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OPERATING MANUAL

EDITION 11/2022

ORDER NUMBER DOC

2428311

PILOT GM 1030G

3.3

TYPE PLATE

Designation

1 Maximum air inlet pressure
2 Spray gun model and manufacturer
3 Explosion protection identification and year of manufacture serial number (YB-SN)

GM 1030G

Walther Spritz- und Lackiersysteme GmbH

D-42327

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Содержание GM 1030G

Страница 1: ...l 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 ...

Страница 2: ......

Страница 3: ...fe Work Environment 10 4 3 Personnel Qualifications 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 1...

Страница 4: ... 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...

Страница 5: ...ning 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 ...

Страница 6: ... 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 releva...

Страница 7: ...on the basis of this operating manual Follow the instructions in the operating manual 2 3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS As defined 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 ...

Страница 8: ...missible 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 temperatur...

Страница 9: ...C2428311 PILOT GM 1030G 3 3 TYPE PLATE Designation 1 Maximum air inlet pressure 2 Spray gun model and manufacturer 3 Explosion protection identification and year of manufacture serial number YB SN GM 1030G Walther Spritz und Lackiersysteme GmbH D 42327 ...

Страница 10: ...sure 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 Prote...

Страница 11: ...rotection cream if necessary Use a mask or breathing apparatus if necessary For sufficient health and environmental safety Operate the device in a spray booth or on a spraying wall with the ventilation extraction switched on Wear suitable protective clothing when working with hot products 4 6 SAFE HANDLING OF WALTHER SPRAY DEVICES Danger due to injection of products or flushing agent into the skin...

Страница 12: ...he device Preference should be given to non ignitable cleaning and flushing agents When carrying out cleaning work with flammable cleaning agents make sure that all equipment and resources e g collection tank funnel transport cart are conductive or static dissipative and grounded Observe the material manufacturer s specifications Ensure that the flash point of the cleaning agent is at least 15 K a...

Страница 13: ... and repair Danger to life and equipment damage Only a WALTHER Spritz und Lackiersysteme service center or a suitably trained person may carry out repairs and replace parts Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel Use only WALTHER original spare parts and accessories Do not change or modify the device if ch...

Страница 14: ...racted In this way the spray product moves through the nozzle H to the workpiece surface to be coated The closing of the spray gun takes place in the reverse order The product flow rate is dependent on the diameter of the nozzle H and the setting of the product pressure on the pressure vessel or product pressure regulator With the shaping air adjustment D the spray pattern can be optimally adjuste...

Страница 15: ...Description Units Value Maximum air inlet pressure bar MPa psi 8 0 8 116 recommended 2 0 2 29 Cup connection mm M16x1 5 Air connection Inches G1 4 Weight g oz 419 14 8 pH range of the product pH 3 5 9 0 Maximum product temperature C F 40 104 Operating temperature C F 5 40 41 104 Sound level at 0 3 MPa 3 bar 43 5 psi air pressure and 0 3 MPa 3 bar 43 5 psi product pressure dB A 84 1 A rated sound p...

Страница 16: ...psi 0 1 1 14 5 0 2 2 29 0 0 3 3 43 5 0 4 4 58 0 0 5 5 72 5 0 6 6 87 0 HVLP round A 103 165 225 283 340 400 HVLP flat B 197 322 429 542 648 754 HVLP round C 79 123 166 213 259 306 HVLP flat D 155 244 328 412 502 592 Conventional round E 71 111 153 196 238 283 Conventional flat F 160 257 345 437 528 619 Information on air flow in nl min with an inlet pressure between 0 1 1 14 5 and 0 6 6 87 0 MPa ba...

Страница 17: ...t condensation 6 3 INSTALLATION CONDITIONS The air temperature at the installation site must be in a range between 4 C and 40 C 39 F and 104 F The relative air humidity at the installation site must be between 10 and 95 without condensation 6 4 INSTALLATION AND CONNECTION The PILOT manual gun GM 1030G must be combined with various components to make up a spraying system Your WALTHER distributor wo...

Страница 18: ... before commissioning 6 5 GROUNDING WARNING Heavy paint mist if earthing is insufﬁcient Danger of poisoning Insufﬁcient paint application quality Earth all unit components Earth the workpieces being painted A conductive connection potential equalization cable must be established between original tank and the equipment 6 6 SAFETY CHECKS Carry out safety checks in accordance with Chapter 8 2 3 6 7 P...

Страница 19: ...ermissible pressures for all the system components 4 Make sure that the device and all other conductive parts within the work area are grounded 5 Connect air hose to spray gun and to oil free dry air supply 6 Pull the trigger and check whether the spray gun closes correctly upon release 7 Relieve the pressure from the spray gun and device 6 8 2 VERIFYING A SAFE OPERATIONAL CONDITION A skilled pers...

Страница 20: ...t the regular safety checks are carried out in accordance with Chapter 8 2 3 commissioning is carried out in accordance with Chapter 6 8 7 2 1 STARTING TO SPRAY WITH ATOMIZING AIR 1 Set air pressure regulator to approx 0 1 to 0 4 MPa 1 to 4 bar 14 5 to 58 psi 2 Open air regulation A below on the gun 3 Spray on a test object pull trigger 4 Adjust the product pressure and air pressure in accordance ...

Страница 21: ...n Reduce the atomizing air pressure The spray pattern is divided in the middle Increase the nozzle diameter Reduce the atomizing air pressure Increase the product pressure Spray patter is too round Reduce product pressure Increase the atomizing air pressure Note The flow rate can be changed by changing the product pressure or limiting the needle stroke Use of another nozzle see Chapters 10 8 and 1...

Страница 22: ...e regulator 1 only serves to make fine adjustments More product Less product 7 4 PRESSURE RELIEF WORK INTERRUPTION The pressure must always be relieved after the spraying tasks are finished before servicing or repairing the spraying system before carrying out cleaning tasks on the spraying system before moving the spraying system to another location before something must be checked on the spraying...

Страница 23: ...ed 1 Relieve the pressure of the spray gun 2 Unscrew air cap nut A 3 Remove air cap B 4 Unscrew nozzle nut C with a size 13 wrench remove air deflector ring D and nozzle E 5 Treat nozzle nut C and nozzle E with cleaning agent until all the remaining product has been dissolved in case of stubborn soiling leave them in cleaning agent for a longer period of time 6 Insert nozzle E in nozzle nut C Inse...

Страница 24: ...use 2 Relieve the pressure of the spray gun according to Chapter 7 4 3 Close air pressure regulator 4 Dismount nozzle and clean separately see Chapter 7 5 5 Point the spray gun into the grounded metal tank for return product 6 Thoroughly rinse out the spray gun with flushing agent 7 Relieve the pressure of the spray gun according to Chapter 7 4 8 Clean the gun body with a cleaning agent recommende...

Страница 25: ...em into operation and check for leaks as described in Chapter 6 8 3 Perform function test as described in Chapter 11 4 Have the system checked for safe condition by a skilled person 8 2 3 SAFETY CHECKS AND MAINTENANCE INTERVALS Every day Check grounding see Chapter 6 5 Check hoses tubes and couplings see Chapter 8 2 4 Flush and clean the spray gun as described in Chapter 8 1 3 Weekly Check spray g...

Страница 26: ... present Meaning xxx bar Pressure yymm Crimping date year month XX Internal code Hose imprinting Meaning WALTHER Name manufacturer yymm Date of manufacture year month xxx bar xx MPa e g 270 bar 27MPa Pressure XX Internal code DNxx e g DN10 Nominal diameter 8 2 4 REPLACING THE AIR HOSE 1 Flush and clean the spray gun as described in Chapter 8 1 3 2 Relieve the pressure of the spray gun and device A...

Страница 27: ... Incorrectly adjusted atomizing air Readjust the atomizing air Unfavorable nozzle size Select a different nozzle 13 2 Air cap damaged Use new air cap Incorrect air cap Use a different type of air cap Spray product viscosity too high Thin in accordance with the spray product manufacturer s instructions Damaged nozzle Attach new nozzle 10 8 Needle or needle packing leaky Needle packing seal on the n...

Страница 28: ...are parts chapter and that are assigned to the device Before all work on the device and in the event of work interruptions Relieve the pressure from the spray gun pressure hoses and all devices Secure the spray gun against actuation Switch off the energy and compressed air supply Observe the operating and service manual for all work Before repair work Flush and clean the system in accordance with ...

Страница 29: ...e of the product pressure generator and of the spray gun in accordance with Chapter 7 4 3 Unscrew needle stroke regulator A by hand 4 Carefully pull out needle B from the rear 5 Remove trigger E and needle carrier G 6 Loosen the clamping sleeve C of the needle packing D from behind using a screwdriver and push it out through the side opening at F 7 Push out needle packing D and coat new needle pac...

Страница 30: ...spring B then tighten with 6 Nm 4 43 lbft 6 Retighten locking cap A with a size 16 mm wrench and a torque of 12 Nm 8 85 lbft 10 6 CHANGING SHAPING AIR REGULATOR 1 Flush and clean the spray gun in accordance with Chapter 8 1 3 2 Relieve the pressure of the product pressure generator and of the spray gun in accordance with Chapter 7 4 3 Unscrew countersunk head screw A with a 2 5 mm Allen wrench 4 P...

Страница 31: ... the pressure of the product pressure generator and of the spray gun in accordance with Chapter 7 4 3 Remove air cap nut A and air cap B 4 Check nozzle nut C for correct seating and if necessary tighten with a size 13 wrench Coat inside with gun grease V0000000001 E Note Tighten only with the trigger pulled 5 Fit air cap B back onto nozzle nut C and tighten air cap A by hand ...

Страница 32: ...ize 13 wrench remove air control ring D and nozzle E 7 Treat parts with cleaning agent until all remaining products has been dissolved Assembly 1 Place nozzle E in nozzle nut C and insert air control ring D in the spray gun Tighten nozzle nut C with a size 13 wrench and with a torque of 12 Nm 8 85 lbft 2 Insert air cap B and tighten by hand with air cap nut A 3 Grease needle F with WALTHER PILOT g...

Страница 33: ...flow through Visual inspection Trigger and flush the spray gun multiple times Check the following Is the product connection sealed when the gun is closed Is the product valve sealed Is there no product discharge at the valve rod seal Product connection 8 bar Air connection 3 bar Size 7 mm wrench for the clamping sleeve Ifproductleaks tightenclampingsleeve Clamping sleeve of the needle packing on t...

Страница 34: ...the devices must be scrapped please differentiate the disposal of the waste materials The following materials have been used Stainless steel Aluminium Brass Plastics The consumable products e g lacquers adhesives solvents must be disposed of in accordance with the applicable specific standards ...

Страница 35: ... V1070030080 Air cap 0 8 1 0 mm Rotating wide beam Rotary jet air cap with wide jet spray pattern for high viscosity adhesives Nozzle sizes 1 8 2 0 V1070030120 Air cap 1 2 1 5 mm Rotary wide jet V1070030180 Air cap 1 8 2 0 mm Rotary wide jet V1070051050 Air cap 0 5 1 8 mm Round jet Round jet air cap for low to medium viscosity materials V1070051200 Air cap 2 0 2 5 mm Round jet V1070051053 Air cap ...

Страница 36: ...ion V18103G1103 GM 1030G ADH nozzle needle set 1 0 mm B_07081 V18103G1123 GM 1030G ADH nozzle needle set 1 2mm V18103G1153 GM 1030G ADH nozzle needle set 1 5 mm V18103G1183 GM 1030G ADH nozzle needle set 1 8 mm V18103G1203 GM 1030G ADH nozzle needle set 2 0 mm V18103G1253 GM 1030G ADH nozzle needle set 2 5 mm V18103G2103 Rotary jet GM 1030G ADH nozzle needle set 1 0 mm V18103G2123 GM 1030G ADH noz...

Страница 37: ... Union nut G 1 4 nickel plated brass V7013150000 Hose clamp 13 15 51 405 Paint cup PA 750 ml M16 A without filter B_08117 54 410 Filter for gravity feed cup 51 405 V0013800000 Flow pressure cup 450 ccm made of light metal 2440655 Adapter GM 1030 for flow pressure cup V3555500010 Compressed air regulator with manometer for pressure cup complete ready for connection with hose V0000104000 Double ball...

Страница 38: ... the following spare parts lists Wear parts Wear parts are not included in the warranty terms Included in service set Note These parts are not covered by warranty terms Not part of standard equipment however available as special accessory Explanation of order no column Item not available as spare part Position does not exist DANGER Improper Maintenance Repair Danger to life and equipment damage On...

Страница 39: ...Conventional 10 hole 1 0 Dispersion adhesive round jet 4 5 Round jet 5 1 Adhesive rotary jet 7 1 Adhesive rotary wide jet 3 3 Nozzle size ø 1 0 2 2mm X X e g Nozzle size 1 5 mm X X 1 5 Adhesive nozzle size ø 1 0 2 5 mm X X Adhesive nozzle size ø 1 0 2 5 mm X X Standard stainless steel 3 e g Order number for a GM 1030G manual gun with needle packing gravi ty feed cup version air cap dispersion ad h...

Страница 40: ...40 OPERATING MANUAL EDITION 11 2022 ORDER NUMBER DOC2428311 PILOT GM 1030G 14 3 EXPLODED VIEW DRAWING OF PILOT GM 1030G 30 30 30 ...

Страница 41: ... cap 1 GM1032400780 13 Threaded bushing 1 GM1032417746 14 Needle stroke regulator set 1 GM1032400778 15 Needle spring set 1 GM1032417736 16 Needle packing set 1 GM1032400771 17 O ring 1 18 Needle carrier set 1 GM1032417744 20 Trigger axis set 1 GM1032417747 21 O ring 1 22 Air valve cone 1 23 Shaping air adjustment 1 GM1032417738 24 Gravity flow cup 750 ml without filter 1 51 405 25 Filter for grav...

Страница 42: ...pplied Standards and Directives EU Mechanical Engineering Directives 2006 42 EC 2014 34 EU ATEX Directives DIN EN ISO 12100 2011 3 DIN EN 1127 1 2019 DIN EN 1953 2013 DIN EN ISO 80079 36 2016 Specification according 2014 34 EU Category 2 Part marking II 2G Ex h IIC T6 Gb Tech File Ref PTB 21 ATEX D104 Authorized with the compilation of the technical file Nico Kowalski WALTHER Spritz und Lackiersys...

Страница 43: ...OPERATING MANUAL ...

Страница 44: ...anks Agitator Systems Airless Equipment and Fluid Pumps Material Circulation Systems Paint Mist Extraction Systems Supply Air Systems Occupational Safety and Accessory Items Walther Spritz und Lackiersysteme GmbH Kärntner Straße 18 30 D 42327 Wuppertal T 49 202 787 0 F 49 202 787 2217 info walther pilot de www walther pilot de Technical changes and errors excepted WALTHER PILOT Order no 2428311 Au...

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