WAGNER GM 50000EAC Translation Of The Original Operating Manual
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WAGNER GM 50000EAC Translation Of The Original Operating Manual

WAGNER GM 50000EAC Translation Of The Original Operating Manual

Electrostatic aircoat spray gun
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Electrostatic AirCoat Spray Gun
for manual operation
for fl at or round jet nozzles
Translation of the Original
Operating Manual
Version 05/2015
B_03154

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Summary of Contents for WAGNER GM 50000EAC

  • Page 1 Translation of the Original Operating Manual Version 05/2015 Electrostatic AirCoat Spray Gun for manual operation for fl at or round jet nozzles B_03154...

  • 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 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Table of Contents ASSEMBLY AND COMMISSIONING Training Assembly/Commissioning Staff Storage Conditions Installation Conditions Assembly and Installation 6.4.1 Typical Electrostatic Spraying System 6.4.2 Ventilation of the Spray Booth 6.4.3 Air Supply 6.4.4 Product Supply 6.4.5 Grounding Preparation of Lacquer...
  • Page 5 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Table of Contents TROUBLESHOOTING AND RECTIFICATION REPAIR WORK 10.1 Repair Staff 10.2 Safety Instructions 10.3 Spray Gun 10.3.1 Tools 10.3.2 Disassembly of the Spray Gun 10.3.3 Cleaning the Parts After Disassembly 10.3.4 Assembling the Spray Gun FUNCTIONAL CHECK AFTER REPAIR 11.1 Checking the High-voltage...

  • Page 6: About These Instructions

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 operating and service staff .

  • Page 7: Languages

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL LANGUAGES The GM 5000EAC operating manual is available in the following languages: Language Order No. Language Order No. German 2310481 English 2319150 French 2320152 Italian 2320153 Spanish 2320154 Dutch 2358832 Danish 2359979 Swedish 2360027 Additional languages on request or at: ABBREVIATIONS...

  • Page 8: Terminology For The Purpose Of This Manual

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 Staff qualifi cations Trained person Is instructed in the tasks assigned to him/her, the potential risks associated with improper behavior as well as the necessary protective devices and measures.

  • Page 9: Correct Use

    (See Chapter 3. "Explosion Protection Identifi cation".) SAFETY PARAMETERS WAGNER accepts no liability for any damage arising from incorrect use. Use the device only to work with the products recommended by WAGNER. Only operate the device as a whole. Do not deactivate safety fi xtures.

  • Page 10: Processible Working Materials

    VM 5000 control unit or on the spray gun. High kV value, low μA value = ok Low kV value, high μA value = excessive conductivity of the paint No wrap-around Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter application problems.

  • Page 11: Reasonably Foreseeable Misuse

    EDITION 05/2015 ORDER NUMBER DOC2319150 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; performing unauthorized conversions or modifi cations to the device;...

  • Page 12: Identification

    As defi ned in the Directive 94/9/EC (ATEX), the device is suitable for use in potentially explosive areas. Device type: GM 5000EAC electrostatic manual spray gun Manufacturer: J. Wagner AG CH-9450 Altstätten, Switzerland SIRA 11 ATEX5374X European Communities Notifi ed body: PTB...

  • Page 13: Type Plate

    - VM 5000 control unit WARNING Incorrect use! Risk of injury and damage to the device. Connect the GM 5000EAC manual spray gun only to original WAGNER control units. TYPE PLATE 1 Warning: Danger of becoming injured by high-pressure jet 2 Device type...

  • Page 14: General Safety Instructions

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 ELECTRICAL EQUIPMENT Electrical devices and equipment To be provided in accordance with the local safety requirements with regard to the operating mode and ambient infl uences.

  • Page 15: Safety Instructions For Staff

    "Troubleshooting" chapter. If necessary or at least every 12 months, the liquid ejection devices should be checked for safe working conditions by an expert (e.g., WAGNER Service Technician) in accordance with the guidelines for liquid ejection devices (ZH 1/406 and BGR 500 Part 2 Chapter 2.29 and 2.36).

  • Page 16: Grounding The Device

    EDITION 05/2015 ORDER NUMBER DOC2319150 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. See chapter "Grounding".

  • Page 17: Cleaning And Flushing

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 paint manufacturer. Ensure that the fl ash point of the cleaning agent is at least 15 K above the ambient temperature or that cleaning is undertaken at a cleaning station with technical ventilation.

  • Page 18: Handling Hazardous Liquids, Varnishes And Paints

    EDITION 05/2015 ORDER NUMBER DOC2319150 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. Take the specifi ed protective measures, in particular wear safety goggles, protective clothing and gloves, as well as skin protection cream if necessary.

  • Page 19: 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 20: Description

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL DESCRIPTION STRUCTURE (STANDARD VARIANT) Note: The nozzle parts (pos. 6; 7; 13 and 14) do not belong to the basic equipment of the spray gun. The diff erent versions can be found in Chapter 13 "Accessories". B_03156 Description Description...

  • Page 21: Securing The Spray Gun Against Actuation

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 5.1.1 SECURING THE SPRAY GUN AGAINST ACTUATION Secure the spray gun against actuation: Use the trigger lock (11) to engage the trigger (12). Note: To secure the entire spraying system, pressure must be relieved as described in Chapter 7.3.4.
  • Page 22 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL The trigger can be used to activate, one after the other, the various functions of the spray gun. Distance Description AirCoat air opens. AirCoat air opened and electrostatic (high-voltage) activated. Display (2) for "spray current" on the spray gun activated.

  • Page 23: Protective And Monitoring Equipment

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL PROTECTIVE AND MONITORING EQUIPMENT The following functions are provided for safety: - trigger lock (11); - anti-contact guard for fl at jet nozzle (5). WARNING Protective and monitoring equipment! Risk of injury and damage to the device. Protective and monitoring equipment must not be removed, modifi ed or rendered unusable.

  • Page 24: Technical Data

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL TECHNICAL DATA Maximum air pressure 0.8 MPa; 8 bar; 116 psi Maximum product pressure 25 MPa; 250 bar; 3626 psi Fluid inlet NPSM 1/4"-18 Air connection G 1/4" A Input voltage maximum 20 Vpp Input current maximum 1.0 A AC Output voltage...

  • Page 25: Spraying Procedure

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL SPRAYING PROCEDURE 5.6.1 SPRAYING PROCEDURE FOR AIRCOAT ROUND SPRAY In the AirCoat process, the spray product is atomized under a pressure of 3-15 MPa; 30-150 bar; 435-2,176 psi. With the help of an air pressure of 0-0.25 MPa; 0-2.5 bar; 0-36 psi, a soft, spray jet is produced. The spray jet diameter can be adjusted by turning the nozzle nut.

  • Page 26: Electrostatic Effect

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 5.6.3 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 27: Assembly And Commissioning

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 undertake commissioning. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

  • Page 28: Typical Electrostatic Spraying System

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 6.4.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM B_03158 Description GM 5000EACF spray gun Gun cable Grounding cable Description Description Pneumatic pump 10 Compressed air connection 17 Return valve Sliding tables 18 Tank for return fl ow 11 Stop valve Air pressure regulator + air 12 Air pressure regulator...

  • Page 29: Ventilation Of The Spray Booth

    (spraypack). The system shown in the fi gure is only one example of an electrostatic 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 30 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL...

  • Page 31: Air Supply

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 6.4.3 AIR SUPPLY The use of an air fi lter with air regulator (6) 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 32: Grounding

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 6.4.5 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 33 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Grounding scheme (example) Conveyor Control unit Mains cable Work piece Grounding cable Pump or pressure tank Paint tank or tank for return R max < 1 MΩ fl ow Spraying stand B_03234 Floor, static dissipative Minimum cable cross-section Control unit Product supply...

  • Page 34: Preparation Of Lacquer

    Processing of up to 60 DIN/4 seconds is generally possible without problem if high coating thicknesses are required. With the WAGNER AirCoat fl at jet spraying process, the diff erent viscosities of the lacquer are optimally covered by two air cap types. These can be found in "Accessories".

  • Page 35: Commissioning

    Visually check the permissible pressures for all the system components. Check the level of the separating agent in the WAGNER pneumatic pump 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 36: Gun Cables And Gun Cable Extensions

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 6.6.3.1 GUN CABLES AND GUN CABLE EXTENSIONS WARNING Sparks form when the plug is removed! Explosion hazard. When using the spray gun in potentially explosive areas: The cable connection on the gun and the connection to any cable extensions may not be disconnected or connected in this area.

  • Page 37: Verifying A Safe Operational Condition

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 38: Operation

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 and fi t 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 39: Emergency Deactivation

    EDITION 05/2015 ORDER NUMBER DOC2319150 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. Tighten the union nut, especially with nozzle in the cleaning position.

  • Page 40: Work

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL WORK Ensure that: the regular safety checks are carried out in accordance with Chapter 8.2.3, commissioning is carried out in accordance with Chapter 6.6. B_03158...

  • Page 41: Filling With Working Material

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.1 FILLING WITH WORKING MATERIAL 1. Place empty tank (18) under return tube (8). 2. Place suction hose (7) in the tank with working material (19). Note: If the pump is equipped with a rigid suction system, it should only be dipped in into the working material up to the middle of the inlet housing at the maximum! 3.
  • Page 42 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Setting the Spray Pattern Using the Air Pressure Regulator (6) The air pressure regulator regulates the air supply (shaping and atomizing air) to the gun. B_00071 No air Not enough air Correct amount of air Spray pattern and air regulation Air regulation regulates the ratio of shaping/atomizing air.

  • Page 43: Spraying

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.3 SPRAYING 1. Secure gun with trigger lock and insert the desired nozzle. 2. Turn on the control unit. See corresponding operating manual. 3. Start up with product supply set to approx. 8 MPa; 80 bar; 1,160 psi operating pressure. See corresponding operating manual.

  • Page 44: Pressure Relief / Work Interruption

    EDITION 05/2015 ORDER NUMBER DOC2319150 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. - The spraying system is moved to another location.

  • Page 45: Flushing Out Clogged Round Jet Nozzles

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.5 FLUSHING OUT CLOGGED ROUND JET NOZZLES DANGER Exploding gas / air mixture! Danger to life from fl ying parts and burns. Never spray into a closed tank. Ground the tank. 1. Use nozzle spanner (2) to loosen nozzle insert (1) by a half turn.

  • Page 46: Changing From Aircoat Round Jet To Aircoat Flat Jet

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.7 CHANGING FROM AIRCOAT ROUND JET TO AIRCOAT FLAT JET Flush spray gun 1. Switch off control unit. 2. Relieve pressure Chapter 7.3.4. 3. Connect the system to the fl ushing agent supply. 4.
  • Page 47 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL B_03162...

  • Page 48: Replacing The Aircoat Flat Jet Nozzles

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.8 REPLACING THE AIRCOAT FLAT JET NOZZLES 1. Switch off control unit. 2. Relieve pressure Chapter 7.3.4. 3. Secure the spray gun with the trigger lock. 4. Unscrew union nut completely (12) and unscrew air cap (10). 5.

  • Page 49: Cleaning Of The Nozzle Parts

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.9 CLEANING OF THE NOZZLE PARTS The ACF5000 AirCoat nozzles (11), the nozzle inserts (3) and the nozzle screw connection (7) can be placed in a cleaning solvent recommended by the lacquer manufacturer. All other nozzle parts may not be put into cleaning solvent. Clean these parts with a cleaning solvent recommended by the lacquer manufacturer and dry with a cloth or blow gun.

  • Page 50: Eliminate Nozzle Clogging

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.10 ELIMINATE NOZZLE CLOGGING 1. Switch off control unit. 2. Relieve pressure Chapter 7.3.4. 3. Secure the spray gun (1) using the trigger lock (14). 4. Unscrew union nut completely (12) and remove air cap (10). 5.
  • Page 51 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL B_04388 ACF5000 nozzle in spray position ACF5000 nozzle in cleaning position...

  • Page 52: Changing The Valve Housing

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 7.3.11 CHANGING THE VALVE HOUSING NOTICE Changing the valve housing! Damage to the device. Activate the spray gun trigger when changing the valve housing. To prevent damage to the gun (valve seat rubs on the valve needle, valve needle may loosen), activate the spray gun trigger when changing the valve housing.
  • Page 53 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL...

  • Page 54: 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 Chapter "Spare parts" and that are assigned to the unit.
  • Page 55 EDITION 05/2015 ORDER NUMBER DOC2319150 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 switched back on! The spray gun must be separated from the high-voltage supply before any cleaning work is started! Only electrically conductive tanks may be used for cleaning and...

  • Page 56: Cleaning And Flushing The Device

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 8.1.3 CLEANING AND FLUSHING THE DEVICE The spray gun and the device must be cleaned and fl ushed daily. The cleaning and fl ushing agents used must be compatible with the working material. WARNING Incompatibility of cleaning/fl ushing agent and working medium! Risk of explosion and danger of poisoning by toxic gases.
  • Page 57 EDITION 05/2015 ORDER NUMBER DOC2319150 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. Flush spray gun 1. Switch off control unit. 2. Relieve pressure Chapter 7.3.4.

  • Page 58: Maintenance

    In accordance with the guideline for liquid ejection devices (ZH  1/406 and BGR  500 Part 2 Chapter 2.29 and Chapter 2.36): - 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 59: 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 Chapter "Spare parts" and that are assigned to the unit.

  • Page 60: Product Hoses, Tubes And Couplings

    – 6 years from the date of the hose crimping (see fi tting embossing). – 10 years from the date of the hose imprinting. Fitting Hose imprinting Meaning embossing Meaning WAGNER Name / Manufacturer (if present) Date of manufacture yymm xxx bar Pressure...

  • Page 61: Troubleshooting And Rectification

    Connect gun and gun cable/check for defects Check paint resistance (see Chapter 2.5) Seal in end piece defective Repair by WAGNER service Air-passages damp Clean and dry air-passages Back-spray Poor grounding at object Check grounding Distance between spray gun and object...
  • Page 62 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL...

  • Page 63: Repair Work

    In accordance with the guideline for liquid ejection devices (ZH  1/406 and BGR  500 Part 2 Chapter 2.29 and Chapter 2.36): - 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 64: Spray Gun

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 10.3 SPRAY 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 SW2 - Allen wrench SW3 - Allen wrench SW5 - Open-end wrench SW5 - Open-end wrench SW6 - Open-end wrench SW8...

  • Page 65: Disassembly Of The Spray Gun

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 10.3.2 DISASSEMBLY OF THE SPRAY GUN SW12 SW12 B_03194 Air hose When unscrewing the air hose, a second open-ended/box wrench must be used for bracing. Torx® 25 SW19 B_03195 SW21...
  • Page 66 - Screw the wood screw ( 3 mm; 0.12 inches, length 40 mm; 1.6 inches) into the fi tting (25), max. 6 mm deep. - Pull out straight with suitable pliers. Possibly rotate clockwise simultaneously. - Thereafter, the fi tting must be replaced. If the fi tting is broken in the gun adapter, WAGNER Service must be contacted.
  • Page 67 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Valve needle assembly tool, Order No. 2309368 B_04786 Clamping screw assembly tool, Valve housing: Use an assembly tool or socket or ring spanner Order No. 2325263 (no open-end wrench). Valve tip (27) Loosen valve tip by hand using the valve needle assembly tool (Order No.
  • Page 68 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 1. Remove pressure spring (4). 2. Loosen clamping screw (1) with assembly tool (5). B_04787 3. Unscrew valve rod unit (2, 6, 7). The packing (3) is also unscrewed and removed. 4. Only as required: Remove rod seal (10).

  • Page 69: Cleaning The Parts After Disassembly

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 70: Assembling The Spray Gun

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 10.3.4 ASSEMBLING THE SPRAY GUN Assembly aids: Order No. Description 9992698 Vaseline white PHHV II 9992511 Loctite 243 9992609 Anti-seize paste * Use Vaseline sparingly Only as required (if the seal was removed): press in using handle seal assembly tool (Order No.
  • Page 71 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Valve rod unit Set length adjusting measure X with withdrawal nut (7) and then fasten the threaded pin (6) using an Allen key SW2. B_04791 Wear gloves! The outside thread of the packing (9) must be free of lacquer.
  • Page 72 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Gold contact sleeve (10) Check whether the gold contact sleeve is located in the end piece (11). Otherwise, insert the sleeve onto the resistance (12). Ensure the correct B_04379 insertion position and installation direction. Ensure the correct insertion position.
  • Page 73 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Clean and degrease the inside of the adapter and SW19 the cascade, then grease 2.5 Nm the cascade surface with Vaseline. Fitting (25) Before assembling the product hose, SW22 check that no fi tting (25) is in the gun adapter! Check the fi tting for damage and replace if necessary (Order No.
  • Page 74 EDITION 05/2015 ORDER NUMBER DOC2319150 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_03206 0.8 Nm Cover (5) The cover must be handled carefully and not Ensure the SW12...
  • Page 75 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Flat jet nozzle Assembly see Chapter 14.3.1 Diverse nozzle sizes, see Chapter 13.2 Round jet nozzle Assembly see Chapter 14.3.2 Diverse nozzle sizes, see Chapter 13.1 B_03208 Air hose When screwing on the air hose, a second open-ended/ring spanner must be used for bracing.

  • Page 76: Functional Check After Repair

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL FUNCTIONAL CHECK AFTER 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 . 11.1 CHECKING THE HIGH-VOLTAGE Necessary test equipment:...
  • Page 77 EDITION 05/2015 ORDER NUMBER DOC2319150 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. 175519 B_03212...

  • Page 78: Air Test

    EDITION 05/2015 ORDER NUMBER DOC2319150 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 B_03213 The air valve must switch on and off correctly.

  • Page 79: 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 80: Accessories

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL ACCESSORIES 13.1 ROUND SPRAY NOZZLES 13.1.1 ACR 5000 ROUND JET NOZZLE CAP Order No. Designation 2309883 ACR 5000 round jet nozzle cap (with nozzle spanner, without AC round jet nozzle insert) B_03210 13.1.2 AIRCOAT ROUND JET NOZZLE INSERTS The round jet nozzles are especially suited to spray pipes, profi les and complex work pieces.

  • Page 81: Acf5000 Aircoat Flat Jet Nozzles

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 13.2.2 ACF5000 AIRCOAT FLAT JET NOZZLES Application B_03163 395107 07/10 0.18; 0.007 10° Natural lacquer 395207 07/20 20° 395407 07/40 40° 395109 09/10 0.23; 0.009 10° Clear lacquer 395209 09/20 20° Oils 395309 09/30 30°...
  • Page 82 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Application B_03163 395219 19/20 0.48; 0.019 20° Rust proofi ng paints 395319 19/30 30° Latex paints 395419 19/40 40° 395519 19/50 50° 395619 19/60 60° 395819 19/80 80° 395221 21/20 0.53; 0.021 20° Mica paints 395421 21/40...

  • Page 83: Filter

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 13.3 FILTER Order No. Designation 3204604 Edge fi lter 60 mesh (white) 3204605 Edge fi lter 100 mesh (black) B_00019 9999002 Edge fi lter 200 mesh (yellow)

  • Page 84: Hoses And Electric Cables

    Air hose, complete DN6.5 (20.5 m) 2339160 Gun cable GM 5000E (25.0 m) 20.5 m 3676437 Protection hose fabric PP30 (20.5 m) In the large WAGNER Accessories Catalogue for wet coating you will also fi nd reduction and material fi ttings.
  • Page 85 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Hose colors: Product hose yellow Air hose blue Dimensions: Air hose: inside diameter 6.5 mm; 0.26 inch Product hose: inside diameter 4 mm; 0.16 inch, nominal pressure 25 MPa; 250 bar; 3,626 psi Material of product hose: PA (****) (**)

  • Page 86: Hose Sets For Low-Resistance Products

    Air hose, complete DN6.5 (20.5 m) 2339160 Gun cable GM 5000E (25.0 m) 20.5 m 3676437 Protection hose fabric PP30 (20.5 m) In the large WAGNER Accessories Catalogue for wet coating you will also fi nd reduction and material fi ttings.
  • Page 87 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Hose colors: Product hose grey Air hose blue Dimensions: Air hose: inside diameter 6.5 mm; 0.26 inch Product hose: inside diameter 4 mm; 0.16 inch, nominal pressure 25 MPa; 250 bar; 3,626 psi Material of product hose: FEP (**) A****...

  • Page 88: Product Hose 1.5 Mm

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 13.4.3 PRODUCT HOSE 1.5 MM B_04197 Order No. Designation 2352607 Product hose set AC 1.5 mm, complete 13.4.4 GUN CABLES AND GUN CABLE EXTENSIONS GM 5000E gun cable Length 10 m; 32.8 ft 15 m; 49.2 ft 20 m;...

  • Page 89: Miscellaneous

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 13.5 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 2309368 Valve needle assembly tool B_03451...
  • Page 90 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 128901 Nozzle spanner ACR 2325263 Clamping screw assembly tool B_03681 2326485 Wall mount GM 5000E (left/right) B_03699 2324766 Swivel joint air B_03720 2327060 Fitting-SJM-GM5000EAC-1/4"NPS (swivel product) B_03719 2327061 Swivel joint set GM 5000EAC B_03720 B_03719...

  • Page 91: 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 Chapter "Spare parts" and that are assigned to the unit.

  • Page 92: Gm 5000Eac Spray Gun

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 14.2 GM 5000EAC SPRAY GUN Dismantling and assembly See Chapter 10 B_03153...
  • Page 93 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL GM 5000EAC spare parts list Order No. Designation 2309871 Basic version GM 5000EAC Adapter GM 5000EAC, complete For details, see Chapter 14.2.1 2314361 Hook Handle GM 5000EAC, complete For details, see Chapter 14.2.2 9900308 Hexagon socket cylinder head screw 2312183...

  • Page 94: Gm 5000Eac Adapter

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 14.2.1 GM 5000EAC ADAPTER B_04368 Dismantling and assembly See Chapter 10 123 ±0.1 mm 4.8425 ±0.004 inch...
  • Page 95 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL Spare parts list adapter Pos K Order No. Designation Adapter GM 5000EAC, complete 2312175 Valve housing AC, complete 2312186 Valve needle AC, complete 2353476 Adapter GM 5000EAC 2313314 Air manifold ring AC 2307180 O-ring, sheathed 2314283 Contacting AC...

  • Page 96: Gm 5000Eac Handle

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 14.2.2 GM 5000EAC HANDLE Dismantling and assembly See Chapter 10 B_04775...
  • Page 97 Type plate, left GM 5000EAC* 2309810 Type plate, right GM 5000E* 9971364 O-ring 2326336 Service set GM 5000EAC = 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

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 14.3 ACCESSORIES SPARE PARTS LISTS 14.3.1 FAN SPRAY NOZZLES B_03168 Flat jet nozzles spare parts list Order No. Designation 2315775 Union nut AC, complete 2309882 Air cap ACF 5000 - LV (red) 2314203 Air cap ACF 5000 - HV (blue) 2311777 Nozzle guard AC...

  • Page 99: Acr 5000 Round Jet Nozzle Cap

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 14.3.2 ACR 5000 ROUND JET NOZZLE CAP B_03169 ACR 5000 round jet nozzle cap spare parts list Order No. Designation 2309883 Round jet nozzle cap ACR 5000 2307220 Nozzle nut 2315310 O-ring 132351 Nozzle screwed connection holder 2307219 Nozzle body...

  • Page 100: Warranty And Conformity Declarations

    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 101: Ce Declaration Of Conformity

    Spray gun: EC Certifi cate of Conformity The CE certifi cate of conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2310487...

  • Page 102: Ec Type Examination Certificate

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 15.4 EC TYPE EXAMINATION CERTIFICATE...
  • Page 103 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL...
  • Page 104 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL...

  • Page 105: Notes On German Regulations And Guidelines

    EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL 15.5 NOTES ON GERMAN REGULATIONS AND GUIDELINES Technical rule for operating safety Part 2, Chapter 2.36 Working with Liquid Ejection Devices Part 2, Chapter 2.29 Working with Coating Products Avoiding ignition risks Equipment for cleaning work pieces with solvents Guidelines for liquid ejection devices Painting rooms and equipment Electrostatic coating...
  • Page 106 EDITION 05/2015 ORDER NUMBER DOC2319150 OPERATING MANUAL...
  • Page 108 Order No. 2319150 Edition 05/2015 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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