HIGH PERFORMANCE AIRLESS SPRAYER OWNER'S MANUAL
Easy Does It From Set Up to Clean Up

Read Warnings

Assemble Cart

Attach Tip to Gun

Attach Return Hose

Attach Paint Hose

Prepare to Prime

Attach Suction Set

Prime Pump

Set Pressure

Short Term Storage

Clean Up

Questions?. Need Help?
Wagner maintains a toll-free help line for you should you have any comments or problems with this Wagner product. Call us first.for answers fast.
Wagner Technical Service 1-800-328-8251 Hours: Weekdays: 8:00 - 4:30 Central Time Weekends: 9:00 - 4:00 Central Time

Maintenance

Optional Hopper Accessory

PRINTED IN THE U. S. A.

Form No. 0270993-11/93

CONTENTS

General Description.. 2 Safety Precautions.. 3-6 Extension Cord... 7 Grounding Instructions... 7 Pressure Relief Procedure.. 8 Set Up... 9-11 Priming... 12-14 Spraying... 15-18 Short Term Storage.. 19 Cleanup and Long Term Shutdown. 20-22 Maintenance... 23, 24 Optional Hopper... 25 Trouble Shooting.. 26, 27 Parts Lists... 28-30 Accessories List... 31 Warranty... Back Cover

Components:

The shipping carton for your 505 Painting System contains the following components: Cart frame with wheels, motor and pump attached. Cart handle Spare Outlet Spring, P/N 0047485 Pail bracket/cart foot Spare Tip Seal , P/N 0156713 Suction set and return tube Return tube fitting , P/N 0088715 Spray gun and filter Operators manual Spray tip and gasket Three bolts, washers and wing nuts ARE LOCATED IN THE 25-foot 3/16-inch higher pressure hose
LITERATURE SET WITH REGISTRATION CARD

General Description

The Wagner 505 High Performance Airless Sprayer is a precision power tool used for spraying many types of materials. It is a relatively simple machine to operate, however, a basic understanding of its components is necessary. Read and follow this instruction manual carefully for proper operating instructions, maintenance and safety information.

Specifications

Weight:... 27 lbs. (12 kg ) Capacity:.. Up to 1/3 gallon (1-1/4 liters) per minute Power Source:.. 1/3 HP Electric Motor, totally enclosed, fan cooled. Power Requirement:.. 15 amp minimum circuit on 115 VAC, 60 HZ current. Generator 15 amp A/C. Spraying Pressure:.. Up to 2,500 psi. Safety Features:. Spray gun safety lock and pressure diffuser; built-in tip safety guard; priming knob for safe pressure release. Portability:. Compact design, light weight for easy movement. Capability:.. Sprays a variety of paints, oil base, latex, primers, stains, preservatives and other nonabrasive materials, including pesticides and liquid fertilizers. 2
Hydraulic Pump Pressure Control Knob Priming Knob Paint Block Paint Hose On/Off Switch Spray Gun Suction Set
Figure 1 Wagner 505 Airless Sprayer

SAFETY PRECAUTIONS

This manual contains information which must be read and understood before using the equipment. When you come to an area which has one of the following symbols, pay particular attention and make certain to heed the safeguard.

WARNING

Important safety information indicates a hazard which may cause serious injury or loss of life.

CAUTION

Important information that tells how to prevent damage to equipment or how to avoid causes of minor injuries. Notes: Gives important information which should be given special attention.
THIS UNIT IS PROVIDED WITH A THERMALLY PROTECTED AUTOMATIC RESET. IF AN OVERLOAD OCCURS THE THERMALLY PROTECTED AUTOMATIC RESET DISCONNECTS THE MOTOR FROM THE POWER SUPPLY. Motor will restart without warning when protector automatically resets. Always disconnect motor from power supply before working on equipment. When thermally protected automatic reset disconnects the motor from the power supply, relieve pressure by turning priming valve to "prime" A. Turn ON-OFF switch OFF. CAUTION: THE CAUSE OF THE OVERLOAD SHOULD BE CORRECTED BEFORE RESTARTING. (SEE TROUBLE SHOOTING )

HAZARD

Injection Injury - A high pressure stream of paint produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation.

PREVENTION

Maximum operating range of the gun - 2500 PSI fluid pressure. NEVER aim the gun at any part of the body. NEVER allow any part of the body to come in contact with the fluid stream. DO NOT come in contact with a fluid stream created by a leak in the fluid hose. NEVER put hand in front of the gun. Gloves will NOT provide protection against an injection injury. ALWAYS lock the gun trigger,shut fluid pump off and release all pressure before servicing, cleaning tip guard, changing tips, or leaving unattended. Simply turning off the electrical power will not release pressure in the system. The Prime Spray Valve must be turned to the prime A position to relieve the pressure. ALWAYS have the tip guard in place while spraying. The tip guard provides some protection against injection injuries but is mainly a warning device. ALWAYS remove spray tip before flushing or cleaning the system. Refer to Cleaning Instructions.
DO NOT TREAT AS A SIMPLE CUT! Injectioncan lead to amputation. See a physician immediately. NOTE TO PHYSICIAN: Injection into the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. DO NOT delay treatment to research toxicity. Toxicity is a concern with some coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.
Paint hose can develop leaks from wear, kinking, abuse etc. A leak is capable of injecting material into the skin. The paint hose should be inspected before each use. NEVER use a spray gun which does not have a trigger lock and trigger guard in place and in working order. All accessories must be rated at or above 2500 P.S.I. (Includes spray tips, guns, extensions, and hose). In case of skin injection see physician immediately.
Explosion or fire - Solvent and paint fumes can explode or ignite, causing property damage and or severe injury.
Exhaust and fresh air introduction must be provided to keep the air within the spray area free from accumulation of flammable vapors. Avoid all ignition sources such as static electricity sparks, open flames such as pilot lights, hot objects such as cigarettes, and sparks from connecting and disconnecting power cords and working light switches. Fire extinguishing equipment must be present and in working order. Keep the pump away from spray area to avoid solvent and paint fumes. The pump contains arcing parts which emit sparks. Do not spray paints and other inflammable fluids which have a flashpoint below 21 C (70 F). (Flashpoint is the temperature at which a fluid begins giving off a sufficient amount of flammable vapor that could ignite when exposed to a flame or spark.) High velocity flow of material through equipment may develop static electricity. The equipment being used, and objects in and around the spray area must be properly grounded to prevent static discharge and sparks. Use only conductive or grounded high pressure fluid hoses for airless applications. Be sure that gun is grounded through hose connections. Power cord must be connected to a grounded circuit. (See proper grounding instructions.) Follow the material and solvent manufacturer's safety precautions and warnings. WHEN FLUSHING EQUIPMENT use lowest possible pressure.

Explosion hazard incompatible materials - May cause property damage or severe injury.
DO NOT USE BLEACH. DO NOT use halogenated hydrocarbon solvents. Halogenated hydrocarbon solvents such as methylene chloride and 1,1,1 - Trichlorethane are not compatible with aluminum and may cause an explosion. If unsure of a materials compatibility with aluminum, contact your coatings supplier.
Hazardous vapors - Paints, solvents, insecticides, and other materials may be harmful if inhaled causing severe nausea, fainting, or poisoning.
Use a respirator or mask whenever there is a chance that vapors may be inhaled. Read all instructions with the mask to insure that it will provide the necessary protection against the inhalation of harmful vapors.
General - May cause property damage or severe injury.
Read all instructions and safety precautions before operating. Comply with all appropriate local, state and national codes governing ventilation, fire prevention, and operation. The United States Government Safety Standards have been adopted under Occupational Safety and Health Act. These standards, particularly the General Standards, Part 1910 and construction Standard, Part 1926, should be consulted. This high pressure airless pump is designed to be used with authorized parts only. When using this pump with parts that do not comply with the minimum specifications and safety devices of the pump manufacturer, the user assumes all risks and liabilities. Before each use, check all hoses for cuts, leaks, abrasion or bulging of cover or damage or movement of couplings. If any of these conditions exist, replace the hose immediately. Never repair a paint hose. Replace it with another grounded hose. All hoses, swivels, guns, and accessories used with this unit must be pressure rated at or above 2500 PSI. DO NOT spray on windy days.

Extension Cord

Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that will accept the plug on the product. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A 14 or 12 gauge cord is recommended. This product is for use on a nominal 120 volt circuit, and has a grounding plug that looks like plug illustrated in Figure 2 (A) below. A temporary adapter which looks like the adapter illustrated in Figure 2 (B) and (C), may be used to connect this plug to a 2 pole receptacle as shown in Figure 2 (B) if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet as shown in Figure 2 (A) can be installed by a qualified electrician. The green colored rigid ear lug, or the like extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box cover. Whenever the adapter is used, it must be held in place by a metal screw.

Pail Bracket

Bolt, washer and wing nut
Figure 3A - Attaching Pail Bracket
2. Attach cart handle (3). Face the hose hook toward the front of the unit. Use two bolts, washers and wing nuts (4), tightening securely. See Figure 3B.

Cart Handle

Figure 2 Cart Assembly Diagram
Figure 3B - Attaching Cart Handle

ATTACH TIP TO GUN

1. Lock gun. See Figure 4.

Locked Position

Unlocked Position
3. Check seal alignment by removing tip and inspecting tip guard visually, See Figure 6. If needed, remove seal (3) and replace until properly aligned. Replace tip to spray position, (arrow away from gun). Insert red seal (4).
Figure 4 - Gun in Locked & Unlocked Position
Correct Way 2. If spray tip is not pre- assembled, (See Figure 5) insert tip (1) into tip guard, (2) and turn 90 counterclockwise to spray position (arrow pointing away from gun). Cylinder of tip forms a stop for the seal (3). Insert seal (3) aligning the curve of the seal with the curve of the tip. Red Seal 1 4

Wrong Way

Figure 6 - Spray Tip Assembly
4. Attach spray tip to gun. Tighten nut first by hand, then tighten with a wrench. See Figure 7.
Figure 7- Attach Tip to Gun Figure 5 Spray Tip Assembly
NOTE: When attaching tip to gun, align tip guard as
shown in Figure 8. Then tighten with wrench.
INJECTION WARNING POSSIBLE not spray withHAZARD. Do out tip guard in place. Never trigger gun unless tip is in the spray or unclog position. Always engage trigger lock before removing, replacing or cleaning tip.
Figure 8 - Vertical Tip Pattern
ATTACH RETURN HOSE ATTACH PAINT HOSE
1. Be sure motor switch is turned OFF. 2. Screw brass fitting of return tube into upper port on side of pump. (The brass fitting is located in the literature set.) Tighten firmly by hand. See figure above. 3. Press return tube (small tube) to brass fitting and fasten with clamp. See Figure 9.
1. Attach high pressure hose to hose port, using an adjustable wrench to tighten firmly. (See illustration above.) 2. Attach gun to other end of high pressure hose. Tighten securely with two adjustable wrenches. See Figure 10.
Figure 10 - Attaching High Pressure Hose to Gun. Figure 9 - Fastening Return Tube with Clamp
3. Plug unit into a properly grounded outlet or heavy duty grounded extension cord. Do not use more than 100 feet of cord. If you must spray a long distance from a power source, use more paint hose, not more extension cords. Use a minimum size of 16 gauge electric cord for 50 feet; 12-14 gauge for 100 feet.

PRIMING

PREPARE TO PRIME
1. Lay unit back on its handle so inlet valve is facing up. Fill inlet valve with water or light household oil. 2. Make sure Prime/Spray Knob is in Prime A position and Pressure Knob is turned to the lowest pressure. (Counter clockwise) See Figure 11. Turn unit on. Inlet Valve Facing Up PrimeA /Spray B Knob Hose Port

4. Force the inlet valve to open and close by pushing on it with the eraser end of a pencil or screwdriver, it should move up and down about 1/16 inch. Continue until water or oil is sucked into unit. This will assist in wetting the moving parts and breaking loose any old paint residue. See Figure 13.
Figure 13 - Opening Inlet Valve Figure 11 - Prime/Spray Knob
3. Increase pressure half turn. Pressure Control Knob
5. Put palm of hand over inlet valve and feel for a slight suction while increasing the pressure control to the maximum setting. See Figure 14. If suction is felt go to step 6. If no suction is felt see Cleaning and Servicing Outlet Valve. ( Repeat steps 1 through 5 if necessary.)
Figure 14 - Checking for Suction Figure 12 - Pressure Control Knob
6. Turn Pressure Control Knob to minimum pressure and shut off unit. 7. Return unit to upright position. 12
ATTACH SUCTION SET PRIME THE PUMP
1. Attach Suction Tube to inlet valve and tighten firmly by hand. See Figure 15. Be sure threads are straight so the fitting turns freely without binding. (Do Not cross thread)
1. Make sure the PRESSURE CONTROL KNOB is at its lowest setting (counterclockwise). See Figure 18.

Pressure Control Knob

Figure 15 - Attaching Suction Tube
2. Place suction tube and return tube in paint. See Figure 16.
Figure 18 - Set Pressure Control Knob
2. Turn PRIMING KNOB to Prime A position. See Figure 19.
Figure 16 - Place Suction Tube and Return Tube in Paint.
3. Set paint bucket onto pail bracket and attach handle. See Figure 17.

Prime A Spray B Knob

Figure 19 - Priming Knob Setting Figure 17 - Attaching Paint Pail Handle

PRIME THE PUMP

Continued from page 13
3. TURN SPRAYER ON. 4. Turn PRESSURE CONTROL KNOB between half and full pressure. See Figure 20. You should then be able to see the paint move through the suction tube to the pump. Continue until paint flows through the return tube. (Let unit prime 1 to 2 minutes). Always reduce pressure to zero before changing the position of the priming knob. Failure to do so may cause damage to the paint pump diaphragm.
If the Pressure Control Knob is reduced to zero and the Priming Knob is still on spray during sprayer operation, there will be high pressure in the hose and spray gun until the Priming Knob is turned to PRIME A or until the spray gun is triggered to relieve the pressure.

Figure 20 - Turn Pressure Control Knob

SPRAYING

PRACTICE FIRST
1. Be sure paint hose is free of kinks and clear of traffic or objects with sharp cutting edges. 2. Return PRESSURE CONTROL KNOB to its lowest setting (counterclockwise). Figure 21.
Figure 23 - Practice on scrap material.
5. Unlock SPRAY GUN TRIGGER LOCK by turning lock down toward the bottom of the handle. Figure 4 6. Trigger spray gun to bleed air out of hose. 7. When paint reaches spray tip, spray a test area to check spray pattern. See Figure 23.
Figure 21 - Pressure Control Knob Setting
3. Turn PRIMING KNOB to SPRAY B position. Figure 22.
8. Use the lowest pressure setting necessary to get a good spray pattern. If pressure is too high, material is over-atomized. If pressure is too low, tailing will appear or paint will spatter out in gobs rather than in a fine spray. See Figure 24. Most latex paints and stains will require very high pressure, which is why the sprayer is built to deliver up to 2,500 psi when needed.

PrimeA Spray B Knob

GOOD SPRAY PATTERN Figure 22 - Priming Knob Setting
4. Turn PRESSURE CONTROL KNOB completely clockwise to maximum pressure, Figure 21. Paint should then begin to flow into the paint hose, causing it to stiffen.
Figure 24 - Paint Tailing Pattern

SPRAYING TECHNIQUE

1. The key to a good paint job is an even coating over the entire surface. With spray painting, this is done by using even strokes, with your arm moving at a constant speed and keeping the spray gun a constant distance from the surface. 2. In most cases, the best spraying distance is 10 to 12 inches between the spray tip and the surface. 3. As much as possible, keep the spray gun at right angles to the surface. This means moving your entire arm back and forth rather than just flexing your wrist. See Figures 25 and 26. 4. Keep the spray gun perpendicular to the surface, otherwise one end of the pattern will be thicker than the other. See Figure 27.
Even Coat on Work Throughout
Approximately Approximatley 10 to 12 Inches 10 to 12 Inches

Right Way To Spray

Steady Arm
Figure 26 - Result of smooth arm stroke and steady, even speed while spraying.
Approximately 10 to 12 Inches

Right Way

Figure 25 - Result of Flexing Wrist While Spraying
Figure 27 - Right and wrong ways to hold spray gun toward work.
5. The spray gun should be triggered off at the end of each stroke and on again at the beginning of the next. This avoids paint buildup at the end of the stroke which may result in runs and sags. Triggering at the end of the stroke also saves paint and results in a better looking job. See Figure 28.

If Spray Tip Becomes Clogged
The spray gun is equipped with a reversible tip which enables you to quickly and effectively blow out any particles of old paint or other contaminants that may obstruct the paint flow through the tip. If the spray pattern becomes distorted or stops completely while the gun is triggered on, follow these steps. 1. Release the trigger and put on the safety lock. See Figure 4. 2. Rotate the reversible tip cylinder arrow 180 so the point of the arrow is toward the rear of the gun. Figure 29.
Even Steady Stroke Start Stroke Pull Trigger End Stroke Release Trigger
Figure 28 - Proper Way to Trigger Spray Gun
6. Overlap each stroke by about 30%. This will assure a paint coating that is uniform across the work. One way to do this is to point the spray tip at the edge of the last stroke before triggering the gun on. 7. When taking a short break from painting (up to 1 hr.), lock the spray gun trigger OFF, reduce pressure to its minimum (zero) setting and set the unit to prime A. Turn sprayer off and unplug. Refer to Pressure Relief Procedure. 8. If you expect to be gone more than 1 hour follow the short term clean up procedure.

Figure 29 - Reverse Tip

3. Unlock the trigger and squeeze it open, pointing the gun at a scrap piece of wood or cardboard. This allows pressure in the paint hose to blow out the obstruction. When the nozzle is clean, paint will come out in a straight, high pressure stream. 4. Release the trigger and re-lock it. Figure 4 5. Reverse the tip so the arrow points forward again. 6. Unlock the trigger and resume spraying. 17

Continued from page 17

Cleaning The Spray Gun Filter
The spray gun includes a filter to catch particles before they reach the spray tip. If this filter becomes clogged or obstructed it will reduce the flow of paint, changing the spray pattern and possibly damaging the filter. This filter must be cleaned at least daily and perhaps even every four hours with certain types of latex materials.
6. Insert the top of the filter (Figure 30) into the gun body fitting under the tip of the spray gun. See Figure 31.
Spring If the filter is not cleaned at the proper time, it will plug from the top down. When there is about 1 inch of filter that isn't plugged, the heavy flow of paint will blow pin holes in the filter. See Figure 30. This in turn will allow unwanted particles to get into the spray tip, causing spray tip to clog. Gun Body Fitting Sealing Washer

Filter

Filter Housing

Top of Filter

Figure 31 - Gun Filter Cleaning.
7. Replace the spring and sealing washer into the base of the filter housing. 8. Slide the filter housing over the filter and tighten it securely to the gun, using a wrench. 9. Reattach the hose, tightening it securely with two wrenches.
Figure 30 - Gun Filter Cleaning.

Pin Hole

To clean the filter during the painting process: 1. Turn spray PRESSURE CONTROL KNOB to minimum setting and turn PRIMING KNOB to PRIME A. This will bleed off the pressure in the paint hose and filter. Trigger gun to be sure pressure is gone. Refer to Pressure Relief Procedure. 2. Remove spray gun from hose using two adjustable wrenches. See Figure 10 3. Unscrew filter housing, using adjustable wrench on the nut at the bottom of the housing. 4. Remove filter being sure not to lose the spring and sealing washer which is located in the bottom of the filter housing. 5. Clean filter thoroughly (or put in a new filter). To clean the filter, swish it in water or the type of solvent appropriate to the paint you are using. If this isnt sufficient, use a natural or nylon bristle brush dipped in the appropriate solvent or water. Do not use a wire brush or any sharp instrument. 18
10. Turn PRIMING KNOB to SPRAY B , (Figure 10) increase pressure to its previous setting and resume spraying.

Suction Set Screen

The screen at the bottom of the suction set may also need cleaning periodically. Check it every time you change paint buckets. Remove screen by pulling it out of the retainer with a pliers. Clean the screen with water or solvent and a soft-bristle brush, if needed.
Figure 32 - Remove And Clean Screen

CLEAN UP

SHORT-TERM/OVERNIGHT STORAGE
Shut-down 1. Lock the gun and reduce the pressure. Turn the sprayer to prime A and shut it off. Unplug sprayer. Leave the suction set in the paint. Refer to Pressure Relief Procedure. 2. For latex materials only, pour 1/2 cup water slowly on the top of the paint to prevent the paint from drying. For other materials, seal the paint container with a piece of plastic while the suction tube is still in the paint. See Figure 33.
Start-up 1. Remove the gun from the plastic bag. 2. Stir the water into the paint for latex materials. Remove the seal from the paint bucket and stir the paint for all other materials.
Figure 35 - Stir Material Before Spraying

14. Clean spray tip and gun filter with a soft brush. Reassemble spray tip in cleaning position. (Arrow points to back of the gun.)
16. Turn the unit on and unlock gun trigger. Turn to Spray B and point gun to side of cleaning bucket.
Figure 41 - Cleaning Bucket
17. Trigger gun and gradually turn pressure knob clockwise to 1/2 pressure. Continue for approximately 30 seconds. 18. Release and lock trigger, reduce pressure, turn to prime A. Turn unit off. 19. Remove tip assembly. Raise the suction set above the cleaning solution. Turn unit on, turn to spray B increase pressure and allow suction tube to run dry. 15. Attach paint hose to gun,tighten with two wrenches. 20. Remove large suction tube from inlet valve, See Figure 42 and point gun into cleaning bucket, See Figure 41. Reduce pressure about 1/2, unlock gun, trigger gun until hose is pumped dry.
Figure 40 - Attach Paint Hose to Gun
Figure 42 - Removing Large Suction Tube
21. Lock gun, reduce pressure and turn Prime/Spray Knob to prime A. 22. Lay unit back on handle so inlet valve is facing upward. Clean threads of inlet valve with a damp cloth. Fill inlet valve with light household oil. See Figure 43. Slowly increase pressure to distribute the oil through the pump. Turn Prime/Spray Knob from prime A to spray B to distribute oil. Replace large suction tube to inlet valve.
23. Turn Prime/Spray Knob to prime A , reduce pressure, shut sprayer off. Unplug sprayer. Refer to Pressure Relief. 24. Remove and clean suction set filter in clean water or solvent with soft brush. Reassemble.
Figure 43 - Fill Inlet Valve With Oil
Figure 44 - Remove And Clean Filter

IMPORTANT!

Proper cleaning and oiling of the pump after use are the most important steps you can take to insure proper operation after storage.
25. Wipe entire unit, hose and gun with a damp cloth to remove accumulated paint.

MAINTENANCE

CLEANING VALVES
Follow these procedures when encountering problems indicated in the trouble shooting section.
NOTE: The inlet valve must be oiled after every job. This will reduce or eliminate priming problems the next time the sprayer is used. See Figure 43. 4. Thoroughly clean the valve assembly with solvent and brush. 5. A properly seated valve filled with water and held vertically will not drip out the bottom of the valve. If you have properly cleaned the valve and water drips out the bottom, the valve is worn and needs to be replaced. 6. Install cleaned or new valve in the pump block and then fill the valve with light oil or solvent. 7. If none of the above steps work, see Troubleshooting.
Removing and Cleaning Inlet Valve
1. Be sure sprayer is off. 2. Using a 27 millimeter socket or box end wrench, remove the inlet valve assembly. Remove Inlet Valve
Cleaning and Servicing Outlet Valve
Figure 45- Removing Inlet Valve

OPTIONAL HOPPER ASSEMBLY

CONVERTING SPRAYER FOR HOPPER OPERATION
The hopper assembly consists of the hopper, hopper return tube and hopper screen. To make the conversion: 1. Remove suction tube and return tube and brass return tube fitting from the unit. 2. To convert the cart into its horizontal configuration as shown in Figure 49, reverse the positions of the handle and pail bracket. 3. Screw the hopper directly onto the inlet valve where the suction tube was removed. Make the connection hand tight, just tight enough to prevent paint leakage or air suction around the threads. Hopper Return Tube
4. Screw in the plastic return tube fitting into the paint pump port that the brass fitting was removed from. Attach hopper return tube to the fitting where the suction set return tube was removed. The connection needs to be only hand tight. 5. Fit the hopper screen into the bottom of the hopper, being sure it is properly seated.
NOTE: The hopper screen is essential to trap debris and other foreign objects from entering the pump. Do not operate the sprayer without the screen properly in place.

Cleaning Hopper Unit

To clean the hopper unit: Hopper 1. Flush the pump and hose with water or solvent following the same procedure as with the suction tube, being sure the return tube is thoroughly flushed out. 2. Clean the hopper screen with water or appropriate solvent. If necessary use a nylon or natural bristle brush dipped in solvent or soapy water. 3. Wash the hopper thoroughly using soapy water for latex paint, the appropriate solvent with other materials.
Figure 49 - Optional Hopper

TROUBLE SHOOTING

Problem
Sprayer does not start up.
Sprayer not plugged in. ON/OFF switch OFF. Blown fuse in circuit. No voltage or low voltage at wall plug. Unit turned off under pressure. Damaged motor cord or extension cord, or capacity too low. Thermal overload tripped Motor problem. Unit will not prime or has lost prime. No paint. Suction tube not totally immersed in paint. Suction set filter clogged. Hopper screen clogged Suction tube loose at inlet valve. Inlet valve stuck. Outlet valve stuck. Prime spray valve plugged or dirty. Inlet valve worn or damaged. Diaphragm problem. Hydraulic oil level low or empty. Worn spray tip Suction set filter clogged. Optional hopper screen clogged. Gun or spray tip filter plugged.

Remedy

Plug in. Flip switch to ON. Replace fuse. Test power supply voltage. Turn Prime/Spray Knob to Prime position. Replace extension cord. Allow motor to cool,move to a shady spot. Take to Wagner Authorized Service Center. Reprime Unit. Immerse suction tube in paint. Clean filter. Clean screen. Clean connection and tighten. Clean inlet valve. Clean outlet valve. Replace any worn parts. Take to Wagner Authorized Service Center. Clean or replace. Take to Wagner Authorized Service Center. Take to Wagner Authorized Service Center.

Never remove these four bolts! Take to an Authorized Wagner Service Center.
Parts Diagram Paint Pump Assembly
ITEM PART NO. DESCRIPTION Valve, Inlet Assembly (includes item 12) Cap, Outlet Assembly Washer, Sealing, Copper Spring, Outlet Ball, 6mm, Carbide Seat, Ball, Outlet Assembly QTY. ITEM PART NO. DESCRIPTION 0288172 Seal, Outlet Fitting, Outlet Fitting, Return Tube Knob Only Paint Pump with Valve Washer, Sealing, Nylon Repair Kit Replaces both Holder & Seat QTY. 1
Parts Diagram Suction Set Assembly 0270174
ITEM PART NO. DESCRIPTION Suction Tube Complete (Includes Items 2 thru 10) Nut, Suction Elbow, Adapter, 3/4" x 1" Ring, Snap Clamp Hose, Suction QTY. ITEM PART NO. DESCRIPTION Housing, Filter Filter Washer Fitting, Return Hose Clamp Tubing, Return QTY. 1 1
Parts Diagram Optional Hopper Assembly
ITEM 3 PART NO. DESCRIPTION Hopper, Complete (lncludes ltems 2 thru 7) Hopper Filter Screen, Fine (Shown) Filter Screen, Coarse QTY. 1 ITEM PART NO. DESCRIPTION Return Tube Assembly (lncludes ltems 5 & 6) Return Tube Fitting Cover, Hopper QTY. 1 1

Accessories

Part Number Description Part Number 31 Description
Hose, 25' x 3/16", Grounded Hose, 50' x 3/16', Grounded Hose Connector G-09 Spray Gun G-10 Spray Gun Gun Filter Assembly Gun Filters, Medium/Fine Adjustable Tip
Reversible Tip (light), Stains Reversible Tip (Medium), Enamel Reversible Tip (Heavy), Latex Reversible Tip Repair Kit Roller Cover, 9" x 3/8" Nap Roller Cover, 9" x 3/4" Nap Hydraulic Oil (quart) Hydraulic Oil (gallon)

Parts and Accessories

PARTS LIST
Item Part No. Description G-06 Gun Assembly Filter Assembly (Includes Items 3,4,5,6) Spring Seal, Nylon Housing Filter Filter Item Part No. Description Guide, Hose Tip,.011 (Oil based materials) Tip,.013 (Oil based , latex paints and stains) Tip,.015 ( Extra thick materials) Tip, Body Seal Kit
Part Numbers may change without notice due to improvements and modifications.
LIMITED WARRANTY AIRLESS PAINT SPRAY EQUIPMENT
This product, manufactured by Wagner Spray Tech Corporation (Wagner), is warranted to the original retail purchaser against defects in material and workmanship for 30 days from date of purchase for professional/rental use if operated in accordance with Wagner's printed recommendations and instructions. This warranty applies for one year from date of purchase for home use. This warranty does not cover damage resulting from improper use, accidents, user's negligence or normal wear. This warranty does not cover any defects or damages caused by service or repair performed by anyone other than a Wagner Authorized Service Center. This warranty does not apply to accessories.

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO 30 DAYS FOR PROFESSIONAL/RENTAL USE AND ONE YEAR FOR HOME USE FROM DATE OF PURCHASE. WAGNER SHALL NOT IN ANY EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FROM BREACH OF THIS WARRANTY OR ANY OTHER REASON.
If any product is defective in material and/or workmanship during the applicable warranty period, return it with proof of purchase, transportation prepaid to any Wagner Authorized Service Center. (Service Center listing is enclosed with this product.) Wagners Authorized Service Center will either repair or replace the product (at Wagners option) and return it to you, postage prepaid. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION AND EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
Copyright Wagner Spray Tech Corporation,1993. All rights reserved, included right of reproduction in whole or in part, in any form. Printed in U.S.A.
Wagner Spray Tech Corporation 1770 Fernbrook Lane Minneapolis, Minnesota 55447 Telephone (612) 553-7000 33

MODELS 9140, 9140S, 9150, 9170, 9190 AND 9210 HIGH PERFORMANCE AIRLESS SPRAYER

OWNERS

MANUAL
THIS MANUAL FOR COMPLETE INSTRUCTIONS
This pump is available in two models: a stand model and a cart model. The cart model is shown in this manual. All information given for the cart model applies to the stand model except where indicated.

CONTENTS:

SAFETY. 2-3 COMPONENTS AND DESCRIPTION. 4 SETUP. 5 PLUGGING IN THE SPRAYER. 6 PRESSURE RELIEF PROCEDURE. 6 PURGING AND PRIMING. 7 SPRAYING. 8 SPRAYING TROUBLESHOOTING. 9 CLEANUP. 10-11 STORAGE. 12 MAINTENANCE. 13 ACCESSORIES. 13 FLUID SECTION. 14 TROUBLESHOOTING. 15 PARTS LIST. 48-51 WARRANTY. 52
Need help? Call us first for answers fast.
Call Wagner Spray Tech toll-free if you have any comments or problems with this product.

1-800-880-0993

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http://www.wagnerspraytech.com
1770 Fernbrook Lane, Minneapolis, MN 55447

SPECIFICATIONS:

Weight.. lbs lbs lbs lbs (9140S) (9140, 9150) (9170, 9190) (9210) Generator..15 amp A/C Spraying pressure.Up to 2800 PSI Safety features..Spray gun trigger lock and guard; built-in tip safety guard; priming knob for safe pressure release. Capability.Sprays a variety of paints, oil base, latex, primers, stains, preservatives and other nonabrasive materials. Do not use materials with flash points below 70F (21C).
Capacity..Up to.25 gallon (1 liter) per minute (9140, 9140S, 9150) Up to.33 gallon (1.25 liter) per minute (9170) Up to.42 gallon (1.6 liter) per minute (9190) Up to.45 gallon (1.71 liter) per minute (9210) Power source.1/2 Hp universal motor (9140, 9140S, 9150) 5/8 Hp permanent magnet DC motor (9170) 3/4 Hp permanent magnet DC motor (9190) 7/8 Hp permanent magnet DC motor (9210) Power requirement.15 amp minimum circuit on 115 VAC, 60 Hz current

Printed in the U. S. A.

This pump should not be used with textured materials, block filler, or asphalt sealer.

Form No. 0512731G

U.S. Patent No. 6,435,846

English

SAFETY INFORMATION
HAZARD: INJECTION INJURY A high pressure paint stream produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation. SEE A PHYSICIAN IMMEDIATELY. DO NOT TREAT AN INJECTION INJURY AS A SIMPLE CUT! Injection can lead to amputation. See a physician immediately. The maximum operating range of the gun is 2800 PSI/193BAR fluid pressure. PREVENTION: NEVER aim the gun at any part of the body. NEVER allow any part of the body to touch the fluid stream. DO NOT allow body to touch a leak in the fluid hose. NEVER put your hand in front of the gun. Gloves will not provide protection against an injection injury. ALWAYS lock the gun trigger, shut the pump off, and release all pressure before servicing, cleaning the tip or guard, changing tip, or leaving unattended. Pressure will not be released by turning off the motor. The PRIME/SPRAY knob must be turned to PRIME to relieve the pressure. Refer to the PRESSURE RELIEF PROCEDURE (page 6) described in the pump manual. ALWAYS keep the tip guard in place while spraying. The tip guard provides some protection but is mainly a warning device. ALWAYS remove the spray tip before flushing or cleaning the system. Paint hose can develop leaks from wear, kinking and abuse. A leak can inject material into the skin. Inspect the hose before each use. NEVER use a spray gun without a working trigger lock and trigger guard in place. All accessories must be rated at or above 2800 PSI/193 BAR. This includes spray tips, guns, extensions, and hose. NOTE TO PHYSICIAN: Injection into the skin is a traumatic injury. It is important to treat the injury as soon as possible. DO NOT delay treatment to research toxicity. Toxicity is a concern with some coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

READ ALL SAFETY

INFORMATION BEFORE OPERATING THE EQUIPMENT
HAZARD: EXPLOSION OR FIRE Solvent and paint fumes can explode or ignite. Property damage and/or severe injury can occur. PREVENTION: Provide extensive exhaust and fresh air introduction to keep the air within the spray area free from accumulation of flammable vapors. Avoid all ignition sources such as static electric sparks, open flames, pilot lights, electrical appliances, and hot objects. Connecting or disconnecting power cords or working light switches can make sparks. Do not smoke in spray area. Fire extinguisher must be present and in good working order. Place paint pump at least 20 feet from the spray object in a well ventilated area (add more hose if necessary). Flammable vapors are often heavier than air. Floor area must be extremely well ventilated. The paint pump contains arcing parts that emit sparks and can ignite vapors. The equipment and objects in and around the spray area must be properly grounded to prevent static sparks. Use only conductive or grounded high pressure fluid hose. Gun must be grounded through hose connections. Power cord must be connected to a grounded circuit. Always flush unit into a separate metal container, at low pump pressure, with spray tip removed. Hold gun firmly against side of container to ground container and prevent static sparks. Follow the material and solvent manufacturer's warnings and instructions. Use extreme caution when using materials with a flashpoint below 70 F (21 C). Flashpoint is the temperature that a fluid can produce enough vapors to ignite. Plastic can cause static sparks. Never hang plastic to enclose a spray area. Do not use plastic drop cloths when spraying flammable materials. Use lowest possible pressure to flush equipment. GAS ENGINE (WHERE APPLICABLE) Always place pump outside of structure in fresh air. Keep all solvents away from the engine exhaust. Never fill fuel tank with a running or hot engine. Hot surface can ignite spilled fuel. Always attach ground wire from pump unit to a grounded object, such as a metal water pipe. Refer to enigine owners manual for complete safety information.
HAZARD: HAZARDOUS VAPORS Paints, solvents, insecticides, and other materials can be harmful if inhaled or come in contact with the body. Vapors can cause severe nausea, fainting, or poisoning. PREVENTION: Use a respirator or mask if vapors can be inhaled. Read all instructions supplied with the mask to be sure it will provide the necessary protection. Wear protective eyewear. Wear protective clothing as required by coating manufacturer.
HAZARD: EXPLOSION HAZARD DUE TO INCOMPATIBLE MATERIALS Will cause property damage or severe injury. PREVENTION: Do not use materials containing bleach or chlorine. Do not use halogenated hydrocarbon solvents such as bleach, mildewcide, methylene chloride and 1,1,1 trichloroethane. They are not compatible with aluminum. Contact your coating supplier about the compatibility of material with aluminum.

1-800-880-Wagner Spray Tech - All rights reserved.
HAZARD: GENERAL Can cause severe injury or property damage. PREVENTION: Read all instructions and safety precautions before operating equipment. Follow all appropriate local, state, and national codes governing ventilation, fire prevention, and operation. The United States Government Safety Standards have been adopted under the Occupational Safety and Health Act (OSHA). These standards, particularly part 1910 of the General Standards and part 1926 of the Construction Standards should be consulted. Use only manufacturer authorized parts. User assumes all risks and liabilities when using parts that do not meet the minimum specifications and safety requirements of the pump manufacturer. Before each use, check all hoses for cuts, leaks, abrasion or bulging of cover. Check for damage or movement of couplings. Immediately replace the hose if any of these conditions exist. Never repair a paint hose. Replace it with another grounded high-pressure hose. All hoses, swivels, guns, and accessories must be pressure rated at or above 2800PSI/193 BAR. Do not spray outdoors on windy days. Wear clothing to keep paint off skin and hair.

GROUNDING INSTRUCTIONS

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

WARNING

Improper installation of the grounding plug can result in a risk of electric shock. If repair or replacement of the cord or plug is necessary, do not connect the green grounding wire to either flat blade terminal. The wire with insulation having a green outer surface with or without yellow stripes is the grounding wire and must be connected to the grounding pin. Check with a qualified electrician or serviceman if the grounding instructions are not completely understood, or if you are in doubt as to whether the product is properly grounded. Do not modify the plug provided. If the plug will not fit the outlet, have the proper outlet installed by a qualified electrician. This product is for use on a nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated below. Make sure that the product is connected to an outlet having the same configuration as the plug. No adapter should be used with this product. Grounded Outlet

IMPORTANT ELECTRICAL INFORMATION

CAUTION

Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that will accept the plug on the product. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A 14 or 12 gauge cord is recommended. If an extension cord is to be used outdoors, it must be marked with the suffix W-A after the cord type designation. For example, a designation of SJTW-A would indicate that the cord would be appropriate for outdoor use. Do not use more than 100 feet of hose. If you need to paint further than 100 feet from your power source, use more extension cord, not more paint hose.
Grounding Pin Cover for grounded outlet box
IF YOU EXPERIENCE PROBLEMS WITH YOUR SPRAYER AT ANY TIME DURING ASSEMBLY, OPERATION OR CLEANUP, PLEASE REFER TO
THE TROUBLESHOOTING SECTION OF THIS MANUAL (PAGE
15), OR CALL CUSTOMER SERVICE AT:
THE 9140, 9140S AND 9150 SERIES UNITS ARE PROVIDED WITH A NON-RESETABLE THERMAL OVERLOAD. THE 9170, 9190 AND 9210 SERIES UNITS ARE PROVIDED WITH A REPLACEABLE FUSE. Always disconnect the motor from the power supply before working on the equipment. The cause of the overload should be corrected before restarting. Take to Service Center.
2003 Wagner Spray Tech - All rights reserved. 1-800-880-0993
COMPONENTS AND DESCRIPTION

COMPONENTS

The shipping carton for your painting system contains the following: Suction set and return tube Spray gun with filter Spray tip assembly (see chart below) 25 foot long, 1/4 inch diameter pressure hose (9140, 9140S, 9150) 50 foot long, 1/4 inch diameter pressure hose (9170, 9190, 9210) Separating Oil sprayer model (refer to Spray Gun/Tip Chart, below). Spray Hose..The spray hose connects the gun to the pump. Return Tube..Fluid is sent back out through the return tube to the original container. PRIME/SPRAY Knob.The PRIME/SPRAY knob directs fluid to the spray hose when set to SPRAY or the return tube when set to PRIME. The arrows on the PRIME/SPRAY knob shows the rotation directions for PRIME and SPRAY. The PRIME/SPRAY knob is also used to relieve pressure built up in the spray hose (Pressure Relief Procedure, page 6) Pressure Control Dial.The pressure control dial controls the amount of force the pump uses to push the fluid (see graphic below for locations).

Return tube fitting Inlet valve Clip Return tube Suction set
ATTACHING THE PAIL BRACKET (CART MODELS)
1. Position the pail bracket against the unit so that the holes in the unit line up with the holes in the bracket. 2. Insert the bolts through the holes in the bracket and the unit. 3. Tighten the bolts with a 3/16 allen wrench.

LOCKING AND UNLOCKING

Always lock the trigger off when attaching the spray tip or when the spray gun is not in use. Refer to Spray Gun/Tip Chart on page 4 to determine the gun model you have.

GX-06/07

MODELS

GX-06 AND GX-07

The gun is secured when the trigger lock is at a 90 angle (perpendicular) to the trigger in either direction. Gun locked (gun will not spray)

PAINT HOSE

GX-08/10
1. Thread the high pressure hose to the paint hose port. 2. Tighten with an adjustable wrench. 3. Remove pusher stem from inlet valve.

GX-08 AND GX-10

To lock the gun, turn the trigger lock forward and slightly down until it stops. Gun locked (gun will not spray) The spray tip SHOULD NOT be attached until after the sprayer and paint hose have been purged and primed.

BEFORE YOU BEGIN

This column contains instructions that will be repeated throughout this manual.
CHOOSING THE CORRECT SPRAY GUN FILTER
Use the proper gun filter based on the tip size being used.
Part No. Tip Size Filter Type Extrafine Mesh Number Color of Filter Body Qty.

PLUGGING IN

SPRAYER
1. Check that the ON/OFF switch is in the OFF position.

0154918

180 mesh red 0.084 mm

2 pack

0154675

.013 -.015 Fine

100 mesh yellow 0.140 mm
2. Plug the sprayer into a heavy duty grounded extension cord. Refer to Important Electrical Information, page 3).

0154842

.017 -.023 Medium

50 mesh white 0.315 mm

BEFORE YOU PRIME PRESSURE RELIEF PROCEDURE
Be sure to follow the pressure relief procedure (page 6) when shutting the unit off FOR ANY PURPOSE. This procedure is used to relieve pressure from the spray hose. 1. Lock the spray gun off.
Before priming, squirt a teaspoon of separating oil (P/N 0154908 included with unit) into the indicated area. Light household oil can be substituted if necessary. Do not put more than a teaspoon into the lubricating area. Too much oil will leak down into your paint.

IF YOUR UNIT IS NEW.

All units are performance-tested at the factory and are shipped with test fluid in the fluid section to prevent corrosion during shipment and storage. Whether you are going to spray latex or oil-based paints, this fluid must be purged and thoroughly cleaned out of the system (follow Purging and Priming the Pump steps, page 7).
2. Flip the ON/OFF switch to the OFF (O) position.
3. Unlock the spray gun, turn the PRIME/SPRAY knob to PRIME, and trigger spray gun into paint bucket. 4. Lock the spray gun.
IF YOUR UNIT HAS ALREADY BEEN USED.
If the pump has already been used you will need to purge the water or solvent used in cleanup and storage.

PAINT STRAINING

It is recommended that in order to avoid premature tip and gun clogging you should strain your paint before spraying. Follow manufacturers recommendations.

PURGING & PRIMING

PURGING AND PRIMING
1. Place a full container of paint underneath the suction tube. 2. Secure the return tube into a waste container.

Suction tube Return tube

PURGING AND PRIMING THE SPRAY HOSE
1. Unlock the spray gun and turn PRIME/SPRAY knob to PRIME. Your spray tip SHOULD NOT be attached to your spray gun when purging your spray hose. 2. Trigger and HOLD the spray gun into a waste container. 3. While holding the trigger, switch the pump ON (l).
3. Turn the pressure control dial to maximum pressure (+).
4. Turn the PRIME/SPRAY knob to PRIME.
Keep hands clear from fluid stream.
5. Plug in the sprayer, and move the ON/OFF switch to the ON position.
Using a metal container, ground the gun by holding it against the edge of the container while flushing. Failure to do so may lead to a static electric discharge which may cause a fire. If the PRIME/SPRAY knob is still on SPRAY, there will be high pressure in the hose and spray gun until the PRIME/SPRAY knob is turned to PRIME. 5. Release trigger, turn the PRIME/SPRAY knob to PRIME and turn pump o OFF (O). 6. Trigger the gun into the waste container once more to be sure that no pressure is left in the hose. 7. Lock the spray gun off. 8. Thread the spray tip guard assembly onto the gun. Tighten by hand.

6. Switch the pump to OFF (O). 7. Remove the return tube from the waste container and place it in its operating position above the container of paint. Use the metal clip to bind the two hoses together.
Begin tightening the tip at this angle
to achieve the desired spray angle when tight.
Your sprayer is now purged. Move to Purging and Priming the Spray Hose.
Your hose is now purged and primed. You are ready to paint.
7 Customer Service: 800-880-0993
The unit will begin to draw paint up the suction tube, into the pump, and out the return tube. Let the unit cycle long enough to remove test fluid from the pump, or until paint is coming from the return tube.
4. While holding the trigger, turn the PRIME/SPRAY knob to SPRAY. Hold the trigger until all air, water, or solvent is purged from the spray hose and paint is flowing freely (read warnings below).

SPRAYING

PRACTICE
Be sure that the paint hose is free of kinks and clear of objects with sharp cutting edges. 1. Switch the pump ON (l) and turn the PRIME/SPRAY knob to SPRAY.
Keep the spray gun perpendicular to the surface, otherwise one end of the pattern will be thicker than the other.
Approximately 10 to 12 inches Right way

Wrong way

2. Turn the pressure contol dial to its highest setting (+). The spray hose should stiffen as paint begins to flow through it. 3. When the motor shuts off, unlock the spray gun and spray a test area to check the spray pattern. When enough pressure has built up in the hose, the motor will shut off automatically. The motor will cycle on and off automatically as it needs pressure.
The pressure control dial can be adjusted up or down to achieve the desired spray pattern.

Good spray pattern

Paint tailing pattern

SPRAYING TECHNIQUE

The key to a good paint job is an even coating over the entire surface. This is done by using even strokes. Follow the TIPS, below. TIP: Keep your arm moving at a constant speed and keep the spray gun at a constant distance from the surface. The best spraying distance is 10 to 12 inches between the spray tip and the surface.

Even coat throughout

Start stroke Pull trigger Keep steady Release trigger End stroke
Approximately 10 to 12 inches
Keep stroke smooth and at an even speed.
Keep the spray gun at right angles to the surface. This means moving your entire arm back and forth rather than just flexing your wrist. Light Coat Heavy Coat Light Coat
Do not flex wrist while spraying. TIP: The spray gun should be triggered by turning it on and off with each stroke. Do not trigger the gun during the middle of a stroke. This will result in an uneven spray and splotchy coverage.

NEVER POKE THE FILTER WITH A SHARP INSTRUMENT! 5. Replace the cleaned filter, tapered end first, into the gun housing. The tapered end of the filter must be loaded properly into the gun. Improper assembly will result in a plugged tip or no flow from the gun. 6a. For the GX-06/07, replace the spring and the fitting. Tighten with an adjustable wrench. 6b. For the GX-08/10, replace the housing and snap the trigger guard back into the housing.

SUCTION SET SCREEN

The screen at the bottom of the suction set may also need cleaning. Check it every time you change paint buckets. 1. Remove the screen by pulling it out of the retainer with a plier. 2. Clean the screen with the appropriate cleaning solution (warm, soapy water for latex paints, mineral spirits for oil-based paints).
If after having completed all of the steps on this page you are still experiencing problems spraying, refer to the TROUBLESHOOTING guide (page 15).

CLEANUP

IMPORTANT CLEANING NOTES! READ THESE NOTES AND WARNINGS BEFORE YOU START TO CLEAN YOUR SPRAYER!
When using latex paints, clean your sprayer and components using warm, soapy water. When using oil-based paints, use mineral spirits. Do not use mineral spirits on latex paint, or the mixture will turn into a jelly-like substance which is difficult to remove. No matter which cleaning solution you use, make sure to dispose of it properly when finished cleaning your sprayer. Thorough cleaning and lubrication of the sprayer is the most important step you can take to ensure proper operation after storage. CALL IF YOU HAVE ANY QUESTIONS REGARDING THE CLEANUP OF YOUR SPRAYER

PURGING

SUCTION SET
These steps will allow you to recover excess paint left over in the paint hose. 1. Lock the gun and remove spray tip assembly. 2. Submerge suction set into a bucket with appropriate cleaning solution.
1. Lock the gun and turn the pump OFF (O). 2. Remove the suction hose and return tube and clean it using the appropriate cleaning solution.
You should also wipe the threads of the inlet valve, and remove and clean the suction set screen. 3. When suction set is clean, thread the suction tube back onto the inlet valve, and replace the return tube onto the return tube fitting. Replace clip.

Continue cleaning instructions on next column
IMPORTANT! If you used oil-based paints, you must flush the pump again using warm, soapy water to prepare it for storage. Repeat Cleaning the Suction Set instructions.
11 Customer Service: 800-880-0993

STORAGE

SHORT-TERM STORAGE (UP TO 16 HOURS) PREPARING THE SPRAYER TERM STORAGE Follow these steps when using latex paints only. If
using materials that are oil-based, follow the long-term storage steps.
1. Fill a cup or other container with separating oil (approximately 2 ounces) supplied with the unit and submerge the inlet valve into the oil.

SHUTDOWN

1. Lock the spray gun off.
2. Turn the PRIME/SPRAY knob to PRIME. 2. Place a rag over the spray hose port, and turn the switch ON (l). 3. When the oil has been sucked from the cup, switch the pump OFF. 4. Insert the pusher stem into the inlet valve. Make sure the pusher stem is inserted fully.
3. Switch the pump OFF, and unplug the sprayer.

Inlet valve

4. Pour 1/2 cup water slowly on the top of the paint to prevent the paint from drying. 5. Wrap the spray gun assembly in a damp cloth and place it in a plastic bag. Seal the bag shut. 6. Place the sprayer in a safe place out of the sun for shortterm storage.
The pusher stem is designed to do two things: It holds the oil in the valve to keep the carbide seat from rusting. Secondly, it will keep the ball off of the seat to prevent any paint residue deposits that will cause the ball to stick to the seat. Paint deposits or rust formed on the carbide seat will cause priming and operation problems during repeated uses. 5. Wipe the entire unit, hose and gun with a damp cloth to remove accumulated paint. 6. Replace the high pressure hose to the paint hose port.

STARTUP

1. Remove the gun from the plastic bag. 2. Stir the water into the paint. 3. Check to be sure that the PRIME/SPRAY knob is set to PRIME. 4. Plug sprayer in and turn the switch to ON. 5. Turn the l PRIME/SPRAY knob to SPRAY. 6. Test the sprayer on a practice piece and begin spraying.

MAINTENANCE

DAILY MAINTENANCE
The only daily maintenance necessary is thorough cleaning. Follow the cleaning procedures in this manual.

ACCESSORIES

Part # 0279109 Description Separating Oil Hose, Whip End, 5 x 3/16 Hose, Wireless, 25 x 1/4" Hose, Wireless, 50 x 1/4" Hose Connector, 1/4 x 1/4 Pressure Gauge Tip Extension, 12 Tip Extension, 24 Power Roller Gun Attachment 9" Roller Cover, 3/8 Nap 9" Roller Cover, 1/2 Nap 9" Roller Cover, 3/4 Nap 9" Roller Cover, 1-1/4 Nap GX-08 Four Finger Metal Airless Spray Gun GX-07 Two Finger Metal Airless Spray Gun GX-06 Two Finger Plastic Airless Spray Gun GX-10 Two Finger Metal Airless Spray Gun w/Swivel Guard Assembly, F-Thread Guard Assembly, G-Thread 3 Foot Pole Extension w/Swivel 6 Foot Pole Extension w/Swivel 180 Degree Swivel F- to G-Thread Adapter Suction Set Filter (2 Pack) 411 Trade Spray Tip 413 Trade Spray Tip 415 Trade Spray Tip 417 Trade Spray Tip 419 Trade Spray Tip 515 Trade Spray Tip 517 Trade Spray Tip 519 Trade Spray Tip Anti-Seize Compound TR-10 Telescoping Roller, 9", 3/8" Nap Yellow Gun Filter White Gun Filter Pump Saver Plus Protector

EXTENDED MAINTENANCE

Some pump parts eventually wear out from use and must be replaced. The following list indicates the available repair kits for the parts replaced by each kit. However, pump performance is the only reliable indicator of when to replace wear parts. Refer to the Troubleshooting section for more information on when to use these kits. Kit Part # Description 0512228 Fluid Section Seal Kit (9140, 9140S, 9150) 0512222 Valve Replacement Kit (9140, 9140S, 9150) 0512229 Fluid Section Seal Kit (9170, 9190, 9210) 0512224 Valve Replacement Kit (9170, 9190, 9210)

THE INLET

Cleaning or servicing the inlet valve may be required if the unit has priming problems. This may be caused by improper cleaning and/or storage. 1. Unscrew the inlet valve assembly from the unit with a crescent wrench. Housing 2. Unscrew the inlet nut using a 3/8 inch allen Inlet valve wrench. Inlet nut assembly 3. Remove excess paint or rust from the ball and seat or replace with new parts from kit P/N 0512222 (9140, 9140S, 9150) or P/N 0512224 (9170, 9190, 9210). You may also have to clean excess paint inside the housing. 4. Inspect the inlet O-ring on the inlet valve. Clean or replace, and lubricate with a light household oil. 4. Reassemble ball, carbide seat, and O-rings in the order shown below into the inlet valve. Inlet O-ring Models 9140, 9140S and 9150 inlet valve assembly Models 9170, 9190, and 9120 inlet valve assembly
Inlet valve Ball O-ring Carbide seat O-ring Inlet nut
5. Install inlet nut back into inlet valve. Torque to ft/lbs if you have torque wrench. 6. Make sure the inlet valve O-ring is installed on the inlet valve, then install entire inlet valve assembly back into unit. Tighten with an adjustable wrench.
FLUID SECTION SEAL REPLACEMENT INSTRUCTIONS KIT 0512228 (MODELS 9140, 9140S, AND 9150) KIT 0512229 (MODELS 9170, 9190, AND 9210)
Always wear protective eye wear while servicing the pump. Be sure to follow the PRESSURE RELIEF PROCEDURE (page 6) when shutting the unit down for any purpose, including servicing or adjusting. After performing the pressure relief procedure, be sure to unplug the unit before servicing or adjusting. Area must be free of solvents and paint fumes.

DISASSEMBLY OF

FLUID SECTION
1. Remove the suction set. 2. Remove the front cover and the four screws that secure it using a T20 Torx head driver. 3. Remove the yoke screw and washer that secures the dowel pin. The dowel pin connects the yoke to the piston. 4. Using the pliers, pull the dowel pin out. 5a. For models 9140, 9140S, and 9150, rotate the pump shaft so the piston is in the top dead center position. This can be done by pushing on the yoke. This is required to disassemble all the parts. 5b. For models 9170, 9190, and 9210, inspect the yoke assembly and piston. In order to remove all the necessary parts, the piston must not be in the bottom dead center position. If the piston is at the bottom of the stroke, install the front cover and screws, turn the pump on briefly to index the piston, unplug the unit, and repeat step 2. 6. Unscrew and remove the inlet valve assembly using an adjustable wrench. 7. Remove the piston assembly by pushing down on the piston near the yoke. 8. Unscrew and remove the top nut using and adjustable wrench. 9. Remove the worn seals using a flat head screwdriver or punch. Remove the top seal from the top and the bottom seal from the bottom by pressing against the side of the seal and popping it out. Be sure not to scratch the housing where the seals are located. 10. Clean the area where the new seals are to be installed.

used. Be careful not to damage the piston. 6. Apply any type of household grease to the piston and yoke area to prolong life. Apply to the holes in the yoke where the dowel is inserted. 7. Install the dowel pin to connect the yoke to the piston. The piston may have to be moved up or down to do this. 8. Install the yoke screw and washer to secure the dowel pin. 9. Turn pump right side up and apply a few drops of Wagner Separating Oil or light household oil between the top nut and piston. This will prolong the seal life. 10. Install front cover and four (4) screws. 11. Install the suction set.
Top nut Top seal (cup down)
0512228 Kit (9140, 9140S and 9150) 0512229 Kit (9170, 9190, and 9210)
Yoke Retaining ring Washer Dowel Screw

Piston/seal assembly

ASSEMBLY OF
Insertion tool CAUTION! DO NOT attempt to remove the seals from the piston. O-ring
0512228 Kit (9140, 9140S, and 9150) 0512229 Kit (9170, 9190, and 9210)
1. Lubricate the new top seal with Separating Oil (P/N 0154908) or light household oil and by hand place the seal (cup side of seal down) into the top port of the housing. 2. Place a small amount of anti-seize on the threads of the nut. Place the top nut into the top of the housing and tighten with an adjustable wrench. This will drive the top seal into the correct position. 3. Turn the pump upside down. Lubricate the seal on the piston/seal assembly similar to the top seal. Place the piston/seal assembly into the bottom of the housing. Insert the plastic insertion tool and thread into position to properly seat the piston/seal. Thread fully until tight. Remove the insertion tool. 4. Install the new O-ring on the inlet valve assembly, lubricate with Separating Oil (P/N 0154908), thread into the bottom (inlet) of the housing, and tighten with an adjustable wrench. This will drive the bottom seal into the correct position. 5. Align the piston with the yoke. A rubber mallet may be

Inlet valve assembly

SERVICE NOTE--MODEL 9210 The inlet check ball is a wear part. Erosion of the check ball can result in a loss of performance similar to a worn piston and seals. Inspect the inlet ball by removing the inlet valve assembly. If worn, replace the assembly with P/N 0512224. This part number is available at Wagner authorized service centers or by calling 1-800-880-0993.

TROUBLESHOOTING

PROBLEM
A. The sprayer does not start.
1. The sprayer is not plugged in. 2. The ON/OFF switch is set to OFF. 3. The sprayer was turned off while still under pressure. 4. No voltage is coming from the wall plug. 5. The extension cord is damaged or has too low a capacity. 6. A fuse is blown in the sprayer. 7. There is a problem with the motor.

SOLUTION

1. Plug the sprayer in. 2. Turn the ON/OFF switch to ON. 3. Turn pressure control knob to maximum setting (+), or relieve pressure by turning the PRIME/SPRAY valve to PRIME. 4. Properly test the power supply voltage. 5. Replace the extension cord. 6. Take sprayer to Wagner Authorized Service Center. 7. Take sprayer to Wagner Authorized Service Center. 1. Try to prime the unit again. 2. Refill the bucket or immerse the suction tube in paint. 3. Clean the suction set. 4. Clean the tube connection and tighten it securely. 5. Clean the inlet and outlet valves and replace any worn parts.* Inlet may be stuck from old paint. Insert pusher stem to release 6. Replace the inlet valve.* 7. Take sprayer to Wagner Authorized Service Center. 1. Replace the spray tip with a new tip.** 2. Clean the suction set screen. 3. Clean or replace the proper filter. Always keep extra filters on hand. 4. Thin or strain the paint. 5. Clean or replace the outlet valve assembly.* 6. Replace the inlet valve.* 1. Take sprayer to Wagner Authorized Service Center.
B. The sprayer starts but does not draw in paint when the PRIME/SPRAY knob is set to PRIME.
1. The unit will not prime properly or has lost prime. 2. The paint bucket is empty or the suction tube is not totally immersed in the paint. 3. The suction set is clogged. 4. The suction tube is loose at the inlet valve. 5. The inlet or outlet valve is stuck. 6. The inlet valve is worn or damaged. 7. The PRIME/SPRAY valve is plugged.
C. The sprayer draws up paint but the pressure drops when the gun is triggered.
1. The spray tip is worn. 2. The suction set screen is clogged. 3. The gun or spray tip filter is plugged. 4. The paint is too heavy or coarse. 5. The outlet valve assembly is dirty or worn. 6. The inlet valve assembly is damaged or worn.
D. The PRIME/SPRAY valve is on SPRAY and there is flow through the return tube. E. The spray gun leaks.
1. The PRIME/SPRAY valve is dirty or worn.
1. Internal parts of the gun are worn or dirty. 1. The tip was assembled incorrectly. 2. A seal is worn. 1. The spray tip or the gun filter is plugged. 2. The spray tip is in the CLEAN position. 1. The pressure is set too low. 2. The gun, the tip, or the suction filter is plugged. 3. The suction tube is loose at the inlet valve. 4. The tip is worn. 5. The paint is too thick. 6. Pressure loss.
1. Take the sprayer to a Wagner Authorized Service Center. 1. Check the tip assembly and assemble properly. 2. Replace the seal.* 1. Clean the spray tip or gun filter. 2. Put the tip in the SPRAY position. 1. Increase the pressure. 2. Clean the filters. 3. 4. 5. 6. Tighten the suction tube fitting. Replace the spray tip. Thin the paint. Refer to Causes and Solutions for problem C.