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.
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.
EDITION 12/2008 GM 4100AC PART NO. DOC394821 OPERATING MANUAL 1 ABOUT THESE INSTRUCTIONS 4HIS OPERATING MANUAL CONTAINS INFORMATION ON THE OPERATION REPAIR AND MAINTENANCE OF THE UNIT !LWAYS OBSERVE THESE INSTRUCTIONS WHEN OPERATING THE UNIT 4HIS EQUIPMENT CAN BE DANGEROUS IF IT IS NOT OPERATED IN ACCORDANCE WITH THIS MANUAL #OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY AGREEMENT 1.
EDITION 12/2008 PART NO. DOC394821 GM 4100AC OPERATING MANUAL 2 GENERAL SAFETY INSTRUCTIONS 2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR +EEP THESE OPERATING INSTRUCTIONS TO HAND NEAR THE UNIT AT ALL TIMES !LWAYS FOLLOW LOCAL REGULATIONS CONCERNING OCCUPATIONAL SAFETY AND ACCIDENT PREVEN TION 2.1.
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: Never point the spray gun at people. Never reach into the spray jet. 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.
EDITION 12/2008 PART NO. DOC394821 GM 4100AC OPERATING MANUAL 2.2.4 CLEANING $E ENERGIZE THE UNIT ELECTRICALLY $ISCONNECT THE PNEUMATIC SUPPLY LINE 2ELIEVE THE PRESSURE FROM THE UNIT %NSURE THAT THE mASH POINT OF THE CLEANING AGENT IS AT LEAST + ABOVE THE AMBIENT TEM PERATURE 4O CLEAN USE ONLY SOLVENT FREE CLOTHS AND BRUSHES .
EDITION 12/2008 PART NO. DOC394821 GM 4100AC OPERATING MANUAL 2.4 USE IN HAZARDOUS LOCATIONS 2.4.1 CORRECT USE 4HE UNIT IS SUITABLE FOR WORKING LIQUID MATERIALS IN ACCORDANCE WITH THE CLASSIlCATION INTO EXPLOSION CLASSES 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.
EDITION 12/2008 PART NO. DOC394821 GM 4100AC OPERATING MANUAL 3 PRODUCT LIABILITY AND WARRANTY 3.
EDITION 12/2008 PART NO. DOC394821 GM 4100AC OPERATING MANUAL 3.
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.
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.
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.
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.
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 When putting into operation and for all work, read and follow the operating instructions and safety regulations for the additionally required system components.
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 Operate the unit in a spraying booth approved for the working materials. -or Operate the unit on an appropriate spraying wall with the ventilation (extraction) switched on. Observe national and local regulations for the outgoing air speed. SIHI_0028_GB 5.1.
EDITION 12/2008 PART NO. DOC394821 GM 4100AC OPERATING MANUAL 5.1.5 EARTHING 7!2.).' $ISCHARGE OF ELECTROSTATICALLY CHARGED COMPONENTS IN ATMO SPHERES CONTAINING SOLVENTS %XPLOSION HAZARD FROM ELECTROSTATIC SPARKS OR mAMES %ARTH ALL UNIT COMPONENTS %ARTH THE WORKPIECES BEING PAINTED 3)()? ?'" WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning Insufficient paint application quality Earth all unit components. Earth the workpieces being painted.
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: Switch off the energy/compressed air supply. Relieve the pressure from the spray gun and unit. Secure the spray gun against actuation.
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.
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.
EDITION 12/2008 GM 4100AC PART NO. DOC394821 OPERATING MANUAL 5.4.3 REPLACING AIRCOAT NOZZLE CAUTION Defective AirCoat nozzle! Insufficient paint application quality Do 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).
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).
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 Never immerse the spray gun in cleaning agent.
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 Never spray into a closed container. Earth the container. SIHI_0008_GB 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 agent enters the air duct. SIHI_0005_GB 7!2.).
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.
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).
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.
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.
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 Do not clean the nozzle seal with sharp-edged objects. Replace 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).
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 Treat 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).
EDITION 12/2008 GM 4100AC PART NO.
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.
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.
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.
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.
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.
EDITION 12/2008 PART NO. DOC394821 GM 4100AC OPERATING MANUAL 10 SPARE PARTS 10.1 HOW TO ORDER SPARE PARTS? !LWAYS SUPPLY THE FOLLOWING INFORMATION TO ENSURE DELIVERY OF THE RIGHT SPARE PART 0ART .
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.
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.
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.
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: 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 E-Mail: rep-ch@wagner-group.
ED FI CERT I /RDER NUMBER 394821 'ERMANY * 7!'.%2 'MB( /TTO ,ILIENTHAL 3TR 0OSTFACH $ -ARKDORF 4ELEPHONE 4ELEFAX % -AIL SERVICE STANDARD WAGNER GROUP COM 3WITZERLAND * 7!'.
