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

Page 1: ...Version 05 2018 GA 4000ACIC S GA 4000ACIC R AirCoat Automatic spray gun II 2G X B_06647...

Page 2: ......

Page 3: ...cal Devices and Equipment 12 4 1 2 A Safe Work Environment 13 4 1 3 Personnel Qualifications 13 4 2 Safety Instructions for the Personnel 14 4 2 1 Personal Safety Equipment 14 4 2 2 Safe Handling of W...

Page 4: ...ng to Spray with the AirCoat 36 7 2 2 Adjusting the spray pattern 37 7 2 3 Pressure Relief Work Interruption 37 7 2 4 Changing AirCoat nozzle 38 7 2 5 Cleaning AirCoat nozzle 38 7 2 6 Eliminating Nozz...

Page 5: ...le attachment 57 13 3 1 RXX Nozzle inserts 58 13 3 2 Nozzle screw joint complete 58 13 4 Hoses 58 13 5 Miscellaneous 59 14 SPARE PARTS 60 14 1 How can spare parts be ordered 60 14 2 Spare Parts List f...

Page 6: ...MBOLS IN 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...

Page 7: ...ian 2364607 Italian 2312958 Spanish 2312959 Additional languages on request or at www wagner group com 1 4 ABBREVIATIONS Order No Order number Spare part Marking in the spare parts lists Position Numb...

Page 8: ...assigned to him her the potential risks associated with improper behavior as well as the necessary protective devices and measures Electrician Can assess the work assigned to him her and detect possi...

Page 9: ...The device is suitable for use in potentially explosive areas as defined in Directive 2014 34 EU see Explosion protection marking Chapter 3 1 2 4 PROCESSIBLE WORKING MATERIALS Top coat lacquers prime...

Page 10: ...permissible ambient temperature can be found in the Technical Data chapter Safe Handling of WAGNER Spray Devices Mechanical sparks can form if the device comes into contact with metal In an explosive...

Page 11: ...psi 250 bar MAX PRESSURE FLUID 80 C 176 F MAX PRESSURE AIR 0 6 MPa 90 psi 6 bar MAX TEMPERATURE AIR 50 C 125 F SERIAL NO IC XXXXX J WAGNER AG CH 9450 ALTST TTEN MADE IN SWITZERLAND 1 2 3 4 5 B_06637 D...

Page 12: ...ating mode and ambient influences May only be maintained by skilled electricians or under their supervision With open housings the mains voltage poses a danger Operate device in accordance with the sa...

Page 13: ...must not exceed 100 M Protective clothing including gloves must comply with EN 1149 5 The measured insulation resistance must not exceed 100 M Ensure that there are no ignition sources such as naked...

Page 14: ...ue to dangerous fluids or vapors Serious or fatal injuries due to inhalation swallowing or contact with the skin or eyes When preparing or working with lacquer and when cleaning the device follow the...

Page 15: ...nsurance regulation 100 500 section 2 29 and 2 36 For shut down devices the examination can be suspended until the next start up Carry out the work steps as described in the Pressure relief chapter if...

Page 16: ...manufacture 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...

Page 17: ...ining halogenated hydrocarbons Take measures for workplace safety see Chapter 4 1 2 When commissioning or emptying the device please note that depending upon the coating product used depending on the...

Page 18: ...change is necessary contact WAGNER Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are assigned to the unit Do not use any defective components Exclusively use accessor...

Page 19: ...ck pin The device consists of a gun head A gun body B drive C and base plate D The air cap G appropriate nozzle H and various parts for sealing and fastening are attached to the gun head A The product...

Page 20: ...ce Close The piston is relieved and the product valve closes due to the pressure spring which presses against the product valve tappet The air valve is then closed again with a spring force and mechan...

Page 21: ...de of operation the left or the right product channel in the gun head A is locked by the lock pin M and the product entrance ME is always on the opposite side B_03069 ME B D A 4x 4 Nm 2 95 lbft M 5 2...

Page 22: ...ns a soft optimum spray jet is achieved with help of the atomizing air which has a pressure of 0 05 0 25 MPa 0 5 2 5 bar 7 2 36 psi This eliminates most overlapping problems in the peripheral zones Th...

Page 23: ...fine paint particles while at the same time reducing their forwards speed and swirling them to produce a rotating motion The result is a soft extremely well atomized spraying cloud B_00023 Nozzle nut...

Page 24: ...dy of GA 4000ACIC automatic gun 5 3 4 6 Air supply connections supplementary components 5 3 4 4 Round nozzles supplementary components 5 3 4 3 Flat nozzles supplementary components 5 3 4 5 Product con...

Page 25: ...ee Chap 1 3 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 u...

Page 26: ...ed for low viscosity products B_03049 2313493 Air cap LA plus bronze B_03098 2340299 Air cap LV plus blank B_04231 5 3 4 3 ACF3000 AIRCOAT FLAT JET NOZZLES Order No Designation 379XXX A selection guid...

Page 27: ...98090 Straight threaded fitting 6 mm 1 8 0 24 inch 1 8 standard B_00507 9998993 Straight threaded fitting 8 mm 1 8 5 16 1 8 B_00508 5 3 4 7 SHUTTER PIN Order No Designation 2310534 Complete lock pin B...

Page 28: ...re MPa psi bar 0 6 87 6 Maximum product pressure MPa psi bar 25 3625 250 Product connection internal thread inch G1 4 Air connection internal thread inch G1 8 Weight G oz 880 31 Maximum product temper...

Page 29: ...ECTIONS F F E M8 A D C B B_03486 M5 3 2 Pos mm inch A 129 5 08 B 47 1 85 C 77 5 3 05 D 55 2 17 E 18 0 1 0 71 0 004 F 18 0 1 0 71 0 004 Connection data B_3487 M M CA AA Base plate to GA 4000ACIC R G1 8...

Page 30: ...648 M8 3 2 Pos mm inch A 129 5 08 B 52 2 04 C 61 2 40 D 37 5 1 48 E 18 0 1 0 71 0 004 F 18 0 1 0 71 0 004 Connection data B_06649 M M CA AA Base plate to GA 4000ACIC S G1 8 6 mm 0 24 inch control air...

Page 31: ...The air temperature at the storage location must be between 20 C and 60 C 4 F and 140 F The relative air humidity at the storage location must be between 10 and 95 without condensation 6 3 INSTALLATIO...

Page 32: ...ystem E Reciprocator 6 4 2 VENTILATION OF THE SPRAY BOOTH Operate the device in a spray booth approved for the working materials or Operate the device on an appropriate spraying wall with the ventilat...

Page 33: ...CHECKS Carry out safety checks in accordance with Chapter 8 2 3 6 7 LACQUER PREPARATIONS The viscosity of the lacquer is of great importance The best spraying results are obtained with values between...

Page 34: ...0 4 17 18 22 50 50 0 5 19 22 24 60 60 0 6 21 26 27 70 70 0 7 23 28 30 80 80 0 8 25 31 34 90 90 0 9 28 32 37 100 100 1 30 34 41 120 120 1 2 33 41 49 140 140 1 4 37 45 58 160 160 1 6 43 50 66 180 180 1...

Page 35: ...the air cap Fit the 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...

Page 36: ...stance during setting up installation and maintenance work Ensure that The regular safety checks are carried out in accordance with Chapter 8 2 3 commissioning is carried out in accordance with Chapte...

Page 37: ...zes can be mainly used to obtain larger or smaller spray patterns B_03053 Shaping air throttle fully open Shaping air throttle fully closed 7 2 3 PRESSURE RELIEF WORK INTERRUPTION The pressure must al...

Page 38: ...described above if pressure relief is specified in the instructions 7 2 4 CHANGING AIRCOAT NOZZLE NOTICE Defective AirCoat nozzle Insufficient paint application quality Do not use sharp edged objects...

Page 39: ...by hand 8 Switch 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 g...

Page 40: ...re gun remove the control air hose 3 Remove nozzle insert B with nozzle spanner A 4 Fit new nozzle insert in reverse order see Chapter 8 2 6 Note Flush out clogged round jet nozzle 1 Use nozzle spanne...

Page 41: ...Always point the spray gun down when cleaning Ensure that neither paint nor flushing agent enters the air duct Never immerse the spray gun in cleaning agent The spray gun and the device must be cleane...

Page 42: ...epair and replace parts that are listed in the Spare parts chapter and that are assigned to the unit Before all work on the device and in the event of work interruptions Switch off the energy and comp...

Page 43: ...necessary Additionally the operator must regularly check the complete hoses for wear and tear as well as for damage at intervals that he she has set Records of these checks must be kept The complete h...

Page 44: ...19 mm 0 75 inch 6 Assembly Fit product hose by hand and tighten with 2 open ended wrenches 8 2 5 REPLACING THE NOZZLE SEAL NOTICE Shaping air and atomizer air not separate Poor spray pattern Spray je...

Page 45: ...ody Poor spray pattern Handle the nozzle body A with care B_00542 B_00543 E D B C B_03060 A Unscrew the nozzle by hand Hold in position with a size 13 mm 0 51 inch socket wrench Note The sealing fitti...

Page 46: ...worn Replace the nozzle 7 2 4 Product pressure too low Increase the product pressure at pump The product viscosity is too high Dilute the spray product in accordance with the manufacturer s instructi...

Page 47: ...er and that are assigned to the unit Before all work on the device and in the event of work interruptions Switch off the energy and compressed air supply Relieve the pressure from the spray gun and de...

Page 48: ...NOTICE Defective plunger shaft Packing leaking Greater wear on the packing Handle the plunger shaft K with care The plunger shaft has the function of a sliding surface B_03065 K Note Circulation mode...

Page 49: ...NUMBER DOC 2312956 GA 4000ACIC B_03066 F 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 M5 wrench size 3 mm 0 12 inch M5 wre...

Page 50: ...1 2 3 4 6 5 8 8 7 SW15 5 Nm Torx TX40 Order of seals 1 Sealing set GA 4000 packing RP Order No 2339140 Product Order No Order No set of 12 packings 1 PTFE GF 2339141 2 PE 2339142 3 PTFE GF 2339141 4...

Page 51: ...CIC 2 Sealing set GA 4000 packing RP special Order No 2339810 Product 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 2339141 7...

Page 52: ...h 4 Nm 2 95 lbft 25 Nm 8 85 lbft K H G SW 12 0 47 inch 25 Nm 8 85 lbft General note Lightly grease o rings and sliding surfaces with Vaseline white PHV II Note Put distributor seal G on air cap H and...

Page 53: ...53 VERSION 05 2018 ORDER NUMBER DOC 2312956 GA 4000ACIC Dismount union nut and air cap again M5 wrench size 3 mm 0 12 inch 4 Nm 2 95 lbft Wrench size 12 mm 0 47 inch 10 Nm 7 38 lbft B_06661...

Page 54: ...ction and testing depends on the repair carried out and must be documented by the repair personnel 12 DISPOSAL When the equipment must be scrapped please differentiate the disposal of the waste materi...

Page 55: ...40 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 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 3...

Page 56: ...paints 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 8...

Page 57: ...0 011 0 28 20 2396188 11 30 S2 0 011 0 28 30 2368879 11 40 S2 0 011 0 28 40 2368896 11 60 S2 0 011 0 28 60 2368876 11 80 S2 0 011 0 28 80 2368880 13 40 S2 0 013 0 33 40 2368897 13 60 S2 0 013 0 33 60...

Page 58: ...i synthetic resin paint 20 DIN4 seconds 13 3 2NOZZLE SCREW JOINT COMPLETE Order No Designation B_00076 132922 Nozzle screw joint complete 13 4 HOSES Order No Designation 9984405 High pressure hose M16...

Page 59: ...6 Double fitting M16x1 5 for extension for product hose 367560 Double fitting NPSM 1 4 for product hose extension 380941 Standard mounting bracket 180 mm 16 mm 7 1 inches 0 63 inch B_00510 2314079 Cef...

Page 60: ...l mail express delivery air freight courier etc Identification in spare parts lists Explanation of column labeling in the following spare parts lists Wearing part Note These parts are not covered by w...

Page 61: ...18 17 16 16a 14 13 12 10 9 8 7 6 22 23 24 25 26 15 27 28 29 32 39 19 20 B_06662 33 34 11 1 Nm 0 74 lbft Loctite 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...

Page 62: ...2313516 Packing insert GA 4000AC standard version can only be replaced completely 16a 1 2338601 Packing insert GA 4000AC RP 17 1 2314277 Piston housing IC 18 4 2308292 Socket cap screw 19 1 2310534 C...

Page 63: ...4 2338657 Service set Spray gun body GA 4000ACIC RP 8 9 11 14 33 34 2314355 Service set Base plate GA 4000ACIC 23 24 25 2322532 Seal set GA 4000ACIC EPDM 40 41 42 14 4 PACKING INSERT GA 4000AC RP Spar...

Page 64: ...12 13 3 6 5 8 1 12 13 12 13 12 13 11 11 12 12 10 5 Nm Torx TX40 SW15 14 5 SEALING SET GA 4000 PACKING RP AND RP SPECIAL Order No Designation Consisting of spare parts items 2339140 Sealing set GA 400...

Page 65: ...9 36 2016 EN 1953 2013 EN ISO IEC 80079 34 2011 EN ISO 13732 1 2008 EN 14462 2015 EN 1127 1 2011 Applied national technical standards and specifications in particular DGUV regulation 100 500 Chapter 2...

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Page 68: ...68 CERTI F I E D ts liquid wagner group com www wagner group com Document No 11093207 Version G Order No 2312956 Edition 05 2018...