WAGNER GM 4700AC-H, Translation Of The Original Operating Manual

Page 1: ...GM 4700AC GM 4700AC H II 2G X Atex 95 B_02376 AirCoat spray gun for flat and round jet nozzles Version 09 2011 Translation of the original Operating manual ...

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Page 3: ...3 Maximum surface temperature 9 2 4 4 Safety instructions 9 2 5 Reference to German regulations and guidelines 9 3 GUARANTEE AND CONFORMITY DECLARATIONS 10 3 1 Important notes on product liability 10 3 2 Guarantee claim 10 3 3 CE Declaration of Conformity 11 4 DESCRIPTION 12 4 1 Fields of application use in accordance with the instructions 12 4 1 1 Processable materials 12 4 2 Scope of delivery 12...

Page 4: ... 3 Changing or cleaning filter insert 27 6 4 Replacing parts on the valve rod 28 6 4 1 Disassembly 28 6 4 2 Replacement of valve tappet seals 29 6 4 3 Replacing rod seal 35 29 6 4 4 Assembly 30 6 5 Replacing the nozzle seal 31 6 6 Replacing the air sealing ring 32 6 7 Changing round jet sealing nipple 33 7 TROUBLE SHOOTING AND RECTIFICATION 34 8 ACCESSORIES 35 8 1 Round jet nozzle cap 35 8 1 1 Noz...

Page 5: ...lt in death or serious injury Warning possible imminent danger Non observance may result in death or serious injury Caution a possibly hazardous situation Non observance may result in minor injury Note gives information about particular characteristics and how to proceed Notice a possibly hazardous situation Non observance can cause material damage This information warns you of a hazard Possible c...

Page 6: ...parts Inform staff about planned work Observe electrical safety regulations Ensure that the device is operated and repaired only by trained persons Makesurethatthefloorintheareawhereyouareworkingiselectrostaticallyconductive in accordance with EN 61340 4 1 Ensure that all persons within the working area wear electrostatically conductive shoes Ensure that during spraying persons wear electrostatica...

Page 7: ... forces Ensure that you have secure footing when operating the spray gun Only hold the spray gun briefly in any one position Depending on the electrostatic charge and the flow speed of the spray an electrostatic charge may occur in the equipment In the event of discharge this may result in the formation of sparks or flames Ensure that the unit is grounded for every spraying operation Ground the wo...

Page 8: ...s solvents and cleaning agents being used Take the specified protective measures in particular wear safety goggles protective clothing and gloves as well as hand protection cream if necessary Use a mask or breathing apparatus if necessary For sufficient health and environmental safety Operate the unit in a spray booth or on a spraying wall with the ventilation suction switched on Wear suitable pro...

Page 9: ...t with metal In an explosive atmosphere Do not knock or push the unit against steel or rusty iron Do not drop the spray gun Use only tools that are made of a permitted material Ignition temperature of the coating material Ensure that the ignition temperature of the coating material is above the maximum surface temperature Medium supporting atomizing To atomize the material use only weakly oxidizin...

Page 10: ... location other than the address of the purchaser We do not provide guarantee for damage that has been caused or contributed to for the following reasons Unsuitable 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 ...

Page 11: ...al technical standards and specifications in particular a BGR 500 Part 2 chapter 2 36 Working with liquid ejection devices b BGR 500 Part 2 chapter 2 29 Working with coating materials c BGR 104 Explosion protection rules d TRBS 2153 Avoiding ignition risks e BGI 740 Painting rooms and equipment f ZH 1 406 Guidelines for liquid ejection devices Note All titles can be ordered from Heymanns Publishin...

Page 12: ...ation of Conformity 1 2311729 Operating manual German 1 See Chapter 1 Operating manual in local language 1 394335 Spring cap 16 MPa 160 bar 2320 psi For special versions the delivery note applies 4 2 2 STANDARD EQUIPMENT 4 1 FIELDS OF APPLICATION USE IN ACCORDANCE WITH THE INSTRUCTIONS 4 1 1 PROCESSABLE MATERIALS Top coat paints primer paints corrosion protection solvents textured paints lyes stai...

Page 13: ...nlet Inch NPSM1 4 Air connection Inch G1 4 Filter Mesh 50 100 150 200 Weight g oz 595 g 20 9 oz pH range of the material pH 3 5 9 0 Maximum material temperature C F 55 131 80 176 Maximum air temperature C F 43 109 Sound level at 0 3 MPa 3 bar 43 5 psi air pressure and 11 MPa 110 bar 1549 psi material pressure dB A 82 Spring cap type 16 MPa 160 bar 2320 psi is included Filter types see paragraph 8 ...

Page 14: ...d with released locking device E the air valve opens first Atomizing air flows through air connection F to air cap I The material valve opens first if approx 1 2 of the trigger guard s path is covered The quantity of air for the atomization of the jet spray is preset via the external air automatic controller The spray pattern can be adjusted using shaping air regulator B The spray gun is secured w...

Page 15: ...ould be happy to assist you in creating a spraying system solution that meets your individual needs You must familiarize yourself with the operating instructions and the safety regulations for all additional system components before starting with commissioning 5 1 INSTALLATION AND CONNECTION G AirCoat gun H High pressure paint hose electrically conductive I High pressure filter fluid pressure rele...

Page 16: ... flammable vapor mixtures Risk of poisoning and burns Operate the unit in a spray booth approved for the working materials or Operate the unit on an appropriate spraying wall with the ventilation suction switched on Observe national and local regulations for the outgoing air speed WARNING Bursting hose bursting threaded joints Danger to life from injection of material Ensure that the hose material...

Page 17: ...quipment WARNING 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 Discharge of electrostatically charged components in atmospheres containing solvents Explosion hazard from electrostatic sparks or flames Ground all device components Ground the work pieces to be coated ...

Page 18: ...essure is still not completely relieved after this If nozzle is clogged slowly loosen the union nut to release the remaining pressure If material hose is obstructed slowly loosen the hose connections to release the remaining pressure Note Always follow the procedure described above if pressure relief is specified in the instructions Please read the general safety instructions in chapter 2 WARNING ...

Page 19: ... intermixing of the material 5 2 PREPARATION OF PAINTS 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 agents enter the air duct WARNING Unintentional commissioning Risk of injury Before any work on the device in the event of work interruptions and functional faults Switch off the ...

Page 20: ... with the flattened parts X of the nozzle and of 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 unit and all other conductive parts within the work area are grounded 8 Set operating pressure at 100 bar 10 MPa 1450 psi and use a suitable medium to check that connections do not leak Not...

Page 21: ...lat jet nozzle see chap 5 4 3 and chap 8 5 4 1 START UP FOR SPRAYING AIRCOAT 5 4 2 ADJUSTING THE SPRAY PATTERN 1 Start up with material supply set to approx 8 MPa 80 bar 1160 psi operating pressure 2 Spray release locking device and pull trigger and at the same time check the atomization 3 Set the fluid pressure on the fluid pump to the point where a good fluid atomization is achieved 4 Open the a...

Page 22: ...zzle C out of air cap B by hand and treat with cleaning solvent until all remaining paint has been dissolved 6 Assembly Place AirCoat nozzle C in nozzle seal D 7 Fit air cap B over nozzle C Take care with the flattened parts X of the nozzle and of the air cap 8 Fit the union nut with nozzle guard A and tighten by hand CAUTION Defective AirCoat nozzle Insufficient paint application quality Do not u...

Page 23: ... guard A over air cap B onto the spray gun and tighten by hand 8 Switch the material pressure back on 9 Turn the locking device to the spraying position and briefly pull trigger 10 When the blockage has been flushed out secure the gun with the locking device 11 Relieve the pressure of gun and unit 12 Unscrew the union nut with nozzle guard A 13 Remove air cap B and push AirCoat nozzle C out by han...

Page 24: ... device Have repairs and part replacements be carried out by specially trained staff or a WAGNER service center Beforeallworkontheunitandintheeventofworkinterruptions 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 CAUTION Cleaning agent in t...

Page 25: ...nit 7 Secure gun with locking device 8 Clean the spray gun body with a cleaning agent recommended by the manufacturer and dry with a cloth or blow gun 6 1 DECOMMISSIONING AND CLEANING NOTICE 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 agents enter the air duct DANGER Exploding gas air ...

Page 26: ...ose 4 Place size D open ended wrench on the flats of the air connection and counter hold it 5 Loosen the air hose s nut with a size C open ended wrench Assembly 1 Fit the material hose or air hose by hand and tighten with the two open ended wrenches Note Do not unscrew the filter housing The upper nut may only be unscrewed by WAGNER Service Agency Description Spanner A Spanner B Spanner c Spanner ...

Page 27: ...pper filter connection 5 Pull filter insert 64 out of the filter housing 67 6 Thoroughly clean all parts with cleaning agent Assembly 7 Push cleaned or new filter insert 64 with opening downwards into filter housing 67 8 Insert filter housing 67 into the turning handle screw in manually with the turning handle and tighten Spanner A Spanner B size 13 mm wrench size 17 mm wrench 0 51 inch 0 67 inch ...

Page 28: ... screw 22 and remove together with nut 20 6 Remove trigger guard 21 7 Loosen sealing screw 10 with a size 7 mm 0 28 inch single open end wrench 8 Carefully pull valve rod unit B together with sealing screw 10 rearwards out of gun housing A 9 Hold tension sleeve 4 with a size 6 mm 0 24 inch open end wrench and loosen collet chuck 18 with a size 5 mm 0 20 inch open end wrench 10 Carefully pull valve...

Page 29: ...ith new seals For the assembly of the air valve seal 51 a special tool order number 179989 is necessary 3 Screw valve tappet 50 and cover 53 together by hand In small increments carefully tighten with a size 7 mm 0 28 inch open end wrench and a size 13 mm 0 51 inch wrench until a slight resistance is perceptible when moving the valve rod 34 in the valve tappet Note Seal 52 can be pulled out of cov...

Page 30: ...to stop 5 Fix clamping sleeve 4 with size 6 mm 0 24 inch wrench screw the preassembled valve rod to the clamping sleeve and tighten size 5mm 0 20 inch open end wrench tightening moment 5 1 Nm 3 69 lbft Note reference dimension 6 Carefully insert complete valve rod B into the gun housing 7 Screw in sealing screw 10 but do not tighten yet 8 Position trigger guard 21 and secure with screw 22 and nut ...

Page 31: ...rew 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 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 nozz...

Page 32: ...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 together with sealing ring 14 F in gun body 9 Attach union nut 33 and screw in until the sealing ring snaps into place in the mounting groove audible snap 10 Demount union nut 33 and air cap 36 and complete spray gun according to paragraph 5 4 3 6 6 REPLACING THE AIR SEALING RING C...

Page 33: ...LE Unscrew the nozzle by hand Note The sealing nipple E can be pulled out of the nozzle housing using a small eye wood bolt Nozzle wrench D order number 128901 Eject with 1 5 mm 0 06 inch Ø pin Counter hold with a size 13 mm 0 51 inch socket spanner NOTICE Defective nozzle body Poor spray pattern Handle the nozzle body A with care ...

Page 34: ...e at pump The material viscosity is too high Thin material in accordance with the manufacturer s instructions The nozzle is partially clogged Nozzle cleaning 5 4 5 The drilled holes in the air cap are damaged or clogged Clean or replace the air cap 5 4 5 Incorrectly selected air cap Insert the correct air cap solvent water based paint 5 4 5 Valve rod leaks paint path or air path The seals on the v...

Page 35: ...x 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 Volumetric flow in l min cc min water at 10 MPa 100 bar 1450 psi Jet diameter in mm inches at a distance of 30 cm 11 8 inche...

Page 36: ...ERATING MANUAL VERSION 09 2011 ORDER NUMBER DOC2311730 8 4 AIRCOAT NOZZLES ACF3000 Article No 379xxx In order to determine the article number of a nozzle please select the number from the table and replace the three xxx Example nozzle 411 article number 379411 Spray angle Material filter mesh Gap filter Gun filter Drilled hole Material flow Shaping air width mm inch Size Tested with water and 100 ...

Page 37: ...e for nozzles 2315723 Filter insert red 200 0 007 0 011 2315724 Filter insert blue 150 0 011 0 013 2315725 Filter insert yellow 100 0 013 0 019 2315726 Filter insert white 50 0 019 0 023 Order No Description 394933 Swivel set for material NPSM 1 4 and for air hose G1 4 394928 Swivel for material connection NPSM 1 4 364938 Swivel for air connection G1 4 8 6 SWIVEL JOINTS ...

Page 38: ...nch 1 MPa 10 bar 145 psi 2309634 AC hose set DN4 PN270 1 4 NPS 15 0 m PA T Material 1 4 NPS 15 m 49 2 ft DN 4 ID 0 16 inch 27 MPa 270 bar 3916 psi Air G1 4 15 m 49 2 ft DN 6 mm ID 0 24 inch 1 MPa 10 bar 145 psi 2309635 AC hose set DN4 PN270 1 4 NPS 20 0 m PA T Material 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 MPa 10 bar 145 psi 232...

Page 39: ... following information to ensure delivery of the right spare part Order number designation and quantity The quantity need not be the same as the numbers given in the quantity column Stk on the list This number merely indicates how many of the respective parts are used in each module The following information is also required to ensure smooth processing of your order Address for the invoice Address...

Page 40: ...er 8 2 14 1 394339 394339 Sealing ring 15 1 9974245 9974245 O ring 16 1 394922 394922 Valve housing complete 17 1 394338 394338 Seal nozzle 18 1 2312149 2312149 Collet chuck 19 1 394257 394257 Valve tappet complete 20 1 394318 394318 Nut 21 1 394601 394601 Trigger 22 1 394319 394319 Screw 23 1 394334 394334 Locking device 24 1 9935088 9935088 Straight pin 25 1 394313 394313 Air tappet 26 1 9974243...

Page 41: ...35 11 86 87 53 88 36 80 29 65 OPERATING MANUAL VERSION 09 2011 ORDER NUMBER DOC2311730 Mounting materials Pos K Order No Description 80 9992831 Loctite 542 81 9992833 Loctite 638 green 82 9992590 Loctite 222 83 9992609 Anti sieze paste 84 394342 Tool valve rod seal 85 Molykote 86 9992528 Loctite 270 87 9992698 Vaseline white PHHV II 88 179989 Tool air valve seal Detail B ...

Page 42: ...2 Nozzle insert R various dimensions See chapter 8 1 1 62 1 394180 394180 Round jet nozzle cap See chapter 8 1 63 1 132922 132922 Nozzle screw joint complete 64 1 2315723 2315723 Filter insert red 200 mesh 64 1 2315724 2315724 Filter insert blue 150 mesh 64 1 2315725 2315725 Filter insert yellow 100 mesh 64 1 2315726 2315726 Filter insert white 50 mesh 65 1 128389 128389 Seal 66 1 2311491 2311491 ...

Page 43: ...nozzle See chapter 8 2 14 1 394339 Sealing ring 15 1 9974245 O ring 16 1 394922 Valve housing complete 17 1 394338 Seal Nozzle 18 1 2312149 Collet chuck 19 1 394257 Valve tappet complete 20 1 394318 Nut 21 1 394601 Trigger 22 1 394319 Screw 23 1 394334 Safety clip 24 1 9935088 Straight pin 25 1 394313 Air tappet 26 1 9974243 O ring 27 1 394303 Mounting bracket 28 1 9921906 Lock washer 29 1 2324766...

Page 44: ...86 87 53 70 69 88 36 36 36 80 29 OPERATING MANUAL VERSION 09 2011 ORDER NUMBER DOC2311730 Mounting materials Pos K Order No Description 80 9992831 Loctite 542 81 9992833 Loctite 638 green 82 9992590 Loctite 222 83 9992609 Anti sieze paste 84 394342 Tool valve rod seal 85 Molykote 86 9992528 Loctite 270 87 9992698 Vaseline white PHHV II 88 179989 Tool air valve seal Detail B ...

Page 45: ... 8 1 1 62 1 394180 Round jet nozzle cap see chapter 8 1 63 1 132922 Nozzle screw joint complete 64 1 2315723 Filter insert red 200 mesh 64 1 2315724 Filter insert blue 150 mesh 64 1 2315725 Filter insert yellow 100 mesh 64 1 2315726 Filter insert white 50 mesh 65 1 128389 Seal 66 1 2311491 Turning handle 67 1 2320016 Filter housing complete 69 1 9998910 Instruction sticker Hot Surfaces 70 1 999891...

Page 46: ...t B V De Heldinnenlaan 200 NL 3543 MB Utrecht Telephone 31 0 30 241 4155 Telefax 31 0 30 241 1787 E Mail info wsb wagner nl HP www wsb wagner eu Italy WAGNER COLORA S r l Via Fermi 3 I 20875 Burago di Molgora MB Telephone 39 039 625021 Telefax 39 039 6851800 E Mail info wagnercolora com Japan WAGNER Spraytech Ltd 2 35 Shinden Nishimachi J Daito Shi Osaka 574 0057 Telephone 81 0 720 874 3561 Telefa...

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Page 48: ... 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Telefax 49 0 7544 505200 E mail service standard wagner group com Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altstätten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 www wagner group com ...