R 505 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 Spray Short Term Storage OR 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... Maintenance PRINTED IN THE U. S. A.
CONTENTS General Description ....................................................... 2 Safety Precautions ...................................................... 3-6 Extension Cord............................................................... 7 Grounding Instructions ................................................... 7 Pressure Relief Procedure ............................................. 8 Set Up ....................................................................... 9-11 Priming ........................
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.
WARNING HAZARD PREVENTION 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. • 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.
WARNING HAZARD PREVENTION 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.
WARNING PREVENTION HAZARD 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 material’s compatibility with aluminum, contact your coatings supplier.
Extension Cord 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.
Pressure Relief Procedure Follow this procedure after the unit is assembled and before any operation which involves the spray gun such as changing tips or accessories, or cleaning and maintenance. 3. Trigger gun to remove any pressure which may still be in the hose. 1. Make sure PRESSURE CONTROL KNOB is at its lowest setting (counterclockwise). Pressure Control Knob 2. Turn PRIMING KNOB to PRIME A position. 4. Lock gun trigger in the Off position.
SET-UP ASSEMBLE CART Tools needed: Some assembly is required to get your Wagner 505 Airless Sprayer ready to go. You will need two adjustable wrenches, a screw driver and a pair of pliers. Pail Bracket NOTE: Sprayer should remain unplugged during assembly. 1. Slide pail bracket (1) onto cart frame and attach with one bolt, washer and wing nut (2). See Figure 2 and Figure 3 A.
SET-UP ATTACH TIP TO GUN 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). 1. Lock gun. See Figure 4. Locked Position Unlocked Position Figure 4 - Gun in Locked & Unlocked Position Correct Way 2.
SET-UP 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. 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. 3.
PRIMING PREPARE TO PRIME 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. 1. Lay unit back on its handle so inlet valve is facing up. Fill inlet valve with water or light household oil. 2.
PRIMING PRIME THE PUMP ATTACH SUCTION SET 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. 1. Make sure the PRESSURE CONTROL KNOB is at its lowest setting (counterclockwise). See Figure 18. (Do Not cross thread) 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.
PRIMING PRIME THE PUMP Continued from page 13 3. TURN SPRAYER ON. 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. CAUTION 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).
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.
SPRAYING 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. Even Coat on Work Throughout Approximately Approximatley 10toto12 12Inches Inches 10 2. In most cases, the best spraying distance is 10 to 12 inches between the spray tip and the surface. 3.
SPRAYING 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.
SPRAYING Continued from page 17 6. Insert the top of the filter (Figure 30) into the gun body fitting under the tip of the spray gun. See Figure 31. 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.
CLEAN UP SHORT-TERM/OVERNIGHT STORAGE Shut-down Start-up 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. 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. 2.
CLEANUP SHUT DOWN/CLEAN UP 9. To save paint left in the hose, carefully trigger the gun (with spray tip removed) against the inside of the paint container. See Figure 37. Reduce PRESSURE CONTROL KNOB to zero, then turn PRIMING KNOB to SPRAY B . Do not allow paint to build up on Overheating of the motor will result. Do not allow flammable solvents to come in contact with the motor, which could ignite. WARNING the motor.
CLEAN UP 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.
CLEAN UP 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. 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.
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. Removing and Cleaning Inlet Valve 4. Thoroughly clean the valve assembly with solvent and brush. 1. Be sure sprayer is off. 5. A properly seated valve filled with water and held vertically will not drip out the bottom of the valve.
MAINTENANCE CLEANING VALVES 2. If possible, leave the copper washer under the cap in place. At least be sure to replace it with the same side up. (The top will show the imprint of the end cap, while the bottom should be perfectly flat to match seat in the pump casting.) See Paint Pump Assembly Parts Diagram,Item 4 for replacement part number. A spare outlet valve spring is included in the litSpring erature set. Cap Ball Seat Seal 3.
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.
TROUBLE SHOOTING Problem Cause Remedy 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. Plug in. Flip switch to ON. Replace fuse. Test power supply voltage. Sprayer starts up but does not draw in paint. (Make sure prime/ spray knob is in prime position.
TROUBLE SHOOTING Problem Cause Remedy Spray gun won't shut off. Worn ball or seat. Foreign matter or paint buildup or dried paint between ball and seat. (Caused by improper cleaning of gun. Take to Authorized Wagner Service Center. Take to Authorized Wagner Service Center. Spray gun leaks. Worn or dirty internal parts. (Caused by improper cleaning of gun.) Take to Authorized Wagner Service Center. Tip assembly leaks Assembled incorrectly. Worn seal. Check assembly. Replace seal.
1 2 9 3 11 4 10 5 Serial Number Location 6 9 7 8 3 4 Parts Diagram – Final Assembly ITEM PART NO. 1 2 3 4 5 6 0288478 0270357 9821503 9810111 0270356 0270359 DESCRIPTION Grip, Handle Handle, Cart Washer, Lock Nut, Wing Cart Assembly Wheel QTY. 1 1 4 2 1 2 ITEM PART NO. DESCRIPTION 7 8 9 10 0275728 0270358 9800117 ----------- 11 0288186 Cap, Hub Bracket, Pail Bolt, 1/4-20 x 1-1/2 Paint Pump Assembly (See Parts Diagram, Page 29) Housing, Hydraulic 28 QTY.
1 2 3 4 5 12 6 7 Never remove these four bolts! Take to an Authorized Wagner Service Center. CAUTION 3 11 8 10 9 Parts Diagram – Paint Pump Assembly ITEM PART NO. DESCRIPTION 1 0281113 2 3 4 5 6 0089564 9970103 0047485 0093635 0090348 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 1 7 8 9 10 11 12 1 2 1 1 1 29 QTY.
2 11 3 10 12 9 4 5 6 1 5 7 8 Parts Diagram – Suction Set Assembly 0270174 ITEM PART NO. DESCRIPTION 1 0270133 2 3 4 5 6 0090622 0281314 0088931 0089882 0270360 Suction Tube Complete (Includes Items 2 thru 10) Nut, Suction Elbow, Adapter, 3/4" x 1" Ring, Snap Clamp Hose, Suction QTY. 1 1 1 1 2 1 ITEM PART NO. DESCRIPTION 7 8 9 10 11 12 30 0270371 0270369 0090621 0088715 0089096 0270363 Housing, Filter Filter Washer Fitting, Return Hose Clamp Tubing, Return QTY.
1 2 7 3 5 4 6 Parts Diagram – Optional Hopper Assembly ITEM PART NO. DESCRIPTION 1 0288144 2 3 0090283 0089917 0088871 QTY. Hopper, Complete (lncludes ltems 2 thru 7) Hopper Filter Screen, Fine (Shown) Filter Screen, Coarse ITEM PART NO.
Parts and Accessories 1 10 9 3 4 8 7 2 6 5 PARTS LIST Item Part No. 1 2 0293004 0089731 3 4 5 6 0043590 0089694 0089692 0089959 Description G-06 Gun Assembly Filter Assembly (Includes Items 3,4,5,6) Spring Seal, Nylon Housing Filter Filter Item Part No. 7 8 9 10 0293303 0154782 0154783 0154784 0154680 0154693 Description Guide, Hose Tip, .011 (Oil based materials) Tip, .013 (Oil based , latex paints and stains) Tip, .
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.
