Translation of the original Operating manual AC 4600 Professional Edition 06/2012 AirCoat spray guns for flat - and round jet nozzles B_02695 II 2G X (Atex 95)
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro 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 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL Contents 5.1.3 5.1.4 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 Air supply Fluid (paint) hoses Earthing Preparation of paints Starting-up General rules for handling the spray gun Preparation for starting up Works Start-up for spraying Adjusting the spray pattern Changing the AirCoat nozzle Cleaning aircoat nozzle Eliminate nozzle clogging 17 17 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.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL 1 ABOUT THESE INSTRUCTIONS This operating manual contains information on the operation, repair and maintenance of the unit. Always observe these instructions when operating the unit. This equipment can be dangerous if it is not operated in accordance with this manual. Compliance with these instructions constitutes an integral component of the warranty agreement. 1.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 2 GENERAL SAFETY INSTRUCTIONS 2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro 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 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 2.2.4 CLEANING De-energize the unit electrically. Disconnect the pneumatic supply line. Relieve the pressure from the unit. Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature. To clean, use only solvent-free cloths and brushes. Never use hard objects or spray on cleaning agents with a gun. An explosive gas/air mixture forms in closed containers.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 2.4 USE IN AN EXPLOSION HAZARD AREA 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 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 3 3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING 3.1 SCOPE OF GUARANTEE All Wagner professional colour application devices (hereafter referred to as products) are carefully inspected, tested and are subject to strict checks under Wagner quality assurance.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 3.4 EXCLUSION OF GUARANTEE Guarantee claims cannot be considered - for parts that are subject to wear and tear due to use or other natural wear and tear, as well as defects in the product that are a result of natural wear and tear, or wear and tear due to use. This includes in particular cables, valves, packaging, jets, cylinders, pistons, means-carrying housing components, filters, pipes, seals, rotors, stators, etc.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 3.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro 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 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.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 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 Description Maxi. air inlet pressure Maxi. material pressure Paint connection Air connection Filter insert ** Weight pH range of the material Maxi. temperature material Maxi.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL 4.4 FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF SPRAY GUN B C A J I E D H K M L F N G B_02697 Description Description A Suspension hook H Union nut with nozzle guard B Shaping air regulator I Nozzle / Air cap C Spring cover J Gun housing D Trigger guard K Filter housing E Trigger safety L Handle tube F Air connection M Swivel Air G Paint connection N 4.4.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 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 06/2012 PART NO. DOC394871 AC 4600 Pro 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 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 5.1.5 EARTHING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks or flames Earth all unit components. Earth the workpieces being painted. SIHI_0027_GB 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 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 5.3 STARTING-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 06/2012 PART NO. DOC394871 AC 4600 Pro 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 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 5.4 WORKS 5.4.1 START-UP FOR SPRAYING 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 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL 5.4.3 CHANGING THE 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 06/2012 AC 4600 Pro PART NO. DOC394871 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 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 6.0 MAINTENANCE ➞ Observe general safety instructions in chapter 2. The spray gun and the unit must be cleaned every day. The cleaning solvent used for this must be suitable for the spray material. CAUTION Cleaning agent in the air duct! Functional faults caused by swollen seals Never immerse the spray gun in cleaning agent.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro 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.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 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 wrench size A on flats of paint connection and counterhold. 5. Turn nut to the right with open-ended wrench wrench size B and unscrew material hose. Air hose 4. Place open-ended wrench wrench size D on flats of air connection and counterhold.
EDITION 06/2012 AUSGABE 01/2008 BESTELLNUMMER PART NO.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 6.3 CHANGING OR CLEANING FILTER INSERT Close Loosen Counterhold D Loosen E Description B A AC 4600 Professional NPS 1/4“ Key D Key E wrench size wrench size 13 mm 0.51 inch 17 mm 0.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 1. 2. 3. 4. 5. 6. 7. 8. Finishing work and cleaning. Relieve spray gun and unit pressure. Secure gun with trigger safety catch. Losen complete swivel by hand through turning at the handle tube (C) and drive out downward together with the material hose. Pull filter insert (A) out of the filter housing (B). Flush swivel, filter housing and filter insert (A) with cleaning agent.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 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 guard (21). Loosen sealing screw (10) with single open-end wrench (100) with wrench size 7 mm; 0.28 inches.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL 6.4.2 REPLACEMENT OF VALVE ROCKER SEALS 1. Support valve tappet (50) with single open-end wrench with wrench size 13 mm; 0.51 inches and unscrew cover (53) with single open-end wrench with wrench size 7 mm; 0.28 inches. 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 with wrench size 7 mm; 0.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro 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 06/2012 AC 4600 Pro PART NO. DOC394871 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 06/2012 AC 4600 Pro PART NO.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 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.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL 9.2 AIRCOAT NOZZLES ACF3000 B_02280 Sprayangle 379107 07/10 0.007-0.18 100 379207 07/20 0.007-0.18 200 379209 09/20 0.009-0.23 200 0 379309 09/30 0.009-0.23 30 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 379211 11/20 0.011-0.28 200 379311 11/30 0.011-0.28 300 379411 11/40 0.011-0.28 400 379511 11/50 0.011-0.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL B_02280 379219 Marking 19/20 Diameter of bore inch; mm 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 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL 9.3 AIR CAPS Part No. Description 394910 Air cap LV compl. (red) for low viscosity paints B_02257 394911 Air cap HV compl. (blue) for high viscosity paints B_02256 394912 Air cap compl. (green) B_02709 9.4 FILTER INSERT Part No. for 1 piece Part No. for 10 piec. 34383 97022 43235 97023 Filter type Mesh Use for nozzles Gun filter rot 200 0.007“ - 0.015“ Gun filter yellow 100 0.015“ - 0.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 9.6 SWIVELS Part No. Description 347706 Swivel for paint connection (NPSM 1/4“) B_02712 364938 Swivel for air connection G1/4“ B_02687 9.7 MISCELLANEOUS Part No.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 10 SPARE PARTS 10.1 HOW TO ORDER SPARE PARTS? Always supply the following information to ensure delivery of the right spare part: Part Number, description and quantity The quantity need not be the same as the number given in the „Quantity“ column. This number merely indicates how many of the respective parts are used in each sub assembly.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL 10.2 SPARE PARTS LIST AC4600 PROFESSIONAL Spare parts list AC 4600 Professional Part No. Pos K Qty Description 1 1 394150 AC 4600 Professional; NPSM1/4“ (blue) compl. 1 1 394151 AC 4600 Professional; NPSM1/4“ (red) compl. 1 1 394152 AC 4600 Professional; NPSM1/4“ (green) compl.
EDITION 06/2012 AC 4600 Pro PART NO. DOC394871 OPERATING MANUAL Detail B 55 6 62 56 57 58 59 60 80 61 63 5 2 3 8 20 82 B 36 14 21 16 22 23 13 15 35 36 17 24 101 102 84 69 65 5 Nm ±1 3.69 lbft 100 4 70 64 68 11 1 36 66 18 85 19 67 10 12 34 B_02749 50 52 83 53 51 Mounting materials Pos K Part No.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro OPERATING MANUAL Spare parts list AC 4600 Professional Part No. Pos K Qty Description 1 179395 Seal 52 ✭ ◆ 53 ✭ 55 56 57 58 59 60 61 62 63 64 ◆ 1 394322 Cap ◆ 1 1 1 1 1 1 1 1 1 1 394336 128327 132516 132351 394308 394337 132... 394180 132922 43235 65 ✭ 66 ✭ ◆ 1 364340 Nozzle body Sealing nipple Nozzle screw connection compl. Nozzle screw connection holder Union nut Nozzle nut Nozzle insert R (various dimensions see chap. 9.1.
EDITION 06/2012 PART NO. DOC394871 AC 4600 Pro 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.
EDITION 06/2012 AUSGABE 01/2008 BESTELLNUMMER PART NO.
EDITION 06/2012 AUSGABE 01/2008 BESTELLNUMMER PART NO.
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