WA XV User Manual

WALTHER PILOT
Betriebsanleitung / Operating Instructions /
Instructions de Service / Gebruiksaanwijzing
O9000
Automatische Spritzpistolen / Automatic Spray Guns
Pistolets de Pulvérisation Automatiques / Automatische
Spuitpistolen
PILOT WA XV
REV 07/12
Die Beschichtungs-Experten
PILOT WA XV
Stand: April 2008
PILOT WA XV - HVLP
Reparatursets
Maintenance kits
Kits de réparation
Reparatiesets
V 16 115 03... 3 (ММА Ху)
V 16 116 03. . 3 (WA XV ziehbar, needle-pull
à tirette, met trekker)
V 16 117 03. . 3 (WA XV-HVLP)
Listing of Contents
Exploded Drawing
Declaration of CE-Conformity
Replacement parts
1 General
1.1 Identification of Model Version
1:2 Normal Use
1.3 Improper Use
2 Technical Description
3 Safety Instructions
3.1 Safety Warning Symbols
3.2 General Safety Instructions
4 Assembly / Installation
4.1 Mounting of Spray Gun
4.2 Connection of Input Lines
5 Operational Handling
5.1 safety Instructions
5.2 Starting / Stopping Requirements
т Spray Pattern Test
54 Spray Pattern Adjustments
5.5 Retooling of Spray Gun
6 Cleaning and Maintenance
6.1 Safety Instructions
6.2 Cleaning - Complete
6.3 Cleaning - Routine
7 Repairs/Replacements
7.1 Replacement of defective Needle Seal Packings
Той Replacement of Nozzles, Needles, Springs, Seals
8 Troubleshooting and Corrective Action
9 Disposal of Cleaning/Servicing Substances
10 Specification Data
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25
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28
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29
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30
30
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31
31
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32
34
36
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40
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Declaration of CE-Conformity o
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
Karntner Str. 18 - 30
D - 42327 Wuppertal
Tel.: +49(0)202 / 787 - 0
Fax: +49(0)202 / 787 - 2217
www.walther-pilot.de - e-mail: infor?'walther-pilot.de
Type Designation Automatic Spray Gun PILOT WA XV
WA XV V 20 660
WA XV needle-pull V 20 664
WA XV-HVLP V 20 672
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
Tech.File,Ref.:
Category 2 Part marking N2GCTS 2411
Authorized with the compilation of the technical file:
Nico Kowalski, WALTHER Spritz- und Lackiersysteme GmbH, Kárntner 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
iv. (© [ds
Name: Torsten Broker
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.
25
Listing of Replacement Parts
for Model WA XV
Item Part-No.
1
2
Y 01 101 03 000
optional
V 01 10102 ..6°
Description
Air Cap Nut
6-Bore-Air Cap
other Air Cap Versions upon request
optional
V 01 101 07 ..3°
\ 11 301 02 000
V 20 660 02 000
V 20 661 02 000
Material Nozzle
Air Distnbution Ring
Gun Front Attachment
Gun Front Attachment
(Circulation Systems only)
V 09 001 72 000
V 20 660 05 000
V 20 660 06 000
V 20 660 07 000
V 09 001 67 000
V 20 660 01 000
V 20 660 20 000
V 20 660 08 000
\ 00 101 01 000
\ 09 002 07 000
\ 20 660 04 003
V 20 201 02 000
V 09 102 02 000
V 20 660 42 000
V 20 660 32 000
V 09 102 11 000
V 20 660 33 000
V 09 102 09 000
V 20 660 31 000
V 20 651 06 000
V 20 660 34 000
optional
V 20 660 51 . 3°
V 10 506 02 000
V 20 651 07 000
V 20 660 36 003
V 20 606 11 000
V 20 660 35 000
V 20 660 37 000
V 20 660 38 000
V 20 660 39 120
Needle Seal Packing
Mating Bush
Compression Spring
Compression Gland
Seal
Gun Body
Flat-Jet Adjustment
compl.
Cylinder Head Screw
Double Nipple
Usit-Ring
Hexagonal Nut
Sealing Screw
O-Ring
Blanking Cap
Sealing Collar
O-Ring
Screw Plug
O-Ring
Control Piston
Sealing Collar
Backup Washer
Material Needle
Needle Retaining Nut
Needle Spring
Piston End Nut
Piston Spring
Spring Retainer
Spring Bush
Spring Pin
Adjustment Screw
Replacement Parts - other than
Replacement Parts
PILOT WA XV needle-pull Type V 20 664
given values of PILOT WA XV
Item Part-No. Description
27-35 Parts not applicable
36 V20664 05000 Piston End Nut
37 optional Material Needle
V 2066443 .. 3°
38 V2066402000 Stop Pin
39 V20 206 04000 Needle Spring
40 WV 2066404000 Adjustment Screw
41 Y 20 664 03 000 Washer
42 V206/985 000 Flat Washer
43 V 2067984 000 Serrated Lock Washer
44 2066041684 Cylinder Head Screw
Replacement Parts
PILOT WA XV- HVLP Type V 20 672
2 optional Air Cap
for Nozzle Size
V 01 101 86 086” 0.3 - 2.0 mm ©
V 01 101 86 256° 2.5 - 3.0 mm ©
3 V 01101 85..3" Material Nozzle
11 \ 20 671 01 000 Gun Body
20 \20671 32 000 Sealing Collar
30 V20664 05000 Piston End Nut
37 optional Material Needle
V 20 664 43 033 0,3 a for 0 3-Nozzle
V 20 664 43 053 05 e for 0 5-Nozzle
for Nozzle Size
V20664 43083" 0.8 - 1.5 тт е
V 20 664 43 123° 1.8 - 2.0 тт е
V 20 664 43 253* 2.5 - 3.0 тит ©
38 Y 20664 02 000 Stop Pin
39 V 2020604000 Needle Spring
40 V 2066404000 Adjustment Screw
41 V 20 664 03 000 Washer
42 WV 2067985000 Fat Washer
43 V2067984 000 Serrated Lock Washer
44 V 20660 41 684 Cylinder Head Screw
45 V 2067140000 Middle-Air Regulation
* Please make sure to always quote the required size(s)
when placing an order for Replacement Parts! We re-
commend that BOLD-faced replacement parts (i.e.
wearing parts) are held an stock to avoid work stoppa-
ges.
26
1 General
1.1 Identification of Model Version
Model: Automatic Spray Gun PILOT WA XV
Type series: WA XV V 20 660
WA XV needle-pull V 20 664
WA XV-HVLP V 20 672
Manufacturer: WALTHER Spritz- und Lackiersysteme GmbH
Karntner Str. 18-30
D-42327 Wuppertal
Tel.: 0049 (0)202 / 787-0
Fax: OO 49 (0)202 / 787-2217
www.walther-pilot.de - Email: [email protected]
1.2 Normal Use
The automatic spray guns of the WA XV type series are exclusively designed for use
with sprayable material types and grades. All wetted parts are made of stainless spe-
ciality steel so as to permit handling of hydrous and/or aggressive media such as, for
example:
= paints and lacquers
= greases, oils and corrosion preventives
= adhesive compounds
= ceramic glazes
= pickling solutions
If your specific material is not listed above, please contact us for further and detailed
information.
Please note that sprayable material may only be applied to workpieces and/or similar
items.
The temperature of the spraying material shall never exceed 80 degs. C.
The WA XV needle-pull gun is not designed for manual operation, but must be
installed in a suitable gun mounting device.
The term normal use also implies that any and all safety warnings, operational hand-
ling details, etc., as contained 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
authorisation of the relevant supervisory authority.
27
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 require-
ments.
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 Lackier-
systeme must be consulted.
Grounding / Equipotential Bonding
You must ensure that the spray gun is properly earthed (grounded) either separate-
ly or in connection with the equipment with which it is being used
(maximum resistance 10°Q2).
1.3 Improper Use
This spray gun shall not be used for purposes other than set forth in the above
Chapter Normal! Use. Any other form of use and/or application is prohibited and
considered as improper use in contrast to the original engineering design concept.
The term improper use also includes such operations as may be:
= spraying of material onto persons and animals
» spraying of liquid nitrogen, etc.
2 Technical Description
Spray guns of the WALTHER PILOT Type Series WA XV are allautomatic air-con-
trolled guns operating in combination with a 3/2-way control valve in the form of
hand-, foot- or solenoid-actuated valves.
Actuation of the 3/2-way valve directs control air into the cylinder inside the gun so
as to open - in sequence - the atomizing air and the material input.
Closing of the 3/2-way valve is followed by the control air escaping from the cylin-
der inside the gun, upon which the spring-loaded material control needle returns to
its initial position, where it shuts the material and atomizing air Input off.
The material flow rate and the spray jet contour (i.e. flat, wide or round) are adju-
sted at the gun by way of regulating screws.
The material inlet duct of the WA XV needle-pull can be opened by hand so as to
permit, for example, cleaning of a clogged material nozzle.
The model PILOT WA XV-HVLP is a low pressure spray gun and operate with a
spraying pressure of 0.7 bar using an inlet pressure of 3.5 bar.
The gun front attachment with twin connector for material input permits inclusion of
the PILOT spray gun in a circulation system the closed loop layout of which is desi-
gned to operate several spray guns.
This spray gun can be connected to material pressure tanks, pumping and circula-
tion systems.
28
3 Safety Instructions
3.1 Safety Warning Symbols
Warning
This pictograph and the accompanying warning note "Warning" indicates possible
risks and dangers for yourself and others, likely to result in injuries of any descripti-
on.
Caution
This pictograph and the accompanying Warning note "Caution"-indicates possible
damage to equipment, workpieces, etc.
Notice
This pictograph and the accompanying note "Notice"indicates additional and useful
information to help you handling the spray gun with even greater confidence and
efficiency.
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 smoking
are strictly prohibited within the working area. WARNING — during the spraying of
flammable matenals (e.g. lacquers, adhesives, cleaning agents, etc.), there is an
increased risk to health as well as an increased risk of explosion and fire.
= You must ensure that the spray gun is properly earthed (grounded) either separate-
М or in connection with the equipment with which it is being used (max. resistance
1050).
. Before carrying out maintenance or servicing work, always ensure that the air and
matenal feed to the spray gun have been depressunsed. Risk of injury!
. When spraying materials, do not place your hands or other parts of the body in
front of he 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 brea-
thing masks and protective overalls when using the gun. Airborne particles repre-
sent 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. 86 dB (A).
. After camying 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 quarantee safe and
fault-free operation for original parts.
For further information on the safe use of the spray qun and the spraying matenals, ple-
ase contact WALTHER Spntz- und Lackiersysteme GmbH, D-42327 Wuppertal,
Germany.
29
4 Assembly / Installation
This WALTHER PILOT spray gun is delivered in completely assembled condition -
but requires the following preparations before it can be taken into operation:
4.1 Mounting of Spray Gun
Install the gun in a suitable and stable mounting device as shown in the following
example:
4.2 Connection of Input Lines
Warning
1.
Slide the gun with its 12 mm @ mounting
bore ® onto the rod @ of the mounting
device.
. Adjust the gun an the mounting rod to
point at the workpiece. Point the gun an
the mounting rod - by sliding and turning
it up or down - at the workpiece.
Lock the gun in the desired position by
tightening the cap screw @ with a Size 8
mm hex. hd. socket wrench.
Make sure not to confuse the control and atomizing air connections - Risk of Injury.
PILOT WA XV
-HVLP
. Connect the Input line for
= Atomizing air to the "SPRITZLUFT" inlet
fitting (G 1/4") of the gun.
= Control air to the "STEUERLUFT" inlet
fitting (G 1/4") of the gun.
- Material to inlet Fitting @ (G 3/8") of the
gun.
. Use the tool wrench to tighten the three
hex. nuts @.
The spray gun is now properly installed and connected and ready for operation.
30
5 Operational Handling
5.1 Safety Instructions
Your special attention is drawn to the following Safety Warnings prior to taking this
spray gun into operation!
= Make sure to wear proper respiratory protection masks and protective Overalls
whenever you are operating this spray gun. Remember: Air-Borne particles
represent a health hazard.
= Make sure to wear suitable Kearing protectors. Remember: Spray guns pro-
duce sound levels of up to about 86 dB (A), which are highly likely to cause
hearing defects.
= Make sure your working area is absolutely free from open fires and naked
lights -and anybody smoking. Remember: Spraying of readily flammable
media such as, for example, paints, adhesive compounds, cleaning solutions,
etc., is always accompanied by the risk of fire and explosion.
5.2 Starting / Stopping Requirements
The following requirements must be met before this spray gun can be taken into
operation:
= atomizing air must be available at the gun.
» material pressure must be available at the gun.
= control air must be avaiable at the gun.
Caution
The material pressure shall not exceed
= 10 bar in the WA XV
* 15 bar in the WA XV needle-pull / WA XV-HVLP
as, otherwise, the functional reliability of the spray gun will suffer.
Adjust the control air pressure to
* 8 bar maximal
in order to operate the spray gun.
The operation of the spray gun can be started/stopped by way of the 3/2-way con-
trol valve (see the Operating Instructions of the plant systems manufacturer).
Warning
lt is important to remember that the spray gun must be relieved of all pressures
whenever work is terminated - lines left in pressurized condition could burst, with
their contents likely to injure anybody present nearby.
5.3 Spray Pattern Test
Spray pattern tests should be performed whenever:
* the spray gun is taken into operation for the first time.
» the spraying medium is changed.
» the spray gun was taken apart for servicing or repairs.
The spray pattern is best tested using a workpiece sample, a sheet of metal, card-
board or paper.
31
Warning
Keep away from the front of the spray gun - imminent Risk of Injury.
Warning
Make sure that nobody is present in the spraying zone when the gun is started
- imminent Risk of Injury.
1. Start the gun to produce a spray pattern sample (see 5.2 Starting / Stopping
Requirements).
2. Inspect the sample and readjust the settings of the gun as may be required
(see 5.4 Spray Pattern Adjustments).
5.4 Spray Pattern Adjustments
The spray pattern of the PILOT WA XV / WA XV needle-pull / WA XV-HVLP can be
adjusted as follows.
Wide and / or Flat Jet Pattern
. Loosen the knurled air cap retaining ring
O slightly.
Rotate the air cap @ horns into
= a vertical position
= flat jet pattern
= a horizontal position
= wide jet pattern
Tighten the air cap retaining ring ®.
Wide / Flat and / or Round Jet Pattern
ao
4.
5.
Loosen the lock nut @ using a Size 11
mm wrench.
Turn the fine-adjusting screw @ in
* - direction = increase roundness of
spray jet contour
« + direction = increase wideness/
flatness of spray jet contour
Once the desired spray jet contour is
adjusted tighten the lock nut @.
32
Middle-air adjustment (only PILOT WA XV-HVLP)
The adjusting screw © is used to adjusted the middle-
air.
Adjustment of the Material Flow Rate
1. Turn the material Input regulating screw © from its normal position (= notch
mark an the matrial needle adjuster) in
» —direction = decrease of flow rate.
« + direction = increase of flow rate.
Adjustment of the Material Pressure
This adjustment can only be made at the controls of the pumping or circulation
system or material pressure tank. Please comply with the Operating Instructions and
Safety Warnings issued by the manufacturers concerned.
Adjustment of the Atomisation Air Pressure
The atomizing air Pressure is to be adjusted at the air Pressure reducing valve of the
compressor system. Please comply with the Operating Instructions and Safety War-
nings issued by the manufacturer.
If you wish to change the spraying Pattern beyond the adjustments outlined so far,
you must retool the spray gun (see 5.5 Retooling of Spray Gun). WALTHER offer a
great variety of air cap/material nozzle/-needle combinations for this purpose.
Correcting of Spray Pattern Imperfections
The table below shows what to do to correct a spray pattem.
CC. desired spray pattern
Spray pattern test Fault Required adjustment
TE > Spray pattern is split in the | * setting a wider spray pattem
“E | centre
= Spray pattern is too thick at | = Setting a more rounded spray pattern
= the ends
Een The spray pattern shows » Increase the atomising air pressure
rather large droplets
Maternal application in the * Decrease the atomising air pressure
centre of the spray pattem
Is very thin
a Sora Нет is split in * Increase the nozzle diameter
> @ pray pa « Reduce atomising air pressure
a the centre A
« Increase material pressure
Spray pattem is very spher- | = Reduce matenal pressure
nn ical « Increase atomising air pressure
33
5.5 Retooling of Spray Gun 8. Remove the piston © very carefully from
the gun body (use a suitable pair of pliers).
Combinations of air cap, material nozzle + needle, designed to match specific
spraying media types and grades, form a unit - namely the nozzle insert assembly,
which must always be interchanged as a complete assembly to maintain the desi-
red spray- finish quality standard.
9. Remove the piston end nute from the con-
trol piston @ (use Size 13 mm and 22 mm
wrenches). The material needle © is now
freely accessible and can be pulled out.
Warning
Prior to retooling: make sure that the spray gun is in unpressurized condition, i.e.
all air and material inputs must be shut off - if not, imminent Risk of Injury.
10. Unscrew the two needle retaining nuts &.
Replacement of Air Cap
1. Unscrew the knurled air cap retaining
ring O.
Installation of the new nozzle insert assembly and of the remaining parts in reverse
2. Pull the air cap @ off the gun front order.
attachment.
3. Position the required air cap an the gun WA XV needle-pull / WA XV-HVLP:
front attachment.
1. Remove all pressures from the gun (see
4. Screw the air cap retaining ring @ onto 5.2 Starting / Stopping Requirements).
the gun front attachment.
2. Remove the air control head (see 5.5
Replacement of Air Cap).
3. Unscrew the material nozzle from the gun
Replacement of Material Nozzle and Needle front attachment (12 mm wrench).
WA XV / WA XV-HVLP: 4. Remove the cap screw and pull the was-
her off.
1. Remove all Pressures from the gun (see
TEATRE AQUA 5. Remove the material input regulating
screw.
2. Remove the air control head (see 5.5
Replacement of Air Cap). 6. Pull the needle spring @ out.
. Unscrew the material nozzle © from the 7. Pull the stop piston @ plus material need-
gun front attachment (use a Size 12 mm le @ out.
wrench). :
8. Unscrew the material needle @ from the
. Unscrew the material Input regulating
screw @.
. Pull the two spring pins @ off.
. Unscrew the spring retaining bush ©
(use a Size 27 mm wrench).
. Remove the compression spring © from
the gun body.
stop pin @.
Installation of the new nozzle insert assembly and of the remaining parts in reverse
order.
35
6 Cleaning and Maintenance 3. Use a suitable cloth with a compatible cleaning solution to clean the gun body
6.1 Safety Instructions and all remaining parts.
4. Apply a thin film of the appropriate grease type/grade to the:
= Prior to any servicing and repair work: Make sure that the spray gun is in + sealing collar of the piston
unpressurised condition, i.e. all air and material inputs must be shut off - if not, » O-ring of the piston
imminent Risk of Injury . - material control needle
= No open fires and naked lights as well as smoking are allowed in the work - needle spring
area. This is a major requirement to prevent the euer present risk of fire and » inside of the gun body
explosion, particularly when spraying readily flammable media such as, for Make sure to use a non-acidic, non-resinogenic grease type/ grade and apply
example cleaning solutions, etc. same with a soft brush. Assemble the spray gun in reverse order.
» ltis important that all processing specifications and safety warnings issued by
the manufacturer of cleaning media are duly complied with. Remember:
Aggressive and corrosive media represents risks and hazards to personal
health.
6.3 Cleaning - Routine
The spray gun need not necessarily be dismantled for cleaning if and when the
spraying medium is changed in regular intervals or upon termination of work
6.2 Cleaning - Complete (depending, of course, an the material used).
The spray gun should be frequently cleaned and lubricated so as to ensure a long
service life and functional reliability. Cleaning of the gun only with cleaning solutions
recommended by the manufacturer of the spraying material used at the time. It is
im-portant to make sure that cleaning solutions do not contain any of the following
Notice
It is recommended practice to clean and lubricate the spray gun frequently in
accordance with Chapter 6.2 Cleaning - Complete, as this will greatly help towards
ensuring a Jong service life and functional reliability.
constituents:
= halogenated hydrocarbons (e.g. 1,1,1-trichloroethane; methylene chloride, etc.) The following requirements must be met before the routine cleaning work can be
= acids and acidiferous cleaning solutions performed:
= regenerated solvents (so-called cleaning dilutions) = the material tank must be clean and then filled with a compatible cleaning
= paint removers solution.
= cleaning solution should neuer be sprayed - yet the material pressure must be
The above constituents cause chemical reactions with electroplated components available at the gun.
resulting in corrosion damage.
WALTHER Spritz- und Lackiersysteme is not liable for any damages resulting from The spraying system must be in Operation if a spray gun is to be cleaned.
improper treatement of the gun. 1. Take the spray gun into Operation (see 5.2 Starting / Stopping Requirements).
2. Do not stop the spray gun until clear cleaning solution emerges from the nozz-
Clean the spray gun le.
= prior to each change of the spraying medium.
= atleast once a week. Only WA XV needle-pull / WA XV-HVLP
» as often as may be required by the spraying medium handled and the resultant The material Input can be released by hand so that the complete spraying system
degree of fouling. must not be taken into operation.
1. Pull the disk © at the end of the spray gun back.
The material inlet is now open and both the
material duct and the material needle will be
washed clean.
Caution
Never immerse the spray gun in solvent or any other cleaning solution as such
measure is highly likely to affect the functional reliability and efficiency of the gun.
A Caution 2. Do not let go of the disk @ until clear cleaning
Do not use any hard, pointed or sharp-edged objects when cleaning the spray gun. solution emerges from the nozzle.
Any damage of the precision-made parts are likely to affect your spraying results.
All pressures should now be removed from the
complete spraying system - which should be left in
this condition until it is taken into operation again.
1. Dismantle the spray gun (see 5.5 Retooling the Spray Gun).
2. Use a soft brush together with a compatible cleaning solution to clean the air
cap and nozzle.
36 37
A
7 Repairs / Replacements
Warning
Prior to any repairs/replacements: Make sure that the spray gun is in unpressurised
condition, i.e. all air and material inputs must be shut off - if not, imminent Risk of Injury.
7.1 Replacement of defective Needle Seal Packings
1. Remove all pressures from the gun -see
5.2 Starting / Stopping Requirements.
2. Pull the white protective cover © off the
gun body.
3. Unscrew the hex. nut @ with a Size 17 mm
wrench.
4. Pull the "USIT" ring © off.
5. Pull the gun front attachment @ carefully
off the gun body.
6. Remove the gasket @ - and replace same
if damaged.
7. Unscrew the packing seal @ with a Size
11 mm from the gun front attachment.
8. Remove the compression spring @ (re-
place if damaged) and the counter bush
@ from the threaded socket.
9. Remove the needle seal packing @ from
its seat - use a strong wire with one end
bent to form a small hook.
10. Lubricate the new needle seal packing with a non-acidic, non-resinogenic
grease type / grade.
11. Install the new needle seal packing in the gun body.
Installation of the remaining parts in reverse order.
Caution
Never reinstall a used needle seal packing as, otherwise, the functional sealing
reliability of the spray gun will suffer.
38
7.2 Replacement of Nozzles, Needles, Springs and Seals
For replacement of any of the following parts dismantle the spray gun in accor-
dance with 5.5 Replacement of Material Nozzle and Needle:
+ Material Nozzle
= Piston Spring
+ Material Needle”
+ Needle Spring”
«= Piston Sealing Collar
« Piston O-Ring”
Caution
Parts marked * must be lubricated with a non-acidic, non-resinogenic grease type /
grade prior to installation.
WALTHER Repair kits are also available for WA XV, WA XV needle-pull and WA
XV-HVLP spray guns. Wearing parts are also shown (in boldface) in the Listing of
Replacement Parts.
Repair kit-material side:
WA XV: Art. No.: V 16 115 03..3
WA XV needle pull: Art. No.: V 16 116 03..3
WA XV-HVLP: Art. No.: V 16 117 03..3
8 Troubleshooting and Corrective Action
Warning
Prior to any servicing and repair work: Make sure that the spray gun is in unpressuri-
zed condition, i.e. all air and material inputs must be shut off - if not, imminent Risk of
Injury.
Fault Cause Remedy
Material nozzle or needle fou- | Remove see 5.5 Matenal Nozzle or
led or damaged Needle and clean or replace
Gun is dripping
Packing gland too tight Loosen packing gland shightly use a
Size 11 wrench
Increase control air pressure to
max. & bar (see operating
Instructions of plant systems manuf-
acturer)
Gun fails to open | Control air pressure too low
Top-up material level (see operating
Spray jet pulsa- Level in matenal tank too low Instructions of plant systems manuf-
ting or unsteady
acturer)
Material leaks Needle seal packing leaks Te see /.1 Needle Seal pak-
пи Packing gland to loose Tighten packing gland slightly use a
Size 11 mm wrench
39
9 Disposal of Cleaning / Servicing Substances
Disposal of any such substances must be in accordance with all applicable local and
national regulations, directives and laws.
Warning
Particular attention is drawn to all processing specifications and safety wamings
issued by the manufacturers of spraying and cleaning media. Remember: The
improper disposal of any toxic waste material represents a serious threat to the
environment, i.e. to the health of mankind and animal life.
10 Specification Data
Weight: 920 g
Connections:
Atomizing Air G 1/4"
Control Air С 1/4"
Material Inlet G 3/8"
Pressure Ranges:
Control Air Pressure max. 8 bar
Material Pressure max. 10 bar (WA XV)
max. 15 bar (WA XV needle-pull / WA XV-HVLP)
Atomising Air Pressure see table
max. Operating Temperature
of Spray Gun 80 °C
Sound Level
(measured at a distance of
1 m from the spray gun) 86 dB (A)
Air consumption (six-bore air cap):
1.0 bar Atomizing Air Input 8.2 m*/h
2.0 bar Atomizing Air Input 12.1 m*/h
3.0 bar Atomizing Air Input 16.0 m?/h
4.0 bar Atomizing Air Input 20.1 m*/h
5.0 bar Atomizing Air Input 24.0 m*/h
6.0 bar Atomizing Air Input 28.0 m*/h
Right to effect technical changes reserved.
40
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