WAGNER P20 0552488 User manual

Edition 8 / 2012 0552 874B
GB
Operating manual
Models:
0552488
0552490
P20
Airless high-pressure spraying unit

2 P20
GB
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 safety catch on the trigger.
3. Check allowable operating pressure of high-pressure hose and spray
gun.
4. 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 safety catch on the trigger.
3. Switch o unit.
Original Operating Manual

P20 3
GB
Contents
Contents
Page
1. Safety regulations for Airless spraying...................................... 4
1.1 Explanation of symbols used.............................................................. 4
1.2 Earthing instructions.............................................................................. 5
2. General view of application............................................................. 6
2.1 Application ................................................................................................ 6
2.2 Coating materials .................................................................................... 6
3. Description of unit................................................................................ 6
3.1 Airless process .......................................................................................... 6
3.2 Functioning of the unit ......................................................................... 6
3.3 Legend for explanatory diagram P20 .............................................. 7
3.4 Explanatory diagram P20 ..................................................................... 7
3.5 Technical data .......................................................................................... 8
3.6 Transportation in vehicle...................................................................... 8
4. Starting operation................................................................................ 8
4.1 High-pressure hose, spray gun and separating oil ..................... 8
4.2 Connection to the mains network .................................................... 8
4.3 Cleaning preserving agent when
starting-up of operation initially........................................................ 8
4.4 Taking the unit into operation with coating material................ 9
5. Spraying technique ............................................................................. 9
6. Handling the high-pressure hose ...............................................10
6.1 High-pressure hose...............................................................................10
7. Interruption of work..........................................................................10
8. Cleaning the unit (shutting down) .............................................10
8.1 Cleaning unit from outside................................................................10
8.2 Suction lter............................................................................................11
8.3 Cleaning Airless spray gun.................................................................11
Page
9. Remedy in case of faults..................................................................12
10. Servicing..................................................................................................13
10.1 General servicing...................................................................................13
10.2 High-pressure hose...............................................................................13
11. Repairs at the unit ..............................................................................13
11.1 Relief valve...............................................................................................13
11.2 Inlet and outlet valve...........................................................................14
11.3 Packings....................................................................................................15
11.4 P20 connection diagram ....................................................................16
12. Appendix.................................................................................................17
12.1 Selection of tip .......................................................................................17
12.2 Servicing and cleaning of Airless hard-metal tips.....................17
12.3 Spray gun accessories..........................................................................17
12.4 Airless tip table.......................................................................................18
12.5 TempSpray...............................................................................................18
Spare parts lists .................................................................................................20
Accessories for P20.............................................................................................20
Spare parts list for main assembly ................................................................22
Spare parts list for uid section......................................................................24
Spare parts list for drive assembly ................................................................26
Spare parts list for motor assembly..............................................................27
Spare parts list of frame ....................................................................................28
Spare parts list for suction system ................................................................29
WAGNER-Service companies.......................................................................30
Important notes on product liability ......................................................32
3+2 years guarantee for professional nishing ................................32

4 P20
GB
Safety Regulations
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.
Attention
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
i
Notes give important information which should
be given special attention.
Refer to the operating manual for additional
safety instructions.
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 AN INJECTION INJURY AS A SIMPLE
CUT! Injection can lead to amputation. See a
physician immediately.
The maximum operating range of the unit is 214 bar
(21.4 MPa, 3100 PSI) uid pressure.
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.
 • 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.
 • 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.
NOTE TO PHYSICIAN:
Injection into the skin is a traumatic injury. It is important to
treat the injury as soon as possible. DO NOT delay treatment
to research toxicity. Toxicity is a concern with some coatings
injected directly into the blood stream. Consultation with
a plastic surgeon or reconstructive hand surgeon may be
advisable.
HAZARD: EXPLOSION OR FIRE
Solvent and paint fumes can explode or ignite.
Severe injury and/or property damage can occur.
PREVENTION:
 • Donotusetheunitinworkplaceswhicharecoveredtothe
explosion protection regulations.
 • Provideextensiveexhaustandfreshairintroductionto
keep the air within the spray area free from accumulation of
ammable vapors.
 • Avoidallignitionsourcessuchasstaticelectricitysparks,
electrical appliances, ames, pilot lights, hot objects, and
sparks from connecting and disconnecting power cords or
working light switches.
 • Plasticcancausestaticsparks.Neverhangplastictoenclose
spray area. Do not use plastic drop cloths when spraying
ammable materials.
 • Alwaysushunitintoseparatemetalcontainer,atlowpump
pressure, with spray tip removed. Hold gun rmly against side
of container to ground container and prevent static sparks.
 • Whencleaningtheunitwithsolvents,thesolventshould
never be sprayed or pumped back into a container with a
small opening (bunghole). An explosive gas/air mixture can be
produced. The container must be earthed..
 • Donotsmokeinsprayarea.
 • Fireextinguishermustbepresentandingoodworkingorder.
 • Placesprayeratleast6.1m(20feet)fromthesprayobject
in a well ventilated area (add more hose if necessary).
Flammable vapors are often heavier than air. Floor area must
be extremely well ventilated. The pump contains arcing parts
that emit sparks and can ignite vapors.
 • Theequipmentandobjectsinandaroundthesprayareamust
be properly grounded to prevent static sparks.
 • Useonlyconductiveorearthedhighpressureuidhose.Gun
must be earthed through hose connections.
 • Powercordmustbeconnectedtoagroundedcircuit(electric
units only).
 • Theunitmustbeconnectedtoanearthedobject.Usethe
green earthing wire to connect the unit to a water pipe, steel
beam, or other electrically earthed surface.
 • Followmaterialandsolventmanufacturer’swarningsand
instructions.Befamiliarwiththecoatingmaterial’sMSDS
sheet and technical information to ensure safe use.

P20 5
GB
Safety regulations
 • Donotusematerialswithaashpointbelow21°C(70°F).
Flashpoint is the temperature at which a uid can produce
enough vapors to ignite.
 • Uselowestpossiblepressuretoushequipment.
HAZARD: EXPLOSION HAZARD DUE TO
INCOMPATIBLE MATERIALS
Will cause severe injury or property damage.
PREVENTION:
 • Donotusematerialscontainingbleachorchlorine.
 • Donotusehalogenatedhydrocarbonsolventssuchas
methylene chloride and 1,1,1 - trichloroethane. They are not
compatible with aluminum and may cause an explosion. If
youareunsureofamaterial’scompatibilitywithaluminum,
contactyourcoating’ssupplier.
HAZARD: HAZARDOUS VAPORS
Paints, solvents, insecticides, and other materials
can be harmful if inhaled or come in contact with
body. Vapors can cause severe nausea, fainting, or
poisoning.
PREVENTION:
 • Usearespiratorormaskifvaporscanbeinhaled.Readall
instructions supplied with the mask to be sure it will provide
the necessary protection.
 • Wearprotectiveeyewear.
 • Wearprotectiveclothingasrequiredbycoatingmanufacturer.
HAZARD: GENERAL
This product can cause severe injury or property
damage.
PREVENTION:
 • Readallinstructionsandsafetyprecautionsbeforeoperating
equipment.
 • 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
a high pressure has been set on the airless pump. When
cleaning without a spray tip, set the pressure control knob to
the lowest pressure.
 • Incaseofhighoperatingpressure,pullingthetriggercan
eect a recoil force of up to 15 N. If you are not prepared for
this, your hand can be thrust backwards or your balance lost.
This can lead to injury.
 • 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.
 • 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.
 • Cleanupallmaterialandsolventspillsimmediatelytoprevent
sliphazard.
 • ALWAYSfollowthematerialmanufacturer’sinstructionsfor
safe handling of paint and solvents.
 • Donotusethisunitinworkshopsthatarecoveredunderthe
explosion prevention regulations.
 • Alwaysunplugcordfromoutletbeforeworkingonequipment
(electric units only).
 • Alwayskeepthepowercordpluginsightduringusageto
prevent any accidental shutdown or startup.
 • Dangerofshortcircuitthroughpenetratingwater!Never
spray down the unit with high-pressure or high-pressure
steam cleaners.
 • 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moveunitwhileunitisrunning.
 • Donotsprayonwindydays.
 • 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 or lower than 197 k½/m (60
k½/ft.).
i
For reasons of function, safety and durability use
only original WAGNER high-pressure hoses.
1.2 Earthing Instructions
Electric models must be earthed. In the event of an electrical short
circuit, 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 earthing wire with an appropriate earthing plug. The
plug must be plugged into an outlet that is properly installed and
earthed in accordance with all local codes and ordinances.
DANGER — Improper installation of the earthing
plug can result in a risk of electric shock. If repair
or replacement of the cord or plug is necessary, do
not connect the green earthing wire to either blade
terminal. The wire with insulation having a green
outer surface with or without yellow stripes is the
earthing wire and must be connected to the earthing
pin.
Check with a qualied electrician or serviceman if the earthing
instructions are not completely understood, or if you are in doubt as
to whether the product is properly earthed. Do not modify the plug
provided. If the plug will not t the outlet, have the proper outlet
installed by a qualied electrician.
Caution – The power cord for this equipment acts as
an emergency stop/emergency switching o device.
The power cord must be placed near an easily
accessible, unobstructed socket-outlet.

6 P20
GB
Safety regulations Description of unit
Work or repairs at the electrical equipment:
These may only be carried out by a skilled electrician. No liability is
assumed for incorrect installation.
A list of the materials used in the construction of the equipment
will be made available on request to validate compatibility with the
coating materials to be used.
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.
2. General view of application
2.1 Application
All painting jobs in the workshop and on the building site, small
dispersion work with the spray gun or internally fed Airless roller.
Examples of objects of spraying
Doors, door frames, balustrades, furniture, wooden cladding, fences
radiators (heating) and steel parts, internal ceilings and walls.
2.2 Coating materials
Processible coating materials
i
Pay attention to the Airless quality of the coating
materials to be processed.
Dilutable lacquers and paints or those containing solvents, two-
component coating materials, dispersions, latex paints.
No other materials should be used for spraying without WAGNER’s
approval.
Filtering
Despite suction lter and insertion lter in the spray gun, ltering of
the coating material is generally advisable.
Stir coating material before commencement of work.
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.
Viscosity
With this unit it is possible to process highly viscous coating materials
of up to around 20.000 MPa·s.
If highly viscous coating materials cannot be taken in by suction, they
mustbedilutedinaccordancewiththemanufacturer’sinstructions.
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 materials.
Coating materials with sharp-edged additional materials
These have a strong wear and tear eect on valves, high-pressure
hose, spray gun and tip. The durability of these parts cane be reduced
appreciably through this.
3. Description of unit
3.1 Airless process
The main areas of application are thick layers of highly viscous
coating material for large areas and a high consumption of material.
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 214 bar (21.4 MPa), the coating material is atomised. This high
pressure has the eect of micro ne atomisation 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 atomisation,
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
In the following there is a short description of the technical
construction for better understanding of the function.
Wagner P20 units are electrically driven high-pressure spraying units.
A gear unit transfers the driving force to a crankshaft. The crankshaft
moves the pistons of the material feed pump up and down.
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 knob controls the volume and the operating
pressure of the coating material.

P20 7
GB
Description of unit
3
4
5
6
7
10
11
12
13
9
1
2
8
3.3 Legend for explanatory diagram P20
1 Spray gun
2 High-pressure hose
3 Return hose
4 Suction hose
5 Frame
6 Drip cup
7 Power cord
8 Relief valve
Lever position vertical – PRIME ( kcirculation)
  Leverpositionhorizontal–SPRAY(p)
9 Pressure control knob
10 ON/OFF switch
11 Circuit breaker
12 Pressure gauge
13 Oil cup for EasyGlide (EasyGlide prevents increased wear of
the packings)
3.4 Explanatory diagram P20

8 P20
GB
Description of unit Starting operation
3.5 Technical data
Voltage: 100~110VoltAC,50/60Hz
Max. current consumption: 9.5A@110VAC
Power cord: 3 x 1.5 mm2– 6 m
Acceptance capacity: 900 Watt
Max. operating pressure: 214 bar (21.4 MPa)
Volume ow at 12 MPa
(120 bar) with water: 1.62 l/min
Max tip size: 0.021 inch – 0.53 mm
Max. temperature of the
coating material: 43°C
Max viscosity: 20.000 MPa·s
Weight: 15.2 kg
Special high-pressure hose: 6,35 mm, 15 m-18 NPSM
Dimensions (L X W X H): 480 x 360 x 405 mm
Vibration: Spray gun does not
exceed 2.5m/s2
Max sound pressure level: 80 dB (A) *
* Place of measuring: 1 m in distance from the unit and 1.6
m above the oor, 12 MPa (120 bar) operating pressure,
reverberant oor.
3.6 Transportation in vehicle
Secure the unit with a suitable fastening.
4. Starting operation
4.1 High-pressure hose, spray gun and
separating oil
1. Screw the pressure gauge (1) to the coating material outlet
(Fig. 2, Item 2).
2. Screw the high-pressure hose (3) to the coating material
outlet on the pressure gauge (Fig. 2, Item 4).
3. Screw the spray gun (5) with the selected tip onto the high-
pressure hose.
4. Tighten the union nuts at the high-pressure hoses rmly so
that coating material does not leak.
5
1
4
2
3
5. Fill the oil cup with EasyGlide (Fig. 3). Do not use too much
EasyGlide, i.e. ensure that no EasyGlide drips into the coating
material container.
Attention
EasyGlide prevents increased wear and tear to the
packings.
4.2 Connection to the mains network
Attention
The unit must be connected to an appropriately-
grounded safety outlet.
Before connecting the unit to the mains supply, ensure that the line
voltagematchesthatspeciedontheunit’sratingplate.
4.3 Cleaning preserving agent when starting-up
of operation initially
1. Immerse the suction tube (Fig. 4 Item 2) return hose (1) into a
container with a suitable cleaning agent.
2. Turn the pressure control knob counterclockwise (3) to
minimum pressure.
3. Open the relief valve (4), valve position PRIME
(kcirculation).
4. Switch the unit (5) ON.
5. Wait until the cleaning agent exudes from the return hose.
 6. Closethereliefvalve,valvepositionSPRAY(pspray).
7. Pull the trigger of the spray gun.
8. Spray the cleaning agent from the unit into an open collecting
container.

P20 9
GB
Spraying Technique
1
2
4
5
3
4.4 Taking the unit into operation with coating
material
1. Immerse the suction tube (Fig. 4, Item 2) and return hose (1)
into the coating material container.
2. Turn the pressure control knob counterclockwise (3) to
minimum pressure.
3. Open the relief valve (4), valve position PRIME
(kcirculation).
4. Switch the unit (5) ON.
5. Wait until the coating material exudes from the return hose.
 6. Closethereliefvalve,valvepositionSPRAY(pspray).
7. Trigger the spray gun several times and spray into a collecting
container until the coating material exits the spray gun
without interruption.
8. Increase the pressure by slowly turning up the pressure
control knob.
Check the spray pattern and increase the pressure until the
atomizationiscorrect.
Always turn the pressure control knob to the lowest setting
withgoodatomization.
9. The unit is ready to spray.
5. Spraying technique
Injection hazard. Do not spray without the tip guard
in place. NEVER trigger the gun unless the tip is
completely turned to either the spray or the unclog
position. ALWAYS engage the gun trigger lock
before removing, replacing or cleaning tip.
The key to a good paint job is an even coating over the entire surface.
Keepyourarmmovingataconstantspeedandkeepthespraygunat
a constant distance from the surface. The best spraying distance is 25
to 30 cm between the spray tip and the surface.
25 - 30 cm
Keepthespraygunatrightanglestothesurface.Thismeansmoving
your entire arm back and forth rather than just exing your wrist.
Keepthespraygunperpendiculartothesurface,otherwiseoneend
of the pattern will be thicker than the other.
Trigger gun after starting the stroke. Release the trigger before
ending the stroke. The spray gun should be moving when the trigger
is pulled and released. Overlap each stroke by about 30%. This will
ensure an even coating.
25 - 30 cm25 - 30 cm
i
If very sharp edges result or if there are streaks in the
spray jet – increase the operating pressure or dilute
the coating material.

10 P20
GB
Handling the high-pressure hose Cleaning the unit (shutting down)
6. Handling the high-pressure hose
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.
Danger of injury through leaking high-pressure
hose. Replace any damaged high-pressure hose
immediately.
Never repair defective high-pressure hoses yourself!
6.1 High-pressure hose
The unit is equipped with a high-pressure hose specially suited for
piston pumps.
i
Only use WAGNER original-high-pressure hoses in
order to ensure functionality, safety and durability.
7. Interruption of work
1. Open the relief valve, valve position PRIME
(kcirculation).
2. Switch the unit OFF.
3. Turn the pressure control knob counterclockwise to minimum
pressure.
4. Pull the trigger of the spray gun in order to release the
pressure from the high-pressure hose and spray gun.
5. Secure the spray gun, refer to the operating manual of the
spray gun.
6. If a standard tip is to be cleaned, see Page 17, Section 12.2.
If a non-standard tip is installed, proceed according to the
relevant operating manual.
7. Depending on the model, leave the suction tube or the
suction hose and return hose immersed in the coating
material or swivel or immerse it into a corresponding cleaning
agent.
Attention
If fast-drying or two-component coating material is
used, ensure that the unit is rinsed with a suitable
cleaning agent within the processing time.
8. Cleaning the unit (shutting down)
A clean state is the best method of ensuring operation without
problems.Afteryouhavenishedspraying,cleantheunit.Underno
circumstances may any remaining coating material dry and harden in
the unit.
The cleaning agent used for cleaning (only with an ignition point
above21°C)mustbesuitableforthecoatingmaterialused.
 • Secure the spray gun, refer to the operating manual of the
spray gun.
Clean and remove tip.
For a standard tip, refer to Page 17, Section 12.2.
If a non-standard tip is installed, proceed according to the relevant
operating manual.
1. Remove suction hose from the coating material.
 2. Closethereliefvalve,valvepositionSPRAY(pspray).
3. Switch the unit ON.
4. Pull the trigger of the spray gun in order to pump the
remaining coating material from the suction hose, high-
pressure hose and the spray gun into an open container.
Attention
The container must be earthed in case of coating
materials which contain solvents.
Caution! Do not pump or spray into a container with
a small opening (bunghole)!
Refer to the safety regulations.
5. Immerse suction hose with return hose into a container with a
suitable cleaning agent.
6. Turn the pressure control knob counterclockwise to minimum
pressure.
7. Open the relief valve, valve position PRIME
(kcirculation).
8. Pump a suitable cleaning agent in the circuit for a few
minutes.
 9. Closethereliefvalve,valvepositionSPRAY(pspray).
10. Pull the trigger of the spray gun.
11. Pump the remaining cleaning agent into an open container
until the unit is empty.
12. Switch the unit OFF.
8.1 Cleaning unit from outside
First of all pull out mains plug from socket.
Attention
Danger of short circult through penetrating water!
Never spray down the unit with high-pressure or
high-pressure steam cleaners.
Wipe down unit externally with a cloth which has been immersed in a
suitable cleaning agent.

P20 11
GB
Cleaning the unit (shutting down)
8.2 Suction lter
i
A clean suction lter always guarantees maximum
feed quantity, constant spraying pressure and
problem-free functioning of the unit.
1. Screw o the lter (Fig. 5) from suction pipe.
2. Clean or replace the lter.
Carry out cleaning with a hard brush and an appropriate cleaning
agent.
8.3 Cleaning Airless spray gun
1. Rinse Airless spray gun with an appropriate cleaning agent.
2. Clean tip thoroughly with appropriate cleaning agent so that
no coating material residue remains.
3. Thoroughly clean the outside of the Airless spray gun.
Intake lter in Airless spray gun (Fig. 6)
Disassembly
1. Pull protective guard (1) forward vigorously.
2. Screw grip (2) out of the gun housing. Remove intake lter (3).
3. Intake lter congested or defective – replace.
Assembly
1. Place intake lter (3) with the long cone into the gun housing.
2. Screw in grip (2) into the gun housing and tighten.
3. Slot in protective guard (1).
Warning:
keep clear
of tip
250bar
max.3600 psi
3
2
1

12 P20
GB
Remedy in case of faults
Type of malfunction
 A. Unitdoesnotstart
 B. Unitdoesnotdrawinmaterial
 C. Unitdrawsinmaterial,butthe
pressure does not build up
D. Coating material exits at the top of
the uid section
E. Increased pulsation at the spray
gun
F. Poor spray pattern
 G. Unitlosespower
Possible cause
1. No voltage applied.
2. Pressure setting too low.
3. ON/OFF switch defective.
 1. ReliefvalveissettoSPRAY(pspray).
2. Filter projects over the uid level and
sucks air.
3. Filter clogged.
4. Suction hose/suction tube is loose, i.e.
the unit is sucking in outside air.
1. Tip heavily worn.
2. Tip too large.
3. Pressure setting too low.
4. Filter clogged.
5. Coating material ows through the
return hose when the relief valve is in
theSPRAY(pspray) position.
6. Packings sticky or worn.
 7. Valveballsworn.
 8. Valveseatsworn.
 1. Upperpackingisworn.
2. Piston is worn.
1. Incorrect high-pressure hose type.
2. Tip worn or too large.
3. Pressure too high.
1. Tip is too large for the coating
material which is to be sprayed.
2. Pressure setting incorrect.
 3. Volumetoolow.
4. Coating material viscosity too high.
1. Pressure setting too low.
Measures for eliminating the malfunction
1. Check voltage supply.
2. Turn up pressure control knob.
3. Replace.
1. Set relief valve to PRIME (kcirculation).
2. Rell the coating material.
3. Clean or replace the lter.
4. Clean connecting points. Replace O-rings if necessary.
Secure suction hose with retaining clip.
1. Replace
2. Replace tip.
3. Turn pressure control knob clockwise to increase.
4. Clean or replace the lter.
5. Remove and clean or replace relief valve.
6. Remove and clean or replace packings.
7. Remove and replace valve balls.
8. Remove and replace valve seats.
1. Remove and replace packing.
2. Remove and replace piston.
1. Only use WAGNER original-high-pressure hoses in order
to ensure functionality, safety and durability.
2. Replace tip.
3. Turn pressure control knob to a lower number.
1. Replace tip.
2. Turn pressure control knob until a satisfactory spraying
pattern is achieved.
3. Clean or replace all lters.
 4. Thinoutaccordingtothemanufacturer’sinstructions.
1. Turn pressure control knob clockwise to increase.
9. Remedy in case of faults

P20 13
GB
Servicing Repairs at the unit
10. Servicing
10.1 General servicing
Servicing of the unit should be carried out once annually by the
WAGNER service.
1. Check high-pressure hoses, device connecting line and plug
for damage.
2. Check the inlet valve, outlet valve and lter for wear.
10.2 High-pressure hose
Inspect the high-pressure hose visually for any notches or bulges, in
particular at the transition in the ttings. It must be possible to turn
the union nuts freely.
11. Repairs at the unit
Switch the unit OFF.
Before all repair work: Unplug the power plug from
the outlet.
11.1 Relief valve
 1. Useadriftpunchof2mmtoremovethegroovedpin(Fig.8,
Item 1) from the relief valve handle (2).
2. Remove the relief valve handle (2) and cam base (3).
 3. Usingawrench,removethevalvehousing(4)fromthepump
manifold (6).
4. Ensure that the seal (5) is seated correctly, then screw the
new valve housing (4) completely into the pump manifold (6).
Tighten securely with a wrench.
5. Align the cam base (3) with the hole in the pump manifold (6).
Lubricate the cam base with grease and slide on the cam base.
6. Bring the hole in the valve shaft (7) and in the relief valve
handle (2) into alignment.
7. Insert the grooved pin (1) to secure the relief valve handle in
position.
175
4
23
6

14 P20
GB
Repairs at the unit
11.2 Inlet and outlet valve
1. Remove the four screws in the front cover and then remove
the front cover.
2. Switch the unit ON and then OFF so that the piston rod is
positioned in the lower stroke position.
Danger of crushing - do not reach with the ngers or
tool between the moving parts.
 3. Unplugthepowerplugfromtheoutlet.
4. Remove the retaining clip from the connecting bend at the
suction hose and pull o the suction hose.
5. Screw o the return hose.
 6. Swiveltheunit90°totherearinordertoworkmoreeasilyon
the material feed pump.
 7. Unscrewtheinletvalvehousing(Fig.9,Item1)fromthepump
manifold.
8. Remove the lower seal (2), lower ball guide (3), inlet valve ball
(4), inlet valve seat (5) and O-ring (6).
9. Clean all the parts with the corresponding cleaning agent.
Check the inlet valve housing (1), inlet valve seat (5) and inlet
valve ball (4) for wear and replace the parts if necessary. If the
worn inlet valve seat (5) is unused on one side, install it the
other way round.
2
3
4
5
6
1
 10. Unscrewoutletvalvehousing(Fig.10,Item7)fromthepiston
(8) with adjusting wrench.
11. Remove the upper ball guide (10), crush washer (9) outlet
valve ball (11), and outlet valve seat (12).
12. Clean all the parts with the corresponding cleaning agent.
Check outlet valve housing (7), outlet valve seat (12), outlet
valve ball (11) and upper ball guide (10) for wear and replace
parts if necessary. If the worn outlet valve seat (12) is unused
on one side, install it the other way round.
13. Carry out installation in the reverse order. Lubricate O-ring
(Fig. 9, Item 6) with machine grease and ensure proper seating
in the inlet valve housing (Fig. 9, Item 1).
9
10
11
12
8
7

P20 15
GB
Repairs at the unit
11.3 Packings
1. Remove inlet valve housing in accordance with the steps in
Chapter 11.2, Page 14.
2. It is not necessary to remove the outlet valve.
 3. Unscrewbothcylinderheadscrews(Fig.11,Item1)from
the pump manifold (2) with a 3/8 inch hexagon socket head
wrench.
4. Slide the pump manifold (2) and piston (3) forward until the
piston is out of the T-slot (10) on the slider assembly (5).
5. Push piston (3) downward out of the pump manifold (2).
 6. Unscrewretainernut(6)fromthepumpmanifold(2)and
remove piston guide (7).
7. Remove upper packing (8) and lower packing (9) from the
pump manifold (2).
5
6
7
8
2
4
1
9
3
10
8. Clean pump manifold (2).
9. Lubricate upper packing (8) and lower packing (9) with
machine grease.
10. Insert upper packing (Fig. 12) with O-ring (1) and protruding
lip (2) downward.
1
2
11. Insert lower packings (Fig. 13) with O-ring (1) and protruding
lip (2) upward.
1
2
12. Insert piston guide (Fig. 11, Item 7) into the retainer nut (6).
Screw retainer nut (6) into the pump manifold (2) and tighten
by hand.
13. Push installation tool (included with the replacement
packings) for the piston (3) from above onto the piston.
14. Lubricate installation tool and piston (3) with machine grease.
15. Guide piston (3) through the lower packings (9) into the pump
manifold(2)frombelow.Usingarubbermallet,lightlytapthe
piston (3) from below until it can be seen above the pump
manifold.
16. Remove installation tool from piston (3).
17. Carefully tighten retainer nut (6) with adjusting wrench.
18. Slide the top of the piston (3) into the T-slot (10) on the slider
assembly (4).
19. Position the pump manifold (2) underneath the gear unit
housing and push up until it rests against the gear unit
housing.
20. Attach pump manifold (2) to the gear unit housing. Ensure
that the pressure sensor does not damage the pressure sensor
seal (10).
21. Screw pump manifold (2) tightly to gear unit housing.
22. Lubricate O-ring (Fig. 9, Item 6) between pump manifold (2)
and inlet valve housing with machine grease. Screw inlet valve
housing to the pump manifold.
23. Push connection bend of suction hose into the inlet valve
housing (Fig. 9, Item 1) and secure with retaining clip. Screw
on return hose and clamp to suction hose.
24. Install front cover.

16 P20
GB
Repairs at the unit
11.4 P20 connection diagram
++
MB
FB
MB
FB
M
F
M
F
M
F
F
F
F
F
F
1
2
3
4
M
F
F
WH6
WH1
WH2
WH7
WH4
WH5
Red
Red
Blue Blue
Brown /
black Blue /
white
Brown /
black Blue /
white
Motor
EMI
lter
Microswitch
Power cord
Switch
Capacitors
Black Black
White
White
Black
Black
Black
Red
Circuit breaker

P20 17
GB
Appendix
12. Appendix
12.1 Selection of tip
To achieve faultless and rational working, the selection of the tip is of the greatest importance.
In many cases the correct tip can only be determined by means of a spraying test.
Some rules for this:
The spray jet must be even.
If streaks appear in the spray jet the spraying pressure is either too low or the viscosity of the coating material to high.
Remedy:Increasepressureordilutecoatingmaterial.Eachpumpconveysacertainquantityinproportiontothesizeofthetip:
The following principle is valid: large tip = low pressure
small tip = high pressure
There is a large range of tips with various spraying angles.
12.2 Servicing and cleaning of Airless hard-metal tips
Standard tips
Ifadierenttiptypehasbeentted,thencleanitaccordingtomanufacturer’sinstructions.
The tip has a bore processed with the greatest precision. Careful handling is necessary to achieve long durability. Do not forget the fact that the
hard-metalinsertisbrittle!Neverthrowthetiporhandlewithsharpmetalobjects.
The following points must be observed to keep the tip clean and ready for use:
1. Turn the relief valve handle fully counterclockwise (kCirculation).
2. Switch o the gasoline engine.
3. Dismount the tip from the spray gun.
4. Place tip in an appropriate cleaning agent until all coating material residue is dissolved.
5. If there is pressure air, blow out tip.
6. Remove any residue by means of a sharp wooden rod (toothpick).
7. Check the tip with the help of a magnifying glass and, if necessary, repeat points 4 to 6.
12.3 Spray gun accessories
Flat jet adjusting tip
up to 250 bar (25 MPa
Tip marking Bore mm
Spray width at about 30 cm
removal of spray object Pressure
100 bar (10 MPa)
Use
Flat jet
adjusting tip
Order No.
15
20
28
41
49
0.13 - 0.46
0.18 - 0.48
0.28 - 0.66
0.43 - 0.88
0.53 - 1.37
5 - 35 cm
5 - 50 cm
8 - 55 cm
10 - 60 cm
10 - 40 cm
Paints
Paints, llers
Paints, dispersions
Rust protection paints
- dispersions
Large-area coats
0999 057
0999 053
0999 054
0999 055
0999 056
Contact protection
for the at jet adjustment tip
Order No. 0097 294
Tip extension
with slewable
knee joint
(without tip)
Tip extension
Length 100 cm Order no. 0096 015
Length 200 cm Order no. 0096 016
Length 300 cm Order no. 0096 017
15 cm, F-thread, Order no. 0556 051 15 cm, G-thread, Order no. 0556 074
30 cm, F-thread, Order no. 0556 052 30 cm, G-thread, Order no. 0556 075
45 cm, F-thread, Order no. 0556 053 45 cm, G-thread, Order no. 0556 076
60 cm, F-thread, Order no. 0556 054 60 cm, G-thread, Order no. 0556 077

18 P20
GB
Appendix
Application Tip Spray Bore Spraying
marking angle inch / mm width mm 1) Order no.
Natural paints 407 40° 0.007/0.18 160 0552407
Clear paints 507 50° 0.007/0.18 190 –––––––
Oils 209 20° 0.009/0.23 145 0552209
 309 30° 0.009/0.23 160 0552309
 409 40° 0.009/0.23 190 0552409
 509 50° 0.009/0.23 205 0552509
 609 60° 0.009/0.23 220 0552609
Synthetic-resin paints 111 10° 0.011/0.28 85 0552111
PVC paints 211 20° 0.011/0.28 95 0552211
 311 30° 0.011/0.28 125 0552311
 411 40° 0.011/0.28 195 0552411
 511 50° 0.011/0.28 215 0552511
 611 60° 0.011/0.28 265 0552611
Paints, primers 113 10° 0.013/0.33 100 0552113
Zinc chromate base 213 20° 0.013/0.33 110 0552213
Fillers 313 30° 0.013/0.33 135 0552313
 413 40° 0.013/0.33 200 0552413
 513 50° 0.013/0.33 245 0552513
 613 60° 0.013/0.33 275 0552613
 813 80° 0.013/0.33 305 0552813
Fillers 115 10° 0.015/0.38 90 0552115
Spray plasters 215 20° 0.015/0.38 100 0552215
Rust protection paints 315 30° 0.015/0.38 160 0552315
 415 40° 0.015/0.38 200 0552415
 515 50° 0.015/0.38 245 0552515
 615 60° 0.015/0.38 265 0552615
 715 70° 0.015/0.38 290 0552715
 815 80° 0.015/0.38 325 0552815
Spray plasters 217 20° 0.017/0.43 110 0552217
Rust protection paints 317 30° 0.017/0.43 150 0552317
Red lead 417 40° 0.017/0.43 180 0552417
Latex paints 517 50° 0.017/0.43 225 0552517
 617 60° 0.017/0.43 280 0552617
 717 70° 0.017/0.43 325 0552717
 219 20° 0.019/0.48 145 0552219
 319 30° 0.019/0.48 160 0552319
 419 40° 0.019/0.48 185 0552419
 519 50° 0.019/0.48 260 0552519
 619 60° 0.019/0.48 295 0552619
 719 70° 0.019/0.48 320 0552719
 819 80° 0.019/0.48 400 0552819
Mica paints 221 20° 0.021/0.53 145 0552221
Zinc dust paints 421 40° 0.021/0.53 190 0552421
Dispersions 521 50° 0.021/0.53 245 0552521
 621 60° 0.021/0.53 290 0552621
 821 80° 0.021/0.53 375 0552821
Rust protection paints 223 20° 0.023/0.58 155 0552223
 423 40° 0.023/0.58 180 0552423
 523 50° 0.023/0.58 245 0552523
 623 60° 0.023/0.58 275 0552623
 723 70° 0.023/0.58 325 0552723
 823 80° 0.023/0.58 345 0552823
Dispersions 225 20° 0.025/0.64 130 0552225
Binder, glue  425 40° 0.025/0.64 190 0552425
and ller paints 525 50° 0.025/0.64 230 0552525
 625 60° 0.025/0.64 250 0552625
 825 80° 0.025/0.64 295 0552825
 227 20° 0.027/0.69 160 0552227
 427 40° 0.027/0.69 180 0552427
 527 50° 0.027/0.69 200 0552527
 627 60° 0.027/0.69 265 0552627
 827 80° 0.027/0.69 340 0552827
 629 60° 0.029/0.75 285 0552629
 231 20° 0.031/0.79 155 0552231
 431 40° 0.031/0.79 185 0552431
 531 50° 0.031/0.79 220 0552531
 631 60° 0.031/0.79 270 0552631
 433 40° 0.033/0.83 220 0552433
 235 20° 0.035/0.90 160 0552235
 435 40° 0.035/0.90 195 0552435
 535 50° 0.035/0.90 235 0552535
 635 60° 0.035/0.90 295 0552635
 839 80° 0.039/0.99 480 –––––––
 243 20° 0.043/1.10 185 0552243
Large-area coatings 543 50° 0.043/1.10 340 0552543
 552 50° 0.052/1.30 350 0552552
1) Spray width at about 30 cm to the object and 100 bar (10 MPa) pressure with synthetic-resin paint 20 DIN seconds.
12.4 Airless tip table
WAGNER without tip without tip
Trade Tip 2 Fthread(11/16-16UN) Gthread(7/8-14UN)
up to 270 bar for Wagner spray guns for Graco/Titan spray guns
(27 MPa) Order no. 0556 042 Order no. 0556 041
Spray gun lter “RED”Spray gun lter “WHITE”
Spray gun lter “YELLOW”Spray gun lter “GREEN”

P20 19
GB
Appendix
12.5 TempSpray
The paint material is heated to the required temperature uniformly by an electric heating element, which is located inside the hose (regulated
from20°Cto60°C).
Advantages:
 • Constantpainttemperatureevenatlowoutsidetemperatures
 • Considerablybetterworkingofhighviscositycoatingmaterials
 • Increasedapplicationeciency
 • Savingsinsolventsduetoreductioninviscosity
 • Adaptabletoallairlessunits
Order No. Description
2311659
2311852
TempSpray H 126 (ideal for lacquer jobs)
Basic unit 1/4“ incl. stainless steel hose, DN6, 1/4“, 10m
Spraypackconsistingof:basicunit(2311659),AirlessgunAG14NPS1/4“,incl.TradeTip2nozzlerholder(F-thread)and
Trade Tip 2 Fine Finish 410
2311660
2311853
TempSpray H 226 (ideal for dispersions/materials with high viscosity)
Basic unit 1/4“ incl. Hose reel, heated hose DN10, 15m, hose 1/4“ DN4, 1m
Spraypackconsistingof:Basicunit(2311660),AirlessgunAG14NPS1/4“,incl.TradeTip2nozzlerholder(F-thread)and
TradeTip2nozzle419
2311661
2311854
TempSpray H 326 (ideal for dispersions/materials with high viscosity)
Basic unit 1/4“ incl. Hose reel, heated hose DN10, 30m, hose 1/4“ DN4, 1m
Spraypackconsistingof:Basicunit(2311661),AirlessgunAG14NPS1/4“,incl.TradeTip2nozzlerholder(F-thread)and
TradeTip2nozzle421
TempSpray H 126
TempSpray H 226
TempSpray H 326

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gAccessories illustration
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