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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2.2.4 Risks caused by electrostatic charging
WARNING
The high ow velocities associated with the Airless spraying method may
cause electrostatic charging.
Static discharges can cause re and explosion.
➤Always use open containers!
➤Never spray solvents or solvent containing materials into cone-top
cans or drums with bunghole!
➤Stand the containers on a grounded surface.
➤When using metal containers watch out for contact between spray gun
and container wall.
➤Only use conductive material hoses.
All original material hoses from WIWA are conductive and perfectly
adapted to our equipment.
2.2.5 Explosion protection
WARNING
Devices and machines designed without explosion protection must not be
used in workshops that come under the explosion protection ordinance.
Explosion protected devices and machines full the explosion protection
requirements of the Directive 94/9/EC for the explosion group, unit category
and temperature class specied on the type plate or in the declaration of
conformity.
The operator is responsible for determining the zone allocation according
to the Directive of EC 94/9/EC, Appendix II, no. 2.1-2.3 when observing the
measures of the responsible inspecting authority. The operator is responsi-
ble for checking and ensuring that all technical data and markings according
to ATEX correspond with the necessary requirements.
Please note that several components have their own type plate with sepa-
rate marking according to ATEX. In this case the lowest explosion protection
of all attached markings applies for the entire machine. Applications where
the malfunction of the unit can lead to danger to personnel must be provided
with respective safety measures by the operator.
However, if agitators, heaters or other electrically accessories are addition-
ally mounted, one must check the explosion protection. Plugs for heaters,
agitators, etc. that do not have explosion protection, may only be plugged in
outside of areas that fall under the explosion protection ordinance, even if
the accessory equipment as such is explosion protected.
Safety
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WARNING
Heating up cleaning agents can cause an explosion. This may result in
serious injury to persons and damage to property.
➤Pay attention to the ashpoint and the ignition temperature of the
cleaning agent.
➤Switch off the material ow heater if you need to perform the following
work: Cleaning, pressure testing, decommissioning, maintenance and
repair.
2.2.6 Health risks
Follow the safety notes and dosing information of the manufacturer and
the generally applicable regulations when handling paints, solvents, oils,
greases and other chemical substances.
CAUTION
Depending on the materials being applied solvent vapours may be gener-
ated which could cause damage to health and objects.
➤Always ensure sufcient aeration and ventilation at the workplace.
➤Always observe the processing instructions issued by the material
manufacturers.
When cleaning your skin, use only appropriate skin protection,
skin cleaning and skin care products.
2.3 Safety features
WARNING
If one of the safety features is missing or not fully functional, the operating
safety of the spray gun cannot be guaranteed!
➤If you discover any faults on the safety features or other deciencies
on the spray gun, stop operation of the spray gun immediately.
➤Only resume operation with the spray gun after the fault has been
completely rectied.
Check that the safety features function correctly in a depressurised state:
➤before initial commissioning,
➤always before starting work,
➤after set-up work,
➤after all cleaning, servicing and repair work.
Safety
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The machine is equipped with the following safety features:
➤Compressed air shut-off valve
➤Material shut-off valves
➤Safety catch
➤Guard
2.3.1 Compressed air shut-off valve
If the compressed air supply is interrupted when the trigger is pulled, the
spray gun does not shut off and the material ow is not interrupted.
➤Only close the ball valve on the compressed air supply when the spray
gun is secured.
➤The compressed air supply must always be present during operation.
As long as the compressed air shut-off
valve is opened, the ball valves for poly
and iso are closed, purging air ows
through the mixing chamber. This is to
prevent contamination of the material
channels in the spray gun. This set-up
should be done during short breaks in
work, (Fig. 2.2 Compressed air shut-off
valve “ON/I”).
Fig. 2.1 Com-
pressed air shut-off
valve “OFF/0”
Fig. 2.2 Com-
pressed air shut-off
valve “ON/I”
Only turn off the compressed air shut-off valve during long breaks in work
and when work has nished, (Fig. 2.1 Compressed air shut-off valve
“OFF/0”).
2.3.2 Material shut-off valves
WARNING
High pressure is present on both ball valves during operation. Unintended
material leakage can cause serious injuries and material damage.
Only open the material shut-off valves:
➤with the spray gun connected,
➤if the material outlets are pointed towards the surface to be coated or
into a suitable container.
The material ow for each component is controlled separately by opening
and closing the ball valves. You can see if the ball valve is opened or closed
by the position of the lettering on each ball valve as well as a through-hole:
Safety
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➤Ball valve open
=> Lettering in the direction of the
material ow
➤Ball valve closed
=> Lettering perpendicular to the
material ow
During long breaks as well as dur-
ing all conversion, maintenance and
cleaning work, both ball valves must
always be closed, (Fig. 2.4 Material
shut-off valve “OFF/0”). Fig. 2.3 Material
shut-off valve “ON/I" Fig. 2.4 Material
shut-off valve
“OFF/0”
2.3.3 Safety catch
Setting the safety lever to horizontal position locks the spray gun against ac-
cidental operation, (Fig. 2.6 Safety lever “OFF/0”).
The trigger can only be operated when
the safety lever is open, (Fig. 2.5
Safety lever “ON/I”).
The spray gun must be locked for each
break, even for short interruptions of
work.
Fig. 2.5 Safety lever
“ON/I”
Fig. 2.6 Safety lever
“OFF/0”
2.3.4 Guard
The guard secures the spray gun against accidental
operation of the trigger, e.g. when bumping into build-
ing components or if the spray gun is dropped, (Fig.
2.7).
Fig. 2.7
2.4 Operating and maintenance personnel
2.4.1 Operator's duties
The spray gun operator:
➤is responsible for the training of the operating and maintenance staff,
➤must instruct the operating and maintenance staff to correctly handle
the spray gun as well as to wear the correct work clothing and personal
protective equipment,
➤must make the user manual available to the operating and maintenance
staff and ensure that it always remains available,
Safety
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➤must ensure that the operating and maintenance staff have read and
understood the user manual.
Only then may the spray gun be brought into service.
2.4.2 Personnel qualication
A differentiation is made between two groups of people in dependence on
their qualications:
➤Instructed operators have been veriably instructed by the operator in
the activities they are tasked with and the potential risks connected with
them in the case of incorrect behaviour.
➤Trained personnel have been instructed by the spray gun manufacturer
such that they are capable of carrying out maintenance and repair work
on the spray gun and recognising potential risks on their own initiative
and of avoiding these risks.
2.4.3 Authorized operating personnel
Activity Qualication
Set-up and operation Instructed operator
Cleaning Instructed operator
Servicing Trained personnel
Repair Trained personnel
Juveniles under 16 years old may not operate this spray gun.
2.4.4 Personal Protective Equipment (PPE)
Wear protective clothing
Always wear the protective clothing prescribed for your work environment
(mining, closed rooms, etc.) and also follow the recommendations in the
safety data sheet issued by the material manufacturer.
Use eye protection
Indicates the requirement to wear protective goggles to protect against
eye injuries caused by material splatter gases, fumes or dust.
Use hearing protection
The spray gun itself causes low noise levels. However, pay attention to
the sound pressure levels generated by the spraying equipment used.
Operating personnel should be provided with suitable noise protection
equipment. The machine operator is responsible for adhering to the ac-
cident prevention regulation “Noise” (BGV B3). For this purpose, pay
special attention to the conditions of the installation location – the noise
burden will increase if the machine is installed in or on hollow bodies, for
example.
Safety
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Wear a respiratory protection mask
We strongly recommend that you wear a respiratory protection mask,
even though the paint mist has been minimized in the airless spray paint-
ing method given a correct pressure setting and correct working methods.
Wear protective gloves
When applying heated materials you should wear protective gloves with
lower arm protection, to protect you against burn injuries.
Wear protective footwear
Wear protective footwear to prevent injuries to the feet due to objects that
may fall, drop or roll around and to prevent slipping on a slippery oor.
2.5 Notes on warranty
2.5.1 Conversions and alterations
➤Unauthorized conversions or alterations should not be undertaken on
safety grounds.
➤Protective equipment should not be dismantled, converted or bypassed.
➤Use of components which have not been manufactured or delivered by
WIWA renders any warranty null and void.
➤The spray gun should only be operated within the prescriptive limit val-
ues and device parameters.
2.5.2 Accessories and spare parts
➤If you use original accessories and spare parts from WIWA, their suitabil-
ity for use with our equipment is guaranteed.
➤It is, however, mandatory to respect the safety regulations of the acces-
sories and spare parts. You will nd these safety regulations in the cor-
responding operating manuals for the accessories and spare parts.
➤If third-party accessories or spare parts are used, WIWA cannot guaran-
tee the safety of the whole device.
Liability for damages or injuries incurred because of the use of those ac-
cessories and spare parts becomes null and void.
Safety
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2.6 Emergency procedures
2.6.1 Take the spray gun out of service and depressurise it
In an emergency, immediately shut down the spray gun and depressurise it.
1. Stop the spraying process.
Release the trigger and secure it with the safety lever.
2. Close both material shut-off valves.
3. Pull the trigger on the spray gun to release the pressure once again.
4. Secure the trigger again with the safety lever.
5. Close the compressed air supply to the spray gun by shutting the com-
pressed air shut-off valve.
6. Before maintenance or repair work, take the associated dual component
system out of service. To do this, follow the operating manual for the
system.
2.6.2 Leakages
WARNING
In case of leakages material can escape under very high pressure and
cause serious bodily injuries and material damage.
➤Immediately shut-down the spray gun and release the pressure.
➤Retighten any screw ttings and replace defective components (only
by trained personnel).
➤Do not try to seal leaks on the connections and high-pressure hoses
with the hand or by wrapping fabric around them.
➤Do not repair material hoses!
➤Check hoses and screw ttings before bringing the spray gun into use
again for leaks.
2.6.3 Injuries
If injured by processing materials or solvents always have the safety data
sheet (address, phone number, material designation and material number of
supplier or manufacturer) available for the attending physician.
Safety
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3 Description of device
The WIWA PUGUN 4040 is a pneumatically driven spray gun which works on
the counterow principle.
The spray gun is connected by a hose package to the dual component sys-
tem on the material and compressed air sides.
When the trigger is pulled, the material channels in the spray gun are
opened – this is controlled by compressed air.
The two components only meet in the mixing chamber with a pressure of
up to 250 bar / 3626 psi. The mixed material is then discharged through a
nozzle. As the mixing chamber is easy to replace, the material discharge
quantity of the WIWA PUGUN 4040 can be varied.
When the material ow is closed, material is prevented from accumulating
in the mixing chamber and the nozzle by continuous purge air. This also
prevents the nozzle becoming clogged.
Round and at stream tip nozzles can be used.
The technical data for your spray gun can be found in chapter “9.1 Technical
data”, page 9-1.
3.1 Proper and intended use
The spray gun is suitable for processing polyurea and PUR foam as well as
solvent-free dual-component plastics (polyurethane).
This spray gun enables the seamless and jointless application of coatings
and linings.
In addition to hand-held use, the spray gun can also be used in an automati-
cally driven coating system with the optional adapter.
To get best work results, the use of the spray gun with a WIWA polyurea
system is particularly recommended.
Any other use is deemed to not be intended use.
Any other use is considered to be unintended. If you intend to use the
spray gun for other purposes or with other materials and thus not for the
purpose it is intended for, you must ask WIWA for permission – otherwise
the warranty will be invalidated.
Intended use also includes observance of the technical documentation
and compliance with the prescribed operating, maintenance and repair
instructions.
Description of device
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3.2 Spray gun components
Fig. 3.1 Left side view
➀
➁
➂
➃➄➅
➆
➇
➈
Fig. 3.2 Right side view
➉
1312
11 1514
16
Item Description
1 Guard
2Trigger
3 Safety lever
4 Grease nipple
5 Iso ball valve
6 Male adapter to connect the ISO material hose
7 Compressed air shut-off valve
8Air connection nipple for compressed air
9 Gun handle
10 Male adapter to connect the Poly material hose
11 Poly ball valve
12 Drive
13 Gun body
14 Adapter plate
15 Nozzle
16 Manifold
Description of device
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3.3 Optional expansion parts and accessories
3.3.1 Adapter for automatic operation
To use the spray gun in an automatic system,
the gun handle must be replaced with an
adapter, (Fig. 3.3).
Fig. 3.3
3.4 Type plate
The type plate (Fig. 3.4) is found on the cover of
the drive.
Please check that the details on the type plate
match those contained in chapter “9.1 Technical
data”, page 9-1.
If there are any discrepancies, of if the type
plate is missing, please notify us immediately.
Fig. 3.4
Description of device
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