wiwa 500 Instruction Manual

WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestraße 1 – 3
35633 Lahnau, Germany
Tel. [phone]
Fax [phone]
E-mail: [email protected]
Internet: www.wiwa.de
WIWA Wilhelm Wagner LP
3734A Cook Blvd.
Chesapeake, VA 23323, USA
Tel. [phone]
Toll free [phone]
Fax [phone]
E-mail: [email protected]
Internet: www.wiwa.com
user's handbook Airless Spray Gun
SP500 • 550001 • e • 05.08
Für künftige Verwendung aufbewahren! • Keep for future use! • A conserver soigneusement • Opbevares for fremtidig anvendelse! • Skal
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user's handbook
WIWA Airless Spray Gun
❍ 500 ❍ 500 D ❍ 500 F

2 user's handbook Airless Spray Gun
SP500 • 550001 • e • 05.08
e
1 Contents
First read, then start
Remember that Airless Paint Spra-
ying Equipment works under extreme
pressure and that high levels of spra-
ying pressure are created!
Never hold your nger or hand in front of the ➤
gun and never reach into the spray.
Never point the spray gun towards yourself,➤
other people or other living creatures.
Always pay close attention to the references➤
and specications found in the user's hand-
book!
Before each usage, be especially certain to:
Check the grounding conditions (for the unit➤
and the object to be sprayed).
Check the seal of all connecting and moun-➤
ted parts.
Observe the maximal allowed pressure of ➤
the unit and accessory parts.
Before beginning any work on the equip-
ment, and at any pause during operation, it
is absolutely required to:
Shut down the spraying equipment in ac-➤
cordance with the instructions in the User's
Handbook.
Release the pressure found in the spray gun➤
and hose.
Secure the spray gun.➤
Pay attention to safety!
The accident prevention regulation "Handling of
Coating Materials" (BGV D25) and the guide-
lines covering uid sprayers (ZH1/406) from the
German Employer's Liability Insurance Associ-
ation are to be observed without fail. To ensure
a safe operating environment, the condition of
uid sprayers must be inspected by an expert
every 12 months or sooner, if deemed necessa-
ry. A written record of the inspection results is to
be kept.
Remaining paint and solvent are to be dispo-
sed of according to legal regulations. This also
applies for environmently friendly water based
lacquer or enamel systems.
In case of injuries, consult a physician or go to
the next hospital without delay. If paint/material
or solvent has gone into the skin, the physician
has to be informed about the type of paint/ma-
terial or the solvent applied. Therefore, always
ensure that the product specication sheet, with
address and telephone number of the manufac-
turer, is at your disposal!
1.1 Preface
This User’s Handbook must always
be available to operating staff!
The operating authority of the equip-
ment must ensure that a user`s hand-
book is available to the operator in a
language which he understands.
Dear customer!
Thank you for your decision to purchase
equipment.
In the user’s handbook, you can nd all infor-
mation required for the proper handling of your
Spray Gun. However, for safe operati-
on, there are further essential details which you
should adhere to:
Please read and observe the guidlines valid for
your country.
In Germany, the "Richtlinien für Flüssigkeits-
strahler" (Guidelines for Fluid Sprayers) publis-
hed by: Hauptverband der Gewerblichen Be-
rufsgenossenschaften (Industrial Employer's
Liability Insurance Association) are valid.
Manufacturer’s notes and operating guidelines
for coating and pumping materials should be
observed at all times.
No method of operation should be exercised
which impairs the safety of products
and the operating personnel.
We wish you much success and excellent work-
ing results when using your Spray
Gun.
WIWA Wilhelm Wagner GmbH & Co. KG

user's handbook Airless Spray Gun 3
SP500 • 550001 • e • 05.08
e
Copyright
The copyright for this user’s handbook remains with WIWA
Wilhelm Wagner GmbH & Co. KG. The user’s handbook is
intended for preparation, operating and maintenance staff. It
contains technical regulations and drawings which may not, in
whole or in part, be copied, distributed or be used by or passed
on as information to others for whatever purposes without
authorisation.
WIWA WILHELM WAGNER GmbH & Co. KG
Gewerbestraße 1-3 • 35633 Lahnau
Tel.: [phone] • Fax.: [phone]
Note:
We reserve the right to make changes to the contents of this
handbook. WIWA Wilhelm Wagner GmbH & Co. KG. is not
liable for any mistakes found in this documentation or any
assessable damages resulting from it's delivery or usage, as
far as legally allowed.
The manufacturer reserves the right to make technical changes
in order to improve the products, which may not be documen-
ted in this user’s handbook.
Contents 1
1.2 Table of contents
1 Contents 2
First read, then start 2
1.1 Preface 2
1.2 Table od contents 3
2 Safety 4
2.1 Description of symbols 4
2.2 Dangers arising from the equipment 4
2.3 Spray gun applications 5
2.4 Modications and emissions 6
2.5 Sources of danger 6
2.6 Operating staff 7
2.7 Installation site 8
2.8 Behavior in case of emergency 8
2.9 Protective equipment 9
2.10 Service and auxiliary materials 9
3 Equipment description 11
3.1 Spray gun models 11
3.2 Spray gun accessories 12
4 Set-up for operation 14
Installation of the spray tip 14
Installation of the lter insert 14
Connection of the material hose 14
5 Operation 15
Working pressure 15
Spraying - painting 15
Pausing while working 15
Spraying tips 15
Cleaning 15
6 Operational disturbances
and trouble-shooting 17
7 Maintenance and repair 18
7.1 Packing and needle exchange 18
7.2 Pressure unit and handle grip 19
8 Appendix 21
8.1 Declaration of conformity 21
8.2 Technical data and spare parts lists 22

4 user's handbook Airless Spray Gun
SP500 • 550001 • e • 05.08
e
2.1 Description of symbols
The signs and symbols used in this manual
have the following meaning:
Note
marks a section of text which is espe-
cially relevant to safety. Special attention
should be paid to this section and it's
contents strictly observed.
WARNING
marks a situation which could be dan-
gerous. If not observed,death or very
serious injuries could result.
DANGER OF EXPLOSION
marks a situation, where there is danger
of explosion.
Observation of this information is absolu-
tely essential.
ELECTRICAL VOLTAGE
marks a situation, where there is a dan-
ger of explosion through an electostatic
charge.
Observation of this information is absolu-
tely essential.
USE EAR PLUGS
For health reasons, it is very important to
pay attention to this warning.
USE BREATHING PROTECTION
For health reasons, it is very important to
pay attention to this warning.
WEAR PROTECTIVE GLOVES
To prevent burns, wear protective gloves
with lower arm protection.
Observation of this information is essen-
tial.
HEALTH DANGER
marks materials which are hazardous to
your health.
Observation of this information is absolu-
tely essential.
FIRST AID
In case of injuries or accidents, these in-
structions should be absolutely adhered
to.
2.2 Dangers arising from the
equipment
This spray gun was designed and built in ac-
cordance with all safety aspects. It corresponds
with the present standards of technical regulati-
ons and current rules for accident prevention.
It left the factory in perfect condition, insuring
a high level of safety. However, the following
dangers exist if operated incorrectly or used
inappropriately:
to life and limb of operator➤ or third personso
for the machine and other property belonging➤
to owner of machine
for the efcient working of the machine ➤
All personnel involved in the starting, operation,
and maintenance of the spray gun and associ-
ated equipment must read the following notes
and observe them. It is a matter of their safety!
We recommend that the operation management
have this conrmed in writing.
Additionally, please pay attention to the
following:
Please, read and observe the guidlines valid for
your country.
In Germany the "Richtlinien für Flüssigkeits-
strahler" (Guidelines for Fluid Sprayers) pub-
lished by: Hauptverband der Gewerblichen
Berufsgenossenschaften (Industrial Employer's
Liability Insurance Association) are valid.
We recommend adding a copy of all guidelines
and accident prevention regulations into the
user's manual.
Manufacturer’s notes and operating guideli-
nes for coating material and pumping material
should be observed at all times.
2 Safety

user's handbook Airless Spray Gun 5
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Safety 2
In principle, no method of working should be
exercised which impairs the safety of
products or the operating personnel.
2.3 Spray Gun Applications
This spray gun is suitable for the Airless-spray-
ing, transfer and injection of sprayable materi-
als.
The maximum allowable
operating pressure for the
500 Series Spray
Gun is 500 Bar.
Each Spray Gun has
a label showing the maximum
allowable operating pressure
(picture 2.3.1)
Using this equipment in areas requiring pro-
tection from explosions
Marking: II 2G cT4
This equipment fullls the explosion-proof
requirements found in the guideline 94/9/EC
for the type of explosion, equipment cata-
gory and temperature class found on the
nameplate).
This equipment is able to be installed in areas
requiring Zone I explosion protection. Due to
the possibility that explosive gases and over-
spray may be created, this unit is to be consi-
dered as Group II, Equipment Catagory 2G.
The ash point for the materials being spray-
ed, as well as the solvent being used, must be
above 200°C.
When operating this equipment, the User‘s
Handbook must be followed closely.
The required inspection and maintenance inter-
vals must be adhered to strictly.
All information found on the unit‘s signs or
plates must be adhered to and not excee-
ded. Do not allow this unit to be overloaded.
It is the responsibility of the operator of this
equipment to determine the explosion risk
(zone determination according to EC regulation
94/9/EC, Appendix II, Nr. 2.1-2.3) in the area
of usage, in accordance with local regulatory
authority guidelines. Furthermore, it is the
responsibility of the operator on-sight to
check and ensure that the technical speci-
cations and markings according to ATEX
are compliant with local requirements.
Please observe that some components have
their own nameplate with separate markings ac-
cording to ATEX. The marking with the lowest
rating for explosion protection becomes
valid for the entire system. If the intended ap-
plication could lead to injury of personnel if this
equipment malfunctions, on-sight precautions
and preventive measures must be implemented
If this equipment appears to be malfunctio-
ning or behaving strangely during operati-
on, the unit must be shut down immediately
and Customer Service contacted as
soon as possible.
It must be ensured that the unit is grounded
either separately or together with the equipment
it is mounted to (maximum resistance 106 Ω).
Other usage is not in accordance with regula-
tions. Before equipment is used for
other purposes or with other materials, and
therefore not according to the regulations, per-
mission should be obtained from the manufac-
turer as the guarantee is otherwise invalid. The
observation of technical documentation and the
compliance with specied operational, mainte-
nance and starting guidelines are manditory in
accordance with the valid regulations.
picture 2.3.1

6 user's handbook Airless Spray Gun
SP500 • 550001 • e • 05.08
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2.4 Modications and emissions
Rebuilds and changes
For safety reasons, it is not allowed to carry
out rebuilds or changes without authorization.
Protective equipment may not be dismounted,
altered or neglected.
If using components which are not produced
or delivered by , warranty coverage is
negated as well as liability.
The spray gun may only be operated within the
prescribed limits and machine parameters.
Danger caused by attachments and spare
parts
If you use original attachments and original
spare parts from , the compatability
with our equipment is guaranteed. It is, howe-
ver, essential that the safety regulations of the
attachments and spare parts are observed. You
can nd these safety regulations in the User’s
Handbook located with the spare parts lists.
If you use attachments and spare parts from
another source, cannot guarantee the
safety of the entire system.
In this case, our guarantee does not cover any
damage or injury caused by such attachments
and spare parts.
Emissions
It is possible for solvent vapours to occur,
depending on the materials used. Therefore,
please ensure the workplace is sufciently ven-
tilated in order to avoid damage to health and
property. Always observe the processing infor-
mation given by the material manufacturer.
The spray gun itself produces no noise. Ple-
ase observe the maximum noise level of the
spraying equipment.
2.5 Sources of danger
Pay attention to the following
notes:
The spray gun must meet or exceed the➤
maximum operational pressure of the paint
spraying equipment being used.
Because of the electrostatic charges produ-➤
ced by spraying, the spray gun may only be
mounted to conductive hoses. All original
hoses are conductive and matched
to spray equipment.
Please, always use an open container. Due➤
to possible electro static charges, it is impe-
rative to ensure that the spraying gun has
contact to the container walls when working
with metal containers.
It is possible for a static charge to occur due➤
to the high ow speeds during the airless
spraying procedure. Static charges can lead
to re and explosions.
➤ Therefore, the complete unit (including
the spray gun) and the object to be
sprayed must be grounded properly.
The original airless spray machine
is tted with a ground cable as standard. If
lost or defective, please, order an immediate
replacement (order no.: 0474487).
Never point the spray gun towards yourself,
other people or other living creatures.
➤ Never point the spray gun to-
wards yourself, other people or
other living creatures.
Never➤ hold your nger or hand in front of the
gun and never reach into the spray.
Hold the spray gun securely, as the high➤
operating pressure can result in severe kick-
back.
Never➤ try to seal leaks on joints and high
pressure hoses with your hand or by binding
the spot. Should a leak occur, the whole
system (gun, hose, pressure lter, pump,
etc.) are to be depressurized immediately.
Defective parts are to be replaced.
The spray gun is to be secured and the safe-➤
ty device checked during every interruption
while working, regardless how short.
2 Safety

user's handbook Airless Spray Gun 7
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Safety 2
➤ If working with heated materials, al-
ways wear the proper hand protection.
BURN DANGER!
The entire system is to be depressurized ➤
upon work interruption or shift end. Read
and follow the instructions in the User's
Handbook for the spray equipment. The
spray gun should be opened shortly after
the equipment is shut down to release any
pressure in the spray lines.
The entire system is to be depressurized ➤
before maintenance and cleaning work is
carried out. Read and follow the User's
Handbook for the spray equipment.
Remove the spray gun from the spraying
equipment before carrying out this work.
Never➤ spray solvents or materials containing
solvents into a narrow-necked can or barrel
with bung hole.
DANGER OF EXPLOSION!
➤ Always use an open container. Due
to possible electrostatic charges, it
is imperative to ensure that the
spray gun is grounded to the contai-
ner walls when working with metal
containers.
Never dip a hot spray gun into solvent.➤
DANGER OF EXPLOSION!
Never use this equipment outdoors during a➤
thunderstorm.
In closed or pressurised systems where➤
aluminium or galvanised parts come into
contact with the solvent, dangerous chemical
reactions can occur if 1.1.1-Trichlorethylene,
Methylene Chloride or other solvents contai-
ning halogenated chlorinated hydrocarbons
(CFCs) are used. If you wish to work with the
above solvents, or with lacquers and paints
which contain them, we recommend you
contact either the customer service of your
distributor or directly.
Smoking, open ames or any other possible ➤
ignition sources are not allowed anywhere
near the area of operation
A list of materials used in the construction of➤
the spray gun can be provided upon request
in order to determine the compatibility with
the materials to be sprayed.
2.6 Operating staff
Authorised Operators
People under the age of 16 should not operate
this equipment. The management in charge of
the operation of the spray gun must make the
User’s Handbook available to the operator and
must make sure that he has read and under-
stood it. Only then may the system be put into
operation.
We recommend that the manager has this
conrmed in writing.
The operator of the spray gun is required to re-
port any changes in the spray gun which might
affect its safety supervisor, as he must ensure
that the spray gun functions safely.
The responsibilities for the different activities
on the system must be laid down clearly and
adhered to. No unclear responsibilities may
remain as these could endanger the safety of
the user.
The operator must make sure that only autho-
rised persons work on the equipment. He is re-
sponsible for third parties in the working vicinity
of the system.
The operator of the equipment is required to
repeat instruction about dangers and safety
measures at regular intervals (at least once a
year, for young persons twice a year).
Personal protective equipment
We call to your attention that the valid guide-➤
lines and requirements in accordance with
work surroundings (mining, closed areas
etc.) must be absolutely adhered to.
Please wear the prescribed protective➤
clothing at all times, as solvent vapours
and solvent splashes cannot be completely
avoided.
➤ Although spraying fog is kept to a
minimum when the correct pres-
sure setting and proper method of
operation are observed, the operat-
ing painter should wear a protective
breathing mask.

8 user's handbook Airless Spray Gun
SP500 • 550001 • e • 05.08
e
➤ To avoid burns, use protective gloves
when working with heated materials.
➤ Never use solvent or other materials
which present a health hazard for
cleaning skin. Only suitable skin pro-
tective, skin cleansing and skin care.
2.7 Installation site
Safety measures at installation site
Ensure there is sufcient ventilation at the ➤
workplace to prevent damage to health and
property. Observe the manufacturer’s pro-
cessing instructions at all times.
Despite the fact that no legal regulations➤
exist covering the low-fog airless spraying
method, dangerous solvent fumes and par-
ticles of paint should be removed by vaccu-
um.
Protect all objects in the vecinty of the ob-➤
jects to be sprayed from damage by over-
spray.
The owner / operator of this equipment is ➤
required to ensure that proper protection
against lightning strikes is available.
Comply strictly with the current rules
for accident prevention.
2.8 Behavior in case of emergency
Leaks
If leaks occur in the spray gun, the
equipment must be shut down imme-
diately and the entire system depres-
surized:
Follow the instructions in the User's Handbook
for the spraying equipment.
Replace defective parts immediately.
Injury
➤ Should an injury occur through con-
tact with liquid spray, we recommend
a doctor be called immediately.
Inform the doctor of the material sprayed➤
(e.g.paint) and the solvent (thinner). Have
the product data sheet at hand (address
and telephone number of supplier or ma-
nufacturer, name of material and material
number).
Know the local emergency phone numbers.➤
Be familiar with the rst-aid measures.➤
Fires
Read the instructions for re alarm and es-➤
cape routes put up in your factory.
Know the local emergency phone numbers.➤
Know the location and operation of re ➤
alarms, re extinguishers and sprinkler in-
stallations.
Take care that sufcient information for re ➤
prevention is provided.
Do not use any other extinguishing agents➤
than those which are prescribed by the ma-
nufacturer of the materials.
2 Safety

user's handbook Airless Spray Gun 9
SP500 • 550001 • e • 05.08
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Safety 2
2.9 Protective equipment
The safety devices on the spray gun
are pressribed by law and may not be
removed for any reason.
All equipment is delivered with the following
safety devices (picture 2.10.1):
1. Finger Guard (Typ Guard)
Spray Gun Safety2.
Hand Guard3.
Spray Gun safety
By turning the safety lever to the horizontal
position, the spray gun is secured against acci-
dental operation.
The spray gun safety must be engaged upon
each work interruption, however short.
Hand Guard
The hand guard protects against accidental
operation of the spray gun, for example, by
contact with the workpiece or through dropping
the spray gun.
Tip Guard
The tip guard prevents damage to the tip, for
example, through dropping the spray gun.
Additionally, it protects the hand against contact
with the spray stream directly at the tip.
To prevent serious injury and
property damage, never operate
the spray gun without the tip
guard.
Pict. 2.10.1
1 2
3
All protection devices must be checked!
Before each commissioning of the spray gun!➤
Before beginning work on or with the spray➤
gun!
After all aligning work!➤
After cleaning and servicing!➤
After maintenance and repair!➤
Check list for inspecting the protection
features when the unit is in a depressurized
state
The safety lever on the Airless spray gun➤
should be checked for proper function.
The tip guard should be checked for tight-➤
ness.
The hand guard should be checked for da-➤
mage and for proper mounting.
If a protective device is not fully
operative, or another defect is de-
tected on the spray gun. interrupt
the compressed air supply to the
spray gun immediately and open
the drain valve.
The machine may be restarted only
if perfect function is restore
2.10 Service and
auxiliary materials
Alignment, servicing, maintenance and re-
pair of the spray gun
Alignment when changing production, as well
as servicing and cleaning, may be carried out
by trained operating personnel only.
Maintenance and repair may be carried out by
trained, qualied personnel only.
Before beginning such work, the spray equip-
ment must be turned off and the pressure relea-
sed. Follow the instructions in the User`s Guide
for the spray equipment.
Operate the spray gun again momentarily to

10 user's handbook Airless Spray Gun
SP500 • 550001 • e • 05.08
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release any residual pressure before the spray
gun is removed from the spray equipment.
Proceed carefully! Residual pressure could be
present!
In any case, the function of all protective de-
vices, as well as perfect function of the machi-
ne, must be checked after completion of the
work.
Handling of auxiliary materials
When handling auxillary materials suchas
paint, solvents, oils, grease and other chemical
substances, comply with the safety and dosing
instructions of the manufacturer and the gener-
ally applicable regulations.
Leftover solvents, oils, grease and other chemi-
cal substances must be collected according to
the legal regulations for recycling and waste
disposal.
The local ofcial laws for the protection of waste
water must be observed.
2 Safety