4.1.1 Electrical Equipment 4.1.2 Personnel Qualifi cations 4.1.3 Safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Spray Devices 4.2.2 Grounding the Device 4.2.3 Product Hoses 4.2.4 Cleaning and Flushing 4.2.5 Handling Hazardous Liquids, Lacquers and Paints 4.2.6...
Page 4
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Table of Contents Product Filter and Return Flow 5.7.1 High-Pressure Filter (Option) 5.7.2 Relief Combination and Inline Filter up to 270 bar (Option) Stroke Count (Option) Feed Pump (Option) ASSEMBLY AND COMMISSIONING Training Assembly/Commissioning Staff Storage and Installation Conditions...
Page 5
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Table of Contents ACCESSORIES 12.1 Product Outlet 12.2 Product Inlet 12.3 Trolley, Rack and Wall Bracket Accessories SPARE PARTS 13.1 How Can Spare Parts Be Ordered? 13.2 Overview of the Components 13.3 Air Motors 13.3.1 Wildcat and Puma Air Motor Regulators...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL ABOUT THIS MANUAL PREFACE The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL LANGUAGES The operating manual is available in the following languages: Language Order No. Language Order No. Language Order No. German 2302505 English 2303659 French 2303661 Italian 2303663 Spanish 2303665 Dutch 2303662...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal fl ushing of paint-wetted parts with fl ushing agent Staff qualifi cations Trained person Is instructed in the tasks assigned to him/her, the potential...
See Chapter 3. SAFETY PARAMETERS WAGNER accepts no liability for any damage arising from incorrect use. Use the device only to work with the products recommended by WAGNER. Operate the device only as a whole. Do not deactivate safety fi xtures.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL REASONABLY FORESEEABLE MISUSE The forms of misuse listed below may result in physical injury or property damage: coating work pieces which are not grounded; unauthorized conversions or modifi cations to the pneumatic pump; processing dry or similar coating products, e.g., powder;...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL IDENTIFICATION EXPLOSION PROTECTION IDENTIFICATION As defi ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially explosive areas. CE mark (European Communities) Explosion-proof equipment Device class II (not mining) Category 2 device (suitable for zone 1) Ex-atmosphere gas...
VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Safe handling of WAGNER spray devices Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere: Do not knock or push the device against steel or rusty iron.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention.
For electrostatic application: Anyone fi tted with a pacemaker must not enter the high-voltage area! 4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or fl ushing agents: Never point the spray gun at people.
ORDER NUMBER DOC2303659 OPERATING MANUAL If needed, the liquid ejection devices must be checked by an expert (e.g. a WAGNER service technician) at least every 12 months to verify that they are safe to use in accordance with DGUV regulation 100-500.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Make sure that the hoses are laid only in suitable places. Do not lay hoses: - in high-traffic areas, - on sharp edges, - on moving parts or - on hot surfaces.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Only electrically conductive tanks may be used for cleaning and fl ushing agents. The tanks must be grounded. An explosive gas/air mixture forms in closed tanks. Never spray into a closed tank when using solvents for fl ushing. External cleaning When cleaning the exterior of the device or its parts, also observe the following: Disconnect the pneumatic supply line.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL PROTECTIVE AND MONITORING EQUIPMENT Safety valve The air motor is fi tted with a safety valve. The safety valve has been set and sealed at the factory. In case of pressures over and above the permissible operating pressure, the valve, which is held with a spring, automatically opens and releases the excess pressure.
PTFE Packings Standard = Ultra high molecular weight polyethylene = PTFE with graphite 5.5.2 RECOMMENDED PACKINGS WAGNER packings are manufactured in four diff erent materials: Product Color Leather dark brown PTFE with graphite black Ultra high molecular weight polyethylene transparent...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 5.5.3.1 TECHNICAL DATA FOR WILDCAT AND PUMA Description Units Pump ratio 18 :1 28 : 1 Volume fl ow per double stroke cm3; cc 14.4 22.4 Maximum operating overpressure 2089 3249 Maximum possible strokes in operation...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 5.5.3.2 MEASUREMENTS AND CONNECTIONS FOR WILDCAT AND PUMA mm; inch mm; inch 722; 28.4 169; 6.7 Wall mount ~ 321; 12.6 261.5; 10.3 460.5; 18.1 134; 5.3 182; 7.2 80;...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 5.5.4 VOLUME FLOW Wagner AL nozzles Volume fl ow* in l/min 7 MPa 10 MPa 15 MPa Maximum ranges for 70 bar 100 bar 150 bar continuous operation...
5.5.5 PERFORMANCE DIAGRAMS Stroke frequency /min Example diagram Water fl ow rate l/min <gpm> PUMA 28-40 WILDCAT 18-40 Stroke frequency /min Stroke frequency /min Water fl ow rate Water fl ow rate A = 8 bar (0.8 MPa; 116 psi) air pressure A = 8 bar (0.8 MPa;...
These have been developed especially B_03908 for WAGNER pneumatic pumps. The fi lter inserts can be exchanged depending on the product to be used. The high-pressure fi lter corresponding to the device can be found in the "Accessories"...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 5.7.2 RELIEF COMBINATION AND INLINE FILTER UP TO 270 BAR (OPTION) Instead of the standard high-pressure fi lter, the lower- cost ventilation combination can be used if only a small volume of product is to be processed.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL FEED PUMP (OPTION) A feed pump can be used with high-viscosity products or longer feed lines. Dimensioning of the feed pump The IceBreaker piston pumps pump the working material to the product output with up and down strokes but only draw in new product on the up stroke.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRAINING ASSEMBLY/COMMISSIONING STAFF The assembly and commissioning staff must have all technical skills necessary to safely commission the device. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL ASSEMBLY AND INSTALLATION This pump can be used as part of a spraying system for Airless or AirCoat applications. The individual components are shown in the accessories, or can be arranged with a spraypack confi gurator. The nozzles must be selected according to the gun operating manual.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL GROUNDING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Clean the piston pump only with a damp cloth. Ground all device components. Ground the workpieces to be coated.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Safe operation of the IceBreaker pump is only guaranteed with a grounding connection. Connect all ground cables using a short and direct route. Procedure: 1. Ground the pump, connect the grounding cable to potential equalization on-site.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF The operating staff must be qualifi ed and fi t to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from fl ying parts. Ensure that the pump and suction system are always completely filled with fl ushing agent or working material.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL SPRAYING 1. Visual check: personal protective equipment, grounding and all devices closed ready to use. 2. Secure the spray gun and place the nozzle in the gun. 3. Set required working pressure on the open pressure regulator (1).
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL BASIC FLUSHING Procedure 1. Visual check: personal protective equipment, grounding and all devices ready to use. 2. Place an empty, grounded collection Closed tank (5) under the return tube (4). 3.
DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare Parts"...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 8.1.3 DECOMMISSIONING AND CLEANING The device should be cleaned for maintenance purposes. Ensure that no remaining product dries on and sticks to the device. 1. Carry out work interruption Chapter 7.5.
- Commissioning in accordance with Chapter 6.6. According to DGUV regulation 100-500: - The liquid ejection devices should be checked by an expert (e.g. WAGNER service technician) to ensure their safe operational condition as required and at least every 12 months.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 8.2.3 REGULAR MAINTENANCE WORK 1. Check the level of separating agent in the separating agent cup every day, and top up if necessary. 2. Check and clean the high-pressure fi lter every day or as required. (See Chapter 8.2.8) 3.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 8.2.6 EMPTYING THE PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from fl ying parts. Ignition of potentially explosive surrounding atmosphere. Empty the device slowly and in a controlled manner.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 8.2.7 FILLING THE EMPTY PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from fl ying parts. Ignition of potentially explosive surrounding atmosphere. Fill the device slowly and in a controlled manner.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 8.2.8 CLEANING THE HIGH-PRESSURE FILTER 1. Flush the pump and HP fi lter in accordance with Chapter 7.6, Filter installation position and while doing so: Preferred Turned over - At the preferred fi lter installation position: Flush via the return fl ow valve (1).
– 6 years from the date of the hose crimping (see fi tting embossing). – 10 years from the date of the hose imprinting. Fitting Hose imprinting Meaning embossing Meaning Name / WAGNER (if present) Manufacturer xxx bar Pressure Date of yymm manufacture...
The air motor is iced up There is a lot of condensation water Install a water separator. in the air supply. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL REPAIRS 10.1 REPAIR PERSONNEL Repair work should be undertaken carefully by qualifi ed and trained personnel. They should be informed of specifi c hazards during their training. The repairs must be carried out in accordance with the corresponding service manual.
Page 47
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 12.2 PRODUCT INLET For trouble-free intake, use hoses which are as short as possible. The maximum hose length is dependent upon the viscosity of the product, the suction height, and the nominal diameter of the hose.
Page 51
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL DN16 DN25 B_03921...
DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare Parts"...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 13.2 OVERVIEW OF THE COMPONENTS Designation Order No. Order No. Order No. Order No. Piston pump 2329456 2329458 2329467 2329469 Fluid section 2329641 2329643 2329641 2329643 Air motor 2329613 2329617 Connection set for air motor - fl uid section...
DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare Parts"...
Page 57
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 10-15 Nm; 7-11 lbft 20-25 Nm; 15-19 lbft 40 Nm; 30 lbft 2-3 Nm; appr. 2 lbft 53a, 53b 25 Nm; 19 lbft B_03927 Pressure regulator (pos. 100): For details, see Chapter 13.3.1 Do not dismount the piston (pos.
Page 59
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Air motor spare parts list Designation Order No. Order No. Loctite 542, 50ml; 50cc 9992831 Molykote DX grease 9992616 Mobilux EP 2 grease 9998808 Service set 366995 367995 = Wearing parts = Included in service set.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 13.3.1 WILDCAT AND PUMA AIR MOTOR REGULATORS B_03935 Pos. 3: Screw in the pressure gauge until the white sealing ring is completely in the fi lter control valve. Thereafter continue turning the pressure gauge only to align the display scale.
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 13.4 CONNECTION SETS 25 Nm; 18 lbft Assembly with air motor and fl uid section: see Chapter 13.2 B_05262 WILDCAT PUMA Connection set Spare parts list for connection sets LM-FS 1 Designation Order No.
DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare Parts"...
Page 63
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL +10 Nm 70 Nm + 7 lbft 52 lbft 40 Nm; 30 lbft 100 Nm 74 lbft B_05264 Pos. 4 Tighten by hand on block. Use a standard wrench only if necessary. In this case use a spanner to hold pos.
Page 64
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL Fluid sections spare parts list Designation Order No. Order No. Sealing collar TG (small) 123398 Sealing collar T (small) 123426 Sealing collar PE (small) 123427 123427 Packing PE/TG, complete (large) 367991 Packing PE/T, complete (large) 367992...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 13.6 INLET VALVE WITH VALVE DEPRESSOR 70 cm3 40 cm3 B_04072 Spare parts list for inlet valve with valve depressor Order No. for fl uid section Designation 40 cm3 Inlet valve with valve depressor 2329689 Ball guide, inlet...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 13.9 HIGH-PRESSURE FILTER 270 BAR 90 Nm; 66 lbft Tighten pos. 3 by hand 27 MPa; 270 bar; 3916 psi Identifi cation of the fi lter 140 Nm; 103 lbft B_04069...
Page 69
DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare Parts"...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 13.10 HIGH-PRESSURE FILTER 530 BAR 90 Nm; 66 lbft Tighten pos. 3 by hand 53 MPa; 530 bar; 7687 psi Identifi cation of the fi lter 140 Nm 103 lbft Stainless steel Carbon steel B_03934...
Page 71
DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare Parts"...
Wildcat & Puma 40 cm3 VERSION 05/2015 ORDER NUMBER DOC2303659 OPERATING MANUAL 13.11 AIRCOAT REGULATOR AND AIRCOAT FILTER REGULATOR AirCoat Regulator AirCoat fi lter regulator B_05400 B_05401 Pos 3 or 4: * Observe the fl ow direction Pos. 4: (direction of arrow to the housing) Before assembling, remove both threaded Pos.
SCOPE OF GUARANTEE All Wagner professional color application devices (hereafter referred to as "products") are carefully inspected, tested, and 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 authorized specialist shop, and which relate to the products listed on the Internet at www.wagner-group.com/profi...
- 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 modifi cations or additions have been carried out.
T4: With dry-running protection EC Certifi cate of Conformity The CE certifi cate of conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2302304 14.7...
Page 78
Heidersdorf in Sachsen J. Wagner GmbH Service support center Olbernhauer Strasse 11 09526 Heidersdorf Phone +49 03 73 61 / 1 57 07 Fax +49 03 73 61 / 1 57 08 WAGNER CONTACT NETWORK GERMANY; AVAILABLE ON THE INTERNET AT: WWW.WAGNER-GROUP.COM/PROFI...
Page 80
J. Wagner Ges.m.b.H. Wagner Spraytech Wagner Spraytech (UK) Limited Ottogasse 2/20 Scandinavia A/S The Coach House 2333 Leopoldsdorf Helgeshøj Allé 28 2 Main Road Austria Middleton Cheney OX17 2ND 2630 Taastrup Tel. +43/ 2235 / 44 158 Great Britain Denmark...