WAGNER GM 2600 Air Assisted Airless Spray Gun Owner’s Manual

WAGNER GM 2600 Air Assisted Airless Spray Gun

Safety Precautions

WARNING

HAZARD: Injection injury – A high pressure stream produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation. See a physician immediately.

DO NOT TREAT AN INJECTION INJURY AS A SIMPLE CUT!
Injection can lead to amputation. See a physician immediately.
The maximum operating range of the gun is 3600 PSI /24.8 MPa fluid pressure.

PREVENTION:

• NEVER aim the gun at any part of the body.

• NEVER allow any part of the body to touch the fluid stream.
  DO NOT allow body to touch a leak in the fluid hose.

• NEVER put hand in front of the gun. Gloves will not provide protection against an injection injury.

• ALWAYS lock the gun trigger, shut the pump off, and release all pressure before servicing, cleaning the tip or guard, changing tip, or leaving unattended. Pressure will not be released by turning off the motor. The PRIME/SPRAY valve must be turned to PRIME to relieve the pressure. Refer to the PRESSURE RELIEF PROCEDURE described in the pump manual.

• ALWAYS keep the tip guard in place while spraying. The tip guard provides some protection but is mainly a warning device.

• ALWAYS remove the spray tip before flushing or cleaning the system.

• The paint hose can develop leaks from wear, kinking and abuse. A leak can inject material into the skin. Inspect the hose before each use.

• All accessories must be rated at or above the maximum operating pressure range of the airless sprayer. This includes spray tips, guns, extensions, and hose.

NOTE TO PHYSICIAN:

Injection into the skin is a traumatic injury. It is important to treat the injury as soon as possible. DO NOT delay treatment to research toxicity. Toxicity is a concern with some coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

HAZARD: EXPLOSION OR FIRE – Solvent and paint fumes can explode or ignite. Severe injury and/or property damage can occur.

PREVENTION:

• Provide extensive exhaust and fresh air introduction to keep the air within the spray area free from accumulation of flammable vapors.

• Avoid all ignition sources such as static electricity sparks, electrical appliances, flames, pilot lights, hot objects, and sparks from connecting and disconnecting power cords or working light switches.

• Do not smoke in spray area.

• Fire extinguisher must be present and in good working order.

• Place pump at least 25 feet (7.6 m) from the spray object in a well ventilated area (add more hose if necessary).
  Flammable vapors are often heavier than air. Floor area must be extremely well ventilated. The pump contains arcing parts that emit sparks and can ignite vapors.

• The equipment and objects in and around the spray area must be properly grounded to prevent static sparks.

• Use only conductive or grounded high pressure fluid hose.
  Gun must be grounded through hose connections.

• Power cord must be connected to a grounded circuit.

• Always flush unit into a separate metal container, at low pump pressure, with spray tip removed. Hold gun firmly against side of container to ground container and prevent static sparks.

• Follow the material and solvent manufacturer’s warnings and instructions.

• Use extreme caution when using materials with a flashpoint below 70° F (21° C). Flashpoint is the temperature that a fluid can produce enough vapors to ignite.

• Plastic can cause static sparks. Never hang plastic to enclose a spray area. Do not use plastic drop cloths when spraying flammable materials.

• Use lowest possible pressure to flush equipment.

HAZARD: EXPLOSION HAZARD DUE TO INCOMPATIBLE MATERIALS – will cause severe injury or property damage.

PREVENTION:

• Do not use materials containing bleach or chlorine.
• Do not use halogenated hydrocarbon solvents such as bleach, mildewcide, methylene chloride and 1,1,1 – trichloroethane. They are not compatible with aluminum.
• Contact your coating supplier about the compatibility of material with aluminum.

HAZARD: HAZARDOUS VAPORS – Paints, solvents, insecticides, and other materials can be harmful if inhaled or come in contact with the body. Vapors can cause severe nausea, fainting, or poisoning.

PREVENTION:

• Use a respirator or mask if vapors can be inhaled. Read all instructions supplied with the mask to be sure it will provide the necessary protection.
• Wear protective eyewear.
• Wear protective clothing as required by coating manufacturer.

HAZARD: GENERAL – Can cause severe injury or property damage.

PREVENTION:

• Read all instructions and safety precautions before operating equipment.
• Always disconnect the motor from the power supply before working on the equipment.
• Follow all appropriate local, state, and national codes governing ventilation, fire prevention, and operation.
• The United States Government Safety Standards have been adopted under the Occupational Safety and Health Act (OSHA). These standards, particularly part 1910 of the General Standards and part 1926 of the Construction Standards should be consulted.
• Use only manufacturer authorized parts. User assumes all risks and liabilities when using parts that do not meet the minimum specifications and safety devices of the pump manufacturer.
• Before each use, check all hoses for cuts, leaks, abrasion or bulging of cover. Check for damage or movement of couplings. Immediately replace the hose if any of these conditions exist. Never repair a paint hose. Replace it with another grounded high-pressure hose.
• All hoses, swivels, guns, and accessories must be pressure rated at or above the maximum operating pressure range of the airless sprayer.
• Do not spray outdoors on windy days.
• Wear clothing to keep paint off skin and hair.

Specifications

• Maximum air input pressure …………145 PSI (1 MPa)
• Maximum working pressure………….3600 PSI (25 MPa)
• Material quantity ………………………..according to tip
• Air connector ……………………………..NPSM 1/4″
• Material connector ………………………NPSM 1/4″
• Filter ………………………………………….100 mesh
• Length ……………………………………….8.5” (216 mm)
• Height………………………………………..9.8” (250 mm)
• Weight ……………………………………….1 lb. (420 g)

Introduction

In the air assisted/airless spraying process, the spraying material is atomized under pressure at 400 – 2800 PSI (3 – 19 MPa). The atomizing air at 7 – 32 PSI (0 – 0.22 MPa) produces a soft spray jet that eliminates problems of overlaps in the boundary zone. The soft spray jet prevents the spraying material from rebounding to the gun. The form air reduces or increases the spray jet width, depending on the adjustment of the air adjustment knob. Due to the cleaning-friendly design of the tip and the lack of air holes near the material outlet, the tip is virtually self-cleaning.

When the trigger of the gun is pulled, the air valve opens allowing atomizing and fan jet air to flow up to the tip. The material valve opens only when the trigger is pulled to its fullest extent.
The amount of air for the spray jet width is adjusted using the air adjustment knob. The spray gun is locked off by turning the gun lock nut clockwise (when looking from the back of the gun) until it stops. This closes the material valve in the gun.
The air input should be adjusted at the source to approximately 0 – 32 PSI (0 – 0.22 MPa).

Advantages of the adjustable air assisted/airless process:

• high coverage capacity
• low fogging tendency
• fine finish
• high viscosity materials applied without problems
• higher tool-life of the Brilliant-tip
• adjustability of spray jet width

Materials that can be sprayed using this gun include:

• Water, oil, and solvent based primers and topcoats
• 2K finishing enamels and primers
• Release agents

Operation

Use the following procedure to setup and spray with the spray gun.

1. Lock the gun by turning the gun lock nut clockwise (when looking from the back of the gun) until it stops. This closes the material valve in the gun.
2. Unscrew the tip guard and remove the air cap.
3. Insert the AirCoat tip into the inlet seal sleeve.
4. Place the air cap on the tip. Make sure that the air cap pins are aligned with the slots on the tip
5. Set the desired spraying plane with the horns of the air cap and replace the tip guard.
6. Set up the spray unit (refer to the spray unit’s Owner’s Manual).
7. Connect the material hose from the spray unit to the material inlet fitting on the gun.
8. Connect the air hose from the spray unit to the air inlet fitting on the gun.
9. Start up the spray unit (refer to the spray unit’s Owner’s Manual).
10. Adjust the material pressure at the pump to approximately 400 PSI (3 MPa). Pull the trigger and increase the pump pressure until the spray pattern is acceptable. Open the atomizing air at the external air regulator and adjust the air pressure to the best spray pattern (to a maximum of 32 PSI (0.22 MPa)) . The form air may be adjusted using the air adjustment knob to the required spray jet width.

CAUTION
Do not turn the air adjustment knob using pliers. Overtightening and damage to the gun may occur.

Cleanup

WARNING

• Release system and spray gun pressure before cleaning or performing maintenance on the gun.
• Use only the cleaning solvent recommended by the material manufacturer.
• Never spray into an enclosed vessel (this will create an explosive gas / air mixture).

NOTE: Do not immerse the spray gun in solvent.

Daily cleaning

1. Flush out the spray gun material tube thoroughly with the appropriate solvent.
   NOTE: When using two component materials more frequent flushing may be required.

2. Unscrew the tip guard and remove the air cap. Take out the tip and immerse in the appropriate solvent until all traces of material are dissolved. Remove the tip and put into the appropriate solvent for 1 to 2 days until all material residues are gone.
   NOTE: Handle the tip with care. Do not clean it with sharp metal objects. Use tip cleaning brush (P/N 9997001) only. If necessary, use corresponding tip cleaning needle (P/N 8612001, set of 12) for cleaning tip.

3. Clean the spray gun body using a brush.

CAUTION

Hold spray gun downward or horizontal while cleaning the spray gun. Cleaning solvent must not be allowed to enter the air channels as this will cause swelling of the O-rings.

Maintenance

Adjusting the Needle Packing
If material begins leaking at the valve rod, flush the gun and carefully tighten the packing screw using the gun spanner that came with this gun.

NOTE: If leaking continues, replace the needle packing and the o-ring.

Replacing the Valve Rod Seals
Refer to the valve rod complete illustration at the bottom of the page.

1. Pull the trigger and unscrew the gun lock nut. Remove the compression spring.
2. Remove the flat-head screw and take off the trigger.
3. Unscrew the packing screw from the sealing sleeve.
4. Carefully withdraw the complete valve rod from the back of the gun.
5. Holding the valve rod mounting with the gun spanner, unscrew the valve ball holder using pliers.
6. Remove the components from the needle.
7. Remove the compression ring and needle packing.

Repairing Air Valve Seals

1. Holding the valve push-rod with the universal spanner, unscrew the push-rod cap.
2. Change compression ring (with O-ring), needle packing, rear seal, and, if necessary, the push-rod seal and air valve seal of the air valve
3. Reassemble in reversed order
4. The trigger must be pulled before replacing the gun lock nut and the compression spring. Screw on the nut until a noticeable resistance is felt at the trigger. Release the trigger. The lever travel is now correctly set for air and material release.

Cleaning/Changing the Filter

1. Remove the high pressure hose from the material inlet fitting.
2. Holding the material tube at the wrench flats with one wrench, unscrew the material inlet fitting another wrench.
3. Pull out the cylindrical filter.
4. Rinse the filter in a cleaning solvent or exchange with a new filter.
5. Push the cone end of the new or cleaned filter into the into the material tube.
6. Make sure the spring is in position in the material inlet fitting.
7. Holding the material tube at the wrench flats with one wrench, thread the material inlet fitting into the material tube. Tighten securely.
8. Reattach the high pressure hose to the material inlet fitting.

NOTE: Make sure the correct filter is being used for the tip and material being used (refer to the “Gun Filter Chart” below and the “AirCoat Tip Chart” in the Accessories section).

Gun Filter Chart

Part Number| For Tip Sizes| Filter Mesh| Color of Filter Body
---|---|---|---
0034383 (1 pc.)

0089960 (2 pc.)

| 0.007″ – 0.011″| 180| red
0089324 (1 pc.)

0089959 (2 pc.)

| 0.013″ – 0.015″| 100| yellow
0034377 (1 pc.)

0089958 (2 pc.)

| 0.018″ – 0.036″| 50| white

Troubleshooting

Parts List

NOTE: Refer to the “AirCoat Tip Chart” in the Accessories section of this manual for additional tip sizes (item16).

Accessories

AirCoat Tip Chart

Part Number| Orifice Size| Spraying Angle| Fan Width| Gun Filter Mesh
---|---|---|---|---
0143209| 0.009″| 20º| 4.75″| 180 (red)
0143409| 0.009″| 40º| 6.75″| 180 (red)
0143609| 0.009″| 60º| 8.75″| 180 (red)
0143111| 0.011″| 10º| 4″| 180 (red)
0143211| 0.011″| 20º| 5″| 180 (red)
0143411| 0.011″| 40º| 7.5″| 180 (red)
0143511| 0.011″| 50º| 8.25″| 180 (red)
0143113| 0.013″| 10º| 4″| 100 (yellow)
0143213| 0.013″| 20º| 4.75″| 100 (yellow)
0143413| 0.013″| 40º| 8″| 100 (yellow)
0143513| 0.013″| 50º| 8.75″| 100 (yellow)
0143613| 0.013″| 60º| 10″| 100 (yellow)
0143813| 0.013″| 80º| 12.5″| 100 (yellow)
0143115| 0.015″| 10º| 4.5″| 100 (yellow)
0143215| 0.015″| 20º| 5.75″| 100 (yellow)
0143415| 0.015″| 40º| 8.25″| 100 (yellow)
0143615| 0.015″| 60º| 10.5″| 100 (yellow)
0143815| 0.015″| 80º| 13″| 100 (yellow)
0143218| 0.018″| 20º| 5.5″| 50 (white)
0143418| 0.018″| 40º| 10″| 50 (white)

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