WAGNER GM 1-350 User manual

B_5040
Airless manual gun
Version 02/2015
Original Service Manual

2
GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
Table of Contents
1 ABOUT THESE INSTRUCTIONS 3
1.1 Preface 3
1.2 Warnings, Notices and Symbols in these Instructions 3
1.3 Languages 4
1.4 Abbreviations 4
2 REPAIR WORK 5
2.1 General Notices 5
2.2 Repair Sta 5
2.3 Safety Instructions 6
2.4 Replacing the Valve Rod 7
2.4.1 Disassembling 7
2.4.2 Assembly 8
2.5 Replacing the Filter Tube 9
2.5.1 Required Tools and Aids 9
2.5.2 Required Spare Parts 9
2.5.3 Safety Instructions 10
2.5.4 Disassembly/Assembly 10
3 FUNCTIONAL CHECK AFTER REPAIR 12
4 SPARE PARTS 13
4.1 How Can Spare Parts Be Ordered? 13
4.2 Spare Parts List GM 1-350/530 14

3
GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
1 ABOUT THESE INSTRUCTIONS
This service manual contains information on the maintenance and repair of the devices.
This device can be hazardous if it is not operated in accordance with the information
provided in this service manual and the relevant operating manual.
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 danger 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 danger 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 danger 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 danger and its consequences.
NOTICE
1.1 PREFACE

4
GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
1.3 LANGUAGES
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2348756 English 2349369
French 2355489 Italian 2355491
Spanish 2355493 Russian 2356564
Chinese 2356565
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
Wrench size
Manual gun (gun, manual)
DN Nominal diameter
Additional languages on request or at:
The service manual is available in the following languages:
Language: Order No. Language: Order No.
German 2355505 English 2355506

5
GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
2 REPAIR WORK
2.2 REPAIR STAFF
Repair work must be carried out carefully by qualied and trained sta. 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 ensure that the device is checked for being in a reliable state after
repair work is completed.
2.1 GENERAL NOTICES
The following points must be noted for every repair carried out on the device:
• Observe the safety instructions in Chapter 4 of the associated operating manual (see
Chapter 1).
• Decommissioning and cleaning as in Chapter 8.1.3 of the operating manual.
• Loosening of the various connections using the appropriate tools (product hoses and
air hoses).
• Defective product hoses may not be repaired, but must instead be replaced as a complete
part for safety reasons.
• After assembly, the repaired components and complete system must be checked in
accordance with Chapter 3.

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GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
2.3 SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and in Chapter 8.1.2 of the corresponding
operating manual.
Before repair work
- Flush and clean the system. Chapter 8.1.3 in the operating manual.
After repair work
- Carry out safety checks in accordance with Chapter 8.2.3. of the operating manual.
- Commission the system and check for leaks as described in Chapter 6.8 of the
operating manual.
- Function test in accordance with Chapter 3.
In accordance with the guideline for liquid ejection devices (ZH1/406 and BGR500
Part2 Chapter 2.29 and Chapter 2.36):
- The liquid ejection devices should be checked by an expert (e.g. Wagner service
technician) for their safe working conditions as required and at least every
12months.
- 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 Chapter
"Spare parts" and that are assigned to the unit.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy and compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service manuals at all times
when carrying out work.

7
GM 1-350/530
B_5050
A
B
C
D
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
2.4 REPLACING THE VALVE ROD
1. Flush and clean the spray gun as described in Chapter 8.1.3.
2. Relieve the pressure on the spray gun and product pressure generator in
accordance with Chapter 7.3.2.
3. Secure the spray gun with the locking device.
4. Unscrew preload nut (A) using open-end wrench (wrench size 30 mm; 1.18 inches)
and remove pressure springs (B).
5. The valve rod (D) is unscrewed on the pressure plate (C) using wrench size 10.
Attention: when unscrewing, ensure that the pressure plate is pushed fully onto the
valve rod.
6. Carefully remove the pressure plate (C) and valve rod (D) from the gun housing,
replace the valve rod (D).
2.4.1 DISASSEMBLING
Note:
The valve rod can only be ordered as a module; individual valve rod parts are not
available.

8
GM 1-350/530
B_5053
A
B
C
D
1
3 Nm; 2.2 lbft
B_5052
D
1
C
1
B_5309
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
2.4.2 ASSEMBLY
1. The valve rod (D) is screwed into the gun housing using the pressure plate (C). Here,
ensure that the pressure plate with the recess is pushed completely onto the valve
rod's wrench size (drive coupler) in order to transfer the torque (see Detail 1).
2. Using a wrench size 6 on the pressure plate (C), screw the pressure plate and valve
rod (D) into the gun housing, tightening torque 6 Nm ± 1 Nm; 4.43 lbft.
3. Insert the pressure spring (B) and tighten the preload nut (A).
4. Adjust the valve rod (D) using the Allen wrench (size 3) so that no actuation occurs
in the secured position. Opening stroke 1.2 ± 0.1 mm.
Drive coupler
NOTICE
Unsuitable tool!
Damage to seals and sealing surfaces
Do not hold the valve rod with pliers or a similar tool.
Wrench
size SW 3
Drive coupler

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GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
2.5 REPLACING THE FILTER TUBE
The following tools and aids are required for carrying out the repair work on the spray
gun described below:
Description
- Allen wrench SW 6
- Hot-air gun
- Suitable oven for curing the adhesive
2.5.1 REQUIRED TOOLS AND AIDS
2.5.2 REQUIRED SPARE PARTS
The following spare parts are required for carrying out the repair work on the spray gun
described below:
Description Order No.
- Filter socket with seal 2353611
- Loctite 648 9992804

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GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
Disassembly:
1. Flush and clean the spray gun as described in Chapter 8.1.3 of the operating
manual.
2. Relieve the pressure on the spray gun and product pressure generator in
accordance with Chapter 7.3.2 of the operating manual.
3. Secure the spray gun with the locking device.
4. Use the guard bracket (B) with integrated hex tool to loosen and unscrew the lter
housing (A) (counterclockwise).
5. Remove the lter insert (C) from the lter housing (A).
6. Remove gun handle (D).
7. The lter socket (E) is secured with Loctite 648. Heat the area around the lter
socket to approx. 150 °C; 302 °F.
8. Remove the lter socket (E) using an Allen wrench (size 6).
9. Remove and replace the seal of the lter socket (F).
10. Thoroughly clean all parts with ushing agent.
Assembly:
11. Screw the lter socket (E) with the new seal (F) back into the gun housing and
secure the screw connection with Loctite 648. Place the spray gun into a suitable
oven to cure the adhesive (max. 70 °C; 158 °F).
12. Reassemble the spray gun in reverse order.
Note:
The lter socket seal (F) becomes unusable by heating. When replacing the lter socket,
also replace the seal.
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
2.5.3 SAFETY INSTRUCTIONS
2.5.4 DISASSEMBLY/ASSEMBLY

11
GM 1-350/530
B
A
C
D
E
SW6
B_5055
Loctite 648
F16 Nm ; 11.8 lbft
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506

12
GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
3 FUNCTIONAL CHECK AFTER REPAIR
After all repairs, the gun 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.
Injection and nal inspection
Activities Aid tools
1. Trigger lever function test
- The trigger lever must be pulled as far as it will go. Manual inspection
Make sure that the trigger lever can move slightly in its rest position.
- Put the trigger lever locking device into locking position, congure
product pressure and pull the trigger lever.
(Beware of the the recoil; ensure rm footing and hold gun tight)
No product may not leak out or escape.
- Check that the trigger lever locking device is not reset by the trigger
lever when pulling in the locking position.
2. Leak test
- Connect the spray gun and gradually increase the pressure until the
maximum pressure specied on the type plate has been reached.
Visual inspection
- Trigger and ush the spray gun multiple times.
- Make sure that:
The product connection is sealed when the spray gun is closed.
The product valve is sealed.
Product does not discharge at the valve rod seal.
350 bar or 530 bar product
connection
3. Flush the spray gun
- Stop the material supply, open the ushing valve, pull the trigger
lever, and ush the spray gun or blow it out with air.
Flush the spray gun without nozzle.
- Close the ushing valve. When almost no material is escaping any
longer, remove the product connection hose and blow the rest of the
test medium out of the spray gun using an air gun.

13
GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
4 SPARE PARTS
4.1 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 "K" (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 Chapter
"Spare parts" and that are assigned to the unit.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy and compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service manuals at all times
when carrying out work.

14
GM 1-350/530
1
3
14
15
2
4
19
11
16 Nm ;
11.8 lbft
9
10
18
6
16 17
8
9
70 Nm;
51.6 lbft
13 12
5
7
3 Nm;
2.2 lbft
6
4
B_5046
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
4.2 SPARE PARTS LIST GM 1350/530

15
GM 1-350/530
SERVICE MANUAL
VERSION 02/2015 ORDER NUMBER DOC2355506
Spare parts list GM 1
35 MPa
Order No.
53 MPa
Order No.
Designation
1 1 2347536 2346856 GM1
2 1 2346614 2346614 Handle
3 1 2353559 2353559 Filter housing with guard bracket
4 1 - 2353599 Trigger guard 4F, complete
4 1 2353600 - Trigger guard 2F, complete
5 1 347335 347335 Pressure spring
6 1 - 2353606 Preload nut, 530bar
6 1 2353607 - Preload nut, 350bar
71 2353556 2353556 Valve rod unit
81 2353546 2353546 Intermediate piece "G" 7/8-14-UNF
9 2 9910403 9910403 Cap nut
10 1 2343085 2343085 Bolt
11 1 2353611 2353611 Filter socket with seal
12 1 2353613 2353613 Spray gun body
13 2 43411 43411 Actuating pins
14 1 364340 364340 Seal, lter
15 1 - - Filter insert, yellow (middle), 100 mesh per inch *
1 2315723 2315723 * Filter insert, red (ne), 200 mesh per inch – 10 pieces
1 2315724 2315724 * Filter insert, blue (middle), 150 mesh per inch – 10 pieces
1 2315725 2315725 * Filter insert, yellow (middle), 100 mesh per inch – 10 pieces
1 2315726 2315726 * Filter insert, white (coarse), 50 mesh per inch – 10 pieces
16 1 2353548 2353548 Seal kit PT-HD GM1 – 5 pieces
17 1 2353549 2353549 Nozzle holder PT-HD GM1
18 1 9992590 9992590 Loctite 222
19 1 9992804 9992804 Loctite 648
20 1 2353551 2353551 Service set GM1
Wearing parts
= Included in service set
Not part of the standard equipment, but available as a special accessory

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F
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D
Order No. 2355506
Edition 02/2015
Germany
Phone
Telefax
E-mail
Switzerland
Phone
Telefax
More contact addresses on the internet at:
Company/Locations/WAGNER worldwide
Subject to changes without notice
Document No. 11170009 Version -