Walther FSP-01 User manual

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 1 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
Assembly Instructions
FSP-01 FINE-SPRAY Pistol with Handgrip
Article Number: F01-….
Fig.: FSP-01 HD with regulating screw
Fig.: FSP-01 KLS and HVLP
NOTE
Please read the Assembly Instructions carefully before first using the incomplete device and
strictly adhere to the instructions!
The incomplete device may only be worked with and worked on by persons who are familiar
with the assembly instructions and the current regulations for industrial safety and accident
prevention.
Keep a translated version of the “Original Assembly Instructions“at the incomplete device!
The instructions have to be available anytime!

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 2 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
Contents
page
EC DECLARATION OF INCORPORATION ....................................................................................................................... 3
1INTRODUCTION ................................................................................................................................................. 4
1.1 TARGET GROUP OF THE ASSEMBLY INSTRUCTIONS ............................................................................................................ 4
1.2 LIST OF SIGNS AND SYMBOLS ....................................................................................................................................... 4
2SAFETY............................................................................................................................................................... 4
2.1 GENERAL INFORMATION ............................................................................................................................................. 4
2.2 DANGERS FROM TO RESIDUAL ENERGY........................................................................................................................... 4
2.3 WARRANTY AND LIABILITY........................................................................................................................................... 4
2.4 CORRECT USE ........................................................................................................................................................... 5
2.5 INCORRECT USE ........................................................................................................................................................ 5
2.6 QUALIFICATION OF PERSONNEL .................................................................................................................................... 5
3TRANSPORT ....................................................................................................................................................... 6
3.1 PACKAGING .............................................................................................................................................................. 6
3.2 TASKS BEFORE TRANSPORT .......................................................................................................................................... 6
4FUNCTIONAL DESCRIPTION ............................................................................................................................... 6
4.1 FUNCTION................................................................................................................................................................ 6
4.2 TECHNICAL DATA........................................................................................................................................................ 7
5INITIAL START-UP ............................................................................................................................................... 7
5.1 INSTALLATION ........................................................................................................................................................... 7
6OPERATION ....................................................................................................................................................... 7
6.1 GENERAL INFORMATION ............................................................................................................................................. 7
6.2 OPERATING INSTRUCTIONS .......................................................................................................................................... 7
7TAKING OUT OF SERVICE ................................................................................................................................... 9
7.1 SHORT INTERRUPTION ................................................................................................................................................ 9
7.2 LONG-TERM INTERRUPTION......................................................................................................................................... 9
7.3 FINAL SHUTDOWN OF DEVICE ...................................................................................................................................... 9
8MAINTENANCE AND REPAIR .............................................................................................................................. 9
8.1 GENERAL INFORMATION ............................................................................................................................................. 9
8.2 CLEANING .............................................................................................................................................................. 10
8.3 REPLACING THE NOZZLE SET ...................................................................................................................................... 10
8.4 REPLACING THE NEEDLE-VALVE UNIT .......................................................................................................................... 10
8.5 SPARE PARTS .......................................................................................................................................................... 11
8.6 CUSTOMER SERVICE /SUPPORT.................................................................................................................................. 11
9TROUBLESHOOTING ........................................................................................................................................ 11
9.1 GENERAL INFORMATION ........................................................................................................................................... 11
9.2 CASES OF FAILURE.................................................................................................................................................... 11
9.3 SPRAY IMAGE/TYPE OF DEFECT ................................................................................................................................. 12
10 APPENDIX ........................................................................................................................................................ 13
10.1 SPARE PARTS DRAWING FOR FSP-01 (KLS AND HVLP).............................................................................................. 13
10.1.1 Spare Parts List for FSP-01 (KLS and HVLP)........................................................................................... 14
10.1.2 Needles, Nozzles and Air Caps for FSP-01 (KLS) .................................................................................... 15
10.1.3 Needles, Nozzles and Air Caps for FSP-01 (HVLP) ................................................................................. 16
10.2 SPARE PARTS DRAWING FOR FSP-01 HD WITH REGULATING SCREW ............................................................................ 17
10.2.1 Spare Parts List for FSP-01 HD with Regulating screw.......................................................................... 18
10.2.2 Needles, Nozzles and Air Caps for FSP-01 HD with Regulating Screw .................................................. 19

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 3 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
EC Declaration of Incorporation
in accordance with EU Machinery Directive 2006/42/EU, dated 17 May 2006, Appendix II B
We herewith confirm that the below mentioned incomplete device meets the basic requirements for safety
and health as stated in EU Machinery Directive 2006/42/EU for its design and construction as well as for the
configuration released by us on the market. This machine component will not be operated before it has been
determined that the incomplete system where the machine component will be installed also meets the
requirements of the Directive (2006/42/EG).
Manufacturer Walther Systemtechnik GmbH
Hockenheimer Straße 3
D- 76726 Germersheim
Description FSP-01 Fine-Spray Pistol, article-No. F01-…
We also declare the conformity with other, product-relevant directives/guidelines:
Mach. Direct. 2006/42/EU App. I, Clause: 1.1.2, 1.1.3, 1.1.5, 1.1.6, 1.3.2, 1.3.3,
1.3.4, 1.5.8, 1.5.9
Applied harmonized standards, in particular:
DIN EN ISO 12100 Safety of Machinery –General Design Principles –
Risk Assessment and Risk Reduction (ISO
12100:2010)
In addition, we also confirm that the special documentation according to Appendix VII Part B has
been prepared.
The manufacturer, respectively his authorized representative obligates himself to submit this documentation
to the market surveillance authorities, if requested.
This EC Declaration of Incorporation becomes invalid if the incomplete device will be altered or changed
without consent of Walther Systemtechnik GmbH.
Authorized representative for Technical Documentation:
Stefan Hirl, Hockenheimer Straße 3, D- 76726 Germersheim
Germersheim, 30 October 2015
(place, date) (Stefan Hirl, management)

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 4 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
1 Introduction
1.1 Target Group of the Assembly Instructions
Operating personal
Maintenance personal
1.2 List of Signs and Symbols
The assembly instructions warn users of operations which may put their health at risk. The warnings are
indicated by combinations of text and symbols as follows:
DANGER
Describes a potentially dangerous situation.
Death, grievous bodily harm or severe material damage WILL occur if the respective
measures of precaution have not been taken
WARNING
Describes a potentially dangerous situation.
Death, grievous bodily harm or severe material damage MAY occur if the respective
measures of precaution have not been taken
CAUTION
Describes a potentially dangerous situation.
Slight injuries CAN occur if the respective measures of precaution have not been
taken. This signal word is also used to describe possible property damages.
IMPORTANT
Indicates tips for usage and other particularly useful information.
No dangerous situation.
2 Safety
2.1 General Information
The construction of this device is according to the latest technology and is absolutely reliable. The individual
components as well as the complete device are continuously checked by our quality management.
2.2 Dangers from to Residual Energy
Please instruct the operating personnel on the respective measures to be taken against the occurance of
mechanical, hydraulic, pneumatic and electric / electronic residual energies.
2.3 Warranty and Liability
According to the conditions laid down by the German Engineering Federation (VDMA), Walther Systemtech-
nik GmbH has a guarantee of 12 months under normal European operating conditions on its own parts
(spare parts are excluded); or according to the conditions of the manufacturer.
This guarantee can only be granted by Walther Systemtechnik GmbH, if:
the user has thorough knowledge of the content of the assembly instructions;
the user follows the instructions and notes contained in the assembly instructions;
the user does not rebuild or make changes on parts of the device without prior consent of WST Sys-
temtechnik GmbH.

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 5 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
2.4 Correct Use
The FSP-01 FINE-SPRAY spraying pistol is designed and constructed for finest application of thin materials,
e.g. release agents, colors or other fluids of low viscosity at room temperature. It is not suitable for spraying
aggressive fluids such as acids, alkaline solutions, cleaning agents, chemicals, etc. In case of doubt, please
contact the manufacturer.
WARNING
Do not use any solvents, cleaning liquids or coating materials containing 1,1,1 Tri-
chloromethane or Methylene Chloride i.e. agents of the group of chlorinated hydrocar-
bons. These chemicals may react with aluminum, anodized or zinced parts. The chem-
ical reaction may be explosive.
2.5 Incorrect Use
Operating the device with insufficient knowledge about the operation, maintenance and care of the
device.
Making changes, extensions or alterations on the device that may hamper its safety without the prior
consent of Walther Systemtechnik GmbH.
Operating the device with defective safety installations or not properly attached or malfunctioning
safety devices.
Using unsuitable materials.
Handling the device while energized.
2.6 Qualification of Personnel
Only trained and instructed personnel may conduct work on the equipment.
The responsibilities of the personnel for assembly work, operation, repair work or maintenance work must be
clearly assigned to individuals!
Persons in training may work with the equipment only under supervision of an experienced person.
Personnel
Task
Instructed
Personnel
Personnel with Technical
Qualification
Specialist
Supervisor
Packaging, Transport
X
-
-
-
Commissioning
X
X
-
Operation
X
-
Troubleshooting, general
X
X
-
Troubleshooting
mechanical
-
X
-
-
Troubleshooting electrical
-
-
X
-
Setting up
-
X
-
-
Maintenance
-
X
-
-
Repair
-
X
X
-
Taking out of service,
Storage
-
X
X
-

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 6 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
3 Transport
3.1 Packaging
The type of packaging depends on the individual mode of shipping. If not separately contracted, the
packaging is in accordance with the rules and regulations of Walther Systemtechnik GmbH. This rule is in
accordance with the Federal Association for Packaging HPE.
3.2 Tasks before Transport
The following has to be done before transport:
Disconnect all power lines.
The actual transport of the incomplete device and its individual parts requires special care in order to prevent
damages from external forceful impact or careless on- and off-loading. Depending on the mode of
transportation, suitable transport and load securing has to be selected. The incomplete device will be aligned
and leveled by appropriate fastening elements.
4 Functional Description
4.1 Function
CAUTION
Use of other media can result in malfunctions, property damage, or destruction of the
machine.
The FSP-01 Fine-Spray Pistol is designed and constructed for finest application of thin materials, e.g. re-
lease agents, colours or other fluids of low viscosity up to 50 bar material pressure. Depending on the air cap
used, this valve sprays in flat- or round-spray. Depending on the viscosity of the fluid, the application can be
adjusted individually via nozzle dimension, atomizing air pressure and material pressure. The supply of at-
omizing air and material takes place via two hoses.
The FSP-01 Fine-Spray Pistol has been thoroughly tested before leaving the factory. No more adjustment is
necessary prior to setting up spray operation. If fluid output, however, requires to be regulated individually,
apply needle regulator (24.1) for quantity of fluid flow. To spray with a spray gun definite volume of atomising
air and a definite pressure of materials is needed. The needle will be opened by activating the trigger and the
material flows out of from the nozzle. The air pressure atomises the material and forms it to a jet. The needle
function is: Opening by trigger and closing by spring force.

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 7 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
4.2 Technical data
KLS and HVLP
Weight [g]
approx. 240
Control air pressure [bar]
max. 6
Material pressure [bar]
max. 4
With Adjusting Screw
Weight [g]
approx. 270
Air consumption [l/min]
approx. 90 (at 3 bar and 0.5mm nozzle)
Control air pressure [bar]
max. 6
Material pressure [bar]
max. 50
5 Initial Start-up
5.1 Installation
Connect hoses
Material: spray medium to pistol connection “M” (26.1)
Air: spray air to pistol connection “AIR” (26.0)
Set atomizing air pressure via reducing valve (not part of the spray gun).
Set material pressure via a second reducing valve (not part of the spray gun). The supply pressure
and the spray air pressure will determine the drop-size of the spray medium in the jet.
6 Operation
6.1 General Information
This device may only be operated if the safety-related equipment is permanently effective and not suspend-
ed during operation or altered in its intended effectiveness.
6.2 Operating Instructions
CAUTION
Never point the jet at people. The wearing of eye protection is strongly recommended.
The spraying process can create noise depending on the air and fluid pressures used.
Ear protection should be worn, if required.
WARNING
Danger caused by flammable, harmful fluid. Always follow the safety instructions on the
container or the safety data sheet for the fluid.

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 8 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
Activate releasing trigger (19.1). Spray operation starts. You will notice that you receive so called “pre-air”
prior to opening fluid flow when pulling the trigger. When releasing the trigger you still have “purging-air” after
needle has closed nozzle and fluid flow was stopped. This prevents that fluid forms drops instead of the de-
sired atomization.
IMPORTANT
After the spraying operation the pistol should be briefly blown free of any residues, in
order that the nozzle does not clog up and hamper the atomizing process.
Depending on the viscosity of the medium, the following nozzle bores are available: 0.2 ; 0.3 ; 0.5 ; 0.8 and
1.0 mm (only one size of air cap is required for all standard nozzles).
The standard spray pistol is equipped with a flat-spray cap 3.1.1. A round-spray cap 3.1.2 can be used and
ordered as an accessory.
Flat-spray air caps can be individually positioned horizontally, vertically etc. by means of turning the air cap.
The spraying air must be controlled as such, that it is switched on before the needle opens and is switched
off after the nozzle has closed again (resulting in minimum maintenance work).
The valves can be controlled for intermittent or continuous use. According to the individual application, the
control air must be adjusted to the operating cycles and to the higher or lower material pressures. 30 tacts
per second can be reached under appropriate operating conditions (material pressure, control air pressure,
needle stroke, short conductions)
IMPORTANT
The spraying material amount can be adjusted to the individual requirements by turning
the regulating screw (24.1.0) (if provided):
Right turn: decrease in material amount
Left turn: increase in material amount
Nozzle and needle can be damaged by wrong handling. Only decrease the material
flow (by a right turn of the regulating knob) if material spills out. Do not turn the regulat-
ing knob further to the right after the nozzle is closed!
It is harmless to leave fluid in the valve during longer standstills, if system stays under pressure (no connec-
tion to outside air).

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 9 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
7 Taking out of Service
7.1 Short Interruption
A short interruption (15 min or more) has to be followed by a fine spraying.
IMPORTANT
Please follow the Operating Instructions!
7.2 Long-term Interruption
The following has to be observed for a long-term interruption of the device/machine:
Depressurize material supply lines
Take off air cap (3) and clean nozzle (2) with a special thinner and a soft cloth. Make sure that no cloth
fibers are left on the nozzle tip.
IMPORTANT
Please follow the maintenance instructions!
7.3 Final Shutdown of Device
The following is important for a shutdown of the machine / device:
Clean spray pistol with a special thinner.
IMPORTANT
Please follow the maintenance instructions!
8 Maintenance and Repair
8.1 General Information
CAUTION
Before starting any maintenance or repair work, ensure that all air-operated tools are
depressurized and disconnected from the air supply.
Before opening the spray valve it must be disconnected from the air and fluid supply.
Otherwise, ejected components can cause injuries
The FSP-01 Fine-Spray Pistols are high precision tools. Always keep clean and observe minimum
instructions to maintain a long life of the valve. Always use clean and filtered material only. The control air
must also be clean and should be slightly oiled, if necessary. Maintenance also depends on the individual
operating conditions and the type of media used.
Particularly when using the spraying pistol as a color marking device, the spraying cap should be removed
before longer standstills. The spraying nozzle should be cleaned with a soft cloth and the special dilution.
Please make sure that no cloth fibers remain on the nozzle tip. Then spray the valve free by keeping the
manual switch of PLC control or the auxiliary switch on the 3/2-way solenoid valve (green button) pressed for
some time.

Rev. 1.0
Assembly Instructions - FSP-01 Fine-Spray Pistol with Handgrip
Page 10 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
8.2 Cleaning
Only use soft brushes for outside cleaning of the nozzle tips. Never use metal tools with sharp edges. Before
starting any repair or maintenance work, make sure that the work place as well as the device itself are thor-
oughly cleaned. Do not start any repair work on the installed device. Remove the device from the machines
first. (Disconnect from the air and fluid supply!)
To clean the gun, spray solvent until pure solvent leaves nozzle.
Do not submerge entire gun in solvent.
For longer working interruptions it is advisable to clean air cap and nozzle by putting these parts only
into solvent. If necessary, use soft brush.
To clean small drill holes, use our special nozzle cleaning needles or a soft brush.
Moving parts and threads should always be greased slightly and regularly.
IMPORTANT
Hold the spraying valve downwards when doing so, in order that the medium does not
flow into the air ducts. Collect the escaping medium in a container and dispose of it
appropriately.
8.3 Replacing the Nozzle Set
A nozzle set includes needle (1.1.1), nozzle (2.1.1) and air cap (3.1.1). If nozzle size is to be changed,
always change all three parts. Change the complete set also when only one of the parts is defect.
Remove screw (21.1)
Pull out valve spring (20.1)
Pull out needle/valve cartridge
Unscrew the collar ring (4.1.1), remove air cap (3.1.1 or 3.1.2)
Unscrew nozzle (2.1.1)
Re-assemble in reverse order.
8.4 Replacing the Needle-Valve Unit
Remove screw (21.1)
Pull out valve spring (20.1)
Pull out needle/valve cartridge
Unscrew valve lock (18.1)
Pull out needle spring (17.1)
Pull out needle (1.1.1)
Re-assemble in reserve order. OBSERVE!!!
Needle nuts (16.1) must be counter-screwed on the needle 1.1.1 in such a way that “pre-air” (when trigger is
released) and “purging-air” (when spraying process is finished) work properly.
The correct position of needle nuts on the needle or the extension needle is 8.8 –9.0mm from the end of the
needle. This does also apply for a retrograde mounting of extension needles.