WAGNER Wildcat 18-40 Operational manual

Wildcat 10-70 / 18-40
Puma 28-40 / 15-70
Puma 21-110 / 15-150
Leopard 35-70
Leopard 35-150 / 48-110
Jaguar 75-150
IceBreaker Piston Pumps
Flow rate 40 cm3 – 150 cm3
Version 08/2018
B_06985

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VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 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 Abbreviations 7
1.6 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Types 8
2.1.1 Pneumatic Pumps and Their Spraypacks 8
2.1.2 Special Versions for Acidic Hardeners and Their Spraypacks 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 8
2.4.1 Special Versions for Acidic Hardeners 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 19
5.5.1 Materials of Paint-wetted Parts 19
5.5.2 Recommended Packings 20
5.5.3 Technical Data for Wildcat and Puma 21
5.5.4 Measurements and Connections for Wildcat and Puma 22

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5.5.5 Technical Data for Leopard and Jaguar 23
5.5.6 Measurements and Connections for Leopard and Jaguar 24
5.5.7 Volume Flow 25
5.5.8 Performance diagrams 25
5.6 Operating elements 28
5.6.1 Pressure Regulator Unit 28
5.7 Product Filter and Return Line 28
5.7.1 High-pressure Filter (Option) 28
5.7.2 Relief Combination and Inline Filter up to 270 Bar (Option) 29
5.8 Stroke Count (Option) 29
5.9 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
7.6 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 Maintenance Instructions 40
8.2.3 Safety Checks and Maintenance Intervals 41
8.2.4 Emptying Pump 43
8.2.5 Filling the Empty Pump 44
8.2.6 Cleaning and Replacing the Filter 45
9 TROUBLESHOOTING AND RECTIFICATION 47
10 REPAIR WORK 48
10.1 Repair Personnel 48
10.2 Repair Notes 48
10.3 Tools 48
10.4 Cleaning the Parts After Disassembly 49
10.5 Assembly of the Device 49

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11 FUNCTION TEST AFTER REPAIR WORK 50
12 DISPOSAL 50
13 ACCESSORIES 52
13.1 Wildcat and Puma Pumps 52
13.1.1 Product Outlet and Miscellaneous 52
13.1.2 Product inlet 54
13.1.3 Trolley, Frame and Wall Mount Accessories 56
13.2 Leopard and Jaguar Pumps 58
13.2.1 Product Outlet and Miscellaneous 58
13.2.2 Product inlet 60
13.2.3 Trolley and Wall Mount 62
14 SPARE PARTS 63
14.1 How can spare parts be ordered? 63
14.2 Overview of the Components 64
14.3 Air Motors 68
14.3.1 Wildcat, Puma and Leopard Air Motors 68
14.3.2 Wildcat and Puma Air Motor Regulators 71
14.3.3 Leopard Air Motor Regulator 72
14.3.4 Jaguar Air Motor 73
14.3.5 Jaguar Air Motor Regulator 76
14.4 Connection Sets 77
14.4.1 Connection Sets for 40–70 cm377
14.4.2 Connection Sets for 110–150 cm378
14.5 Fluid Sections 80
14.5.1 Fluid Sections 40 cm3 80
14.5.2 Fluid Sections 70 cm3 82
14.5.3 Fluid Sections 110 cm3 84
14.5.4 Fluid Sections 150 cm386
14.6 Inlet Valve with Valve Depressor 88
14.7 Relief Combination 270 Bar 88
14.8 Straight Inline Filter, 270 bar 89
14.9 Angled Inline Filter, 530 Bar 89
14.10 High-pressure Filter, 270 Bar 90
14.11 High-pressure Filter, 530 Bar 92
14.12 AirCoat Regulator and AirCoat Filter Regulator 94
14.13 Trolley for Wildcat, Puma and Leopard 95
14.14 Trolley for Leopard 48-110 and Jaguar 96
15 EU DECLARATION OF CONFORMITY 97

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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 2333537
Translation of the original operating manual
Language Order No. Language Order No.
French 2333539 English 2333538
Spanish 2333541 Italian 2333540
Japanese 2338088 Russian 2351629
Dutch 2367552 Hungarian 2352104
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 ABBREVIATIONS
Number of pieces Stainless steel
Position Polyethylene
Marking in the spare parts lists Ultra-high molecular weight polyethylene
Order No. Order number Polytetrauorethylene
Double stroke PTFE with graphite
DN Nominal diameter PTFE
PN Nominal pressure Leather
Two components -- --
1.6 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
2.1.1 PNEUMATIC PUMPS AND THEIR SPRAYPACKS
Wildcat Puma Leopard Jaguar
10-70 28-40 35-70 75-150
18-40 15-70 35-150 --
-- 21-110 48-110 --
-- 15-150 -- --
2.1.2 SPECIAL VERSIONS FOR ACIDIC HARDENERS AND THEIR SPRAYPACKS
Wildcat Leopard
10-70 (TC 1.4404) 35-70 (TC 1.4404)
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).
2.4 PROCESSIBLE WORKING MATERIALS
Fluid materials like paints and lacquers.
Application
Water-dilutable products
Solvent-based lacquers and paints
Primers
Epoxy and polyurethane lacquers, phenolic
lacquers
Liquid plastics
Wax-based underside protection
Chemically aggressive products that attack
carbide seats
Special versions for 2K products:
Wildcat 10-70 TC and Leopard 35-70 TC -- -- -- --
recommended limited suitability not suitable -- not compatible with 2K products

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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
Fields of application
Furniture industry
Kitchen manufacturers
Joinery
Window factories
Steel-processing industry
Construction of vehicles
Shipbuilding
recommended limited suitability not suitable
2.4.1 SPECIAL VERSIONS FOR ACIDIC HARDENERS
WARNING
Acidic hardeners!
Risk of burns and injury for skin, tissue and organs.
Observe the lacquer manufacturer's safety data sheets and take prescribed safety
measures.
Special versions:
Wildcat 10-70 TC and Leopard 35-70 TC
Check products for compatibility: see Chapter 5.5.1.
Parts made of stainless steel 1.4404 are labeled with
"1.4404" (see example).
Further information about operation with acidic
hardeners can be found in the operating manual for the
entire system.
1.4404
B_06427
Maximum pressure
for the uid
section's output
Designation "1.4404"
Example of hardener pump
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
Wildcat 10-70, Wildcat 18-40
Puma 28-40, Puma 15-70, Puma 21-110, Puma 15-150
Leopard 35-70, Leopard 35-150, Leopard 48-110
Jaguar 75-150
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 Wildcat, Puma, Leopard and Jaguar 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.

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Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
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.
Air in the pump uid
Ignitable gas mixtures can form if air enters the pump uid.
Prevent the pump from taking in air and running dry.
If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until
the air has escaped.
Air in the pumped uid can be caused by damaged packings.
Avoid operating the pump with damaged packing.
Ensure that the separating agent tank is lled with sucient separating agent.
Periodically check that the pump is working smoothly, paying special attention to
the presence of air in the pumped uid.
Filling and emptying
Ignitable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance and/or repair purposes.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
3.3 TYPE PLATES
Designation
1 Manufacturer and CE Identication
2 Pump type
3 Maximum product pressure
4 Pump ratio
5 Flow rate per double stroke
6 Maximum air inlet pressure
7 Maximum product temperature
8 Model year - serial number
9 Read the operating manual before use
1
2
4
5
6
7
8
9
3
B_06856
Pumpentyp / Pump type
Max. Materialdruck / Fluid pressure
Übersetzungsverhältnis / Ratio
Fördermenge DH / Delivery DS
Max. Luftdruck / Air pressure
Max. Temp. Material / Fluid
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
Wagner International AG
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN
II 2 G Ex h IIB T3/T4 Gb X

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock
Prepare device 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. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform personnel about planned
work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or vapors!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 M).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product hoses / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M.
Ensure that during spraying, persons wear electrically conductive gloves. The
grounding takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M.
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. No smoking.

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Ensure that the pipe joints, hoses, equipment parts and connections are
permanently, technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking
tightness strength of the connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics applications: anyone who belongs to a risk group according to EMF
Directive 2013/35/EU (e.g. those with active implants), must not enter the high-
voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, 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 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 products.

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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
− Disconnect the control unit from the mains.
– In the event of functional faults, remedy the fault as described in the
"Troubleshooting" chapter.
If necessary or at least every 12 months, the liquid ejection devices must be
checked for safe working conditions by an expert (e.g. WAGNER Service Technician)
in accordance with the guidelines for liquid ejection devices (ZH 1/406 and DGUV
100-500 Chapters 2.29 and 2.36).
− For shut-down devices, the check can be postponed until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby, the user can lose his
balance and injure himself when falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
4.2.3 GROUNDING THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the
spray gun handle or the trigger.

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4.2.4 PRODUCT HOSE
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure
generated.
Ensure that the following information can be seen on the high-pressure hose:
− manufacturer
− permissible operating pressure
− date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
− in high-traffic areas
− on sharp edges
− on moving parts
− on hot surfaces
Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), or that the
hoses are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 M.
Suction hoses may not be subjected to pressure.
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 tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.

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4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure
that all equipment and resources (e.g., collection tank, funnel, transport cart) are
conductive or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with units containing aluminium or galvanized and zinc-plated parts. They
may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
−depending upon the coating product used,
−depending on the ushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of
equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External Cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects,
and never spray cleaning agents with a spray gun. Cleaning the device must not
damage it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F:
– Identify the device with a warning label "Warning – hot surface".
Part no.
9998910 instruction label
9998911 protection label
Note: Order the two stickers together.

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4.2.7 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are
assigned to the unit.
Do not use any defective components.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
- Relieve the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
- Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.

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VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3
5 DESCRIPTION
5.1 COMPONENTS
Designation
1 Control housing with integrated silencer
2 Air pressure regulator
3 Ball valve
4 Air motor
5 Compressed air inlet
6 Mounting ange
7 Separating agent cup
8 Product outlet
9 Fluid section
10 Product inlet
11 Grounding connection
B_06986
10
9
8
7
5
3
2
1
4
11
6
5.2 MODE OF OPERATION
The piston pump is driven with compressed air (2). This compressed air moves the air
piston up and down in the air motor (4) and it also moves the associated pump piston up
and down in the uid section (9).
In the control housing (1), the air pressure is redirected at the end of each stroke with the
help of the reversing valve. The working material is sucked up during the upwards stroke
and is continuously conveyed towards the product outlet (8) in both stroke directions.
5.2.1 AIR MOTOR
The air motor (4) with its pneumatic reverse (1) does not require pneumatic oil.
The compressed air is fed to the motor via the air regulator (2) and the ball valve (3).
The air motor (4) is tted with a safety valve in accordance with Chapter 5.3.
5.2.2 FLUID SECTION
The uid section (9) has been designed as a piston pump with exchangeable ball valves.
The hard chrome-plated pump piston runs in two xed packings which are self-adjusting
by means of a pressure spring, thus resulting in a long service life.
Between the air motor (4) and the uid section (9) there is a separating agent cup (7) for
holding the separating agent.

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VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3
5.3 PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Overpressure!
Danger to life from bursting device components.
Never change the safety valve setting.
The air motor is tted with a safety valve. The safety valve has been set and sealed at the
factory. In case of pressures over and above the permissible operating pressure, the spring-
loaded valve, automatically opens and releases the excess pressure.
The control housing is equipped with noise insulation. Never operate the device without
noise insulation.
The connection set is equipped with a coupling cover. Never operate the device without
a coupling cover.
5.4 INCLUDED ITEMS
Pneumatic piston pump
– Fluid section
– Air motor
– Connection set for air motor - uid section
– Air pressure regulator for air motor
The standard equipment includes:
Order No. Designation
1 9992504 Separating agent 250 ml; 250 cc
1 2333537 Operating manual, in German
1 see Chapter 15 Declaration of Conformity
1 see Chapter 1.3 Operating manual in the local language
The delivery note shows the exact scope of delivery. Accessories: see Chapter 13.
5.5 DATA
5.5.1 MATERIALS OF PAINTWETTED PARTS
Paint-wetted part Product
Housing Stainless steel
Piston Stainless steel and hard chrome
Valve balls Stainless steel
Valve seats Carbide
O-rings PTFE
Packings Standard
= PTFE with graphite = Ultra high molecular weight polyethylene
5.5.1.1 MATERIALS OF THE PAINTWETTED PARTS FOR ACIDIC HARDENERS
Special versions for working with acidic hardeners
Pumps Product
Wildcat 10-70 TC 1.4404
Leopard 35-70 TC 1.4404
1.4301, 1.4404, 1.4408, 1.4571
Fluoroelastomer, carbide, Polyethylene, Polytetrauorethylene

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VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3
5.5.2 RECOMMENDED PACKINGS
WAGNER packings for this device:
Product Color
Leather dark brown
PTFE with graphite black
Ultra high molecular weight
polyethylene
transparent
PTFE white
Each product has the following properties, which inuence the packings:
Designation L TG PE T
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 products
Standard combinations
Standard pumps PE / TG
Heavy duty (high-pressure) pumps PE/L
Hardener pumps in 2K systems: PE/T