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Translation of the original
Operating manual
GM 4600AC
AirCoat Spray gun for fl at - and round jet nozzles
Edition 02/2008
II 2G X (Atex 95)
B_02669
EDITION 02/2008
OPERATING MANUAL
Contents
Part No. DOC394861
1.1 Languages
1.2 Warnings, notes and symbols in these instructions
2
2.1
GENERAL SAFETY INSTRUCTIONS
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 hazardous locations
2.4.3 Maximum surface temperature
2.5 German regulations and guidelines
3
3.1
PRODUCT LIABILITY AND WARRANTY
Important notes on product liability
3.2 Warranty
3.3 CE-conformity
4 DESCRIPTION
4.1 Fields of application, using in accordance with the instructions
4.2 scope of delivery
4.2.1 Variant for application range up to 16 MPa; 160 bar; 2320 psi
4.2.2 Variant for application range up to 25 MPa, 250 bar, 3625 psi
4.2.4 Spray gun confi guration
4.3 Data
4.3.1 Materials of the parts transporting paint
4.3.2 Technical data
4.4.1 Design of spray gun
4.4.2 Functions of the gun
5
5.1
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
GM 4600AC
14
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3
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
Contents
5.1.5 Earthing
5.2 Preparation of paints
5.3 Start-up
5.3.1 General rules for handling the spray gun
5.3.2 Preparation for starting up
5.4 Works
5.4.1 Start-up for spraying AirCoat
5.4.2 Adjusting the spray pattern
5.4.3 Replacing AirCoat nozzle
5.4.4 Cleaning aircoat nozzle
5.4.5 Eliminate nozzle clogging
6.0 MAINTENANCE
6.1 Finishing work and cleaning
6.2
6.3
Replacing the material hose or air hose
Changing or cleaning fi lter insert
6.4 Replacing parts on the valve rod
6.4.1 Disassembling
6.4.2 Replacement of valve rocker seals
6.4.3 Replacing the rod seal (35)
6.4.4 Assembling
6.5
6.6
Replacing the nozzle seal
Replacing the „air“ sealing ring
7 TROUBLE SHOOTING AND SOLUTION
9 ACCESSORIES
9.1 Round-jet nozzle cap
9.1.1 Nozzle inserts RXX
9.1.2 Nozzle screwed connection complete
9.2 AirCoat nozzles ACF3000
9.5 Swivels
9.6 Hoses
9.7 Miscellaneous
10.1 How to order spare parts?
10.2 Spare parts list GM 4600AC
GM 4600AC
20
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GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
1 ABOUT THESE INSTRUCTIONS
4HISOPERATINGMANUALCONTAINSINFORMATIONONTHEOPERATIONREPAIRANDMAINTENANCEOF
THEUNIT
!LWAYSOBSERVETHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY
AGREEMENT
1.1 LANGUAGES
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE
'ERMAN
0ART.O
394860
,ANGUAGE
%NGLISH
&RENCH
394862
$UTCH
)TALIAN
$ANISH
0ART.O
394861
2301130
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.
$!.'%2
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
Warning - possible danger. Non-observance can result in death, serious injury and serious material damage.
3)()??'"
7!2.).'
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
Caution - a possibly hazardous situation. Non-observance can result in minor injury.
#!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
Caution - a possibly hazardous situation. Non-observance can cause material damage.
3)()??'"
#!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLECONSEQUENCESOFFAILINGTOOBSERVETHEWARNINGINSTRUCTIONS4HESIGNALWORD
POINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
Note provide information on particular characteristics and how to proceed.
5
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
+EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
2.1.1 ELECTRICAL EQUIPMENT
%LECTRICALPLANTANDUNIT
4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE
OPERATINGMODEANDAMBIENTINmUENCES
-AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION
-USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU
LATIONS
-USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS
-USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD
-USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT
PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS
2.1.2 PERSONNEL QUALIFICATIONS
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
2.1.3 A SAFE WORK ENVIRONMENT
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eMEASUREMENTINACCORDANCEWITH$).
%NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH
LEATHERSOLES
%NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA
THEHANDLEOFTHESPRAYGUN
#USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS
%NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION
%NSURETHATTHEREARENOIGNITIONSOURCESSUCHASNAKEDmAMEGLOWINGWIRESORHOT
SURFACESINTHEVICINITY$ONOTSMOKE
2.2 SAFETY INSTRUCTIONS FOR STAFF
!LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
6
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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.
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:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
2.2.2 EARTH THE UNIT
Electrostatic charges can occur on the unit due to the electrostatic charge and the flow speed involved in spraying. These can cause sparks and flames upon discharge.
Ensure that the unit is always earthed.
Earth the work pieces to be coated.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing antistatic shoes.
When spraying, wear antistatic gloves to earth yourself via the spray gun handle.
2.2.3 PAINT HOSES
%NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
%NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
%NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE n -ANUFACTURER n 0ERMISSIBLEOPERATINGOVERPRESSURE n $ATEOFMANUFACTURE
4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN
-/HM
7
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
2.2.4 CLEANING
$EENERGIZETHEUNITELECTRICALLY
$ISCONNECTTHEPNEUMATICSUPPLYLINE
2ELIEVETHEPRESSUREFROMTHEUNIT
%NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM
PERATURE
4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON
CLEANINGAGENTSWITHAGUN
!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS
7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER
%ARTHTHECONTAINER
2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK
INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING
USED
4AKE THE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE
CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY
5SEAMASKORBREATHINGAPPARATUSIFNECESSARY
&ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTION SWITCHEDON
7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS
2.2.6 TOUCHING HOT SURFACES
4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES
7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&
)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh
/RDER.O
)NFORMATIONLABEL
3AFETYLABEL
2.3 CORRECT USE
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
8
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
#%
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8
2.4 USE IN HAZARDOUS LOCATIONS
2.4.1 CORRECT USE
4HEUNITISSUITABLEFORWORKINGLIQUIDMATERIALSINACCORDANCEWITHTHECLASSIlCATIONINTO
EXPLOSIONCLASSES
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
!SDElNEDINTHE$IRECTIVE#%!4%8 THEUNITISSUITABLEFORUSEINAREASWHERE
THEREISANEXPLOSIONHAZARD
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#ATEGORY:ONE
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3PECIALIDENTIlCATION
2.4.3 MAXIMUM SURFACE TEMPERATURE
The maximum surface temperature corresponds to the permissible material temperature.
This and the permissible ambient temperature can be found in the„Technical Data“ chapter.
2.4.4 SAFETY INSTRUCTIONS
3AFEHANDLINGOF7!'.%2SPRAYUNITS
-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL
)NANEXPLOSIVEATMOSPHERE
$ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON
$ONOTDROPTHESPRAYGUN
5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL
)GNITIONTEMPERATUREOFTHECOATINGMATERIAL
%NSURETHATTHEIGNITIONTEMPERATUREOFTHECOATINGMATERIALISABOVETHEMAXIMUM
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-EDIUMSUPPORTINGATOMIZING
4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR
#LEANING
)FTHEREAREDEPOSITSONTHESURFACESTHEUNITMAYFORMELECTROSTATICCHARGES&LAMESOR
SPARKSCANFORMIFTHEREISADISCHARGE
2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
2.5 GERMAN REGULATIONS AND GUIDELINES
See chapter 3.3
9
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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!'
10
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
3.3 CE-CONFORMITY
Herewith we declare that the supplied version of
GM 4600AC 16 MPa NPSM1/4“ 0394004
GM 4600AC 25 MPa NPSM1/4“ 0394014
GM 4600AC 0394020
Complies with the following guidelines:
2006/42/EG
94/9/EG
Applied standards, in particular:
DIN EN ISO 12100-1, 2004-04
DIN EN ISO 12100-2, 2004-04
DIN EN ISO 14121,2007-12
DIN EN ISO 3746, 1995-12
DIN EN 1127-1, 2008-02
DIN EN 1953, 1998-12
DIN EN 13463-1, 2002-04
DIN EN ISO 13732-1, 2006-12
Applied national technical standards and specifi cations, in particular: a) BGR 500 b) BGR 500 c) BGR 104 d) BGR 132
Part 2, chap. 2.29„Using coating materials“
Part 2, chap. 2.36 „Working with liquid ejection devices“
Explosion protection rules
Avoiding ignition risks e) BGR 180 Setting up for cleaning with solvents for cleaning workpieces with solvents f ) BGI 740 Painting rooms and equipment g) ZH 1/406 Guidelines for liquid ejection devices
Note: All titles can be ordered from Heymanns Publishing House in Cologne or download from 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:
0394891
11
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
4 DESCRIPTION
4.1 FIELDS 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 PROCESSIBLE 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.
Hot coating substances!
Burns
WARNING
Wear antistatic protective gloves.
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 consult your Wagner branch and/ or the paint manufacturer.
4.2 SCOPE OF DELIVERY
These AirCoat gun is available in two different variants. The nozzle size depends on the paint and on the application. Therefore the air cap and the nozzle are not included in the scope of supply. For a gun accessories look in chapter 9.
4.2.1 VARIANT FOR APPLICATION RANGE UP TO 16 MPA; 160 BAR; 2320 PSI
Qty
1
Part No.
0394004
Description
GM 4600AC 16 MPa; NPSM1/4“ Paint connection
4.2.2 VARIANT FOR APPLICATION RANGE UP TO 25 MPA, 250 BAR, 3625 PSI
Qty
1
Part No.
Description
0394014 GM 4600AC 25 MPa ; NPSM1/4“ Paint connection
4.2.3 STANDARD EQUIPMENTS
The standard equipment includes:
0394004
Qty
1
1
0394014 AirCoat hand gun GM 4600AC
Qty
1
1
Part No.
0394891
394860
Description
CE-conformity
Operating manual German
1 1 see chap. 1 Operating manual for the other language
For special versions the delivery note applies.
12
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
4.2.4 SPRAY GUN CONFIGURATION
A B CCC
GM 4600AC
B_02670
Basis number GM 4600AC
0 3 9 4 0 2 0 -
A B C C C -> Key
1 1 4 1 1 -> For example: Part number
Table A: Maxi. material pression selection
1 160 bar; 16 MPa; 2320 psi
2 250 bar; 25 MPa; 3625 psi
Table B: Air cap selection
1 Suitable for low viscosity paints (red)
2 Suitable for high viscosity paints (blue)
Table CCC: AirCoat nozzle selection ACF3000
CCC = the last three digits of the article number -> 0379CCC
107 1 = Spray angle x 10 = 10 0 . 07 = Diameter of bore in mm/1000 (0.007 mm)
411 4 = Spray angle x 10 = 40 0 . 11 = Diameter of bore in mm/1000 (0.011 mm)
317 3 = Spray angle x 10 = 30 0 . 17 = Diameter of bore in mm/1000 (0.017 mm)
625 6 = Spray angle x 10 = 60 0 . 25 = Diameter of bore in mm/1000 (0.025 mm)
835 8 = Spray angle x 10 = 80 0 . 35 = Diameter of bore in mm/1000 (0.035 mm)
The complete fl at-jet nozzle range is described in chapter 9.2.
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GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
4.3 DATA
4.3.1 MATERIALS OF THE PARTS TRANSPORTING PAINT
Metal
Tungsten carbide Stainless steel 1.4305
Plastics
POM
Stainless steel 1.4301
Stainless steel 1.4104
PTFE
FPM
PA
4.3.2 TECHNICAL DATA
Description
Maxi. air pressure
Maxi. material pressure
Paint connection
Air connection
Filter
Weight
Maxi. temperature material
Maxi. temperature air
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure and 11 MPa; 110 bar; 1549 psi material pressure ***
Units
AirCoat spray gun
0394004 0394014
MPa/ psi/ bar 0.8/ 120/ 8
MPa/ psi/ bar 16/ 2320/ 160 25/ 3625/ 250
Inches
Inches
NPSM1/4
G1/4“
Mesh g/ oz
°C/ °F
°C/ °F dB(A)
100
526 g/ 18.6 oz
55/ 131
43/ 109
< 82
** Filter types see chapter 9.6
*** A rated sound pressure level measured at o.5m distance according to DIN EN ISO 3746-
1995.
Dimensions A
D
C
E
F
G
D
E
Dim.
A
B
C
152
39
-
mm
173
216
48 inches
6.81
8.50
1.89
5.98
1.54
NPSM1/4“
G1/4“ F
G
B_02671
14
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
4.4 FUNCTIONAL DESCRIPTION
4.4.1 DESIGN OF SPRAY GUN
A
J
Part No. DOC394861
H
K
I
B_02672
Description
A Suspension hook
B Fan air regulator
C Tension nut
D Trigger
E Trigger safety
F Air connection
G Paint connection
H Union nut with nozzle guard
I Nozzle / Air cap
J Gun housing
K Filter housing
B
C
E
D
F
G
4.4.2 FUNCTIONS OF THE GUN
Pulling the trigger (D) approximately 1/2 way opens the air valve allowing atomising and shaping-air to fl ow through the air cap. When the trigger is pulled further, more resistance is felt and the material valve is opened. The atomising air control (B) 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).
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GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
5 STARTING UP AND OPERATING
5.1 INSTALLATION AND CONNECTION
5.1.1 TYPICAL AIRCOAT SPRAYING SYSTEM
WARNING
Incorrect installation/operation!
Risk of injury and damage to equipment
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
E D F G
C
B
M
I
K
A
H
J
L
B_02673
A Material pump
B Pressure air shut off valve
C Pressure regulator
D Air pressure regulator with fi lter
E Earthing cable
F Air hose, el. conductive
G AirCoat gun
H
I
J
K
L
M
High-pressure paint hose
High-pressure fi lter/Relief valve
Return
Stand trolley
Suction system
Compressed air main
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.
The operating instructions and the safety regulations for the additional system components used must be read before starting-up.
16
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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.
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
&LUSHTHESPRAYGUNANDPAINTSUPPLYWITHASUITABLECLEANINGAGENT
3)()??'"
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of material
Ensure that the hose material is chemically resistant.
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.
Ensure that the following information can be seen on the highpressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
SIHI_0029_GB
17
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
5.1.5 EARTHING
7!2.).'
$ISCHARGE OF ELECTROSTATICALLY CHARGED COMPONENTS IN ATMO
SPHERESCONTAININGSOLVENTS
%XPLOSIONHAZARDFROMELECTROSTATICSPARKSORmAMES
%ARTHALLUNITCOMPONENTS
%ARTHTHEWORKPIECESBEINGPAINTED
3)()??'"
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.
5.2 PREPARATION OF PAINTS
The viscosity of the paints is of great importance. The best results are usually obtained with paints between 80 and 260 milli Pascal x Sec (mPas).
Please also read the technical data sheet for the paint for optimal processing, viscosity adjustment and intermixing of the material.
18
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
5.3 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.
Relieve the pressure from the spray gun and unit.
Secure the spray gun against actuation.
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
Always point the spray gun down when cleaning.
Ensure that neither paint nor cleaning agent enters the air duct.
SIHI_0005_GB
Air
Material
B_02674
Trigger safety catch in on
(safe) position
19
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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. Insert suitable gun fi lter
5. Place the nozzle into the nozzle seal. Fit the air cap over the nozzle, ensuring that the location fl ats (X) are in line. Fit the union nut with nozzle guard and tighten by hand.
6. Visually check the permissible pressures for all the system components.
7. Make sure that the unit and all other conductive parts within the work area are earthed.
8. Set material pressure 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.
9. Relieve spray gun and unit pressure and secure the spray gun.
B_02261 x
20
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
5.4 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. Set the fl uid pressure to the point where a further increase in fl uid pressure would signifi cantly improve fl uid atomization.
4. Open air pressure controller for the atomizer air and adjust so as to achieve optimal atomization. (The interrelation between spray pattern and atomizer air is shown in the fi gure below).
5. Adjust the pressure to get the optimum spraying fi nish. Relation between spray pattern and shaping air see illustration.
Note:
Repeat point 4 and 5 until the optimum spray pattern is reached (process iterative).
Spray pattern
No atomizing air too little atomizing air
Note
The paint output volume can be changed by:
•
Changing the material pressure or
•
Fitting another fl at jet nozzle (see chap. 5.4.3 and chap. 9).
B_00071 correct amount of air
5.4.2 ADJUSTING THE SPRAY PATTERN
The spray pattern can be adjusted to suit the object being sprayed using the fan air regulator. The illustration below shows the infl uence of the shaping air regulator on the spraying pattern.
Other nozzle sizes can be used to obtain larger or smaller spraying patterns.
Shaping air fully open
Shaping air fully closed
B_02262
21
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
5.4.3 REPLACING AIRCOAT NOZZLE
Defective AirCoat nozzle!
Insufficient paint application quality
CAUTION
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. Secure gun with trigger safety catch.
3. Screw off the union nut (A).
4. Remove air cap (B).
5. Press AirCoat nozzle (C) out of the air cap (B) 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. Fit the air cap (B) over the nozzle (C), ensuring that the location fl ats (X) are in line.
8. Fit the union nut with nozzle guard (A) and tighten by hand.
x
B_02261
A
B
C
D
B_02675
22
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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 recommended by the paint manufacturer.
5.4.5 ELIMINATE NOZZLE CLOGGING
1. Relieve spray gun and unit pressure.
2. Secure gun with trigger safety catch.
3. Unscrew the union nut with nozzle guard (A).
4. Remove air cap (B).
5. Pull out the clogged nozzle (C) from the air cap (B), reverse it and replace it into nozzle seal (D).
6. Fit the air cap (B) over the nozzle (C), ensuring that the location fl ats (X) are in line.
7. Fit the union 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 spray gun and unit pressure.
12. Unscrew the union nut with nozzle guard (A).
13. Remove air cap (B) and reverse nozzle (C) again. Clean nozzle and replace on the nozzle seal (D) in spray position.
14. Fit the air cap (B) over the nozzle (C), ensuring that the location fl ats (X) are in line.
15. Fit the union 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.
B_02261 x
Nozzle in „spray“ position
D
A
B
C
Nozzle in „cleaning“ position
B_02676
23
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
6.0 MAINTENANCE
➞
Observe safety instructions 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
Never immerse the spray gun in cleaning agent.
SIHI_0066_GB
WARNING
Incorrect maintenance/repair!
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.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying out all work.
SIHI_0004_GB
24
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
6.1 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.
Ensure that neither paint nor cleaning agent enters the air duct.
SIHI_0005_GB
7!2.).'
%XPLOSIVEATMOSPHERE
%XPLOSIVEGASESAREPRODUCEDWHENALUMINIUMCOMESINTOCONTACT
WITHHALOGENIZEDHYDROCARBONS
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 spray gun and unit pressure.
2. Secure gun with trigger safety catch.
3. Connect cleaning supply.
4. Remove AirCoat jet nozzle and clean separately (see chapter 5.4.3).
5. Pressurize the cleaning supply to approx. 4 MPa; 40 bar; 580 psi 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.
25
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
6.2 REPLACING THE MATERIAL HOSE OR AIR HOSE
1. Finishing work and cleaning.
2. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
Paint hose
4. Place open-ended wrench SW A on fl ats of paint connection and counter hold.
5. Turn nut to the right with open-ended wrench SW D and unscrew material hose.
Air hose
4. Place open-ended wrench SW D on fl ats of air connection and counter hold.
5. Turn nut to the right with open-ended wrench SW C and unscrew air hose.
6. Assembly:
Fit the material hose respectively air hose by hand and tighten with 2 open-ended wrenches.
Counter hold
D
C
Counter hold
A
B
B_02678
Note:
Do not unscrew the fi lter housing. The nut must only be unscrewed by WAGNER- Service-Agency.
B_02679
Description
GM 4600AC with fi lter NPS1/4“
Key A
SW 17 mm
0.669 inch
Key B
SW 19 mm
0.748 inch
Key C
SW 17 mm
0.669 inch
Key D
SW 14 mm
0.551 inch
26
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
6.3 CHANGING OR CLEANING FILTER INSERT
1. Finishing work and cleaning.
2. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
4. Place open-ended wrench A on fl ats of fi lter housing (30) and counter hold.
5. Turn nut to the right with open-ended wrench B and unscrew pivot joint (67) with material hose.
6. Remove the fi lter insert (64), seal (65) and compression spring (66).
7. Thoroughly clean all parts with cleaning agent.
8. Assembly:
Push cleaned or new fi lter insert (64) with cone upwards into the fi lter housing (30)
9. Insert compression spring (66) into fi lter connection piece (67). Screw on the fi lter connection piece with seal (65) and material hose by hand and tighten using the two open-end wrenches A and B.
Counter hold
A 30
64
65
66
67
B
B_02677
Description
GM 4600AC with fi lter NPS1/4“
Key A
SW 15 mm
0.590 inches
Key B
SW 17 mm
0.669 inches
B_02679
Note:
Do not unscrew the fi lter housing. The nut must only be unscrewed by WAGNER-Service-Agency.
27
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
6.4 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. Loosen screw (22) and remove together with nut (20).
6. Remove trigger (21).
7. Loosen sealing screw (10) with single open-end wrench SW 7 mm; 0.28 inches.
CAUTION
Unsuitable tool!
Damage to seals and sealing surfaces
Do not hold the valve rod with pliers or a similar tool.
SIHI_0006_GB
8. Carefully pull the complete valve rod (B) together with sealing screw out of the gun housing (A) toward the rear.
9. Hold the clamping sleeve (4) with open-end wrench SW 6 mm; 0.24 inches and loosen the collet chuck (18) with socket SW 2 mm; 0.08 inches.
10. Carefully pull the valve rod (34) out toward the front. Replace the relevant parts.
B
5
2
3
4
18
19
10
11
12
34
50
51
52
53
22
21
A
20
B_02680
28
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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.
2. Remove air valve seal (51) and seal (52) and replace with new seals.
3. Screw valve tappet (50) and cover (53) together by hand. Carefully tighten in small increments with open-end wrench SW 7 mm; 0.28 inches and SW
13 mm; 0.51 inches until a slight resistance is perceptible when moving the valve rod (34) in the valve tappet.
Note:
The seal (52) can be pulled out of the cover (53) with the help of an eye bolt.
6.4.3 REPLACING THE ROD SEAL (35)
1. Carefully pull the rod seal (35) out of the gun housing.
2. Clean sealing surfaces in the gun housing.
3. Mount new rod seal (35) to the rod seal tool (84).
Note:
Note installation position of the rod seal (35).
22
84
Spraying direction
35
B_02688
4. Insert rod seal tool (84) together with rod seal (35) into the hole.
5. Fit trigger guard (21) with screw (22) to body of gun and
6. Carefully push the tool with the rod seal (35) over the trigger guard (21) into the recess in the housing.
7. Remove trigger guard (21), screw (22) and rod seal tool (84).
B_02274
50
51
52
53
21
B_02268
6.4.4 ASSEMBLING
1. Fit seal collar (11) to valve rod (34), together with inserted O-ring (12) and sealing screw
(10).
2. Push completely assembled valve tappet (19) onto valve rod (34).
3. Insert preassembled valve rod into the collet chuck (18) as far as the stop.
4. Fix clamping sleeve (4) with wrench size 6 mm; 0.24 inches, screw the preassembled valve rod to the clamping sleeve and tighten. (Socket SW 2 mm; 0.08 inches).
5. Carefully insert the complete valve rod (B) into the gun housing..
6. Screw in sealing screw (10) but do not tighten yet.
7. Position trigger guard (21) and secure with screw (22) and nut (20).
8. Insert compression springs (3) and (2) and screw on the spring cover (5).
9. Carefully tighten the seal collar (11, 12) with the sealing screw (10). Ensure that the trigger guard moves easily.
10. Start-up in accordance with chapter 5.3.
Note:
Only use silicone and resin free grease.
29
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
6.5 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. Finishing work and cleaning.
2. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
4. Unscrew the union nut with nozzle guard (33).
5. Remove air cap (36) and nozzle (13).
6. Carefully release the nozzle seal (17) with the help of a screwdriver.
7. Fit new nozzle seal to valve housing (16).
8. Continue assembly in the reverse order.
16
14 (F)
17
13
36
33
GM 4600AC
B_02681
30
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
6.6 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. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
4. Unscrew the union nut with nozzle guard (33).
5. Remove air cap (36) and nozzle (13) .
6. Remove defective sealing ring (14/F) with the help of pipe tongs or with a large screwdriver.
7. Assembly: Fit new distributor seal (14/F) to air cap (36).
8. Place air cap in body of gun together with sealing ring (14).
9. Attach union nut (33) and screw in until the sealing ring snaps into place in the mounting groove (snap hear able).
10. Demount union nut (33) and air cap (36) and complete spray gun according to paragraph 5.4.3.
/
2
13
36
33
14 (F)
0
1
B_02682
31
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
7 TROUBLE SHOOTING AND SOLUTION
Malfunction
Insuffi cient material discharge
Poor spray pattern
Valve rod leaks (Paint- or air path)
Spray gun will not shut-off correctly
Cause
Nozzle too small
Remedy
Select larger nozzle
Material pressure to low Increase material pressure
Filter of gun or highpressure fi lter at pump clogged
Nozzle is clogged
Clean or replace fi lter
Nozzle cleaning
Valve stem defective
Wrongly adjusted atomizing air
Replace valve rod
Readjust the atomizing air
Nozzle to large Select smaller nozzle
Material pressure to low Increase pressure at pump
Material viscosity to high
Thin material in accordance with the manufacturer‘s instructions
Partial nozzle blockage Nozzle cleaning
Readjust the atomizing air Wrongly adjusted atomizing air
Air cap faulty (blocked holes, damaged seal)
Wrong air cap type
Clean or replace air cap
Replace as required air cap
(solvent / water based)
Paint seal (packing) damaged or worn, valve stem damaged
Adjust or replace packing or replace valve stem complete
Air valve seals damaged Replace air valve seals
Pretension to low
Worn valveseat / valve ball
Re tighten sealing screw
Replace parts
Packing-screw too tight, or packing stuck with dried paint
Replace the seals
See chapter
9
6.1
5.4.5
6.4
5.4.1
9.1
6.4
6.4
6.4
5.4.5
5.4.1
5.4.5
5.4.5
6.4
32
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
9 ACCESSORIES
9.1 ROUND-JET NOZZLE CAP
Part No. DOC394861
9.1
Part No.
Description
0394180 Round-jet nozzle cap
(without nozzle insert)
B_02276
9.1.2
9.1.1
9.1.1 NOZZLE INSERTS RXX
Part No.
0132720
0132721
0132722
0132723
0132724
0132725
0132726
0132727
0132728
0132729
0132730
0132731
Description
Nozzle insert R11
Nozzle insert R12
Nozzle insert R13
Nozzle insert R14
Nozzle insert R15
Nozzle insert R16
Nozzle insert R17
Nozzle insert R18
Nozzle insert R19
Nozzle insert R20
Nozzle insert R21
Nozzle insert R22
Marking Volume fl ow*
11
12
0.16; 160
0.22; 220
13
14
15
16
17
18
19
0.27; 270
0.34; 340
0.38; 380
0.43; 430
0.48; 480
0.53; 530
0.59; 590
20
21
22
0.65; 650
0.71; 710
0.77; 770
Jet ø ** approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
** Jet width in mm; inches at a distance of 30 cm; 11.8 inches from the object and at a pressure of 10 MPa; 100 bar; 1450 ps with synthetic enamel 20 DIN4 - Sek.
B_02277
9.1.2 NOZZLE SCREWED CONNECTION COMPLETE
Part No.
Description
0132922 Nozzle screwed connection complete
B_02278
33
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
9.2 AIRCOAT NOZZLES ACF3000
Part No.
Marking
Diameter of
bore mm; inches
Sprayangle
Recommended edge filter
Use
Natural paint
Transparent lacquer
Oils
B_02280
Synthetic resin paints
PVC paint
Paints
Undercoat
Priming paint
Filler
Filler
Rustproofing paint
Rustproofing paint
Latex paint
34
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
Part No.
Marking
Diameter of
bore mm; inches
Sprayangle
Recommended edge filter
Use
Rustproofing paint
Latex paint
B_02280
Mica paint
Zinc dust coating
Rustproofing paint
Distemper
35
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
9.3 AIR CAPS
Part No.
Description
0394910 Air cap LV complete (red) for low viscosity paints
0394911 Air cap HV complete (blue) for high viscosity paints
9.4 FILTER INSERT
Part No. for 1 piece
Part No. for 10 piece
Filter types
0034383 0097022 Gun fi lter red
Mesh Use for nozzles
200 0.007“ - 0.015“
GM 4600AC
B_02257
B_02256
"?
0043235 0097023 Gun fi lter yellow 100 0.015“ - 0.019“
"?
0034377 0097024 Gun fi lter white 50 0.017“ - 0.021“
"?
9.5 SWIVELS
Part No.
Description
0394933
Set Swivel for paint- (NPSM 1/4“) and for air connection (G1/4“)
B_02689
B_02687
0394928 Swivel for paint connection (NPSM 1/4“)
B_02689
0364938 Swivel for air connection G1/4“
B_02687
36
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
9.6 HOSES
Part No.
Description
0394100 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“; 7.5 m; 24.6 ft; DN 6 mm; ID 0.24 inch; 0.8 MPa; 8 bar; 116 psi
0394101 Hose set AC Material DN4; Air DN6
Consisting of paint- air- and protective hose.
Material:
NPSM1/4“; 7.5 m; 24.6 ft; DN 4 mm; ID 0.16 inch; 27 MPa; 270 bar; 3916 psi
Air:
G1/4“; 7.5 m; 24.6 ft; DN 6 mm; ID 0.24 inch; 0.8 MPa; 8 bar; 116 psi
9987136 Protective hose per meter
9.7 MISCELLANEOUS
Part No.
9997001
Description
Nozzle cleaning brush
0394941 Service-Set GM 4600AC
0394904 Conversion kit 16 MPa; 160 bar; 2320 ps
0394905 Conversion kits 25 MPa; 250 bar; 3625 psi
0367560
9985720
Double connector NPSM1/4“ (outside thread) for paint hose extension
Double nipple G1/4“ (outside thread) for air hose extension
B_02685
B_02686
37
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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
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.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying out all work.
38
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
10.2 SPARE PARTS LIST GM 4600AC
Spare parts list GM 4600AC
16 MPa
Pos
1
K Qty
1
Part No.
0394004
2 1
3 1
4 1
5 1
5 1
6 1
10 1
11 ✭ ◆
12 ✭ ◆
1
1
13 ◆ ● 1
14 ✭ ◆
15 ✭ ◆
16 ✭ ◆
17 ✭ ◆
18
1
1
1
1
1
9999501
9999500
0394256
0394335
-
0394924
0394327
0394328
9971445
0379xxx
0394339
9974245
0394922
0394338
0394330
25 MPa
Part No.
03940014 GM 4600AC; XX MPa; NPSM1/4“
9999501
9999500
0394256
-
0394333
0394924
0394327
0394328
9971445
0379xxx
0394339
9974245
0394922
0394338
Description
Screw spring Material
Screw spring Air
Tension sleeve compl.
Spring cap 16 MPa; 160 bar: 2320 psi
Spring cap 25 MPa; 250 bar: 3625 psi
Air tappet assy.
Sealing screw
Sealing collar
O-ring
AC nozzle (see chapter 9.2)
Sealing ring
O-ring
Valve seat compl.
Nozzle seal
0394330 Chuck
19 1
20 1
21 1
22 1
23 1
24 1
34 ✭ ◆
35 ✭ ◆
1
1
36 ◆ ● 1
36 ◆ ● 1
50 1
0394257
0394318
0394310
0394319
0394334
9935088
0394920
0394323
0394910
0394911
0394257
0394318
0394310
0394319
0394334
9935088
0394920
0394323
0394910
0394911
Valve tappet compl.
Nut
Trigger
Screw
Safety catch
Cylindrical shaft
Valve rod compl.
Valve rod seal
Air cap LV complete (red)
Air cap HV complete (blue)
0394309 0394309 Valve tappet
51 ✭ ◆
52 ✭ ◆
53 ✭ ◆
55
56
●
◆ ●
1
1
1
1
1
0179338
0179395
0394322
0394336
0128327
0179338
0179395
0394322
0394336
0128327
Air valve seal
Seal
Cap
Nozzle body
Sealing nipple
◆ = Wearing part
✭
= Included in service set
●
= Not part of standard equipment for spray gun. Available, however, as additional
extra
39
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
5
6
1
80
5
2
3
B
23
22
82
21
20
55
56
57
58
62
59
63
60
61
14
15
16
13
36
35
24 17
36
64
84
B_02748
Detail B
83
4
82
18
19
10
11
12
34
67
50
51
52
53
66
65
Mounting materials
Pos K
80
●
81 ●
Part No.
9992831
Description
Loctite 542
9992833 Loctite 638 green
82
83
●
●
9992590 Loctite 222
9992698 Vaseline white PHHV II
84 ✭ ● 0394342 Tool valve rod seal
40
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
Spare parts list GM 4600AC
Pos
57
58
59
60
61
62
63
64
K Qty
◆ ● 1
●
◆ ●
●
●
●
◆ ●
◆
1
1
1
1
1
1
1
16 MPa
Part No.
0132516
0132351
0394308
0394337
0132...
0394180
0132922
0043235
25 MPa
Part No.
Description
0132516 Nozzle screwed connection compl.
0132351 Nozzle screwed connection holder
0394308 Union nut
0394337 Nozzle nut
0132...
Nozzle insert R (various dimensions see chapter 9.1.1)
0394180 Round-jet nozzle cap
(see chapter 9.1)
0132922 Nozzle screwed connection compl.
0043235 Filter insert yellow, 100 mesh
(other fi lter types see chapter 9.2)
0128389 Seal 65 ✭ ◆
66 ✭ ◆
67
1
1
0128389
0043590 0043590 Compression spring
1
1
0394610
0394941
0394610
0394941
Pivot joint NPS 1/4“
Service-Set GM 4600AC
◆ = Wearing part
✭
= Included in service set
●
= Not part of standard equipment for spray gun. Available, however, as additional
extra
41
GM 4600AC
EDITION 02/2008
OPERATING MANUAL
Part No. DOC394861
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 58
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
42
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/RDERNUMBER 394861
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