Airless manual gun Original Service Manual
Contents
1. Original Service Manual A WAGNER GM 1 350 GM 1 530 Version 02 2015 Airless manual gun Ex Il 2G X Atex VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 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 Staff 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 VERSION 02 2015 SERVICE MANUAL GM 1 350 530 ORDER NUMBER DOC2355506 A WAGNER 1 ABOUT THESE INSTRUCTIONS 1 1 PREFACE 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 catego2. MANUAL WAGNER 2 5 3 SAFETY INSTRUCTIONS WARNING 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 2 5 4 DISASSEMBLY ASSEMBLY 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 filter housing A counterclockwise 5 Remove the filter insert C from the filter housing A 6 Remove gun handle D 7 The filter socket E is secured with Loctite 648 Heat the area around the filter socket to approx 150 C 302 F 8 Remove the filter socket E using an Allen wrench size 6 9 Remove and replace the seal of the filter socket F 10 Thoroughly clean all parts with flushing agent Assembly 11 Screw the filter 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 filter socket seal F becomes unusable by heating When re
3. WAGNER 1 3 LANGUAGES The service manual is available in the following languages Language Order No Language Order No German 2355505 English 2355506 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 Additional languages on request or at www wagner group com 1 4 ABBREVIATIONS Order No Order number ET Spare part K Marking in the spare parts lists Pos Position Stk Number of pieces sw Wrench size GM Manual gun gun manual DN Nominal diameter VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 2 REPAIR WORK 2 1 GENERAL NOTICES The following points must be noted for every repair carried out on the device e 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 e Loosening of the various connections using the appropriate tools product hoses and air hoses e Defective product hoses may not be repaired but must instead be replaced as a complete part for safety reasons e After assembly the repaired components and complete system must be checked in accordance with Chapter 3 2 2 REPAIR STAFF Repair work must be carried out careful
4. 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 Ibft 3 Insert the pressure spring B and tighten the preload nut A 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 NOTICE Unsuitable tool Damage to seals and sealing surfaces gt Do not hold the valve rod with pliers or a similar tool B 3 Nm 2 2 Ibft PS Drive coupler Wrench size SW 3 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 2 5 REPLACING THE FILTER TUBE 2 5 1 REQUIRED TOOLS AND AIDS 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 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 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE
5. worldwide Subject to changes without notice
6. 3 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 xe 1 364340 364340 Seal filter 15 loe 1 Filter insert yellow middle 100 mesh per inch e ej 1 2315723 2315723 Filter insert red fine 200 mesh per inch 10 pieces e 0 1 2315724 2315724 Filter insert blue middle 150 mesh per inch 10 pieces e ej 1 2315725 2315725 Filter insert yellow middle 100 mesh per inch 10 pieces eo ej 1 2315726 2315726 Filter insert white coarse 50 mesh per inch 10 pieces 16 xe 1 2353548 2353548 Seal kit PT HD GM1 5 pieces 17 e 1 2353549 2353549 Nozzle holder PT HD GM1 18 1 9992590 9992590 Loctite 222 19 1 9992804 9992804 Loctite 648 20 e 1 2353551 2353551 Service set GM1 4 Wearing parts x Included in service set e Not part of the standard equipment but available as a special accessory 15 Document No 11170009 Version Order No 2355506 Edition 02 2015 Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Phone 49 0 7544 5050 Telefax 49 0 7544 505200 E mail service standard wagner group com Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altstatten Phone 41 0 71 757 2211 Telefax 41 0 71 757 2222 More contact addresses on the internet at WWW wagner group com Company Locations WAGNER
7. airs 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 off 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 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 2 4 REPLACING THE VALVE ROD 2 4 1 DISASSEMBLING 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 Note The valve rod can only be ordered as a module individual valve rod parts are not available VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 2 4 2 ASSEMBLY 1 The valve rod D is screwed into the gun
8. ection The product valve is sealed Product does not discharge at the valve rod seal 3 Flush the spray gun Stop the material supply open the flushing valve pull the trigger lever and flush the spray gun or blow it out with air Flush the spray gun without nozzle Close the flushing 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 12 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 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 Stk 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 Identification 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 O Not part of standard equipment available however as additi
9. ly by qualified and trained staff They should be informed of specific 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 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 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 gt 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 rep
10. onal 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 off 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 13 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 4 2 SPARE PARTS LIST GM 1 350 530 3Nm 70 Nm 51 6 Ibft 14 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER Spare parts list GM 1 Pos K Stk 35 MPa 53 MPa_ Designation Order No Order No 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 7 1 2353556 2353556 Valve rod unit 8 x 1 2353546 2353546 Intermediate piece G 7 8 14 UNF 9 2 991040
11. placing the filter socket also replace the seal 10 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER SW6 16 Nm 11 8 Ibft o Loctite 648 11 VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL WAGNER 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 staff Injection and final 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 configure product pressure and pull the trigger lever Beware of the the recoil ensure firm 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 Visual inspection maximum pressure specified on the type plate has been reached Trigger and flush the spray gun multiple times Make sure that 350 bar or 530 bar product The product connection is sealed when the spray gun is closed conn
12. ries 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 1 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 A 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 ZN CAUTION This notice warns you of a hazard Possible consequences of not observing the warning instructions The signal word indicates the hazard level 2 The measures for preventing the danger and its consequences NOTICE 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 Note provides information about particular characteristics and how to proceed VERSION 02 2015 ORDER NUMBER DOC2355506 GM 1 350 530 A SERVICE MANUAL
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