WAGNER AirCoat GM 4100 AC User manual

B_02254
GM 4100 AC
AirCoat Manual Gun for Flat
and Round Jet Nozzles
Version 01/2018

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VERSION 01/2018 ORDER NUMBER DOC 394821
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 8
2.5 Misuse 8
3 IDENTIFICATION 9
3.1 Explosion Protection Identication 9
3.2 Identication "X" 9
3.3 Type plate 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 11
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 12
4.2.1 Personal Safety Equipment 12
4.2.2 Safe Handling of WAGNER Spray Devices 13
4.2.3 Grounding the Unit 13
4.2.4 Product hoses 14
4.2.5 Cleaning and Flushing 15
4.2.6 Touching Hot Surfaces 15
4.2.7 Maintenance and Repair 16
4.2.8 Protective and Monitoring Equipment 16
5 DESCRIPTION 17
5.1 Components 17
5.2 Mode of Operation 17
5.3 Protective and Monitoring Equipment 17
5.4 Included Items 17
5.4.1 Version for application up to 25 MPa; 250 bar; 3,625 psi 17
5.4.2 Standard equipment 17
5.5 Data 18
5.5.1 Materials of Paint-wetted Parts 18
5.5.2 Technical data 18
5.5.3 Dimensions and Connections 18

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6 ASSEMBLY AND COMMISSIONING 19
6.1 Training of Assembly/Commissioning Personnel 19
6.2 Storage Conditions 19
6.3 Installation Conditions 19
6.4 Installation and Connection 20
6.4.1 Typical AirCoat spraying system 20
6.4.2 Ventilation of the Spray Booth 20
6.4.3 Air Supply Lines 21
6.4.4 Product supply lines 21
6.5 Grounding 21
6.6 Safety Checks 21
6.7 Lacquer Preparations 21
6.8 Commissioning 22
6.8.1 Procedure 22
6.8.2 Verifying a Safe Operational Condition 22
7 OPERATION 23
7.1 Training the Operating Personnel 23
7.2 Tasks 23
7.2.1 Starting to Spray with the AirCoat 23
7.2.2 Adjusting the Spray Pattern 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
8.1.1 Cleaning Personnel 27
8.1.2 Flushing and Cleaning the Spray Gun 27
8.2 Maintenance 28
8.2.1 Maintenance Personnel 28
8.2.2 Safety instructions 28
8.2.3 Safety Checks and Maintenance Intervals 29
8.2.4 Replacing the Product Hose or Air Hose 30
8.2.5 Changing or Cleaning the Edge Filter 31
9 TROUBLESHOOTING AND RECTIFICATION 32
10 REPAIR WORK 33
10.1 Repair Personnel 33
10.2 Repair Notes 33
10.3 Tools 33
10.4 Replacing Parts on the Valve Rod 34
10.4.1 Replacing Valve Tappet Seals 35
10.4.2 Replacing the Rod Seal (35) 35
10.4.3 Assembly 36
10.5 Replacing the Nozzle Seal 36
10.6 Replacing the "Air" Sealing Ring 37
10.7 Replacing the Spring Cap 37

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11 FUNCTION TEST AFTER REPAIR WORK 38
12 DISPOSAL 39
13 ACCESSORIES 40
13.1 Round Jet Nozzle Attachment 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 Miscellaneous 44
14 SPARE PARTS 45
14.1 How can spare parts be ordered? 45
14.2 Spare Parts List GM 4700AC 46
15 EU DECLARATION OF CONFORMITY 48

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VERSION 01/2018 ORDER NUMBER DOC 394821
1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS 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 the
following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential risk.
Non-observance can result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Notice Provides information about particular characteristics and
how to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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VERSION 01/2018 ORDER NUMBER DOC 394821
1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 394820
Translation of the original operating manual
Language Order no. Language Order no.
English 394821 Danish 2301125
French 2301121 Dutch 2301122
Italian 2301118 Swedish 2301129
Spanish 2301119 -- --
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order
no.
Order number for low-viscosity (LV) products
Spare part for high-viscosity (HV) products
Marking in the spare parts lists Low air
Position Manual gun
Number of pieces AirCoat
Wrench size -- --
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Product pressure
generator
Pump or pressure tank.
Personnel qualications
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 and measures.
Electrically trained
person
Is instructed by an electrician about the tasks 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 possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.

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VERSION 01/2018 ORDER NUMBER DOC 394821
2 CORRECT USE
2.1 DEVICE TYPE
Manual gun for manually coating work pieces.
GM 4100 AC
2.2 TYPE OF USE
The automatic spray gun is suitable for atomizing liquid products, particularly coating
products, using the AirCoat process.
– Non-ignitable products.
– Products in accordance with their classication in explosion class IIB.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in Directive
2014/34/EU (ATEX), (see Explosion protection marking Chapter 3.1).
2.4 PROCESSIBLE WORKING MATERIALS
Top-coat lacquers, primer paints, corrosion protection, textured lacquers, lyes, staining
solvents, clear lacquers, separating agents, etc. with a solvent or water base. If you want to
spray working materials other than the aforementioned, contact a WAGNER representative.
Note:
Contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
no dry coating products, e.g. powder are processed;
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.

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VERSION 01/2018 ORDER NUMBER DOC 394821
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: AirCoat manual gun GM 4100 AC
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
II 2G X
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (zone 1)
G Ex-atmosphere gas
X Special notice
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
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 atmosphere:
knocking or pushing metal against metal is to be avoided;
do not drop the device.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.

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VERSION 01/2018 ORDER NUMBER DOC 394821
3.3 TYPE PLATE
WARNING
SKIN INJECTION HAZARD
READ INSTRUCTION MANUAL
II 2GX
Serial-No. XXXXX
Max. p 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 pressure
3 Maximum product pressure see spring cap
4 Maximum product temperature
5 Warning
6 Danger of injury from injection/read operating manual