WAGNER TOPFINISH GM 1030P User manual

B_06965
TOPFINISH GM 1030P
Airspray manual gun for at
and round jet nozzles
Version 02/2019

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Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 8
2.5 Misuse 8
3 IDENTIFICATION 9
3.1 Explosion Protection Identication 9
3.2 Identication "X" 9
3.3 Type Plate 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 11
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 12
4.2.1 Personal Safety Equipment 12
4.2.2 Safe Handling of WAGNER Spray Devices 13
4.2.3 Grounding the Device 13
4.2.4 Product Hoses 14
4.2.5 Cleaning and Flushing 14
4.2.6 Maintenance and Repair 15
4.2.7 Protective and Monitoring Equipment 15
5 DESCRIPTION 16
5.1 Components 16
5.2 Mode of Operation 16
5.3 Standard Equipment 16
5.4 Data 17
5.4.1 Materials of Paint-wetted Parts 17
5.4.2 Technical Data 17
5.4.3 Dimensions and Connections 17
5.4.4 Air Flow 18

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6 ASSEMBLY AND COMMISSIONING 19
6.1 Training of Assembly/Commissioning Personnel 19
6.2 Storage Conditions 19
6.3 Installation Conditions 20
6.4 Installation and Connection 20
6.4.1 Typical Airspray Spraying System 20
6.4.2 Ventilation of the Spray Booth 20
6.4.3 Air Supply Lines 21
6.4.4 Product Supply Lines 21
6.5 Grounding 21
6.6 Safety Checks 21
6.7 Lacquer Preparations 21
6.8 Commissioning 22
6.8.1 Procedure 22
6.8.2 Verifying a Safe Operational Condition 22
7 OPERATION 23
7.1 Training the Operating Personnel 23
7.2 Tasks 23
7.2.1 Starting to Spray with the Airspray 23
7.3 Adjusting the Spray Pattern 24
7.3.1 Adjusting Spray Pattern 25
7.3.2 Setting the Product Flow Rate 25
7.4 Pressure Relief / Work Interruption 27
7.5 Cleaning the Nozzle and Eliminating Nozzle Clogging 28
8 CLEANING AND MAINTENANCE 29
8.1 Cleaning 29
8.1.1 Safety Instructions 29
8.1.2 Cleaning Personnel 29
8.1.3 Flushing and Cleaning the Spray Gun 29
8.2 Maintenance 30
8.2.1 Maintenance Personnel 30
8.2.2 Safety Instructions 30
8.2.3 Safety Checks and Maintenance Intervals 31
8.2.4 Replacing the Product Hose or Air Hose 32
9 TROUBLESHOOTING AND RECTIFICATION 33
10 REPAIR WORK 34
10.1 Repair Personnel 34
10.2 Repair Notes 34
10.3 Tools 35
10.4 Changing Needle Packings 36
10.5 Changing the Air Valve 37
10.6 Changing Shaping Air Regulator 38
10.7 Changing Shaping Air Regulator 110 39
10.8 Tightening Nozzle Nut 40
10.9 Replacing Nozzle or Needle 41

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11 FUNCTION TEST 42
12 DISPOSAL 43
13 ACCESSORIES 44
13.1 Air caps 44
13.2 Nozzles and Needles 45
13.3 Nozzles 45
13.4 Hose Sets 46
13.5 Additional Accessories 47
14 SPARE PARTS 48
14.1 How Can Spare Parts Be Ordered? 48
14.2 Spare Parts List Topnish GM 1030P 49
15 EU DECLARATION OF CONFORMITY 50

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1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential danger.
Non-observance may result in death or serious injury.
CAUTION Potentially dangerous situation.
Non-observance may result in minor injury.
NOTICE Potentially dangerous situation.
Non-observance may result in damage to property.
Note: Provides information about particular characteristics and
how to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2397373
Translation of the original operating manual
Language Order no. Language Order no.
English 2397374 Russian 2406532
French 2397375 Chinese 2406533
Italian 2397376
Spanish 2397378
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number Wrench size
Spare part for low-viscosity (LV) products
Marking in the spare parts lists for high-viscosity (HV) products
Position Low air
Number of pieces Manual gun
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Product pressure
generator
Pump or pressure tank.
Personnel 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 in
accordance with
TRBS 1203
(2010/Revision 2012)
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.

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2 CORRECT USE
2.1 DEVICE TYPE
Manual gun for manually coating work pieces.
Topnish GM 1030P
2.2 TYPE OF USE
The spray gun is suitable for atomizing liquid products, particularly coating products,
using the Airspray process:
– Non-ignitable products.
– Ignitable products.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in
Directive 2014/34/EU (ATEX), (see Explosion protection marking Chapter 3.1).
2.4 PROCESSIBLE WORKING MATERIALS
Lacquers and paints, greases, oils and corrosion inhibitor, glue, ceramic glazes, stains.
If you want to spray working materials other than the aforementioned, contact a WAGNER
representative.
Note:
Contact your localWAGNER dealer and the lacquer manufacturer if you encounter application
problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g., powder are processed.
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: Airspray manual gun Topnish GM 1030P
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
II 2G X
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (zone 1)
G Ex-atmosphere gas
X Special notice
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.4.2.
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
do not drop the device.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.

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3.3 TYPE PLATE
B_06966
3
1
max. p air
max. p fluid
8 bar (116 psi)
II 2G X
YB-SN: YY-XXXX
GM 1030P
Wagner Int. AG, CH-9450 Altstaetten
2
Designation
1 Maximum air inlet pressure/product pressure
2 Spray gun model and manufacturer
3 Explosion protection identication and year of manufacture serial number (YB-SN)

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning accident prevention regulations.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Danger of electric shock!
Danger to life from electric shock
Prepare device 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, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if device poses a danger or is damaged.
Must be de-energized before work is commenced. Inform personnel about planned
work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or vapors!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 MΩ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ensure that product hoses/air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 MΩ.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.

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Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
– Periodic preventative maintenance and service (replacing hoses, checking
tightness of connections, etc.).
– Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning accident prevention regulations.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with lacquer and when cleaning the device, follow the
processing 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 hand 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.

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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in
Chapter„9 Troubleshooting and Rectication“.
If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER
service technician) at least every 12 months for their work-safe condition in
accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36.
– For shut down devices, the examination can be suspended until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges.
Flames or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the
spray gun handle or the trigger.

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4.2.4 PRODUCT HOSES
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hoses and the ttings are suitable for the pressure generated.
Ensure that the following information can be seen on the pressure hose used:
– 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.
Ensure that no work is ever performed with a damaged hose.
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 MΩ.
Suction hoses may not be subjected to pressure.
4.2.5 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure
that all equipment and resources (e.g., collection tank, funnel, transport cart) are
conductive or static dissipative and grounded.
Observe the 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.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with devices containing aluminium or galvanized/zinc-plated parts.
They may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
– depending upon the coating product used,
– depending on the flushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and items of equipment.

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Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External Cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects
and never spray cleaning agents with a gun. Cleaning the device must not damage
it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
4.2.6 MAINTENANCE AND REPAIR
Danger due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are
assigned to the device.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Relieve the pressure from the spray gun, pressure hoses and all devices.
– Secure the spray gun against actuation.
– Switch o the energy and compressed air supply.
– Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
4.2.7 PROTECTIVE AND MONITORING EQUIPMENT
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
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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5 DESCRIPTION
5.1 COMPONENTS
Designation
B_06967
G
A
H
D
B
E
F
C
I
J
K
A Suspension hook
B Needle stroke regulator
C Needle stroke regulator lock
D Shaping air regulator
E Air connection
F Air regulation
G Trigger
H Fluid inlet
I Nozzle / air cap
J Air cap nut
K Spray gun housing
5.2 MODE OF OPERATION
When pressing the trigger (G), rst the atomizing air is released and then the material needle is
retracted. In this way, the spray product moves through the nozzle (I) to the workpiece surface
to be coated. The closing of the spray gun takes place in the reverse order.The product ow rate
is dependent on the diameter of the nozzle (I) and the setting of the material pressure on
the pressure vessel or product pressure regulator. The spray pattern is adjusted optimally
to suit the object being sprayed using the shaping air regulator (D). The ow rate can be
regulated by rotating the needle stroke regulator (B) and this setting can be xed using
the needle stroke regulator lock (C). The air supply is regulated using the air regulator (D).
5.3 STANDARD EQUIPMENT
Order no. Designation
1 2402429 CE Declaration of Conformity
1 2397373 Operating manual, in German
1see Chapter 1.3 Operating manual in local language
For special versions the delivery note applies.

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5.4 DATA
5.4.1 MATERIALS OF PAINT-WETTED PARTS
Metals Plastics
Stainless steel 1.4305 PE-UHMW
5.4.2 TECHNICAL DATA
Description Units Value
Maximum air inlet pressure bar; MPa; psi 8; 0.8; 116
recommended: 2; 0.2; 29
Maximum product pressure bar; MPa; psi 8; 0.8; 116
Fluid inlet inch G3/8"
Air connection inch G1/4"
Weight g; oz 486; 17.1
pH range of the product pH 3.5–9.0
Maximum product temperature °C; °F 40; 104
Operating temperature °C; °F 5–40; 41–104
5.4.3 DIMENSIONS AND CONNECTIONS
Dimensions AC
B
B_06968
D
E
mm; inch
A 168; 6.61
B 189; 7.44
C 41; 1.61
D G3/8"
E G1/4"

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5.4.4 AIR FLOW
0
100
200
300
400
500
600
700
800
900
0 1 2 3 4 5 6 7
1
3
4
5
6
7
8
9
11
10
12
2
B_07145
Flow diagram
Gun inlet pressure in bar
Air ow in nl/min
Inlet pressure (MPa; bar; psi) 0.1; 1; 14.5 0.2; 2; 29.0 0.3; 3; 43.5 0.4; 4; 58.0 0.5; 5; 72.5 0.6; 6; 87.0
HVLP, round 1 123 200 272 343 412 485
HVLP, at 2 206 323 429 540 651 770
HVLP+, round 3 109 171 230 293 352 416
HVLP+, at 4 163 246 329 410 493 579
Conv12, round 5 110 172 232 293 351 418
Conv12, at 6 173 264 352 437 529 623
Conv14, round 7 108 170 228 287 345 406
Conv14, at 8 174 268 354 444 532 624
Conv10, round 9 105 163 219 277 334 392
Conv10, at 10 168 259 346 431 518 607
Conv8, round 11 103 160 215 271 328 388
Conv8, at 12 167 256 341 424 509 595
Information on air ow in nl/min with an inlet pressure between 0.1; 1; 14.5 and 0.6; 6; 87.0 (MPa; bar; psi).

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6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL
The assembly and commissioning personnel 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.
A skilled person must check to ensure that the device is in a reliable state after it is
assembled and commissioned.
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).

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6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 5 °C and 40 °C
(41 °F and 104 °F).
The relative air humidity at the installation site must be between 10 and 95% (without
condensation).
6.4 INSTALLATION AND CONNECTION
The Airspray manual gun Topnish GM 1030P must be supplemented with various
components to make up a spraying system. The system shown in the gure is only one
example of an Airspray 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.
6.4.1 TYPICAL AIRSPRAY SPRAYING SYSTEM
F
GB
D
E
H
B_06969
C
A
Designation Designation
A Airspray spray gun E Return line
B Air hose, electrically conductive F Product pump
C Protective hose G Pressure regulator
D Product hose H Suction system
6.4.2 VENTILATION OF THE SPRAY BOOTH
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.