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VERSION 02/2018

ORDER NUMBER DOC 2340282

IceBreaker 150-300 cm

1.4

SERVICE MANUAL

The service manual is available in the following languages:

Language

Order no.

Language

Order no.

German

2335993

English

2335994

Additional languages on request or at:

www.wagner-group.com

1.5

CONTINUOUS-FLOW HEATER OPERATING MANUAL

The operating manual Continuous-flow heater is available in the following languages:

Language

Order no.

Language

Order no.

German

65860

English

65860

French

65860

Italian

65860

Additional languages on request or at:

www.wagner-group.com

1.6

ABBREVIATIONS

Number of pieces

Double stroke

Position

DN Nominal diameter

Marking in the spare parts lists

PN Nominal pressure

Order no. Order number

Two components

Ultra-high molecular weight polyethylene

PTFE

Polytetrafluorethylene

Stainless steel

PTFE with graphite

Polyethylene

: Heavy duty corrosion

protection

Leather

1.7

TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning

Manual cleaning of devices and device parts with cleaning

agent.

Flushing

Internal flushing of paint-wetted parts with flushing agent.

Product pressure

generator

Pump or pressure tank.

Personnel qualifications

Trained person

Is instructed in the tasks assigned to him/her, the potential risks

associated with improper behavior as well as the necessary

protective devices and measures.

Electrically trained

person

Is instructed by an electrician about the tasks assigned to him/

her, the potential risks associated with improper behavior as well

as the necessary protective devices and measures.

Electrician

Can assess the work assigned to him/her and detect possible

hazards based on his/her technical training, knowledge,

experience and knowledge of the relevant provisions.

Skilled person in

accordance with TRBS

1203

(2010/Revision 2012)

A person, who, based on his/her technical training, experience

and recent vocational experience, has sufficient technical

knowledge in the areas of explosion protection, protection

from pressure hazards and electric hazards (if applicable) and

is familiar with the relevant and generally accepted rules of

technology so that he/she can inspect and assess the status of

devices and coating systems based on workplace safety.

Содержание Jaguar 75-150

Страница 1: ...Jaguar 75 150 Jaguar 55 200 PROTEC 60 240 Tiger 72 300 Icebreaker Piston Pumps Protective Coating PC Flow rate 150 cm 3 300 cm 3 Version 02 2018 B_04259...

Страница 2: ......

Страница 3: ...1 1 Electrical Devices and Equipment 12 4 1 2 A Safe Work Environment 12 4 1 3 Personnel Qualifications 13 4 2 Safety Instructions for the Personnel 13 4 2 1 Personal Safety Equipment 13 4 2 2 Safe Ha...

Страница 4: ...supply lines 33 6 6 Grounding 33 6 7 Commissioning 35 7 OPERATION 36 7 1 Training the Operating Personnel 36 7 2 Emergency Stop 36 7 3 Tasks 36 7 4 Pressure Relief Work Interruption 37 7 5 Basic Flush...

Страница 5: ...erview of the Components 54 14 3 Air Motors 56 14 3 1 9 Jaguar Air Motor 56 14 3 2 Air Motor Regulator for Jaguar and PROTEC 59 14 3 3 10 PROTEC Air Motor 60 14 3 4 12 Tiger Air Motor 64 14 3 5 Tiger...

Страница 6: ...ng categories DANGER Immediate risk of danger Non observance will result in death or serious injury WARNING Potential risk Non observance can result in death or serious injury CAUTION Potentially haza...

Страница 7: ...ning agent Flushing Internal flushing of paint wetted parts with flushing agent Product pressure generator Pump or pressure tank Personnel qualifications Trained person Is instructed in the tasks assi...

Страница 8: ...dance with their classification in explosion class IIB WAGNER explicitly prohibits any other use The device may only be operated under the following conditions Use the device only to work with the pro...

Страница 9: ...d in Chapter 5 5 Check if the fluids and solvents used are compatible with the pump construction materials as indicated in Chapter 5 5 1 Use suitable combinations of devices packings valves etc Wear c...

Страница 10: ...2 IDENTIFICATION X The maximum surface temperature corresponds to the permissible product temperature This and the permissible ambient temperature can be found in Chapter 5 5 3 and 5 5 5 Technical dat...

Страница 11: ...fficient separating agent Periodically check that the pump is working smoothly paying special attention to the presence of air in the pumped fluid Filling and emptying Ignitable gas mixtures can form...

Страница 12: ...devices 4 1 2 A SAFE WORK ENVIRONMENT Hazard due to dangerous fluids or vapors Severe or fatal injuries due to explosion hazard or inhalation swallowing or contact with the skin or eyes Ensure that t...

Страница 13: ...out the required personnel qualifications 4 2 SAFETY INSTRUCTIONS FOR THE PERSONNEL Always follow the information in this manual particularly the safety instructions and the warning instructions Alway...

Страница 14: ...500 Chapters 2 29 and 2 36 For shut down devices the check can be postponed until the next start up In the event of skin injuries caused by lacquer or flushing agents Note the lacquer or flushing agen...

Страница 15: ...never run over by vehicles e g fork lift trucks or that the hoses are never put under pressure from the outside in any other way Ensure that the hoses are never kinked Observe maximum bending radii En...

Страница 16: ...duct used depending on the flushing agent solvent used an explosive mixture may temporarily exist inside the lines and components of equipment Only electrically conductive tanks may be used for cleani...

Страница 17: ...ted in Chapter 13 and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun high pressure hoses and all devices Sec...

Страница 18: ...rected at the end of each stroke with the help of the reversing valve The working material is sucked up during the upwards stroke and is continuously conveyed towards the product outlet 8 in both stro...

Страница 19: ...the permissible operating pressure the valve which is held with a spring automatically opens and releases the excess pressure 5 4 INCLUDED ITEMS Consists of Fluid section Air motor Connection element...

Страница 20: ...nufactured in four different materials Product Color Leather dark brown PTFE with graphite black Ultra high molecular weight polyethylene transparent PTFE white Each product has the following properti...

Страница 21: ...uble stroke nl scf 79 9 2 82 103 1 3 64 Air motor piston diameter mm inch 220 8 7 250 9 8 Air motor piston stroke mm inch 150 6 Sound pressure level at maximum permissible air pressure dB A 83 83 Soun...

Страница 22: ...157 45 5 1169 46 0 B 304 12 C 582 22 9 D 470 18 5 483 19 0 E 675 26 6 687 27 0 F 244 9 6 G 230 9 1 H 110 4 3 I 20 48 0 8 1 9 J M8 K G1 internal thread L1 M24 1 5 external thread L2 G3 8 G1 2 M G1 O 13...

Страница 23: ...scf 170 6 Air motor piston diameter mm inch 300 11 8 Air motor piston stroke mm inch 150 5 9 Sound pressure level at maximum permissible air pressure 82 Sound pressure level at 0 6 MPa 6 bar 87 psi ai...

Страница 24: ...TIGER mm inch A 1106 43 5 B 340 13 4 C 562 22 1 D 518 20 4 E 588 23 1 F 244 9 6 G 230 9 1 H 110 4 3 I 20 48 0 8 1 9 J M8 K G1 1 2 L1 M24 1 5 L2 G3 4 M G 1 O 135 5 3 P 238 9 4 Q 9 0 35 R 9 0 35 S 206...

Страница 25: ...0 30 0 35 0 43 0 50 0 013 0 33 10 20 30 40 50 60 80 0 45 0 53 0 62 0 68 0 015 0 38 10 20 30 40 50 60 80 0 58 0 67 0 81 0 91 0 017 0 43 20 30 40 50 60 70 0 73 0 79 1 06 1 23 0 019 0 48 20 30 40 50 60...

Страница 26: ...C bar MPa psi nl min scfm l min gpm A C B 14 4 3 8 12 3 2 9 6 2 5 7 2 1 9 4 8 1 3 2 4 0 6 B_05288 0 300 30 4350 200 20 2900 100 10 1450 0 10 20 30 40 50 60 9000 318 6000 212 3000 106 0 18 4 8 15 4 12...

Страница 27: ...of the pump can be performed see Chapter 7 4 a high pressure filter with a return line or a relief combination is mandatory 5 7 1 HIGH PRESSURE FILTER OPTION To ensure problem free operation it is re...

Страница 28: ...of the PC air filter set on the heavy duty PC trolley 1 1 Mount the air filter 2 2 Mount the air filter 2 on trolley 1 3 Mount the air connection 3 on the air motor 4 Mount the air hose between 2 and...

Страница 29: ...perature is set using the temperature regulator The coating product temperature can be read off the thermometer on the coating product output Description of heater and thermometer see heater operating...

Страница 30: ...exceeded B_05173 Feed pump Main pump IceBreaker Protection of feed pump If the maximum pressure of the feed pump is lower than the maximum pressure of the main pump this could be exceeded if the main...

Страница 31: ...must be stored in a dry location free from vibrations and with a minimum of dust The device must be stored in closed rooms The air temperature at the storage location must be between 20 C and 60 C 4 F...

Страница 32: ...ump can be used as part of a spraying system for Airless applications The individual componentsareshownintheaccessories orcanbearrangedwithaspraypackconfigurator The nozzles must be selected according...

Страница 33: ...5 3 PRODUCT SUPPLY LINES DANGER Bursting hose bursting threaded joints Danger to life from injection of product Ensure that the hose material is chemically resistant to the sprayed products Ensure th...

Страница 34: ...mp is only guaranteed with a grounding connection Connect all grounding cables using a short and direct route B_05443 Procedure 1 Screw on grounding cable with eyelet 2 Clamp the grounding cable clip...

Страница 35: ...ent in accordance with Chapter 8 2 3 1 Fill the pump with flushing agent The devices are tested during manufacturing with emulsifying oil pure oil or solvent Possible residues must be flushed out of t...

Страница 36: ...te system training 7 2 EMERGENCY STOP In the case of unforeseen occurrences B_04267 3 2 Open Closed Open Close ball valve 2 Open return valve 3 7 3 TASKS Ensure that commissioning is carried out in ac...

Страница 37: ...essed air source and pneumatic pump Outlet equipment return valve mounted between pump and spray gun Process for relieving pressure 1 Close the spray gun 2 Close ball valve 2 3 Release the system of p...

Страница 38: ...5 MPa 0 5 bar 7 25 psi Flushing via the return valve 5 Open return valve 3 6 Slowly open the ball valve 2 7 Adjust the air pressure on the pressure regulator 1 so that the pump runs smoothly 8 Flush t...

Страница 39: ...apter 8 2 4 4 Service spray gun in accordance to its operating instructions 5 Clean and check the suction system and the suction filter 6 When using a product filter check filter insert and filter hou...

Страница 40: ...nly WAGNER original spare parts and accessories Only repair and replace parts that are listed in the Spare parts chapter and that are assigned to the unit Before all work on the device and in the even...

Страница 41: ...V regulation 100 500 Chapter 2 29 and 2 36 The liquid ejection devices should be checked by an expert e g WAGNER service technician for their safe working conditions as required and at least every 12...

Страница 42: ...must regularly check the complete hoses for wear and tear as well as for damage at intervals that he she has set Records of these checks must be kept The complete hose is to be replaced as soon as on...

Страница 43: ...owly open the ball valve 2 6 Slowly turn air pressure up on the pressure regulator 1 and only until the pump is running normally approx 0 05 MPa 0 5 bar 7 25 psi 7 Be ready for the switch from working...

Страница 44: ...th a rigid suction system it should only be dipped in into the working product up to the middle of the inlet housing at the maximum 4 Close pressure regulator 1 0 MPa 0 bar 0 psi 5 Open return valve 3...

Страница 45: ...nut 3 and lift slightly so that it does not get dirty in the next step 7 Remove the filter housing 2 with the union nut 3 The cone spring 12 remains in the filter housing 2 If the O ring 5 is not dam...

Страница 46: ...g manual of spray gun Irregular operation of product pump spray jet collapses pulsation Viscosity is too high Thin spraying product Spraying pressure is too low Increase incoming air pressure Use a sm...

Страница 47: ...the Spare parts chapter and that are assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun high pressure hoses and all devi...

Страница 48: ...are parts can be found as well as for wearing parts such as seals Defective parts O rings and seal sets must always be replaced Use greases and glues in accordance with Chapter 14 Observe torque speci...

Страница 49: ...st on the device the product pressure with the flushing agent is slowly increased in increments until the maximum pressure indicated on the type plate is reached Close pump outlet In each position for...

Страница 50: ...847 Piston pump PE TG Tiger PE L 1 9992504 Separating agent 250 ml 250 cc 2 236219 Grounding cable 3 m 9 8 ft 8 2339900 HP filter DN12 PN530 SSt with carbon steel ball valve 9 2339850 Y distributor M3...

Страница 51: ...the nut hit the cam with a rubber mallet Pos 6 Before assembling the suction bend check if the inlet housing is screwed on firmly Set the desired orientation of the suction bend during assembly A 233...

Страница 52: ...14 7 Wearing part 13 3 ACCESSORIES FOR TROLLEY AND WALL MOUNT 2 1 B_04271 3 3a 4 Pos 2 When using a wall mount the fluid section must be turned by 180 Designation Order no Order no Order no Order no...

Страница 53: ...sts Wearing parts Wearing parts are not included in the warranty terms Included in service set Notice These parts are not covered by warranty terms Not part of standard equipment available however as...

Страница 54: ...Order no Order no Order no 1 Piston pump 2339845 2339846 2351205 2 Fluid section 2340007 2340008 2349152 3 Air motor 2329625 2342487 2351208 4 Connection set for air motor fluid section 2350033 235003...

Страница 55: ...htening torque pos 2 and 3 Designation Order no 1 Piston pump 2339847 2 Fluid section 2340009 3 Air motor 2329627 4 Connection set for air motor fluid section 2350037 9 Grounding cable complete 236219...

Страница 56: ...54 80 11 36 55 56 10 103 43 52 50 60 59 61 34 41 5 41 71 72 6 39 32 2 3 53 88 51 75 36 4 47 15 58 8 10 Nm 6 7 lbft 140 Nm 103 lbft 40 Nm 30 lbft 70 Nm 52 lbft 28 87 77 48 76 79 106 110 108 78 85 90 91...

Страница 57: ...le 28 6 9974143 O ring 29 2 9974217 Rod seal 30 2 369290 Pilot valve 31 1 9943131 Spool sleeve combination assembly ISO3 32 1 9962019 Permaglide bushing 33 1 369385 Piston 9 34 1 9974125 Seal wiper ri...

Страница 58: ...amping washer 89 1 369317 Control flange 90 1 369026 Air hose rear 91 1 369025 Air hose front 92 1 369326 Lock space 9 93 2 369329 Damper ISO3 94 1 9943131 Spool sleeve assembly ISO3 95 1 9999151 Velc...

Страница 59: ...te 2 1 2309974 Pressure regulator valve 9 3 1 2346229 Distribution piece 4 1 9998725 Pressure gauge 0 10 bar d50 5 2 9900360 Hexagon socket cylinder head screw 6 2 9907087 Hexagon socket cylinder head...

Страница 60: ...17 18 19 15 10 Nm 7 lbft 40 Nm 30 lbft 70 Nm 52 lbft 39 103 102 B_05278 101 103 1 21 22 23 23 24 48 34 35 31 25 26 27 28 30 38 39 40 35 41 42 43 44 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 80 7...

Страница 61: ...er ring 4 1 369325 Lifting eye nut 5 1 9925034 Washer 6 1 2353725 Wagner Protec 10 label 7 1 369311 Hood 9 8 2 9999151 Velcro fastener adhesive part 9 2 9999152 Velcro fastener coating part 10 1 36931...

Страница 62: ...ISO 3 41 1 2354548 Lock space 10 42 1 2354549 Cover 43 1 9971375 O ring 44 1 9999360 Securing ring 45 1 9998274 Threaded plug G1 4 46 1 367324 Filter holder 47 1 367314 Control air filter 48 1 369313...

Страница 63: ...ange 10 81 1 2347218 Rod seal 82 2 9998675 Threaded plug G1 8 83 1 2347211 Scraper ring 84 1 2347187 Permaglide bushing 85 1 367258 Grounding complete 86 1 Base 87 1 9952667 Clamping bracket 88 1 9921...

Страница 64: ...2 44 36 38 46 42 85 37 45 112 116 86 71 73 50 78 60 67 77 52 63 116 116 116 114 116 70 72 58 87 57 61 54 56 62 55 66 76 42 66 65 74 53 69 83 74 81 51 68 75 a 48 49 47 4 79 108 115 116 116 1 109 111 11...

Страница 65: ...in 18 2 370309 Valve cover 19 2 370310 Spiral spring 20 2 370311 Screw plug 21 2 370312 Valve body 22 2 9922724 Lock washer 23 2 9974102 O ring 24 1 370316 Flange 12 25 1 9962026 Permaglide bushing 26...

Страница 66: ...900314 Socket cap screw 72 4 9920102 Washer 73 3 9925029 Washer 74 5 9971004 O ring 75 1 9971129 O ring 76 1 9971372 O ring 77 2 9974132 O ring 78 1 9992757 Threaded elbow fitting 8 1 8 79 1 9998613 F...

Страница 67: ...12 complete 2 1 2309974 Pressure regulator valve 12 3 1 2310588 Distribution piece LR D Maxi 12 4 1 9998725 Pressure gauge 0 10 bar d50 5 4 9900360 Hexagon socket cylinder head screw 6 2 9907087 Hexag...

Страница 68: ...2 300 Designation Order no Order no Order no Order no 1 1 2350033 2350036 2351190 2350037 Connection set LM FS 2 2 368532 Coupling cover stroke 150 3 1 368529 2337924 2337929 370529 Coupling 4 1 36853...

Страница 69: ...69...

Страница 70: ...2 11 3 13 46 25 7 42 27 9 4 50 51 8 B_05282 160 Nm 118 lbft 1 100 Nm 74 lbft 61 29 Regarding position 4 Tighten by hand on block If necessary hit the cam with a rubber mallet and use a spanner to hold...

Страница 71: ...ing collar PE small 103 1 368991 Packing PE TG complete large 1 368993 Packing PE L complete large 104 1 368992 Packing PE T complete large 22 2 368522 Sealing collar TG large 2 368922 Sealing collar...

Страница 72: ...Tighten by hand on block If necessary hit the cam with a rubber mallet and use a spanner to hold position 3 Pos K Qty 200 cm3 240 cm3 Designation PE TG PE L PE T PE TG PE L PE T Order no Order no Orde...

Страница 73: ...2346791 Sealing collar PE small 103 1 2341474 2353075 Packing PE TG complete large 1 2342074 2353076 Packing PE L complete large 104 1 2345986 2353077 Packing PE T complete large 22 2 2336688 2346778...

Страница 74: ...50 300 cm3 14 4 3FLUID SECTION 300 CM3 60 60 60 62 61 61 300 Nm 221 lbft 250 260 Nm 184 191 lbft 60 60 60 25 26 40 3 4 5 4 5 4 6 7 21 24 9 8 12 28 27 29 103 100 20 19 23 18 17 15 16 15 16 15 14 22 10...

Страница 75: ...aling collar T 34 50 17 1 369519 Pressure ring 34 50 18 1 9998671 Spiral wave spring crest to crest 35 8 52 19 1 369510 Valve seat outlet 300 20 1 9971470 O ring 21 1 370505 Piston 300 22 1 370506 Val...

Страница 76: ...2 IceBreaker 150 300 cm3 14 5 HIGH PRESSURE FILTER 90 Nm 66 lbft 140 Nm 103 lbft 12 21 11 10 1 4 7 33 2 3 5 B_04278 23 36 35 36 34 34 20 34 Identification of the filter Tighten pos 3 by hand 530 bar 7...

Страница 77: ...11 1 Filter cartridge 291564 Filter sieve 20 mesh per inch rough 3514069 Filter sieve 50 mesh per inch rough 3514068 Filter sieve 100 mesh per inch medium 295721 Filter sieve 200 mesh per inch fine 1...

Страница 78: ...r of the hose Order no Designation 1 2325815 Suction hose DN38 PC complete 2 2329134 LP hose DN38 PN10 EPDM 3 2329591 Heavy duty clamp 48 51 mm 4 2336488 Cone coupling ID38 5 367525 O ring 6 Suction t...

Страница 79: ...r 3 above the crossbar 4 B_05285 3 3 4 Assembly for Tiger Mount bracket holder 3 below the crossbar 4 B_05286 4 3 3 Order no Designation 1 1 2339705 PC heavy duty trolley 3 1 Bracket holder 5 4 990024...

Страница 80: ...t PC For installation see Chapter 13 3 2 4 9900240 Hexagon screw without shaft 3 10 9955841 Contact washer 4 2 2395578 Connection profile 5 4 9900344 Hexagon socket cylinder head screw 6 4 9955841 Con...

Страница 81: ...4 1 393369 Elbow 5 3 3306773 Contact washer 6 3 9900150 Hexagon screw without shaft 7 6 3155404 Contact washer M08 8 3 9910107 Hexagon nut M8 9 3 9900109 Hexagon screw without shaft 10 1 2333393 Fitti...

Страница 82: ...09 1998 A1 2009 AC 2010 DIN EN 14462 2015 EN ISO 80079 37 2016 DIN EN ISO 4413 2010 DIN EN 12621 2006 A1 2010 EN ISO IEC 80079 34 2011 DIN EN ISO 4414 2010 DIN EN 1127 1 2011 Applied national technica...

Страница 83: ......

Страница 84: ...ts liquid wagner group com www wagner group com CERTI F I E D Document No 11154963 Version C Order no 2340282 Edition 02 2018...

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