Electrical Devices and Equipment 4.1.2 A Safe Work Environment 4.1.3 Personnel Qualifications Safety Instructions for the Personnel 4.2.1 Personal Safety Equipment 4.2.2 Safe Handling of WAGNER Spray Devices 4.2.3 Grounding the Unit 4.2.4 Product hoses 4.2.5 Cleaning and Flushing 4.2.6 Touching Hot Surfaces 4.2.7...
Page 4
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 COMMISSIONING Training of Assembly/Commissioning Personnel Storage Conditions Installation Conditions Installation and Connection 6.4.1 Typical AirCoat spraying system 6.4.2 Ventilation of the Spray Booth 6.4.3 Air Supply Lines 6.4.4 Product supply lines Grounding Safety Checks Lacquer Preparations 6.7.1...
Page 5
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 FUNCTION TEST AFTER REPAIR WORK DISPOSAL ACCESSORIES 13.1 AirCoat Nozzles ACF3000 13.2 AirCoat Nozzles ACF3000 S2 (4 pieces) 13.3 Round jet nozzle attachment 13.3.1 RXX Nozzle inserts 13.3.2 Nozzle screw joint, complete 13.4 Hoses 13.5...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 ABOUT THESE INSTRUCTIONS 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.
2327992 French 2312957 Hungarian 2364607 Italian 2312958 Spanish 2312959 Additional languages on request or at: www.wagner-group.com ABBREVIATIONS Order No. Order number Spare part Marking in the spare parts lists Position Number of pieces Wrench size (tool) Torx size (tool) (replaceable packing)
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal flushing of paint-wetted parts with compressed air Product pressure Pump or pressure tank generator Personnel qualifications Trained person...
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. Only operate the device as a whole. Do not deactivate safety fixtures.
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.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 TYPE PLATE SERIAL.NO: IC-XXXXX II 2 G X J. WAGNER AG CH-9450 ALTSTÄTTEN MADE IN SWITZERLAND B_06637 Designation 1 Maximum product pressure 2 Maximum product temperature 3 Serial number 4 Maximum air temperature...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 BASIC SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention. 4.1.1 ELECTRICAL DEVICES AND EQUIPMENT Electric shock hazard! Danger to life from electric shock.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 4.1.2 A SAFE WORK ENVIRONMENT Hazard due to dangerous fluids or vapors! Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with the skin or eyes. Ensure that the floor in the working are is static dissipative in accordance with EN 61340-4-1 (resistance must not exceed 100 M ).
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 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 occupational safety and accident prevention. In electrostatics applications: Persons belonging to a risk group according to EMF guideline 2013/35/EU (e.g., carriers of active implants), must not enter the high- voltage area.
"Troubleshooting" chapter. If necessary or at least every 12 months, the liquid ejection devices must be checked for safe working conditions by an expert (e.g. WAGNER Service Technician) in accordance with the guidelines for liquid ejection devices (DGUV [German Statutory Accident Insurance] regulation 100-500 section 2.29 and 2.36).
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 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 flushing agents used.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 4.2.5 CLEANING AND FLUSHING Hazard due to cleaning and flushing! Explosion hazard and damage to the device. Preference should be given to non-ignitable cleaning and flushing agents. When carrying out cleaning work with flammable cleaning agents, make sure that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded.
Hazard 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. Do not change or modify the device; if change is necessary, contact WAGNER.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 DESCRIPTION COMPONENTS B_06650 B_06651 Designation A Gun head B Spray gun body C Tension sleeve drive D Base plate E Atomizing air connection (blue) F Union nut G Air cap (blue, red or bronze) H Nozzle Standard holder Connecting fitting (product)
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 FUNCTIONAL DESCRIPTION 5.2.1 MODE OF OPERATION Diagram: SA = Shaping air AA = Atomizing air CA = Control air Nozzle M = Product C = Circulation AA / SA B_00521 Open: The piston in the drive is charged with control air and moves toward the rear. This ensures that the air valve which releases the shaping and atomizing air is opened first.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.2.2 MODE "NC" AND "C" DANGER Spurting out of liquids with high pressure! Danger to life and equipment damage. For the operating mode NC (no product circulation), the spray gun may only be connected if the lock pin is installed.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.2.3 SPRAYING PROCEDURE 5.2.3.1 AIRCOAT FLAT SPRAYING PROCEDURE For normal applications with the AirCoat flat jet process, the spray product is atomized at a pressure of 3-12 MPa; 30-120 bar; 435-1740 psi. For normal applications, a soft, optimum spray jet is achieved with help of the atomizing air, which has a pressure of 0.05-0.25 MPa;...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.2.3.2 AIRCOAT ROUND SPRAYING PROCEDURE For normal applications with the AirCoat round jet process, the spray product is atomized at a pressure of 3-12 MPa; 30-120 bar; 435-1740 psi. For normal applications, the air at 0.05-0.25 MPa; 0.5-2.5 bar; 7.2-36 psi produces a soft spray jet.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.3.2 OVERVIEW The Aircoat automatic gun is composed of the gun body and supplementary components. Circulation operating mode is possible. 5.3.3 Gun body of GA 4000ACIC automatic gun 5.3.4.4 Round nozzles, supplementary components 5.3.4.3 Flat nozzles,...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.3.3 STANDARD VARIANT Order No. Designation 2312132 AirCoat automatic gun GA 4000ACIC 2338603 AirCoat automatic gun GA 4000ACIC (RP) The basic equipment includes: Order No. Designation 2315627 CE Declaration of Conformity 2312955 Operating manual, German See Chap.
Page 26
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.3.4.2 AIR CAPS Order No. Designation 2308809 Air cap HV plus (blue) for high viscosity products B_03048 2308808 Air cap LV plus (red) for low viscosity products B_03049 2313493 Air cap LA plus (bronze) B_03098 2340299 Air cap LV plus (blank)
Page 27
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.3.4.5 PRODUCT CONNECTIONS Order No. Designation 350550 Straight connecting fitting B_03074 2314065 Connecting fitting 90°; 1/4–NPSM B_03097 2328186 90° connecting fitting; G1/4" B_06645 5.3.4.6 AIR SUPPLY CONNECTIONS Order No. Designation 9998090 Straight threaded fitting 6 mm–1/8";...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 DATA 5.4.1 MATERIALS OF PAINT-WETTED PARTS Metals Plastics Carbide Stainless steel 1.4305 Stainless steel 1.4310 Stainless steel 1.4104 PTFE PA 6.6 UHMW-PE EPDM 5.4.2 TECHNICAL DATA Description Units Value Maximum air inlet pressure MPa;...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 5.4.3 MEASUREMENTS AND CONNECTIONS inch 5.08 Ø 3.2 1.85 77.5 3.05 2.17 18±0.1 0.71±0.004 18±0.1 0.71±0.004 B_03486 Connection data: Base plate to GA 4000ACIC R G1/8" -> 6 mm; 0.24 inch control air G1/8"...
Page 30
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 inch Ø 3.2 5.08 2.04 2.40 37.5 1.48 18±0.1 0.71±0.004 18±0.1 0.71±0.004 B_06648 Connection data: Base plate to GA 4000ACIC S G1/8" -> 6 mm; 0.24 inch control air G1/8" -> 8 mm; 0.31 inch atomizing air G1/4"...
The spray gun must be combined with various components to make up a spraying system. The spraying system shown in the figure is only one example of an AirCoat spraying system. Your WAGNER distributor would be happy to assist you in creating a spraying system solution that meets your individual needs.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 6.4.1 TYPICAL AIRCOAT SPRAYING SYSTEM B_00559 Designation Designation A Control cabinet F Paint supply B Conveyor G Part recognition C Work piece H Spray guns D Spray booth Supply air system and exhaust air system E Reciprocator 6.4.2 VENTILATION OF THE SPRAY BOOTH...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 6.4.4 PRODUCT SUPPLY LINES NOTICE Impurities in the spraying system! Spray gun blockage, products harden in the spraying system. Flush the spray gun and paint supply with a suitable flushing agent. GROUNDING A conductive connection (potential equalization cable) must be established between original tank and the equipment.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 COMMISSIONING 6.8.1 PREPARATION BEFORE COMMISSIONING NOTICE Impurities in the spraying system! Spray gun blockage. Flush the spray gun and paint supply with a suitable flushing agent before commissioning. 6.8.2 COMMISSIONING 1. Mount spray gun to reciprocator. 2.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 OPERATION TRAINING THE OPERATING PERSONNEL The operating personnel must be qualified to operate the entire system. The operating personnel must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures. Before work commences, the operating personnel must receive appropriate system training.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 Spray pattern shapes Correct amount of shaping air/ No shaping air/ Too little shaping atomizing air atomizing air air/atomizing air B_00071 Note: The flow rate can be changed by: – changing the product pressure or –...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 Pressure Relief Procedure: 1. Turn compressed air regulator for shaping and atomizing air on the superordinate control to "0". 2. Close the compressed air supply on the material side upon the product pressure generator. 3.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 7.2.6 ELIMINATING NOZZLE CLOGGING 1. Relieve the pressure of gun and device. 2. Secure gun (remove the control air hose). 3. Unscrew union nut (A). 4. Remove air cap (B). 5. Push AirCoat nozzle (C) out of air cap (B) by hand and place on nozzle seal (D) the other way round with the nozzle tip towards the rear.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 7.2.7 REPLACING NOZZLE INSERT OF ROUND JET NOZZLE 1. Relieve the pressure of gun and device. 2. Secure gun (remove the control air hose). 3. Remove nozzle insert (B) with nozzle spanner (A). 4.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING PERSONNEL Cleaning work should be undertaken regularly and carefully by qualified and trained personnel. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: –...
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 "Spare parts" chapter and that are assigned to the unit.
– 10 years from the date of the hose imprinting. Fitting embossing Meaning xxx bar Pressure yymm Crimping date (year/month) Internal code Hose imprinting Meaning Wagner Name/Manufacturer yymm Date of manufacture (year/month) xxx bar (xx MPa) Pressure e.g., 270 bar (27 MPa) Internal code DNxx (e.g., DN10) Nominal diameter...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 8.2.4 REPLACING THE PAINT HOSE 1. Decommissioning work and cleaning. 2. Relieve the pressure of gun and device. 3. Secure gun (remove the control air hose). 4. Place open-ended wrench size 17 mm; 0.67 inch on flats of product connection and counterhold.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 8.2.6 REPLACING THE SEALING FITTING OF THE ROUND JET NOZZLE NOTICE Defective nozzle body! Poor spray pattern. Handle the nozzle body (A) with care. Unscrew the nozzle by hand. B_06658 Hold in position with a size 13 mm;...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 TROUBLESHOOTING AND RECTIFICATION Functional fault Cause Remedy See Chapter Insufficient product Nozzle too small Select larger nozzle. output Product pressure too Increase product pressure. low. Filter upstream of gun Clean or replace filter. or high-pressure filter clogged at pump.
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 "Spare parts" chapter and that are assigned to the unit.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 10.3 REPLACING PARTS OF THE GUN BODY 10.3.1 DISASSEMBLY OF GA 4000ACIC NOTICE Defective plunger shaft! Packing leaking. Greater wear on the packing. Handle the plunger shaft (K) with care. The plunger shaft has the function of a sliding surface. Note: The complete base plate (B) does not have to be removed.
Page 49
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 Blow gun M5 wrench size 3 mm; 0.12 inch Note: Stuck components can be pushed out with a drift 3 mm; 0.12 inch. Note: Pull out distributor seal (F) using pliers. M5 wrench size 12 mm; 0.47 B_03066 inch...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 10.3.2 PACKING INSERT GA 4000AC (RP) 180° 5 Nm (Torx TX40) SW15 B_04227 Order of seals: 1) Sealing set GA 4000 packing RP: Order No. 2339140 Product Order No. Order No. (set of 12 packings) PTFE + GF 2339141 2339142...
Page 51
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 2) Sealing set GA 4000 packing RP special: Order No. 2339810 Product Order No. Order No. (set of 12 packings) PTFE 2339143 2339142 PTFE 2339143 2339142 PTFE + GF 2339141 PTFE + GF 2339141 Mobilux®...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 10.3.3 ASSEMBLY OF GA 4000ACIC General note: Lightly grease o-rings and sliding SW 15; 0.59 inch surfaces with Vaseline white PHV II. 25 Nm; 8.85 lbft SW 12; 0.47 inch 25 Nm; 8.85 lbft M5 SW 3;...
Page 53
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 Dismount union nut and air cap again. Wrench size 12 mm; 0.47 inch 10 Nm; 7.38 lbft M5 wrench size 3 mm; 0.12 inch 4 Nm; 2.95 lbft B_06661...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 11 FUNCTION TEST AFTER REPAIR WORK After all repair work, the spray 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 personnel.
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 "Spare parts" chapter and that are assigned to the unit.
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 14.2 SPARE PARTS LIST FOR GA 4000ACIC 10 Nm; 7.38 lbft 4 Nm; 2.95 lbft 16 / 16a 25 Nm; 18.44 lbft 25 Nm; 18.44 lbft 1 Nm; 0.74 lbft B_06662 Special version in EPDM* Loctite®...
Page 62
ORDER NUMBER DOC 2312956 Order No. Designation 2312132 Spray gun body, GA 4000ACIC 2338603 Spray gun body, GA 4000ACIC (RP) 2363386 Base plate, GA 4000ACIC-S, complete 2308810 Base plate, GA 4000ACIC-R, complete 2309945 Helical spring 2314274 End cap short 2308808...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 = Not part of the standard equipment but available as a special accessory Order No. Designation 2314242 Base plate, GA 4000ACIC R 2322531 Piston seal EPDM 2322530 O-ring 9974179 O-ring 2322532 Seal set, GA 4000ACIC (EPDM) = Wearing parts ->...
GA 4000ACIC VERSION 05/2018 ORDER NUMBER DOC 2312956 Packing insert 5 Nm (Torx TX40) B_04229 SW15 12 12 14.5 SEALING SET GA 4000 PACKING RP AND RP SPECIAL Order No. Designation Consisting of spare parts items 2339140 Sealing set GA 4000 packing RP 3, 6, 7, 8, 9, 12, 14 2339810 Sealing set GA 4000 packing RP special...
Identification: II 2G X EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2315627...
Page 68
Order No. 2312956 Edition 05/2018 ts-liquid@wagner-group.com www.wagner-group.com...
Need help?
Do you have a question about the GA 4000ACIC-S and is the answer not in the manual?
Questions and answers