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)
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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
GENERAL SAFETY INSTRUCTIONS
Safety instructions for the operator
6
6
6
6
6
6
7
7
7
8
8
8
8
9
9
9
9
9
9
2.1.1 Electrical equipment
2.1.2 Personnel qualifications
2.1.3 A safe work environment
2.2
Safety instructions for staff
2.2.1 Safe handling of WAGNER spray units
2.2.2 Earth the unit
2.2.3 Paint hoses
2.2.4 Cleaning
2.2.5 Handling hazardous liquids, varnishes and paints
2.2.6 Touching hot surfaces
2.3
2.4
Correct use
Use in an explosion hazard area
2.4.1 Correct use
2.4.2 Explosion protection identification
2.4.3 Maximum surface temperature
2.4.4 Safety instructions
2.5
German regulations and guidelines
3
3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING
Scope of guarantee
Guarantee period and registration
Handling
Exclusion of guarantee
Additional regulations
10
10
10
10
11
11
12
3.1
3.2
3.3
3.4
3.5
3.6
CE-conformity
4
4.1
DESCRIPTION
13
13
13
13
13
13
14
14
14
15
15
15
Fields of application, using in accordance with the instructions
4.1.1 Processible materials
4.2 Scope of delivery
4.2.1 Variant with nozzle ACF3000 11/40
4.2.2 Variant without nozzles
4.3
Data
4.3.1 Materials of the parts transporting paint
4.3.2 Technical data
4.4
4.4.1 Design of spray gun
4.4.2 Functions of the gun
Functional description
5
5.1
STARTING UP AND OPERATING
Installation and connection
16
16
16
17
5.1.1 Typical AirCoat spraying system
5.1.2 Ventilation of the spray booth
3
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
Contents
5.1.3 Air supply
5.1.4 Fluid (paint) hoses
5.1.5 Earthing
17
17
18
18
19
19
20
21
21
21
22
23
23
5.2
5.3
Preparation of paints
Starting-up
5.3.1 General rules for handling the spray gun
5.3.2 Preparation for starting up
5.4
Works
5.4.1 Start-up for spraying
5.4.2 Adjusting the spray pattern
5.4.3 Changing the AirCoat nozzle
5.4.4 Cleaning aircoat nozzle
5.4.5 Eliminate nozzle clogging
6.0
6.1
6.2
6.3
6.4
MAINTENANCE
24
25
26
28
30
30
31
31
31
32
33
Finishing work and cleaning
Replacing the material hose or air hose
Changing or cleaning filter insert
Replacing parts on the valve rod
6.4.1 Disassembling
6.4.2 Replacement of valve rocker seals
6.4.3 Replacing the rod seal (35)
6.4.4 Assembly
6.5
6.6
Replacing the nozzle seal
Replacing the„air“ sealing ring
7
TROUBLE SHOOTING AND SOLUTION
34
9
9.1
ACCESSORIES
Round jet nozzle cap
35
35
35
35
36
38
38
38
39
39
9.1.1 Nozzle inserts RXX
9.1.2 Nozzle screwed connection compl.
9.2
9.3
9.4
9.5
9.6
9.7
AirCoat nozzles ACF3000
Air caps
Filter insert
Hoses
Swivels
Miscellaneous
10
10.1
10.2
SPARE PARTS
How to order spare parts?
Spare parts list AC4600 Professional
40
40
41
4
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
1 ABOUT THESE INSTRUCTIONS
This operating manual contains information on the operation, repair and maintenance of
the unit.
œ 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.
1.1 LANGUAGES
4HIS OPERATING MANUAL IS AVAILABLE IN THE FOLLOWING LANGUAGESꢀ
,ANGUAGEꢀ
'ERMAN
&RENCH
)TALIAN
$ANISH
0ART .Oꢁ
394870
394872
394874
394876
,ANGUAGEꢀ
%NGLISH
$UTCH
3PANISH
3WEDISH
0ART .Oꢁ
394871
394873
394875
394877
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
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 following categories:
DANGER
This line warns of the hazard!
Danger - imminent danger. Non-observance will result
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
in death or serious.
œ
The measures for preventing the hazard and its consequences.
SIHI_0100_GB
Warning - possible danger. Non-observance can result
in death or serious injury.
WARNING
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
œ
The measures for preventing the hazard and its consequences.
SIHI_0103_GB
Caution - a possibly hazardous situation.
Non-observance can result in minor injury.
CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
œ
The measures for preventing the hazard and its consequences.
SIHI_0101_GB
Notice - a possibly hazardous situation.
Non-observance can cause material damage.
NOTICE
SIHI_0102_GB
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word
points out the hazard level.
➞
The measures for preventing the hazard and its consequences.
Note - provide information on particular characteristics and how to proceed.
5
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
œ Keep these operating instructions to hand near the unit at all times.
œ Always follow local regulations concerning occupational safety and accident prevention.
2.1.1 ELECTRICAL EQUIPMENT
Electrical plant and unit
œ To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
œ May only be maintained by skilled electricians or under their supervision.
œ Must be operated in accordance with the safety regulations and electrotechnical
regulations.
œ Must be repaired immediately in the event of problems.
œ Must be put out of operation if they pose a hazard.
œ Must be de-energized before work is commenced on active parts. Inform staff about
planned work, observe electrical safety regulations.
2.1.2 PERSONNEL QUALIFICATIONS
œ %NSURE THAT THE UNIT IS OPERATED AND REPAIRED ONLY BY TRAINED PERSONSꢁ
2.1.3 A SAFE WORK ENVIRONMENT
Make sure that the floor in the area where you are working is derivable in accordance
with EN 61340-4-1.
Ensure that all persons within the working area wear derivable shoes.
Ensure that during spraying,persons wear derivable gloves so that they are earthed via
the handle of the spray gun.
Customer to provide paint mist extraction units conforming to local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure
– Personal safety equipment (breathing and skin protection)
Ensure that there are no ignition sources such as naked flame, glowing wires or hot
surfaces in the vicinity. Do not smoke.
2.2 SAFETY INSTRUCTIONS FOR STAFF
œ Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
œ Always follow local regulations concerning occupational safety and accident
prevention.
6
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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:
œ
œ
Never point the spray gun at people.
Never reach into the spray jet.
œ 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
chapter „Trouble shooting“.
In the event of skin injuries caused by paint or cleaning agents:
œ
œ
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
œ
œ
Ensure that you have a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
2.2.2 EARTH THE UNIT
Depending on the electrostatic charge and the flow speed of the spray, an electrostatic
charge may occur in the equipment.This could cause a spark or flame on discharging.
œ
œ
œ
Ensure that the unit is earthed for every spraying operation.
Earth the work pieces being painted.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing
derivable shoes.
œ
When spraying, wear derivable gloves to earth yourself via the spray gun handle.
2.2.3 PAINT HOSES
œ
œ
œ
Ensure that the hose material is chemically resistant to the sprayed materials.
Ensure that the material hose is suitable for the pressure generated in the unit.
Ensure that the following information is visible on the high pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture.
œ
The electrical resistance of the complete high pressure hose must be less than 1 MOhm.
7
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
2.2.4 CLEANING
œ De-energize the unit electrically.
œ Disconnect the pneumatic supply line.
œ Relieve the pressure from the unit.
œ Ensure that the flash point of the cleaning agent is at least 5 K above the ambient
temperature.
œ 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.
œ When cleaning units with solvents, never spray into a closed container.
œ Earth the container.
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
œ When preparing or working with paint and when cleaning the unit, follow the working
instructions of the manufacturer of the paints, solvents and cleaning agents being
used.
œ Take the specified protective measures, in particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
œ Use a mask or breathing apparatus if necessary.
œ For sufficient health and environmental safety: Operate the unit in a spray booth or on
a spraying wall with the ventilation (extraction) switched on.
œ Wear suitable protective clothing when working with hot materials.
2.2.6 TOUCHING HOT SURFACES
➞
➞
Touch hot surfaces only if you are wearing protective gloves.
When operating the unit with a coating material with a temperature of > 43 °C; 109.4 °F:
- Identify the unit with a warning label that says„Warning - hot surface“.
Order No.
9998910 Information label
9998911 Safety label
2.3 CORRECT USE
7!'.%2 ACCEPTS NO LIABILITY FOR ANY DAMAGE ARISING FROM INCORRECT USEꢁ
œ 5SE THE UNIT ONLY TO WORK WITH THE MATERIALS RECOMMENDED BY 7!'.%2ꢁ
œ /PERATE THE UNIT ONLY AS AN ENTIRE UNITꢁ
œ $O NOT DEACTIVATE SAFETY EQUIPMENTꢁ
œ 5SE ONLY 7!'.%2 ORIGINAL SPARE PARTS AND ACCESSORIESꢁ
8
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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 CLASSESꢁ
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.
II 2G X
CE:
Ex:
II:
Communautés Européennes
Symbol for explosion protection
Unit class II
2:
Category 2 (Zone 1)
G:
X:
Ex-atmosphere gas
See: "Special Notes" in the operating manual
2.4.3 MAXIMUM SURFACE TEMPERATURE
X: The maximum surface temperature corresponds to the permissible material temperature.
This and the permissible ambient temperature can be found in the Technical Data.
2.4.4 SAFETY INSTRUCTIONS
3AFE HANDLING OF 7!'.%2 SPRAY UNITS
-ECHANICAL SPARKS CAN FORM IF THE UNIT COMES INTO CONTACT WITH METALꢁ
)N AN EXPLOSIVE ATMOSPHEREꢀ
œ $O NOT KNOCK OR PUSH THE UNIT AGAINST STEEL OR RUSTY IRONꢁ
œ $O NOT DROP THE SPRAY GUNꢁ
œ 5SE ONLY TOOLS THAT ARE MADE OF A PERMITTED MATERIALꢁ
)GNITION TEMPERATURE OF THE COATING MATERIAL
œ %NSURE THAT THE IGNITION TEMPERATURE OF THE COATING MATERIAL IS ABOVE THE MAXIMUM
SURFACE TEMPERATUREꢁ
-EDIUM SUPPORTING ATOMIZING
œ 4O ATOMIZE THE MATERIALꢂUSE ONLY WEAKLY OXIDIZING GASESꢂEꢁGꢁAIRꢁ
#LEANING
)F THERE ARE DEPOSITS ON THE SURFACESꢂ THE UNIT MAY FORM ELECTROSTATIC CHARGESꢁ &LAMES OR
SPARKS CAN FORM IF THERE IS A DISCHARGEꢁ
œ 2EMOVE DEPOSITS FROM THE SURFACES TO MAINTAIN CONDUCTIVITYꢁ
2.5 GERMAN REGULATIONS AND GUIDELINES
See chapter 3.3
9
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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.
Wagner exclusively issues extended guarantees to commercial or professional users (here-
after referred to as„customer“) who have purchased the product in an authorised special-
ist shop, and which relate to the products listed for that customer on the Internet under
The buyer‘s claim for liability for defects from the purchase agreement with the seller as
well as statutory rights are not impaired by this guarantee.
We provide a guarantee in that we decide whether to replace or repair the product or
individual parts, or take the device back and reimburse the purchase price. The costs for
materials and working hours are our responsibility. Replaced products or parts become
our property.
3.2 GUARANTEE PERIOD AND REGISTRATION
The guarantee period amounts to 36 months. For industrial use or equal wear, such as shift
operations in particular, or in the event of rentals it amounts to 12 months.
Systems driven by petrol or air are also guaranteed for a 12 month period.
The guarantee period begins with the day of delivery by the authorised specialist shop.The
date on the original purchase document is authoritative.
For all products bought in authorised specialist shops from 01.02.2009 the guarantee pe-
riod is extended to 24 months providing the buyer of these devices registers in accordance
with the following conditions within 4 weeks of the day of delivery by the authorised spe-
cialist shop. Registration can be completed on the Internet under
The guarantee certificate is valid as confirmation,as is the original purchase document that
carries the date of the purchase. Registration is only possible if the buyer is in agreement
with having the data being stored that is entered during registration.
When services are carried out under guarantee the guarantee period for the product is
neither extended nor renewed.
Once the guarantee period has expired, claims made against the guarantee or from the
guarantee can no longer be enforced.
3.3 HANDLING
If defects can be seen in the materials, processing or performance of the device during the
guarantee period, guarantee claims must be made immediately, or at the latest within a
period of 2 weeks.
The authorised specialist shop that delivered the device is entitled to accept guarantee
claims. Guarantee claims may also be made to the service centres named in our operating
instructions. The product has to be sent without charge or presented together with the
original purchase document that includes details of the purchase date and the name of
the product. In order to claim for an extension to the guarantee, the guarantee certificate
must be included.
The costs as well as the risk of loss or damage to the product in transit or by the centre that
accepts the guarantee claims or who delivers the repaired product, are the responsibility
of the customer.
10
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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. Damage
due to wear and tear that is caused in particular by sanded coating materials, such as
dispersions, plaster, putty, adhesives, glazes, quartz foundation.
- in the event of errors in devices that are due to non-compliance with the operating
instructions,unsuitable or unprofessional use,incorrect assembly and/or commissioning
by the buyer or by a third party, or utilisation other than is intended, abnormal ambient
conditions,unsuitable coating materials,unsuitable operating conditions,operation with
the incorrect mains voltage supply/frequency, over-operation or defective servicing or
care and/or cleaning.
- for errors in the device that have been caused by using accessory parts, additional
components or spare parts that are not original Wagner parts.
- for products to which modifications or additions have been carried out.
- for products where the serial number has been removed or is illegible
- for products to which attempts at repairs have been carried out by unauthorised
persons.
- for products with slight deviations from the target properties, which are negligible with
regard to the value and usability of the device.
- for products that have been partially or fully taken apart.
3.5 ADDITIONAL REGULATIONS
The above guarantees apply exclusively to products that have been bought by authorised
specialist shops in the EU, CIS, Australia and are used within the reference country.
If the check shows that the case is not a guarantee case, repairs are carried out at the ex-
pense of the buyer.
The above regulations manage the legal relationship to us concludingly. Additional claims,
in particular for damages and losses of any type, which occur as a result of the product or
its use,are excluded from the product liability act except with regard to the area of applica-
tion.
Claims for liability for defects to the specialist trader remain unaffected.
German law applies to this guarantee. The contractual language is German. In the event
that the meaning of the German and a foreign text of this guarantee deviate from one
another, the meaning of the German text has priority.
J.Wagner GmbH
Division Professional Finishing
Otto Lilienthal Strasse 18
88677 Markdorf
Federal Republic of Germany
Wagner professional guarantee
(Status 01.02.2009)
11
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
3.6 CE-CONFORMITY
Herewith we declare that the supplied version of
AC 4600 Pro (blue)
AC 4600 Pro (red)
AC 4600 Pro (green)
GM 4600 Pro Box
Complies with the following guidelines:
98/37/EG
94/9/EG
Applied standards, in particular:
DIN EN ISO 12100-1, 2004-04
DIN EN ISO 12100-2, 2004-04
DIN EN 1127-1, 2008-02
DIN EN ISO 14121,2007-12
DIN EN ISO 3746, 1995-12
DIN EN 13463-1, 2002-04
DIN EN 1953, 1998-12
DIN EN ISO 13732-1, 2006-12
Applied national technical standards and specifications, in particular:
a) BGR 500
b) BGR 500
c) BGR 104
Part 2, Chap. 2.29„Using coating materials“
Part 2, Chap. 2.36„Working with liquid ejection devices“
Explosion protection rules
d) TRBS 2153 Avoiding ignition risks
e) BGR 180
Setting up for cleaning with solvents for cleaning workpieces with
solvents
f) BGI 740
g) ZH 1/406
Painting rooms and equipment
Guidelines for liquid ejection devices
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they are
to be found in the Internet.
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:
398892
12
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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. If you want to spray other working materials than the
aforementioned, turn please to a Wagner agency.
WARNING
Hot coating substances!
Burns
œ Wear antistatic protective gloves.
œ When operating the unit with a coating material with a temperature
greater than 43 °C; 109.4 °F: Identify the unit with a warning sticker
"Warning - hot surface".
SIHI_0019_GB
Note: Please contact your local WAGNER dealer and the paint manufacturer if you encounter
application problems.
4.2 SCOPE OF DELIVERY
These AirCoat gun is available with three different variants.
4.2.1 VARIANT WITH NOZZLE ACF3000 11/40
Qty
1
Part No.
394150
394151
394152
Description
AC 4600 Professional (blue)
AC 4600 Professional (red)
AC 4600 Professional (green)
1
1
4.2.2 VARIANT WITHOUT NOZZLES
Qty
1
Part No. Description
394156
394157
394158
AC 4600 Professional (blue)
1
AC 4600 Professional (red)
AC 4600 Professional (green)
1
The standard equipment for each variant includes:
Qty
1
Part No.
398892
394870
Description
CE-conformity
1
Operating manual German
1
see chap. 1 Operating manual for the other language
For special versions the delivery note applies.
13
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
4.3 DATA
4.3.1 MATERIALS OF THE PARTS TRANSPORTING PAINT
Metal
Plastic
Tungsten carbide
Stainless steel 1.4301
Stainless steel 1.4305
Stainless steel 1.4104
POM
PTFE
FPM
PA
4.3.2 TECHNICAL DATA
Description
Units
MPa/ psi/ bar
MPa/ psi/ bar
Inch
Value
Maxi. air inlet pressure
Maxi. material pressure
Paint connection
Air connection
0.8/ 120/ 8
25/ 3625/ 250
NPSM1/4
G1/4“
Inch
Filter insert **
Mesh
100
Weight
g/ oz
pH
°C/ °F
°C/ °F
671 / 23.7
3.5 - 9
55/ 131
43/ 109
< 82
pH range of the material
Maxi. temperature material
Maxi. temperature air
Sound level at 0.3 MPa; 3 bar; 43.5 psi air
pressure and 11 MPa; 110 bar; 1549 psi material
pressure***
dB(A)
** Other filter types see chapter 9.4
*** A rated sound pressure level measured at 0.5m distance according to DIN EN ISO 3746
-1995.
C
E
Dimensions
A
D
Dim.
A
mm
inch
7.13
181
248
48
B
9.76
C
1.88
G
D
160
38.5
-
6.30
E
1.52
F
NPSM1/4“
G1/4“
G
-
F
B_02696
14
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AC 4600 Pro
EDITION 06/2012
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
F
L
B_02697
N
G
Description
Description
H
I
Union nut with nozzle guard
Nozzle / Air cap
Gun housing
A
B
C
D
E
Suspension hook
Shaping air regulator
Spring cover
J
K
L
Filter housing
Trigger guard
Handle tube
Trigger safety
M
N
Swivel Air
F
Air connection
Paint connection
Swivel Material
G
4.4.2 FUNCTIONS OF THE GUN
If the trigger (D) is operated with released locking (E), first the air valve opens. Atomizing
air to flow through via air connection (F) to the air cap (I). The material valve opens only if
approx. 1/2 of the trigger guard way are bridged.The quantity of air for the atomization of
the jet spray becomes preset over the external air automatic controller. The atomizing air
control (B) adjusts the total quantity 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.
15
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AC 4600 Pro
EDITION 06/2012
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
œ When putting into operation and for all work, read and follow
the operating instructions and safety regulations for the additionally
required system components.
SIHI_0050_GB
E
G
D
F
C
B
M
I
K
H
J
A
L
B_02673
G
AirCoat Gun
High-pressure fluid hose
A
B
C
D
E
Paint-pump
H
I
Pressure air shut off valve
Pressure regulator
High pressure filters/ Relief valve
Return
J
Air pressure regulator with filter
Earthing cable
K
L
Stand trolley
Suction system
F
Air hose, el. conductive
M
Compressed air main
The pray gun 4600AC Professional 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 design-
ing 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.
16
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
5.1.2 VENTILATION OF THE SPRAY BOOTH
WARNING
Toxic and/or flammable vapor mixtures!
Risk of poisoning and burns
œ Operate the unit in a spraying booth approved for the working
materials.
-or-
œ Operate the unit on an appropriate spraying wall with the
ventilation (extraction) switched on.
œ Observe national and local regulations for the outgoing air
speed.
SIHI_0028_GB
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
CAUTION
Impurities in the spraying system!
Spray gun blockage, materials harden in the spraying system
œ Flush the spray gun and paint supply with a suitable cleaning agent.
SIHI_0001_GB
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of material
œ Ensure that the hose material is chemically resistant.
œ 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.
œ Ensure that the following information can be seen on the high
pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
SIHI_0029_GB
17
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
5.1.5 EARTHING
WARNING
Discharge of electrostatically charged components in atmospheres
containing solvents!
Explosion hazard from electrostatic sparks or flames
œ Earth all unit components.
œ Earth the workpieces being painted.
SIHI_0027_GB
WARNING
Heavy paint mist if earthing is insufficient!
Risk of poisoning
Insufficient paint application quality
œ Earth all unit components.
œ Earth the workpieces being painted.
SIHI_0003_GB
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 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.
18
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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:
œ Switch off the energy/compressed air supply.
œ Relieve the pressure from the spray gun and unit.
œ Secure the spray gun against actuation.
œ By functional faults: Identify and correct the problem, proceed
as described in chap„Trouble shooting“.
SIHI_0065_GB
CAUTION
Cleaning agent in the air duct!
Functional faults caused by swollen seals
Always point the spray gun down when cleaning.
Ensure that neither paint nor cleaning agent enters the air duct.
SIHI_0005_GB
Trigger safety catch in on
(safe) position
Air
B_02700
Material
19
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
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.
x
8. Set material pressure at 100 bar; 10 MPa; 1450 psi and use a suitable medium (solvent
or water) to check that connections do not leak.
B_02261
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.
WARNING
Operating the gun with a coating material with a temperature
higher than 43°C; 109.4°F
Burns from hot surface (to 60°C; 140°F)
œ Wear antistatic protective gloves:
œ Identify the spray gun with a warning label that says „Warning
- hot surface“( Part No. 9998910 or 9998911).
SIHI_0135_GB
20
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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. Open air pressure controller for the atomizer air and adjust so as to achieve optimal
atomization. (The interrelation between spray pattern and atomizer air is shown in the
figure below).
5. Use the shaping air controller on the gun to adjust the shaping air to atomizer air ratio,
until the optimal spray pattern is achieved.
Note:
Repeat point 4 and 5 until the optimum spray pattern is reached (process iterative).
Spray pattern
B_00071
No atomizing air
Too little atomizing air
Correct amount of air
Note
The paint output volume can be changed by:
Changing the material pressure or
Fitting another flat jet nozzle (see chap. 5.4.3 and chap. 9).
•
•
5.4.2 ADJUSTING THE SPRAY PATTERN
The spray pattern can be adjusted to suit the object being sprayed using the fan air regula-
tor.The illustration below shows the influence of the shaping air regulator on the spraying
pattern. Other nozzle sizes can be used to obtain larger or smaller spraying patterns.
Shaping air
fully open
Shaping air
fully closed
B_02262
21
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
5.4.3 CHANGING THE AIRCOAT NOZZLE
CAUTION
Defective AirCoat nozzle!
Insufficient paint application quality
œ Do not use sharp-edged objects to treat hard metal on the AirCoat nozzle.
SIHI_0020_GB
1. Relieve spray gun and unit pressure.
2. Secure gun with trigger safety catch.
3. Screw off the union nut (A).
4. Remove air cap (B).
5. Press AirCoat nozzle (C) out of the air cap (B) by hand and brush with cleaning solvent
until all remaining paint has been dissolved.
6. Mounting:
x
Place AirCoat nozzle (C) in nozzle seal (D).
7. Fit the aircap (B) over the nozzle (C), ensuring that the location flats (X) are in line.
8. Fit the union nut with nozzle guard (A) and tighten by hand.
B_02261
D
C
B
A
B_02701
22
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AC 4600 Pro
EDITION 06/2012
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 recommend-
ed by the paint manufacturer.
5.4.5 ELIMINATE NOZZLE CLOGGING
1. Relieve spray gun and unit pressure.
2. Secure gun with trigger safety catch.
3. Unscrew the union nut with nozzle guard (A).
4. Remove air cap (B).
5. Pull out the clogged nozzle (C) from the air cap (B), reverse it and replace it into nozzle
seal (D).
6. Fit the aircap (B) over the nozzle (C), ensuring that the location flats (X) are in line.
7. Fit the union nut with nozzle guard (A) over the air cap (B) onto the spray gun and
tighten by hand.
8. Switch the material pressure back on.
x
9. Turn the safety catch to the spraying position and briefly pull trigger.
10. When the blockage has been flushed out secure the gun with safety catch.
11. Relieve spray gun and unit pressure.
12. Unscrew the union nut with nozzle guard (A).
13. Remove air cap (B) and reverse nozzle (C) again.Clean nozzle and replace on the nozzle
seal (D) in spray position.
B_02261
14. Refit air cap (B) on the nozzle (C).
Take care that the nozzle fitted is correctly (see flat side X).
15. Fit the union nut with nozzle guard (A) over the air cap (B) onto the spray gun and
tighten by hand.
16. Switch the material pressure and the air pressure back on.
Nozzle in„spray“ position
D
C
B
A
Nozzle in„cleaning“ position
B_02702
23
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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
œ Never immerse the spray gun in cleaning agent.
SIHI_0066_GB
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the equipment
œ Repairs and part replacement may only be carried out by specially
trained staff or a WAGNER service center.
œ Before all work on the unit and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
œ Observe the operating and service instructions when carrying
out all work.
SIHI_0004_GB
24
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
6.1 FINISHING WORK AND CLEANING
DANGER
Exploding gas/ air mixture!
Danger to life from flying parts and burns
œ Never spray into a closed container.
œ Earth the container.
SIHI_0008_GB
CAUTION
Cleaning agent in the air duct!
Functional faults caused by swollen seals
Always point the spray gun down when cleaning.
Ensure that neither paint nor cleaning agent enters the air duct.
SIHI_0005_GB
WARNING
Explosive atmosphere!
Explosive gases are produced when aluminium comes into contact
with halogenized hydrocarbons
œ To clean aluminium, do not use liquids containing halogenized
hydrocarbons.
SIHI_0009_GB
Note:
Methylene chloride is not recommended as a flushing or cleaning solvent with this gun or
any system components.
1. Relieve spray gun and unit pressure.
2. Secure gun with trigger safety catch.
3. Connect cleaning supply.
4. Remove AirCoat -jet nozzle and clean separately (see chapter 5.4.3).
5. Pressurize the cleaning supply to approx. 4 MPa; 40 bar; 580 psi and thoroughly flush
the spray gun.
6. Relieve spray gun and unit pressure.
7. Secure gun with trigger safety catch.
8. Clean gun body with a cleaning agent recommended by the manufacturer, and dry
with a cloth.
25
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AC 4600 Pro
EDITION 06/2012
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.
5. Turn nut to the right with open-ended wrench wrench size C and unscrew air hose.
6. Mounting:
Fit the material hose respectively air hose by hand and tighten with 2 open-ended
wrenches.
Counterhold
D
C
Counterhold
A
Note:
B
Do not unscrew the filter
housing.The nut must only be
unscrewed by WAGNER- Serv-
ice-Agency.
B_02703
B_02704
Description
Key A
Key B
Key C
Key D
wrench size wrench size wrench size wrench size
17 mm
0.67 inch
19 mm
0.75 inch
17 mm
0.67 inch
14 mm
0.55 inch
AC 4600 Professional NPS 1/4“
26
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AC 4600 Pro
EADUISTGIOANBE0061/2/2001028
BPAESRTENLOLN. UDMOMC3E9R4D87O1C394870
OBEPTERRIAETBISNAGNMLEAITNUUNAGL
27
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
6.3 CHANGING OR CLEANING FILTER INSERT
Close
Loosen
Counterhold
D
Loosen
E
Description
Key D
Key E
wrench size wrench size
B
13 mm
0.51 inch
17 mm
0.67 inch
A
X
AC 4600 Professional NPS 1/4“
C
"?ꢃꢃꢃꢄꢅ
B_02705
28
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
1. Finishing work and cleaning.
2. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
4. Losen complete swivel by hand through turning at the handle
tube (C) and drive out downward together with the material
hose.
5. Pull filter insert (A) out of the filter housing (B).
6. Flush swivel, filter housing and filter insert (A) with cleaning
agent.
7. Push in cleaned or new filter insert (A) with cone (X) upward into
the filter housing.
8. Put handle tube with female hexagon on swivel and screw from
down over the filter insert onto the filter housing by hand.
Note:
Do not unscrew the filter housing. The
nut must only be unscrewed byWAGNER
- Service-Agency.
B_02704
29
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
6.4 REPLACING PARTS ON THE VALVE ROD
6.4.1 DISASSEMBLING
1. Finishing work and cleaning.
2. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
4. Unscrew spring cover (5) and remove compression springs (2) and (3).
5. Loosen screw (22) and remove together with nut (20).
6. Remove trigger guard (21).
7. Loosen sealing screw (10) with single open-end wrench (100) with wrench size 7 mm;
0.28 inches.
CAUTION
Unsuitable tool!
Damage to seals and sealing surfaces
œ Do not hold the valve rod with pliers or a similar tool.
SIHI_0006_GB
8. Carefully pull the complete valve rod (B) together with sealing screw out of the gun
housing (A) toward the rear.
9. Hold the clamping sleeve (4) with open-end wrench (101) wrench size 6 mm; 0.24
inches and loosen the collet chuck (18) with open-end wrench (102) wrench size 5
mm; 0.20 inches.
10. Carefully pull the valve rod (34) out toward the front. Replace the relevant parts.
87.9 mm 0.15
B
5
2
A
3
20
102
101
5 Nm
3.69 lbft
1
100
21
4
85
18
22
19
10
12
11
34
50
51
83
52
53
B_02706
30
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AC 4600 Pro
EDITION 06/2012
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.
50
51
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; 0.28
inches and with wrench size 13 mm; 0.51 inches until a slight resistance
is perceptible when moving the valve rod (34) in the valve tappet.
Note:
52
53
B_02274
The seal (52) can be pulled out of the cover (53) with the help of an eyebolt.
6.4.3 REPLACING THE ROD SEAL (35)
1. Carefully pull the rod seal (35) out of the gun housing.
2. Clean sealing surfaces in the gun housing.
3. Mount new rod seal (35) to the rod seal tool (84).
22
Note
84
35
Installation position of the
Spraying direction
rod seal (35)
21
B_02688
4. Insert rod seal tool (84) together with rod seal (35) into the hole.
5. Fit trigger guard (21) with screw (22) to body of gun and
6. Carefully push the tool with the rod seal (35) over the trigger guard (21)
into the recess in the housing.
7. Remove trigger guard (21), screw (22) and rod seal tool (84).
B_02268
6.4.4 ASSEMBLY
1. Fit seal collar (11) to valve rod (14),together with inserted O-ring (12) and sealing screw
(10).
2. Push completely assembled valve tappet (19) onto valve rod (14).
3. Insert preassembled valve rod into the collet chuck (18) as far as the stop.
4. Fix clamping sleeve (4) with wrench size 6 mm; 0.24 inches, screw the preassembled
valve rod to the clamping sleeve and tighten (open-end wrench with wrench size 5
mm; 0.20 inches).
5. Carefully insert the complete valve rod (B) into the gun housing.
6. Screw in sealing screw (10) but do not tighten yet.
7. Position trigger guard (21) and secure with screw (22) and nut (20).
8. Insert compression springs (3) and (2) and screw on the spring cover (5).
9. Carefully tighten the seal collar (11, 12) by turning the sealing screw (10). Ensure that
the trigger guard moves easily.
10. Start up in accordance with chapter 5.3.
Note:
Only use silicone and resin free grease.
31
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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
œ Do not clean the nozzle seal with sharp-edged objects.
œ Replace the nozzle seal if the sealing surface is damaged.
SIHI_0021_GB
1. Finishing work and cleaning.
2. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
4. Unscrew the union nut with nozzle guard (33).
5. Remove air cap (36) and nozzle (13).
6. Carefully release the nozzle seal (17) with the help of a screwdriver.
7. Fit new nozzle seal to valve housing (16).
8. Continue assembly in the reverse order.
14 (F)
16
17
13
36
33
B_02707
32
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AC 4600 Pro
EDITION 06/2012
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
œ Treat the distributor seal (F) with care.
SIHI_0030_GB
1. Finishing work and cleaning.
2. Relieve spray gun and unit pressure.
3. Secure gun with trigger safety catch.
4. Unscrew the union nut with nozzle guard (33).
5. Remove air cap (36) and nozzle (13).
6. Remove defective sealing ring (14/F) with the help of pipe tongs or with a large
screwdriver.
7. Mounting:
Fit new distributor seal (14/F) to air cap (36).
8. Place air cap in body of gun together with sealing ring (14).
9. Attach union nut (33) and screw in until the sealing ring snaps into place in the
mounting groove (snap hearable).
10. Demount union nut (33) and air cap (36) and complete spray gun according to
paragraph 5.4.3.
13
36
33
2
/
14 (F)
0
1
B_02708
33
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
7 TROUBLE SHOOTING AND SOLUTION
Functional fault
Cause
Remedy
see chapter
Insufficient material
discharge
Nozzle too small
Select larger nozzle
9
Material pressure to low Increase material pressure
Filter of gun or high-
pressure filter at pump
clogged
Clean or replace filter
6.3
Nozzle is clogged
Nozzle cleaning
5.4.5
6.4
Valve stem defective
Replace valve rod
Readjust atomizing air
Poor spray
pattern
Wrongly adjusted
atomizing air
5.4.1
Nozzle to large
Select smaller nozzle
9.1
Material pressure to low Increase pressure at pump
Material viscosity to
high
Thin material in accordance
with the manufacturer‘s
instructions
Partial nozzle blockage Nozzle cleaning
5.4.5
5.4.1
Wrongly adjusted
atomizing air
Readjust the atomizing air
Aircap faulty (blocked
holes, damaged seal)
Clean or replace air cap
Wrong aircap type
Replace as required aircap
(solvent / water based)
Valve rod leaks (Paint- or
air path)
Paint seal (packing)
damaged or worn, valve replace valve stem complete
stem damaged
Adjust or replace packing or
6.4
6.4
Air valve seals damaged Replace air valve seals
Pretension to low
Re tighten sealing screw
Spray gun will not shut-off Worn valve seat / valve Replace parts
6.4
6.4
correctly
ball
Packing-screw too tight, Replace the seals
or packing stuck with
dried paint
34
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
9 ACCESSORIES
9.1 ROUND JET NOZZLE CAP
9.1
Part No.
Description
9.1.2
394180
Round jet nozzle cap
(without nozzle insert)
B_02276
9.1.1
9.1.1 NOZZLE INSERTS RXX
Part No.
132720
132721
132722
132723
132724
132725
132726
132727
132728
132729
132730
132731
Description
Marking
11
Volume flow*
0.16; 160
0.22; 220
0.27; 270
0.34; 340
0.38; 380
0.43; 430
0.48; 480
0.53; 530
0.59; 590
0.65; 650
0.71; 710
0.77; 770
Jet-ø **
Nozzle insert R11
Nozzle insert R12
Nozzle insert R13
Nozzle insert R14
Nozzle insert R15
Nozzle insert R16
Nozzle insert R17
Nozzle insert R18
Nozzle insert R19
Nozzle insert R20
Nozzle insert R21
Nozzle insert R22
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
approx. 250; 9.84
12
13
14
B_02277
15
16
17
18
19
20
21
22
*
Volume flow in ml/min; cc/min water at 10 MPa; 100 bar; 1450 psi.
** Jet width in mm; inches at a distance of 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.
9.1.2 NOZZLE SCREWED CONNECTION COMPL.
Part No.
Description
132922
Nozzle screwed connection compl.
B_02278
35
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
9.2 AIRCOAT NOZZLES ACF3000
B_02280
Diameter of
bore
inch; mm
Recommended edge filter
Spray-
angle
Part No.
Marking
Use
100
200
200
300
400
500
600
100
200
300
400
500
600
100
200
300
400
500
600
800
100
200
300
400
500
600
800
200
300
400
500
600
800
Natural paint
379107
379207
379209
379309
379409
379509
379609
379111
379211
379311
379411
379511
379611
379113
379213
379313
379413
379513
379613
379813
379115
379215
379315
379415
379515
379615
379815
379217
379317
379417
379517
379617
379817
07/10
07/20
09/20
09/30
09/40
09/50
09/60
11/10
11/20
11/30
11/40
11/50
11/60
13/10
13/20
13/30
13/40
13/50
13/60
13/80
15/10
15/20
15/30
15/40
15/50
15/60
15/80
17/20
17/30
17/40
17/50
17/60
17/80
0.007-0.18
0.007-0.18
0.009-0.23
0.009-0.23
0.009-0.23
0.009-0.23
0.009-0.23
0.011-0.28
0.011-0.28
0.011-0.28
0.011-0.28
0.011-0.28
0.011-0.28
0.013-0.33
0.013-0.33
0.013-0.33
0.013-0.33
0.013-0.33
0.013-0.33
0.013-0.33
0.015-0.38
0.015-0.38
0.015-0.38
0.015-0.38
0.015-0.38
0.015-0.38
0.015-0.38
0.017-0.43
0.017-0.43
0.017-0.43
0.017-0.43
0.017-0.43
0.017-0.43
Transparent lacquer
Oils
Synthetic resin paints
PVC paint
Paints
Undercoat
Priming paint
Filler
Filler
Rustproofing paint
Rustproofing paint
Latex paint
36
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
B_02280
Diameter of
Recommended edge filter
Spray-
bore
Part No.
Marking
angle
Use
inch; mm
200
300
400
500
600
800
200
400
500
600
800
400
600
800
400
600
800
400
600
800
400
600
800
400
600
800
400
600
800
Rustproofing paint
Latex paint
379219
379319
379419
379519
379619
379819
379221
379421
379521
379621
379821
379423
379623
379823
379425
379625
379825
379427
379627
379827
379429
379629
379829
379431
379631
379831
379435
379635
379835
19/20
19/30
19/40
19/50
19/60
19/80
21/20
21/40
21/50
21/60
21/80
23/40
23/60
23/80
25/40
25/60
25/80
27/40
27/60
27/80
29/40
29/60
29/80
31/40
31/60
31/80
35/40
35/60
35/80
0.019-0.48
0.019-0.48
0.019-0.48
0.019-0.48
0.019-0.48
0.019-0.48
0.021-0.53
0.021-0.53
0.021-0.53
0.021-0.53
0.021-0.53
0.023-0.58
0.023-0.58
0.023-0.58
0.025-0.64
0.025-0.64
0.025-0.64
0.027-0.69
0.027-0.69
0.027-0.69
0.029-0.75
0.029-0.75
0.029-0.75
0.031-0.79
0.031-0.79
0.031-0.79
0.035-0.90
0.035-0.90
0.035-0.90
Mica paint
Zinc dust coating
Rustproofing paint
Distemper
37
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
9.3 AIR CAPS
Part No. Description
394910
394911
394912
Air cap LV compl. (red) for low viscosity paints
Air cap HV compl. (blue) for high viscosity paints
Air cap compl. (green)
B_02257
B_02256
B_02709
9.4 FILTER INSERT
Part No.
for 1 piece for 10 piec.
Part No.
Filter type
Mesh
Use for
nozzles
34383
43235
34377
97022
97023
97024
Gun filter rot
200
0.007“ - 0.015“
0.015“ - 0.019“
0.017“ - 0.021“
"?ꢃꢃꢃꢆꢄ
Gun filter yellow
Gun filter white
100
50
"?ꢃꢃꢃꢆꢇ
"?ꢃꢈꢃꢉꢊ
9.5 HOSES
Part No.
Description
9984595
9984596
Hose set AC Material DN3; Air DN6 7.5 m; 24.61 ft
Hose set AC Material DN3; Air DN6 10 m; 32.81 ft
Consisting of Material-, Air- and protective hose.
Material: NPSM1/4“; DN 3 mm; ID 0.12 inch; 27 MPa; 270 bar;
3916 psi
Air: G1/4“; DN 6 mm; ID 0.24 inch; 0.8 MPa; 8 bar; 116 psi
38
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
9.6 SWIVELS
Part No. Description
347706
364938
Swivel for paint connection (NPSM 1/4“)
Swivel for air connection G1/4“
B_02712
B_02687
9.7 MISCELLANEOUS
Part No.
Description
9997001
Nozzle cleaning brush
394942
394904
394905
367560
9985720
394090
Service set AC 4600 Professional
Conversion kit 16 MPa; 160 bar; 2320 ps
Conversion kit 25 MPa; 250 bar; 3625 psi
Double connection NPSM1/4“ (outside thread)
for paint hose extension
B_02685
B_02686
Double nipple G1/4“ (outside thread)
for air hose extension
Nozzle extension AC 300
(not approved for use in explosive areas)
B_02713
39
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
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.
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 required (air freight or mail, sea route or overland route, etc.)
Marks in spare parts lists
Note to column„K“ in the following spare parts lists.
U
L
=
=
Wearing parts
Note: No liability is assumed for wearing parts
Not part of standard equipment, available, however, as additional extra.
WARNING
Incorrect maintenance/repair!
Risk of injury and damage to the equipment
œ Repairs and part replacement may only be carried out by specially
trained staff or a WAGNER service center.
œ Before all work on the unit and in the event of work interruptions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
œ Observe the operating and service instructions when carrying
out all work.
SIHI_0004_GB
40
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
10.2 SPARE PARTS LIST AC4600 PROFESSIONAL
Spare parts list AC 4600 Professional
Pos
1
K
Qty
1
Part No.
394150
394151
394152
9999501
9999500
2312140
394333
394924
2311320
394327
Description
AC 4600 Professional; NPSM1/4“ (blue) compl.
AC 4600 Professional; NPSM1/4“ (red) compl.
AC 4600 Professional; NPSM1/4“ (green) compl.
Screw spring Paint
1
1
1
1
2
1
3
1
Screw spring Air
4
1
Tension sleeve
5
1
Spring cover 25 MPa; 250 bar; 3625 psi
Air tappet complete
6
1
8
◆
1
Valve rod unit assy.
10
11
12
13
1
Sealing screw
◆
◆
◆
✭
✭
1
1
1
394328
9971445
379411
Gasket
O-ring
Nozzle ACF3000 11/40
(other nozzle sizes see chapter 9.2)
14
15
16
17
18
19
20
21
22
23
24
3 4
3 5
◆
◆
◆
◆
✭
✭
✭
✭
1
1
1
1
1
1
1
1
1
1
1
1
394339
9974245
394922
394338
2312149
394257
394318
394601
394319
394334
9935088
394920
Sealing ring
O-ring
Valve seat compl.
Seal Nozzle
Chuck
Valve tappet compl.
Nut
Trigger
Screw
Safety catch
Cylindrical shaft
Valve rod compl.
◆
◆
✭
✭
1
1
1
1
1
1
394323
394910
394911
394912
394309
179338
Rod seals
36
36
36
50
51
Air cap LV compl. (red)
Air cap HV compl. (blue)
Air cap (green)
Valve tappet
◆
◆
◆
Air valve seal
◆
✭
◆ = Wearing part
✭ = Included in service set
● = Not part of standard equipment for spray gun. Available, however, as additional
extra
41
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
Detail B
62
55
56
63
57
58
59
60
6
80
61
5
2
3
8
20
82
B
36
14
21
16
22
23
13
15
35
36
36
17
24
101
84
102
69
65
100
1
70
64
66
68
4
11
85
18
19
67
10
12
34
B_02749
50
52
83
53
51
Mounting materials
Pos
80
81
82
83
84
85
K
●
●
●
●
Part No. Description
9992831 Loctite 542
9992833 Loctite 638 green
9992590 Loctite 222
9992698 Vaseline white PHHV II
394342
-
Tool valve rod seal
Molykote
✭ ●
●
42
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
Spare parts list AC 4600 Professional
Pos
K
Qty
Part No.
Description
52
1
179395
Seal
◆
✭
✭
53
1
394322
Cap
◆
55
56
57
58
59
60
61
62
63
64
1
1
1
1
1
1
1
1
1
1
394336
128327
132516
132351
394308
394337
132...
Nozzle body
●
Sealing nipple
◆ ●
◆ ●
●
Nozzle screw connection compl.
Nozzle screw connection holder
Union nut
●
Nozzle nut
●
Nozzle insert R (various dimensions see chap. 9.1.1)
Round jet nozzle cap (see chap. 9.1)
◆ ●
●
394180
132922
43235
Nozzle screw connection compl.
◆ ●
◆
Filter insert yellow, 100 mesh
(other filter types see chapter 9.2)
◆
◆
◆
65
66
1
1
364340
43590
Seal filter
✭
✭
Compression spring
67
68
69
70
1
1
1
1
1
347706
364349
364938
394615
394942
Swivel compl. paint
Handle tube
Swivel Air
◆
Filter tube AC 4600 Pro NPS 1/4“
Service set AC 4600 Professional
◆ = Wearing part
✭ = Included in service set
● = Not part of standard equipment for spray gun. Available, however, as additional
extra
43
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AC 4600 Pro
EDITION 06/2012
PART NO. DOC394871
OPERATING MANUAL
Germany
Switzerland
J.WAGNER GmbH
J.WAGNER AG
Otto-Lilienthal-Str. 18
Postfach 1120
Industriestrasse 22
Postfach 663
D- 88677 Markdorf
CH- 9450 Altstätten
Telephone: +41 (0)71 757 2211
Telefax: +41 (0)71 757 2222
Telephone: +49 7544 5050
Telefax: +49 7544 505200
E-Mail: [email protected]
E-Mail: [email protected]
Belgium
Denmark
WSB Finishing Equipment
Veilinglaan 56/58
B- 1861 Wolvertem
WAGNER Industrial Solution Scandinavia
Viborgvej 100, Skærgær
DK- 8600 Silkeborg
Telephone: +32 (0)2 269 4675
Telefax: +32 (0)2 269 7845
Telephone: +45 70 200 245
Telefax: +45 86 856 027
United Kingdom
France
WAGNER Spraytech (UK) Ltd.
Haslemere Way
J.WAGNER France S.A.R.L.
Parc de Gutenberg - Bâtiment F8
8, voie la Cardon
F- 91127 Palaiseau-Cedex
Telephone: +33 1 825 011 111
Telefax: +33 1 698 172 57
E-Mail: [email protected]
Tramway Industrial Estate
GB- Banbury, OXON OX16 8TY
Telephone: +44 (0)1295 265 353
Telefax: +44 (0)1295 269861
E-Mail: [email protected]
Netherlands
Italy
WSB Finishing Equipment B.V.
De Heldinnenlaan 200
NL- 3543 MB Utrecht
WAGNER COLORA S.r.l
Via Fermi, 3
I- 20875 Burago di Molgora (MB)
Telephone: +31 (0) 30 241 4155
Telefax: +31 (0) 30 241 1787
Telephone: +39 039 625021
Telefax: +39 039 6851800
E-Mail: [email protected]
Australia
Austria
WAGNER Spraytech Australia PTY.Ltd.
14-16 Kevlar Close
Braeside,Vic. 3195
J.WAGNER GmbH
Otto-Lilienthal-Str. 18
Postfach 1120
D- 88677 Markdorf
Telephone: 03 9587 2000
Telefax:
E-Mail:
Telephone: +49 (0) 7544 5050
Telefax: +49 (0) 7544 505200
E-Mail: [email protected]
Sweden
Spain
WAGNER Industrial Solutions Scandinavia
Skolgatan 61
WAGNER Spraytech Iberica S.A.
Ctra. N- 340, Km. 1245,4
SE- 568 31 Skillingaryd
E- 08750 Molins de Rei (Barcelona)
Telephone: +34 (0) 93 680 0028
Telefax: +34 (0) 93 668 0156
E-Mail: [email protected]
Telephone: +46 (0) 370 798 30
Telefax: +46 (0) 370 798 48
E-Mail: [email protected]
Ireland
New Zealand
Mark John Ltd.
50 C Robinhood Industrial Estate
Clondalkin
Co. Dublin
Telephone: 51 61 22
E-Mail:
WAGNER Spraytech (NZ) Ltd.
Auckland Office
308 Church Street
Te Papapa, Auckland
Telephone: (9) 641 169
E-Mail:
www.wagner-group.com/profi
44
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AC 4600 Pro
EADUISTGIOANBE0061/2/2001028
BPAESRTENLOLN. UDMOMC3E9R4D87O1C394870
OBEPTERRIAETBISNAGNMLEAITNUUNAGL
45
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AC 4600 Pro
EADUISTGIOANBE0061/2/2001028
BPAESRTENLOLN. UDMOMC3E9R4D87O1C394870
OBEPTERRIAETBISNAGNMLEAITNUUNAGL
46
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