WAGNER HEAVYCOAT HC730 User manual

HEAVYCOAT HC
730 • 750 • 770
owner‘s manual • betriebsanleitung
mode d‘emploi
0118 • Form No. 0537814C
wagner-group.com
GB F D
HC730 GAS
HC750 SSP 230V
HC750 GAS
HC770 GAS
HC750 230V

2
original operating manual HeavyCoat
Warning!
Attention: Danger of injury by injection!
Airless units develop extremely high spraying pressures.
Be safety conscious!
1
2
3
Never put your ngers, hands or any other parts of the body into
the spray jet!
Never point the spray gun at yourself, other persons or animals.
Never use the spray gun without safety guard.
Do not treat a spraying injury as a harmless cut. In case of injury
to the skin through coating materials or solvents, consult a doctor
immediately for quick and expert treatment. Inform the doctor
about the coating material or solvent used.
The operating instructions state that the following points must
always be observed before starting up:
1. Faulty units must not be used.
2. Secure Wagner spray gun using the trigger lock on the trigger.
3. Ensure that the unit is properly earthed.
4. Check allowable operating pressure of high-pressure hose and spray gun.
5. Check all connections for leaks.
The instructions regarding regular cleaning and maintenance of
the unit must be strictly observed.
Before any work is done on the unit or for every break in work the
following rules must be observed:
1. Release the pressure from spray gun and hose.
2. Secure the Wagner spray gun using the trigger lock on the trigger.
3. Switch o unit.

3
contents
HeavyCoat
1 SAFETY REGULATIONS FOR AIRLESS
SPRAYING ______________________________ 4
1.1 Explanation of symbols used_____________________4
1.2 Safety hazards ________________________________4
1.3 Setup on an uneven surface _____________________6
1.4 Electrical safety _______________________________6
1.5 Gasoline engine safety__________________________6
1.6 Fueling (gas engine) ___________________________7
2 MAIN AREAS OF APPLICATION ____________ 8
2.1 Application___________________________________8
2.2 Coating materials______________________________8
3 DESCRIPTION OF UNIT ___________________ 9
3.1 Airless process ________________________________9
3.2 Functioning of the unit _________________________9
3.3 System diagram - gasoline HeavyCoat units _______10
3.4 System diagram - electric HeavyCoat units ________11
3.5 Technical data for HeavyCoat units ______________12
3.6 Transportation _______________________________13
3.7 Crane transport ______________________________13
4 OPERATION ____________________________ 13
4.1 Setup ______________________________________13
4.2 Starting the engine (gas models) ________________15
4.3 Preparing a new sprayer _______________________15
4.4 Preparing to paint ____________________________16
4.5 Painting ____________________________________17
4.6 Pressure relief procedure_______________________17
5 SPRAYING _____________________________ 18
5.1 Cleaning a clogged tip_________________________18
5.2 Interruption of work __________________________19
5.3 Handling the high pressure hose ________________19
6 CLEANUP ______________________________ 20
6.1 Special cleanup instructions for use with
ammable solvents ___________________________20
6.2 Cleaning the sprayer __________________________20
6.3 Cleaning the outside of the sprayer ______________20
6.4 Cleaning the lter screen_______________________21
6.5 Cleaning the airless spray gun __________________21
7 MAINTENANCE _________________________ 22
7.1 Daily maintenance____________________________22
7.2 Lubricating the upper packings _________________22
7.3 Maintaining the lter assembly__________________22
7.4 Maintaining the hydraulic system________________23
7.5 Maintaining the uid section ___________________24
7.6 High pressure hose ___________________________25
7.7 Basic engine maintenance______________________25
7.8 Servicing the hydraulic motor___________________26
7.9 Servicing the uid section ______________________28
7.10 Replacing the belt ____________________________30
8 TROUBLESHOOTING ____________________ 31
8.1 Airless gun __________________________________31
8.2 Fluid section_________________________________31
8.3 Hydraulic motors _____________________________32
8.4 Spray patterns _______________________________33
9 APPENDIX _____________________________ 34
9.1 Selection of tip _______________________________34
9.2 Servicing and cleaning of Airless hard-metal tips ___34
9.4 2Speed Tip table _____________________________35
9.5 Airless tip table____________________________ 36/37
ACCESSORIES AND SPARE PARTS ____________110
Spare parts list for the main assembly I____________ 110/111
Spare parts list for the main assembly II ___________ 112/113
Spare parts list for the cart assembly______________ 114/115
Spare parts list for the hydraulic system ___________ 116/117
Spare parts list for the uid section •
HeavyCoat 730 _______________________________ 118/119
Spare parts list for the uid section •
HeavyCoat 750 / 770 __________________________ 120/121
Spare parts list for the shovel valve HC 750 SSP ____ 122/123
Spare parts list for the hydraulic motor assembly ___ 124/125
Spare parts list for the high-pressure lter _________ 126/127
Spare parts list for bleed valve assembly __________ 128/129
Spare parts list for solenoid assembly_____________ 130/131
CONNECTION DIAGRAM 230V ______________132
CONNECTION DIAGRAM GAS ENGINE _______133
HYDRAULIC DIAGRAM ______________________134
ACCESSORIES FOR HC UNITS I _______________135
ACCESSORIES FOR HC UNITS II ___________136/137
IMPORTANT NOTES ON PRODUCT LIABILITY __138
3+2 YEARS GUARANTEE FOR PROFESSIONAL
FINISHING ________________________________138
SALES AND SERVICE COMPANIES ________147/148

4
safety precautions HeavyCoat
1 SAFETY REGULATIONS FOR AIRLESS
SPRAYING
1.1 EXPLANATION OF SYMBOLS USED
This manual contains information that must be read and
understood before using the equipment. When you come to
an area that has one of the following symbols, pay particular
attention and make certain to heed the safeguard.
This symbol indicates a potential hazard
that may cause serious injury or loss of life.
Important safety information will follow.
At
tention
This symbol indicates a potential hazard
to you or to the equipment. Important
information that tells how to prevent
damage to the equipment or how to avoid
causes of minor injuries will follow.
Danger of skin injection
Danger of re from solvent and paint fumes
Danger of explosion from solvent, paint
fumes and incompatible materials
Danger of injury from inhalation of harmful
vapors
Danger of injury from electric shock
i
Notes give important information which
should be given special attention.
1.2 SAFETY HAZARDS
HAZARD: INJECTION INJURY
A high pressure stream produced by this
equipment can pierce the skin and underlying
tissues, leading to serious injury and possible
amputation.
Do not treat a spraying injury as a harmless cut. In
case of injury to the skin through coating materials
or solvents, consult a doctor immediately for
quick and expert treatment. Inform the doctor
about the coating material or solvent used.
PREVENTION:
• NEVER aim the gun at any part of the body.
• NEVER allow any part of the body to touch the uid stream.
DO NOT allow body to touch a leak in the uid hose.
• NEVER put your hand in front of the gun. Gloves will not
provide protection against an injection injury.
• ALWAYS lock the gun trigger, shut the uid pump o and
release all pressure before servicing, cleaning the tip guard,
changing tips, or leaving unattended. Pressure will not be
released by turning o the engine. The PRIME/SPRAY valve
or pressure bleed valve must be turned to their appropriate
positions to relieve system pressure.
• ALWAYS keep tip guard in place while spraying. The tip
guard provides some protection but is mainly a warning
device.
• ALWAYS remove the spray tip before ushing or cleaning
the system.
• NEVER use a spray gun without a working trigger lock and
trigger guard in place.
• All accessories must be rated at or above the maximum
operating pressure range of the sprayer. This includes
spray tips, guns, extensions, and hose.

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safety precautions
HeavyCoat
HAZARD: HIGH PRESSURE HOSE
The paint hose can develop leaks from wear,
kinking and abuse. A leak can inject material into
the skin. Inspect the hose before each use.
PREVENTION:
• Avoid sharp bending or kinking of the high-pressure hose.
The smallest bending radius amounts to about 20 cm.
• Do not drive over the high-pressure hose. Protect against
sharp objects and edges.
• Replace any damaged high-pressure hose immediately.
• Never repair damaged high-pressure hoses yourself!
• Electrostatic charging of spray guns and the high-pressure
hose is discharged through the high-pressure hose. For this
reason the electric resistance between the connections of
the high-pressure hose must be equal to or lower than
1MΩ.
• For reasons of function, safety and durability use only
original Wagner high-pressure hoses.
• Before each use, check all hoses for cuts, leaks, abrasion
or bulging of cover. Check for damage or movement of
couplings. Immediately replace the hose if any of these
conditions exist. Never repair a paint hose. Replace it with
another earthed high-pressure hose.
• Make sure power cord, air hose and spray hoses are routed
in such a manner to minimize slip, trip and fall hazard.
HAZARD: EXPLOSION OR FIRE
Flammable vapors, such as solvent and paint
vapors, in work area can ignite or explode.
PREVENTION:
• Use equipment only in well ventilated area. Keep a good
supply of fresh air moving through the area to keep the air
within the spray area free from accumulation of ammable
vapors. Keep pump assembly in well ventilated area. Do
not spray pump assembly.
• Electric models only - Do not use materials with a ashpoint
below 38º C (100º F). Flashpoint is the temperature at which
a uid can produce enough vapors to ignite.
• Gas models only - Do not ll fuel tank while engine is
running or hot; shut o engine and allow to cool. Fuel is
ammable and can ignite or explode if spilled on a hot
surface.
• Eliminate all ignition sources, such as pilot lights, cigarettes,
portable electric lamps and plastic drop cloths (potential
static arc).
• Keep work area free of debris, including solvent, rags and
gasoline.
• Do not plug or unplug power cords, or turn power or light
switches on or o when ammable vapors are present.
• Ground equipment and conductive objects in work
area. Make sure the grounding cable (not equipped) is
connected from the grounding lug to a true earth ground.
• Use only grounded hoses.
• Hold spray gun rmly to the side of a grounded pail when
triggering into pail.
• If there is static sparking or if you feel a shock, stop
operation immediately.
• Know the contents of the paint and solvents being sprayed.
Read all material Safety Data Sheets (SDS) and container
labels provided with the paints and solvents. Follow the
paint and solvent manufacturer’s safety instructions.
• Do not use a paint or solvent containing halogenated
hydrocarbons. Such as chlorine, bleach, mildewcide,
methylene chloride and trichloroethane. They are not
compatible with aluminum. Contact the coating supplier
about compatibility of material with aluminum.
• Keep a re extinguisher in work area.

6
safety precautions HeavyCoat
HAZARD: HAZARDOUS VAPORS
Paints, solvents, and other materials can be
harmful if inhaled or come in contact with body.
Vapors can cause severe nausea, fainting, or
poisoning.
PREVENTION:
• Wear respiratory protection when spraying. Read all
instructions supplied with the mask to be sure it will
provide the necessary protection.
• All local regulations regarding protection against
hazardous vapors must be observed.
• Wear protective eyewear.
• Protective clothing, gloves and possibly skin protection
cream are necessary for the protection of the skin. Observe
the regulations of the manufacturer concerning coating
materials, solvents and cleaning agents in preparation,
processing and cleaning units.
HAZARD: GENERAL
This product can cause severe injury or property
damage.
PREVENTION:
• Follow all appropriate local, state, and national codes
governing ventilation, re prevention, and operation.
• Pulling the trigger causes a recoil force to the hand that is
holding the spray gun. The recoil force of the spray gun
is particularly powerful when the tip has been removed
and high pressure has been set on the airless pump. When
cleaning without a spray tip, set the pressure control knob
to the lowest pressure.
• Use only manufacturer authorized parts. User assumes all
risks and liabilities when using parts that do not meet the
minimum specications and safety devices of the pump
manufacturer.
• ALWAYS follow the material manufacturer’s instructions
for safe handling of paint and solvents.
• Clean up all material and solvent spills immediately to
prevent slip hazard.
• Wear ear protection. This unit can produce noise levels
above 85 dB(A).
• Never leave this equipment unattended. Keep away from
children or anyone not familiar with the operation of airless
equipment.
• Do not spray on windy days.
• The device and all related liquids (i.e. hydraulic oil) must be
disposed of in an environmentally friendly way.
1.3 SETUP ON AN UNEVEN SURFACE
The front end must always point downwards in order to avoid
sliding away.
If possible do not use the unit on an inclined surface since the
unit tends to wander due to the resulting vibrations.
1.4 ELECTRIC SAFETY
Electric models must be grounded/earthed. In the event
of an electrical short circuit, grounding/earthing reduces
the risk of electric shock by providing an escape wire for the
electric current. This product is equipped with a cord having
an grounding/earthing wire with an appropriate grounding/
earthing plug. Connection to the power cord only through a
special feed point, e.g. through an error protection insallation
with INF < 30 mA.
DANGER — Work or repairs at the electrical
equipment may only be carried out by a skilled
electrician. No liability is assumed for incorrect
installation. Switch the unit o. Before all repair
work, unplug the power plug from the outlet.
Danger of short-circuits caused by water
ingressing into the electrical equipment. Never
spray down the unit with high-pressure or high-
pressure steam cleaners.
1.5 GASOLINE ENGINE SAFETY
1. Gas engines are designed to give safe and dependable
service if operated according to instructions. Read and
understand the engine manufacturer’s Owner’s Manual
before operating the engine. Failure to do so could result
in personal injury or equipment damage.
2. To prevent re hazards and to provide adequate
ventilation, keep the engine at least 1 meter (3 feet) away
from buildings and other equipment during operation. Do
not place ammable objects close to the engine.

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safety precautions
HeavyCoat
3. People who are not operating the device must stay away
from the area of operation due to a possibility of burns from
hot engine components or injury from any equipment the
engine may be used to operate.
4. Know how to stop the engine quickly, and understand the
operation of all controls. Never permit anyone to operate
the engine without proper instructions.
5. Gasoline is extremely ammable and is explosive under
certain conditions.
6. Refuel in a well-ventilated area with the engine stopped.
Do not smoke or allow ames or sparks in the refueling
area or where gasoline is stored.
7. Do not overll the fuel tank. After refueling, make sure the
tank cap is closed properly and securely.
8. Be careful not to spill fuel when refueling. Fuel vapor or
spilled fuel may ignite. If any fuel is spilled, make sure the
area is dry before starting the engine.
9. Never run the engine in an enclosed or conned area.
Exhaust contains poisonous carbon monoxide gas;
exposure may cause loss of consciousness and may lead
to death.
10. The muer becomes very hot during operation and
remains hot for a while after stopping the engine. Be
careful not to touch the muer while it is hot. To avoid
severe burns or re hazards, let the engine cool before
transporting it or storing it indoors.
11. Never ship/transport sprayer with gasoline in the tank.
DO NOT use this equipment to spray water or
acid.
1.6 FUELING GAS ENGINE
Gasoline is extremely ammable and is explosive
under certain conditions.
FUEL SPECIFICATIONS
Use automotive gasoline that has a pump octane number of 86
or higher, or that has a research octane number of 91 or higher.
Use of a lower octane gasoline can cause persistent “pinging” or
heavy “spark knock” (a metallic rapping noise) which, if severe,
can lead to engine damage.
i
If “spark knock” or “pinging” occurs at a steady
engine speed under normal load, change brands
of gasoline. If spark knock or pinging persists,
consult an authorized dealer of the engine
manufacturer. Failure to do so is considered
misuse, and damage caused by misuse is not
covered by the engine manufacturer’s limited
warranty.
Occasionally you may experience light spark
knock while operating under heavy loads. This
is no cause for concern, it simply means your
engine is operating eciently.
• Unleaded fuel produces fewer engine and spark plug
deposits and extends the life of the exhaust system
components.
• Never use stale or contaminated gasoline or an oil/gasoline
mixture. Avoid getting dirt, dust, or water in the fuel tank.
GASOLINES CONTAINING ALCOHOL
If you decide to use a gasoline containing alcohol (gasohol), be
sure its octane rating is at least as high as that recommended
by the engine manufacturer. There are two types of “gasohol”:
one containing ethanol, and the other containing methanol.
Do not use gasohol that contains more than 10% ethanol. Do
not use gasoline containing methanol (methyl or wood alcohol)
that does not also contain co-solvents and corrosion inhibitors
for methanol. Never use gasoline containing more than 5%
methanol, even if it has co-solvents and corrosion inhibitors.
i
Fuel system damage or engine performance
problems resulting from the use of fuels that
contain alcohol is not covered under the
warranty. The engine manufacturer cannot
endorse the use of fuels containing methanol
since evidence of their suitability is incomplete
at this time.
Before buying gasoline from an unfamiliar
station, try to nd out if the gasoline contains
alcohol. If it does, conrm the type and
percentage of alcohol used. If you notice any
undesirable operating characteristics while using
a gasoline that contains alcohol, or one that you
think contains alcohol, switch to a gasoline that
you know does not contain alcohol.

8
main areas of application HeavyCoat
2 MAIN AREAS OF APPLICATION
2.1 APPLICATION
The main area of application are thick layers of highly viscous
coating material for large areas and a high consumption of
material.
Priming and nal coating of large areas, sealing, impregnation,
construction sanitation, façade protection and renovation, rust
protection and building protection, roof coating, roof sealing,
concrete sanitation, as well as heavy corrosion protection.
EXAMPLES OF OBJECTS TO BE SPRAYED
Large-scale construction sites, cooling towers, bridges, sewage
treatment plants and terraces.
OPERATING TEMPERATURE
This equipment will operate correctly in its intended ambient,
at a minimum between +10°C and +40°C.
RELATIVE HUMIDITY
The equipment will operate correctly within an environment
at 50% RH, +40°C. Higher RH may be allowed at lower
temperatures.
Measures shall be taken by the Purchaser to avoid the harmful
eects of occasional condensation.
ALTITUDE
This equipment will operate correctly up to 2100 m above
mean sea level.
TRANSPORTATION AND STORAGE
This equipment will withstand, or has been protected against,
transportation and storage temperatures of -25°C to +55°C and
for short periods up to +70°C.
It has been packaged to prevent damage from the eects of
normal humidity, vibration and shock.
RECOMMENDED HOSE CONFIGURATION
Wagner recommends to use the following hose diameters and
lengths:
DN 12 mm, 15 m, connection thread 1/2
DN 6 mm, 60 m, connection thread 1/4
If using a dierent hose conguration, make sure that the
operating pressure indicated at the pressure gauge is not
above 250 bar. Reduce the pressure if necessary.
2.2 COATING MATERIALS
PROCESSIBLE COATING MATERIALS
Diluting lacquers and paints or those containing solvents, two-
component coating materials, dispersion and latex paints.
No other materials should be used for spraying without
Wagner‘s approval.
i
Pay attention to the Airless quality of the coating
materials to be processed.
VISCOSITY
The unit is able to process coating materials with up to 50.000
/ 65.000 mPas. If highly viscous coating materials cannot be
taken in or the performance of the unit is to low, the paint must
be diluted in accordance with the manufacturer‘s instructions.
i
Attention: Make sure, when stirring up with
motor-driven agitators that no air bubbles are
stirred in. Air bubbles disturb when spraying and
can, in fact, lead to interruption of operation.
COATING MATERIALS WITH ABRASIVE MATERIALS
These particles have a strong wear and tear eect on valves and
tips, but also on the spray gun. This impairs the durability of
these wearing parts considerably.
TWOCOMPONENT COATING MATERIAL
The appropriate processing time must be adhered to exactly.
Within this time rinse through and clean the unit meticulously
with the appropriate cleaning agents.
FILTERING
Sucient ltering is required for fault-free operation. The unit
is equipped with a suction lter, an insertion lter in the spray
gun and a high pressure lter on the unit. Regular inspection
of these lters for damage or soiling is urgently recommended.
If using this sprayer with textured materials, it is important that
the lter inside of the spray gun be removed. See section 6.5.

9
description of unit
HeavyCoat
3 DESCRIPTION OF UNIT
3.1 AIRLESS PROCESS
A piston pump takes in the coating material by suction and
conveys it to the tip. Pressed through the tip at a pressure of
up to a maximum of 3600 PSI (250 bar, 25 MPa), the coating
material is atomised. This high pressure has the eect of micro
ne atomization of the coating material.
As no air is used in this process, it is described as an AIRLESS
process.
This method of spraying has the advantages of nest
atomization, cloudless operation and a smooth, bubble-free
surface. As well as these, the advantages of the speed of work
and convenience must be mentioned.
3.2 FUNCTIONING OF THE UNIT
The following section contains a brief description of the
technical construction for better understanding of the function
of the unit.
i
This manual gives information for both electric
motor and gasoline engine HeavyCoat models.
Wagner HeavyCoat are high-pressure spraying units driven by
either a gasoline engine or electric motor.
The gasoline engine or electric motor (g. 2, item 1) drives the
hydraulic pump (3) by means of a V-belt which is under the belt
cover (2). Hydraulic oil ows to the hydraulic motor (4) and then
moves the piston up and down in the material feed pump (5).
With device HC 750 SSP the piston in the material feed pump
moves a shovel valve (6). The shovel valve feeds high-viscosity
coating materials.
The inlet valve is opened automatically by the upwards
movement of the piston. The outlet valve is opened when the
piston moves downward.
The coating material ows under high pressure through the
high-pressure hose to the spray gun. When the coating material
exits from the tip it atomizes.
The pressure control valve (7) controls the volume and the
operating pressure of the coating material.
5
4
1
6
7
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730 14
15
16
1
5
3
2
4
8
7
6
9
13
10
11
12
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10
description of unit HeavyCoat
3.3 SYSTEM DIAGRAM  GASOLINE HEAVYCOAT UNITS
1. Extractable handle
2. Oil cup for separating oil (separating
oil prevents increased wear and tear
of the packings)
3. High-pressure lter
4. High-pressure hose outlet
5. Hydraulic motor
11. Gasoline engine
12. Oil measuring stick
13. Pressure control knob
14. Tip guard with airless tip
15. Spray gun
16. High-pressure hose
17. Grounding lug
6. Relief valve handle:
Turn left for circulation k
Turn right for spray p
7. Manometer
8. Bleed hose
9. Suction tube
10. V-belt under the belt cover