HeavyCoat 970 E SSP - Paint spray WAGNER - Free user manual and instructions

USER MANUAL HeavyCoat 970 E SSP WAGNER

Warning! Attention: Danger of injury by injection! Airless units develop extremely high spraying pressures. Be safety conscious!

Never put your ngers, hands or any other parts of the body into the spray jet! Never point the spray gun at yourself, other persons or animals. Never use the spray gun without safety guard. Do not treat a spraying injury as a harmless cut. In case of injury to the skin through coating materials or solvents, consult a doctor immediately for quick and expert treatment. Inform the doctor about the coating material or solvent used. The operating instructions state that the following points must always be observed before starting up: 1. Faulty units must not be used. 2. Secure WAGNER spray gun using the safety catch on the trigger. 3. Ensure that the unit is properly earthed. 4. Check allowable operating pressure of high-pressure hose and spray gun. 5. Check all connections for leaks. The instructions regarding regular cleaning and maintenance of the unit must be strictly observed. Before any work is done on the unit or for every break in work the following rules must be observed: 1. Release the pressure from spray gun and hose. 2. Secure the WAGNER spray gun using the safety catch on the trigger. 3. Switch o unit.Original Operating ManualHC 950 • HC 970 25

4.2 High-pressure hose, spray gun and separating oil ...................36

4.3 Gasoline engine (gas units only) ......................................................36

4.4 Connection to the mains (electric units only) .............................36

4.5 Flushing preserving uid during initial start-up ........................36

4.6 Taking the unit into operation with coating material..............37

10.2 Checking the oil level in the hydraulic oil tank ..........................42

10.3 Oil and oil lter change of the hydraulic oil pump ...................42

11.2 Servicing and cleaning of Airless hard-metal tips ....................43

1. Safety regulations for Airless spraying

1.1 Explanation of symbols used

This manual contains information that must be read and understood before using the equipment. When you come to an area that has one of the following symbols, pay particular attention and make certain to heed the safeguard.This symbol indicates a potential hazard that may cause serious injury or loss of life. Important safety information will follow.

tentionThis symbol indicates a potential hazard to you or to the equipment. Important information that tells how to prevent damage to the equipment or how to avoid causes of minor injuries will follow.Danger of skin injectionDanger of fire from solvent and paint fumesDanger of explosion from solvent, paint fumes and incompatible materialsDanger of injury from inhalation of harmful vapors

Notes give important information which should be given special attention.

HAZARD: INJECTION INJURY

A high pressure stream produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation.Do not treat a spraying injury as a harmless cut. In case of injury to the skin through coating materials or solvents, consult a doctor immediately for quick and expert treatment. Inform the doctor about the coating material or solvent used.PREVENTION: • NEVER aim the gun at any part of the body. • NEVER allow any part of the body to touch the uid stream. DO NOT allow body to touch a leak in the uid hose. • NEVER put your hand in front of the gun. Gloves will not provide protection against an injection injury. • ALWAYS lock the gun trigger, shut the uid pump o and release all pressure before servicing, cleaning the tip guard, changing tips, or leaving unattended. Pressure will not be released by turning o the engine. The PRIME/SPRAY valve or pressure bleed valve must be turned to their appropriate positions to relieve system pressure. • ALWAYS keep tip guard in place while spraying. The tip guard provides some protection but is mainly a warning device. • ALWAYS remove the spray tip before ushing or cleaning the system. • NEVER use a spray gun without a working trigger lock and trigger guard in place. • All accessories must be rated at or above the maximum operating pressure range of the sprayer. This includes spray tips, guns, extensions, and hose. HAZARD

: HIGH PRESSURE HOSE

The paint hose can develop leaks from wear, kinking and abuse. A leak can inject material into the skin. Inspect the hose before each use.PREVENTION: • High-pressure hoses must be checked thoroughly before they are used. • Replace any damaged high-pressure hose immediately. • Never repair defective high-pressure hoses yourself! • Avoid sharp bends and folds: the smallest bending radius is about 20 cm. • Do not drive over the high-pressure hose. Protect against sharp objects and edges. • Never pull on the high-pressure hose to move the device. • Do not twist the high-pressure hose. • Do not put the high-pressure hose into solvents. Use only a wet cloth to wipe down the outside of the hose. • Lay the high-pressure hose in such a way as to ensure that it cannot be tripped over.

Only use WAGNER original-high-pressure hoses in order to ensure functionality, safety and durability.

HAZARD: EXPLOSION OR FIRE

Flammable vapors, such as solvent and paint vapors, in work area can ignite or explode. PREVENTION: • Use equipment only in well ventilated area. Keep a good supply of fresh air moving through the area to keep the air within the spray area free from accumulation of ammable vapors. Keep pump assembly in well ventilated area. Do not spray pump assembly. • Electric models only - Do not use materials with a ashpoint below 38º C (100º F). Flashpoint is the temperature at which a uid can produce enough vapors to ignite. • Gas models only - Do not ll fuel tank while engine is running or hot; shut o engine and allow to cool. Fuel is ammable and can ignite or explode if spilled on a hot surface. • Eliminate all ignition sources, such as pilot lights, cigarettes, portable electric lamps and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline. • Do not plug or unplug power cords, or turn power or light switches on or o when ammable vapors are present. • Ground equipment and conductive objects in work area. Make sure the grounding cable (not equipped) is connected from the grounding lug to a true earth ground. • Use only grounded hoses. • Hold spray gun rmly to the side of a grounded pail when triggering into pail. • If there is static sparking or if you feel a shock, stop operation immediately. • Know the contents of the paint and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and containerHC 950 • HC 970 27

Safety precautions labels provided with the paints and solvents. Follow the paint and solvent manufacturer’s safety instructions.

• Do not use a paint or solvent containing halogenated hydrocarbons. Such as chlorine, bleach, mildewcide, methylene chloride and trichloroethane. They are not compatible with aluminum. Contact the coating supplier about compatibility of material with aluminum.

• Keep a re extinguisher in work area.

HAZARD: HAZARDOUS VAPORS

Paints, solvents, and other materials can be harmful if inhaled or come in contact with body. Vapors can cause severe nausea, fainting, or poisoning. PREVENTION:

• Wear respiratory protection when spraying. Read all instructions supplied with the mask to be sure it will provide the necessary protection.

• All local regulations regarding protection against hazardous vapors must be observed.

• Wear protective eyewear.

• Protective clothing, gloves and possibly skin protection cream are necessary for the protection of the skin. Observe the regulations of the manufacturer concerning coating materials, solvents and cleaning agents in preparation, processing and cleaning units. HAZARD: GENERAL This product can cause severe injury or property damage. PREVENTION:

• Follow all appropriate local, state, and national codes governing ventilation, re prevention, and operation.

• Pulling the trigger causes a recoil force to the hand that is holding the spray gun. The recoil force of the spray gun is particularly powerful when the tip has been removed and a high pressure has been set on the airless pump. When cleaning without a spray tip, set the pressure control knob to the lowest pressure.

• Use only manufacturer authorized parts. User assumes all risks and liabilities when using parts that do not meet the minimum specications and safety devices of the pump manufacturer.

• ALWAYS follow the material manufacturer’s instructions for safe handling of paint and solvents.

• Clean up all material and solvent spills immediately to prevent slip hazard.

• Wear ear protection. This unit can produce noise levels above 85 dB(A).

• Never leave this equipment unattended. Keep away from children or anyone not familiar with the operation of airless equipment.

• Do not spray on windy days.

• The device and all related liquids (i.e. hydraulic oil) must be disposed of in an environmentally friendly way.

Electric models must be earthed. In the event of an electrical short circuit, earthing reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having an earthing wire with an appropriate earthing plug. Connection to the mains only through a special feed point, e.g. through an error protection insallation with INF < 30 mA. DANGER — Work or repairs at the electrical equipment may only be carried out by a skilled electrician. No liability is assumed for incorrect installation. Switch the unit o. Before all repair work, unplug the power plug from the outlet. Danger of short-circuits caused by water ingressing into the electrical equipment. Never spray down the unit with high-pressure or high- pressure steam cleaners. Work or repairs at the electrical equipment: These may only be carried out by a skilled electrician. No liability is assumed for incorrect installation.28 HC 950 • HC 970

1.3 Gasoline Engine Safety

Always place sprayer outside of structure in fresh air. Keep all solvents away from engine exhaust. Never ll fuel tank with a running or hot engine. Hot surface can ignite spilled fuel. Always attach ground wire from pump to a grounded object. Refer to engine owner’s manual for complete safety information.

1. Gas engines are designed to give safe and dependable service

if operated according to instructions. Read and understand the engine manufacturer’s Owner’s Manual before operating the engine. Failure to do so could result in personal injury or equipment damage.

2. To prevent re hazards and to provide adequate ventilation,

keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Do not place ammable objects close to the engine.

3. People who are not operating the device must stay away from

the area of operation due to a possibility of burns from hot engine components or injury from any equipment the engine may be used to operate.

4. Know how to stop the engine quickly, and understand the

operation of all controls. Never permit anyone to operate the engine without proper instructions.

5. Gasoline is extremely ammable and is explosive under

6. Refuel in a well-ventilated area with the engine stopped. Do

not smoke or allow ames or sparks in the refueling area or where gasoline is stored.

7. Do not overll the fuel tank. After refueling, make sure the

tank cap is closed properly and securely.

8. Be careful not to spill fuel when refueling. Fuel vapor or

spilled fuel may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

9. Never run the engine in an enclosed or conned area. Exhaust

contains poisonous carbon monoxide gas; exposure may cause loss of consciousness and may lead to death.

10. The muer becomes very hot during operation and remains

hot for a while after stopping the engine. Be careful not to touch the muer while it is hot. To avoid severe burns or re hazards, let the engine cool before transporting it or storing it indoors.

11. Never ship/transport sprayer with gasoline in the tank.

DO NOT use this equipment to spray water or acid.

1.4 Setting up on uneven surfaces

The front side of the unit must point downwards to prevent sliding away.

2. General view of application

Examples of objects to be sprayed

2.2 Coating materials

Pay attention to the Airless quality of the coating materials to be processed.

Make sure when stirring with motor-driven agitators that no air bubbles are stirred in. Air bubbles disturb when spraying and can, in fact, lead to interruption of operation. Viscosity

Two-component coating material

Coating materials with sharp-edged additional materials

3. Description of unit

3.2 Functioning of the unit

1 Spray gun 2 High-pressure hose 3 Gasoline engine 4 Extractable handle 5 V-belt under the belt cover 6 Return hose 7 Suction tube 8 High-pressure lter 9 Material feed pump — HC 950, HC 970 10 Material feed pump — HC 950-SSP, HC 970-SSP 11 Pressure gauge 12 Oil cup for separating oil (separating oil prevents increased wear and tear of the packings) 13 Ball valve: horizontal position – hydraulic motor switched o vertical position – hydraulic motor switched on 14 Handle for swiveling the material feed pump 15 Hydraulic motor 16 Relief valve handle: Turn left for circulation k Turn right for spray p 17 Hydraulic oil pump 18 Pressure control knob 19 Oil measuring stick

3.5 Illustration legend for electric HC units

1 Spray gun 2 High-pressure hose 3 Electric motor 4 ON/OFF switch 5 Control lamp that shows unit operational 6 Power cord 7 Extractable handle 8 V-belt under the belt cover 9 Return hose 10 Suction tube 11 High-pressure lter 12 Material feed pump — HC 950, HC 970 13 Material feed pump — HC 950-SSP, HC 970-SSP 14 Pressure gauge 15 Oil cup for separating oil (separating oil prevents increased wear and tear of the packings) 16 Ball valve: horizontal position – hydraulic motor switched o vertical position – hydraulic motor switched on 17 Handle for swiveling the material feed pump 18 Hydraulic motor 19 Relief valve handle: Turn left for circulation k Turn right for spray p 20 Hydraulic oil pump 21 Pressure control knob 22 Oil measuring stick

3.6 Illustration of electric HC units

11 l/min: R R Max. size of tip with a spray gun

Fluid outlet tting 3/8 inch – 9.5 mm: R 1/2 inch – 12.7 mm: R R R Max. temperature of the coating material 43° C: R R R R Max. Viscosity

Filter insert (standard equipment) 0 Mesh: R R R R Weight 76 kg R R 88 kg R R Hydraulic oil lling quantity

Special high-pressure hose DN 10 mm, 15 m, connection thread NPSM 3/8: R DN 13 mm, 15 m, connection thread NPSM 1/2: R R R Hose whip DN 10 mm, 2.5 m, connection thread NPSM 3/8: R R R Dimensions L x W x H 1185 x 955 x 655 mm: R R 1200 x 955 x 655 mm: R R Max.sound pressure level: 92 dB (A)* R R 98 dB (A)* R R

• Place of measurement: 1 m distance from unit and 1.60 m above reverberant oor, 120 bar (12 MPa) operating pressure.

HC 950 (0528501) HC 950-SSP (0528503) HC 970 (0528509) HC 970-SSP (0528507) Voltage R R : R R Fuse protection R R R R Power cord R R R R Capacity R R R R Max operating pressure R R R R Maximum volume ow R R R R Volume ow at 12 MPa (120 bar) R R R R Max. size of tip with a spray gun R R R R Fluid outlet tting

R R R Max. temperature of the coating material R R R R Max. Viscosity R R R R Filter insert (standard equipment) R R R R Weight:

Hydraulic oil lling quantity R R R R Max. tire pressure R R R R Special high-pressure hose

R R R Hose whip R R R Dimensions L x W x H R R R R Max. sound pressure level: R R R R

Description of unit Operating Temperature This equipment will operate correctly in its intended ambient, at a minimum between +10°C and +40°C. Relative Humidity The equipment will operate correctly within an environment at 50% RH, +40°C. Higher RH may be allowed at lower temperatures. Measures shall be taken by the Purchaser to avoid the harmful eects of occasional condensation. Altitude This equipment will operate correctly up to 2100 m above mean sea level. Transportation and Storage This equipment will withstand, or has been protected against, transportation and storage temperatures of -25°C to +55°C and for short periods up to +70°C. It has been packaged to prevent damage from the eects of normal humidity, vibration and shock.

Attention Do not lift by cart handle when loading or unloading. Device is very heavy. Three-person lift is required. Handle Pull out the handle (g. 5, item 1) until it will come no further. Push in the snap buttons (2) on the sides of the handle and insert the handle.

3.10 Transport in vehicle

Push locking pin (g. 6, item 1) in the swivel mechanism (2) for the material feed pump (3) and swivel it to a horizontal position. Ensure that the locking pin locks. Roll the high-pressure hose over the hose rack on the handle. Secure the unit with a suitable fastening.

3.11 Crane transport

Hanging points for crane straps or ropes, see gure 7.2. Operating position I (g. 10) Swiveling the material feed pump to a vertical position allows the material feed pump to be immersed in the coating material container.

3. Operating position II (g. 11)

Swivel material feed pump to a slanted (45°) postion if using the container suction system (accessory). In this position, there is open space under the material feed pump.

4. Starting operation

4.1 Changing the material feed pump position

Be careful, as the moving parts of the swivel mechanism can crush ngers and feet. 1. Grip handle (g. 8, item 1) with one hand. 2. Push locking pin (2) with the other hand. 3. Swivel material feed pump up or down to the desired position, until the locking pin (2) locks into the new position.

Transport unit only when the material feed pump is in the horizontal position.Swiveling the material feed pump to a horizontal position also allows removal of the pump from the coating material container.Ensure that the locking pin locks.HC 950 • HC 970 35 Starting operation36 HC 950 • HC 970

4.2 High-pressure hose, spray gun and separating

1. Screw the high-pressure hose (g. 12, item 1) onto the hose

into the high-pressure hose. Screw on hose whip (4).

3. Screw connection socket (5) to the spray gun (6).

4. Screw spray gun with selected tip to the high-pressure hose or

hose whip (4), depending on the model.

5. Tighten union nuts at high-pressure hose and, depending on

the model, at the hose whip to prevent coating material from leaking.

6. Fill in EasyGlide (g. 13). Do not ll in too much separating

oil, i.e. ensure that no separating oil drips into the coating material container. Attention EasyGlide prevents increased wear and tear to the packings.

4.3 Gasoline engine (gas units only)

1. Fill in the supplied engine oil.

The gasoline engine is transported without engine oil. The oil-level sensor prevents the engine from being started when the oil level is too low. For oil grades and quantities please refer to the engine instructions.

2. Fill the gasoline tank.

For information on the gasoline please refer to the engine instructions.

4.4 Connection to the mains (electric units only)

Attention The connection must take place through a properly earthed two-pole and earth socket outlet. Before connecting the unit to the mains supply, make sure that the line voltage matches the specications on the unit’s rating plate. The green indicator light will light up as soon as the mains plug has been connected.

4.5 Flushing preserving uid during initial

pump to a container with suitable cleaning agent.

2. Turn the pressure control knob (2) on the hydraulic pump to

the left (pressure reduction) until it stops.

4. Start the engine or turn on the electric motor.

a. To start the gas engine, refer to the engine manual. b. To start the electric motor:

• For HC 920 and HC 950 units, move the switch to “1” (ON).

• For HC 970 units, rst set the switch to “Y” and then to “∆” (ON).

The direction of the rotation of the pulley must correspond to the arrow (4) on the belt cover. If the belt is running opposite the direction of the arrow: Switch unit to “O” (OFF). Unplug power plug and turn the polarity changer (5) in the power plug by 180º with a screwdriver. Plug in power plug again.

5. Move the hydraulic ball valve (6) on the material feed pump

to its vertical position (open). This will switch on the hydraulic motor. Hydraulic oil ows to the hydraulic motor of the material feed pump.

6. Turn the pressure control knob (2) to the right (pressure

increase) until cleaning agent exits the return hose.

7. Turn relief valve handle (3) fully clockwise (p spray).

8. Pull the trigger of the spray gun.

9. Spray the cleaning agent from the unit into an open collecting

container.HC 950 • HC 970 37 Starting operation Interruption of work

4.6 Taking the unit into operation with coating

material If the unit is located on a non-conductive surface (e.g. a wood oor), earth the unit with an earthing cable. 1. Push locking pin (g. 14, item 1) and swivel material feed pump into the coating material container. 2. Turn the pressure control knob (2) on the hydraulic pump to the left (pressure reduction) until it stops. 3. Turn the relief valve handle (3) fully counterclockwise (k Circulation). 4. Start the engine or turn on the electric motor. a. To start the gas engine, refer to the engine manual. b. To start the electric motor: • For HC 950 units, move the switch to “1” (ON). • For HC 970 units, rst set the switch to “Y” and then to “∆” (ON). The direction of the rotation of the pulley must correspond to the arrow (4) on the belt cover. If the belt is running opposite the direction of the arrow: Switch unit to “O” (OFF). Unplug power plug and turn the polarity changer (5) in the power plug by 180º with a screwdriver. Plug in power plug again. 5. Move the hydraulic ball valve (6) on the material feed pump to its vertical position (open). This will switch on the hydraulic motor. Hydraulic oil ows to the hydraulic motor of the material feed pump. 6. Turn the pressure control knob (2) to the right (pressure increase) until coating material exits the return hose. 7. Turn relief valve handle (3) fully clockwise (p spray). 8. Pull the trigger of the spray gun, then set the desired operating pressure by means of the pressure control knob (2). 9. The unit is ready to spray.

5. Spraying technique

Move the spray gun evenly during the spraying process. Otherwise the spray pattern will be uneven. Carry out the spray movement with the arm, not with the wrist. Observe a parallel distance of approx. 30 cm between the spray gun and the object of spraying. The lateral edge of the spray jet should not be too distinct. The spray edge should be gradual in order to facilitate overlapping of the next coat. Always move the spray gun parallel and at an angle of 90° to the surface to be coated in order to minimize the paint mist.

If very sharp edges result or if there are streaks in the spray jet – increase the operating pressure or dilute the coating material.

6. Handling the high-pressure hose

The unit is equipped with a high-pressure hose specially suited for piston pumps.Danger of injury through leaking high-pressure hose. Replace any damaged high-pressure hose immediately.Never repair defective high-pressure hoses yourself!The high-pressure hose is to be handled with care. Avoid sharp bends and folds: the smallest bending radius is about 20 cm.Do not drive over the high-pressure hose. Protect against sharp objects and edges.Never pull on the high-pressure hose to move the device.Make sure that the high-pressure hose cannot twist. This can be avoided by using a Wagner spray gun with a swivel joint and a hose system. When using the high-pressure hose while working on scaolding, it is best to always guide the hose along the outside of the scaolding.The risk of damage rises with the age of the high-pressure hose. Wagner recommends replacing high-pressure hoses after 6 years.Use only WAGNER original-high-pressure hoses in order to ensure functionality, safety and durability.

7. Interruption of work

1. Move the hydraulic ball valve on the material feed pump to its horzontal position (closed). Flow of hydraulic oil to hydraulic motor of material feed pump is interrupted. 2. Turn the relief valve handle (3) fully counterclockwise (k Circulation). 3. Turn o the gasoline engine or electric motor. 4. Pull the trigger of the spray gun in order to release the pressure from the high-pressure hose and spray gun. 5. Secure the spray gun, refer to the operating manual of the spray gun. 6. If a standard tip is to be cleaned, see page 43, point 11.2. If a non-standard tip is installed, proceed according to the relevant operating manual. 7. Leave the suction tube immersed in the coating material or immerse it in the corresponding cleaning agent. Attention If fast-drying or two-component coating material is used, ensure that the unit is rinsed with a suitable cleaning agent within the processing time.38 HC 950 • HC 970

Cleaning the unit (shutting down)

8. Cleaning the unit (shutting down)

A clean state is the best method of ensuring operation without problems. After you have nished spraying, clean the unit. Under no circumstances may any remaining coating material dry and harden in the unit. The cleaning agent used for cleaning (only with an ignition point above 21 °C) must be suitable for the coating material used.

• Secure the spray gun, refer to the operating manual of the spray gun. Clean and remove tip. For a standard tip, refer to page 43, point 11.2. If a non-standard tip is installed, proceed according to the relevant operating manual.

1. Push locking pin and swivel material feed pump out of

2. Pull the trigger of the spray gun in order to pump the

remaining coating material from the suction tube, high- pressure hose and the spray gun into an open container. Attention The container must be earthed in case of coating materials which contain solvents. Caution! Do not pump or spray into a container with a small opening (bunghole)! Refer to the safety regulations.

3. Push locking pin and swivel material feed pump to a container

with suitable cleaning agent.

5. Pump a suitable cleaning agent in the circuit for a few

7. Pump the remaining cleaning agent into an open container

until the unit is empty.

9. Move the hydraulic ball valve on the material feed pump to its

horzontal position (closed).

10. Turn o the gasoline engine or electric motor.

8.1 Cleaning the unit from the outside

Gasoline units — Switch o the gasoline engine and let it cool down. Electric units — Unplug the mains plug from the socket. Danger of short-circuits through penetrating water. Never spray down the unit with high-pressure or high-pressure steam cleaners. Attention Do not put the high-pressure hose into solvents. Use only a wet cloth to wipe down the outside of the hose. Wipe the unit o with a cloth soaked in a suitable cleaning agent.

8.2 Cleaning the high-pressure lter

Clean the lter cartridge regularly. A soiled or clogged high-pressure lter can cause a poor spray pattern or a clogged tip. Disassembly

1. Move the hydraulic ball valve on the material feed pump to its

horzontal position (closed). Flow of hydraulic oil to hydraulic motor of material feed pump is interrupted.

3. Turn o the gasoline engine or electric motor.

4. Unscrew the housing cover (g. 15, item 1).

5. Pull lter cartridge (3) out of housing (8).

6. Clean the pressure spring (2) and lter cartridge (3) with an

appropriate cleaning agent, clean the inside of the housing (8) and housing cover (1).

7. Check ball in the lter cartridge (3) for wear and replace lter

cartridge, if necessary.

8. If ball in lter cartridge (3) is thoroughly worn, aremove O-ring

(6) and valve seat (7). Replace worn valve seat, if necessary.

9. Always replace O-ring (6) after removal.

10. Pull o pressure spring (2) from housing cover (1).

Measure length of pressure spring, and replace if shorter than 19 mm. Assembly

1. Insert valve seat (7) with the ball seat surface facing up into

2. Insert O-ring (6) into the housing (8).

3. Insert lter cartridge (3).

4. Place thin seal (5) on threaded section of housing (8).

5. Place thick seal (4) on top of thin seal (5).

6. Slide pressure spring (2) onto housing cover pin (2).

7. Screw on housing cover (1) and tighten by hand.HC 950 • HC 970 39

Cleaning the unit (shutting down)

– Rinse Airless spray gun with an appropriate cleaning agent. – Clean tip thoroughly with appropriate cleaning agent so that no coating material residue remains. – Thoroughly clean the outside of the Airless spray gun. Intake lter in Airless spray gun (g. 16) Dismounting

1. Pull protective guard (1) forward vigorously.

2. Screw handle (2) out of the gun housing. Remove intake lter

3. Intake lter congested or defective – replace.

1. Place intake lter (3) with the long cone into the gun housing.

2. Screw handle (2) into the gun housing and tight en.

3. Snap in protective guard (1).

Remedy in case of faults

Type of malfunction A. Gasoline engine does not start up Type of malfunction A. Unit does not start B. HC 970 units: Piston rod in the material feed pump is not moving up and down. Type of malfunction A. Hydraulic motor stuck in the lower position. B. Hydraulic motor stuck in the upper position. C. Low pressure. The piston rod moves correctly in the downward stroke, but the upward stroke is sluggish. The outside of the hydraulic motor is very hot. D. Low pressure. The outside of the hydrau lic motor becomes very hot when stroking upward and downward. Possible cause

3. Gasoline cock closed.

5. Engine defective.

6. Oil level insucient.

1. Indicator light does not indicate unit

2. The unit has switched o

automatically because of an overload.

1. Direction of the rotation of the electric

motor is incorrect Possible cause

1. Outlet valve seat in the material feed

2. Reversing valve in the hydraulic

motor is stuck or the upper or lower hexagonal nut on the valve rod has become loose.

1. Reversing valve is stuck.

2. Pressure spring on valve rod is broken.

3. Pressure spring stop on valve rod is

4. Air in the hydraulic motor.

5. Air in the material feed pump.

1. Faulty piston packing in hydraulic

2. Piston rod is broken.

1. Middle O-ring on reversing valve is

2. Packings in the material feed pump

are worn. Measures for eliminating the malfunction

4. Please refer to the engine instructions.

5. Bring to the Honda service point.

Measures for eliminating the malfunction

1. Check power supply.

Measures for eliminating the malfunction

1. Ball valve on the material feed pump – lever position

vertical. Screw out sealing screw on hydraulic motor. Press down reversing valve on hydraulic motor. Remount sealing screw. Start unit. The piston rod moves upward and then gets stuck in the lower position. The cause is a loose outlet valve seat.

2. Take unit to a Wagner authorized service center.

1. Take unit to a Wagner authorized service center.

2. Take unit to a Wagner authorized service center.

3. Take unit to a Wagner authorized service center.

4. Turn back pressure control knob.

Vent air at low pressure during a 5 – 10 minute endurance run. Do not let the material feed pump run dry. Check for leaks:

• Loose connections on hydraulic oil tank

• Loose connections on the hydraulic oil pump

• Loose hydraulic oil hose connections

• Level of oil in hydraulic tank is too low

5. Ball valve on the material feed pump – lever position

vertical. Screw out sealing screw on hydraulic motor. Press down reversing valve on hydraulic motor. Remount sealing screw. Start unit. Prevent the material feed pump from sucking up air.

1. Take unit to a Wagner authorized service center.

2. Take unit to a Wagner authorized service center.

1. Take unit to a Wagner authorized service center.

Remedy in case of faults Type of malfunction A. A sucient amount of coating material is ejected only with an upward stroke, or upward motion of the piston rod is slow and downward motion is fast B. A sucient amount of coating material is ejected only with a downward stroke, or downward motion of the piston rod is slow and upward motion is fast. C. Piston rod moves up and down quickly. D. Piston rod moves up and down slowly when the spray gun is closed. E. Not enough pressure to the spray gun. F. Piston rod sputters when stroking upward or downward. Possible cause

1. Inlet valve is leaky due to impurities or

2. Coating material viscosity is too high,

preventing it from being sucked up.

1. Outlet valve leaky.

2. Lower packing is worn.

1. Suction tube projects over the uid

level and sucks in air.

2. Coating material viscosity is too high,

preventing it from being sucked up.

3. Ball in inlet valve housing is stuck.

1. Loose connections.

2. Relief valve is not closed completely.

3. Relief valve worn.

4. Lower packing worn.

5. Ball in inlet valve housing and ball

in outlet valve seat are not sealing properly.

2. Filter cartridge in high-pressure lter

3. High-pressure hose is too long.

1. Solvent has made the upper packing

expand. Measures for eliminating the malfunction

1. Clean and check the inlet valve housing. Insert ball and ll

with water; if leaky, replace ball.

2. Thin out according to the manufacturer’s instructions.

1. Dismantle and check outlet valve seat. Insert ball and ll

with water; if leaky, replace ball.

1. Rell the coating material

2. Thin out the coating material according to manufacturer’s

3. Vent air from material feed pump and turn the relief valve

knob to the left (k Circulation).

1. Dismantle inlet valve housing, clean ball and valve seat.

Check all connections between the material feed pump and spray gun.

4. If the measures described above do not help, replace

5. Dismantle inlet valve housing and outlet valve seat. Clean

balls and valve seats.

10.1 General servicing

The unit should be serviced once a year by the Wagner Service.

1. For servicing of the gasoline engine, refer to the engine

2. Check the high-pressure hoses for damage.

3. Check the inlet and outlet vents for wear.

4. Check oil level in hydraulic oil tank.

5. Carry out an oil change if necessary.

10.2 Checking the oil level in the hydraulic oil tank

Gasoline units — Check oil level daily. Electric units — Switch o unit “O” (OFF). Remove the mains plug from the socket.

1. Turn oil measuring stick (g. 17, item 1) to the left and pull out.

2. The oil level should be visible between the marking (see

arrows) on the oil measuring stick.

3. If necessary, rell oil. For information on the oil grade, refer to

the oil change section, chapter 10.3.

10.3 Oil and oil lter change ot the hydraulic oil

pump Carry out oil and oil lter change once every 12 months. Danger to the environment Do not dispose of waste oil into the sewer or soil. Polluting the ground water is a crime. Waste oil can be returned where hydraulic oil is bought.

Carry out an oil change while the unit is still warm from operation. Electric units — Switch o unit “O” (OFF). Remove the mains plug from the socket.

1. Turn o the gasoline engine or electric motor.

2. Move the hydraulic ball valve (g. 18, item 1) on the material

feed pump to its vertical position (open).

3. Remove the screws on the hydraulic oil pump cover (2) and

4. Turn oil measuring stick (3) to the left and pull out.

5. Screw out oil lter (4) with a strap spanner and replace.

6. Screw out sealing screw (5) under the hydraulic oil tank. Drain

7. Replace the sealing screw into the hydraulic oil tank.

8. Fill in 4.7 liters of ESSO ISO 32 hydraulic oil.

When oil is lled in, air can enter the hydraulic system. Therefore, the system must be vented.

9. Let the unit run for at least ve minutes at low pressure to

10.4 High-pressure hose

Inspect the high-pressure hose visually for any notches or bulges, in particular at the transition in the ttings. It must be possible to turn the union nuts freely.

The risk of damage rises with the age of the high- pressure hose. Wagner recommends replacing high- pressure hoses after 6 years.HC 950 • HC 970 43

11.1 Selection of tip

To achieve faultless and rational working, the selection of the tip is of the greatest importance. In many cases the correct tip can only be determined by means of a spraying test. Some rules for this: The spray jet must be even. If streaks appear in the spray jet the spraying pressure is either too low or the viscosity of the coating material to high. Remedy: Increase pressure or dilute coating material. Each pump conveys a certain quantity in proportion to the size of the tip: The following principle is valid: large tip = low pressure small tip = high pressure There is a large range of tips with various spraying angles.

11.2 Servicing and cleaning of Airless hard-metal tips

Standard tips If a dierent tip type has been tted, then clean it according to manufacturer’s instructions. The tip has a bore processed with the greatest precision. Careful handling is necessary to achieve long durability. Do not forget the fact that the hard-metal insert is brittle! Never throw the tip or handle with sharp metal objects. The following points must be observed to keep the tip clean and ready for use:

1. Turn the relief valve handle fully counterclockwise (k Circulation).

2. Switch o the gasoline engine.

3. Dismount the tip from the spray gun.

4. Place tip in an appropriate cleaning agent until all coating material residue is dissolved.

5. If there is pressure air, blow out tip.

6. Remove any residue by means of a sharp wooden rod (toothpick).

7. Check the tip with the help of a magnifying glass and, if necessary, repeat points 4 to 6.

11.3 Spray gun accessories

Flat jet adjusting tip up to 250 bar (25 MPa Contact protection for the at jet adjustment tip Order No. 0097 294 Tip extension with slewable knee joint (without tip) Tip extension Length: 100 cm Order no. 0096 015 Length: 200 cm Order no. 0096 016 Length: 300 cm Order no. 0096 017 15 cm, F-thread, Order no. 0556 051 15 cm, G-thread, Order no. 0556 074 30 cm, F-thread, Order no. 0556 052 30 cm, G-thread, Order no. 0556 075 45 cm, F-thread, Order no. 0556 053 45 cm, G-thread, Order no. 0556 076 60 cm, F-thread, Order no. 0556 054 60 cm, G-thread, Order no. 0556 077 Tip marking Bore mm Spray width at about 30 cm removal of spray object Pressure 100 bar (10 MPa) Use Flat jet adjusting tip Order No. 15 0.13 - 0.46 5 - 35 cm Paints 0999 057 20 0.18 - 0.48 5 - 50 cm Paints, llers 0999 053 28 0.28 - 0.66 8 - 55 cm Paints, dispersions 0999 054 41 0.43 - 0.88 10 - 60 cm Rust protection paints - dispersions

Wagner TradeTip 3 tip up to 270 bar (27 MPa) without tip F thread (11/16 - 16 UN) for Wagner spray guns Order no. 0289391 without tip G thread (7/8 - 14 UN) for Graco/Titan spray guns Order no. 0289390

All of the tips in the table below are supplied together with the appropriate gun lter. Application Tip marking Spray angle Bore inch / mm Spraying width mm 1) Gun lter Order no. Water-thinnable and solvent-based paints and varnishes, oils, separat- ing agents

Synthetic-resin paints PVC paints

yellow yellow yellow yellow yellow yellow yellow yellow

Rust protection paints Latex paints Dispersions

Rust protection paints Latex paints Dispersions

1)Spray width at about 30 cm to the object and 100 bar (10 MPa) pressure with synthetic-resin paint 20 DIN seconds.HC 950 • HC 970 45

Appendix Application Tip marking Spray angle Bore inch / mm Spraying width mm 1) Gun lter Order no. Roof coatings 223

1)Spray width at about 30 cm to the object and 100 bar (10 MPa) pressure with synthetic-resin paint 20 DIN seconds.46 HC 950 • HC 970

The innovative changeover nozzle from WAGNER combines two nozzle cores into one nozzle. 2 Speed Tip holder Order no. 0271065 Tip table Object size Painting material Lacquer (L) Emulsion (D) Filler (S) Small

Important notes on product liability As a result of an EC regulation being eective as from January 1, 1990, the manufacturer shall only be liable for his product if all parts come from him or are released by him, and if the devices are properly mounted and operated. If the user applies outside accessories and spare parts, the manufacturer´s liability can fully or partially be inapplicable; in extreme cases usage of the entire device can be prohibited by the competent authorities (employer´s liability insurance association and factory inspectorate division). Only the usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed. 3+2 years guarantee for professional nishing Wagner professional guarantee (Status 01.02.2009)

1. Scope of guarantee

All Wagner professional colour application devices (hereafter referred to as products) are carefully inspected, tested and are subject to strict checks under Wagner quality assurance. Wagner exclusively issues extended guarantees to commercial or professional users (hereafter referred to as “customer”) who have purchased the product in an authorised specialist shop, and which relate to the products listed for that customer on the Internet under www.wagner- group.com/pro-guarantee. The buyer’s claim for liability for defects from the purchase agreement with the seller as well as statutory rights are not impaired by this guarantee. We provide a guarantee in that we decide whether to replace or repair the product or individual parts, or take the device back and reimburse the purchase price. The costs for materials and working hours are our responsibility. Replaced products or parts become our property.

2. Guarantee period and registration

The guarantee period amounts to 36 months. For industrial use or equal wear, such as shift operations in particular, or in the event of rentals it amounts to 12 months. Systems driven by petrol or air are also guaranteed for a 12 month period. The guarantee period begins with the day of delivery by the authorised specialist shop. The date on the original purchase document is authoritative. For all products bought in authorised specialist shops from 01.02.2009 the guarantee period is extended to 24 months providing the buyer of these devices registers in accordance with the following conditions within 4 weeks of the day of delivery by the authorised specialist shop. Registration can be completed on the Internet under www.wagner-group. com/pro-guarantee. The guarantee certicate is valid as conrmation, as is the original purchase document that carries the date of the purchase. Registration is only possible if the buyer is in agreement with having the data being stored that is entered during registration. When services are carried out under guarantee the guarantee period for the product is neither extended nor renewed. Once the guarantee period has expired, claims made against the guarantee or from the guarantee can no longer be enforced.

If defects can be seen in the materials, processing or performance of the device during the guarantee period, guarantee claims must be made immediately, or at the latest within a period of 2 weeks. The authorised specialist shop that delivered the device is entitled to accept guarantee claims. Guarantee claims may also be made to the service centres named in our operating instructions. The product has to be sent without charge or presented together with the original purchase document that includes details of the purchase date and the name of the product. In order to claim for an extension to the guarantee, the guarantee certicate must be included. The costs as well as the risk of loss or damage to the product in transit or by the centre that accepts the guarantee claims or who delivers the repaired product, are the responsibility of the customer.

4. Exclusion of guarantee

Guarantee claims cannot be considered - for parts that are subject to wear and tear due to use or other natural wear and tear, as well as defects in the product that are a result of natural wear and tear, or wear and tear due to use. This includes in particular cables, valves, packaging, jets, cylinders, pistons, means- carrying housing components, lters, pipes, seals, rotors, stators, etc. Damage due to wear and tear that is caused in particular by sanded coating materials, such as dispersions, plaster, putty, adhesives, glazes, quartz foundation. - in the event of errors in devices that are due to non-compliance with the operating instructions, unsuitable or unprofessional use, incorrect assembly and/or commissioning by the buyer or by a third party, or utilisation other than is intended, abnormal ambient conditions, unsuitable coating materials, unsuitable operating conditions, operation with the incorrect mains voltage supply/frequency, over- operation or defective servicing or care and/or cleaning. - for errors in the device that have been caused by using accessory parts, additional components or spare parts that are not original Wagner parts. - for products to which modications or additions have been carried out. - for products where the serial number has been removed or is illegible - for products to which attempts at repairs have been carried out by unauthorised persons. - for products with slight deviations from the target properties, which are negligible with regard to the value and usability of the device. - for products that have been partially or fully taken apart.

5. Additional regulations.

The above guarantees apply exclusively to products that have been bought by authorised specialist shops in the EU, CIS, Australia and are used within the reference country. If the check shows that the case is not a guarantee case, repairs are carried out at the expense of the buyer. The above regulations manage the legal relationship to us concludingly. Additional claims, in particular for damages and losses of any type, which occur as a result of the product or its use, are excluded from the product liability act except with regard to the area of application. Claims for liability for defects to the specialist trader remain unaected. German law applies to this guarantee. The contractual language is German. In the event that the meaning of the German and a foreign text of this guarantee deviate from one another, the meaning of the German text has priority. J. Wagner GmbH Division Professional Finishing Otto Lilienthal Strasse 18 88677 Markdorf Federal Republic of Germany122 HC 950 • HC 970