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User`s Handbook: WIWA Airless

1. Lifting screw 3 Vent hole 4 Flushing solvent drainage 11 Flushing solvent inlet 5 High pressure filter 6 Suction hose 8 Suction sieve 15 Conncetion for fluid hose 7 Suction pipe 17 Drain hose and valve 9 Muffler 10 Cart 13 Spanner with chain 14 Fluid section 16 Ground cable User s Handbook WIWA Airless 21 AA014 e206 02 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Machine description Designation of components 21 Adjusting screw for air maintenance unit 24 Air inlet for air maintenance unit 22 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG 19 Spraygun 22 Drain valve for air maintenance unit 23 Safety valve for air maintenance unit User s Handbook WIWA Airless AA014e 06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Start up Erection and Preparation User s Handbook WIWA Airless AA014e 06 03 WIA 4 4 1 1 Job You wish to erect the machine at the site and prepare it for operation Prerequisite The material to be worked with is prepared All materials to be sprayed should be marked with information on viscosity proces sing temperatures mixing propo
2. Cut off the compressed air supply with the compressed air tap lock Open the drain valve Replace defective parts immediately Injury Should an injury occur through contact with liquid spray we recommend a doc tor be called immediately Inform the doctor of the material sprayed e g paint and the solvent thinner Have the product data sheet at hand address and telephone number of supplier or manufacturer name of material and material number Memorize where you can call for aid Memorize the local emergency phone numbers In any case become familiar with the first aid measures Fires STOP Read the instructions for fire alarm and escape routes put up in your factory Memorize the local emergency phone numbers Memorize the location and operation of fire alarms fire extinguishers and sprinkler installations Take care that sufficient information notes labels for fire prevention are provided Do not apply any other extinguishing agents than those which are prescribed by the manufacturer of the materials 16 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA000 e 06 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de WIWA Safety 2 Protective equipment 2 10 All equipment is delivered with the following protective fitting Safety valve picture 2 10 1
3. User s Handbook WIWA Airless AA000 e 06 03 WIA Remedies open Air supply tap Clean Filter insert and exchange if necessary Airless Models Perfect and Effective only Press pin pos 12 chap 3 2 with small screwdriver Use only filtered air Overhaul Air motor according to the Spare Parts List and Repair Instructions Call Customer Service Clean Sieve Replace Hose Trigger gun without spray tip open Relief tap at High pressure filter see Spare Parts List on High Pressure Filter Knock lightly on the side of the Bottom valve with a hammer Unscrew Suction system Using a pin or a screw driver from underneath release Ball in Bottom valve Unscrew Bottom valve and clean thoroughly Ball with seat see Repair Instructions on Material pump Replace with new parts see Repair Instructions on Material Pump Increase air pressure at Air regulator Check that cross section of air line is correct Use smaller spray tip or bigger pump Replace with new spray tip Reduce if possible the air inlet pressure If not available install Air maintenace unit with Oiler Fill Oiler with anti freeze Glycol and adjust according to the operating instructions standard values 1 droplet by approx 10 cycles 39 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0
4. The safety valve prevents the maximum admissible entry air pressure being exceeded In the event that the fixed maximum entry air pressure setting is surpassed the saftey valve blows open Grounding cable picture 2 10 2 In order to avoid an electro static charge being built the airless machine must be EE grounded to an electrically conductive object by using the grounding cable Air Supply Shut Off The compressed air tap lock enables an immediate shut down of the unit picture 2 10 3 Tap lock at air maintencance unit off picture 2 10 4 Tap lock at air maintencance unit on Gun Safety picture 2 10 5 The gun s safety prevents it from being activated accidentally All protection devices must be checked Before each commissioning of the machine Before beginning work on or with the machine After all aligning work After cleaning and servicing After maintenance and repair Check list for inspecting the protection features when the unit is ina depressurized state Inspect the safety valve leading or seal for damage Inspect the safety valve for visible damage Inspect the grounding cable for damage Inspect the grounding cable s connection to the unit and to the conduct Inspect the compressed air tap lock for perfect functioning Inspect the functioning of the airless spraying gun s safety lever picture 2 10 5 If a protective device is not fully operative or another defect is detected on the machine interru
5. 27 completely including the six washers Pos 25 Place screwdrivers on both sides in the groove between the flange Pos 41 and the spring housing Pos 12 Pry down on the flange Attention Residual material could be released Remove the pressure cylinder Pos 32 including the counter ring Pos 29 and spring Pos 28 Remove the four threaded bolts Pos 24 from the air motor Attention Do not loosen the two lower bolts These are needed as support for the spring housing Place large screwdrivers on both sides in the groove between the spring housing Pos 12 and intermediate body Pos 3 Pry off the spring housing Pos 12 and pull it away from the dual piston Pos 14 Uncouple the dual piston Pos 14 together with the intermediate body Pos 3 from the motor axle Pull the dual piston Pos 14 out of the intermediate body Pos 3 Remove the spring Pos 10 from the spring housing Pos 12 Using a screwdriver pry the seals Pos 11 13 out of the spring housing Pos 12 Remove the complete packing Pos 7 9 from the intermediate body Pos 3 Remove the spring Pos 28 and the complete packing Pos 29 31 from the pressure cylinder Pos 32 Place the male adapter Pos 38 in a stock and tighten on the flats Loosen the pressure cylinder Pos 32 with an open end wrench SW 75 Remove the male adapter Pos 38 from the stock and unscrew it from the pressure cylinder Pos 32 Remove the valve plate Pos 37 the sealing ring Pos 36 and the
6. Place the dual piston Pos 14 with the wrench flats in a stock The coupling should face downwards Place the ring Pos 15 and the cylinder pin Pos 23 in the dual piston Secure these parts with the retaining ring Pos 16 For this use circlip pliers for internal rings size J2 Place the ball Pos 17 the seal Pos 18 and the valve plate Pos 19 in the dual piston Pos 14 Grease the threads on the screw Pos 20 Screw in the screw Pos 20 into the dual piston Pos 14 with an Remove the dual piston from the stock Clean the threads of the threaded pin Pos 34 as well as the corresponding threaded hole in the pressure cylinder Pos 32 Place the cylinder pin Pos 33 in the pressure cylinder Pos 32 secure the threaded pin Pos 34 with hard setting Loctite Screw the threaded pin Pos 34 into the pressure cylinder Place the ball Pos 35 the seal Pos 36 and the valve plate Pos 37 inset face towards the ball in the pressure cylinder Pos 32 Grease the threads of the male adapter Pos 38 Screw the male adapter Pos 38 into the pressure cylinder Pos 32 Place the male adapter Pos 38 in a stock and tighten the pressure cylinder Pos 32 with an open end wrench SW 75 Place the counterring Pos 31 in the pressure cylinder Pos 32 with the smooth surface down Place the complete packing in the pressure cylinder Pos 32 Assembly order Teflon packing ring Pos 30 6 crowned surface up dual sattel ring Pos 30 5 leather pac
7. ll 2G cT4 This equipment fulfills the explosion proof requirements found in the guideli ne 94 9 EC ATEX 95 for the type of explosion equipment catagory and tem perature class found on the nameplate This equipment is able to be installed in areas requiring Zone explosion protec tion Due to the possibility that explosive gases and overspray may be created this unit is to be considered as Group II Equipment Catagory 2G The flash point for the materials being sprayed as well as the solvent being used must be above 200 C This corresponds to the temperature class T3 When operating this equipment the User s Handbook must be followed closely The required inspection and maintenance intervals must be adhered to strictly All information found on the unit s signs or plates must be adhered to and not exceeded Do not allow this unit to be overloaded It is the responsibility of the operator of this equipment to determine the explosion risk zone determination according to EC regulation 94 9 EC Appendix II Nr 2 1 2 3 in the area of usage in accordance with local regulatory authority guidelines Furthermore it is the responsibility of the operator on sight to check and ensure that the technical specifications and markings according to ATEX are compliant with local requirements Please observe that some components have their own nameplate with separate markings according to ATEX The marking with the lowest rating for explosion prote
8. 0000045 e assembly paste for version R or RS pate d assemblage de version R et RS Diese Zeichnung darf nicht kopiert vervielfaltigt oder dritten Personen zuganglich gemacht werden Widerrechtliche Benutzung hat rechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecution copyright 2005 WIWA Wilhelm Wagner GmbH Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de High Pressure Filter Model 13 R 10 3 Troubleshooting 10 3 1 This chapter contains information on how to troubleshoot the high pressure filter Before The disassembly and reassembly are described step by step In addition you will beginning any repairs find an exploded line drawing of the high pressure filter as well as the related or maintenance on the spare parts lists at the conclusion of the troubleshooting section unit read all The appendix includes the spare parts list for either the Model 13 R or the Model instructions found in 13 R Sonder special version the User s Handbook and observe them closely The User s Manual must be available at all times when working on the unit A Pump does not work although the 1 High pressure filter is cl
9. 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Safety Installation Site User s Handbook WIWA Airless AA000 e 06 03 WIA 2 2 8 Safety measures at installation site The system must have a fixed position and sufficient space to ensure safe opera ting The passage to the safety fittings must not be blocked Keep the working area especially all gangways and standing areas clean Remo ve spilled paint or solvent immediately Ensure there is sufficient ventilation at the workplace to prevent damage to health and property Observe the manufacturer s processing instructions at all times Despite the fact that no legal regulations exist covering the low fog airless spraying method dangerous solvent fumes and particles of paint should be removed of per vaccuum The owner operator of this equipment is required to ensure that proper protection against lightning strikes is available Comply strictly with the current rules for accident prevention 15 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany 7 2 fl F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 G Se j E mail info wiwa de Internet www wiwa de Safety 2 Behavior in case of emergency 2 9 Leaks STOP If leaks occur in the system it must be shut down immediately and the entire sy stem depressurized
10. 35633 Lahnau Germany OH Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 x E d E mail info wiwa de Internet www wiwa de Safety 2 Sources of danger 2 6 2 regulation covering explosion prevention even if the accessory being used is explosion protected Due to electro static charges only conductive material hoses should be used All original WIWA material hoses are conductive and compatible with our equipment The maximum admissible working pressure on the hoses must correspond to the maximum operating pressure of each airless machine If the material being used clogs or clumps within the machine reminant pres sure may still exist despite depressurization efforts This must be kept in mind when carrying out repairs Special care must be taken when dismantling the high pressure filter material hoses and high pressure spray gun to ensure that no accidents occur due to escaping reminant pressure We recommend covering the material hoses fittings with a cloth during uns crewing in order to capture any fluid which might escape When working on the high pressure filter picture 2 6 4 for example to change the filter the machine must first be turned off and depressurized Never remove the safety valve fitted and sealed on the operation side and never adjust its setting picture 2 6 5 Should the safety valve need replacing please see the machine card for its order number Chapter 9 3 Please ensure
11. 7 2 fl F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 G Se j E mail info wiwa de Internet www wiwa de Safety 2 Dangers arising from the equipment 2 3 corresponds with the present standards of technical regulations and current rules for accident prevention It left the factory in perfect condition and warrants a high level of safety However the following dangers exist if operated incorrectly or used inappropriately STOP This machine was designed and built in accordance with all safety aspects It to life and limb of operator or third persons for the machine and other property belonging to owner of machine for the efficient working of the machine All personnel involved in the starting operation and maintenance of the machine must read the following notes carefully and observe them It is a matter of their safety We recommend that the machine operation management have this confirmed in writing Additionally please pay attention to the following Please read and observe the guidlines valid for your country In Germany the Richtlinien fur Flussigkeitsstrahler Guidelines for liquid sprayers Published by Hauptverband der Gewerblichen Berufsgenossenschaften are valid We recommend adding a copy of all guidelines and accident prevention regulations into the user s manual Manufacturer s notes and operating guidelines for coating material and pumping material should be observed at all times In princi
12. Akt 20 07 07 ICT La b um 45 nach 3 hinten gedreht Ass routed 45 Ensemble tourn par 45 t P l g e a D A s dy Ji Dt GON Dt H r EE TT 13 Pos Nr in Klammern sind keine Betandteile dieser Baugruppe items markedthus are not part of assembly shown Les pi ces entre paranth ses ne font pas partiedu sous groupe Diese Zeichnung darf nicht kopiert vervielfaltigt oder dritten Personen zuganglich gemacht werden Widerrechtliche Benutzung hat strafrechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecution Bestell Nr Order No Pieces V D2 R Artikelbezeichnung Part D scription D signation des articles Reference 1 0411965 Kupplung coupling accouplement 2 0411949 Winkel elbow coude 3 0621749 T Stuck t piece pi ce ent 4 0621730 Langnippel extension nipple nipple longue 5 0468622 Kugelhahn ball valve vanne 6 0648094 1 Doppelnippel male adaptor raccord double m le copyright 2005 WIWA Wilhelm Wagner GmbH Co KG WIWA Wilhelm Wagner GmbH amp Co KG WIWA LP GewerbestraBe 1 3 35633 Lahnau Germany 1244A Exec Blvd Suite 101 Chesapeake VA 23320 USA Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 Tel 1 866 661 2139 Fax 1 757 436 2103 Z
13. Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Disturbances during operation and Trouble shooting Faults E Pump cycles unevenly and does not reach the required spraying pressure The uneven cycling of the pump is recognizable by the difference of the cycling speed of the upward and downward strokes 40 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG Probable Causes The viscosity of the coating material is too high suction loss Suction system is not tight spray jet pulsates Bottom valve is not tight pump stalls on the upward stroke when gun is closed Piston valve is not tight pump stalls on the downward stroke when gun is closed Upper or lower packing corroded wear and tear WIA 8 2 Remedies Thin down coating material Use bigger pump Check all seals on fittings of Suction pipe and hose and exchange if necessary See Spare Parts List on Flexible suction assembly and or Direct suction assembly Unscrew Bottom valve Thorougly clean Ball with seat and exchange if necessary see Repair Instructions on Material Pump Check and clean Ball with seat of Dual Piston and exchange if necessary see Repair Instructions on Material Pump Exchange packings see Repair Instructions on Material Pump User s Handbook WIWA Airless AA0002e 06 03 GZ0000 ON 1 p10 SSeUdINd YMIM esees6 z p oe WUEO
14. Pi ces d usure usuelles E Sicherungsmittel 50 ml Engineering adhesive 50 ml Colle industrielle 50ml Best Nr 0000015 2D Teile des Dichtungssatzes Parts of seal kit e Pi ces de kit de joints O Schmiermittel saurefreies Fett Lubrication grease acid free SR Teile des Reparatursatzes Parts of repair kit e Pi ces de kit de reparation Mati re graisse sans acide Best Nr 0000025 Pos Nr in Klammern sind keine Bestandteile dieser Baugruppe Items marked thus are not part of assembly shown Les pi ces entre paranth ses ne font pas partie du sous groupe Diese Zeichnung darf nicht kopiert vervielf ltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat strafrechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without the authorization of WIWA Unauthorized use is subject to prosecution Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de PIA 10 1 10 1 1 Material Pump 275 120 R 0641416 Troubleshooting AN Before beginning any repairs or maintenance on the unit read all instructions found in In this chapter you will find information pertaining to troubleshooting the material pump
15. Pos 58 from the lower housing Place the cylinder onto an even padded surface Press the piston plate Pos 60 and guide axle Pos 58 out of the cylinder use a rubber mallet if necessary Step 13 Remove the o ring Pos 61 and guide ring Pos 59 from the piston plate Pos 60 Span the piston plate Pos 60 in a bench vise The motor axle Pos 69 must be facing upward Remove the motor axle Pos 69 from the piston plate with an open end wrench SW 30 If the motor axle can not be turned the connection between the motor axle and piston plate has to be heated with a gas torch to release the grip of the sealant applied to the threadings Remove the disc Pos 63 and o ring Pos 62 from the piston plate Pos 60 Remove the guide axle Pos 58 the stop bolt Pos 67 the disc Pos 66 the spring Pos 65 and the stop guide Pos 64 from the motor axle Pos 69 Repair Manual 3 RA076 078 080 e 09 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 10 2 Disassembly 10 2 2 Step 14 Remove the o ring Pos 72 from the bottom housing Pos 77 Using circlip pliers J 2 remove the retaining ring Pos 75 from the bottom housing Pos 77 Press the guide bush Pos 49 out of the bottom housing Pos 77 from below wth the disassembled motor axle if necessary
16. Pos 68 and set it into the motor axle Pos 69 Push the other spring Pos 65 over the stop guide Pos 64 Push the stop guide Pos 64 with the flange facing upward over the wrench flats of the guide axle Pos 58 Lightly grease the axle and all axle mounted components Place the guide axle Pos 58 into the motor axle Pos 69 Span the piston plate Pos 60 in a bench vise Apply high strength thread sealant i e Loctite to the threading of the motor axle Pos 69 Push the guide axle Pos 58 through the hole in the piston plate Screw the motor axle into the piston plate Pos 60 using an open end wrench SW 30 Remove the piston plate Pos 60 from the bench vise Grease the outer rim of the piston plate Pos 60 Fit the o ring Pos 61 and guide ring Pos 59 into the groove on the outer rim of the piston plate Pos 60 Apply grease again to the o ring Pos 61 Place the cylinder Pos 71 onto the bottom housing Pos 77 Evenly grease the inner wall of the cylinder Pos 71 Grease the motor axle Pos 69 Press the piston plate Pos 60 incl the complete motor axle assembly into the cylinder Pos 71 through the bottom housing Pos 77 Use a rubber mallet to fit the piston plate into the cylinder if necessary Warning The piston plate should only be pressed into the cylinder until the upper rim is cleared Use two open end wrenches SW 30 46 to mount the coupling onto the motor axle 5 Copyright 2002 WIWA Wilhelm Wagn
17. acid free SR Teile des Reparatursatzes Parts of repair kit e Pi ces de kit de reparation Mati re graisse sans acide Best Nr 0000025 Pos Nr in Klammern sind keine Bestandteile dieser Baugruppe Items marked thus are not part of assembly shown Les pi ces entre paranth ses ne font pas partie du sous groupe Diese Zeichnung darf nicht kopiert vervielf ltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat strafrechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without the authorization of WIWA Unauthorized use is subject to prosecution Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de WIA Typ 275 120 R 001 Akt 08 05 Materialpumpe Material Pump Section fluide Bestell Nr e Order No R f rence 0641416 Serie Serie S rie Best Nr Order No Pieces V D2 R R f rence Pi ce Artikelbezeichnung Part Description D signation des articles W bm 31 0641479 1 Gegenring counter ring bague de retenue 32 0641480 1 Druckzylinder pressure cylinder cylindre de pression 33 0638858 1 R Zylinderstift cylindrical pin goupille cylindrique 34 0638682 1 Gewindestift
18. maximum operating pressures given by us are to be adhered to in prin ciple for all WIWA parts eg pump heater hoses gun safety valve By differing allowable operating pressures the lowest value is always the maximum allowable operating pressure for the entire system Example Pump up to 420 bar Material hose up to 600 bar Spraying gun up to 500 bar Easy clean up to 350 bar The maximum allowable operating pressure for this system would be 350 bar x Smoking open flames or any other possible ignition sources are not allowed anywhere near the area of operation User s Handbook WIWA Airless 13 AA014 e206 03 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany S E E E E E E F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 G d E E mail info wiwa de Internet www wiwa de Safety 2 Operating staff 2 7 Authorised Operators STOP People under the age of 16 should not operate this equipment The management in charge of the operation of the machine must make the user s handbook available to the operator and must make sure that he has read and understood it Only then may the system be put into operation We recommend the manager has this confirmed in writing The operator of the machine is obliged to report any changes in the machine which might affect its safety to the manager as he must ensure that the machine is functional The responsibilities for the differen
19. that new safety valves are set and sealed to the maximum permitted air inlet pressure for the WIWA spray machine see type plate machi ne card chapter 9 3 During operation ensure that sufficient feed of material is available to the pump in order to avoid heating due to friction caused when the material pump runs dry Observe closely no empty feed containers may be present during operation the suction system may not be clogged buckled or defect in any other way if the unit stops processing material shut it down immediately picture 2 6 5 In closed or pressurised systems where aluminium or galvanised parts come into contact with the solvent dangerous chemical reactions can occur if 1 1 1 Trichlorethylene Methylene Chloride or other solvents containing halogenated chlorinated hydrocarbons CFCs are used If you wish to work with the above solvents or with lacquers and paints which contain them we recommend you contact either WIWA customer services or WIWA directly We call your attention to the fact that a series of airless equipment including versions which are rust and acid proof is available for such materials 12 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de WITA Safety 2 Sources of danger 2 6 3 The
20. the gasket Pos 16 onto the upper housing Place one after the other the lower housing Pos 15 the intermediate ring Pos 5 and the upper housing Pos 3 with muffler onto the upper housing Pos 18 Using an open end wrench SW 17 cross tighten the 4 dome nuts Pos 1 with washers Pos 2 onto the fittings Pos 8 Mount the material pump according to the instructions found in Chapter 10 1 3 Repair Manual 8 RA076 078 080 e 09 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG W bm WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 7 E mail info wiwa de Internet www wiwa de Materialpumpe Material Pump Section fluide Typ 275 120 R Bestell Nr e Order No R f rence 0641416 Serie Serie S rie 001 Akt 08 05 1V Verschlei teile e Wear parts Pi ces d usure usuelles E Sicherungsmittel 50 ml Engineering adhesive 50 ml Colle industrielle 50ml Best Nr 0000015 2D Teile des Dichtungssatzes Parts of seal kit e Pi ces de kit de joints O Schmiermittel saurefreies Fett Lubrication grease acid free SR Teile des Reparatursatzes Parts of repair kit e Pi ces de kit de reparation Mati re graisse sans acide Best Nr 0000025 Pos Nr in Klammern sind keine Bestandteile dieser Baugruppe Items marked thus are not part of as
21. threaded pin bouchon filete 35 0410551 1 V R Kugel ball bille 36 0223387 1 D R Dichtring gasket bague d tanch it ST 0418501 1 V Ventilplatte valve plate plateau de soupape 38 0639223 1 Doppelnippel male adaptor raccord double male 39 0471100 1 Sicherungsring retaining ring circlip 40 0465542 1 Ring ring joint 41 0643418 1 Flansch flange collet 0641556 R Dichtungssatz seal kit jeu de joints 0641557 Reparatursatz repair kit jeu de reparation optional erhaltlich optional disponible en option 8 Manschetten oben packing ring upper joints superieures 0641472 V Manschette Teflon schwarz packing ring Teflon black joints Teflon noir 0641468 V Manschette Leder packing ring leather joints cuir 0647055 V Manschette Teflon natur wei packing ring Teflon natur white joints Teflon blanc 0647056 V Manschette PUR rot packing ring PUR red joints PUR rouge 0647057 V Manschette SDM gr n packing ring SDM green joints SDM vert optional erhaltlich optional lower disponible en option 30 Manschetten unten packing ring joints inferieures 0641477 V Manschette Teflon schwarz packing ring Teflon black joints Teflon noir 0641469 V Manschette Leder packing ring leather joints cuir 0647058 V Manschette Teflon natur wei packing ring Teflon natur white joints Teflon blanc 0647059 V Manschette PUR rot packing ring PUR red joints PUR rouge 0647060 V Manschette SDM gr n packing ring SDM green joints SDM vert 1V Verschlei teile e Wear parts
22. 476862 1 Gewindestift threaded pin bouchon filete 22 2 0488755 1 Zylinderstift cylindrical pin goupille cylindrique 22 3 0641494 1 Ventilgehause valve housing corps de vanne 22 4 0410217 1 Kugel ball bille 23 0473243 1 Zylinderstift cylindrical pin goupille cylindrique 24 0643417 6 Stehbolzen threaded bolt boulon 25 0460389 6 U Scheibe washer rondelle 26 0460966 6 Mutter nut coru 27 0641463 6 Hutmutter dome nut crou borgne 28 0639226 1 Druckfeder spring ressort 29 0641476 1 Gegenring counter ring bague de retenue 30 0641482 1 V R Manschettensatz gemischt packing ring set mixed jeu de joints compos bestehend aus Pos 30 1 30 6 consiting of pos 30 1 30 6 consistant en pos 30 1 30 6 30 1 0641477 1 V R Manschette Teflon schwarz packing ring Teflon black joints Teflon 30 2 0641469 1 V R Manschette Leder packing ring leather joints cuir 30 3 0641477 1 V R Manschette Teflon schwarz packing ring Teflon black joints Teflon 30 4 0641469 1 V R Manschette Leder packing ring leather joints cuir 30 5 0641478 1 V R Doppelsattelring dual sattle ring bague de retenue double 30 6 0641477 1 V R Manschette Teflon schwarz packing ring Teflon black joints Teflon 1V Verschlei teile e Wear parts Pi ces d usure usuelles E Sicherungsmittel 50 ml Engineering adhesive 50 ml Colle industrielle 50ml Best Nr 0000015 2D Teile des Dichtungssatzes Parts of seal kit e Pi ces de kit de joints O Schmiermittel saurefreies Fett Lubrication grease
23. 9 3 This user s manual is valid only in connection with the following machine chart The machine chart includes all machine specifications and details which are important and relevant for safety exact designation and manufacturing data technical specification and limit values equipment and checking certificate e data for purchase e machine features machine components and accessories included in the supply with article and spare parts number Please pay attention that the machine chart specification is in accordance with the CH machine label picture 9 3 1 In case of any deviations or default of a label we picture 9 3 1 would ask you to advise us without delay User s Handbook WIWA Airless 43 AA0002e 06 02 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG MACHINE CARD FOR WIWA PROFESSIONAL SERIES Manufacturer WIWA Wilhelm Wagner GmbH amp Co KG 35633 Lahnau 1 Distributor WIWA Wilhelm Wagner LP 107 N Main St Alger OH 45812 Telephone 855 757 0141 Description WIWA 75 1 Herkules Part No 7000202 Production Year 2012 Customer Golden State Delivery Date Sept 2012 Working Pressure max in psi 6615 Pressure Ratio 75 1 Air Inlet Pressure max in psi 15 Output per cycle fl oz 9 3 Machine Specifications Spare Parts Part No Description Reference Number 0641427 High Pressure Pump consisting of 0640818 Air Motor 333 120 0640818 0641416 Material Pump 275 120 0641416 0065285 Hi
24. A A Ensure that no loose items i e paint cans are transported with the unit when it is loaded lifted or suspended Parts or equipment dismounted for transportation purposes must be properly remounted according to application by a specialist before start up On the air motor s cylinder cover there are two lifting rings picture 2 12 1 which picture 2 12 1 allow the unit to be lifted safely by means of a hoist User s Handbook WIWA Airless 19 AA014 e 01 03 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Machine description 3 Designation of components 1 9 1 10 2 3 11 12 4 b 13 14 15 6 7 16 8 17 1 Lifting ring 2 Air motor A Vent hole 4 Flushing solvent drainage 5 High pressure filter 6 Suction hose 7 Suction pipe 8 Suction sieve 9 Muffler 10 Cart 11 Flushing solvent inlet 12 Airmaintencance unit with safety valve and air stop cock 13 Spanner with chain 14 Material pump 15 Connection for fluid hose 16 Ground cable 17 Dram hose 20 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Machine description 3 Designation of components 2
25. E mail info wiwa de Internet www wiwa de E mail s_nelsen wiwa com Internet www wiwa com Wartungseinheit kpl Air Maintenance Unit cpl unite d entretien cpl LM 300 333 Bestell Nr Order No R f rence 0648095 Serie Serie S rie 000 Akt 20 07 07 Pos Bestell Nr Pos Order No Pieces V D2 R Artikelbezeichnung Part D scription D signation des articles Code R f rence Forts 0649744 Dichtung gasket joint 8 0647298 Wartungseinheit maintenance unit unit d entretien 9 0642261 Muffennippel socket nipple raccord de manchon 10 0621722 Rohrverschraubung pipe fitting raccord viss 11 0621730 Langnippel extension nipple nipple longue 12 0648417 1 Verschraubung screw fitting vissage 13 0643925 0 8m Schlauch hose flexible 1V Verschlei teile Wear parts Pi ces d usure usuelles 2D Teile des Dichtungssatzes Parts of seal kt Pi ces de kit de joints 3R Teile des Reparatursatzes Parts of repair kit Pi ces de kit de reparation Ra Teile des Reparatursatzes gro Parts of repair kit big e Pi ces de kit de reparation grand 3Rx Teile des Reparatursatzes klein Parts of repair kit small Pi ces de kit de reparation petit Sicherungsmittel Thread sealant produit d etanch ite Schmiermittel Lubrication grease Mati re graisse Symbol Beschreibung Artikel Bestell Nr Symbol Beschreibung Bestell Nr Symbol Description Article Order No Symbol Description Order
26. H amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany 7 2 fl F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 G Se j E mail info wiwa de Internet www wiwa de Safety 2 Description of symbols 2 1 The signs and symbols used in this manual have the following meaning STOP marks a section of text which is especially relevant to safety Special attention should be paid to this section and it s contents strictly observed Gel KJ Co SMOKING PROHIBITED marks a situation in which a fire hazard arises through the use of flammable or explodable solid fluid or gaseous materials WARNING marks a situation which could be dangerous If not observed death or very serious injuries could result DANGER OF EXPLOSION marks a situation where there is danger of explosion Observation of this information is absolutely essential ELECTRICAL VOLTAGE marks a situation where there is a danger of explosion through an electostatic charge Observation of this information is absolutely essential USE EAR PLUGS For health reasons it is very important to pay attention to this warning USE BREATHING PROTECTION For health reasons it is very important to pay attention to this warning HEALTH DANGER marks materials which are hazardous to your health Observation of this information is absolutely essential FIRST AID In case of injuries or accidents these instructions should be absolutely adhe
27. L ZS Lop L GZ L L9 oes duind ZS 8 OS Oe ll ll OZI OZI ww 8 40 S uolsid JOJO Jy lt Ts d ece Oz eee Oz eee DOE ww J euuelIp uo sid jojouu Ji Ser 98009 82009 ZS08v 9r09b S 0S L90SE 41 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG s Handbook WIWA Airless User e 05 03 AA014 WIWA Gewerbestr 1 3 35633 Lahnau Germany R E E E E F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 i E mail info wiwa de Internet www wiwa de 3 Appendix 9 Certificate of Training and Operation 9 2 This certificate corresponds to the EU guideline for working substances 85 655 EWG Paragraph Il Article 7 The owner of the following machine has trained the operating personnel Make Model Year of Construction Order Number The training was conducted by the following designated person Foreman or responsible Superior Name Department The persons trained have read and understood the user s handbook for the above mentioned machine especially the chapter Safety and are certain that they can operate this machine safely Personnel Electric Electronics Date Name 42 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA0002e 06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de TIA Appendix 9 Machine cart and spare parts lists
28. Materialkarte Order number for safety valve see card of machines Reference de soupape de suret voir carte machine V Verschlei teile e Wear parts Pieces d usure usuelles Sicherungsmittel 50ml Thread sealant 50ml produit d etanch ite 50ml 2D Teile des Dichtungssatzes Parts of seal kit Pi ces de kit de joints schwach light leger Best Nr 0000016 3R Teile des Reparatursatzes Parts of repair kit Pi ces de kit de reparation D mittel medium medium Best Nr 0000015 9 hochfest high streng hautesistance Best Nr 0000014 Schmiermittel Lubrication grease Mati re graisse Pos Nr in Klammern sind keine Betandteile dieser Baugruppe Fett s urefrei acid free sans acide Best Nr 0000025 e items markedthus are not part of assembly shown Sp lmittel lubricating fluid produit de nettoyage Best Nr 0163333 e Les pieces entre paranth ses ne font pas partiedu sous groupe M Montagepaste f r R und RS Ausf hrung Best Nr 0000045 e assembly paste for version R or RS pate d assemblage de version R et RS Diese Zeichnung darf nicht kopiert vervielf ltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat rechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecu
29. Mount the 4 o rings Pos 39 in the grooves on the control cylinder Pos 13 Lightly grease the control cylinder Place the control housing onto your workbench with the side having the least number of holes facing upward Place the control cylinder Pos 13 into the control housing Pos 14 from above until the retaining ring rests on the housing Note You can use a bench vise to press the control cylinder into the control housing Repair Manual T RA076 078 080 e 09 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 374 GAA E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 10 2 Assembly 10 2 3 Step 2 Place the gasket Pos 17 onto the upper housing Warning The side with the silver markings must face upward Ensure that the holes in the gasket are aligned perfectly with the holes found in the upper housing Press the control housing Pos 14 with the retaining ring facing upward over the threaded bolts Pos 10 and onto the upper housing Pos 18 Place the cover Pos 11 onto the control housing Pos 14 The groove for the retaining ring must be facing downward Place the 4 washers Pos 9 onto the threaded bolts Pos 10 Screw the 4 fittings Pos 8 onto the threaded bolts Pos 10 using an open end wrench SW 17 Warning Cross tighten them evenly to a max torque of 25 Nm 18 4 ft lb Step 1 Place
30. No Symbole Description L article R ferenz Symbole Description R ferenz schwach light leger 50 ml 222 0000016 Fett s urefrei acid free sans acide 0000025 mittel medium medium 50 ml 243 0000015 Sp lmittel lubricating fluid produit de nettoyage 0163333 mittel Kunststoff Stahl medium plastic steel 480 0000107 Montagepaste f r R und RS Ausf hrung assem Schw medium plastique acier 20 ml bly paste for version R or RS pate d assemblage 0000045 o hochfest high streng hautesistance 50 ml 601 0000014 de version R et RS hochfest f r Cr Ni Teile for Cr Ni steel parts 2701 0000303 pour partes fabriqu de Cr Ni 50 ml e Rohrdichtungspaste pipe sealant pate 225 0000017 d tanch it pour tuyaux 50 ml a Aktivator activator activateur 500 ml 734 0000018 Aktivator fur Kunststoffteile activator for pla 770 0000108 stic parts activateur pour pi ces de plastique 10 ml Gewindeband threaded tape ruban de 0000099 filetage copyright 2005 WIWA Wilhelm Wagner GmbH Co KG Ansaugleitung Suction System Syst me d aspiration Bestell Nr e Order No R f rence 0652416 Serie Serie S rie 000 Datum Date Date 12 02 10 FTA NW32 RS DR Pos Nr in Klammern sind keine Betandteile dieser Baugruppe items markedthus are not part of assembly shown Les pi ces entre paranth ses ne font pas partie du sous gro
31. Pieces V D R Artikelbezeichnung Part D scription R f rence 1 0218359 Kappe cap 2 0414719 Stiftschl ssel mit Kette spanner with chain 3 0218375 O Ring o ring 4 0218367 Stehbolzen threaded bolt 5 0468029 Reduziernippel reducing nipple 6 0218286 1 Mutter nut V Verschlei teile e Wear parts Pieces d usure usuelles Sicherungsmittel 50ml Thread sealant 50ml produit d etanch ite 50ml 2D Teile des Dichtungssatzes Parts of seal kit Pi ces de kit de joints r schwach light leger 3R Teile des Reparatursatzes Parts of repair kit Pi ces de kit de reparation D mittel medium medium Q hochfest high streng hautesistance Schmiermittel Lubrication grease Mati re graisse Pos Nr in Klammern sind keine Betandteile dieser Baugruppe D Fett saurefrei acid free sans acide e items markedthus are not part of assembly shown I Sp lmittel lubricating fluid produit de nettoyage e Les pieces entre paranth ses ne font pas partiedu sous groupe M Montagepaste f r R und RS Ausfiihrung Best Nr 0000015 Best Nr 0000014 Best Nr 0000025 Best Nr 0163333 Best Nr 0000045 e assembly paste for version R or RS pate d assemblage de version R et RS Diese Zeichnung darf nicht kopiert vervielfaltigt oder dritten Personen zuganglich gemacht werden Widerrechtliche Benutzung hat rechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or p
32. Repair Manual 4 RA076 078 080 e 09 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 Assembly Repair Manual RA076 078 080 e 09 03 Step 14 Step 13 Step 12 10 2 10 2 3 General Instructions Please note the below instructions are numbered in reverse order to correspond to the same steps found in the previous chapter Begin with Step 14 Before assembly clean all components thoroughly Replace damaged parts with new ones Motor axle guide axle and cylinder may not show any signs of wear or sco ring Procedure Lightly grease the guide bush Pos 49 Place the guide bush Pos 49 into the bottom housing Pos 77 use a rubber mallet if necessary Use circlip pliers J 2 to mount the retaining ring Pos 75 to the bottom housing Pos 77 Grease the o ring groove in the bottom housing Pos 77 and mount the o ring Pos 72 Place the o ring Pos 62 and the disc Pos 63 into the piston plate Pos 60 Apply high strength thread sealant i e Loctite to the threading of the stop bolt Pos 67 Screw the stop bolt Pos 67 with disc Pos 66 into the guide axle Pos 58 on the side without wrench flats Span the stop bolt in a bench vise and tighten the guide axle with an open end wrench SW 12 Grease the spring
33. The disassembly and assembly are described step for step In addition you will find an exploded line drawing of the material pump as well as the related spare parts lists at the conclusion of the troubleshooting section First check the faults cause in the table found in Chapter 10 1 1 Disassemble the material pump as necessary according to Chapter 10 1 2 Once the fault has been repaired reassemble the material pump according to the instructions found in Chapter 10 1 3 the User s Handbook and observe them closely The User s Manual must be available at all times when working on the unit The assembly instructions include additional information concerning the use of grease Loc Tite allowable torque etc A Pump operates but no spray material reaches the spray tip B Pump operates irregularly noticable by different speeds for upward and downward strokes and does not produce the required spraying pressure C Spray material reaches spray gun but pump does not stop operating when gun is closed Repair Manual MP RM075 076 ses 02 2 Suction hose is clogged 3 The ball in the bottom valve does not lift sticks Bottom valve does not close Bottom valve leaking Pump always stops on upwards stroke when spray gun is closed Piston valve leaking Pump always stops on downward stroke when spray gun is closed Upper or lower packing leaking worn Packing or valve worn 1 Suct
34. UODI e GLO000 ON 489piO BSEYDINd YMIM IW OG Ielu euu Buluino s S AJipd pue adueuajurew 104 pasinbas sjeuajeyy 9 0 ON JOPIO SSEYDINd YMIM Dn Huyesiiqn VAAIAA 24 Bsn o pu uuulo591 M pinbil Duugaugn 9 90 ON JOPIO BSCUDING YMIM JuUebe Bulzeey nue VAAIAA 24 PUSWILUODSJ m uoll93 oid wnwdo 104 slliun 3upBu lulBuli wie 40j Juabe bulzaas nuy s1 1 Gol 6LGZE90 ON JEPIO BSEYIINd VANAA 004 llo 9 euin ud OSS3 saliddns Ayojoe ay SJIUN BOUBUBJUIEW Ie J10 HO DJEUINBU sjenajyew Ai 9u uSEelN 0c SE9SP NIC pue LOZLE N3 NIG O00ZLE N NIC FFZ8 OSI N3 NIG psepueys Bulmoj o out o Hulpsoooe p uluuj8 p u q sey sejd yJOM 4 Je Dote I A Sinsseid punos au d 08 gp peol un Buruuny t gp 4 aip ye Buruuny opd YIOM 3y Je p y 9A 1inss id punos T S ed BY p 1 unoui jem 1uBISA JEN S LOL dt eo By payunow peo JuBI A JON gt o gt E UU HXAAXT p lunoui jem suoisu uuidq 2 e OOOLX00SX00S BO WW HXMXJ p unoui Wed SUCISUBWIG Zei ef youl tun ocueu luleu jeu JY gt o 3 S 8 XZ V SdN b L youl Us 1nss id uBiu ezis d Xe D CT n 88z vez 66 89 Op lev 4eq ainssaid Buljesado Xen CS 2 9 9 Z 9 9 Z 1eq inss id sie umdut Xew Z E g e d S 2 OSS OSS O9 O9 GlZ GlZ w39 ap Jad nd nO g q 09 09 el el Ge Ge LU 1nd no Ao J 9 1J VE S O Lo L 8Z
35. WIWA GmbH amp Co KG WIWA LP Gewerbestr 1 3 35633 Lahnau Germany 1244A Exec Blvd Suite 101 e Chesapeake VA 23320 USA s Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 Tel 1 866 661 2139 Fax 1 757 436 2103 E d 3 E mail info wiwa de Internet www wiwa de E mail info wiwa com Internet www wiwa com User s Handbook WIWA Airless O Herkules 35061 gt Herkules 35075 O Herkules 48046 O Herkules 48057 O Herkules 60028 O Herkules 60036 User s Handbook WIWA Airless AA014 e 08 03 1 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA GmbH 8 Co KG WIWA LP f E d Gewerbestr 1 3 35633 Lahnau Germany 1244A Exec Blvd Suite 101 Chesapeake VA 23320 USA i F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 Tel 1 866 661 2139 Fax 1 757 436 2103 ws E mail info wiwa de Internet www wiwa de E mail info wiwa com Internet www wiwa com Declaration of Conformity We WIWA Wilhelm Wagner GmbH amp Co KG GewerbestraBe 1 3 D 35633 Lahnau hereby declare in sole responsibility that the product Airless Farbspritzgerat machine types Herkules 35061 35075 48046 48057 60028 60036 to which this declaration relates complies with the following standards and documents in accordance with the EC Machinery Directive 98 37 EC DIN EN 292 Part 1 edition 11 91 German version EN 292 1 1991 DIN EN 292 Part 2 edition 06 95 German ver
36. address and telephone number of the manufacturer is at your disposal User s Handbook WIWA Airless 3 AA000 e 06 02 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany S E E E E E E F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 G d E E mail info wiwa de Internet www wiwa de Contents 1 Preface 1 1 This User s Handbook must always be available to operating staff The operating authority of the equipment must ensure that a user s handbook is available to the operator in a language which he understands Dear customer Thank you for your decision to purchase WIWA equipment In the user s handbook you can find all information required for the proper han dling of your WIWA Airless Paint Spraying Machine However for safe operation there are further essential details which you should adhere to Please read and observe the guidlines valid for your country In Germany the Richtlinien f r Fl ssigkeitsstrahler Guidelines for fluid sprayers published by Hauptverband der Gewerblichen Berufsgenossenschaften Industrial Employer s Liability Insurance Association are valid Manufacturer s notes and operating guidelines for coating and pumping materials should be observed at all times No method of operation should be exercised which impairs the safety of WIWA products and the operating personnel We wish you much success and excellent working result
37. assed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecution copyright 2005 WIWA Wilhelm Wagner GmbH Co KG WIWA Wilhelm Wagner GmbH amp Co KG WIWA LP GewerbestraBe 1 3 35633 Lahnau Germany 244A Exec Blvd Suite 101 Cheseppeake VA 23320 USA Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 Tel 1 866 661 2139 Fax 1 757 4386 2103 E mail info wiwa de Internet www wiwa de E mail s nelsen wiwa com Internet www wiwa com WIA Typ 13 R Akt 11 07 05 Hochdruckfilter High pressure filter Filtre haute pression Bestell Nr e Order No R f rence 0065285 Serie Serie S rie 002 Bestell Nr oS Order No Pieces V D2 R Artikelbezeichnung Part D scription D signation des articles Code R f rence Forts 7 0646988 Kugelhahn beinhaltet ball valvei includes vanne inclus 0646990 Dichtungssatz fur Kugelhahn seal kit for ball valve jeu de joints pour vanne 0646991 Kugel fur Kugelhahn ball for ball valve bille pour vanne 0646989 Schaltgriff handle grip manette de changement 8 0646729 1 Entlastungsschlauch drain hose flexible de d charge 9 0460230 1 U Scheibe washer rondelle 10 0460567 1 Schraube screw vis 11 0474487 1 Erdungskabel ground wire cable de terre 12 0410209 1 Kugel ball bille 13 0216011 1 Hutmutter dome nut crou capuchon 14 0467766 1 Doppelnippel male adaptor raccord double ma
38. away from the carrier Pos 27 to expose the wrench flats Use two open end wrenches SW 12 14 to remove the control axle Pos 38 from the guide axle Pos 58 If the control axle can not be turned the connection between the control and guide axles has to be heated with a gas torch to release the grip of the sealant applied to the threadings Pull the carrier Pos 27 and dampening spacer Pos 47 from the control axle Pos 38 Step 10 Remove the 8 dome nuts Pos 52 spring rings Pos 51 and washers Pos 50 from the bottom housing Pos 77 with 2 open end wrenches SW 19 Remove the 6 threaded bolts Pos 48 together with the washers Pos 32 spring rings Pos 31 and dome nuts Pos 30 from the cylinder cover Pos 33 Remove the 2 threaded bolts Pos 48 with the ring nuts not pictured as well Step 11 Remove the cylinder cover Pos 33 from the cylinder Remove the o ring Pos 70 from the cylinder cover Carefully remove the lip seal Pos 57 from the cylinder cover Pos 33 using a small flathead screwdriver Remove the disc Pos 56 Using circlip pliers J 2 remove the retaining ring Pos 55 Using a punch OD 15mm 0 6 in tap out the sintered bearing Pos 54 Pull the 2 air inlet pipes Pos 74 and o rings Pos 73 76 out of the cylinder cover Pos 33 and bottom housing Pos 77 Step 12 Using 2 open end wrenches SW30 SW46 remove the coupling from the motor axle Pos 69 Remove the cylinder Pos 71 incl piston plate Pos 60 and guide axle
39. ball Pos 35 from the pressure cylinder Pos 32 Loosen the threaded pin Pos 34 as necessary to remove the cylinder pin Pos 33 The cylinder pin Pos 34 must be heated to loosen the Loctite 2 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Material Pump 275 120 R 0641416 10 1 Disassembly 10 1 2 Step 9 Place the dual piston Pos 14 with the wrench flats and the screw Pos 20 facing upwards in a stock Loosen and remove the screw Pos 20 with a wrench SW 41 Remove the valve plate Pos 19 the ball Pos 17 and the seal Pos 18 from the dual piston Pos 14 Loosen the retaining ring Pos 16 with circlip pliers for internal rings size J2 19 60mm Remove the cylinder pin Pos 23 and the ring Pos 15 from the dual piston Pos 14 Repair Manual MP 3 RMO075 076 e 09 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Material Pump 275 120 R 0641416 10 1 Assembly Step 9 Step 8 Step 7 Step 6 Repair Manual MP RM075 076 e 09 03 10 1 3 General Instructions Clean all parts thoroughly before assembly Replace all damaged parts as well as seals and used packings Procedure
40. be filled with lubricant fluid see chapter 7 2 Maintenance Plan We recommend using WIWA lubricant order no 0163333 Fill the maintenance unit with pneumatic oil and antifreeze and take the setting as described in chapter 7 3 Maintenance on the maintenance unit This does not apply to machines delivered in a standard version with only a compressed air regulator Please use only the pneumatic oil listed in chapter 9 1 For optimal protection we recommend the use of WIWA pneumatic oil order no 0632579 or the WIWA antifreeze order no 0631387 Result The machine is now ready for operation Continue with the first cleaning chapter 4 2 picture 4 1 4 24 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany E E F F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 z E d E mail info wiwa de Internet www wiwa de Start up 4 First cleaning 4 2 1 Job This machine was factory tested after assembly for perfect functioning with a test medium The entire system should be flushed with Wash Thinner before spray operation begins so that the material to be sprayed is not affected by the test medium Prerequisite You will need 1 open container with cleaning material at least 5 Itr of Wash Thinner or sol vent called container A below A B e 1 empty open container for the mixture o
41. bound air supply and depressurize the unit Disconnect the material pump from the air motor To accomplish this follow the instructions found in Chapter 10 1 2 Procedure Using an open end wrench SW 17 remove the 4 dome nuts Pos 1 and washers Pos 2 Remove the complete upper housing Pos 3 and muffler assembly Remove the intermediate ring Pos 5 and the lower housing Pos 15 from the upper housing Pos 18 Remove the gasket Pos 16 from the upper housing Using an open end wrench SW 17 unscrew the four threaded pins Pos 8 and washers Pos 9 from the threaded bolts Pos 10 Remove the cover Pos 11 from the control housing Pos 14 Remove the control housing Pos 14 incl Pos 12 13 39 from the upper housing Pos 18 Remove the gasket Pos 17 from the upper housing Using circlip pliers A3 remove the retaining ring Pos 12 from the control housing Pos 14 Use an appropriate punch to tap the control cylinder Pos 13 out of the control housing Warning To avoid damage do not pull the control cylinder out of the housing with pliers Remove the 4 o rings Pos 39 from the control cylinder Pos 13 Using two open end wrenches SW 17 remove the two nuts Pos 6 from the control piston Pos 7 Remove the control piston Pos 7 Remove the retaining screw Pos 23 with a socket wrench SW 32 Remove the spring Pos 22 Using circlip pliers J 2 remove the toggle Pos 20 incl toggle bearing Pos 21 and the bear
42. can be ended If your system is fitted with an air maintenance unit you can now set it as described in the Maintenance and Starting Up of the Air Maintenance Unit Ge chapter 7 3 After long periods without use you should carry out the following in order to test the tightness of the seals and joints in the equipment but only with the gun closed and secured Increase the pressure on the compressed air regulator to the given maximum air inlet pressure Now inspect the joints on the parts which carry material for tightness Turn the air regulator slowly back to 1 2 bar by turning the regulating screw to the left Now take the suction pipe out of the solvent container and pump out the solvent remaining in the pump completely Turn the air regulator back by turning the regulator screw to the left until it moves freely Close the main air supply tap Close the spray gun and secure the safety catch Hold the relief hose into open container B B Place the suction pipe with sieve in material container C Open the main air supply tap and adjust air regulator to 1 2 bar Open the relief tap on the high pressure filter Close the relief tap when the material to be processed comes out of the relief hose C Disengage the safety catch from the spray gun and trigger Spray the rest of the solvent remaining in the hose and gun into container B until the material to be User s Handbook WIWA Airless 29 AA014 e 06 03 Copyri
43. ccidents Working with liquid jet STOP intervals by a specialist WIWA Service The equipment must be checked before the first start up after changes and repairs of equipment parts having an effect on safety after an interruption of operation of more than 6 months however at least every 12 months For equipment which has been taken out of operation the check can be post poned up to the next start up The results of the checks must be recorded in writing and kept until the next check The checking certificate or a copy of it must be available at the place where the equipment is used User s Handbook WIWA Airless 35 AA000 e 06 02 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany OH Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 x E d E mail info wiwa de Internet www wiwa de Maintenance Repair 7 Maintenance plan 7 2 Before each start up check the level of the lubricating liquid and if necessary refill lubricating liquid Flushing solvent quantity The sight glass has to be half filled by flushing solvent Check lubricant once every 50 operating hours for discolouration with spraying material If slightly discoloured Change the lubricant By draining a small amount the degree of discolouration can be controlled Once finished refill an equal amount of clean lubricant to that which was drained If heavily discolour
44. ction becomes valid for the entire system If the intended application could lead to injury of personnel if this equipment malfunctions on sight precautions and preventive measures must be implemented picture 2 4 1 If this equipment appears to be malfunctioning or behaving strangely during ground screw on the high operation the unit must be shut down immediately and WIWA Customer pressure filter Service contacted as soon as possible It must be ensured that the unit is grounded either separately or together with the equipment it is mounted to maximum resistance 10 Q picture 2 4 1 ground potential equalization User s Handbook WIWA Airless 9 AA014 e208 03 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany 7 2 fl F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 G Se j E mail info wiwa de Internet www wiwa de Safety Machine surroundings 10 2 2 5 Rebuilds and changes For safety reasons it is not allowed to carry out rebuilds or changes without autho rization Protective equipment may not be dismounted changed or neglected If using components which are not produced or delivered by WIWA warranty coverage is negated as well as liability The machine may only be operated within the prescribed limits and machine parameters Danger caused by attachments and spare parts If you use original attachments and original spare parts fr
45. cure the trigger when making a pause in working for a couple of minutes Place the tip in a container with applicable solvent This will prevent the tip from becoming clogged with hardend paint Spraying tips Replace the spraying tip before it is worn out Worn tips lead to excessive paint consumption and lower the quality of the paint s coating 31 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Operation 5 Change of material 5 3 1 Shutting down Carry out all points found in Shutting Down chapter 6 2 Filter inspection When changing materials also inspect the filter insert Open the drain cock to ensure that the machine is absolutely free of pressure Unscrew the high pressure filters s cap with the spanner picture 5 3 1 Loosen the nut and remove the filter insert picture 5 3 2 Clean the filter insert with solvent Should the filter insert show any signs of damage replace it with a new one Reset the filter insert onto the threaded bolt and tighten it by rescrewing the nut Screw the cap back onto the high pressure filter and tighten it with the spanner For R and RD version high pressure filters To avoid seizing lightly grease the threads before assembly 3 Starting up Then carry out all points in Starting Up chapter 4 32 User s Ha
46. d spanner Pos 2 to loosen the filter cap Pos 1 and remove it from the filter housing Pos 16 15 Remove the o ring Pos 3 from the housing Pos 16 15 Using an open end wrench SW 13 remove the nut Pos 21 20 from the threaded bolt Pos 4 Remove the filter insert Pos 20 19 from the threaded bolt Pos 4 Clean the filter insert Pos 20 19 using the solvent or thinner recommended by the coatings material manufacturer Assemble the parts in reverse order Replacing the high pressure ball valve Remove the drain hose Pos 9 using an open end wrench SW 17 Loosen the nut Pos 6 with an open end wrench Do this while holding the reducing nipple Pos 5 in place Loosen the ball valve Pos 7 using an open end wrench SW 17 Mount a new ball valve in the reverse order Please note The numbers found in parenthesis refer to Model 13 R Sonder special version 19 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Wilhelm Wagner GmbH amp Co KG WIWA LP GewerbestraBe 1 3 35633 Lahnau Germany 1244A Exec Blvd Suite 101 Chesapeake VA 23320 USA Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 Tel 1 866 661 2139 Fax 1 757 436 2103 Z E mail info wiwa de Internet www wiwa de E mail s_nelsen wiwa com Internet www wiwa com Wartungseinheit kpl Air Maintenance Unit cpl unite d entretien cpl LM 300 333 Bestell Nr Order No R f rence 0648095 Serie Serie S rie 000
47. diate body Pos 3 Couple the dual piston Pos 14 in the motor axle of the air motor Push the intermediate body Pos 3 onto the air motor Adjust the intermediate body Pos 3 with the type plate to the front Step 3 Screw the threaded bolts Pos 24 in the lower piece of the air motor Attention Screw the two side bolts only about half way in and the others completely Push the spring housing Pos 12 with the spring over the dual piston Pos 14 onto the intermediate body Pos 3 Adjust the spring housing Pos 12 with the material outlet to the front Step 2 Push the second spring Pos 28 from underneath into the spring housing Push the complete pressure cylinder Pos 32 over the dual piston Pos 14 onto the spring housing Pos 12 Tip Use the help of a second person push the flange Pos 41 over both side bolts Pos 24 Step 1 Screw a nut Pos 26 onto each of these threaded bolts Pos 24 with a washer Repair Manual MP RM075 076 e 09 03 Pos 25 Alternately tighten both nuts evenly with an open end wrench SW 24 This will push the pressure cylinder onto the spring housing and the spring housing onto the intermediate body Screw the rest of the nuts Pos 26 with washers Pos 25 onto the other threaded bolts Pos 24 as soon as the threads become visible Tighten the pump in an X pattern evenly together Attention The pump components must remain square The proper tightening torque is 120 Nm Screw on the cap nuts Pos 27 and t
48. e 5 1 2 28 ITA 5 5 1 1 Please wear protective clothing at all times as solvent vapours and splashes of solvent cannot be avoided completely Inspect the seal of all system components and tighten the connections if necessary Job You want to prepare the machine for coating or painting work Prerequisite You will need e 1 open container with cleaning material solvent belonging to the coating material and recommended by the material manufacturer called container A below e 1 empty open container for the soiled cleaning material material mixture abbreviated as container B below 1 material container called container C below Do not use narrow necked cans or barrels with bung holes Procedure Place a filter insert which is appropriate for the coating material and suits the spray nozzle being used into the high pressure filter The mesh opening should always be slightly smaller than the bore of the nozzle used Filter insert Nozzle size M 200 white up to 0 23mm 009 M 150 red over 0 23mm 009 upto 0 33m 013 M 100 black over 0 33mm 013 upto 0 38m 015 M 70 yellow over 0 38mm 015 upto 0 66m 026 M 50 orange over 0 66mm 026 Do not use filter inserts for materials with coarse pigments or fibre filled materials The suction sieve which is fitted as standard should however stay in the sieve casing or be exchanged for a coarser sieve The use of a WIWA Easy Clean reversible
49. e spray gun into the open container B and spray against the inside wall for at least 10 seconds If using metal containers the spray gun must always remain in contact with the wall of the container because of possible electrostatic loading We recommend a cleaning period of approx one minute for a good cleaning result In order to avoid the danger of explosion caused by the heating of cleaning material it should not be pumped for longer periods a maximum of 5 A B minutes of time Result max 2 bar The machine is now completely cleansed Continue with the pressure check found min 10 sec in chapter 4 3 min 10 sec max 5 min 26 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Start up 4 First cleaning 4 3 Job You want to inspect the seal all system components Procedure Warning If using a fluid heater the heater may not be turned on at any time while making the pressure test The entire machine must be cooled completeley DANGER OF EXPLOSION Observe the flash point for the solvent being used Close the gun and secure it with the safety catch picture 4 3 1 Set the maximum permitted pressure by turning the regulating screw on the air regulator to the right picture 4 3 2 Observe the maxi
50. ed and large proportion of spraying material is present Clean the lubricant chamber change the upper pump packing see list of spare parts for material pump and fill with new lubricant We recommend using WIWA flushing agent order no 0163333 You will find further maintenance information for each component located in the appendix of each spare parts list Fill lubricant Air motor Fluid pump Sight glass Lubricant drain picture 7 2 1 Filling and draining lubricant 36 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Maintenance Repair 7 Maintenance of the high pressure filter Typ 13 Sonder 7 3 1 Always disconnect the power supply and drain any pressure before starting maintenance work on the high pressure filter Clean the filter insert in the high pressure filter daily or after every change of material Apply the drain tap often to avoid clogging of the draining system e Change and clean the filter insert and o ring Unscrew the cap Pos 1 with the spanner Pos 2 picture 7 3 1 neue 7 3 1 Unscrew the nut Pos 21 with a fork wrench and remove the filter insert Pos 20 picture 7 3 2 Clean the filter insert Pos 20 Use only the appropriate solvent for the material being worked
51. ent This prevents remaining material from drying out lt Take the suction pipe out of the material container C Wipe remaining paint from the suction pipe and suction sieve Place the suction pipe with sieve in the open container A with the solvent C belonging to the coating material Open the main air supply tap and set the air regulator to 1 2 bar by turning the regulating screw to the right Hold the airless spray gun in such a way that the material released or the soiled solvent is sprayed sideways onto the inside wall of the open container B Pump until clean solvent is emitted User s Handbook WIWA Airless 33 AA000 e 06 02 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 JE r a E mail info wiwa de Internet www wiwa de e z Shutting down 6 2 When using metal containers ensure that the spray gun maintains contact with the inside wall of the container because of possible electrostatic charging As soon as clean solvent is released the rinsing process can be ended Warning If using a fluid heater the entire machine must be cooled completeley before cleaning it with solvent DANGER OF EXPLOSION Observe the flash point for the solvent being d used Es In order to avoid unnecessary material wastage we recommend spraying the material remaining in the hoses back in
52. er Best Nr DI mittel e medium medium Best Nr 9 hochfest high streng hautesistance Best Nr Schmiermittel Lubrication grease Mati re graisse Fett saurefrei acid free sans acide Best Nr SpUlmittel lubricating fluid produit de nettoyage Best Nr M Montagepaste f r R und RS Ausf hrung Best Nr e assembly paste for version R or RS pate d assemblage de version R et RS Diese Zeichnung darf nicht kopiert vervielfaltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat rechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecution copyright 2005 WIWA Wilhelm Wagner GmbH Co KG 0000016 0000015 0000014 0000025 0163333 0000045 WIWA Wilhelm Wagner GmbH amp Co KG WIWA LP GewerbestraBe 1 3 35633 Lahnau Germany 1244A Exec Blvd Suite 101 Chesapeake VA 23320 USA Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 Tel 1 866 661 2139 Fax 1 757 4386 2103 E mail info wiwa de Internet www wiwa de E mail s nelsen wiwa com Internet www wiwa com WIA D333 120 Akt 16 12 05 Luftmotor Air Motor Motor pneumatique Bestell Nr e Order No R f rence 0640818 Serie Serie S rie 001 Bestell Nr Order No R f rence Pieces V D R3 Ar
53. er GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 10 2 Assembly 10 2 3 Step 11 Place an o ring Pos 76 onto each of the air inlet pipes Pos 74 Lightly grease the o rings Pos 76 Place the air inlet pipes Pos 74 into the bottom housing Pos 77 Place the o ring Pos 70 into the greased groove in the cylinder cover Pos 33 Set the sintered bearing Pos 54 into the cylinder cover Pos 33 Using circlip pliers J 2 mount the retaining ring Pos 55 over the sintered bearing Pos 54 Press the disc Pos 56 onto the retaining ring Pos 55 Grease the lip seal Pos 57 Place the lip seal Pos 57 onto the disc Pos 56 and grease it again Warning Lay the lip seal flatside down into the groove so that the seal s ridge rests into the groove in the cylinder cover Place an o ring Pos 73 onto each of the air inlet pipes Pos 74 Lightly grease the o rings Pos 73 Place the cylinder cover Pos 33 onto the cylinder Pos 71 The cover must fit exactly onto the air inlet pipes Step 10 Mount the 8 threaded bolts Pos 48 16 washers Pos 32450 16 spring rings Pos 31 51 and 14 dome nuts Pos 30 52 and 2 ring nuts not pictured hand tight Warning Mount the threaded bolts with the ring nuts not pictured opposite of one another in front of or behind the air inlet pipes Position the air inl
54. ermany 1244A Exec Blvd Suite 101 Chesapeake VA 23320 USA Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 Tel 1 866 661 2139 Fax 1 757 4386 2103 E mail info wiwa de Internet www wiwa de E mail s nelsen wiwa com Internet www wiwa com ATA D333 120 Akt 16 12 05 Luftmotor Air Motor Motor pneumatique Bestell Nr e Order No R f rence 0640818 Serie Serie S rie 001 Ge Bestell Nr oS Order No Pieces V D2 R Artikelbezeichnung Part D scription D signation des articles Code Reference Forts 75 0471666 Winkel elbow coude 76 0643956 1 T St ck t piece pi ce en t 77 0490997 1 Regelventil control valve soupape de r glage 78 0640920 1 Verschraubung screw fitting vissage 79 0632715 1 Druckluftschlauch compressed air hose flexible l air comprim 80 0463175 1 Verschraubung screw fitting vissage 81 0632081 1 R ckschlagventil non return valve soupape de non retour 82 0413666 1 T St ck T piece piece en T 83 0463175 1 Verschraubung screw fitting vissage 84 0632715 1 Druckluftschlauch compressed air hose flexible l air comprim 85 0640920 1 Verschraubung screw fitting vissage 86 0632081 1 R ckschlagventil non return valve soupape de non retour ohne Abbildung not illustrated sans illustration 0463787 2 Ringmutter ring nut crou anneau 0640899 Dichtungssatz seal kit jeu de joint 0640900 Reparatursatz repair kit jeu de r paration Bestell Nr fur Sicherheitsventil siehe
55. et pipes vertically to the upper and bottom housings Cross tighten the eight threaded bolts with two open end wrenches SW 19 Step 9 If the guide axle Pos 58 is not positioned outside of the cylinder cover screw an M 8 outer threading bolt through the cylinder cover and into the axle Pull the axle upward until visible and remove the M 8 bolt Or Carefully press the piston plate Pos 60 into the cylinder until the axle is visible Press the dampening spacer Pos 47 onto the axle Pos 58 Completely degrease the axle Set the carrier Pos 27 with the hole facing downward onto the axle Pos 58 Apply high strength thread sealant i e Loctite to the threadings of the control axle Pos 38 Using two open end wrenches SW 12 14 mount the control axle Pos 38 to the guide axle Pos 58 Press the dampening spacer Pos 26 onto the control axle Apply some grease to the upper rim of the larger section outer diameter of the control axle Lightly grease the dampening spacers carrier and guide axle as well Place the o rings Pos 28 46 onto the cylinder cover Pos 33 Step 8 Set the sintered bearing Pos 24 into the upper housing Pos 18 Using circlip pliers J 2 set the retaining ring Pos 25 into the groove on the upper housing Step 7 Mount the de icing assembly to the upper housing Screw both non return valves Pos 83 88 incl the fittings Pos 82 87 into the two 1 4 holes in the sides of the upper housing Connect the control
56. f cleaning material and test medium called container B below Do not use narrow necked cans or barrels with bung hole When being used for the first time the sticker with the text remove before use and the sealing plug is to be removed from the ventilation hole overflow The ventilation hole is located in the elbow with the openeing facing downward picture 4 2 1 Please check whether the material hoses comply with the maximum working pressure and the prescribed safety factor They should not have any leaks kinks signs of wear or bulges The hose fittings must be securely attached and also comply with maximum pressure When using a fluid heater please be sure to observe that it is cold during the cleaning process picture 4 2 Procedure Please wear protective clothing at all times as solvent vapours and splashes of solvent cannot be avoided completely The main air supply tap must be closed Attach the material hose to the secured airless spray gun picture 4 2 2 Connect the material hose with attached gun without the nozzle to the outlet of the high pressure filter picture 4 2 3 Remove the filter insert from the high pressure filter in accordance with chapter Vids Release the locknut on the air pressure regulator picture 4 2 4 Adjust the air pressure regulator back by turning the regulating screw to the left until it turns freely Connect the air maintenance unit or air pressure regulato
57. g joint 05 3 0221759 1 Ventilgeh use valve housing corps de vanne 06 0641470 1 Einsatz insert insertion 07 0641471 1 Sattelring saddle ring bague de retenue 08 0641481 1 V R Manschettensatz gemischt packing ring set mixed jeu de joints compos bestehend aus Pos 8 1 8 5 consiting of pos 8 1 8 5 consistant en pos 8 1 8 5 08 1 0641472 1 V R Manschette Teflon schwarz packing ring Teflon black joints Teflon 08 2 0641468 1 V R Manschette Leder packing ring leather joints cuir 08 3 0641472 1 V R Manschette Teflon schwarz packing ring Teflon black joints Teflon 08 4 0641468 1 V R Manschette Leder packing ring leather joints cuir 08 5 0641472 1 V R Manschette Teflon schwarz packing ring Teflon black joints Teflon 09 0641473 1 Gegenring counter ring bague de retenue 10 0639226 1 Druckfeder spring ressort 11 0465755 1 D R Dichtring gasket bague d tanch it 12 0641475 1 Federgeh use spring housing logement de ressort 13 0465755 1 D R Dichtring gasket joint 14 0641474 1 V Doppelkolben dual piston piston double 15 0612030 1 Ring ring joint 16 0473251 1 K Ring K ring K joint 17 0412414 1 V R Kugel ball bille 18 0223255 1 D R Dichtung gasket joint 19 0418498 1 V Ventilplatte valve plate plateau de soupape 20 0223263 1 Schraube screw vis 21 0218618 1 Dichtung gasket joint 22 0641495 1 Ruckschlagventil non return valve soupape de non retour bestehend aus Pos 22 1 22 4 consiting of pos 22 1 22 4 consistant en pos 22 1 22 4 22 1 0
58. gh Pressure Filter 0065285 0467782 M30 Filter Insert 0601578 Safety Valve 75 psi 0648095 Air Maintenance Unit 0648095 4300000 Cart 0652416 Suction Hose 0652416 0638163 Suction Strainer 0474487 Ground Wire 0163333 Throat Seal Liquid 0632579 Pneumatic Oil 8 22 2012 WIWA Wilhelm Wagner GmbH amp Co KG WIWA LP GewerbestraBe 1 3 35633 Lahnau Germany Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 E mail info wiwa de Internet www wiwa de Luftmotor Air Motor Motor pneumatique 0640818 Bestell Nr e Order No R f rence Enteisung Deicing CO PL bm Bild 0640814E_1 tif 1244A Exec Blvd Suite 101 Chesapeake VA 23320 USA Tel 1 866 661 2139 Fax 1 757 436 2103 E mail s_nelsen wiwa com Internet www wiwa com TIA D333 120 Serie Serie S rie 001 B 2mm Spiel gt E 61 3 62 F g 63 _ 64 o ag Luftmotor Air Motor Akt 16 12 05 V Verschlei teile e Wear parts Pieces d usure usuelles 2D Teile des Dichtungssatzes Parts of seal kit Pi ces de kit de joints 3R Teile des Reparatursatzes Parts of repair kit e Pi ces de kit de reparation Pos Nr in Klammern sind keine Betandteile dieser Baugruppe e items markedthus are not part of assembly shown e Les pieces entre paranth ses ne font pas partiedu sous groupe Sicherungsmittel 50ml Thread sealant 50ml produit d etanch ite 50ml schwach light leg
59. ght 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa Operation Equipment preparation WIWA 5 5 1 3 processed comes out of the gun Ensure contact with the container wall When using a fluid heater the following steps must be stricktly adhered to Before allowing the fluid heaters to heat the materials to be sprayed must be circulated in a cold condition as there may be solvent residue in the fluid heaters or somewhere else in the systems Be certain to ensure that the fluid heaters are turned off during preparation RISK OF EXPLOSION Always observe the flash point of the solvent being used as stated in the manufacturer s data sheet Close the airless spray gun and secure the safety catch Clean the gun outlet with solvent and a brush Mount a spraying tip or an Easy Clean reversible tip cleaning device with tip see list of spare parts for spray gun chapter 9 3 Regulate working pressure with the air regulator Result The machine s preparation is completed You may now commence with coating 30 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG User s Handbook WIWA Airless AA014 e 06 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Operation Coating ope
60. ght 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA000 ee06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Contents 1 Table of contents 1 2 1 Contents 1 1 Preface 1 2 Table of contents 2 Safety 2 1 Description of symbols 22 Warning instructions located on the machine 23 Dangers arising from the equipment 24 Application of the machine 25 Machine surroundings 2 6 Sources of danger 2 f Operating staff 2 8 Installation site 2 9 Behavior in case of emergency 2 10 Protective equipment 2 11 Handling of the machine and auxiliary material 2 12 Transportation of the machine and additional equipment 3 Machine description 3 1 Designation of components 4 Start up 4 1 Erection and preparation 4 2 First cleaning 43 Checking pressure 5 Operation 5 1 Equipment preparation 5 2 Coating operation 5 3 Change of material 6 Shutting down 7 Maintenance Repair 7 1 Checks 7 2 Maintenance plan 7 3 Diverse maintenance instructions 8 Disturbances during operation and Trouble shooting 9 Appendix 9 1 Technical specification and Machinery materials 9 2 Certificate of Training and Operation 93 Machine chart and spare parts lists 10 Instructions for Repair 10 1 Material Pump 10 2 Air Motor 10 3 High Pressure Filter User s Handbook WIWA Airless 5 AA000 e 06 02 Copyright 2001 WIWA Wilhelm Wagner Gmb
61. hlei teile e Wear parts Pieces d usure usuelles Sicherungsmittel 50ml Thread sealant 50ml produit d etanch ite 50ml 2D Teile des Dichtungssatzes Parts of seal kit Pi ces de kit de joints schwach light leger Best Nr 0000016 3R Teile des Reparatursatzes Parts of repair kit Pi ces de kit de reparation D mittel medium medium Best Nr 0000015 9 hochfest high streng hautesistance Best Nr 0000014 Schmiermittel Lubrication grease Mati re graisse Pos Nr in Klammern sind keine Betandteile dieser Baugruppe Fett saurefrei acid free sans acide Best Nr 0000025 e items markedthus are not part of assembly shown Sp lmittel lubricating fluid produit de nettoyage Best Nr 0163333 e Les pieces entre paranth ses ne font pas partiedu sous groupe M Montagepaste f r R und RS Ausf hrung Best Nr 0000045 e assembly paste for version R or RS pate d assemblage de version R et RS Diese Zeichnung darf nicht kopiert vervielf ltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat rechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecution copyright 2005 WIWA Wilhelm Wagner GmbH Co KG WIWA Wilhelm Wagner GmbH amp Co KG WIWA LP GewerbestraBe 1 3 35633 Lahnau G
62. ift cylindical pin goupille cylindrique 28 0463795 6 Hutmutter dome nut crou borgne 29 0460931 8 Federring spring ring rondelle lastique 30 0461091 8 U Scheibe washer rondelle 31 0640811 1 Zylinderdeckel kpl cylinder cover couvercle de cylindre 32 0631415 3 Langnippel extension nipple nipple long 33 0415200 3 Winkel elbow coude 34 0463825 3 Schalld mpfer muffler silencieux 35 0638181 1 Steuerachse control axle axe de contr le 36 0632936 4 D R O Ring o ring joint torique 37 1 Sicherheitsventil safety valve soupape de s curit V Verschlei teile e Wear parts Pi ces d usure usuelles Sicherungsmittel 50ml Thread sealant 50ml produit d etanch ite 50ml 2D Teile des Dichtungssatzes Parts of seal kit Pi ces de kit de joints schwach light leger Best Nr 0000016 3R Teile des Reparatursatzes Parts of repair kit Pi ces de kit de reparation D mittel medium medium Best Nr 0000015 hochfest high streng hautesistance Best Nr 0000014 Schmiermittel Lubrication grease Mati re graisse Pos Nr in Klammern sind keine Betandteile dieser Baugruppe Fett saurefrei e acid free sans acide Best Nr 0000025 e items markedthus are not part of assembly shown Sp lmittel lubricating fluid produit de nettoyage Best Nr 0163333 e Les pieces entre paranth ses ne font pas partiedu sous groupe M Montagepaste f r R und RS Ausf hrung Best Nr 0000045 e assembly paste fo
63. ighten them likewise to a torque of 120 Nm Remount the other components suction line high pressure filter etc Inspect the material pump for leaks 5 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Wilhelm Wagner GmbH amp Co KG GewerbestraBe 1 3 35633 Lahnau Germany Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 E mail info wiwa de Internet www wiwa de WIWA LP 244A Exec Blvd Suite 101 Cheseppeake VA 23320 USA Tel 1 866 661 2139 Fax 1 757 436 2103 E mail e nelsen wiwa com Internet www wiwa com Hochdruckfilter e High pressure filter Filtre haute pression Bestell Nr e Order No R f rence 0065285 Einla B inlet entr e 1514 1213 1 Serie Serie S rie 002 ATA Typ 13 R Akt 11 07 05 Tabelle 1 Filtereins tze filter inserts filtre filtre seuls Werkstoff WICHTIG Vorschriftm ige Erdung ee eet GE WARNING Ground as prescribed maille Reference ATTENTION Mettez a la masse mee E M 50 0162787 M 70 Standard 0162779 M 100 0162760 M 150 0162752 M 200 0162744 Bild 0065285_1 tif HU WM Dm Material Mati re premi re Gewebe Edelstahl Fassung Kunststoff Screen wire special steel Rim plastik Fil toile m tallique acier special Support Mati re artificille D signation des articles capot clef avec chaine joint torique boulon raccord de reduction crou Best Nr 0000016 Bestell Nr Order No
64. ing auxillary materials suchas paint solvents oils grease and other chemical substances comply with the safety and dosing instructions of the manu facturer and the generally applicable regulations Left over solvents oils grease and other chemical substances must be collected according to the legal regulations for recycling and waste disposal The local official laws for the protection of waste water must be observed 18 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA000 ee06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de VIWA Safety 2 Transportation of the machine and additional equipment 2 12 Interrupt the complete power supply of the machine even for short transport routes Before transportation empty the machine Pay attention when loading with our without hoisting devices When loading the machine with hoisting devices pay attention to sufficient load capacity Secure the hoist tightly to both eye bolts Ensure that the load is evenly distributed Warning The maximum load per eye bolt is 100kg 220lbs Never stand under swiveling loads or in the loading area due to exposing your life to danger Only use suitable transportation vehicles with sufficient load capacity Secure the load on the transportation vehicle against slipping and falling down
65. ing bush Pos 19 if necessary Repeat these steps for the retaining screw on the other side Remove the 2 screws Pos 45 and washers Pos 44 Remove the cover Pos 43 from the upper housing Screw a nut M 8 onto each of the four threaded bolts Pos 10 and counter each with a second nut Using an open end wrench SW 13 remove the 4 threaded bolts from the upper housing Remove the 6 screws Pos 41 and washers Pos 42 from the upper housing Pos 18 with an open end wrench SW 17 Remove the upper housing Pos 18 from the cylinder cover Pos 33 Remove the compressed air hoses Pos 81 86 with an open end wrench SW 14 Using an open end wrench SW 19 remove the non return valves Pos 83 88 incl the fittings Pos 82 87 and the control valve Pos 79 incl the fitting Pos 80 2 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 10 2 Disassembly 10 2 2 Step 8 Using circlip pliers J 2 remove the retaining ring Pos 25 from the upper housing Pos 18 Use a punch OD 20mm 0 8 in to tap out the sintered bearing Pos 24 Step 9 Remove the o rings Pos 28 46 from the cylinder cover Pos 33 Remove the dampening spacer Pos 26 from the control axle Pos 38 Pull the control axle Pos 38 upward and push the dampening spacer Pos 47
66. ion screen is clogged 1 Clean the screen 2 Replace hose 3 Operate spray gun without tip 1 Open the drain valve on the high pressure filter Tap the bottom valve lightly on the side with a hammer Remove suction system and use a rod or screwdriver to loosen the ball in the bottom valve from below Remove bottom valve and clean the ball and seat thoroughly Steps 1 4 amp 8 Remove bottom valve and clean ball and seat thoroughly or replace ball and valve seat as necessary Steps1 4 8 2 Clean the ball and seat in the piston valve and inspect and replace as necessary Steps1 4 9 3 Replace packing 1 Steps 1 7 Replace worn parts Steps 1 9 1 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Material Pump 275 120 R 0641416 10 1 Disassembly Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Repair Manual MP RM075 076 e 09 03 10 1 2 General Instructions For simple disassembly assembly place the high pressure pump in a horizontal position by laying the cart down Procedure Loosen and remove the six cap nuts Pos 27 with an open end wrench SW 24 Use a second open end wrench SW 24 on the nut Pos 26 in the opposite direction as necessary Remove the six nuts Pos
67. iration WIWA Taicang Co Ltd No 87 East Suzhou Rd Taicang City Jiangsu Province 215400 P R China Tel 86 512 5354 8858 Fax 86 512 5354 8859 E mail info wiwa china com Internet www wiwa com Ansaugleitung Bestell Nr e Order No R f rence 0652416 ee d ZLA Suction System Serie Serie S rie 000 Syst me d aspiration Datum Date Date 12 02 10 NW32 RS Sicherungsmittel Thread sealant produit d etanch ite Betriebsmittel Machinery materials Equipement de production Symbol Beschreibung Artikel Bestell Nr Symbol Beschreibung Bestell Nr Symbol Description Article Order No Symbol Description Order No Symbole Description L article R ferenz Symbole Description R ferenz schwach light leger 50 ml 222 0000016 Fett saurefrei acid free sans acide 0000025 mittel medium medium 50 ml 243 0000015 Trennmittel release agent agent s parateur 0163333 bei Verarbeitung von lsozyanat for application 0640651 SE mittel Kunststoff Stahl medium plastic steel 480 0000107 with isozyanate pour l application de l isozyanate medium plastique acier 20 ml Montagepaste f r R und RS Ausfihrung as hochfest high streng hautesistance 50 ml 601 0000014 sembly paste for version R or RS pate d as 0000045 hochfest f r Cr Ni Teile for Cr Ni steel parts 2701 0000303 semblage de version R et RS pour partes fabriqu de Cr Ni 50 ml Rohrdichtungspas
68. king ring Pos 30 4 Teflon packing ring Pos 30 3 leather packing ring Pos 30 2 Teflon packing ring Pos 30 7 counter ring Pos 29 packing is delivered as a unit Attention The packing should not extend above the pressure cylinder Always use new packings Place the saddle ring Pos 7 with the smooth surface down in the intermediate body Pos 3 Place the complete packing in the intermediate body Pos 3 Assembly order Teflon packing ring Pos 8 1 crowned surface down leather packing ring Pos 8 2 Teflon packing ring Pos 8 3 leather packing ring Pos 8 4 Teflon packing ring Pos 8 5 counter ring Pos 9 packing is delivered as a unit Attention The packing should not extend above the intermediate body Pos 3 There should be approx 2 3 mm space between the intermediate body Pos 3 and the counter ring Pos 9 otherwise the packing cannot be adjusted later as necessary Always use new packings 4 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Material Pump 275 120 R 0641416 10 1 Assembly 10 1 3 Step 5 Place the seals Pos 11 13 in the spring housing Pos 12 Place the spring Pos 10 in the spring housing Pos 12 Step 4 Inspect the seal Pos 2 Replace as necessary Push the dual piston Pos 14 small end first through the packing in the interme
69. le 15 0472417 1 Geh use kpl bestehend aus housing cpl consisting of corps cpl consistant en 0639130 1 Geh use housing corps 0639132 1 Anschlussnippel connecting nipple raccord double male 16 0631730 1 Doppelnippel male adaptor raccord double male 17 0631745 1 Anschlussnippel connecting nipple raccord 18 0161179 1 Anschlussnippel connecting nipple raccord 19 1 Filtereinsatz siehe Tabelle filter insert see table filtre seul voir tableau 20 0485977 1 Mutter nut crou ohne Abbildung not illustrated non illustr 0620238 1 Plastikkappe plastic cap capuchon en plastique V Verschlei teile e Wear parts Pieces d usure usuelles Sicherungsmittel 50ml Thread sealant 50ml produit d etanch ite 50ml 2D Teile des Dichtungssatzes Parts of seal kit Pi ces de kit de joints r schwach light leger Best Nr 0000016 3R Teile des Reparatursatzes Parts of repair kit Pi ces de kit de reparation D mittel e medium medium Best Nr 0000015 Q hochfest high streng hautesistance Best Nr 0000014 Schmiermittel Lubrication grease Mati re graisse Pos Nr in Klammern sind keine Betandteile dieser Baugruppe E Fett saurefrei acid free sans acide Best Nr 0000025 e items markedthus are not part of assembly shown I Sp lmittel lubricating fluid produit de nettoyage Best Nr 0163333 e Les pieces entre paranth ses ne font pas partiedu sous groupe M Montagepaste f r R und RS Ausfiihrung Best Nr
70. mum allowable operational pressure for all accessory components By differing allowable operating pressures the lowest value is always the maximum allowable operating pressure for the entire system see example in chapter 2 6 If the pressure is increased by approx 10 for a short length of time the safety valve must blow off picture 4 3 3 Now check that all parts of the system are tight hose gun high pressure filter and joints Now adjust back the air inlet pressure by turning the regulating screw of the air regulator to the left to approx 1 2 bar Remove the suction pipe with sieve from the open container A Wash Thinner To relieve pressure now disengaged the gun safety catch and hold it into open container B j 4 3 ini ene soe Slowly trigger the gun and pump the remaining wash thinner out of the system completely Ensure contact with the container wall is maintained Adjust back the air regulator by turning the regulating screw until it moves freely Close the main air supply tap Close gun and secure safety catch Result The start up proceedures are finished The machine is ready for use User s Handbook WIWA Airless 27 AA014 e 06 03 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Operation Equipment preparation pictur
71. narrow necked can or barrels with bung hole DANGER OF EXPLOSION picture 2 6 3 Please always use an open container Due to possible electro static charges it is imperative to ensure that the spraying gun has contact to the container walls when working with metal containers It is possible for a static charge to occur due to the high flow speeds during the airless spraying procedure Static charges can lead to fire and explosions The equipment must therefore always be appropriately grounded picture 2 6 3 The original WIWA airless spray machine is fitted with a ground cable as stan dard If lost or defective please order an immediate replacement order no 0474487 Never use this equipment outdoors during a thunderstorm Spaying machines which are not protected against explosions may not be used in workplaces which fall under the regulation covering explosion protection Pneumatically driven airless spraying machines are not affected by this Should however additional electrically driven accessories be mounted to these machines such as agitators or heaters the regulation covering explosi on prevention must be checked for compliance Plugs for heaters agitators etc which are not protected against explosions may only be plugged into sockets located outside of areas that fall under the User s Handbook WIWA Airless 11 AA014 e 06 03 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3
72. ndbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de WIA Shutting down 6 1 Please wear protective clothing at all times as solvent vapours and splashes of solvent cannot be avoided completely Job Once the job is completed the machine is to be cleaned and shut down Prerequisite You will need 1 open container with at least 5 Itr of cleaning material the solvent must correspond to the coating material and be recommended by the material manufacturer called container A below e 1 empty open container for the soiled cleaning material material mixture abbreviated as container B below JUL Ui 1 material container called container C below Do not use narrow necked cans or barrels with bung holes Procedure Close the main air supply tap Turn back the air regulator by turning the the regulator screw to the left until it moves freely The pressure gauge must show 0 bar Close and secure the airless spray gun Open the relief tap on the high pressure filter drain screw for a short time Allow pressure to escape and close again Remove and clean the standard tip or Easy Clean reversible tip cleaning device with tip We recommend storing the used tip or Easy Clean with tip in the appropriate solv
73. ng to improve the hold on the toggle Lead the toggle bearing with toggle into the bearing bush Pos 19 The toggle must fit into the groove on the carrier Pos 27 This can be controlled through the opening behind the cover Pos 43 Place the spring Pos 22 onto the retaining screw Pos 23 and grease the spring well Screw the retaining screw Pos 23 with spring Pos 22 hand tight into the upper housing Pos 18 Repeat these steps for the second toggle Screw each retaining screw two complete turns with a socket wrench SW 32 Then use the wrench to apply pressure to each screw until fully tightened Control the position of each toggle by moving the control axle up and down To do this apply compressed air to one of the holes with an exhaust port at the side of the upper housing At the same time cover the other hole Repeat this step using the holes without exhaust ports on the side Mount the cover Pos 43 with the 2 screws Pos 45 and washers Pos 44 to the upper housing Step 4 Place the control piston Pos 7 onto the control axle Pos 38 The longer side with the groove must face upward Screw the two nuts Pos 6 onto the control axle Pos 38 using two open end wrenches SW 17 Warning The distance between the countered nuts and the control piston must be 2 mm 08 in Lightly grease the control piston Step 3 Use circlip pliers A 3 to mount the retaining ring Pos 12 to the outermost groove on the control cylinder
74. ogged 1 Clean and or replace the filter insert spray gun is triggered without tip or the filter s drain valve is opened B Material leaks out of the gap between 1 O ring is damaged 1 Replace the o ring the base housing and the cap PLEASE NOTE Clean the filter insert daily and whenever the coating material is changed Replace the filter insert whenever necessary Open the drain valve regularly to avoid it from becoming clogged For R and RD version high pressure filters To avoid seizing lightly grease the threads before assembly WARNING Whenever work is to performed on the high pressure filters the airless pump or system must be completely shut down and remaining pressure drained from the highpressure filters as described in the User s Handbook Exchange any damaged parts for new ones Before starting to work with the unit again ensure that it has been grounded correctly Repair Manual HDF 18 RA e 01 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de HP Filter Model 13 R Disassembly Assembly High pressure filter Repair Manual HDF PIA 10 3 10 3 2 Exchanging the filter insert or o ring Close the air tap lock on the airless pump Drain remaining pressure by opening the filter ball valve Pos 7 Use the include
75. om WIWA Wilhelm Wag ner GmbH amp Co KG the compatability with our equipment is guaranteed It is however essential that the safety regulations of the attachments and spare parts are observed You can find these safety regulations in the User s Handbook located with the spare parts lists If you use attachments and spare parts from another source WIWA cannot guarantee the safety of the entire system In this case our guarantee does not cover any damage or injury caused by such attachments and spare parts Emissions It is possible for solvent vapours to occur depending on the materials used Therefore please ensure the workplace is sufficiently ventilated in order to avoid damage to health and property Always observe the processing information given by the material manufacturer The sound pressure level of the equipment is below 85 db A Nevertheless appropriate means of noise protection should be made available to the operating staff The operator is responsible for compliance with the rules covering the prevention of accidents due to noise VGB 121 Therefore pay special attention to the environmental conditions at the site e g noise can be increased if the machine is installed in or on hollow bodies Exact details regarding noise emission are mentioned in the Chapter 9 1 Technical specification User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA0002e 06 02 WIWA Gewerbe
76. ple no method of working should be exercised which impairs the safety of WIWA products or the operating personnel 8 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 07 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de WIA Safety 2 Application of the machine 2 4 These units have been designed to spray lacquers and varnishes paints high viscosity coarsely pigmented two component tar and epoxy materials bitumen high built materials low solvent and solvent free coatings insulating material antifoulings glassflake materials flame resistant and fibre filled coatings They are optimal for coating large surfaces and providing thick coatings A particular advange of these units is the additional air hose leading to the air motor which prevents icing from occuring Other usage is not in line with regulations Before WIWA equipment is used for other purposes or with other materials and therefore not according to the regulations permission should be obtained from the manufacturer as the guarantee is otherwise invalid The observation of technical documentation and the compliance with specified operational maintenance and starting guidelines are manditory in accordance with the valid regulations Using this equipment in areas requiring protection from explosions Marking Ex
77. pt the compressed air supply to the machine immediately and open the drain valve The machine may be restarted only if perfect operation is restored User s Handbook WIWA Airless 17 AA014 e206 02 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany E j F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E d E mail info wiwa de Internet www wiwa de _ Safety 2 Handling of the machine and auxiliary materials 2 11 Alignment servicing maintenance and repair of the machine Alignment when changing production as well as servicing and cleaning may be carried out by trained operating personnel only Maintenance and repair may be carried out by trained qualified personnel only Before starting work the compressed air supply of the machine must be shut off picture 2 11 1 Version with the compressed air tap lock located on the maintenance unit picture 2 11 2 Version with the compressed air tap lock located on the compressed air regulator i vw D c picture 2 11 1 picture 2 11 2 Make sure that the machine is absolutely free from pressure For this hold the drain hose into an open container and open the drain valve In any case the function of all protective devices as well as perfect function of the STOP machine must be checked after completion of the work Taal ha Handling of auxiliary materials When handl
78. r of the system to the main air supply line Insert the suction pipe with sieve in the open container A Warning If using a fluid heater the heater may not be turned on at any time during the cleaning of the entire system DANGER OF EXPLOSION Observe the flash point for the solvent being used User s Handbook WIWA Airless 25 AA014 e 06 03 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany sF FEE E F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de l Start up 4 First cleaning 4 2 2 Open the relief tap on the high pressure filter and put the relief hose into the open container B Open the main air supply tap Adjust the air regulator to a maximum of 2 bar 30 psi by slowly turning the regulating screw to the right picture 4 2 4 Activate the de icing system by slowly turning the control screw to the right picture 4 2 5 We recommend minimum 1 complete turn maximum 3 complete turns Adjust the de icing system according to your individual requirements as factors such as pressure number of cycles per minute humidity and ambient tempera ture can affect the amount of air that is required to avoid ice build up Allow the Wash Thinner soiled with the test medium to run out of the relief hose into the open container B for at least 10 seconds Close the relief tap Hold th
79. r version R or RS pate d assemblage de version R et RS Diese Zeichnung darf nicht kopiert vervielf ltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat rechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecution copyright 2005 WIWA Wilhelm Wagner GmbH Co KG WIWA Wilhelm Wagner GmbH amp Co KG WIWA LP GewerbestraBe 1 3 35633 Lahnau Germany 1244A Exec Blvd Suite 101 Chesapeake VA 23320 USA Tel 49 0 6441 609 0 Fax 49 0 6441 609 50 Tel 1 866 661 2139 Fax 1 757 4386 2103 E mail info wiwa de Internet www wiwa de E mail s nelsen wiwa com Internet www wiwa com WIA D333 120 Akt 16 12 05 Luftmotor Air Motor Motor pneumatique Bestell Nr e Order No R f rence 0640818 Serie Serie S rie 001 Bestell Nr oS Order No Pieces V D2 R Artikelbezeichnung Part D scription D signation des articles SC R f rence 38 0461385 Schraube screw vis 39 0460613 6 U Scheibe washer rondelle 40 0220736 1 Deckel cover couvercle 41 0460230 2 U Scheibe washer rondelle 42 0460443 2 Schraube screw vis 43 0310360 2 D R O Ring o ring joint torique 44 0466875 1 V R Dampfungsscheibe dampening spacer rondelle insonorisante 45 0640809 8 Stehbolzen th
80. rable Dimensions and weights of the equipment are indicated in Chapter 9 1 For transportation purposes some components are packed separately 1 Fluid hose picture 4 1 1 2 Airless spray gun picture 4 1 2 Add these components as pictured pictures 4 1 1 to 4 1 4 Airless machines work with high pressures Inspect all turnable parts nuts screws and hose connectons and pull on them tightly to ensure that no material could leak out of these fittings which could lead to injuries In order to prevent static charging the airless system must be grounded by con necting the ground cable to a conductive object picture 4 1 3 23 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Start up 4 Erection and Preparation 4 1 2 The object to be coated must also be grounded Please check the permissible maximum air pressure for the material hose and spray gun It must be greater than or equal to the maximum operational pressure for the system which is shown on the type plate on the high pressure pump or on the machine card chapter 9 3 i Compare the maximum operating pressure of the safety valve picture 4 1 4 with picture 4 1 1 picture 4 1 2 the information on the machine card chapter 9 3 or the type plate This informati on must correspond The machine maynow
81. ration ca 30 40 cm picture 5 2 1 thin coat here too thin coat thick Wall eg gaan GE incorrect picture 5 2 2 User s Handbook WIWA Airless AA014 e e 06 03 HIFA 5 5 2 Disengage the gun safety catch and trigger to begin coating Working pressure The optimal working pressure is reached when there is an even coating of material with graduated edges Operate machine with only as much compressed air as is necessary to achieve good atomisation at the recommended spraying distance of 30cm If the pressure is too high it leads to increased material consumption and paint mist If pressure is too low it results in stripes and varying coating thickness Spraying painting Hold the spraying gun at a right angle 90 to the area to be sprayed As soon as the spraying gun is held at another angle the coating will become uneven and spotted picture 5 2 1 Move your spraying arm evenly Be certain to move at a constant speed and to keep the spraying gun parallel to the area being sprayed Manouver the spraying gun using your arm not your wrist Waving with the spraying gun leads to an uneven coating picture 5 2 2 Have the spraying gun in motion before pulling the trigger This will assure an even soft and smooth overlapping of the spray jet and will avoid excessive material being coated when beginning spraying Release the trigger before ending your movement Pausing while working Se
82. readed bolt boulon 46 0478695 1 V D R Fuhrungsbuchdse kpl guide bush coussinet 47 0461091 8 U Scheibe washer rondelle 48 0460931 8 Federring spring ring rondelle lastique 49 0463795 8 Hutmutter dome nut crou borgne 50 0163635 1 Einf llstutzen filler neck tube de remplissage 51 0221295 1 Sinterlager sintered bearing coussinet fritt 52 0461334 1 R Sicherungsring s ring anneau gt S lt 53 0468266 1 Scheibe disc disque 54 0469270 1 V D R Nutring lip seal joint 55 0639761 1 Achse axle axe 56 0638168 1 V D R Fuhrungsband guide ring bague de guidage 57 0640819 1 Kolbenplatte piston plate plateau de piston 58 0638195 1 V D R O Ring o ring joint torique 59 0311235 1 V D R O Ring o ring joint torique 60 0221368 1 V R Scheibe disc disque 61 0221414 1 Anschlagbuchse oben 62 0415170 1 Druckfeder spring ressort 63 0638831 1 Scheibe disc disque 64 0221406 1 Anschlagbolzen stop bolt boulon de but e 65 0415170 1 Druckfeder spring ressort 66 0638833 1 V Motorachse motor axle axe de moteur 67 0638194 1 D R O Ring o ring joint torique 68 0639759 1 V Zylinder cylinder cylindre 69 0638194 1 D R O Ring o ring joint torique 70 0314463 2 D R O Ring o ring joint torique 71 0639762 2 Bel ftungsrohr air inlet pipe tube de prise d air 72 0461237 1 R Sicherungsring s ring anneau gt S lt 73 0314463 2 D R O Ring o ring joint torique 74 0640813 1 Unterteil kpl bottom cpl patrie inf rieure V Versc
83. red to mx o P P Pe 6 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 07 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany P Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 i E mail info wiwa de Internet www wiwa de r Safety 2 Warning instructions located on the machine 2 2 User s Handbook WIWA Airless AA014 e 07 03 Warning signs and symbols which have been placed on the machine are there to inform of possible dangers and must be observed Warning signs and symbols may not be removed from the machine Damaged and illegible warning signs and symbols are to be replaced immediately The following signs are located on the machine On the high pressure filter picture 2 2 1 Warning sign covering the grounding of the machine The propietor is required according to the German Accident Prevention Regula tion Unfallverh tungsvorschrift VGB 23 to ensure that the machine is properly grounded Please observe our instruction manual On the material pump cylinder Nameplate picture 2 2 2 Please observe that the information located on the nameplate corresponds to data found on the machine card Chapter 9 3 We request immediate notification should there be any discrepancies or if the nameplate is missing T Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany
84. rences and specifications found in the user s handbook Before each usage be especially certain to Check the grounding conditions for the unit and the object to be sprayed Check the seal of all connecting and mounted parts Observe the maximal allowed pressure of the unit and accessory parts Beforebeginning any work on the equipment and at any pause during operation be absolutely required to Turn off the spraying equipment at the air pressure stop valve Release the pressure found in the spraying gun and hose Secure the spraying gun Pay attention to safety The accident prevention regulation Handling of Coating Materials VBG 23 and the guidelines covering fluid sprayers ZH1 406 from the German Employer s Liability Insurance Association are to be observed without fail To ensure a safe operating environment the condition of fluid sprayers must be inspected by an expert every 12 months or sooner if deemed necessary A written record of the inspection results is to be kept Remaining paint and solvent are to be disposed of according to legal regulations This also applies for environmently friendly water lacquer or enamel systems In case of injuries consult a physician or go to the next hospital without delay If paint material or solvent has gone into the skin the physician has to be informed about the type of paint material or the solvent applied Therefore always ensure that the product specification sheet with
85. rtions etc If this is not the case please acquire this data from the relevant manufacturer The material to be sprayed must be slowly but thoroughly stirred before beginning to work When dealing with two component materials the working life must be observed The machine must be flushed and completely cleaned with the specified cleaning agent within the working life as givin by the manufacturer Please observe that the hardening time shortens by higher temperatures It is recommendable to allow the solvent to circulate for a while It must be made certain that no particles of paint remain in either the pump or the filter WIWA offers a broad selection of special attachments for the optimised preparation of spraying materials eg agitators in various sizes material pre warming containers in various sizes fluid heaters Procedure The machine is to be set up securely on a level and solid surface All operating elements must be easily accessible In order that the necessary volume of air is guaranteed the compressor capacity must comply with the amount of air nee ded by the machine and the diameter of the air supply hoses must correspond to the joints Information on air consumption can be found on the machine card chapter 9 3 High pressure spraying machines and systems can be integrated into spraying chambers either inside or outside of production facilities To avoid possible soiling an outside installation is prefe
86. s when appliying your WIWA Airless Paint Spraying Machine WIWA Wilhelm Wagner GmbH A Co KG Copyright The copyright for this user s handbook remains with WIWA Wilhelm Wagner GmbH amp Co KG The user s handbook is intended for preparation operating and maintenance staff It contains technical regulations and drawings which may not in whole or in part be copied distributed or be used by or passed on as information to others for whatever purposes without authorisation WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestra e 1 3 35633 Lahnau Tel 06441 609 0 e Fax 06441 6095 0 This user s handbook is only valid in conjunction with the machine card which is presented in chapter 9 3 of the user s handbook for the equipment you have purchased Please ensure that the data on the type plate corresponds with the information on the machine card If they do not correspond or the user s handbook has been compiled wrongly or the type plate is missing we would ask you to inform us immediately Note We reserve the right to make changes to the contents of this handbook WIWA Wilhelm Wagner GmbH amp Co KG is not liable for any mistakes found in this documentation or any assessable damages resulting from it s delivery or usage as far as legally allowed The manufacturer reserves the right to make technical changes in order to improve the products which may not be documented in this user s handbook 4 User s Handbook WIWA Airless Copyri
87. screw picture 7 3 3 on the fog oiler has to be set accordingly Condensed water drain water cutoff picture 7 3 4 EES Before each application and in case of high air humidity the occurring con densed water should be discharged via the drain valve on the water cutoff even during operation picture 7 3 4 Only use the lubricants and anti freezing agent as indicated in Chapter 9 1 38 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Disturbances during operation and Trouble shooting Faults Probable Causes A Pump does not work despite 1 Air supply tap closed triggering the gun without spray tip and or opening the relief tap at the 2 High pressure filter clogged high pressure filter 3 Air motor blocked 4 Air motor defective B Pump cycles but will not prime 1 Suction sieve clogged 2 Suction hose clogged 3 Ball at Bottom valve does not rise becomes stuck 4 Bottom valve does not close C Pump cycles but does not stall when 1 Packing and or valve worn gun is closed D Pump cycles evenly but required 1 Air supply pressure too low spraying pressure is not reached 2 Spray tip new is too big 3 Spray tip wears off becomes too big 4 Air motor frosts cycling too slow
88. sembly shown Les pi ces entre paranth ses ne font pas partie du sous groupe Diese Zeichnung darf nicht kopiert vervielf ltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat strafrechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without the authorization of WIWA Unauthorized use is subject to prosecution Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG W bm WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 7 E mail info wiwa de Internet www wiwa de Materialpumpe Material Pump Section fluide Typ 275 120 R Bestell Nr e Order No R f rence 0641416 Serie Serie S rie 001 Akt 08 05 Best Nr Stuck Order No Pieces V D2 R Artikelbezeichnung Part Description D signation des articles Reference Piece 01 0223506 Kupplungssttck coupling piece pi ce d accouplement 02 0641496 O Ring o ring joint 03 0641465 Zwischenk6rper intermediate body corps interm diaire 04 0640052 Schauglas sight glass verre indicateur 05 0163686 1 AblaBventil drain valve soupape de d charge bestehend aus Pos 5 1 5 3 consiting of pos 5 1 5 3 consistant en pos 5 1 5 3 05 1 0210714 1 Abla schraube draining screw vis de remplissage 05 2 0310239 1 D R O Ring o rin
89. sion EN 292 2 1991 A1 1995 DIN EN 1050 edition 01 97 German version EN 1050 1996 DIN EN 983 edition 09 96 German version EN 983 1996 Third Ordinance of the Equipment Safety Act January 18 1991 The following standard was used for noise measurements DIN EN ISO 3744 edition 11 95 German version EN ISO 3744 1995 Lahnau 01 07 2003 Place date 2 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG in accordance with the EC Guideline 94 9 EG Appendix VIII DIN EN 1127 1 edition 1997 10 German version EN 1127 1 1997 DIN EN 13463 1 edition 2001 01 German version EN 13463 1 2001 The required documentation is on file at TUV Anlagentechnik GmbH EU Code 0035 The equipment listed is classified in Group Il Category 2G dy yy d D Ze w Heidrun Wagner rczak Managing Director User s Handbook WIWA Airless AA014 e 08 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Ae Safety Information 0 First read then start 0 1 Remember that Airless Paint Spraying Equipment works under extreme pressure and that high levels of spraying pressure are created Never hold your finger or hand in front of the gun and never reach into the spray Never point the spray gun towards yourself other people or other living creatures Always pay close attention to the refe
90. str 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de VIWA Safety 2 Sources of danger 2 6 1 Remember that WIWA Airless Paint Spraying Machine work under extreme pres sure procedures and that they can cause life endangering injuries if used inappro priately Pay attention to the following notes Material hoses must conform with maximum working pressure whereby a safety factor must be included in the statement Material hoses are never to be patched Never point the spray gun towards yourself other people or other living crea tures Never hold your finger or hand in front of the gun and never reach into the spray Never try to seal leaks on joints and high pressure hoses with your hand or by binding the spot Should a leak occur the whole system gun hose pressure filter pump etc are to be depressurized immediately Defective parts are to be replaced If working with heated materials always wear the proper hand protection BURN DANGER GE 262 The gun is to be secured and the safety device checked during every interrup Tap lock in closed position tion while working regardless how short picture 2 6 1 The entire system is to be depressurized before maintenance and cleaning work is carried out The compressed air tap lock must be closed picture 2 6 2 Never spray solvents or materials containing solvents into a
91. t activities on the system must be laid down clearly and adhered to No unclear competences may remain as these could endanger the safety of the users The operator must make sure that only authorised persons work on the machine He is responsible to third parties in the working vicinity of the system The operator of the equipment is obliged to repeat instructions about dangers and safety measures at regular intervals at least once a year for young persons twice a year Personal protective equipment We call to your attention that the valid guidelines and requirements in accordance with work surroundings mining closed areas etc must be absolutely adhered to Please wear the prescribed protective clothing at all times as solvent vapours and solvent splashes cannot be completely avoided The sound pressure level of the equipment is below 85 db A Nevertheless appropriate noise protection means should be made available to the operating staff Although spraying fog is kept to a minimum when the correct pressure setting and proper method of operation are observed the operating painter should wear a protective breathing mask Never use solvent or other materials which present a health hazard for cleaning skin Only suitable skin protective skin cleansing and skin care materials may be used 14 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA000 ee06 03 WIWA Gewerbestr 1
92. te pipe sealant pate 225 0000017 d tanch it pour tuyaux 50 ml Aktivator activator activateur 500 ml 734 0000018 Aktivator fur Kunststoffteile activator for 770 0000108 plastic parts activateur pour pi ces de plasti que 10 ml Gewindeband threaded tape ruban de 0000099 filetage Hauptsitz und Produktion Headquarter amp Production TINAL WIWA Taicang Co Ltd 3734A Cook Blvd Chesapeake VA 23323 USA No 87 East Suzhou Rd Taicang City WIWA Wilhelm Wagner GmbH amp Co KG Tel 1 757 436 2223 Fax 1 757 436 2103 Jiangsu Province 215400 P R China AAWO EALE T eee Tel Toll Free 1 866 661 2139 Tel 86 512 5354 8858 Fax 86 512 5354 8859 Tel 49 6441 609 0 Fax 49 6441 609 50 edel SES rae E mail sales wiwalp com E mail info wiwa china com E mail info wiwa de Int Int A Internet wuaww wiwa d nternet www wiwa com nternet www wiwa com copyright 2008 WIWA Wilhelm Wagner GmbH Co KG
93. tikelbezeichnung Part D scription D signation des articles 1 0460249 4 Hutmutter dome nut crou borgne 2 0460613 4 U Scheibe washer rondelle 3 0644737 1 Geh use Oberteil housing carcasse 4 0460648 2 Mutter nut crou et 0638193 1 V R Steuerkolben kpl control piston piston de contr le 6 0640826 4 Gewindest ck threaded piece douille filet e 7 0460214 4 U Scheibe washer rondelle 8 0475289 4 Stehbolzen threaded bolt boulon 9 0638173 1 Deckel cover couvercle 10 0638196 1 Sicherungsring s ring anneau gt S lt 11 0638185 1 Steuerzylinder control cylinder cylindre de contr le 12 0638189 1 Steuergeh use kpl control housing carcasse de contr le 13 0475483 1 Geh use Unterteil housing carcasse 14 0465615 1 D R Dichtung gasket joint 15 0638179 1 D R Dichtung gasket joint 16 0641833 1 Oberteil kpl upper part cpl partie sup rieure cpl 17 0220779 2 Lagerbuchse bearing bush bouchon 18 0163813 2 V Schnapper toggle bascule 19 0220787 2 V Schnapperlager toggle bearing roulement 20 0415154 2 V Druckfeder spring ressort 21 0220760 2 Halteschraube retaining screw crou de retenue 22 0220671 1 Sinterlager sintered bearing coussinet fritt 23 0461296 1 Sicherungsring s ring anneau gt S lt 24 0415278 1 V R Dampfungsscheibe dampening spacer rondelle insonorisante 25 0220752 1 V R Mitnehmer carrier toc d entrainement 26 0604356 2 D R O Ring o ring joint torique 27 0461288 1 Zylinderst
94. tion copyright 2005 WIWA Wilhelm Wagner GmbH Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 10 2 Troubleshooting 10 2 1 In this chapter you will find information pertaining to troubleshooting the air motor AN Before The disassembly and reassembly are described step by step In addition you will beginning any repairs find an exploded line drawing of the air motor as well as the related spare parts or maintenance on the lists at the conclusion of the troubleshooting section unit read all First check the fault s cause in the table found in Chapter 10 2 1 instructions found in Disassemble the air motor as necessary according to Chapter 10 2 2 the User s Handbook Once the fault has be repaired reassemble the air motor according to the and observe them instructions found in Chapter 10 2 3 Please note that the steps are to be closely followed in the reverse order from 14 to 1 as they correspond with the steps 1 to 14 in the section on disassembly The User s Manual The assembly instructions include information concerning the use of grease thread must be available at sealant allowable torque etc all times when working on the unit A Inbound air used to drive the motor is 1 Control piston is worn Pos 7 1 Replace leaking from the control piston into the Step 1 4 mufflers Pos 37 air mo
95. tip cleaning device with the appropriate nozzle is especially recommended with such materials When changing materials the filter insert in the high pressure filter and the material sieve in the suction system are to be cleaned or replaced The main air supply tap must be closed Adjust back the air regulator by turning the regulating screw to the leftuntil it moves freely Bilder 5 1 3 Connect to main air supply line Insert suction pipe with sieve in open container A User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA014 e 06 03 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Operation 5 Equipment preparation 5 1 2 The relief tap on the high pressure filter must be closed Open main air supply tap Check whether the de icing control screw is open Disengage safety catch on airless spray gun without nozzle Hold gun into open container B and trigger Adjust air regulator to 1 2 bar by turning the regulating screw to the right Hold the airless spray gun in such a way that the emerged solvent is sprayed sideways onto the inside wall of the open container B When using metal containers ensure that the spray gun maintains contact with the inside wall of the container because of possible electrostatic charging As soon as clean solvent is released the flushing process
96. to material container C until solvent is first emitted Close the airless spray gun and secure Turn back the air regulator by turning the regulator screw to the left until it moves freely The pressure gauge must show 0 bar Open the relief tap drain screw in order to release pressure C Remove and clean the filter insert Then screw the high pressure filter s cover back on We recommend storing the filter insert in solvent Hold the relief hose in container B Open the main air supply tap Set the air regulator at approx 1 2 bar and leave the relief tap open for approx 10 seconds so that the remaining solvent paint mixture is removed Close the relief tap drain screw B Turn the pressure completely back down using the maintenace unit and air regulator The pressure gauge must show 0 bar Close the air regulator by turning the regulating screw to the left Close the main air supply tap Open the relief tap drain screw for a short period so that pressure can escape then close it again 34 User s Handbook WIWA Airless Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG AA000 ee06 02 WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de WIA Maintenance Repair 7 Checks 7 1 systems VGB 87 the equipment must be checked and overhauled at regular According to the rules for the prevention of a
97. tor continues to run but becomes slower at the same 2 Lip seal is worn Pos 57 2 Replace inbound air pressure Step 1 11 3 O ring is worn Pos 61 3 Replace Step 1 13 4 Gasket is defect Pos 17 4 Replace Step 1 2 5 O ring is worn Pos 62 4 Replace Step 1 13 B Air blows out of the lower motor 1 Guide bush is worn Pos 49 1 Replace housing drain hole Pos 77 air motor Step 1 14 continues to run C Ilnbound air used to drive the motor is 1 Toggle Pos 20 is no longer seated in 1 Repair leaking from the control piston into the either the toggle bearing Pos 21 or Step 1 5 muffler Pos 37 air motor is blocked the carrier Pos 27 2 Guide axle spring Pos 65 and or 68 is 2 Replace broken Step 1 13 D Air motor doesn t run See C above E Air motor is not able to reach its full 1 Insufficient inbound air 1 Check the size of the inbound air line performance level and the compressor s output 2 Muffler is clogged Pos 37 2 Replace Step 1 Repair Manual 1 RA076 078 080 e 09 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 Disassembly Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Repair Manual RA076 078 080 e 09 03 10 2 10 2 2 General Instructions Turn off the in
98. upe Diese Zeichnung darf nicht kopiert vervielfaltigt oder dritten Personen zug nglich gemacht werden Widerrechtliche Benutzung hat strafrechtliche Folgen This drawing should not be in whole or in part copied distributed or be used by or passed on as information to others for competition purposes or for whatever purposes without authorization Unauthorized use is subject to prosecution Bestell Nr Order No R f rence 0638163 V Verschlei teile Wear parts Pi ces d usure usuelles Artikelbezeichnung Ansaugsieb 2D Teile des Dichtungssatzes Parts of seal Kit Pi ces de kit de joints 3R Teile des Reparatursatzes Parts of repair kit Pi ces de kit de reparation SRG Teile des Reparatursatzes gro Parts of repair kit big e Pi ces de kit de reparation grand 3Rk Teile des Reparatursatzes klein Parts of repair kit small Pi ces de kit de reparation petit Hauptsitz und Produktion Headquarter amp Production WIWA Wilhelm Wagner GmbH amp Co KG GewerbestraBe 1 3 35633 Lahnau Germany Tel 49 6441 609 0 Fax 49 6441 609 50 E mail info wiwa de Internet www wiwa de copyright 2008 WIWA Wilhelm Wagner GmbH Co KG WIWA LP 3734A Cook Blvd Chesapeake VA 23323 USA Tel 1 757 436 2223 Fax 1 757 436 2103 Tel Toll Free 1 866 661 2139 E mail sales wiwalp com Internet www wiwa com Part Description suction strainer D signation des articles filtre d asp
99. valve Pos 79 with the fitting Pos 80 to the t piece located at the air inlet Connect the valves with the air hoses Pos 81 86 Tighten them with an open end wrench SW 14 Repair Manual 6 RA076 078 080 e 09 03 Copyright 2002 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 E mail info wiwa de Internet www wiwa de Air Motor 333 120 0640818 10 2 Assembly 10 2 3 Step 6 Place the upper housing Pos 18 onto the cylinder cover Pos 33 Warning The pin Pos 29 on the bottom of the upper housing must fit into the corresponding hole in the cylinder cover Position the upper housing so that the air inlet is facing to the rear Use an open end wrench SW 17 to tighten the 6 bolts Pos 41 incl washers Pos 42 into the upper housing Cross tighten them evenly Screw the 4 threaded bolts Pos 10 into the upper housing Pos 18 Check the movement of the control axle Pos 38 It should move smoothly without any sticking Any friction must be corrected by repositioning the air inlet pipes Step 5 Position the control axle Pos 38 so that the carrier Pos 27 is located at the holes for the toggle bearings Pos 21 The grooves in the carrier must face toward the holes Lightly grease the bearing bush Pos 19 and place it into the hole Grease the toggle bearing Pos 21 and toggle Pos 20 Apply the grease to the groove of the toggle beari
100. with Replace the filter insert should any sign of damage be present Replace the o ring Pos 3 should any sign of leakage be present Mount the high pressure filter in reserve order For R and RD version high pressure filters To avoid seizing lightly grease the threads before assembly The mentioned position numbers refer to the spare parts lists located in the appendix chapter 9 3 ay A ae picture 7 3 2 User s Handbook WIWA Airless 37 AA014 e 06 03 Copyright 2001 WIWA Wilhelm Wagner GmbH amp Co KG WIWA Gewerbestr 1 3 35633 Lahnau Germany E E E F Tel 49 0 64 41 6 09 0 Fax 49 0 64 41 6 09 50 RS E mail info wiwa de Internet www wiwa de _ Maintenance Repair 7 Maintenance of the maintenance unit 3 part 7 3 2 adjusting screw oil Lubricant and or anti freezing agent fog oiler Check the air motor s lubricant in the fog oiler of the air maintenance unit and refill if required picture 7 3 3 High air humidity can cause icing of the motor In case of icing only use pure anti freezing agent Adjustment of the fog oiler on the air maintenance unit Water cutoff Fog oiler picture 7 3 3 Let the air motor run slowly at an air inlet pressure of approx 4 bar 3 part maintenance unit Check the sight glass on the fog oiler to ensure that one drop of lubricant is fed into the compressed air at every 10 15 double strokes of the air motor If this not the case the adjusting

User`s Handbook: WIWA Airless

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