Wagner SprayTech GM300AC Paint Sprayer User manual

Translation of the original

Operating manual

GM 3000AC

AirCoat spray gun with fl at or round jet nozzles

Edition 05/2007

"?

II 2G X (Atex 95)

"?

EDITION 05/2007

OPERATING MANUAL

Contents

PART NO. DOC364831

1.1 Languages

1.2 Warnings, notes and symbols in these instructions

2 GENERAL SAFETY INSTRUCTIONS

2.1 Safety instructions for the operator

2.1.3 A safe work environment

2.2 Safety instructions for staff

2.2.1 Safe handling of WAGNER spray units

2.2.2 Earth the unit

2.2.4 Cleaning

2.2.5 Handling hazardous liquids, varnishes and paints

2.2.6 Touching hot surfaces

2.4 Use in an explosion hazard area

2.4.3 Max. surface temperature

2.5 German regualtions and guidelines

3 PRODUCT LIABILITY AND WARRANTY

3.1 Important notes on product liability

3.2 Warranty

3.3 CE-conformity

4 DESCRIPTION

4.1 Area of application, using in accordance with the instructions

4.2 Scope of supply

4.2.1 HV-variants

4.2.2 LV-variants

4.2.3 Hot spraying HV-variants

4.2.4 LV-variants 160 bar; 16 MPa; 2320 psi

4.3 Data

4.3.1 Materials of paint wetted parts

4.3 Technical Data

4.4.1 Design of spraygun

4.4.2 Operation of the spraygun

4.5.2 Aircoat round jet process

5 PREPARATION BEFORE STARTING WORK

5.1 Set up and connect

GM 3000AC

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3

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Contents

5.1.1

5.1.2

Typical aircoat installation

Ventilation of the spray booth

5.1.4 Fluid (paint) hoses

5.1.5 Earthing

5.2 Preparation of paints

5.2.1 Viscosity conversion table

5.3 Start-up

5.3.1 General rules for making adjustments to the spray gun

5.3.2 Preparation

5.4 Working

5.4.1 Start-up aircoat spraying

5.4.2 Adjusting the spray pattern

5.4.3 Changing aircoat nozzle

5.4.4 Cleaning aircoat nozzles

5.4.5 Unblocking clogged nozzle

6 MAINTENANCE

6.1 Finishing work and cleaning

6.2 Changing or cleaning fi lter

6.3 Changing material hose

6.4 Replacing parts of the valve stem

6.4.1 Dismantling

6.4.2 Replacing seals in the valve tappet

6.4.3 Reassembling

6.5 Replacing nozzle seal

6.6 Replacing seal (distributor)

6.7 Changing or cleaning edge fi lter (optional)

7 TROUBLE SHOOTING AND SOLUTIONS

8.1 Filter housing connection

8.2 pivot joint paint

8.3 Pivot joint paint LW

9 ACCESSORIES

9.1 AirCoat nozzles ACF3000

46

46

9.3 Aircoat-nozzle round ACR3000

9.3.1 Nozzle inserts RXX

9.3.2 Nozzle screw joint assy.

9.4 fi lters for spray gun

9.5 Swivel for guns without fi lters

9.6 Hoses

48

48

49

49

49

50

51

9.7 Miscellaneous 51

38

39

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44

10.1

10.2

10.3

10.4

How to order spare parts?

Spare parts list GM 3000AC with fi lter

Spare parts list GM 3000AC without fi lter

Spare parts list GM 3000AC-H without fi lter

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4

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

1 ABOUT THESE INSTRUCTIONS

4HISOPERATINGMANUALCONTAINSINFORMATIONONTHEOPERATIONREPAIRANDMAINTENANCEOF

THEUNIT

œ !LWAYSOBSERVETHESEINSTRUCTIONSWHENOPERATINGTHEUNIT

4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL

#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY

AGREEMENT

1.1 LANGUAGES

This operating manual is available in the following languages:

Language: Part No.

Language:

English

Dutch

Spanish

Swedish

Polish

Part No.

364831

364833

364835

364837

364839

1.2 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. These warning instructions fall into the following categories:

Danger - imminent danger. Non-observance will result in death, serious injury and serious material damage.

3)()??'"

$!.'%2

4HISLINEWARNSOFTHEHAZARD

0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC

TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL

œ 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

Warning - possible danger. Non-observance can result in death, serious injury and serious material damage.

7!2.).'

4HISLINEWARNSOFTHEHAZARD

0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC

TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL

œ 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

3)()??'"

Caution - a possibly hazardous situation. Non-observance can result in minor injury.

#!54)/.

4HISLINEWARNSOFTHEHAZARD

0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC

TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL

œ 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

3)()??'"

Caution - a possibly hazardous situation. Non-observance can cause material damage.

3)()??'"

#!54)/.

4HISLINEWARNSOFTHEHAZARD

0OSSIBLECONSEQUENCESOFFAILINGTOOBSERVETHEWARNINGINSTRUCTIONS4HESIGNALWORD

POINTSOUTTHEHAZARDLEVEL

œ 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

Note provide information on particular characteristics and how to proceed.

5

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

2 GENERAL SAFETY INSTRUCTIONS

2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

œ +EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES

œ !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN

TION

2.1.1 ELECTRICAL EQUIPMENT

%LECTRICALPLANTANDUNIT

œ 4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE

OPERATINGMODEANDAMBIENTINmUENCES

œ -AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION

œ -USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU

LATIONS

œ -USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS

œ -USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD

œ -USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT

PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS

2.1.2 PERSONNEL QUALIFICATIONS

œ %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS

2.1.3 A SAFE WORK ENVIRONMENT

œ %NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART

eMEASUREMENTINACCORDANCEWITH$).

œ %NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH

LEATHERSOLES

œ %NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA

THEHANDLEOFTHESPRAYGUN

œ #USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS

œ %NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION

œ %NSURETHAT THEREARENOIGNITIONSOURCESSUCHASNAKEDmAMEGLOWINGWIRESORHOT

SURFACESINTHEVICINITY$ONOTSMOKE

2.2 SAFETY INSTRUCTIONS FOR STAFF

œ !LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN

STRUCTIONSANDTHEWARNINGINSTRUCTIONS

œ !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN

TION

6

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

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:

œ Never point the spray gun at people.

œ Never reach into the spray jet.

œ Before all work on the unit, in the event of work interruptions and functional faults:

– Switch off the energy/compressed air supply.

– Secure the spray gun against actuation.

– Relieve the pressure from the spray gun and unit.

– By functional faults: Identify and correct the problem, proceed as described in chap. „Trouble shooting“.

In the event of skin injuries caused by paint or cleaning agents:

œ Note down the paint or cleaning agent that you have been using.

œ Consult a doctor immediately.

Avoid danger of injury through recoil forces:

œ Ensure that you have a firm footing when operating the spray gun.

œ Only hold the spray gun briefly in any one position.

2.2.2 EARTH THE UNIT

%LECTROSTATICCHARGESCANOCCURONTHEUNITDUETOTHEELECTROSTATICCHARGEANDTHEmOW

SPEEDINVOLVEDINSPRAYING4HESECANCAUSESPARKSANDmAMESUPONDISCHARGE

œ %NSURETHATTHEUNITISEARTHEDFOREVERYSPRAYINGOPERATION

œ %ARTHTHEWORKPIECESTOBECOATED

œ %NSURETHATALLPERSONSINSIDETHEWORKINGAREAAREEARTHEDEGTHATTHEYAREWEARING

ANTISTATICSHOES

œ 7HENSPRAYINGWEARANTISTATICGLOVESTOEARTHYOURSELFVIATHESPRAYGUNHANDLE

2.2.3 MATERIAL HOSES

œ %NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS

œ %NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT

œ %NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE n -ANUFACTURER n 0ERMISSIBLEOPERATINGOVERPRESSURE n $ATEOFMANUFACTURE

œ 4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN

-/HM

7

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

2.2.4 CLEANING

œ $EENERGIZETHEUNITELECTRICALLY

œ $ISCONNECTTHEPNEUMATICSUPPLYLINE

œ 2ELIEVETHEPRESSUREFROMTHEUNIT

œ %NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM

PERATURE

œ 4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON

CLEANINGAGENTSWITHAGUN

!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS

œ 7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER

œ %ARTHTHECONTAINER

2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS

œ 7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK

INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING

USED

œ 4AKE THE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE

CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY

œ 5SEAMASKORBREATHINGAPPARATUSIFNECESSARY

œ &ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON

ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTION SWITCHEDON

œ 7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS

2.2.6 TOUCHING HOT SURFACES

œ 4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES

œ 7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&

)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh

/RDER.O

)NFORMATIONLABEL

3AFETYLABEL

2.3 CORRECT USE

7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE

œ 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2

œ /PERATETHEUNITONLYASANENTIREUNIT

œ $ONOTDEACTIVATESAFETYEQUIPMENT

œ 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES

8

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

#%

%X

))

'

8

2.4 USE IN AN EXPLOSION HAZARD AREA

2.4.1 CORRECT USE

4HEUNITISSUITABLEFORWORKINGLIQUIDMATERIALSINACCORDANCEWITHTHECLASSIlCATIONINTO

EXPLOSIONCLASSES

2.4.2 EXPLOSION PROTECTION IDENTIFICATION

!SDElNEDINTHE$IRECTIVE#%!4%8 THEUNITISSUITABLEFORUSEINAREASWHERE

THEREISANEXPLOSIONHAZARD

))'8

#OMMUNAUTÏS%UROPÏENNES

3YMBOLFOREXPLOSIONPROTECTION

5NITCLASS))

#ATEGORY:ONE

%XATMOSPHEREGAS

3PECIALIDENTIlCATION

2.4.3 MAX. SURFACE TEMPERATURE

4HEUNIT@SMAXIMUMSURFACETEMPERATUREDEPENDSONTHETEMPERATUREOFTHECOATINGMA

TERIAL

4HEUNITISSUITABLEFORCOATINGMATERIALSWITHAMAXTEMPERATUREOF²#²&

!MBIENTTEMPERATURE

0ERMISSIBLEAMBIENTTEMPERATURE²#TO²#²&TO²&

2.4.4 SAFETY INSTRUCTIONS

3AFEHANDLINGOF7!'.%2SPRAYUNITS

-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL

)NANEXPLOSIVEATMOSPHERE

œ $ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON

œ $ONOTDROPTHESPRAYGUN

œ 5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL

)GNITIONTEMPERATUREOFTHECOATINGMATERIAL

œ %NSURETHATTHEIGNITIONTEMPERATUREOFTHECOATINGMATERIALISABOVETHEMAXIMUM

SURFACETEMPERATURE

-EDIUMSUPPORTINGATOMIZING

œ 4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR

#LEANING

)FTHEREAREDEPOSITSONTHESURFACESTHEUNITMAYFORMELECTROSTATICCHARGES&LAMESOR

SPARKSCANFORMIFTHEREISADISCHARGE

œ 2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY

9

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

2.5 GERMAN REGUALTIONS AND GUIDELINES a) BGV D15 Working with liquid ejection devices b) BGV D25 Using coating materials c) CHV 9 d) BGR 104

Regulations on flammable liquids

Explosion protection rules e) BGR 132 f ) BGR 180

Avoiding ignition risks

Setting up for cleaning with solvents for cleaning workpieces with solvents g) ZH 1/406 Guidelines for liquid ejection devices h) BGI 740 Painting rooms and equipment

Note: All titles can be ordered from Heymanns Publishing House in Cologne or download from Internet

10

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

3 PRODUCT LIABILITY AND WARRANTY

3.1 IMPORTANT NOTES ON PRODUCT LIABILITY

!SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL

ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE

DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED

)FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE

FULLYORPARTIALLYNULLANDVOID

4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE

GULATIONSAREOBSERVED

3.2 WARRANTY

4HISUNITISCOVEREDBYOURWARRANTYONTHEFOLLOWINGTERMS

7EWILLATOURDISCRETIONREPAIRORREPLACEFREEOFCHARGEALLPARTSWHICHWITHINMONTHS

INSINGLESHIFTMONTHSINSHIFTORMONTHSINSHIFTOPERATIONFROMDATEOFRECEIPTBY

THE0URCHASERAREFOUNDTOBEWHOLLYORSUBSTANTIALLYUNUSABLEDUETOCAUSESPRIORTOTHE

SALEINPARTICULARFAULTYDESIGNDEFECTIVEMATERIALSORPOORWORKMANSHIP

4HETERMSOFTHEWARRANTYAREMETATOURDISCRETIONBYTHEREPAIRORREPLACEMENTOFTHE

UNITORPARTSTHEREOF4HERESULTINGCOSTSINPARTICULARSHIPPINGCHARGESROADTOLLSLABOUR

ANDMATERIALCOSTSWILLBEBORNEBYUSEXCEPTWHERETHESECOSTSAREINCREASEDDUETOTHE

SUBSEQUENTSHIPMENTOFTHEUNITTOALOCATIONOTHERTHANTHEADDRESSOFTHEPURCHASER

4HISWARRANTYDOESNOTCOVERDAMAGECAUSEDBY

5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A

THIRD PARTY NORMAL WEAR NEGLIGENT HANDLING DEFECTIVE MAINTENANCE UNSUITABLE COATING

PRODUCTS SUBSTITUTE MATERIALS AND THE ACTION OF CHEMICAL ELECTROCHEMICAL OR ELECTRICAL

AGENTSEXCEPTWHENTHEDAMAGEISATTRIBUTABLETOUS

!BRASIVE COATING PRODUCTS SUCH AS REDLEAD EMULSIONS GLAZES LIQUID ABRASIVES ZINC DUST

PAINTSANDSIMILARREDUCETHESERVICELIFEOFVALVESPACKINGSSPRAYGUNSNOZZLESCYLINDERS

PISTONSETC!NYWEARRESULTINGFROMTHEAFOREMENTIONEDCAUSESISNOTCOVEREDBYTHIS

WARRANTY

#OMPONENTSNOTMANUFACTUREDBY7AGNERARESUBJECTTOTHEWARRANTYTERMSOFTHEORIGI

NALMAKER

4HEREPLACEMENTOFAPARTDOESNOTEXTENDTHEWARRANTYPERIODOFTHEUNIT

4HEUNITSHOULDBEINSPECTEDIMMEDIATELYUPONRECEIPT

4OAVOIDLOSSWARRANTYANIYAPPARENTDEFECTSHOULDBENOTIlEDTOUSORTHEDEALERINWRI

TINGWITHINDAYSFROMDATEOFSALEOFTHEUNIT

4HERIGHTTOCOMMISSIONWARRANTYSERVICESTOATHIRDPARTYISRESERVED

7ARRANTYCLAIMSARESUBJECTTOPROOFOFPURCHASEBYSUBMITTINGANINVOICEORDELIVERYNOTE

)FANINSPECTIONlNDSDAMAGENOTCOVEREDBYTHEPRESENTWARRANTYTHEREPAIRWILLBECAR

RIEDOUTATTHEEXPENSEOFTHEPURCHASER

.OTETHATTHISWARRANTYDOESNOTINANYWAYRESTRICTLEGALLYENTITLEDCLAIMSORTHOSECONTRAC

TUALLYAGREEDTOINOURGENERALTERMSANDCONDITIONS

*7AGNER!'

11

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

3.3 CE-CONFORMITY

Herewith we declare that the supplied version of

0364001 Spray gun GM 3000AC Filter M16x1.5 HV

0364002 Spray gun GM 3000AC Filter NPS1/4“ HV

0364003 Spray gun GM 3000AC M16x1.5 HV

0364004 Spray gun GM 3000AC NPS1/4“ HV

0364005 Spray gun GM 3000AC Filter M16x1.5 LV

0364006 Spray gun GM 3000AC Filter NPS1/4“ LV

0364007 Spray gun GM 3000AC M16x1.5 LV

0364008 Spray gun GM 3000AC NPS1/4“ LV

0364016 Spray gun GM 3000AC 160 bar Filter NPS1/4“ LV

0364018 Spray gun GM 3000AC 160 bar NPS1/4“ LV

0364020 Spray gun GM 3000AC-H M16x1.5 HV

Complies with the following provisons apllying to it:

98/37/EG

94/9/EG

Applied standards, in particular:

EN 292-1 EN 1127-1

EN 292-2

EN 563

EN 1050

EN 1953

EN 3746

EN 13463-1

Applied national technical standards and specifi cations, in particular: see chapter. 2.5

GM 3000AC

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:

GM 3000AC 0364900_a

12

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

4 DESCRIPTION

4.1 AREA OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS

The gun is suitable for atomising liquid materials, particularly coating materials, using the

AirCoat process.

4.1.1 PROCESSABLE MATERIALS

.

Top-coat paints, primer paints, corrosion protection solvents, textured paints, lyes, staining solvents, clear paints, parting solvents, etc. on a solvent or water basis

WARNING

Hot coating substances!

Burns

œ Wear antistatic protective gloves.

œ When operating the unit with a coating material with a temperature greater than 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, contact your WAGNER branch and the paint manufacturer.

4.2 SCOPE OF SUPPLY

The AirCoat gun is available in different variants as shown below. In accessories different fl at nozzles and round jet nozzles are available. The nozzle size depends on the paint and on the application. Therefore the nozzle is not included in the scope of supply. For a nozzle list and other accessories look in chapter 9.

4.2.1 HV-VARIANTS

These guns have a blue air cap. This air cap is specially designed for high viscosity (HV) material.

Qty

1

1

1

1

1

1

Part-No.

AirCoat gun

0364001 GM 3000AC with fi lter + M16x1.5“ material connector HV

0364002 GM 3000AC with fi lter + NPSM1/4“ material connectors HV

0364030 GM 3000AC with fi lter + NPSM1/4“ material connector HV USA

0364003 GM 3000AC without fi lter + M16x1.5“ material connector HV

0364004 GM 3000AC without fi lter + NPSM1/4“ material connector HV

0364031 GM 3000AC with fi lter + NPSM1/4“ material connector HV USA

13

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

4.2.2 LV-VARIANTS

These guns have a red air cap. This air cap is specially designed for low viscosity (LV) material.

Qty

1

Part-No.

0364005

AirCoat gun

GM 3000AC with fi lter + M16x1.5“ material connector LV

1

1

1

1

1

0364006 GM 3000AC with fi lter + NPSM1/4“ material connector LV

0364032 GM 3000AC with fi lter + NPSM1/4“ material connector LV USA

0364007 GM 3000AC without fi lter + M16x1.5“ material connector LV

0364008 GM 3000AC without fi lter + NPSM1/4“ material connector LV

0364033 GM 3000AC with fi lter + NPSM1/4“ material connector LV USA

4.2.3 HOT SPRAYING HV-VARIANTS

These guns have a blue air cap. This air cap is specially designed for high viscosity (HV) material and for hot spraying.

Qty Part-No.

AirCoat gun

1 0364020 GM 3000AC-H without fi lter + M16x1.5 material connector HV

4.2.4 LV-VARIANTS 160 BAR; 16 MPA; 2320 PSI

These guns have a red air cap. This air cap is specially designed for low viscosity (LV) material.

Qty Part-No.

AirCoat gun

1 0364016 GM 3000AC 16 MPa; 160 bar; 2320 psi with fi lter + NPSM1/4“ material connector LV

1 0364034 GM 3000AC 16 MPa; 160 bar; 2320 psi with fi lter + NPSM1/4“ material connector LV USA

1 0364018 GM 3000AC 16 MPa; 160 bar; 2320 psi without fi lter + NPSM1/4“ material connector LV

1 0364035 GM 3000AC 16 MPa; 160 bar; 2320 psi without fi lter + NPSM1/4“ material connector LV USA

14

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

4.2.5 STANDARD EQUIPMENT

The standard equipment includes:

Quantity Description

Part No.

AirCoat manual gun GM 3000AC

1 1 1 1 1 1 1 1 1 1 1 8780111 Double-ended open-jaw spanner 13x17

1 1 1 1 1 1 1 1 1 1 1 9991401 Double-ended open-jaw spanner 17x19

1 1 1 0043235 Push-in fi ltre yellow (installed: push-in fi ltre red)

1 1 0034383 Push-in fi ltre red (installed: push-in fi ltre yellow)

1 1 1 1 1 0364911 Air cap HV (blue)

1 1 1 1 1 1 0364910 Air cap HV (red)

1 1 1 1 1 1 1 1 1 1 1 0364900 CE-Declaration of Conformity

1 1 1 1 1 1 1 1 1 1 1 364830 Operating manual German

1 1 1 1 1 1 1 1 1 1 1 see 1.0

An operating manual in the local language

The standard equipment includes:

Quantity Description

Part No.

AirCoat manual gun GM 3000AC USA

1 1 1 1 1 1 8780111 Double-ended open-jaw spanner 13x17

1 1 1 1 1 1 9991401 Double-ended open-jaw spanner 17x19

1 0043235 Push-in fi ltre yellow (installed: push-in fi ltre red)

1 1 0034383 Push-in fi ltre red (installed: push-in fi ltre yellow)

1 1 0364911 Air cap HV (blue)

1 1 1 1 0364910 Air cap HV (red)

1 1 1 1 1 1 0364900 CE-Declaration of Conformity

1 1 1 1 1 1 364831 Operating manual English

1 1 1 1 1 1 see 1.0

An operating manual in the local language

For special versions the delivery note applies.

4.3 DATA

4.3.1 MATERIALS OF PAINT WETTED PARTS

Steel

Tungsten carbide Stainl. steel 1.4305

Plastics

UHMW-PE

Stainl. steel 1.4310

Stainl. steel 1.4104

PTFE

FPM

POM

PA 6.6

15

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

4.3 TECHNICAL DATA

Description Units

Max. air pressure MPa psi bar

MPa Max. material pressure

Materia connector

M16x1.5

psi bar

Mat. fl ow volume l/min cc/min.

mm x x -

25

3625

250 x -

0.8

120

8

* x x -

16

2320

160

-

Material connector

NPS 1/4“

Inches g oz

x x x x x

Air connection Inches G1/4“

Filter (accessory) Meshes ** ** ** ** ** ** ** ** -

Weight 723

25.5

723

25.5

520

18.3

520

18.3

723

25.5

520

18.3

723

25.5

723

25.5

520

18.3

520

18.3

723

25.5

520

18.3

520

18.3

723

25.5

520

18.3

723

25.5

520

18.3

Max. temperature material

Max. temperature air

Sound level at 0.3

MPa; 3 bar; 43.5 psi air pressure and

11 MPa; 110 bar;

°C

°F

°C

°F dB(A) 76.0

55

131

43

109

76.5

80

176

76.0

55

131

76.5

1549 psi material pressure ***

* According to nozzle, see chapter 9.1.

** Filter types see paragr. 9.6

*** A rated sound pressure level meassured in 0.5m distance according to DIN EN ISO 3746-1995

Dimensions

GM 3000AC with fi lter

MMINCHES

GM 3000AC without fi lter

MMINCHES

"?

"?

16

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

+

,

!

(

)

*

4.4 FUNCTIONAL DESCRIPTION

4.4.1 DESIGN OF SPRAYGUN

"

#

$

%

.

&

!

*

(

)

'

"?

-

"?

GM 3000AC with fi lter

'

GM 3000AC without fi lter

Description

A Suspension hook

B Shaping air control knob

C Tension cap

D Trigger

E Safety catch

F Air connector

G Material connector

Description

H Aircap nut and nozzle guard

I Nozzle / air cap

J Spraygun body

K Filter housing

L Tube handle

M Pivot joint, material

N Pivot joint, air

4.4.2 OPERATION OF THE SPRAYGUN

Pulling the trigger (D) approximately 1/2 way opens the air valve allowing atomising and shaping-air to fl ow through the aircap. When the trigger is pulled further, more resistance is felt and the material valve is opened. The atomising air control adjusts the total quantity of air fl owing trough the spray gun.

The spray gun is rendered safe with the trigger safety catch (E). (Turn the trigger safety catch in the spraying direction and fasten in the groove)

$

%

"

#

&

17

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

4.5 JET PROCESS

4.5.1 AIRCOAT FLAT JET PROCESS

With the AirCoat process the spray material is atomized at a pressure of 3-12 MPa; 30-120 bar; 435-1740 psi. A soft, fl at spray is achieved with help of the AirCoat air, which has a pressure of 0.05-0.25 MPa; 0.5-2.5 bar; 7.2-36 psi. The shaping air (C) provides the potential to make the width of the spray jet larger and smaller.

Air cap

Shaping air

B_00001

Advantages

• High painting capacity

• Low mist formation

• Good fi nish

• High-solids paints can easily be applied

• Adjustable spray fan.

Atomizing air

18

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

4.5.2 AIRCOAT ROUND JET PROCESS

In the AirCoat process, high pressure of 3-12 MPa; 30-120 bar; 435-1740 psi is used to atomize the material.

The AirCoat air at 0.05-0.25 MPa; 0.5-2.5 bar; 7.2-36 psi produces a soft jet, which largely eliminates the problem of overlapping boundaries.

The spray jet can be adjusted by turning the nozzle nut. The multi-channel swirl nozzle produces fi ne paint particles, while at the same time reducing their forwards speed and swirling them to produce a rotating motion. The result is a soft, extremely well atomized spraying cloud.

Nozzle nut

AirCoat-air

Material

AirCoat-air

"?

Multi-channel swirl nozzle

Advantages

• High painting capacity

• Low fogging tendency

• Good fi nish

• High- viscosity paints can easily be applied

Spray jet

19

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5 PREPARATION BEFORE STARTING WORK

5.1 SET UP AND CONNECT

5.1.1 TYPICAL AIRCOAT INSTALLATION

WARNING

Incorrect installation/operation!

Risk of injury and damage to equipment

œ When putting into operation and for all work, read and follow the operating instructions and safety regulations for the additionally required system components.

SIHI_0050_GB

"

# % $ & '

+

-

)

(

*

!

,

"?

A Paint-pump

B Air shut-off valve

D Air regulator with fi lter

F Air hose (electrically conductive)

G AirCoat spray gun

H HP-fl uid hose

I HP-fi lter/ relief valve

The spray gun GM 3000AC must be used a part of an AirCoat spraying system. The Air-

Coat system shown in the fi gure is only one example of an AirCoat spraying system. Contact your WAGNER distributor for assistance in designing a system to meet your needs.

The operating instructions and the safety re gulations for the additional system components used must be read before starting-up

M Mains air inlet

20

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.1.2 VENTILATION OF THE SPRAY BOOTH

WARNING

Toxic and/or flammable vapor mixtures!

Risk of poisoning and burns

œ Operate the unit in a spraying booth approved for the working materials.

-or-

œ Operate the unit on an appropriate spraying wall with the ventilation (extraction) switched on.

œ Observe national and local regulations for the outgoing air speed.

SIHI_0028_GB

5.1.3 AIR SUPPLY

The use of an air fi lter with the air regulator (D) ensures that only dry, clean atomising air gets into the spray gun. Dirt and moisture in the atomising air reduce the spraying quality and the appearance of the fi nished piece.

5.1.4 FLUID (PAINT) HOSES

#!54)/.

)MPURITIESINTHESPRAYINGSYSTEM

3PRAYGUNBLOCKAGEMATERIALSHARDENINTHESPRAYINGSYSTEM

œ &LUSHTHESPRAYGUNANDPAINTSUPPLYWITHASUITABLECLEANINGAGENT

3)()??'"

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of material

œ Ensure that the hose material is chemically resistant.

œ Ensure that the spray gun, threaded joints and material hose between the unit and the spray gun is suitable for the pressure generated in the unit.

œ Ensure that the following information can be seen on the highpressure hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture.

SIHI_0029_GB

21

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.1.5 EARTHING

7!2.).'

$ISCHARGE OF ELECTROSTATICALLY CHARGED COMPONENTS IN ATMO

SPHERESCONTAININGSOLVENTS

%XPLOSIONHAZARDFROMELECTROSTATICSPARKSORmAMES

œ %ARTHALLUNITCOMPONENTS

œ %ARTHTHEWORKPIECESBEINGPAINTED

3)()??'"

WARNING

Heavy paint mist if earthing is insufficient!

Risk of poisoning

Insufficient paint application quality

œ Earth all unit components.

œ Earth the workpieces being painted.

SIHI_0003_GB

Any material containers and the unit must be connected by a potential equalisation (earth) cable.

5.2 PREPARATION OF PAINTS

The viscosity of the paint is of great importance. The best results are obtained for paints of

80 and 150 milli Pascal x Sec (mPas).

In most cases, the application of paints of up to 260 mPas for high fi lm-thicknesses does not cause any problems.

22

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.2.1 VISCOSITY CONVERSION TABLE

MILLI0ASCALX

3ECM0AS

#ENTIPOISE 0OISE $).#UP

MMIN

&ORD#UP :AHN

23

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.3 START-UP

5.3.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN

➞ See safety regulations 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:

œ Switch off the energy/compressed air supply.

œ Relieve the pressure from the spray gun and unit.

œ Secure the spray gun against actuation.

œ By functional faults: Identify and correct the problem, proceed as described in chap„Trouble shooting“.

SIHI_0065_GB

CAUTION

Cleaning agent in the air duct!

Functional faults caused by swollen seals

œ Always point the spray gun down when cleaning.

œ Ensure that neither paint nor cleaning agent enters the air duct.

SIHI_0005_GB

Trigger safety catch in on

(safe) position

Air

"?

Material

Air

B 00036

Material

24

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.3.2 PREPARATION

1. Secure the spraygun.

2. Connect material hose to spray gun and to pump.

3. Connect air hose to spray gun and to oil-free, dry air supply with regulator.

4. Insert suitable gun fi lter.

5. Tighten the complete gun handle/ swivel assembly.

6. Place the nozzle into the nozzle seal. Fit the aircap over the nozzle, ensuring that the location fl ats (X) are in line. Fit the aircap nut with nozzle guard and tighten by hand.

Note:

The pin in the housing is to adjust the spray jet in the horizontal or vertical position.

7. Visually check the permissible pressures for all the system components.

8. Make sure that the spraying unit and all other conductive parts within the work area are earthed

9. Set material pressure approx. 100 bar; 10 MPa; 1450 psi and use a suitable medium

(solvent or water) to check that connections do not leak.

Note:

Pull the trigger and then release, checking that the gun closes cleany.

10. Relieve spray gun and unit pressure and secure the spraygun.

X

"?

25

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.4 WORKING

5.4.1 START-UP AIRCOAT SPRAYING

1. Set material pressure to approx. 8MPa; 80 bar; 1160 psi at material pump.

2. Spray (release trigger safety catch and pull trigger) and check the atomisation.

3. Set the fl uid pressure to the point where a further increase in fl uid pressure would signifi cantly improve fl uid atomization.

4. Now open AirCoat-air on the atomizing air regulator and set.

5. Adjust the pressure to get the optimum spraying fi nish. Relation between spray pattern and atomizing air see illustration. Set the minimum air pressure necessary to achieve the best possible spray pattern.

Note:

Repeat point 4 and 5 until the optimum spray pattern is reached

Spray patterns

B_00071 no atomizing air too little atomizing air correct amount of atomizing air

5.4.2 ADJUSTING THE SPRAY PATTERN

The spray pattern can be adjusted to suit the object Being sprayed using the shaping air regulator. The illustration below shows the infl uence of the shaping air regulator on the spraying pattern.

Other tip sizes can be used to obtain larger or smaller spraying patterns.

Shaping air fully closed

Shaping air fully open

Note

The paint output volume can be changed by:

• Changing the material pressure.

• Fitting another fl at jet nozzle. See accessories.

"?

Viewed from rear of spraygun

26

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.4.3 CHANGING AIRCOAT NOZZLE

Defective AirCoat nozzle!

Insufficient paint application quality

CAUTION

œ Do not use sharp-edged objects to treat hard metal on the AirCoat nozzle.

SIHI_0020_GB

CAUTION

Defective nozzle seal!

Material sprays into the air cap next to the nozzle

Risk of contamination

œ Do not clean the nozzle seal with sharp-edged objects.

œ Replace the nozzle seal if the sealing surface is damaged.

SIHI_0021_GB

1. Relieve the pressure from the gun and unit.

2. Secure gun with trigger safety catch.

3. Unscrew aircap nut (A)

4. Remove air cap (B) and nozzle (C).

5. Press AirCoat nozzle (C) out of the air cap by hand and brush with cleaning solvent until all remaining paint has been dissolved.

6. Assembly:

Place AirCoat nozzle (C) in nozzle seal (D).

7. Place air cap (B) on the nozzle (C). Take care that the nozzle fi tted is correctly (see fl ats

X)

8. Fit the aircap nut with nozzle guard (A) over the air cap (B) onto the spray gun and tighten by hand.

X

"?

B

C

D

A

B_00042

27

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

5.4.4 CLEANING AIRCOAT NOZZLES

For disassembly and assembly see AirCoat nozzles section 5.4.3.

The AirCoat nozzle (C) can be placed into a cleaning solvent which has been recommended by the paint manufacturer.

5.4.5 UNBLOCKING CLOGGED NOZZLE

1. Relieve the pressure from the gun and unit.

2. Secure gun with trigger safety catch.

3. Unscrew aircap nut with nozzle guard (A).

4. Remove aircap (B).

5. Pull out the clogged nozzle (C) from the air cap (B), reverse it and replace it into nozzle seal

(D).

6. Place air cap (B) on the nozzle (C). Take care that the nozzle fi tted is correctly

7. Fit the aircap nut with nozzle guard (A) over the air cap (B) onto the spray gun and tighten by hand.

8. Switch the material pressure back on.

9. Turn the safety catch to the spraying position and briefl y pull trigger.

10. When the blockage has been fl ushed out secure the gun with safety catch.

11. Relieve the pressure from the gun and unit.

12. Unscrew aircap nut with nozzle guard (A).

13. Remove air cap (B) and reverse nozzle (C) again.

14. Refi t air cap (B) on the nozzle (C). Take care that the nozzle fi tted is correctly (see fl at side X)

15. Fit the aircap nut with nozzle guard (A) over the air cap (B) onto the spray gun and tighten by hand.

16. Switch the material pressure and the air pressure back on.

X

"?

Nozzle in „spray“ position

D

A

B

C

B_00039

Nozzle in „cleaning“ position

28

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6 MAINTENANCE

➞ See safety regulations in chapter 2.

The spray gun and the unit must be cleaned every day. Use only the cleaning solvent recommended by the material manufacture.

CAUTION

Cleaning agent in the air duct!

Functional faults caused by swollen seals

œ Never immerse the spray gun in cleaning agent.

SIHI_0066_GB

WARNING

Incorrect maintenance/repair!

Risk of injury and damage to the equipment

œ Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center.

œ Before all work on the unit and in the event of work interruptions:

- Switch off the energy/compressed air supply.

- Relieve the pressure from the spray gun and unit.

- Secure the spray gun against actuation.

œ Observe the operating and service instructions when carrying out all work.

SIHI_0004_GB

29

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6.1 FINISHING WORK AND CLEANING

DANGER

Exploding gas/ air mixture!

Danger to life from flying parts and burns

œ Never spray into a closed container.

œ Earth the container.

SIHI_0008_GB

CAUTION

Cleaning agent in the air duct!

Functional faults caused by swollen seals

œ Always point the spray gun down when cleaning.

œ Ensure that neither paint nor cleaning agent enters the air duct.

SIHI_0005_GB

7!2.).'

%XPLOSIVEATMOSPHERE

%XPLOSIVEGASESAREPRODUCEDWHENALUMINIUMCOMESINTOCONTACT

WITHHALOGENIZEDHYDROCARBONS

œ 4OCLEANALUMINIUMDONOTUSELIQUIDSCONTAININGHALOGENIZED

HYDROCARBONS

3)()??'"

Note:

Methylene chloride is not recommended as a fl ushing or cleaning solvent with this gun or any system components.

1. Relieve the pressure from the gun and unit.

2. Secure gun with trigger safety catch.

3. Replace material with cleaning agent.

4. Remove and clean the AirCoat nozzle. (see section 5.4.3)

5. Pressurize the cleaning supply to approx. 4 MPa; 40 bar; 580 psi max. and thoroughly fl ush the spray gun.

6. Relieve spray gun and unit pressure!

7. Secure gun with trigger safety catch.

8. Clean gun body with a cleaning agent recommended by the manufacturer, and dry with a cloth.

30

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6.2 CHANGING OR CLEANING FILTER

1. Take spraygun out of operation and clean.

2. Relieve the pressure from the gun and unit.

3. Secure gun with trigger safety catch.

4. Unscrew the complete swivel assembly with the fi lter housing, and remove downwards with the hose.

5. Remove the fi lter insert (A) from the fi lter housing (B).

6. Clean the swivel, fi lter housing and fi lter (A) with cleaning agent.

7. Fit the cleaned or new fi lter insert (A) into the fi lter housing with the conical end (X) pointing upwards.

8. Push the fi lter housing over the swivel hexagon, then slide the whole assembly over the gun fi lter and tighten by hand.

"?

X

Unscrew

Tighten

Counter

37MMIN

Note:

In case of diffi culty unsrewing the fi lter housing use 2 open-ended wrenches

(13 mm; 0.512 inch / 17 mm; 0.70 inch)

Unscrew

37MM

IN

"

!

#

"?

Note:

Do not unscrew the paint connection. The nut must only be unscrewed by

WAGNER- Service-Agency.

"?

31

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6.3 CHANGING MATERIAL HOSE

1. Put out of operation and clean.

2. Relieve the pressure from the gun and unit.

3. Secure gun with trigger safety catch.

4. Place open-ended wrench 13 mm; 0.51 inch respectively 17 mm; 0.70 inch on fl ats of paint connection respectively swivel and counterhold.

5. Turn nut to the right with open-ended wrench 19 mm; 0.75 inch and unscrew material hose.

6. Assembly:

Fit the material hose by hand and tighten with 2 open-ended wrenches

13 mm; 0.51 inch; 19 mm; 0.75 inch respectively 17 mm; 0.70 inch; 19 mm; 0.75 inch

SW 19 mm; 0.75 inch

SW 19 mm; 0.75 inch

SW 13 mm; 0.51 inch

Counterpressure

B_00059

SW 17 mm; 0.70 inc

Counterpressure

Note:

Do not unscrew the paint connection. The nut must only be unscrewed by WAGNER- Service-Agency.

B_00036

"?

32

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6.4 REPLACING PARTS OF THE VALVE STEM

6.4.1 DISMANTLING

1. Take spraygun out of operation and clean.

2. Relieve the pressure from the gun and unit.

3. Secure gun with trigger safety catch.

4. Unscrew the tension cap (A) remove the springs (B) and (C).

5. Remove trigger pin (H) and screw (J).

6. Remove the trigger (I).

7. Loosen packing screw (G) with open-ended wrench 7 mm; 0.275 inch .

8. Push the valve tappet (E) together with the valve rod (D) backwards by hand.

9. Using pliers pull out parts (E) and (D).

CAUTION

Unsuitable tool!

Damage to seals and sealing surfaces

œ Do not hold the valve rod with pliers or a similar tool.

SIHI_0006_GB

10. Remove packing screw (G) with open-ended wrench 7 mm; 0.275 inch.

11. Remove sealing package (F).

Note:

If parts remain stuck in the hole then remove the air cap (M) with the nozzle (L), then the valve seat holder (K) using a 12 mm; 0.472 inch wrench and remove. The stuck components can then be pushed out with a drift max. ø 4.5 mm; 0.177 inch.

12. Exchange any worn parts.

Tightening torque 10 Nm; 7.4 lbft

R E

D

Sealing surface

N

M

L

K

H

J

I

F

G

C

B

A

Tightening torque 8 Nm; 5.9 lbft

B_00064

33

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6.4.2 REPLACING SEALS IN THE VALVE TAPPET

1. Heat valve tappet assy. to about 150°C; 302°F.

2. Place a 7 mm; o.28 inch wrench on the valve tappet (E) and hold. Unscrew the tappet cap (Q) with an 8 mm; 0.31 inch wrench.

3. Remove and replace tappet seal (O) and seal (P).

Note:

The seal (O) can be unscrewed from the valve tappet (E) using a small screwdriver pushed into it

2

3

1

/

0

%

,OCTITE

When the air-valve leaks:

4. Remove the air-valve seal (R) from the gun-housing and replace. Clean sealing surfaces in the gun housing.

Disassembly tool for airvalve seal (R)

Part-No. 036 943

R

When the slide cap (S) is damaged:

5. Cut the slide cap (S) with a shrap knife and press a new one onto the tappet cap.

Assembly tool for airvalve seal (R)

Part-No. 0364942

"?

6.4.3 REASSEMBLING

1. Screw in the valve seat (K) and tighten using a 12 mm; 0.472 inch torque wrench to a torque of 10 Nm; 7.4 lbft.

2 See section 5.4.3 for reassembly of air-cap.

3. Lightly grease the tappet seal (O) and the seal (P) and assemble on valve tappet (E).

4. Push in valve stem (D).

Note:

Only silicon-free or resin-free grease is permitted to be used.

5. Screw the air valve tappet (E) and tappet cap (Q) together using loctite 243 by hand.

Carefully tighten using 7 mm; 0.275 inch / 8 mm; 0.314 inch wrenches until slight resistance is felt when sliding the valve stem in and out.

6. Place the seal package (F) on the valve rod (D) and insert into the hole in the housing from the rear.

34

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

7. Pull the valve rod (D) out again.

8. Screw in the packing screw (G) and do not tighten fully .

9. Put trigger (I) in position, and insert trigger pin (H) and screw ( J).

10. Place the valve tappet (E) over the valve rod (D). Push both parts from behind into the housing.

11. Place the springs (C) and (B) in place and tighten tension cap (A).to a torque of 8 Nm;

5.9 lbft.

12. Tighten seal package (F) with packing screw (G) carefully. Take care of a smooth movement of trigger.

13. Start-up see chapter 5.3.

Note:

Ensure that the springs plates in the sealing package (F) are in the correct position.

6.5 REPLACING NOZZLE SEAL

CAUTION

Forming air and atomizer air not separate !

Poor spray pattern

Spray jet cannot be adjusted

"?

œ Treat the distributor seal (F) with care.

SIHI_0030_GB

1. Take out of operation and clean.

2. Relieve the pressure from the gun and unit.

3. Secure gun with trigger safety catch.

4. Unscrew aircap nut with nozzle guard (A)

5. Remove air cap (B) and nozzle (C).

6. Prise the tip seal (D) out using a small screwdriver.

7. Push the new nozzle seal into the valve seat holder (E).

8. Re-assemble aircap in reverse order

E

F

D

B

C

A

B_00033

35

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6.6 REPLACING SEAL (DISTRIBUTOR)

1. Take out of operation and clean.

2. Relieve the pressure from the gun and unit.

3. Secure gun with trigger safety catch.

4. Unscrew aircap nut with nozzle guard (A)

5. Remove air cap (B) and nozzle (C).

6. Pull the damaged seal (F) out using a pliers

7. Assembly: Put the new seal (F) on the air cap (B).

8. Place the air cap and seal into gun housing.

9. Set aircap nut (A) and screw in as far as the seal ring (F) in the groove catches. (snap hearable)

10. Disassemble aircap nut and aircap an complete the spray gun. See chapter 5.4.3.

A

B

C

1.

3.

F

2.

5.

4.

B_00066

36

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

6.7 CHANGING OR CLEANING EDGE FILTER (OPTIONAL)

1. Put out of operation and clean.

2. Relieve the pressure from the gun and unit.

3. Secure gun with trigger safety catch.

4. Place open-ended wrench 19 mm; 0.75 inch respectively 17 mm; 0.70 inch on fl ats of fi lter housing (B) respectively swivel (C) and counterhold.

5. Turn nut to the right with open-ended wrench 17 mm; 0.70 inch and unscrew pivot joint (C) with material hose.

6. Remove edge fi lter (A)

7. Clean the fi lter housing (B) respectively swivel (C) and edge fi lter (A) with cleaning agent.

8. Assembly:

Fit the cleaned or new edge fi lter into the pivot joint (C).

9. Fit pivot joint with the material hose by hand and tighten with 2 open-ended wrenches

17 mm; 0.70 inch / 19 mm; 0.748 inch.

B

SW 19 mm; 0.75 inch

Counterpressure

A

SW 17 mm;

0.70 inch

B_00067

C

37

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

7 TROUBLE SHOOTING AND SOLUTIONS

Problem

Paint output too low

Cause

Nozzle too small

Solution

Select larger nozzle (see para. 9.1)

Paint pressure too low Adjust at pump as required.

Gun fi lter blocked or HP fi lter at pump clogged

Clean/ replace fi lters (see para. 6.1)

Nozzle blocked or

Trigger/ valve stem defective

Clean nozzle (see section 5.4.5)

Replace valve stem

Poor quality spray pattern Incorrect atomizing air pressure

Re-adjust (see para. 5.4.1)

Nozzle too large Select smaller nozzle (see para. 9.1)

Paint pressure too low Increase pressure at pump

Material viscosity too high

Thin material acc. to manufacturer‘s instruction.

Leaking valve stem seals

(paint or air)

Partial nozzle blokkage Clean nozzle (see para. 5.4.5)

Incorrect fanair adjustment (fan to wide or to narrow)

Re-adjust fanair control on spraygun (see para. 5.4.1)

Clean or replace aircap Aircap faulty (blocked holes, damaged seal)

Wrong aircap type Replace as requiered (solvent / waterbased)

Adjust or replace packing or replace valve stem cpl.

Spaygun will not shut-off correctly

Paint seal (packing) amaged or worn, valve stem damaged.

Air valve seals damaged.

Pretension to low

Worn valveseat / valve ball

Replace air valve seals (see para. 6.3)

Tighten the sealing screw

Replace as required

Packing-screw too tight, or packing stuck with dried paint

Retension or replace packing

38

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

8 REPAIR WORK

WARNING

Incorrect maintenance/repair!

Risk of injury and damage to the equipment

œ Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center.

œ Before all work on the unit and in the event of work interruptions:

- Switch off the energy/compressed air supply.

- Relieve the pressure from the spray gun and unit.

- Secure the spray gun against actuation.

œ Observe the operating and service instructions when carrying out all work.

SIHI_0004_GB

➞ See safety regulations in chapter 2.

8.1 FILTER HOUSING CONNECTION

1

Heat up to approx. 150°C;

302°F with a hot air fans .

2

3

SW 13 mm

4

15 Nm; 11.1 lbft

5

6

B_00031

7

39

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Disassembly

1. Remove all moving parts of the spray-gun

2. Heat up to approx. 150°C; 302°F the area of the banjo bolt (4).

3. Unscrew banjo bolt (4) with open-end wrench (size 13 mm; 0.51 inch) and remove fi lter housing (5) with seal material (7) or material outlet fi tting (8).

4. Clean all reusable parts using a suitable solvent.

❋ Heat up to approx. 150°C;

302°F with a hot air fans .

2

3

4

SW 13 mm

15 Nm; 11.1 lbft

❋

8

6

B_00030

1

40

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Repair spare parts

Item K Qty Part-No.

Description

1 1 0364927 Gun housing pre-assembled fi lter

5

6

3

4

1

2

1

1

8

9

7

8

1

1

1

1

1

1

1

1

1

1

1

1

0364928

0364929

0364934

0364339

9922720

0364336

0364343

9992833

0364340

0364353

0364355

9992528

Gun housing pre-assy. M16x1.5

Gun housing pre-assy. NPSM1/4“

Gun housing AC-H M16x1.5

Seal material inlet

Snap ring

Banjo bolt

Filter housing bended

Loctite 638 green

Seal fi lter

Material outlet fi tting M16x1.5

Material outlet fi tting NPSM1/4“

Loctite 270

Assembly

1. Push the new banjo bolt (4) onto fi lter housing (5) or onto material outlet nipple (8).

2. Place the snap ring (3) in the groove of fi lter housing (5) and place the seal material (2) onto fi lter housing (5).

3. Apply loctite 638 to the thread of the bajo bolt (4) and of the fi lter pipe (5).

that it is in the correct position. Tighten the banjo bolt (4) using a torque wrench to a torque of 15 Nm; 11 lbft.

5. Put the cemented joint for 30 minutes at 40°C; 104°F in a oven.

6. Assemble the spraygun and check the gun for leaks using solvent or spray oil and a max. pressure of 25 MPa; 250 bar; 3626 psi or 16 MPa; 160 bar; 2320 psi.

7. Check the gun for leaks using solvent or spray oil and a max. pressure of 25 MPa; 250 bar; 3626 psi or 16 MPa; 160 bar; 2320 psi

41

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

8.2 PIVOT JOINT PAINT

7!2.).'

$EFECTIVEPARTS

,EAKAGECAUSEDBYDEFECTIVEPARTS

4HERESULTINGSPRAYJETCANINJECTMATERIALINTOTHEBODYSKINEYES

ETC

œ !LWAYSREPLACEDEFECTIVEPARTS/RINGSANDSEALSETS

œ %NSURETHATADHESIONPOINTSARECLEANANDFREEOFGREASE

3)()??'"

Disassembly

1. Remove pressure spring (1) and unscrew adjuster screw (2).

2. Remove o-ring (3) and gasket (4).

Item K Qty Part-No.

Description

1 1 0043590 Pressure spring

4

5

2

3

1

1

1

1

0364374

9971147

0364375

0364923

Adjuster screw

O-ring

Gasket

Pivot joint paint M16x1,5

5

6

7

1

1

1

0364924 Pivot joint paint NPSM1/4“-18

9992528 Loctite 270

9992695 Castor oil

Assembly

1. Lightly grease o-ring (3) using castor oil and push it onto gasket (4). Insert the gasket assy. into connection piece.

Note

By assembling do not damage gasket (4).

2. Screw adjuster screw (2) into connection piece using Loctite

270.

Note

Do not thighten fully the adjuster screw.

3. Tighten the adjuster screw (2) using a torque wrench to a torque of 1.5 Nm ± 0.5 Nm ; 1.84 lbft ± 0.37 lbft .

4. Push the pressure spring (1) onto the adjuster screw (2).

5. Put the assembled part for 30 minutes at 40°C; 104°F in a oven.

Note

The part must be placed in the oven on the connection piece.

(Pressure spring downstairs)

6. Check the pivot joint for leaks using solvent or spray oil and a max. pressure of 25 MPa; 250 bar; 3626 psi or 16 MPa; 160 bar;

2320 psi.

1.0 Nm

±0.5 Nm

;

0.74 lbft

±0.36lbft

6

7

"?

B_01293

1

2

3

4

42

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Dimensional accuracy:

If the distance „x“ between pinhead (1) and distance piece (2) is larger than 1.5 mm; 0.06 inches, the pivot joint must be replaced.

2

1

B_01292

X

43

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

8.3 PIVOT JOINT PAINT LW

7!2.).'

$EFECTIVEPARTS

,EAKAGECAUSEDBYDEFECTIVEPARTS

4HERESULTINGSPRAYJETCANINJECTMATERIALINTOTHEBODYSKINEYES

ETC

œ !LWAYSREPLACEDEFECTIVEPARTS/RINGSANDSEALSETS

œ %NSURETHATADHESIONPOINTSARECLEANANDFREEOFGREASE

3)()??'"

Disassembly

1. Unscrew the fi lter housing (1) from the connection piece and remove the edge fi lter

(6) and nipple (5).

2. Unscrew adjuster screw (2). Remove o-ring (3) and gasket (4).

9

10

7

8

6

7

5

5

Item K Qty Part-No.

Description

1 1 0364379 Filter housing M16x1.5 LW

3

4

1

2

1

1

1

1

0364380

0364374

9971147

0364375

Filter housing NPS1/4“-18 LW

Adjuster screw

O-ring

Gasket

1

1

1

1

1

1

1

1

0179456

0179457

3204605

0364925

0364926

9992528

9992695

9992698

Nipple for M16x1.5

Nipple for NPS1/4“-18

Edge fi lter 100 meshes

Pivot joint paint LW M16x1.5 fi lter

Pivot joint paint LW NPS1/4“-18 fi lter

Loctite 270

Castor oil

Vaseline white PHHV II

Note:

All reusable parts should be cleaned thoroughly using a suitable solvent.

"?

44

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Assembly

1. Lightly grease o-ring (3) using castor oil and push it onto gasket

(4). Insert the gasket assy. into connection piece.

Note

By assembling do not damage gasket (4)

10

2. Screw adjuster screw (2) into connection piece using Loctite

270.

Note

Do not thighten fully the adjuster screw.

3. Tighten the adjuster screw (2) using a torque wrench to a torque of 1.5 Nm ±0.5 Nm ; 1.11 lbft ±0.37 lbft

4. Put the assembled part for 30 minutes at 40°C; 104°F in a oven.

Note

The part must be placed in the oven on the fi lter housing (1).

5. Press nipple (5) into fi lter housing (1). Place the edge fi lter (6) into connection piece. Screw the fi lter housing (1) and pivot joint together. (Lightly grease the thread with vaseline)

6. Check the pivot joint for leaks using solvent or spray oil and a max. pressure of 25 MPa; 250 bar; 3626 psi or 16 MPa; 160 bar;

2320 psi.

1.0 Nm

±0.5 Nm

;

0.74 lbft

±0.36lbft

8

9

10

B_01296

5

1

6

2

3

4

Dimensional accuracy:

If the distance „x“ between pinhead (1) and distance piece (2) is larger than 1.5 mm; 0.06 inches, the pivot joint must be replaced.

2

1

B_01295

X

45

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

9 ACCESSORIES

9.1 AIRCOAT NOZZLES ACF3000

0ART.O

-ARKING

3IZE

MMINCH

3PRAYING

ANGLE

2ECOMMENDEDGUNlLTER

2ECOMMENDEDEDGElLTER

!PPLICATION

.ATURALPAINT

4RANSPARENTPAINT

/IL

3YNTHETICRESINPAINT

06#PAINT

0AINTUNDERCOAT

0RIMINGPAINT

&ILLER

&ILLER

2USTPROOlNGPAINT

2USTPROOlNGPAINT

,ATEXPAINT

46

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

0ART.O

-ARKING

3IZE

INCHMM

3PRAYING

ANGLE

2ECOMMENDEDGUNlLTER

2ECOMMENDEDEDGElLTER

!PPLICATION

2USTPROOlNGPAINT

,ATEXPAINT

$ISTEMPERPAINT

:INCDUSTCOATING

2USTPROOlNGPAINT

-ICAPAINT

47

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

9.2 AIR CAPS

Part No.

Description

0364911 Air cap HV (blue) for high viscosity paints

0364910 Air cap LV (red) for low viscosity paints

9.3 AIRCOAT-NOZZLE ROUND ACR3000

Part No.

Description

0371011 Nozzle ACR3000 R11

0371012 Nozzle ACR3000 R12

0371013 Nozzle ACR3000 R13

0371014 Nozzle ACR3000 R14

0371015 Nozzle ACR3000 R15

0371016 Nozzle ACR3000 R16

0371017 Nozzle ACR3000 R17

0371018 Nozzle ACR3000 R18

0371019 Nozzle ACR3000 R19

0371020 Nozzle ACR3000 R20

0371021 Nozzle ACR3000 R21

0371022 Nozzle ACR3000 R22

GM 3000AC

"?

"?

"?

48

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

9.3.1 NOZZLE INSERTS RXX

Part No.

Description

0132720 Nozzle insert R11

0132721 Nozzle insert R12

0132722 Nozzle insert R13

0132723 Nozzle insert R14

0132724 Nozzle insert R15

0132725 Nozzle insert R16

0132726 Nozzle insert R17

0132727 Nozzle insert R18

0132728 Nozzle insert R19

0132729 Nozzle insert R20

0132730 Nozzle insert R21

0132731 Nozzle insert R22

20

21

22

16

17

18

19

Marking

11

12

13

14

15

Jet witdh** ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

ca. 250; 9.84

** Jet width in mm; inch at a distance of 30 cm; 11.8 inches from the object and at a pressure of 10 MPa; 100 bar; 1450 psi, synthetic resin paint, 20 DIN4 seconds

"?

9.3.2 NOZZLE SCREW JOINT ASSY.

Part No.

Description

0132922 Nozzle screw joint assy.

B_00076

9.4 FILTERS FOR SPRAY GUN

Part No.

for 1 piece

Part No. for 10 pcs.

Filter Type

0034383 0097022 Gun fi lter (red)

Meshsize For use with nozzle sizes:

200 0.007“ - 0.015“

"?

0043235 0097023 Gun fi lter (yellow) 100 0.015“ - 0.019“

"?

0034377 0097024 Gun fi lter (white) 50 0.017“ - 0.021“

"?

49

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

9.5 SWIVEL FOR GUNS WITHOUT FILTERS

Part No.

Description

0364930 Set swivel M16x1,5 for paint connection and air connection.

GM 3000AC

"?

0364931 Set swivel NPSM1/4“ for paint connection and air connection.

"?

0364925 Swivel material connection M16x1,6 with fi lter 100 meshes

"?

0364926 Swivel material connection NPSM1/4“ with fi lter 100 meshes

"?

3204605 Filter for swivel 100 meshes

"?

3204604 Filter for swivel 60 meshes

"?

9999002 Filter for swivel 200 meshes

"?

50

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

9.6 HOSES

Part No.

Description

9984564

HP-Twin hose

M16x1.5; 7.5 m; DN 4 mm; 27 MPa; 270 bar,

M16x1.5; 24.6 ft; ID 0.16 in; 3916 psi for guns with fi lter

9984565

HP-Twin hose

M16x1.5; 7.5 m; DN 4 mm; 27 MPa; 270 bar,

M16x1.5; 24.6 ft; ID 0.16 in; 3916 psi for guns without fi lter

9984509

HP-Twin hose

M16x1.5; 7.5 m; DN 4 mm; 27 MPa; 270 bar,

M16x1.5; 24.6 ft; ID 0.16 in; 3916 psi for extension HP twin hose

9984609

HP-Twin hose

NPSM1/4“; 7.5 m; DN 4 mm; 27 MPa; 270 bar,

NPSM1/4“; 24.6 ft; ID 0.16 in; 3916 psi for extension HP twin hose

9984664

HP-Twin hose

NPSM1/4“; 7.5 m; DN 4 mm; 27 MPa; 270 bar,

NPSM1/4“; 24.6 ft; ID 0.16 in; 3916 psi for guns with fi lter

9984665

HP-Twin hose

NPSM1/4“; 7.5 m; DN 4 mm; 27 MPa; 270 bar,

NPSM1/4“; 24.6 ft; ID 0.16 in; 3916 psi for guns without fi lter

9.7 MISCELLANEOUS

Part No.

Description

9997001 Nozzle cleaning brush

8612001 Nozzle cleaning needle set (12 pieces)

0364940 Service kit GM3000AC for gun with fi lter

0364941 Service kit GM3000AC for gun without fi lter

9985720 Double nipple R1/4“ for extension for air hose

0123446 Double nipple M16x1.5 for extension for material hose

0367560 Double connection NPSM1/4“ for extension for material hose

0364966 Conversion kit 16 MPa; 160 bar; 2320 psi GM3000AC

Note:

Valid for gun-serial-number „02001“ and higher

GM 3000AC

"?

"?

51

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

10 SPARE PARTS

10.1 HOW TO ORDER SPARE PARTS?

!LWAYSSUPPLYTHEFOLLOWINGINFORMATIONTOENSUREDELIVERYOFTHERIGHTSPAREPART

0ART.UMBERDESCRIPTIONANDQUANTITY

4HEQUANTITYNEEDNOTBETHESAMEASTHENUMBERGIVENINTHEu1UANTITYhCOLUMN4HIS

NUMBERMERELYINDICATESHOWMANYOFTHERESPECTIVEPARTSAREUSEDINEACHSUBASSEMBLY

4HEFOLLOWINGINFORMATIONISALSOREQUIREDTOENSURESMOOTHPROCESSINGOFYOURORDER

!DDRESSFORTHEINVOICE

!DDRESSFORDELIVERY

.AMEOFTHEPERSONTOBECONTACTEDINTHEEVENTOFANYQUERIES

4YPEOFDELIVERYREQUIREDAIRFREIGHTORMAILSEAROUTEOROVERLANDROUTEETC

-ARKSINSPAREPARTSLISTS

.OTETOCOLUMNu+hINTHEFOLLOWINGSPAREPARTSLISTS

U 7EARINGPARTS

.OTE.OLIABILITYISASSUMEDFORWEARINGPARTS

L .OTPARTOFSTANDARDEQUIPMENTAVAILABLEHOWEVERASADDITIONALEXTRA

SIHI_0004_GB

WARNING

Incorrect maintenance/repair!

Risk of injury and damage to the equipment

œ Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center.

œ Before all work on the unit and in the event of work interruptions:

- Switch off the energy/compressed air supply.

- Relieve the pressure from the spray gun and unit.

- Secure the spray gun against actuation.

œ Observe the operating and service instructions when carrying out all work.

52

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

10.2 SPARE PARTS LIST GM 3000AC WITH FILTER

Spare parts list GM 3000AC with fi lter

Item K Qty Part-No.

Description

1 1 0364927 Gun housing pre-assembled fi lter

0364921 Aircap nut assy.

2 1

4 ◆★ 1

7 ◆★ 1

8 1

0364922 Valve seat assy.

0364920 Valve rod (assembled)

0364923 Swivel joint (paint) M16x1.5 assy.

8

9

1

1

0364924 Swivel joint (paint) NPSM1/4“ assy.

0364347 Fan air control knob

12

13

14

10

10

11

15 1

16 1

17 ◆★ 1

18 ◆★ 1

19 ◆★ 1

22 ◆★ 1

23 ◆★ 1

24 1

1

1

1

1

1

1

0364346

0364366

0364327

Tension nut 25 MPa; 250 bar; 3626 psi

Tension nut 16MPa; 160 bar; 2320 psi

Trigger

0364350 Safety catch

0364317 Air connection

0364348 Atomizing air plug

0364337 Retaining screw

0364349 Housing cover

0364301 Seal (distributor)

0364328 Seal (nozzle)

0364318 Seal (air valve)

0364345 Shaft collar

0364340 Seal (fi lter)

9998580 Pressure spring (air)

25

26

28

1

1

2

9998581

9900808

9907146

Pressure spring (paint)

Screw M3x8 mm; 0.31 inches long

Screw M4x10 mm; 0.39 inches long

29 1

30 ◆★ 1

31 ◆★ 1

32 ◆★ 1

33 ◆ 1

50

51

1

1

0364938

9971390

9971353

9971182

Swivel joint (air) R1/4“

O-ring

O-ring

O-ring

00.....

Gun fi lter (see chapter 9.4)

0364309 Valve tappet

0364910 Air cap LV (red)

51 1 0364911 Air cap HV (blue)

52 ◆★ 1 0364319 Seal (tappet)

◆ = Wearing part

✭ = Included in service-kit

●

= Not part of standard equipment for the spray gun. but is available as an optional extra

53

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

GM 3000AC with fi lter

PART NO. DOC364831

25

24

10

83

70

72

71 74 75

73

76

77

10 Nm;

7.38 lbft

1

83

15

32 14

30

9

52

50

12

31

8 Nm;

5.9 lbft

7

54

19

55 53

28

29

80

59

58

57

83

80

2.5 - 3 Nm;

1.84 - 2.21 lbft

56

51

17

18

4

60

22

26

2 61

11

81

13

33

Assembly materials

Item K Part-No.

Description

80 ● 9992511 Loctite 243

81 ● 9992590 Loctite 222

82 ● 9992528 Loctite 270

83 ● 9992698 Vaseline white PHHV II

84 ● 9992695 Castor oil

B_00045

16

23

8

61

54

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Spare parts list GM 3000AC with fi lter

Item K Qty Part-No.

Description

53 ◆★ 1 0364320 Seal (rod)

54 1

55 ◆★ 1

0364311

0364338

Tappet cap

Slide cap

56 1

57 ◆★ 1

0364305

0364306

Packing screw

Packing

58 1

59 ★ 1

60 ◆● 1

61 ◆● 1

0364307

0335707

0379...

Pressure ring

Spring plate set

AC-nozzle ../.. see chapter 9.1

9984564 HP-twin-hose M16x1.5; 7.5 m; DN 4 mm; 27 MPa; 270 bar, M16x1.5; 24.6 ft; ID 0.16 inches; 3916 psi

70 ● 1

71 ● 1

72 ● 1

73 ◆● 1

74 ● 1

0364400

9922722

0364302

0132...

Nozzle nut

Snap ring

Union nut

Nozzle insert ACR... (see chapter 9.3.)

0132351 Nozzle screw joint holder

75 ◆● 1

76 ◆● 1

0132516 Nozzle screw joint assy.

0128327 Sealing nipple

77 ● 1 0364401 Nozzle housing

● 1 0364940 Service kit GM3000AC with fi lter

◆ = Wearing part

✭

= Included in service-kit

●

= Not part of standard equipment for the spray gun. but is available as an optional extra

55

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

10.3 SPARE PARTS LIST GM 3000AC WITHOUT FILTER

Spare parts list GM3000 AC without fi ltre

Item K Qty Part-No.

Description

1 1 0364928 Gun housing pre-assembled M16x1.5

10

10

1

2

4 ◆★ 1

7 ◆★ 1

9 1

1

1

1

1

0364929

0364921

0364922 Valve seat assy.

0364920 Valve rod (assembled)

0364347

0364346

0364366

Gun housing pre-assembled NPSM1/4“

Aircap nut assy.

Fan air control knob

Tension nut 25 MPa; 250 bar; 3626 psi

Tension nut 16MPa; 160 bar; 2320 psi

11

12

13

14

1

1

1

1

0364327 Trigger

0364350 Safety catch

0364361 Air connection LW

0364348 Atomizing air plug

15 1

17 ◆★ 1

18 ◆★ 1

19 ◆★ 1

22 ◆ 1

24 1

25

26

28 2

30 ◆★ 1

31 ◆★ 1

32 ◆★ 1

1

1

0364337

0364301

0364328

Retaining screw

Seal (distributor)

Seal (nozzle)

0364318 Seal (air valve)

0364345 Shaft collar

9998580 Pressure spring (air)

9998581 Pressure spring (paint)

9900808 Screw M3x8 mm; 0.31 inches long

9907146 Screw M4x10 mm; 0.39 inches long

9971390 O-ring

9971353 O-ring

9971182 O-ring

50

51

1

1

51 1

52 ◆★ 1

53 ◆★ 1

54 1

55 ◆★ 1

0364309 Valve tappet

0364910 Air cap LV (red)

0364911 Air cap HV (blue)

0364319 Seal (tappet)

0364320 Seal (rod)

0364311 Tappet cap

0364338 Slide cap

56 1

57 ◆★ 1

0364305

0364306

Packing screw

Packing

58 1 0364307 Pressure ring

◆

= Wearing part

✭ = Included in service-set

●

= Not part of standard equipment for the spray gun. but is available as an optional extra

56

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

GM3000 AC without fi ltre

25

24

10

8 Nm;

5.9 lbft

83

70

72

71 74 75

73

76

77

83

15 32

30

14

9

52

50

2

17

18

4

51

60

22

26

11

81

10 Nm;

7.38 lbft

1

12

31

63

7

19

55 53

54

80

13

62

28

64

83

59

58

57

56

80

2.5 - 3 Nm;

1.84 - 2.21 lbft

61

Assembly materials

Item K Part-No.

Description

80 ● 9992511 Loctite 243

81 ● 9992590 Loctite 222

82 ● 9992528 Loctite 270

83 ● 9992698 Vaseline white PHHV II

84 ● 9992695 Castor oil

B_00046

57

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Spare parts list GM3000 AC without fi ltre

Item K Qty Part-No.

Description

59 ★ 1 0335707 Spring plate set

60 ◆● 1

61 ◆● 1

0379...

9984565

AC-nozzle ../.. see chapter 9.1

HP-twin-hose M16x1.5; 7.5 m; DN 4 mm; 27 MPa; 270 bar, M16x1.5; 24.6 ft; ID 0.16 in; 3916 psi

62 ◆● 1

63 ● 1

3204...

0364925

Filter see chapter 9.4

Swivel mat. connection M16x1.5

63 ● 1

64 ● 1

70 ● 1

71 ● 1

72 ● 1

73 ◆● 1

74 ● 1

75 ◆● 1

76 ◆● 1

0364926

0364938

0364400

9922722

0364302

0132...

0132351

0132516

Swivel mat. connection NPSM1/4“

Swivel joint (air) R1/4“

Nozzle nut

Snap ring

Union nut

Nozzle insert ACR... (see chapter 9.3)

Nozzle screw joint holder

Nozzle screw joint assy.

0128327 Sealing nipple

77 ● 1

● 1

0364401 Nozzle housing

0364941 Service kit GM3000AC without fi lter

◆

= Wearing part

✭

= Included in service-set

● = Not part of standard equipment for the spray gun. but is available as an optional extra

58

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

10.4 SPARE PARTS LIST GM 3000AC-H WITHOUT FILTER

11

12

13

14

Spare parts list GM 3000AC-H without fi ltre

Item K Qty Part-No.

Description

1 1 0364934 Gun housing AC-H pre-assembled M16x1.5

2 1 0364921 Aircap nut assy.

4 ◆★ 1 0364922 Valve seat assy.

7 ◆★ 1 0364920 Valve rod (assembled)

9 1 0364347 Fan air control knob

10 1 0364346 Tension nut 25 MPa; 250 bar; 3626 psi

1 0364327 Trigger

1 0364350 Safety catch

1 0364361 Air connection LW

1 0364348 Atomizing air plug

15 1 0364337 Retaining screw

17 ◆★ 1 0364301 Seal (distributor)

18 ◆★ 1 0364328 Seal (nozzle)

19 ◆★ 1 0364318 Seal (air valve)

22 ◆ 1 0364345 Shaft collar

24 1 9998580 Pressure spring (air)

25

26

1

1

9998581

9900808

Pressure spring (paint)

Screw M3x8 mm; 0.31 inches long

28 2 9907146 Screw M4x10 mm; 0.39 inches long

30 ◆★ 1 9971390 O-ring

31 ◆★ 1 9971353 O-ring

32 ◆★ 1 9971182 O-ring

50 1 0364309 Valve tappet

51 1 0364911 Air cap HV (blue)

52 ◆★ 1 0364319 Seal (tappet)

53 ◆★ 1 0364320 Seal (rod)

54 1 0364311 Tappet cap

55 ◆★ 1 0364338 Slide cap

56 1 0364305 Packing screw

57 ◆★ 1 0364306 Packing

58 1 0364307 Pressure ring

59 ✭ 1

60 ◆● 1

0335707

0379...

Spring plate set

AC-nozzle ../.. see chapter 9.1

◆ = Wearing part

✭

= Included in service kit

●

= Not part of standard equipment for the spray gun. but is available as an optional extra

59

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

GM 3000AC-H without fi ltre

25

24

10

8 Nm;

5.9 lbft

83

77

70

72 71 74 75

73

76

10 Nm;

7.38 lbft

1

66

65

83

15 32

30

14

9

52

50

51

60

17

22

26

18

4

67

12

31

7

80

19

55 53

54

13

62

28

64

83

59

58

57

56

80

2.5 - 3 Nm;

1.84 - 2.21 lbft

2

63

61

11

81

B_00047

Assembly materials

Item K Part-No.

Description

80 ● 9992511 Loctite 243

81 ● 9992590 Loctite 222

82 ● 9992528 Loctite 270

83 ● 9992698 Vaseline white PHHV II

84 ● 9992695 Castor oil

60

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Spare parts list GM 3000AC-H without fi ltre

Item K Qty Part-No.

Description

61 ◆● 1 9984565 HP-twin-hose M16x1.5; 7.5 m; DN 4 mm; 27 MPa; 270 bar,

M16x1.5; 24.6 ft; ID 0.16 inches; 3916 psi

62 ◆● 1 00...

Filter see chapter 9.4

63 ◆● 1 0364925 Swivel mat. connection M16x1.5

64 ◆● 1 0364938 Swivel joint (air) R1/4“

65 1 9998910 Instruction sticker

66 1 9998911 Protection sticker

67 1 9982606 Protection hose 70 mm; 2.75 inches

70

71

72

●

●

●

1

1

1

73 ◆● 1

0364400

9922722

0364302

0132...

Nozzle nut

Snap ring

Union nut

Nozzle insert ACR... (see chapter 9.3)

74 ● 1 0132351 Nozzle screw joint holder

75 ◆● 1 0132516 Nozzle screw joint assy.

76 ◆● 1 0128327 Sealing nipple

77 ●

●

1 0364401 Nozzle housing

1 0364941 Service kit GM3000AC without fi lter

◆

= Wearing part

✭

= Included in service kit

● = Not part of standard equipment for the spray gun. but is available as an optional extra

61

GM 3000AC

EDITION 05/2007

OPERATING MANUAL

PART NO. DOC364831

Germany

J. WAGNER GmbH

Otto-Lilienthal-Str. 18

Postfach 1120

D- 88677 Markdorf

Telephone: ++49/ (0)7544 / 5050

Telefax: ++49/ (0)7544 / 505200

E-Mail:[email protected]

Belgium

WAGNER Spraytech Benelux BV

Veilinglaan 56

B- 1861 Wolvertem

Telephone: ++32/ (0)2 / 269 4675

Telefax: ++32/ (0)2 / 269 7845

E-Mail: [email protected]

United Kingdom

WAGNER Spraytech (UK) Ltd.

Haslemere Way

Tramway Industrial Estate

GB- Banbury, OXON OX16 8TY

Telephone: ++44/ (0)1295 / 265 353

Telefax: ++44/ (0)1295 / 269861

E-Mail: [email protected]

Netherlands

WAGNER SPRAYTECH Benelux BV

Zonnebaan 10

NL- 3542 EC Utrecht

PO Box 1656

3600 BR Maarssen

Telephone: ++31/ (0)30 / 241 4155

Telefax: ++31/ (0)30 / 241 1787

E-Mail: [email protected]

Japan

WAGNER Spraytech Ltd.

2-35, Shinden Nishimachi

J- Daito Shi, Osaka, 574-0057

Telephone: ++81/ (0)720 / 874 3561

Telefax: ++81/ (0)720 / 874 3426

E-Mail: [email protected]

Sweden

WAGNER Industrial Solutions Scandinavia AB

Karbingatan 28

S- 25467 Helsingborg

Telephone: ++46/ (0)42 150 020

Telefax: ++46/ (0)42 150 035

E-Mail: [email protected]

Czechoslovakia

WAGNER s.r.o.

Na Belidle 1/63

C- 15000 Praha 5

Telephone: ++420/ (0)2/ 573 123 24

Telefax: ++420/ (0)2/ 545 001

E-Mail: [email protected]

Switzerland

J. WAGNER AG

Industriestrasse 22

Postfach 663

CH- 9450 Altstätten

Telephone: ++41/ (0)71 / 757 2211

Telefax: ++41/ (0)71 / 757 2222

E-Mail: [email protected]

Denmark

WAGNER Spraytech Scandinavia A/S

Helgeshøj Allé 28

DK- 2630 Tåstrup

Telephone: ++45/ 43 271 818

Telefax: ++45/ 43 43 05 28

E-Mail [email protected]

France

J. WAGNER France S.A.R.L.

5, Ave. du 1er Mai – BP 47

F- 91122 Palaiseau-Cedex

Telephone: ++33/ (0)1 / 69 19 46 76

Telefax: ++33/ (0)1 / 69 81 72 57

E-Mail: [email protected]

Italy

WAGNER COLORA S.r.l

Via Fermi, 3

I- 20040 Burago di Molgora (MI)

Telephone: ++39/ 039 / 625021

Telefax: ++39/ 039 / 6851800

E-Mail: [email protected]

Austria

J. WAGNER GmbH

Otto-Lilienthal-Str. 18

Postfach 1120

D- 88677 Markdorf

Telephone: ++49/ (0)7544 / 5050

Telefax: ++49/ (0)7544 / 505200

E-Mail:[email protected]

Spain

WAGNER Spraytech Iberica S.A.

Ctra. N- 340, Km. 1245,4

E- 08750 Molins de Rei (Barcelona)

Telephone: ++34/ (0)93/ 680 0028

Telefax: ++34/ (0)93/ 668 0156

E-Mail: [email protected]

USA

Walter Pilot North America

46890 Continental Drive

Chesterfield, MI 48047 USA

Telephone: ++1/ 877 / 925-8437

Telefax: ++1/ 586 / 598-1457 http://www.waltherpilotna.com

62

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GM 3000 AC

Für pneumatische

Kolbenpumpen

For pneumatic piston pumps

Für Membran-Anlagen

For diaphragm pumps

Für 2K-Anlagen

For 2-K-units

Die Kombination von innovativer Düse und zwei verschiedenen Luftkappen macht die GM 3000 AC zu einem

Allrounder bei der Verarbeitung aller wasser- und lösemittelhaltigen Lacke

(wie z.B. Acryllack, 2 K-Lack, DD-

Lack), Beizen und Lasuren.

The combination of innovative nozzle and two different air caps makes the GM 3000

AC to an high grade allrounder for the application of all water based and solvent based lacquers (such as e.g. acrylic-,

2 component-, DD lacquer), stains and varnishes.

Das Beste auf einen Blick:

➞ hohe Beschichtungsgeschwindigkeit

➞ gleichmäßiger Materialauftrag

➞ weich auslaufende Randzonen

➞ weniger Overspray im Vergleich zum Airless- und Luftspritzen

➞ gute Zerstäubung schon ab 60 bar

Materialdruck

➞ deshalb geringerer Düsen- und

Geräteverschleiß

➞ ergonomische Pistole mit vielen

Extras für hohen Arbeitskomfort, wie die Wendedüse und das handlösbare Filtergehäuse

The best features at-a-glance:

➞ high coating speed

➞ uniform application of material

➞ soft run-out at the edges of zones

➞ less overspray than with Airless and air-spraying

➞ good atomisation right from a material pressure of 60 bar

➞ thus less nozzle and equipment wear

➞ the ergonomic gun with many extras for a higher level of working convenience, such as the reversible nozzle and the manually released fi lter housing

Das Ergebnis:

beste Verarbeitungseigenschaften für eine hochwertige

Oberfl ächenbeschichtung.

The result:

the best application characteristics for high-grade surface coating.

Erkundigen Sie sich nach weiteren Produkten aus unserem

Hause: Niederdruckluftspritzgeräte, Kolben- und Membranpumpen, 2K-Anlagen, Putzspritzanlagen, Materialförderlogistik

…

und vieles mehr.

Ask about other products from our company: Low pressure air spraying equipments, piston and diaphragm pumps, 2-K units, plaster spraying equipments, material feed logistics…

and much more.

www.wagner-group.com

CER

TIFIED