WALTHER PILOT PILOT II Operating instructions

Category
Power fine-spray systems
Type
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
16 17
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.
1
AirCap
optional: 1
V1020901..5*
2
AdjustingCollar
1
V1020902004
3
MaterialNozzle
optional: 1
V1020903..3*
4
GunBody
1
V1020101000
5
Gravity-FeedCupSize3:350cm
3
1
V0013001030
6
Gravity-FeedCupCover-Size3
1
V0013003030
7
Packing(7Diskeach)
1
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Screwcompl. 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
6
).
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.Awide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
6
).
• 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sprayguninsolventoranyothercleaningsolution.Thefunctio-
nalreliabilityandefficiencyoftheguncanotherwisenotbeguaranteed.Donotuse
anyhard,sharporpointedobjectswhencleaningthespraygun.WALTHERisnot
responsibleforanydamageresultingfromimpropercleaning.
Thegundoesnotneedtobedismantledforcleaning.
1. Fillthecleanedgravity-feedcupwithacleaningfluidcompatiblewiththespray-
edmaterial.
2. Operatethespraygun.
3. Donotstopthespraygununtilclearcleaningfluidemergesfromthenozzle.
Theentiresystemshouldthenbedepressuriseduntilthe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
DetailedCleaning
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
(see7Retooling...)
Removeandreplace
Removematerialneedle(see7.2)
andloosenthe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
Tightenpacking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
Keepitlevel
Tightenthe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
turnair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.
WALTHERSpritz-undLackiersystemeGmbH
KärntnerStr.18-30•D-42327Wuppertal
Tel.:0202/787-0•Fax:0202/787-2217
www.walther-pilot.de
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
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WALTHER PILOT PILOT II Operating instructions

Category
Power fine-spray systems
Type
Operating instructions

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