Translation of the original
Operating Manual
ZIP52 ALU SP
ZIP 52 INOX SP
ZIP 52 ACETAL SP
ZIP 52 PERFECT FLOW SP
Edition 01 / 2010
Diaphragms pump
ZIP 52 FINISHING
ZIP 52 PF
II 2G IIB T4
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
Contents
1
1.1
1.2
ABOUT THESE INSTRUCTIONS
Languages
Warnings, notes and symbols in these instructions
5
5
5
2
2.1
GENERAL SAFETY INSTRUCTIONS
Safety instructions for the operator
6
6
6
6
6
6
7
7
7
8
8
8
8
9
9
9
9
9
11
2.1.1 Electrical equipment
2.1.2 Personnel qualifications
2.1.3 A safe work environment
2.2
Safety instructions for staff
2.2.1 Safe handling of WAGNER spray units
2.2.2 Earth the unit
2.2.3 Material hoses
2.2.4 Cleaning
2.2.5 Handling hazardous liquids, varnishes and paints
2.2.6 Touching hot surfaces
2.3
2.4
Correct use
Use in an explosion hazard area
2.4.1 Correct use
2.4.2 Explosion protection identification
2.4.3 Max. surface temperature
2.4.4 Safety regulations
3
PRODUCT LIABILITY AND WARRANTY (STATUS 01.02.2009)
Scope of guarantee
Guarantee period and registration (3+2)
Handling
Exclusion of guarantee
Additional regulations
3.1
3.2
3.3
3.4
3.5
3.6
11
11
11
12
12
13
CE-conformity
4
4.1
DESCRIPTION
Field of application
14
14
14
14
14
14
15
16
18
18
19
4.1.1 Using in accordance with the instructions
4.2
4.3
4.3.1 Materials of the parts transporting paint
4.3.2 technical data
4.3.3 Dimensions and connections
Extent of delivery
Data
4.4
Functioning
4.4.1 Pump
4.4.2 Pressure regulator
4.4.2.1 Technical sheet fine flow controller cod. 2301832, 2301836, 2301837
20
5
5.1
STARTING UP AND OPERATING
Installation and connection
21
21
21
22
24
5.1.1 Pump installation
5.1.2 Earthing
5.2
Start up
3
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
Contents
5.2.1 Safety regulations
5.2.2 Emergency stopping
5.2.3 Washing
5.2.4 Unit pressure tightness test
5.3 Work
5.3.1 Spraying
5.3.2 Painting hints
5.3.3 Working breaks
5.3.4 Shutting down and cleaning
24
25
26
26
27
27
28
28
29
29
5.4
Storing for longer periods of time
6
FAULT LOCATION, MAINTENANCE AND REPAIR
Trouble shooting and solution
Maintenance
Filter cleaning operations
Machine maintenance
30
30
31
32
33
6.1
6.2
6.3
6.4
7
ACCESSORIES
35
7.1
7.2
Accessories only for 2301832, 2301836, 2301837
Pump zip 52 finishing with wall supporting kit cod. T760.00M
35
36
37
38
39
7.2.1 Overall dimensions cod. T760.00M
7.3 Pump zip 52 finishing with stand kit cod. T760.00S
7.3.1 Overall dimensions cod. T760.00S
7.4
Pump zip 52 finishing with handle+wheels kit cod.T760.00R
for stand pumps cod.T760.00S
40
41
42
43
7.4.1 Overall dimensions cod. T760.00R
7.5 Pompa zip 52 finishing with trolley kit cod. T760.00SR
7.5.1 Overall dimensions cod. T760.00SR
8
SPARE PARTS
44
44
46
47
47
50
53
55
57
59
61
8.1
8.2
8.3
How to order spare parts
Overview modules
Exploded view
8.3.1 Pump cod. 2301832, 2301836, 2301837
8.3.2 Pump cod. 2301838
8.3.3 Pump ZIP 52
8.3.4 Air motor pump ZIP52
8.3.5 Fine flow controller T0180.00A,T0180.00AI
8.3.6 Material filter 1/2 aluminium cod.T4005.00ALS (for 2301838)
8.3.7 Suction pipe + re-cycle pipe cod. T406.00,T406.00A
9
EUROPEAN SERVICE NETWORK
65
4
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
1 ABOUT THESE INSTRUCTIONS
4HIS OPERATING MANUAL CONTAINS INFORMATION ABOUT THE OPERATIONꢁREPAIR AND MAINTENANCE
OF THE UNITꢂ
œ !LWAYS FOLLOW THESE INSTRUCTIONS WHEN OPERATING THE UNITꢂ
1.1 LANGUAGES
4HIS OPERATING MANUAL IS AVAILABLE IN THE FOLLOWING LANGUAGESꢀ
,ANGUAGEꢀ
'ERMAN
&RENCH
)TALIAN
$ANISH
0ART .Oꢁ
ZZB012GER
ZZB012FRE
ZZB012ITA
--
,ANGUAGEꢀ
%NGLISH
$UTCH
3PANISH
3WEDISH
4URKISH
0ART .Oꢁ
ZZB012ENG
--
--
--
--
0ORTUGUESE
--
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
7ARNING INSTRUCTIONS IN THIS MANUAL POINT OUT PARTICULAR DANGERS TO USERS AND EQUIPMENT
AND STATE MEASURES FOR AVOIDING THE HAZARDꢂ4HESE WARNING INSTRUCTIONS FALL INTO THE FOLLOꢃ
WING CATEGORIESꢀ
$!.'%2
4HIS LINE WARNS OF THE HAZARD ꢃ
$ANGER ꢃ IMMINENT DANGERꢂ.ONꢃOBSERVANCE WILL RESULT
IN DEATHꢁSERIOUS INJURY AND SERIOUS MATERIAL DAMAGE
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUCꢃ
TIONSꢂ 4HE SIGNAL WORD POINTS OUT THE HAZARD LEVELꢂ
œ 4HE MEASURES FOR PREVENTING THE HAZARD AND ITS CONSEQUENCESꢂ
3)()?ꢄꢅꢄꢄ?'"
7ARNING ꢃ POSSIBLE DANGERꢂ.ONꢃOBSERVANCE CAN RESULT
IN DEATHꢁSERIOUS INJURY AND SERIOUS MATERIAL DAMAGEꢂ
7!2.).'
4HIS LINE WARNS OF THE HAZARD ꢃ
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUCꢃ
TIONSꢂ 4HE SIGNAL WORD POINTS OUT THE HAZARD LEVELꢂ
œ 4HE MEASURES FOR PREVENTING THE HAZARD AND ITS CONSEQUENCESꢂ
3)()?ꢄꢅꢄꢆ?'"
#AUTION ꢃ A POSSIBLY HAZARDOUS SITUATIONꢂ .ONꢃOBSERꢃ
VANCE CAN RESULT IN MINOR INJURYꢂ
#!54)/.
4HIS LINE WARNS OF THE HAZARD ꢃ
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUCꢃ
TIONSꢂ 4HE SIGNAL WORD POINTS OUT THE HAZARD LEVELꢂ
œ 4HE MEASURES FOR PREVENTING THE HAZARD AND ITS CONSEQUENCESꢂ
3)()?ꢄꢅꢄꢅ?'"
3)()?ꢄꢅꢄꢇ?'"
#AUTION ꢃ A POSSIBLY HAZARDOUS SITUATIONꢂ .ONꢃOBSERꢃ
VANCE CAN CAUSE MATERIAL DAMAGEꢂ
#!54)/.
4HIS LINE WARNS OF THE HAZARD ꢃ
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUCTIONSꢂ 4HE SIGNAL WORD
POINTS OUT THE HAZARD LEVELꢂ
œ 4HE MEASURES FOR PREVENTING THE HAZARD AND ITS CONSEQUENCESꢂ
.OTE ꢂ PROVIDE INFORMATION ON PARTICULAR CHARACTERISTICS AND HOW TO PROCEEDꢂ
5
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
œ +EEP THESE OPERATING INSTRUCTIONS TO HAND NEAR THE UNIT AT ALL TIMESꢂ
œ !LWAYS FOLLOW LOCAL REGULATIONS CONCERNING OCCUPATIONAL SAFETY AND ACCIDENT PREVENꢃ
TIONꢂ
2.1.1 ELECTRICAL EQUIPMENT
%LECTRICAL PLANT AND UNIT
œ 4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE
OPERATING MODE AND AMBIENT INmUENCESꢂ
œ -AY ONLY BE MAINTAINED BY SKILLED ELECTRICIANS OR UNDER THEIR SUPERVISIONꢂ
œ -UST BE OPERATED IN ACCORDANCE WITH THE SAFETY REGULATIONS AND ELECTROTECHNICAL REGUꢃ
LATIONSꢂ
œ -UST BE REPAIRED IMMEDIATELY IN THE EVENT OF PROBLEMSꢂ
œ -UST BE PUT OUT OF OPERATION IF THEY POSE A HAZARDꢂ
œ -UST BE DEꢃENERGIZED BEFORE WORK IS COMMENCED ON ACTIVE PARTSꢂ )NFORM STAFF ABOUT
PLANNED WORKꢁOBSERVE ELECTRICAL SAFETY REGULATIONSꢂ
2.1.2 PERSONNEL QUALIFICATIONS
œ %NSURE THAT THE UNIT IS OPERATED AND REPAIRED ONLY BY TRAINED PERSONSꢂ
2.1.3 A SAFE WORK ENVIRONMENT
œ Ensure that the floor of the working area is anti-static in accordance with EN 50053 Part 1
§7-2.
œ Ensure that all persons within the working area wear anti-static shoes, e.g. shoes with
leather soles.
œ Ensure that during spraying,persons wear anti-static gloves so that they are earthed via
the handle of the spray gun.
œ Customer to provide paint mist extraction systems conforming to local regulations.
œ Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure
– Personal safety equipment (breathing and skin protection)
œ Ensure that there are no ignition sources such as naked flame, glowing wires or hot
surfaces in the vicinity. Do not smoke.
2.2 SAFETY INSTRUCTIONS FOR STAFF
œ !LWAYS FOLLOW THE INFORMATION IN THESE INSTRUCTIONSꢁ PARTICULARLY THE GENERAL SAFETY INꢃ
STRUCTIONS AND THE WARNING INSTRUCTIONSꢂ
œ !LWAYS FOLLOW LOCAL REGULATIONS CONCERNING OCCUPATIONAL SAFETY AND ACCIDENT PREVENꢃ
TIONꢂ
6
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning agents:
œ
œ
œ
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the unit, in the event of work interruptions and functional
faults:
– Switch off the energy/compressed air supply
– Secure the spray gun against actuation.
– Relieve the pressure from the spray gun and unit.
– By functional faults: If possible, remove the defect as described in
chap. „Trouble shooting“, otherwise apply to an authorised after-sale service point.
In the event of skin injuries caused by paint or cleaning agents:
œ
œ
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
œ
œ
Ensure that you have a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
2.2.2 EARTH THE UNIT
Electrostatic charges can occur on the unit due to the electrostatic charge and the flow
speed involved in spraying.These can cause sparks and flames upon discharge.
œ Ensure that the unit is earthed for every spraying operation.
œ Earth the workpieces to be coated.
œ Ensure that all persons inside the working area are earthed, e.g. that they are wearing
antistatic shoes.
œ When spraying, wear antistatic shoes to earth yourself via the spray gun handle.
If gloves are used, they must be antistatic
2.2.3 MATERIAL HOSES
œ %NSURE THAT THE HOSE MATERIAL IS CHEMICALLY RESISTANT TO THE SPRAYED MATERIALSꢂ
œ %NSURE THAT THE MATERIAL HOSE IS SUITABLE FOR THE PRESSURE GENERATED IN THE UNITꢂ
œ %NSURE THAT THE FOLLOWING INFORMATION IS VISIBLE ON THE HIGHꢃPRESSURE HOSEꢀ
n -ANUFACTURER
n 0ERMISSIBLE OPERATING OVERPRESSURE
n $ATE OF MANUFACTUREꢂ
œ 4HE ELECTRICAL RESISTANCE OF THE COMPLETE HIGHꢃPRESSURE HOSE MUST BE LESS THAN
ꢅ -/HMꢂ
7
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EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2.2.4 CLEANING
œ $EꢃENERGIZE THE UNIT ELECTRICALLYꢂ
œ $ISCONNECT THE PNEUMATIC SUPPLY LINEꢂ
œ 2ELIEVE THE PRESSURE FROM THE UNITꢂ
œ %NSURE THAT THE mASH POINT OF THE CLEANING AGENT IS AT LEAST ꢈ + ABOVE THE AMBIENT TEMꢃ
PERATUREꢂ
œ 4O CLEANꢁ USE ONLY SOLVENTꢃFREE CLOTHS AND BRUSHESꢂ .EVER USE HARD OBJECTS OR SPRAY ON
CLEANING AGENTS WITH A GUNꢂ
!N EXPLOSIVE GASꢉAIR MIXTURE FORMS IN CLOSED CONTAINERSꢂ
œ 7HEN CLEANING UNITS WITH SOLVENTSꢁNEVER SPRAY INTO A CLOSED CONTAINERꢂ
œ %ARTH THE CONTAINERꢂ
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
œ 7HEN PREPARING OR WORKING WITH PAINT AND WHEN CLEANING THE UNITꢁ FOLLOW THE WORKꢃ
ING INSTRUCTIONS OF THE MANUFACTURER OF THE PAINTSꢁ SOLVENTS AND CLEANING AGENTS BEING
USEDꢂ
œ 4AKE THE SPECIlED PROTECTIVE MEASURESꢁ IN PARTICULAR WEAR SAFETY GOGGLESꢁ PROTECTIVE
CLOTHING AND GLOVESꢁAS WELL AS HAND PROTECTION CREAM IF NECESSARYꢂ
œ 5SE A MASK OR BREATHING APPARATUS IF NECESSARYꢂ
œ &OR SUFlCIENT HEALTH AND ENVIRONMENTAL SAFETYꢀ/PERATE THE UNIT IN A SPRAY BOOTH OR ON
A SPRAYING WALL WITH THE VENTILATION ꢊEXTRACTION SWITCHED ONꢂ
œ 7EAR SUITABLE PROTECTIVE CLOTHING WHEN WORKING WITH HOT MATERIALSꢂ
2.2.6 TOUCHING HOT SURFACES
œ 4OUCH HOT SURFACES ONLY IF YOU ARE WEARING PROTECTIVE GLOVESꢂ
œ 7HEN OPERATING THE UNIT WITH A COATING MATERIAL WITH A TEMPERATURE OF ꢋꢌꢆ²#ꢍ ꢅꢄꢎꢂꢌ²&ꢀ
ꢃ )DENTIFY THE UNIT WITH A WARNING LABEL THAT SAYSu7ARNING ꢃ HOT SURFACEhꢂ
/RDER .Oꢁ
ꢎꢎꢎꢏꢎꢅꢄ )NFORMATION LABEL
ꢎꢎꢎꢏꢎꢅꢅ 3AFETY LABEL
2.3 CORRECT USE
7!'.%2 ACCEPTS NO LIABILITY FOR ANY DAMAGE ARISING FROM INCORRECT USEꢂ
œ 5SE THE UNIT ONLY TO WORK WITH THE MATERIALS RECOMMENDED BY 7!'.%2ꢂ
œ /PERATE THE UNIT ONLY AS AN ENTIRE UNITꢂ
œ $O NOT DEACTIVATE SAFETY EQUIPMENTꢂ
œ 5SE ONLY 7!'.%2 ORIGINAL SPARE PARTS AND ACCESSORIESꢂ
8
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2.4 USE IN AN EXPLOSION HAZARD AREA
2.4.1 CORRECT USE
4HE UNIT IS SUITABLE FOR WORKING LIQUID MATERIALS IN ACCORDANCE WITH THE CLASSIlCATION INTO
EXPLOSION CLASSESꢂ
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
As defined in the Directive 94/9/CE (ATEX 95), the unit is suitable for use in areas where
there is an explosion hazard.
II 2G IIB T4
CE:
Ex:
II:
Communautés Européennes
Symbol for explosion protection
Unit class II
2:
Category 2 (Zone 1)
G:
Ex-atmosphere gas
IIB:
T4:
Explosion class
Temperature class: maximum surface temperature < 135°C; 275°F.
2.4.3 MAX. SURFACE TEMPERATURE
Max. surface temperature:
Permissible ambient temperature:
same as the permissible material temperature
see under Technical data, Section 4.3.2
2.4.4 SAFETY REGULATIONS
3AFE HANDLING OF 7!'.%2 SPRAY UNITS
4HE MAXIMUM SURFACE TEMPERATURE OF THE PISTON PUMP CAN BE REACHED IF IT RUNS DRYꢂ
œ %NSURE THAT THE PISTON PUMP IS lLLED WITH SUFlCIENT WORKING OR CLEANING MEDIUMꢂ
œ %NSURE THAT THE SEPARATING AGENT CONTAINER IS lLLED WITH SUFlCIENT SEPARATING AGENTꢂ
-ECHANICAL SPARKS CAN FORM IF THE UNIT COMES INTO CONTACT WITH METALꢂ
)N AN EXPLOSIVE ATMOSPHEREꢀ
œ $O NOT KNOCK OR PUSH THE UNIT AGAINST STEEL OR RUSTY IRONꢂ
œ $O NOT DROP THE UNITꢂ
œ 5SE ONLY TOOLS THAT ARE MADE OF A PERMITTED MATERIALꢂ
)GNITION TEMPERATURE OF THE COATING MATERIAL
œ %NSURE THAT THE IGNITION TEMPERATURE OF THE COATING MATERIAL IS ABOVE THE MAXIMUM
SURFACE TEMPERATUREꢂ
-EDIUM SUPPORTING ATOMIZING
œ 4O ATOMIZE THE MATERIALꢁUSE ONLY WEAKLY OXIDIZING GASESꢁEꢂGꢂAIRꢂ
9
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
3URFACE SPRAYINGꢄELECTROSTATIC
œ $O NOT SPRAY UNIT PARTS WITH ELECTROSTATIC ꢊEꢂGꢂELECTROSTATIC SPRAY GUN ꢂ
#LEANING
)F THERE ARE DEPOSITS ON THE SURFACESꢁ THE UNIT MAY FORM ELECTROSTATIC CHARGESꢂ &LAMES OR
SPARKS CAN FORM IF THERE IS A DISCHARGEꢂ
œ 2EMOVE DEPOSITS FROM THE SURFACES TO MAINTAIN CONDUCTIVITYꢂ
œ 5SE ONLY A DAMP CLOTH TO CLEAN THE UNITꢂ
10
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
(STATUS 01.02.2009)
3 PRODUCT LIABILITY AND WARRANTY
3.1 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 (he-
reafter referred to as “customer”) who have purchased the product in an authorised spe-
cialist shop,and which relate to the products listed for that customer on the Internet under
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.
3.2 GUARANTEE PERIOD AND REGISTRATION (3+2)
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 pe-
riod is extended to 24 months providing the buyer of these devices registers in accordan-
ce with the following conditions within 4 weeks of the day of delivery by the authorised
specialist shop.
rantee. The guarantee certificate is valid as confirmation, as is the original purchase docu-
ment 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.
3.3 HANDLING
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 certificate
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.
11
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
3.4 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, filters, pipes, seals, rotors, stators, etc. Damage due to wear
and tear that is caused in particular by sanded coating materials, such as dispersions, pla-
ster, putty, adhesives, glazes, quartz foundation.
- in the event of errors in devices that are due to non-compliance with the operating in-
structions, 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 con-
ditions, 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 com-
ponents or spare parts that are not original Wagner parts.
- for products to which modifications 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 per-
sons.
- 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.
3.5 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 appli-
cation.
Claims for liability for defects to the specialist trader remain unaffected.
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 Germany
12
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
3.6 CE-CONFORMITY
Herewith we declare that the supplied version of:
Pneumatic pumps with article no.
2301832
2301836
2301837
2301838
Complies with the following provisons applying to it:
2006/42/EC
94/9/EC Atex
Applied standards, in particular:
UNI EN 12100-1
UNI EN 12100-2
UNI EN 563
UNI EN 809
UNI EN 1127-1
EN 12621
UNI EN ISO 14121-1
UNI EN ISO 3746
UNI EN ISO 13463
Marking:
II 2G IIB T4
%# #ERTIlCATE OF #ONFORMITY
4HE CERTIlCATE IS ENCLOSED WITH THIS PRODUCTꢂ4HE CERTIlCATE OF CONFORMITY CAN BE REORDERED
FROM YOUR 7!'.%2 REPRESENTATIVEꢁQUOTING THE PRODUCT AND SERIAL NUMBERꢂ
0ART NUMBERꢀ
ZDI.20
13
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EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
4 DESCRIPTION
4.1 FIELD OF APPLICATION
4.1.1 USING IN ACCORDANCE WITH THE INSTRUCTIONS
The pneumatic diaphragm pump is suitable for process liquid materials.
CAUTION
Abrasive fluids and pigments !
Greater wear of the parts carrying the material.
œ Use suitable pump model (delivery per cycle, material, valves, etc.)
see chapter 4.3.2.
œ
Verify that fluids and solvents used are compatible with the constrution material
of the pump as described in chapter 4.3.1.
SIHC_0067_GB
4.2 EXTENT OF DELIVERY
Pneumatic diaphragm pump
consisting of:
- Material pump / Air motor
- Material regulator/Antipulsator and/or filter
- Support pump with regulators
- Suction hose
- Connections
CE-conformity see
Chapter 3
Operating manual in english
Operating manual for the other language see
Part No. : ZZB012ENG
Chapter 1
The delivery note shows the exact scope of delivery.
Accessories: see chapter 7.
4.3 DATA
4.3.1 MATERIALS OF THE PARTS TRANSPORTING PAINT
2301832
2301836
2301837
Acetal
2301838
Aluminium
Stainless steel
Stainless steel
PE
Covers/Manifolds
Balls
Aluminium
Stainless steel
Stainless steel Stainless steel
Stainless steel Stainless steel
Stainless steel
Stainless steel
PE
Valve seats
Diaphragms
PE
PE
Static gaskets (product
side)
PTFE
PTFE
PTFE
PTFE
14
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
4.3.2 TECHNICAL DATA
Description
Units
2301832 2301836 2301837 2301838
Transmission ratio
1 :1
52
1 :1
52
1 :1
52
1 :1
28
Fluid max flow rate
Max. operating pressure
l/min
MPa
bar
psi
8
8
8
8
116
1682
116
1682
116
1682
116
1682
Min. - Max. air inlet pressure.
Ø air inlet connection (female)
MPa
bar
psi
0.1-0.8
1-8
15-116
0.1-0.8
1-8
15-116
0.1-0.8
1-8
15-116
0.1-0.8
1-8
15-116
BSP
1/4“
99
1/4“
99
1/4“
97
1/4“
99
Sound power at max. flow rate
feeding 8 bar; 116 psi *.
dB(A)
Sound pressure equivalent to max.flow rate
feeding 8 bar; 116 psi *.
dB(A)
dB(A)
Inch
85
76
85
76
85
73
85
76
Sound pressure equivalent to 50 cycles/min
feeding 5 bar; 72,5 psi*.
Material outlet connection (female) (M16x1,5)
Weight
G 1/4“
G 1/4“
G 1/4“
G 1/4“
kg
lb
3.8
8.4
6.1
13.4
2.9
6.4
3.8
8.4
Max. material pressure at pump inlet
Range of material temperature
MPa
bar
psi
0,1
1
14,5
0,1
1
14,5
°C; F
+4° ÷ +40°; (+39 ÷ +104)
+4° ÷ +90°;
(+39 ÷
+176)
Range of the ambient temperature
Allowable sloping position at work
°C; F
<) °
+4° ÷ +40°; (+39 ÷ +104)
10
* A rated sound pressure level measured at 1m distance according to UNI EN ISO 3744.
7!2.).'
/UTGOING AIR CONTAINING OILꢃ
2ISK OF POISONING IF INHALEDꢂ
&UNCTION PROBLEM AIRMOTOR
œ 0ROVIDE WATERꢃFREE AND OILꢃFREE COMPRESSED AIR ꢊQUALITY STANDARD
ꢈꢂꢈꢂꢌ AS PER )3/ ꢏꢈꢐꢆꢂꢅ ꢈꢂꢈꢂꢌ ꢑ ꢌꢄ ›M ꢉ ꢒꢐ ꢉ ꢈ MGꢉMÃꢂ
3)()?ꢄꢄꢓꢏ?'"
15
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
4.3.3 DIMENSIONS AND CONNECTIONS
F
I
H
S
S
D
G
C
E
B
A
J
F
R
Q
K
L
16
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
Mounting for wall for 2301832, 2301836,2301837
M
N
O
P
C_00041
M
2301832
mm; inch
2301836
mm; inch
2301837
mm; inch
2301838
mm; inch
2301832 2301836 2301837 2301838
mm; inch mm; inch mm; inch mm; inch
A
B
C
D
E
F
G
H
I
295; 11,6 295; 11,6
280; 11 280; 11
189; 7,44 189; 7,44 189; 7,44
ø9; ø0.35 ø9; ø0.35 ø9; ø0.35
360; 14,1 360; 14,1 360; 14,1
280; 11
280; 11
-
-
-
-
M ø9; ø0.35 ø9; ø0.35 ø9; ø0.35
-
-
-
-
N
O
P
Q
R
S
-
38.3; 1.5 38.3; 1.5 38.3; 1.5
80; 3.2 80; 3.2 80; 3.2
189; 7.4 189; 7.4 189; 7.4
-
-
-
-
G1/4”
940; 37
G1/4“
158; 6,2
ø16
G1/4“
158; 6,2
ø16
G1/4“
158; 6,2
ø16
G1/4“
-
-
-
-
-
G1/4”
G1/4”
G1/4”
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
250; 9,8
250; 9,8 260; 10,2 250; 9,8
-
-
-
-
J
K
L
360; 14,1
335; 13,1
405; 15,9
17
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
4.4 FUNCTIONING
4.4.1 PUMP
A
B
C
M
P
Diaphragms
Connecting shaft
Check valves
Driving chambers
Pumping chambers
Air motor
Q
R
Inversion valve
General information
The principle lying behind the functioning of diaphragm pumps driven by compressed air
is just as simple as it is effective.Two diaphragms (A), which are connected to one another
by means of a connecting shaft (B) so as to be integral, divide two adjacent capacities into
four chambers.The inner ones function as driving chambers (M) while the outer ones func-
tion as pumping,chambers (P).A pneumatic distributor alternately conveys compressed air
into one of the driving chambers, thus producing the diaphragms movement and conse-
quently causing one of the pumping chambers to empty (as a result of volume decrease),
while at the same time the other fills up (as a result of volume increase). A series of check
valves (C) prevents the liquid from flowing back, thus producing the suction and delivery
phases in each pumping chamber.
Air motor (Q)
The pneumatic motor must be powered
at a pressure not exceeding the value giv-
en on the plate. Each component linked
to the pump outlet must have an operat-
ing pressure equal to or higher than the
pressure generated by the pump itself.
This fi nal pressure is given on
the plate (see the picture on the right).
7!2.).'
/VERPRESSUREꢃ
2ISK OF INJURY FROM BURSTING COMPONENTSꢂ
œ .EVER CHANGE THE SAFETY VALVE SETTINGꢂ
3)()?ꢄꢄꢇꢓ?'"
18
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
4.4.2 PRESSURE REGULATOR
a
Antipulsation Reducer Filter with pneum.control
(FINE FLOW CONTROLLER)
b
c
d
e
f
Atomising air pressure reducer
Atomising air connection
Pump motor feeding air manometer
Controlling air manometer of pneumatic paint pressure reducer
Atomising air manometer
g
h
i
Controlling air pressure reducer of pneumatic paint reducer
PM motor feeding air pressure reducer
On-off and feeding air inlet valve
Re-cycle on-off valve
l
m
n
Fluid suction pipe
Fluid delivery connection
Figure: Pump 2301832, 2301836,
2301837
l
a
b
c
d
e
f
Pump feeding air pressure reducer
Atomising air pressure reducer
Pump feeding air manometer
Atomising air manometer
Atomising air connection
Fluid suction pipe
g
i
g
h
i
Filter material
Compressed air connection
Fluid delivery connection
l
Recycling valve
c
f
a
b
h
d
e
Figure: Pump 2301838
19
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
4.4.2.1
TECHNICAL SHEET FINE FLOW CONTROLLER COD. 2301832, 2301836, 2301837
Part in contact with the product
Regulator body:(p):
Konsistal (for T0180.00A)
Regulator body: (p):
Stainless Stell (for T0180.00AI)
Antipulsation body (q):
Product diaphragm::
Shutter ball:
PP
PTFE
Stainless Stell
Tungsten carbide
Shutter seat::
Reducer section performances
with fluids having a viscosity of 45 mPa.s
(corresponding to about 20 s. Ford 4)
Inlet pressure : 5 Bar
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0
0
0
1
2
Portata/Flow rate/Débit/Förderung [l/min.]
Max allowed fluid temperature (°C):
Max inlet pressure (Bar):
40
14
Guiding air inlet max. pressure (Bar)
Adjustment range (Bar)
8
0.5 ÷ 8
1/4”Fem.
1/4”Fem.
1/8”Fem.
Product inlet connection (BSP)
Product outlet connection (BSP) 2x
Air inlet connection (BSP)
2x
FILTER CARTRIDGE - INCLUDED(Mesh)
OPTIONAL (Mesh)
100
60 and 150
Dimensions
Diameter (mm):
Height (mm):
weight (gr):
90
165
850 (for T0180.00A)
1455 (for T0180.00AI)
weight (gr):
20
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
5 STARTING UP AND OPERATING
5.1 INSTALLATION AND CONNECTION
5.1.1 PUMP INSTALLATION
Note
The pneumatic motor must be supplied with clean
industrial air; make sure efficient filtering and con-
densate separation systems are installed on the air
line. All impurities and the eventual condensate that
has built up inside the air filter on top of the pump
must be drained daily.
NOTE: Consult specific catalogues when choosing
the pipes. The driving air pipe must be properly di-
mensioned.
Procedure for 2301832, 2301836, 2301837 :
1. Mount the pump onto a basement
2. Connect the air atomization and paint delivery
hoses, respectively, to the corresponding
attachments (C: air - N: paint), carefully
tightening the fittings.
Procedure for 2301838 :
1. Connect the air to the pump in the (H) fitting,
installing an on-off valve on the line to stop the
feeding air in case of emergency.
2. Connect the spraying air to its fitting (E). Carry
out the same operation for the paint delivery
pipe, to be connected to its fitting (I).
7!2.).'
)NCLINED SURFACEꢃ
2ISK OF ACCIDENTS IF THE UNIT ROLLS AWAYꢉFALLSꢂ
œ 0OSITION THE CARRIAGE WITH THE PISTON PUMP HORIZONTALLYꢂ
œ )F THE SURFACE IS INCLINEDꢁPOSITION THE FEET OF THE CARRIAGE TOWARDS
THE GRADIENTꢂ
œ 3ECURE THE CARRIAGEꢂ
3)()?ꢄꢄꢅꢇ?'"
21
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
5.1.2 EARTHING
7!2.).'
$ISCHARGE OF ELECTROSTATICALLY CHARGED COMPONENTS IN ATMOꢂ
SPHERES CONTAINING SOLVENTSꢃ
%XPLOSION HAZARD FROM ELECTROSTATIC SPARKSꢂ
œ #LEAN THE PISTON PUMP ONLY WITH A DAMP CLOTHꢂ
3)()?ꢄꢄꢌꢅ?'"
7!2.).'
(EAVY PAINT MIST IF EARTHING IS INSUFlCIENTꢃ
2ISK OF POISONINGꢂ
)NSUFlCIENT PAINT APPLICATION QUALITYꢂ
œ %ARTH ALL UNIT COMPONENTSꢂ
œ %ARTH THE WORKPIECES BEING PAINTEDꢂ
3)()?ꢄꢄꢄꢆ?'"
Earthing schema (example)
Conveyor
Workpiece
Spraying stand
2 MAX ꢔ ꢅ -Ω
Paint container
"?ꢄꢄꢆꢄꢌ
Anti-static floor
22
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
Cable cross sections
Pump
4 mm²; AWG 11
6 mm²; AWG 10
16 mm²; AWG 5
16 mm²; AWG 5
16 mm²; AWG 5
Paint container
Conveyor
Spraying booth
Spraying stand
Procedure:
1. Screw on earthing cable with eye.
2. Clamptheearthingcablecliptoaearthconnection
on site.
3. Earth the material (paint) container to a local
earth connection.
4. Earth the other parts of the system to a local earth
connection.
23
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
5.2 START UP
5.2.1 SAFETY REGULATIONS
Every time before starting up the following points should be observed as laid down in the
operating instructions:
- That it is possible to observe the safety regulations in Chap. 2.
- The starting up procedure, has been carried out properly.
7!2.).'
(IGHꢂPRESSURE SPRAY JETꢃ
$ANGER TO LIFE FROM INJECTING PAINT OR SOLVENTꢂ
œ .EVER REACH INTO THE SPRAY JETꢂ
œ .EVER POINT THE SPRAY GUN AT PEOPLEꢂ
œ #ONSULT A DOCTOR IMMEDIATELY IN THE EVENT OF SKIN INJURIES CAUSED
BY PAINT OR SOLVENTꢂ)NFORM THE DOCTOR ABOUT THE PAINT OR SOLVENT
USEDꢂ
œ .EVER SEAL DEFECTIVE HIGHꢃPRESSURE PARTSꢁ INSTEAD RELIEVE THE
PRESSURE FROM THEM AND REPLACEꢂ
3)()?ꢄꢄꢅꢓ?'"
7!2.).'
4OXIC ANDꢅOR mAMMABLE VAPOR MIXTURESꢃ
2ISK OF POISONING AND BURNSꢂ
œ /PERATE THE UNIT IN A SPRAYING BOOTH APPROVED FOR THE WORKING
MATERIALSꢂ
ꢃORꢃ
œ /PERATE THE UNIT ON AN APPROPRIATE SPRAYING WALL WITH THE VENTIꢃ
LATION ꢊEXTRACTION SWITCHED ONꢂ
œ /BSERVE NATIONAL AND LOCAL REGULATIONS FOR THE OUTGOING AIR
SPEEDꢂ
3)()?ꢄꢄꢇꢏ?'"
7!2.).'
'AS MIXTURES CAN EXPLODE IF THERE IS AN INCOMPLETELY lLLED
PUMPꢃ
$ANGER TO LIFE FROM mYING PARTSꢂ
œ %NSURE THAT THE PISTON PUMP AND SUCTION SYSTEM ARE ALWAYS
COMPLETELY lLLED WITH CLEANING AGENT OR WORKING MEDIUMꢂ
œ $O NOT SPRAY THE UNIT EMPTY AFTER CLEANINGꢂ
3)()?ꢄꢄꢇꢈ?'"
24
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
Before every start-up, the following points should be observed as laid down in the operating
manual:
- If installed secure gun with safety catch
- Check the permissible pressures
- Check all connections for leaks
- Check hose for damage
It should be ensured that the unit is in the following state before carrying out any work on it:
- The pressure should be released from the pump and high-pressure hose with gun (if
installed).
- The gun should be secured with safety catch (if installed).
- The air supply should be interrupted
5.2.2 EMERGENCY STOPPING
Emergency stopping for 2301832, 2301836,
2301837
To stop the equipment in good time, close the air on-off valve
(I) or release pressure through the regulator knob (H) thus stop-
ping the feeding air to the motor.
Carry out the pump priming operations correctly to prevent
pressurized air babbles from being trapped.
Pneumatic pumps can keep all components connected to the
delivery under pressure, even when the driving air feed is clo-
sed.To prevent harm to people, as well as to avoid damaging
things or the environment, after stopping the pump it is best
to release the pressure by keeping the delivery valve open or
opening the recycling valve (L).
Emergency stopping for 2301838
To stop the equipment in good time, close the air on-off valve
on the feeding line or release pressure through the regulator
knob (A) thus stopping the feeding air to the motor.
Carry out the pump priming operations correctly to prevent
pressurized air babbles from being trapped.
Pneumatic pumps can keep all components connected to the
delivery under pressure, even when the driving air feed is clo-
sed.To prevent harm to people, as well as to avoid damaging
things or the environment, after stopping the pump it is best
to release the pressure by keeping the delivery valve open or
opening the recycling valve (L).
25
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
5.2.3 WASHING
The pump has been tested using mineral oil. Before using it, it
is best to let it wash once using an adequate solvent. To do this,
place the metallic side of the suction pipe (M) inside a container
full of solvent.
M
Open the re-cycle valve (L).
Make sure that the pressure regulator knob (H) is turned fully
anti-clockwise (0 bar pressure). Open the air cutoff valve (I) (on
the compressed air line for 2301838) and turn the motor air pres-
sure regulator (H) knob clockwise until the pump starts. It is best
to keep the atomization air valve (B) closed during washing ope-
rations.
2301832,2301836,
2301837
Set the motor air pressure to 2 bar.
The pump sucks solvent and pours it back into the container
through the re-cycle system, thus cleaning itself.
Let the solvent flow inside the pump for 2 or 3 minutes.
2301838
NOTE: In case the pump does not start, check that the gauge (C)
reads at least 2 bar, close the delivery air on-off valve, discharge
the residual pressure by turning the knob of the relative regula-
tor anticlockwise, and then reset the pressure using the regulator
and instantly reopen the air on-off valve. If necessary, repeat the
operation several times.
Keeping the gun on the solvent container, pull the trigger and let the solvent re-cycle
for some minutes through the gun delivery pipe. If the solvent flow coming out from the
gun is poor, use the recycling valve lever (L) to obtain a higher pressure from the gun. At
this point, all components have been through the first washing, the equipment has no
unwanted fluid inside and is ready for painting; lift the suction pipe from the dirty solvent
container and empty the pump completely.
Plunge the suction pipe and refill the pump with clean solvent,the turn off the air using the
motor air pressure regulator (H).
NOTE:In case you are pumping liquids,such as catalyzed resins,which are bound to harden
up, once: you have finished using the pump you must wash it, as well as anything that may
be connected to it, in a thorough way, using a solvent suitable for the type of resin being
used.You must then leave the pump full of solvent until it is next used.
5.2.4 UNIT PRESSURE TIGHTNESS TEST
Close the gun, close the re-cycle valve (L), gradually increase the motor feeding air pressu-
re (H) and the reducer controlling air (G) until reaching the max. acceptable value for the
pump and connected equipment,make sure there are no leaks from fittings or pipe as well
as from pump and antipulsation tank reducer filter.
26
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
5.3 WORK
5.3.1 SPRAYING
for 2301832, 2301836, 2301837
Make sure that the pressure regulator knob (H) is turned fully anti-
clockwise (0 bar pressure).
Open the air cutoff valve (I) and turn the motor air pressure regulator knob
(H) clockwise until the pump starts.
(Set the air pressure on the gauge (D) to 2 bar).
Open the re-cycle valve (L).
Lift the suction pipe and wait until the pump is completely empty from
the solvent previously pumped for the first washing.
NOTE:The solvent used for the first washing may contain testing fluid resi-
dues, therefore avoid using it to dilute the paint.
Insert the suction pipe (M) into the paint container.
Wait until the pump is full. Close the re-cycle valve (L). If the product re-
quires a continuous agitation, adjust the re-cycle valve opening so as to
obtain the desired delivery.
Set the motor air pressure (H) on the gauge (D) to 5-5,5 bar or even more,
if the paint viscosity requires it.
Open the gun (T) and drain the solvent contained inside the hose. Close
the gun (T) as soon as paint starts coming out.The pump stops while it is
still pressurized.
Set the paint pressure using the regulator (G) until obtaining a pressure of
1-1,5 bar on manometer (E).
Adjust the atomising air pressure using the regulator (B) and make sure
the pressure on manometer (F) is 1,5-2 bar.You can now start painting.
for 2301838
Make sure that the pressure regulator knob (A) is turned fully anti-
clockwise (0 bar pressure).
Open the air cutoff valve and turn the motor air pressure regulator knob
(A) clockwise until the pump starts. (Set the air pressure on the gauge (C)
to 2 bar).
Open the re-cycle valve (L).
Lift the suction pipe and wait until the pump is completely empty from
the solvent previously pumped for the first washing.
NOTE:The solvent used for the first washing may contain oil residues, the-
refore avoid using it to dilute the paint.
Insert the suction pipe (F) into the paint container.
Wait until the pump is full. Close the re-cycle valve (L). If the product re-
quires a continuous agitation, adjust the re-cycle valve opening so as to
obtain the desired delivery.
Set the motor air pressure (A) on the gauge (C) to 3-5 bar or even more, if
the paint viscosity requires it.
Open the gun (T) and drain the solvent contained inside the hose. Close
the gun (T) as soon as paint starts coming out.The pump stops while it is
still pressurized.
Adjust the atomising air pressure using the regulator (B) and make sure
the pressure on manometer (D) is 1,5- 2 bar.
You can now start painting.
27
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
5.3.2 PAINTING HINTS
If the pump speeds up suddenly and starts to shake, it means that there is no paint left
inside it and that it is sucking air; you must therefore supply it with new paint. If the pump
starts shaking like it would do if there were no paint left (but in fact there is), you must
clean the suction pipe filter (see the“Filter cleaning operations”paragraph 6.3
WARNING
Overpressure!
Risk of injury from bursting components.
Frequently check for blocked recirculation pipe - the pipeline
must be completely free.
œ
SIHC_0001_GB
5.3.3 WORKING BREAKS
Each time you stop spraying,close the motor input air valve (H) and open the re-cycle valve
to release the pressure.
When using catalized paints, the interruption must be considerably shorter than the mix-
ture lifetime.
In case it is not so,wash the system thoroughly.
If the system has been used with two component material:
7!2.).'
(ARDENED MATERIAL IN THE SPRAYING SYSTEM WHEN ꢆꢂCOMPONENT
MATERIAL IS WORKEDꢃ
$ESTRUCTION OF THE PUMP AND INJECTION SYSTEMꢂ
œ &OLLOW THE MANUFACTURER@S WORKING INSTRUCTIONSꢁ PARTICULARLY REꢃ
GARDING THE POT LIFEꢂ
œ 2INSE THOROUGHLY BEFORE THE END OF THE POT LIFEꢂ
œ 4HE POTLIFE TIME DECREASES AT RAISING TEMPERATUREꢂ
3)()?ꢄꢄꢓꢎ?'"
28
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
5.3.4 SHUTTING DOWN AND CLEANING
Note
The device should be cleaned for maintenance purposes, etc. Ensure that no remaining
material dries and sticks.
Procedure:
1. Working breaks -> procedure on chapter 5.3.2.
2. Basic cleaning -> procedure on chapter 5.2.3.
3. Maintain the gun as laid down in the operating instructions.
4. Clean and check the suction system and, in particular, the suction filter.
5. When using a high-pressure filter: Clean and check the filter insert.
6. Clean the outside of the system.
7!2.).'
"RITTLE lLTER PRESSURE REGULATORꢃ
4HE CONTAINER ON THE lLTER PRESSURE REGULATOR BECOMES BRITTLE
THROUGH CONTACT WITH SOLVENTS AND CAN BURSTꢂ
&LYING PARTS CAN CAUSE INJURYꢂ
œ $O NOT CLEAN THE CONTAINER ON THE PRESSURE REGULATOR WITH SOLꢃ
VENTꢂ
3)()?ꢄꢄꢅꢌ?'"
7. Put the whole system back together.
8. Fill the system with solvent as laid down in Paragraph 5.2.3.
7!2.).'
'AS MIXTURES CAN EXPLODE IF THERE IS AN INCOMPLETELY lLLED
PUMPꢃ
$ANGER TO LIFE FROM mYING PARTSꢂ
œ %NSURE THAT THE PISTON PUMP AND SUCTION SYSTEM ARE ALWAYS
COMPLETELY lLLED WITH CLEANING AGENT OR WORKING MEDIUMꢂ
œ $O NOT SPRAY THE UNIT EMPTY AFTER CLEANINGꢂ
3)()?ꢄꢄꢇꢈ?'"
5.4 STORING FOR LONGER PERIODS OF TIME
When storing the device for longer periods of time it is necessary to thoroughly clean it
and protect it from corrosion. Replace solvent in the material pump with a suitable preser-
ving oil.
Procedure:
1. Carry out Paragraph 5.3.4„Shutting down and cleaning“, points 1 through 8.
2. Cleaning with preserving agent acc. Paragraph 5.2.3.
3. Protect the air motor with pneumatic oil: connect an oiler to the compressed air inlet
and run for a few double strokes.
29
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
6 FAULT LOCATION, MAINTENANCE AND REPAIR
6.1 TROUBLE SHOOTING AND SOLUTION
Problem
Solution
The pump does not
start
Check the line and the air cutoff valve
Check the air treatment group if installed
Check the opening of any valves present on the
suction and delivery lines.
Close the air on-off valve and reopen it rapidly after
having increased the pressure
Only for FINISHING: check the pressure value of the
paint reducer
The unit is working
(i.e.:the pump is
Accurately clean the filter if
installed
moving),but not
liquid is coming out
Check liquid level
Check suction pipe
Poor spray pattern
See gun instructions
The product flow
into the delivery is
discontinuous
Check that the suction pipe is not clogged
Check that the pump is not cavitating
There may be impurities on the valve seats
Partial obstruction on delivery line
The pump delivery
decreases during
work
Slight variations of product characteristics (such as
viscosity)
Ice formation inside the air outlet pipes
Complete obstruction on delivery line
The pump delivery
decreases during
work, up to the
point when it stops
completely
Strong variations of product characteristics (such as
viscosity)
The unit stops
frequently
Increase the air pressure
Adjust the lubricator output if
installed
Put antifreezer in the lubricator and put an efficient
condensate separator on the air line if installed
The equipment
Check the product cutoff valve and the outlet valve
seals
remains in operation
even with the delivery
on-off valve closed.
There may be impurities on
the valve seats
If the problem is not listed above consult your WAGNER Service Center.
30
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
6.2 MAINTENANCE
7!2.).'
)NCORRECT MAINTENANCEꢅREPAIRꢃ
$ANGER TO LIFE AND EQUIPMENT DAMAGEꢂ
œ /NLY A 7!'.%2 SERVICE CENTER OR A SUITABLY TRAINED PERSON MAY
CARRY OUT REPAIRS AND REPLACE PARTSꢂ
œ /NLY REPAIR AND REPLACE PARTS THAT ARE LISTED IN THE CHAPTER ꢕ3PARE
PARTS CATALOGꢕꢂ
œ "EFORE ALL WORK ON THE UNIT AND IN THE EVENT OF WORK INTERRUPꢃ
TIONSꢀ
ꢃ $ISCONNECT THE CONTROL UNIT FROM THE MAINSꢂ
ꢃ 2ELIEVE THE PRESSURE FROM THE SPRAY GUN AND UNITꢂ
ꢃ 3ECURE THE SPRAY GUN AGAINST ACTUATIONꢂ
œ /BSERVE THE OPERATING AND SERVICE INSTRUCTIONS WHEN CARRYING
OUT ALL WORKꢂ
3)()?ꢄꢄꢌꢏ?'"
1. Every shut down should be carried out as laid down in paragraph 5.3.3 !
2. Check and replace if necessary hoses, tubes, couplings every days.
WAGNER recommends to check the whole spray system every year from a technical expert
(e.g.WAGNER service technician).
31
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
6.3 FILTER CLEANING OPERATIONS
Before you clean the filters, you
must close the compressed air
input valve and release the pres-
sure contained inside the pump
and the pipes attached to it.
This pump has one filter inside the
suction pipe and another inside
the delivery circuit.
ALL FILTERS MUST BE CLEANED
DAILY.
IT IS ALSO NECESSARY TO CLEAN
THEM WHEN USING A DIFFERENT
COLOUR PAINT FROM THE ONE
PREVIOUSLY USED.
To clean the suction pipe (M) filter
undo the spring, take out the filte-
ring disk, leave it in some solvent,
brush it and spray it with compres-
sed air.
To clean the antipulsation filter,
unscrew the plastic ring nut (O)
from the reducer body (P), lift the
cup (Q) paying attention to the
PTFE gasket on the edge. Remove
the filter (R ) from the seat (S), pul-
ling it upward, since it has a very
simple fixing (clip).
Plunge the filtering cartridge into
the solvent, then brush and blow
it. Make sure to clean also the filter
inner side with solvent and blow it
with compressed air if necessary.
To reassemble the filter, push it on
the seat until hearing the fixing
clip;
do not push the filter any further,
to avoid damaging it. Reposition
the cup making sure the gasket is
in the perfect position, then screw
the ring nut.
32
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
6.4 MACHINE MAINTENANCE
The following instructions are general.
Refer to the specific diagrams of each pump model to operate correctly.
ATTENTION: Before you perform any maintenance or cleaning operation:
- Supply yourself with the proper equipment,
- Wear the garments and specific protection devices with regard to the
nature of the fluids with which you will come into contact,
- Close the compressed air delivery and discharge the pressure from the
pump and pipes connected to it,
- If necessary, depending on the intervention, disconnect the product and air
side connection pipes, remove the pump from the base or support it is faste-
ned to and turn it over on top of a container suitable for collecting any liquid
it may contain.
After the pump has been reassembled following maintenance operations, re-
set and check the efficiency of the earthing connection of the individual parts
of the pump.
6.1
1) Diaphragm replacement (Preventive maintenance)
Mark the coupled parts with a felt-tip pin so as to make subsequent reassembly
easier.
a) Remove the suction and delivery manifolds. (6.1).
b) Disassemble the fastening nuts and remove the external covers. (6.2).
c) Turn the two end nuts of the external diaphragm disks in contraposition
with the appropriate spanners and disassemble one of them.
d) Remove the freed diaphragm with its relative internal disk, and extract the
shaft from the motor block.(6.3).
6.2
e) Lock the end of the shaft released from the diaphragm in a vice (adopting
the proper precautions to avoid damaging it) and disassemble the external
diaphragm disk from the opposite end. Now remove the second diaphragm
with its internal disk.
f) Assemble the new diaphragm with its internal disk and opportunely tighten
it with the relevant external disk.
g) Free the shaft from the vice, put it inside the motor block after lubricating
it with grease, assemble the internal diaphragm disk, diaphragm and external
disk, and then properly tighten it by using two spanners in contraposition on
the nuts of the external disks.
h) Reassemble the external covers and then the manifolds while making sure
you check the positioning of the suction and delivery valves, the relative seals
and proper tightening of the screws. (6.4).
2) Diaphragm replacement (due to breakage)
In the case the diaphragms are replaced as a consequence of breaking, it is ne-
cessary to clean all the internal parts of the motor and check the condition of
the seals and reversing valve, which may have been damaged by contact with
the pumped fluid.
a) Follow the sequence described under paragraph 1, points a), b), c), d) and e).
b) Disassemble the pressure side cover and extract the reversing valve.
33
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
6.4
c) Remove the rod guide bushings
placed at the two ends of the
motor block, the shaft seals and
feeler pin underneath and extract
the feeler pins. (6.4).
d) Clean all the components, the
lines and spaces inside the motor
block.
Thoroughly blow the housing
cavity of the safety valve with a jet
of compressed air.
e) Check the condition of the
reversing valve and replace it, if
necessary.
f) Reassemble all the parts
described under point c) while
paying attention that you properly
orient the seal lip of the gaskets.
g) Reassemble the valve in its
housing, check that the shoe is in
the end of stroke position both
vertically and horizontally, and
then put the pressure side cover
on.
As you are performing the
operations described above,check
the positioning of the valves seals
and cover.
h) Reassemble the remaining
components by following the
instructions under paragraph 1,
points f), g), h).
3) Cleaning and/or replacement of
the suction and delivery valves
a)Removethesuctionanddelivery
manifolds.
b) Extract the gaskets, seats and
ball valves from the external cover
and manifold housings.
c) Check the condition of wear
of the ball guide/stops inside the
covers and manifold.
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
7 ACCESSORIES
7.1 ACCESSORIES ONLY FOR 2301832, 2301836, 2301837
35
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
7.2 PUMP ZIP 52 FINISHING WITH WALL SUPPORTING KIT COD. T760.00M
36
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
T760.00M
Spare parts list
Pos
51
52
53
54
55
58
Description
Right wall bracket
Left wall bracket
TCEI 8x20 screw
RWasher 8
Qty.
No.
1
1
4
4
4
4
E3101.92B
E3101.92A
K120.62
K509.62
K312.62
K572.62
Nut
Washer
7.2.1 OVERALL DIMENSIONS COD. T760.00M
37
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
7.3 PUMP ZIP 52 FINISHING WITH STAND KIT COD. T760.00S
38
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
T760.00S
Spare parts list
Pos
21
34
38
39
40
41
42
43
44
45
57
Description
Washer
Qty.
5
Code
K505.62
K311.62A
E3107.92
E3107.92A
H1156.62
R204.07
R244.07
K184.62
K1015.62
H009.62
K564.72
Nut
5
Right stand
Left stand
1
1
Stand pin
1
Finned push rod
Plyers foot
TCEI 6x45 screw
TCEI 8x40 screw
Gun hook
4
4
4
2
1
Contact washer
4
7.3.1 OVERALL DIMENSIONS COD. T760.00S
39
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
7.4 PUMP ZIP 52 FINISHING WITH HANDLE+WHEELS KIT COD.T760.00R FOR STAND PUMPS COD.
T760.00S
40
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
T760.00R
Spare parts list
Pos
34
46
47
48
49
50
57
Description
Nut
Qty.
2
Code
K311.62A
R118.00
K607.02
E3108.92
K159.62
K502.62
K564.72
Wheel
2
Benzing ring
Trolley handle
TCEI 6x50 screw
Washer
2
1
2
4
Contact washer
4
7.4.1 OVERALL DIMENSIONS COD. T760.00R
41
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
7.5 POMPA ZIP 52 FINISHING WITH TROLLEY KIT COD. T760.00SR
42
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
T760.00SR
Spare parts list
Pos
21
34
38
39
40
41
42
43
44
45
46
47
48
49
50
57
Description
Washer
Qty.
2
Code
K505.62
K311.62A
E3107.92
E3107.92A
H1156.62
R204.07
R244.07
K184.62
K1015.62
H009.62
R118.00
K607.02
E3108.92
K159.62
K502.62
K564.72
Nut
5
Right stand
Left stand
1
1
Stand pin
1
Finned push rod
Plyers foot
TCEI 6x45 screw
TCEI 8x40 screw
Gun hook
4
4
4
2
1
Wheel
2
Benzing ring
Trolley handle
TCEI 6x50 screw
Washer
2
1
2
4
Contact washer
7
7.5.1 OVERALL DIMENSIONS COD. T760.00SR
43
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8 SPARE PARTS
8.1 HOW TO ORDER SPARE PARTS
!LWAYS SUPPLY THE FOLLOWING INFORMATION TO ENSURE DELIVERY OF THE RIGHT SPARE PARTꢀ
0ART .UMBERꢄDESCRIPTION AND QUANTITY
4HE QUANTITY NEED NOT BE THE SAME AS THE NUMBER GIVEN IN THE u1UANTITYh COLUMNꢂ 4HIS
NUMBER MERELY INDICATES HOW MANY OF THE RESPECTIVE PARTS ARE USED IN EACH SUBASSEMBLYꢂ
4HE FOLLOWING INFORMATION IS ALSO REQUIRED TO ENSURE SMOOTH PROCESSING OF YOUR ORDERꢀ
ꢃ !DDRESS FOR THE INVOICE
ꢃ !DDRESS FOR DELIVERY
ꢃ .AME OF THE PERSON TO BE CONTACTED IN THE EVENT OF ANY QUERIES
ꢃ 4YPE OF DELIVERY REQUIRED ꢊAIR FREIGHT OR MAILꢁSEA ROUTE OR OVERLAND ROUTEꢁETCꢂ
-ARKS IN SPARE PARTS LISTS
7!2.).'
)NCORRECT MAINTENANCEꢅREPAIRꢃ
2ISK OF INJURY AND DAMAGE TO THE EQUIPMENTꢂ
œ 2EPAIRS AND PART REPLACEMENT MAY ONLY BE CARRIED OUT BY SPEꢃ
CIALLY TRAINED STAFF OR A 7!'.%2 SERVICE CENTERꢂ
œ "EFORE ALL WORK ON THE UNIT AND IN THE EVENT OF WORK INTERRUPꢃ
TIONSꢀ
ꢃ 3WITCH OFF THE ENERGYꢉCOMPRESSED AIR SUPPLYꢂ
ꢃ 2ELIEVE THE PRESSURE FROM THE SPRAY GUN AND UNITꢂ
ꢃ 3ECURE THE SPRAY GUN AGAINST ACTUATIONꢂ
œ /BSERVE THE OPERATING AND SERVICE INSTRUCTIONS WHEN CARRYING
OUT ALL WORKꢂ
3)()?ꢄꢄꢄꢌ?'"
44
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
45
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.2 OVERVIEW MODULES
ZIP52 FINISHING - PF
Pos Description
2301832
No.
2301836
2301837
No.
2301838
No.
Qty
No.
Qty
Qty
Qty
1
2
Pump ZIP52 (see the
exploded view 8.3.3)
Aluminium
1
Inox
1
Plastic
1
Alluminium
-
1
Fine Flow Controller
(see the exploded view
8.3.1, 8.3.5)
T0180.00A
-
1
-
T0180.00AI
1
-
T0180.00A
T0180.00AI
1
-
-
3
Material tank filter (see
the exploded view
8.3.6)
-
-
T4005.00ALS
1
4
5
Suction pipe (see the
exploded view 8.3.7)
T406.00
1
-
T406.00
1
-
T406.00
1
-
T406.00
1
2
Leg
See
See
See
E111.92B
Accessories
Accessories
Accessories
-
Pump equipped with protection panel - air pressure
reducers and manometers to adjust: pump motor
feeding air, fluid reducer controlling air, atomising air ,
re-cycle pipe with lever valve support.
support trestle -
relevant gauges for
pump feeding air
and atomising air
- recycling pipe with
manual valve.
2301832, 2301836, 2301837
2301838
46
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.3 EXPLODED VIEW
8.3.1 PUMP COD. 2301832, 2301836, 2301837
(2301832)
a) Exploded view parts. 1,3, 36 in the following pages
47
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
7!2.).'
)NCORRECT MAINTENANCEꢅREPAIRꢃ
2ISK OF INJURY AND DAMAGE TO THE EQUIPMENTꢂ
œ 2EPAIRS AND PART REPLACEMENT MAY ONLY BE CARRIED OUT BY SPEꢃ
CIALLY TRAINED STAFF OR A 7!'.%2 SERVICE CENTERꢂ
œ "EFORE ALL WORK ON THE UNIT AND IN THE EVENT OF WORK INTERRUPꢃ
TIONSꢀ
ꢃ 3WITCH OFF THE ENERGYꢉCOMPRESSED AIR SUPPLYꢂ
ꢃ 2ELIEVE THE PRESSURE FROM THE SPRAY GUN AND UNITꢂ
ꢃ 3ECURE THE SPRAY GUN AGAINST ACTUATIONꢂ
œ /BSERVE THE OPERATING AND SERVICE INSTRUCTIONS WHEN CARRYING
OUT ALL WORKꢂ
3)()?ꢄꢄꢄꢌ?'"
2301837
Code
2301832
Code
2301836
Code
Spare parts list
Pos
Description
Qty.
Qty.
Qty.
1
ZIP 52 pump
1
see explod.
view
1
see explod.
view
1
see explod.
view
2
3
4
5
Fine Flow controller
Pump support
1
1
1
1
T0180.00AI
E3105.92
E3106.92
B274.03
1
1
1
1
T0180.00AI
E3105.92
E3106.92
B274.03
1
1
1
1
T0180.00AI
E3105.92
E3106.92
B274.03
Reducer support
Flexible pipe holder 1/2”x16
stainless steel
6
7
8
9
Nipple 1/4”
Fitting spec.1/2”
Paint hose
1
1
1
2
M801.03B
B0264.03
S591.00C
M336.00
1
1
1
2
M801.03B
B0264.03
S591.00C
M336.00
1
1
2
M247.00
S591.00C
M336.00
Rapid revolving connector L
1/4”x8
10
11
12
13
14
15
Fitting 1/4x8
1
3
3
1
1
4
M057.07
P904.00
M286.00
Z547.00
Z548.00
M335.00
Pressure gauge
3
3
1
1
4
P904.00
M286.00
Z547.00
Z548.00
M335.00
3
3
1
1
4
P904.00
M286.00
Z547.00
Z548.00
M335.00
Rapid connector D1/8”x4 F
Control plate
“ZIP52 finishing”label
Rapid revolving connector L
1/8”x4
16
17
18
19
20
Plug 1/4”
1
1
1
1
4
M826.03B
M513.00IA
M881.03
1
1
1
1
4
M259.00
M109.00
M213.04
M205.04
K107.62
1
1
1
1
4
M826.03B
M513.00IA
M881.03
Cock FF 1/4”lever
Fitting L MF 1/4”
Conical nipple 1/4”
TCEI M6x20 screw
M801.03C
K107.62
M801.03C
K107.62
48
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2301837
2301832
2301836
Spare parts list
Pos
21
22
23
24
25
26
27
28
29
30
Description
Qty.
8
Code
Qty.
8
Code
Qty.
8
Code
Washer
K505.62
T139.01
M404.00
M250.00
M239.00
M101.00
L212.06
S455.07A
S455.07
M354.00
K505.62
T139.01
M404.00
M250.00
M239.00
M101.00
L212.06
S455.07A
S455.07
M354.00
K505.62
T139.01
M404.00
M250.00
M239.00
M101.00
L212.06
S455.07A
S455.07
M354.00
Air manifold
1
1
1
Hollow screw 1/4”
Reduction MF 3/8”x1/4”
Fitting D MF 1/4”
Throttle cock MF 1/4”
O-ring
3
3
3
1
1
1
1
1
1
1
1
1
3
3
3
Paint reducer air pipe
1
1
1
Manometer reducer pipe
3
1
3
3
Rapid revolving connector L
1/4”x4
1
1
31
32
33
34
35
36
37
38
56
Fitting L MM 1/4”
Extension MF 1/4”
Air pressure reducer 1/4”
Nut
1
1
M215.04
M204.04
P123.00
2
1
3
4
M215.04
M204.04
P123.00
K311.62A
S401.00
1
1
3
4
M215.04
M204.04
P123.00
3
4
K311.62A
K311.62A
Re-cyle pipe
2 mt
1
S103.07N 2 mt
2 mt S103.07N
Suction pipe
T406.00
S455.07B
M801.03B
H261.03
1
1
2
1
T406.00
1
1
2
1
T406.00
S455.07B
M801.03B
H261.03
Pump feeding air pipe
Nipple 1/4”
1
S455.07B
M801.03B
H261.03
2
Contact spring
1
49
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.3.2 PUMP COD. 2301838
18 a
a) Exploded view parts. 18 in the following pages
50
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
7!2.).'
)NCORRECT MAINTENANCEꢅREPAIRꢃ
2ISK OF INJURY AND DAMAGE TO THE EQUIPMENTꢂ
œ 2EPAIRS AND PART REPLACEMENT MAY ONLY BE CARRIED OUT BY SPEꢃ
CIALLY TRAINED STAFF OR A 7!'.%2 SERVICE CENTERꢂ
œ "EFORE ALL WORK ON THE UNIT AND IN THE EVENT OF WORK INTERRUPꢃ
TIONSꢀ
ꢃ 3WITCH OFF THE ENERGYꢉCOMPRESSED AIR SUPPLYꢂ
ꢃ 2ELIEVE THE PRESSURE FROM THE SPRAY GUN AND UNITꢂ
ꢃ 3ECURE THE SPRAY GUN AGAINST ACTUATIONꢂ
œ /BSERVE THE OPERATING AND SERVICE INSTRUCTIONS WHEN CARRYING
OUT ALL WORKꢂ
3)()?ꢄꢄꢄꢌ?'"
2301838
Spare parts list
Pos
Description
Qty.
Code
1
ZIP52 PF pump
1
U551.AHSS1
see explod. view
2
3
Pump support
1
2
4
2
2
3
1
1
1
1
1
E3112.92
E111.92B
R211.07
Leg
4
Finned push rod
5
Air pressure reducer 1/4”
Pressure gauge
P123.00E
P936.00
6
7
Rapid revolving connector L 1/4”x8
Conical nipple 1/4”
Fitting T MFM 1/4”
Flexible pipe holder 1/2”x16
Cylindrical plug ½”
Cock MF 1/4”lever
M336.00
M205.04
M340.00
M208.04
M254.14A
M109.00
8
9
10
11
12
13
14
15
16
17
18
19
Re-cyle pipe
Suction pipe ST
Pipe
1
S401.00
T406.00
1
300 mm
S103.07N
M215.04
Fitting L MM 1/4”
Reduced nipple
Material filter
Nipple
1
1
1
1
M618.62
T4005.00ALS
M631.62
51
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2301838
Spare parts list
Pos
20
21
22
23
24
25
26
27
28
29
Description
Plug E.I. 1/4”
Fitting L MF 1/4”
TCEI M6x20 screw
Washer
Qty.
1
Code
M623.12
M213.04
K107.62
K505.62
K311.62
K166.62
K501.62
K302.62
K134.62
K564.72
1
4
8
Self-tightening nut
Vite TCEI M4x50
Washer
8
2
4
Nut
2
TCEI M6x55 screw
Contact washer
4
8
52
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.3.3 PUMP ZIP 52
53
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2301837
2301832
2301836
2301838
Spare parts list
Pos
Description
Suction manifold
Delivery manifold
Outer diaphragm disk
Diaphragm cover
Product diaphragm
Socket screw
Screw
Qty.
1
Code
F833.07G-A
F859.07G
F834.07D
F831.07G-A
G921.07B
K1076.62
K128.62
Code
F184.01
F185.01
F834.07R
F978.01
G921.07B
K142.62
K183.62
K311.62
K508.62
K1012.62
K1040.62
K1041.62
K1044.62
K311.62A
T6103.00
T6105.00
Y622.00A
Z535.00X
Z543.00A
B0177.14A
K564.72
-
Code
F188.03
F189.03
F834.07R
F192.03
G921.07B
K142.62
K142.62
K311.62
K508.62
K1012.62
K1040.62
K1041.62
K1042.03
K311.62
T6103.00
T6105.00
Y622.00A
Z535.00X
Z543.00A
-
Code
F184.01
F185.01
F834.07R
F978.01
G921.07B
K142.62
K183.62
K311.62
K508.62
K1012.62
K1040.62
K1041.62
K1044.62
K311.62A
T6103.00S
T6105.00
Y622.00A
Z535.00X
Z543.00A
B0177.14A
K564.72
-
1
2
3
1
2
4
2
5
2
7
4
8
8
9
Nut
24
16
1
K311.62
10
11
12
13
14
15
17
18
19
20
22
23
24
25
26
Washer
K508.62
Self-tapping screw
Screw
K1012.62
K1040.62
K1041.62
K1043.62
K311.62
4
Rivet
2
Screw
12
8
Nut
Motor
1
T6103.00
T6105.00
Y622.00A
Z535.00X
Z543.00A
B0177.14A
K564.72
Fluid valve unit
Lug
4
1
Cover plate
Cover round plate
Nipple
1
2
1
Contact washer
Ball guide insert
Washer
4
K564.72
-
2
F856.07D
K505.62
4
-
-
-
Reversing valve set ZIP52
Fluid service set
1
P4003.00
T9080.00B
T9083.00B
T9077.00
P4003.00
T9080.00B
-
P4003.00
T9080.00B
-
P4003.00
T9080.00B
-
1
Kit PE Diaphragms - Gasket
Product o-ring set
1
1
T9077.00
T9077.00
T9077.00
54
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.3.4 AIR MOTOR PUMP ZIP52
55
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
2301837,
2301832,
2301836
2301838
Spare parts list
Pos
Description
Qty.
Code
Code
Motor ZIP52 Without cycle counter
connection
1
T6103.00
T6103.00S
Motor ZIP52 With cycle counter
connection
1
T6103.00C
T6103.00G
1
Feeler pin
2
2
1
1
2
1
B0146.04
B0147.71
B0150.03
F194.91
F829.07
F830.07
B0146.04
B0147.71
B0150.03S
F194.91
2
3
4
5
6
Inner diaphragm disk
Shaft
Cover (pressure side)
Bushing guide rod
Cover (discharge side)
Motor block with safety valve
T6103.00,T6103.00S
T6103.00C,T6103.00G
Reversing valve gasket
Pressure cover gasket
Silencer
F829.07
F830.07
7
1
1
1
1
1
4
6
2
2
1
1
1
1
1
T6103.00A
T6103.00F
G925.06
G7020.06
H618.07
K1038.62
K1039.62
L470.06
T6103.00A
T6103.00F
G925.06
G7020.06
H618.07
K1038.62
K1039.62
L470.06
8
9
10
11
12
13
14
15
16
17
18
19
Screw
Screw
Lip gasket
Lip gasket
L471.06
L471.06
Reversing valve
Safety valve
P4003.00 (*)
(**)
P4003.00 (*)
(**)
Side plate
Z546.00
K174.62
K535.07
Z546.00
K174.62
K535.07
Screw (T6103.00C o T6103.00G)
Washer(T6103.00C o T6103.00G)
(*) The spare part includes the reversing valve gasket code G925.06
and pressure cover gasket code G7020.06
(**)
Not available separately. See pos. 7
56
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.3.5 FINE FLOW CONTROLLER T0180.00A,T0180.00AI
57
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
T0180.00A,
T0180.00AI
Spare parts list
Pos
Description
Qty.
Code
1
2
Paint diaphragm disk
Air diaphragm disk
1
1
A588.03
A590.03
3
4
Ball guide body
1
B0172.03
Reducer body – fluid side
T0180.00A
T0180.00AI
1
1
B0180.01
B0180.03
5
6
7
8
9
Valve stem
1
1
1
1
1
1
1
1
1
1
6
1
6
1
1
1
1
B391.03
B563.01
T6007.00A
F991.07
F992.07
G725.05
G726.06
G640.05B
H285.03
K311.62
K515.62
K811.03
K1055.62
L148.06
Reducer body – air side
Complete ball seat body
Lockring
Cup
10 PTFE paint pressure reducer diaphragm
11 Paint pressure reducer diaphragm
12 Gasket
13 Conical spring
14 Self-tightening nut
15 Washer
16 Ball 1/4”
17 TCEI M5x30 screw
18 O-ring
19 O-ring
L118.06A
T500.00A
T9086.00
20 Filter with collar
Service set FFC pos. 10-11-12-16-18-19
58
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.3.6 MATERIAL FILTER 1/2 ALUMINIUM COD.T4005.00ALS (FOR 2301838)
59
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
T4005.00ALS
Spare parts list
Pos
Description
Qty.
1
Code
1
Filter body
B0259.01
B0127.01
T454.00
H282.03
H1152.03
B0128.03
G605.07
2
3
4
5
6
7
Filter cover
1
Tank filter
1
Stainless steel spring
Filter tie rod
1
1
Filter lockring
Tank seal Joint reservoir
1
1
60
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
8.3.7 SUCTION PIPE + RE-CYCLE PIPE COD. T406.00,T406.00A
10
10
61
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
T406.00,
T406.00A
Spare parts list
Pos
Description
Suction pipe spring
Filter disk
Qty.
Code
1
2
3
4
1
1
2
H206.03
H401.07
R601.00
Hose clamp
Solvent resistant Suction tube
T406.00 (3811721) (L=900 mm)
T406.00A (3811722) (L=1200 mm)
1
1
S402.06A
S402.06C
5
6
7
8
9
Metal suction pipe
1
1
1
1
1
2
1
1
4
S637.03
T453.03
F141.07
T404.00
T420.00
E0107.03
T406.00
S401.00
R602.07A
Suction pipe filter
ST Suction pipe cup
Suction pipe ST - stiff part
Suction pipe ST - complete metallic part
10 Contact clip
56 Suction pipe
57 Re-cycle pipe
58 Plastic clamp
62
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
63
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
64
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
9 EUROPEAN SERVICE NETWORK
A
J.Wagner Ges.m.b.H.
Ottogasse 2/20
2333 Leopoldsdorf
Österreich
Tel. +43/ 2235 / 44 158
Telefax +43/ 2235 / 44 163
DK Wagner Spraytech
Scandinavia A/S
Helgeshøj Allé 28
2630 Taastrup
GB Wagner Spraytech (UK) Limited
The Coach House
2 Main Road
Middleton Cheney OX17 2ND
Great Britain
UK-Helpline 0844 335 0517
5 p per minute (landline)
Denmark
Tel. +45/43/ 27 18 18
Telefax +45/43/ 43 05 28
B
Wagner Spraytech
Benelux b.v.
E
Wagner Spraytech Iberica
S.A.
I
Wagner Colora
Via Fermi, 3
Veilinglaan 56
1861 Meise-Wolvertem
Belgium
Tel. +32/2/269 46 75
Telefax +32/2/269 78 45
P.O. Box 132, Crta. N-340
08750 Molins de Rey
Barcelona / Espania
Tel. +34/93/6800028
Telefax +34/93/66800555
20040 Burago di Molgora (MI)
Italia
Tel. +39/ 039 / 625 021
Telefax +39/ 039 / 685 18 00
CH Wagner International AG F
Industriestrasse 22
J.Wagner France S.A.R.L
Parc de Gutenberg - Bâtiment F
8 voie la Cardon,
NL Wagner Spraytech Benelux
b.v.
9450 Altstätten
Zonneban 10,
Schweiz
91127 Palaiseau Cedex
France
Tel. +33/1/825 011 111
Telefax +33/1/698 172 57
3542 EC Utrecht
Netherlands
Tel. +31/ 30/241 41 55
Telefax +31/ 30/241 17 87
Tel. +41/71 / 7 57 22 11
Telefax +41/71 / 7 57 22 22
D
J.Wagner GmbH
Otto-Lilienthal-Straße 18
D-88677 Markdorf
CZ Wagner, spol. s r.o.
Nedasovská str. 345
155 21 Praha 5 -Zlicín
Czechia
S
Wagner Spraytech
Scandinavia A/S
Helgeshøj Allé 28
2630 Taastrup
Postfach 11 20
D-88669 Markdorf
Deutschland
Tel.: +49 / 75 44 / 505 - 664
Fax: +49 / 75 44 / 505 -155
Tel. +42/ 2 / 579 50 412
Telefax +42/ 2 / 579 51 052
Denmark
Tel. +45/43/ 21 18 18
Telefax +45/43/ 43 05 28
65
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
66
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ZIP52 FINISHING - PF .
EDITION 01 /2010
PART NO. ZZB012ENG
OPERATING MANUAL
67
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