Wagner SprayTech Power Screwdriver 20 30 User Manual

Translation of the Original  
Operating Manual  
Version 03/2013  
Piston Pumps  
Flow Rate 15 cm3 - 30 cm3  
B_04119  
II 2G IIB c T3 X  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
Contents  
1
ABOUT THIS OPERATING MANUAL  
Preface  
Warnings, Notices, and Symbols in this Operating Manual  
Languages  
5
5
5
6
6
1.1  
1.2  
1.3  
1.4  
Abbreviations in the Text  
2
CORRECT USE  
Device Types  
Type of Use  
Use in an Explosion Hazard Area  
Safety Parameters  
Processible Materials  
Reasonably Foreseeable Misuse  
Residual Risks  
7
7
7
7
7
8
8
9
2.1  
2.2  
2.3  
2.4  
2.5  
2.6  
2.7  
3
3.1  
3.2  
IDENTIFICATION  
Explosion Protection Identification  
Identification X  
10  
10  
10  
4
4.1  
GENERAL SAFETY INSTRUCTIONS  
Safety Instructions for the Operator  
11  
11  
11  
11  
11  
12  
12  
13  
13  
14  
14  
14  
15  
15  
15  
4.1.1 Electrical Equipment  
4.1.2 Staff Qualifications  
4.1.3 Safe Work Environment  
4.2  
Safety Instructions for Staff  
4.2.1 Safe Handling of WAGNER Spray Devices  
4.2.2 Grounding the Device  
4.2.3 Material Hoses  
4.2.4 Cleaning  
4.2.5 Handling Hazardous Liquids, Varnishes, and Paints  
4.2.6 Touching Hot Surfaces  
4.3  
Use in Areas Subject to Explosion Hazards  
4.3.1 Safety Regulations  
4.3.2 Operation without Fluid  
5
5.1  
DESCRIPTION  
Field of Application  
16  
16  
16  
16  
17  
17  
17  
18  
20  
21  
22  
25  
25  
26  
27  
27  
5.1.1 Correct Use  
5.1.2 Processible Materials  
5.2  
5.3  
5.3.1 Materials of Paint-wetted Parts  
5.3.2 Technical Data  
5.3.3 Measurements and Connections for FineFinish 40-15  
5.3.4 Measurements and Connections for FineFinish 20-30  
5.3.5 Performance Diagrams  
Scope of Delivery  
Data  
5.4  
Function  
5.4.1 Pump  
5.4.2 Pressure Regulator Unit  
5.4.3 Safety and Motor Pressure Relief Valve  
5.4.4 Return Valve  
3
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VERSION 03/2013  
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OPERATING MANUAL  
Contents  
6
ASSEMBLY AND COMMISSIONING  
Transportation  
Storage  
Assembling the Pump  
Grounding  
Commissioning  
28  
28  
28  
29  
30  
32  
32  
34  
35  
6.1  
6.2  
6.3  
6.4  
6.5  
6.5.1 Safety Instructions  
6.5.2 Filling with Separating Agent  
6.5.3 Basic Flushing  
7
7.1  
7.2  
OPERATION  
Filling with Working Material  
Work  
36  
36  
37  
37  
38  
39  
40  
7.2.1 Spraying  
7.2.2 Pressure Relief/Work Interruption  
7.2.3 Decommissioning and Cleaning  
7.3  
Long-term Storage  
8
TROUBLESHOOTING AND RECTIFICATION  
41  
9
9.1  
9.2  
MAINTENANCE  
High-pressure Hoses  
Decommissioning  
42  
43  
43  
10  
ACCESSORIES  
44  
11  
11.1  
11.2  
SPARE PARTS  
How Can Spare Parts Be Ordered?  
Overview of the Components  
47  
47  
48  
48  
49  
50  
53  
54  
54  
56  
58  
59  
60  
61  
11.2.1 Components for FineFinish 40-15  
11.2.2 Components for FineFinish 20-30  
11.3  
11.3.1 Reversing Valve  
11.4 Fluid sections  
11.4.1 Fluid Section 15  
11.4.2 Fluid Section 30  
11.5  
11.6  
11.7  
11.8  
Air Motor  
Air Regulator Set  
Air Regulator Set for AirCoat Air  
Trolley, 4"  
4-Wheel Trolley  
12  
3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING  
Scope of Guarantee  
Guarantee Period and Registration  
Handling  
Exclusion of Guarantee  
Additional Regulations  
62  
62  
62  
62  
63  
63  
65  
65  
12.1  
12.2  
12.3  
12.4  
12.5  
12.6  
12.7  
CE Declaration of Conformity  
Reference to German Regulations and Guidelines  
4
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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.  
Non-observance will result in death or serious injury.  
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.  
WARNING  
Warning - possible imminent danger.  
Non-observance may result in death or serious injury.  
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  
Caution - a possibly hazardous situation.  
Non-observance may result in minor injury.  
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  
Notice - a possibly hazardous situation.  
Non-observance may result in material damage.  
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.  
5
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VERSION 03/2013  
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OPERATING MANUAL  
1.3 LANGUAGES  
The operating manual is available in the following languages:  
Language  
German  
French  
Italian  
Portuguese  
Danish  
Order No.  
2310798  
2310800  
2310802  
2310804  
2310805  
Language  
English  
Spanish  
Dutch  
Order No.  
2310799  
2310803  
2310801  
2310806  
Swedish  
1.4 ABBREVIATIONS IN THE TEXT  
Number of pieces  
Position  
Marking in the spare parts lists  
Order No. Order No.  
No.  
Number  
Double stroke  
Stainless steel  
Two components  
6
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VERSION 03/2013  
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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 such as paints and varnishes in  
accordance with their 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 materials 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.  
7
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OPERATING MANUAL  
2.5 PROCESSIBLE MATERIALS  
Fluid materials such as paints and varnishes.  
NOTICE  
Abrasive materials and pigments!  
Greater wear of parts carrying the material.  
Use the application-oriented model (flow rate/cycle, material, valves, etc.) as  
indicated in Chapter 5.3.2.  
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 powder or similar coating materials, 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 material and  
incorrectly set values for processing.  
Wagner pneumatic pumps are not designed for pumping food.  
8
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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  
Source  
Consequences  
Specific measures Lifecycle phase  
Skin contact with  
paints and cleaning and cleaning agents  
agents  
Handling of paints Skin irritations,  
Wear protective  
clothing,  
Observe safety data maintenance,  
Operation,  
allergies  
sheets  
disassembly  
Paint in air outside Painting outside the Inhalation of  
the defined working defined working substances which are  
area area hazardous to health  
Observe working  
and operating  
instructions  
Operation,  
maintenance  
9
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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 container is filled with sufficient separating agent.  
Ignition temperature of the coating material  
Ensure that the ignition temperature of the coating material is above the maximum  
surface temperature.  
Ambient temperature  
The permissible ambient temperature is: +5 °C to +60 °C; +41 °C to 140 °F.  
Medium supporting atomizing  
To atomize the material, use only weakly oxidizing gases, e.g. air.  
10  
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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 electrically conductive in accordance with  
EN 61340-4-1 (resistance must not exceed 100 Mohm).  
Ensure that all persons within the working area wear electrostatically conductive shoes.  
Footwear must comply with EN 20344. The measured insulation resistance must not  
exceed 100 Mohm.  
Ensure that during spraying, persons wear electrically conductive 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:  
– Material/air hoses adapted to the working pressure.  
– Personal safety equipment (breathing and skin protection).  
Ensure that there are no ignition sources such as naked flames, sparks, glowing wires,  
or hot surfaces in the vicinity. Do not smoke.  
11  
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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 emitters 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 rm footing when operating the spray gun.  
Only hold the spray gun briefly in a position.  
12  
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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  
electrostatically conductive shoes.  
Wear electrostatically conductive gloves when spraying. The grounding takes place via  
the spray gun handle.  
4.2.3 MATERIAL HOSES  
Ensure that the hose material is chemically resistant to the sprayed materials.  
Ensure that the material hose is suitable for the pressure generated in the 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-trafc 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 container, ensure that air or suitable gas can  
enter the container to avoid a vacuum being generated in the container itself. Thus a  
negative pressure is avoided. The vacuum could implode the container (squeeze) and can  
cause it to break. The container would leak and the liquid would flow out.  
The pressure created by the pump is a multiplication of the inlet air pressure.  
13  
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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 ash 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 containers.  
When cleaning devices with solvents, never spray into a closed container.  
Only use electrically conductive containers for cleaning liquids.  
The containers must be grounded.  
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES, AND PAINTS  
When preparing or working with paint and when cleaning the device, follow the  
working instructions of the manufacturer of the paints, solvents, and cleaning agents  
being used.  
Take the specified protective measures. In particular, wear safety goggles, protective  
clothing, and gloves, as well as hand protection cream if necessary.  
Use a mask or 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 materials.  
4.2.6 TOUCHING HOT SURFACES  
Only touch hot surfaces if you are wearing protective gloves.  
When operating the device with a coating material with a temperature of > 43 °C; 109 °F:  
- Identify the device with a warning label "Warning - hot surface".  
Order No.  
9998910  
9998911  
Instruction label  
Protection sticker  
Note: Order the two stickers together.  
14  
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VERSION 03/2013  
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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 unit 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 material  
Check that the ignition temperature of the pumped material is higher than the max.  
allowable surface temperature.  
Medium supporting atomizing  
To atomize the material, 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 container is filled with sufficient separating agent.  
15  
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OPERATING MANUAL  
5 DESCRIPTION  
5.1 FIELD OF APPLICATION  
5.1.1 CORRECT USE  
The pneumatic piston pump is suitable for conveying and processing (AirCoat technique)  
liquid materials in accordance with Chapter 5.1.2.  
5.1.2 PROCESSIBLE MATERIALS  
Application  
Water-based materials  
Solvent-based materials  
Low viscosity (<40 sec. DIN No. 4)  
Medium viscosity (40 to 60 sec. DIN No. 4)  
High viscosity ( >60 sec. DIN No. 4)  
UV - sensitive materials  
Shear sensitive materials  
Humidity sensitive materials  
Legend  
recommended  
limited suitability  
less suitable  
NOTICE  
Abrasive materials and pigments!  
Greater wear of parts carrying the material.  
Use suitable combinations of devices (packings, valves, etc.)  
16  
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OPERATING MANUAL  
5.2 SCOPE OF DELIVERY  
Pneumatic piston pump consisting of:  
-
-
-
Fluid section  
Air motor  
Connection elements  
Separating agent 250 ml  
Conformity certificate GM2000W  
Operating manual, German  
Order No.: 9992504  
see Chapter 12  
Order No.: 2310798  
see Chapter 1  
Operating manual in the local language  
The delivery note shows the exact scope of delivery.  
Accessories: see Chapter 10.  
5.3 DATA  
5.3.1 MATERIALS OF PAINT-WETTED PARTS  
Pump housing  
Piston  
Valve balls  
Valve seats  
Static seals  
Packings  
Stainless steel  
Stainless steel  
Stainless steel  
Stainless steel  
Ultra high molecular weight polyethylene  
PTFE  
=
17  
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OPERATING MANUAL  
5.3.2 TECHNICAL DATA  
Description  
Units  
20:1  
Pump ratio  
40:1  
Volume flow per double stroke  
Maximum operating overpressure  
cm3; cc  
MPa  
bar  
15  
25.0  
250  
3626  
60  
30  
16.0  
160  
2320  
60  
psi  
Maximum possible strokes in operation  
Minimum/maximum air inlet pressure  
/min  
MPa  
bar  
0.2-0.8  
2-8  
psi  
28-116  
8.0  
0.31  
9.0  
0.35  
3.9  
Ø air inlet connection (inside thread)  
Minimum Ø of the compressed air supply line  
Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke  
Air motor piston diameter  
mm  
inch  
mm  
inch  
nl  
scf  
0.14  
80  
3.15  
60  
mm  
inch  
mm  
inch  
Air motor piston stroke  
2.4  
Sound pressure level at maximum permissible air pressure* dB(A)  
72  
Sound pressure level at 0.6 MPa; 6 bar; 87 psi air pressure*  
Sound pressure level at 0.4 MPa; 4 bar; 58 psi air pressure*  
Material inlet (outside thread)  
dB(A)  
dB(A)  
mm  
69  
65  
M36x2  
Material outlet (outside thread)  
Weight  
inch  
kg  
NPS 1/4"  
9
11  
lb  
19.8  
24.7  
Material pH value  
Maximum material pressure at pump inlet  
pH  
MPa  
bar  
psi  
3.5 ÷ 9  
2
20  
90  
Material temperature  
+5 ÷ +80  
+41 ÷ +176  
+5 ÷ +60  
+41 ÷ +140  
10  
Ambient temperature  
Allowable inclination for operation  
*
A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.  
18  
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OPERATING MANUAL  
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 in accordance with ISO 8573.1)  
5.5.4 = 40 μm / +7 / 5 mg/m³.  
19  
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VERSION 03/2013  
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OPERATING MANUAL  
5.3.3 MEASUREMENTS AND CONNECTIONS FOR FINEFINISH 40-15  
mm  
104  
108.5  
621  
276.5  
134  
inch  
4.09  
4.27  
24.45  
10.89  
5.28  
A
B
C
D
E
F1  
F2  
G
H1  
H2  
I
J
K
L
M
N
O
P
Q
R
G 1/4"  
NPS 1/4"  
M36x2  
G 1/4"  
8
210  
207  
86  
7
182  
80  
106  
96.5  
ø 9  
ø 7  
149  
ø 25  
0.31  
8.27  
8.15  
3.39  
0.28  
7.17  
3.15  
4.17  
3.8  
A
H1  
ø 0.35  
ø 0.28  
5.87  
B
L
H2  
S
T
ø 1  
K
I
J
F1  
F2  
Wall mount  
S
N
R
Q
G
M/2  
M
B_04120  
20  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
5.3.4 MEASUREMENTS AND CONNECTIONS FOR FINEFINISH 20-30  
mm  
104  
108.5  
643  
201  
134.5  
inch  
4.09  
4.27  
25.3  
7.91  
5.3  
A
B
C
D
E
F1  
F2  
G
H1  
H2  
I
J
K
L
M
N
O
P
Q
R
G 3/8"  
NPS 1/4"  
M36x2  
G 1/4"  
8
210  
207  
80  
7
182  
80  
106  
96.5  
ø 9  
ø 7  
149  
ø 25  
0.31  
8.27  
8.15  
3.15  
0.28  
7.17  
3.15  
4.17  
3.8  
A
H1  
B
ø 0.35  
ø 0.28  
5.87  
L
H2  
S
T
ø 0.98  
J
K
I
F1  
F2  
S
Wall mount  
N
R
Q
G
M/2  
M
B_04100  
21  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
5.3.5 PERFORMANCE DIAGRAMS  
Example  
Stroke frequency /min  
ꢀ BAR  
ꢁ BAR  
ꢂ BAR  
"?ꢃꢃꢄꢃꢅ  
Water delivery rate l/min <gpm>  
22  
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VERSION 03/2013  
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OPERATING MANUAL  
Diagram of FineFinish 40-15  
Stroke frequency /min  
bar (MPa)  
<psi>  
nl/min  
<scfm>  
0
10  
20  
30  
40  
50  
60  
300  
<11>  
300 (30)  
<4350>  
A
B
A
240  
240 (24)  
<8>  
<3480>  
B
180  
<6>  
180 (18)  
<2610>  
C
C
120  
<4>  
120 (12)  
<1740>  
60  
<2>  
60 (6)  
<870>  
0
0
0
0.15 0.30 0.45 0.60 0.75 0.90 l/min  
<0.04> <0.08> <0.12> <0.16> <0.20> <0.24> <gpm>  
C_00054  
Material flow - water  
A = 8 bar; 0.8 MPa; 116 psi air pressure  
B = 6 bar; 0.6 MPa; 87 psi air pressure  
C = 4 bar; 0.4 MPa; 58 psi air pressure  
Diagram of FineFinish 20-30  
Stroke frequency /min  
bar (MPa)  
<psi>  
nl/min  
<scfm>  
0
10  
20  
30  
40  
50  
60  
150 (15)  
<2176>  
350  
<12.5>  
A
B
A
120 (12)  
<1740>  
280  
<10>  
B
90 (9)  
<1305>  
210  
<7.5>  
C
C
60 (6)  
<870>  
140  
<5>  
30 (3)  
<435>  
70  
<2.5>  
0
0
0
0.30  
0.60 0.90 1.20 1.50 1.80 l/min  
C_00142  
<0.08> <0.16> <0.23> <0.31> <0.39> <0.47> <gpm>  
Material flow - water  
A = 8 bar; 0.8 MPa; 116 psi air pressure  
B = 6 bar; 0.6 MPa; 87 psi air pressure  
C = 4 bar; 0.4 MPa; 58 psi air pressure  
23  
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OPERATING MANUAL  
24  
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VERSION 03/2013  
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OPERATING MANUAL  
5.4 FUNCTION  
5.4.1 PUMP  
11  
1
8
2
9
1
2
3
4
Air motor  
Air inlet  
Mounting flange  
Separating fluid  
container  
3
5
6
7
8
9
Material outlet  
Fluid section  
Material inlet  
Grounding connection  
Reversing valve  
4
8
10  
13  
12  
6
5
10 Safety valve  
(air motor ventilation)  
14  
11 Air pressure regulator  
12 Ball valve  
B_04121  
13 Air outlet to the  
reversing valve  
14 Air inlet into the  
reversing valve  
7
7
Function principle  
The piston pump is driven with compressed air (11). This compressed air moves the air piston up and down in  
the air motor (1) and it also moves the associated pump piston up and down in the fluid section (6). At the end  
of each stroke, the compressed air is redirected by a reversing valve (9).  
The working material is sucked up during the upwards stroke and is continuously conveyed towards the  
material outlet (5) in both stroke directions.  
Air motor  
The air motor (1) with its pneumatic reverse (9) does not require pneumatic oil.  
The compressed air is fed to the motor via an air regulator (11) and the ball valve (12).  
The air motor is to be equipped with a safety valve (10) in accordance with Chapter 5.4.3. The safety valve (10)  
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 (6)  
The fluid section has been designed as a piston pump with exchangeable ball valves. The  
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 (4) for holding  
the separating agent.  
25  
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VERSION 03/2013  
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OPERATING MANUAL  
5.4.2 PRESSURE REGULATOR UNIT  
1
2
3
4
5
6
7
Pressure regulator  
Ball valve  
Pressure gage (air inlet pressure)  
Pressure gage for AirCoat air (option)  
Compressed air inlet  
Pressure regulator AirCoat (option)  
Safety and motor pressure relief valve  
1
2
3
1
2
3
4
6
5
7
7
5
B_04122  
Ball valve positions:  
open  
1
2
Open: working position  
Closed: the air motor may still be  
under pressure.  
1
2
closed  
B_04123  
26  
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VERSION 03/2013  
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OPERATING MANUAL  
5.4.3 SAFETY AND MOTOR PRESSURE RELIEF VALVE  
Safety valve  
The safety valve (10) has been factory adjusted so as to ensure that if pressure exceeds the  
permitted operating pressure, the valve, which is held with a spring, automatically opens  
and releases the excess pressure.  
As well as handling pressure limits, the valve is also used as a pressure relief valve for the  
air motor.  
10  
Pressure relief of the air motor:  
10  
2
1
2
Close ball valve (2).  
Pull back the ring on the safety  
valve (10) and hold it there until  
the pressure in the air motor has  
been equalized.  
B_04124  
WARNING  
Overpressure!  
Risk of injury from bursting components.  
Never change the safety valve setting.  
5.4.4 RETURN VALVE  
So that the complete pressure relief of the pump can be  
performed (see Chapter 7.2.2), the installation of a return  
valve is mandatory.  
The suitable return valves (ball valves), return pipes and hoses  
for the device can be found in the accessories list.  
2
1
2
3
Material outlet  
Return valve  
Material return line  
1
B_04075  
3
27  
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VERSION 03/2013  
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OPERATING MANUAL  
6 ASSEMBLY AND COMMISSIONING  
6.1 TRANSPORTATION  
The pump can be moved on a trolley or manually without lifting equipment.  
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.  
28  
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VERSION 03/2013  
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OPERATING MANUAL  
6.3 ASSEMBLING THE PUMP  
Notice  
This pump can be used as part of a spraying system for Airless  
or AirCoat applications. Individual supplement components  
for this pump can be found in the Wagner Accessories  
Catalogue, or can be put together with the Spraypack  
Configurator. The nozzles must be selected according to the  
gun instructions. In the case of spraypack orders, the pumps  
(1) are already pre-mounted on a trolley (6) or on a stand at  
the factory.  
Example:  
Airless system  
3
6
1
2
8
4
Procedure:  
5
1
2
Mount pump (1) on stand, trolley (6), or wall mount.  
Mount an AirCoat system with the pressure regulator  
(7) and secure the thread at the air inlet to the pump  
(1) with Loctite 270.  
B_04076  
3
4
Mount suction system (5).  
Mount the return valve (8) for pressure relief or  
material circulation.  
5
6
Mount return tube (4) or return hose.  
Connect the high pressure hose (2) and gun (3) in  
accordance with the gun operating manual.  
Example:  
AirCoat system  
7
3
1
8
6
2
4
5
B_04077  
WARNING  
Inclined ground!  
Risk of accidents if the device rolls away/falls.  
29  
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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.  
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  
Note for the sprayer  
Safety shoes and gloves, if  
used, must be electrostatically  
conductive.  
Work piece  
Spraying stand  
R max < 1 MΩ  
Paint container  
B_00304  
Floor, electrostatically conductive  
30  
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VERSION 03/2013  
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OPERATING MANUAL  
Cable cross sections  
Pump  
4 mm2;  
Paint container  
Conveyor  
Spray booth  
Spraying stand  
6 mm2;  
16 mm2;  
16 mm2;  
16 mm2;  
Procedure:  
1
2
3
4
Screw on grounding cable with eye.  
Clamp the grounding cable clip to a grounding connection on site.  
Ground the material (paint) container to an on-site grounding connection.  
Ground the other parts of the system to an on-site grounding connection.  
Grounding cable  
B_04127  
31  
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VERSION 03/2013  
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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 lled 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.  
32  
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OPERATING MANUAL  
Before every start-up, the following points should be observed as laid down in the  
operating manual:  
-
-
-
Check the permissible pressures.  
Check all connecting parts for leaks.  
Check hoses for damage.  
It should be ensured that the device is in the following state before carrying out any work  
on it:  
-
-
-
Interrupt the air supply (2).  
Depressurize the air motor (pull the ring on the safety valve (10)).  
Relieve the pressure from the fluid section.  
10  
closed  
open  
10  
2
C_00157  
B_04124  
EMERGENCY STOP  
2
In the case of unforeseen occurrences  
the ball valve (2) should be closed  
immediately.  
Open the safety valve (10) and relieve the  
material-conveying parts completely of  
pressure via the return valve (3).  
B_04078  
3
33  
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OPERATING MANUAL  
6.5.2 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 container is filled with sufficient separating agent.  
Filling level 2 cm; 0.8 inch under the cup edge.  
Pour the supplied separating agent into the intended opening.  
Filling level:  
2 cm; 0.8 inch under the cup edge  
Separating agent: See accessories.  
Notice  
Maximum permissible inclination of pump for moving, transportation  
etc. after filling it with separating agent 30°.  
The pump must be vertical during operation.  
B_04130  
34  
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OPERATING MANUAL  
6.5.3 BASIC FLUSHING  
Before each basic flushing, the nozzle must be removed from the pistol. The data in the  
gun's operating manual are to be observed.  
With AirCoat systems, carry out the basic flushing of the system without atomizing air (8)  
.
1
2
3
4
5
6
7
8
9
Place empty container (5) under return tube (4).  
Place suction hose (7) in the container with flushing agent (6).  
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 container (5).  
Close ball valve (2).  
Close return valve (3).  
Point the gun (9), without nozzle, into container (5) and open it.  
10 Slowly open the ball valve (2).  
11 Rinse until clean flushing agent flows from the gun.  
12 Close ball valve (2).  
13 Relieve the system pressure, either by opening the return valve (3) or via the trigger  
on the gun (9).  
14 When there is no pressure remaining in the system, close the gun (9) or the return  
valve (3).  
15 Secure the gun.  
16 Dispose of the contents of the container (5) according to the local regulations.  
closed  
1
8
2
open  
7
3
4
6
9
5
B_04079  
35  
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OPERATING MANUAL  
7 OPERATION  
7.1  
FILLING WITH WORKING MATERIAL  
Note:  
Before each filling, the nozzle must be removed from the pistol. The data in the gun's  
operating manual are to be observed.  
In case of AirCoat systems, carry out the filling of the system without atomizing air (8).  
1
2
3
4
5
6
7
8
9
Place empty container (5) under return tube (4).  
Place suction hose (7) in the container with working material (6).  
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.  
Spray until clean working material flows into the container (5).  
Close ball valve (2).  
Close return valve (3).  
Point the gun (9), without nozzle, into container (5) and open it.  
10 Slowly open the ball valve (2).  
11 Spray until clean working material flows from the gun (9).  
12 Close ball valve (2).  
13 Relieve the system pressure, either by opening the return valve (3) or via the trigger  
on the gun (9).  
14 When there is no pressure remaining in the system, close the gun (9) or the return  
valve (3).  
15 Secure the gun.  
16 Dispose of the contents of the container (5) according to the local regulations.  
36  
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OPERATING MANUAL  
7.2 WORK  
7.2.1 SPRAYING  
System example for  
the AirCoat procedure  
closed  
open  
1
8
2
9
7
3
4
6
5
B_04080  
1
2
3
4
5
6
Secure the gun and insert the nozzle into the gun.  
Close return valve (3).  
Slowly open the ball valve (2).  
Set required working pressure on the pressure regulator (1).  
Optimize the spraying results according to the data in the gun operating manual.  
Start work process.  
37  
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OPERATING MANUAL  
7.2.2 PRESSURE RELIEF/WORK INTERRUPTION  
Pressure relief of the material  
1
2
3
Close the spray gun.  
Close ball valve (2).  
Relieve the system pressure, either by opening the gun or by opening the return  
valve (3).  
4
5
Close and secure gun.  
Open and close the return valve (3) to completely depressurize the system.  
Pressure relief of the air (in case of longer work interruptions)  
1
2
3
Carry out pressure relief of the material (as mentioned above).  
Ensure that the ball valve (2) is closed.  
Pull back the ring on the safety valve (10) and hold it there until the pressure in the  
air motor has been equalized.  
10  
10  
2
B_04124  
If the system has been used with 2-component materials:  
NOTICE  
Hardened working material in the spraying system when two-component material  
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.  
38  
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OPERATING MANUAL  
7.2.3 DECOMMISSIONING AND CLEANING  
Notice  
The device should be cleaned for maintenance purposes. Ensure that no remaining  
material dries and sticks.  
Procedure:  
1
2
3
4
5
Carry out pressure relief of the material and air -> Chapter 7.2.2.  
Basic cleaning -> carry out the steps in Chapter 6.5.3.  
Maintain the gun according to the operating manual.  
Clean and check the suction system and the suction filter.  
Clean the outside of the system.  
WARNING  
Brittle filter pressure regulator!  
The container on the filter pressure regulator becomes brittle  
through contact with solvents and can burst.  
Flying parts can cause injury.  
Do not clean the container on the filter pressure regulator with  
solvent.  
6
7
8
Put the whole system back together.  
Check the level of the separating agent -> Chapter 6.5.2.  
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 lled  
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.  
39  
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OPERATING MANUAL  
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. For the last rinse, replace the water or solvent in the material  
pump with a suitable preservative. Fill separating agent cup with separating agent. Store  
pump vertically.  
Procedure:  
1
2
3
4
Chapter 7.2.3 "Decommissioning and Cleaning", perform points 1 to 7.  
Flush with preservative according to Chapter 6.5.3 and paint supplier's instructions.  
If the discharge duct is to be removed, seal material outlet with plug.  
If the suction system is to be removed, seal material inlet with plug.  
40  
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OPERATING MANUAL  
8 TROUBLESHOOTING AND RECTIFICATION  
Problem  
Cause  
Remedy  
Pump does not work. Air motor does not work or stops.  
Open and close ball valve on the pressure  
regulator unit or briefly disconnect  
compressed air supply.  
No pressure indication on the  
pressure gage  
Disconnect compressed air supply briefly or  
repair or change pressure regulator.  
(air pressure regulator defective).  
Spray nozzle is clogged.  
Insufficient compressed air supply.  
Filter insert in spray gun is clogged.  
Clean the nozzle according to the instructions.  
Check compressed air supply.  
Clean the parts and use a suitable working  
material.  
Fluid section or high pressure hose  
are blocked (e.g., two-component  
material hardened).  
Dismount and clean fluid section, replace  
high-pressure hose.  
Sometimes, the pump stops at a  
switching point.  
Press the starter on the reversing valve and  
restart the pump.  
Clean the slide on the reverse valve carefully  
and if necessary lubricate it with a light  
layer of oil.  
Poor spray pattern  
Irregular pump  
See gun instructions.  
Viscosity is too high.  
Thin spraying material.  
operation: spray jet  
collapses (pulsation).  
Spraying pressure is too low.  
Increase air inlet pressure.  
Use a smaller nozzle.  
Valves are clogged.  
Clean pump, if necessary leave it to soak in  
solvent.  
Foreign body in suction valve.  
Dismount suction valve housing, clean, and  
check valve seat.  
Diameter of compressed air line too Assemble a larger incoming line  
small. -> Technical Data, Chapter 5.3.2.  
Valves, packings, or pistons are worn Replace the parts.  
out.  
Pressure regulator filter is clogged.  
Check filter and clean it if necessary.  
The pump runs evenly, The suction system's union nut is  
Tighten union nut.  
does not however,  
suck up material.  
loose; the pump is taking in air.  
Suction filter is clogged.  
Clean filter.  
Ball in suction or piston valve is stuck. Clean balls and valve seats.  
Packings, valves, or pistons are worn Replace the parts.  
out.  
Pump runs when the  
gun is closed.  
Air motor is iced up.  
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  
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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
3
4
Check and clean the high pressure filter every day or as required (if available).  
Every decommissioning should be carried out as laid down in Chapter 7.2.3!  
Check hoses, pipes, and couplings every day and replace if necessary.  
In accordance with the guideline for liquid emitters (ZH 1/406 and BGR 500 Part 2  
Chapter 2.36):  
- The liquid emitters 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.  
42  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
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 material.  
Ensure that the hose material is chemically resistant to the  
sprayed materials.  
Ensure that the spray gun, threaded joints, and material hose  
between the device and the spray gun are suitable for the  
pressure generated in the device.  
Ensure that the following information can be seen on the high-  
pressure hose:  
- Manufacturer  
- Permissible operating pressure  
- Date of manufacture  
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 materials (paints, adhesives, sealers, solvents) must be disposed of  
according to the valid specific standards.  
43  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
10 ACCESSORIES  
Accessories  
Designation  
Order No.  
2329450  
Order No.  
2329452  
1
2
3
4
5
Pump PE/T  
AirCoat regulator set  
Grounding cable, complete 3 m; 9.8 ft  
Separating agent 250 ml  
Separating agent 500 ml  
T6145.00A  
236219  
9992504  
9992505  
Material outlet accessories  
Designation  
Order No.  
2334488  
2334472  
2331752  
2329046  
11  
12  
13  
14  
Ball valve R1/4"-G1/4"-PN350-SSt  
Ball valve R1/4"-G1/4"-PN350-CS  
Return tube DN6-G1/4"-100mm-PA  
Return hose DN6-PN310-G1/4"-PA  
Material inlet accessories  
Designation  
Order No.  
2324158  
2324110  
2323225  
2332169  
2323396  
15  
16  
17  
18  
19  
Suction pipe DN16-SSt, complete  
Suction hose DN16-SSt, complete  
Suction elbow for top reservoir SSt  
Top reservoir set, 5 l for piston pump  
Suction filter DN16-18mesh-SSt  
Wearing part  
44  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
3
2
x
x
1
11  
4/5  
12  
13  
14  
18  
15  
16  
17  
19  
B_04081  
45  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
Trolley, rack and wall bracket accessories  
Designation  
Order No.  
2332143  
2332374  
T6196.00  
2325901  
21  
22  
23  
24  
Wall mount 4", complete  
4-leg stand  
Trolley, 4 wheels  
Trolley 4", complete  
21  
22  
23  
24  
B_04113  
46  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
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 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.  
47  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.2 OVERVIEW OF THE COMPONENTS  
11.2.1 COMPONENTS FOR FINEFINISH 40-15  
Designation  
Order No.  
2329450  
2329635  
U3B08018060  
A359.71A  
E516.71A  
9900353  
2332394  
9920106  
9900330  
3055157  
H115.62  
1
1
1
1
1
1
2
1
4
4
3
3
1
1
2
3
4
5
6
7
8
9
Fluid section 15 PE/T EM  
Air motor M80 EM  
D 25 X 160 Spacer  
Safety fixture spacer  
Hexagon socket head cap screw  
Holder plate  
Washer  
Hexagon socket head cap screw  
10 Hexagon nut with clamp  
11 Tie rod  
12 Pump air regulator set  
13 Screwing in angle  
T6140.00A  
9998253  
13  
3
12  
7
8
9
20 Nm; 14.7 lbft  
4
1
6
5
11  
2
10  
30 Nm; 22.1 lbft  
B_04135  
48  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.2.2 COMPONENTS FOR FINEFINISH 20-30  
Designation  
Order No.  
2329452  
2329639  
U3B08018060  
A359.71A  
E516.71A  
9900353  
2332394  
9901115  
9920106  
2332990  
9906024  
T6140.00  
9998253  
9992590  
1
1
1
1
1
1
2
1
4
4
4
4
1
1
1
2
3
4
5
6
7
8
9
Fluid section 30 PE/T EM  
Air motor M80 EM  
D 25 X 160 Spacer  
Safety fixture spacer  
Hexagon socket head cap screw  
Holder plate  
Threaded bolt  
Washer  
10 Hexagon extension nut  
11 Hexagon socket head cap screw  
12 Pump air regulator set  
13 Screwing in angle  
14 Loctite 222 50ml; 50cc  
13  
3
12  
7
8
9
14  
1
10  
30 Nm; 22.1 lbft  
4
6
5
7
2
11  
B_04115  
30 Nm; 22.1 lbft  
49  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.3 AIR MOTOR  
WARNING  
Incorrect maintenance/repair!  
Risk of injury and equipment damage.  
Have repairs and part replacements 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.  
Air motor spare parts list EM M80  
Designation  
Order No.  
U3B08018060  
F132.91C  
L108.06  
D608.81  
3055157  
9920106  
G903.06  
L413.06  
A164.01  
L802.08  
L110.06  
D404.12  
L109.06  
A408.12  
T616.00C  
--  
1
2
3
4
5
6
7
8
Air motor EM M80  
Motor flange, upper, M50 EM  
O-ring  
Cylinder motor  
Hexagon nut with clamp  
Washer  
Steamer  
Gasket DE 80  
Motor piston  
Sliding ring  
O-ring  
Piston rod, M80 EM  
O-ring  
Air tube, M80 EM  
Motor flange, complete M80 EM, at bottom  
Type plate  
Grounding, complete  
Rod seal  
Sensor below, M80  
Lock washer for shaft  
Washer  
Pilot valve  
Threaded elbow fitting  
Silencer  
1
1
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
2
1
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
367258  
L403.06  
T703.00  
K606.02  
A160.01A  
369290  
9992757  
H505.07  
M432.00  
Reducing nipple  
= Wearing part  
= Included in service set  
= Not part of the standard equipment but available as an accessory.  
50  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
30 Nm; 22 lbft  
28  
2
3
29  
4
16  
35 Nm; 25.8 lbft  
30  
5
6
7
29  
29  
29  
9
13  
30  
29  
4.5 Nm;  
3.3 lbf  
t
7
14  
11  
1
10  
13  
3
36  
29  
35  
31  
17  
32  
33  
15  
34  
24  
19  
22  
27  
20 Nm; 14.7 lbft  
27  
29  
25  
23  
18  
Installation instructions:  
Mount piston rod (12) always  
from bottom to top by the  
assigned rod seal (18).  
12  
20  
21  
20  
B_04347  
51  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
Air motor spare parts list EM M80  
Designation  
Order No.  
9992831  
9907241  
9998808  
9998157  
27  
28  
29  
30  
31  
Loctite 542  
1
4
1
1
1
Hexagon socket head cap screw  
Mobilux EP 2 grease  
Loctite 480  
Reversing valve ISO N/1  
(consisting of items 32 to 36)  
Reversing valve  
P498.00KNE  
32  
1
P498.00  
(spare parts list, see Chapter 11.3.1)  
33  
34  
35  
36  
Valve plate  
Valve sealing  
Washer, A4.3  
Hexagon socket head cap screw  
1
1
4
4
A818.71B  
G735.06AB  
9920104  
9900386  
Service set EM Air motor M80  
1
T910.00  
= Wearing part  
= Included in service set  
= Not part of the standard equipment but available as an accessory.  
WARNING  
Incorrect maintenance/repair!  
Risk of injury and equipment damage.  
Have repairs and part replacements 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.  
52  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.3.1 REVERSING VALVE  
4
1
2
3
B_03139  
Spare parts list for the reversing valve  
Designation  
Order No.  
P498.00  
9971123  
P521.00  
P520.00  
1
2
3
4
Reversing valve  
O-ring  
Reversing valve gasket  
Steamer  
1
6
1
2
= Wearing part  
53  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.4 FLUID SECTIONS  
11.4.1 FLUID SECTION 15  
30 Nm; 22.1 lbft  
24  
8
29  
36  
22  
2.5 Nm; 1.84 lbft  
2
25  
25  
30  
26  
9
3
4
30  
26  
23  
20  
30  
10  
27  
28  
31  
27  
28  
11  
30  
27  
28  
28  
28  
5
27  
27  
27  
1
21  
12  
6
35  
33  
13  
7
14  
19  
30  
15  
10  
17  
16  
34  
35  
31  
18  
32  
B_03445  
54  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
Spare parts list for fluid section 15  
Designation  
Order No.  
2329635  
A661.12  
K617.03  
A662.12  
T9037.00E  
H204.03  
A658.03  
H203.03  
T9038.00E  
L107.06  
B534.03  
T6157.00I  
A170.03  
K801.03  
A169.03  
K803.03  
K601.03  
2323838  
9992831  
A171.03  
A172.03  
A411.03  
A410.03  
T6158.00  
G101.05  
G101.08E  
G104.05  
G104.08E  
9900136  
9998808  
9992609  
2329898  
B0461.03A  
2323718  
9992528  
9992590  
1
2
3
Fluid section 15 SS PE/T EM  
Connecting flange 15  
Snap ring  
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
6
5
1
1
1
1
1
1
1
1
4
5
6
Snap ring flange 15  
Packing PE/T 13/25  
Spring, upper  
7
Tube 15  
8
Spring  
9
Packing PE/T 18/29  
O-ring  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
Cylinder 15  
Piston 15 SS  
Support spring  
Ball  
Valve screw 15  
Ball  
Securing ring  
Inlet housing 15  
Loctite 542  
Support ring, outside  
Support ring, inside  
Support ring, inside  
Support ring, outside  
Connector  
Sealing collar T 18/29  
Sealing collar PE 18/29  
Sealing collar T 13/25  
Sealing collar PE 13/25  
Hexagon screw without shaft  
Mobilux EP 2 grease  
Anti-seize paste  
Sealing sleeve  
Fitting-DF-MM-R1/4"-1/4"NPS-PN350  
Hexagon plug  
Loctite 270  
Loctite 222  
Service set EM 15 PE/T  
1
T9039.00E  
= Wearing part  
= Included in service set  
= Not part of the standard equipment but available as an accessory.  
55  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.4.2 FLUID SECTION 30  
30 Nm; 22.1 lbft  
41  
3
2
21  
22  
4
42  
5
6
7
8
7
23  
24  
42  
8
10  
7
8
25  
7
26  
26  
28  
8
42  
9
27  
27  
29  
11  
12  
45  
1
42  
14  
30  
15  
42  
13  
16  
31  
45  
44  
32  
33  
34  
17  
35  
18  
36  
37  
19  
20  
43  
B_04116  
56  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
Spare parts list for fluid section 30  
Designation  
Order No.  
2329639  
T6158.00  
9900136  
B0388.62  
L112.06  
G119.08  
G101.08E  
G101.05  
G120.08  
T920.00D  
A114.03  
H203.03  
L170.06  
B0391.03  
B0461.03  
2323718  
T6181.00  
A156.03  
K802.03  
A155.03  
B0387.62  
9907087  
H222.03  
B0099.03  
G185.05  
G152.05  
G152.08E  
G184.05  
T941.00G  
K640.02  
B0392.03  
A961.03B  
K803.03  
L170.06  
1
2
Fluid section 30 PE/T, complete  
Connector  
1
1
1
1
1
1
4
4
1
1
1
1
2
1
1
1
1
1
1
1
1
3
1
1
1
2
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
3
4
5
Hexagon screw without shaft  
Connecting flange 30  
O-ring  
6
7
8
9
Support ring, outside  
Sealing collar PE 18/29  
Sealing collar T 18/29  
Support ring, inside  
Packing PE/T, complete 18/29  
Support ring plate  
Spring  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
41  
42  
43  
44  
45  
O-ring  
Tube 30  
Fitting-DF-MM-R3/8"-1/4"NPS-PN350  
Hexagon plug  
Piston 30  
Support spring  
Ball  
Valve screw 30  
Lower pump flange  
Hexagon socket head cap screw  
Pressure spring  
Ring  
Support ring, inside  
Sealing collar T 25/36  
Sealing collar PE 25/36  
Support ring, outside  
Packing PE/T, complete 25/36  
Round wire snap ring for waves  
Cylinder 30  
Ball stopper  
Ball  
O-ring  
Inlet fitting  
Sealing sleeve  
Valve screw 30  
Loctite 222  
Mobilux EP 1 grease  
Loctite 542  
2323833  
2329898  
B0389.03  
9992590  
9998008  
9992831  
9992609  
9992528  
Anti-seize paste  
Loctite 270  
Service set EM 20 PE/T  
1
T940.00G  
= Wearing part  
= Included in service set  
= Not part of the standard equipment but available as an accessory.  
57  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.5 AIR REGULATOR SET  
14  
14  
14  
9
5
4
14  
8
1
13  
2
3
10  
14  
11  
12  
B_04117  
Spare parts list for air regulator set  
Designation  
Order No. Order No.  
T6140.00A T6140.00  
9906026  
1
2
Pump air regulator set  
Hexagon socket head cap screw  
Pressure gage 0-1 MPa; 0-10 bar; 0-145 psi (d40)  
Reducer  
1
2
1
1
3
4
9998677  
9985682  
5
8
Screw-in connection's elbow  
Ball valve, FM  
1
1
9998039  
M101.00  
9
Safety valve 1/4"  
T-connection  
Straight threaded fitting  
Hose, black AD8 x 1.25 (0.32 m; 1.05 ft long)  
Filter regulator, CZ 1/4  
Loctite 542  
1
1
1
P484.00C1 P484.00C0  
M297.00  
10  
11  
12  
13  
14  
9992743  
9982078  
P124.00M  
9992831  
0.32 m  
1
1
= Wearing part  
58  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.6 AIR REGULATOR SET FOR AIRCOAT AIR  
7
6
4
7
5
1
3
7
2
B_03436  
Spare parts list for air regulator set for AirCoat Air  
Designation  
Order No.  
T6145.00A  
9998677  
9992129  
9998719  
9985694  
P123.00  
1
2
3
4
5
6
7
AirCoat regulator set  
Pressure gage 0-1 MPa; 0-10 bar; 0-145 psi (d40)  
Elbow with taper  
Detachable double nipple  
T-piece  
1
1
1
1
1
1
1
Air pressure regulator, 1/4"  
Loctite 270  
9992528  
= Wearing part  
59  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.7 TROLLEY, 4"  
15  
5
17  
10  
13  
14  
4
2
9
5
16  
6
1
3
7
A
8
Distance  
11  
12  
B_04074  
Spare parts list for trolley, 4"  
Designation  
Trolley, complete  
Order No.  
2325901  
--  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
1
1
1
4
6
2
4
4
1
2
2
2
2
4
1
2
2
Stand left 4" (welded)  
Stand right 4" (welded)  
Hexagon screw DIN931 M6x75  
Self-locking hexagon nut, M6  
Wheel, D250  
Washer  
Cotter pin  
Wheel axle 4"  
Connecting part 4"  
Tube plug, ribbed  
Saddle feet for round tubes  
Plug  
Hexagon screw  
Wall mount  
--  
9907140  
9910204  
2304440  
340372  
9995302  
--  
367943  
--  
--  
--  
9900218  
2332143  
3061695  
9998747  
Hexagon screw without shaft M6x55  
Handle  
= Wearing parts  
60  
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VERSION 03/2013  
ORDER NUMBER DOC 2310799  
OPERATING MANUAL  
11.8 4-WHEEL TROLLEY  
4
12  
3
2
8
13  
5
1
6
10  
9
11  
7
B_03439  
14  
Designation  
Trolley, 4 wheels  
Hexagon nut with clamp  
Stand, right  
Stand, left  
Spray gun hook  
Stand pin  
Plug  
Contact washer, M08  
Washer  
Wheel  
Hexagon socket head cap screw  
Hexagon socket head cap screw  
Hexagon socket head cap screw  
Hexagon nut with clamp  
Order No.  
T6196.00  
9910204  
E3107.92B  
E3107.92C  
H009.62  
H1156.62  
R204.07  
3155404  
9920106  
R120.00F  
9900311  
9900389  
9900309  
3055157  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
1
5
1
1
1
1
4
4
4
4
4
4
2
4
= Wearing part  
61  
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VERSION 03/2013  
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OPERATING MANUAL  
12 3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING  
12.1 SCOPE OF GUARANTEE  
All Wagner professional colour application devices (hereafter referred to as products)  
are carefully inspected, tested, and subject to strict checks under Wagner quality  
assurance. Wagner exclusively issues extended guarantees to commercial or professional  
users (hereafter referred to as "customer") who have purchased the product in an  
authorized specialist shop, and which relate to the products listed on the Internet at  
.
The buyer’s claim for liability for defects from the purchase agreement with the seller and  
statutory rights are not impaired by this guarantee.  
We provide a guarantee in that we decide whether to replace or repair the product or  
individual parts, or take the device back and reimburse the purchase price. The costs for  
materials and working hours are our responsibility. Replaced products or parts become  
our property.  
12.2 GUARANTEE PERIOD AND REGISTRATION  
The guarantee period amounts to 36 months. For industrial use or equal wear, such as shift  
operations in particular, or in the event of rentals, it amounts to 12 months.  
Systems driven by petrol or air are also guaranteed for a 12 month period.  
The guarantee period begins with the day of delivery by the authorized specialist shop.  
The date on the original purchase document is authoritative.  
For all products bought in authorized specialist shops from 2009-02-01 the guarantee  
period is extended to 24 months providing the buyer of these devices registers in  
accordance with the following conditions within 4 weeks of the day of delivery by the  
authorized specialist shop.  
Registration can be completed on the Internet at  
The guarantee certificate is valid as confirmation, as is the original purchase document  
that carries the date of the purchase. Registration is only possible if the buyer agrees to the  
data that is entered during registration being stored.  
When services are carried out under guarantee the guarantee period for the product is  
neither extended nor renewed.  
Once the guarantee period has expired, claims made against the guarantee or from the  
guarantee can no longer be enforced.  
12.3 HANDLING  
If defects can be seen in the materials, processing, or performance of the device during the  
guarantee period, guarantee claims must be made immediately, or at the latest within a  
period of 2 weeks.  
The authorized specialist shop that delivered the device is entitled to accept guarantee  
claims. Guarantee claims may also be made to the service centers named in the operating  
manual. The product has to be sent without charge or presented together with the  
original purchase document that includes details of the purchase date and the name of  
the product. In order to claim for an extension to the guarantee, the guarantee certificate  
must be included.  
The costs as well as the risk of loss or damage to the product in transit or by the center that  
accepts the guarantee claims or who delivers the repaired product, are the responsibility  
of the customer.  
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VERSION 03/2013  
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OPERATING MANUAL  
12.4 EXCLUSION OF GUARANTEE  
Guarantee claims cannot be considered  
- for parts that are subject to wear and tear due to use or other natural wear and tear, as  
well as defects in the product that are a result of natural wear and tear, or wear and tear  
due to use. This includes in particular cables, valves, packings, nozzles, cylinders, pistons,  
means-carrying housing components, filters, pipes, seals, rotors, stators, etc. Damage  
due to wear and tear that is caused in particular by sanded coating materials, such as  
dispersions, plasters, putties, adhesives, glazes, quartz foundation.  
- in the event of errors in devices that are due to non-compliance with the operating  
instructions, unsuitable or unprofessional use, incorrect assembly and/or commissioning  
by the buyer or by a third party, utilization other than is intended, abnormal ambient  
conditions, unsuitable coating materials, the influence of chemical, electrochemical, or  
electrical agents, unsuitable operating conditions, operation with the incorrect mains  
voltage supply/frequency, overload, or defective servicing or care and/or cleaning.  
- for errors in the device that have been caused by using accessory parts, additional  
components, or spare parts that are not original Wagner parts.  
- for products to which modifications or additions have been carried out.  
- for products where the serial number has been removed or is illegible.  
- for products to which attempts at repairs have been carried out by unauthorized persons.  
- for products with slight deviations from the target properties, which are negligible with  
regard to the value and usability of the device.  
- for products that have been partially or fully taken apart.  
12.5 ADDITIONAL REGULATIONS  
Theaboveguaranteesapplyexclusivelytoproductsthathavebeenboughtfromauthorized  
specialist shops in the EU, CIS, Australia and are used within the reference country.  
If an inspection finds damage not covered by the present guarantee, repairs are carried out  
at the expense of the buyer.  
The above regulations manage the legal relationship to us concludingly. Additional claims,  
in particular for damages and losses of any type, which occur as a result of the product  
or its use, are excluded from the product liability act except with regard to the area of  
application.  
Claims for liability for defects to the specialist trader remain unaffected.  
German law applies to this guarantee. The contractual language is German. In the event  
that the meaning of the German and a foreign text of this guarantee deviate from one  
another, the meaning of the German text has priority.  
Germany  
Wagner professional guarantee  
(As of 2009-02-01)  
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OPERATING MANUAL  
12.6 CE DECLARATION OF CONFORMITY  
Herewith we declare that the supplied version of pneumatic pumps and their spraypacks  
FineFinish  
comply with the following guidelines:  
2006/42/EC  
94/9/EC  
Applied standards, in particular:  
Applied national technical standards and specifications, in particular:  
Part 2 Chapter 2.29 and Chapter 2.36  
Identification:  
II 2G IIB c T3 X  
EC 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:  
2312813  
12.7 REFERENCE TO GERMAN REGULATIONS AND GUIDELINES  
Part 2, Chapter 2.36 Working with Liquid Ejection Devices  
Part 2, Chapter 2.29 Working with Coating Materials  
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.  
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A
DK  
GB  
Tel.  
Fax  
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D
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Tel. +49 / 75 44 / 505 -1664  
Fax  
Subject to changes and errors.  
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