WAGNER Jaguar 75-150 User manual

Jaguar 75-150
Jaguar 55-200
PROTEC 60-240
Tiger 72-300
Icebreaker Piston Pumps
Protective Coating (PC)
Flow rate 150 cm3 – 300 cm3
Version 02/2018
B_04259

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VERSION 02/2018 ORDER NUMBER DOC 2340282 IceBreaker 150-300 cm3
Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 6
1.4 Service Manual 7
1.5 Continuous-ow heater operating manual 7
1.6 Abbreviations 7
1.7 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Types 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Identication "X" 10
3.3 Type plates 11
4 BASIC SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 13
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Spray Devices 14
4.2.3 Grounding the Unit 14
4.2.4 Product hose 15
4.2.5 Cleaning and Flushing 16
4.2.6 Touching Hot Surfaces 16
4.2.7 Maintenance and Repair 17
4.2.8 Protective and Monitoring Equipment 17
5 DESCRIPTION 18
5.1 Components 18
5.2 Mode of Operation 18
5.2.1 Air motor 18
5.2.2 Fluid section 18
5.3 Protective and monitoring equipment 19
5.4 Included Items 19
5.5 Data 20
5.5.1 Materials of Paint-wetted Parts 20
5.5.2 Recommended Packings 20
5.5.3 Technical Data for Jaguar and PROTEC 21
5.5.4 Dimensions and Connections for Jaguar and PROTEC 22
5.5.5 Technical Data for Tiger 23
5.5.6 Dimensions and Connections for Tiger 24

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5.5.7 Volume Flow 25
5.5.8 Performance diagrams 26
5.6 Operating elements 27
5.6.1 Pressure Regulator Unit 27
5.7 Product Filter and Return Line 27
5.7.1 High-pressure Filter (Option) 27
5.8 PC Air Filter Set (Option) 28
5.9 PC Heater Set (Option) 29
5.10 Feed Pump (Option) 30
6 ASSEMBLY AND COMMISSIONING 31
6.1 Training of Assembly/Commissioning Personnel 31
6.2 Storage Conditions 31
6.3 Installation Conditions 31
6.4 Transportation 31
6.5 Assembly and Installation 32
6.5.1 Ventilation of the Spray Booth 33
6.5.2 Air Supply Lines 33
6.5.3 Product supply lines 33
6.6 Grounding 33
6.7 Commissioning 35
7 OPERATION 36
7.1 Training the Operating Personnel 36
7.2 Emergency Stop 36
7.3 Tasks 36
7.4 Pressure Relief / Work Interruption 37
7.5 Basic Flushing 38
7.5.1 Filling with Working Material 38
8 CLEANING AND MAINTENANCE 39
8.1 Cleaning 39
8.1.1 Cleaning Personnel 39
8.1.2 Decommissioning and Cleaning 39
8.1.3 Long-term Storage 39
8.2 Maintenance 40
8.2.1 Maintenance Personnel 40
8.2.2 Safety instructions 40
8.2.3 Safety Checks and Maintenance Work 41
8.2.4 Emptying Pump 43
8.2.5 Filling the Empty Pump 44
8.2.6 Cleaning and Replacing the High-pressure Filter 45
9 TROUBLESHOOTING AND RECTIFICATION 46
10 REPAIR WORK 47
10.1 Repair Personnel 47
10.2 Repair Notes 47
10.3 Tools 47
10.4 Cleaning the Parts After Disassembly 48
10.5 Assembly of the Device 48

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11 FUNCTION TEST AFTER REPAIR WORK 49
12 DISPOSAL 49
13 ACCESSORIES 50
13.1 Accessories for Product Outlet 50
13.2 Accessories for Product Inlet 51
13.2.1 Suction hose 51
13.2.2 20 Liter Tank 52
13.3 Accessories for Trolley and Wall Mount 52
14 SPARE PARTS 53
14.1 How can spare parts be ordered? 53
14.2 Overview of the Components 54
14.3 Air Motors 56
14.3.1 9" Jaguar Air Motor 56
14.3.2 Air Motor Regulator for Jaguar and PROTEC 59
14.3.3 10" PROTEC Air Motor 60
14.3.4 12" Tiger Air Motor 64
14.3.5 Tiger Air Motor Regulator 67
14.3.6 Connection Sets 68
14.4 Fluid Sections 70
14.4.1 Fluid section 150 cm3 70
14.4.2 Fluid Section 200 cm3 – 240 cm3 72
14.4.3 Fluid section 300 cm3 74
14.5 High-pressure Filter 76
14.6 DN38 suction hose 78
14.7 PC Suction Tube 78
14.8 PC heavy duty trolley 79
14.8.1 PC air lter set 80
14.8.2 PC heater set 81
15 EU DECLARATION OF CONFORMITY 82

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VERSION 02/2018 ORDER NUMBER DOC 2340282 IceBreaker 150-300 cm3
1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.The operating manual is part of the device and must be available
to the operating and service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual. Operating and service personnel should be instructed according to the
safety instructions. This equipment can be dangerous if it is not operated according to the
instructions in this operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential risk.
Non-observance can result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Notice Provides information about particular characteristics and how to
proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.
1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2340281
Translation of the original operating manual
Language Order no. Language Order no.
English 2340282 Russian 2351798
French 2340285 Turkish 2386997
Italian 2340284 Japanese 2359824
Spanish 2340286 Dutch 2367470
Finnish 2391504 Swedish 2391503
Additional languages on request or at: www.wagner-group.com

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1.4 SERVICE MANUAL
The service manual is available in the following languages:
Language Order no. Language Order no.
German 2335993 English 2335994
Additional languages on request or at: www.wagner-group.com
1.5 CONTINUOUSFLOW HEATER OPERATING MANUAL
The operating manual Continuous-ow heater is available in the following languages:
Language Order no. Language Order no.
German 65860 English 65860
French 65860 Italian 65860
Additional languages on request or at: www.wagner-group.com
1.6 ABBREVIATIONS
Number of pieces Double stroke
Position DN Nominal diameter
Marking in the spare parts lists PN Nominal pressure
Order no. Order number Two components
Ultra-high molecular weight polyethylene PTFE
Polytetrauorethylene Stainless steel
PTFE with graphite Polyethylene
: Heavy duty corrosion
protection
Leather
1.7 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Product pressure
generator
Pump or pressure tank.
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as well
as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge,
experience and knowledge of the relevant provisions.
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.

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2 CORRECT USE
2.1 DEVICE TYPES
Pneumatic pump with spraypack:
Jaguar PROTEC Tiger
75-150 60-240 72-300
55-200 -- --
2.2 TYPE OF USE
The device is suitable for processing liquid products like paints and lacquers:
– Non-ignitable products.
– Products in accordance with their classication in explosion class IIB.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).

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VERSION 02/2018 ORDER NUMBER DOC 2340282 IceBreaker 150-300 cm3
2.4 PROCESSIBLE WORKING MATERIALS
Fluid materials like paints and lacquers.
Application /
Water-dilutable products
Solvent-based products
Primers
Epoxy and polyurethane lacquers, phenolic
lacquers
Underside protection, re protection
materials
recommended limited suitability not suitable
NOTICE
Abrasive working materials and pigments!
Greater wear of product-wetted parts.
Use the application-oriented model (ow rate/cycle, product, valves, etc.) as
indicated in Chapter 5.5.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.5.1.
Use suitable combinations of devices (packings, valves etc.)
Wear caused by abrasive working materials is not covered by the warranty.
Typical applications
Application /
Steel-processing industry
Rail vehicle
Shipbuilding
Tank construction
Pipeline construction
Wind energy
recommended limited suitability not suitable
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g., powder are processed.
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device types: IceBreaker piston pump
Jaguar 75-150
Jaguar 55-200
PROTEC 60-240
Tiger 72-300
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
European Communities
Symbol for explosion protection
Device class II
Category 2 (zone 1)
Ex-atmosphere gas
Explosion protection
Ignition protection for non-electrical devices
Explosion group
Maximum surface temperature < 200 °C; 392 °F (without drying
protection active)
Maximum surface temperature < 135 °C; 275 °F (with drying protection
active)
High safety level
There are special instructions to ensure safe operation.
See the following Chapter "Identication X".
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.5.3 and 5.5.5
(Technical data regarding the Jaguar, Tiger and PROTEC pumps).
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
Do not drop the device or components.
Maximum surface temperature
The maximum surface temperature of the piston pump can be reached if it runs dry.
Ensure that the piston pump is lled with sucient working or ushing agent.
Ensure that the separating agent tank is lled with sucient separating agent.
Ignition temperature of the coating product
Ensure that the ignition temperature of the surrounding gases (pumping product,
cleaning agents) is higher than the maximum permitted surface temperature of the
device.
Ambient temperature
The permissible ambient temperature range is: 5 °C to 50 °C; 41 °F to 122 °F.