Page 1
B_03229
C
us
Electrostatic Air Spray Gun
for manual operation
for at or round jet nozzles
Version 04/2016
Translation of the Original
Operating Manual
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.4 Abbreviations 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Type 10
2.2 Type of Use 10
2.3 Use in an Explosion Hazard Area 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Reasonably Foreseeable Misuse 12
2.7 Residual Risks 12
3 IDENTIFICATION 13
3.1 Explosion Protection Identi cation FM 13
3.2 Type Plate 14
4 GENERAL SAFETY INSTRUCTIONS 15
4.1 Safety Instructions for the Operator 15
4.1.1 Electrical Equipment 15
4.1.2 Personnel Quali cations 15
4.1.3 Safe Work Environment 15
4.2 Safety Instructions for Sta 16
4.2.1 Safe Handling of WAGNER Spray Devices 16
4.2.2 Grounding the Device 17
4.2.3 Product Hoses 17
4.2.4 Cleaning and Flushing 18
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 19
4.2.6 Touching Hot Surfaces 19
4.3 Protective and Monitoring Equipment 19
4.4 Use in Areas Subject to Explosion Hazards 20
4.4.1 Safety Regulations 20
4.5 Safety-Relevant Information about Discharges 20
5 DESCRIPTION 21
5.1 Structure (Standard Variant) 21
5.2 Mode of Operation 22
5.3 Scope of Delivery 24
5.3.1 Design Variants 25
5.4 Technical Data 26
5.5 Spraying Procedure 28
5.5.1 Spraying Procedure for Round Jet Air Atomizing 28
5.5.2 Spraying Procedure for Flat Jet Air Atomizing 29
5.5.3 Electrostatic E ect 30
5.6 The WAGNER Electrostatic Air Spraying System 31
5.6.1 Pressure Settings for Round Jet Nozzles 31
5.6.2 Pressure Settings for Flat Jet Nozzles 32
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Table of Contents
5.6.3 Adjusting Screw 32
5.6.4 Electrostatic and Atomization 33
5.6.5 Discharge Quantity Measurements 33
6 ASSEMBLY AND COMMISSIONING 34
6.1 Training Assembly/Commissioning Sta 34
6.2 Storage Conditions 34
6.3 Installation Conditions 34
6.4 Transportation 34
6.5 Assembly and Installation 35
6.5.1 Typical Electrostatic Air Spraying System 35
6.5.2 Ventilation of the Spray Booth 36
6.5.3 Air Supply 37
6.5.4 Product Supply 37
6.5.5 Grounding 38
6.6 Preparation of Lacquer 40
6.6.1 Viscosity Conversion Table 40
6.7 Commissioning 41
6.7.1 Safety Instructions 41
6.7.2 Preparation for Commissioning 41
6.7.3 Commissioning 41
6.7.3.1 Gun Cables and Gun Cable Extensions 42
6.7.4 Verifying a Safe Operational Condition 43
7 OPERATION 44
7.1 Training the Operating Sta 44
7.2 Safety Instructions 44
7.2.1 Emergency Deactivation 45
7.2.2 General Rules for Making Adjustments to the Spray Gun 45
7.3 Working 46
7.3.1 Filling with Working Material 46
7.3.2 Checking the Spray Pattern (Without Electrostatics) 47
7.3.3 Spraying 48
7.3.4 Pressure Relief/Work Interruption 50
7.3.5 Changing from Air Round Jet to Air Flat Jet 51
7.3.6 Cleaning of the Nozzle Parts 52
7.3.7 Changing the Valve Housing 52
8 CLEANING AND MAINTENANCE 53
8.1 Cleaning 53
8.1.1 Cleaning Sta 53
8.1.2 Safety Instructions 53
8.1.3 Cleaning and Flushing the Device 55
8.2 Maintenance 57
8.2.1 Maintenance Sta 57
8.2.2 Safety Instructions 57
8.2.3 Safety Checks 58
8.2.4 Product Hoses, Tubes and Couplings 59
9 TROUBLE SHOOTING AND RECTIFICATION 60
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Table of Contents
10 REPAIR WORK 61
10.1 Repair Sta 61
10.2 Safety Instructions 61
10.3 Dismantling of the Gun 62
10.3.1 Tools 62
10.3.2 Dismantling of the Spray Gun 63
10.3.3 Cleaning the Parts After Disassembly 66
10.3.4 Assembling the Spray Gun 67
11 FUNCTION TEST AFTER THE REPAIR 72
11.1 Checking the High voltage 72
11.2 Air Test 74
11.3 Product Pressure Test 74
11.4 Test of Spray Pattern 74
12 DISPOSAL 75
13 ACCESSORIES 76
13.1 Valve Housing 76
13.2 Valve Tips 76
13.3 Round Spray Nozzles 76
13.3.1 AR 5000 Air Caps 76
13.3.2 AR 5000 Nozzles 76
13.3.3 Nozzle set EARV 77
13.4 Flat Jet Nozzles 77
13.4.1 AF 5000 Air Caps 77
13.4.2 AF 5000 Nozzles 78
13.5 Hoses and Electric Cables 79
13.5.1 Standard Hose Sets and Components 79
13.5.2 Hose Sets for Low-resistance Products 81
13.5.3 Spiral Hose (no FM Approval) 84
13.5.4 Gun Cables and Gun Cable Extensions 84
13.5.5 Air Regulation 84
13.5.6 4 Finger Trigger 85
13.6 Miscellaneous 86
14 SPARE PARTS 87
14.1 How Can Spare Parts Be Ordered? 87
14.2 GM 5000EA Spray Gun 88
14.2.1 Basic version GM 5000EA 88
14.2.2 Spiral Hose for GM 5000EA 90
14.2.3 4 Finger Trigger for GM 5000EA 92
14.2.4 GM 5000EA Adapter 94
14.2.5 GM 5000EA Handle 96
14.3 Accessories Spare Parts Lists 98
14.3.1 AR 5000 Nozzle (D8) 99
14.3.2 AR 5000 Nozzle (D12) 99
14.3.3 Nozzle Set EARV 5000 100
15 WARRANTY 101
15.1 Important Notes Regarding Product Liability 101
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Table of Contents
15.2 Warranty Claim 101
15.3 FM Approval 102
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OPERATING MANUAL
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1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating 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 - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its
consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
1 ABOUT THESE INSTRUCTIONS
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.
Electrostatic spray guns may only be operated by trained personnel.
1.1 PREFACE
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1.3 LANGUAGES
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Electrostatics Air
Manual gun
Low R Low-resistance
Polyether ether ketone (high temperature-resistant thermoplastic plastic)
Stainless steel
Position
Number of pieces
Wrench size
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:
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OPERATING MANUAL
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Product pressure
generator
Pump or pressure tank
Sta quali 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.
Electrically trained
person
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.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person A person who, based on his/her technical training, experience
and recent vocational experience, has su cient technical
knowledge in the area of electrostatic coating 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.
in the context of BGI 764
Additional requirements for skilled persons can also be
referred to in TRBS1203(2010): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards,
and explosion protection (where applicable).
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic manual spray gun for manual coating of grounded work pieces.
2.2 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.
WAGNER forbids any other use!
2.4 SAFETY PARAMETERS
2.3 USE IN AN EXPLOSION HAZARD AREA
The GM 5000EA electrostatic manual spray gun is suitable for coating electrically
conductive objects with liquid coating products and can be used in potentially explosive
areas (see explosion protection marking in Chapter 3).
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 xtures.
Use only WAGNER original spare parts and accessories.
The device may only be operated under the following conditions:
The operating personnel must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be
observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.
The electrostatic manual spray gun may only be operated if all parameters are set and all
measurements/safety checks are carried out correctly.
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2.5 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 > 150 kΩ (according to the WAGNER scale).
Equipped with a special product hose for low-resistance sprayed substances (available
as an accessory), you can also successfully process sprayed substances with an
electrical resistance > 50 kΩ (according to the WAGNER scale).
The application e ectiveness is always dependant on the composition of the product
being used, e.g. pigments or resin.
Conversion of Paint Resistance
There are paint resistance measuring devices available on the market that do not directly
measure the speci c paint resistance.
Multiplying the result of the measurement with the device-speci c cell constant (K), we
obtain the speci c resistance value of the product.
Example:
With WAGNER's paint resistance measuring device the cell constant is K =123.
Measured value according to the WAGNER
scale
Speci c resistance (RS)
Notice
Using sprayed substances with too low an electrical resistance, the application of
electrostatics does not show any e ect, i.e. there is no "paint wrap around" on the object
to be sprayed.
The suitability of the spray product with regard to the charging ability can be read from the
actual values for high-voltage (kV) and for the spray current (μA) shown in the illuminated
displays either on the 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.
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2.6 REASONABLY FORESEEABLE MISUSE
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Speci c measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing
Operation,
allergies maintenance,
Observe safety data
sheets
disassembly
Lacquer in air
outside the de ned
working area
Lacquering outside
the de ned working
area
Inhalation of
substances
hazardous to health
Observe work and
operation instructions
Operation,
maintenance
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 modi cations to the device;
processing inadmissible coating products;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described
in the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food;
use in the pharmaceutical sector.
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C
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OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION FM
This device has been manufactured and tested by FM, according to the FM (Factory Mutual)
standard "Class Number 7260" (Approval Standard for Electrostatic Finishing Equipment).
All tested combinations of devices including accessories are given in the FM Control
Document with part number 2316160.
Temperature notes
- Maximum surface temperature: 85 °C; 185 °F
- Maximum permissible product temperature: 50 °C; 122 °F
- Permissible ambient temperature: 0 to +40 °C; +32 to +104 °F
For electrostatic nishing applications using class I,
group D, spray product
In accordance with document 2316160
Cable connections
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)
Incorrect use!
Risk of injury and damage to the device.
Connect the GM 5000EA manual spray gun only to original
WAGNER control units.
WARNING
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GM 5000EA
B_04191
1
GM 5000EA
Art. Nr.:
0.8MPa; 8bar; 116psimax. mat. pressure:
max. air pressure: 0.8MPa, 8bar; 116psi
2344472
current: max. 100μA D C
high voltage: max. 70kV DC
J. Wagner AG
CH-9450 Altstätten
In accordance
with 2316160
FM
CUS
APPROVED
For Electro. Fin. Appl. CL. I, GP. D, Spray Matl.
Ta = 0°C to 40°C, Temp code = T6
1
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3.2 TYPE PLATE
Serial number
The serial number (S) on the underside
of the handle.
1 Warning: Danger of becoming injured by high-
pressure jet
2 Device type
3 Article number
4 Maximum high voltage
5 Maximum current
6 Maximum product pressure
7 Maximum air pressure
8 Do not dispose of used electrical equipment with
household refuse.
9 Identi cation and test centre
10
Type plate left Type plate right
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OPERATING MANUAL
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
Ensure that the device is only operated, maintained and repaired by trained persons.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
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
100megohms.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle or the trigger guard.
If protective clothing is worn, including gloves, it has to comply with EN1149-5. The
measured insulation resistance must not exceed 100 megohms.
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that the following components of a safe working environment are available:
- Product/air hoses adapted to the working pressure.
- Personal safety equipment (breathing and skin protection).
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient in uences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Connect 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.
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4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
Anyone tted with a pacemaker must not enter the high-voltage area!
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
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.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun brie y in a position.
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 and 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.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
used ushing agents.
Ensure that the product hose is 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 lifts), 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.
Make sure that the hoses are never used to pull or move the equipment.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coe cient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.2 GROUNDING THE DEVICE
Friction, 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".
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.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
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4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non- ammable cleaning and ushing agents.
Observe the speci cations 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.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items 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:
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 electrical component is cleaned with nor even immersed into solvent.
Which cleaning agent is used to clean the spray gun depends on which parts of the
spray gun have to be cleaned and which product has to be removed. When cleaning the
spray gun, only use non-polar cleaning agents to prevent conductive residues on the
surface of the spray gun. Should it however, be necessary to use a polar cleaning agent,
all residues of this cleaning agent have to be removed by using a non-conductive and
non-polar cleaning agent, once the cleaning is nished.
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4.2.6 TOUCHING HOT SURFACES
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.
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 speci ed protective measures, in particular wear safety goggles, protective
clothing and gloves, as well as skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For su cient 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.
4.3 PROTECTIVE AND MONITORING EQUIPMENT
Protective and monitoring equipment must not be removed, modi ed 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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4.4 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
The spray gun may be used in potentially explosive areas. The following safety regulations
must be observed and followed.
4.4.1 SAFETY REGULATIONS
Observe safety instructions in Chapter 3.2.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Surface spraying, electrostatics
Never spray device parts using electrostatic equipment (electrostatic spray gun!).
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.
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.
Do not drop the spray gun.
Use only tools that are made of a permitted material.
4.5 SAFETYRELEVANT INFORMATION ABOUT DISCHARGES
The plastic parts of the spray gun are charged electrostatically by the high-voltage eld
of the spray gun. Contact with plastic parts harmless discharges (brush discharges) may
occur. They are completely non-hazardous for human health.
When keeping a distance of 4 to 10 mm; 0.15 to 0.4 inch between spray gun and object to
be sprayed, the corona discharge at the end of the electrode is visible in the dark.
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5 DESCRIPTION
Description
1 Suspension hook
2 Display (spray current and recipe)
3 Display standby and fault
4 Operating button (standby and recipe
change)
5 Air cap (accessories: see Chapter 13)
6 Union nut
7 Flat spray nozzle AF 5000 x.x
(accessories: see Chapter 13)
8 Adapter
9Cover
10 Handle
Description
11 Adjusting screw (stop)
12 Trigger lever
14 Nozzle AR 5000 (accessories: see Chapter 13)
15 Sealing plug
16 Air regulation
17 Electric cable connection
18 Atomizing air connection
19 Product connection
20 Air cap AR 5000 (accessories: see Chapter 13)
21 Type plate left
22 Type plate right
Note:
The nozzle parts (pos. 5; 7; 14 and 20) do not belong to the basic equipment of the spray
gun. The di erent versions can be found in Chapter 13 "Accessories".
5.1 STRUCTURE STANDARD VARIANT
Note:
The gun type (T) is speci ed on the type plate and the serial number (S) is
speci ed on the underside of the handle.
Page 22
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GM 5000EA
R1
R3
R2
B_03182
2
4
3
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.2 MODE OF OPERATION
Display (2)
= Recipe values changed temporarily:
If the operating key (4) is pressed for 2 seconds, the saved recipe
values for the previously selected recipes numbers will be
reloaded from the memory.
When the spray gun is connected to the control unit and the
control unit is switched on, the pre-de ned recipe (R1, R2 or
R3) is shown on the gun display (2) as follows.
Recipe 1
Recipe 2
Recipe 3
Recipe change R1 R2 R3 R1.
Press the operating button (4) and hold the button pressed for
at least 2 seconds to go forward 1 recipe.
During spraying mode (trigger lever pressed), the status is shown in the display (2) by LEDs.
LED display Description
LEDs 1 - 3 light up green The spray gun is working in an optimal
high-voltage spray current range.
One or both right-hand LEDs illuminate
in orange.
Spray current too high.
Possible causes:
(Warning display: You can continue
working without any limitations.)
- Spray gun too close to the work piece
- Contamination of the spray gun
- Paint conductivity too high
Page 23
23
GM 5000EA
R1
R3
R2
B_03183
16
2
4
3
1
2
3
4
B_03157
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Distance Description
1 Atomizing air open.
2 Atomizing air open and electrostatically (high
voltage) activated.
Display (2) for "spray current" on the spray
gun to activated.
3 Atomizing air open, electrostatically (high
voltage) activated and product valve open.
4 Overall way of trigger.
The trigger can be used to activate, one after the other, the
various functions of the spray gun.
- An increase in the force needed to pull the trigger back will
be perceived at the position where the product valve opens.
- For spraying without high voltage, the high voltage can
be switched o using the operating button (4). Press the
operating button (4) brie y: High voltage is switched o .
The standby display (3) illuminates.
- In the event of a malfunction the spray gun switches to
"standby" operating mode and the display (3) illuminates.
- The relationship between forming air and atomizing air is
set using the air regulator (16).
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.3 SCOPE OF DELIVERY
Order No. Description
2344471 GM 5000EA spray gun (USA)
2363670 GM 5000EA spray gun spiral hose (USA)*
2367744 GM 5000EA spray gun 4 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. Description
2309368 Valve needle assembly tool
2325263 Clamping screw assembly tool
2319653 Protection gloves against spray mist
2316160 FM Control Document
see Chapter 1.3 Operating manual in local language
The spray gun basic version can be adapted optimally to any application depending upon
the requirements and the desired accessories with the help of spray gun con guration.
The delivery note shows the exact scope of delivery.
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25
GM 5000EA
B_06068
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.3.1 DESIGN VARIANTS
Basic version GM 5000EA (USA)
Order No. 2344471
GM 5000EA 4 nger trigger (USA)
Order No. 2367744
Spiral hose GM 5000EA (USA)
(no FM approval, in submission)
Order No. 2363670
for processing of metallic lacquers
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.4 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
Output voltage maximum 70 kV DC
Output current maximum 100 µA DC
Ambient temperature 0 °C - 40 °C; 32 °F - 104 °F
Maximum permissible product temperature: 50 °C; 122 °F
Maximum surface temperature 85 °C; 185 °F
Compressed air quality: free from oil and water
Quality standard 6.5.2 according to ISO 8573.1, 2010
6: Particle density ≤ 5mg/m
5: Humidity: pressure dew point ≤ +7°C
2: Oil content ≤ 0.1mg/m
Weight (without hose set) 630 g (incl. union nut, nozzle and air cap)
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure
and 0.3 MPa; 3 bar; 43.5 psi product pressure *
73 dB(A)
* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.
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27
GM 5000EA
B_03230
C
A
B
C
A
B
B_03231
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
with at jet nozzle
mm inch
A 261 10.28
B 46 1.81
C 245 9.65
Dimensions
with round jet nozzle
mm inch
A 261 10.28
B 46 1.81
C 245 9.65
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GM 5000EA
B_03446
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.5 SPRAYING PROCEDURE
Spray pattern
Union nut
Spray product
Atomizing air
Advantages
- Thin layers
- Uniform coating thickness
- Perfect nish
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. There are various nozzles and air caps available as
accessories for the respective spray product and the discharge quantities.
5.5.1 SPRAYING PROCEDURE FOR ROUND JET AIR ATOMIZING
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B_00180
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EDITION 04/2016 ORDER NUMBER DOC2344499
5.5.2 SPRAYING PROCEDURE FOR FLAT JET AIR ATOMIZING
Shaping air
Air cap
Spray pattern
Atomizing air
Advantages
- Large range of adjustment of the spray jet
- Thin layers
- Uniform coating thickness
- Perfect nish
Spray product Spray angle
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. The shaping air allows modi cation of the spray jet. There are various
nozzles and air caps available as accessories for the respective spray product and the discharge quantities.
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GM 5000EA
"?
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Electrode
Paint particle
Object to be
sprayed is grounded
5.5.3 ELECTROSTATIC EFFECT
The spray gun produces an electrostatic 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 nely dispersed to the object
to be sprayed.
Advantages
- Very high application e ectiveness
- Low over spray
- Coating of entire circumferences due to the electrostatic e ect
- Savings in working time
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GM 5000EA
B_03266
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.6 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
Round jet for smaller delicate parts
Options for in uencing the jet spray / spray pattern:
Description Modi cation
Product pressure
+ or -
Atomizing air pressure + or -
Air regulation from open to closed
Stop screw product valve
from open to closed
Nozzle sizes Flow rate
Electrostatics + or - or o
5.6.1 PRESSURE SETTINGS FOR ROUND JET NOZZLES
Air regulation
closed
Air regulation
opened
There are 4 nozzle sizes, D8, D12, EARV LV and EARV HV available. The air cap and nozzle are
adjusted according to size to each other and may not be exchanged. During the calibration
of the product pressure
and the atomizing air pressure, the air control lever must
be in a central position as shown in the photo.
Pressure setting Nozzle D8 (small) Nozzle D12 (large) / EARV
Product pressure 0.8 bar to 1.2 bar 0.8 bar to 1.6 bar
Atomizing air pressure
2.0 bar to 2.3 bar 2.3 bar to 3.0 bar
The table contains default values. Depending on the product, conditions and the desired
result di erent values are possible or necessary.
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GM 5000EA
B_04382
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Spraying direction
Rotate upward
Stop to front
Smaller cross-section
Rotate downward
Stop to back
Larger cross-section
5.6.2 PRESSURE SETTINGS FOR FLAT JET NOZZLES
5.6.3 ADJUSTING SCREW
By turning the lateral adjusting screw of the gun, the outlet cross-section can be
adjusted on the product valve. This cross-section is minimized by turning the screw
upwards. With the same pressure settings, this results in a reduction of the ow rate and
ner atomization.
Note: The spray pattern is reduced with this setting.
There are 8 at jet nozzle sizes from 0.6 up to 2.0 available. There are 2 air cap types
(s = small, w = wide) with 3 di erent nozzle sizes each. Each air cap can be used in
combination with 2 to 3 nozzles sizes. Only matching nozzle components may be used.
Pressure settings Air cap 0.6-0.8 Air cap 1.0-1.4 Air cap 1.6-2.0
Product pressure
0.5 bar to 1.0 bar 1.0 bar to 2.0 bar 1.0 bar to 3.0 bar
Atomizing air pressure
1.0 bar to 3.0 bar 1.5 bar to 4.0 bar 1.5 bar to 5.0 bar
The table contains default values. Depending on the product, conditions and the desired
result di erent values are possible or necessary.
Air cap type suitable nozzle sizes
0.4–0.8S / 0.4–0.8W 0.6 / 0.8
1.0–1.4S / 1.0–1.4W 1.0 / 1.2 /1.4
1.6–2.0S / 1.6–2.0W 1.6 / 1.8 /2.0
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GM 5000EA
0
100
200
300
400
500
600
700
0.6mm
0.8mm
1.0mm
1.2mm
1.4mm
1.6mm
1.8mm
2.0mm
123
B_03455
0
100
200
300
400
500
600
123
D8
D12
B_03456
/EARV
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.6.4 ELECTROSTATIC AND ATOMIZATION
The electrostatic charging of the spray cloud produces a more homogeneous distribution
of paint particles on the object. - See also Chapter 5.5.3.
5.6.5 DISCHARGE QUANTITY MEASUREMENTS
Product pressure in bar
Discharge quantities in g/min
Flat spray nozzles
Device: GM 5000EA / at jet nozzle Product hose: Length 7.5 m; 24.6 ft
Viscosity: 22 DIN/4 seconds Inside diameter 6 mm; 0.24 inches
Product pressure in bar
Discharge quantities in g/min
Round spray nozzles
Device: GM 5000EA / round jet nozzle Product hose: Length 7.5 m; 24.6 ft
Viscosity: 22 DIN/4 seconds Inside diameter 6 mm; 0.24 inches
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF
Incorrect installation/operation!
Risk of injury and damage to the device.
The assembly and commissioning sta must have the technical
skills to safely commission the device.
When assembling, commissioning and carrying out all work,
read and follow the operating manuals and safety regulations
for the additionally required system components.
WARNING
6.2 STORAGE CONDITIONS
Until the point of assembly, the device must be stored in a dry location, free from vibrations
and with a minimum of dust. The device must be stored in closed rooms.
The air temperature at the storage location must be between -20 °C and +60 °C (-4 °F and
+140 °F).
The relative air humidity at the storage location must be between 10 and 95% (without
condensation).
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 0 °C and 40 °C; 32
°F and 132 °F.
The relative air humidity at the installation site must be between 10 and 95% (without
condensation).
A skilled person must check to ensure that the device is in a reliable state after it is installed
and commissioned.
6.4 TRANSPORTATION
Protect valve needle with protection cap (Order No. 2315709).
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GM 5000EA
1
2
4
11
10
12
13
14
10
3
5
9
6
6
7
8
8
15
B_03233
P
ZL
L
FL
P
MAT
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Description
1 Pressure tank
2 Stop valve
3 Air pressure regulator tank
4 Air pressure regulator with air lter
5 Grounding cable
6 Air hose
Description
7 Air regulation
8 Gun cable
9 VM 5000 control unit
10 Product hose
11 Compressed air main
12 GM 5000EA R spray gun
13 Tank for return ow
14 Protective hose
15 Mains cable
Example:
Electrostatic air
spraying system with
pressure tank
6.5.1 TYPICAL ELECTROSTATIC AIR SPRAYING SYSTEM
Check the delivery package against the delivery note. Become familiar with the function
of the spray gun and all the other components used. Carefully read the accompanying
operating manual. Note the special requirements of the designated electrostatic air spray
procedure.
6.5 ASSEMBLY AND INSTALLATION
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OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
6.5.2 VENTILATION OF THE SPRAY BOOTH
The GM 5000 EA spray gun must be combined with various components to make up a
spraying system (spray pack). The system shown in the 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.
Incorrect installation/operation!
Risk of injury and damage to the device.
When commissioning and for all work, read and follow the
operating manual and safety regulations for the additionally
required system components.
WARNING
Toxic and/or ammable vapor mixtures!
Risk of poisoning and burns.
Operate the device in a spray booth approved for the working
materials.
-or Operate the device on an appropriate spraying wall with the
ventilation (extraction) switched on.
Observe national and local regulations for the exhaust air speed.
WARNING
The electrostatic spraying equipment may only be operated in de ned spraying areas and
in accordance with the EN 12215 standard or under comparable ventilation conditions.
The electrostatic spraying equipment must be locked to the technical ventilation so that
the coating product supply and the high voltage are not e ective as long as the technical
ventilation is not operated with the minimum exhaust air volume ow or a larger exhaust
air volume ow.
Ensure that the excess coating product (overspray) will be collected up safely.
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
6.5.3 AIR SUPPLY
6.5.4 PRODUCT SUPPLY
The use of an air 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.
Impurities in the spraying system!
Spray gun blockage, products harden in the spraying system.
Flush the spray gun and paint supply with a suitable ushing agent.
NOTICE
Bursting hose, bursting threaded joints!
Danger to life from injection of product.
Ensure that the hose material is chemically resistant to the
sprayed products.
Ensure that the spray gun, threaded joints and product hose
between the device and the spray gun are suitable for the
pressure generated in the device.
Ensure that the following information can be seen on the high-
pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
DANGER
Hose connections!
Risk of injury and damage to the device.
Do not exchange hose connections of product hose and air
hose.
WARNING
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
6.5.5 GROUNDING
Perfect grounding of all conductive parts such as 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.
Parts of the booth must be grounded in accordance with EN 12215.
Discharge of electrostatically charged components in
atmospheres containing solvents!
Explosion hazard from electrostatic sparks or ames.
Ground all device components.
Ground the work pieces to be coated.
WARNING
Heavy paint mist if grounding is insu cient!
Danger of poisoning.
Insu cient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
WARNING
A poorly grounded work piece causes:
- very bad wrap around,
- uneven coating,
- back spraying to the spray gun (contamination) and coater.
Prerequisites for perfect grounding and coating are:
- Clean work piece suspension.
- Grounding of spray booth, conveyor system and suspension on the building side in
accordance with the operating manuals or the manufacturer's information.
- Grounding of all conductive parts within the working area.
- The grounding resistance of the work piece may not exceed 1 MΩ (megohm).
(Ground leakage resistance measured at 500 V or 1000 V)
- Connect the control unit to the signal ground.
- Connect all ground cables using a short and direct route.
- Safety shoes and gloves, if used, must be static dissipative.
Page 39
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GM 5000EA
B_03234
R max < 1 MΩ
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Control unit
Grounding
cable
Spraying stand
Floor, static dissipative
Work piece
Pump or
pressure tank
Paint tank or
tank for return
ow
Grounding scheme (example)
Conveyor
Mains cable
Minimum cable cross-section
Control unit
Product supply
Paint tank
Conveyor
16 mm / AWG 6Booth
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 VM500 or
VM5000 control unit.
Note for the sprayer
Safety shoes and gloves, if used, must be static dissipative.
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
6.6 PREPARATION OF LACQUER
6.6.1 VISCOSITY CONVERSION TABLE
mPa s
10 10 0.1 5 16
15 15 0.15 8 17
20 20 0.2 10 18
25 25 0.25 14 12 19
30 30 0.3 15 14 20
40 40 0.4 17 18 22
50 50 0.5 19 22 24
60 60 0.6 21 26 27
70 70 0.7 23 28 30
80 80 0.8 25 31 34
90 90 0.9 28 32 37
100 100 1 30 34 41
120 120 1.2 33 41 49
140 140 1.4 37 45 58
160 160 1.6 43 50 66
180 180 1.8 46 54 74
200 200 2 49 58 82
220 220 2.2 52 62
240 240 2.4 56 65
260 260 2.6 62 68
280 280 2.8 65 70
300 300 3 70 74
320 320 3.2
340 340 3.4
360 360 3.6 80
380 380 3.8
400 400 4 90
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 ow cup DIN4mm;
0.16 inches).
In the case of application problems contact the lacquer manufacturer.
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
6.7 COMMISSIONING
The following points must be noted:
Make sure that all other conductive parts within the work area are grounded (see
Chapter 6.5.5).
Connect the product hose to the spray gun and the product pump or the pressure
tank.
Check that all product-conveying connections are correctly connected.
Connect air hose to spray gun and to supply of oil-free dry air, approx. 0.25 MPa; 2.5
bar; 36 psi. For compressed air quality see Chapter 5.4.
Check that all air-conveying connections are correctly connected.
Connect the electric cable to the spray gun and to the VM 5000 or VM 500 control
unit. 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 ll the separating agent up if necessary.
Provide product tank, tanks for ushing agent and an empty tank for return ow.
Connect the system to the air and power supply.
A basic ushing of system must be carried out before commissioning. Make sure that
no nozzle is inserted into the gun.
6.7.1 SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 7.2.
Observe the general rules for making adjustments to the spray gun. Chapter 7.2.2
6.7.2 PREPARATION FOR COMMISSIONING
Impurities in the spraying system!
Clogging of the spray gun
Flush the spray gun and paint supply with a suitable ushing agent before
commissioning.
NOTICE
6.7.3 COMMISSIONING
Page 42
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GM 5000EA
B_03691
84
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Attention: gun cable to control unit
Secure the cover sleeve with the warning sign by means of the screw (84) on the connector.
GM 5000E gun cable
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.
WARNING
6.7.3.1 GUN CABLES AND GUN CABLE EXTENSIONS
The following points must be noted:
The cable connection to the gun and the connection to a cable extension may not be
disconnected or connected in a potentially explosive area.
Only disconnect or connect all cable extensions from the gun cable and the cable
extension when the control unit is switched o .
In order that the GM 5000EA spray gun is grounded, it must be connected via the gun
cable with the VM500 or VM5000 control unit.
Gun cable is available in various lengths. Order No., see Chapter 13.5.3.
Warning:
"Do not disconnect under voltage"
Page 43
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GM 5000EA
B_03690
84
84
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
A skilled person must check to ensure that the device and the spraying system are in a safe
state after they are installed and commissioned.
This includes:
- Carry out a safety checks in accordance with Chapter 8.2.3.
- Function test in accordance with Chapter 11.
6.7.4 VERIFYING A SAFE OPERATIONAL CONDITION
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.
An extension to a total length of up to 40 m will cause a power loss of up to 10%. The gun
cable can be extended to a total length of 80m, however, a power loss of up to 30% will
be caused.
GM 5000E gun cable
Extension cable to the
control unit
Page 44
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
7 OPERATION
7.1 TRAINING THE OPERATING STAFF
7.2 SAFETY INSTRUCTIONS
Incorrect operation!
Risk of injury and damage to the device.
If contact with lacquers or cleaning agents causes skin irritation,
appropriate precautionary measures must be taken, e.g.,
wearing protective clothing.
The footwear worn by operating sta must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
WARNING
Observe safety instructions in Chapter 4.
Incorrect operation!
Risk of injury and damage to the device.
The operating sta must be quali ed to operate the entire
system.
The operating sta must be familiar with the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Before work commences, the operating sta must receive
appropriate system training.
WARNING
Unintentional putting into operation!
Risk of injury
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 unit.
Secure the spray gun against actuation.
In the event of functional faults: remedy the fault as described in
the "Troubleshooting" chapter.
WARNING
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Discharge of electrostatically charged components in
atmospheres containing solvents!
Explosion hazard from electrostatic spark-over.
Use gun only with tted nozzle, air cap and union nut.
WARNING
7.2.2 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN
High-voltage eld!
Danger to life from malfunction of heart pacemaker
Make sure that persons with pacemakers:
Do not work with the electrostatic spray gun.
Do not enter the high-voltage area.
DANGER
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused
by paint or solvent. Inform the doctor about the paint or solvent
used.
Never seal defective high-pressure parts; instead relieve the pressure
from them and replace them immediately.
Wear the appropriate protective clothing, gloves, eyewear and
respiratory protection.
WARNING
In the case of unforeseen occurrences, proceed as follows:
1. Switch o control unit.
2. Close the compressed air supply.
3. Relieve pressure according to the operating manual of the product pressure
generator.
4. Point the spray gun toward the grounded collecting tray.
5. Pull the trigger of the spray gun until no further pressure is present.
7.2.1 EMERGENCY DEACTIVATION
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GM 5000EA
1
2
4
11
10
12
13
14
10
3
5
9
6
6
7
8
8
15
B_03233
P
ZL
L
FL
P
MAT
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
7.3 WORKING
1. Provide an empty tank for return (13).
2. Put the tank with working material into the pressure tank (1) and close the pressure
tank.
3. Open stop valve (2).
4.
Adjust to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar; 7 to 22 psi on the pressure regulator (3).
5. Point the gun, without nozzle, into tank (13) and open it.
6. Close stop valve (2) as soon as pure working material without any air inclusions starts
coming from the gun.
7. Close the spray gun if the pressure tank is depressurised.
8. Dispose of the contents of the tank (13) according to the local regulations.
7.3.1 FILLING WITH WORKING MATERIAL
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
Page 47
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GM 5000EA
B_04383
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
7.3.2 CHECKING THE SPRAY PATTERN WITHOUT ELECTROSTATICS
Start air-spraying (without electrostatics)
1. Switch o 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;
7 to 22 psi operating pressure.
See corresponding operating manual.
3. Set atomizing air regulator (4) to approx. 1–4 bar.
4. Open air regulator at the rear of the gun.
5. Spray (actuate trigger) and check the atomization.
6. Set the uid pressure on the product pressure generator until good product
atomization is achieved.
7. Adjust the atomizing air regulator (4) until optimal atomization is achieved.
8. Flat jet process: with the air adjustment on the gun, set the ratio of shaping air/
atomizing air so as to achieve an optimum spray pattern.
Changing the Flow Rate
Adapt product pressure.
Use a di erent nozzle (see Chapter 13).
Limit the valve needle stroke with the adjustment screw on the side of the gun.
Spray pattern and air regulation
The spray pattern can be optimally adjusted to suit the object being sprayed using the air
regulator. The illustration shows the in uence of the regulator on the spraying pattern.
Other nozzle sizes can be used to obtain larger or smaller spraying patterns.
Round-jet method
Open air regulation.
The size of the air cap should
match with the nozzle size.
Flat jet method
Air regulation closed.
Air regulation fully
opened.
Page 48
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GM 5000EA
B_04383
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
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;
7 to 22 psi operating pressure. See corresponding operating manual.
4. Set atomizing air regulator (4) to approx. 1–4 bar.
5. Open air regulator at the rear of the gun.
6. Spray on a test object (pull trigger).
Pressing the trigger on the spray gun switches the high-voltage supply on.
7. Adjust the product pressure and atomizing air in accordance with the nozzle and
object.
Rule of thumb: Set atomizing air pressure approx. three times higher than the
product pressure.
Flat-jet method: Changing the spray jet width
8. Change the width of the spray jet by turning the air regulator (at the rear of the spray
gun, see photo) or by appropriate selection of the nozzle.
Flow rate
9. Product quantity may be able to be reduced by:
- Minimizing the product pressure.
- Use a di erent nozzle size.
See Chapter 13.
- Limit the valve needle stroke with the adjustment screw on the side of the gun.
Round-jet method
Open air regulation.
The size of the air cap should
match with the nozzle size.
Flat jet method
Air regulation closed.
Air regulation fully
opened.
Page 49
49
GM 5000EA
B_06064
≤ 90°
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Adjustable EARV5000 round jet nozzle
By turning the union nut the spray pattern can be adjusted to suit the object being
sprayed. The illustration shows the in uence of the turning on the spraying pattern.
1. Set the union nut as far as the stop.
2. Open maximum 1/4 turn. The atomizing is good in this area.
The union nut should not protrude beyond the nozzle body.
Always fully open the air regulation.
Low viskosity, diameter big
Low viskosity, diameter small
High viskosity, diameter big
High viskosity, diameter small
Spray pattern
Marking on union nut
Page 50
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
7.3.4 PRESSURE RELIEF/WORK INTERRUPTION
Process for relieving pressure
1. Switch o control unit.
2. Close the compressed air supply.
3. Relieve pressure according to the operating manual of the product pressure
generator.
4. Point the spray gun toward the grounded collecting tray.
5. Pull the trigger of the spray gun until no further pressure is present.
The pressure must always be relieved when:
- The spraying tasks are nished.
- The spraying system is maintained.
- Cleaning tasks are carried out on the spraying system.
- The spraying system is moved to another location.
- Something must be checked on the spraying system.
- The nozzle is removed from the gun.
Observe general safety instructions in Chapter 4.
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused
by paint or solvent. Inform the doctor about the paint or solvent
used.
Never seal defective high-pressure parts; instead relieve the
pressure from them and replace them.
Wear the appropriate protective clothing, gloves, eyewear and
respiratory protection.
WARNING
Page 51
51
GM 5000EA
B_03268
1
3
4
7
2
5
6
8
2
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
7.3.5 CHANGING FROM AIR ROUND JET TO AIR FLAT JET
Defective electrode!
Material damage due to functional faults.
Do not damage the electrode.
NOTICE
Flush spray gun
1. Switch o control unit.
2. Relieve pressure.
Chapter 7.3.4
3. Connect the system to the
ushing agent supply.
4. Set product pressure. Close
atomizing air regulator.
5. Thoroughly ush out the
spray gun.
6. Relieve pressure.
Chapter 7.3.4
Changing from round jet to at jet
7. Unscrew the union nut (2) by hand.
8. Remove AR 5000 air cap (3). Unscrew AR 5000 nozzle (4)
by hand and remove it.
9. Clean the spray gun front carefully with damp cloth. Pay
attention to the electrode (1). Use the protection cap for
the valve needle (8).
10. Screw in and slightly tighten AF 5000 at jet nozzle (6) by hand.
11. Put the AF 5000 air cap (5) in place. Screw the union nut (2) onto the spray gun
body.
12. Set the desired at jet level with the air cap horns (7) and then slightly tighten the
union nut by hand.
Changing from at jet to round jet
7. Unscrew the union nut (2) by hand.
8. Remove AF 5000 air cap (5).
9. Unscrew and remove AF 5000 at jet nozzle (6) by hand.
10. Clean the spray gun front carefully with damp cloth. Pay attention to the
electrode(1). Use the protection cap for the valve needle (8).
11. Screw on and slightly tighten AR 5000 nozzle (4) by hand.
12. Position AR 5000 air cap (3). Screw the union nut (2) onto the spray gun body and
slightly tighten by hand.
Page 52
52
GM 5000EA
B_03518
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
7.3.7 CHANGING THE VALVE HOUSING
Changing the valve housing!
Damage to the device.
Activate the spray gun trigger when changing the valve housing.
NOTICE
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.
Use a socket or ring spanner (not
a wrench) to tighten the valve
housing.
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.
They may only remain in a cleaning solvent for a short time.
Clean these parts with a brush and dry them with a cloth or a blow gun.
Valve housing and valve tip are available in various materials:
Valve housing Valve tip
Material of the valve seat Product
Standard version Steel PEEK
Special accessories PEEK Steel
When wear-related problems occur, the valve housing and/or valve tip can be exchanged.
Order No., see Chapter 13.
Page 53
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
8 CLEANING AND MAINTENANCE
Cleaning work should be undertaken regularly and carefully by quali ed and trained sta .
They should be informed of speci c hazards during their training.
The following hazards may arise during cleaning work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable cleaning tools and aids
8.1 CLEANING
8.1.2 SAFETY INSTRUCTIONS
8.1.1 CLEANING STAFF
Observe safety instructions in Chapter 4.
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.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy supply and the compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating and service manual for all work.
Page 54
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
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
ushing agents. Ground the tank.
Which cleaning agent is used to clean the spray gun depends
on which parts of the spray gun have to be cleaned and which
product has to be removed. When cleaning the spray gun, only
use non-polar cleaning agents to prevent conductive residues
on the surface of the spray gun. Should it however, be necessary
to use a polar cleaning agent, all residues of this cleaning agent
have to be removed by using a non-conductive and non-polar
cleaning agent, once the cleaning is nished.
Preference should be given to non- ammable cleaning and
ushing agents.
Only cleaning and ushing agents, which contain ingredients
of explosion class IIA and IIB may be used (maximum ignition
energy 0.24 mJ).
The cleaning and ushing agent's ash point must be at least
15K above the ambient temperature.
Ensure that no electric component is cleaned with or immersed
into solvent.
DANGER
Page 55
55
GM 5000EA
B_03447
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
The spraying system and the spray gun must be cleaned and ushed daily. The cleaning
and ushing agents used must be compatible with the working material.
8.1.3 CLEANING AND FLUSHING THE DEVICE
Incompatibility of cleaning/ ushing agent and working
medium!
Risk of explosion and danger of poisoning by toxic gases
Examine the compatibility of the cleaning and ushing agents
and working media on the basis of the safety data sheets.
WARNING
Damage to electrical devices!
Never immerse the spray gun in cleaning agent.
NOTICE
NOTICE
Liquid in air tube!
Functional faults caused by swollen seals.
Discharge current to ground No high voltage
Always point the spray gun down when cleaning.
Ensure that neither lacquers nor cleaning or ushing agent enters the air duct.
When taking a break from work or when stored for a longer period, the spray gun
should be positioned with the adapter pointing downwards.
Page 56
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
DANGER
Clean nozzle
1. Switch o control unit.
2. Relieve pressure. Chapter 7.3.4
3. Close air pressure regulator.
4. Dismount nozzle and clean separately.
Chapter 7.3.6
Flush spraying system and spray gun
5. Connect spraying system to ushing agent supply in accordance with operating
manual for the product pressure generator.
6. Point the spray gun toward the collecting tray and actuate the trigger. Flush the gun
thoroughly as soon as clean ushing agent emerges.
7. Remove ushing agent supply.
Blowing out the air passages of the spray gun
8. Close pump pressure regulator. Switch on compressed air supply and open air
pressure regulator.
9. Actuate the trigger of the spray gun and thoroughly blow out the air passages.
10. Switch o the compressed air supply.
Clean the outside of the spray gun
11. Clean the spray gun body and other components of the spraying system with a
cleaning agent recommended by the lacquer manufacturer and dry with a cloth or
blow gun.
Cleaning the nozzle parts
See Chapter 7.3.6
Page 57
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Incorrect maintenance/repair!
Danger to life and equipment damage.
Repair or replacement of devices or parts of devices are only
allowed to be performed outside the hazard area by quali ed
personnel.
DANGER
8.2 MAINTENANCE
Maintenance work should be undertaken regularly and carefully by quali ed and trained
sta . They should be informed of speci c hazards during their training.
The following hazards may arise during maintenance work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable tools and aids
An authorized person must ensure that the device is checked for being in a reliable state
after maintenance work is completed.
8.2.1 MAINTENANCE STAFF
8.2.2 SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 8.1.2.
Prior to maintenance
- Flush and clean the system. Chapter 8.1.3.
After maintenance
- Carry out a safety checks in accordance with Chapter 8.2.3.
- Put the system into operation (Chapter 6.7) and check for leaks (Chapter 11.3).
- Carry out a function test, if required, in accordance with Chapter 11.
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.
- For shut down devices, the examination can be suspended until the next start-up.
Page 58
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
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.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy supply and the compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating and service manual for all work.
For the safe operation of electrostatic manual coating systems for ammable liquid coating products,
intervals for periodical inspections are de ned as follows:
Inspection point Inspection interval Remarks
Gun cleaning, gun ushing daily Chapter 4.2.4, Chapter 8.1
Hoses, tubes, couplings daily Chapter 8.2.4
Grounding weekly Chapter 4.2.2, Chapter 6.5.5
Inspection for damage weekly Chapter 8.1.3, 8.2, 10
Locking of the technical ventilation with the
electrostatic manual spraying unit
annually Chapter 6.5.2
The above recommended intervals are maximum values and may be modi ed by the operator depending on
the local and operational conditions and the contamination.
Damaged devices must be decommissioned and repaired immediately.
8.2.3 SAFETY CHECKS
Page 59
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Bursting hose, bursting threaded joints!
Danger to life from injection of product and from ying parts.
Ensure that the hose material is chemically resistant to the
sprayed products and the used ushing agents.
Ensure that the spray gun, threaded joints, and product hose
between the device and the spray gun are suitable for the
generated pressure.
Ensure that the following information can be seen on the hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
DANGER
The service life of the complete hoses between product pressure generator and application
device is reduced due to environmental in uences even when handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
Before every commissioning, check all connections for leaks.
Additionally, the operator must regularly check the complete hoses for wear and tear
as well as for damage at intervals that he/she has set. Records of these checks must
be kept.
Undamaged complete hoses are to be replaced when one of the two following
intervals has been exceeded:
– 6 years from the date of the hose crimping (see tting embossing).
– 10 years from the date of the hose imprinting.
Fitting
embossing
Meaning
(if present)
xxx bar Pressure
yymm
Crimping date
(year/month)
XX Internal code
Hose imprinting Meaning
WAGNER
Name /
Manufacturer
yymm
Date of
manufacture (year/
month)
xxx bar (xx MPa)
Pressure
e.g., 270 bar
(27MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
8.2.4 PRODUCT HOSES, TUBES AND COUPLINGS
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Functional fault Cause Remedy
Insu cient product output Nozzle too small Select larger nozzle (see Accessories).
Product pressure too low Increase product pressure.
Product pressure generator blocked Clean or replace lter.
Nozzle is clogged Clean or replace nozzle.
Product valve travel set too small Increase product valve travel by turning
the adjusting screw.
Poor spray pattern Wrongly adjusted atomizing air Readjust the atomizing air.
Unfavorable nozzle size Select a di erent nozzle (see
Accessories).
Product pressure too high/too low Adapt product pressure.
Spray product viscosity too high Thin product in accordance with the
manufacturer's instructions.
Damaged nozzle Attach new nozzle.
Poor wrap-around Poor grounding at object Check grounding of object or hanger
with ohmmeter.
Lacquer resistance too high/too low Check lacquer resistance, see
Chapter2.5
Spraying pressure too high Readjust spraying pressure.
No wrap-around No high voltage Switch on high voltage at the control
unit. / Repair malfunction as explained
in the control unit operating manuals.
Connect gun and gun cable/check for
defect.
Check lacquer resistance, see
Chapter2.5
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.
Distance between spray gun and
object too large
Reduce distance between spray gun
and work piece.
High voltage set wrongly (too high) Adapt high voltage to product.
Loosen the nozzle union nut for
round jet method
Slightly tighten union nut by hand.
Valve rod leaks Seals at the valve rod are damaged Replace the seals (see Chapter 10).
Loose packing Tighten.
9 TROUBLE SHOOTING AND RECTIFICATION
Page 61
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
10 REPAIR WORK
10.1 REPAIR STAFF
Repair work should be undertaken carefully by quali ed and trained personnel. They
should be informed of speci c hazards during their training.
The following hazards may arise during repair work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable tools and aids
A skilled person must check to ensure that the device is in a reliable state after it is repaired.
Carry out function test in accordance with Chapter 11.
10.2 SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 8.1.2.
Before a Repair
- Flush and clean the system.
Chapter 8.1.3.
After a Repair
- Carry out a safety checks in accordance with Chapter 8.2.3.
- Put the system into operation (Chapter 6.7) and check for leaks (Chapter 11.3).
- Function test in accordance with Chapter 11.
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.
- For shut down devices, the examination can be suspended until the next start-up.
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.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy supply and the compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating and service manual for all work.
Page 62
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
10.3 DISMANTLING OF THE GUN
10.3.1 TOOLS
For disassembling and assembling the spray gun, the following tools are required:
- Allen wrench SW 2
- Allen wrench SW 3
- Allen wrench SW 5
- Wrench size 5
- Wrench size 6
- Wrench size 8
- Wrench size 11
- Wrench size 12
- Wrench size 14
- Wrench size 19
- Ring spanner SW9
- Ring spanner SW11
- Torx
wrench 20
- Torx wrench 25
- Slide gauge
- Valve needle assembly tool, Order No. 2309368
- Clamping screw assembly tool, Order No. 2325263
Only as required:
- Handle seal assembly tool (Order No. 2342334, not included in scope of delivery)
Plastic parts
Gently handle all plastic parts.
Brand notice:
The brands speci ed in this document are property of the respective owners. Loctite®, for
example, is a registered brand of Henkel.
Page 63
63
GM 5000EA
B_03247
SW3
SW19
SW19
Torx® 25
1
2
3
B_03246
SW3
SW12
SW12
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
10.3.2 DISMANTLING OF THE SPRAY GUN
Air hose
When unscrewing the air hose, a second
open-ended/box wrench must be used
for bracing.
Page 64
64
GM 5000EA
B_03248
SW19
SW19
4
5
6
B_04369
n
o
n
o
p
9
8
B_04370
SW11
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Carefully release the
cascade without pliers.
O-ring (8): 1. Use
screwdriver no. 1 to press
under the O-ring.
2. Lever up the O-ring and
remove it.
Air distribution (9): 1. Locate the start of the thread for recessed internal
threading.
2. Lever under the air distribution ring directly in front of the start of the
thread using screwdriver no. 1.
3. As soon as the ring disengages, carefully undo it on all sides.
Valve needle assembly tool
Order No. 2309368
Valve needle Air
Loosen valve tip by hand using the valve needle assembly tool (Order No. 2309368).
Valve housing: Use socket or ring
spanner (not a wrench).
Page 65
65
GM 5000EA
7
B_04371
SW6
SW5
SW2
1
4
5
2
6
7
3
10
8
9
B_04799
3
Torx® 20
5
4
SW5
B_04798
SW14
1
2
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
1. Remove pressure spring (4).
2. Loosen clamping screw (1) with
assembly tool (5).
3. Unscrew valve rod unit (2, 6, 7).
The packing (3) is also unscrewed
and removed.
4. Only as required:
Remove rod seal (10). Do not
damage the housing in the
process.
Two gold contact sleeves
either remain in the handle (1)
or are seated on the two gold
pins (2). Do not lose!
1. Loosen the oval head screw (3).
2. Pull the air valve (4) out o the drilled hole. Do not
turn! Do not damage the cylindrical surfaces. Ideally
press on the tappet from behind using a transversely
held screwdriver, for example.
3. Only as required:
Press out seal (5) using a handle seal assembly tool
(Order No. 2342334, not included in scope of delivery).
Page 66
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
10.3.3 CLEANING THE PARTS AFTER DISASSEMBLY
In Chapter 14 the part numbers for gun spare parts can be found as well as for wearing
parts such as seals.
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.
The adapter, plug, inside handle and all dismantled parts must be clean and dry
after cleaning. Care should be taken that these parts remain free of solvents, grease
or sweat from the hands (salt water). Clean and mount wearing gloves.
Spare parts may have safety-relevant properties.
Only repair and replace parts that are listed in the "Spare parts" chapter and that are
assigned to the unit.
Defective parts, O-rings and seal sets must always be re-placed.
ATTENTION
Incompatibility of cleaning agent and working medium!
Risk of explosion and danger of poisoning by toxic gases.
Examine the compatibility of the cleaning agents and working
media on the basis of the safety data sheets.
WARNING
Page 67
67
GM 5000EA
1
B_03448
2
B_04376
SW14
3 Nm
Torx® 20
4
2
6
5
2
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
(sparingly)
10.3.4 ASSEMBLING THE SPRAY GUN
Assembly aids:
Order No. Description
2 * 9992698 Vaseline white PHHV II
4 9992511 Loctite® 243
* Use Vaseline sparingly
Ensure the correct
insertion position!
Ensure the correct
insertion position!
Only as required (if the
seal was removed):
press in using handle
seal assembly tool
(Order No. 2342334, not
included in scope of
delivery)
Recess for pin
Hold the air valve so that
the pin points to the left.
Gold contact sleeves
Check whether the two gold contact sleeves are
in the handle (5). Otherwise, insert the sleeves
onto the two gold pins of the plug (6). Slide plug
into handle.
Page 68
68
GM 5000EA
B_04791
SW2
1Nm
X
6
7
3
B_04372
0.5 Nm
SW6
0.4 - 0.5 Nm
SW5
2
1
4
5
8
9
10
8
7
11
2
2
9
2
2
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Wear gloves!
The outside thread of the packing (9) must be free
of lacquer.
Valve rod unit (8) and packing (9):
- grease,
- slide together,
- screw together (10).
Grease clamping screw (1) and mount using
assembly tool (5).
Insert spring (4).
Coat the hollow
section with a brush.
Note: avoid the pin
and hexagon.
(sparingly)
Valve rod unit
Set length adjusting measure
X with withdrawal nut (7) and
then fasten the threaded pin (6)
using an Allen wrench SW2.
Only as required (if the rod seal was
removed): Press in rod seal (11). In the
process, press only on the lowest area
of the rod seal.
Page 69
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GM 5000EA
4
5
SW11
B_04373
1.8 Nm;
1.33 lb ft
0.1 Nm
0.07 lb ft
2
3
(1)
(4)
6
7
B_03255
SW3
0.8 Nm
SW19
SW19
B_04374
SW19
2.5 Nm
2
2
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Ensure the correct
insertion position!
Valve needle assembly tool,
Order No. 2309368
1. Move the valve rod to the rear position so that the sealing
area does not become scratched (1).
2. Very slightly tighten valve tip (2) using an assembly tool
with three ngers.
3. Use socket or ring spanner (no wrench) to tighten the valve
housing (3).
4.
Slide the valve rod to the forward position (at the valve seat) (4).
Clean and degrease the inside of the
adapter and the cascade, then grease the
cascade surface with Vaseline.
Ensure that the spring is inserted in the adapter.
Ensure that the at gasket is inserted in the handle.
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GM 5000EA
8
B_03256
Torx® 25
SW3
0.8 Nm
SW12
SW12
2
B_04375
7
5
6
R1
R3
R2
9
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Push the trigger upward into the
air valve piston. The recess in the
trigger must engage correctly in the
indentation of the piston.
Ensure the correct
insertion position.
1. Press metal sleeve (6) back in cover (5) (e.g., press on table). In the process, only exert
counter pressure on the sleeve bracket and not on the entire cover.
2. Position cover straight and level, and carefully press in. Use only minimal force, gently
rocking from side to side if necessary.
3. Ensure that the cover is ush mounted on all sides.
4. Press back on metal sleeve for a ush t (e.g., press on table).
5. Position bracket (7).
6. Mount screw, plug, and air regulation.
(sparingly)
Cover (5)
The cover must be
handled carefully and not
be twisted or distorted in
any way.
Page 71
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GM 5000EA
10
B_03258
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Flat jet nozzle
Diverse nozzle sizes, see Chapter 13.4.
Round jet nozzle
Diverse nozzle sizes, see Chapter 13.3.
Air hose
When screwing on the air hose, a
second open-ended/ring spanner must
be used for bracing.
Page 72
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
11 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 sta .
11.1 CHECKING THE HIGH VOLTAGE
Necessary test equipment:
VM 500 or VM 5000 control unit and HV200 high-voltage tester.
High-voltage measurement on spraying gun.
Connect gun cable to control unit. Take the spray gun in your hand and hold it in open
space. Switch on control unit and actuate trigger guard.
The high voltage should be 60 to 65 kV in dry ambient air. The value can be checked with
the display on the control unit (VM 5000).
Note:
The gun must be clean and dry and must not have any paint or cleaning agent residues.
In the case of ambient air with a high air humidity, the measured value can reduce to 50
to 55 kV.
High-voltage measurement with high-voltage tester
Place the ball of the high-voltage tester on the gun electrode and turn on the high voltage.
The measured value should be 70 to 80 kV.
Notes
- When measuring the high voltage the gun and the measuring device should be held at
arms length as far from the body as possible.
- There should be no chargeable objects within a radius of 1 m; 3.28 ft of the place
where the measurements are taken.
- The placing of the measuring ball of the high-voltage measuring device reduces the
spraying of the high-voltage electrode. As a result the high-voltage value increases
compared to the spraying in the free space.
Page 73
73
GM 5000EA
B_03259
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
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
Page 74
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GM 5000EA
B_03260
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
11.2 AIR TEST
11.3 PRODUCT PRESSURE TEST
Connect test or air hose to spray gun.
The following air tests are to be carried out twice each:
- at 0.1MPa; 1bar; 14.5psi
- at 0.8MPa; 8bar; 116psi
Checking the air valve
The air valve must switch on and o correctly.
Air seal
Without activating the trigger, test for air seal at the points
marked in the illustration.
Connect low-pressure hose to the spray gun.
Spray gun with suitable medium (e.g., ushing agent or Marcol 52) and a maximum
pressure of 0.8 MPa; 8 bar; 116 psi. Increase the pressure gradually while doing so.
Observe the following gun components:
Product connection, nozzle body, product valve (no post-spraying).
Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
DANGER
11.4 TEST OF SPRAY PATTERN
Check spray pattern in accordance with Chapter 7.3.2.
Page 75
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
12 DISPOSAL
Do not dispose of used electrical equipment with household
refuse!
In accordance with European Directive 2002/96/EC on the disposal
of used electrical equipment and its implementation in national
law, this product may not be disposed of with the household refuse,
but must be recycled in an environmentally correct manner.
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. Please contact one of our service
points, one of our representatives or us directly to arrange this.
NOTICE
Consumable products
Consumable products (lacquers, adhesives, ushing and cleaning agents) must be
disposed of in accordance with all applicable legal requirements.
Page 76
76
GM 5000EA
B_03697
B_03697
B_03698
B_03698
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
13 ACCESSORIES
Order No. Designation
2312179
Valve housing Air, complete (steel)
(standard version)
2312176 Valve housing Air, complete (PEEK)
Order No. Designation
2312184
Valve tip Air, complete (PEEK)
(standard version)
2312185 Valve tip Air, complete (steel)
13.1 VALVE HOUSING
13.2 VALVE TIPS
B_03238
B_03238
B_03239
B_03239
13.3.2 AR 5000 NOZZLES
Order No. Designation
2310557 Air cap AR 5000 (D8)
2315049 Air cap AR 5000 (D12)
13.3 ROUND SPRAY NOZZLES
13.3.1 AR 5000 AIR CAPS
Order No. Designation
2310558 Nozzle, AR 5000 (D8)
2315050 Nozzle, AR 5000 (D12)
Discharge quantity measurements: see Chapter 5.6.5
Page 77
77
GM 5000EA
B_03240
B_03240
B_03240
B_03240
B_03240
B_03240
B_06044
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Order No. Designation
2310506 Air cap, AF 5000–0.4-0.8S
2310507 Air cap, AF 5000–1.0-1.4S
2310508 Air cap, AF 5000–1.6-2.0S
2314255 Air cap, AF 5000–0.4-0.8W (wide)
2314256 Air cap, AF 5000-1.0-1.4W (wide)
2314258 Air cap, AF 5000–1.6-2.0W (wide)
13.4 FLAT JET NOZZLES
13.4.1 AF 5000 AIR CAPS
13.3.3 NOZZLE SET EARV
Order No. Designation
Markings on union
nut
2361290
Nozzle set EARV 5000 LV
B_05984
suitable for low viscosity products
2365979
Nozzle set EARV 5000 HV
B_05985
suitable for high viscosity products
Mounting tool
353210 Air nozzle spanner
"?
Spare parts see Chapter 14.4.3.
Page 78
78
GM 5000EA
B_03241
B_03241
B_03241
B_03241
B_03241
B_03241
B_03241
B_03241
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Order No. Designation
2310539 Nozzle, AF 5000–0.6 mm (black)
2310540 Nozzle, AF 5000–0.8 mm (yellow)
2310541 Nozzle, AF 5000–1.0 mm (red)
2310542 Nozzle, AF 5000–1.2 mm (green)
2310543 Nozzle, AF 5000–1.4 mm (brown)
2310544 Nozzle, AF 5000–1.6 mm (white)
2310545 Nozzle, AF 5000–1.8 mm (blue)
2310546 Nozzle, AF 5000–2.0 mm (black)
Discharge quantity measurements: see Chapter 5.6.5
13.4.2 AF 5000 NOZZLES
Page 79
79
GM 5000EA
2
3
4
5
B_03245
1
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
13.5 HOSES AND ELECTRIC CABLES
13.5.1 STANDARD HOSE SETS AND COMPONENTS
Order No. Designation
1 1 2356991 Hose set GM 5000EA USA (7.5 m)
Consists of:
2 1 2356965 Low pressure hose DN6-PN20-NPSM 3/8"-7.5 m-PA
3 1 2356978 Air hose, complete DN8 USA (8.0 m)
4 1 2339157 Gun cable GM 5000E (10.0 m)
5 8 m 3676437 Protection hose fabric PP30 (8.0 m)
Order No. Designation
1 1 2356992 Hose set GM 5000EA USA (10 m)
Consists of:
2 1 2356966 Low pressure hose DN6-PN20-NPSM 3/8"-10 m-PA
3 1 2356979 Air hose, complete DN8 USA (10.5 m)
4 1 2339158 Gun cable GM 5000E (15.0 m)
5 10.5 m 3676437 Protection hose fabric PP30 (10.5 m)
Order No. Designation
1 1 2356993 Hose set GM 5000EA USA (15 m)
Consists of:
2 1 2356967 Low pressure hose DN8-PN17-NPSM 3/8"-15 m-PA
3 1 2356980 Air hose, complete DN8 USA (15.5 m)
4 1 2339159 Gun cable GM 5000E (20.0 m)
5 15.5 m 3676437 Protection hose fabric PP30 (15.5 m)
Order No. Designation
1 1 2356994 Hose set GM 5000EA USA (20 m)
Consists of:
2 1 2356968 Low pressure hose DN8-PN17-NPSM 3/8"-20 m-PA
3 1 2356981 Air hose, complete DN8 USA (20.5 m)
4 1 2339160 Gun cable GM 5000E (25.0 m)
5 20.5 m 3676437 Protection hose fabric PP30 (20.5 m)
Page 80
80
GM 5000EA
B
A****
1
2
3
A
BC
D
E
(**)
B_03840
(*)(***)
1
2
3
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Hose colors:
Product hose black
Air hose blue
Dimensions:
Air hose: inside diameter 8 mm; 0.32 inch
Product hose 7.5 m and 10 m: inside diameter 6 mm; 0.24 inch, nominal pressure 2 MPa; 20 bar; 290.07 psi
Product hose 15 m and 20 m: inside diameter 8 mm; 0.32 inch, nominal pressure 1.7 MPa; 17 bar; 246.56 psi
Material of product hose: PA
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±2 300±10 20±10 1500
+100
2356993 Hose set GM 5000EA USA (15 m) 29±2 47±2 300±10 20±10 1500
+100
2356994 Hose set GM 5000EA USA (20 m) 29±2 47±2 300±10 20±10 1500
+100
Notes:
(*) Melt the hose ends at both sides (gun/pump) and turn approx. 5 cm of each hose end to the inside.
(**) Fix the protective hose with cable ties on both sides only once at the product hose (internally).
(***) Fix the hose set within the protective hose approx. once per meter by means of adhesive tape, starting
at distance E.
Cable ties are only permitted at the ends of the protective hose (see **)!
1 Product hose
2 Air hose
3 Electrical cable
Page 81
81
GM 5000EA
B_03244
2
3
4
5
1
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
13.5.2 HOSE SETS FOR LOWRESISTANCE PRODUCTS
Order No. Designation
1 1 2357021 Hose set GM 5000EA USA (7.5 m), Low R
Consists of:
2 1 2310464 Product hose EA, complete (7.5 m) Low R
3 1 2345340 Air hose, complete (8.0 m)
4 1 2339157 Gun cable GM 5000E (10.0 m)
5 8 m 3676437 Protection hose fabric PP30 (8.0 m)
1 2307288 Nipple
1 9971025 O-ring
Order No. Designation
1 1 2357022 Hose set GM 5000EA USA (10.0 m), Low R
Consists of:
2 1 2310465 Product hose EA, complete (10.0 m) Low R
3 1 2345341 Air hose, complete (10.5 m)
4 1 2339158 Gun cable GM 5000E (15.0 m)
5 10.5 m 3676437 Protection hose fabric PP30 (10.5 m)
1 2307288 Nipple
1 9971025 O-ring
Order No. Designation
1 1 2357023 Hose set GM 5000EA USA (15.0 m), Low R
Consists of:
2 1 2310466 Product hose EA, complete (15.0 m) Low R
3 1 2345342 Air hose, complete (15.5 m)
4 1 2339159 Gun cable GM 5000E (20.0 m)
5 15.5 m 3676437 Protection hose fabric PP30 (15.5 m)
1 2307288 Nipple
1 9971025 O-ring
Page 82
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Order No. Designation
1 1 2357024 Hose set GM 5000EA USA (20.0 m), Low R
Consists of:
2 1 2310467 Product hose EA, complete (20.0 m) Low R
3 1 2345343 Air hose, complete (20.5 m)
4 1 2339160 Gun cable GM 5000E (25.0 m)
5 20.5 m 3676437 Protection hose fabric PP30 (20.5 m)
1 2307288 Nipple
1 9971025 O-ring
Page 83
83
GM 5000EA
B
FC
D
E
(**)
B_03841
(*)(***)
1
2
3
A****
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Hose colors:
Product hose grey
Air hose blue
Dimensions:
Air hose: inside diameter 8 mm; 0.32 inch
Product hose: inside diameter 6 mm; 0.24 inch, nominal pressure 2 MPa; 20 bar; 290.07 psi
Material of product hose: FEP
Order No. Description A [mm] B [mm] C [mm] D [mm] E [mm] F [mm]
2357021 Hose set GM 5000EA (7.5m) Low R 200±2 171±2 300±10 20±10 1500
+100
182±1
2357022 Hose set GM 5000EA (10 m), Low R 200±2 171±2 300±10 20±10 1500
+100
182±1
2357023 Hose set GM 5000EA (15 m), Low R 200±2 171±2 300±10 20±10 1500
+100
182±1
2357024 Hose set GM 5000EA (20 m), Low R 200±2 171±2 300±10 20±10 1500
+100
182±1
Notes:
(*) Melt the hose ends at both sides (gun/pump) and turn approx. 5 cm of each hose end to the inside.
(**) Fix the protective hose with cable ties on both sides only once at the product hose (internally).
(***) Fix the hose set within the protective hose approx. once per meter by means of adhesive tape, starting
at distance E.
Cable ties are only permitted at the ends of the protective hose (see **)!
(****) If the air swivel joint (Order No. 2324766) is used, the hose set has to be adapted accordingly.
Dimension A becomes 231±2 mm!
1 Product hose
2 Electrical cable
3 Air hose
Page 84
84
GM 5000EA
B_06059
B_05763
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
13.5.4 GUN CABLES AND GUN CABLE EXTENSIONS
GM 5000E gun cable
Length 10 m; 32.8ft 15 m; 49.2ft 20 m; 65.6ft 25 m; 82.0ft 32 m; 105ft 62 m; 203ft
Order No. 2339157 2339158 2339159 2339160 2344995 2344996
GM 5000E extension cable
Max. total length of 80m; 262ft (see
Chapter 6.7.3.1)
Length 10 m; 32.8ft 20 m; 65.6ft
Order No. 2339161 2339162
13.5.5 AIR REGULATION
Order No. Designation
2357053 Air regulation PB, complete
13.5.3 SPIRAL HOSE NO FM APPROVAL
Order No. Designation
1 1 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.
Due to the spiral the conductive bridges will be interrupted by sedimentation of the
metallic particles.
For details of spiral hose assembly, refer to the supplied assembly manual.
Page 85
85
GM 5000EA
B_06061
B_06062
B_06063
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
13.5.6 4 FINGER TRIGGER
Order No. Designation
2367641 4 nger trigger
Order No. Designation
2367508 Hose holder 4 nger trigger open
Order No. Designation
2367381 Hose holder 4 nger trigger closed
Page 86
86
GM 5000EA
P_00265
B_03224
B_03451
B_03693
B_03692
B_03681
B_03699
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Order No. Designation
2319653 Protective gun coating
259010 High-voltage tester, HV 200 N
2326041 Paint resistance meter
999080 Wet lm thickness gauge
50342 Viscosity cup DIN 4 mm; 0.16 inch
2309368 Valve needle assembly tool
2325263 Clamping screw assembly tool
2326485 Wall mount, GM 5000E (left/right)
13.6 MISCELLANEOUS
Page 87
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14 SPARE PARTS
14.1 HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
Order number, designation and quantity
The quantity need not be the same as the number given in the quantity column "
" on
the list. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
Address for the invoice
Address for delivery
Name of the person to be contacted in the event of any queries
Type of delivery (normal mail, express delivery, air freight, courier, etc.)
Identi cation in spare parts lists.
Explanation of column "
" (labeling) in the following spare parts lists:
Wearing parts
Note: These parts are not covered by warranty terms.
Not part of standard equipment, available, however, as additional extra.
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.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy supply and the compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating and service manual for all work.
Page 88
88
GM 5000EA
B_03235
2
20
21
19
7
5
8
9
10
22
12
11
13
14
15
18
16
17
6
1
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14.2 GM 5000EA SPRAY GUN
Dismantling and assembling
see Chapter 10
14.2.1 BASIC VERSION GM 5000EA
Page 89
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
GM 5000EA spare parts list
Order No. Designation
1 1 2344471 Basic version GM 5000EA
2 1 2315709 Protection cap valve needle
51 -
Adapter GM 5000EA, complete
For details, see Chapter 14.2.4
6
1 2314361 Hook
71 -
Handle ES 5000 Air (USA), complete
For details, see Chapter 14.2.5
8 2 9900308 Hexagon socket cylinder head screw
9 1 2312183 Lid, complete (including item 22)
10 1 9900386 Hexagon socket cylinder head screw
11 1 2311970 Sealing plug
12 1 2307104 Screw plug
13 1 2312180 Air regulation, complete (including item 14)
14
1 9971182 O-ring
15 1 9971182 O-ring
16
1 2314360 Trigger
17 1 2311849 Cylindrical helical spring
18 2 2310617 Oval head screw with hexagon socket
19 1 2352728 Product hose Air (USA), complete
20 1 2307039 Union nut
21
1 2311217 O-ring
22 1 2308699 Cover seal
1 2326335 Service set GA 5000EA
= Wearing part
= Included in service set
Page 90
90
GM 5000EA
B_06066
2
20
21
19
7
5
8
9
10
22
12
11
13
14
15
18
16
17
6
1
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14.2.2 SPIRAL HOSE FOR GM 5000EA
Dismantling and assembling
see Chapter 10
Page 91
91
GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
GM 5000EA spare parts list
Order No. Designation
1 1 2363670 Spiral hose for GM 5000EA*
2 1 2315709 Protection cap valve needle
51 -
Adapter GM 5000EA, complete
For details, see Chapter 14.2.4
6
1 2314361 Hook
71 -
Handle ES 5000 Air (USA), complete
For details, see Chapter 14.2.5
8 2 9900308 Hexagon socket cylinder head screw
9 1 2312183 Lid, complete (including item 22)
10 1 9900386 Hexagon socket cylinder head screw
11 1 2311970 Sealing plug
12 1 2307104 Screw plug
13 1 2312180 Air regulation, complete (including item 14)
14
1 9971182 O-ring
15 1 9971182 O-ring
16
1 2314360 Trigger
17 1 2311849 Cylindrical helical spring
18 2 2310617 Oval head screw with hexagon socket
19 1 2355047 Spiral hose, complete (USA)*
20 1 2307039 Union nut
21
1 2311217 O-ring
22 1 2308699 Cover seal
1 2326335 Service set GA 5000EA
* no FM approval, in submission
= Wearing part
= Included in service set
Page 92
92
GM 5000EA
B_06065
2
20
21
19
7
5
8
9
10
22
12
11
13
14
15
18
16
17
6
1
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14.2.3 4 FINGER TRIGGER FOR GM 5000EA
Dismantling and assembling
see Chapter 10
Page 93
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
GM 5000EA spare parts list
Order No. Designation
1 1 2367744 4 nger trigger for GM 5000EA
2 1 2315709 Protection cap valve needle
51 -
Adapter GM 5000EA, complete
For details, see Chapter 14.2.4
6
1 2314361 Hook
71 -
Handle ES 5000 Air (USA), complete
For details, see Chapter 14.5.
8 2 9900308 Hexagon socket cylinder head screw
9 1 2312183 Lid, complete (including item 22)
10 1 9900386 Hexagon socket cylinder head screw
11 1 2311970 Sealing plug
12 1 2307104 Screw plug
13 1 2312180 Air regulation, complete (including item 14)
14
1 9971182 O-ring
15 1 9971182 O-ring
16
1 2367641 4 nger trigger
17 1 2311849 Cylindrical helical spring
18 2 2310617 Oval head screw with hexagon socket
19 1 2352728 Product hose Air (USA), complete
20 1 2307039 Union nut
21
1 2311217 O-ring
22 1 2308699 Cover seal
1 2326335 Service set GA 5000EA
= Wearing part
= Included in service set
Page 94
94
GM 5000EA
B_04367
2
1
12
10
9
8
3
4
24
5
6
7
21
22
11
25
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14.2.4 GM 5000EA ADAPTER
Dismantling and assembling
see Chapter 10
Page 95
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Spare parts list adapter
Order No. Designation
1 1 - Adapter GM 5000EA, complete
2
1 2309391 Air manifold ring, Air
3 1 2307180 O-ring, sheathed
4
1 2312179 Valve housing Air, complete (steel)
1 2312176 Valve housing Air, complete (PEEK)
5
1 2312184 Valve tip Air, complete (PEEK)
1 2312185 Valve tip Air, complete (steel)
6 1 2314271 Adapter GM 5000EA
7 1 2312181 Cascade, complete
8
1 9974166 O-ring
9 1 2307062 Clamping screw valve rod
10 1 2311562 Rod seal
11
1 2312177 Valve rod unit Air
12 1 2357106 Packing, complete
21 1 2307059 Withdrawal nut
22 1 9901411 Threaded pin with hexagon socket
24 1 2325263 Clamping screw assembly tool
25 1 2357665 Clamping screw valve rod, complete
1 2326335 Service set GA 5000EA
= Wearing part
= Included in service set
= Not part of the standard equipment but available as a special accessory.
Page 96
96
GM 5000EA
B_06067
7
8
9
12
6
3
2
1
4
24
25
10
18
13
5
23
26
4 4
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14.2.5 GM 5000EA HANDLE
Dismantling and assembling
see Chapter 10
Page 97
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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Handle spare parts list
Order No. Designation
1 1 - Handle GM 5000EA (USA), complete
2 1 2354402 Fitting (USA)
3
1 9971025 O-ring
4 1 2307290 Hose holder
4 2367508 Hose holder 4 nger trigger open
4 1 2367381 Hose holder 4 nger trigger closed
5 1 2312182 Plug, complete (including item 23)
6 1 2314270 Handle, complete
7
1 2307232 Adapter seal
8 1 2325789 Adjusting screw complete
9 1 2309825 Oval head screw with hexagon socket
10 1 2310692 Seal
12 1 2307281 Threaded bolt
13 1 2312189 Air valve
18
1 9974218 O-ring
23
1 9974166 O-ring
24 1 2344489 Type plate left, GM5000EA - FM*
25 1 2344490 Type plate right, GM5000E - FM*
26 1 9971364 O-ring
1 2326335 Service set GA 5000EA
= Wearing part
= Included in service set
Note:
* Type plates may only from WAGNER sta or a skilled person be replaced!
Page 98
98
GM 5000EA
B_04094
4
3
B_03843
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
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).
NOTICE
Incorrect assembly!
Damage to the parts or device.
Do not deteriorate the edges of the parts (see detail) during assembly (press parts
carefully on stop).
Page 99
99
GM 5000EA
B_03264
4
3
2
1
B_03263
4
3
2
1
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14.3.2 AR 5000 NOZZLE D12
AR 5000 nozzle (D12) spare parts list
Order No. Designation
1 1 2315050 Nozzle AR 5000, complete (D12)
2
1 2327661 Nozzle, AR (D12)
3
1 2327662 Nozzle attachment, AR (D12)
4
1 2327663 Air di user, AR (D12)
= Wearing part
14.3.1 AR 5000 NOZZLE D8
AR 5000 nozzle (D8) spare parts list
Order No. Designation
1 1 2310558 Nozzle AR 5000, complete (D8)
2
1 2327658 Nozzle, AR (D8)
3
1 2327659 Nozzle attachment, AR (D8)
4 1 2327660 Air di user, AR (D8)
= Wearing part
Page 100
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GM 5000EA
B_06045
1
3
2
5
4
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
14.3.3 NOZZLE SET EARV 5000
LV HV
EAWRV 5000 spare parts list
Low-viscosity (LV)
products
High-viscosity (HV)
products
Designation Order No. Order No.
1 1 Nozzle set EARV 5000 2361290 2365979
2
1 Nozzle, EARV 2361273
3 1 Nozzle insert EARV 2361274
4 1 Union nut, EARV 2361272 2365978
5
1 O-ring, sheathed 2311217
= Wearing part
Markings on union nut
LV HV
Low-viscosity (LV)
products
High-viscosity (HV)
products
B_05984
B_05985
Mounting tool
353210 Air nozzle spanner
"?
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