WAGNER AirCoat GM 4100 AC, Operating Manual

Page 1: ...B_02254 GM 4100 AC AirCoat Manual Gun for Flat and Round Jet Nozzles Version 01 2018...

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Page 3: ...or 11 4 1 1 Electrical Devices and Equipment 11 4 1 2 A Safe Work Environment 11 4 1 3 Personnel Qualifications 12 4 2 Safety Instructions for the Personnel 12 4 2 1 Personal Safety Equipment 12 4 2 2...

Page 4: ...ttern 24 7 3 Pressure Relief Work Interruption 24 7 4 Changing AirCoat Nozzle 25 7 4 1 Cleaning AirCoat Nozzle 25 7 4 2 Eliminating Nozzle Clogging 26 8 CLEANING AND MAINTENANCE 27 8 1 Cleaning 27 8 1...

Page 5: ...t 40 13 1 1 Nozzle Inserts RXX 40 13 1 2 Nozzle Screw Joint Complete 40 13 2 AirCoat Nozzles ACF3000 41 13 3 Air caps 42 13 4 Anodized Union Nut 43 13 5 Swivel Joints and Filter 43 13 6 Hoses 44 13 7...

Page 6: ...N THESE INSTRUCTIONS Warning instructions in this manual highlight particular dangers to users and to the device and state measures for avoiding the hazard These warning instructions fall into the fol...

Page 7: ...r pressure tank Personnel qualifications Trained person Is instructed in the tasks assigned to him her the potential risks associated with improper behavior as well as the necessary protective devices...

Page 8: ...his operating manual 2 3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS The device is suitable for use in potentially explosive areas as defined in Directive 2014 34 EU ATEX see Explosion protection marking C...

Page 9: ...This and the permissible ambient temperature can be found in Chapter 5 5 2 Safe Handling of WAGNER Spray Devices Mechanical sparks can form if the device comes into contact with metal In an explosive...

Page 10: ...air 0 8 MPa 115 psi Max p fluid see tension nut Max T fluid 55 C 131 F Wagner International AG Altstaetten Made in Switzerland B_04173 1 2 3 4 6 5 Designation 1 Serial number 2 Maximum air inlet press...

Page 11: ...nd wire connection Keep liquids away from electrical devices 4 1 2 A SAFE WORK ENVIRONMENT Hazard due to dangerous fluids or vapors Severe or fatal injuries due to explosion hazard or inhalation swall...

Page 12: ...ions The device must only be operated maintained and repaired by trained personnel Refer to the operating instructions for information about the required personnel qualifications 4 2 SAFETY INSTRUCTIO...

Page 13: ...29 and 2 36 For shut down devices the examination can be suspended until the next start up In the event of skin injuries caused by lacquer or flushing agents Note the lacquer or flushing agent that yo...

Page 14: ...ture Make sure that the hoses are laid only in suitable places Hoses should not be laid in the following places under any circumstances in high traf c areas on sharp edges on moving parts or on hot su...

Page 15: ...depending on the flushing agent solvent used an explosive mixture may temporarily exist inside the lines and components of equipment Only electrically conductive tanks may be used for cleaning and fl...

Page 16: ...efore all work on the device and in the event of work interruptions Relieve the pressure from the spray gun high pressure hoses and all devices Secure the spray gun against actuation Switch off the en...

Page 17: ...QUIPMENT The spray gun is secured with the locking device E the locking device turned in the spraying direction and fastened in the groove The nozzle holder H has an anti contact guard 5 4 INCLUDED IT...

Page 18: ...Air connection inch G1 4 Filter Mesh see Chapter 13 5 Weight g oz 437 15 4 pH range of the product pH 3 5 9 0 Maximum product temperature C F 55 131 Maximum air temperature C F 43 109 Sound level at...

Page 19: ...reliable state after it is installed and commissioned 6 2 STORAGE CONDITIONS Until the point of assembly the device must be stored in a dry location free from vibrations and with a minimum of dust Th...

Page 20: ...ing 6 4 1 TYPICAL AIRCOAT SPRAYING SYSTEM A B C E D F H G J L K M B_02259 N I Designation Designation A Product pump H High pressure product hose B Compressed air shut off valve I High pressure filter...

Page 21: ...ngs and product hose between the device and the spray gun are suitable for the pressure generated in the device Ensure that the following information can be seen on the high pressure hose manufacturer...

Page 22: ...in the air cap 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 device and all other conductive pa...

Page 23: ...pressure 2 Spray release locking device and pull trigger and at the same time observe how the product is atomizing 3 Set the spray pressure on the product pump to a point where good product atomizatio...

Page 24: ...etween compressed air source and pneumatic pump Outlet equipment return valve mounted between pump and spray gun Pressure relief procedure 1 Close and secure the spray gun 2 Relieve the air and produc...

Page 25: ...3 Unscrew union nut A 4 Remove air cap B 5 Press AirCoat nozzle C out of air cap B by hand and treat with cleaning agent until all remaining paint has been dissolved Assembly 6 Fit nozzle C in nozzle...

Page 26: ...t with nozzle guard A over the air cap B onto the spray gun and tighten by hand 8 Switch the product pressure back on 9 Turn the locking device to the spraying position and briefly pull trigger 10 Whe...

Page 27: ...grounding and all devices ready to use B_02260 Trigger locking device in secured position Air Product 2 Relieve the pressure of the product pressure generator and of the spray gun in accordance with C...

Page 28: ...ry out repairs and replace parts Use only WAGNER original spare parts and accessories Only repair and replace parts that are listed in the Spare parts chapter and that are assigned to the unit Before...

Page 29: ...e of the complete hoses between product pressure generator and application device is reduced due to environmental influences even when handled correctly Check hoses pipes and couplings every day and r...

Page 30: ...ng the size B open end wrench Air hose 4 Place the size D open end wrench on the upper part of the air connection and hold it in place 5 Loosen the air hose s nut with a size C open end wrench Assembl...

Page 31: ...n place 5 Loosen the product hose 33 with a size B open end wrench 6 Place the size B open end wrench on the filter housing 30 and hold it in place 7 Loosen the filter housing 30 with a size A open en...

Page 32: ...he product pressure at pump The spray product viscosity is too high Dilute the spray product in accordance with the manufacturer s instructions The product temperature is too low Nozzle partially clog...

Page 33: ...e assigned to the unit Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun high pressure hoses and all devices Secure the spray gun against act...

Page 34: ...trigger locking device 4 Unscrew spring cap 5 and remove pressure springs 2 and 3 5 Loosen the screw 22 and remove together with the nut 20 6 Remove the trigger 21 7 Loosen the sealing screw 10 using...

Page 35: ...e 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 10 4 2REPLACING THE ROD SEAL 35 1 Carefully pull the rod seal 35 out...

Page 36: ...cap 5 tightening torque 12 Nm 8 85 lb ft 9 Carefully tighten the sealing collar 11 12 over the sealing screw 10 Ensure that the trigger moves smoothly 10 Commissioning in accordance with Chapter 6 8...

Page 37: ...rigger locking device 4 Unscrew the union nut with nozzle guard 33 5 Remove the air cap 36 together with the nozzle 13 6 Remove the defective sealing ring 14 with the help of pipe tongs or with a larg...

Page 38: ...move slightly in its rest position Put the trigger lever locking device into the locking position configure the air product pressure and pull the trigger lever Neither air nor product may leak or esc...

Page 39: ...shing valve pull trigger lever and flush gun or blow out with air Flush the gun without the valve and air cap In doing so you can remove the air connection hose Close the flushing valve When almost no...

Page 40: ...5 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 Nozz...

Page 41: ...28 40 379511 11 50 0 011 0 28 50 379611 11 60 0 011 0 28 60 379113 13 10 0 013 0 33 10 Lacquers 379213 13 20 0 013 0 33 20 Base coat 379313 13 30 0 013 0 33 30 Primer 379413 13 40 0 013 0 33 40 Filler...

Page 42: ...21 80 0 021 0 53 80 379423 23 40 0 023 0 58 40 379623 23 60 0 023 0 58 60 379823 23 80 0 023 0 58 80 379425 25 40 0 025 0 64 40 379625 25 60 0 025 0 64 60 379825 25 80 0 025 0 64 80 379427 27 40 0 02...

Page 43: ...oatings B_03764 13 5 SWIVEL JOINTS AND FILTER Order no Designation 394931 Swivel joint set for product connection NPSM 1 4 and for air connection G1 4 B_02273 394926 Swivel joint for product connectio...

Page 44: ...ID 0 24 inch 1 MPa 10 bar 145 psi 2309635 AC hose set DN4 PN270 1 4 NPS 20 0 m PA T Product 1 4 NPS 20 m 65 6 ft DN 4 ID 0 16 inch 27 MPa 270 bar 3916 psi Air G1 4 20 m 65 6 ft DN 6 mm ID 0 24 inch 1...

Page 45: ...earing parts Wearing parts are not included in the warranty terms Included in service set Notice These parts are not covered by warranty terms Not part of standard equipment available however as addit...

Page 46: ...1 80 83 85 5 Nm 1 3 69 lbft 2 64 55 56 57 58 59 60 61 62 63 Order no Designation 1 1 394012 GM 4100AC XX MPa NPSM1 4 2 1 9999501 Helical spring material 3 1 9999500 Helical spring air 4 1 2312140 Clam...

Page 47: ...09 Valve tappet 51 1 179338 Air valve seal 52 1 179395 Seal 53 1 394322 Cap 55 1 394336 Nozzle body 56 1 128327 Sealing fitting 57 1 132516 Nozzle screw joint complete 58 1 132351 Nozzle screwed conne...

Page 48: ...3 EN ISO 80079 36 2016 EN ISO 13732 1 2008 EN ISO IEC 80079 34 2011 EN 14462 2015 Applied national technical standards and specifications in particular DGUV regulation 100 500 Chapter 2 29 DGUV regula...

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Page 52: ...52 CERTI F I E D ts liquid wagner group com www wagner group com Order no 394821 Edition 01 2018 Document No 11057585 Version I...