 cc 9992511 114 1 Loctite 542 50 ml; 50 cc 9992831 115 1 Molykote DX grease 9992616 116 1 Mobilux

EP 2 grease 9998808

118 1 Fluid warning label 2332082

1 Service set, air motor 12" 370987

= Wearing part

= Included in service set

150 cm3 - 300 cm3

536

9105

B_03955

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.3.5 TIGER AIR MOTOR REGULATOR

Tiger air motor regulator spare parts list

Designation Order No.

1 1 Pressure regulator unit 12", complete 2328610 2

1 Pressure regulator valve 12" 2309974 3 1 Distibutor block LR-D Maxi 12 2310588 4 1 Pressure gauge 0-10 bar (d50) 9998725 5 4 Hexagon socket cylinder head screw 9900360 6 2 Hexagon socket cylinder head screw 9907087 7

1 O-ring 9974166 8 2 O-ring 3105540 9 1 O-ring 9971405

1 Elbow ball valve LR-D Maxi 12 2310638

11 1 Molykote DX grease 9992616 12 1 Mobilux EP 2 grease 9998808 = Wearing part

150 cm3 - 300 cm3

B_05263

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.4 CONNECTION SETS

Jaguar 75-150

Jaguar 55-200

PROTEC

60-240

Tiger

72-300

Spare parts list for connection sets

Connection set

LM-FS 5 LM-FS 8 LM-FS 11 LM-FS 9

Designation Order No. Order No. Order No. Order No.

1 1 Connection set LM-FS … 2350033 2350036 2351190 2350037 2 2 Coupling cover stroke 150 368532 3 1 Coupling 368529 2337924 2337929 370529 4 1 Spring 368530 370530 5 3 Washer, A12, DIN 125-1 9920107 9925011 6 3 Hexagon screws 9900157 9907209 7

1 O-ring 9974116 8 1 Separating oil cup stroke 150 368531 9 3 Threaded bolt 368533 2359164 370533

10 1 Mobilux

EP 2 grease 9998808

= Wearing parts

= Included in the service set of the  uid section PE/TG or PE/L (see Chapter 13.5).

Tightening torque

Jaguar

75-150

Jaguar 55-200

PROTEC

60-240

Tiger

72-300

50Nm;

37lbft

70Nm; 52lbft

Assembly with air motor and  uid section: see Chapter 13.2

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.5.1 FLUID SECTION 150 CM3

Only for

2K systems

(hardener

pump)

Spare parts list for  uid section

Designation Order No. Order No. Order No.

1 1 Fluid section 2340007 2 1 Pipe 368552 3 1 Cylinder 368553 4 1 Inlet housing 150-PC 2338688 5

1 Piston 368555 6 1 Valve screw 368506 7

1 Ball guide, inlet 2338788 8 1 Connecting  ange 368551 9 1 Valve seat, inlet 368509

1 Valve seat, outlet 368510

11 1 Snap ring  ange 368561 12 2 Snap ring half 368512 13 1 Securing ring 368513 16 1 Support ring 368516 17 1 Pressure ring 367519 18 1 Support ring 368518 19 1 Pressure ring 368519

Wearing parts

Included in service set. (More parts, see Chapter 13.4)

13.5 FLUID SECTIONS

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains. Observe the operating manual and service manuals at all times

when carrying out work.

150 cm3 - 300 cm3

70 Nm

+10 Nm

52 lbft

+ 7 lbft

106

21 20 21

23 22

103 104

100

101

22 23

6 25

13 46

42 27

B_05282

160 Nm 118 lbft

100 Nm

74 lbft

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Regarding position 4: Tighten by hand on block. If necessary, hit the cam with a rubber mallet and use a spanner to hold position 3.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Only for

2K systems

(hardener

pump)

Spare parts list for  uid section

Designation Order No. Order No. Order No.

100

1 Packing PE/TG, complete (small) 367991 1 Packing PE/L complete (small) 367993

101 1 Packing PE/T, complete (small) 367992

2 Sealing collar TG (small) 367522 2 Sealing collar L (small) 367922 2 Sealing collar T (small) 367900

21 3 Sealing collar PE (small) 367523

103

1 Packing PE/TG, complete (large) 368991 1 Packing PE/L, complete (large) 368993

104 1 Packing PE/T, complete (large) 368992

2 Sealing collar TG (large) 368522 2 Sealing collar L (large) 368922

2 Sealing collar T (large) 368900 23 3 Sealing collar PE (large) 368523 25

2 O-ring 368525 27 1 O-ring 368527 28 1 O-ring 368528 40 1 Wave spring (small) 9998670 41 1 Wave spring (large) 9998671 42

1 Ball (large) 9943082 43 1 Ball (small) 9941512 44

1 O-ring 9974092 46 1 O-ring 9974107 50 3 Hexagon screw 9907142 51 3 Washer 9925011 60 1 Mobilux EP 2 grease 9998808 61 1 Anti-seize paste tube 9992609 62 1 Molykote

DX grease 9992616

106 1 Fitting SF-MM-G3/8"-M24x1.5-PN530-SSt 2329922

Service-Sets

1 Service set PE/TG 368990

1 Service set PE/L 2342071

1 Service set PE/T 368994

Wearing parts

Included in service set. (More parts, see Chapter 13.4)

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.5.2 FLUID SECTIONS 200 CM3  240 CM3

Only for

2K systems

(hardener pump)

Only for

2K systems

(hardener pump)

Spare parts list for  uid section

PE/T PE/T

Designation

Order

No.

Order

No.

Order

No.

Order

No.

Order

No.

Order

No.

1 1 Fluid section 2340008 2349152 2 1 Pipe 2336658 2346793 3 1 Cylinder 2336669 2346786 4 1 Inlet housing 2338107 5

1 Piston 2336666 2346787 6 1 Valve screw 2336692 7 1 Ball guide, inlet 2336668 8 1 Connecting  ange 2336661 9

1 Valve seat, inlet 369509

1 Valve seat, outlet 2336695

11 1 Snap ring  ange 2336689 12 2 Snap ring half 2336785 13 1 Securing ring 2336690 16 1 Support ring 2336670 2346767 17 1 Pressure ring 2336680 2346789 18 1 Support ring 2336686 2346780 19 1 Pressure ring 2336694 2346774

100

Packing PE/TG, complete (small)

2341473 2353071

Packing PE/L complete (small)

2342073 2353072

101

Packing PE/T, complete (small)

2345985 2353074

Sealing collar TG (small)

2336679 2346790

2 Sealing collar L (small) 2341945 2353078

2 Sealing collar T (small) 2343776 2348802

21 3

Sealing collar PE (small)

2336674 2346791

Wearing parts

Included in service set (more parts, see Chapter 13.4).

150 cm3 - 300 cm3

100 Nm

+10 Nm

74 lbft

+ 7 lbft

106

44 16

21 20 21 20

103 104

100

101

22 23

43 28

B_05283

200 Nm 148 lbft

120 Nm

89 lbft

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Regarding position 4: Tighten by hand on block. If necessary, hit the cam with a rubber mallet and use a spanner to hold position 3.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Only for

2K systems

(hardener pump)

Only for

2K systems

(hardener pump)

Spare parts list for  uid section

PE/T PE/T

Designation

Order

No.

Order

No.

Order

No.

Order

No.

Order

No.

Order

No.

103

Packing PE/TG, complete (large)

2341474 2353075

Packing PE/L, complete (large)

2342074 2353076

104

Packing PE/T, complete (large)

2345986 2353077

Sealing collar TG (large)

2336688 2346778

2 Sealing collar L (large) 2341943 2353079 2 Sealing collar T (large) 2343775 2348801

23 3

Sealing collar PE (large)

2336687 2346779

1 O-ring 369527 26 1 O-ring 2336684 2346782 27 1 O-ring 9974194 28 1 O-ring 2338256 40

1 Wave spring (small) 2338091 41 1 Wave spring (large) 2338092 42 1 Ball (large) 9943086 43

1 Ball (small) 9941513 44

1 O-ring 9974132 46

1 O-ring 2336683 50 3 Hexagon screw 9907142 51 3 Washer 9925011 60 1 Mobilux

EP 2 grease 9998808 61 1 Anti-seize paste tube 9992609 62 1 Molykote

DX grease 9992616

106 1

Fitting SF-MM-G1/2"M24-PN530-SSt

2337413

Service sets:

1 Service set PE/TG 2341476 2352899 1 Service set PE/L 2342072 2353053

1 Service set PE/T 2345981 2353055 Wearing parts Included in service set (more parts, see Chapter 13.4).

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Only for

2K systems

(hardener

pump)

Spare parts list for  uid section

Designation Order No. Order No.

1 1 Fluid section 300 cm3 2340009 -3 1 Support ring 35.8/52-300 369516 4

3 Sealing collar PE 35.8/52 368523

2 Sealing collar L 35.8/52 368922 2 Sealing collar T 35.8/52 368900

6 1 Pressure ring 35.8/52 368519

Spirawave, crest-to-crest

35.8/52

9998671

8 2 Snap ring half 300 369512 9 1 Retaining ring 300 369513

2 O-ring 369525

= Wearing part

Included in service set (more parts, see Chapter 13.4).

13.5.3 FLUID SECTION 300 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.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains. Observe the operating manual and service manuals at all times

when carrying out work.

150 cm3 - 300 cm3

300 Nm; 221 lbft

250-260 Nm; 184-191 lbft

103

100

34 31

B_05284

140 Nm; 103 lbft

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Regarding position 33: Tighten by hand on block. If necessary, hit the cam with a rubber mallet and use a spanner to hold position 11.

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Only for

2K systems

(hardener

pump)

Spare parts list for  uid section

Designation Order No. Order No.

1 Cylinder 300 370503 12 1 Snap ring  ange 300 370511 13 1 O-ring 9974118 14 1 Support ring 34/50-300 369518 15 3 Sealing collar PE 34/50 369523

2 Sealing collar L 34/50 369922

2 Sealing collar T 34/50 369900 17 1 Pressure ring 34/50 369519

Spirawave, crest-to-crest

35.8/52

9998671

19 1 Valve seat outlet 300 369510 20

1 O-ring 369528 21 1 Piston 300 370505 22 1 Valve screw 300 370506 23 1 Shoulder ring 300 370514 24

1 Ball 9941505 25 1 Connecting  ange 370501 26 1 Tube 300 370502 27 4 Hexagon screw 9907210 28 4 Washer 9920110 29

1 O-ring 9974117 30

1 Ball guide 2336668 31 1 Valve seat inlet 300 369509 32

1 O-ring 369527 33 1 Inlet housing 300 2338595 34

1 Ball 9943086 40 1 Rotary connection G3/4" 2329923 60 1 Mobilux

EP 2 grease 9998808 61 1 Anti-seize paste tube 9992609 62 1 Molykote

DX grease 9992616

Packing, upper:

100

1 Packing PE/L, complete 368993 1 Packing PE/T, complete 368992

Packing, lower:

103

1 Packing PE/L, complete 369993 1 Packing PE/T, complete 369992

Service sets:

Service set 300 PE/L 370989 Service set 300 PE/T 369964

= Wearing part

Included in service set (more parts, see Chapter 13.4).

150 cm3 - 300 cm3

90 Nm; 66 lbft

140 Nm 103 lbft

B_04278

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.6 HIGHPRESSURE FILTER UP TO 530 BAR; 7687 PSI

Identi cation of the  lter

Tighten pos. 3 by hand

530 bar; 7687 psi

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Ball valve version in: Carbon steel

Designation Order No.

1 1 HP  lter DN12-PN530, complete 2339900 2 1 Filter housing 2324542 3 1 Union nut 2324543 4 1 Fitting DF-MM-G1/2-3/8NPSM-530 bar-SSt 2330781 5

1 O-ring 9955863

7 1 Distribution housing for ball valve 2324670 10 1 Filter support 9894245 11

1 Filter cartridge *

* Filter sieve, 20 mesh per inch (rough) 291564 * Filter sieve, 50 mesh per inch (rough) 3514069 * Filter sieve, 100 mesh per inch (medium) 3514068 * Filter sieve, 200 mesh per inch ( ne) 295721

1 Cone spring 3514058 20 1 Ball Valve 9998679 21 1 Pressure ring d45 2325562 23 1 Hexagon plug 2323718 33 1 Double connector 2325826 34 1 Loctite

542 50 ml; 50 cc 9992831 35 1 Mobilux EP2 grease 9998808 36 1 Anti-seize paste tube 9992609

= Wearing parts

= Not part of the standard equipment but available as a special accessory

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the Chapter

"Spare parts" and that are assigned to the unit.

Before all work on the device and in the event of work

interruptions:

- Relieve pressure from spray guns and devices.

- Secure spray guns against actuation.

- Switch o the energy/compressed air supply.

- Disconnect the control unit from the mains. Observe the operating manual and service manuals at all times

when carrying out work.

150 cm3 - 300 cm3

DN38

* (8)

B_04730

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

For trouble-free intake, 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.

Designation Order No.

Suction hose DN38-PC, complete 2325815 2 LP hose DN38-PN10-EPDM 2329134 3 Heavy duty clamp 48-51 mm 2329591 4 Cone coupling ID38 2336488 5

O-ring 367525 6 Suction pipe DN38 -7

Suction  lter DN38-12.8mesh-SSt 2329596 8 Vaseline white PHHV II 9992698

= Wearing part

Assembly on the pump: see Chapter 12.2.1.

In the case or assembly di culties with the hinge bolt clamps, apply a small amount of Vaseline to the outside of both ends of the hose.

Align the clamps' clamping screw downwards.

** Remove the supplied O-ring.

13.7 SUCTION HOSE DN38

150 cm3 - 300 cm3

B_05447

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

Designation Order No.

1 Suction tube PC complete 2348257 2 Sealing sleeve 2329898 3 Fitting-DF-MM-R1"-M36x2-SSt 2328438 4

O-ring, PTFE 9955863 5 Union nut GF-374 2348210 6 Suction adapter 2348094 7 O-ring, PTFE 369527

= Wearing part

Assembly on the pump and 20 liter tank: see Chapter 12.2.2.

13.8 SUCTION TUBE PC

150 cm3 - 300 cm3

B_05277

5 6 7

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.9 PC HEAVY DUTY TROLLEY

Spare parts list for PC heavy duty trolley 9" 10" 12"

Designation

Order No. for

Jaguar

Order No. for

PROTEC

Order No. for

Tiger 75-150 60-240 72-300 55-200

1 1 PC heavy duty trolley 2339705 3 1 Bracket holder -5 4 Hexagon screw 9900246 6 4 Washer, A8.4 9920102 7 4 Contact washer, M8 3155404 8 4 Self-locking hexagon nut, M8 9910208 9 4 Washer, A6.4 or A8.4 9920102

10 4 Hexagon screw 9900130

= Wearing parts

Assembly for Jaguar and PROTEC

Mount bracket holder (3) above the crossbar (4).

B_05285

Assembly for Tiger

Mount bracket holder (3) below the crossbar (4).

B_05286

150 cm3 - 300 cm3

B_04280

567

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.9.1 AIR FILTER SET PC

Designation Order No.

Air  lter set PC.

2339851

For installation, see Chapter 12.3.

2 1 Filter LF-1-D-Maxi 2330030

1 Filter cartridge 40 μm 2347890 3 1 Elbow 90° GF-92 9985613 4 2 Hose  tting-G1"- NW25 9985671 5 2 Heavy duty clamp 2336526 6 4 Contact washer 9955841 7 4 Hexagon screw without shaft 9900140 8 2 Sealing ring 1" 9974135 9 1 m LP hose DN25-PN10-EPDM 2323474

10 1 Loctite

638 9999042

= Wearing parts

If necessary turn the adaptor plate 180° so that the air  lter can be mounted on the trolley.

Observe the air  lter's  ow direction.

150 cm3 - 300 cm3

B_04281

314

80 Nm; 59 lbft

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

13.9.2 HEATER SET PC

Designation Order No.

1 1 Heater set PC (for installation, see Chapter 12.3) 2339728

2 1

Heater (for details and spare parts, see the operating manual, continuous- ow heater, order No. 65860.)

65021

2 Sealing ring 9970110 4 1 Elbow 393369 5 3 Contact washer 3306773 6 3 Hexagon screw without shaft 9900150 7 6 Contact washer, M08 3155404 8 3 Hexagon nut, M8 9910107 9 3 Hexagon screw without shaft 9900109

10 1 Fitting-RF-FF-M20x1.5-G3/8-PN530-SSt 2333393 11 1 Fitting-DF-MM-G3/8-G3/8-PN530-SSt 2330775 12 1 Fitting SF-FM-M20-M24-PN530-SSt 2339609 13 1 Fitting-RF-FM-M24-G3/8-PN530-SSt 2339606 14

2 Filling part 2339756

15 1 HPP hose DN10-PN550 PA W-G 0.735 m 2334063 16 1 Mobilux EP 2 grease 9998808 17 1 Molykote DX grease 9992616 18 1 Continuous- ow heater operating manual 65860

= Wearing parts

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

14.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY

14.2 WARRANTY CLAIM

14 WARRANTY AND CONFORMITY DECLARATIONS

As a result of an EC regulation e ective from January 1, 1990, the manufacturer shall only be liable for his product if all parts originate from him or are approved by him, and if the devices are properly mounted, operated and maintained. The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

Full warranty is provided for this device: We will at our discretion repair or replace free of charge all parts which within 36 months in single-shift, 18 months in double-shift or 9 months in triple-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship. The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see  t. The resulting costs, in particular shipping charges, road tolls, labour and material costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address of the purchaser. We do not provide warranty for damage that has been caused or contributed to for the following reasons: Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute products and the in uence of chemical, electrochemical or electrical agents, except when the damage is attributable to us. Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust paints and so forth reduce the service life of valves, packaging, spray guns, nozzles, cylinders, pistons etc. Wear and tear due to such causes are not covered by this warranty. Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer. Replacement of a component does not extend the period of warranty of the device. The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14days upon receipt of the device. We reserve the right to have the warranty compliance met by a contracting company. The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions.

J. Wagner AG

150 cm3 - 300 cm3

OPERATING MANUAL

VERSION 05/2015 ORDER NUMBER DOC2340282

14.3 CE DECLARATION OF CONFORMITY

Herewith we declare that the supplied version of pneumatic pumps and their spraypacks:

EC Certi cate of Conformity

The CE certi cate of conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number.

Order number: 2302304

complies with the following guidelines:

2006/42/EC 94/9/EC

Applied standards, in particular:

DIN EN ISO 12100: 2010 DIN EN ISO 13732-1: 2008 DIN EN 13463-1: 2009 DIN EN809: 1998+A1: 2009+AC: 2010 DIN EN14462: 2005+A1: 2009 DIN EN 13463-5: 2011 DIN EN ISO 4413: 2010 DIN EN12621: 2006+A1: 2010 DIN EN ISO/IEC 80079-34: 2011 DIN EN ISO 4414: 2010 DIN EN 1127-1: 2011

Applied national technical standards and speci cations, in particular:

DGUV regulation 100-500

Identi cation:

T3: Without dry running protection. T4: With dry running protection.

14.4 NOTES ON NATIONAL REGULATIONS AND GUIDELINES

Plant Safety Ordinance Painting rooms and equipment Equipment for cleaning work pieces with solvents

DGUV regulation 100-500

Operating working materials

Avoidance of ignition dangers due to electrostatic charges

Checking working materials and systems which require monitoring

Part 1: Checking systems in areas subject to explosion hazards and checking of work

stations in areas subject to explosion hazards

Part 3: Repairs to devices, protective systems, safety, control and regulation  xtures,

in the sense of the 94/9/EC Directive - Determination of checking necessity according to § 14 sec. 6 BetrSichV (Industrial Safety Regulations)

Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they can be found on the Internet.

Order No. 2340282 Edition 05/2015

Germany

Phone Telefax E-mail

Switzerland

Phone Telefax

More contact addresses on the internet at:

Company/Locations/WAGNER worldwide

Subject to changes without notice

Document No. 11154963

Version B

WAGNER Jaguar, Tiger, PROTEC Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual