wiwa PUGUN 4040 User manual

Translation of the original operating manual
•1306Rev03_550014_PUGUN4040_en•ski
PUGUN 4040
Design:
❍Hand-held gun
❍Automatic gun
Serial no.:
… … … … … … … …
Operating Manual

EC-Declaration of Conformity
in accordance with Appendix II No. 1 A of the Machine Directive 2006 / 42 /
EC, last amended by 2009 / 127 / EC
The company WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr. 1-3
35633 Lahnau
Germany
hereby declares that the machine type PUGUN 4040
with the serial number:
conforms with the regulations of the above mentioned directive.
Responsible for documentation: WIWA GmbH / Tel. [phone]
Lahnau,
Place, Date Heidrun Wagner-Turczak
Managing director
0-1 Translation of the original operating manual
•1306Rev03_550014_PUGUN4040_en•ski
12.03.201412.03.2014

Contents
1 Foreword................................................................................................ 1-1
2 Safety ..................................................................................................... 2-1
2.1 Explanation of symbols 2-1
2.2 Safety notes 2-3
2.2.1 Operating pressure 2-3
2.2.2 Risks caused by the spray jet 2-4
2.2.3 Risks produced by the material used 2-4
2.2.4 Risks caused by electrostatic charging 2-5
2.2.5 Explosion protection 2-5
2.2.6 Health risks 2-6
2.3 Safety features 2-6
2.3.1 Compressed air shut-off valve 2-7
2.3.2 Material shut-off valves 2-7
2.3.3 Safety catch 2-8
2.3.4 Guard 2-8
2.4 Operating and maintenance personnel 2-8
2.4.1 Operator's duties 2-8
2.4.2 Personnel qualication 2-9
2.4.3 Authorized operating personnel 2-9
2.4.4 Personal Protective Equipment (PPE) 2-9
2.5 Notes on warranty 2-10
2.5.1 Conversions and alterations 2-10
2.5.2 Accessories and spare parts 2-10
2.6 Emergency procedures 2-11
2.6.1 Take the spray gun out of service and depressurise it 2-11
2.6.2 Leakages 2-11
2.6.3 Injuries 2-11
3 Description of device............................................................................ 3-1
3.1 Proper and intended use 3-1
3.2 Spray gun components 3-2
3.3 Optional expansion parts and accessories 3-3
3.3.1 Adapter for automatic operation 3-3
3.4 Type plate 3-3
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4 Transport, installation and assembly.................................................. 4-1
4.1 Transport 4-1
4.2 Installation location 4-1
4.3 Assembly 4-2
4.3.1 Compressed air connection 4-3
4.3.2 Connecting the material hoses 4-3
4.3.3 Put on protective cover 4-4
4.3.4 Earthing/grounding 4-5
5 Operation............................................................................................... 5-1
5.1 Putting the spray gun into operation 5-1
5.1.1 Initial commissioning 5-2
5.1.2 Cleaning before spraying 5-2
5.1.3 Venting 5-2
5.1.4 Spraying 5-5
5.1.5 Notes on spraying 5-6
5.2 Pressure relief 5-6
5.3 Decommissioning 5-8
5.3.1 Short work breaks 5-8
5.3.2 Longer work breaks and end of work 5-8
5.4 Hose package disassembly 5-9
6 Cleaning, maintenance and repair ...................................................... 6-1
6.1 Regular inspections 6-3
6.3 Tools required 6-4
6.5 External cleaning 6-5
6.6 Cleaning the manifold 6-6
6.7 Cleaning the material sieves and sieve housings 6-6
6.7.1 Removing the material sieve and sieve housing 6-6
6.7.2 Install the material sieves and sieve housings 6-7
6.7.3 Selecting the material sieves 6-7
6.8 Cleaning the press pieces and the mixing chamber 6-7
6.8.1 Removing the press pieces 6-8
6.8.2 Removing the mixing chamber 6-8
6.8.3 Cleaning and installing the mixing chamber and press pieces 6-9
6.8.4 Selecting the mixing chamber and nozzles 6-10
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7 Possible conversions........................................................................... 7-1
7.1 Material supply hoses position 7-1
7.1.1 Material supply hoses connection at the bottom 7-2
7.1.2 Material supply hoses connection at the top 7-2
7.1.3 Material supply hoses connection at the side 7-2
7.2 Conversion to an automatic spray gun 7-3
7.3 Connecting mounted accessories 7-4
8 Malfunctions and troubleshooting..................................................... 8-1
9 Appendix................................................................................................ 9-1
9.1 Technical data 9-1
9.2 Optional upgrades 9-1
9.3 Storing the machine and additional equipment 9-1
9.4 Disposal of the spray gun and additional equipment 9-1
10 Spare parts lists................................................................................ 10-1
10.1 PU gun with accessories 10-1
10.2 PU gun 10-2
10.2.1 Gun handle 10-3
10.2.2 Housing 10-4
10.2.3 Gun body 10-5
10.2.4 Manifold 10-6
10.3 Description of the symbols in the spare parts lists 10-7
10.3.1 Labelling of wearing parts, seal kit, and repair kit 10-7
10.3.2 Securing means 10-7
10.3.3 Operating materials 10-7
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1 Foreword
Dear Customer!
We are delighted that you have decided to buy one of our devices.
This operating manual is intended for the operating and maintenance per-
sonnel. It contains all the information required to working with this device.
The machine operator must ensure that operators and maintenance per-
sonnel always have an operating manual at their disposal in a language
that they understand.
Safe and reliable operation of the device requires further information in addi-
tion to this operating manual.
➤Read and comply with the applicable guidelines for your country.
In Germany, these are the “Richtlinien für Flüssigkeitsstrahler” (Guide-
lines for Liquid Jets), published by: Hauptverband der Gewerblichen
Berufsgenossenschaften.
➤Moreover the manufacturer's instructions and guidelines for coating or
feeder materials are to be observed at all times.
We strongly recommend to add all relevant guidelines and accident preven-
tion instructions to this operating manual.
However, if you have any questions, please do not hesitate to contact us.
WIWA Wilhelm Wagner GmbH & Co. KG. hopes that you have excellent
work results using your device.
Copyright
© 2013 WIWA
This User Guide remains the copyright of
WIWA Wilhelm Wagner GmbH & Co. KG.
Gewerbestr. 1-3 • 35633 Lahnau • Germany
Tel.: [phone] • Fax.: [phone] • E-mail: [email protected] •
Internet: www.wiwa.de
This operating manual is solely intended for personnel involved in prepara-
tion, operation and servicing.
It is prohibited to pass on this operating manual for reproduction, utilisation
or communication of its contents, unless this has been explicitly permit-
ted. Non-compliance may result in claims for damage compensation. All
rights reserved in the event of registration of the patented design, industrial
design or registered design.
This operating manual only applies in conjunction with the machine card
that was given to you with the user manual for your equipment. Please
check that the data on the type plate match those on the machine card.
Please notify us immediately if there are discrepancies, if the user manual
has been incorrectly compiled or if the type plate is missing.
Foreword
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2 Safety
The spray gun has been designed and manufactured while taking into con-
sideration all safety-related aspects. It complies with the current standard of
technology and relevant accident prevention regulations. The device left the
factory in perfect condition and guarantees a high level of technical reliability
and safety. Nevertheless, there are certain risks that can arise from incorrect
operation or misuse:
➤to life and limb of the operator or third party,
➤to the device and other valuable property of the owner,
➤to the efcient working capacity of the device.
In principle you should refrain from any work method that could affect the
safety of operating personnel and spray gun. All persons involved in set-up,
commissioning, operation, maintenance, repair and servicing of the spray
gun must have read and understood the operating manual beforehand, es-
pecially the chapter “Safety”.
Your safety is at stake!
We recommend that the device operator obtains written conrmation that
this has been done.
2.1 Explanation of symbols
Safety information warns you of potential risks of accidents and tell you the
measures that are needed to prevent accidents.
In WIWA operating manuals, safety information is specially highlighted and
marked as follows:
DANGER
Indicates danger of accidents; if you ignore the safety notes, there is a
high risk of severe injury resulting up to and including death!
WARNING
Indicates danger of accidents; if you ignore the safety notes, severe injury
can result up to and including death!
CAUTION
Indicates danger of accidents; if you ignore the safety notes, severe injury
can result!
Indicates important information on correct use of the device. Ignoring it
can result in damage to the device or in its vicinity.
Safety
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In the safety notes about the risk of accidents, different pictograms are
shown after each hazard source - examples:
General accident risk
Risk of explosion from explosive atmosphere
Risk of explosion from explosive substances
Danger of injury due to electric voltage or electrostatic charging
Risk of crushing by moving machine parts
Risk of burning due to hot surfaces
Mandatory safety instructions concern protective gear to be worn in the rst
instance. They are particularly highlighted and marked as follows:
Wear protective clothing
Highlights the order to wear the prescribed protective clothing to protect
against skin injuries caused by spraying material or gases.
Use eye protection
Indicates the requirement to wear protective goggles to protect against
eye injuries caused by gases, fumes or dust.
Wear ear defenders
Indicates the requirement to wear ear defenders to prevent your hearing
from being damaged by noise.
Use a respiratory protection mask
Highlights the order to use a respiratory protection mask to prevent your
respiratory tract from being damaged by gases, fumes or dusts.
Wear protective gloves
Highlights the order to wear protective gloves with lower arm protection to
protect against burn injuries caused by heated materials.
Wear protective footwear
Highlights the order to wear protective footwear to prevent injuries to the
feet due to objects that may fall, drop or roll around or to hot or caustic
liquids.
Safety
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Indicates reference to guidelines, work instructions and operating manuals
that contain important information which you must observe at all times.
Further pictograms:
Container “empty”
Identies an empty collecting vessel to be used by the user to collect con-
taminated spraying material.
2.2 Safety notes
Please remember that the spray gun works at high pressure and may cause
life-threatening injuries if used inappropriately!
Always observe and follow all instructions in this operating manual and
in the separate operating manuals of individual machine parts and/or the
optionally available accessory devices.
The accident prevention instructions “Application of Coating Materials”
(BGR 500, chap. 2.25) and the guidelines for liquid jets ZH1/406 of the
employer's liability insurance association must strictly be complied with.
2.2.1 Operating pressure
WARNING
Components that do not comply with the maximum permissible operating
pressure can burst and cause serious injury.
➤The specied maximum operating pressures must generally be
complied with for all components. In case of varying operating pres-
sures, the lowest value is always the one to be taken as the maximum
operating pressure for the entire machine.
➤Material hoses and hose assemblies must comply with the maximum
working pressure, including the required safety factor.
➤Material hoses must be leak tight and free of kinks, signs of abrasion
or bulges.
➤Hose connections must be tight.
Safety
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2.2.2 Risks caused by the spray jet
WARNING
The material is discharged from the spray gun under very high pressure.
Due to its cutting effect the spray jet can cause severe injuries by pen-
etrating the skin or entering into the eyes.
➤Never point the spray gun at yourself, other persons or animals.
➤Do not hold your ngers or hands in front of the spray gun!
➤Do not reach with your hands into the spray jet.
WARNING
Unintentional material release from the spray gun may cause personal
injury or damage to property.
➤Always secure the spray gun during every work break!
➤Always check that the safety mechanism on the spray gun works
before each use!
➤Depressurise the spray gun before any assembly, repair or mainte-
nance work.
2.2.3 Risks produced by the material used
WARNING
Isocyanates are highly-reactive organic compounds which can cause
health risks from vapours, fumes and other small particles during their
use.
➤Always observe and follow the instructions of the material manufac-
turer.
➤The spray gun operator must ensure that, when processing this mate-
rial, each person in the working area has been tted with protective
clothing.
➤The spray gun operator must ensure that there is adequate ventilation
of the work place.
The Iso material has a tendency to react when it comes into contact with
moisture in the air. Crystallisation or gelling may result and can cause
damage to the spray gun by blockages.
➤During use, purge air must always be available.
➤Never use regenerated cleaning agents which may contain moisture.
➤Keep a strict separation of both components, even with cleaning
agents.
Safety
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