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WAGNER GM 5000EA Operating Manual

Electrostatic air spray gun for manual operation for flat or round jet nozzles
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Electrostatic Air Spray Gun
for manual operation
for fl at or round jet nozzles
C
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Translation of the Original
Operating Manual
Version 04/2016
B_03229

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Summary of Contents for WAGNER GM 5000EA

  • Page 1 Translation of the Original Operating Manual Version 04/2016 Electrostatic Air Spray Gun for manual operation for fl at or round jet nozzles B_03229...

  • Page 3: Table Of Contents

    4.1.1 Electrical Equipment 4.1.2 Personnel Qualifi cations 4.1.3 Safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Spray Devices 4.2.2 Grounding the Device 4.2.3 Product Hoses 4.2.4 Cleaning and Flushing 4.2.5 Handling Hazardous Liquids, Varnishes and Paints 4.2.6...
  • Page 4 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Table of Contents 5.6.3 Adjusting Screw 5.6.4 Electrostatic and Atomization 5.6.5 Discharge Quantity Measurements ASSEMBLY AND COMMISSIONING Training Assembly/Commissioning Staff Storage Conditions Installation Conditions Transportation Assembly and Installation 6.5.1 Typical Electrostatic Air Spraying System 6.5.2...
  • Page 5 How Can Spare Parts Be Ordered? 14.2 GM 5000EA Spray Gun 14.2.1 Basic version GM 5000EA 14.2.2 Spiral Hose for GM 5000EA 14.2.3 4 Finger Trigger for GM 5000EA 14.2.4 GM 5000EA Adapter 14.2.5 GM 5000EA Handle 14.3 Accessories Spare Parts Lists 14.3.1 AR 5000 Nozzle (D8)
  • Page 6 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Table of Contents 15.2 Warranty Claim 15.3 FM Approval...

  • Page 7: About These Instructions

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL ABOUT THESE INSTRUCTIONS PREFACE The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel.

  • Page 8: Languages

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL LANGUAGES The GM 5000EA operating manual is available in the following languages: Language Order No. Language Order No. German 2356789 English 2344499 Additional languages on request or at: ABBREVIATIONS Order No.

  • Page 9: Terminology For The Purpose Of This Manual

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal fl ushing of paint-wetted parts with fl ushing agent Product pressure...

  • Page 10: Correct Use

    Electrostatic manual spray gun for manual coating of grounded work pieces. TYPE OF USE The GM 5000EA electrostatic manual spray gun is suitable for spraying liquid products, particularly coating products, using the air atomizing method. Coating products which contain ingredients of explosion class IIA and IIB substances (maximum ignition energy 0.24 mJ) may be used.

  • Page 11: Processible Working Materials

    PROCESSIBLE WORKING MATERIALS Lacquers which contain ingredients of explosion class IIA and IIB substances (maximum ignition energy 0.24 mJ) can be processed with the GM 5000EA spray gun. The spray gun basic version is suitable for processing sprayed substances with an electrical resistance of >...

  • Page 12: Reasonably Foreseeable Misuse

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL REASONABLY FORESEEABLE MISUSE The forms of misuse listed below may result in physical injury or property damage: use with non-authorized control units; coating work pieces which are not grounded; working with an ungrounded lacquer supply system;...

  • Page 13: Identification

    Only cable assigned to the device may be used (see Chapter 13). Permissible Device Combinations The GM 5000EA manual spray gun may only be connected to the control units listed below: - VM 500 control unit (USA) - VM 5000 control unit (USA)

  • Page 14: Type Plate

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL TYPE PLATE Type plate left Type plate right J. Wagner AG CH-9450 Altstätten GM 5000EA In accordance Art. Nr.: 2344472 with 2316160 high voltage: max. 70kV DC APPROVED current: max. 100μA DC max.

  • Page 15: General Safety Instructions

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention. 4.1.1...

  • Page 16: Safety Instructions For Staff

    The liquid ejection devices are with need, at least however every 12 months to examine by experts (e.g., WAGNER Service Technician) in accordance with the guidelines for liquid ejection devices (DGUV regulation 100-500). - For shut down devices, the examination can be suspended until the next start-up.

  • Page 17: Grounding The Device

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 4.2.2 GROUNDING THE DEVICE Friction, fl owing liquids and air or electrostatic coating processes create charges. Flames or sparks can form during discharge. Grounding prevents electrostatic charging. Ensure that the device is grounded.

  • Page 18: Cleaning And Flushing

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 4.2.4 CLEANING AND FLUSHING Relieve the pressure from the device. De-energize the device electrically. Preference should be given to non-fl ammable cleaning and fl ushing agents. Observe the specifi cations of the lacquer manufacturer.

  • Page 19: Handling Hazardous Liquids, Varnishes And Paints

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS When preparing or working with lacquer and when cleaning the device, follow the working instructions of the manufacturer of the lacquers, solvents and cleaning agents being used.

  • Page 20: Use In Areas Subject To Explosion Hazards

    4.4.1 SAFETY REGULATIONS Observe safety instructions in Chapter 3.2. Safe handling of WAGNER spray devices Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere: Do not knock or push the device against steel or rusty iron.

  • Page 21: Description

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL DESCRIPTION STRUCTURE (STANDARD VARIANT) Note: The nozzle parts (pos. 5; 7; 14 and 20) do not belong to the basic equipment of the spray gun. The diff erent versions can be found in Chapter 13 "Accessories".

  • Page 22: Mode Of Operation

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL MODE OF OPERATION When the spray gun is connected to the control unit and the control unit is switched on, the pre-defi ned recipe (R1, R2 or R3) is shown on the gun display (2) as follows.
  • Page 23 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL The trigger can be used to activate, one after the other, the various functions of the spray gun. Distance Description Atomizing air open. Atomizing air open and electrostatically (high voltage) activated.

  • Page 24: Scope Of Delivery

    GM 5000EA spray gun (USA) 2363670 GM 5000EA spray gun spiral hose (USA)* 2367744 GM 5000EA spray gun 4 fi nger trigger (USA) All variants without control unit, product and air hose, electric cable, air cap and nozzle. * no FM approval, in submission Each spray gun includes the following as standard equipment: Order No.

  • Page 25: Design Variants

    5.3.1 DESIGN VARIANTS Basic version GM 5000EA (USA) Order No. 2344471 Spiral hose GM 5000EA (USA) (no FM approval, in submission) Order No. 2363670 for processing of metallic lacquers GM 5000EA 4 fi nger trigger (USA) Order No. 2367744 B_06068...

  • Page 26: Technical Data

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL TECHNICAL DATA Maximum air pressure 0.8 MPa; 8 bar; 116 psi Maximum product pressure 0.8 MPa; 8 bar; 116 psi Fluid inlet NPSM 3/8"–18 Air connection NPSM 1/4"–18 Input voltage maximum 20 Vpp Input current maximum 1.0 A AC...
  • Page 27 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Dimensions with fl at jet nozzle inch 10.28 1.81 9.65 B_03231 with round jet nozzle inch 10.28 1.81 9.65 B_03230...

  • Page 28: Spraying Procedure

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL SPRAYING PROCEDURE 5.5.1 SPRAYING PROCEDURE FOR ROUND JET AIR ATOMIZING In this process, the spray product is fed to the nozzle with a pressure of approx. 0.05–0.2 MPa; 0.5–2 bar; 7–29 psi. The atomizing air at approx. 0.25 - 0.4 MPa; 0.25 - 4 bar; 36 - 58 psi produces a soft round jet, which largely eliminates the problem of overlapping boundaries.

  • Page 29: Spraying Procedure For Flat Jet Air Atomizing

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 5.5.2 SPRAYING PROCEDURE FOR FLAT JET AIR ATOMIZING In this process, the spray product is fed to the nozzle at a pressure of 0.05–0.2 MPa; 0.5–2 bar; 7–29 psi. The atomizing air at approx. 0.25 - 0.4 MPa; 2.5 - 4 bar; 36 - 58 psi produces a soft round jet, which largely eliminates the problem of overlapping boundaries.

  • Page 30: Electrostatic Effect

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 5.5.3 ELECTROSTATIC EFFECT The spray gun produces an electrostatic fi eld by means of the high-voltage electrode. As a result, the paint particles atomized by the spray gun are carried to the grounded work piece by kinetic and electrostatic energy, where they adhere fi nely dispersed to the object to be sprayed.

  • Page 31: The Wagner Electrostatic Air Spraying System

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL THE WAGNER ELECTROSTATIC AIR SPRAYING SYSTEM The nozzle range (chapter 13) provided by WAGNER allows optimum coating results for any application. General criteria for selection of nozzles Flat jet for large-surface parts...

  • Page 32: Pressure Settings For Flat Jet Nozzles

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 5.6.2 PRESSURE SETTINGS FOR FLAT JET NOZZLES There are 8 fl at jet nozzle sizes from 0.6 up to 2.0 available. There are 2 air cap types (s = small, w = wide) with 3 diff erent nozzle sizes each. Each air cap can be used in combination with 2 to 3 nozzles sizes.

  • Page 33: Electrostatic And Atomization

    - See also Chapter 5.5.3. 5.6.5 DISCHARGE QUANTITY MEASUREMENTS Flat spray nozzles Device: GM 5000EA / fl at jet nozzle Product hose: Length 7.5 m; 24.6 ft Viscosity: 22 DIN/4 seconds Inside diameter 6 mm; 0.24 inches 2.

  • Page 34: Assembly And Commissioning

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRAINING ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the device. The assembly and commissioning staff must have the technical skills to safely commission the device.

  • Page 35: Assembly And Installation

    VM 5000 control unit Air pressure regulator with air fi lter Product hose Grounding cable Compressed air main Air hose GM 5000EA R spray gun Tank for return fl ow Protective hose Mains cable Example: Electrostatic air spraying system with...

  • Page 36: Ventilation Of The Spray Booth

    (spray pack). The system shown in the fi gure is only one example of an electrostatic air spraying system. Your WAGNER distributor would be happy to assist you in creating a spraying system solution that meets your individual needs. You must familiarize yourself with the operating manuals and the safety regulations of all additional system components before starting commissioning.

  • Page 37: Air Supply

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 6.5.3 AIR SUPPLY The use of an air fi lter with air regulator (4) ensures that only dry, clean atomizing air gets into the spray gun. Dirt and moisture in the atomizing air worsens the spraying quality and spraying pattern.

  • Page 38: Grounding

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 6.5.5 GROUNDING Perfect grounding of all conductive parts such as fl oors, walls, roofs is important for optimum coating and safety. Barriers, work pieces, transport devices, coating product tank, coating product supply or construction parts in the spray area with exception of the high-voltage parts during normal operation.
  • Page 39 Spraying stand Grounding of spray gun The spray gun is grounded via the spray gun cable. The GM 5000EA spray gun must be connected by the gun cable with the VM 500 or VM 5000 control unit. Note for the sprayer Safety shoes and gloves, if used, must be static dissipative.

  • Page 40: Preparation Of Lacquer

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL PREPARATION OF LACQUER The viscosity of the lacquer is of great importance. The best spraying results are obtained with values between 15 and 30 DIN/4 seconds (measured in immersion fl ow cup DIN 4 mm;...

  • Page 41: Commissioning

    See Chapter 6.7.3.1 Visually check the permissible pressures for all the system components. When using a WAGNER pneumatic pump: Check the level of the separating agent and fi ll the separating agent up if necessary. Provide product tank, tanks for fl ushing agent and an empty tank for return fl ow.

  • Page 42: Gun Cables And Gun Cable Extensions

    Only disconnect or connect all cable extensions from the gun cable and the cable extension when the control unit is switched off . In order that the GM 5000EA spray gun is grounded, it must be connected via the gun cable with the VM 500 or VM 5000 control unit.

  • Page 43: Verifying A Safe Operational Condition

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Attention: guns with electric extension cable Secure the cover sleeves with the warning sign by means of the screws (84) on the connectors. Power loss In order to prevent power losses, keep the cable length as short as possible. The maximum power is available with the standard cable length of 10 m.

  • Page 44: Operation

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualifi ed to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.

  • Page 45: Emergency Deactivation

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic spark-over. Use gun only with fi tted nozzle, air cap and union nut. 7.2.1 EMERGENCY DEACTIVATION In the case of unforeseen occurrences, proceed as follows: 1.

  • Page 46: Working

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL WORKING Ensure that: the regular safety checks are carried out in accordance with Chapter 8.2.3, commissioning is carried out in accordance with Chapter 6.7. Example: Spraying system with pressure tank B_03233 7.3.1...

  • Page 47: Checking The Spray Pattern (Without Electrostatics)

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 7.3.2 CHECKING THE SPRAY PATTERN (WITHOUT ELECTROSTATICS) Start air-spraying (without electrostatics) 1. Switch off control unit (the grounding of the spray gun via the gun cable is maintained). 2. Start up with product supply generator set to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar;...

  • Page 48: Spraying

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 7.3.3 SPRAYING 1. Insert the desired nozzle into the spray gun. 2. Turn on the control unit. See corresponding operating manual. 3. Start up with product supply generator set to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar;...
  • Page 49 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Adjustable EARV 5000 round jet nozzle By turning the union nut the spray pattern can be adjusted to suit the object being sprayed. The illustration shows the infl uence of the turning on the spraying pattern.

  • Page 50: Pressure Relief/Work Interruption

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 7.3.4 PRESSURE RELIEF/WORK INTERRUPTION The pressure must always be relieved when: - The spraying tasks are fi nished. - The spraying system is maintained. - Cleaning tasks are carried out on the spraying system.

  • Page 51: Changing From Air Round Jet To Air Flat Jet

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 7.3.5 CHANGING FROM AIR ROUND JET TO AIR FLAT JET NOTICE Defective electrode! Material damage due to functional faults. Do not damage the electrode. Flush spray gun 1. Switch off control unit.

  • Page 52: Cleaning Of The Nozzle Parts

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 7.3.6 CLEANING OF THE NOZZLE PARTS The nozzle parts (2, 3, 4, 5 and 6) may only be immersed into a cleaning solvent recommended by the lacquer manufacturer and must be removed again immediately.

  • Page 53: Cleaning And Maintenance

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.
  • Page 54 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL DANGER Explosive powder/air mixes! Danger to life and equipment damage. Before starting cleaning, rinsing, or other manual work, the high voltage must be shut down and locked to prevent it from being...

  • Page 55: Cleaning And Flushing The Device

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 8.1.3 CLEANING AND FLUSHING THE DEVICE The spraying system and the spray gun must be cleaned and fl ushed daily. The cleaning and fl ushing agents used must be compatible with the working material.
  • Page 56 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL DANGER Exploding gas / air mixture! Danger to life from fl ying parts and burns. Never spray into a closed tank. Ground the tank. Clean nozzle 1. Switch off control unit.

  • Page 57: Maintenance

    In accordance with the guideline for liquid ejection devices (DGUV regulation 100-500): - The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months.

  • Page 58: Safety Checks

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 59: Product Hoses, Tubes And Couplings

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 8.2.4 PRODUCT HOSES, TUBES AND COUPLINGS DANGER Bursting hose, bursting threaded joints! Danger to life from injection of product and from fl ying parts. Ensure that the hose material is chemically resistant to the sprayed products and the used fl ushing agents.

  • Page 60: Trouble Shooting And Rectification

    Connect gun and gun cable/check for defect. Check lacquer resistance, see Chapter 2.5 Seal in end piece defective Repair by WAGNER Service Department. Air-passages damp Clean and dry air passages. Back-spray Poor grounding at object Check grounding.

  • Page 61: Repair Work

    In accordance with the guideline for liquid ejection devices (DGUV regulation 100-500): - The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months.

  • Page 62: Dismantling Of The Gun

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 10.3 DISMANTLING OF THE GUN Plastic parts Gently handle all plastic parts. 10.3.1 TOOLS For disassembling and assembling the spray gun, the following tools are required: - Allen wrench SW 2...

  • Page 63: Dismantling Of The Spray Gun

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 10.3.2 DISMANTLING OF THE SPRAY GUN SW12 SW12 B_03246 Air hose When unscrewing the air hose, a second open-ended/box wrench must be used for bracing. Torx® 25 SW19 B_03247 SW19...
  • Page 64 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Carefully release the cascade without pliers. SW19 Valve needle assembly tool B_03248 SW19 Order No. 2309368 B_04370 SW11 Valve housing: Use socket or ring spanner (not a wrench). Valve needle Air Loosen valve tip by hand using the valve needle assembly tool (Order No.
  • Page 65 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 1. Remove pressure spring (4). 2. Loosen clamping screw (1) with assembly tool (5). B_04371 3. Unscrew valve rod unit (2, 6, 7). The packing (3) is also unscrewed and removed.

  • Page 66: Cleaning The Parts After Disassembly

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 10.3.3 CLEANING THE PARTS AFTER DISASSEMBLY ATTENTION Please note: All reusable parts (except for the parts conducting high-voltage such as cascade, adapter, plug compl. etc.) should be cleaned thoroughly using a suitable cleaning agent.

  • Page 67: Assembling The Spray Gun

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 10.3.4 ASSEMBLING THE SPRAY GUN Assembly aids: Order No. Description 9992698 Vaseline white PHHV II 9992511 Loctite® 243 * Use Vaseline sparingly Only as required (if the seal was removed): press in using handle seal assembly tool (Order No.
  • Page 68 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Valve rod unit Set length adjusting measure X with withdrawal nut (7) and then fasten the threaded pin (6) using an Allen wrench SW2. B_04791 Wear gloves! The outside thread of the packing (9) must be free of lacquer.
  • Page 69 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Valve needle assembly tool, Order No. 2309368 B_04373 0.1 Nm 0.07 lb ft SW11 Ensure the correct 1.8 Nm; insertion position! 1.33 lb ft 1. Move the valve rod to the rear position so that the sealing area does not become scratched (1).
  • Page 70 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Push the trigger upward into the air valve piston. The recess in the trigger must engage correctly in the indentation of the piston. Torx® 25 B_03256 0.8 Nm Cover (5) The cover must be...
  • Page 71 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Flat jet nozzle Diverse nozzle sizes, see Chapter 13.4. Round jet nozzle Diverse nozzle sizes, see Chapter 13.3. B_03258 Air hose When screwing on the air hose, a second open-ended/ring spanner must...

  • Page 72: Function Test After The Repair

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL FUNCTION TEST AFTER THE REPAIR After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair staff .
  • Page 73 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Disruptive discharge test Check the gun against ground with the grounding rod. No sparks should be formed. Note: in the vicinity of the electrode harmless corona discharges can occur. Grounding rod Order No.

  • Page 74: Air Test

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 11.2 AIR TEST Connect test or air hose to spray gun. The following air tests are to be carried out twice each: - at 0.1 MPa; 1 bar; 14.5 psi - at 0.8 MPa; 8 bar; 116 psi Checking the air valve The air valve must switch on and off correctly.

  • Page 75: Disposal

    WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way.

  • Page 76: Accessories

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL ACCESSORIES 13.1 VALVE HOUSING Order No. Designation Valve housing Air, complete (steel) 2312179 (standard version) B_03697 2312176 Valve housing Air, complete (PEEK) B_03697 13.2 VALVE TIPS Order No. Designation Valve tip Air, complete (PEEK)

  • Page 77: Nozzle Set Earv

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 13.3.3 NOZZLE SET EARV Markings on union Order No. Designation Nozzle set EARV 5000 LV 2361290 suitable for low viscosity products B_05984 Nozzle set EARV 5000 HV 2365979 suitable for high viscosity products...

  • Page 78: Af 5000 Nozzles

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 13.4.2 AF 5000 NOZZLES Order No. Designation 2310539 Nozzle, AF 5000–0.6 mm (black) B_03241 2310540 Nozzle, AF 5000–0.8 mm (yellow) B_03241 2310541 Nozzle, AF 5000–1.0 mm (red) B_03241 2310542 Nozzle, AF 5000–1.2 mm (green)

  • Page 79: Hoses And Electric Cables

    HOSES AND ELECTRIC CABLES 13.5.1 STANDARD HOSE SETS AND COMPONENTS B_03245 Order No. Designation 2356991 Hose set GM 5000EA USA (7.5 m) Consists of: 2356965 Low pressure hose DN6-PN20-NPSM 3/8"-7.5 m-PA 2356978 Air hose, complete DN8 USA (8.0 m) 2339157 Gun cable GM 5000E (10.0 m)
  • Page 80 2 Air hose 3 Electrical cable Order No. Description A [mm] B [mm] C [mm] D [mm] E [mm] 2356991 Hose set GM 5000EA USA (7.5 m) 29±2 47±2 300±10 20±10 1500 +100 2356992 Hose set GM 5000EA USA (10 m) 29±2 47±2...

  • Page 81: Hose Sets For Low-Resistance Products

    OPERATING MANUAL 13.5.2 HOSE SETS FOR LOW-RESISTANCE PRODUCTS B_03244 Order No. Designation 2357021 Hose set GM 5000EA USA (7.5 m), Low R Consists of: 2310464 Product hose EA, complete (7.5 m) Low R 2345340 Air hose, complete (8.0 m) 2339157 Gun cable GM 5000E (10.0 m)
  • Page 82 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Order No. Designation 2357024 Hose set GM 5000EA USA (20.0 m), Low R Consists of: 2310467 Product hose EA, complete (20.0 m) Low R 2345343 Air hose, complete (20.5 m) 2339160 Gun cable GM 5000E (25.0 m)
  • Page 83 +100 2357021 Hose set GM 5000EA (7.5m) Low R 200±2 171±2 300±10 20±10 1500 182±1 2357022 Hose set GM 5000EA (10 m), Low R 200±2 171±2 300±10 20±10 1500 +100 182±1 +100 2357023 Hose set GM 5000EA (15 m), Low R 200±2...

  • Page 84: Spiral Hose (No Fm Approval)

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 13.5.3 SPIRAL HOSE (NO FM APPROVAL) Order No. Designation 2355047 Spiral hose, complete (USA) The spiral hose can only be used along with standard hose set. Application: This hose is used primarily for processing of metallic lacquers.

  • Page 85: Finger Trigger

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 13.5.6 4 FINGER TRIGGER Order No. Designation 2367641 4 fi nger trigger B_06062 Order No. Designation 2367508 Hose holder 4 fi nger trigger open B_06063 Order No. Designation 2367381 Hose holder 4 fi nger trigger closed...

  • Page 86: Miscellaneous

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 13.6 MISCELLANEOUS Order No. Designation 2319653 Protective gun coating B_03693 259010 High-voltage tester, HV 200 N P_00265 2326041 Paint resistance meter B_03692 999080 Wet fi lm thickness gauge B_03224 50342 Viscosity cup DIN 4 mm; 0.16 inch...

  • Page 87: Spare Parts

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 88: Gm 5000Ea Spray Gun

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.2 GM 5000EA SPRAY GUN 14.2.1 BASIC VERSION GM 5000EA Dismantling and assembling see Chapter 10 B_03235...
  • Page 89 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL GM 5000EA spare parts list Order No. Designation 2344471 Basic version GM 5000EA 2315709 Protection cap valve needle Adapter GM 5000EA, complete For details, see Chapter 14.2.4 2314361 Hook Handle ES 5000 Air (USA), complete For details, see Chapter 14.2.5...

  • Page 90: Spiral Hose For Gm 5000Ea

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.2.2 SPIRAL HOSE FOR GM 5000EA Dismantling and assembling see Chapter 10 B_06066...
  • Page 91 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL GM 5000EA spare parts list Order No. Designation 2363670 Spiral hose for GM 5000EA* 2315709 Protection cap valve needle Adapter GM 5000EA, complete For details, see Chapter 14.2.4 2314361 Hook Handle ES 5000 Air (USA), complete For details, see Chapter 14.2.5...

  • Page 92: Finger Trigger For Gm 5000Ea

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.2.3 4 FINGER TRIGGER FOR GM 5000EA Dismantling and assembling see Chapter 10 B_06065...
  • Page 93 EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL GM 5000EA spare parts list Order No. Designation 2367744 4 fi nger trigger for GM 5000EA 2315709 Protection cap valve needle Adapter GM 5000EA, complete For details, see Chapter 14.2.4 2314361 Hook Handle ES 5000 Air (USA), complete For details, see Chapter 14.5.

  • Page 94: Gm 5000Ea Adapter

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.2.4 GM 5000EA ADAPTER Dismantling and assembling see Chapter 10 B_04367...
  • Page 95 GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL Spare parts list adapter Order No. Designation Adapter GM 5000EA, complete 2309391 Air manifold ring, Air 2307180 O-ring, sheathed 2312179 Valve housing Air, complete (steel) 2312176 Valve housing Air, complete (PEEK)

  • Page 96: Gm 5000Ea Handle

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.2.5 GM 5000EA HANDLE Dismantling and assembling see Chapter 10 B_06067...
  • Page 97 Type plate left, GM5000EA - FM* 2344490 Type plate right, GM5000E - FM* 9971364 O-ring 2326335 Service set GA 5000EA = Wearing part = Included in service set Note: * Type plates may only from WAGNER staff or a skilled person be replaced!

  • Page 98: Accessories Spare Parts Lists

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.3 ACCESSORIES SPARE PARTS LISTS Notes concerning AR5000 D8 nd D12 nozzles: Parts 3 and 4 can be pushed out of the nozzle with a suitable pin ( 2.0 – 2.3 mm; 0.08 – 0.09 inch).

  • Page 99: Ar 5000 Nozzle (D8)

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.3.1 AR 5000 NOZZLE (D8) B_03263 AR 5000 nozzle (D8) spare parts list Order No. Designation 2310558 Nozzle AR 5000, complete (D8) 2327658 Nozzle, AR (D8) 2327659 Nozzle attachment, AR (D8)

  • Page 100: Nozzle Set Earv 5000

    GM 5000EA EDITION 04/2016 ORDER NUMBER DOC2344499 OPERATING MANUAL 14.3.3 NOZZLE SET EARV 5000 Low-viscosity (LV) High-viscosity (HV) EAWRV 5000 spare parts list products products Designation Order No. Order No. Nozzle set EARV 5000 2361290 2365979 Nozzle, EARV 2361273 Nozzle insert EARV...

  • Page 101: Warranty

    The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.
  • Page 102 HAZARDOUS LOCATION ELECTRICAL EQUIPMENT This certificate is issued for the following equipment: The GM 5000EA Air Spray and GM 5000EAC Air Coat Spray Manual Applicators for use in Electrostatic Finishing Applications using Class I, Group D, Spray Material when configured with VM 500 or VM 5000 Low Voltage Control Units in accordance with FM Control Document 2316160.
  • Page 104 Order No. 2344499 Edition 04/2016 Germany Phone Telefax E-mail Switzerland Phone Telefax More contact addresses on the internet at: Company/Locations/WAGNER worldwide Subject to changes without notice...

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