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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VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 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 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.