wiwa 410.09 User manual

Translation of the Original Operation Manual
BetonP_BA_en_1302 · jw
Operating Manual
MORTAR PUMP
Type:
❍410.09
Type:
❍600.12
Serial number
⸏⸏⸏⸏⸏⸏⸏⸏

Translation of the Original Operation Manual for Mortar Pumps 3
BetonP_BA_en_1302•jw
Table of Contents
1 Foreword ..............................................................................................5
2 Safety....................................................................................................6
2.1 Explanation of symbols ......................................................................6
2.2 Safety notes .......................................................................................8
2.3 Health risks.........................................................................................8
2.4 Information signs on the device..........................................................9
2.5 Safety features ...................................................................................9
2.5.1 Safety valve......................................................................................10
2.5.2 Compressed air shut-off valve..........................................................10
2.6 Information on explosion protection ................................................. 11
2.7 Notes on warranty ............................................................................ 11
2.7.1 Conversions and alterations............................................................. 11
2.7.2 Accessories and spare parts ............................................................ 11
2.8 Operating and maintenance personnel ............................................12
2.8.1 Machine owner's duties ....................................................................12
2.8.2 Personnel qualification .....................................................................12
2.8.3 Authorized operating personnel .......................................................12
2.8.4 Personal Protective Equipment (PPE) .............................................12
2.9 Emergency procedures ....................................................................13
2.9.1 Leakages..........................................................................................13
2.9.2 Injuries..............................................................................................13
2.10 Handling auxiliary materials .............................................................14
3 Machine Description .........................................................................15
3.1 Intended use.....................................................................................15
3.2 Machine structure.............................................................................16
4 Installation and transportation.........................................................17
4.1 Safety measures at the installation location .....................................17
4.2 Transporting the machine.................................................................17
5 Assembly............................................................................................18
6 Putting into operation .......................................................................19
6.1 Preparing..........................................................................................19
6.2 Initial cleaning...................................................................................19

4 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
7 Operation............................................................................................20
7.1 General notes...................................................................................20
7.2 Spraying ...........................................................................................20
7.2.1 Setting the working pressure............................................................21
7.3 Flushing............................................................................................21
8 Decommissioning..............................................................................22
8.1 Interrupting work...............................................................................22
8.2 Finishing work ..................................................................................22
8.2.1 Cleaning the machine.......................................................................22
8.2.2 Filing the machine with solvent ........................................................23
9 Maintenance/repairs..........................................................................23
9.1 Recurring inspections.......................................................................24
9.2 Maintenance plan .............................................................................25
9.3 Air maintenance unit.........................................................................25
9.3.1 Checking the fill level of the lubricant (or anti-freeze) ......................25
9.3.2 Setting the fog oiler ..........................................................................26
9.3.3 Draining the condensation water......................................................26
10 Malfunctions and troubleshooting...................................................27
11 Appendix ............................................................................................28
11.1 Technical data ..................................................................................28
11.2 Accessories ......................................................................................28
11.3 Operating materials ..........................................................................29
11.4 Instruction Certificate........................................................................29
11.5 Machine card and lists of spare parts...............................................30

Translation of the Original Operation Manual for Mortar Pumps 5
BetonP_BA_en_1302•jw
Foreword
1 Foreword
The owner of the machine must ensure that its operator always has an
operating manual at their disposal in a language they understand.
Operating personnel must always have access to this user manual!
Dear Customer!
We are delighted about your decision to buy one of our machines. The user
manual contains all information required to operate and handle your
mortar pump. However, other information is also essential for safe operation:
Read and comply with the applicable guidelines for your country.
In Germany, these are the „Richtlinien für Flüssigkeitsstrahler“,
(Guidelines for Liquid Jets), issued by: the Hauptverband der
Gewerblichen Berufsgenossenschaften.
Moreover you must respect at all times the manufacturer's instructions
and coating or feeder materials.
In principle, you must refrain from any work method that could affect the
safety of products and operating personnel.
Wishing you lots of success and good work results, your
Wilhelm Wagner GmbH & Co. KG.
Copyright
© 2013 WIWA
The copyright in this user manual is retained by
WIWA WILHELM WAGNER GmbH & Co. KG
Gewerbestraße 1-3 • 35633 Lahnau
Tel.:+496441609-0•Fax.:+496441609-50•
E-mail:[email protected]•Internet:www.wiwa.de
This operating manual is solely intended for personnel involved in preparation, operation and servicing.
It is prohibited to pass on this operating manual for reproduction, utilisation or communication of its con-
tents, unless this has been explicitly permitted. Infringements incur an obligation to pay damage compen-
sation. 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 type plate data is identical with the information 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.

6 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Safety
2 Safety
This machine has been designed and manufactured under due consideration
of all safety-related aspects. It complies with the current standard of
technology and the valid accident prevention instructions. The machine
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 machine and other material assets of the owner,
to the efficient working capacity of the machine.
You must refrain from any working methods that could affect the safety
of operating personnel and equipment. All the people that are involved
in set-up, commissioning, operation, maintenance, repair and servicing
of the spray gun must have read and understood the operating manual
beforehand, especially the chapter entitled "Safety".
Your safety is at stake!
Werecommendtotheownerofthisunittohavethisconrmedinwriting.
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 machine. Ignoring it
can result in damage to the machine or in its vicinity.
In the safety notes about the risk of accidents, different pictograms are
shown after each hazard source - examples:
General accident risk

Translation of the Original Operation Manual for Mortar Pumps 7
BetonP_BA_en_1302•jw
Safety
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
Indicates the requirement 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
Indicates the requirement to wear a respiratory protection mask to prevent
your respiratory tract from being damaged by gases, fumes or dusts.
Wear protective gloves
Indicates the requirement to wear protective gloves with lower arm protection
to protect against burn injuries caused by heated materials.
Wear protective footwear
Wear
Indicates the requirement to wear protective footwear to prevent injuries
to the feet due to objects that may fall or drop and to prevent sliding on
slippery floors.

8 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Safety
Indicates references to guidelines, work instructions and operating manuals
that contain important information which you must observe at all times.
2.2 Safety notes
CAUTION
Mortar pumps can cause life-threatening injuries if used improperly.
Please observe the safety notes below and act accordingly:
WARNING
Components that do not comply with the maximum permissible operating
pressure can burst and cause serious injury.
The specified maximum operating pressures must generally be complied
with for all components. In case of varying operating pressures, 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.
WARNING
If material pumps run dry, the generated friction heat can cause fire or an
explosion.
Always make sure that the material drums do not run dry during operation.
However, should this happen, stop the corresponding pump immediately
and top up material.
2.3 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.

Translation of the Original Operation Manual for Mortar Pumps 9
BetonP_BA_en_1302•jw
Safety
CAUTION
Depending on the materials being applied solvent vapours may be generated
which could cause damage to health and objects.
Always ensure sufficient aeration and ventilation at the workplace.
Always observe the processing instructions issued by the material
manufacturers.
CAUTION
Solvents are not suitable for cleaning you skin and can damage your health.
Use only appropriate skin protection, skin cleaning and skin care products.
In closed or pressurized systems dangerous chemical reactions may occur
if parts made of aluminium or galvanized parts come into contact with
1.1.1 - trichloroethane, methylene chloride or other solvents containing
halogenated hydrocarbons (CFC's). If you want to process materials
containing the afore mentioned substances, we recommend to consult the
material manufacturer to clarify the usability of such substances.
For these materials, we have available a range of rust- and acid-proof ma-
chines.
2.4 Information signs on the device
The warning signs and symbols on the machine refer to possible danger areas
and must be respected at all costs.
Warning signs and symbols must not be removed from the device.
Warning signs that are damaged and illegible must be replaced immediately.
The following signs are located on the device:
Type plate
Please check that the type label data are identical with those on the machine
card. In case of discrepancies or if the type plate is missing, please notify us
immediately.

10 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Safety
2.5 Safety features
WARNING
If one of the safety features is missing or not fully functional, the operating
safety of the machine cannot be guaranteed!
If you discover any faults in the safety features or other deficiencies on
the machine, stop operation of the machine immediately.
Only resume operation of the machine after the fault has been completely
eliminated.
Check the safety features with the device depressurised:
before commissioning!
always before starting work!
after all setup work!
after cleaning, maintenance and repair work!
Checklist for testing the safety features:
 Is the ground cable undamaged?
 Is the ground cable connected correctly to the device as well as to the
conductor?
 Is it possible to activate the compressed air shut-off valve?
2.5.1 Safety valve
Fig. 2.1
The safety valve makes sure that the maximum
permissible air inlet pressure on the air motor is
not exceeded.
The safety valve will open and vent off air when the
air inlet pressure exceeds the set limiting value.
CAUTION
Never remove the safety valve that is fitted and lead-sealed at the
factory or change its settings.
If the safety valve needs to be replaced, you can find the corresponding
order number on the machine card.
When using new safety valves make sure that they have been set to
the maximum permissible air inlet pressure of the WIWA mortar pump
(see type plate/machine card) and are lead-sealed.

Translation of the Original Operation Manual for Mortar Pumps 11
BetonP_BA_en_1302•jw
Safety
2.5.2 Compressed air shut-off valve
I
0
Fig. 2.2
The red compressed air shut-off valve on the air
maintenance unit interrupts the air supply for the
entire device. After the air supply has been cut off,
the device is still under pressure.
2.6 Information on explosion protection
WARNING
Machines that are designed without explosion protection must not be used
in workshops that come under the explosion protection ordinance.
Explosion-protected devices are labelled as such by means of an
EC declaration of conformity in accordance with ATEX 94 /9 /EC and
the Ex marking on the type plate.
Explosion-protected machines meet the explosion protection requirements
of 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 responsible
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 separate
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
additionally 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.
2.7 Notes on warranty
2.7.1 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 machine must only be operated within the specified limiting values
and machine parameters.

12 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Safety
2.7.2 Accessories and spare parts
If you use original accessories and spare parts from WIWA, their suitability
for use with our machines is guaranteed.
It is, however, mandatory to respect the safety regulations of the accessories
and spare parts. You will find these safety regulations in the corresponding
operating manuals for the accessories and spare parts.
If third-party accessories or spare parts are used, WIWA cannot guarantee
the safety of the whole machine. Liability for damages or injuries incurred
because of the use of those accessories and spare parts becomes null
and void.
2.8 Operating and maintenance personnel
2.8.1 Machine owner's duties
The machine owner:
is responsible for the training of the operating and maintenance staff,
must instruct the operating and maintenance staff in correct handling of
the machine as well as in wearing 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,
must ensure that the operating and maintenance staff have read and
understood the user manual.
Only then may the machine be brought into service.
2.8.2 Personnel qualication
A differentiation is made between two groups of people in dependence on
theirqualications:
Instructed operators have been verifiably instructed by the machine owner
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 machine builder such that they
are capable of carrying out maintenance and repair work on the system and
recognising potential risks on their own initiative and of avoiding these risks.
2.8.3 Authorized operating personnel
Activity Qualification
Setup and operation Instructed operator
Cleaning Instructed operator
Servicing Trained personnel
Repair Trained personnel
Juveniles under the age of 16 are not allowed to operate this machine.

Translation of the Original Operation Manual for Mortar Pumps 13
BetonP_BA_en_1302•jw
Safety
2.8.4 Personal Protective Equipment (PPE)
Wear protective clothing
Always wear the protective clothing prescribed for your work environment
(mining, closed rooms, etc.) and follow the recommendations in the safety
data sheet issued by the material manufacturer.
Use eye protection
Wear protective goggles to protect against eye injuries caused by material
splatter gases, fumes or dust.
Wear ear defenders
Operating personnel should be provided with suitable noise protection
equipment. The operator is responsible for adhering to the accident prevention
regulation "Noise" (BGV B3). For this reason, pay special attention to the
conditions at the installation location – the noise burden, for example, will
increase if the system is installed in or on hollow bodies.
Use a respiratory protection mask
We strongly recommend wearing a respiratory protection mask, even though
the paint mist has been minimized in Airless spray painting applications with
correct pressure setting and working mode.
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 sliding on slippery floors.
2.9 Emergency procedures
2.9.1 Leakages
In case of leakages, you must shut down the system immediately and the
complete system must be depressurized.
Interrupt the compressed air supply
Depressurize the entire system
Replace defective parts immediately.
2.9.2 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.

14 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Safety
2.10 Handling auxiliary materials
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.
Rests of paints, solvents, oils, greases and other chemical substances must
be collected in accordance with statutory provisions concerning recycling and
waste disposal.
The official local waste water laws are valid.

Translation of the Original Operation Manual for Mortar Pumps 15
BetonP_BA_en_1302•jw
Machine Description
3 Machine Description
3.1 Intended use
The WIWA range of mortar pumps is suitable for processing epoxy- and water-
based high-density solids and mortars with grain sizes of 0-4mm such as cement
mortar, cement-bonded fire protection materials and filled vinyl esters. You can
easily flush through and clean WIWA mortar pumps with thinner. This makes
these pumps highly suitable for processing epoxy-based materials too. By using
quick-release couplings, you can quickly dismantle, clean and reassemble the
material pumps that comprise only a few parts. The feed hopper is detachable.
The large-volume pumps are fitted with extra-large outlets and due to the slow
pump speed have low wear even with high material throughput.
Possible areas of application include, for example
the decks of ships and ferries
concrete repair and building renovation
water-proofing of basements
fire protection
Your unit has been specially adapted to the processing material
and is suitable for this purpose only. For the specific Technical
Data for your device, refer to the machine card.
WIWA mortar pumps are not suitable for conventional spraying.
Any other use is deemed not to be the intended use. The manufacturer's approval
must be obtained before the unit is used for any other purpose or with other
materials, i.e. not in accordance with the intended use, otherwise the warranty
will become null and void.
Intended use also includes compliance with the technical documentation and
adherence to the prescribed operating, servicing and maintenance guidelines.

16 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Machine Description
3.2 Machine structure
Item Designation
1 Air motor
2 Safety valve
3 Air maintenance unit (see detail)
4 Cart
5 Material pump
6 Feed drum 25 l
7 Material shut-off valve
8 Control air feed to switch the air motor ON
and OFF
9 Atomizer air OPEN/CLOSED
10 Atomizer air regulator
Item Designation
11 Compressed air shut-off valve
12 Oil filler hole
13 Inspection glass
14 Fog oiler setting screw
15 Pneumatic regulator with pressure gauge
16 Slide for opening the containers
17 Oil tank
18 Water separator
19 Drain valve
Type 410.09
Type 600.12
6
5
1
3
4
2
Spray tube (optional)
7
8910
OFF
ON
12
1819
11
13
14 15
16
17
Detail: 3Air maintenance unit
Type 410.09

Translation of the Original Operation Manual for Mortar Pumps 17
BetonP_BA_en_1302•jw
Installation and transportation
4 Installation and transportation
4.1 Safety measures at the installation location
The access to the safety features must be kept clear.
Always keep the working area, especially all walkways and standing
areas, clean and tidy. Clean up spilled paint or solvents immediately.
Always ensure for sufficient aeration and ventilation at the workplace
to avoid damage to health and material objects. Always observe the
processing instructions issued by the material manufacturers.
The owner must protect the machine by implementing appropriate
lightning protection measures.
Strictly comply with the valid accident prevention instructions.
4.2 Transporting the machine
Disconnect the entire power supply for the machine, even for short
transport distances.
Empty the machine before transport.
Caution when loading! Risk of injury! Never stand under suspended loads
or inside the loading area.
Ensure sufficient load bearing capacity of the hoisting gear.
Use only suitable transport vehicles.
Secure the load on the transport vehicle from slipping and falling off.
Parts or equipment that have been removed for transport purposes must
be attached professionally and in accordance with the intended use
before commissioning.

18 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Assembly
5 Assembly
1. Mount the feed drum onto the cart (Fig. 5.1) and bolt the material feed on
the container outflow securely to the pump (Fig. 5.2).
Fig. 5.1 Fig. 5.2
2. Connect the atomizer air hose (e) and the control air pipe (b) to the air
maintenance unit (Fig. 5.3).
3. Connect the material hose (d) to the pump (Fig. 5.3).
ef d
b c
a
Fig. 5.3
Item Designation
a Air hose (on-site)
b Control air pipe
c Compressed air supply of air motor
d Material hose
e Atomizer air hose
f Condensate drain
4. Connect the atomizer air hose, the control air pipe and the material hose
to the spray tube (Fig. 5.4).

Translation of the Original Operation Manual for Mortar Pumps 19
BetonP_BA_en_1302•jw
Putting into operation
b
d
e
Fig. 5.4
5. Connect the on-site air hose (a) (Fig. 5.3). Keep the compressed air shut-
off valve closed.
6 Putting into operation
6.1 Preparing
Make sure all system parts are leak-free at all times!
If the system has been at a standstill for a long time, test if for leaks.
Check that all the rotatable parts, nuts, screws and hose connections are
seated tightly and tighten them if necessary such that no material can
emerge from connections and cause injuries.
Check the stated maximum operating pressures. The specified maximum
operating pressures must always be adhered to for all WIWA parts
(pump, safety valve, material hose, spray gun, etc.) The data on these
parts must match or be higher than the values stated on the type plate
and the machine card.
Top up the fog oiler on the air maintenance unit with pneumatic oil or
anti-freeze and make the settings in accordance with Chapter “9.3 Air
maintenance unit”.
6.2 Initial cleaning
The machine was tested with a test medium before it left the factory. Before
using the machine for the first time, you must flush out this test medium.
You require:
At least 5 l of cleaning agent that matches the processed material.
Follow the recommendations of the material manufacturer.
1 empty, open container "B"

20 Translation of the Original Operation Manual for Mortar Pumps
 BetonP_BA_en_1302•jw
Operation
1. Have you turned the air pressure regulator all the way back?
2. Is the compressed air pipe connected?
3. Fill the cleaning agent into the feed drum
4. Hold the spray tube in container "B", open the material shut-off valve first
and then the control air feed on the spray tube.
5. Open the compressed air shut-off valve and set the air pressure regulator
to about 2 bar.
6. Allow the cleaning agent to run completely via the spray tube into
container "B".
7. Let the pump run for a little while even after all the cleaning agent has
been used to ensure that the cleaning agent drains completely from the
machine too.
8. Connect the control air feed to the spray tube first and then connect the
material shut-off valve.
9. Turn the air pressure regulator all the way back.
10.Close the compressed air shut-off valve.
7 Operation
7.1 General notes
Always follow the processing instructions provided by the material
manufacturers. All the materials to be processed should be supplied
by the manufacturer with data concerning the viscosity, application
temperatures, mixing ratios, etc. If this is not the case, please consult the
respective manufacturer about this data.
For optimum preparation of the materials, WIWA offers a wide range of
accessories, e.g.:
– agitators in various sizes
– material preheating containers in different sizes
– material flow heaters
7.2 Spraying
Wear the specified protective clothing.
Flush the machine as described in Chapter 7.3 every time before
carrying out recommissioning.
1. Have you closed the compressed air shut-off valve?
2. Have you turned the air pressure regulator all the way back?
3. Have you closed the material shut-off valve and the control air feed on
the spray tube?
4. Mix the spraying material well and fill it in the feed drum.