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GA 4000ACIC-S
GA 4000ACIC-R
AirCoat
Automatic spray gun
Version 05/2018
B_06647
II 2G X
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VERSION 05/2018
ORDER NUMBER DOC 2312956
GA 4000ACIC
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 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Identication "X" 10
3.3 Type plate 11
4 BASIC SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 13
4.1.3 Personnel Qualications 13
4.2 Safety Instructions for the Personnel 14
4.2.1 Personal Safety Equipment 14
4.2.2 Safe Handling of WAGNER Spray Devices 15
4.2.3 Grounding the Unit 15
4.2.4 Product hoses 16
4.2.5 Cleaning and Flushing 17
4.2.6 Touching Hot Surfaces 18
4.2.7 Maintenance and Repair 18
4.2.8 Protective and Monitoring Equipment 18
5 DESCRIPTION 19
5.1 Components 19
5.2 Functional Description 20
5.2.1 Mode of Operation 20
5.2.2 Mode "NC" and "C" 21
5.2.3 Spraying procedure 22
5.3 Included Items 23
5.3.1 Type description 23
5.3.2 Overview 24
5.3.3 Standard variant 25
5.3.4 Supplementary components 25
5.4 Data 28
5.4.1 Materials of Paint-wetted Parts 28
5.4.2 Technical data 28
5.4.3 Measurements and connections 29
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6 COMMISSIONING 31
6.1 Training of Assembly/Commissioning Personnel 31
6.2 Storage Conditions 31
6.3 Installation Conditions 31
6.4 Installation and Connection 31
6.4.1 Typical AirCoat spraying system 32
6.4.2 Ventilation of the Spray Booth 32
6.4.3 Air Supply Lines 32
6.4.4 Product supply lines 33
6.5 Grounding 33
6.6 Safety Checks 33
6.7 Lacquer Preparations 33
6.7.1 Viscosity conversion table 34
6.8 Commissioning 35
6.8.1 Preparation Before Commissioning 35
6.8.2 Commissioning 35
6.8.3 Verifying a Safe Operational Condition 35
7 OPERATION 36
7.1 Training the Operating Personnel 36
7.2 Tasks 36
7.2.1 Starting to Spray with the AirCoat 36
7.2.2 Adjusting the spray pattern 37
7.2.3 Pressure Relief/Work Interruption 37
7.2.4 Changing AirCoat nozzle 38
7.2.5 Cleaning AirCoat nozzle 38
7.2.6 Eliminating Nozzle Clogging 39
7.2.7 Replacing nozzle insert of round jet nozzle 40
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GA 4000ACIC
8 CLEANING AND MAINTENANCE 41
8.1 Cleaning 41
8.1.1 Cleaning Personnel 41
8.1.2 Flushing and Cleaning the Gun 41
8.2 Maintenance 42
8.2.1 Maintenance Personnel 42
8.2.2 Maintenance Instructions 42
8.2.3 Safety Checks 43
8.2.4 Replacing the paint hose 44
8.2.5 Replacing the nozzle seal 44
8.2.6 Replacing the Sealing Fitting of the Round Jet Nozzle 45
9 TROUBLESHOOTING AND RECTIFICATION 46
10 REPAIR WORK 47
10.1 Repair Personnel 47
10.2 Repair Notes 47
10.3 Replacing parts of the gun body 48
10.3.1 Disassembly of GA 4000ACIC 48
10.3.2 Packing insert GA 4000AC (RP) 50
10.3.3 Assembly of GA 4000ACIC 52
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11 FUNCTION TEST AFTER REPAIR WORK 54
12 DISPOSAL 54
13 ACCESSORIES 55
13.1 AirCoat Nozzles ACF3000 55
13.2 AirCoat Nozzles ACF3000 S2 (4 pieces) 57
13.3 Round jet nozzle attachment 57
13.3.1 RXX Nozzle inserts 58
13.3.2 Nozzle screw joint, complete 58
13.4 Hoses 58
13.5 Miscellaneous 59
14 SPARE PARTS 60
14.1 How can spare parts be ordered? 60
14.2 Spare Parts List for GA 4000ACIC 61
14.3 Service sets and spare parts groups 63
14.4 Packing insert GA 4000AC (RP) 63
14.5 Sealing Set GA 4000 Packing RP and RP Special 64
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GA 4000ACIC
15 DECLARATION OF CONFORMITY 65
15.1 EU Declaration of Conformity 65
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GA 4000ACIC
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
WARNING
CAUTION
NOTICE
Notice
Explanation of warning notice:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance may result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and
how to proceed.
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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1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No.
German 2312955 Swedish 2316798
English 2312956 Russian 2327992
French 2312957 Hungarian 2364607
Italian 2312958 -- -Spanish 2312959 -- --
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
Wrench size (tool)
TX Torx size (tool)
RP (replaceable packing)
PTFE Polytetrauorethylene (PTFE)
GF Fiber optics
PE Polyethylene
UWMW-PE Ultra-high molecular polyethylene
FPM Fluoropolymer rubber (Viton)
POM Polyoxymethylene (Acetal)
PA Polyamide
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GA 4000ACIC
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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 compressed air
Product pressure
generator
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person in
accordance with
TRBS 1203
(2010/Revision 2012)
Pump or pressure tank
associated with improper behavior as well as the necessary
protective devices and measures.
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.
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient 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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2 CORRECT USE
2.1 DEVICE TYPE
Automatic gun for automatic coating of work pieces.
2.2 TYPE OF USE
The gun is suitable for atomizing liquid products, particularly coating products, using the
AirCoat process.
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.
Only operate the device as a whole.
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.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in Directive
2014/34/EU, (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.
When operating the device with a coating product with a temperature of > 43 °C; 109.4
°F, identify the device with a warning label that says "Warning - hot surface" according to
Chapter 4.2.6.
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.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: AirCoat automatic gun
Manufacturer: Wagner International AG
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 the "Technical Data"
chapter.
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device 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 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.
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MAX. TEMPERATURE FLUID
25 MPa / 3625 psi / 250 bar
MAX. PRESSURE FLUID
3.3 TYPE PLATE
ORDER NUMBER DOC 2312956
GA 4000ACIC
1 2
GA 4000ACIC
80°C / 176°F
B_06637
Designation
1 Maximum product pressure
2 Maximum product temperature
3 Serial number
4 Maximum air temperature
5 Maximum air inlet pressure
SERIAL.NO: IC-XXXXX
J. WAGNER AG
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
II 2 G X
4 5
MAX. PRESSURE AIR
0.6 MPa / 90 psi / 6 bar
MAX. TEMPERATURE AIR
50°C / 125°F
GA 4000ACIC
3
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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock.
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform personnel about planned
work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
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4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or vapors!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 M ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product/air hoses that have been adapted to the working pressure are
used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M .
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M .
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. No smoking.
Ensure that the pipe joints, hoses, equipment parts and connections are
permanently, technically leak-proof:
– Periodic preventative maintenance and service (replacing hoses, checking
tightness of connections, etc.).
– Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g. daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
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GA 4000ACIC
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics applications: Persons belonging to a risk group according to EMF
guideline 2013/35/EU (e.g., carriers of active implants), must not enter the highvoltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied 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 sucient health and environmental safety: Operate the device in a spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.
If necessary or at least every 12 months, the liquid ejection devices must be checked
for safe working conditions by an expert (e.g. WAGNER Service Technician) in
accordance with the guidelines for liquid ejection devices (DGUV [German Statutory
Accident Insurance] regulation 100-500 section 2.29 and 2.36).
– For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure relief" chapter:
– if pressure relief is required,
– if the spraying work is interrupted or stopped.
– before the device is cleaned on the outside, checked, or serviced,
– before the spray nozzle is installed or cleaned.
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GA 4000ACIC
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
4.2.3 GROUNDING THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
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4.2.4 PRODUCT HOSES
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure
generated.
Ensure that the following information can be seen on the high-pressure hose:
– manufacturer,
– permissible operating pressure,
– date of manufacture.
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), or that the
hoses are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 M .
Suction hoses may not be subjected to pressure.
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4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure
that all equipment and resources (e.g., collection tank, funnel, transport cart) are
conductive or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Explosive gases are produced when aluminum comes into contact with
halogenated hydrocarbons. To clean aluminum, do not use liquids containing
halogenated hydrocarbons.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
– depending upon the coating product used,
– depending on the flushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of
equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
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GA 4000ACIC
External Cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects
and never spray cleaning agents with a gun. Cleaning the device must not damage
it in any way.
Ensure that no electrical component is cleaned with or even immersed in solvent.
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4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries.
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F:
– Identify the device with a warning label "Warning – hot surface".
Order No.
9998910 Instruction label
9998911 protection label
Note: Order the two stickers together.
4.2.7 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are
assigned to the unit.
Do not use any defective components.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
Observe the operating and service manual for all work.
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GA 4000ACIC
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
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5 DESCRIPTION
5.1 COMPONENTS
A
F
I
G
H
B_06650
N
ORDER NUMBER DOC 2312956
B
D
J
C
L
E
GA 4000ACIC
B_06651
K
M
Designation
A Gun head
B Spray gun body
C Tension sleeve drive
D Base plate
E Atomizing air connection (blue)
F Union nut
G Air cap (blue, red or bronze)
H Nozzle
I Standard holder
J Connecting tting (product)
K Connecting tting (product)
L Connection for control air (red)
M Shaping air throttle
N Product channel lock pin
The device consists of a gun head (A), gun body (B), drive (C) and base plate (D). The air cap
(G), appropriate nozzle (H) and various parts for sealing and fastening are attached to the
gun head (A). The product valve and packing are housed in the gun head (A). The clamping
mechanism for the packing is installed in the gun body (B). The gun body also serves as
a connecting piece between the drive (C) and the gun head (A). The drive (C) consists a
diaphragm and a pressure spring for the product valve. The base plate (D) contains all
connections (E, J, K) and a shaping air throttle (M). It can be used to connect the gun to the
corresponding reciprocator or gun holder.
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5.2 FUNCTIONAL DESCRIPTION
5.2.1 MODE OF OPERATION
ORDER NUMBER DOC 2312956
GA 4000ACIC
Diagram:
SA = Shaping air
AA = Atomizing air
CA = Control air
M = Product
C = Circulation
Open:
The piston in the drive is charged with control air and moves toward the rear. This ensures
that the air valve which releases the shaping and atomizing air is opened rst. The product
valve is then opened with a mechanical delay. In this position, the pressurized coating
product is applied to the work piece.
Close:
The piston is relieved, and the product valve closes due to the pressure spring which
presses against the product valve tappet. The air valve is then closed, again with a spring
force and mechanical delay.
M
AA / SA
CA
B_00521
C
Nozzle
SA
AA
Additional functions:
The shaping air throttle is used to regulate the shaping air volume, while the atomizing air
is adjusted via an external pressure regulator. The two air streams do not ow separately
until they are downstream of the air valve, so that the pressure of the shaping air
corresponds roughly to that of the atomizing air and so that they inuence each other
during adjustment.
The product connections and the paint channels in the base plate are arranged so that
several guns can run in circulation mode.
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5.2.2 MODE "NC" AND "C"
DANGER
Spurting out of liquids with high pressure!
Danger to life and equipment damage.
For the operating mode NC (no product circulation), the spray gun may only be
connected if the lock pin is installed.
5.2.2.1 MODE "NC" WITHOUT PRODUCT CIRCULATION
GA 4000ACIC
In this mode of operation, the left or the right
product channel in the gun head (A) is locked by
the lock pin (M) and the product entrance (ME) is
always on the opposite side.
5.2.2.2 MODE "C" WITH PRODUCT CIRCULATION
In this mode of operation, the lock pin (M)
must be removed from the left or right product
channel in the gun head (A). Screw on additional
connection tting (J). The product entrance (ME)
and the product return (MR) are freely selectable
in this mode of operation.
A
M
4x 4 Nm; 2.95 lbft
A
B
M
B_03069
ME
D
4x 4 Nm; 2.95 lbft
B
MR
ME
J
B_03489
D
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5.2.3 SPRAYING PROCEDURE
5.2.3.1 AIRCOAT FLAT SPRAYING PROCEDURE
For normal applications with the AirCoat at jet process, the spray product is atomized at
a pressure of 3-12 MPa; 30-120 bar; 435-1740 psi. For normal applications, a soft, optimum
spray jet is achieved with help of the atomizing air, which has a pressure of 0.05-0.25 MPa;
0.5-2.5 bar; 7.2-36 psi. This eliminates most overlapping problems in the peripheral zones.
The shaping air allows the width of the spray jet to be increased or decreased.
Air cap
Variable spray jet width
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GA 4000ACIC
Atomizing air
Advantages:
– Large application volume.
– Low fogging tendency.
– Good nish.
– High-viscosity products can easily be applied.
– Jet width adjustment.
Shaping air
B_03073
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5.2.3.2 AIRCOAT ROUND SPRAYING PROCEDURE
For normal applications with the AirCoat round jet process, the spray product is atomized
at a pressure of 3-12 MPa; 30-120 bar; 435-1740 psi.
For normal applications, the air at 0.05-0.25 MPa; 0.5-2.5 bar; 7.2-36 psi produces a soft
spray jet. The spray jet can be adjusted by turning the nozzle nut.
The multi-channel swirl nozzle produces ne paint particles, while at the same time
reducing their forwards speed and swirling them to produce a rotating motion. The result
is a soft, extremely well atomized spraying cloud.
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GA 4000ACIC
AirCoat air
Spray product
AirCoat air
B_00023
Multi-channel swirl nozzle
Advantages:
– Large application volume.
– Low fogging tendency.
– Good nish.
– High-viscosity products can easily be applied.
5.3 INCLUDED ITEMS
5.3.1 TYPE DESCRIPTION
GA 4000 AC XX
① ② ③ ④
Nozzle nut
Spray jet
①
GA = Automatic gun
②
4000 = Gun type
③
AC = AirCoat spraying process
④
IC = Shaping and atomizing air controlled via valve within gun.
EC = Shaping and atomizing air controlled via valve outside of gun.
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VERSION 05/2018
5.3.2 OVERVIEW
The Aircoat automatic gun is composed of the gun body and supplementary components.
Circulation operating mode is possible.
5.3.4.4 Round nozzles, supplementary
components
5.3.4.3 Flat nozzles,
supplementary components
ORDER NUMBER DOC 2312956
5.3.3 Gun body of GA 4000ACIC
automatic gun
5.3.4.7 Lock pin, supplementary
components
GA 4000ACIC
5.3.4.6 Air supply connections,
supplementary components
5.3.4.2 Air caps, supplementary
components
5.3.4.1 Base plates,
supplementary
components
13.5 Mounting
brackets, accessories
5.3.4.5 Product connections,
supplementary components
B_06652
24
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VERSION 05/2018
ORDER NUMBER DOC 2312956
GA 4000ACIC
5.3.3 STANDARD VARIANT
Order No. Designation
1 2312132 AirCoat automatic gun GA 4000ACIC
1 2338603 AirCoat automatic gun GA 4000ACIC (RP)
The basic equipment includes:
Order No. Designation
1 2315627 CE Declaration of Conformity
1 2312955 Operating manual, German
1 See Chap. 1.3 Operating manual in local language
The supplementary components can be used to harmonize and supplement the
standard equipment of the automatic gun perfectly to any application depending upon
requirements and accessory requests.
The delivery note shows the exact scope of delivery.
5.3.4 SUPPLEMENTARY COMPONENTS
5.3.4.1 BASE PLATE
Order No. Designation
2308810
2363386
Base plate GA 4000ACIC R (including seals and air
connections)
Base plate, GA 4000ACIC S (including seals and air
connections)
B_03484
B_06653
25
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VERSION 05/2018
B_00021
ORDER NUMBER DOC 2312956
5.3.4.2 AIR CAPS
Order No. Designation
2308809 Air cap HV plus (blue) for high viscosity products
2308808 Air cap LV plus (red) for low viscosity products
GA 4000ACIC
B_03048
B_03049
2313493 Air cap LA plus (bronze)
2340299 Air cap LV plus (blank)
5.3.4.3 ACF3000 AIRCOAT FLAT JET NOZZLES
Order No. Designation
379XXX A selection guide for nozzles can be found in Chapter 13
5.3.4.4 AIRCOAT ROUND JET NOZZLES ACR3000
Order No. Designation
B_03098
B_04231
132XXX A selection guide for nozzles can be found in Chapter 13
B_03061
26
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VERSION 05/2018
ORDER NUMBER DOC 2312956
5.3.4.5 PRODUCT CONNECTIONS
Order No. Designation
350550 Straight connecting tting
2314065 Connecting tting 90°; 1/4–NPSM
2328186 90° connecting tting; G1/4"
5.3.4.6 AIR SUPPLY CONNECTIONS
Order No. Designation
GA 4000ACIC
B_03074
B_03097
B_06645
9998090 Straight threaded tting 6 mm–1/8"; 0.24 inch–1/8" * standard
9998993 Straight threaded tting 8 mm–1/8"; 5/16"–1/8"
5.3.4.7 SHUTTER PIN
Order No. Designation
2310534 Complete lock pin
5.3.4.8 PACKING INSERT GA 4000AC
Order No. Designation
2313516 Packing Insert GA 4000AC
2338601 Packing insert GA 4000AC (RP)
5.3.4.9 VALVE MOUNTING
B_00507
B_00508
B_03050
B_04228
Order No. Designation
2314279 Valve mounting GA 4000AC complete (80° angle)
2340315 Valve mounting GA 4000AC complete (50° angle)
B_04232
27
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VERSION 05/2018
5.4 DATA
5.4.1 MATERIALS OF PAINTWETTED PARTS
Metals Plastics
Carbide Stainless steel 1.4305 POM FPM
Stainless steel 1.4310 Stainless steel 1.4104 PTFE PA 6.6
5.4.2 TECHNICAL DATA
Description Units Value
Maximum air inlet pressure MPa; psi; bar 0.6; 87; 6
Maximum product pressure MPa; psi; bar 25; 3625; 250
Product connection (internal thread) inch G1/4"
Air connection (internal thread) inch G1/8"
Weight G; oz 880; 31
Maximum product temperature °C; °F 80; 176
Maximum air temperature °C; °F 50; 122
Maximum ambient temperature °C; °F 5–40; 41–104
Sound level at 0.3 MPa; 3 bar; 43.5 psi air
pressure and 11 MPa; 110 bar; 1549 psi
product pressure***
ORDER NUMBER DOC 2312956
UHMW-PE EPDM
dB(A) 82.0
GA 4000ACIC
*** A rated sound pressure level measured at 0.5 m distance, Lpa 0.5 m, according to DIN EN
14462: 2005.
28
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VERSION 05/2018
M
5.4.3 MEASUREMENTS AND CONNECTIONS
ORDER NUMBER DOC 2312956
GA 4000ACIC
M5
Ø 3.2
F F
E
A
D
Connection data:
Base plate to GA 4000ACIC R
M8
Pos mm inch
A 129 5.08
B 47 1.85
C 77.5 3.05
D 55 2.17
E 18±0.1 0.71±0.004
F 18±0.1 0.71±0.004
B
C
B_03486
G1/8" -> 6 mm; 0.24 inch control air
G1/8" -> 8 mm; 0.31 inch atomizing air
G1/4" -> 1/4–NPSM product
AA
CA
M
B_3487
29
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VERSION 05/2018
ORDER NUMBER DOC 2312956
GA 4000ACIC
Ø 3.2
F F
E
A
D
Connection data:
Base plate to GA 4000ACIC S
M8
Pos mm inch
A 129 5.08
B 52 2.04
C 61 2.40
D 37.5 1.48
E 18±0.1 0.71±0.004
F 18±0.1 0.71±0.004
B
C
B_06648
G1/8" -> 6 mm; 0.24 inch control air
G1/8" -> 8 mm; 0.31 inch atomizing air
G1/4" -> 1/4–NPSM product
G1/4" -> G1/4" product
M
AA
M
CA
B_06649
30
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VERSION 05/2018
ORDER NUMBER DOC 2312956
GA 4000ACIC
6 COMMISSIONING
6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL
The assembly and commissioning personnel must have the technical skills to safely
commission the device.
When assembling, commissioning and carrying out all work, read and follow the
operating manuals and safety regulations for the additionally required system
components.
A skilled person must check to ensure that the device is in a reliable state after it is installed
and commissioned.
6.2 STORAGE CONDITIONS
Until the point of assembly, the device must be stored in a dry location, free from vibrations
and with a minimum of dust. The device must be stored in closed rooms.
The air temperature at the storage location must be between -20 °C and +60 °C (-4 °F and
+140 °F).
The relative air humidity at the storage location must be between 10 and 95% (without
condensation).
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 0 °C and 40 °C (32
°F and 132 °F).
The relative air humidity at the installation site must be between 10 and 95% (without
condensation).
6.4 INSTALLATION AND CONNECTION
The spray gun must be combined with various components to make up a spraying system.
The spraying system shown in the gure is only one example of an AirCoat spraying
system. Your WAGNER distributor would be happy to assist you in creating a spraying
system solution that meets your individual needs.
You must familiarize yourself with the operating manuals and the safety regulations of all
additional system components before starting commissioning.
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6.4.1 TYPICAL AIRCOAT SPRAYING SYSTEM
ORDER NUMBER DOC 2312956
GA 4000ACIC
B_00559
Designation Designation
A Control cabinet F Paint supply
B Conveyor G Part recognition
C Work piece H Spray guns
D Spray booth I Supply air system and exhaust air
system
E Reciprocator
6.4.2 VENTILATION OF THE SPRAY BOOTH
Operate the device in a spray booth approved for the working materials.
-or-
Operate the device on an appropriate spraying wall with the ventilation (extraction)
switched on.
Observe national and local regulations for the exhaust air speed.
6.4.3 AIR SUPPLY LINES
Ensure that only dry, clean atomizing air is used in the spray gun! Dirt and moisture in the
atomizing air worsens the spraying quality and spray pattern.
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VERSION 05/2018
6.4.4 PRODUCT SUPPLY LINES
ORDER NUMBER DOC 2312956
GA 4000ACIC
NOTICE
Impurities in the spraying system!
Spray gun blockage, products harden in the spraying system.
Flush the spray gun and paint supply with a suitable ushing agent.
6.5 GROUNDING
A conductive connection (potential equalization cable) must be established between
original tank and the equipment.
Ground all device components.
Ground the work pieces to be coated.
6.6 SAFETY CHECKS
Carry out safety checks in accordance with Chapter 8.2.3.
6.7 LACQUER PREPARATIONS
The viscosity of the lacquer is of great importance. The best spraying results are obtained
with values between 80 and 260 millipascal x Sec (mPas).
Processing of up to 260 mPas is generally possible without problems if high coating
thicknesses are required. It is important for the optimum coating quality that the paint
temperature is kept constant during coating.
Please also read the technical data sheet of the lacquer for optimal processing, viscosity
adjustment and intermixing of the product.
In the case of application problems contact the lacquer manufacturer.
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VERSION 05/2018
6.7.1 VISCOSITY CONVERSION TABLE
10 10 0.1 5 16
15 15 0.15 8 17
20 20 0.2 10 18
25 25 0.25 14 12 19
30 30 0.3 15 14 20
40 40 0.4 17 18 22
50 50 0.5 19 22 24
60 60 0.6 21 26 27
70 70 0.7 23 28 30
80 80 0.8 25 31 34
90 90 0.9 28 32 37
100 100 1 30 34 41
120 120 1.2 33 41 49
140 140 1.4 37 45 58
160 160 1.6 43 50 66
180 180 1.8 46 54 74
200 200 2 49 58 82
220 220 2.2 52 62
240 240 2.4 56 65
260 260 2.6 62 68
280 280 2.8 65 70
300 300 3 70 74
320 320 3.2
340 340 3.4
360 360 3.6 80
380 380 3.8
400 400 4 90
ORDER NUMBER DOC 2312956
GA 4000ACIC
34
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VERSION 05/2018
6.8 COMMISSIONING
6.8.1 PREPARATION BEFORE COMMISSIONING
ORDER NUMBER DOC 2312956
NOTICE
Impurities in the spraying system!
Spray gun blockage.
Flush the spray gun and paint supply with a suitable ushing agent before
commissioning.
6.8.2 COMMISSIONING
GA 4000ACIC
1. Mount spray gun to reciprocator.
2. Connect product hoses (supply and return ow) to spray gun and product supply
system.
3. Fit nozzle on nozzle seal. Fit air cap over nozzle.
Note the attened parts (X) on the nozzle and in the air cap.
Fit the union nut and tighten by hand.
4. Connect control air hose and atomizing air hose to spray gun and to oil-free, dry air
supply.
5. Visually check the permissible pressures for all the system components.
6. Make sure that the device and all other conductive parts within the work area are
grounded.
7. Set operating pressure to 100 MPa; 10 bar; 1,450 psi and use a suitable medium to
check no connections are leaking.
8. Relieve the pressure from the spray gun and device.
6.8.3 VERIFYING A SAFE OPERATIONAL CONDITION
A skilled person must check to ensure that the device is in a reliable state after it is
installed and commissioned.
This includes:
– Carry out safety checks in accordance with Chapter 8.2.3.
X
B_03071
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VERSION 05/2018
ORDER NUMBER DOC 2312956
7 OPERATION
7.1 TRAINING THE OPERATING PERSONNEL
The operating personnel must be qualied to operate the entire system.
The operating personnel must be familiar with the potential risks associated with
improper behavior as well as the necessary protective devices and measures.
Before work commences, the operating personnel must receive appropriate system
training.
7.2 TASKS
CAUTION
Spurting out of liquids with high pressure!
Risk of injury and damage to the device.
No persons should be located in the hazard area during operation.
Make sure to keep a safe distance during setting up, installation and maintenance
work.
GA 4000ACIC
Ensure that:
The regular safety checks are carried out in accordance with Chapter 8.2.3,
commissioning is carried out in accordance with Chapter 6.8.
7.2.1 STARTING TO SPRAY WITH THE AIRCOAT
1. Set product supply to operating pressure of approx. 8 MPa; 80 bar; 1160 psi and start
up.
2. Spray (release control air) and check the atomization.
3. Set the spray pressure on the product supply such that optimum product atomization
is attained.
4. Open air pressure regulator for atomizing air and set.
5. Adjust the amount of air at the shaping air throttle until the optimum spray pattern
is reached.
The relation between the spray pattern and shaping is shown in the illustration below.
Note:
Repeat points 4 and 5 until the optimum spray pattern is reached (iterative process).
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VERSION 05/2018
ORDER NUMBER DOC 2312956
Spray pattern shapes
No shaping air/
atomizing air
Too little shaping
air/atomizing air
Note:
The ow rate can be changed by:
– changing the product pressure or
– Using a dierent at jet nozzle (see Chapter 7.2.4 and Chapter 13).
7.2.2 ADJUSTING THE SPRAY PATTERN
The spray pattern can be adjusted to suit the
object being sprayed using the shaping air
regulator. The illustration shows the inuence of
the shaping air regulator on the spray pattern.
Other nozzle sizes can be mainly used to obtain
larger or smaller spray patterns.
Shaping air
throttle fully
open.
GA 4000ACIC
Correct amount
of shaping air/
atomizing air
B_00071
Shaping air
throttle fully
closed.
B_03053
7.2.3 PRESSURE RELIEF/WORK INTERRUPTION
The pressure must always be relieved:
– when the spraying tasks are nished,
– before carrying out maintenance work on the spraying system,
– before carrying out cleaning tasks on the spraying system,
– before moving the spraying system to another location,
– if something must be checked on the spraying system,
– if the nozzle or the lter is removed from the spray gun.
The components for pressure relief on a CE-compliant spray system include:
– Air cock with pressure relief hole mounted between compressed air source and pneumatic pump.
– Product pressure relief valve mounted between pump and spray gun.
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VERSION 05/2018
Pressure Relief Procedure:
1. Turn compressed air regulator for shaping and atomizing air on the superordinate control to "0".
2. Close the compressed air supply on the material side upon the product pressure generator.
3. Open product pressure relief valve (see system description) and relieve pressure from the system.
4. Leave product pressure relief valve open.
If the pressure is still not completely relieved after this:
– If the nozzle is obstructed: loosen the union nut, remove the air cap and nozzle to release remaining
pressure.
– If product hose is obstructed: slowly loosen the hose connections to release the remaining pressure.
Note:
Always follow the procedure described above if pressure relief is specied in the instructions.
7.2.4 CHANGING AIRCOAT NOZZLE
ORDER NUMBER DOC 2312956
GA 4000ACIC
NOTICE
Defective AirCoat nozzle!
Insucient paint application quality.
Do not use sharp-edged objects to treat carbide on the AirCoat nozzle.
1. Relieve the pressure of gun and device.
2. Secure gun (remove the control air hose).
3. Unscrew union nut (A).
4. Remove air cap (B).
5. Press AirCoat nozzle (C) out of air cap (B) by
hand and treat with cleaning agent until all
remaining paint has been dissolved.
Assembly:
6. Fit AirCoat nozzle (C) in nozzle seal (D).
7. Fit air cap (B) over nozzle (C).
Note the attened parts (X) on the nozzle and
in the air cap.
8. Fit the union nut with nozzle guard (A) and
tighten by hand.
7.2.5 CLEANING AIRCOAT NOZZLE
For disassembly and assembly of AirCoat nozzles, see Chapter 7.2.4.
The AirCoat nozzle (C) can be placed into a cleaning solution which has been recommended
by the paint manufacturer.
B
A
D
C
X
B_03071
B_06654
38
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VERSION 05/2018
ORDER NUMBER DOC 2312956
7.2.6 ELIMINATING NOZZLE CLOGGING
GA 4000ACIC
1. Relieve the pressure of gun and device.
2. Secure gun (remove the control air hose).
3. Unscrew union nut (A).
4. Remove air cap (B).
5. Push AirCoat nozzle (C) out of air cap (B) by hand and place on nozzle seal (D) the
other way round with the nozzle tip towards the rear.
6. Fit air cap (B) on nozzle (C).
Note the attened parts (X) on the nozzle and in the air cap.
7. Screw on the union nut (A) over the air cap (B) onto the spray gun and tighten by
hand.
8. Switch the product pressure back on.
9. Spray (connect control air hose).
10. When the blockage has been ushed out, switch o the spray gun.
11. Relieve the pressure of gun and device.
12. Secure gun (remove the control air hose).
13. Unscrew union nut (A).
14. Remove air cap (B) and push AirCoat nozzle (C) out by hand.
Clean nozzle and nozzle seal and ret nozzle in spraying position on nozzle seal (D).
15. Fit air cap (B) on nozzle (C).
Note the attened parts (X) on the nozzle and in the air cap.
16. Screw on the union nut (A) over the air cap (B) onto the spray gun and tighten by
hand.
17. Connect control air.
Switch the product pressure and the air pressure back on.
X
B_03071
C
B
A
Nozzle in cleaning position
Nozzle in spray position
D
B_06655
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VERSION 05/2018
7.2.7 REPLACING NOZZLE INSERT OF ROUND JET NOZZLE
1. Relieve the pressure of gun and device.
2. Secure gun (remove the control air hose).
3. Remove nozzle insert (B) with nozzle spanner (A).
4. Fit new nozzle insert in reverse order (see Chapter 8.2.6).
Note:
Flush out clogged round jet nozzle:
1. Use nozzle spanner (A) to loosen nozzle insert (B) by a half
turn.
2. Remove the nozzle spanner and switch on the spray gun
briey.
3. After ushing the nozzle, re-tighten the nozzle insert.
ORDER NUMBER DOC 2312956
GA 4000ACIC
B_06656
B
A
40
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VERSION 05/2018
ORDER NUMBER DOC 2312956
GA 4000ACIC
8 CLEANING AND MAINTENANCE
8.1 CLEANING
8.1.1 CLEANING PERSONNEL
Cleaning work should be undertaken regularly and carefully by qualied and trained
personnel. They should be informed of specic hazards during their training.
The following hazards may arise during cleaning work:
– risk to health from inhaling solvent vapors,
– use of unsuitable cleaning tools and aids.
8.1.2 FLUSHING AND CLEANING THE GUN
NOTICE
Flushing agent in the air duct!
Functional faults caused by swollen seals.
When cleaning, always operate the spray gun at at least 0.05 MPa; 0.5 bar; 7.25 psi
shaping air.
Always point the spray gun down when cleaning.
Ensure that neither paint nor ushing agent enters the air duct.
Never immerse the spray gun in cleaning agent.
The spray gun and the device must be cleaned and ushed daily. The cleaning/ushing
agents used for cleaning or ushing must correspond with the working material.
1. Relieve the pressure of gun and device.
2. Secure gun (remove the control air hose).
3. Connect the cleaning agent supply.
4. Dismount AirCoat nozzle and clean separately (see Chapter 7.2.4).
5. Pressurize the cleaning agent supply to a maximum pressure of 4 MPa; 40 bar; 580 psi
and thoroughly ush the spray gun.
6. Relieve the pressure of gun and device.
7. Secure gun (remove the control air hose).
8. Clean outside of spray gun with a cleaning agent recommended by the lacquer
manufacturer and dry with a cloth or blow gun.
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VERSION 05/2018
8.2 MAINTENANCE
8.2.1 MAINTENANCE PERSONNEL
Maintenance work should be undertaken regularly and carefully by qualied and trained
personnel. They should be informed of specic hazards during their training.
The following hazards may arise during maintenance work:
– risk to health from inhaling solvent vapors,
– use of unsuitable tools and aids.
An authorized person must ensure that the device is checked for being in a reliable state
after maintenance work is completed.
8.2.2 MAINTENANCE INSTRUCTIONS
ORDER NUMBER DOC 2312956
GA 4000ACIC
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Only repair and replace parts that are listed in the "Spare parts" chapter and that are
assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
Observe the operating and service manual for all work.
Prior to Maintenance
– Flush and clean the system. Chapter 8.1.2
After maintenance
– Carry out safety checks in accordance with Chapter 8.2.3.
– Put the system into operation and check for leaks as described in Chapter 6.8.
In accordance with the guideline for liquid ejection devices (DGUV regulation 100500 sections 2.29 and 2.36):
- The liquid ejection devices should be checked by an expert (e.g., WAGNER service
technician) for their safe working conditions as required and at minimum every
12 months.
– For shut down devices, the examination can be suspended until the next start-up.
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VERSION 05/2018
8.2.3 SAFETY CHECKS
8.2.3.1 GROUNDING CHECK
Daily: Before starting work, carry out a visual inspection to ensure that the system is
grounded.
8.2.3.2 PRODUCT HOSES, PIPES AND COUPLINGS
The service life of the complete hoses between product pressure generator and application
device is reduced due to environmental inuences even when handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
Additionally, the operator must regularly check the complete hoses for wear and
tear as well as for damage at intervals that he/she has set. Records of these checks
must be kept.
The complete hose is to be replaced as soon as one of the two following intervals
has been exceeded:
– 6 years from the date of the hose crimping (see tting embossing).
– 10 years from the date of the hose imprinting.
ORDER NUMBER DOC 2312956
GA 4000ACIC
Fitting embossing Meaning
xxx bar Pressure
yymm Crimping date (year/month)
XX Internal code
Hose imprinting Meaning
Wagner Name/Manufacturer
yymm Date of manufacture (year/month)
xxx bar (xx MPa)
e.g., 270 bar (27 MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
Pressure
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VERSION 05/2018
8.2.4 REPLACING THE PAINT HOSE
1. Decommissioning work and cleaning.
2. Relieve the pressure of gun and device.
3. Secure gun (remove the control air hose).
4. Place open-ended wrench size 17 mm; 0.67 inch
on ats of product connection and counterhold.
5. Unscrew nut of product hose with open-ended
wrench size 19 mm; 0.75 inch.
6. Assembly:
Fit product hose by hand and tighten with 2
open-ended wrenches.
ORDER NUMBER DOC 2312956
GA 4000ACIC
SW17 mm
8.2.5 REPLACING THE NOZZLE SEAL
NOTICE
Shaping air and atomizer air not separate!
Poor spray pattern.
Spray jet cannot be adjusted.
Treat the distributor seal (F) with care.
1. Decommissioning work and cleaning.
2. Relieve the pressure of gun and device.
3. Secure gun (remove the control air hose).
4. Unscrew union nut (A).
5. Remove air cap (B) and nozzle (C).
6. Release the nozzle seal (D) with the help of a screwdriver.
7. Fit new nozzle seal to valve housing (E).
8. Assemble in reverse order.
SW19 mm
B_03058
E
D
C
B
A
F
B_06657
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VERSION 05/2018
ORDER NUMBER DOC 2312956
8.2.6 REPLACING THE SEALING FITTING OF THE ROUND JET NOZZLE
NOTICE
Defective nozzle body!
Poor spray pattern.
Handle the nozzle body (A) with care.
Unscrew the nozzle by hand.
B_06658
GA 4000ACIC
Nozzle wrench (D)
Order no. 128901
Eject with
1.5 mm; 0.06 inch pin.
D
Note:
The sealing tting (E) can be pulled out of
the nozzle body using a small eye wood bolt.
Hold in position with a size 13
mm; 0.51 inch socket wrench.
A
B_03060
C
B
B_00542
B_00543
E
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VERSION 05/2018
ORDER NUMBER DOC 2312956
GA 4000ACIC
9 TROUBLESHOOTING AND RECTIFICATION
Functional fault Cause Remedy See Chapter
Insucient product
output
Poor spray pattern Atomizing air incorrectly
Air valve leaking / air
leaks
Packing leaking. Packing worn. Replace packing.
Spray gun will not shut
o correctly/product
valve leaking.
Nozzle too small Select larger nozzle. 13
Product pressure too
low.
Filter upstream of gun
or high-pressure lter
clogged at pump.
Nozzle clogged. Clean the nozzle. 7.2.6
The valve rod path is too
short.
adjusted.
Nozzle is too large. Select a smaller nozzle.
Nozzle worn. Replace the nozzle. 7.2.4
Product pressure too
low.
The product viscosity is
too high.
Nozzle partially clogged. Clean the nozzle. 7.2.5and7.2.6
The drilled holes in the
air cap are damaged or
clogged.
Incorrectly selected air
cap.
The seals on the valve
rod are damaged or
the valve rod itself is
damaged.
Air valve seals are leaky. Replace the air valve seal. 8.2.5
The valve seat or the
valve ball is damaged.
Increase product pressure.
Clean or replace lter.
Increase the control air pressure.
Replace the valve rod.
Readjust the atomizing air. 7.2.1
Increase the product pressure at
pump.
Dilute the spray product
in accordance with the
manufacturer's instructions.
Clean or replace the air cap.
Use suitable air cap (high
viscosity/low viscosity).
Replace the entire valve rod or
the individual seals.
Replace the parts.
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ORDER NUMBER DOC 2312956
GA 4000ACIC
10 REPAIR WORK
10.1 REPAIR PERSONNEL
Repair work should be undertaken carefully by qualied and trained personnel. They
should be informed of specic hazards during their training.
The following hazards may arise during repair work:
– risk to health from inhaling solvent vapors,
– use of unsuitable tools and aids.
A skilled person must check to ensure that the device is in a reliable state after it is repaired.
10.2 REPAIR NOTES
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Only repair and replace parts that are listed in the "Spare parts" chapter and that are
assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
Observe the operating and service manual for all work.
Before Repair Work
– Flush and clean the system according to Chapter 8.1.2.
After Repair Work
– Carry out safety checks in accordance with Chapter 8.2.3.
– Put the system into operation and check for leaks as described in Chapter 6.8.
– Function test in accordance with Chapter 11.
In accordance with the guideline for liquid ejection devices (DGUV regulation 100500 sections 2.29 and 2.36):
- The liquid ejection devices should be checked by an expert (e.g., WAGNER service
technician) for their safe working conditions as required and at minimum every
12 months.
– For shut down devices, the examination can be suspended until the next start-up.
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10.3 REPLACING PARTS OF THE GUN BODY
10.3.1 DISASSEMBLY OF GA 4000ACIC
NOTICE
Defective plunger shaft!
Packing leaking.
Greater wear on the packing.
Handle the plunger shaft (K) with care.
The plunger shaft has the function of a sliding surface.
Note:
The complete base plate (B) does not
have to be removed.
GA 4000ACIC
M5 wrench size 3 mm; 0.12 inch
B_06660
B_06659
B
K
B_03065
Note:
Circulation mode
without lock pin
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ORDER NUMBER DOC 2312956
M5 wrench size 3 mm; 0.12
inch
GA 4000ACIC
Blow gun
Note:
Stuck components can be pushed
out with a drift
Note:
Pull out distributor seal (F) using
pliers.
M5 wrench size 12 mm; 0.47
inch
3 mm; 0.12 inch.
B_03066
F
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10.3.2 PACKING INSERT GA 4000AC RP
ORDER NUMBER DOC 2312956
GA 4000ACIC
180°
SW15
B_04227
Order of seals:
1) Sealing set GA 4000 packing RP: Order No. 2339140
Product Order No. Order No. (set of 12 packings)
1 PTFE + GF - 2339141
2 PE - 2339142
3 PTFE + GF - 2339141
4 PE - 2339142
5 PTFE + GF - 2339141
6 PTFE + GF - 2339141
7 Mobilux® EP 2 grease 380924 -8 Vaseline white 9992698 --
8
5 Nm (Torx TX40)
5
6
7
8
3
4
2
1
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2) Sealing set GA 4000 packing RP special: Order No. 2339810
Product Order No. Order No. (set of 12 packings)
1 PTFE - 2339143
2 PE - 2339142
3 PTFE - 2339143
4 PE - 2339142
5 PTFE + GF - 2339141
6 PTFE + GF - 2339141
7 Mobilux® EP 2 grease 380924 -8 Vaseline white 9992698 --
ORDER NUMBER DOC 2312956
GA 4000ACIC
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10.3.3 ASSEMBLY OF GA 4000ACIC
General note:
Lightly grease o-rings and sliding
surfaces with Vaseline white PHV II.
GA 4000ACIC
SW 15; 0.59 inch
25 Nm; 8.85 lbft
SW 12; 0.47 inch
25 Nm; 8.85 lbft
Note:
Put distributor seal (G) on air cap (H) and place seal
and air cap in gun housing. Screw union nut (K) in until
the distributor seal ring catches in the groove (audible
click).
M5 SW 3; 0.12 inch
4 Nm; 2.95 lbft
G
H
K
B_03067
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Dismount union nut and air cap again.
ORDER NUMBER DOC 2312956
GA 4000ACIC
Wrench size 12 mm; 0.47 inch
10 Nm; 7.38 lbft
M5 wrench size 3 mm; 0.12 inch
4 Nm; 2.95 lbft
B_06661
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GA 4000ACIC
11 FUNCTION TEST AFTER REPAIR WORK
After all repair work, the spray gun must be checked for safe condition before
recommissioning. The necessary scope of inspection and testing depends on the repair
carried out and must be documented by the repair personnel.
12 DISPOSAL
When the equipment must be scrapped, please differentiate the disposal of the waste
materials.
The following materials have been used:
– Stainless steel
– Aluminum
– Elastomers
– Plastic
– Carbide
The consumable products (lacquers, adhesives, solvents) must be disposed of in accordance
with the applicable specific standards.
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GA 4000ACIC
13 ACCESSORIES
13.1 AIRCOAT NOZZLES ACF3000
Recommended gun lter
Recommended edge lter
Order No.
379107 07/10 0.007-0.18 10° Natural lacquer
379207 07/20 0.007-0.18 20°
379209 09/20 0.009-0.23 20° Clear lacquer
379309 09/30 0.009-0.23 30° Oils
379409 09/40 0.009-0.23 40°
379509 09/50 0.009-0.23 50°
379609 09/60 0.009-0.23 60°
379111 11/10 0.011-0.28 10° Synthetic resin lacquer
379211 11/20 0.011-0.28 20° PVC lacquer
379311 11/30 0.011-0.28 30°
379411 11/40 0.011-0.28 40°
379511 11/50 0.011-0.28 50°
379611 11/60 0.011-0.28 60°
379113 13/10 0.013-0.33 10° Lacquers
379213 13/20 0.013-0.33 20° Base coat
379313 13/30 0.013-0.33 30° Primer
379413 13/40 0.013-0.33 40° Filler
379513 13/50 0.013-0.33 50°
379613 13/60 0.013-0.33 60°
379813 13/80 0.013-0.33 80°
379115 15/10 0.015-0.38 10° Filler
379215 15/20 0.015-0.38 20° Rust proong paints
379315 15/30 0.015-0.38 30°
379415 15/40 0.015-0.38 40°
379515 15/50 0.015-0.38 50°
379615 15/60 0.015-0.38 60°
379815 15/80 0.015-0.38 80°
379217 17/20 0.017-0.43 20° Rust proong paints
379317 17/30 0.017-0.43 30° Latex paints
379417 17/40 0.017-0.43 40°
379517 17/50 0.017-0.43 50°
379617 17/60 0.017-0.43 60°
379817 17/80 0.017-0.43 80°
Marking
Drilled hole Spray angle
Red 200 mesh
Yellow 100 mesh
Application
200 mesh
100 mesh
60 mesh
B_00021
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GA 4000ACIC
Order No.
379219 19/20 0.019-0.48 20° Rust proong paints
379319 19/30 0.019-0.48 30° Latex paints
379419 19/40 0.019-0.48 40°
379519 19/50 0.019-0.48 50°
379619 19/60 0.019-0.48 60°
379819 19/80 0.019-0.48 80°
379221 21/20 0.021-0.53 20° Mica paints
379421 21/40 0.021-0.53 40° Zinc rich paints
379521 21/50 0.021-0.53 50° Rust proong paints
379621 21/60 0.021-0.53 60° Glue paints
379821 21/80 0.021-0.53 80°
379423 23/40 0.023-0.58 40°
379623 23/60 0.023-0.58 60°
379823 23/80 0.023-0.58 80°
379425 25/40 0.025-0.64 40°
379625 25/60 0.025-0.64 60°
379825 25/80 0.025-0.64 80°
379427 27/40 0.027-0.69 40°
379627 27/60 0.027-0.69 60°
379827 27/80 0.027-0.69 80°
379429 29/40 0.029-0.75 40°
379629 29/60 0.029-0.75 60°
379829 29/80 0.029-0.75 80°
379431 31/40 0.031-0.79 40°
379531 31/60 0.031-0.79 60°
379631 31/80 0.031-0.79 80°
379435 35/40 0.035-0.90 40°
379635 35/60 0.035-0.90 60°
379835 35/80 0.035-0.90 80°
Marking
inch; mm
Drilled hole
Recommended gun lter
Recommended edge lter
Spray angle
Yellow 100 mesh
60 mesh
White 50 mesh
Application
B_00021
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GA 4000ACIC
13.2 AIRCOAT NOZZLES ACF3000 S2 4 PIECES
Order No. Marking Drilled hole inch; mm Spray angle
2391811 9/40 S2 0.009; 0.23 40°
2391809 11/10 S2 0.011; 0.28 10°
2368877 11/20 S2 0.011; 0.28 20°
2396188 11/30 S2 0.011; 0.28 30°
2368879 11/40 S2 0.011; 0.28 40°
2368896 11/60 S2 0.011; 0.28 60°
2368876 11/80 S2 0.011; 0.28 80°
2368880 13/40 S2 0.013; 0.33 40°
2368897 13/60 S2 0.013; 0.33 60°
2368898 13/80 S2 0.013; 0.33 80°
2368899 15/60 S2 0.015; 0.38 60°
2396189 17/80 S2 0.017; 0.43 80°
13.3 ROUND JET NOZZLE ATTACHMENT
B_00021
Order No. Designation
394180 Round jet nozzle attachment (without
nozzle insert)
13.2
13.2.2
B_06639
13.2.1
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GA 4000ACIC
13.3.1 RXX NOZZLE INSERTS
Order No. Designation Marking Jet **
132720 Nozzle insert R11 11 approx. 250; 9.84
132721 Nozzle insert R12 12 approx. 250; 9.84
132722 Nozzle insert R13 13 approx. 250; 9.84
132723 Nozzle insert R14 14 approx. 250; 9.84
132724 Nozzle insert R15 15 approx. 250; 9.84
132725 Nozzle insert R16 16 approx. 250; 9.84
132726 Nozzle insert R17 17 approx. 250; 9.84
132727 Nozzle insert R18 18 approx. 250; 9.84
132728 Nozzle insert R19 19 approx. 250; 9.84
132729 Nozzle insert R20 20 approx. 250; 9.84
132730 Nozzle insert R21 21 approx. 250; 9.84
132731 Nozzle insert R22 22 approx. 250; 9.84
** Jet width in mm; inches at a distance of approx. 30 cm; 11.8 inches from the object
and at a pressure of 10 MPa; 100 bar; 1450 psi, synthetic resin paint, 20 DIN4 seconds.
B_00027
13.3.2 NOZZLE SCREW JOINT, COMPLETE
Order No. Designation
132922 Nozzle screw joint, complete
13.4 HOSES
Order No. Designation
9984405 High-pressure hose M16x1.5, 1 m; 3.28 ft, DN 4 mm; ID 0.16 inch, 27 MPa;
270 bar; 3916 psi
9984507 High-pressure hose M16x1.5, 15 m; 98.4 ft, DN 6 mm; ID 0.24 inch, 27 MPa;
270 bar; 3916 psi
9984510 High-pressure hose M16x1.5, 7.5 m; 24.6 ft, DN 4 mm; ID 0.16 inch, 27 MPa;
270 bar; 3916 psi
9984573 High-pressure hose NPSM1/4", 7.5 m; 24.6 ft, DN 4 mm; ID 0.16 inch,
27MPa; 270 bar; 3916 psi
9984574 High-pressure hose NPSM1/4"; 15 m; 98.4 ft, DN 6 mm; ID 0.24 inch,
27MPa; 270 bar; 3916 psi
9982035 Air hose, red, outer 6 mm; 0.24 inch, inner 4 mm; 0.16 inch, polyamide,
per meter
9982061 Air hose, blue, outer 6 mm; 0.24 inch, inner 4 mm; 0.16 inch,
polyamide, per meter
9982033 Air hose, green, outer 6 mm; 0.24 inch, inner 4 mm; 0.16 inch,
polyamide, per meter
9982062 Air hose, blue, outer 8 mm; 0.32 inch, inner 5.5 mm; 0.22 inch,
polyamide, per meter
B_00076
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B_00585
ORDER NUMBER DOC 2312956
13.5 MISCELLANEOUS
Order No. Designation
9997001 Nozzle cleaning brush
8612001 Nozzle cleaning needle set, 12 pieces
123446 Double tting M16x1.5 (for extension for product hose)
367560 Double tting NPSM 1/4" for product hose extension
GA 4000ACIC
380941
Standard mounting bracket, 180 mm; 16 mm, 7.1 inches; 0.63
inch
2314079 Cea adapter plate
380942 Rotary gun holder (standard)
380945 Rotary holder, 40/40/5
380943 Complete swivel drive
B_00510
B_03099
B_00586
380944 Cross clamp for swivel drive
B_00584
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GA 4000ACIC
14 SPARE PARTS
14.1 HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
Order number, designation and quantity
The quantity need not be the same as the number given in the quantity column " " on
the list. This number merely indicates how many of the respective parts are used in each
component.
The following information is also required to ensure smooth processing of your order:
– address for the invoice,
– address for delivery,
– name of the person to be contacted in the event of any queries,
– type of delivery (normal mail, express delivery, air freight, courier, etc.).
Identication in spare parts lists.
Explanation of column " " (labeling) in the following spare parts lists:
Wearing part
Note: These parts are not covered by warranty terms.
Not part of standard equipment, available, however, as additional extra.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Only repair and replace parts that are listed in the "Spare parts" chapter and that are
assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
Observe the operating and service manual for all work.
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14.2 SPARE PARTS LIST FOR GA 4000ACIC
GA 4000ACIC
1
1a
5
38
36
4
35
34
33
4 Nm; 2.95 lbft
37
10
9
8
7
6
12
13
16 / 16a
14
15
17
25 Nm; 18.44 lbft
20
10 Nm;
7.38 lbft
18
19
B_06662
Special version in EPDM*
37
41
42
43
40
25 Nm; 18.44 lbft
2
11
1 Nm;
0.74 lbft
30
31
3 Nm; 2.21 lbft
3
21
39
22
23
24
25
32
Loctite® 243
26
27
28
29
* EPDM version suitable for UV lacquers and acetone
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Order No. Designation
1 1 2312132 Spray gun body, GA 4000ACIC
1a 1 2338603 Spray gun body, GA 4000ACIC (RP)
2 1 2363386 Base plate, GA 4000ACIC-S, complete
3 1 2308810 Base plate, GA 4000ACIC-R, complete
4 1 2309945 Helical spring
5 1 2314274 End cap short
6 1 2308808 Air cap LV plus (red)
6 1 2308809 Air cap HV plus (blue)
6 1 2313493 Air cap LA plus (bronze)
6 1 2340299 Air cap LV plus (blank)
7 1 379… AC nozzle
8 1 394339 Sealing ring
9 1 364328 Nozzle seal
10 1 2314279 Valve housing, complete
11 1 9974245 O-ring
12 4 2307893 Socket cap screw
13 1 2314278 Head piece
14 2 9974153 O-ring
15 1 367528 O-ring
16 1 2313516 Packing insert GA 4000AC (standard version, can only be replaced
16a 1 2338601 Packing insert GA 4000AC (RP)
17 1 2314277 Piston housing IC
18 4 2308292 Socket cap screw
19 1 2310534 Complete product channel lock pin
20 1 2307873 O-ring
21 1 2307739 Mounting nut
22 1 2307868 Round spray jet reduction
23 1 9971388 O-ring
24 2 2310473 Sealing product
25 5 9974265 O-ring
26 1 9998993 Straight screw-in tting
27 1 9998090 Straight screw-in tting
28 1 9998618 Coding ring blue
29 1 9998995 Coding ring red
30 1 2382911 Product adapter plate
31 2 2310556 Hexagon socket countersunk head screw
32 1 2316367 Adapter plate IC-S
33 1 248314 O-ring
34 1 9971025 O-ring
35 1 2314275 IC piston, complete
36 1 2346098 IC valve rod, complete
37 1 9992698 Vaseline white PHHV
38 1 9998991 Helical spring
= Wearing parts
-> For service sets, see Chapter 14.3.
ORDER NUMBER DOC 2312956
completely)
GA 4000ACIC
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= Not part of the standard equipment but available as a special accessory
Order No. Designation
39 1 2314242 Base plate, GA 4000ACIC R
40 1 2322531 Piston seal EPDM
41 1 2322530 O-ring
42 1 9974179 O-ring
43 1 2322532 Seal set, GA 4000ACIC (EPDM)
= Wearing parts
-> For service sets, see Chapter 14.3.
= Not part of the standard equipment but available as a special accessory
14.3 SERVICE SETS AND SPARE PARTS GROUPS
Order No. Designation Consisting of spare parts items
2314353 Service set - Spray gun body, GA 4000ACIC 8, 9, 11, 14, 16, 33, 34
2338657 Service set - Spray gun body, GA 4000ACIC
(RP)
2314355 Service set - Base plate, GA 4000ACIC 23, 24, 25
2322532 Seal set, GA 4000ACIC (EPDM) 40, 41, 42
ORDER NUMBER DOC 2312956
8, 9, 11, 14, 33, 34
GA 4000ACIC
14.4 PACKING INSERT GA 4000AC RP
Spare parts list set of 12
packings
Designation Order No. Order No.
1 Packing insert GA 4000AC (RP) 1 2338601 -2 Housing 1 -- -3 PE sealing washer 2 -- 2339142
4 Housing insert 1 -- -5 Housing screw 1 -- -6 Pressure disk 1 2338567 -7 O-ring 1 9974196 -8 O-ring 1 367528 --
9 O-ring 1 2338570 -10 Mobilux® EP 2 grease 1 9998808 -11 Vaseline white, PHHV II 1 9992698 -12 PTFE + GF sealing washer 4 -- 2339141
13 PTFE sealing washer 2 -- 2339143
14 Assembly manual for GA4000AC packing (RP) 1 2338708 --
= Wearing parts
-> For sealing sets, see Chapter 14.5.
= Not part of the standard equipment but available as a special accessory.
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Packing insert
ORDER NUMBER DOC 2312956
1
12,
3
9
4
12
13
GA 4000ACIC
8
5
6
12,
3
13
5 Nm
(Torx TX40)
11
2
B_04229
14.5 SEALING SET GA 4000 PACKING RP AND RP SPECIAL
Order No. Designation Consisting of spare parts items
2339140 Sealing set GA 4000 packing RP 3, 6, 7, 8, 9, 12, 14
2339810 Sealing set GA 4000 packing RP special 3, 6, 7, 8, 9, 12, 13, 14
7
11
SW15
12
12
10
12,
13
3
3
12,
13
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15 DECLARATION OF CONFORMITY
15.1 EU DECLARATION OF CONFORMITY
Herewith we declare that the supplied version of:
GA 4000ACIC
complies with the following guidelines:
2006/42/EC
2014/34/EU
Applied standards, in particular:
EN ISO 12100: 2010 EN ISO 80079-36: 2016
EN 1953:2013 EN ISO/IEC 80079-34: 2011
EN ISO 13732-1: 2008
EN 14462:2015
EN 1127-1:2011
Applied national technical standards and specications, in particular:
DGUV regulation 100-500
Chapter 2.29
DGUV regulation 100-500
Chapter 2.36
TRGS 727
GA 4000ACIC
Identication:
EU Declaration of Conformity
The EU Declaration of Conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number: 2315627
II 2G X
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E
R
T
I
F
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Order No. 2312956
Edition 05/2018
ts-liquid@wagner-group.com
Document No. 11093207
Version G
www.wagner-group.com
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