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wiwa 500 Operation Manual

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Operation Manual
WIWA 500
sp01_BA_en_B0550001 ✓(2021/01/29)

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Summary of Contents for wiwa 500

  • Page 1 Operation Manual WIWA 500 sp01_BA_en_B0550001 ✓(2021/01/29)

  • Page 2: Ec Declaration Of Conformity

    EC declaration of conformity in accordance with Annex II, No. 1 A of Machine Directive 2006 / 42 / EC, as amended by 2009 / 127 / EC The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany...

  • Page 3: Eu Declaration Of Conformity

    EU declaration of conformity in accordance with ATEX Directives The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany hereby declares that the spray WIWA 500 gun type conforms with the provisions of Directive 2014 / 34 / EU.

  • Page 5: Table Of Contents

    Contents Contents 1 Foreword 2 Safety 2.1 Explanation of symbols ....2.2 Safety notes ......2.2.1 Working pressure .
  • Page 6 Contents 5 Operation 5.1 Putting the spray gun into operation ..5.1.1 Setting the spraying pressure ..5.1.2 Tips for good coatings ....5.1.3 Tips for good coatings –...

  • Page 7: Foreword

    In Germany, these are: DGUV 100-500, chap. 2.29 “Processing coating materials”, DGUV 100-500, chap. 2.36 “Working with fluid jets”, both from the professional association for gas, district heating and water management.
  • Page 8 Copyright © 2025 WIWA The copyright to this operation manual belongs to WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestraße 1–3 • 35633 Lahnau • Germany Phone: +49 (0)6441 609-0 • Fax: +49 (0)6441 609-2450 Email: info@wiwa.de • Website: www.wiwa.de This operation manual is intended exclusively for the preparation, operating and maintenance personnel.

  • Page 9: Safety

    2.1 Explanation of symbols Safety notes give warning of potential accident risks and describes the measures required for accident prevention. In the WIWA operation manuals, safety notes are highlighted and labeled as follows: DANGER Signals a risk of accidents that are very likely to result in serious...
  • Page 10 Safety CAUTION Signals a risk of accidents that may result in injuries, if the safety note is not observed! Signals important information for working correctly with the spray gun. A failure to observe this may result in damage to the machine or its environment.
  • Page 11 Safety Risk of burning due to hot surfaces Risk of freezing due to cold surfaces The first line of the safety instructions indicates the personal protective equipment that must be worn. This is also highlighted and labeled as follows: Wear protective clothing Signals an instruction to wear the prescribed protective clothing, in order to prevent skin injuries due to the processing material or gases.

  • Page 12: Safety Notes

    Safety Signals references to directives, work instructions and operation manuals that contain very important information and must be ob- served. 2.2 Safety notes WARNING Always remember that the spray gun is operated with very high pres- sures and can cause life-threatening injuries if handled incorrectly! Always observe and follow all the information in this operation manual and in the operation manual of the spraying device on which the spray gun is operated.

  • Page 13: Risks Due To The Spray Jet

    Safety 2.2.2 Risks due to the spray jet WARNING The material exits the spray gun under very high pressure. The spray jet can cause serious injuries through its cutting action, or by penetrating the skin or eyes. Never aim the spray gun at yourself, other persons or animals! Never hold your fingers or hand in front of the spray gun! Never reach into the spray jet! Always hold the spray gun tightly in your hands while working...

  • Page 14: Risks Due To Electrostatic Charge

    Never spray solvents or materials containing solvents into narrow- mouthed cans or drums with a bung opening! Only use electrically conductive material hoses. All original ma- terial hoses from WIWA are conductive and designed for our devices. Only use electrically conductive accessories/accessory parts.

  • Page 15: Explosion Protection

    Safety 2.2.5 Explosion protection The following short designations are used in the instructions of WIWA: Ex protection: Explosion protection Ex area: potentially explosive or non-explosion protected area Non-Ex area: non-explosive or explosion protected area Ex zone: Explosion protection zone according to ATEX Directive...

  • Page 16: Health Risks

    Safety 2.2.6 Health risks CAUTION Depending on the materials being processed, solvent vapors may arise, which could cause damage to health and property. Make sure the workplace is sufficiently ventilated and aired. Always observe the safety data sheets and processing instruc- tions of the material manufacturer.

  • Page 17: Safety Features

    Safety 2.3 Safety features WARNING If one of the safety features is missing or is not fully functional, the operating safety of the device is not guaranteed! Take the device out of service immediately if you detect defects on the safety features or any other faults on the device. Only put the device back into operation once the faults have been fully rectified.

  • Page 18: Nozzle Protector

    Safety 2.3.1 Nozzle protector The nozzle protector prevents damage to the spray nozzle, which can arise e .g. if the spray gun falls down. Furthermore, contact with the palm of your hand with the spray jet directly at the nozzle outlet is prevented. WARNING If the spray gun is operated without the nozzle protector, serious injuries and property damage can result.

  • Page 19: Operating And Maintenance Personnel

    Safety 2.4 Operating and maintenance personnel 2.4.1 Obligations of the owner The owner: is responsible for training the operating and maintenance person- nel, must instruct the operating and maintenance personnel on correct handling of the spray gun, and on wearing the correct work clothing and protective equipment, must make work aids, such as lifting gear for transporting the spray- ing device or container, available to the operating and maintenance...

  • Page 20: Personal Protective Equipment

    Safety Activity Qualification Set-up and operation Instructed operator Cleaning Instructed operator Maintenance Trained personnel Repair Trained personnel Children, young persons under the age of 16 and untrained person- nel may not operate this spray gun. 2.4.4 Personal protective equipment Wear protective clothing Always wear the protective clothing stipulated for your working envi- ronment (e.g.

  • Page 21: Warranty And Liability

    When maintaining and repairing the spray gun, only original spare parts from WIWA may be used. If spare parts are used, that have not been produced or supplied by WIWA, the warranty is voided and all liability shall be excluded. Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 sp01_BA_en_B0550001...

  • Page 22: Accessories

    Safety 2.5.2 Accessories If you use original WIWA accessories, their suitability for use in our machines is guaranteed. If you use third-party accessories, these must be suitable for the spray gun – in particular with respect to the working pressure, the connection variables, and use in Ex-zones, if applicable.

  • Page 23: Injuries

    Safety 2.6.2 Injuries In case of injuries caused by processing material or cleaning agents, always have the safety data sheet ready to show to the doctor (supplier or manufacturer address, their telephone number, material designation and material number). Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 sp01_BA_en_B0550001...

  • Page 24: Description

    CE mark Max. material temper- ature Fig. 4: Data on the gun body 3.1 Intended use The WIWA 500 is intended for applying low-viscosity to high-viscosity materials in the commercial and industrial sector. Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 sp01_BA_en_B0550001...

  • Page 25: Erroneous Use

    WIWA, accessories are used that are not suitable for the machine (see section 2.5.2 on page 16),...

  • Page 26: Model Overview

    Description 3.3 Model overview The model designation 500 (= 500 bar max. working pressure) is specified by the following letters: D = swivel joint F = front connection FI = push-in filter M200 in the handle Model Art. no. Material...
  • Page 27 Description Model Art. no. Material Nozzle Nozzle Other connec- connec- protector tion tion 500 FD 0658752 Front ” UNS standard Front con- swivel joint nection ” NPSM, valve needle ⌀ 5 mm 500 FD 0669799 Front ” UNS standard Valve...
  • Page 28 Max. working pressure: 500 bar Max. material temperature: 80 ˚C The model series 500 D and 500 FD are equipped with a swivel joint at the material inlet, which enables the flexible use of the spray gun without twisting the material hose.

  • Page 29: Construction

    Description 3.4 Construction Fig. 5: Model series 500 F and 500 D Designation Nozzle protector Gun body Safety lever Suspension hook Guard bracket Four-finger trigger Gun handle Swivel joint Connection for the material hose Original Operation Manual ✓(2021/01/29), Status: 2025/01/08...
  • Page 30 Description Variant with two-component external mixing Fig. 6: Model 500 FD with external mixing Designation Swivel head Nozzle protector for component B (accelerator) Spray pipe for component B Nozzle protector for component A Gun body for component A Gun body for component B...

  • Page 31: Optional Expansions And Accessories

    The following list contains just some of the most common accessories and expansions. The detailed accessory catalog can be found at www.wiwa.de. For further information and order numbers, you can also contact a WIWA dealer or WIWA customer service. Standard nozzles The standard nozzles can be used for all airless spray guns.
  • Page 32 Description Art. no. Mesh Color size 0638201 M 30 green 0414700 M 50 white 0646606 M 65 black 0467448 M 100 yellow 0638200 M 150 blue 0467456 M 200 Standard nozzle protector The nozzle protector prevents damage to the spray nozzles (e.
  • Page 33 Description Reversing switch The reversing switch is used for accommodating the reversible nozzle. Easy cleaning and flush- ing of the spray nozzles is possi- ble by reversing the switch lever. The spray direction is in the di- rection of the arrow, opposite of flushing.

  • Page 34: Transport And Assembly

    Transport and assembly 4 Transport and assembly The spray gun left the factory in faultless condition, packaged correctly for transport. Check the spray gun at the time of receipt for any transport damage and for completeness. 4.1 Scope of delivery The spray gun is delivered with: a nozzle protector, which is already installed on the spray gun, the operation manual,...

  • Page 35: Inserting The Spray Nozzle

    Transport and assembly 4.2.1 Inserting the spray nozzle The spray nozzle is not supplied as standard. Select a spray nozzle from our accessories catalogue that is suitable for the spray gun’s area of application, the application material and the object to be coated.

  • Page 36: Connecting The Material Hose

    Assemble a material hose to the inlet thread of each component for the model 500 FD with external mixing. Pay attention to the correct component assignment. The spray gun is now ready for operation.

  • Page 37: Operation

    Operation 5 Operation Observe and follow the operation manual of the spraying device. 5.1 Putting the spray gun into operation 1. Make sure that the spraying device is ready for operation and that the compressed air regulator for flushing is completely throttled back if required.

  • Page 38: Tips For Good Coatings

    Operation 5.1.2 Tips for good coatings Hold the spray gun at a right angle (90°) to the surface to be coated. As soon as you hold the spray gun at a dif- ferent angle, the coating will become uneven and patchy (see Fig.

  • Page 39: Tips For Good Coatings - With External Mixing

    Operation 5.1.3 Tips for good coatings – with external mixing Set the reversing switch with the nozzle for component B so that the material hits component A at a right angle 90° (see Fig. 12). Fig. 12: Setting angle of nozzle for com- ponent B 5.2 Work interruption 1.

  • Page 40: Maintenance

    Maintenance or repair work on the spray gun may only be per- formed by WIWA customer service or personnel trained to do Observe and follow the operation manual of the spraying device. Prior to maintenance or repair work: 1.

  • Page 41: Maintenance Schedule

    Maintenance 6.1 Maintenance schedule Time frame Activity for further reading As needed Lubricate spray gun section 6.2 on page Set the play of the section 6.3 on page trigger At the end of work Clean the push-in section 6.4 on page filter (if present) 6.2 Lubricating the spray gun The spray gun must be lubricated in order to maintain the ease of...

  • Page 42: Cleaning The Push-In Filter

    Maintenance 1. Insert the supplied hexagon socket wrench in one of the holes on the guide sleeve (see Fig. 14 on page 36). 2. Turn the guide sleeve until the threaded pin is positioned in the gap between the trig- ger and the gun body (see Fig.
  • Page 43 Maintenance 1. Disassemble the material hose from the spray gun. 2. Unscrew the double nipple and the swivel joint from the gun handle, paying attention to the gasket while doing so. 3. Release the screw with which the securing bracket is fastened to the gun body.

  • Page 44: Replacing The Packing And Valve Needle

    Maintenance 6.5 Replacing the packing and valve needle Fig. 17: Packing and valve needle Description 1. Unscrew the nozzle protector including spray nozzle and Valve seat gasket from the spray gun Gasket (SW 22). Valve needle 2. Hold the trigger completely Insert depressed.
  • Page 45 Maintenance 9. Remove the gasket that is now exposed. Unscrew the packing gland screw. 10. Remove the packing from the insert – possibly press it out from the opposite side using a mandrel, a screw or the like. 11. Clean all parts with the cleaning agent recommended by the mate- rial manufacturer.

  • Page 46: Cleaning The Guide Sleeve

    Maintenance 6.6 Cleaning the guide sleeve Fig. 18: Guide sleeve Description 1. Insert the supplied hexagon socket wrench in one of the Gun body holes on the guide sleeve (see Threaded pin Fig. 14 on page 36). Press-on plug 2. Turn the guide sleeve until the Guide sleeve threaded pin is positioned at the recess of the gun body...

  • Page 47: Replacing The Gaskets On The Gun Handle

    Maintenance 10. Insert the pressure springs in the guide sleeve. 11. Wet the thread of the screw plug with weak thread locker (e.g Loctite red) and screw the screw plug back tightly into the gun body. 12. Set a play of 2-3 mm on the trigger (see section 6.3 on page 35 from work step 4).
  • Page 48 Maintenance 1. Disassemble the material Description hose from the spray gun. Gun body 2. Unscrew the double nipple and the swivel joint from the Gasket gun handle, paying attention Handle to the gasket while doing so. Gasket 3. Release the screw with which Double nipple or swivel the securing bracket is fas- joint...

  • Page 49: Eliminating Operational Faults

    Eliminating operational faults 7 Eliminating operational faults Only eliminate operational faults if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.4.4 on page 14. fault possible cause remedy Spray gun does not Valve seat or valve Replace packing and close correctly...

  • Page 50: Spare Parts List

    Spare parts list 8 Spare parts list Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 sp01_BA_en_B0550001...
  • Page 51 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 52 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 53 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 54 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 55 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 56 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 57 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 58 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 59 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 60 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 61 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 62 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 63 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 64 Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 Hauptsitz und Produktion / Headquarter & Production WIWA Subsidiary USA sp01_BA_en_B0550001 WIWA Wilhelm Wagner GmbH & Co. KG 107 N.Main St. • P.O.Box 398, Alger, OH 45812 Gewerbestraße 1-3 • 35633 Lahnau, Germany Tel: +1-419-757-0141 • Fax: +1-419-549-5173 •...
  • Page 65 Spare parts list Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 sp01_BA_en_B0550001...
  • Page 66 Spare parts list Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 sp01_BA_en_B0550001...
  • Page 67 Spare parts list Original Operation Manual ✓(2021/01/29), Status: 2025/01/08 sp01_BA_en_B0550001...
  • Page 68 Headquarter and production WIWA Wilhelm Wagner GmbH & Co. Gewerbestraße 1–3 35633 Lahnau Germany Phone: +49 (0)6441 609-0 Fax: +49 (0)6441 609-2450 Email: info@wiwa.de Website: www.wiwa.de WIWA subsidiary USA WIWA LLC – USA, Kanada, Lateinamerika 107 N. Main St. P.O. Box 398, Alger, OH 45812...

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