5.2
Starting / Stopping Requirements
The following requirements must be met beforethis spray gun can be taken into ope-
ration:
• The atomizing air pressure must be available at the gun.
Caution
The air pressure shal I not exceed 8 bar, as otherwise the functional reliability of the
spray gun will suffer.
Warning
It is important to remember that the spray gun must be relieved of all pressures when
work is terminated - lines left in pressurized condition could burst with their contents
likely to injure anybody standing 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, cardbo-
ard or paper.
Warning
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!
Warning
Make sure that nobody is present in the spraying zone when the gun is started - im-
minent risk of injury.
1. Start the gun to produce a spray pattern sample (see 5.2 Starting / Stopping Re-
quirements).
2. Inspect the sample and adjust the settings of the gun, if necessary (see 5.4 Spray
Pattern Adjustments).
5.4
Spray Pattern Adjustments
The spray pattern of the PILOT IV can be adjusted as follows.
Wide and / or Round Jet Pattern
The regulating screw (Item 21) controls the width of the jet. By turning it to the left a
wide-jet pattern will emerge; by screwing it to the right a round-jet pattern can be
achieved.
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Adjusting the Material Flow Rate
The material flow rate can be adjusted by screwing in / screwing out the set screw
(Item 14). The material rate is increased by turning it to the left (screwing out) and
decreased by turning it to the right (screwing in).
Adjustment of the Atomizing Air Pressure
The atomizing air pressure is to be adjusted at the 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,
the spray gun must be retooled (see 5.5 Retooling the spray gun).
WALTHER offers a great variety of air cap / material nozzle / needle combinations
for this purpose.
5.5
Retooling the Spray Gun
Combinations of air cap, material nozzle and needle, designed to match specific
spraying media type and grades, form a unit - namely the nozzle insert assembly,
which must always be interchanged as a complete assembly to maintain the des-
ired spray-finish quality standard.
Warning
Prior to retooling: Make sure that the spray gun is in unpressurized condition, i.e.
the air input must be shut off - if not, imminent risk of injury.
Note
Please use the exploded view at the beginning of these operating instructions in
order to perform the following procedures.
Replacement of Material Nozzle and Air Cap
1. Unscrew the retaining nut of the air cap (Item 1).
2. Remove the air cap (Item 2).
3. Unscrew the material nozzle (Item 3) from the gun body using a size 12 wrench.
Installation is performed in reverse order.
Replacement of Material Needle
1. Unscrew the adjusting screw (Item 12- 14).
2. Remove the spring (Item 11).
3. Pull out the material needle (Item 9) from the gun body.
Installation is performed in reverse order. The setting dimension for the needle-
controlled initial air input is 64 mm, measured from the point of the material control
needle to the needle retaining nut (Item 10).
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