WAGNER ProSpray 22 User manual

®
Operating manual
Airless high-pressure spraying unit
ProSpray 22

24 ProSpray 22
g
Warning!
Never put your fingers, 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. Ensure that the unit is properly earthed. The connection
must take place through a correctly earthed two-pole and earth
socket outlet.
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 safety catch
on the trigger.
3. Switch off unit.
①
②
③
Be safety-conscious!
Attention: Danger of injury by injection!
Airless units develop extremely high spraying pressures.
Danger
Danger

Page
1. Safety regulations for Airless spraying...... 26
2. General view of application ........................ 28
2.1 Application .................................................... 28
2.2 Coating materials .......................................... 28
3. Description of unit ...................................... 28
3.1 Airless process .............................................. 28
3.2 Functioning of the unit .................................. 28
3.3 Legend for explanatory diagram
ProSpray 22 .................................................. 29
3.4 Explanatory diagram ProSpray 22 ................ 29
3.5 Technical data................................................ 30
3.6 Transportation in vehicle................................ 30
4. Starting operation........................................ 30
4.1 High-pressure hose, spray gun and
separating oil ................................................30/31
4.2 Control panel indicators ................................ 31
4.3 Pressure control knob settings...................... 31
4.4 Connection to the mains network.................. 32
4.5 Cleaning preserving agent when
starting-up of operation initially .................... 32
4.6 Taking the unit into operation
with coating material...................................... 32
4.7 Digital Electronic Spray Control (ESC) system 33
5. Spraying technique...................................... 34
6. Handling the high-pressure hose .............. 34
6.1 High-pressure hose ...................................... 34
7. Interruption of work .................................... 34
8. Cleaning the unit (shutting down) ..............34/35
8.1 Cleaning unit from outside ............................ 35
8.2 Suction filter .................................................. 35
8.3 Cleaning Airless spray gun ............................ 35
Page
9. Remedy in case of faults ............................ 36
10. Servicing ...................................................... 38
10.1 General servicing .......................................... 38
10.2 High-pressure hose ...................................... 38
11. Repairs at the unit ...................................... 38
11.1 Relief valve .................................................... 38
11.2 Inlet and outlet valve......................................38/39
11.3 Packings ........................................................39/40
11.4 ProSpray 22 connection diagram.................. 41
12. Accessories and spare parts...................... 42
12.1 Accessories for ProSpray 22 ........................ 42
Accessories illustration for ProSpray 22........ 96
12.2 Spare parts list for main assembly ................ 42
Spare parts diagram for main assembly........ 97
12.3 Spare parts list for fluid section .................... 43
Spare parts diagram for fluid section ............ 98
12.4 Spare parts list for drive assembly ................ 44
Spare parts diagram for drive assembly........ 99
12.5 Spare parts list of frame ................................ 44
Spare parts diagram of frame........................ 100
12.6 Spare parts list for suction system ................ 44
Spare parts diagram for suction system........ 100
13. Appendix ...................................................... 45
13.1 Selection of tip ............................................ 45
13.2 Servicing and cleaning of Airless
hard-metal tips .............................................. 45
13.3 Spray gun accessories .................................. 45
13.4 Airless tip table ............................................ 46
Sales and service companies .............................. 47
Important notes on product liability .................... 101
Warranty.................................................................. 101
CE Declaration of conformity .............................. 103
Contents
ProSpray 22 25
g
Contents

1. Safety regulations for Airless
spraying
All local regulations in force must be observed.
For secure handling of Airless high-pressure spraying
units the following safety regulations are to be ob-
served:
PFlash point
Only use coating materials with a flash
point of 21 °C or above without additional
heating.
The flash point is the lowest temperature
at which vapours develop from the coat-
ing material.
These vapours are sufficient to form an inflammable
mixture over the air above the coating material.
PExplosion protection
Do not use the unit in work places which
are covered to the explosion protection
regulations.
PDanger of explosion and fire through
sources of flame during spraying
work
There may be no sources of flame such as,
for example, open fires, smoking of ciga-
rettes, cigars or tobacco pipes, sparks,
glowing wires, hot surfaces, etc. in the
vicinity.
PDanger of injury through the spray jet
Caution! Danger of injury through injection!
Never point the spray gun at yourself, other persons
or animals.
Never use the spray gun without spray jet safety guard.
The spray jet may not come into contact with any
part of the body.
In working with Airless spray guns, the high spray
pressures arising can cause very dangerous injuries.
If contact is made with the spray jet, coating material
can be injected into the skin. Do not treat a spray in-
jury as a harmless cut. In the case of injury to the
skin through coating material or solvents, consult a
doctor for quick and correct treatment. Inform the
doctor about the coating material or solvent used.
Danger
Danger
Danger
Danger
PSecure spray gun against
unintended operation
Always secure the spray gun when mounting or dis-
mounting the tip and in case of interruption to work.
PRecoil of spray gun
In case of high operating pressure, pulling
the trigger can effect 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.
PRespiratory protection for protec-
tion against vapours of solvents
Wear respiratory protection when spraying.
The user must be provided with a breathing mask.
PPrevention of occupational illnesses
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 prepa-
ration, processing and cleaning units.
PMax. operating pressure
Max. permissible operating pressure for spray gun,
spray gun accessories and high-pressure hose may
not fall short of the maximum operating pressure of
230 bar (23 MPa) stated on the unit.
PHigh-pressure hose (safety note)
Electrostatic charging of spray guns and the high-pres-
sure hose is discharged through the high-pressure hose.
For this reason the electric resistance between the con-
nections of the high-pressure hose must be equal or
lower than 1 MΩ.
For reasons of function, safety and durability
use only original WAGNER high-pressure
hoses.
i
Danger
26 ProSpray 22
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Safety regulations

PElectrostatic charging (formation of
sparks or flame)
Under certain circumstances, electrostat-
ic charging can occur on the unit due to
the rate of flow of the coating material
when spraying. On discharging this can
result in the emergence of sparks or fire.
It is therefore necessary that the unit is always earth-
ed through the electrical installation. The connection
must take place through a correctly earthed two-
pole-and-earth socket outlet.
PUsing unit on construction sites
Connection to the mains only through a special feed
point, e.g. through an error protection installation
with INF ≤30 mA.
PSetting up the unit
When working indoors
Vapors containing solvents may not be al-
lowed to build up in the area of the device.
Setting up the unit on the side a way from
the sprayed object.
A minimum distance of 5 m between the
unit and spray gun is to be maintained.
When working outdoors
Vapors containing solvents may not be allowed to
blow toward the unit.
Note the direction of the wind.
Set the unit up in such a way that vapors
containing solvents do not reach the unit
and build up there.
A minimum distance of 5 m between the
unit and spray gun is to be maintained.
PVentilation when spraying in rooms
Adequate ventilation must be guaranteed for the removal
of the solvent vapours.
PSuction installations
These are to be set-up by the user of the unit according
to local regulations.
PEarthing of the object
The object to be coated must be earthed.
PCleaning units with solvents
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.
Danger
Danger
Danger
Danger
PCleaning the unit
Danger of short circuit through pene-
trating water!
Never spray down the unit with high-pres-
sure or high-pressure steam cleaners.
PWork or repairs on the electrical
equipment
Only have this work carried out by a qualified electrician.
No liability will be taken for incorrect installation.
PWorking on electrical components
Remove the mains plug from the socket for all such
works.
Danger
ProSpray 22 27
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Safety regulations

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 inter-
nally fed Airless roller.
Examples of objects of spraying
Doors, door frames, balustrades, furniture, wooden
cladding, fences radiators (heating) and steel parts, inter-
nal ceilings and walls.
2.2 Coating materials
Processible coating materials
Dilutable lacquers and paints or those containing sol-
vents, two-component coating materials, dispersions, la-
tex paints.
No other materials should be used for spraying without
WAGNER’s approval.
Filtering
Despite suction filter and insertion filter in the spray gun,
filtering of the coating material is generally advisable.
Stir coating material before commencement of work.
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 ex-
actly. 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 effect on valves,
high-pressure hose, spray gun and tip. The durability of
these parts cane be reduced appreciably through this.
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.
i
Pay attention to the Airless quality of the
coating materials to be processed.
i
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 con-
sumption 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 230 bar (23 MPa), the
coating material is atomised. This high pressure has the
effect of micro fine 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 finest
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 techni-
cal construction for better understanding of the function.
WAGNER ProSpray 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 flows under high pressure through
the high-pressure hose to the spray gun. When the coat-
ing material exits from the tip it atomizes.
The pressure regulator controls the volume and the oper-
ating pressure of the coating material.
28 ProSpray 22
g
General view of application Description of unit

ProSpray 22 29
g
Description of unit
3.3 Legend for explanatory diagram ProSpray 22
1 Spray gun
2 High-pressure hose
3 Return hose
4Suction hose
5 Frame
6 Drip cup
7 Power cord
8 Relief valve
Lever position vertical – PRIME ( kcirculation)
Lever position horizontal – SPRAY ( p)
9 ON/OFF switch
10 Control system cover
11 Digital Electronic Spray Control (ESC) system
12 Control panel indicators
13 Pressure control knob
14 Oil cup for EasyGlide (EasyGlide prevents
increased wear of the packings)
3.4 Explanatory diagram ProSpray 22
MPa 23
22.5
MPa
5
4
3
6
14
13
12
9
11 10
7
2
1
8

30 ProSpray 22
g
Description of unit Starting operation
3.5 Technical data ProSpray 22
Voltage: 230 V AC, 50/60 Hz or
120 V AC, 50/60 Hz
Max. current consumption:
230 V AC 7 A
120 V AC 12 A
Power cord: 3 x 1.5 mm2 – 6 m
Acceptance capacity: 1035 Watts
Max. operating pressure: 23 MPa (230 bar)
Volume flow at 120 bar
(12 MPa) with water: 1.89 l/min
Max. tip size: 0.022 inch – 0.56 mm
Max. temperature of the
coating material: 43°C
Max. viscosity: 20.000 MPa·s
Weight: 15.5 kg
Special high-pressure hose: DN 6 mm, 15 m connecting
thread M 16 x 1.5
Dimensions (L x W x H): 480 x 345 x 405 mm
Max. sound pressure level: 80 dB (A) *
* Place of measuring: 1 m in distance from the unit and 1.6
m above the floor, 12 MPa (120 bar) operating pressure,
reverberant floor.
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 high-pressure hose (2) to the coating mate-
rial outlet (Fig. 2, Item 1).
2. Screw the spray gun (3) with the selected tip onto the
high-pressure hose.
3. Tighten the union nuts at the high-pressure hoses
firmly so that coating material does not leak.
EasyGlide prevents increased wear
and tear to the packings.
Attention
3
1
2

4. Fill in EasyGlide (Fig. 3). Do not fill in too much
EasyGlide, i.e. ensure that no EasyGlide drips into the
coating material container.
4.2 Control Panel Indicators
The following is a description of the control panel
indicators.
Pressure Indicator
The pressure indicator shows the current operating
pressure of the sprayer. It has three different
indications: blinking yellow, solid yellow, and solid
green.
Blinking Yellow
When the pressure indicator is blinking yellow, the
sprayer is operating between 0 and 1.4 MPa. A blinking
yellow pressure indicator means:
• The sprayer is plugged in and turned “ON”
• The sprayer is at priming pressure (little or no
pressure)
• It is safe to move the relief valve between positions
•It is safe to change or replace the spray tip
If the pressure indicator begins blinking yellow
when the pressure control knob is set at a higher
pressure and the relief valve is in the SPRAY posi-
tion, either the spray tip is worn or the sprayer is
in need of service/repair.
i
m
a
x
.
2
3
M
P
a
Ü12 M Pa
Ü23 M Pa
SERVICE
P N 0 5 518 8 3
Pressure
Indicator
Service
Indicator
ProSpray 22 31
g
Starting operation
Solid Yellow
When the pressure indicator is solid yellow, the sprayer
is operating between 1.4 and 12 MPa. A solid yellow
pressure indicator means:
• The sprayer is at the proper pressure setting for
spraying stain, lacquer, varnish, and multi-colors
• If the pressure indicator goes to solid yellow when
the pressure is set so that it starts at solid green, it
indicates one of the following:
a. Tip Wear Indicator — when spraying with latex or
at high pressure the solid yellow appears. This
means the tip is worn and needs to be replaced.
b. Tip Too Large — when a tip that is too large for
the sprayer is put in the gun, the pressure
indicator will turn from solid green to solid yellow.
c. Fluid Section Wear — if a solid yellow pressure
indicator appears when using a new tip and the
pressure is set at maximum, service may be
required (worn packings, worn piston, stuck valve,
etc...).
Solid Green
When the pressure indicator is solid green, the sprayer
is operating between 12 and 23 MPa. A solid green
pressure indicator means:
• The sprayer is at the proper pressure setting for
spraying oil-based and latex house paints
• The sprayer is operating at peak performance at a
high pressure setting
Service Indicator
The Service indicator is on when the motor is
commanded to run. This indicator is used by service
centers to troubleshoot motor problems.
4.3 Pressure control knob settings
(Fig. 5)
1. Minimum pressure setting
2. Yellow zone – From minimum pressure to 120 bar
(12 MPa)
3. Green zone – From 120 bar (12 MPa) to 230 bar
(23 MPa)
4 White zone – no pressure generation
5. Blue zone – pulsating pressure for cleaning
m
a
x
.
2
3
M
P
a
Ü12 M Pa
Ü23 M Pa
SERVICE
P N 0 5 518 8 3
1
5
4
2 3

32 ProSpray 22
g
Starting operation
4.4 Connection to the mains network
Before connecting the unit to the mains supply, ensure
that the line voltage matches that specified on the unit’s
rating plate.
4.5 Cleaning preserving agent when
starting-up of operation initially
1. Immerse suction hose (Fig. 6, Pos. 1) and return hose
(2) into a container with suitable cleaning agent.
2. Turn the pressure control knob (3) to the yellow zone
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.
5
3
1
2
4
The unit must be connected to an
appropriately-grounded safety outlet.
Attention
4.6. Taking the unit into operation with
coating material
1. Immerse suction hose (Fig. 6, Pos. 1) and return hose
(2) into the coating material container.
2. Turn the pressure control knob (3) to the yellow zone
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 pres-
sure 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.

Volume Pumped Screen
The Volume Pumped screen
shows the total number of
gallons or liters sprayed by the
sprayer.
To select the Volume Pumped
screen, press the #4 key.
Job Volume Screen
The Job Volume screen allows
the user to reset a gallon
counter to track usage on
specific jobs.
To select the Job Volume
screen, press the #4 key.
Unit Serial # Screen
The Unit Serial # screen shows
the sprayers serial number.
To select the Unit Serial #
screen, press the #4 key.
Timers Screen
The Timers screen shows the
total time the sprayer has been
turned on as well as the total
time the sprayer has been running (pumping).
To select the Timers screen,
press the #4 key.
Job Timers Screen
The Job Timers screen allows
the user to reset the “ON
TIME” and “RUN TIME” to
track time on specific jobs.
To select the Job TImers
screen, press the #4 key. The
screen will toggle between the
timers and a screen that allows the user to reset the timers.
Service Time Screen
The Service Time screen
allows the user to set a service
time interval (in hours). Below
the set time, the screens shows the current amount of hours on
the sprayer. To select the Service TImer screen, press the #4
key.
The screen will toggle between
the service hours and a screen
that allows the user to change
the service time interval.
When the service time interval is set and met by the run hours,
the display will toggle between the "Main screen" and a
"Service Required" screen at sprayer startup. To stop the
toggling, scroll to the "Service Time" screen and either set a
new service time interval or set the service time to "0".
Pressure Screen
The Pressure screen allows
the user to see the current set
point pressure as well as the
actual working pressure.
To select the Pressure screen,
press the #4 key. This screen
is also the Main Screen.
SET MPa 23.0
ACTUAL MPa 22.5
PRESSURE
SELECT-4 MENU-1
SERVICE @ XXXHR
RUN HOURS XX
SERVICE TIME
SELECT-4 MENU-1
ON TIME XXXXX:XX
RUN TIME XXXX:XX
JOB TIMERS
SELECT-4 MENU-1
ON TIME XXXXX:XX
RUN TIME XXXX:XX
TIMERS
SELECT-4 MENU-1
SER # XXXXXXXXXX
PRESS 1 FOR MENU
UNIT SERIAL #
SELECT-4 MENU-1
JOB LITERS XXXX
MENU-1 RESET-3
JOB VOLUME
SELECT-4 MENU-1
LITERS XXXXXX
PRESS 1 FOR MENU
VOLUME PUMPED
SELECT-4 MENU-1
4.7. Digital ESC System
The Digital ESC System increases the functionality of the sprayer.
It is installed directly below the pressure control knob on the
control panel. It consists of a display and four function keys. The
display shows various menu screens that allow the user to
customize and monitor sprayer operation using the function keys.
Function Keys
The function keys are numbered 1–4. Each key is labeled with
an additional function as well.
#1/Menu Key
Pressing the #1 key scrolls through the available menu screens
or performs a function described on the active menu screen.
#2/+ Key
Pressing the #2 key performs a function described on the
active menu screen or increases a value.
#3/- Key
Pressing the #3 key performs a function described on the
active menu screen or decrease a value.
#4/Select Key
Pressing the #4 key selects the active menu screen or
performs a function described on the active menu screen.
Menu Screens
Several menu screens are available for the user to customize
and monitor sprayer operation. They include Main Screen,
User Pre-Sets, Volume Pumped, Job Volume, Unit Serial #,
TImers, Job Timers, Service Time, Pressure, Security Code,
Prime, and Pulse Clean.
Main Screen
The Main Screen is the default
screen for the control system at
sprayer startup. Pressing the #2 key switches between PSI
and MPa units of measure. Press the #1 key to scroll
through the remaining menu screens.
User Pre-Sets Screen
The User Pre-Sets screen
allows the user to set four
different pressure settings and save them for future use. To
select the User Pre-Sets screen, press the #4 key.
Press keys 1 through 4 from
the Select screen to select or
change a pre-set pressure.
Press the #4 key to select the
setting and the Main Screen
will appear.
Press the #2 key to change the
setting. On the following
screen, use the #2/+ key to
increase the setting or the #3/- screen to decrease the setting.
Once the desired setting has been reached, press the #4 key
to set and the Main Screen will appear. To select or change
the remaining three pre-sets, scroll to the User Pre-Sets screen
and repeat the above procedure.
PRE-SET #1 5.2
PRESS +/- TO CHG
MPa SETTING 5.2
SELECT-4 CHG-2
SELECT
PRE-SETS 1-4
USER PRE-SETS
SELECT-4 MENU-1
SET MPa 23.0
ACTUAL MPa 22.5
The pressure control knob overrides the Digital
ESC System settings. Anytime the pressure
control knob is turned, the sprayer pressure will
change accordingly.
i
SET MPa 23.0
ACTUAL MPa 22.5
MENU +–SELECT
4321
Display
Function
Keys
ProSpray 22 33
g
Starting operation

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.
6.1 High-pressure hose
The unit is equipped with a high-pressure hose specially
suited for piston pumps.
7. Interruption of work
1. Open the relief valve, valve position PRIME
(kcirculation).
2. Switch the unit OFF.
3. Turn the pressure control knob into the black zone
until it stops (no pressure generation).
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 45, Sec-
tion 13.2.
If a non-standard tip is installed, proceed according
to the relevant operating manual.
7. Leave suction hose and return hose immersed in
coating material or immerse them into a correspond-
ing cleaning agent.
8. Cleaning the unit (shutting down)
A clean state is the best method of ensuring operation
without problems. After you have finished spraying,
clean the unit. Under no circumstances may any remain-
ing coating material dry and harden in the unit.
The cleaning agent used for cleaning (only with an igni-
tion point above 21 °C) must be suitable for the coating
material used.
If fast-drying or two-component coating
material is used, ensure that the unit is
rinsed with a suitable cleaning agent with-
in the processing time.
Attention
Only use WAGNER original-high-pressure
hoses in order to ensure functionality, safety
and durability.
i
Danger of injury through leaking high-
pressure hose. Replace any damaged
high-pressure hose immediately.
Never repair defective high-pressure
hoses yourself!
Danger
34 ProSpray 22
g
Spraying technique Cleaning the unit (shutting down)
Security Code Screen
The Security Code screen
allows the user to set a four
digit security code to prevent
unauthorized use of the sprayer. If a security code has been
set, the control system display will ask for the code at startup.
If the correct code is entered, the display will show the Main
Screen and the sprayer will operate. If the wrong code is
entered, the display will continue to ask for the correct code
and the sprayer will be disabled. To set or change the security
code, press the #2 key.
Enter the old security code
number to access the screen
that allows the code change. If
the wrong code is entered, the display will continue to ask for
the correct code and the security code cannot be changed.
Enter the new security code.
Once the new code is entered,
the display will automatically
ask that the new code be re-entered for verification. If the same
new code is re-entered, the display will confirm that the new
code has been accepted and return to the Main Screen. If the
new code is re-entered incorrectly, the display will return to the
“Enter New Code Number” screen and the process will repeat.
Prime Screen
The Prime screen appears
when the pressure control knob
is set at the “Min” setting in the
yellow zone.
Clean Screen
The Clean screen appears
when the pressure control knob
is set at the CLEAN position in
the blue zone and the relief valve is in the PRIME position.
5. Spraying technique
Move the spray gun evenly during the spraying process.
Otherwise the spray pattern will be uneven. Carry out the
spray movement with the arm, not with the wrist. Ob-
serve a parallel distance of approx. 30 cm between the
spray gun and the object of spraying. The lateral edge of
the spray jet should not be too distinct. The spray edge
should be gradual in order to facilitate overlapping of the
next coat. Always move the spray gun parallel and at an
angle of 90°to the surface to be coated in order to mini-
mize the paint mist.
If very sharp edges result or if there are
streaks in the spray jet – increase the operat-
ing pressure or dilute the coating material.
i
If there is no action at any menu screen for 30
seconds, the display will go back to the Main
Screen.
i
CLEAN
MPa XXXX
PRIME
To inactivate the security function, enter “1111” at
the “Enter New Code Number” screen (this is the
default code that leaves the sprayer unlocked).
As a result, the Main Screen will appear at sprayer
startup.
i
ENTER NEW CODE
NUMBER
ENTER OLD CODE
NUMBER
If the sprayer is new, no security code is set and
the Main Screen will appear at startup. Also,
when setting a security code for the first time, the
“Enter Old Code Number” screen will not appear.
i
SECURITY CODE
SELECT-4 MENU-1

ProSpray 22 35
g
• Secure the spray gun, refer to the operating manual
of the spray gun.
Clean and remove tip.
For a standard tip, refer to Page 45, Section 13.2.
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.
5. Immerse suction hose with return hose into a con-
tainer with a suitable cleaning agent.
6. Turn the pressure control knob into the blue zone -
pulsating pressure for unit cleaning.
7. Open the relief valve, valve position PRIME (kcircu-
lation).
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
Wipe down unit externally with a cloth which has been
immersed in a suitable cleaning agent.
Danger of short circult through pane-
trating water!
Never spray down the unit with
high-pressure or high-pressure steam
cleaners.
Danger
First of all pull out mains plug from
socket.
Danger
Caution! Do not pump or spray into a
container with a small opening (bung-
hole)!
Refer to the safety regulations.
Danger
The container must be earthed in case of
coating materials which contain solvents.
Attention
Cleaning the unit (shutting down)
8.2 Suction filter
– Screw off the filter (Fig. 7) from suction pipe.
– Clean or replace the filter.
Carry out cleaning with a hard brush and an appropri-
ate cleaning agent.
8.3 Cleaning Airless spray gun
–Rinse Airless spray gun with an appropriate clean-
ing agent.
–Clean tip thoroughly with appropriate cleaning
agent so that no coating material residue remains.
–Thoroughly clean the outside of the Airless spray
gun.
Intake filter in Airless spray gun
Dismounting (Fig. 8)
1. Pull protective guard (1) forward vigorously.
2. Screw grip (2) out of the gun housing. Remove
intake filter (3).
3. Intake filter congested or defective – replace.
Mounting
1. Place intake filter (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
250 bar
max.3600 psi
3
2
1
Aclean suction filter always guarantees
maximum feed quantity, constant spraying
pressure and problem-free functioning
of the unit.
i

36 ProSpray 22
g
Remedy in case of faults
9. Remedy in case of faults
Unit does not start
Unit does not suck in
Unit sucks, but the
pressure does not
build up
Coating material exits
at the top of the fluid
section
No voltage applied.
Pressure setting too low.
ON/OFF switch defective.
Relief valve is set to SPRAY
(pspray).
Filter projects over the fluid
level and sucks air.
Filter clogged.
Suction hose is loose, i.e. the
unit is sucking in outside air.
Tip heavily worn.
Tip too large.
Pressure setting too low.
Filter clogged.
Coating material flows
through the return hose when
the relief valve is in the SPRAY
(pspray) position.
Packings sticky or worn.
Valve balls worn.
Valve seats worn.
Upper packing is worn.
Piston is worn.
Check voltage supply.
Turn up pressure control knob.
Replace
Set relief valve to PRIME (kcirculation).
Refill the coating material.
Clean or replace the filter.
Clean connecting points. Replace O-rings if
necessary. Secure suction hose with retaining clip.
Replace
For selection of a smaller tip, see Tip table on
Page 46.
Turn pressure control knob to a higher number.
Clean or replace the filter.
Remove and clean or replace relief valve.
Remove and clean or replace packings.
Remove and replace valve balls.
Remove and replace valve seats.
Remove and replace packing.
Remove and replace piston.
Type of malfunction Possible cause Measures for eliminating the malfunction

ProSpray 22 37
g
Remedy in case of faults
Increased pulsation at
the spray gun
Poor spray pattern
Unit loses power
Incorrect high-pressure hose
type.
Tip worn or too large.
Pressure too high.
Tip is too large for the coating
material which is to be sprayed.
Pressure setting incorrect.
Volume too low.
Coating material viscosity
too high.
Pressure setting too low.
Only use WAGNER original-high-pressure hoses
in order to ensure functionality, safety and durability.
Replace tip.
Turn pressure control knob to a lower number.
Replace tip, see Tip table on Page 46.
Turn pressure control knob until a satisfactory
spraying pattern is achieved.
Clean or replace all filters.
Thin out according to the manufacturer’s instructions.
Turn pressure control knob to a higher number.
Type of malfunction Possible cause Measures for eliminating the malfunction
Digital ESC System Error Messages
The following error message screens appear whenever the
Digital ESC System detects a problem with the sprayer. Once
a problem occurs and the error message appears, the sprayer
will shut down.
Check Paint Screen (E1)
The Check Paint screen
appears when the pump
pressure drops to a very low
level and the pressure control knob has not been adjusted.
Check the paint level and refill. Restart the sprayer by
following the “Painting” procedure in the Operation section of
this manual.
Check Transducer Screen (E2)
The Check Transducer screen
appears when the transducer
has become disconnected or
is defective. Take the sprayer to a Wagner authorized service
center for repair.
Check Motor Screen (E3)
The Check Motor screen
appears when the motor or
motor sensor is defective.
Take the sprayer to a Wagner authorized service center for
repair.
Low Voltage Screen (E4)
The Low Voltage screen
appears when the sprayer
shuts down because of low
input voltage. Check the power supply and correct the
problem. Restart the sprayer by following the “Painting”
procedure in the Operation section of this manual.
LOW VOLTAGE
CHECK MOTOR
CHECK TRANSDUCER
CHECK PAINT
Before proceeding, follow the Pressure
Relief Procedure outlined previously in this
manual. Additionally, follow all other
warnings to reduce the risk of an injection
injury, injury from moving parts or electric
shock. Always unplug the sprayer before
servicing!
Danger
High Motor Temperature Screen (E5)
The High Motor Temperature
screen appears when the
temperature of the motor has
risen too high. Take the sprayer to a Wagner authorized
service center for repair.
High Control Temperature Screen (E6)
The High Control Temperature
screen appears when the
temperature of the Digital ESC
System has risen too high. Take the sprayer to a Wagner
authorized service center for repair.
High Load Check Mechanism Screen (E7)
The High Load Check
Mechanism screen appears
when the sprayer shuts down
because of high current or when the sprayer goes into current
fold back mode.. Take the sprayer to a Wagner authorized
service center for repair.
Exceeded Pressure Limit Screen (E8)
The Exceeded Pressure Limit
screen appears when the
sprayer pressure exceeds
3300 PSI / 22.8 MPa. Take the sprayer to a Wagner
authorized service center for repair.
Communication Error Screen (E9)
The Communication Error
screen appears when the
Digital ESC System loses
communication with the control panel. Take the sprayer to a
Wagner authorized service center for repair.
COMMUNICATION
ERROR
EXCEEDED
PRESSURE LIMIT
HIGH LOAD
CHECK MECHANISM
HIGH CONTROL
TEMPERATURE
HIGH MOTOR
TEMPERATURE

38 ProSpray 22
g
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 filter 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 fittings. It
must be possible to turn the union nuts freely.
11. Repairs at the unit
11.1 Relief valve
1. Use a drift punch of 2 mm to remove the grooved pin
(Fig. 9, 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.
17
5
6
4
23
Switch the unit OFF.
Before all repair work: Unplug the
power plug from the outlet.
Danger
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 con-
necting rod is positioned in the lower stroke position.
3.
4. Remove the retaining clip from the connecting bend
at the suction hose and pull off the suction hose.
5. Screw off 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. 10, 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
Unplug the power plug from the outlet.
Danger
Danger of crushing - do not reach with
the fingers or tool between the moving
parts.
Danger

ProSpray 22 39
g
Repairs at the unit
10. Unscrew outlet valve housing (Fig. 11, Item 7) from
the piston (8) with adjusting wrench.
11. Remove the upper ball guide (10), 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, in-
stall it the other way round.
13. Carry out installation in the reverse order. Lubricate
O-ring (Fig. 10, Item 6) with machine grease and en-
sure proper seating in the inlet valve housing (Fig. 10,
Item 1).
10
11
12
8
7
11.3 Packings
1. Remove inlet valve housing in accordance with the
steps in Chapter 11.2, Page 38.
2. It is not necessary to remove the outlet valve.
3. Slide the retaining ring (10) up on the connecting rod
(5) to expose the connecting pin (11).
4. Push the connecting pin (11) forward through the
connecting rod (5) and piston (3). The connecting
pin will fall into a recessed area of the gear unit hous-
ing where it can be retrieved.
5. Unscrew both cylinder head screws (Fig. 12, Item 1)
from the pump manifold (2) with a 3/8 inch hexagon
socket head wrench.
6. Pull the pump manifold (2) down off of the gear unit
housing..
7. Push piston (3) downward out of the pump manifold
(2).
8. Unscrew retainer nut (6) from the pump manifold (2)
and remove piston guide (7).
9. Remove upper packing (8) and lower packing (9)
from the pump manifold (2).
5
10
6
7
8
1
2
9
3
11

40 ProSpray 22
g
Repairs at the unit
10. Clean pump manifold (2).
11. Lubricate upper packing (8) and lower packing (9)
with machine grease.
12. Insert upper packing (Fig. 13) with O-ring (1) and pro-
truding lip (2) downward.
13. Insert lower packing (Fig. 14) with the beveled edge
(1) facing upward.
14. Insert piston guide (Fig. 12, Item 7) into the retainer
nut (6). Screw retainer nut (6) into the pump manifold
(2) and tighten by hand.
15. Push installation tool (included with the replacement
packings) for the piston (3) from above onto the pis-
ton.
16. Lubricate installation tool and piston (3) with machine
grease.
17. 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.
18. Remove installation tool from piston (3).
19. Carefully tighten retainer nut (6) with adjusting
wrench.
20. Position the pump manifold (2) underneath the gear
unit housing and push up until it rests against the
gear unit housing. When the connecting pin hole on
the piston rod (3) lines up with the hole in the con-
necting rod (5), insert the connecting pin (11).
21. Slide the retaining ring (10) down over the connecting
pin (11).
22. Attach pump manifold (2) to the gear unit housing.
Ensure that the pressure sensor does not damage
the pressure sensor seal (10).
23 Screw pump manifold (2) tightly to gear unit housing.
24. Lubricate O-ring (Fig. 10, Item 6) between pump
manifold (2) and inlet valve housing with machine
grease. Screw inlet valve housing to the pump mani-
fold.
25. Push connection bend of suction hose into the inlet
valve housing (Fig. 10, Item 1) and secure with retain-
ing clip. Screw on return hose and clamp to suction
hose.
26. Install front cover.
1
1
2

ProSpray 22 41
g
Repairs at the unit
11.4 ProSpray 22 connection diagram
Potentiometer
Motor
Pressure Sensor
Pressure Sensor
Jumper
Plug
WHITE
WHITE
WHITE
BLACK
GREEN
Control Panel
Board
Surge
Suppressor Electronic Pressure
Control (EPC)
J16
AC-Motor
AC-NeutAC-Line
AC-Motor
J9
J2 J1
J12 J7
Switch
Ground
120 V AC
Potentiometer
Motor
Pressure Sensor
Pressure Sensor
Jumper
Plug
BLUE
WHITE
WHITE
BROWN
GREEN
Control Panel
Board
Surge
Suppressor Electronic Pressure
Control (EPC)
J16
AC-Motor
AC-NeutAC-Line
AC-Motor
J9
J2 J1
J12 J7
Switch
Ground
240 V AC

42 ProSpray 22
g
Item Order No. Description
4 9984 573 High-pressure hose DN 4 mm, 7.5 m
with stainless steel nipple
9984 574 High-pressure hose DN 6 mm, 15 m
for dispersion
9984 575 High-pressure hose DN 6 mm, 30 m
for dispersion
5 0034 038 Double socket for coupling high-pressure
hoses
6 0034 950 Metex-Reuse
Reuse for pre-filtering of coating material
in vessel.
Place suction pipe in the reuse.
0034 952 Sieve package (5 pcs) for paint
0034 951 Sieve package (5 pcs) for dispersion
Accessories and spare parts
12. Accessories and spare parts
12.1 Accessories for ProSpray 22
(accessories illustration, see Page 96)
Item Order No. Description
1 0149 040 Spray gun G 08
(aluminium model)
0335 002 Spray gun G 12
(aluminium model)
0257 001 Spray gun AG-09 S
(stainless steel model)
2 0096 004 Pole gun 30 cm
0096 019 Pole gun 100 cm
0096 005 Pole gun 150 cm
0096 006 Pole gun 270 cm
30345 010 In-line roller IR-100
12.2 Spare parts list for main assembly
(spare parts diagram, see Page 97)
Item Order No. Description
1 0551 810 Motor cover
2 0551 440 Screw (4)
39800 308 Cylinder head screw (4)
4 ------------ Power cord, (see below)
5 9800 340 Ground screw
60551 659 Screw (4)
7 0551 720 Pressure control knob
8 0551 721 Digital Electronic Spray Control (ESC)
System
Item Order No. Description
9 0551 722 Digital ESC system cover
10 0551 723 Screw (2)
11 0508 555 Hexagonal bolt (4)
12 0551 645 Control panel
13 0551 811 Fluid section
14 0508 553 Cylinder head screw (2)
AS-3112
0551 726
220V~240V
0508 771
110V~120V
0508 772
220V~240V
0551 727
100V
BS-546 CEE 7/7 NEMA 5-15P