WAGNER GM 4700AC, GM 4700AC-H Original Operating Manual
AirCoat Manual Gun for Flat
and Round Jet Nozzles
Version 06/2018
B_02376
VERSION 06/2018
ORDER NUMBER DOC2311730
Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 8
2.5 Misuse 8
3 IDENTIFICATION 9
3.1 Explosion Protection Identication 9
3.2 Identication "X" 9
3.3 Type plate 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 11
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 12
4.2.1 Personal Safety Equipment 12
4.2.2 Safe Handling of WAGNER Spray Devices 13
4.2.3 Grounding the Unit 13
4.2.4 Product hoses 14
4.2.5 Cleaning and Flushing 15
4.2.6 Touching Hot Surfaces 15
4.2.7 Maintenance and Repair 16
4.2.8 Protective and Monitoring Equipment 16
5 DESCRIPTION 17
5.1 Components 17
5.2 Mode of Operation 17
5.3 Protective and Monitoring Equipment 17
5.4 Included Items 17
5.4.1 Version for application up to 25 MPa; 250 bar; 3625 psi 17
5.4.2 Standard equipment 17
5.5 Data 18
5.5.1 Materials of Paint-wetted Parts 18
5.5.2 Technical data 18
5.5.3 Dimensions and Connections 18
6 ASSEMBLY AND COMMISSIONING 19
6.1 Training of Assembly/Commissioning Personnel 19
6.2 Storage Conditions 19
6.3 Installation Conditions 19
6.4 Installation and Connection 20
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6.4.1 Typical AirCoat spraying system 20
6.4.2 Ventilation of the Spray Booth 20
6.4.3 Air Supply Lines 21
6.4.4 Product supply lines 21
6.5 Grounding 21
6.6 Safety Checks 21
6.7 Lacquer Preparations 21
6.8 Commissioning 22
6.8.1 Procedure 22
6.8.2 Verifying a Safe Operational Condition 22
7 OPERATION 23
7.1 Training the Operating Personnel 23
7.2 Tasks 23
7.2.1 Starting to Spray with the AirCoat 23
7.2.2 Adjusting the Spray Pattern 24
7.3 Pressure Relief/Work Interruption 24
7.4 Changing AirCoat nozzle 25
7.4.1 Cleaning AirCoat nozzle 25
7.4.2 Eliminating Nozzle Clogging 26
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8 CLEANING AND MAINTENANCE 27
8.1 Cleaning 27
8.1.1 Cleaning Personnel 27
8.1.2 Flushing and Cleaning the Spray Gun 27
8.2 Maintenance 28
8.2.1 Maintenance Personnel 28
8.2.2 Safety instructions 28
8.2.3 Safety Checks and Maintenance Intervals 29
8.2.4 Replacing the Product Hose or Air Hose 30
8.2.5 Changing or Cleaning Filter Insert 31
9 TROUBLESHOOTING AND RECTIFICATION 32
10 REPAIR WORK 33
10.1 Repair Personnel 33
10.2 Repair Notes 33
10.3 Tools 33
10.4 Replacing Parts on the Valve Rod 34
10.4.1 Replacing Valve Tappet Seals 35
10.4.2 Replacing the Rod Seal 35
10.4.3 Assembly 36
10.5 Replacing the Nozzle Seal 37
10.6 Replacing the "Air" Sealing Ring 37
10.7 Replacing the Sealing Fitting of the Round Jet Nozzle 38
10.8 Replacing the Spring Cap 38
10.9 Replacing the Filter Connection (only GM 4700AC) 39
10.9.1 Disassembly 39
10.9.2 Assembly 40
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11 FUNCTION TEST AFTER REPAIR WORK 41
12 DISPOSAL 42
13 ACCESSORIES 43
13.1 Round jet nozzle attachment 43
13.1.1 Nozzle Inserts RXX 43
13.1.2 Nozzle screw joint, complete 43
13.2 Air caps 44
13.3 Anodized Union Nut 44
13.4 AirCoat Nozzles ACF3000 44
13.5 AirCoat Pre-atomizer Nozzles AC3000 Plus 45
13.6 Push-in Filter 45
13.7 Swivel joints 46
13.8 Hose Sets for GM 4700AC 46
13.9 Hose Sets for GM 4700AC-H 46
13.10 Nozzle Extensions 46
13.11 Miscellaneous 47
14 SPARE PARTS 49
14.1 How can spare parts be ordered? 49
14.2 Spare Parts List GM 4700AC 50
14.2.1 Assembly Aids GM 4700AC and GM 4700AC-H 52
14.3 Spare Parts List GM 4700AC-H 53
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15 EU DECLARATION OF CONFORMITY 55
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1 ABOUT THESE INSTRUCTIONS
1.1 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.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
DANGER
WARNING
CAUTION
NOTICE
Notice
Explanation of warning notice:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance can result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and
how to proceed.
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.
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1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2311729
Translation of the original operating manual
Language Order no. Language Order no.
English 2311730 Danish 2369072
French 2311731 Dutch 2326027
Italian 2311732 Swedish 2391439
Spanish 2311733 Danish 2369072
Chinese 2328826 Finnish 2391441
Russian 2328825 Hungarian 2354518
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number Number of pieces
Spare part Wrench size
Marking in the spare parts lists Manual gun
Low Air AirCoat
for high-viscosity products Processing heated product (hot)
for low-viscosity products 2-component product
Position Nominal diameter
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Product pressure
generator
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
Pump or pressure tank.
associated with improper behavior as well as the necessary
protective devices and measures.
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as well
as the necessary protective devices and measures.
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.
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2 CORRECT USE
2.1 DEVICE TYPE
Manual gun for manually coating work pieces.
GM 4700AC
GM 4700AC-H
2.2 TYPE OF USE
The automatic spray gun is suitable for atomizing liquid products, particularly coating
products, using the AirCoat process.
– Non-ignitable products.
– Products in accordance with their classication in explosion class IIB.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in Directive
2014/34/EU (ATEX), (see Explosion protection marking Chapter 3.1).
2.4 PROCESSIBLE WORKING MATERIALS
Top-coat lacquers, primer paints, corrosion protection, textured lacquers, lyes, staining
solvents, clear lacquers, separating agents, etc. with a solvent or water base. If you want to
spray products other than the aforementioned, please contact a WAGNER representative.
Note:
Contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
no dry coating products, e.g. powder are processed;
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: AirCoat manual gun GM 4700AC
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
II 2G X
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (zone 1)
G Ex-atmosphere gas
X Special notice
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.5.2.
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
do not drop the device.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.
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3.3 TYPE PLATE
Serial-No. XXXXX
1
Max. p air 0.8 MPa (115 psi)
2
Max. p fluid see tension nut
3
Max. T fluid 55°C (131°F)
4
Wagner International AG, Altstaetten
Made in Switzerland
ORDER NUMBER DOC2311730
WARNING
SKIN INJECTION HAZARD
READ INSTRUCTION MANUAL
B_04161
5
6
II 2GX
Designation
1 Serial number
2 Maximum air inlet pressure
3 Maximum product pressure see spring cap
4 Maximum product temperature
(GM 4700AC = 55°C; GM 4700AC-H = 80°C - see Chapter 5.5.2)
5 Warning
6 Danger of injury from injection/read operating manual
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4 BASIC SAFETY INSTRUCTIONS
4.1 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 DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform personnel about planned
work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or vapors!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 MΩ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product hoses / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 MΩ.
Ensure that during spraying, persons wear electrically conductive gloves. The
grounding takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.
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Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. No smoking.
Ensure that the pipe joints, hoses, equipment parts and connections are
permanently, technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking
tightness strength of the connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
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 specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.
If necessary or at least every 12 months, the liquid ejection devices must 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 DGUV
100-500 Chapters 2.29 and 2.36).
– For shut down devices, the examination can be suspended until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby, the user can lose his
balance and injure himself when falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
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4.2.3 GROUNDING THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the
spray gun handle or the trigger.
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4.2.4 PRODUCT HOSES
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure
generated.
Ensure that the following information can be seen on the high-pressure hose:
– manufacturer,
– permissible operating pressure,
– date of manufacture.
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), or that the
hoses are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 MΩ.
Suction hoses may not be subjected to pressure.
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4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure
that all equipment and resources (e.g., collection tank, funnel, transport cart) are
conductive or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the 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.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with units containing aluminium or galvanized and zinc-plated parts. They
may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
– depending upon the coating product used,
– depending on the flushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of
equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External Cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects
and never spray cleaning agents with a gun. Cleaning the device must not damage
it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
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4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F:
- Identify the device with a warning label "Warning - hot surface".
Order no.
9998910 instruction label
9998911 protection label
Note: Order the two stickers together.
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4.2.7 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are
assigned to the unit.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
- Relieve the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
- Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
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4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
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5 DESCRIPTION
5.1 COMPONENTS
ORDER NUMBER DOC2311730
Designation
A
A Suspension hook
B Shaping air regulator
J
C Spring cap
D Trigger
I
E Trigger locking device
F Air connection
G Fluid inlet
H
H Union nut with nozzle protection
I Nozzle / Air cap
K
J Gun housing
K Turning handle with lter housing
P_02379
5.2 MODE OF OPERATION
If the trigger (D) is operated when the trigger locking device (E) is released, then the air
valve opens rst. Atomizing air ows through the air connection (F) to the air cap (I). The
product valve opens rst if approx. 1/2 of the trigger's path is covered. The quantity of air
for the atomization of the spray jet is preset via the external air automatic controller. The
spray pattern can be adjusted using the shaping air regulator (B).
5.3 PROTECTIVE AND MONITORING EQUIPMENT
B
C
E
D
F
G
The spray gun is secured with the locking device (E) (the locking device turned in the spraying
direction and fastened in the groove). The nozzle holder (H) has an anti-contact guard.
5.4 INCLUDED ITEMS
This AirCoat manual gun is available in two dierent versions. The choice of nozzle depends
on the application, therefore this component is not included in the standard scope of
delivery. A selection guide for spray gun accessories can be found in Chapter 13.
5.4.1 VERSION FOR APPLICATION UP TO 25 MPA; 250 BAR; 3625 PSI
Order no. Designation
1 2313585 GM 4700AC 25 MPa, NPSM1/4" product connection
1 2315700 GM 4700AC-H 35 MPa, NPSM1/4" product connection
(H = for processing heated product)
Please always order the nozzle separately.
5.4.2 STANDARD EQUIPMENT
Order no. Designation
1 2316429 CE Declaration of Conformity
1 2311729 Operating manual, in German
1 see Chapter 1.3 Operating manual in local language
1 394335 Spring cap 16 MPa; 160 bar; 2320 psi
For special versions the delivery note applies.
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