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Translation of the Original
Operating Manual
Version 09/2013
IceBreaker Piston Pumps
Flow Rate 150 cm3–300 cm3
B_04259
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
Table of Contents
1
1.1
1.2
1.3
1.4
ABOUT THIS OPERATING MANUAL
Preface
Warnings, Notices, and Symbols in this Operating Manual
Languages
Abbreviations in the Text
6
6
6
7
7
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
CORRECT USE
Device Types
Type of Use
Use in an Explosion Hazard Area
Safety Parameters
Processible Working Materials
Reasonably Foreseeable Misuse
Residual Risks
8
8
8
8
8
9
9
10
3
3.1
3.2
IDENTIFICATION
Explosion Protection Identification
Identification X
11
11
11
4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.3
4.3.1
4.3.2
GENERAL SAFETY INSTRUCTIONS
Safety Instructions for the Operator
Electrical Equipment
Staff Qualifications
Safe Work Environment
Safety Instructions for Staff
Safe Handling of WAGNER Spray Devices
Grounding the Device
Product Hoses
Cleaning
Handling Hazardous Liquids, Lacquers and Paints
Touching Hot Surfaces
Use in Areas Subject to Explosion Hazards
Safety Regulations
Operation without Fluid
12
12
12
12
12
13
13
14
14
15
15
15
16
16
16
5
5.1
5.1.1
5.1.2
5.1.3
5.2
5.3
5.3.1
5.3.2
5.3.3
5.3.3.1
5.3.3.2
5.3.3.3
5.3.3.4
DESCRIPTION
Areas of Application
Correct Use
Processible Working Materials
Recommended Application Areas
Scope of Delivery
Data
Materials of Paint-wetted Parts
Recommended Packings
Technical Data
Technical Data for Jaguar
Measurements and Connections for Jaguar
Technical Data for Tiger
Measurements and Connections for Tiger
17
17
17
17
18
18
19
19
19
20
20
21
22
23
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OPERATING MANUAL
Table of Contents
5.3.4
5.3.5
5.4
5.4.1
5.4.2
5.4.3
5.4.3.1
5.4.4
5.4.5
Volume Flow
Performance Diagrams
Function
Pump
Pressure Regulator Unit
High-pressure Filter (Option)
High-pressure Filter (Option)
Air Filter Set PC (Option)
Heater Set PC (Option)
24
24
27
27
28
28
28
29
30
6
6.1
6.2
6.3
6.4
6.5
6.5.1
6.5.2
6.5.3
ASSEMBLY AND COMMISSIONING
Transportation
Storage
Assembling the Pump
Grounding
Commissioning
Safety Instructions
Filling with Separating Agent
Basic Flushing
31
31
31
32
33
35
35
36
37
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.3
OPERATION
Filling with Working Material
Work
Spraying
Pressure Relief/Work Interruption
Decommissioning and Cleaning
Long-term Storage
38
38
39
39
39
40
40
8
TROUBLESHOOTING AND RECTIFICATION
41
9
9.1
9.2
MAINTENANCE
High-pressure Hoses
Decommissioning
42
43
43
10
10.1
10.1.1
10.1.2
10.1.3
10.2
ACCESSORIES
Accessories for Jaguar and Tiger Pumps
Product Outlet Accessories
Product Inlet Accessories
Accessories for Trolley and Wall Mount
Spraypacks
44
44
44
46
47
48
11
11.1
11.2
11.3
11.3.1
11.3.2
11.3.3
11.3.4
SPARE PARTS
How Can Spare Parts Be Ordered?
Overview of the Components
Air Motors
Jaguar Air Motor
Jaguar Air Motor Regulator
Tiger Air Motor
Tiger Air Motor Regulator
49
49
50
52
52
56
57
61
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OPERATING MANUAL
Table of Contents
11.4
11.4.1
11.4.2
11.4.3
11.5
11.6
11.6.1
11.6.2
Fluid Sections
Fluid Section 150 cm3
Fluid Section 200 cm3
Fluid Section 300 cm3
High-pressure Filter (up to 530 bar; 7,687 psi)
Trolley PC
Air Filter Set PC
Heater Set PC
62
62
65
68
71
73
74
75
12
12.1
12.2
12.3
12.4
WARRANTY AND CONFORMITY DECLARATIONS
Important Notes Regarding Product Liability
Warranty Claim
CE Declaration of Conformity
Notes to German Regulations and Guidelines
76
76
76
77
77
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ORDER NUMBER DOC 2340282
OPERATING MANUAL
1
ABOUT THIS OPERATING MANUAL
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 staff.
Operating and service staff should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2
WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
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
This notice warns you of a hazard!
Danger - immediate risk of danger.
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
Non-observance will result in death or serious injury.
The following are measures which can be taken to prevent
the hazard and its consequences.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
Notice - a possibly hazardous situation.
Non-observance may result in material damage.
NOTICE
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The following are measures which can be taken to prevent the hazard and its
consequences.
Note - provides information about particular characteristics and how to proceed.
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OPERATING MANUAL
1.3
LANGUAGES
The operating manual is available in the following languages:
Language
Order No.
Language
Order No.
German
2340281
English
2340282
Italian
2340284
Spanish
2340286
Language
French
Order No.
2340285
The corresponding service instructions are available under the following
order number:
Language
Order No.
Language
Order No.
German
2335993
English
2335994
1.4
ABBREVIATIONS IN THE TEXT
Order No.
No.
Number of pieces
Position
Marking in the spare parts lists
Order number
Order number (shortened form)
Double stroke
Stainless steel
Two components
: Heavy duty corrosion protection
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OPERATING MANUAL
2
CORRECT USE
2.1
DEVICE TYPES
Pneumatic pump with spraypack:
2.2
TYPE OF USE
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classification into explosion classes IIA or IIB.
2.3
USE IN AN EXPLOSION HAZARD AREA
The pneumatic pump can be employed in explosion hazard zones (Zone 1).
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 fixtures.
Use only WAGNER original spare parts and accessories.
The pneumatic pump may only be operated under the following conditions:
The operating staff 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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OPERATING MANUAL
2.5
PROCESSIBLE WORKING MATERIALS
Fluid products such as paints and lacquers.
NOTICE
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Use the application-oriented model (flow rate/cycle, product, valves, etc.) as indicated
in Chapter 5.3.3.
Check if the fluids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.3.1.
2.6
REASONABLY FORESEEABLE MISUSE
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modifications to the pneumatic pump,
processing dry or similar coating products, and
using defective components, spare parts, or accessories other than those described
in Chapter 10 of this operating manual.
The forms of misuse listed below may result in health issues and/or material damage:
use of powder as coating product and
incorrectly set values for processing.
Wagner pneumatic pumps are not designed for pumping food.
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OPERATING MANUAL
2.7
RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk
Skin contact with
lacquers and
cleaning agents
Source
Handling of
lacquers and
cleaning agents
Consequences
Skin irritations,
allergies
Paint in air outside Painting outside the Inhalation of
substances which
the defined working defined working
area
are hazardous to
area
health
Specific measures Lifecycle phase
Wear protective
Operation,
clothing,
observe safety data maintenance,
sheets
disassembly
Operation,
Observe working
and operating
instructions
maintenance
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OPERATING MANUAL
3
IDENTIFICATION
3.1
EXPLOSION PROTECTION IDENTIFICATION
As defined in Directive 94/9/EC (ATEX 95), the device is suitable for use in areas where there
is an explosion hazard.
European Communities
Symbol for explosion protection
Device class II
Category 2 (Zone 1)
Ex-atmosphere gas
Explosion group
Constructional safety
Temperature class: maximum surface temperature < 200 °C; 392 °F
Special Notes (see Chapter 3.2)
3.2
IDENTIFICATION X
Maximum surface temperature
The maximum surface temperature of the piston pump can be reached if it runs dry.
Ensure that the piston pump is filled with sufficient working or flushing agent.
Ensure that the separating agent tank is filled with sufficient separating agent.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Ambient temperature
The permissible ambient temperature is: +5 °C to +60 °C; +41 °C to 140 °F.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g. air.
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OPERATING MANUAL
4
GENERAL SAFETY INSTRUCTIONS
4.1
SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the unit 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 influences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform staff about
planned work. Observe electrical safety regulations.
4.1.2
STAFF QUALIFICATIONS
Ensure that the device is operated and repaired only by trained persons.
4.1.3
SAFE WORK ENVIRONMENT
Ensure that the floor in the working area is dissipative in accordance with EN 61340-4-1
(Resistance must not exceed 100 MOhm).
Ensure that all persons within the working area wear dissipative shoes. Footwear must
comply with EN 20344. The measured insulation resistance must not exceed 100 Mohm.
Ensure that during spraying, persons wear dissipative gloves. The grounding takes
place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5.
The measured insulation resistance must not exceed 100 Mohm.
Paint mist extraction systems must be fitted on site according to local regulations.
Ensure that the following components of a safe working environment are available:
– Product/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked flames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
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OPERATING MANUAL
4.2
SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
4.2.1
SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning 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:
– Switch off the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– In the event of functional faults: remedy the fault as described in the "Troubleshooting"
chapter.
The liquid ejection devices are to be checked for safe working conditions by an expert
(e.g. Wagner Service Technician) as often as necessary or at least every 12 months,
in accordance with the guidelines for liquid emitters (ZH 1/406 and BGR 500 Part 2
Chapter 2.36).
– For shut down devices, the examination can be suspended until the next commissioning.
Carry out the work steps as described in the "Pressure Relief/Work Interruptions" 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 cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briefly in a position.
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OPERATING MANUAL
4.2.2
GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, flowing liquids, and air or electrostatic coating processes create charges.
Flames or sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. that they are wearing
dissipative shoes.
Wear dissipative gloves when spraying. The grounding takes place via the spray gun handle.
4.2.3
PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products.
Ensure that the product hose is suitable for the pressure generated in the device.
Ensure that the following information can be seen on the high-pressure hose:
- Manufacturer
- Permissible operating overpressure
- Date of manufacture
Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid
in the following places:
– in high-traffic areas,
– on sharp edges,
– on moving parts, or
– on hot surfaces
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the complete high-pressure hose must be less than 1 Mohm.
Several liquids have a high expansion coefficient. In some cases their volume can rise with
consequent damage to pipes, fittings, etc. and cause fluid leakage.
When the pump sucks liquid from a closed tank, ensure that air or suitable gas can enter
the tank to avoid a vacuum being generated in the tank itself. 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 flow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
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OPERATING MANUAL
4.2.4
CLEANING
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature.
To clean, use cloths and brushes moistened with solvent. Never use hard objects or spray
on cleaning agents with a gun.
Preferably, non-combustible cleaning agents should be used.
An explosive gas/air mixture forms in closed tanks.
When cleaning devices with solvents, never spray into a closed tank.
Only use electrically conductive tanks for cleaning liquids.
The tanks must be grounded.
4.2.5
HANDLING HAZARDOUS LIQUIDS, LACQUERS 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 specified protective measures, in particular wear safety goggles, protective clothing
and gloves, as well as hand protection cream if necessary.
Use a mask or a breathing apparatus if necessary.
For sufficient health and environmental safety: operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
4.2.6
TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the unit with a coating product with a temperature of > 43 °C; 109.4 °F:
- Identify the device with a warning label "Warning - hot surface".
Order No.
9998910
Instruction label
9998911
Protection sticker
Note: Order the two stickers together.
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OPERATING MANUAL
4.3
USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
The pneumatic pump may be used in areas subject to explosion hazards. The following
safety regulations must be observed and followed.
4.3.1
SAFETY REGULATIONS
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.
Only use tools that are made of a permitted material.
Ignition temperature of the pumped product
Check that the ignition temperature of the pumped product is higher than the max.
allowable surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g. air.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Only use a damp cloth to clean the device.
4.3.2
OPERATION WITHOUT FLUID
Avoid running the pump so that it sucks in air (without fluid inside). The air, combined with
the vapor of flammable fluids, can generate internal areas with an explosion hazard.
Periodically check that the pump is working smoothly, paying special attention to the
presence of air in the pumped fluid, which may be caused by damaged packings.
Avoid operating the pump with damaged packings.
Ensure that the separating agent tank is filled with sufficient separating agent.
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ORDER NUMBER DOC 2340282
OPERATING MANUAL
5
DESCRIPTION
5.1
AREAS OF APPLICATION
5.1.1
CORRECT USE
The pneumatic piston pump is suitable for processing liquid products according to Chapter 5.1.2.
5.1.2
PROCESSIBLE WORKING MATERIALS
Application
Water-dilutable products
Solvent-based lacquers and paints
Primers
Epoxy and polyurethane lacquers, phenolic lacquers
Underside protection, fire protection materials
Legend
recommended
limited suitability
less suitable
NOTICE
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Use suitable combinations of devices (packings, valves, etc.)
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OPERATING MANUAL
5.1.3
RECOMMENDED APPLICATION AREAS
Application
Steel-processing industry
Rail vehicle
Shipbuilding
Tank construction
Pipeline construction
Wind energy
Legend
recommended
5.2
limited suitability
less suitable
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
Conformity certificate GM2000W
Operating manual, German
Operating manual in the local language
Order No.:
see
Order No.:
see
9992504
Chapter 12
2340281
Chapter 1
The delivery note shows the exact scope of delivery. Accessories: see Chapter 10.
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OPERATING MANUAL
5.3 DATA
5.3.1 MATERIALS OF PAINT-WETTED PARTS
Housing
Stainless steel
Piston
Stainless steel and hard chrome
Valve balls
Stainless steel
Valve seats
Carbide
O-rings
Teflon
Packings
Standard
Packings for Tiger 72-300
Standard
Ultra high molecular weight polyethylene
Teflon (PTFE) with graphite
Leather
5.3.2
RECOMMENDED PACKINGS
WAGNER packings are manufactured in four different materials:
Material
Color
Leather
dark brown
Teflon with graphite
black
Ultra high molecular weight transparent
polyethylene
Each product has the following properties, which influence the packings:
Mechanical stability
Friction coefficient
Sealing force
Chemical resistance
Temperature resistance
for abrasive products
poor
poor
good*
poor
good
good
very good
good
good
poor - good
good
good
good
very good
very good
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Air motor switching problems.
Provide compressed air free from oil and water
(quality standard 5.5.4 according to ISO 8573.1)
5.5.4 = 40 μm / +7 / 5 mg/m³.
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OPERATING MANUAL
5.3.3
5.3.3.1
TECHNICAL DATA
TECHNICAL DATA FOR JAGUAR
Description
Pump ratio
Volume flow per double stroke
Maximum operating overpressure
Maximum possible strokes in operation
Maximum recommended strokes per minute in
continuous operation
Minimum/maximum air inlet pressure
Devices
cm3; cc
MPa
bar
psi
/min
/min
MPa
bar
psi
Ø air inlet connection (inside thread)
inch
Minimum Ø of the compressed air supply line
mm; inch
Air consumption at 0.6 MPa; 6 bar; 87 psi
nl
per double stroke
scf
Air motor piston diameter
mm; inch
Air motor piston stroke
mm; inch
Sound pressure level at maximum permissible air
dB(A)
pressure*
Sound pressure level at 0.6 MPa; 6 bar; 87 psi air
dB(A)
pressure*
Sound pressure level at 0.4 MPa; 4 bar; 58 psi air
dB(A)
pressure*
Product inlet connection (inside thread)
mm
Product outlet (outside thread)
mm
Weight
kg; lb
Product pH value
pH
Maximum product pressure at pump inlet
MPa
bar
psi
Product temperature
75:1
150
53
530
7687
60
40
55:1
200
44
440
6382
60
40
0.25-0.71
2.5-7.1
36-103
G1"
25; 0.98
79.9
2.82
220; 8.7
150; 6
83
0.25-0.80
2.5-8.0
36-116
G1"
25; 0.98
79.9
2.82
220; 8.7
150; 6
83
81
81
69
69
G1 1/2"
G1 1/2"
M24x1.5
M24x1.5
53; 117
53; 117
3.5 ÷ 9
3.5 ÷ 9
2
2
20
20
290
290
+5 ÷ +80;
+5 ÷ +80;
+41 ÷ +176 +41 ÷ +176
Ambient temperature
+5 ÷ +60;
+5 ÷ +60;
+41 ÷ +140 +41 ÷ +140
Allowable inclination for operation
± 10
± 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).
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OPERATING MANUAL
5.3.3.2
A
B
C
D
E
F
G
H
I
J
K
L1
L2
M
O
P
Q
R
S
T
MEASUREMENTS AND CONNECTIONS FOR JAGUAR
mm; inch
1145; 45.0
304; 12
~582; 22.9
470; 18.5
675; 26.6
244; 9.6
230; 9.1
110; 4.3
20x48; 0.8x1.9
M8
G1 1/2"
M24x1.5
G3/8"
G1"
135.5; 5.3
238; 9.4
9; ø 0.35
9; 0.35
206; 8.1
17; 0.67
mm; inch
1157; 45.5
304; 12
~582; 22.9
470; 18.5
687; 27.0
244; 9.6
230; 9.1
110; 4.3
20x48; 0.8x1.9
M8
G1 1/2"
M24x1.5
G1/2"
G1"
135.5; 5.3
238; 9.4
9; ø 0.35
9; 0.35
206; 8.1
17; 0.67
C
Jaguar wall mount
B
T
S
H
F
R
Ih
Ib
O
I (IbxIh)
G/2
Q
D
P
G
B_03905
G M
(E)
A
L1
H
J
L2
B_04260
K
21
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
5.3.3.3
TECHNICAL DATA FOR TIGER
Description
Devices
Pump ratio
cm3; cc
72 :1
MPa; bar; psi
53; 530; 7687
Volume flow per double stroke (
)
Maximum operating overpressure
Maximum possible strokes in operation
/min
Maximum recommended strokes per minute in
continuous operation
/min
Minimum/maximum air inlet pressure
300
40
30
MPa; bar; psi
0.25-0.74; 2.5-7.4; 36-107
inch
G 1"
mm; inch
25; 1.0
nl; scf
170; 6
Air motor piston diameter
mm; inch
300; 11.8
Air motor piston stroke
mm; inch
150; 5.9
Air inlet (inside thread)
Minimum Ø of the compressed air supply line
Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke
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
kg; lb
M24x1.5
pH
3.5 ÷ 9
MPa; bar; psi
2; 20; 290
Weight
Product pH value
Max. product pressure at pump inlet
80; 176
Product temperature
+5 ÷ +80; 41 ÷ 176
Ambient temperature
+5 ÷ +60; 41 ÷ 140
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).
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water
(quality standard 5.5.4 according to ISO 8573.1)
5.5.4 = 40 μm / +7 / 5 mg/m³.
22
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
5.3.3.4
MEASUREMENTS AND CONNECTIONS FOR TIGER
A
Unit
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
1106
43.5
340
13.4
562
22.1
518
20.4
588
23.1
244
9.6
230
9.1
B
C
D
E
F
G
H
I
J
K
L1
L2
M
O
P
Unit
mm
inch
mm
inch
mm
110
4.3
20x48
0.8x1.9
M8
G1 1/2"
M24x1.5
G3/4"
G 1"
135
5.3
238
9.4
Q
R
S
mm
mm
inch
inch
mm
inch
mm
inch
Unit
mm
inch
mm
inch
mm
inch
mm
inch
9
0.35
9
0.35
206
8.1
32
1.3
T
T
C
F
B
Wall mount
S
H
R
I
O
Ib
G/2
G
Q
M
J
H
L1
A
B_03905
L2
(E)
G
P
I (IbxIh)
D
Ih
K
B_04261
23
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
VOLUME FLOW
Wagner AL nozzles
inch
mm Spray angle
0.007
0.18 40°
0.009
0.23 20-30-40-50-60°
0.011
0.28 10-20-30-40-50-60°
0.013
0.33 10-20-30-40-50-60-80°
0.015
0.38 10-20-30-40-50-60-80°
0.017
0.43 20-30-40-50-60-70°
0.019
0.48 20-30-40-50-60-70-80°
0.021
0.53 20-40-50-60-80°
0.023
0.58 20-40-50-60-70-80°
0.025
0.64 20-40-50-60-80°
0.027
0.69 20-40-50-60-80°
0.029
0.75 60°
0.031
0.79 20-40-50-60°
0.025
0.90 20-40-50-60°
0.043
1.10 20-50°
0.052
1.30 50°
* Volume flow refers to water.
5.3.5
Volume flow* in l/min
at
at
at
7 MPa
10 MPa
15 MPa
70 bar
100 bar 150 bar
1015 psi 1450 psi 2175 psi
0.1650
0.2000
0.2400
0.2060
0.2500
0.3090
0.2950
0.3450
0.4260
0.4530
0.5280
0.6600
0.5770
0.6720
0.8130
0.7310
0.7860
1.0640
0.9260
1.0920
1.3700
1.1430
1.3600
1.6900
1.3700
1.5900
2.0100
1.6200
1.9100
2.4000
1.8300
2.1300
2.6800
2.1900
2.5100
3.1700
2.4000
2.7700
3.4900
3.2200
3.7400
4.6900
5.0700
6.0400
7.4600
5.1200
6.5000
7.5200
PERFORMANCE DIAGRAMS
Stroke frequency
Example
/min
Product pressure bar (MPa) psi
B
AR
BAR
AR
BAR
B
AR
BAR
B
Air consumption nl/min <scfm>
5.3.4
"?
Water flow rate l/min <gpm>
24
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
Diagram for Jaguar 75-150
Stroke frequency
/min
NLMIN
BAR-0A
PSI
!
!
"
"
#
#
Air consumption
Product pressure
SCFM
"?
LMIN
GPM
Water flow 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
Diagram for Jaguar 55-200
Stroke frequency
/min
nl/min
bar (MPa)
<psi>
<scfm>
10
20
30
40
50
60
5000
<7250>
<175>
4000
A
<5800>
<140>
C
B
300 (30)
Product pressure
B
A
400 (40)
3000
<4350>
<105>
200 (20)
2000
C
<2900>
<70>
100 (10)
1000
<1450>
<35>
0
B_04262
Air consumption
500 (50)
0
0
0
2
4
6
8
10
12
l/min
<0.5>
<1.1>
<1.6>
<2.1>
<2.7>
<3.2>
<gpm>
Water flow 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
25
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
Diagram for Tiger 72–300
/min
Stroke frequency
BAR-0A
NLMIN
!
!
"
"
Product pressure
SCFM
#
#
"?
LMIN
GPM
Air consumption
PSI
Water flow 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
26
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
5.4 FUNCTION
5.4.1 PUMP
1
1
2
3
4
5
6
7
8
9
10
11
Control housing with integrated silencer
Air pressure regulator
Ball valve
Air motor
Compressed air inlet
Mounting flange
Separating agent cup
Product outlet
Fluid section
Product inlet
Grounding connection
2
4
3
11
6
5
7
8
9
B_04263
10
Function principle
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 fluid 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 pressure regulator (2) and the ball valve (3).
The air motor is fitted with a safety valve. The safety valve has been set and sealed at the
factory. In case of pressures over and above the permissible operating pressure, the valve,
which is held with a spring, automatically opens and releases the excess pressure.
WARNING
Overpressure!
Risk of injury from bursting components.
Never change the safety valve setting.
Fluid section (9)
The fluid section has been designed as a piston pump with exchangeable ball valves. The
hard chrome-plated pump piston runs in two fixed packings which are self-adjusting by
means of a pressure spring, thus resulting in a long service life.
Between the air motor and the fluid section there is a separating agent cup (7) for holding
the separating agent.
27
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
5.4.2
1
2
3
4
PRESSURE REGULATOR UNIT
Pressure regulator
Ball valve
Pressure gauge
Compressed air inlet
1
2
3
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
5.4.3
B_03907
HIGH-PRESSURE FILTER (OPTION)
So that the complete pressure relief of the pump can be performed
(see Chapter 7.2.2), a high-pressure filter with a return line or a
relief combination, is mandatory.
1
5.4.3.1
HIGH-PRESSURE FILTER (OPTION)
To ensure problem-free operation it is recommended that
a WAGNER high-pressure filter be used. These have been
2
developed especially for WAGNER pneumatic pumps. The filter
inserts can be exchanged depending on the product to be
Closed
used. The respective high-pressure filters and their inserts for
the device can be found in the accessories list.
1
2
3
B_04264
3
Open
Fluid section connection
Product outlet
Return line
Preferred filter
installation position
B_04265
28
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
5.4.4
AIR FILTER SET PC (OPTION)
The air filter serves to filter the inlet's compressed air.
Assembly of the air filter set PC on the trolley PC (1):
1.
Mount the air filter (2).
2.
Mount the air filter (2) on trolley PC (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 filter can be
assembled on the trolley. Observe
the air filter's flow direction.
3
1
3
2
Loctite 638
B_04282
29
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
5.4.5
HEATER SET PC (OPTION)
The electric, continuous-flow heater with explosion protection is downstream of the pump.
The coating product can only be heated to maximum 80 °C. The continuous-flow heater is
fitted with a temperature limiter.
The temperature is set using the temperature regulator. The coating product temperature
is read off the thermometer on the coating product output.
For description, see heater operating manual (Order No. 65860).
Assembly of the heater set PC on the trolley PC:
1.
Mount heater (2).
2.
Mount heater (2) on trolley PC (1).
3.
Connect heater in accordance with the operating manual.
4.
Mount enclosed fitting (3) on the fluid section's outlet fitting.
1
2
3
Molykote
Molykote
80 Nm; 59 lbft
B_04283
Molykote
30
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
6
ASSEMBLY AND COMMISSIONING
6.1
TRANSPORTATION
The pump must be moved on a trolley (heavy duty trolley) or with lifting equipment or a
crane.
Only pumps without carriages may be
lifted by the ring nut or lifting eye bolt
(see accessories) and transported short
distances.
B_04065
6.2
STORAGE
Store the pump in a closed and dry environment.
Thoroughly clean the pump, if a long-term decommissioning is planned.
When resuming pump operation, proceed as described in the following sections.
WARNING
Discharge of electrostatically charged components in
atmospheres containing solvents!
Explosion hazard from electrostatic sparks.
Only use a damp cloth to clean the pump.
31
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
6.3
ASSEMBLING THE PUMP
Note:
This pump can be used as part of a spraying system for Airless or AirCoat applications. The
individual components are shown in the accessories, or can be arranged with a spraypack
configurator. The nozzles must be selected according to the gun operating manual.
Procedure:
a) Mount pump (1) on stand, trolley (6), or wall mount. When using a wall mount, the
fluid section must be turned by 180°.
b) Mount high pressure filter (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
2
1
6
3
5
4
B_04266
WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
Position the trolley with the piston pump horizontally.
If the surface is inclined, position the feet of the trolley towards
the gradient.
Secure the trolley.
32
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
6.4
GROUNDING
WARNING
Discharge of electrostatically charged components in
atmospheres containing solvents!
Explosion hazard from electrostatic sparks.
Only use a damp cloth to clean the piston pump.
Ground all device components.
Ground the work pieces to be coated.
WARNING
Heavy paint mist if grounding is insufficient!
Danger of poisoning.
Insufficient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
Grounding scheme (example)
Conveyor
Work piece
Spraying stand
R max < 1 MΩ
Paint tank
B_00304
Floor, static dissipative
33
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
The grounding connection is mandatory with the IceBreaker Pumps.
Cable cross sections
Pump
Paint tank
Conveyor
Booth
Spraying stand
4 mm2;
6 mm2;
16 mm2;
16 mm2;
16 mm2;
Procedure:
1. Screw on grounding cable with eye.
2. Clamp the grounding cable clip to a grounding
connection on site.
3. Ground the product (paint) tank to an on-site
grounding connection.
4. Ground the other parts of the system to an on-site
grounding connection.
16 mm2;
B_03916
34
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
6.5 COMMISSIONING
6.5.1 SAFETY INSTRUCTIONS
Before carrying out any work, the following points must be observed in accordance with
the operating manual:
- Observe all safety regulations in accordance with Chapter 4.
- Carry out commissioning properly.
WARNING
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused
by paint or solvent. Inform the doctor about the paint or solvent
used.
Never seal defective high-pressure parts; instead relieve the
pressure from them and replace them.
WARNING
Toxic and/or flammable vapor mixtures!
Risk of poisoning and burns.
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.
WARNING
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from flying parts.
Ensure that the pump and suction system are always completely
filled with flushing agent or working medium.
Do not spray the device empty after cleaning.
35
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
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 connecting parts for leaks.
- Check hoses for damage.
Closed
It should be ensured that the device is in the following state before carrying
out any work on it:
- The pressure should be released from the pump and high-pressure
hose with gun.
- The gun should be secured with the safety clip.
- The air supply should be interrupted.
EMERGENCY STOP
In case of unforeseen occurrences the ball valve (2) should be closed
immediately and the return valve (3) opened.
6.5.2
2
Open
Open
B_04267
3
FILLING WITH SEPARATING AGENT
NOTICE
Piston pump runs dry!
High wear/damage to the packings.
Paint or solvent can escape if the seals are dry.
Ensure that the separating agent tank is filled with sufficient separating agent.
Filling level 1 cm; 0.4 inch under the cup edge.
Place the supplied separating agent into the separating agent cup.
Filling level:
1 cm; 0.4 inch under the cup edge
Separating agent: Order No. 9992504
Note:
Maximum permissible inclination of pump for moving, transportation,
etc. after filling it with separating agent ± 30°.
The pump must be vertical during operation.
B_03918
36
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
6.5.3
BASIC FLUSHING
1
Closed
2
Open
7
3
4
6
5
B_04268
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Place empty tank (5) under return tube (4).
Place suction hose (7) in the tank with flushing agent (6).
Adjust the pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.25 psi.
Open return valve (3).
Slowly open the ball valve (2).
Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly.
Flush the system until clean flushing agent flows into the tank (5).
Close ball valve (2).
Close return valve (3).
Point the gun, without nozzle, into tank (5) and open it.
Slowly open the ball valve (2).
Rinse until clean flushing agent flows from the gun.
Close ball valve (2).
When there is no pressure remaining in the system, close the gun.
Secure the gun.
Dispose of the contents of the tank (5) according to the local regulations.
37
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
7
7.1
OPERATION
FILLING WITH WORKING MATERIAL
1
Closed
2
Open
7
3
4
6
5
B_04268
1. Place empty tank (5) under return tube (4).
2. Place suction hose (7) in the 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!
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Adjust the pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.25 psi.
Open return valve (3).
Slowly open the ball valve (2).
Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly.
Close ball valve (2) as soon as pure working material starts coming from the return
tube (4).
Close return valve (3).
Point the gun, without nozzle, into tank (5) and open it.
Slowly open the ball valve (2).
Close ball valve (2) as soon as pure working material starts coming from the gun.
When there is no pressure remaining in the system, close the gun.
Secure the gun.
Dispose of the contents of the tank (5) according to the local regulations.
38
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
7.2
WORK
7.2.1
SPRAYING
1
Closed
2
Open
7
3
4
6
5
B_04268
1.
2.
3.
4.
5.
Secure gun and place nozzle in the gun.
Slowly open the ball valve (2).
Set required working pressure on the pressure regulator (1).
Optimize the spraying results as laid down in the gun instructions.
Start work process.
7.2.2
1.
2.
3.
4.
PRESSURE RELIEF/WORK INTERRUPTION
Close gun.
Close ball valve (2).
Release the system by opening the gun.
Close and secure gun.
5 Open and close the return valve (3) to completely depressurize the system.
If the system has been used with 2K products:
NOTICE
Hardened working material in the spraying system when 2K product is processed!
Destruction of pump and injection system.
Follow the manufacturer's processing rules, particularly regarding the pot life.
Flush thoroughly before the end of the pot life.
The pot life is decreased by warmth.
39
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
7.2.3
DECOMMISSIONING AND CLEANING
Note:
The device should be cleaned for maintenance purposes. Ensure that no remaining
product dries and sticks.
Procedure:
1. Work interruption -> carry out the steps in Chapter 7.2.2.
2. Basic flushing -> carry out the steps in Chapter 6.5.3.
3. Maintain the gun according to the operating manual.
4. Clean and check the suction system and the suction filter.
5. When using a high-pressure filter: clean and check filter insert and filter housing.
6. Clean the outside of the system.
WARNING
Brittle filter pressure regulator!
The tank on the filter pressure regulator becomes brittle through
contact with solvents and can burst.
Flying parts can cause injury.
Do not clean the tank on the filter pressure regulator with solvents.
7. Put the whole system back together.
8. Check the level of the separating agent -> Chapter 6.5.2.
9. Fill the system with flushing agent as laid down in Chapter 7.1 "Filling with Working
Material".
WARNING
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from flying parts.
Ensure that the pump and suction system are always completely
filled with flushing agent or working medium.
Do not spray the device empty after cleaning.
7.3
LONG-TERM STORAGE
When storing the device for longer periods of time, it is necessary to thoroughly clean it and
protect it from corrosion. Replace the water or solvent in the product pump with a suitable
preservative, fill separating agent cup with separating agent.
Procedure:
1. Carry out points 1 through 9 in Chapter 7.2.3 "Decommissioning and Cleaning".
2. Flush with preservative according Chapter 6.5.3.
40
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
8
TROUBLESHOOTING AND RECTIFICATION
Problem
The pump does not work
Poor spray pattern
Irregular operation of
product pump: spray jet
collapses (pulsation)
The pump runs smoothly
but does not suck up any
product
Pump runs when the gun
is closed.
Air motor is iced up.
Cause
Air motor does not work or stops.
Remedy
Open and close ball valve on the pressure
regulator unit or briefly disconnect
compressed air supply.
No pressure indication on the Disconnect compressed air supply briefly
pressure gage (air pressure regulator or repair or change pressure regulator.
defective).
Spray nozzle is clogged.
Clean the nozzle according to the
instructions.
Insufficient compressed air supply. Check compressed air supply.
Filter insert in spray gun or high- Clean the parts and use a suitable
pressure filter is clogged.
working material.
Fluid section or high-pressure Dismount and clean fluid section, replace
hose are blocked (e.g. 2K product high-pressure hose.
hardened).
Grease in spool and sleeve
Degrease spool and sleeve assembly.
assembly.
Pump stops at the stroke end
Check detent element (see service manual).
occasionally.
See gun instructions.
Viscosity is too high.
Thin spraying product.
Spraying pressure is too low.
Increase air inlet pressure. Use a smaller
nozzle.
Valves are clogged.
Clean product pump, if necessary leave to
soak in flushing agent.
Foreign body in suction valve.
Dismount suction valve housing, clean,
and check valve seat.
Diameter of compressed air line too Assemble a larger supply line
small.
-> Technical data, Chapter 5.3.3
Valves, packings, or pistons are
Replace the parts.
worn out.
Control air filter or work air filter is Check filter and clean it if necessary.
clogged.
The suction system's union nut is
Tighten union nut.
loose; the pump is taking in air.
Suction filter is clogged.
Clean filter.
Ball in suction or piston valve is
Clean with flushing agent
sticking.
(if necessary vent device).
Packings, valves, or pistons are worn Replace the parts.
out.
There is a lot of condensation water Install a water separator.
in the air supply.
If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service
Center.
41
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
9
MAINTENANCE
WARNING
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may
carry out repairs and replace parts.
Only repair and replace parts that are listed in the "Spare Parts"
chapter and that are assigned to the device.
Before all work on the device and in the event of work interruptions:
- Disconnect the control unit from the mains.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
1. Check the level of separating agent in the separating agent cup every day, and top
up if necessary.
2. Check and clean the high-pressure filter every day or as required.
3. Each decommissioning procedure should be carried out as laid down in Chapter 7.2.3.
4. Check hoses, pipes, and couplings every day and replace if necessary.
In accordance with the guideline for liquid ejection devices (ZH 1/406 and BGR 500
Part 2 Chapter 2.36):
- The liquid ejection devices should be checked by an expert (e.g. Wagner service
technician) for their safe working conditions as required and at least every 12 months.
- If devices have been decommissioned, the examination can be suspended until the
next start-up.
The service instructions are available in German and English.
For order number see Chapter 1.
42
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
9.1
HIGH-PRESSURE HOSES
The service life of the fluid hoses is reduced due to environmental influences even when
handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
As a precaution, fluid hoses should be replaced after a period specified by the operator.
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of product.
Ensure that the hose material is chemically resistant to the sprayed
products.
Ensure that the spray gun, threaded joints, and product hose
between the device and the spray gun are suitable for the
pressure generated in the device.
Ensure that the following information can be seen on the highpressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
9.2
DECOMMISSIONING
When the equipment must be scrapped, please differentiate the disposal of the waste materials.
The following materials have been used:
Steel
Aluminum
Elastomers
Plastics
Carbide
The consumable products (paints, adhesives, sealers, solvents) must be disposed of according
to the valid specific standards.
43
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
10 ACCESSORIES
10.1
10.1.1
ACCESSORIES FOR JAGUAR AND TIGER PUMPS
PRODUCT OUTLET ACCESSORIES
Accessories list
Designation
A
Piston pump PE/TG
1
Separating agent 250 ml; 250 cc
2
Grounding cable 3 m; 9.8 ft
8
HP filter DN12 PN530-SSt with carbon steel ball valve
9
Y-distributor
15
Return tube DN6-G1/4"-100mm-PE
22
Outside thread grommet 1"-NW25
23
Sealing ring 1"
24
Regulator lock
= Wearing parts
No.
2339845
No.
2339846
9992504
236219
2339900
2339390
2331752
9985671
9974135
2334958
No.
2339847
44
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
24
A
2
23
22
1
8
9
x
15
B_04269
45
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
10.1.2
PRODUCT INLET ACCESSORIES
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 list
Designation
A
Piston pump PE/TG
1
Suction hose DN38-SSt, complete
2
Fitting-EF-FM-G1 1/2-G1 1/2-PN25-TG
3
Fitting-DF-MM-G1 1/2-Rd55x1/6-PN25-CS
4
Suction filter DN38-12.8mesh-SSt
5
Loctite 638
= Wearing parts
No.
2339845
No.
2339846
2325815
2329019
2336489
2329596
9992833
No.
2339847
5
2
3
1
DN38
B_04270
4
Regarding position 2:
Before assembling the suction bend, check if the
inlet housing is screwed on firmly.
Set the desired orientation of the suction bend
during assembly.
Regarding position 1:
For the assembly or disassembly of the nut, hit the
cam with a rubber mallet.
46
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
10.1.3
ACCESSORIES FOR TROLLEY AND WALL MOUNT
Accessories list
Designation
A
Piston pump PE/TG
1
Trolley Heavy Duty, complete
2
Wall bracket 9", complete
3
Air Filter Set PC
4
Heater set PC
= Wearing parts
1
No.
2339845
No.
2339846
2339705
369020
2339851
2339728
No.
2339847
2
Regarding position 2:
When using a wall mount, the fluid section must
be turned by 180°.
B_04271
3
4
47
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
10.2
SPRAYPACKS
Spraypack Spraypack Spraypack
1
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
Designation
Spraypack
Jaguar piston pump 75-150-PC PE/TG
Jaguar piston pump 55-200-PC PE/TG
Tiger piston pump 72-300-PC PE/L
Trolley PC
Air Filter Set PC
HP filter DN12-PN530-SSt, complete
Return tube
Airless gun G-15 for Profi Tip HP
Wagner Profi Tip Nozzle
HP-Hose-DN10-PN530-3/8"NPS-15,0m-PA
HP-Hose-DN6-PN530-1/4"NPS-1,5m-PA
Fitting-DF-MM-3/8"NPS-1/4"NPS-PN530-SSt
Suction hose DN38-SSt, complete
Fitting-EF-FM-G1 1/2-G1 1/2-PN25-TG
Fitting-DF-MM-G1 1/2-Rd55x1/6-PN25-CS
No.
2339869
2339845
No.
2339872
No.
2339874
2339846
2339847
2339705
2339851
2339900
2331752
347012
1006521
9987118
9987117
367561
2325815
2329019
2336489
48
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11 SPARE PARTS
11.1
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 lists. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
- Billing address
- Delivery address
- Name of the person to be contacted in the event of any queries
- Type of delivery (normal mail, express delivery, air freight, courier, etc.)
Identification in spare parts lists
Explanation of column " " (labeling) in the following spare parts lists:
Wearing parts
Note: No liability is assumed for wearing parts.
Not part of the standard equipment but available as a special accessory.
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained staff or a WAGNER service center.
Before all work on the device and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
The service instructions are available separately. See Chapter 1.
49
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11.2
OVERVIEW OF THE COMPONENTS
Designation
1 Piston pump
2 Fluid section
3 Air motor
4 Spring
5 Coupling
9 Grounding cable, complete
10 Molykote DX grease
Tightening torque for air motor/fluid section
Order No.
2339845
2340007
2329625
368530
368529
236219
9992616
50 Nm; 37 lbft
Order No.
2339846
2340008
2342487
370530
2327924
236219
9992616
70 Nm; 52 lbft
3
9
1
5
4
10
Tightening torque pos. 2 and 3
2
B_04273
50
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
Designation
1 Piston pump
2 Fluid section
3 Air motor
4 Spring
5 Coupling
6 Grounding cable, complete
7 Molykote DX grease
Tightening torque for air motor/fluid section
Order No.
2339847
2340009
2329627
370530
370529
236219
9992616
70 Nm; 52 lbft
3
6
1
5
4
7
Tightening torque
2
B_04274
51
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11.3
11.3.1
AIR MOTORS
JAGUAR AIR MOTOR
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained staff or a WAGNER service center.
Before all work on the device and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
Jaguar air motor 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 filter
369313
14
1 Control air filter
367314
15
1 Fluid warning label
2332082
16
1 Shoulder screw
369318
1 Sound deadening pad
369906
17
18
2 Cotter pin
369320
23
1 Filter holder
367324
25
1 Throttle
367325
28
6 O-ring
9974143
29
2 Rod seal
9974217
30
2 Pilot valve
369290
31
1 Spool-sleeve combination assembly, ISO 3
369907
32
1 Permaglide bushing
9962019
= Wearing parts
= Included in service set
= Not part of the standard equipment but available as a special accessory.
52
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
83 40 Nm / 30 lbft
82
106
81
15
4
72
49
96
46
12
71
41
97
95
17
16 70 Nm / 52 lbft
54
80
109
110
39
5
6
41
11
110
36
51
107
84
33
110
43
55
56
10
140 Nm / 103 lbft
8-10 Nm / 6-7 lbft
106
103
1
88
53
20 Nm
108
30
29
40
9
35
37
94
57
87
85
110
76
18
28
79 15 lbft
78
74
93
109
3
75
32
34
92
37
31
61
48
8
1:2
87
89
13
90
98
77
91
54
25
14
23
36
58
110
60
59
2
52
50
47
40 Nm /
30 lbft
29
30
108
110
105
B_03928
Do not dismount the piston (pos. 94).
Pressure regulator (pos. 105),
for details see Chapter 11.3.5
53
114
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
Jaguar air motor spare parts list
Designation
Order No.
Order No.
33
1 Piston 9
369385
1 Seal wiper ring
9974125
34
35
1 Safety valve
368286
368288
36
2 O-ring
9974133
37
2 O-ring
9971056
39
2 O-ring
9974089
2 O-ring
9974132
40
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
1 Sealing ring
9970149
57
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 profile E5
9974124
76
2 Threaded elbow fitting
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
82
1 Shoulder ring
369324
83
1 Hexagon screw
9900150
1 O-ring
9974262
84
85
1 Air pipe
369306
87
3 O-ring
9971004
88
2 Damping washer
369304
= Wearing parts
= Included in service set
= Not part of the standard equipment but available as a special accessory.
54
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
Jaguar air motor spare parts list
Designation
Order No.
Order No.
1 Control flange
369317
1 Air hose back
369026
1 Air hose front
369025
1 Lock space 9
369326
2 Damper ISO3
369329
1 Spool & sleeve assembly ISO3
9943131
1 Velcro fastener adhesive part
9999151
1 Velcro fastener coating part
9999152
1 Adhesive
9992816
1 Viton B O-ring
9971372
1 Sound absorbing mat 9/12"
369330
1 Pressure regulator unit 9, complete
2328609
1 Loctite 222 50ml; 50cc
9992590
1 Loctite 243 50ml; 50cc
9992511
1 Loctite 542 50ml; 50cc
9992831
1 Molykote DX grease
9992616
1 Beacon grease
9998808
1 Wearing parts set A25R-1 (for pos. 20)
115436
1 Piston 9 with SOFT O-ring
369971
1 Service set
369987
= Wearing parts
= Included in service set
= Not part of the standard equipment but available as a special accessory.
89
90
91
92
93
94
95
96
97
98
103
105
106
107
108
109
110
111
114
55
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
11.3.2
JAGUAR AIR MOTOR REGULATOR
7
11
10
2
9
14
14
14
1
3
8
9
12
6
7
9
5
4
13
B_03937
12
12
5
Jaguar air motor regulator spare parts list
Designation
1
1 Pressure regulator unit 9", complete
2
1 Pressure regulator valve 9"
3
1 Distribution piece 9"
4
1 Pressure gauge 0-10 bar (d50)
5
2 Hexagon socket head cap screw
6
2 Hexagon socket head cap screw
7
2 Hexagon socket head cap screw
8
1 O-ring
9
2 O-ring
10
1 O-ring
11
1 Edge ball valve 9"
12
1 Molykote DX grease
13
1 Loctite, 542 50 ml; 50 cc
14
1 Beacon grease
= Wearing parts
= Included in service set
6
Order No.
2328609
2309974
2309963
9998725
9900360
9907087
9900356
9974166
3105540
9971405
2310637
9992616
9992831
9998808
56
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11.3.3
TIGER AIR MOTOR
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained staff or a WAGNER service center.
Before all work on the device and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
Tiger air motor spare parts list
Designation
1
1
Air motor, complete
2
1
Shoulder ring
3
1
Lifting eye nut
1
Pressure regulator unit 12 (incl. Pos. 40)
4
5
2
Control air pipe 150
6
1
Pistonwasher 12
7
2
Damping washer 12
8
1
Piston 12
9
1
Piston rod 12/150
10
1
Hexagon nut
11
1
O-ring
13
1
Base
14
1
Clamping bracket
15
1
Spring washer
16
1
Socket cap screw with slit
17
1
Gauging pin
18
2
Valve cover
19
2
Spiral spring
20
2
Screw plug
2
Valve body
21
22
2
Lock washer
23
2
O-ring
24
1
Flange 12
25
1
Permaglide bushing
= Wearing parts
= Included in service set
Order No.
2329627
369324
369325
2328610
367405
370303
370304
370385
370402
9913051
9974261
9952668
9952667
9921505
9900701
370307
370309
370310
370311
370312
9922724
9974102
370316
9962026
57
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
39
113
40 Nm / 30 lbft
112
3/2
44
200 Nm / 148 lbft
10
6
11
116
36
8
7
111
38
109
111
9
116
108
116
46 70 Nm / 51 lbft
42
85
37
45
115
86
8-10 Nm / 6-7 lbft
73
116
70
78
53
56
51
60
67
77
52
63
66
64
65
69
74
59
116
72
35
58
87
83
74
81
66
54
57
62
55
30
76
116
29
42
116
48 47 49
75 a) 68
28
25
116
16
15
14
116
4
31
33
5
20 Nm /
15 lbft
61
79
118
71
50
116
32
80
112
116
1
74
107
114
13
24
27
60 Nm / 44 lbft
41
43
26
23
21
17
22
18
19
20
B_03954
58
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
Tiger air motor spare parts list
Designation
26
1
O-ring
27
1
Scraper ring d35
28
1
Rod seal d35
29
1
Threaded plug
30
2
Threaded plug
31
1
Air tube 12
32
1
Cylinder tube 12/150
33
1
O-ring
35
4
O-ring
36
1
Hood 9
1
Sound absorbing mat 9
37
38
1
WAGNER 12 Tiger label
39
1
Hexagon screw
41
8
Hexagon screw
42
5
Screw
43
8
Washer
44
1
Washer
45
1
Silencer 9
46
1
Shoulder screw 9
1
Control air filter
47
48
1
Filter holder
49
1
Throttle
50
1
Connecting part 9
51
1
Filter compressed air 9
52
2
Discharger Gasket DE 50
53
1
Stop plate 12
54
1
Sealing plug 12
55
1
Control housing 12
56
2
Securing ring
57
1
Spool and sleeve assembly
6
O-ring
58
59
1
Safety valve 0.78 MPa; 7.8 bar; 113 psi
1
Sealing ring
60
2
O-ring
61
62
2
Threaded elbow fitting 8-1/4"
63
2
Threaded elbow fitting 8-1/8"
64
1
Air hose front
65
1
Air hose back
66
2
Air hose down
67
1
Gauging pin
68
1
Control-flange 12
69
1
Compressed air tube 12
70
4
Socket cap screw
= Wearing parts
= Included in service set
Order No.
9971446
9974158
9974159
9998675
9998274
370306
370403
9971129
9974089
369311
369319
2330374
9900150
9907208
9907125
9920107
9925034
369310
369318
367314
367324
367325
369309
369313
369312
370313
370314
370315
370330
9943121
9974160
2302480
9970149
9974092
9998253
9992757
370233
370234
370235
370308
370317
370404
9900313
59
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
Tiger air motor spare parts list
Designation
71
3
Socket cap screw
72
4
Washer
73
3
Washer
5
O-ring
74
75
1
O-ring
76
1
O-ring
2
O-ring
77
78
1
Threaded elbow fitting 8-1/8"
79
1
Threaded connector L
80
1
IceBreaker label
81
2
Pin for control flange
82
1
Straight threaded fitting
83
1
Straight threaded fitting
84
2
Screw SFS Plastite 45
85
2
Washer
1
O-ring
86
90
1
Elbow ball valve housing 12
107
1
Warning label
108
1
Velcro fastener adhesive part
109
1
Velcro fastener coating part
111
1
"Miranit" adhesive
112
1
Loctite 222 50 ml; 50 cc
113
1
Loctite 243 50 ml; 50 cc
114
1
Loctite 542 50 ml; 50 cc
115
1
Molykote DX grease
116
1
Beacon grease
118
1
Fluid warning label
1
Service set, air motor 12
= Wearing parts
= Included in service set
Order No.
9900314
9920102
9925029
9971004
9971129
9971372
9974132
9992757
9998613
2330382
370318
9992744
9992743
9907125
9925031
9974165
370323
2332077
9999151
9999152
9992816
9992590
9992511
9992831
9992616
9998808
2332082
370987
60
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
11.3.4
TIGER AIR MOTOR REGULATOR
Tiger air motor regulator spare parts list
Designation
1
1
Pressure regulator unit 12", complete
1
Pressure regulator valve 12"
2
3
1
Distibutor block LR-D Maxi 12
4
1
Pressure gauge 0-10 bar (d50)
5
4
Hexagon socket head cap screw
6
2
Hexagon socket head cap screw
7
1
O-ring
8
2
O-ring
9
1
O-ring
10
1
Elbow ball valve LR-D Maxi 12
11
1
Molykote DX grease
12
1
Beacon grease
= Wearing parts
= Included in service set
5
10
Order No.
2328610
2309974
2310588
9998725
9900360
9907087
9974166
3105540
9971405
2310638
9992616
9998808
9
2
12
8
12
8
1
7
12
11
11
4
11
B_03955
5
3
6
61
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11.4 FLUID SECTIONS
11.4.1 FLUID SECTION 150 CM3
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained staff or a WAGNER service center.
Before all work on the device and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
Spare parts list for fluid section
Designation
1
1 Fluid section
2
1 Pipe
3
1 Cylinder
4
1 Inlet housing 150
5
1 Piston
6
1 Valve screw
7
1 Ball guide, inlet
8
1 Connecting flange
9
1 Valve seat, inlet
10
1 Valve seat, outlet
11
1 Snap ring flange
12
2 Snap ring half
13
1 Securing ring
16
1 Support ring
17
1 Pressure ring
18
1 Support ring
19
1 Pressure ring
100
1 Packing PE/TG, complete (small)
101
1 Packing PE/L complete (small)
Wearing parts
included in service set
Special accessories
No.
No.
2340007
368552
368553
2327888
368555
368506
2338788
368551
368509
368510
368561
368512
368513
368516
367519
368518
368519
367991
367993
62
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
32
31
50 Nm
37 lbft
60
5
60
56
43
28
10
6
25
60
45
61
70 Nm +10 Nm
52 lbft + 7 lbft
12
60
8
11
55
54
50 Nm
37 lbft
1
60
17
40
2
62
44
16
21
20
21
20
21
3
100
101
106
61
100 Nm
74 lbft
41
19
23
22
60
23
22
23
18
60
61
13
46
25
7
42
27
9
60
61
4
62
103
104
50
51
160 Nm
118 lbft
B 04275
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.
63
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
Spare parts list for fluid section
20
20
21
103
104
22
22
23
25
27
28
31
32
40
41
42
43
44
45
46
50
51
54
55
56
60
61
62
106
Designation
Sealing collar TG (small)
Sealing collar L (small)
Sealing collar PE (small)
Packing PE/TG, complete (large)
Packing PE/L complete (large)
Sealing collar TG (large)
Sealing collar L (large)
Sealing collar PE (large)
O-ring
O-ring
O-ring
Separating agent cup
Coupling cover
Wave spring (small)
Wave spring (large)
Ball (large)
Ball (small)
O-ring
O-ring
O-ring
Hexagon screw
Washer
Washer
Hexagon screw
Threaded bolt
Mobilux EP 2 grease
Anti-seize paste tube
Molykote DX grease
Fitting SF-MM-G3/8"-M24-PN530-SSt
Service set PE/TG
Service set PE/L
2
2
3
1
1
2
2
3
2
1
1
1
2
1
1
1
1
1
1
1
3
3
3
3
3
1
1
1
1
1
1
Wearing parts
included in service set
Special accessories
No.
367522
No.
367922
367523
368991
368993
368522
368922
368523
368525
368527
368528
368531
368532
9998670
9998671
9943082
9941512
9974092
9974116
9974107
9907142
9925011
9920107
9900157
368533
9998808
9992609
9992616
2329922
368990
2342071
64
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11.4.2
FLUID SECTION 200 CM3
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained staff or a WAGNER service center.
Before all work on the device and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
Spare parts list for fluid section
Designation
1
1 Fluid section
2
1 Pipe
3
1 Cylinder
4
1 Inlet housing
5
1 Piston
6
1 Valve screw
7
1 Ball guide, inlet
8
1 Connecting flange
9
1 Valve seat, inlet
10
1 Valve seat, outlet
11
1 Snap ring flange
12
2 Snap ring half
13
1 Securing ring
16
1 Support ring
17
1 Pressure ring
18
1 Support ring
19
1 Pressure ring
100
1 Packing PE/TG, complete (small)
101
1 Packing PE/L complete (small)
20
2 Sealing collar TG (small)
20
2 Sealing collar L (small)
21
3 Sealing collar PE (small)
103
1 Packing PE/TG, complete (large)
Wearing parts
included in service set
Special accessories
No.
No.
2340008
2336658
2336669
2338107
2336666
2336692
2336668
2336661
369509
2336695
2336689
2336785
2336690
2336670
2336680
2336686
2336694
2341473
2342073
2336679
2341945
2336674
2341474
65
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
70 Nm
52 lbft
32
31
45
56
60
8
54
60
5
55
70 Nm
52 lbft
62
44
16
21
20
21
20
21
17
1
60
43
28
10
6
2
120 Nm
89 lbft
23
22
23
18
60
100
74 lbft
62
11
26
51
50
61
41
19
23
22
61
Nm +10 Nm
+ 7 lbft
100
101
106
40
60
12
13
3
46
103
104
60
7
42
9
25
27
4
200 Nm
148 lbft
61
60
61
B_04276
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.
66
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
Spare parts list for fluid section
Designation
1 Packing PE/L complete (large)
2 Sealing collar TG (large)
2 Sealing collar L (large)
3 Sealing collar PE (large)
1 O-ring
1 O-ring
1 O-ring
1 O-ring
1 Separating agent cup
2 Coupling cover
1 Wave spring (small)
1 Wave spring (large)
1 Ball (large)
1 Ball (small)
1 O-ring
1 O-ring
1 O-ring
3 Hexagon screw
3 Washer
3 Washer
3 Hexagon screw
3 Threaded bolt
1 Mobilux EP 2 grease
1 Anti-seize paste tube
1 Molykote DX grease
1 Fitting SF-MM-G1/2"-M24-PN530-SSt
1 Service set PE/TG
1 Service set PE/L
Wearing parts
included in service set
Special accessories
104
22
22
23
25
26
27
28
31
32
40
41
42
43
44
45
46
50
51
54
55
56
60
61
62
106
No.
No.
2342074
2336688
2341943
2336687
369527
2336684
9974194
2338256
368531
368532
2338091
2338092
9943086
9941513
9974132
9974116
2336683
9907142
9925011
9920107
9900157
368533
9998808
9992609
9992616
2337413
2341476
2342072
67
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11.4.3
FLUID SECTION 300 CM3
WARNING
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained staff or a WAGNER service center.
Before all work on the device and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
Spare parts list for fluid section
Designation
1
1
Fluid section 300 cm3
2
2
Coupling cover stroke 150
3
1
Support ring 35.8/52-300
3
Sealing collar PE 35.8/ 52
4
5
2
Sealing collar L 35.8/ 52
6
1
Pressure ring 35.8/52
7
1
Spirawave, crest-to-crest 35.8/52
8
2
Snap ring half 300
9
1
Retaining ring 300
10
2
O-ring
11
1
Cylinder 300
12
1
Snap ring flange 300
13
1
O-ring
14
1
Support ring 34/50-300
15
3
Sealing collar PE 34/50
16
2
Sealing collar L 34/50
17
1
Pressure ring 34/50
18
1
Spirawave, crest-to-crest 35.8/52
19
1
Valve seat outlet 300
20
1
O-ring
21
1
Piston 300
22
1
Valve screw 300
23
1
Shoulder ring 300
24
1
Ball
25
1
Connecting flange
u = Wearing part
H = Included in service set
Order No.
2329666
368532
369516
368523
368922
368519
9998671
369512
369513
369525
370503
370511
9974118
369518
369523
369922
369519
9998671
369510
369528
370505
370506
370514
9941505
370501
68
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
3
4
2
60
5
4
100
5
39
4
62
6
70 Nm;
52 lbft
35
7
40
61
26
140 Nm; 103 lbft
60
38
25
8
62
36
37
21
70 Nm; 52 lbft
29
12
28
1
24
19
23
18
17
15
16
15
16
15
14
20
60
27
300 Nm; 221 lbft
10
60
60
11
61
61
9
60
103
13
22
250-260 Nm;
184-191 lbft
10
30
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.
34
31
32
60
33
B_04277
69
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
Spare parts list for fluid section
Designation
26
1
Tube 300
27
4
Hexagon screw
28
4
Washer
1
O-ring
29
30
1
Ball guide
31
1
Valve seat inlet 300
32
1
O-ring
33
1
Inlet housing 300
1
Ball
34
35
3
Threaded bolt M16x169
36
3
Hexagon screw
37
3
Washer
38
1
O-ring
39
1
Separating oil cup stroke 150
40
1
Rotary connection G3/4"
60
1
Mobilux EP 2 grease
61
1
Anti-sieze paste tube
62
1
Molykote DX grease
Packing, upper:
100
1
Packing PE/L, complete
Packing, lower:
103
1
Packing PE/L, complete
Service sets:
Service set 300 PE/L
u = Wearing part
H = Included in service set
Order No.
370502
9907210
9920110
9974117
2336668
369509
369527
2338595
9943086
370533
9907209
9925011
9974116
368531
2329923
9998808
9992609
9992616
368993
369993
370989
70
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
11.5
HIGH-PRESSURE FILTER (UP TO 530 BAR; 7,687 PSI)
90 Nm; 66 lbft
3
23
34
Tighten pos. 3 by hand
2
21
35
5
12
Identification of the filter
1
11
10
36
36
140 Nm
103 lbft
7
34
4
20
33
34
B_04278
71
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
Ball valve version in:
1
2
3
4
5
7
10
11
1
1
1
1
1
1
1
1
Designation
HP filter DN12-PN530, complete
Filter housing
Union nut
Fitting
O-ring
Distribution housing for ball valve
Filter support
Filter cartridge *
* Filter cartridge 200
* Filter cartridge 100
* Filter cartridge 50
* Filter cartridge 20
Cone spring
Ball valve
Pressure ring d45
Hexagon plug
Double connector
Loctite 542 50 ml; 50 cc
Mobilux EP 2 grease
Anti-seize paste tube
Carbon steel
Order No.
2339900
2324542
2324543
2330781
9955863
2324670
9894245
295721
3514068
3514069
291564
3514058
9998679
2325562
2323718
2325826
9992831
9998808
9992609
12
1
1
20
21
1
23
1
33
1
34
1
35
1
36
1
= Wearing parts
= Not part of the standard equipment but available as a special accessory.
WARNING
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may
carry out repairs and replace parts.
Only repair and replace parts that are listed in the "Spare Parts
Catalogue" chapter and that are assigned to the device.
Before all work on the device and in the event of work interruptions:
- Disconnect the control unit from the mains.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
72
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
11.6
TROLLEY PC
5
6
7
8
1
9
B_04279
Designation
1
1 Trolley PC
5
4 Hexagon screw
6
4 Washer, A8.4
7
4 Contact washer, M8
8
4 Self-locking hexagon nut, M8
9
4 Hexagon screw
= Wearing parts
Order No.
2339389
9900246
9920102
3155404
9910208
9900130
73
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
11.6.1
AIR FILTER SET PC
8
4
5
5
4
8
7
6
1
3
10
2
B_04280
Designation
1
1 Air Filter Set PC
1 Filter LF-1-D-Maxi
2
3
1 Elbow 90° GF-92
4
2 Hose nozzle G1"- NW25
5
2 Heavy duty clamp
6
4 Contact washer
7
4 Hexagon screw without shaft
8
2 Sealing ring 1"
9
1 m LP hose DN25-PN10-EPDM
10
1 Loctite 638
= Wearing parts
If necessary turn the adaptor plate
180° so that the air filter can be
mounted on the trolley. Observe
the air filter's flow direction.
Order No.
2339851
2330030
9985613
9985671
2336526
9955841
9900140
9974135
2323474
9999042
74
VERSION 09/2013
150 cm3 - 300 cm3
ORDER NUMBER DOC 2340282
OPERATING MANUAL
11.6.2
HEATER SET PC
8
2
12
3
4
7
5
6
14
7
8
1
13
17
11
10
3
17
14
B_04281
80 Nm; 59 lbft
17
Designation
1
1 Heater set PC
2
1 Heater
3
2 Sealing ring
4
1 Elbow
5
3 Contact washer
6
3 Hexagon screw without shaft
7
6 Contact washer, M08
8
3 Hexagon nut, M8
9
3 Hexagon screw without shaft
10
1 Fitting-RF-FF-M20x1.5-G3/8-PN530-SSt
11
1 Fitting-DF-MM-G3/8-G3/8-PN530-SSt
12
1 Fitting SF-FM-M20-M24-PN530-SSt
13
1 Fitting-RF-FM-M24-G3/8-PN530-SSt
14
2 Filler part
1 HPP hose DN10-PN550 PA W-G 0.735 m
15
16
1 Mobilux EP 2 grease
17
1 Molykote DX grease
18
1 Continuous-flow heater operating manual
= Wearing parts
Order No.
2339728
65021
9970110
393369
3306773
9900150
3155404
9910107
9900109
2333393
2330775
2339609
2339606
2339756
2334063
9998808
9992616
65860
75
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
12 WARRANTY AND CONFORMITY DECLARATIONS
12.1
IMPORTANT NOTES REGARDING PRODUCT LIABILITY
As a result of an EC regulation effective 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.
12.2
WARRANTY CLAIM
Full warranty is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 36 months
in single-shift, 18 months in double-shift or 9 months in triple-shift operation from date
of receipt by the purchaser are found to be wholly or substantially unusable due to causes
prior to the sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see fit. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the 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 influence 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
76
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
12.3
CE DECLARATION OF CONFORMITY
Herewith we declare that the supplied
version of pneumatic pumps and their
spraypacks:
complies with the following guidelines:
2006/42/EC
94/9/EC
Applied standards, in particular:
DIN EN ISO 12100: 2011
DIN EN ISO 13732-1: 2008
DIN EN 809: 2012
DIN EN 14462: 2010
DIN EN ISO 4413: 2011
DIN EN 12621: 2011
DIN EN ISO 4414: 2011
DIN EN 1127-1: 2011
DIN EN 13463-1: 2009
DIN EN 13463-5: 2011
DIN EN ISO 80079-34: 2012
Applied national technical standards and specifications, in particular:
Part 2 Chapter 2.29 and Chapter 2.36
Identification:
CE Certificate of Conformity
The CE certificate 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
12.4
NOTES TO GERMAN REGULATIONS AND GUIDELINES
Part 2, Chapter 2.36 Working with Liquid Ejection Devices
Part 2, Chapter 2.29 Working with Coating Products
Explosion protection rules
Avoiding ignition risks
Equipment for cleaning work pieces with solvents
Guidelines for liquid ejection devices
Painting rooms and equipment
Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they can
be found on the Internet.
77
VERSION 09/2013
ORDER NUMBER DOC 2340282
150 cm3 - 300 cm3
OPERATING MANUAL
78
ED
FI
CERT
I
Order No.
Edition
2340282
09/2013
Germany
Phone
Fax
E-mail
Switzerland
Document No. 11154963
Version -
Phone
Fax
More contact adresses on the Internet at:
Enterprises/Sites/WAGNER worldwide
Subject to changes without notice