wiwa 500 User manual

Operating instructions
Original operation manual
SP500_0550001-en_1604 • jw
Airless spray gun
WIWA 500

2 Original operation manual WIWA 500
SP500_0550001-en_1604 • jw

Contents
4 Original operation manual WIWA 500
SP500_0550001-en_1604 • jw
Contents
1 Foreword ................................................................................. 7
2 Safety....................................................................................... 8
2.1 Explanation of symbols............................................................. 8
2.2 Safety information................................................................... 10
2.2.1 Operating pressure........................................................ 10
2.2.2 Risks due to the spray jet ...............................................11
2.2.3 Risks due to electrostatic charging.................................11
2.2.4 Risk due to hot surfaces ................................................ 12
2.2.5 Explosion protection ...................................................... 12
2.2.6 Health risks.................................................................... 13
2.3 Safety equipment.................................................................... 14
2.3.1 Nozzle protector ............................................................ 15
2.3.2 Safety lever.................................................................... 15
2.3.3 Guard bracket................................................................ 15
2.4 Operating and maintenance personnel .................................. 15
2.4.1 Obligations of the device owner .................................... 15
2.4.2 Personnel qualications................................................. 16
2.4.3 Authorised operator ....................................................... 16
2.4.4 Personal protective equipment ...................................... 16
2.5 Guarantee instructions ........................................................... 17
2.5.1 Spare parts .................................................................... 17
2.5.2 Accessories ................................................................... 18
2.6 Behaviour in an emergency.................................................... 18
2.6.1 Leaks............................................................................. 18
2.6.2 Injuries ........................................................................... 18
3 Device description................................................................ 19
3.1 Intended use........................................................................... 19
3.2 Erroneous use ........................................................................ 19
3.3 Model designation and overview ............................................ 20
3.4 Device design ......................................................................... 23
3.5 Optional expansions and accessories .................................... 24
4 Transport and assembly ...................................................... 26
4.1 Scope of delivery .................................................................... 26
4.2 Installation .............................................................................. 26

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4.2.1 Installing the spray nozzle ............................................. 26
4.2.2 Installing the push-in lter in the handle ........................ 27
4.2.3 Connecting the material hose........................................ 27
5 Operation............................................................................... 29
5.1 Putting the spray gun into operation....................................... 29
5.1.1 Setting the spray pressure............................................. 29
5.1.2 Tips for good coatings ................................................... 29
5.2 Work interruption .................................................................... 30
6 Maintenance and repair ....................................................... 31
6.1 Maintenance schedule............................................................ 31
6.1.1 Lubricating the spray gun .............................................. 32
6.1.2 Setting the play or grip width of the trigger .................... 32
6.1.3 Cleaning the push-in lter.............................................. 33
7 Troubleshooting ................................................................... 35
7.1.1 Replacing the packing and valve needle ....................... 35
7.1.2 Cleaning the guide sleeve ............................................. 37
7.1.3 Replacing the seals on the gun handle ......................... 39

6 Original operation manual WIWA 500
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Copyright
© 2016 WIWA
The copyright to these operating instructions belongs to
WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr. 1-3 • 35633 Lahnau • Germany
Tel.: [phone] • Fax.: [phone] • Email: [email protected]
Website: www.wiwa.de
These operating instructions are intended exclusively for the preparation,
operating and maintenance personnel. It is expressly prohibited to distribute
these operating instructions, duplicate, exploit or communicate their
contents, unless expressly authorised to do so. Infringement will lead to
compensation. All rights to any patent, utility model or design registrations
reserved.

Foreword
Original operation manual WIWA 500 7
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1 Foreword
Valued Customer!
We are delighted that you have opted for one of our spray guns.
These operating instructions are directed at the operating and
maintenance personnel. They contain all information required in
order to handle this device.
The device operator must ensure that the operating and
maintenance personnel always have access to a copy of
the operating instructions in a language that they understand.
In addition to the operating instructions, further information is also
essential for the safe operation of the device. Read and observe
the directives and accident prevention regulations valid in your
country.
In Germany, these are:
➤ZH 1/406 "Guidelines for liquid jet sprayers (spray devices)"
from the Federation of Institutions for Statutory Accident
Insurance and Prevention,
➤BGR 500, chap. 2.29 "Processing Coating Materials",
➤BGR 500, chap. 2.36 "Working with liquid jet sprayers", both
from the professional association for gas, district heating and
water management.
We recommend enclosing all relevant directives and accident
prevention regulations with the operating instructions.
Furthermore, always observe the manufacturer's instructions and
processing guidelines for coating or conveyance materials.
If questions should arise, we shall be happy to assist you.
We wish you excellent working results with your spray gun
WIWA Wilhelm Wagner GmbH & Co. KG.

Safety
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2 Safety
This device has been designed and manufactured considering all
safety aspects. It reects current engineering practice and the valid
accident prevention regulations. The device left the factory in
faultless condition and guarantees a high level of technical safety.
However, erroneous operation and misuse result in a risk to:
➤the life and limb of the operator or third parties,
➤the device and other property of the owner,
➤efcient work with the device.
It is fundamentally prohibited to implement any methods of work
that have a negative inuence on the safety of the operating
personnel and the device. All persons involved in the installation,
commissioning, operation, care, repair and maintenance of
the device must have read and understood the operating
instructions beforehand - in particular the "Safety" chapter.
Your safety depends on it!
We recommend that the device owner has this conrmed in writing.
2.1 Explanation of symbols
Safety information warns of potential accident risks and describes
the measures required for accident prevention.
In the operating instructions from WIWA, safety information is
highlighted and labelled as follows:
DANGER
Signals a risk of accidents that are very likely to result in serious
injuries and even death, if the safety information is not observed!
WARNING
Signals a risk of accidents that may result in serious injuries and
even death, if the safety information is not observed!
CAUTION
Signals a risk of accidents that may result in injuries, if the safety
information is not observed!

Safety
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Signals important information for working correctly with
the device. A failure to observe this may result in damage to
the device or its environment.
Different pictograms are used in the safety information for accident
risks that may result in injury, depending on the hazard source -
examples:
General risk of accident
Risk of explosion due to explosive atmosphere
Risk of explosion due to explosive substances
Risk of accident due to electricity
or electrostatic charge
Risk of crushing due to moving machine parts
Risk of burning due to hot surfaces
The rst line of the safety instructions indicates safety devices
that must be incorporated. This is also highlighted and labelled as
follows:
Wear protective clothing
Signals an instruction to wear the prescribed protective clothing,
in order to prevent skin injuries due to spray material or gases.
Use eye protection
Signals an instruction to wear safety goggles, in order to prevent
eye injuries due to material spray, gases, vapours or dust.
Use hearing protection
Signals an instruction to wear hearing protection, in order to
prevent damage to hearing caused by noise.

Safety
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Use respiratory protection
Signals an instruction to use respiratory protection, in order
to prevent damage to the respiratory tract caused by gases,
vapours or dust.
Wear protective gloves
Signals an instruction to wear protective gloves with forearm
protection, in order to prevent a risk of burns due to heated
material.
Wear safety shoes
Signals an instruction to wear safety shoes, in order to prevent
foot injuries due to falling, toppling or rolling objects, as well as
slipping on slippery oors.
Signals references to directives, work instructions and operating
instructions that contain very important information and must be
observed.
2.2 Safety information
Always remember that the spray gun is operated with very high
pressures and can cause life-threatening injuries if handled
incorrectly!
Always observe and follow all the information in these operating
instructions and in the operating instructions of the spraying
device on which the spray gun is operated.
2.2.1 Operating pressure
WARNING
Devices which are subjected to a higher pressure than
the maximum permitted operating pressure for which they are
designed can burst and cause serious injuries.
➤The maximum permitted operating pressure of the spray gun
must be the same or greater than the maximum permitted
operating pressure of the spraying device on which it is
operated.
➤Material hoses and hose connections must comply with
the maximum operating pressure including the required
safety factor.

Safety
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➤Material hoses must not exhibit leaks, kinks, signs of wear or
bulges.
➤Hose connections must be tight.
2.2.2 Risks due to the spray jet
WARNING
The material exits the spray gun under very high pressure.
The spray jet can cause serious injuries through its cutting action,
or by penetrating the skin or eyes.
➤Never aim the spray gun at yourself, other persons or
animals!
➤Never hold the nger or hand in front of the spray gun!
➤Never reach into the spray jet!
➤Always hold the spray gun tightly in your hands while working
since great recoil forces can arise at high working pressures.
WARNING
An unintended ejection of material from the spray gun can cause
personal injury and property damage.
➤Lock the spray gun with all interruptions to work!
➤Prior to each start-up, always check the spray gun lock!
2.2.3 Risks due to electrostatic charging
WARNING
The high ow speeds with the airless spray process can result
in an electrostatic charge. Static charges can result in re and
explosions.
➤Make sure that the spraying device, on which the spray
gun is operated, and the object to be coated, are correctly
earthed!
➤Always use open containers!
➤Never spray solvents or materials containing solvents into
narrow-mouthed cans or barrels with a bung opening!

Safety
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➤Set the container down on an earthed surface.
➤Use electrically conductive containers.
➤Always ensure contact between the spray gun and
the container wall.
➤Only use electrically conductive material hoses.
All original material hoses from WIWA are conductive and
designed for our devices.
WARNING
Dirty devices can become electrostatically charged. Fire and
explosion can be triggered by severe static discharges.
➤Keep the machine clean.
➤Always perform the cleaning work outside of EX zones.
2.2.4 Risk due to hot surfaces
CAUTION
The spray gun can get hot when using material heaters on
the spraying device being used. A risk of burns exists.
➤When processing heated materials always wear protective
gloves with forearm protection.
2.2.5 Explosion protection
WARNING
Devices that are not explosion-protected must not be used
in operating facilities that fall under the explosion protection
ordinance!
Explosion-protected devices full the requirements of directive
94/9/EC for the device group, device category and temperature
class cited on the device or in the declaration of conformity.

Safety
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The owner is responsible for designating the zoning according
to the stipulated guidelines of 94/9/EC, Annex II, No. 2.1-2.3 in
accordance with the provisions of the responsible regulatory body.
The owner is required to check and ensure that all technical data
and labelling comply with the applicable stipulations according to
ATEX.
For applications, whereby a failure of the device could lead
to dangers to personnel, the owner is required to implement
appropriate safety measures.
WARNING
Heating solvents can lead to an explosion. Serious physical
injuries and property damage may result.
➤Observe the ashpoint and ignition temperature of solvents.
➤Never immerse a hot spray gun in solvent.
2.2.6 Health risks
CAUTION
Depending on the materials being processed, solvent vapours
may arise, which could lead to damage to health and property.
➤Make sure the workplace is sufciently ventilated and aired.
➤Always observe the processing instructions of the material
manufacturer.
When handling paint, solvents, oils, greases, and other chemical
substances, observe the safety and portioning instructions of
the manufacturer and the generally applicable regulations.
Only use suitable skin protection, skin cleansing and skincare
products for cleansing the skin.
In systems that are closed or under pressure, dangerous
chemical reactions may arise, if parts produced from aluminium
or galvanised parts come into contact with 1.1.1 - trichloroethane,
methylene chloride or other solvents that contain halogenated
chlorinated hydrocarbons (CFCs). If you wish to process materials

Safety
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that contain the aforementioned substances, we recommend
that you contact the material manufacturer in order to clarify their
suitability for use.
The WIWA 500 F spray gun is suitable for such materials.
2.3 Safety equipment
WARNING
If safety equipment is missing or is not fully functional,
the operating safety of the device is not guaranteed!
➤Put the device out of operation immediately if you detect
safety equipment defects or any other faults on the device.
➤Only put the device back into operation once the faults have
been fully rectied.
The spray gun is equipped with the following safety equipment:
No. Designation
1 Nozzle protector
2 Safety lever
3 Guard bracket
Always check the safety
equipment on
the pressureless device:
➤Prior to starting up,
➤Before starting work,
➤After set-up work,
➤After cleaning,
maintenance and repair
work.
Check list:
5Function of the safety
lever
OK?
Fig. 1: Safety equipment
1
3
2
5Nozzle protector securely installed?
5Securing bracket securely installed and undamaged?

Safety
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2.3.1 Nozzle protector
The nozzle protector prevents damage to the spray nozzle, which
can arise e.g. if the spray gun falls down.
Furthermore, contact with the palm of your hand with the spray jet
directly at the nozzle outlet is prevented.
WARNING
If the spray gun is operated without the nozzle protector, serious
injuries and property damage can result.
➤Never put the spray gun into operation without the nozzle
protector.
2.3.2 Safety lever
The spray gun is secured
against unintentional actuation
with the safety lever. Put
the safety lever horizontal for
this.
The spray gun must be
secured during each
interruption of work - even if
it is very short.
Secure
Release
Fig. 2: Safety lever
2.3.3 Guard bracket
The guard bracket secures the spray gun against an unintentional
actuation of the trigger - e.g. due to the spray gun being bumped or
falling down.
2.4 Operating and maintenance personnel
2.4.1 Obligations of the device owner
The device owner:
➤is responsible for training the operating and maintenance
personnel,
➤must instruct the operating and maintenance personnel on
correct handling of the device, and on wearing the correct work
clothing and protective equipment,
➤must make the user manual accessible to the operating and

Safety
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maintenance personnel and must ensure that this remains
constantly available,
➤must ensure that the operating and maintenance personnel
have read and understood the user manual.
➤Only then are they permitted to put the device into operation.
2.4.2 Personnel qualications
Differentiation is made between 2 groups of personnel, depending
on their qualications:
➤Instructed operator has received veried instruction from
the device owner regarding the tasks entrusted to him and
the possible risks in the event of incorrect conduct.
➤Trained personnel are capable - due to instruction provided
by the device manufacturer - of carrying out maintenance and
repair work on the device, independently recognising possible
dangers and avoiding risks.
2.4.3 Authorised operator
Activity Qualication
Set-up and operation Instructed operator
Cleaning Instructed operator
Maintenance Trained personnel
Repair Trained personnel
Young persons under the age of 16 are not permitted to operate
this device.
2.4.4 Personal protective equipment
Wear protective clothing
Always wear the protective clothing stipulated for your work-
ing environment (e.g. mining, enclosed spaces etc.) and also
observe the recommendations in the safety data sheet of the
material manufacturer.

Safety
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Use eye protection
Wear safety goggles to prevent eye injuries due to material spray,
gases, vapours, or dust.
Use hearing protection
The spray gun itself does not cause any noise. However,
depending on the sound pressure level of the spraying device
used, the operating personnel must be provided with suitable
noise protection devices, if necessary.
Use respiratory protection
Although the airless spray process minimises the material mist
with the right pressure setting and correct method of work, we
recommend that you wear a respirator.
Wear protective gloves
When processing heated materials, wear protective gloves with
forearm protection in order to prevent burns.
Wear safety shoes
Wear safety shoes to prevent foot injuries due to falling, toppling
or rolling objects, as well as slipping on slippery oors.
2.5 Guarantee instructions
Observe our general terms and conditions of business (T&Cs) at
www.wiwa.de.
2.5.1 Spare parts
➤When maintaining and repairing the device, only use original
spare parts from WIWA.
➤If spare parts are used, that have not been produced or
supplied by WIWA then the guarantee is voided and all liability
shall be excluded.

Safety
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2.5.2 Accessories
➤If you use original accessories from WIWA, their suitability for
use in our devices is guaranteed.
➤If you use third-party accessories, these must be suitable for
the device - in particular with respect to the operating pressure
and the connection variables. WIWA shall not be liable for any
damage or injuries arising due to these parts.
➤It is essential to observe the safety provisions applicable
to the accessories. You can nd these safety provisions in
the separate operating instructions for the accessories.
2.6 Behaviour in an emergency
2.6.1 Leaks
WARNING
In case of leaks, material may escape under very high pressure
and cause serious physical injuries and property damage.
➤Immediately shut down the spraying device and de-
pressurise it. Observe and follow the information in the user
manual of the spraying device for this.
➤Tighten threaded connections and replace defective parts
(must be performed by trained personnel).
➤Do not seal leaks at connections and on high pressure hoses
with the hand or by wrapping.
➤Do not patch material hoses!
➤Check hoses and threaded connections for leak-tightness
when starting the spraying device up again.
2.6.2 Injuries
In case of injuries caused by processing material or solvents,
always have the manufacturer's datasheet ready to show the doctor
(supplier or manufacturer address, their telephone number, material
designation and material number).

Device description
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3 Device description
The spray guns of series WIWA 500 with light-moving four-nger
trigger were specially developed for coating large areas
➤with a maximum permitted
operating pressure of 500
bar and
➤a maximum permitted
material temperature
of 80°C.
This data is also noted directly
on the gun body like the CE
and ATEX marking.
No. Meaning
1 ATEX marking
2 Max. operat. pressure
3 CE marking
4 Max. material temperat.
Fig. 3: Data on the gun body
1
2
3
4
The spray guns of series WIWA 500 can be used in connection with
all known airless spraying devices.
3.1 Intended use
The spray guns of series WIWA 500 are intended for applying low-
viscosity to high-viscosity materials in the commercial
and industrial sector.
Intended use also includes:
➤observing the technical documentation and
➤complying with the operating, maintenance and servicing
guidelines.
3.2 Erroneous use
Any use other than that stipulated in the technical documentation
is deemed to be erroneous use and may result in personal injury
or property damage.
Erroneous use applies in particular if
➤impermissible materials are processed,

Device description
20 Original operation manual WIWA 500
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➤ unauthorised modications or changes are implemented,
➤ safety equipment is modied, removed or bypassed,
➤unsuitable spare or accessory parts are used (see chap. 2.5.1
and 2.5.2),
➤machines that are not marked as EX machines are used in
potentially explosive areas,
➤the machine is operated outside of the operating limits
(see type plate).
3.3 Model designation and overview
The model designation 500 (= 500 bar max. operating pressure)
is specied by the following letters:
DSwivel joint FI Push-in lter in the handle
FFront connection HS Hot spraying
Art. no. Model Description
with 2-nger trigger
0657415 WIWA 500 F 2-nger trigger with front connection and 1/4"
swivel joint, plastic handle, with reversing switch,
7/8" thread insert
with 4-nger trigger
0011479 WIWA 500 4-nger trigger without 1/4" NPSM swivel joint
with 11/16 UNS nozzle connection thread with
standard nozzle protector
0015091 WIWA 500 FI 4-nger trigger without 1/4" NPSM swivel joint with
11/16 UNS nozzle connection thread and M 200
push-in lter in the handle, with standard nozzle
protector
0648246 WIWA 500 4-nger trigger 1/4" NPSM, 7/8" thread insert, with-
out nozzle protector
0662604 WIWA 500 4-nger trigger without 1/4” NPSM swivel joint
with 11/16 UNS nozzle connection thread, without
nozzle protector