WAGNER GM 4700AC User manual

II 2G X (Atex)
B_02376
AirCoat manual gun for at and
round jet nozzles
Version 06/2014
Translation of the Original
Operating Manual

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GM 4700AC
OPERATING MANUAL
VERSION 06/2014 ORDER NUMBER DOC2311730
Table of Contents
1 ABOUT THIS MANUAL 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 Use in Potentially Explosive Areas 9
2.4 Safety Parameters 9
2.5 Processible Working Materials 10
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 11
3 IDENTIFICATION 12
3.1 CE Explosion Protection Identication 12
3.2 Identication "X" 12
3.3 Type Plate 13
4 GENERAL SAFETY INSTRUCTIONS 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Equipment 14
4.1.2 Sta Qualications 14
4.1.3 Safe Work Environment 14
4.2 Safety Instructions for Sta 15
4.2.1 Safe Handling of WAGNER Spray Devices 15
4.2.2 Grounding the Device 16
4.2.3 Product Hoses 16
4.2.4 Cleaning and Flushing 17
4.2.5 Handling Hazardous Liquids, Lacquers and Paints 17
4.2.6 Touching Hot Surfaces 18
5 DESCRIPTION 19
5.1 Design 19
5.2 Mode of Operation 20
5.3 Protective and Monitoring Equipment 20
5.4 Scope of Delivery 20
5.4.1 Versions for Application up to 25 MPa; 250 bar; 3625 psi 20
5.4.2 Standard Equipment 20
5.5 Data 21
5.5.1 Materials of Paint-wetted Parts 21
5.5.2 Technical Data 21
6 ASSEMBLY AND COMMISSIONING 22
6.1 Training Assembly/Commissioning Sta 22
6.2 Storage Conditions 22
6.3 Installation Conditions 22
6.4 Assembly and Installation 23
6.4.1 Typical AirCoat Spraying System 23

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6.4.2 Ventilation of the Spray Booth 24
6.4.3 Air Supply 24
6.4.4 Product Supply 24
6.5 Grounding 25
6.6 Safety Checks 25
6.7 Preparation of Lacquer 25
6.8 Commissioning 26
6.8.1 Safety Instructions 26
6.8.2 Preparation for Commissioning 26
6.8.3 Commissioning 26
6.8.4 Verifying a Safe Operational Condition 26
7 OPERATION 27
7.1 Training the Operating Sta 27
7.2 Safety Instructions 27
7.2.1 General Rules for Making Adjustments to the Spray Gun 28
7.3 Work 29
7.3.1 Starting to Spray with the AirCoat 29
7.3.2 Adjusting the Spray Pattern 30
7.3.3 Pressure Relief/Work Interruption 31
7.3.4 Changing the AirCoat Nozzle 33
7.3.5 Cleaning AirCoat Nozzle 34
7.3.6 Eliminate Nozzle Clogging 34
8 CLEANING AND MAINTENANCE 35
8.1 Cleaning 35
8.1.1 Cleaning Sta 35
8.1.2 Safety Instructions 35
8.1.3 Flushing and Cleaning the Gun 36
8.2 Maintenance 38
8.2.1 Maintenance Sta 38
8.2.2 Safety Instructions 38
8.2.3 Safety Checks 39
8.2.3.1 Grounding Check 39
8.2.3.2 Product Hoses, Tubes and Couplings 40
8.3 Replacing the Product Hose or Air Hose 41
8.4 Changing or Cleaning Filter Insert 42
9 TROUBLESHOOTING AND RECTIFICATION 44
10 REPAIR WORK 46
10.1 Repair Sta 46
10.2 Safety Instructions 46
10.3 Disassembly of the Gun 47
10.4 Replacing Parts on the Valve Rod 48
10.4.1 Disassembling 48
10.4.2 Replacing Valve Tappet Seals 49
10.4.3 Replacing the Rod Seal (35) 49
10.4.4 Assembly 50
10.5 Replacing the Nozzle Seal 52
10.6 Replacing the "Air" Sealing Ring 53
Table of Contents

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10.7 Replacing the Sealing Fitting of the Round Jet Nozzle 54
10.8 Replace Filter Connection (only GM 4700AC) 56
10.8.1 Required Tools and Aids 56
10.8.2 Safety Instructions 56
10.8.3 Disassembly 57
10.8.4 Assembly 58
11 FUNCTIONAL CHECK AFTER REPAIR 60
12 DISPOSAL 62
13 ACCESSORIES 63
13.1 Round Jet Nozzle Cap 63
13.1.1 Nozzle Inserts RXX 63
13.1.2 Complete Nozzle Screw Joint 63
13.2 Air Caps 64
13.3 Anodized Union Nut 64
13.4 AirCoat Nozzles ACF3000 65
13.5 AirCoat Pre-atomizer Nozzles ACF3000 Plus 65
13.6 Filter Insert 66
13.7 Swivel Joints 66
13.8 Hoses 67
13.9 Nozzle Extensions 67
13.10 Miscellaneous 68
14 SPARE PARTS 69
14.1 How Can Spare Parts Be Ordered? 69
14.2 Spare Parts GM 4700AC 70
14.3 Spare Parts GM 4700AC-H 73
15 WARRANTY AND CONFORMITY DECLARATIONS 76
15.1 Important Notes Regarding Product Liability 76
15.2 Warranty Claim 76
15.3 CE Declaration of Conformity 77
15.4 Notes on German Regulations and Guidelines 78
Table of Contents

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1 ABOUT THIS MANUAL
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 sta.
The device may only be operated by trained sta and in compliance with this operating
manual.
Operating and service sta should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the danger. 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 danger!
Potential consequences from failure to observe the warning
instructions are here.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
DANGER
This notice warns you of a danger!
Potential consequences from failure to observe the warning
instructions are here.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
WARNING
This notice warns you of a danger!
Potential consequences from failure to observe the warning
instructions are here.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
CAUTION
This notice warns you of a danger!
Potential consequences from failure to observe the warning instructions are here. The
signal word indicates the hazard level.
The measures for preventing the danger and its consequences.
NOTICE
1.1 PREFACE

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1.3 LANGUAGES
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2311729 English 2311730
French 2311731 Dutch 2326027
Italian 2311732 Spanish 2311733
Russian 2328825 Chinese 2328826
1.4 ABBREVIATIONS
Order No. Order number
ET Spare part
Marking in the spare parts lists
LA Low Air
HV for highly viscous materials
LV for low viscosity materials
Position
Number of pieces
Width across ats
GM Manual gun
AC AirCoat
H Processing heated material (hot)
2K 2-component material
DN Nominal diameter

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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 ink-guiding 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 areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.
In accordance with
TRBS 1203 (2010)

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2 CORRECT USE
2.1 DEVICE TYPE
AirCoat manual gun for manually coating work pieces.
2.2 TYPE OF USE
The gun is suitable for atomizing liquid products, particularly coating products, using the
AirCoat process.
2.4 SAFETY PARAMETERS
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in the 94/9/EC (ATEX)
Directive, (see Explosion protection marking Chapter 3.1).
WAGNER shall not accept any liability for any damage resulting from incorrect use.
Only use the device 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 sta must be trained based on 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.

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Note:
Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.
2.5 PROCESSIBLE WORKING MATERIALS
Top-coat paints, primer paints, corrosion protection, textured lacquers, lyes, staining
solvents, clear lacquers, separating agents, etc. with a solvent or water base. If you want
to spray working materials other than the aforementioned, please contact a Wagner
representative.
WARNING
Hot coating products!
Burns
Wear antistatic protective gloves.
When operating the device with a coating product with a
temperature of > 43 °C;109.4 °F, identify the device with a
warning label that says "Warning - hot surface".
2.6 REASONABLY FORESEEABLE MISUSE
The forms of misuse listed below may result in physical injury or property damage:
Unauthorized conversions or modications to the system;
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.

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2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
Where appropriate, 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 irritation, Wear protective
clothing
Operation,
allergies Observe safety data
sheets
maintenance,
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

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3 IDENTIFICATION
3.1 CE EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 94/9/EC (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: AirCoat manual gun
Manufacturer: J. Wagner AG
CH-9450 Altstätten, Switzerland
II 2G X
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (Zone 1)
G Ex-atmosphere gas
X Special Notice
3.2 IDENTIFICATION "X"
X: The maximum surface temperature corresponds to the permissible product
temperature.
This and the permissible ambient temperature can be found in the "Technical Data"
chapter.
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.
Only use tools that are made of a permitted material.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.

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GM 4700AC
WARNING
SKIN INJECTION HAZARD
READ INSTRUCTION MANUAL
II 2GX
Serial-No. XXXXX
Max. p air 0.8 MPa (115 psi)
Max. p fluid see tension nut
Max. T fluid 55°C (131°F)
J. Wagner AG, Altstaetten
Made in Switzerland
B_04161
1
2
3
4
6
5
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3.3 TYPE PLATE
1 Serial No.
2 Maximum air inlet pressure
3 Maximum product pressure see spring cap
4 Maximum product temperature
5 Warning
6 Danger of injury from injection/read 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 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual on hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
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.
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.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated, maintained and repaired only by trained sta.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (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
100 megohms.
Ensure that during spraying, persons wear static dissipative gloves. Grounding takes
place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5. 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).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.

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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 to prevent actuation.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
If necessary or at least every 12 months, the liquid ejection devices should be checked
for safe working conditions by an expert (e.g., Wagner ServiceTechnician) in accordance
with the guidelines for liquid ejection devices (ZH1/406 and BGR500 Part2 Chapter2.29
and 2.36).
- If devices have been decommissioned, 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.
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.

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4.2.3 PRODUCT HOSES
4.2.2 GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids, and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
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.
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
- At sharp edges
- On moving parts
- 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 device.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 megohm.
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 tubes, 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.

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4.2.5 HANDLING HAZARDOUS LIQUIDS, LACQUERS 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.
4.2.4 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 paint 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
there can be a temporarily explosive mixture inside the lines and pieces 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.

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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;
109.4 °F:
- Mark the device with a warning label "Warning – hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two labels together.

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GM 4700AC
A
J
I
H
K
B
C
E
F
G
D
P_02379
OPERATING MANUAL
VERSION 06/2014 ORDER NUMBER DOC2311730
5 DESCRIPTION
Designation
A Suspension hook
B Regulator for shaping air
C Spring cap
D Trigger
E Trigger locking device
F Air connection
G Fluid inlet
H Union nut with nozzle protection
I Nozzle / Air cap
J Gun housing
K Turning handle with lter housing
5.1 DESIGN

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If the trigger guard (D) is operated when the trigger guard locking device (E) is released,
then the air valve opens rst. Atomizing air ows through the air connection (F) to the
air cap (I). The material valve opens only when approx. 1/2 of the trigger guard's path is
covered. The quantity of air for the atomization of the jet spray is preset via the external air
automatic controller. The spray pattern can be adjusted using the shaping air regulator (B).
5.2 MODE OF OPERATION
Order No. Designation
1 2313585 GM 4700AC 25 MPa, NPSM1/4" product connection
1 2315700 GM 4700AC-H 25 MPa, NPSM1/4" product connection
(H = for processing heated material)
This AirCoat manual gun is available in two dierent versions. The choice of air cap and
nozzle depends on the application, therefore these components are not included in the
scope of delivery. A selection guide for gun accessories can be found in Chapter 13.
Order No. Designation
1 2316429 CE Declaration of Conformity
1 2311729 Operating manual, German
1 see Chapter 1.3 Operating manual in local language
1 394335 Spring cap 16 MPa; 160 bar; 2320 psi
For special versions the delivery note applies.
5.4.2 STANDARD EQUIPMENT
5.4 SCOPE OF DELIVERY
5.4.1 VERSIONS FOR APPLICATION UP TO 25 MPA; 250 BAR; 3625 PSI
The standard equipment for guns includes:
The spray gun is secured with the locking device (E) (the locking device turned in the
spraying direction and fastened in the groove).
5.3 PROTECTIVE AND MONITORING EQUIPMENT