WAGNER GM 4600AC User manual
GM 4600AC
II 2G X (Atex 95)
B_02669
AirCoat Spray gun
for flat - and round jet nozzles
Edition 02/2008
Translation of the original
Operating manual
3
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Languages 5
1.2 Warnings, notes and symbols in these instructions 5
2 GENERAL SAFETY INSTRUCTIONS 6
2.1 Safety instructions for the operator 6
2.1.1 Electrical equipment 6
2.1.2 Personnel qualifications 6
2.1.3 A safe work environment 6
2.2 Safety instructions for staff 6
2.2.1 Safe handling of WAGNER spray units 7
2.2.2 Earth the unit 7
2.2.3 Paint hoses 7
2.2.4 Cleaning 8
2.2.5 Handling hazardous liquids, varnishes and paints 8
2.2.6 Touching hot surfaces 8
2.3 Correct use 8
2.4 Use in hazardous locations 9
2.4.1 Correct use 9
2.4.2 Explosion protection identification 9
2.4.3 Maximum surface temperature 9
2.4.4 Safety instructions 9
2.5 German regulations and guidelines 9
3 PRODUCT LIABILITY AND WARRANTY 10
3.1 Important notes on product liability 10
3.2 Warranty 10
3.3 CE-conformity 11
4 DESCRIPTION 12
4.1 Fields of application,using in accordance with the instructions 12
4.1.1 Processible materials 12
4.2 scope of delivery 12
4.2.1 Variant for application range up to 16 MPa; 160 bar; 2320 psi 12
4.2.2 Variant for application range up to 25 MPa, 250 bar, 3625 psi 12
4.2.3 Standard equipments 12
4.2.4 Spray gun configuration 13
4.3 Data 14
4.3.1 Materials of the parts transporting paint 14
4.3.2 Technical data 14
4.4 Functional description 15
4.4.1 Design of spray gun 15
4.4.2 Functions of the gun 15
5 STARTING UP AND OPERATING 16
5.1 Installation and connection 16
5.1.1 Typical AirCoat spraying system 16
5.1.2 Ventilation of the spray booth 17
5.1.3 Air supply 17
5.1.4 Fluid (paint) hoses 17
4
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
Contents
5.1.5 Earthing 18
5.2 Preparation of paints 18
5.3 Start-up 19
5.3.1 General rules for handling the spray gun 19
5.3.2 Preparation for starting up 20
5.4 Works 21
5.4.1 Start-up for spraying AirCoat 21
5.4.2 Adjusting the spray pattern 21
5.4.3 Replacing AirCoat nozzle 22
5.4.4 Cleaning aircoat nozzle 23
5.4.5 Eliminate nozzle clogging 23
6.0 MAINTENANCE 24
6.1 Finishing work and cleaning 25
6.2 Replacing the material hose or air hose 26
6.3 Changing or cleaning filter insert 27
6.4 Replacing parts on the valve rod 28
6.4.1 Disassembling 28
6.4.2 Replacement of valve rocker seals 29
6.4.3 Replacing the rod seal (35) 29
6.4.4 Assembling 29
6.5 Replacing the nozzle seal 30
6.6 Replacing the„air“ sealing ring 31
7 TROUBLE SHOOTING AND SOLUTION 32
9 ACCESSORIES 33
9.1 Round-jet nozzle cap 33
9.1.1 Nozzle inserts RXX 33
9.1.2 Nozzle screwed connection complete 33
9.2 AirCoat nozzles ACF3000 34
9.3 Air caps 36
9.4 Filter insert 36
9.5 Swivels 36
9.6 Hoses 37
9.7 Miscellaneous 37
10 SPARE PARTS 38
10.1 How to order spare parts? 38
10.2 Spare parts list GM 4600AC 39
5
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
4HISOPERATINGMANUALCONTAINSINFORMATIONONTHEOPERATIONREPAIRANDMAINTENANCEOF
THEUNIT
!LWAYSOBSERVETHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY
AGREEMENT
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
Warning instructions in this manual point out particular dangers to users and equipment
and state measures for avoiding the hazard.These warning instructions fall into the follo-
wing categories:
Danger - imminent danger.Non-observance will result
in death, serious injury and serious material damage.
Warning - possible danger.Non-observance can result
in death, serious injury and serious material damage.
Caution - a possibly hazardous situation. Non-obser-
vance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation. Non-obser-
vance can cause material damage.
3)()??'"
$!.'%2
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
7!2.).'
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
#!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'" #!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLECONSEQUENCESOFFAILINGTOOBSERVETHEWARNINGINSTRUCTIONS4HESIGNALWORD
POINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
394860 394861
394862 2301130
2301151 2301153
2301154 2301155
6
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL EQUIPMENT
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 A SAFE WORK ENVIRONMENT
2.2 SAFETY INSTRUCTIONS FOR STAFF
+EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
%LECTRICALPLANTANDUNIT
4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE
OPERATINGMODEANDAMBIENTINmUENCES
-AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION
-USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU
LATIONS
-USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS
-USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD
-USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT
PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
%NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART
eMEASUREMENTINACCORDANCEWITH$).
%NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH
LEATHERSOLES
%NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA
THEHANDLEOFTHESPRAYGUN
#USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS
%NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE
n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE
n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION
%NSURETHATTHEREARENOIGNITIONSOURCES SUCH AS NAKEDmAME GLOWING WIRES OR HOT
SURFACESINTHEVICINITY$ONOTSMOKE
!LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
7
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
2.2.2 EARTH THE UNIT
2.2.3 PAINT HOSES
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.
– Relieve the pressure from the spray gun and unit.
– By functional faults: Identify and correct the problem, proceed as described in
chap. „Trouble shooting“.
In the event of skin injuries caused by paint or cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
Electrostatic charges can occur on the unit due to the electrostatic charge and the flow
speed involved in spraying.These can cause sparks and flames upon discharge.
Ensure that the unit is always earthed.
Earth the work pieces to be coated.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing
antistatic shoes.
When spraying, wear antistatic gloves to earth yourself via the spray gun handle.
%NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
%NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
%NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE
n -ANUFACTURER
n 0ERMISSIBLEOPERATINGOVERPRESSURE
n $ATEOFMANUFACTURE
4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN
-/HM
8
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
2.2.4 CLEANING
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
2.2.6 TOUCHING HOT SURFACES
2.3 CORRECT USE
$EENERGIZETHEUNITELECTRICALLY
$ISCONNECTTHEPNEUMATICSUPPLYLINE
2ELIEVETHEPRESSUREFROMTHEUNIT
%NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM
PERATURE
4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON
CLEANINGAGENTSWITHAGUN
!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS
7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER
%ARTHTHECONTAINER
7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK
INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING
USED
4AKETHE SPECIlEDPROTECTIVEMEASURESIN PARTICULARWEARSAFETY GOGGLES PROTECTIVE
CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY
5SEAMASKORBREATHINGAPPARATUSIFNECESSARY
&ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON
7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS
4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES
7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&
)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh
/RDER.O
)NFORMATIONLABEL
3AFETYLABEL
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
9
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
2.4.1 CORRECT USE
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
2.4.3 MAXIMUM SURFACE TEMPERATURE
2.4.4 SAFETY INSTRUCTIONS
2.4 USE IN HAZARDOUS LOCATIONS
4HEUNITISSUITABLEFORWORKINGLIQUIDMATERIALSINACCORDANCEWITHTHECLASSIlCATIONINTO
EXPLOSIONCLASSES
!SDElNEDINTHE$IRECTIVE#%!4%8THEUNITISSUITABLEFORUSEINAREASWHERE
THEREISANEXPLOSIONHAZARD
))'8
#% #OMMUNAUTÏS%UROPÏENNES
%X 3YMBOLFOREXPLOSIONPROTECTION
)) 5NITCLASS))
#ATEGORY:ONE
' %XATMOSPHEREGAS
8 3PECIALIDENTIlCATION
3AFEHANDLINGOF7!'.%2SPRAYUNITS
-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL
)NANEXPLOSIVEATMOSPHERE
$ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON
$ONOTDROPTHESPRAYGUN
5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL
)GNITIONTEMPERATUREOFTHECOATINGMATERIAL
%NSURETHAT THE IGNITION TEMPERATURE OFTHECOATINGMATERIALISABOVETHEMAXIMUM
SURFACETEMPERATURE
-EDIUMSUPPORTINGATOMIZING
4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR
#LEANING
)FTHEREAREDEPOSITSONTHE SURFACESTHEUNITMAYFORMELECTROSTATICCHARGES &LAMESOR
SPARKSCANFORMIFTHEREISADISCHARGE
2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
The maximum surface temperature corresponds to the permissible material temperature
.
This and the permissible ambient temperature can be found in the„Technical Data“ chap
-
ter.
2.5 GERMAN REGULATIONS AND GUIDELINES
See chapter 3.3
10
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
3 PRODUCT LIABILITY AND WARRANTY
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 WARRANTY
!SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL
ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE
DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED
)FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE
FULLYORPARTIALLYNULLANDVOID
4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE
GULATIONSAREOBSERVED
4HISUNITISCOVEREDBYOURWARRANTYONTHEFOLLOWINGTERMS
7EWILLATOURDISCRETIONREPAIRORREPLACEFREEOFCHARGEALLPARTSWHICHWITHINMONTHS
INSINGLESHIFTMONTHSINSHIFTORMONTHSINSHIFTOPERATIONFROMDATEOFRECEIPTBY
THE0URCHASERAREFOUNDTOBEWHOLLYORSUBSTANTIALLYUNUSABLEDUETOCAUSESPRIORTOTHE
SALEINPARTICULARFAULTYDESIGNDEFECTIVEMATERIALSORPOORWORKMANSHIP
4HETERMSOFTHEWARRANTYAREMETATOURDISCRETIONBYTHEREPAIRORREPLACEMENTOFTHE
UNITORPARTSTHEREOF4HERESULTINGCOSTSINPARTICULARSHIPPINGCHARGESROADTOLLSLABOUR
ANDMATERIALCOSTSWILLBEBORNEBYUSEXCEPTWHERETHESECOSTSAREINCREASEDDUETOTHE
SUBSEQUENTSHIPMENTOFTHEUNITTOALOCATIONOTHERTHANTHEADDRESSOFTHEPURCHASER
4HISWARRANTYDOESNOTCOVERDAMAGECAUSEDBY
5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A
THIRDPARTYNORMALWEARNEGLIGENT HANDLING DEFECTIVE MAINTENANCE UNSUITABLE COATING
PRODUCTS SUBSTITUTE MATERIALS AND THE ACTION OF CHEMICAL ELECTROCHEMICAL OR ELECTRICAL
AGENTSEXCEPTWHENTHEDAMAGEISATTRIBUTABLETOUS
!BRASIVECOATING PRODUCTSSUCH ASREDLEAD EMULSIONS GLAZES LIQUID ABRASIVES ZINC DUST
PAINTSANDSIMILARREDUCETHESERVICELIFEOFVALVESPACKINGSSPRAYGUNSNOZZLESCYLINDERS
PISTONSETC!NYWEARRESULTINGFROMTHEAFOREMENTIONEDCAUSESISNOTCOVEREDBYTHIS
WARRANTY
#OMPONENTSNOTMANUFACTUREDBY7AGNERARESUBJECTTOTHEWARRANTYTERMSOFTHEORIGI
NALMAKER
4HEREPLACEMENTOFAPARTDOESNOTEXTENDTHEWARRANTYPERIODOFTHEUNIT
4HEUNITSHOULDBEINSPECTEDIMMEDIATELYUPONRECEIPT
4OAVOIDLOSSWARRANTYANIYAPPARENTDEFECTSHOULDBENOTIlEDTOUSORTHEDEALERINWRI
TINGWITHINDAYSFROMDATEOFSALEOFTHEUNIT
4HERIGHTTOCOMMISSIONWARRANTYSERVICESTOATHIRDPARTYISRESERVED
7ARRANTYCLAIMSARESUBJECTTOPROOFOFPURCHASEBYSUBMITTINGANINVOICEORDELIVERYNOTE
)FANINSPECTIONlNDSDAMAGENOTCOVEREDBYTHEPRESENTWARRANTYTHEREPAIRWILLBECAR
RIEDOUTATTHEEXPENSEOFTHEPURCHASER
.OTETHATTHISWARRANTYDOESNOTINANYWAYRESTRICTLEGALLYENTITLEDCLAIMSORTHOSECONTRAC
TUALLYAGREEDTOINOURGENERALTERMSANDCONDITIONS
*7AGNER!'
11
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
3.3 CE-CONFORMITY
0394891
CE Certificate of Conformity
The certificate is enclosed with this product.The certificate of conformity can be reordered
from your WAGNER representative, quoting the product and serial number.
Part number:
Herewith we declare that the supplied version of
GM 4600AC 16 MPa NPSM1/4“ 0394004
GM 4600AC 25 MPa NPSM1/4“ 0394014
GM 4600AC 0394020
Complies with the following guidelines:
2006/42/EG
94/9/EG
Applied standards, in particular:
DIN EN ISO 12100-1, 2004-04 DIN EN 1127-1, 2008-02
DIN EN ISO 12100-2, 2004-04 DIN EN 1953, 1998-12
DIN EN ISO 14121,2007-12 DIN EN 13463-1, 2002-04
DIN EN ISO 3746, 1995-12 DIN EN ISO 13732-1, 2006-12
Applied national technical standards and specifications, in particular:
a) BGR 500 Part 2, chap. 2.29„Using coating materials“
b) BGR 500 Part 2, chap. 2.36 „Working with liquid ejection devices“
c) BGR 104 Explosion protection rules
d) BGR 132 Avoiding ignition risks
e) BGR 180 Setting up for cleaning with solvents for cleaning workpieces with
solvents
f) BGI 740 Painting rooms and equipment
g) ZH 1/406 Guidelines for liquid ejection devices
Note: All titles can be ordered from Heymanns Publishing House in Cologne or down-
load from Internet.
12
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
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 PROCESSIBLE 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.
Note: In the event of application problems consult your Wagner branch and/ or the
paint manufacturer.
4 DESCRIPTION
SIHI_0019_GB
WARNING
Hot coating substances!
Burns
Wear antistatic protective gloves.
When operating the unit with a coating material with a temper-
ature greater than 43°C; 109.4°F:Identify the unit with a warning
sticker "Warning - hot surface".
4.2.2 VARIANT FOR APPLICATION RANGE UP TO 25 MPA, 250 BAR, 3625 PSI
Qty Part No. Description
1 0394014 GM 4600AC 25 MPa ; NPSM1/4“ Paint connection
4.2.1 VARIANT FOR APPLICATION RANGE UP TO 16 MPA; 160 BAR; 2320 PSI
Qty Part No. Description
1 0394004 GM 4600AC 16 MPa; NPSM1/4“ Paint connection
4.2 SCOPE OF DELIVERY
These AirCoat gun is available in two different variants. The nozzle size depends on the
paint and on the application. Therefore the air cap and the nozzle are not included in the
scope of supply.For a gun accessories look in chapter 9.
0394004 0394014 AirCoat hand gun GM 4600AC
Qty Qty Part No. Description
1 1 0394891 CE-conformity
1 1 394860 Operating manual German
1 1 see chap.1 Operating manual for the other language
For special versions the delivery note applies.
4.2.3 STANDARD EQUIPMENTS
The standard equipment includes:
13
GM 4600AC
B_02670
AB CCC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
4.2.4 SPRAY GUN CONFIGURATION
Basis number GM 4600AC - A B C C C -> Key
0 3 9 4 0 2 0 - 1 1 4 1 1 -> For example: Part number
Table A: Maxi. material pression selection
1 160 bar; 16 MPa; 2320 psi
2 250 bar; 25 MPa; 3625 psi
Table B: Air cap selection
1 Suitable for low viscosity paints (red)
2 Suitable for high viscosity paints (blue)
Table CCC: AirCoat nozzle selection ACF3000
CCC = the last three digits of the article number -> 0379CCC
107 1 = Spray angle x 10 = 100. 07 = Diameter of bore in mm/1000 (0.007 mm)
411 4 = Spray angle x 10 = 400. 11 = Diameter of bore in mm/1000 (0.011 mm)
317 3 = Spray angle x 10 = 300. 17 = Diameter of bore in mm/1000 (0.017 mm)
625 6 = Spray angle x 10 = 600. 25 = Diameter of bore in mm/1000 (0.025 mm)
835 8 = Spray angle x 10 = 800. 35 = Diameter of bore in mm/1000 (0.035 mm)
The complete flat-jet nozzle range is described in chapter 9.2.
14
GM 4600AC
A
D
E
C
B
B_02671
F
G
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
Metal Plastics
Tungsten carbide Stainless steel 1.4305 POM FPM
Stainless steel 1.4301 Stainless steel 1.4104 PTFE PA
4.3 DATA
4.3.1 MATERIALS OF THE PARTS TRANSPORTING PAINT
4.3.2 TECHNICAL DATA
AirCoat spray gun
Description Units 0394004 0394014
Maxi. air pressure MPa/ psi/ bar 0.8/ 120/ 8
Maxi. material pressure MPa/ psi/ bar 16/ 2320/ 160 25/ 3625/ 250
Paint connection Inches NPSM1/4
Air connection Inches G1/4“
Filter Mesh 100
Weight g/ oz 526 g/ 18.6 oz
Maxi. temperature material °C/ °F 55/ 131
Maxi. temperature air °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
** Filter types see chapter 9.6
*** A rated sound pressure level measured at o.5m distance according to DIN EN ISO 3746-
1995.
Dimensions
Dim. mm inches
A 173 6.81
B 216 8.50
C 48 1.89
D 152 5.98
E 39 1.54
F - NPSM1/4“
G - G1/4“
15
GM 4600AC
B_02672
A
H
I
J
K
B
C
D
E
F
G
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
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
4.4.2 FUNCTIONS OF THE GUN
Pulling the trigger (D) approximately 1/2 way opens the air valve allowing atomising and
shaping-air to flow through the air cap.When the trigger is pulled further, more resistance
is felt and the material valve is opened.The atomising air control (B) adjusts the total quan-
tity of air flowing trough the spray gun.
The spray gun is rendered safe with the trigger safety catch (E). (Turn the trigger safety
catch in the spraying direction and fasten in the groove).
4.4 FUNCTIONAL DESCRIPTION
4.4.1 DESIGN OF SPRAY GUN
16
GM 4600AC
C
D
EFG
K
AH
J
L
I
M
B
B_02673
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
5 STARTING UP AND OPERATING
5.1.1 TYPICAL AIRCOAT SPRAYING SYSTEM
A Material pump
B Pressure air shut off valve
C Pressure regulator
D Air pressure regulator with filter
E Earthing cable
F Air hose, el. conductive
The pray gun GM 4600AC must be used a part of a spraying system. The spraying system
shown in the figure is only one example of an electrostatic Aircoat spraying system. It is
not an actual system design. Contact your Wagner distributor for assistance in designing a
system to meet your needs.
The operating instructions and the safety regulations for the additional system compo-
nents used must be read before starting-up.
5.1 INSTALLATION AND CONNECTION
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 addi-
tionally required system components.
SIHI_0050_GB
G AirCoat gun
H High-pressure paint hose
I High-pressure filter/Relief valve
J Return
K Stand trolley
L Suction system
M Compressed air main
17
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
5.1.2 VENTILATION OF THE SPRAY BOOTH
5.1.3 AIR SUPPLY
The use of an air filter with the air regulator (D) ensures that only dry, clean atomising air
gets into the spray gun. Dirt and moisture in the atomising air reduce the spraying quality
and the appearance of the finished piece.
5.1.4 FLUID (PAINT) HOSES
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 venti-
lation (extraction) switched on.
Observe national and local regulations for the outgoing air
speed.
SIHI_0028_GB
#!54)/.
)MPURITIESINTHESPRAYINGSYSTEM
3PRAYGUNBLOCKAGEMATERIALSHARDENINTHESPRAYINGSYSTEM
&LUSHTHESPRAYGUNANDPAINTSUPPLYWITHASUITABLECLEANINGAGENT
3)()??'"
SIHI_0029_GB
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of material
Ensure that the hose material is chemically resistant.
Ensure that the spray gun,
threaded joints
and material hose
between the unit and the spray gun is suitable for the pressure
generated in the unit.
Ensure that the following information can be seen on the high-
pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
18
GM 4600AC
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
5.1.5 EARTHING
Any material containers and the unit must be connected by a potential equalisation (earth)
cable.
5.2 PREPARATION OF PAINTS
The viscosity of the paints is of great importance.The best results are usually obtained with
paints between 80 and 260 milli Pascal x Sec (mPas).
Please also read the technical data sheet for the paint for optimal processing, viscosity
adjustment and intermixing of the material.
7!2.).'
$ISCHARGE OF ELECTROSTATICALLY CHARGED COMPONENTS IN ATMO
SPHERESCONTAININGSOLVENTS
%XPLOSIONHAZARDFROMELECTROSTATICSPARKSORmAMES
%ARTHALLUNITCOMPONENTS
%ARTHTHEWORKPIECESBEINGPAINTED
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.
SIHI_0003_GB
19
GM 4600AC
B_02674
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
5.3 START-UP
Trigger safety catch in on
(safe) position
Air
Material
5.3.1 GENERAL RULES FOR HANDLING THE SPRAY GUN
➞ Observe general safety instructions in chapter 2.
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
SIHI_0065_GB
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.
By functional faults: Identify and correct the problem, proceed
as described in chap„Trouble shooting“.
20
GM 4600AC
B_02261
x
OPERATING MANUAL
EDITION 02/2008 Part No. DOC394861
5.3.2 PREPARATION FOR STARTING UP
1. Secure the spray gun.
2. Connect material hose to the spray gun and material supply system.
3. Connect air hose to spray gun and to oil-free, dry air supply with regulator.
4. Insert suitable gun filter
5. 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. 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
earthed.
8. Set material pressure 100 bar; 10 MPa; 1450 psi and use a suitable medium (solvent or
water) to check that connections do not leak.
Note:
Pull the trigger and then release, checking that the gun closes cleany.
9. Relieve spray gun and unit pressure and secure the spray gun.
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