WALTHER PILOT PILOT II Operating instructions

WALTHER PILOT

Betriebsanleitung / Operating Instructions

Instructions de Service / Instrucciones de Servicio

Fließbecher-Spritzpistole / Gravity Feed Cup-Spray Gun

Pistolet de Pulvérisation avec Godet Gravité

Pistola de Pulverización con Depósito de Gravedad

PILOT II

REV. 04/11

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Contents

 ExplodedDrawing 1

 DeclarationofCE-Conformity 17

 Replacementparts 18

1 General 20

1.1 Identificationofmodelversion 20

1.2 Normaluse 20

1.3 Improperuse 21

2 Technicaldescription 21

3 SafetyInstructions 21

3.1 Identificationofsafetyinstructions 21

3.2 GeneralSafetyInstructions 22

4 Connectionofinputlines 22

5 Operationalhandling 23

6 Adjustingthespraypattern 23

6.1 Correctionofspraypattern 24

7 Retoolingandrepairs 24

7.1 Replacementofthematerialnozzleandtheaircap 24

7.2 Replacementofthematerialneedle 25

7.3 Replacementofthedefectiveneedlepacking 25

8 Cleaningandservice 25

9 Troubleshooting 26

10 Disposalofcleaningandservicingsubstances 27

11 Technicaldata 27

DeclarationofCE-Conformity

We,themanufacturersoftheequipment,herebydeclareunderoursolerespon-

sibilitythattheproduct(s)describedbelowconformtotheessentialsafetyrequirements.

Thisdeclarationwillberenderedinvalidifanychangesaremadetotheequipmentwit-

houtpriorconsultationwithus

Manufacturer WALTHERSpritz-undLackiersystemeGmbH

KärntnerStr.18-30

D-42327Wuppertal

Tel.:+49(0)202/787-0

Fax:+49(0)202/787-2217

www.walther-pilot.de•e-mail:[email protected]

TypeDesignation Hand-heldSprayGunPILOTII

withGravity-Feed-Cup V10201

Intendedpurpose Processingofsprayablemedia

AppliedStandardsandDirectives

EU-MechanicalEngineeringDirectives2006/42/EC

94/9EC(ATEXDirectives)

ENISO12100-1

ENISO12100-2 DINEN1953

DINEN1127-1 DINEN13463-1

Specificationaccording94/9/EC

Category2 Partmarking

II2GcT6

Tech.File,Ref.:

2403

Authorizedwiththecompilationofthetechnicalfile:

NicoKowalski,WALTHERSpritz-undLackiersystemeGmbH,KärntnerStr.18-30

D-42327Wuppertal

Specialremarks:

Thenamedproductisintendedforinstallationinotherequipment.Commissioningis

prohibiteduntilsuchtimeastheendproducthasbeenprovedtoconformtothepro-

visionoftheDirectives2006/42/EC.

Wuppertal,the1stofJanuary2010

Name:TorstenBröker

Position:Manager,DesignandDevelopment

ThisDeclarationdoesnotgiveassuranceofpropertiesinthesenseofproductliability.Thesafetyinstructions

providedintheproductdocumentationmustbeobservedatalltimes.

i.V.

18 19

ListofReplacementPartsPILOTII

PILOTII

V10201

Item Description Qty. Article-No.

AirCap

optional: 1

V1020901..5*

AdjustingCollar

V1020902004

MaterialNozzle

optional: 1

V1020903..3*

GunBody

V1020101000

Gravity-FeedCupSize3:350cm

V0013001030

Gravity-FeedCupCover-Size3

V0013003030

Packing(7Diskeach)

V0910115000

8 PackingGland 1 V1020103000

9 MaterialNeedle optional: 1 V1020601..3*

10 NeedleRetainingNut 2 V1020602000

11 NeedleSpring 1 V1020604000

AdjustingScrewcompl. 1 V1020605060

consistingof:

12 SpringBushing 1 V1020606000

13 Counternut 1 V1150607000

14 AdjustingScrew 1 V1020605000

15 ValveHousing 1 V1020414000

16 Seal 1 V0910114000

17 ValveSpring 1 V1020403000

18 ValveCone 1 V1090402000

19 ValveShank 1 V1044401000

20 AirTube 1 V0010109000

21 GunHandle 1 V0010110000

22 AirTubeNut 1 V0010108000

23 ReducerFitting 1 V0010105000

24 Trigger 1 V0010302000

25 U-bolt 1 V0010303000

26 NutforU-bolt 1 V0010304000

27 TriggerScrew 2 V0010305000

28 ValveBushing 1 V1020106000

Repairkit

WALTHERsuppliesrepairkitcontainingallwearingpartsforthehand-heldspray

gunPILOTII.Thispartsareshowninboldfaceprintinthelistofthereplacement

parts:

Article-No.: V1600251..3

Nozzleset

Thenozzlesetconsistsofaircap,materialnozzleandmaterialneedle.

Article-No.: V1500251..3

Nozzlesizesavailable: •0,5•0,8•1,0•1,2•1,5•1,8•2,0•2,5

  •3,0•3,5mmø

*Pleasemakesuretoalwaysquotetherequiredsize/swhenplacinganorder

forreplacementparts!

Itisrecommendedtokeepinstockallbold-printedparts(wearingparts).

20 21

1 General

1.1 Identificationofmodelversion

Model:  Hand-heldSprayGunPILOTIIwithGravity-FeedCup

Type:  V10201

Manufacturer: WALTHERSpritz-undLackiersystemeGmbH

 KärntnerStr.18-30

 D-42327Wuppertal

 Tel.:0049202/787-0

 Fax:0049202/787-2217

  www.walther-pilot.de•Email:[email protected]

1.2 Normaluse

Thehand-heldspraygunPILOTIIaredesignedtobeusedexclusivelyforsprayable

media.Aggressivematerialsarenotallowedtoused,becausethewettedpartsare

notmadeofstainlessspecialtysteel.Sprayonlymaterials,whichnotcorrodethe

brass-gunbody.

Ifthematerialyouintendtosprayisnotincluded,pleasecontactWALTHERSpritz-

undLackiersystemeGmbH,Wuppertal,forfurtherinformation.

Pleasenotethatsprayablematerialsmayonlybeappliedtoworkpiecesand/orsimi-

larobjects.

Thetemperatureofthesprayingmaterialmustnotexceed43°C.Theterm"normal

use”alsoimpliesthatallsafetywarnings,operatinghandlingdetails,etc.,asstatedin

theseoperatinginstructionsarecarefullyread,understoodanddulycompliedwith.

ThisequipmentcomplieswiththeexplosionprotectionrequirementsofDirective94/

9/EC(ATEX)fortheexplosiongroup,equipmentcategoryandtemperatureclass

indicatedonthetypeplate.Whenusingtheequipment,therequirementsspecifiedin

theseOperatingInstructionsmustbeobservedatalltimes.

Thetechnicaldataindicatedontheequipmentratingplatesandthespecificationsin

thechapter"TechnicalData"mustbecompliedwithatalltimesandmustnotbe

exceeded.Anoverloadingoftheequipmentmustberuledout.

Theequipmentmaybeusedinpotentiallyexplosiveatmospheresonlywiththeautho-

risationoftherelevantsupervisoryauthority.

Therelevantsupervisoryauthorityortheoperatoroftheequipmentarerespon-

siblefordeterminingtheexplosionhazard(zoneclassification).

Theoperatormustcheckandensurethatalltechnicaldataandthemarkingofthe

equipmentinaccordancewithATEXarecompliantwiththenecessaryrequirements.

Theoperatormustprovidecorrespondingsafetymeasuresforallapplicationsin

whichthebreakdownoftheequipmentmightleadtodangertopersons.

Ifanyirregularitiesareobservedwhiletheequipmentisinoperation,theequipment

mustbeputoutofoperationimmediatelyandWALTHERmustbeconsulted.

Grounding/EquipotentialBonding

Measuresmustbetakentoensurethatthespraygunissufficientlygrounded

(earthed)bymeansofaconductiveairhose(maximumresistance10

Ω).

1.3 Improperuse

Thesprayguncannotbeusedforanyapplicationnotincludedintheinstructions.

Anyotheruseisimproper,e.g.:

• Sprayingindirectionofpeopleoranimals.

• Sprayingliquidnitrogen.

2 Technicaldescription

Thehand-heldspraygunPILOTIIisalight,easytohandleandhigh-performance

gravityfeedcupspraygun,especiallydesignedfortheprocessingofpaintsand

lacquersonsmallandnarrowworkpieces.Awideselectionofmaterialnozzles

allowsthepprocessingofalmostanytypeofmaterial.



Opentheairsupplyandadjusttheairpressurereducingvalvetothedesiredato-

mizingairrate.

Pullingofthetrigger(Item24)openstheaircontrolvalve(forinitialairinput),follo-

wedbypull-backofthematerialcontrolneedle.Releaseofthetriggershutsthe

guninreverseorder.

Withthetriggerpulled,thematerialisdrawnintothesprayjetcolumnbywayof

theinjectoreffectoftheatomizingair.Thematerialoutputdependsonthesizeof

thenozzleinstalled-andmayalsobecontrolledbywayofadjustingtheset-screw

(Item14).

Thespraypatternconeangleisadjustedbywayofturningtheaircontrolhead

(Item1)forwardorbackasrequired(thisdoesnotapplytotheflat-jetaircap).

Oncethedesiredsprayjetratiohasbeenobtained,usetheadjustingcollar

(Item2)tolocktheaircapinposition.

3 Safetyinstructions

3.1 Identificationofsafetyinstructions

Warning

Thepictogramandtheurgencylevel“Warning“identifyapossibledangertoper-

sons.

Possibleconsequences:Slighttosevereinjuries.

Attention

Thepictogramandtheurgencylevel“Attention“identifyapossibledangerto

materialassets.

Possibleconsequences:Damagetomaterialassets.

Note

Thepictogramandtheurgencylevel“Note“identifyadditionalinformationforthe

safeandefficientoperationofthespraygun.

22 23

3.2 Generalsafetyinstructions

Allapplicableaccidentpreventionrulesandregulationsaswellasotherrecognised

industrialsafetyandhealthrulesandregulationsmustbeobservedatalltimes.

• Usethespraygunonlyinwell-ventilatedrooms.Fire,nakedflamesandsmo-

kingarestrictlyprohibitedwithintheworkingarea.WARNING–duringthe

sprayingofflammablematerials(e.g.lacquers,adhesives,cleaningagents,

etc.),thereisanincreasedrisktohealthaswellasanincreasedriskofexplo-

sionandfire.

• Measuresmustbetakentoensurethatthespraygunissufficientlygrounded

(earthed)bymeansofaconductiveairhose(maximumresistance10

Ω).

• Beforecarryingoutmaintenanceorservicingwork,alwaysensurethattheair

andmaterialfeedtothespraygunhavebeendepressurised.Riskofinjury!

• Whensprayingmaterials,donotplaceyourhandsorotherpartsofthebodyin

frontofthepressurisednozzleorthespraygun.Riskofinjury!

• Neverpointthespraygunatpersonsoranimals.Riskofinjury!

• Exhaustaircontainingparticles(overspray)mustbekeptawayfromthewor-

kingareaandpersonnel.Inspiteofthesemeasures,alwaysweartheregulati-

onbreathingmasksandprotectiveoverallswhenusingthegun.Airborneparti-

clesrepresentaserioushealthhazard!

• Alwaysobservethesprayingandsafetyinstructionsgivenbythemanufactur-

ersofthesprayingmaterialandthecleaningagent.Aggressiveandcorrosive

materialsinparticularcanbeharmfultohealth.

• Alwayswearhearingprotectionwhenusingthegunorwheninthevicinityofa

gunthatisinuse.

Thenoiselevelgeneratedbythespraygunisapprox.79dB

(A).

• Aftercarryingoutassemblyormaintenancework,alwaysensurethatallnuts,

boltsandscrewconnectionshavebeenfullytightenedbeforethegunisused.

• Useonlyoriginalreplacementparts,sinceWALTHERcanonlyguaranteesafe

andfault-freeoperationfororiginalparts.

Forfurtherinformationonthesafeuseofthespraygunandthesprayingmaterials,

pleasecontactWALTHERSpritz-undLackiersystemeGmbH,D-42327Wuppertal,

Germany.

4 Connectionofinputlines

Warning

Materialandairhoseswhichareinstalledwithahosegrommetmustbeadditonally

securedwithahoseclamp.

Gravity-FeedCup

1. Connecttheairhosetotheairpipe(cleanedcompressedair)oronanairclea-

nerandontheairinletofthespraygun(item23).

2. Fillthegravity-feedcupwithscreenedmaterialandclosethegravity-feedcup.

3. Switchonthepneumaticsystem.Thesprayguncanthenbetakenintooperati-

on.

5 OperationalHandling

Thefollowingrequirementsmustbemetbeforethesprayguncanbeputintoopera-

tion:

Theairpressuremustnotexceed8bar.

1. Beforeusingthegun,firstcarryoutaspraypatterntest.Thespraypattern

canbestbetestedonasampleworkpieceoronasheetofmetal,cardboard

orpaper.

2. Checkthespraypatternsampleand,ifnecessary,adjustthesettingsofthe

spraygun.

Payattentiontothefollowingsafetywarningswhenusingthespraygun!

• Alwayswearproperrespiratoryprotectionmasksandprotectiveoveralls

whenusingthespraygun.Airborneparticlescandamageyourhealth!

• Alwayswearsuitablehearingprotectorsinthevicinityofthespraygun.

Thesespraygunsproducesoundlevelsofapproximately79dB(A).

• Ensurethattheworkingareaisabsolutelyfreefromopenfiresandnaked

lights-andthatsmokingisstrictlyprohibited.Thesprayingofflammable

liquids(e.g.paint,adhesives)isalwaysaccompaniedbytheriskoffireand

explosion.

• Whensprayingmaterials,keephandsandotherpartsofthebodyawayfrom

thenozzleofthegunwhenitisunderpressure.Riskofinjury!

• Relievethespraygunofallpressureswhenworkiscomplete.Linesleftina

pressurisedconditionmightburstandtheircontentsarelikelytoinjureper-

sonsstandingnearby!

6 Adjustingthespraypattern

ThespraypatternofthePILOTIIcanbechangedbyadjustingthegunasfollows:

Settingthematerialflow

rate:

Thematerialoutputdepends

onthesizeofthenozzle

installed-andmayalsobe

controlledbywayofadjusting

theset-screw(Item14).

Settingthesprayjet:

Thesprayjetisadjustedby

wayofturningtheaircap

(Item1)forwardorbackas

required(thisdoesnotapplyto

theflat-jetaircap).Oncethe

desiredsprayjetratiohas

beenobtained,usetheadju-

stingcollar(Item2)tolockthe

aircapinposition.

Airconnection

Gravity-FeedCup

Adjustingtheatomising

airlowrate:

Theatomisingairflowratecan

beadjustedbytheairpressure

reducingvalveintheplant.

24 25

6.1 CorrectionofSprayPatternImperfections

Thefollowingtableshowshowtocorrectadefectivespraypattern.

Spraypattern

test

Fault Requiredadjustment

Spraypatternissplitin

thecentre

•settingawiderspraypattern

Spraypatternistoothick

attheends

•Settingamoreroundedspray

pattern

Thespraypatternshows

ratherlargedroplets

•Increasethenozzleairpres-

sure

Materialapplicationinthe

centreofthespraypattern

isverythin

•Decreasethenozzleairpres-

sure

Spraypatternissplitin

thecentre

•Increasethenozzlediameter

•Reducenozzleairpressure

•Increasematerialpressure

Spraypatternisvery

spherical

•Reducematerialpressure

•Increasenozzleairpressure

7 Retoolingandrepairs

Ifajetcontourotherthanalreadydescribedisdesired,thespraygunhastobe

retooled.Thesuitablematerialaircontrolhead,materialnozzleandneedle-combina-

tionformtogetheraunit-thenozzleset.Alwayschangethecompleteinsertassmbly

tomaintainthedesiredfinishquality.

Warning

Priortoanyretoolsorreplairs:Makesurethatthespraygunisindepressurizedcon-

dition,i.e.allairinputsmustbeshutoff-ifnot,imminentRiskofInjury.

Note

Inordertoperformthefollowingprocedures,pleaserefertotheexplodeddiagramin

thebeginningoftheseoperatinginstructions.

7.1 Replacementofthematerialnozzleandtheaircontrolhead

1. Removeaircap(Item1)fromthegunbody(item4).

2. Removematerialnozzle(Item3)fromgunbody;usingaSize11wrench.

Reassembleinreverseorder.

7.2 Replacementofthematerialneedle

1. Unscrewthespringbushing(Item12)fromthegunbody.

2. Withdrawtheneedlespring(Item11)andpulloutthematerialneedlewith

bothneedleretainingnuts.

3. Removethematerialneedle.

4. Thesettingdimensionfortheneedle-controlledinitialairinputis69mm,

measuredbetweenthepointofthematerialneedleandthefaceofthe1st

needleretainingnut(Item13),withthe2ndnutservingaslocknut.

Reassembleinreverseorder.

7.3 Replacementofthedefectiveneedlepacking

1. Removethematerialneedle,seeabove.

2. Aftertheremoveofthematerialneedleunsrewthepackinggland(Item8),

usingaproperlysizedscrewdriver.Thepacking(Item7)cannowberemoved

fromthegunbody(Useathinwire,oneendofwhichisbentintoahook,for

thispurpose).

Reassembleinreverseorder!

8 Cleaningandservice

Attention

Neverimmersethesprayguninsolventoranyothercleaningsolution.Thefunctio-

nalreliabilityandefficiencyoftheguncanotherwisenotbeguaranteed.Donotuse

anyhard,sharporpointedobjectswhencleaningthespraygun.WALTHERisnot

responsibleforanydamageresultingfromimpropercleaning.

Thegundoesnotneedtobedismantledforcleaning.

1. Fillthecleanedgravity-feedcupwithacleaningfluidcompatiblewiththespray-

edmaterial.

2. Operatethespraygun.

3. Donotstopthespraygununtilclearcleaningfluidemergesfromthenozzle.

Theentiresystemshouldthenbedepressuriseduntilthegunisusedagain.Clean

thespraygunonlywithcleaningagentswhichhavebeenrecommendedbytheman-

ufacturerofthesprayedmaterialandwhichdonotcontainthefollowingconstituents:

• halogenatedhydrocarbons(e.g.1,1,1-trichloroethane,methylenechloride,etc.)

• acidsandacidiccleaningfluids

• regeneratedsolvents(so-calledcleaningthinners)

• paintremovers

Theabove-mentionedconstituentscausechemicalreactionsonelectroplatedcom-

ponents,resultingincorrosiondamage.

Cleanthespraygun

• beforeeachchangeofsprayingmaterial

• atleastonceaweekor

• severaltimesaweekifrequiredbythesprayingmediumanddependingon

thedegreeoffouling.

DesiredSprayPattern

26 27

DetailedCleaning

1. Disassemblethespraygun.

2. Cleantheaircapandthematerialnozzlewithasoftbrushandcleaningfluid.

3. Cleanallothercomponentsandthegunbodywithasoftclothandcleaning

fluid.

4. Coatthefollowingpartswithathinlayerofgrease:

• needlespring

• allslidingpartsandbearingpoints.

Themovinginternalpartsmustbegreasedatleastonceaweek.

Thespringsshouldalwaysbecoatedwithathinlayerofgrease.Forthis,always

useanon-acidic,non-resinogenicgreaseandasoftbrush.Assemblethegunagain

inreverseorder.

9 Troubleshooting

Warning

Priortoanyretoolingthespraygunshouldbedepressurizedstate,i.e.atomising

airaswellasthematerialpressure-riskofinjury.

Fault Cause Remedy

Gundrips

Materialneedleornozzleisfou-

ledordamaged

Needlespring(Item11)defecti-

ve,i.e.damagedorbroken

Packinggland(Item8)istoo

tight

Springretainingbush(Item12)

turnedtoofarbackwards

Cleanorreplace

(see7Retooling...)

Removeandreplace

Removematerialneedle(see7.2)

andloosenthepackinggland

slightlywithascrewdriver

Turninthespringretainingbush

slightly

Materialleakageat

packinggland

Packingglandistooloosen

Packing(Item7)isworn

Tightenpackinggland

Replaceneedlepacking(see7.3)

Gunkeepsblowing

inoffcondition

Valvecone(Item18)leaksor

valveshank(Item19)issluggish

Replacevalveconeor

loosenthevalvebushing(Item28)

SprayJetpulsating

orunsteady

Materiallevelingravity-feedcup

istoolow

Gravity-feedcupheldatexces-

siveworkingangle

Materialnozzle(Item3)istoo

loose

Top-upmateriallevel

Keepitlevel

Tightenthematerialnozzle

SprayJetonesided Aircap(Item1)isfouled Removeandclean

Materialbubblesin

gravity-feedcup

Materialnozzleistooloose Tightenthematerialnozzleand/or

turnaircapslightlybackwards

10 Disposalofcleaningandservicingsubstances

Wastesprayingmediaandwastematerialfromcleaningandservicingmustbe

disposedofinaccordancewithallapplicablelocalandnationalregulations.

Warning

Observetheinstructionsissuedbythemanufacturersofthesprayingand

cleaningmaterialatalltimes.Theimproperdisposalofwastematerialendangers

thehealthofhumanbeingsandanimals!

11 Technicaldata

Weight:   630g

Nozzlesizesavailable:  •0.5•0.8•1.0•1.2•1.5•1.8•2.0

    •2.5•3.0•3.5mmø

AirCaps:   RoundJetAirCap

max.AtomisingAirPressure: 8bar

max.Operatingtemperature: 43°C

NoiseLevel

(measuredatapprox.

1mfromthespraygun)  79dB(A)

AirConsumption

InputPressure  AirConsumption

1.0bar   100l/Min

2.0bar   130l/Min

3.0bar   140l/Min

4.0bar   160l/Min

5.0bar   180l/Min

6.0bar   190l/Min

Righttoeffecttechnicalchangesreserved.

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WALTHERSpritz-undLackiersystemeGmbH

KärntnerStr.18-30•D-42327Wuppertal

Tel.:0202/787-0•Fax:0202/787-2217

www.walther-pilot.de

E-mail:[email protected]

DasWALTHERPILOT-Programm

•Hand-Spritzpistolen

•Automatik-Spritzpistolen

•Niederdruck-Spritzpistolen(SystemHVLP)

•Pulverbeschichtungs-Systeme

•Materialdruckbehälter

•DruckloseBehälter

•Rührwerk-Systeme

•Airless-GeräteundFlüssigkeitspumpen

•Materialumlaufsysteme

•KombinierteSpritz-undTrockenboxen

•AbsaugsystememitTrockenabscheidung

•AbsaugsystememitNassabscheidung

•Pulversprühstände

•Trockner

•Zuluft-Systeme

•AtemschutzsystemeundZubehör

TheWALTHERPILOTprogramme

•Hand-HeldSprayGuns

•AutomaticSprayGuns

•LowPressureSprayGuns(SystemHVLP)

•PowderCoatingSystems

•MaterialPressureTanks

•NonpressurizedTanks

•AgitatorSystems

•AirlessEquipmentandTransferPumps

•MaterialCirculationSystems

•CombinedSprayingandDryingBooths

•DryBackOversprayExtractionSystems

•WetBackOversprayExtractionSystems

•PowderSprayStands

•Dryers

•VentilationSystems

•ProtectiveRespiratorySystemsand

AccessoryItems

LeprogrammedeWALTHERPILOT

•Pistoletsdepulvérisationmanuels

•Pistoletsdepulvérisationautomatiques

•Pistoletsdepulvérisation(SystèmeHVLP)

•Systèmesdepoudrage

•Réservoirssouspression

•Récipientsdemélangeetdestockage

•Appareilsdepulvérisationsansair

•Pompesdetransfert

•Mursàaspirationsèche

•Mursàrideaud'eau

•Cabinesdepoudrage

•Cabinesmixtespeinture-séchage

•Installationsdesoufflage

•Etuves

•Trèsnombreuxaccessoires

ElprogramadeWALTHERPILOT

•Pistolasmanualesdepulverización

•Pistolasautomaticasdepulverización

•Pistolasdebajapresión

•Pistolasdemarcación

•Calderinesapresión

•Calderinessinpresión

•Sistemasderecirculatión

•Agitatores

•Cabinasconseparatiónenseco

•Cabinasconseparatiónenhúmedo

•Cabinascombinadasdepulverizacióny

secado

•Sistemasdeventilación

•Ampliaseleccióndeaccesorios

WALTHER PILOT PILOT II Operating instructions

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