WALTHER PILOT PILOT TERRA User manual

Betriebsanleitung / Operating Instructions
Mode d’emploi / Instrucciones de Servicio
Инструкция по эксплуатации / 使用说明书
Spritzpistole / Spray gun / Pistolet de pulvérisation
Pistola de pulverización / Пистолет-распылитель / 喷枪
PILOT TERRA
WALTHER PILOT
REV. 06/15

2
10
5.3
5.2
8
4
3.1
2
1
5.1
3.3
5.5
5.4
13
3.2
11
PILOT TERRA Fließbecher / Gravity-Feed Cup /
à godet gravité / depósito de gravedad /
Наливной стаканчик / 喷壶
3.1
2
1
11
3
6
7
3.4
PILOT TERRA Materialanschluss / Material Connection /
raccordement matière / toma de material / Патрубок для
материала / 物料连接
Stand: August 2014
12
10
5.3
5.2
8
4
3.3
6
5.5
5.4
7
3.4
5.1
9
3.2

20
Contents
Exploded Drawing 2
Declaration of CE-Conformity 21
Replacement parts 22
1 General 24
1.1 Model identification 24
1.2 Intended use 24
1.3 Inappropriate use 25
2 Technical description 25
3 Safety instructions 25
3.1 Identification of safety instructions 25
3.2 General Safety instructions 26
4 Supply line connection 27
5 Operational Handling 27
6 Spray pattern adjustments 28
6.1 Correcting spray pattern flaws 29
7 Troubleshooting and fault rectification 29
8 Conversion and repair 30
9 Cleaning 31
10 Waste disposal 32
11 Technical Data 32

21
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 require-
ments. This declaration will be rendered invalid if any changes are made to the equip-
ment without 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 Manual Spray Guns PILOT TERRA
PILOT TERRA Gravity-Feed Cup V 11 801
PILOT TERRA Material Connection V 11 802
PILOT TERRA-LVLP Gravity-Feed Cup V 11 811
PILOT TERRA-LVLP Material Connection V 11 812
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 DIN EN 1953
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.:
2417
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 1st of April 2014
Name: Torsten Bröker
Position: Manager, Design and Development
This Declaration does not give assurance of properties in the sense of product liability. The safe-
ty instructions provided in the product documentation must be observed at all times.
p.p.

22
Replacement Parts
PILOT TERRA
Gravity-feed cup
PILOT TERRA
Material Connection
V 11 801 03 XX3
V 11 811 03 XX3 (LVLP)
V 11 802 03 XX3
V 11 812 03 XX3 (LVLP)
N° Description Qty. Article-No. Qty. Article-No.
1Air cap nut compl. 1 2337082 12337082
2Air cap 1V 11 801 40 006 1V 11 801 40 006
Air cap (LVLP) V 11 801 45 1MP V 11 801 45 1MP
3
3.1 Material nozzle*
1V 15 118 03 XX3* 1V 15 118 13 XX3*
3.2 Needle seal Packing comp.
3.3 Material needle compl.*
3.4 Needle spring
4Gun body compl. 12337094 12337105
5
5.1 Valve shaft seal
1V 17 118 01 000 1V 17 118 02 000
5.2 Valve cone compl.
5.3 Valve spring
5.4 Washer
5.5 O-Ring
6Spring bushing 12337086 12337086
7Adjusting screw 12337087 12337087
8Round/ wide jet adjustment
compl. 1V 11 801 05 000 1V 11 802 05 000
9Double nipple
(Material connection)--1V 00 101 04 000
10 Double nipple
(Air connection)1V 00 101 01 000 1V 00 101 01 000
11 Trigger compl. 1V 11 801 07 000 1V 11 801 07 000
12 Gun key 12342434 12342434
13 Gravity-feed cup compl. 1V 00 130 00 100 --
* When ordering replacements please quote the respective sizes.
Accessories
Walther Pilot gun grease
(Pads 8 - 10 g)
Article-No.
V 00 000 00 001

23
Nozzle / needle sets
The nozzle / needle sets consist material nozzle, needle seal packing comp., mate-
rial needle compl. and needle spring (No3).
Article-No.
PILOT TERRA Gravity-feed cup V 15 118 03 XX3*
PILOT TERRA Material Connection V 15 118 13 XX3*
Nozzle sizes optional:
▪ 1,0 ▪ 1,4 ▪ 1,8 mm ø
Air valve sets
WALTHER has PILOT TERRA Gravity-feed cup and PILOT TERRA material
connection air valve sets available for the manual spray guns containing the fol-
lowing items:
Valve shaft seal, valve cone compl., valve spring, washer and O-Ring (No 5).
Article-No.
PILOT TERRA Gravity-feed cup V 17 118 01 000
PILOT TERRA Material Connection V 17 118 02 000

24
1 General
1.1 Model Identification
Model: Manual Spray Gun PILOT TERRA
Type: PILOT TERRA Gravity-Feed Cup V 11 801
PILOT TERRA Material Connection V 11 802
PILOT TERRA-LVLP Gravity-Feed Cup V 11 811
PILOT TERRA-LVLP Material Connection V 11 812
Manufacturer: WALTHER Spritz- und Lackiersysteme GmbH
Kärntner Str. 18-30
D-42327 Wuppertal
Tel.: +202 / 787-0
Fax: +202 / 787-2217
www.walther-pilot.de • Email: [email protected]
1.2 Intended use
The manual spray guns PILOT TERRA Gravity-Feed Cup and PILOT TERRA
Material Connection are designed to be used exclusively for sprayable media, such
as:
• paints and lacquers
• greases, oils and corrosion preventives
• ceramic glazes
Aggressive materials must not be sprayed.
If the material you intend to spray is not included in the above list, please contact
WALTHER Spritz- und Lackiersysteme GmbH, Wuppertal, for further information.
Please note that sprayable materials may only be applied to workpieces and /or
similar 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
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

25
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 106Ω).
1.3 Inappropriate use
The spray gun can’t be used for any application not included in the instructions. Any
other use is improper. Some sample of improper use:
• Spray in direction of people or animals
• Spray liquid nitrogen
2 Technical Description
PILOT TERRA: Manual spray gun for conventional atomisation
PILOT TERRA-LVLP: Manual spray gun vapour-reduced
Model versions: • with gravity-feed cup
• with material connection
When pulling the trigger (No11) the valve cone opens first (No5.2) (pre-air) and the
material needle (No3.3) is pulled back only after this. Closing takes place in reverse
order.
The material flow rate is dependent on the diameter of the nozzle and the adjustment
of the material pressure at the pressure tank or material pressure regulator. In addi-
tion, the material flow rate can be controlled by screwing the adjusting screw (N° 7)
in or out.
3 Safety instructions
3.1 Identification of safety instructions
Warning
The pictogram and the urgency level “Warning“ identify a possible danger to
persons.
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.

26
Note
The pictogram and the urgency level “Note“ identify additional information for the
safe and efficient operation of the spray gun.
3.2 General Safety instructions
► All applicable accident prevention rules and regulations as well as other recog-
nised 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 explosi-
on and fire.
►You must ensure that the spray gun is properly earthed (grounded) either sepa-
rately or in connection with the equipment with which it is being used (max.
resistance 106 Ω).
►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 mate-
rials 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. 86
dB(A).
►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!
►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 mate-
rials, please contact WALTHER Spritz- und Lackiersysteme GmbH, D-42327
Wuppertal, Germany.

27
4 Supply line Connection
Warning
Air hoses which are installed with a hose grommet must be additonally secured with
a hose clamp.
5 Operational Handling
The following requirements must have been met before you can operate the spray
gun:
• The spray air pressure must be applied at the spray gun.
• The material pressure must be applied at the spray gun.
Note
The material pressure shall not exceed • 5 bar, as, otherwise, the functional relia-
bility of the spray gun will suffer.
Design: Gravity-feed cup
1. Fasten the compressed air hose to the air con-
nection (No10) of the spray gun.
2. Fill the gravity-feed cup with the material to be
sprayed. Close the cup.
3. Switch on the pneumatic system.
The spray gun can be taken into operation.
Design: Material connection
1. Fasten the compressed air hose to the air con-
nection (No10) of the spray gun.
2. Fasten the material supply hose to the material
connection (No9) of the spray gun.
3. To allow the air in the material hose to escape,
operate the trigger, until a uniform material
spray exits the nozzle; the gun can now be
closed again.
The gun is now ready to be operated.
Air connection
Material
connection
Air connection

28
Warning
Always relieve the pressure from the spray gun after work is completed. The pres-
surized lines may rupture and persons standing nearby may be injured by the
escaping material.
Note
The gun must be flushed with a suitable solvent before initial commissioning to
prevent contamination of the spraying material.
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 can be tested using a work piece sample, a sheet of metal, card-
board or paper.
6 Spray pattern adjustments
The spray pattern of the PILOT TERRA can be changed by adjusting the gun as
follows:
Round / Wide Jet adjustment
The adjusting screw is used to adjust the width
of the spray jet. The jet can be changed to a
wide jet by turning the screw anti-clockwise
(screwing out) and to a round jet by turning the
screw clockwise (screwing in).
Setting the Material Flow Rate
The material flow rate can be adjusted by
screwing the adjusting screw in or out. The
flow rate is increased by turning the screw
anti-clockwise (screwing out) and decreased
by turning the screw clockwise (screwing in).
Air connection
Material
connection

29
6.1 Correcting spray pattern flaws
The following table shows the settings you can use to change the 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
7Troubleshooting and fault rectification
Warning
Prior to any seervicing and repair work: Make sure that the spray gun is in unpres-
surized condition, i.e. air input must be shut off - if not, imminent risk of injury.
Fault Cause Remedy
Gun is dripping
Material needle or nozzle soiled or
damaged
Spring bushing (N° 6) turned too
far to the back
• Clean or replace
• Adjust by turning
clockwise
Pulsating or
unsteady jet
Not enough material in material
tank
Cup is tilted too much during
spraying operation
Material nozzle loose or damaged
• Top-up material level
• Keep it level
• Fasten or replace
Gun keeps blo-
wing in off-position
Valve spring (N° 5.3) or
valve cone (N° 5.2) damaged • Replace
desired spray result

30
8 Conversion and repair
If a jet contour other than those already described is desired, the spray gun has to
be re-tooled. Air cap, material nozzle and needle packing together form a unit - the
nozzle insert assembly. Always change the complete insert assembly to maintain the
desired spray finish quality.
Warning
Prior to any repairs/replacements: Make sure that the spray gun is in unpressurized
condition, i.e. air must be shut off - if not, imminent Risk of Injury.
Note
In order to perform the following procedures, please refer to the exploded diagram at
the beginning of these operating instructions.
Replacement of the material nozzle and the air cap
1. Unscrew the air cap nut (N° 1).
2. Remove the air cap (N° 2).
3. Unscrew the nozzle (N° 3.1) (ws 19) from the gun body (N° 4).
Reassemble in reverse order.
Replacement of the material needle
1. Remove the adjusting screw (N° 7).
2. Remove the needle spring (N° 3.4).
3. Pull the material needle (N° 3.3) out of the gun body.
Reassemble in reverse order.
Replacement of the needle seal
1. Disassemble the needle as described above.
2. Unscrew the lever shank screw and the lever screw and remove the trigger
(N° 11).
3. Remove the needle packing gland out of the gun body.
4. Remove the needle seal (N° 3.2) (Use a thin wire, one end of which is bent into
a hook, for this purpose).
Reassemble in reverse order.
Note
Never reinstall a used needle seal, as otherwise the functional sealing reliability of
the spray gun will not be guaranteed.
Note
All movable and sliding parts (except the material needle!) must be greased with
WALTHER PILOT gun grease (Art.-Nr.: V 00 000 00 001) before installation in the
gun body.

31
9 Cleaning
Attention
Never place the spray gun in solvent or another cleaning agent. The perfect function
of the spray gun can otherwise not be guaranteed. Do not use any hard or pointed
objects for cleaning. WALTHER, Wuppertal, will not accept warranty claims for
damages resulting from inappropriate cleaning.
The gun does not need to be dismantled for cleaning.
1. Fill the cleaned gravity-feed cup with a cleaning fluid compatible with the
sprayed material.
2. Operate the spray gun.
3. Do not stop the spray gun until clear cleaning fluid emerges from the nozzle.
The entire system should then be depressurised until the gun is used again.
Clean the spray gun only with cleaning agents which have been recommended by
the manufacturer 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
components, 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.
Complete Cleaning
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
WALTHER PILOT gun grease and a soft brush. Assemble the gun again in reverse
order.

32
10 Waste Disposal
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:
PILOT TERRA with grafity-feed cup: 530 g
PILOT TERRA with material connection: 425 g
Connections
Atomizing Air: G 1/4“
Material Inlet: G 3/8“
Nozzle sizes available: 1,0 • 1,4 • 1,8 mm ø
Air Caps: 6-bore-air cap
8-bore-air cap (LVLP)
Pressure ranges
Input air pressure: max. 8 bar
Material pressure: max. 5 bar
max. operating temperature: 43°C
Noise Level
(measured at approx.1 m
from the spray gun) 83 db (A)
Air consumption:
Atomising air pressure Round jet in l/min. Wide jet in l/min.
1 bar 100 130
2 bar 170 210
3 bar 230 290
4 bar 290 360
5 bar 360 450
Type LVLP: At an inlet pressure of 3.5 bar, the air consumption is 270 l/min.
Right to effect technical changes reserved.

48
Índice de contenido
Vista desarrollada 2
Declaración de conformidad CE 49
Lista de las partes de recambio 50
1 Aspectos generales 52
1.1 Identificación de los modelos 52
1.2 Uso previsto 52
1.3 Uso no apropiado 53
2 Descripción técnica 53
3 Indicaciones de seguridad 53
3.1 Identificación de las indicaciones de seguridad 53
3.2 Indicaciones de seguridad generales 54
4 Conexión de los empalmes de alimentación 55
5 Puesta en servicio y manejo 55
6 Modificar el diagrama de pulverización 56
6.1 Eliminar fallos en un diagrama de pulverización 57
7 Búsqueda y eliminación de errores 57
8 Reequipamiento y reparación 58
9 Limpieza 59
10 Eliminación de desechos 60
11 Datos técnicos 60

49
Declaración de conformidad CE
Como fabricante de este aparato, certificamos bajo nuestra plena responsabilidad que
el producto descrito más abajo cumple con los requisitos de seguridad y protección de
la salud en vigor. Cualquier modificación sin autorización previa o uso inadecuado del
aparato anulan la validez de esta declaración.
Fabricante 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]
Denominación del
modelo
Pistolas de pulverización PILOT TERRA
PILOT TERRA con depósito de gravedad V 11 801
PILOT TERRA con toma de material V 11 802
PILOT TERRA-LVLP con depósito de gravedad V 11 811
PILOT TERRA-LVLP con toma de material V 11 812
Uso aplicación de materiales pulverizables
Normas y directivas aplicadas
Directiva EU sobre las máquinas 2006 / 42 / EC
94 / 9 EC (directivas ATEX)
DIN EN ISO 12100-1
DIN EN ISO 12100-2 DIN EN 1953
EN 1127-1 DIN EN 13463-1
Especificación en el sentido de 94 / 9 / EC
Categoría 2 designación del
aparato II 2 G c T 6 Tech.File,Ref.:
2417
Persona autorizada para la compilación de la documentación técnica:
Nico Kowalski, WALTHER Spritz- und Lackiersysteme GmbH, Kärntner Str. 18 - 30
D- 42327 Wuppertal
Indicaciones particulares:
Este aparato está diseñado para integrarse a otro equipo. La puesta en marcha no
se autoriza hasta que la conformidad del producto final con los requisitos de la direc-
tiva 2006 / 42 / EC no haya sido establecida.
Wuppertal, el 01 de abril 2010
Nombre: Torsten Bröker
Puesto: Jefe de la construcción y del desarrollo
Esta declaración no constituye una declaración de responsabilidad en cuanto a la caracteristicas
estipuladas en la garantía del aparato. Las consignas de seguridad de las instrucciones de uso
deben seguirse.
p.p.

50
Partes de recambio :
PILOT TERRA
Depósito de gravedad
PILOT TERRA
Toma de material
V 11 801 03 XX3
V 11 811 03 XX3 (LVLP)
V 11 802 03 XX3
V 11 812 03 XX3 (LVLP)
Pos. Description Uds. Referencia N° Uds. Referencia N°
1tuerca del cabezal de aire
compl. 12337082 12337082
2cabezal de aire 1V 11 801 40 006 1V 11 801 40 006
cabezal de aire (LVLP) V 11 801 45 1MP V 11 801 45 1MP
3
3.1 Tobera*
1V 15 118 03 XX3* 1V 15 118 13 XX3*
3.2 Guarnición de aguja compl.
3.3 Aguja de material compl.*
3.4 Resorte de aguja
4Cuerpo de la pistola compl. 12337094 12337105
5
5.1 Junta de vástago de válvula
1V 17 118 01 000 1V 17 118 02 000
5.2 Cono de válvula compl.
5.3 Resorte de válvula
5.4 Arandela
5.5 Junta tórica
6Casquillo de resorte 12337086 12337086
7Tornillo de ajuste 12337087 12337087
8Regulación del chorro
ancho/redondo completa 1V 11 801 05 000 1V 11 802 05 000
9 Boquilla
(Toma de material)--1V 00 101 04 000
10 Boquilla
(Toma de aire)1V 00 101 01 000 1V 00 101 01 000
11 Gatillo compl. 1 V 11 801 07 000 1V 11 801 07 000
12 Llave de la pistola 12342434 12342434
13 Depósito de gravedad compl. 1V 00 130 00 100 --
* Al encárganos piezas de recambio, indíquenos siempre los respectivos tamaños.
Accesorios
Grasa de pistola WALTHER PILOT
(almohadilla 8 - 10 g)
Referencia N°
V 00 000 00 001