Das WALTHER PILOT-

Programm

• Hand-Spritzpistolen

• Automatik-Spritzpistolen

• Niederdruck-Spritzpistolen

(System HVLP)

• Zweikomponenten-

Spritzpistolen

• Materialdruckbehälter

• Drucklose Behälter

• Rührwerk-Systeme

• Airless-Geräte und

Flüssigkeitspumpen

• Materialumlaufsysteme

• Kombinierte Spritz- und

Trockenboxen

• Absaugsysteme mit

Trockenabscheidung

• Absaugsysteme mit

Nassabscheidung

• Trockner

• Zuluft-Systeme

• Atemschutzsysteme und

Zubehör

The WALTHER PILOT

Programme

• Hand-Held Spray Guns

• Automatic Spray Guns

• Low Pressure Spray Guns

(System HVLP)

• Two-Component Spray Guns

• 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

• Dryers

• Ventilation Systems

• Protective Respiratory Systems

and Accessory Items

WALTHER PILOT

Betriebsanleitung / Operating Instructions

Zweikomponenten-Spritzpistole

Two-Component-Spray Gun

PILOT Misch-N

Typ / Type

24 320

REV. 03/10

WALTHER Spritz- und Lackiersysteme

Kärntner Str. 18-30

42327 Wuppertal Germany

Telefon: 0202 / 787-0

Telefax: 0202 / 787-217 www.walther-pilot.de • Email: [email protected]

EG-Konformitätserklärung

Wir, der Gerätehersteller, erklären in alleiniger Verantwortung, dass das Produkt in der untenstehenden Beschreibung den einschlägigen grundlegenden Sicherheits- und

Gesundheitsanforderungen entspricht. Bei einer nicht mit uns abgestimmten Änderung an dem

Gerät oder bei einer unsachgemäßen Verwendung verliert diese Erklärung ihre Gültigkeit.

Hersteller

Typenbezeichnung

WALTHER Spritz- und Lackiersysteme GmbH

Kärntner Str. 18 - 30

D - 42327 Wuppertal

Tel.: +49(0)202 / 787 - 0

Fax: +49(0)202 / 787 - 217 www.walther-pilot.de • e-mail: [email protected]

Zwei-Komponenten Handspritzpistole

PILOT Misch-N 24 320

Verwendungszweck Verarbeitung spritzbarer Materialien

Angewandte Normen und Richtlinien

EG-Maschinenrichtlinien 2006 / 42 / EG

94 / 9 EG (ATEX Richtlinien)

DIN EN ISO 12100 Teil 1

DIN EN ISO 12100 Teil 2

DIN EN 1127-1

DIN EN 1953

DIN EN 13463-1

Spezifikation im Sinne der Richtlinie 94 / 9 / EG

Kategorie 2 Gerätebezeichnung

II 2 G c T 6

Tech.File,Ref.:

2409

Bevollmächtigt mit der Zusammenstellung der technischen Unterlagen:

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

D- 42327 Wuppertal

Besondere Hinweise :

Das Produkt ist zum Einbau in ein anderes Gerät bestimmt. Die Inbetriebnahme ist so lange untersagt, bis die Konformität des Endproduktes mit der Richtlinie 2006 / 42 / EG festgestellt ist.

Wuppertal,den 07. Juli 2003 i.V.

Name: Torsten Bröker

Stellung im Betrieb: Leiter der Konstruktion und Entwicklung

Diese Erklärung ist keine Zusicherung von Eigenschaften im Sinne der Produkthaftung. Die Sicherheitshinweise der Produktdokumentation sind zu beachten.

Declaration of CE-Conformity

We, the manufacturers of the equipment, hereby declare under our sole responsibility 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 without prior consultation with us.

Manufacturer

Type Designation

WALTHER Spritz- und Lackiersysteme GmbH

Kärntner Str. 18 - 30

D - 42327 Wuppertal

Tel.: +49(0)202 / 787 - 0

Fax: +49(0)202 / 787 - 217 www.walther-pilot.de • e-mail: [email protected]

Two-Component Manual spray Gun

PILOT Misch-N 24 320

Intended purpose Processing of sprayable media

Applied Standards and Directives

EU-Mechanical Engineering Directives 2006 / 42 / EC

94 / 9 EC (ATEX Directives)

DIN EN ISO 12100-1

DIN EN ISO 12100-2

EN 1127-1

DIN EN 1953

DIN EN 13463-1

Specification according 94 / 9 / EC

Category 2 Part marking II 2 G c T 6

Tech.File,Ref.:

2409

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 provision of the Directives

2006 / 42 / EC.

Wuppertal, the 7th of July 2003 i.V.

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.

Listing of Replacement Parts

Item

1

2

3

4

5

6

7

V 24 329 05 000

V 24 329 04 . . 0*

V 09 101 75 000

V 24 329 01 . . 3*

V 11 306 21 . . 3*

V 24 321 01 000

V 10 361 08 000

Discription

Air cap nut

Air cap

Air cap seal

Material nozzle

Material needle

Gun body

Needle packing

15

16

17

18

19

20

21

22

23

8

9

10

11

12

13

14

24

25

26

27

28

29

30

31

32

V 01 101 01 000

V 10 306 06 000

V 10 306 08 000

V 10 902 00 000

V 24 321 05 000

V 24 321 06 000

V 10 301 09 000

V 24 321 03 000

V 00 101 03 000

V 00 101 02 003

V 24 381 05 000

V 00 101 12 005

V 24 321 09 003

V 24 306 05 000

V 10 306 04 000

V 20 001 06 000

V 10 904 04 000

V 10 304 03 000

V 10 904 02 000

V 10 304 01 000

V 09 101 02 020

V 10 901 06 000

V 00 101 01 000

V 09 101 76 010

V 24 321 04 000

Needle gland nut

Driving bushing

Counter-screw

Wide jet regulator

Lever shank screw

Distance bushing

Lever screw

Double nipple

Cap nut

Hose grommet

Double nipple

Cap nut

Hose grommet

Spring bushing

Needle spring

Counter-screw

Valve housing

Valve spring

Valve cone

Valve shaft

Packing

Valve compression gland

Double nipple

Seal

Trigger

The wearing parts are shown in boldface print in the list of the replacement parts. We recommand that wearing parts are held on stock.

Nozzle sets constist of air control head, material nozzle and material needle.

Nozzle sets No.: V 15 019 02 . . 3

* Please quote the respective sizes when ordering replacements.

(Nozzle sizes optional:0,5 • 0,8 • 1,0 • 1,2 • 1,5 • 1,8 • 2,0 • 2,5 mm ø)

Contents

5 Operation

5.2 Requirements at the Start and Finish of Operation

5.5 Retooling the Spray Gun / Repairs

6 Cleaning

6.2 General Cleaning Procedure

7 Troubleshooting

8 Disposal of Cleaning and Servicing Substances

9 Specifications

1

1 General Information

1.1 Identification of Model Version

Model: Two-Component Spray Gun PILOT Misch-N

Type:

Manufacturer: WALTHER Spritz- und Lackiersysteme GmbH

Kärntner Straße 18-30

Tel: +49 202 787-0 www.walther-pilot.de • Email:[email protected]

The hand-held spray gun PILOT Misch-N is a two-component manual spray gun for materials with a short pot life.

The hand-held spray gun PILOT Misch-N is designed exclusively for use with sprayable media, including water-based and aggressive media, such as:

• paints and laquers

• greases, oils and corrosion preventives

• ceramic glazes

• pickling solutions

Since all wetted parts are made of stainless steel, water-based media may be used as well.

If you have any questions, please contact WALTHER Spritz- und Lackiersysteme

GmbH, Wuppertal.

Sprayable material should only be applied to work pieces or similar objects.

The temperature of the material to be sprayed should at no time exceed 43° C.

The term Normal Use also implies that any and all safety warnings and instructions laid down in these operating instructions have been read, understood and are 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 authorisation of the relevant supervisory authority.

The relevant supervisory authority or the operator of the equipment are responsible 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 Spritz-und

Lackiersysteme 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 106 ).

1.3 Improper Use

The spray gun must not be used for purposes other than those laid down in the above section 1.2 Normal Use.

Any other form of use is prohibited.

Improper use includes

• the spraying of material on persons and animals

• the use of liquid nitrogen.

The model Pilot Misch-N feeds both material components to the separate connections. Mixing takes place only in the spray jet. The mixing ratio and the material flow rate are determined by the different nozzle sizes and the material pressure.

When the trigger (item 32) is actuated, the valve cone (item 26) opens first of all (pre-air), after which the material supply is opened as the material needle

(item 5) is pulled back. Closing takes place in the reverse order.

The width of the spray jet can be infinitely varied by the wide jet regulator

(item 11).

2

3

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 smoking 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 explosion 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 106 ).

Before carrying out maintenance or servicing work, always ensure that the air and material feed to the spray gun have been de-pressurised. 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!

Always observe the spraying and safety instructions given by the manufacturers of the spraying material and the cleaning agent. Aggressive and corrosive materials in particular can be harmful to health.

Exhaust air containing particles (overspray) must be kept away from the working area and personnel. In spite of these measures, always wear the regulation breathing masks and protective overalls when using the gun. Airborne particles represent a serious health hazard!

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. 85 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

Note

Please refer to the exploded view supplied with this manual when performing the installation steps described on the following pages.

Warning

The air pressure of the gun must not exceed 8 bar; otherwise safe operation of the gun cannot be guaranteed.

Warning

Material and air hoses which are installed with a hose grommet must be additionally secured with a hose clamp.

1. Connect the air hoses (cleaned compressed air) to the material pressure tanks

and the air inlet (item 30)of the spray gun.

2. Fill the material pressure tanks for component A and component B with the res-

pective material and close the lid.

3. Fasten the material inlet hose to its respective material pressure tank or the

material pressure regulator, if a pump system is used, and to the material

inlets (item 15 and 18) of the spray gun.

4. Switch on the pressurised air and adjust

the air pressure reduction valve to the

required atomizing air pressure. Adjust

the air pressure reduction valves on the

material pressure tanks to the required

pressure.

If the material is fed via a pump system

the pressure is adjusted via an adjusting

key on the material pressure control.

5. Open the material tap at the material out-

let of the relevant pressure tank.

6. To bleed any air left left in the material

hose actuate the trigger until a uniform jet

emerges from the nozzle.

The spray gun is now ready for operation.

Material connection

(item 15)(R

1/4’’-1/4’’)

Material connection

(item 18)

(R 1/4’’-3/8’’)

Air supply

4

5 Operation

Please pay special attention to the following safety instructions when using the spray gun!

• Be sure to wear the required respiratory protection masks and protective over-

alls whenever you are operating the spray gun. Airborne particles represent a

health hazard.

• Be sure to wear suitable ear protection. The spray gun produces sound levels of

approx. 83 dB (A).

• No open fires, naked lights or smoking in the working area. The spraying of readily

inflammable media is accompanied by an increased risk of fire and explosion.

5.2 Requirements at the Start and Finish of Operation

The following requirements must be met before the spray gun is operated:

• The atomizing air pressure must be available at the gun

• The material pressure must be available at the gun.

Caution

The material pressure should not exceed 8 bar. The air pressure should not exceed 8 bar. Otherwise the operational reliability of the spray gun will be impaired.

Warning

It is important to remember to relieve the spray gun of all pressures when work is terminated. Lines left under pressure may burst and the released material may injure any persons in the vicinity.

5

Spray pattern tests should be performed whenever:

• the spray gun is taken into operation for the first time

• the spraying medium has been changed

• the spray gun was taken apart for maintenance or repair works.

The spray pattern is best tested using a workpiece sample, a sheet of metal, cardboard or paper.

Warning

Keep your hands or other parts of the body away from the spray gun nozzle under pressure - risk of injury.

Warning

Make sure that no other people are in the spraying zone when the spray gun is started - risk of injury.

1. Start the gun to produce a spray pattern sample (see 5.2 Requirements

at the Start and Finish of Operation).

2. Inspect the sample and, if necessary, adjust the settings of the gun (see

5.4 Spray Pattern Adjustment).

The spray pattern of the Pilot Misch-N can be adjusted as follows:

Adjusting the Material Flow Rate

The material flow rate is determined by the nozzle size and the material pressure.

Adjusting the Material Pressure

The material pressure can only be adjusted at the pump or the pressure tank.

Please follow the instructions and safety instructions issued by the manufacturer.

Adjusting the Flat-Jet

The width of the spray jet can be infinitely varied by the wide jet regulator

(item 11).

5.5 Retooling the Spray Gun / Repairs

Air control head, material control nozzle and needle packing, all chosen for a particular spraying material, together form a unit - the nozzle insert assembly. Always change the complete insert assembly to maintain the desired spray finish quality.

Warning

Air and material inputs must be shut off prior to retooling - risk of injury.

Note

Please refer to the exploded view supplied with this manual when performing the installation steps described on the following pages.

Replacement of Material Nozzle and Air Control Head

1. Unscrew the air cap nut (item 1).

2. Remove the air control head (item 2).

3. Remove the material control nozzle (item 4) from the gun body (item 6), using

wrench (width over flats 12.)

4. Remove the air cap seal (item 3) from the material nozzle.

Reassembly of the new nozzle insert and the remaining parts is performed in reverse order. When mounting observe that the hole of the air control head exact matches with the guide pin of the gun body. The nozzles are useable for different application.

6

7

Replacement of Material Control Needle

1. Unscrew the spring bushing (Item 21).

2. Remove the spring spring (Item 22).

3. Remove the material needle (Item 4) with the driving bushing (item 9) and the

counter-screw (item 10) from the gun body. Remove the needle from the dring

bushing.

The distance between the tip of the material needle and the driving bushing should be 78 ± 0.5 mm. Control the distance and ensure with the counter-screw.

Reassembly is performed in reverse order.

Replacement of Valve Cone

1. Unscrew the valve housing (item 24) from the gun body.

2. Remove the valve spring (item 25) and the valve cone (item 26) from the gun

body.

Reassembly is performed in reverse order.

Replacement of Defective Needle Seal Packings

1. Remove the material control needle as described in "Replacement of

Material Control Needle “.

2. Unscrew the needle packing gland (item 8) from the gun body

3. Remove the needle seal packing (item 7) from the gun body. Use a strong wire

with one end bent to form a small hook.

Reassembly of replacement parts is performed in reverse order.

Note

Prior to assembly all moveable and sliding parts should be lubricated with a non-acidic, non-resinogenic grease.

Note

The wearing parts are shown in boldface print in the list of the replacement parts.

6 Cleaning

• Prior to any service work all air and material inputs should be shut off - risk of

injury.

• Open fires, naked lights and smoking are prohibited in the working area. There

is an increased risk of fire and explosion, when spraying readily flammable

media, such as cleaning solutions.

• Follow the safety instructions issued by the manufacturer of the cleaning

media. Aggressive and caustic cleaning agents in particular represent health

hazards.

6.2 General Cleaning Procedure

The spray gun should be frequently cleaned and lubricated to ensure reliable operation and long life.

Caution

Never immerse the spray gun in solvents or other cleaning fluids as this will impair the functional reliability and efficiency of the gun.

Caution

Do not use any hard or sharp-pointed objects when cleaning the spray gun, as the precision-made parts can easily be damaged and are likely to affect your spraying results.

Only use cleaning solutions recommended by the manufacturer of the spraying material. These solutions should not contain any of the following constituents:

• halogenated hydrocarbons

(e.g. 1,1,1-trichloroethane, methylene chloride etc.)

• acids and acidic cleaning solutions

• regenerated solvents (so-called cleaning dilutions)

• paint removers.

These constituents cause chemical reactions with electroplated components resulting in corrosion damage.

WALTHER Spritz-und Lackiersysteme is not liable for any damages resulting from improper treatment of the gun.

The spray gun should be cleaned

• prior to every change of the spraying medium

• at least once a week

• as often as necessary because of the spraying medium used and the resulting

level of soiling.

8

9

Following these recommendations will ensure safe spray gun operation and performance.

1. Dismantle the gun as described in section 5.5 Retooling the Spray Gun.

2. Clean the air control head and nozzle with a brush dipped in the recommen-

ded cleaning solution.

3. Clean the gun body and all remaining parts with a soft cloth and the recom-

mended cleaning solution.

4. Apply a thin layer of grease to the following parts:

• material control needle

• needle spring

• all sliding parts and bearings.

• The moveable inner parts should be greased at least once a week.

• The springs should at all times be coated with a thin layer of grease.

Use non-acidic, non-resinogenic grease and a brush. The spray gun is then reassembled in reverse order.

It is not always necessary to dismantle the spray gun for cleaning purposes when paint colour is changed at regular intervals or at the end of a work period (depending, of course, on the material used).

For routine cleaning purposes please observe the following steps:

1. Fill the clean material pressure tanks with a cleaning solution compatible

with the material used.

2. Start the spray gun (see 5.2 Requirements at the Start and Finish of

Operation).

3. Do not stop the gun until only clear cleaning solution emerges from the

nozzle.

The complete spraying system should stay depressurised until the gun is used again.

7 Troubleshooting

Warning

Prior to any servicing and repair work the spray gun should be in unpressurised state, i.e. all control air and atomizing air pressure as well as all material inputs must be shut off - risk of injury.

Fault Cause Remedy

Gun is dripping

Material control needle or nozzle soiled Clean

Material control needle or nozzle damaged Replace; see 5.5 Retooling the

Spray Gun

Needle spring (item 22) defective

Spring bushing (item 21) is screwed back too fast

Remove material needle and replace spring

Slightly unscrew

Needle gland nut (item 8) turned too far

Slightly unscrew

Material leaks behind the needle pakking

Needle gland nut is loosen

Needle packing (item 7) defective

Tighten

Replace

Pulsating or unsteady spray jet

Level in material tank too low

Top up material level (see

Manufacturer`s Operating Instr.)

Material soiled

Replace the material filter (see

Manufacturer`s Operating Instr.)

Material control nozzle is loose or damaged

Tighten or replace

Air cap seal (item 3) is damaged

Replace

Gun keeps blowing in offposition

Valve spring (item 25) or valve cone (Item 26) damaged

Replace

Packing (item 28) is screwed too tight

Slightly unscrew

Spray jet is one-side

Air cap (item 2) soiled

Clean

Air cap nut (item 1) is loosen

Tighten

10

11

8 Disposal of Cleaning and Servicing Substances

The disposal of substances used for cleaning and servicing should be in accordance with local, national and international laws and directives.

Warning

Particular attention should be paid to the spray and cleaning media manufacturers' instructions. Improper disposal represents a serious threat to the health of humans and animals.

9 Specifications

Air Control Head:

Nozzle sizes optional:

External mixing air cap

0.5 • 0.8 • 1.0 • 1.2 • 1.5 • 1.8 • 2.0 • 2.5 mm ø

Pressure Ranges:

Max. Atomizing Pressure

Max. Material Pressure

Max. Operating Temperature of Spray Gun

Noise Level

(measured at a distance of

ca. 1 m from spray gun)

Air consumption in litres/min.:

8 bar

8 bar

43 °C

83 dB (A)

1.0 bar

2.0 bar

3.0 bar

4.0 bar

5.0 bar

6.0 bar

230

290

340

390

430

470

280

390

450

510

550

600

Right to effect technical changes reserved.