3-in-1 electrostatic, aircoat & airless system (125 pages)
Summary of Contents for WAGNER GM 4100AC
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Translation of the original Operating manual GM 4100AC Edition 12/2008 AirCoat Spray gun for fl at - and round jet nozzles B_02254 II 2G X (Atex 95)
Safety instructions for the operator 2.1.1 Electrical equipment 2.1.2 Personnel qualifi cations 2.1.3 A safe work environment Safety instructions for staff 2.2.1 Safe handling of WAGNER spray units 2.2.2 Earth the unit 2.2.3 Paint hoses 2.2.4 Cleaning 2.2.5 Handling hazardous liquids, varnishes and paints 2.2.6...
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TROUBLE SHOOTING AND SOLUTION ACCESSORIES Round-jet nozzle cap 9.1.1 Nozzle inserts RXX 9.1.2 Nozzle screwed connection complete AirCoat nozzles ACF3000 Air caps Swivels and fi lter Hoses Miscellaneous SPARE PARTS 10.1 How to order spare parts? 10.2 Spare parts list GM 4100AC...
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 394820 394821 2301121 2301122 2301118 2301119 2301125 2301129 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR 2.1.1 ELECTRICAL EQUIPMENT 2.1.2 PERSONNEL QUALIFICATIONS 2.1.3 A SAFE WORK ENVIRONMENT SAFETY INSTRUCTIONS FOR STAFF...
EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never reach into the spray jet.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL USE IN HAZARDOUS LOCATIONS 2.4.1 CORRECT USE 2.4.2 EXPLOSION PROTECTION IDENTIFICATION As defined in the Directive 94/9/CE (ATEX 95), the unit is suitable for use in areas where there is an explosion hazard.
Note: All titles can be ordered from Heymanns Publishing House in Cologne or of the Internet download. CE Certificate of Conformity The certificate is enclosed with this product.The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number: 394891...
"Warning - hot surface". SIHI_0019_GB Note: Please contact your local WAGNER dealer and the paint manufacturer if you encounter application problems. EXTENT OF DELIVERY These AirCoat gun is available in two different variants. The nozzle size depends on the paint and on the ap- plication, Therefore the air cap and the nozzle are not included in the scope of supply.
Air hose, el. conductive Compressed air main The pray gun GM 4100AC must be used a part of a spraying system. The spraying system shown in the fi gure is only one example of an Aircoat spraying system. It is not an actual system design.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 5.1.2 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials. -or- Operate the unit on an appropriate spraying wall with the venti- lation (extraction) switched on.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 5.1.5 EARTHING WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning Insufficient paint application quality Earth all unit components. Earth the workpieces being painted. SIHI_0003_GB Any material containers and the unit must be connected by a potential equalisation (earth) cable.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL START UP 5.3.1 GENERAL RULES FOR HANDLING THE SPRAY GUN ➞ Observe general safety instructions in chapter 2. WARNING Unintentional putting into operation! Risk of injury Before all work on the unit, in the event of work interruptions and functional faults: Switch off the energy/compressed air supply.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 5.3.2 PREPARATION FOR STARTING UP 1. Secure the spray gun. 2. Connect material hose to the spray gun and material supply system. 3. Connect air hose to spray gun and to oil-free, dry air supply with regulator.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL WORKS 5.4.1 START-UP FOR SPRAYING AIRCOAT 1. Start up with material supply set to approx. 8 MPa; 80 bar; 1160 psi operating pressure. 2. Spray (release trigger safety catch and pull trigger) and check the atomisation.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 5.4.3 REPLACING AIRCOAT NOZZLE CAUTION Defective AirCoat nozzle! Insufficient paint application quality Do not use sharp-edged objects to treat hard metal on the AirCoat nozzle. SIHI_0020_GB 1. Relieve spray gun and unit pressure.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 5.4.4 CLEANING AIRCOAT NOZZLE For disassembly and assembly of AirCoat nozzles see chapter 5.4.3. The AirCoat nozzle (C) can be placed into a cleaning solvent which has been recommend- ed by the paint manufacturer.
Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe- cially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup- tions: - Switch off the energy/compressed air supply.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL FINISHING WORK AND CLEANING DANGER Exploding gas/ air mixture! Danger to life from flying parts and burns Never spray into a closed container. Earth the container. SIHI_0008_GB CAUTION Cleaning agent in the air duct! Functional faults caused by swollen seals Always point the spray gun down when cleaning.
WAGNER- Serv- ice-Agency. B_02266 Description Wrench A Wrench B Wrench C Wrench D SW 17 mm SW 19 mm SW 17 mm SW 14 mm GM 4100AC with fi lter NPS1/4“ 0.669 inches 0.748 inches 0.669 inches 0.551 inches...
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL CHANGING OR CLEANING FILTER INSERT 1. Finishing work and cleaning. 2. Relieve spray gun and unit pressure. 3. Secure gun with trigger safety catch. 4. Place open-ended wrench A on fl ats of fi lter housing (30) and counter hold.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL REPLACING PARTS ON THE VALVE ROD 6.4.1 DISASSEMBLING 1. Finishing work and cleaning. 2. Relieve spray gun and unit pressure. 3. Secure gun with trigger safety catch. 4. Unscrew spring cover (5) and remove compression springs (2) and (3).
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 6.4.2 REPLACEMENT OF VALVE ROCKER SEALS 1. Support valve tappet (50) with single open-end wrench SW 13 mm; 0.51 inch and unscrew cover (53) with single open-end wrench SW 7 mm; 0.28 inch.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL REPLACING THE NOZZLE SEAL CAUTION Defective nozzle seal! Material sprays into the air cap next to the nozzle Risk of contamination Do not clean the nozzle seal with sharp-edged objects. Replace the nozzle seal if the sealing surface is damaged.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL REPLACING THE „AIR“ SEALING RING CAUTION Forming air and atomizer air not separate! Poor spray pattern Spray jet cannot be adjusted Treat the distributor seal (F) with care. SIHI_0030_GB 1. Finishing work and cleaning.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL TROUBLE SHOOTING AND SOLUTION Functional fault Cause Remedy See in chapter Insuffi cient material Nozzle too small Select larger nozzle discharge Material pressure to low Increase material pressure Filter of gun or high- Clean or replace fi...
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL AIR CAPS Part No. Description 394910 Air cap LV assy. (red) for low viscosity paints B_02257 394911 Air cap HV assy. (blue) for high viscosity paints B_02256 SWIVELS AND FILTER Part No.
Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe- cially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup- tions: - Switch off the energy/compressed air supply.
GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL 10.2 SPARE PARTS LIST GM 4100AC Spare parts list GM 4100AC 16 MPa 25 MPa Part No. Part No. Description 394002 3940012 GM 4100AC; XX MPa; NPSM1/4“ 9999501 9999501 Screw spring Material...
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GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL Detail A B_02747 Mounting materials Part No. Description ● 9992831 Loctite 542 ● 9992833 Loctite 638 green ● 9992590 Loctite 222 ● 9992698 Vaseline white PHHV II ✭ ● 394342 Tool valve rod seal...
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GM 4100AC EDITION 12/2008 PART NO. DOC394821 OPERATING MANUAL Spare parts list GM 4100AC 16 MPa 25 MPa Part No. Part No. Description 51 ✭ ◆ 179338 179338 Air valve seal 52 ✭ ◆ 179395 179395 Seal 53 ✭ ◆...