WAGNER GA 4000ACIC-R, Translation Of The Original Operating Manual

Page 1: ...B_03045 AirCoat Automatic Spray Gun Version 06 2013 Translation of the Original Operating Manual...

Page 2: ......

Page 3: ...Staff Qualifications 12 4 1 3 Safe Work Environment 12 4 2 Safety Instructions for Staff 13 4 2 1 Safe Handling of WAGNER Spray Devices 13 4 2 2 Grounding the Unit 13 4 2 3 Product Hoses 14 4 2 4 Clea...

Page 4: ...Booth 29 6 1 3 Air Supply 29 6 1 4 Product Supply 29 6 1 5 Grounding the System 30 6 2 Lacquer Preparations 31 6 2 1 Viscosity Conversion Table 31 6 3 Commissioning 32 6 3 1 General Rules for Handlin...

Page 5: ...iscellaneous 53 11 SPARE PARTS 55 11 1 How Can Spare Parts Be Ordered 55 11 2 Spare Parts List for GA 4000ACIC 56 11 3 Service Sets and Spare Parts Groups 58 11 4 Packing Insert GA 4000AC RP 58 11 5 S...

Page 6: ...istics and how to proceed This notice warns you of a hazard Possible consequences of not observing the warning instructions The signal word indicates the hazard level The following are measures which...

Page 7: ...12956 French 2312957 Italian 2312958 Spanish 2312959 Swedish 2316798 Russian 2327992 1 4 ABBREVIATIONS IN THE TEXT Number of pieces Position Marking in the spare parts lists Order No Order number repl...

Page 8: ...REA AirCoat automatic spray gun with the type designation GA 4000ACIC The device is suitable for processing liquid products such as paints and lacquers in accordance with their classification into exp...

Page 9: ...The operating staff have previously been trained on the basis of this operating manual The safety regulations listed in this operating manual must be observed The operating maintenance and repair inf...

Page 10: ...serve safety data sheets maintenance disassembly Lacquer in air outside the defined working area Lacquering outside the defined working area Inhalation of substances hazardous to health Observe workin...

Page 11: ...re there is an explosion hazard European Communities Symbol for explosion protection Device class II Category 2 Zone 1 Ex atmosphere gas Special Notice Maximum product temperature C 80 F 176 Permissib...

Page 12: ...mmissioned if they pose a hazard Must be de energized before work is commenced on active parts Inform staff about planned work Observe electrical safety regulations Ensure that the device is operated...

Page 13: ...orking conditions by an expert e g Wagner Service Technician as often as necessary or at least every 12 months in accordance with the guidelines for liquid ejection devices ZH 1 406 and BGR 500 Part 2...

Page 14: ...goggles protective clothing and gloves as well as hand protection cream if necessary Use a mask or a breathing apparatus if necessary For sufficient health and environmental safety operate the device...

Page 15: ...lowing safety regulations must be observed and followed Safe handling of WAGNER spray devices Mechanical sparks can form if the device comes into contact with metal In an explosive atmosphere Do not k...

Page 16: ...n type AirCoat spraying process Shaping and atomizing air controlled via valve within gun Shaping and atomizing air controlled via valve outside of gun The device is suitable for processing liquid pro...

Page 17: ...Gun Body of GA 4000ACIC Automatic Gun 5 2 4 6 Air Supply Connections Supplementary Component 5 2 4 4 Round Nozzles Supplementary Component 5 2 4 3 Flat Nozzles Supplementary Component 5 2 4 5 Product...

Page 18: ...Operating manual in local language The supplementary components can be used to harmonize and supplement the standard equipment of the automatic gun perfectly to any application depending upon require...

Page 19: ...les Order No Designation 379XXX Chapter 10 contains assistance for selecting nozzles 5 2 4 3 AIRCOAT FLAT JET NOZZLES ACF3000 5 2 4 4 AIRCOAT ROUND JET NOZZLES ACR3000 Order No Designation 2308809 Air...

Page 20: ...tting 6 mm 1 8 0 24 inch 1 8 Standard 9998993 Straight threaded fitting 8 mm 1 8 5 16 1 8 5 2 4 6 AIR SUPPLY CONNECTIONS 5 2 4 7 LOCK PIN Order No Designation 2310534 Complete lock pin Order No Design...

Page 21: ...1 4 Air connection internal thread inch G1 8 Weight standard equipment g 880 oz 31 Maximum product temperature C 80 F 176 Maximum air temperature C 50 F 122 Maximum ambient temperature C 5 40 F 41 104...

Page 22: ...ORDER NUMBER DOC 2312956 5 3 2 MEASUREMENTS AND CONNECTIONS Connection data Base plate to GA 4000ACIC R G1 8 6 mm 0 24 inch control air G1 8 8 mm 0 31 inch atomizing air G1 4 NPS1 4 product mm inch A...

Page 23: ...Stainless steel 1 4310 Stainless steel 1 4305 Stainless steel 1 4104 5 3 3 MATERIALS OF PAINT WETTED PARTS Connection data Base plate to GA 4000ACIC S G1 8 6 mm 0 24 inch control air G1 8 8 mm 0 31 in...

Page 24: ...channel lock pin The device consists of a gun head A gun body B a drive C and a base plate D The air cap G the appropriate nozzle H and various parts for sealing and fastening are attached to the gun...

Page 25: ...uct is applied to the work piece Nozzle 5 4 3 FUNCTIONS OF THE SPRAY GUN 5 4 2 2 MODE C WITH PRODUCT CIRCULATION In this mode of operation the lock pin M must be removed from the left or right product...

Page 26: ...they influence each other during adjustment The product connections and the paint channels in the base plate are arranged so that several guns can run in circulation mode 5 5 SPRAYING PROCESS With th...

Page 27: ...djusted by turning the nozzle nut The multi channel swirl nozzle produces fine paint particles while at the same time reducing their forwards speed and swirling them to produce a rotating motion The r...

Page 28: ...supply G Part recognition H Spray guns I Supply air system and exhaust air system The spray gun must be used a part of an spraying system The spraying system shown in the figure is only one example of...

Page 29: ...ntilation extraction switched on Observe national and local regulations for the outgoing air speed WARNING Bursting hose bursting threaded joints Danger to life from injection of product Ensure that t...

Page 30: ...e equipment Heavy paint mist if grounding is insufficient Risk of poisoning Insufficient paint application quality Ground all device components Ground the work pieces to be coated WARNING Dischargeofe...

Page 31: ...t constant during coating Should you experience application problems please contact the lacquer manufacturer 6 2 LACQUER PREPARATIONS 10 10 0 1 5 16 15 15 0 15 8 17 20 20 0 2 10 18 25 25 0 25 14 12 19...

Page 32: ...of injury Before any work on the device in the event of work interruptions and malfunctions Switch off the energy compressed air supply Relieve the pressure from the spray gun and device Secure the sp...

Page 33: ...air cap Fit the air union nut and tighten by hand 4 Connect control air hose and atomizing air hose to spray gun and to oil free dry air supply 5 Visually check the permissible pressures for all the s...

Page 34: ...lustration below Note Repeat points 4 and 5 until the optimum spray pattern is reached iterative process Spray pattern shapes No shaping air atomizing air Too little shaping air atomizing air Correct...

Page 35: ...he nozzle and in the air cap 8 Screw on union nut A and tighten by hand For disassembly and assembly see AirCoat nozzles section 7 3 TheAirCoatnozzle C canbeplacedintoacleaningsolutionwhichhasbeenreco...

Page 36: ...tch the product pressure back on 9 Spray connect control air hose 10 When the blockage has been flushed out switch off the spray gun 11 Relieve the pressure of gun and device 12 Secure gun remove the...

Page 37: ...ve nozzle insert B with nozzle spanner A 4 Fit new nozzle insert in reverse order see chapter 9 4 Note Flush out clogged round jet nozzle 1 Use nozzle spanner A to loosen nozzle insert B by a half tur...

Page 38: ...aller nozzle see chapter 10 1 Product pressure too low Increase the product pressure at pump The product viscosity is too high Thin product in accordance with the manufacturer s instructions The nozzl...

Page 39: ...ecommissioned the examination can be suspended until the next start up Impurities in the spraying system Spray gun blockage products harden in the spraying system Flush the spray gun and paint supply...

Page 40: ...ontrol air hose 8 Clean outside of spray gun with a cleaning agent recommended by the lacquer manufacturer and dry with a cloth or blow gun Cleaning agent in air duct Functional faults When cleaning a...

Page 41: ...2 Relieve the pressure of gun and device 3 Secure gun remove the control air hose 4 Unscrew union nut A 5 Remove air cap B and nozzle C 6 Release the nozzle seal D with the help of a screwdriver 7 Fi...

Page 42: ...ZLE Unscrew the nozzle by hand Counter hold with a size 13 mm 0 51 inch socket wrench Note The sealing fitting E can be pulled out of the nozzle body using a small eye wood bolt Nozzle wrench D order...

Page 43: ...43 OPERATING MANUAL VERSION 06 2013 ORDER NUMBER DOC 2312956...

Page 44: ...1 DISASSEMBLY OF GA 4000ACIC Note Circulation mode without lock pin Note The complete base plate B does not have to be removed Defective plunger shaft Packing leaking Greater wear on the packing Handl...

Page 45: ...VERSION 06 2013 ORDER NUMBER DOC 2312956 Blow gun Note Pull out distributor seal F using pliers Note Stuck components can be pushed out with a drift 3 mm 0 12 inch in diameter M5 wrench size 3 0 12 in...

Page 46: ...2956 9 5 2 PACKING INSERT GA 4000AC RP Order of seals 1 Sealing set GA4000 packing RP order number 2339140 Material Order No Order No set of 12 packings 1 PTFE GF 2339141 2 PE 2339142 3 PTFE GF 233914...

Page 47: ...956 2 Sealing set GA4000 packing RP special order number 2339810 Material Order No Order No set of 12 packings 1 PTFE 2339143 2 PE 2339142 3 PTFE 2339143 4 PE 2339142 5 PTFE GF 2339141 6 PTFE GF 23391...

Page 48: ...L VERSION 06 2013 ORDER NUMBER DOC 2312956 9 5 3 ASSEMBLY OF GA 4000ACIC General note Lightly grease o rings and sliding surfaces with Vaseline white PHV II Note Put distributor seal G on air cap H an...

Page 49: ...49 B_03068 OPERATING MANUAL VERSION 06 2013 ORDER NUMBER DOC 2312956 Dismount union nut and air cap again M5 wrench size 3 mm 0 12 inch 4 Nm 2 95 lbft Wrench size 12 0 47 inch 10 Nm 7 38 lbft...

Page 50: ...0 011 0 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 Lacquer 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...

Page 51: ...ts 379521 21 50 0 021 0 53 50 Rust proofing paints 379621 21 60 0 021 0 53 60 Glue paints 379821 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 37...

Page 52: ...e insert R15 15 Approx 250 9 84 132725 Nozzle insert R16 16 Approx 250 9 84 132726 Nozzle insert R17 17 Approx 250 9 84 132727 Nozzle insert R18 18 Approx 250 9 84 132728 Nozzle insert R19 19 Approx 2...

Page 53: ...r 3916 psi 9982035 Air hose red outer diameter 6 mm 0 24 inch inner diameter 4 mm 0 16 inch polyamide per meter 9982061 Air hose blue outer diameter 6 mm 0 24 inch inner diameter 4 mm 0 16 inch polyam...

Page 54: ...NUAL VERSION 06 2013 ORDER NUMBER DOC 2312956 Order No Designation 2314079 Cefla adapter plate 380942 Rotary gun holder standard 380945 Rotary holder 40 40 5 380943 Complete swivel drive 380944 Cross...

Page 55: ...any queries Type of delivery normal mail express delivery air freight courier etc Identification in spare parts lists Explanation of column labeling in the following spare parts lists Wearing part No...

Page 56: ...2 39 19 20 B_03070 33 34 11 1 Nm 0 74 lbft Locite 243 1 2 25 Nm 18 44 lbft 25 Nm 18 44 lbft 10 Nm 7 38 lbft 37 37 4 Nm 2 95 lbft 21 3 Nm 2 21 lbft 3 40 41 42 43 1a OPERATING MANUAL VERSION 06 2013 ORD...

Page 57: ...516 Standard packing 16a 1 2338601 Packing insert GA 4000AC RP 17 1 2314277 Piston housing IC 18 4 2308292 Socket cap screw 19 1 2310534 Complete product channel lock pin 20 1 2307873 O ring 21 1 2307...

Page 58: ...1 3 PE sealing washer 2 2339142 4 Housing insert 1 5 Housing screw 1 6 Pressure disk 1 2338567 7 O ring 1 9974196 8 O ring 1 367528 9 O ring 1 2338570 10 Mobilux EP 2 grease 1 9998808 11 Vaseline whit...

Page 59: ...NG MANUAL VERSION 06 2013 ORDER NUMBER DOC 2312956 11 5 SEALING SET GA 4000 PACKING RP AND RP SPECIAL Packing insert GA 4000AC RP Order No Designation Consisting of spare parts items 2339140 Sealing s...

Page 60: ...er than the address of the purchaser We do not provide warranty for damage that has been caused or contributed to for the following reasons Unsuitable or improper use faulty assembly or commissioning...

Page 61: ...DIN EN ISO 14462 2010 DIN EN 4413 2011 DIN EN ISO 80079 34 2012 Identification 12 4 NATIONAL TECHNICAL SPECIFICATIONS EC Certificate of Conformity The CE certificate of conformity is enclosed with th...

Page 62: ...trielles wagner france fr Netherlands WAGNER SPRAYTECH Benelux BV Zonnebaan 10 NL 3542 EC Utrecht Telephone 31 0 30 241 4155 Telefax 31 0 30 241 1787 E Mail info wsb wagner nl Italy WAGNER COLORA S r...

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Page 64: ...CERTI F I E D Order No 2312956 Germany Phone Fax E mail Switzerland Phone Fax...