Extrusionspistole deutsch 07.04.qxd
Contents
1. on the safety button of the back bushing Item 18 may also be affect the flow rate 5 4 Regulating Material Pressure The suitable material pressure you place on the pump air pressure regulator on site and the material pressure regulator Pay attention to the instructions and safety of the manufacturer 5 5 Retooling Extrusion Gun Warning Turn off pressure retooling the extrusion gun from the system and check the gauge otherwise there is a risk of injury Warning Disconnect all supply lines before retrofitting any supply of material to the extrusion gun injury L Notice To carry out the operations listed below please use the drawing at the beginning of this manual Change Fluid Nozzle 1 Remove the Cap Nut Item 2 2 Remove the fluid nozzle Item 1 together with adapter Item 3 from the valve Item 5 e Now you can unscrew the step nozzle from the adapter look for the notch indicating the appropriate diameter see drawing and cut it off at the notch LP ELEELE Assemble in reverse order Replacement of Material Filter For appropriate filtering of the material you can use coarse and fine mesh filter 1 Make sure the complete extrusion system is depressurized A 2 Remove the hose material material hoses 3 Remove the material filter Assemble in reverse order Change Material Needle 1 Remove the cap nut Item 2 2 Remove the fluid nozzle Item 1 together with adapter Item 3 from the valve2. sealing effect is not guaranteed 7 3 Replace Leaking Material Needle Disassemble the pistol as described in 5 5 extrusion gun retooling Assemble in reverse order L Notice 12 All moving and sliding parts must be greased before installation in the gun body with an acid free non gumming grease Repair Kit WALTHER PILOT repair kit available that contains all wearing parts for the PILOT EXTRUSION GUN 350 bar Part No V 16 250 00 000 Consisting of material needle assy Item 4 valve item 5 seal 2x item 6 packing support washer item 11 V Pack 6x key 12 packing pressure pin item 13 washer item 15 8 Troubleshooting and Solutions Warning Make sure the entire extrusion system is depressurized before servicing Warning Prior to any repair material supply must be shut off risk of injury Problem Cause Remedy Leak at the nozzle eMaterial needle Item 4 Check settings or Replace material needle Too little material Dirty filter Clean Nozzle too small or Choose larger diameter clogged or clean Fluid pressure too low Increase fluid pressure Valve seat leak Worn seals Replace seals e Worn valve Replace valve Fluid leaks fromgun ePacking Item 12 leaking Replace packing body 9 Disposal The costs incurred in cleaning and maintenance materials should be disposed of in accordance with the laws and regulations properly and professionally Warning Pay particular atte
3. the body and cause serious injury including the need for amputation e Although material injected into the skin may look like an ordinary injury these are extremely serious injuries If injection occurs get immediate medical attention e Nozzle valve should never be pointed at people of body parts e Do not put your hands or fingers over the nozzle valve e Never use the Extrusion gun without the trigger guard e Before each use make sure that the gun trigger safely operates the valve e Always lock the trigger safety valve when not in use e Before performing any cleaning checking or servicing the equipment or clogged valve nozzle following the steps given in 5 2 Starting and shutting down e All fluid connections must be checked and tightened before start up Inspect hoses tubes and couplings daily Replace worn damaged or loose parts immediately Damaged hoses should not be repaired In this case the entire hose should be replaced 4 1 Supply Line Connection Warning Use the pump only in the context of a fluid regulator to prevent the maximum allowable operating pressure of 350 bar can not be exceeded Material connection Attach the supply line at the connection item 20 of the extrusion gun Maintain a tight screw Notice Use only grounded fluid hoses with a maximum total length of 150 m in order to ensure a continuous ground and they must be resilient enough for an operating pressure of 350 bar Check the electri
4. Das WALTHER PILOT Programm e Hand Spritzpistolen e Automatik Spritzpistolen e Niederdruck Spritzpistolen System HVLP e Zweikomponenten Spritzpistolen e Pulverbeschichtungs Systeme e Materialdruckbeh lter e Drucklose Beh lter e R hrwerk Systeme e Airless Gerate und Fl ssigkeitspumpen e Materialumlaufsysteme e Kombinierte Spritz und Trockenboxen e Absaugsysteme mit Trockenabscheidung e Absaugsysteme mit Na abscheidung e Pulverspr hst nde e Trockner e Zuluft Systeme e Atemschutzsysteme und Zubehor AIR Wi WALTHER Spritz und Lackiersysteme K rntner Str 18 30 42327 Wuppertal Telefon 0202 787 0 Telefax 0202 787 217 Die Beschichtungs Experten www walther pilotde E Mail info walther pilot de WALTHER PILOT Operating Manual PILOT Extrusionspistole ATA WALI HER Wy Die Beschichtungs Experten Spare Parts List Part No V 10 250 00 000 350 bar Pos Nr Part Number V 10 250 15 000 V 10 250 17 000 V 10 250 16 000 V 10 250 11 000 V 10 250 12 000 V 10 250 24 000 V 10 250 01 000 V 10 250 23 000 V 10 250 18 000 V 10 250 25 000 V 10 250 20 000 V 10 250 26 000 O O ON OO POD b d N Part Name Step Nozzle Cap Nut Adapter Material Needle Complete Valve Gasket 2 pieces Gun Body Trigger Bolt Screw Safety Guard Packing support washer V Packing 6 St ck Pos Nr Part Number Part Name 13 V 10 250 19 000 Packing
5. Item 5 3 Unscrew the needle securing Item 18 from the gun body Item 7 4 Twist out bolt screw Item 9 to remove the trigger 5 Loosen the cylinder screw Item 17 turn the adjusting nut Item 16 of the fluid needle Item 4 and take the washer Item 15 6 Turn the valve Item 5 out of the gun body Item 7 7 Pull the fluid needle Item 4 from the gun body The assembly is done in reverse order with needle valve and back bushing applied with a high strength adhesive Notice An exact setting dimension does not exist The adjustment nut is screwed as long until the trigger play is approximately 5 mm and is secured to the cylinder screw against rotation 6 Cleaning and Maintenance 6 1 Safety e Turn power off before servicing the extrusion pressure from the system risk of injury e Disconnect all material pressure before performing any maintenance to the extrusion gun e In the workspace Fire naked flame and smoking is prohibited Spraying of highly flammable materials eg cleaning agents there is an increased risk of explosion and fire e Notice the safety precautions of the detergent manufacturer s warnings Aggressive and corrosive cleaning agents can cause health damage 6 2 Basic Cleaning In order for the service life and function of the extrusion gun to be maximized the extrusion gun must be cleaned and lubricated Caution Never place the extrusion gun in solvent or other cleaning agents The proper funct
6. Pressure Pin 14 V 10 250 22 000 Packing Screw 15 V 10 250 13 000 Washer 16 V 10 250 21 000 Adjusting Nut 17 V 10 250 02 000 Cylinder Head Screw 18 V 10 250 10 000 Back Bushing 19 V 10 250 03 000 Screw 20 V 10 250 14 000 Double Nipple Additional Nozzle Option 21 V 10 250 15 OSP Special Nozzle PILOT Extrusionspistole Teflon coated Art Nr V 10 250 40 000 Differing Part 7 V 10 250 01 Tef Gun Body We recommend that you keep all the bold parts wearing parts in stock 18 17 16 lS 14 er 20 Repair Kit V 16 250 00 000 EC Declaration of Conformity We the equipment manufacturer declare under our sole responsibility that the product in the description below corresponds to the relevant basic safety and health requirements Any unauthorized modifications are made to the equipment or improper use of this declaration loses its validity WALTHER Spritz und Lackiersysteme GmbH K rntner Str 18 30 D 42327 Wuppertal Tel 0202 787 0 Fax 0202 787 217 www walther pilot de Email info walther pilot de Typenbezeichnung PILOT Extrusionspistole V 10 250 00 000 V 10 250 40 000 Teflon beschichtet Verwendungszweck Verarbeitung spritzbarer Materialien Angewandte Normen und Richtlinien EG Maschinenrichtlinien 98 37 EG 94 9 EG ATEX Richtlinien DIN EN 292 Teil 1 DIN EN 292 Teil 2 DIN EN 1953 Spezifikation im Sinne der Richtlinie 94 9 EG Tech File Ref Kategorie 2 Ger tebezeichnung Ex I2G
7. cT6 2409 Besondere Hinweise Das Produkt ist zum Einbau in ein anderes Ger t bestimmt Die Inbetriebnahme ist so lange untersagt bis die Konformit t des Endproduktes mit der Richtlinie 98 37 EG festgestellt ist Wuppertal den 7 Juli 2003 iV Cy Im Name Torsten Br ker Stellung im Betrieb Leiter der Konstruktion und Entwicklung Diese Erkl rung ist keine Zusicherung von Eigenschaften im Sinne der Produkthaftung Die Sicherheitshinweise der Produktdokumentation sind zu beachten Contents 1 General 1 1 Model Identification 1 2 Intended Use 1 3 Inappropriate Use 2 Technical Description 3 Safety Instructions 3 1 Identification of Safety Instructions 3 2 General Safety Instructions 4 Assembly 4 1 Supply Line Connection 5 Operation 9 1 Safety Information 5 2 Start up and Shut down 5 3 Setting Material Flow Rate 5 4 Regulating Material Pressure 9 9 Retooling Extrusion Gun 6 Cleaning and Maintenance 6 1 Safety 6 2 Basic Cleaning 6 3 Routine Cleaning 7 Repair 7 1 Replace Leaking Valve Seat 7 2 Replace Leaking Gasket 1 3 Replace Leaking Material Needle 8 Troubleshooting and Solutions 9 Disposal 10 Technical Data 1 General 1 1 Model Identification Models PILOT Extrusion Gun 350 bar Type Part Nr V 10 250 00 000 V 10 250 40 000 Teflon coated Manufacturer WALTHER Spritz und Lackiersysteme GmbH Karntner Str 18 30 D 42327 Wuppertal Tel 0202 787 0 Fax 0202 787 217
8. cal resistance of the fluid hoses at least once a week If the hose does not have a label on which the maximum electrical resistance is specified the maximum resistance values can be obtained from the manufacturer If the resistance exceeds the recommended limits replace the hose immediately concerned The gun is now ready for operation 5 5 Operation 5 1 Safety Observe the operation of the extrusion gun in accordance with the follow the safety instructions e When work is interrupted the extrusion system must be depressurized e Wear proper respiratory protection and work clothes when you extrude the extrusion gun materials Airborne particles hazardous to your health e In the workspace Fire naked flame and smoking is prohibited Spraying of highly flammable materials eg glue there is an increased risk of explosion and fire 5 2 Start up and Shut down Notice Before first using the extrusion gun flush it out with solvent to ensure that it is clean Warning Turn power off before refitting the extrusion pressure from the system and check the gauge otherwise there is a risk of injury Before you can set the extrusion gun in operation the fluid pressure must be available at the extrusion gun Caution The material pressure must not be set higher than 350 bar Start up 1 Before first use the trigger lock is locked by screwing in the safety button until it stops at the back bushing Item 18 2 Set the pump to
9. diameter maximum 3 Safety 3 1 Identification of Safety Instructions Warning This picture and the accompanying warning note Warning indicate possible risk and dangers to yourself Caution This picture and the accompanying note Caution indicate possible damage to equipment workpieces etc 0 85 Notice This picture and the accompanyingnote Notice indicate additional and useful information to help you in handling the spray gun with even greater confidence and efficiency 3 3 2 General Applicable Safety Precautions All applicable accident prevention rules and regulations as well as other recognized industrial safety and health rules and regulations must be observed at all times Use the spray gun only in well ventilated rooms Fires naked light and smoking are strictly prohibited in 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 An adequate grounding of the extrusion gun is to ensure for example through the fluid hose maximum resistance 106Q Before carrying out any maintenence or service work always ensure that the air and material feed to the spray gun have been de pressurized The extremely high pressure at the gun or pump outlet can cause serious injury Risk of injury When spraying make sure your hands and other body parts are clear from the pressurized
10. ion of the extrusion gun can not otherwise be guaranteed Caution When cleaning any hard or sharp objects Precision parts extrusion gun may be damaged and deteriorate the extrusion result 10 To clean the extrusion gun cleaning solutions that are specified by the manufacturer of the extrusion material and do not contain the following ingredients e halogenated hydrocarbons eg 1 1 1 trichloroethane methylene chloride etc e Acids and acidic detergents e regenerated solvents so called cleaning dilutions e Paint stripper The above mentioned Constituents cause electroplated components chemical reactions and lead to corrosion damage For damages resulting from such treatment WALTHER PILOT makes no warranty Clean the extrusion gun before any material change at least once a week e depending on material and depending on the degree several times a week This will give you the safe function of the extrusion gun Warning Turn off the extrusion pressure before cleaning the system see 5 2 Starting and shutting down 1 Disassemble the pistol as described in 5 5 extrusion gun retooling 2 Clean the fluid tip with a brush and cleaning agent 3 Clean all remaining parts and the gun body with a cloth and detergent 4 Lubricate the following parts with a thin film of grease e material needle e valve e all moving parts and bearings e The internal moving parts must be lubricated at least once a week e The springs sh
11. lace Leaking Valve Seat 1 Remove the fluid nozzle in accordance with 5 5 retooling extrusion gun 2 Turn the valve Item 5 out of the gun body Item 7 3 Replace the two seals Item 6 with new ones 4 Before beginning turn the valve again you should secure the thread with a high strength adhesive coat to achieve optimum sealing The assembly of the remaining components is carried out in reverse order 7 2 Replace Leaking Gasket 1 Remove the fluid nozzle and needle material as described in 5 5 extrusion gun retooling 2 Turn the pack screw Item 14 with the packing pressure pin Item 13 from the gun body 11 3 Remove the V pack Item 12 and the packing support plate Item 11 out of the gun body To do this use a solid wire whose end is bent into a small hook 4 Now replace the new packing support washer and new V pack in the gun body To do this use a special tool that has the shape of the packing pressure pin With the difference that the tool has a pin at the front the inner diameter of the V pack Install the components individually 5 Now turn the screw pack with pushpins in again 6 Before the packing bolt is tightened slide in the material needle from the front After tightening the material needle should still be movable The assembly of the remaining components is carried out in reverse order L Notice The parts taken from the gun use parts should not be re used otherwise a functionally reliable
12. minimum speed required to extrude the material with a satisfactory discharge rate 3 Slowly unscrew the safety button back bushing Item 18 and press the trigger Item 8 to achieve the desired discharge rate If there is not enough speed then the appropriate discharge rate can be further tuned alternating between safety button and pump on site air pressure regulator 4 If the settings are correct you can start with the extrusion process Shut down 1 Release the trigger lever fully and screw in the safety button back bushing item 18 until it stops 2 Turn off material supply to the pump 3 Place the trigger guard Item 10 firmly to a grounded metal pail turn on the safety button and pull the trigger lever to relieve the pressure 4 Open the pressure relief valve on site on the pump to increase the pressure from the pump the valve and out of the hoses The pressure relief valve should remain open until work resumes Triggering the gun may not be sufficient to relieve the pressure Keep a container handy to collect any leaking material Warning The entire extrusion line must be always depressurized after work The pressurized pipes can burst and injure persons close by the outflowing material 5 3 Setting the Material Flow Rate The setting of the material flow rate and thus the spray jet width shall be initially based on the selection of a suitable nozzle size Setting the material pressure regulator on the material and
13. normalities are detected during operation the unit must be shut down immediately and it is to keep up with WALTHER PILOT consultation 1 3 Improper Use The extrusion gun shall not be used otherwise than 1 2 Intended use is written in the section Any other use is improper To inappropriate use include for example e spraying of material on people and animals e the spraying of liquid nitrogen 2 Technical Description The WALTHER PILOT extrusion gun is a gun that can be processed by the existing material pressure of the pump extrudable materials The max Operating pressure is 350 bar The gun body is made of cast aluminum and the model V 10 250 40 000 is for easy cleaning Teflon coated The medium to be processed is supplied to the extruding gun of a piston or diaphragm pump under pressure When you press the trigger the medium is pressed out of the stage nozzle extruded In the PILOT extrusion gun the material pressure is controlled by the pump and the amount of material can then be finely adjusted by an additional 18 of the securing bushing Pos The scope of the extrusion gun consists of the airless caterpillar shaped dispensing of pasty materials It can thermoplastics elastomers silicones greases adhesives glues waxes etc depending on the consistency of workable materials are extruded The stage nozzle has different diameter sizes By severing at the respective notch you can the change required nozzle
14. nozzle of the extrusion gun the extremely high injection pressure can Cause serious injury Use diaphragm or piston pumps only in the context of a fluid regulator to prevent the maximum allowable operating pressure of 350 bar can not be exceeded Do not point the extrusion gun towards people 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 presonnel 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 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 canonly 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 4 Assembly Warning Material lines that are attached with a hose must additionally be secured by a hose clamp Warning Risk of Injection Spray from the dispensing valve leaks or ruptured components can inject material into
15. ntion to the instructions of the manufacturer of extrusion and detergent Risk to the health of humans and animals 10 Technical Data Net Weight 570g Nozzle I 1 Nozzle equipment of your choice Stage Nozzle Item 1 Special Nozzle Item 21 Pressure Range 350 bar max pressure Operating Temp 42 C Subject to technical changes 13
16. ould be constantly provided with a thin layer of grease Use an acid free non resinous grease and a brush or enter a drop of oil from a dosage bottle Then the extrusion gun is set together in reverse order 6 3 Routine Cleaning When changing material or after work you can also clean the extrusion gun without having to disassemble it Warning Turn off the extrusion pressure from the system before cleaning see 5 2 Starting and shutting down A A Before you perform the Routine maintenance the following condition must be met e Make sure that the cleaning agent used to the process fits the material Perform the following steps 1 Place the extrusion gun into operation see 5 2 putting into operation 2 Flush the gun with the lowest possible pressure 3 To maintain grounding continuity when flushing must ensure the gun to be pressed firmly against one side of a grounded metal pail then trigger the gun 4 Spray the extrusion gun until only a clear detergent is sprayed from the gun The entire extrusion line should now be depressurized until the next use 7 Repair Warning Turn power the extrusion pressure from the entire system before servicing see 5 2 Starting and shutting down Warning Disconnect all power before any repairs the material feed to the extrusion gun risk of injury gt Notice To carry out the operations listed below please use the drawing at the beginning of this manual 7 1 Rep
17. www walther pilot de Email info walther pilot de 1 2 Intended Use The PILOT Extrusion guns are for the processing of sprayable media such as e Pasty Materials e Greases oils and corrosion inhibitors e Adhesives and glues e Waxes Bitumen Silicones and Kit Using the device in potentially explosive atmospheres The device complies with the ATEX requirements of the directive 94 9 EC ATEX 100a for explosion group category and temperature class marked on the rating plate When operating the device the specifications of this manual must be followed The prescribed inspection and maintenance intervals are required The information on the equipment rating plates or the information in the chapter technical data must be maintained and must not be exceeded An overloading of equipment must be ruled The device may be used in potentially explosive atmospheres only with the competent supervisory authority The competent authority or the operator is responsible for determining the explosion hazard zone classification It is operator must check and ensure that all technical data and the marking according to ATEX conform to the required standards Applications in which the failure of the device could be a danger to persons intro duced are operator must provide appropriate security measures Grounding potential equalization It must be ensured that the extrusion gun is properly grounded maximum resistance 106 QO A A If ab
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