WAGNER Puma User manual

B_03959
Icebreaker Piston Pumps
Flow Rate 300 cm3 - 600 cm3
Version 02/2013
Translation of the Original
Operating Manual

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OPERATING MANUAL
VERSION 02/2013 ORDER NUMBER DOC 2333548
Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations in the Text 7
2 CORRECT USE 8
2.1 Device Types 8
2.2 Type of Use 8
2.3 Use in an Explosion Hazard Area 8
2.4 Safety Parameters 8
2.5 Processible Materials 9
2.6 Reasonably Foreseeable Misuse 9
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identication 11
3.2 Identication X 11
4 GENERAL SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Equipment 12
4.1.2 Personnel Qualications 12
4.1.3 Safe Work Environment 12
4.2 Safety Instructions for Sta 13
4.2.1 Safe Handling of WAGNER Spray Devices 13
4.2.2 Grounding the Device 14
4.2.3 Material Hoses 14
4.2.4 Cleaning 15
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 15
4.2.6 Touching Hot Surfaces 15
4.3 Use in Areas Subject to Explosion Hazards 16
4.3.1 Safety Regulations 16
4.3.2 Operation without Fluid 17
5 DESCRIPTION 18
5.1 Areas of Application 18
5.1.1 Correct Use 18
5.1.2 Processible Materials 18
5.1.3 Recommended Application Areas 19
5.2 Scope of Delivery 19
5.3 Data 20
5.3.1 Materials of Paint-wetted Parts 20
5.3.2 Recommended Packings 20
5.3.3 Technical Data 21
5.3.4 Measurements and Connections 22
5.3.5 Performance Diagrams 24

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5.4 Function 27
5.4.1 Pump 27
5.4.2 Pressure Regulator Unit 28
5.4.3 High-pressure Filter (Option) 29
5.4.4 Stroke Count (Option) 30
6 ASSEMBLY AND COMMISSIONING 31
6.1 Transportation 31
6.2 Storage 31
6.3 Assembling the Pump 32
6.4 Grounding 33
6.5 Commissioning 35
6.5.1 Safety Instructions 35
6.5.2 Filling with Separating Agent 36
6.5.3 Basic Flushing 37
7 OPERATION 38
7.1 Filling with Working Material 38
7.2 Work 39
7.2.1 Spraying 39
7.2.2 Pressure Relief / Work Interruption 39
7.2.3 Decommissioning and Cleaning 40
7.3 Long-term Storage 40
8 TROUBLE SHOOTING AND RECTIFICATION 41
9 MAINTENANCE 42
9.1 High-pressure Hoses 43
9.2 Decommisioning 43
10 ACCESSORIES 44
10.1 Material Outlet Accessories 44
10.2 Material Inlet Accessories 46
10.3 Trolley, Rack and Wall Mount Accessories 48
11 SPARE PARTS 51
11.1 How Can Spare Parts Be Ordered? 51
11.2 Overview of Components 52
11.3 Air Motors 54
11.3.1 Puma and Leopard Air Motors 54
11.3.2 Puma Air Motor Regulator 57
11.3.3 Leopard Air Motor Regulator 58
11.3.4 Jaguar Air Motor 59
11.3.5 Jaguar Air Motor Regulator 63
11.4 Fluid Sections 64
11.4.1 Fluid Section 300 cm³ 64
11.4.2 Fluid Section 600 cm³ 67
11.5 High-pressure Filter (up to 530 bar; 7687 psi) 70
11.6 High-pressure Filter (up to 270 bar; 3916 psi) 72
11.7 Trolley 74
11.8 "Heavy Duty" Trolley 75
Contents

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12 GUARANTEE AND CONFORMITY DECLARATIONS 76
12.1 Important Notes Regarding Product Liability 76
12.2 Warranty Claim 76
12.3 CE Declaration of Conformity 77
12.4 Reference to German Regulations and Guidelines 77
Contents

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1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and
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 - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in material damage.
Note - provides information about particular characteristics and how to proceed.
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
DANGER
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
WARNING
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
CAUTION
This information warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to operating and service
sta.
Operating and service personnel should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.

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1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No.
German 2333547 English 2333548
French 2333549 Italian 2333550
Spanish 2333551
The corresponding service instructions are available under the
following order number:
Language Order No. Language Order No.
German 2336589 English 2336590
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Double stroke
Stainless steel
Two components

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2 CORRECT USE
2.1 DEVICE TYPES
Pneumatic pump with spraypack:
2.2 TYPE OF USE
2.3 USE IN AN EXPLOSION HAZARD AREA
The device is suitable for processing liquid materials like paints and varnishes in accordance
with their classication into explosion classes IIA or IIB.
The pneumatic pump can be employed in explosion hazard zones (Zone 1).
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the materials recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The pneumatic pump may only be operated under the following conditions:
The operating sta must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must
be observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.

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2.5 PROCESSIBLE MATERIALS
Fluid materials like paints and varnishes.
Abrasive materials and pigments!
Greater wear of parts carrying the material.
Use the application-oriented model (ow rate/cycle, material, valves, etc.) as
indicated in Chapter 5.3.3.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.3.1.
NOTICE
2.6 REASONABLY FORESEEABLE MISUSE
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modications to the pneumatic pump,
processing dry or similar coating materials, and
using defective components, spare parts or accessories other than those described in
Chapter 10 of this operating manual.
The forms of misuse listed below may result in health issues and/or equipment damage:
use of powder as coating material and
incorrectly set values for processing.
Wagner pneumatic pumps are not designed for pumping food.

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2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
paints and cleaning
agents
Handling of paints
and cleaning agents
Skin irritations, Wear protective
clothing
Operation,
allergies Observe safety data
sheets
maintenance,
disassembly
Paint in air outside
the dened working
area
Painting outside the
dened working
area
Inhalation of
substances which
are hazardous to
health
Observe working
and operating
instructions
Operation,
maintenance

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3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 94/9/EC (ATEX 95), the device is suitable for use in areas where
there is an explosion hazard.
European Communities
Symbol for explosion protection
Device class II
Category 2 (Zone 1)
Ex-atmosphere gas
Explosion group
Constructional security
Temperature class: maximum surface temperature < 200 °C; 392 °F
Special Notes (see Chapter 3.2)
3 IDENTIFICATION
3.2 IDENTIFICATION X
Maximum surface temperature
The maximum surface temperature of the piston pump can be reached if it runs dry.
Ensure that the piston pump is lled with sucient working or ushing agent.
Ensure that the separating agent container is lled with sucient separating agent.
Ignition temperature of the coating material
Ensure that the ignition temperature of the coating material is above the maximum
surface temperature.
Ambient temperature
The permissible ambient temperature is: +5 °C to +60 °C; +41 °C to 140 °F.
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.

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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated and repaired only by trained persons.
Ensure that the oor in the working area is electrically conductive in accordance with
EN 61340-4-1 (resistance must not exceed 100 MOhm).
Ensure that all persons within the working area wear electrostatically conductive
shoes. Footwear must comply with EN 20344. The measured insulation resistance may
not exceed 100 MOhm.
Ensurethat during spraying, personswearelectrically conductivegloves.Thegrounding
takes place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5. The
measured insulation resistance may not exceed 100 MOhm.
Paint mist extraction systems must be tted on site according to local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires or
hot surfaces in the vicinity. Do not smoke.

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4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
In the event of functional faults: remedy the fault as described in the "Trouble Shooting"
chapter.
The liquid emitters are to be checked for safe working conditions by an expert (e.g.
Wagner Service Technician) as often as necessary or at least every 12 months, in
accordance with the guidelines for liquid emitters (ZH 1/406 and BGR 500 Part 2
Chapter 2.36).
– For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief / Work Interruptions"
chapter:
– if pressure relief is required.
– if the spraying work is interrupted or stopped.
– before the device is cleaned on the outside, checked or serviced.
– before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Alwaysfollow local regulationsconcerningoccupationalsafetyandaccidentprevention.

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Ensure that the hose material is chemically resistant to the sprayed materials.
Ensure that the material hose is suitable for the pressure generated in the device.
Ensure that the following information can be seen on the high pressure hose:
- Manufacturer
- Permissible operating overpressure
- Date of manufacture.
Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid
in the following places:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the complete high pressure hose must be less than 1 MOhm.
Several liquids have a high expansion coecient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed container, ensure that air or suitable gas can
enter the container to avoid a vacuum being generated in the container itself. Thus a
negative pressure is avoided. The vacuum could implode the container (squeeze) and can
cause it to break. The container would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.3 MATERIAL HOSES
4.2.2 GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. that they are wearing
electrostatically conductive shoes.
Wear electrostatically conductive gloves when spraying. The grounding takes place via
the spray gun handle.

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4.2.6 TOUCHING HOT SURFACES
Touch hot surfaces only if you are wearing protective gloves.
When operating the unit with a coating material with a temperature of > 43 °C; 109.4 °F:
- Identify the device with a warning sticker "Warning - hot surface".
Order No.
9998910 Instruction sticker
9998911 Protection sticker
Note: Order the two stickers together.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the paints, solvents and cleaning agents
being used.
Take the specied protective measures. In particular, wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or a breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot materials.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient
temperature.
To clean, use cloths and brushes moistened with solvent. Never use hard objects or
spray on cleaning agents with a gun.
Preferably, non-combustible cleaning agents should be used.
An explosive gas/air mixture forms in closed containers.
When cleaning devices with solvents, never spray into a closed container.
Only use electrically conductive containers for cleaning liquids.
The containers must be grounded.
4.2.4 CLEANING

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4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
The pneumatic pump may be used in areas subject to explosion hazards. The following
safety regulations must be observed and followed.
4.3.1 SAFETY REGULATIONS
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device against steel or rusty iron.
Do not drop the device.
Use only tools that are made of a permitted material.
Ignition temperature of the pumped material
Check that the ignition temperature of the pumped material is higher than the max.
allowable surface temperature.
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.
Surface spraying, electrostatic
Do not spray system parts with electrostatic.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.

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4.3.2 OPERATION WITHOUT FLUID
Avoid running the pump sucking air (without uid inside). The air, combined with the
vapor of ammable uids, can generate internal areas with an explosion hazard.
Periodically check that the pump is working regularly, paying special attention to the
presence of air in the pumped uid, which may be caused by damaged packings.
Avoid operating the pump with damaged packing.
Ensure that the separating agent container is lled with sucient separating agent.

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5 DESCRIPTION
5.1 AREAS OF APPLICATION
5.1.2 PROCESSIBLE MATERIALS
5.1.1 CORRECT USE
The pneumatic piston pump is suitable for processing liquid materials according to
Chapter 5.1.2.
Application
Water-dilutable materials
Solvent based varnish and
paints
Primers
Epoxy and polyurethane
paints and varnish
Liquid plastics
Wax based underside
protection
Oils
Emulsions
Filled paints
Chemically aggressive
materials that attack carbide
seats
Legend
recommended limited suitability less suitable
Abrasive materials and pigments!
Greater wear of parts carrying the material.
Use suitable combinations of devices (packings, valves etc.)
NOTICE

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5.1.3 RECOMMENDED APPLICATION AREAS
5.2 SCOPE OF DELIVERY
Application
Furniture industry
Kitchen manufacturers
Wood industry
Window factories
Steel-processing industry
Construction of vehicles
Automotive industry
Corrosion protection operations
Original equipment
manufacturer
Contract coating companies
Mechanical engineering
Plastics industry
Municipal enterprises
Legend
recommended limited suitability less suitable
Pneumatic piston pump consisting of:
Fluid section
Air motor
Connection elements
Air pressure regulator for air motor and ball valve
The scope of delivery also includes:
Separating agent 250 ml; 250 cc Order No.: 9992504
Conformity certicate See Chapter 12
Operating manual, German Order No.: 2333547
Operating manual in the local language See Chapter 1
The delivery note shows the exact scope of delivery.
Accessories: see Chapter 10.

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5.3 DATA
5.3.1 MATERIALS OF PAINTWETTED PARTS
5.3.2 RECOMMENDED PACKINGS
WAGNER packings are manufactured in four dierent materials:
Code Material Color
dark brown
black
transparent
Leather
PTFE with graphite
Ultra high molecular weight polyethylene
PTFE white
Each material has the following properties, which inuence the packings:
Mechanical stability poor good good poor
Friction coecient poor very good good very good
Sealing force good* good good good
Chemical resistance poor good very good very good
Temperature resistance good poor - good very good poor
* for abrasive materials
Standard combinations:
Standard pumps
Heavy duty (high pressure) pumps
Hardener pumps in 2-component systems
Housing Stainless steel
Piston Stainless steel and hard chrome
Valve balls Stainless steel
Valve seats Carbide
O-rings PTFE
Packings Standard
= Ultra high molecular weight polyethylene
= PTFE with graphite
Outgoing air containing oil!
Risk of poisoning if inhaled.
Air motor switching problems.
Provide compressed air free from oil and water (Quality Standard
5.5.4 according to ISO 8573.1) 5.5.4 = 40 m / +7 / 5 mg/m³.
WARNING