WALTHER PILOT GM 1030G Operational manual

Translation of the Original
Operating Manual
For professional use.
Always observe the information in this manual,
particularly the safety instructions and the warning
instructions. Store the manual in a safe place.
PILOT GM 1030G
PILOT GM 1030G ADH
Gravity-feed cup spray gun
Edition 11/2022

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OPERATING MANUAL
EDITION 11/2022 ORDER NUMBER DOC2428311 PILOT GM 1030G
Table of Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Preface 5
1.2 Warnings, Notices and Symbols in these Instructions 5
1.3 Languages 5
1.4 Abbreviations 6
1.5 Terminology for the Purpose of this Manual 6
2 CORRECT USE 6
2.1 Device type 7
2.2 Type of Use 7
2.3 For Use in Potentially Explosive Areas 7
2.4 Processible Working Materials 7
2.5 Misuse 7
3 IDENTIFICATION 8
3.1 Explosion Protection Identication 8
3.2 Identication "X" 8
3.3 Type Plate 9
4 BASIC SAFETY INSTRUCTIONS 10
4.1 Safety Instructions for the Operator 10
4.2 A Safe Work Environment 10
4.3 Personnel Qualications 11
4.4 Safety Instructions for the Personnel 11
4.5 Personal Safety Equipment 11
4.6 Safe handling of WALTHER spray devices 11
4.7 Grounding the Device 12
4.8 Cleaning and Flushing 12
4.9 Maintenance and Repair 13
4.10 Protective and Monitoring Equipment 13
5 DESCRIPTION 14
5.1 Components 14
5.2 Functioning 14
5.3 Standard equipment 15
5.4 Data 15
5.4.1 Materials of Paint Wetted Parts 15
5.4.2 Technical data 15
5.4.3 Dimensions and Connections 15
5.4.4 Air ow 16
6 ASSEMBLY AND COMMISSIONING 17
6.1 Training of Assembly/Commissioning Personnel 17
6.2 Storage Conditions 17
6.3 Installation Conditions 17
6.4 Installation and Connection 17
6.4.1 Ventilation of the Spray Booth 17
6.4.2 Air Supply Lines 17
6.4.3 Product Supply Lines 18
6.5 Grounding 18

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6.6 Safety Checks 18
6.7 Product Preparation 18
6.8 Start up 19
6.8.1 Procedure 19
6.8.2 Verifying a Safe Operational Condition 19
7 OPERATION 20
7.1 Training the Operating Personnel 20
7.2 Tasks 20
7.2.1 Starting to Spray with Atomizing Air 20
7.3 Adjusting the Spray Pattern 21
7.3.1 Adjusting Spray Pattern 21
7.3.2 Setting the Product Flow Rate 22
7.4 Pressure Relief / Work Interruption 22
7.5 Cleaning the Nozzle and Eliminating Nozzle Clogging 23
8 CLEANING AND MAINTENANCE 24
8.1 Cleaning 24
8.1.1 Safety instructions 24
8.1.2 Cleaning Personnel 24
8.1.3 Flushing and Cleaning the Spray Gun 24
8.2 Maintenance 24
8.2.1 Maintenance Personnel 24
8.2.2 Safety instructions 25
8.2.3 Safety Checks and Maintenance Intervals 25
8.2.4 Replacing the Air Hose 26
9 TROUBLESHOOTING AND RECTIFICATION 27
10 REPAIR WORK 28
10.1 Repair Personnel 28
10.2 Repair Notes 28
10.3 Tools 28
10.4 Replacing the Needle Packing 29
10.5 Changing the Air Valve 30
10.6 Changing Shaping Air Regulator 30
10.7 Tightening Nozzle Nut 31
10.8 Replacing Nozzle or Needle 32
11 FUNCTION TEST 33
12 DISPOSAL 34
13 ACCESSORIES 35
13.1 Air caps 35
13.2 Nozzles and Needles 36
13.3 Additional accessories 37
14 SPARE PARTS 38
14.1 How to Order Spare Parts 38
14.2 Gun variants 39
14.3 Exploded-view Drawing of PILOT GM 1030G 40
14.4 Spare parts list 41
15 EU DECLARATION OF CONFORMITY 42

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1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device. The operating manual is part of the device and must be available
to the operating and service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual. Operating and service personnel should be instructed according to the
safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential danger.
Non-observance may result in death or serious injury.
CAUTION Potentially dangerous situation.
Non-observance may result in minor injury.
NOTICE Potentially dangerous situation.
Non-observance may result in damage to property.
INFO Provides information about particular characteristics and how to
proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
Measures for preventing the hazard and its consequences.
1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2428308
Translation of the original operating manual
Language Order no. Language Order no.
English 2428311 Spanish 2428315
French 2428312 Polish 2444827
Italian 2428313 Chinese 2428318
Additional languages on request or at: www.walther-pilot.de

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1.4 ABBREVIATIONS
Order
no.
Order number Wrench size
Spare part for low-viscosity (LV) products
Marking in the spare parts lists for high-viscosity (HV) products
Position Low air
Number of pieces Manual gun
ADH Adhesive
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Product pressure
generator
Pump or pressure tank.
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as well
as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in
accordance with
TRBS1203
(2010/Revision 2012)
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) and
is familiar with the relevant and generally accepted rules of
technology so that he/she can inspect and assess the status of
devices and coating systems based on workplace safety.

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2 CORRECT USE
2.1 DEVICE TYPE
Manual gun for manually coating work pieces.
PILOT GM 1030G
2.2 TYPE OF USE
The spray gun is suitable for atomizing liquid products, particularly coating products,
using the atomizing air process:
– Non-ignitable products.
– Ignitable products.
WALTHER expressly excludes any other use!
The device may only be operated under the following conditions:
Do not deactivate safety xtures.
Use only WALTHER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
As dened in Directive 2014/34/EU(ATEX), the device is suitable for use in potentially
explosive areas (see 3.1).
2.4 PROCESSIBLE WORKING MATERIALS
Lacquers and paints, greases, oils and corrosion inhibitor, adhesive, ceramic glazes, stains.
If you want to spray working materials other than the aforementioned, contact a WALTER
Spritz- and Lackiersysteme representative.
Info
Contact your local WALTHER Spritz- and Lackiersysteme dealer and the product
manufacturer if you encounter application problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g., powder are processed.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: Manual spray gun PILOT GM 1030G
Manufacturer: WALTHER Spritz- und Lackiersysteme GmbH,
Kärntner Str. 18-30
D-42327 Wuppertal
II 2G X
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (zone 1)
G Ex-atmosphere gas
X Special notice
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.4.2.
Safe handling of WALTHER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
Do not drop the device.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.

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3.3 TYPE PLATE
Designation
1 Maximum air inlet pressure
2 Spray gun model and manufacturer
3 Explosion protection identication and year of manufacture serial number (YB-SN)
GM 1030G
Walther Spritz- und Lackiersysteme GmbH
D-42327

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention regulations.
4.2 A SAFE WORK ENVIRONMENT
Danger due to dangerous uids or vapors!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 MΩ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ensure that product hoses/air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.55) is available and is
used.
Make sure that all people within the work area wear static dissipative shoes. The
footwear must comply with EN ISO 20344. The measured insulation resistance must
not exceed 100 MΩ.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun's handle or its trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. Do not smoke.
Ensure that the pipe joints, hoses, equipment parts and connections are
permanently, technically leak-proof:
– Periodic preventative maintenance and service (replacing hoses, checking
tightness of connections, etc.).
– Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.