WAGNER Wildcat 18-40 User manual

II 2G IIB c T3 X
B_00343
"?
B_00365
Wildcat Puma
10-70 28-40
18-40 15-70
Leopard 21-110
35-70 15-150
35-150 Jaguar
48-110 75-150
Tiger
72-300
IceBreaker Pumps
Feed volume 40 ccm - 300 ccm
Edition 01/2012
Translation of the original
Service manual

3
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Languages 5
1.2 Warnings, notes and symbols in these instructions 6
2 GENERAL SAFETY INSTRUCTIONS 7
2.1 Safety instructions for the operator 7
2.1.1 Electrical equipment 7
2.1.2 Personnel qualifications 7
2.1.3 A safe work environment 7
2.2 Safety instructions for staff 7
2.2.1 Safe handling of WAGNER spray units 8
2.2.2 Earth the unit 8
2.2.3 Paint hoses 8
2.2.4 Cleaning 9
2.2.5 Handling hazardous liquids, varnishes and paints 9
2.2.6 Touching hot surfaces 9
2.3 Correct use 9
2.4 Use in an explosion hazard area 10
2.4.1 Correct use 10
2.4.2 Explosion protection identification 10
2.4.3 Identification X 10
2.4.4 German regulations and guidelines 11
3 GUARANTEE AND CONFORMITY DECLARATIONS 12
3.1 Important notes on product liability 12
3.2 Guarantee claim 12
3.3 CE-conformity 13
4 PRODUCT DESCRIPTION 14
4.1 Modular structure 14
4.2 Date 15
4.2.1 Materials of the parts transporting paint 15
4.2.2 Recommended V-packings 15
4.2.3 Technical data 16
4.2.3.1 Technical Data for Wildcat, Puma 16
4.2.3.2 Technical data for Leopard, Jaguar and Tiger 17
5 REPAIRS 18
5.1 Tools, test devices and assembly aids 18
5.2 Dismantling / mounting 19
6 FUNCTIONAL TEST 20
6.1 Field-test preparation 20
6.2 Dead point test 20
6.3 Pump running-in 20
6.4 Testing air motor for air leaks 21
6.5 Testing pump for fluid leaks 21
6.6 Function test 22
6.7 Test data table 23

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40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Contents
7 SPARE PARTS 24
7.1 How to order spare parts? 24
7.2 Over views modules 25
7.2.1 Wildcat, Puma, Leopard and Jaguar 25
7.2.2 Tiger 29
7.3 Air motors 30
7.3.1 Air motors Wildcat, Puma, Leopard 30
7.3.2 Air regulator for air motors Wildcat, Puma and Leopard 34
7.3.3 Air motor Jaguar 35
7.3.4 Regulator for Jaguar 40
7.3.5 Air motor Tiger 41
7.3.6 Regulator for air motor Tiger 46
7.4 Material pumps 47
7.4.1 Material pumps 40 ccm 47
7.4.2 Material pumps 70 ccm 50
7.4.3 Material pump 110 ccm 53
7.4.4 Material pumps 150 ccm 56
7.4.5 Material pumps 300 ccm 59
7.5 High-pressure filter 62
7.5.1 High-pressure filter Wildcat, Puma, Leopard, Jaguar 62
7.5.2 High-pressure filter Tiger 64
7.6 Filter-relief combination 66
7.7 Distributor 67
7.8 Trolley 68
7.9 Trolley„Heavy Duty“ 69
7.10 Lifting trolley pneumatic 70
7.11 Lifting trolley 74
7.12 Wall lifting gear pneumatic 76
7.13 Wall lifting gear 80
8 ACCESSORIES 82
8.1 Accessories for Wildcat and Puma pumps 82
8.2 Accessories for Leopard and Jaguar pumps 89
8.3 Accessories for Tiger 95

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40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
367865 367866
These service instructions contain information on the maintenance and repair of the units.
For further information on technical data and accessories, please see the respective oper-
ating instructions.
The manuals respective are available in the following languages:
WILDCAT, PUMA, LEOPARD, JAGUAR
Language Part No. Language Part No.
German 367850 English 367851
French 367852 Dutch 367853
Italian 367854 Spanish 367855
Danish 367857 Swedish 367856
Portuguese 367859 Turkish 367858
Polish 367864 Greek 2309490
TIGER
Language Part No. Language Part No.
German 370850 English 370851
French 370852 Dutch 370853
Italian 370854 Spanish 370855
Danish 370857 Swedish 370856
The service instructions are available under the following order numbers:
Language: Part No. Language: Part No.
German English

6
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual point out particular dangers to users and equipment
and state measures for avoiding the hazard.
These warning instructions fall into the following categories:
Danger - imminent danger. Non-observance will result
in death, serious injury and serious material damage.
Warning - possible danger. Non-observance can result
in death, serious injury and serious material damage.
Caution - a possibly hazardous situation.
Non-observance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation.
Non-observance can cause material damage.
SIHI_0100_GB
DANGER
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0103_GB
WARNING
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0101_GB
CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0102_GB CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word
points out the hazard level.
The measures for preventing the hazard and its consequences.

7
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL EQUIPMENT
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 A SAFE WORK ENVIRONMENT
2.2 SAFETY INSTRUCTIONS FOR STAFF
Keep these operating instructions to hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Electrical plant and unit
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
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 put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform staff about
planned work, observe electrical safety regulations.
 %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
Make sure that the floor in the area where you are working is derivable in accordance
with EN 61340-4-1.
Ensure that all persons within the working area wear derivable shoes.
Ensure that during spraying,persons wear derivable gloves so that they are earthed via
the handle of the spray gun.
Customer to provide paint mist extraction units conforming 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 flame, glowing wires or hot
surfaces in the vicinity. Do not smoke.
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.

8
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
2.2.2 EARTH THE UNIT
2.2.3 PAINT HOSES
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 unit, in the event of work interruptions and functional faults:
– Switch off the energy/compressed air supply.
– Secure the spray gun against actuation.
– Relieve the pressure from the spray gun and unit.
– By functional faults: Identify and correct the problem, proceed as described in
chapter „Trouble shooting“.
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 a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
Depending on the electrostatic charge and the flow speed of the spray, an electrostatic
charge may occur in the equipment.This could cause a spark or flame on discharging.
Ensure that the unit is earthed for every spraying operation.
Earth the work pieces being painted.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing
derivable shoes.
When spraying, wear derivable gloves to earth yourself via the spray gun handle.
 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 unit.
 Ensure that the following information is visible on the high pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture.
 The electrical resistance of the complete high pressure hose must be less than 1 MOhm.

9
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2.2.4 CLEANING
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
2.2.6 TOUCHING HOT SURFACES
2.3 CORRECT USE
De-energize the unit electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the unit.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient
temperature.
To clean, use only solvent-free cloths and brushes. Never use hard objects or spray on
cleaning agents with a gun.
An explosive gas/air mixture forms in closed containers.
When cleaning units with solvents, never spray into a closed container.
Earth the container.
When preparing or working with paint and when cleaning the unit, follow the working
instructions of the manufacturer of the paints, solvents and cleaning agents being
used.
Take the specified 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 sufficient health and environmental safety: Operate the unit in a spray booth or on
a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot materials.
➞ 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 unit with a warning label that says„Warning - hot surface“.
Order No.
9998910 Information label
9998911 Safety label
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
 /PERATETHEUNITONLYASANENTIREUNIT
 $ONOTDEACTIVATESAFETYEQUIPMENT
 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES

10
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
2.4.1 CORRECT USE
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
2.4.3 IDENTIFICATION X
2.4 USE IN AN EXPLOSION HAZARD AREA
4HEUNITISSUITABLEFORWORKINGLIQUIDMATERIALSINACCORDANCEWITHTHECLASSIlCATIONINTO
EXPLOSIONCLASSES
As defined in the Directive 94/9/EC (ATEX 95), the unit is suitable for use in areas where
there is an explosion hazard.
II 2G IIB c T3 X
CE: Communautés Européennes
Ex: Symbol for explosion protection
II: Unit class II
2: Category 2 (Zone 1)
G: Ex-atmosphere gas
IIB: Explosion group
c: Constructional security
T3: Temperature class: maximum surface temperature < 200 °C; 392 °F.
X: Special Notes (see chapter 2.4.3)
Maximum surface temperature
The maximum surface temperature of the piston pump can be reached if it runs dry.
Ensure that the piston pump is filled with sufficient working or cleaning medium.
Ensure that the separating fluid container is filled with sufficient separating fluid.
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.
Mechanical sparks can form if the unit comes into contact with metal
In an explosive atmosphere:
Do not knock or push the unit against steel or rusty iron.
Do not drop the unit.
Use only tools that are made of a permitted material.

11
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
Cleaning
If there are deposits on the surfaces, the unit may form electrostatic charges. Flames or
sparks can form if there is a discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the unit.
Surface spraying, electrostatic
Do not spray unit parts with electrostatic (e.g. electrostatic spray gun).
2.4.4 GERMAN REGULATIONS AND GUIDELINES
a) BGR 500 Part 2, Chap. 2.36 Working with liquid ejection devices
b) BGR 500 Part 2, Chap. 2.29 Using coating materials
c) BGR 104 Explosion protection rules
d) TRBS 2153 Avoiding ignition risks
e) BGR 180 Setting up for cleaning with solvents for cleaning workpieces with
solvents
f) ZH 1/406 Guidelines for liquid ejection devices
g) BGI 740 Painting rooms and equipment
h) Betr.Sich.V. Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne,or they are
to be found in the Internet.

12
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
3 GUARANTEE AND CONFORMITY DECLARATIONS
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 GUARANTEE CLAIM
As a result of an EC regulation, effective as from January 1, 1990, the manufacturer shall
only be liable for his product if all parts come from him or are approved by him, and if the
devices are properly fitted , operated and maintained.
If other makes of accessory and spare parts are used, the manufacturer‘s liability could be
fully or partially null and void.
The usage of original WAGNER accessories and spare parts guarantees that all safety
regulations are observed.
Full guarantee is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the Purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of guarantee provided is such that the device or individual components of the
device are either replaced or repaired as we think fit. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the unit to a location other
than the address of the purchaser.
We do not provide guarantee for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electro chemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust
paints and similar reduce the service life of valves, packings, spray guns, tips, cylinders,
pistons etc. Signs of wear and tear due to such causes are not covered by this guarantee.
Components that have not been manufactured by WAGNER are subject to the original
guarantee of the manufacturer.
Replacement of a component does not extend the period of guarantee of the device.
The unit should be inspected immediately upon receipt. To avoid losing the guarantee, we
or the supplier company are to be informed in writing about obvious faults within 14 days
upon receipt of the device.
We reserve the right to have the guarantee compliance met by a contracting company.
The services provided by this guarantee depend on evidence being provided in the form
of an invoice or delivery note. If an examination discovers that no guarantee claim exists,
the costs of repairs are charged to the purchaser.
It is clearly stipulated that this guarantee claim does not represent any constraint to statutory
regulations or regulations agreed contractually in our general terms and conditions.
J. Wagner AG

13
40 ccm - 300 ccm.
Wildcat Puma Leopard Jaguar Tiger
10-70 28-40 35-70 75-150 72-300
18-40 15-70 35-150 38-300 17-1200
21-110 48-110 9-1200
15-150 18-300
8-300 8-600
3-600 4-1200
II 2G IIB c T3 X
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
3.3 CE-CONFORMITY
CE Certificate of Conformity
The certificate is enclosed with this product. The certificate of conformity can be reordered
from your WAGNER representative, quoting the product and serial number.
Part number:
Herewith we declare that the supplied version of
Pneumatic pumps and spraypacks
Complies with the following guidelines;
2006/42/EG 94/9/EG Atex-directives
Applied standards, in particular:
DIN EN ISO 12100-1: 2004 DIN EN 809: 2011 DIN EN 12621/A1: 2010
DIN EN ISO 12100-1/A1: 2009 DIN EN 14462: 2005 DIN EN 13463-1: 2009
DIN EN ISO 12100-2: 2004 DIN EN ISO 14121-1: 2007 DIN EN 13463-5: 2004
DIN EN ISO 12100-2/A1: 2009 DIN EN 1127-1: 2008
DIN EN ISO 13732-1: 2008 DIN EN 12621: 2006
Applied national technical standards and specifications, in particular:
BGR 500 Part 2 Chap. 2.29 and Chap. 2.36 BGR 104 TRBS 2153
Marking:
2302304

14
40 ccm - 300 ccm.
B_02326
WILDCAT
Ø 80 mm
H 75 mm
Ø 3 inch
S 3 inch
PUMA
Ø 100 mm
H 75 mm
Ø 4 inch
S 3 inch
WILDCAT
Ø 80 mm
H 75 mm
Ø 3 inch
S 3 inch
PUMA
Ø 100 mm
H 75 mm
Ø 4 inch
S 3 inch
LEOPARD
Ø 150 mm
H 75 mm
Ø 6 inch
S 3 inch
WILDCAT 18-40
PUMA 28-40
WILDCAT 10-70
PUMA 15-70
LEOPARD 35-70
PUMA
Ø 100 mm
H 150 mm
Ø 4 inch
S 6 inch
LEOPARD
Ø 150 mm
H 150 mm
Ø 6 inch
S 6 inch
LEOPARD
Ø 150 mm
H 150 mm
Ø 6 inch
S 6 inch
JAGUAR
Ø 220 mm
H 150 mm
Ø 9 inch
S 6 inch
TIGER
Ø 300 mm
H 150 mm
Ø 13 inch
S 6 inch
PUMA 15-150
LEOPARD 35-150
JAGUAR 75-150
TIGER 72-300
LEOPARD 48-110
PUMA 21-110
40 cm3
300 cm3
150 cm3
70 cm3
110 cm3
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4 PRODUCT DESCRIPTION
4.1 MODULAR STRUCTURE

15
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SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4.2 DATE
4.2.1 MATERIALS OF THE PARTS TRANSPORTING PAINT
Housing Stainless steel
Piston Stainless steel and hard chrome
Valve balls Stainless steel
Valves seats Hard chrome (without Type ESS -> Stainless steel)
O-rings Teflon
V-packings Standard PE/ TG
PE = Polyethylen UHMW
TG = Teflon (PTFE) with graphite
4.2.2 RECOMMENDED V-PACKINGS
Wagner V-packings are manufactured in four different materials:
Code Material Colour
LLeather dark brown
TG Teflon with graphite black
PE Polyethylen UHMW transparent
TTeflon white
Each material has the following properties, which influence the packings:
LTGPET
Mechanical stability low good good low
Coefficient of friction low very good good very good
Sealing capacity good* good good good
Chemical resistance or
reactivity
low good very good very good
Temperature stability good low - good very good low
* for abrasive materials
Standard combinations
Standard pneumatic pumps PE/TG
Heavy duty (HD) pumps PE/L
Hardener pump in 2C-Systems PE/T

16
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SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4.2.3 TECHNICAL DATA
4.2.3.1 TECHNICAL DATA FOR WILDCAT, PUMA
Description Units WILDCAT
10-70
WILDCAT
18-40
PUMA
28-40
PUMA
15-70
PUMA
21-110
PUMA
15-150
Transmission ratio 10 :1 18 :1 28 : 1 15 :1 21:1 15 :1
Flow volume per double stroke (DS) cm³; cc 70 40 40 70 110 150
Maxi. operating over pressure MPa
bar
psi
8
80
1160
14.4
144
2089
22.4
224
3249
12
120
1740
16.8
168
2436
12
120
1740
Maxi. possible strokes in operation DH/min
DS/min
60 60 60 60 60 60
Min. Maxi. incoming air pressure MPa
bar
psi
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
0.25-0.8
2.5-8
36-116
Ø Incoming air (inside threads) Zoll Inch G 1/2“ G 1/2“ G 1/2“ G 1/2“ G 1/2“ G 1/2“
Min. Ø compressed air hose mm; Inch 9; 0.354 9; 0.354 9; 0.354 9; 0.354 9; 0.354 9; 0.354
Air consumption at 0.6 MPa; 6 bar; 87
psi per DS
nl
scf
5.3
0.19
5.3
0.19
8.3
0.29
8.3
0.29
16.5
0.58
16.5
0.58
Sound pressure level at maxi.
permissible air pressure*.
dB(A) 77 77 78 77 78 78
Sound pressure level at 0.6 MPa; 6
bar; 87 psi air pressure*
dB(A) 74 74 74 74 74 74
Sound pressure level at 0.4 MPa; 4
bar; 58.01 psi air pressure*
dB(A) 69 69 69 69 69 69
Ø piston of air motor mm; Inch 80; 3.2 80; 3.2 100; 4 100; 4 100; 4 100; 4
Mat. inlet connection (inside threads) Zoll Inch G 1“ G 3/4“ G 3/4“ G 1“ G 1“ G 1“
Material outlet connection (inside
threads)
Zoll Inch G 3/8“ G 3/8“ G 3/8“ G 3/8“ G 3/8“ G 3/8“
Weight kg; lb 17; 38 15; 33 16; 35 18; 40 28; 62 28; 62
Material pH value pH 3.5 ÷ 9
Maxi. material pressure at pump inlet MPa;bar; psi 2; 20; 290
Material temperature °C; °F +5° ÷ +80°; +41 ÷ +176
Ambient temperature °C; °F +5° ÷ +60° +41 ÷ +140
Allowable sloping position at work <) ° ± 10
* A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005.
Reference measurements have been made by SUVA (Swiss accident insurance institute).
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled
Function problem airmotor
 Provide water-free and oil-free compressed air (quality standard
5.5.4 as per ISO 8573.1) 5.5.4 = 40 μm / +7 / 5 mg/m³.
SIHI_0068_GB

17
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SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
4.2.3.2 TECHNICAL DATA FOR LEOPARD, JAGUAR AND TIGER
Description Units LEOPARD
35-70
LEOPARD
48-110
LEOPARD
35-150
JAGUAR
75-150
Tiger
72-300
Transmission ratio 35 : 1 48 :1 35 : 1 75:1 72 :1
Flow volume per double stroke (DS) cm³; cc 70 110 150 150 300
Maxi. operating over pressure MPa
bar
psi
25
250
3626
37
370
5366
27
270
3916
53
530
7687
53
530
7687
Maxi. possible strokes in operation DH/min
DS/min
60 60 60 60 40
Min. - Maxi. air inlet pressure MPa
bar
psi
0.25-0.71
2.5-7.1
36-103
0.25-0.8
2.5-8
36-116
0.25-0.77
2.5-7.7
36-112
0.25-0.71
2.5-7.1
36-103
0.25-0.74
2.5-7.4
36-107
Ø air inlet (inside threads) Zoll Inch G 1/2“ G 1/2“ G 1/2“ G 1“ G 1“
Min. Ø compressed air hose mm; Inch 13; 0.512 13; 0.512 13; 0.512 25; 0.984 25; 0.984
Air consumption at 0.6 MPa; 6 bar; 87 psi
per DS
nl; scf 18.6; 0.66 37.3; 1.32 37.3; 1.32 79.9; 2.82 170; 6
Sound pressure level at maxi.
permissible air pressure*
dB(A) 77 78 80 83 82
Sound pressure level at 0.6 MPa; 6 bar;
87 psi air pressure*
dB(A) 74 74 78 81 80
Sound pressure level at 0.4 MPa; 4 bar;
58 psi air pressure*
dB(A) 71 69 74 74 75
Ø piston of air motor mm; Inch 150; 6 150; 6 150; 6 220; 8.7 320; 12.6
Mat. inlet connection (inside threads) Zoll Inch G 1“ G 1“ G 1“ G 1“ G 1 1/2“
Mat. outlet connection (inside threads) Zoll Inch G 3/8“ G 3/8“ G 3/8“ G 3/8“ G 3/4“
Weight kg; lb 26; 57 36; 79 36; 79 53; 117 80; 176
Material pH value pH 3.5 ÷ 9
Maxi. material pressure at pump inlet MPa; bar; psi 2; 20; 290
Material temperature °C; °F +5° ÷ +80°; +41 ÷ +176
Ambient temperature °C; °F +5° ÷ +60°; +41 ÷ +140
Allowable sloping position at work <) ° ± 10
* A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005.
Reference measurements have been made by SUVA (Swiss accident insurance institute).
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled
Function problem airmotor
 Provide water-free and oil-free compressed air (quality standard
5.5.4 as per ISO 8573.1) 5.5.4 = 40 μm / +7 / 5 mg/m³.
SIHI_0068_GB

18
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
5 REPAIRS
5.1 TOOLS,TEST DEVICES AND ASSEMBLY AIDS
Standard tools:
Single-head engineers jaw wrench SW13; size 0.51 inch
Single-head engineers jaw wrench SW17; size 0.67 inch
Single-head engineers jaw wrench SW19; size 0.75 inch
Single-head engineers jaw wrench SW22; size 0.87 inch
Hexagon key SW5; size 0.2 inch
Hexagon key SW6; size 0.24 inch
Hexagon key SW13; size 0.51 inch
Screwdriver size 1
Screwdriver size 5
Screwdriver Torx T25
Circlip pliers
Other tools:
Mandrel for removing inlet valve seat ø 18.3 mm; 0.72 inch
Assembly arbor ø 15.4 mm; 0.60 inch for spool and sleeve assembly
Torque wrench
Assembly aids:
Lubricant Beacon EP 2
Anti-sieze paste
Loctite 243 / 542
Separating fluid (Mesamol)
Vaseline
Test devices
Container for testing fluid (approx.20 l; 0.70 cf)
Earth cable
Suction system
High-pressure hose
Pressure gauge
Gun and nozzle

19
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
5.2 DISMANTLING / MOUNTING
See safety regulations in chapter 2!
After disassembly:
Treat all parts with a suitable cleaning agent.
Inspect all parts for traces of wear and replace if necessary.
Change all parts contained in the service set.
SIHI_0004_GB
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the equipment
 Repairs and part replacement may only be carried out by specially
trained staff or a WAGNER service center.
 Before all work on the unit and in the event of work interruptions:

- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
 Observe the operating and service instructions when carrying
out all work.
WARNING
Overpressure!
Risk of injury from bursting components
Never change the safety valve setting.
SIHI_0026_GB
SIHI_0134_ENG
WARNING
Flying parts!
Risk of injury
➞ Before dismounting a part from the fan motor, this must be
disconnected from the compressed air system:
1. Remove air hose.
2. Set spherical valve to vent position.

20
40 ccm - 300 ccm.
SERVICE MANUAL
EDITION 01/2012 PART NO. DOC367866
6 FUNCTIONAL TEST
6.1 FIELD-TEST PREPARATION
Re-assemble pump and other components on trolley or wall-support.Connect suction and
HP hoses, test gauge, spray gun with suitable nozzle.
SIHI_0117_GB
WARNING
Overpressure!
Risk of injury bursting components
➞ Ensure that the pressure range of all the test components used
lies above the maximum operating pressure of the pump.
6.2 DEAD POINT TEST
Fill pump, hose, gun with test fluid:
Use 0.6 MPa; 6 bar; 87 psi input air, allow pump to cycle slowly (hold gun open with nozzle
under fluid level).
Stop pump at change-over points, check for pressure drop.There should be no significant
less of pressure after change-over
Pilot valves may blow at change over.
Aids:
Flow controller
6.3 PUMP RUNNING-IN
Allow pump 0.7-0.8 MPa; 7-8 bar; 101.5-116 psi to cycle with gun open (Raise operating
pressure to maximum).
So pump cycles around 15-20 cycles/min (DS) / min
For 10 minutes
Control cycle rate with tip size. After test, check tightness of fittings see chapter 7.2.
Test conductivity between piston and pump housing:<100 k
Attention, this test is -relevant.
Aids:
Test stand with adjustable flow
Test medium oil
Torque wrench
Ohmmeter