WAGNER GM 4100AC Operating Manual

Translation of the original
Operating manual
GM 4100AC
Edition 12/2008
AirCoat Spray gun
for flat - and round jet nozzles
B_02254
II 2G X (Atex 95)
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
Contents
1
1.1
1.2
ABOUT THESE INSTRUCTIONS
Languages
Warnings, notes and symbols in these instructions
5
5
5
2
2.1
2.1.1
2.1.2
2.1.3
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.5
GENERAL SAFETY INSTRUCTIONS
Safety instructions for the operator
Electrical equipment
Personnel qualifications
A safe work environment
Safety instructions for staff
Safe handling of WAGNER spray units
Earth the unit
Paint hoses
Cleaning
Handling hazardous liquids, varnishes and paints
Touching hot surfaces
Correct use
Use in hazardous locations
Correct use
Explosion protection identification
Maximum surface temperature
Maximum surface temperature
German regulations and guidelines
6
6
6
6
6
6
7
7
7
8
8
8
8
9
9
9
9
9
9
3
3.1
3.2
3.3
PRODUCT LIABILITY AND WARRANTY
Important notes on product liability
Warranty
CE-conformity
10
10
10
11
4
4.1
4.1.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.3
4.3.1
4.3.2
4.4
4.4.1
4.4.2
DESCRIPTION
Fields of application, using in accordance with the instructions
Processing materials
Extent of delivery
Variant for application range up to 16 MPa; 160 bar; 2320 psi
Variant for application range up to 25 MPa, 250 bar, 3625 psi
Standard equipments
Spray gun configuration
Data
Materials of the parts transporting paint
Technical data
Functional description
Design of spray gun
Functions of the gun
12
12
12
12
12
12
12
13
14
14
14
15
15
15
5
5.1
5.1.1
5.1.2
5.1.3
5.1.4
STARTING UP AND OPERATING
Installation and connection
Typical AirCoat spraying system
Ventilation of the spray booth
Air supply
Fluid (paint) hoses
16
16
16
17
17
17
3
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
Contents
5.1.5
5.2
5.3
5.3.1
5.3.2
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
Earthing
Preparation of paints
Start up
General rules for handling the spray gun
Preparation for starting up
Works
Start-up for spraying AirCoat
Adjusting the spray pattern
Replacing AirCoat nozzle
Cleaning aircoat nozzle
Eliminate nozzle clogging
18
18
19
19
20
21
21
21
22
23
23
6.0
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.5
6.6
MAINTENANCE
Finishing work and cleaning
Replacing the material hose or air hose
Changing or cleaning Filter insert
Replacing parts on the valve rod
Disassembling
Replacement of valve rocker seals
Replacing the rod seal (35)
Assembling
Replacing the nozzle seal
Replacing the „air“ sealing ring
24
25
26
27
28
28
29
29
29
30
31
7
TROUBLE SHOOTING AND SOLUTION
32
9
9.1
9.1.1
9.1.2
9.2
9.3
9.4
9.5
9.6
ACCESSORIES
Round-jet nozzle cap
Nozzle inserts RXX
Nozzle screwed connection complete
AirCoat nozzles ACF3000
Air caps
Swivels and filter
Hoses
Miscellaneous
33
33
33
33
34
36
36
37
37
10
10.1
10.2
SPARE PARTS
How to order spare parts?
Spare parts list GM 4100AC
38
38
39
4
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
1
ABOUT THESE INSTRUCTIONS
4HISOPERATINGMANUALCONTAINSINFORMATIONONTHEOPERATIONREPAIRANDMAINTENANCEOF
THEUNIT
œ !LWAYSOBSERVETHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY
AGREEMENT
1.1
LANGUAGES
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE
0ART.O
,ANGUAGE
'ERMAN
394820
%NGLISH
&RENCH
2301121
$UTCH
)TALIAN
2301118
3PANISH
$ANISH
2301125
3WEDISH
1.2
0ART.O
394821
2301122
2301119
2301129
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
Danger - imminent danger. Non-observance will result
in death, serious injury and serious material damage.
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level.
SIHI_0100_GB
œThe measures for preventing the hazard and its consequences.
WARNING
Warning - possible danger. Non-observance can result
in death, serious injury and serious material damage.
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level.
SIHI_0103_GB
œThe measures for preventing the hazard and its consequences.
CAUTION
Caution - a possibly hazardous situation. Non-observance can result in minor injury.
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level.
œThe measures for preventing the hazard and its consequences.
SIHI_0101_GB
Caution - a possibly hazardous situation. Non-observance can cause material damage.
SIHI_0102_GB
CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word
points out the hazard level.
œThe measures for preventing the hazard and its consequences.
Note - provide information on particular characteristics and how to proceed.
5
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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 %NSURE THAT THERE ARE NO IGNITION SOURCES SUCH AS NAKED mAME GLOWING WIRES OR HOT
SURFACESINTHEVICINITY$ONOTSMOKE
2.2
SAFETY INSTRUCTIONS FOR STAFF
œ !LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
œ !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
6
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
2.2.1
SAFE HANDLING OF WAGNER SPRAY UNITS
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning agents:
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
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.
œ Ensure that the unit is always earthed.
œ Earth the work pieces to be coated.
œ Ensure that all persons inside the working area are earthed, e.g. that they are wearing
antistatic shoes.
œ When spraying, wear antistatic gloves to earth yourself via the spray gun handle.
2.2.3
œ
œ
œ
œ
PAINT HOSES
%NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
%NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
%NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE
n -ANUFACTURER
n 0ERMISSIBLEOPERATINGOVERPRESSURE
n $ATEOFMANUFACTURE
4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN
-/HM
7
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON
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
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
2.4
USE IN HAZARDOUS LOCATIONS
2.4.1
CORRECT USE
4HEUNITISSUITABLEFORWORKINGLIQUIDMATERIALSINACCORDANCEWITHTHECLASSIlCATIONINTO
EXPLOSIONCLASSES
2.4.2
EXPLOSION PROTECTION IDENTIFICATION
As defined in the Directive 94/9/CE (ATEX 95), the unit is suitable for use in areas where
there is an explosion hazard.
II 2G X
CE:
Ex:
II:
2:
G:
X:
Communautés Européennes
Symbol for explosion protection
Unit class II
Category 2 (Zone 1)
Ex-atmosphere gas
See: "Special Notes" in the operating manual
2.4.3
MAXIMUM SURFACE TEMPERATURE
X: The maximum surface temperature corresponds to the permissible material temperature. This and the permissible ambient temperature can be found in the Technical Data.
2.4.4
MAXIMUM SURFACE TEMPERATURE
3AFEHANDLINGOF7!'.%2SPRAYUNITS
-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL
)NANEXPLOSIVEATMOSPHERE
œ $ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON
œ $ONOTDROPTHESPRAYGUN
œ 5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL
)GNITIONTEMPERATUREOFTHECOATINGMATERIAL
œ %NSURETHATTHEIGNITIONTEMPERATUREOFTHECOATINGMATERIALISABOVETHEMAXIMUM
SURFACETEMPERATURE
-EDIUMSUPPORTINGATOMIZING
œ 4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR
#LEANING
)F THERE ARE DEPOSITS ON THE SURFACES THE UNIT MAY FORM ELECTROSTATIC CHARGES &LAMES OR
SPARKSCANFORMIFTHEREISADISCHARGE
œ 2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
2.5
GERMAN REGULATIONS AND GUIDELINES
see chapter 3.3
9
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
3.3
CE-CONFORMITY
Herewith we declare that the supplied version of
GM 4100AC 16 MPa
GM 4100AC 25 MPa
Complies with the following guidelines:
98/37/EG
94/9/EG
Applied standards, in particular:
DIN EN ISO 12100-1, 2004-04
DIN EN ISO 14121,2007-12
DIN EN ISO 12100-2, 2004-04
DIN EN ISO 3746, 1995-12
DIN EN 1127-1, 2008-02
DIN EN 13463-1, 2002-04
DIN EN 1953, 1998-12
DIN EN ISO 13732-1, 2006-12
Applied national technical standards and specifications, in particular:
a)
b)
c)
d)
e)
BGR 500
BGR 500
BGR 104
BGR 132
BGR 180
f ) BGI 740
g) ZH 1/406
Part 2, Chap. 2.29„Using coating materials“
Part 2, Chap. 2.36„Working with liquid ejection devices“
Explosion protection rules
Avoiding ignition risks
Setting up for cleaning with solvents for cleaning workpieces with
solvents
Painting rooms and equipment
Guidelines for liquid ejection devices
Note: All titles can be ordered from Heymanns Publishing House in Cologne or of the
Internet download.
CE Certificate of Conformity
The certificate is enclosed with this product.The certificate of conformity can be reordered
from your WAGNER representative, quoting the product and serial number.
Part number:
394891
11
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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
PROCESSING 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. If you want to spray other working materials than the aforementioned, turn please to a Wagner agency.
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:
4.2
Please contact your local WAGNER dealer and the paint manufacturer if you encounter application
problems.
EXTENT 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
Part-No.
Description
1
394002
GM 4100AC 16 MPa; NPSM1/4“ Paint connection
4.2.2
VARIANT FOR APPLICATION RANGE UP TO 25 MPA, 250 BAR, 3625 PSI
Qty
Part-No.
Description
1
394012
GM 4100AC 25 MPa ; NPSM1/4“ Paint connection
4.2.3
STANDARD EQUIPMENTS
The standard equipment includes:
394002
394012
AirCoat hand gun GM 4100AC
Qty
Qty
Part-No.
Description
1
1
394891
CE-conformity
1
1
394820
1
1
see chap. 1
Operating manual German
Operating manual for the other language
For special versions the delivery note applies.
12
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
4.2.4
SPRAY GUN CONFIGURATION
A
B
CCC
B_02663
Basis number GM 4100AC
0
3
9
4
0
1
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 = 100. 07 = diameter of bore in mm/1000 (0.007 mm)
411
4 = spray angle x 10 = 400. 11 = diameter of bore in mm/1000 (0.011 mm)
317
3 = spray angle x 10 = 300. 17 = diameter of bore in mm/1000 (0.017 mm)
625
6 = spray angle x 10 = 600. 25 = diameter of bore in mm/1000 (0.025 mm)
835
8 = spray angle x 10 = 800. 35 = diameter of bore in mm/1000 (0.035 mm)
The complete flat-jet nozzle range is described in chapter 9.2.
13
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
4.3
DATA
4.3.1
MATERIALS OF THE PARTS TRANSPORTING PAINT
Metal
Plastic
Tungsten carbide
Stainless steel 1.4305
POM
FPM
Stainless steel 1.4301
Stainless steel 1.4104
PTFE
PA
4.3.2
TECHNICAL DATA
AirCoat spray gun
Description
Units
394002
394012
Maxi. air inlet pressure
MPa/ psi/ bar
0.8/ 120/ 8
Maxi. material pressure
MPa/ psi/ bar
16/ 2320/ 160
25/ 3625/ 250
Paint hose connection
Inches
NPSM1/4
Air connection
Inches
G1/4“
Filter
Mesh
100
Weight
g/ oz
437/ 15.4
pH range of the material
pH
3.5 - 9.0
Maxi. temperature material
°C/ °F
55/ 131
Maxi. temperature air
°C/ °F
43/ 109
Sound level at 0.3 MPa; 3 bar; 43.5
dB(A)
< 82
psi air pressure and 11 MPa; 110
bar; 1549 psi material pressure ***
** Filter types see chapter 9.6
*** A rated sound pressure level measured at 0.5 m distance according to DIN EN ISO 37461995.
C
A
D
Dim.
mm
inch
A
173
6.81
B
206
8.11
C
48
1.89
D
152
5.98
E
39
1.54
F
-
NPSM1/4“
G
-
G1/4“
E
B
Dimensions
G
B_02258
F
14
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
4.4
FUNCTIONAL DESCRIPTION
4.4.1
DESIGN OF SPRAY GUN
B
C
A
J
I
E
D
H
L
F
K
B_02255
G
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
L
Handle tube
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 flow 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 flowing 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).
15
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
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
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
E
D
F
G
C
B
M
I
K
H
A
J
L
B_02259
G
AirCoat gun
A
Paint-pump
H
HV-paint hose
B
Compressed air shut off valve
I
HV-filter/Relief valve
C
Pressure regulator
J
Relief
D
Air pressure regulator with filter
K
Stand trolley
E
Earthing cable
L
Suction system
Air hose, el. conductive
M
Compressed air main
F
The pray gun GM 4100AC must be used a part of a spraying system. The spraying system
shown in the figure is only one example of an 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
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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.
-orœ 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 filter 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 finished piece.
5.1.4
FLUID (PAINT) HOSES
CAUTION
Impurities in the spraying system!
Spray gun blockage, materials harden in the spraying system
œ Flush the spray gun and paint supply with a suitable cleaning agent.
SIHI_0001_GB
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of material
œEnsure that the hose material is chemically resistant.
œEnsure 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.
œEnsure that the following information can be seen on the highpressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
SIHI_0029_GB
17
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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
œEarth all unit components.
œEarth 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 spraying results are obtained
with values 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
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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:
œSwitch off the energy/compressed air supply.
œRelieve the pressure from the spray gun and unit.
œSecure the spray gun against actuation.
œBy 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
œAlways point the spray gun down when cleaning.
œEnsure that neither paint nor cleaning agent enters the air duct.
SIHI_0005_GB
Trigger safety catch in on
(safe) position
Air
B_02260
Material
19
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
5.3.2
PREPARATION FOR STARTING UP
1.
2.
3.
4.
5.
Secure the spray gun.
Connect material hose to the spray gun and material supply system.
Connect air hose to spray gun and to oil-free, dry air supply with regulator.
Insert suitable gun filter.
Place the nozzle into the nozzle seal. Fit the air cap over the nozzle, ensuring that the
location flats (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
x
B_02261
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.
20
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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 fluid pressure to the point where a further increase in fluid pressure would
significantly improve fluid 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
figure below).
5. Use the shaping air controller on the gun to adjust the shaping air to atomizer air ratio,
until the optimal spray pattern is achieved.
Note:
Repeat point 4 and 5 until the optimum spray pattern is reached (process iterative).
Spray pattern
B_00071
No atomizing air
Too little atomizing air
Correct amount of air
Note
The paint output volume can be changed by:
Changing the material pressure or
Fitting another flat jet nozzle (see chap. 5.4.3 and chap. 9).
•
•
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 influence 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
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
5.4.3
REPLACING AIRCOAT NOZZLE
CAUTION
Defective AirCoat nozzle!
Insufficient paint application quality
œDo not use sharp-edged objects to treat hard metal on the AirCoat nozzle.
SIHI_0020_GB
1.
2.
3.
4.
5.
Relieve spray gun and unit pressure.
Secure gun with trigger safety catch.
Screw off the union nut (A).
Remove air cap (B).
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 flats (X) are in line.
8. Fit the union nut with nozzle guard (A) and tighten by hand.
x
B_02261
D
B
C
A
B_02263
22
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
5.4.4
CLEANING AIRCOAT NOZZLE
For disassembly and assembly of AirCoat nozzles see chapter 5.4.3.
The AirCoat nozzle (C) can be placed into a cleaning solvent which has been recommended by the paint manufacturer.
5.4.5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
ELIMINATE NOZZLE CLOGGING
Relieve spray gun and unit pressure.
Secure gun with trigger safety catch.
Unscrew the union nut with nozzle guard (A).
Remove air cap (B).
Pull out the clogged nozzle (C) from the air cap (B), reverse it and replace it into nozzle
seal (D).
Refit air cap (B) on the nozzle (C), ensuring that the location flats (X) are in line.
Fit the union nut with nozzle guard (A) over the air cap (B) onto the spray gun and
tighten by hand.
Switch the material pressure back on.
Turn the safety catch to the spraying position and briefly pull trigger.
When the blockage has been flushed out secure the gun with safety catch.
Relieve spray gun and unit pressure
Unscrew the union nut with nozzle guard (A).
Remove air cap (B) and reverse nozzle (C) again. Clean nozzle and replace on the nozzle
seal (D) in spray position.
Refit air cap (B) on the nozzle (C), ensuring that the location flats (X) are in line.
Fit the union nut with nozzle guard (A) over the air cap (B) onto the spray gun and
tighten by hand.
Switch the material pressure and the air pressure back on.
x
B_02261
Nozzle in „spray“ position
D
B
C
A
B_02264
Nozzle in „cleaning“ position
23
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
6.0
MAINTENANCE
➞ Observe general 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
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 interrup tions:
- 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
24
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
6.1
FINISHING WORK AND CLEANING
DANGER
Exploding gas/ air mixture!
Danger to life from flying parts and burns
œNever spray into a closed container.
œEarth the container.
SIHI_0008_GB
CAUTION
Cleaning agent in the air duct!
Functional faults caused by swollen seals
œAlways point the spray gun down when cleaning.
œEnsure 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 flushing or cleaning solvent with this gun or
any system components.
1.
2.
3.
4.
5.
Relieve spray gun and unit pressure.
Secure gun with trigger safety catch.
Connect cleaning supply.
Remove AirCoat nozzle and clean separately (see chap 5.4.3).
Pressurize the cleaning supply to approx. 4 MPa; 40 bar; 580 psi and thoroughly flush
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
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
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.
Material hose
4. Place open-ended wrench SW A on flats 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 flats 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.
D
Counter hold
C
Counter hold
A
Note:
Do not unscrew the filter
housing. The nut must only be
unscrewed by WAGNER- Service-Agency.
B
B_02265
B_02266
Description
Wrench A
Wrench B
Wrench C
GM 4100AC with filter NPS1/4“
SW 17 mm
0.669 inches
SW 19 mm
SW 17 mm
0.748 inches 0.669 inches
Wrench D
SW 14 mm
0.551 inches
26
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
6.3
1.
2.
3.
4.
5.
6.
7.
8.
9.
CHANGING OR CLEANING FILTER INSERT
Finishing work and cleaning.
Relieve spray gun and unit pressure.
Secure gun with trigger safety catch.
Place open-ended wrench A on flats of filter housing (30) and counter hold.
Turn nut to the right with open-ended wrench B and unscrew pivot joint (32) with
material hose.
Remove the material filter (31).
Clean the filter housing (30), filter socket (32) and edge filter with cleaning agent.
Assembly:
Fit the cleaned or new edge filter (31) into the filter socket (32).
Fit filter socket with the material hose by hand and tighten with 2 open-ended
wrenches.
30
Counter hold
A
32
31
B_02272
B
27
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
6.4
REPLACING PARTS ON THE VALVE ROD
6.4.1
1.
2.
3.
4.
5.
6.
7.
DISASSEMBLING
Finishing work and cleaning.
Relieve spray gun and unit pressure.
Secure gun with trigger safety catch.
Unscrew spring cover (5) and remove compression springs (2) and (3).
Loosen screw (22) and remove together with nut (20).
Remove trigger (21).
Loosen sealing screw (10) with single open-end wrench SW 7 mm; 0.28 inches.
CAUTION
Unsuitable tool!
Damage to seals and sealing surfaces
œDo 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
A
3
20
21
4
18
19
22
10 12
11
34
50
51
B_02267
52
53
28
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
6.4.2
REPLACEMENT OF VALVE ROCKER SEALS
1. Support valve tappet (50) with single open-end wrench SW 13 mm; 0.51
inch and unscrew cover (53) with single open-end wrench SW 7 mm; 0.28
inch.
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 inch and SW
13 mm; 0.51 inch 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
50
51
52
53
B_02274
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).
22
84
35
Note:
Note installation position of
the rod seal (35).
21
Spraying direction
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_02268
6.4.4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ASSEMBLING
Fit seal collar (11) to valve rod (14), together with inserted O-ring (12) and sealing screw (10).
Push completely assembled valve tappet (19) onto valve rod (14).
Insert preassembled valve rod into the collet chuck (18) as far as the stop.
Fix clamping sleeve (4) with wrench size 6 mm; 0.24 inch, screw the preassembled valve rod to the clamping
sleeve and tighten. (Socket SW 2 mm; 0.079 inch)
Carefully insert the complete valve rod (B) into the gun housing.
Screw in sealing screw (10) but do not tighten yet.
Position trigger guard (21) and secure with screw (22) and nut (20).
Insert compression springs (3) and (2) and screw on the spring cover (5).
Carefully tighten the seal collar (11, 12) with the sealing screw (10). Ensure that the trigger guard moves
easily.
Start up in accordance with chapter 5.3.
Note:
Only use silicone and resin free grease.
29
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
6.5
REPLACING THE NOZZLE SEAL
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.
œReplace the nozzle seal if the sealing surface is damaged.
SIHI_0021_GB
1.
2.
3.
4.
5.
6.
7.
8.
Finishing work and cleaning.
Relieve spray gun and unit pressure
Secure gun with trigger safety catch.
Unscrew the union nut with nozzle guard (33).
Remove air cap (36) and nozzle (13).
Carefully release the nozzle seal (17) with the help of a screwdriver.
Fit new nozzle seal to valve housing (16).
Continue assembly in the reverse order.
14 (F)
16
17
13
36
33
B_02269
30
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
6.6
REPLACING THE „AIR“ SEALING RING
CAUTION
Forming air and atomizer air not separate!
Poor spray pattern
Spray jet cannot be adjusted
œTreat the distributor seal (F) with care.
SIHI_0030_GB
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Finishing work and cleaning.
Relieve spray gun and unit pressure.
Secure gun with trigger safety catch.
Unscrew the union nut with nozzle guard (33).
Remove air cap (36) and nozzle (13).
Remove defective sealing ring (14/F) with the help of pipe tongs or with a large
screwdriver.
Assembling: Fit new distributor seal (14/F) to air cap (36).
Place air cap in body of gun together with sealing ring (14).
Attach union nut (33) and screw in until the sealing ring snaps into place in the
mounting groove (snap hearable).
Demount union nut (33) and air cap (36) and complete spray gun according to
paragraph 5.4.3.
13
?
?
36
33
14 (F)
?
?
B_02270
31
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
7
TROUBLE SHOOTING AND SOLUTION
Functional fault
Cause
Remedy
Insufficient material
discharge
Nozzle too small
Select larger nozzle
Poor spray pattern
See in chapter
9
Material pressure to low Increase material pressure
Filter of gun or highpressure filter at pump
clogged
Clean or replace filter
Nozzle is clogged
Nozzle cleaning
Valve stem defective
Replace valve rod
Wrongly adjusted
atomizing air
Readjust the atomizing air
Nozzle to large
Select smaller nozzle
6.1
5.4.5
6.4
5.4.1
9
Material pressure to low Increase pressure at pump
Valve rod leaks (Paint- or
air path)
Spray gun will not shut-off
correctly
Material viscosity to
high
Dilute spraying material acc. to
manufacturer‘s instructions
Partial nozzle blockage
Nozzle cleaning
5.4.5
Wrongly adjusted
atomizing air
Readjust the atomizing air
5.4.1
Air cap faulty (blocked
holes, damaged seal)
Clean or replace air cap
5.4.5
Wrong air cap type
Replace as required air cap
(solvent / water based)
4.2.4
Paint seal (packing)
Adjust or replace packing or
damaged or worn, valve replace valve stem complete
stem damaged
6.4
Air valve seals damaged Replace air valve seals
6.4
Pretension to low
Re tighten sealing screw
Worn valveseat / valve
ball
Replace parts
Packing-screw too tight, Replace the seals
or packing stuck with
dried paint
6.4
6.4
32
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
9
ACCESSORIES
9.1
ROUND-JET NOZZLE CAP
9.1
Part No.
Description
394180
Round-jet nozzle cap
(without nozzle insert)
9.1.2
B_02276
9.1.1
9.1.1
NOZZLE INSERTS RXX
Part No.
Description
Marking
Volume flow*
Jet-ø**
132720
Nozzle insert R11
11
0.16; 160
approx. 250; 9.84
132721
Nozzle insert R12
12
0.22; 220
approx. 250; 9.84
132722
Nozzle insert R13
13
0.27; 270
approx. 250; 9.84
132723
Nozzle insert R14
14
0.34; 340
approx. 250; 9.84
132724
Nozzle insert R15
15
0.38; 380
approx. 250; 9.84
132725
Nozzle insert R16
16
0.43; 430
approx. 250; 9.84
132726
Nozzle insert R17
17
0.48; 480
approx. 250; 9.84
132727
Nozzle insert R18
18
0.53; 530
approx. 250; 9.84
132728
Nozzle insert R19
19
0.59; 590
approx. 250; 9.84
132729
Nozzle insert R20
20
0.65; 650
approx. 250; 9.84
132730
Nozzle insert R21
21
0.71; 710
approx. 250; 9.84
132731
Nozzle insert R22
22
0.77; 770
approx. 250; 9.84
B_02277
* Volume flow l/min; cc/min water at approx 10 MPa; 100 bar; 1450 psi.
** Jet width in mm; inch at a distance of 30 cm; 11.8 inch from the object and at a pressure
of 10 MPa; 100 bar; 1450 psi synthetic resin paint 20 DIN4 - sec.
9.1.2
NOZZLE SCREWED CONNECTION COMPLETE
Part No.
Description
132922
Nozzle screwed connection complete
B_02278
33
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
9.2
AIRCOAT NOZZLES ACF3000
B_02280
0.007-0.18
Sprayangle
Recommended edge filter
Use
Natural paint
0
10
0
379207
07/20
0.007-0.18
20
379209
09/20
0.009-0.23
200
379309
09/30
0.009-0.23
300
379409
09/40
0.009-0.23
400
379509
09/50
0.009-0.23
500
379609
09/60
0.009-0.23
600
379111
11/10
0.011-0.28
100
0
379211
11/20
0.011-0.28
20
379311
11/30
0.011-0.28
300
379411
11/40
0.011-0.28
400
379511
11/50
0.011-0.28
500
379611
11/60
0.011-0.28
600
379113
13/10
0.013-0.33
100
0
379213
13/20
0.013-0.33
20
379313
13/30
0.013-0.33
300
379413
13/40
0.013-0.33
400
379513
13/50
0.013-0.33
500
379613
13/60
0.013-0.33
600
379813
13/80
0.013-0.33
800
379115
15/10
0.015-0.38
100
379215
15/20
0.015-0.38
200
379315
15/30
0.015-0.38
300
379415
15/40
0.015-0.38
400
379515
15/50
0.015-0.38
500
379615
15/60
0.015-0.38
600
379815
15/80
0.015-0.38
800
379217
17/20
0.017-0.43
200
379317
17/30
0.017-0.43
300
379417
17/40
0.017-0.43
400
379517
17/50
0.017-0.43
500
379617
17/60
0.017-0.43
600
379817
17/80
0.017-0.43
800
Transparent lacquer
Oils
Synthetic resin paints
PVC paint
Paints
Undercoat
Priming paint
Filler
100 mesh
07/10
Diameter of
bore
mm; inches
200 mesh
379107
Marking
Filler
Rustproofing paint
Rustproofing paint
Latex paint
60 mesh
Part No.
34
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
B_02280
379219
Marking
19/20
Diameter of
bore
mm; inches
0.019-0.48
Sprayangle
Recommended edge filter
Use
Rustproofing paint
Latex paint
0
20
0
379319
19/30
0.019-0.48
30
379419
19/40
0.019-0.48
400
379519
19/50
0.019-0.48
500
379619
19/60
0.019-0.48
600
379819
19/80
0.019-0.48
800
379221
21/20
0.021-0.53
200
379421
21/40
0.021-0.53
400
379521
21/50
0.021-0.53
500
379621
21/60
0.021-0.53
600
379821
21/80
0.021-0.53
800
379423
23/40
0.023-0.58
400
379623
23/60
0.023-0.58
600
379823
23/80
0.023-0.58
800
379425
25/40
0.025-0.64
400
379625
25/60
0.025-0.64
600
379825
25/80
0.025-0.64
800
379427
27/40
0.027-0.69
400
379627
27/60
0.027-0.69
600
379827
27/80
0.027-0.69
800
379429
29/40
0.029-0.75
400
379629
29/60
0.029-0.75
600
379829
29/80
0.029-0.75
800
379431
31/40
0.031-0.79
400
379631
31/60
0.031-0.79
600
379831
31/80
0.031-0.79
800
379435
35/40
0.035-0.90
400
379635
35/60
0.035-0.90
600
379835
35/80
0.035-0.90
800
Mica paint
Zinc dust coating
Rustproofing paint
Distemper
60 mesh
Part No.
35
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
9.3
AIR CAPS
Part No.
Description
394910
Air cap LV assy. (red) for low viscosity paints
394911
Air cap HV assy. (blue) for high viscosity paints
B_02257
B_02256
9.4
SWIVELS AND FILTER
Part No.
Description
394931
Set swivel for paint connection and- (NPSM 1/4“) and
air connection. (G1/4“)
B_02273
394926
Swivel for paint connection (NPSM 1/4“)
with filter 100 mesh
B_02275
364938
Swivel for air connection G1/4“
B_02687
3204605
Filter for swivel 100 mesh
"?
3204604
Filter for swivel 60 mesh
"?
9999002
Filter for swivel 200 mesh
"?
36
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
9.5
HOSES
Part No.
Description
394100
Hose set AC Material DN3; Air DN6
Consisting of: paint- air- and protective hose.
Paint:
NPS1/4“; 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
394101
Hose set AC Material DN4; Air DN6
Consisting of: paint- air- and protective hose..
Paint:
NPS1/4“; 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
9.6
MISCELLANEOUS
Part No.
Description
9997001
Nozzle cleaning brush
394940
Service-Set GM 4100AC
394904
Conversion kit 16 MPa; 160 bar; 2320 ps
394905
Conversion kit 25 MPa; 250 bar; 3625 psi
367560
Double connector NPSM1/4“ (outside thread)
for paint hose extension
B_02685
9985720
Double nipple G1/4“ (outside thread)
for air hose extension
B_02686
37
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
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
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 interrup tions:
- 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
38
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
10.2
SPARE PARTS LIST GM 4100AC
Spare parts list GM 4100AC
16 MPa
Part No.
Pos
K Qty
1
1
394002
2
1
9999501
25 MPa
Part No.
3940012
Description
GM 4100AC; XX MPa; NPSM1/4“
9999501
Screw spring Material
3
1
9999500
9999500
Screw spring Air
4
1
394256
394256
Tension sleeve compl.
5
1
394335
-
Spring cap 16 MPa; 160 bar: 2320 psi
5
1
-
394333
Spring cap 25 MPa; 250 bar: 3625 psi
1
394924
394924
Air tappet complete
6
8
◆
1
2311320
2311320
Valve rod unit assy.
10
1
394327
394327
Sealing screw
11 ✭ ◆
12 ✭ ◆
1
394328
394328
Sealing collar
1
9971445
9971445
O-ring
1
0379xxx
0379xxx
AC nozzle (see chapter 9.2)
14 ✭ ◆
15 ✭ ◆
1
394339
394339
Sealing ring
1
9974245
9974245
O-ring
16 ✭ ◆
17 ✭ ◆
1
394922
394922
Valve seat compl.
1
394338
394338
Seal Nozzle
18
1
394330
394330
Chuck
19
1
394257
394257
Valve tappet compl.
20
1
394318
394318
Nut
21
1
394310
394310
Trigger
22
1
394319
394319
Screw
23
1
394334
394334
Safety catch
1
1
9935088
3204605
9935088
3204605
32
1
394340
394340
Cylindrical shaft
Edge filter 100 mesh
(other sizes see chapter 9.4)
Filter socket NPSM 1/4“
34 ✭ ◆
35 ✭ ◆
1
394920
394920
Valve rod compl.
1
1
1
394323
394910
394911
394323
394910
394911
Valve rod seal
Air cap LV compl. (red)
Air cap HV compl. (blue)
1
394309
394309
Valve tappet
13
◆ ●
24
31
36
36
50
◆
◆ ●
◆ ●
◆ = Wearing part
✭ = Included in service set
● = Not part of standard equipment for spray gun. Available, however, as additional
extra
39
EDITION 12/2008
GM 4100AC
PART NO. DOC394821
OPERATING MANUAL
55
5
1
62
56
57
58
59
60
80
5
61
6
63
2
3
8
82
A
14
20
22
21
36
15
16
23
13
35
17
24
Detail A
36
31
4
18
32
19
10
82
50
51
11
12
84
B_02747
34
52
53
Mounting materials
Pos
K
Part No.
Description
80
●
9992831
Loctite 542
81
●
9992833
Loctite 638 green
82
●
9992590
Loctite 222
83
●
9992698
Vaseline white PHHV II
84
✭●
394342
Tool valve rod seal
40
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
Spare parts list GM 4100AC
16 MPa
Part No.
Pos
K Qty
51 ✭ ◆
1
179338
52 ✭ ◆
53 ✭ ◆
25 MPa
Part No.
179338
Description
Air valve seal
1
179395
179395
Seal
1
394322
394322
Cap
◆●
1
1
1
1
1
1
1
394336
128327
132516
132351
394308
394337
132...
394336
128327
132516
132351
394308
394337
132...
62
●
1
394180
394180
63
◆●
1
1
132922
394940
132922
394940
Nozzle body
Sealing nipple
Nozzle screw connection compl.
Nozzle screwed connection holder
Union nut
Nozzle nut
Nozzle insert R (various dimensions
see chapter 9.1.1)
Round-jet nozzle cap
(see chapter 9.1)
Nozzle screw connection compl.
Service-Set GM 4100AC
55
56
57
58
59
60
61
●
◆●
◆●
●
●
●
◆ = Wearing part
✭ = Included in service set
● = Not part of standard equipment for spray gun. Available, however, as additional
extra
41
EDITION 12/2008
PART NO. DOC394821
GM 4100AC
OPERATING MANUAL
Germany
J. WAGNER GmbH
Otto-Lilienthal-Str. 18
Postfach 1120
D- 88677 Markdorf
Telephone: +49 7544 5050
Telefax: +49 7544 505200
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]
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]
Denmark
WAGNER Industrial Solution Scandinavia AB
Viborgvej 100, Skoergoer
DK- 8600 Silkeborg
Telephone: +45 702 00245
Telefax: +45 868 56027
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]
France
J. WAGNER France S.A.R.L.
Parc de Gutenberg - Bâtiment F8
8, Voie la Cardon
F- 91127 Palaiseau-Cedex
Telephone: +33 1 825 011 111
Telefax: +33 1691 946 55
E-Mail: [email protected]
Netherlands
WAGNER SPRAYTECH Benelux BV
Zonnebaan 10
NL- 3542 EC Utrecht
Italy
WAGNER COLORA S.r.l
Via Fermi, 3
I- 20040 Burago di Molgora (MI)
Telephone: +31 (0) 30 241 4155
Telefax: +31 (0) 30 241 1787
E-Mail: [email protected]
Telephone: +39 039 625021
Telefax: +39 039 6851800
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]
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]
Sweden
WAGNER Industrial Solutions Scandinavia AB
Skolgaten 61
SE- 56831 Skillingaryd
Telephone: +46 (0) 421 500 20
Telefax: +46 (0) 370 798 48
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]
Czechoslovakia
WAGNER s.r.o.
Nedasovská Str. 345
15521 Praha 5 - Zlicin
Telephone: +42 (0) 2 579 50 412
Telefax: +42 (0)2 579 51 052
E-Mail: [email protected]
USA
WAGNER Systems Inc.
300 Airport Road, unit 1
Elgin, IL 60123 USA
Telephone: +1 630 503 2400
Telefax: +1 630 503 2377
E-Mail: [email protected]
42
ED
FI
CERT
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/RDERNUMBER 394821
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