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Summary of Contents for wiwa PUGUN 4040
- Page 1 Operating Manual PUGUN 4040 Design: ❍ Hand-held gun ❍ Automatic gun Serial no.: … … … … … … … … Translation of the original operating manual •1306Rev03_550014_PUGUN4040_en•ski...
- Page 2 35633 Lahnau Germany hereby declares that the machine type PUGUN 4040 with the serial number: conforms with the regulations of the above mentioned directive. Responsible for documentation: WIWA GmbH / Tel. +49 6441 609 0 Lahnau, 12.03.2014 12.03.2014 Place, Date...
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Page 3: Table Of Contents
Contents 1 Foreword....................1-1 2 Safety ..................... 2-1 2.1 Explanation of symbols 2.2 Safety notes 2.2.1 Operating pressure 2.2.2 Risks caused by the spray jet 2.2.3 Risks produced by the material used 2.2.4 Risks caused by electrostatic charging 2.2.5 Explosion protection 2.2.6 Health risks 2.3 Safety features 2.3.1 Compressed air shut-off valve... - Page 4 4 Transport, installation and assembly..........4-1 4.1 Transport 4.2 Installation location 4.3 Assembly 4.3.1 Compressed air connection 4.3.2 Connecting the material hoses 4.3.3 Put on protective cover 4.3.4 Earthing/grounding 5 Operation ....................5-1 5.1 Putting the spray gun into operation 5.1.1 Initial commissioning 5.1.2 Cleaning before spraying 5.1.3 Venting...
- Page 5 7 Possible conversions ................7-1 7.1 Material supply hoses position 7.1.1 Material supply hoses connection at the bottom 7.1.2 Material supply hoses connection at the top 7.1.3 Material supply hoses connection at the side 7.2 Conversion to an automatic spray gun 7.3 Connecting mounted accessories 8 Malfunctions and troubleshooting .............
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Page 6: Foreword
WIWA Wilhelm Wagner GmbH & Co. KG. Gewerbestr. 1-3 • 35633 Lahnau • Germany Tel.: +49 6441 609-0 • Fax.: +49 6441 609-50 • E-mail: info@wiwa.de • Internet: www.wiwa.de This operating manual is solely intended for personnel involved in prepara- tion, operation and servicing. -
Page 7: Safety
2.1 Explanation of symbols Safety information warns you of potential risks of accidents and tell you the measures that are needed to prevent accidents. In WIWA operating manuals, safety information is specially highlighted and marked as follows: DANGER Indicates danger of accidents; if you ignore the safety notes, there is a... - Page 8 Safety In the safety notes about the risk of accidents, different pictograms are shown after each hazard source - examples: General accident risk Risk of explosion from explosive atmosphere Risk of explosion from explosive substances Danger of injury due to electric voltage or electrostatic charging Risk of crushing by moving machine parts Risk of burning due to hot surfaces Mandatory safety instructions concern protective gear to be worn in the first...
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Page 9: Safety Notes
Safety Indicates reference to guidelines, work instructions and operating manuals that contain important information which you must observe at all times. Further pictograms: Container “empty” Identifies an empty collecting vessel to be used by the user to collect con- taminated spraying material. 2.2 Safety notes Please remember that the spray gun works at high pressure and may cause life-threatening injuries if used inappropriately! -
Page 10: Risks Caused By The Spray Jet
Safety 2.2.2 Risks caused by the spray jet WARNING The material is discharged from the spray gun under very high pressure. Due to its cutting effect the spray jet can cause severe injuries by pen- etrating the skin or entering into the eyes. Never point the spray gun at yourself, other persons or animals. -
Page 11: Risks Caused By Electrostatic Charging
When using metal containers watch out for contact between spray gun ➤ and container wall. Only use conductive material hoses. ➤ All original material hoses from WIWA are conductive and perfectly adapted to our equipment. 2.2.5 Explosion protection WARNING Devices and machines designed without explosion protection must not be used in workshops that come under the explosion protection ordinance. -
Page 12: Health Risks
Safety WARNING Heating up cleaning agents can cause an explosion. This may result in serious injury to persons and damage to property. Pay attention to the flashpoint and the ignition temperature of the ➤ cleaning agent. Switch off the material flow heater if you need to perform the following ➤... -
Page 13: Compressed Air Shut-Off Valve
Safety The machine is equipped with the following safety features: Compressed air shut-off valve ➤ Material shut-off valves ➤ Safety catch ➤ Guard ➤ 2.3.1 Compressed air shut-off valve If the compressed air supply is interrupted when the trigger is pulled, the spray gun does not shut off and the material flow is not interrupted. -
Page 14: Safety Catch
Safety Ball valve open ➤ => Lettering in the direction of the material flow Ball valve closed ➤ => Lettering perpendicular to the material flow During long breaks as well as dur- ing all conversion, maintenance and cleaning work, both ball valves must always be closed, (Fig. -
Page 15: Personnel Qualification
Safety must ensure that the operating and maintenance staff have read and ➤ understood the user manual. Only then may the spray gun be brought into service. 2.4.2 Personnel qualification A differentiation is made between two groups of people in dependence on their qualifications: Instructed operators have been verifiably instructed by the operator in ➤... -
Page 16: Notes On Warranty
➤ ues and device parameters. 2.5.2 Accessories and spare parts If you use original accessories and spare parts from WIWA, their suitabil- ➤ ity for use with our equipment is guaranteed. It is, however, mandatory to respect the safety regulations of the acces- ➤... -
Page 17: Emergency Procedures
Safety 2.6 Emergency procedures 2.6.1 Take the spray gun out of service and depressurise it In an emergency, immediately shut down the spray gun and depressurise it. Stop the spraying process. Release the trigger and secure it with the safety lever. Close both material shut-off valves. -
Page 18: Description Of Device
In addition to hand-held use, the spray gun can also be used in an automati- cally driven coating system with the optional adapter. To get best work results, the use of the spray gun with a WIWA polyurea system is particularly recommended. -
Page 19: Spray Gun Components
Description of device 3.2 Spray gun components ➃ ➄ ➅ ➉ ➆ ➇ ➂ ➁ ➈ ➀ Fig. 3.1 Left side view Fig. 3.2 Right side view Item Description Guard Trigger Safety lever Grease nipple Iso ball valve Male adapter to connect the ISO material hose Compressed air shut-off valve Air connection nipple for compressed air Gun handle... -
Page 20: Optional Expansion Parts And Accessories
Description of device 3.3 Optional expansion parts and accessories 3.3.1 Adapter for automatic operation To use the spray gun in an automatic system, the gun handle must be replaced with an adapter, (Fig. 3.3). Fig. 3.3 3.4 Type plate The type plate (Fig. 3.4) is found on the cover of the drive. -
Page 21: Transport, Installation And Assembly
Transport, installation and assembly 4 Transport, installation and assembly The spray gun has left the factory in flawless condition and was appropri- ately packed for transport. Check the spray gun on receipt for any damage in transit and for com- pleteness. -
Page 22: Assembly
Transport, installation and assembly The spray gun may only be used in frost-free conditions to prevent the ➤ material crystallising and thereby damaging the spray gun. Always ensure for sufficient aeration and ventilation at the workplace to ➤ avoid damage to health and material objects. Always observe the processing instructions issued by the material manu- facturers. -
Page 23: Compressed Air Connection
Transport, installation and assembly 4.3.1 Compressed air connection WARNING Unexpected material ejection can cause severe bodily injury as well as property damage. Before fitting the compressed air Close the material shut-off valves for Iso and Poly, (Fig. 2.4 Material ➤ shut-off valve “OFF/0”), Lock the trigger on the gun handle, (Fig. -
Page 24: Put On Protective Cover
Transport, installation and assembly Secure the trigger with the safety lever, (Fig. 4.3). Fig. 4.3 Close both material shut-off valves, (Fig. 4.4): Lettering perpendicular to the material flow. Fig. 4.4 Connect the material hoses, (Fig. 4.5). If required, the connections for the material hoses can be aligned upwards or to the side. -
Page 25: Earthing/Grounding
Both the spraying device and the object to be coated must be properly ➤ earthed. The spray gun is earthed by the connection via the WIWA material hoses. These material hoses are conductive. Observe and follow the instructions in the user manual for the spraying device being used. -
Page 26: Operation
Operation 5 Operation Before starting work, check if: All safety features are present and fully functional, see chapter “2.3 Safety features”, page 2-6? All hose couplings are tight? If required, tighten up these connections. Is the trigger fully functional? Observe and follow the instructions in the user manual for the spraying device being used! During operation, the material being processed heats up. -
Page 27: Initial Commissioning
Operation Short description Test state Comment All safety features function Material screen inserted Mixing chamber inserted Dual component system ready for use 5.1.1 Initial commissioning After assembly in the factory, the spray gun is tested to ensure it works cor- rectly using a testing medium (release agent). - Page 28 Operation Pull the trigger on multiple times to release the pressure. When doing this, hold the spray gun in a container to catch the material, (Fig. 5.2). Fig. 5.2 Secure the trigger with the safety lever, (Fig. 5.3). Fig. 5.3 Close the compressed air shut-off valve, (Fig.
- Page 29 Operation Hold each material outlet of the manifold over ➁ a separate container to catch the material and open the material shut-off valve until the material comes out cleanly and without any bubbles, (Fig. ➁ 5.6). ➀ ...
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Page 30: Spraying
Operation 5.1.4 Spraying Open the compressed air shut-off valve, (Fig. 5.10). Fig. 5.10 Release the safety lever, (Fig. 5.11). Fig. 5.11 Check the trigger functions correctly by opening and closing the lever multiple times, (Fig. 5.12). Fig. 5.12 Open the material shut-off valves, (Fig. 5.13) at low supply pressure. -
Page 31: Notes On Spraying
Operation 5.1.5 Notes on spraying Optimal working pressure is indicated by a uniform application of material with fading out peripheral zones. Operate the unit only with a working pres- ➤ sure as high as necessary, to achieve a good atomization at a recommended spraying dis- tance of approx. - Page 32 Operation Release the trigger, (Fig. 5.17). Fig. 5.17 Close the material shut-off valves (Fig. 5.18). Fig. 5.18 Operate the trigger several times until no more mate- rial comes out, (Fig. 5.19). Fig. 5.19 Release the trigger and secure it, (Fig. 5.20). Fig.
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Page 33: Decommissioning
Operation 5.3 Decommissioning During short work breaks, it is sufficient to stop the supply of material. The compressed air valve remains open allowing purge air to flow through the mixing chamber which prevents contamination and clogging of the material channels in the spray gun. If work is interrupted for a longer period of time, or the spray gun is being taken out of use, all material bearing channels in the spray gun must be preserved. -
Page 34: Hose Package Disassembly
Operation 5.4 Hose package disassembly Switch the dual component system off. Observe and follow the instructions in the user manual for the spraying device being used. Stop spraying in accordance with chapter “5.3.2 Longer work breaks and end of work”, page 5-8. Remove the compressed air connection, (Fig. -
Page 35: Cleaning, Maintenance And Repair
If maintenance and repair work is carried out by persons who have not been trained for this work you endanger yourself, other persons and im- pair the safety and reliability of the machine. Maintenance and repair work may only be carried out by WIWA cus- ➤ tomer services or by trained personnel. - Page 36 Cleaning, maintenance and repair CAUTION When both components come into contact with each other, the material hardens very quickly. The material channels in the spray gun can become blocked. Never sway material bearing parts for one component with the other. ➤...
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Page 37: Regular Inspections
According to the accident prevention instructions for “Work with fluid spraying equipment” BGR 500, chapter 2.36, the spray gun needs to be inspected and serviced regularly by an expert (WIWA Customer Service). The accident prevention instructions “Application of Coating Materials”... -
Page 38: Tools Required
To clean the spray gun, and in particular the nozzle and mixing chamber, we recommend having various brushes to hand. These are not supplied with the spray gun. You can order a 17-part cleaning brush set from WIWA, order no. 0654823. Translation of the original operating manual •1306Rev03_550014_PUGUN4040_en•ski... -
Page 39: External Cleaning
In addition you will need several cleaning cloths. Always use a separate cloth for each component to prevent mutual mixing of the components and the resulting undesired material reactions. 6.4 Recommended operating materials Only user original operating materials from WIWA: Operating materials (l/gal) Order No. -
Page 40: Cleaning The Manifold
Cleaning, maintenance and repair 6.6 Cleaning the manifold Disassemble the manifold, (Fig. 6.1). Carry out the work steps 1 to 5 as de- scribed in chapter “5.1.3 Venting”, page 5-2. ➁ ➀ Fig. 6.1 Thoroughly clean all material residue out of the material outlets using a part cleaner. -
Page 41: Install The Material Sieves And Sieve Housings
Cleaning, maintenance and repair Pull off the sieve housing by lightly pulling it ➁ downwards and carefully tilting it, (Fig. 6.5). Pull the O-rings from the sieve housing and clean ➂ ➁ them. Fig. 6.5 Check if the O-rings have no damage, if so they can be reused, (Fig. -
Page 42: Removing The Press Pieces
Cleaning, maintenance and repair 6.8.1 Removing the press pieces Release the pressure in the spray gun in accordance with chapter “5.2 Pressure relief”, page 5-6. We recommend that you remove the man- ifold from the gun body for the following work, (Fig. -
Page 43: Cleaning And Installing The Mixing Chamber And Press Pieces
Cleaning, maintenance and repair Check if both side holes in the mixing ➃ ➃ chamber as well as the opening in the ➄ insert are free. ➂ ➅ If these are clogged, remove the mixing chamber for cleaning. ➂ ➁ Clamp the mixing chamber shaft ➀... -
Page 44: Selecting The Mixing Chamber And Nozzles
Cleaning, maintenance and repair 6.8.4 Selecting the mixing chamber and nozzles The selection of the mixing chamber depends on the size and nature of the object to be coated. Please observe the notes of the material manufacturer. Mixing chambers with round stream nozzles: A/B - hole ø... -
Page 45: Possible Conversions
Possible conversions 7 Possible conversions The spray gun can be converted or expanded using various optional mount- ed accessories depending on the use to which it will be put. Before each conversion, you must carry out the following work to prevent accidents: Decommissioning Pressure release... -
Page 46: Material Supply Hoses Connection At The Bottom
Possible conversions 7.1.1 Material supply hoses connection at the bottom By default, the material hoses are arranged at the bottom on delivery, (Fig. 7.1 Material supply hoses at bottom). 7.1.2 Material supply hoses connection at the top For this type of connection, the manifold must be rotated through 180°. Note that, as a consequence, the connection for the Iso component is on the right in the spray direction. -
Page 47: Conversion To An Automatic Spray Gun
Possible conversions Loosen the material supply hoses includ- ➀ ing the male nipple and ball valve on both sides of the manifold , (Fig. 7.6). ➀ ➀ Remove the side plugs on the manifold ➁ , (Fig. 7.6). ➁ ➁ Fig. -
Page 48: Connecting Mounted Accessories
Possible conversions Screw the pneumatic connections into ➇ the lid as well as into the adapter. Set the pneumatic connections, (Fig. 7.12): a => ON b => OFF c => FLUSH ➇ Fig. 7.12 Refit the manifold to the gun body. Fasten the automatic gun to the spray system. -
Page 49: Malfunctions And Troubleshooting
Malfunctions and troubleshooting 8 Malfunctions and troubleshooting Fault Possible cause Remedy 1. Trigger cannot be Safety lever closed. Open the safety lever. ➤ ➤ pulled. 2. No or insufficient mate- No spraying material Check the material supply. ➤ ➤ rial discharged despite available. - Page 50 Malfunctions and troubleshooting Fault Possible cause Remedy 8. Gelled or hardened Air in the material hoses. Vent the material supply. ➤ ➤ material in the air chan- nels. Misguided material in the Replace the press seal, O-ring ➤ ➤ spray gun due to leaks and internal O-ring on the press from the press seal, the piece on one or both components.
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Page 51: Appendix
Appendix 9 Appendix 9.1 Technical data Max. operating pressure (bar/psi) 250 / 3626 Max. air inlet pressure (bar / psi) 8 / 116 Max. temperature (°C/°F) 100 / 220 Dimensions LxWxH (mm/inch) 160× 87 × 200 / 6.3 × 3.43 × 7.87 Weight (kg / lbs) approx. -
Page 52: Spare Parts Lists
Spare parts lists ,DE,('&.>1!@(&!F$B1?G-( 4/#5/,,%&'$( (R'2/'%&"$( (]g<g'/*A/a(HIJKLJL( 10 Spare parts lists ,DE:$*!M(&?!#441''.-(1'( Q/')/( (Q/')/( (Qg')/a(HHH( ,DE%('&.>1&!#N14!#441''.(-1'( ( B-56.( (B-5/( (B-5/a(LO<HI<PHLQ( ,DADR!OHOH! 10.1 PU gun with accessories Order no. 0658151, Series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`/(M% J/,a(bM%YMU%ZYU%... -
Page 53: Pu Gun
Translation of the original operating manual 10-2 •1306Rev03_550014_PUGUN4040_en•ski E-‐ M ail: info@wiwa.de E-‐ M ail: jwold@wiwalp.com E-‐ M ail: info@wiwa-‐china.com Internet: www.wiwa.de Internet: www.wiwa.com Internet: wiwa.com © copyright 2008 WIWA Wilhelm Wagner GmbH Co.Kg ... -
Page 54: Gun Handle
E-‐ M ail: info@wiwa.de E-‐ M ail: jwold@wiwalp.com E-‐ M ail: info@wiwa-‐china.com Internet: www.wiwa.de Internet: www.wiwa.com Internet: wiwa.com 10-3 Translation of the original operating manual •1306Rev03_550014_PUGUN4040_en•ski © copyright 2008 WIWA Wilhelm Wagner GmbH Co.Kg ... -
Page 55: Housing
E-‐ M ail: info@wiwa.de E-‐ M ail: jwold@wiwalp.com E-‐ M ail: info@wiwa-‐china.com Internet: www.wiwa.de Internet: www.wiwa.com Internet: wiwa.com © copyright 2008 WIWA Wilhelm Wagner GmbH Co.Kg Translation of the original operating manual 10-4 •1306Rev03_550014_PUGUN4040_en•ski... -
Page 56: Gun Body
E-‐ M ail: info@wiwa.de E-‐ M ail: jwold@wiwalp.com E-‐ M ail: info@wiwa-‐china.com Internet: www.wiwa.de Internet: www.wiwa.com Internet: wiwa.com © copyright 2008 WIWA Wilhelm Wagner GmbH Co.Kg 10-5 Translation of the original operating manual •1306Rev03_550014_PUGUN4040_en•ski... -
Page 57: Manifold
E-‐ M ail: info@wiwa.de E-‐ M ail: jwold@wiwalp.com E-‐ M ail: info@wiwa-‐china.com Internet: www.wiwa.de Internet: www.wiwa.com Internet: wiwa.com © copyright 2008 WIWA Wilhelm Wagner GmbH Co.Kg Translation of the original operating manual 10-6 •1306Rev03_550014_PUGUN4040_en•ski... -
Page 58: Description Of The Symbols In The Spare Parts Lists
Spare parts lists 10.3 Description of the symbols in the spare parts lists The letter symbols used in the component drawings correspond the required securing and equipment needed during assembly. 10.3.1 Labelling of wearing parts, seal kit, and repair kit Symbol Description Wearing part Part of the seal kit... - Page 60 Kuwait, Saudi Arabia, Iran, Oman Rietgans 38 Head office and production site 3752 KH Bunschoten, Netherlands WIWA Wilhelm Wagner GmbH & Co. KG Mobile: +31 6 18 88 40 97 Gewerbestr. 1 - 3 Tel.: +31 33 494 69 81...