WAGNER AC 4600 Operating Manual
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WAGNER AC 4600 Operating Manual

Aircoat spray guns for flat - and round jet nozzles
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AirCoat spray guns
for fl at - and round jet nozzles
II 2G X (Atex 95)
Translation of the original
Operating manual
AC 4600 Professional
Edition 02/2009
B_02695

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Summary of Contents for WAGNER AC 4600

  • Page 1 Translation of the original Operating manual AC 4600 Professional Edition 02/2009 AirCoat spray guns for fl at - and round jet nozzles B_02695 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 AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL Contents 5.1.3 Air supply 5.1.4 Fluid (paint) hoses 5.1.5 Earthing Preparation of paints Starting-up 5.3.1 General rules for handling the spray gun 5.3.2 Preparation for starting up Works 5.4.1 Start-up for spraying 5.4.2...

  • Page 5: About These Instructions

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 394870 394871 394872 394873 394874 394875 394876 394877 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.

  • Page 6: General Safety Instructions

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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...

  • Page 7: Safe Handling Of Wagner Spray Units

    EDITION 02/2009 PART NO. DOC394871 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

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL 2.2.4 CLEANING 2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS 2.2.6 TOUCHING HOT SURFACES CORRECT USE...

  • Page 9: Use In An Explosion Hazard Area

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL USE IN AN EXPLOSION HAZARD AREA 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.

  • Page 10: 3+2 Years Guarantee For Professional Finishing

    SCOPE OF GUARANTEE All Wagner professional colour application devices (hereafter referred to as products) are carefully inspected, tested and are subject to strict checks under Wagner quality assurance. Wagner exclusively issues extended guarantees to commercial or professional users (here- after referred to as „customer“) who have purchased the product in an authorised special- ist shop, and which relate to the products listed for that customer on the Internet under www.wagner-group.com/profi...

  • Page 11: Exclusion Of Guarantee

    - for errors in the device that have been caused by using accessory parts, additional components or spare parts that are not original Wagner parts. - for products to which modifi cations or additions have been carried out.

  • Page 12: Ce-Conformity

    Note: All titles can be ordered from Heymanns Publishing House in Cologne or of the Internet download. txt 00141 GB 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: 398892...

  • Page 13: Description

    43°C; 109.4°F: Identify the unit with a warning sticker "Warning - hot surface". SIHI_0019_GB Note: Please contact your local WAGNER dealer and the paint manufacturer if you encounter application problems. SCOPE OF DELIVERY These AirCoat gun is available with three different variants.

  • Page 14: Data

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL DATA 4.3.1 MATERIALS OF THE PARTS TRANSPORTING PAINT Metal Plastic Tungsten carbide Stainless steel 1.4305 Stainless steel 1.4301 Stainless steel 1.4104 PTFE 4.3.2 TECHNICAL DATA Description Units Value Maxi. air inlet pressure MPa/ psi/ bar 0.8/ 120/ 8...

  • Page 15: Functional Description

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF SPRAY GUN B_02697 Description Description Union nut with nozzle guard Suspension hook Nozzle / Air cap Shaping air regulator Gun housing Spring cover Filter housing...

  • Page 16: Starting Up And Operating

    The pray gun 4600AC Professional 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 design- ing a system to meet your needs.

  • Page 17: Ventilation Of The Spray Booth

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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.

  • Page 18: Earthing

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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.

  • Page 19: Starting-Up

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL STARTING-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

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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.

  • Page 21: Works

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL WORKS 5.4.1 START-UP FOR SPRAYING 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.

  • Page 22: Changing The Aircoat Nozzle

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL 5.4.3 CHANGING THE 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.

  • Page 23: Cleaning Aircoat Nozzle

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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.

  • Page 24: Maintenance

    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.

  • Page 25: Finishing Work And Cleaning

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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.

  • Page 26: Replacing The Material Hose Or Air Hose

    WAGNER- Serv- ice-Agency. B_02704 Description Key A Key B Key C Key D SW 17 mm SW 19 mm SW 17 mm SW 14 mm AC 4600 Professional NPS 1/4“ 0.669 inch 0.748 inch 0.669 inch 0.551 inch...
  • Page 27 AC 4600 Pro AC 4600 Pro EDITION 02/2009 AUSGABE 01/2008 PART NO. DOC394871 BESTELLNUMMER DOC394870 OPERATING MANUAL BETRIEBSANLEITUNG...

  • Page 28: Changing Or Cleaning Fi Lter Insert

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL CHANGING OR CLEANING FILTER INSERT Close Loosen Counterhold Loosen Description Key D Key E SW 13 mm SW 17 mm AC 4600 Professional NPS 1/4“ 0.512 inch 0.669 inch B_02705...
  • Page 29 8. Put handle tube with female hexagon on swivel and screw from down over the fi lter insert onto the fi lter housing by hand. Note: Do not unscrew the fi lter housing. The nut must only be unscrewed by WAGNER - Service-Agency. B_02704...

  • Page 30: Replacing Parts On The Valve Rod

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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).

  • Page 31: Replacement Of Valve Rocker Seals

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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;...

  • Page 32: Replacing The Nozzle Seal

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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.

  • Page 33: Replacing The „Air" Sealing Ring

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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.

  • Page 34: Trouble Shooting And Solution

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL TROUBLE SHOOTING AND SOLUTION Functional fault 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 35: Accessories

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 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...

  • Page 36: Aircoat Nozzles Acf3000

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL AIRCOAT NOZZLES ACF3000 B_02280 Diameter of Recommended edge filter Spray- Part No. Marking bore angle mm; inches Natural paint 379107 07/10 0.007-0.18 379207 07/20 0.007-0.18 Transparent lacquer 379209 09/20 0.009-0.23...
  • Page 37 AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL B_02280 Diameter of Recommended edge filter Spray- bore Part No. Marking angle mm; inches 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...

  • Page 38: Air Caps

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL AIR CAPS Part No. Description 394910 Air cap LV compl. (red) for low viscosity paints B_02257 394911 Air cap HV compl. (blue) for high viscosity paints B_02256 394912 Air cap compl. (green)

  • Page 39: Swivels

    B_02687 MISCELLANEOUS Part No. Description 9997001 Nozzle cleaning brush 394942 Service set AC 4600 Professional 394904 Conversion kit 16 MPa; 160 bar; 2320 ps 394905 Conversion kit 25 MPa; 250 bar; 3625 psi 367560 Double connection NPSM1/4“ (outside thread) for paint hose extension...

  • Page 40: Spare Parts

    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.

  • Page 41: Spare Parts List Ac4600 Professional

    AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL 10.2 SPARE PARTS LIST AC4600 PROFESSIONAL Spare parts list AC 4600 Professional Part No. Description 394150 AC 4600 Professional; NPSM1/4“ (blue) compl. 394151 AC 4600 Professional; NPSM1/4“ (red) compl. 394152 AC 4600 Professional;...
  • Page 42 AC 4600 Pro EDITION 02/2009 PART NO. DOC394871 OPERATING MANUAL Detail B B_02749 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 43 Handle tube ◆ 364938 Swivel Air 394615 Filter tube AC 4600 Pro NPS 1/4“ 394942 Service set AC 4600 Professional ◆ = Wearing part ✭ = Included in service set ● = Not part of standard equipment for spray gun. Available, however, as additional...
  • Page 44 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 AB Veilinglaan 58 Viborgvej 100, Skoergoer B- 1861 Wolvertem DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 702 00245...
  • Page 45 AC 4600 Pro AC 4600 Pro EDITION 02/2009 AUSGABE 01/2008 PART NO. DOC394871 BESTELLNUMMER DOC394870 OPERATING MANUAL BETRIEBSANLEITUNG...
  • Page 48 394871...

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