WAGNER AirCoat GM 4600AC-H Translation Of The Original Operating Manual
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WAGNER AirCoat GM 4600AC-H Translation Of The Original Operating Manual

WAGNER AirCoat GM 4600AC-H Translation Of The Original Operating Manual

Spray gun for flat - and round jet nozzles
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AirCoat Spray gun
for fl at - and round jet nozzles
II 2G X (Atex 95)
Translation of the original
Operating manual
GM 4600AC
GM 4600AC-H
Edition 05/2011
B_02669

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Summary of Contents for WAGNER AirCoat GM 4600AC-H

  • Page 1 Translation of the original Operating manual GM 4600AC GM 4600AC-H Edition 05/2011 AirCoat Spray gun for fl at - and round jet nozzles B_02669 II 2G X (Atex 95)

  • Page 3: Table Of Contents

    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...
  • Page 4 GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL Contents STARTING UP AND OPERATING Installation and connection 5.1.1 Typical AirCoat spraying system 5.1.2 Ventilation of the spray booth 5.1.3 Air supply 5.1.4 Fluid (paint) hoses 5.1.5 Earthing Preparation of paints Start-up 5.3.1 General rules for handling the spray gun...

  • Page 5: About These Instructions

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL ABOUT THESE INSTRUCTIONS This operating manual contains information on the operation, repair and maintenance of the unit. Always observe these instructions when operating the unit. This equipment can be dangerous if it is not operated in accordance with this manual. Compliance with these instructions constitutes an integral component of the warranty agreement.

  • Page 6: General Safety Instructions

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit To be provided in accordance with the local safety requirements with regard to the...

  • Page 7: Safe Handling Of Wagner Spray Units

    EDITION 05/2011 Part No. DOC394861 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.

  • Page 8: Cleaning

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL 2.2.4 CLEANING De-energize the unit electrically. Disconnect the pneumatic supply line. Relieve the pressure from the unit. Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature.

  • Page 9: Use In Hazardous Locations

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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. II 2G X Communautés Européennes Symbol for explosion protection...

  • Page 10: Guarantee And Conformity Declarations

    fitted , operated and maintained. If other makes of accessory and spare parts are used, the manufacturer‘s liability could be fully or partially null and void. The usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed. GUARANTEE CLAIM...

  • Page 11: Ce-Conformity

    Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they are to be found in the Internet. 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...

  • Page 12: Description

    43 °C; 109.4 °F: Identify the unit with a warning sticker "Warning - hot surface". SIHI 0019 GB Note: In the event of application problems consult your Wagner branch and/ or the paint manufacturer. SCOPE OF DELIVERY These AirCoat gun is available in two different variants. The nozzle size depends on the paint and on the ap- plication.

  • Page 13: Spray Gun Configuration

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL 4.2.4 SPRAY GUN CONFIGURATION B_02670 Basis number GM 4600AC -> Key -> For example: Part number Table A: Maxi. material pression selection 160 bar; 16 MPa; 2320 psi 250 bar; 25 MPa; 3625 psi Table B: Air cap selection Suitable for low viscosity paints (red) Suitable for high viscosity paints (blue)

  • Page 14: Data

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL DATA 4.3.1 MATERIALS OF THE PARTS TRANSPORTING PAINT Metal Plastics Tungsten carbide Stainless steel 1.4305 Stainless steel 1.4301 Stainless steel 1.4104 PTFE 4.3.2 TECHNICAL DATA AirCoat spray gun Description Units 394004 394014;...

  • Page 15: Functional Description

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF SPRAY GUN B_02672 Description Suspension hook Fan air regulator Tension nut Trigger Trigger safety Air connection Paint connection Union nut with nozzle guard Nozzle / Air cap Gun housing Filter housing 4.4.2...

  • Page 16: Starting Up And Operating

    The pray gun GM 4600AC must be used a part of a spraying system. The spraying system shown in the fi gure is only one example of an electrostatic Aircoat spraying system. It is not an actual system design. Contact your Wagner distributor for assistance in designing a system to meet your needs.

  • Page 17: Ventilation Of The Spray Booth

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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 ventilation (extraction) switched on.

  • Page 18: Earthing

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL 5.1.5 EARTHING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks or flames Earth all unit components. Earth the workpieces being painted. SIHI_0027_GB WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning Insufficient paint application quality Earth all unit components.

  • Page 19: Start-Up

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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.

  • Page 20: Preparation For Starting Up

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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. 4.

  • Page 21: Works

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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. 3.

  • Page 22: Replacing Aircoat Nozzle

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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. 2.

  • Page 23: Cleaning Aircoat Nozzle

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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. 5.4.5 ELIMINATE NOZZLE CLOGGING 1.

  • Page 24: Maintenance

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 25: Finishing Work And Cleaning

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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 keep the attachment of the spray gun held downwards when cleaning.

  • Page 26: Replacing The Material Hose Or Air Hose

    Fit the material hose respectively air hose by hand and tighten with 2 open-ended wrenches. Counter hold Counter hold B_02678 Note: Do not unscrew the fi lter housing. The nut must only be unscrewed by WAGNER- Serv- ice-Agency. B_02679 Description Key A Key B Key C Key D...

  • Page 27: Changing Or Cleaning Filter Insert

    (65) and material hose by hand and tighten using the two open-end wrenches A and B. Note: Do not unscrew the fi lter Counter hold housing. The nut must only be unscrewed by WAGNER-Serv- ice-Agency. B_02679 B_02677 Description Key A...

  • Page 28: Replacing Parts On The Valve Rod

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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). 5.

  • Page 29: Replacement Of Valve Rocker Seals

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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 inches and unscrew cover (53) with single open-end wrench SW 7 mm; 0.28 inches.

  • Page 30: Replacing The Nozzle Seal

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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. SIHI_0021_GB 1.

  • Page 31: Replacing The „Air" Sealing Ring

    GM 4600AC EDITION 05/2011 Part No. DOC394861 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. 2.

  • Page 32: Trouble Shooting And Solution

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL TROUBLE SHOOTING AND SOLUTION Malfunction Cause Remedy See 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...

  • Page 33: Accessories

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL ACCESSORIES ROUND-JET NOZZLE CAP Part No. Description 9.1.2 394180 Round-jet nozzle cap (without nozzle insert) B_02276 9.1.1 9.1.1 NOZZLE INSERTS RXX Part No. Description Marking Volume fl ow* Jet ø ** 132720 Nozzle insert R11 0.16;...

  • Page 34: Aircoat Nozzles Acf3000

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL AIRCOAT NOZZLES ACF3000 B_02280 Recommended gunfilter Size Spraying Part-No. Marking inch; mm angle Application Natural paint 379107 07/10 0.007-0.18 379207 07/20 0.007-0.18 Transparent paint 379209 09/20 0.009-0.23 379309 09/30 0.009-0.23 379409 09/40 0.009-0.23 379509...
  • Page 35 GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL B_02280 Recommended gunfilter Size Spraying Part No. Marking inch; mm angle Application Rustproofing paint 379219 19/20 0.019-0.48 Latex paint 379319 19/30 0.019-0.48 379419 19/40 0.019-0.48 379519 19/50 0.019-0.48 379619 19/60 0.019-0.48 379819 19/80 0.019-0.48...

  • Page 36: Air Caps

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL AIR CAPS Part No. Description 2313494 Air cap LV complete (red) for low viscosity paints B_02257 2313497 Air cap HV complete (blue) for high viscosity paints B_02256 2313498 Air cap LA plus (bronze) small air, to clean easily B_02396 FILTER INSERT Part No.

  • Page 37: Hoses

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL HOSES Part No. Description 2309705 Hose set AC Material DN3, Air DN6, consisting of paint- air- and protective hose Material: NPSM1/4“ 7.5 m; 24.6 ft, DN 3 mm; ID 0.12 inch, 27 MPa; 270 bar; 3916 psi Air: G1/4“...

  • Page 38: Spare Parts

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 39: Spare Parts List Gm 4600Ac

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL 10.2 SPARE PARTS LIST GM 4600AC Spare parts list GM 4600AC 16 MPa 25 MPa Part No. Part No. Description 394004 3940014 GM 4600AC; XX MPa; NPSM1/4“ 9999501 9999501 Screw spring Material 9999500 9999500 Screw spring Air...
  • Page 40 GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL GM 4600AC Detail B B_02748 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...
  • Page 41 GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL Spare parts list GM 4600AC 16 MPa 25 MPa Part No. Part No. Description ◆ ● 128327 128327 Sealing nipple ◆ ● 132516 132516 Nozzle screwed connection compl. ● 132351 132351 Nozzle screwed connection holder ●...

  • Page 42: Spare Parts List Gm 4600Ac-H

    GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL 10.3 SPARE PARTS LIST GM 4600AC-H Spare parts list GM 4600AC-H 25 MPa Part No. Description 2303491 GM 4600AC-H; 25 MPa; NPSM1/4“ 9999501 Screw spring Material 9999500 Screw spring Air 394256 Tension sleeve compl.
  • Page 43 GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL GM 4600AC-H B_02880 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...
  • Page 44 GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL Spare parts list GM 4600AC-H 25 MPa Part No. Description ● 394336 Nozzle body ◆ ● 128327 Sealing nipple ◆ ● 132516 Nozzle screwed connection compl. ● 132351 Nozzle screwed connection holder ●...
  • Page 45 GM 4600AC GM 4600AC EDITION 05/2011 Part No. DOC394861 OPERATING MANUAL...
  • Page 46 Telephone: +41 (0)71 757 2211 Telefax: +49 7544 505200 Telefax: +41 (0)71 757 2222 E-Mail: service.standard@wagner-group.com E-Mail: rep-ch@wagner-group.ch Belgium Denmark WAGNER Spraytech Benelux BV WAGNER Industrial Solution Scandinavia Veilinglaan 58 Viborgvej 100, Skærgær B- 1861 Wolvertem DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675...
  • Page 48 394861...

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