Walther Systemtechnik 9741970.0 Series, 9741970.00, 9741970.02, 9741970.03, 9741970.04 Assembly Instructions Manual

Rev. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 1 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

Assembly Instructions

Dosing Valve Station

Dosing Volume: 5.0 – 54.0 cm³
Article Number: 9741970.00 Standard

9741970.02 Magnetic Tape

9741970.03 Initiator

9741970.04 Magnet Tape and Proximity Switch

9741970.00

9741970.02

9741970.03

9741970.04

IMPORTANT

Please read this Assembly Instruction carefully before unpacking and start of operation with
the incomplete device, and make sure you follow it strictly!

The incomplete device will only be used, serviced or repaired by persons who are familiar
with the Assembly Instruction as well the guiding rules on work 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. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 2 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

Table of Contents

Page

EC DECLARATION OF INCORPORATION ....................................................................................................................... 4

1 SAFETY NOTES ................................................................................................................................................... 5

1.1 SYMBOLS FOR HAZARDS, DIRECTIVES AND INFORMATION .................................................................................................. 5

1.2 BASIC SAFETY DIRECTIONS ........................................................................................................................................... 6

1.3 RELEVANCE OF ASSEMBLY INSTRUCTIONS ....................................................................................................................... 6

1.4 RESPONSIBILITIES OF OPERATING COMPANY AND STAFF .................................................................................................... 6

1.5 TRAINING OF STAFF .................................................................................................................................................... 6

1.6 HAZARDS WHEN WORKING WITH THE DEVICE ................................................................................................................. 7

1.7 SAFETY HAZARDS CAUSED BY FLUIDS ............................................................................................................................. 7

1.8 SAFETY AND PROTECTION DEVICES ................................................................................................................................ 7

1.9 PERSONAL PROTECTIVE GEAR AND ADDITIONAL MEASURES ............................................................................................... 7

1.10 CORRECT USE ...................................................................................................................................................... 7

1.11 INCORRECT USE .................................................................................................................................................... 7

1.12 SERVICE, MAINTENANCE, TROUBLESHOOTING ............................................................................................................ 7

1.13 WARRANTY AND LIABILITY ...................................................................................................................................... 8

1.14 COPYRIGHT .......................................................................................................................................................... 8

1.15 QUALIFICATION OF PERSONNEL ............................................................................................................................... 8

2 TRANSPORT ....................................................................................................................................................... 9

2.1 PACKAGING .............................................................................................................................................................. 9

2.2 TASKS BEFORE TRANSPORT .......................................................................................................................................... 9

3 DESCRIPTION OF FUNCTION .............................................................................................................................. 9

3.1 PURPOSE OF THE PARTLY COMPLETED DEVICE ................................................................................................................. 9

3.2 TYPE LABEL .............................................................................................................................................................. 9

3.3 FUNCTIONAL DESCRIPTION ........................................................................................................................................ 10

3.4 VERSIONS .............................................................................................................................................................. 10

3.5 TOTAL VIEW / DESCRIPTION ....................................................................................................................................... 10

3.5.1 9741970.00 Standard ................................................................................................................................ 10

3.5.2 9741970.02 Magnetic Ring ....................................................................................................................... 11

3.5.3 9741970.03 Initiator .................................................................................................................................. 11

3.5.4 9741970.04 Magnetic Ring and Proximity Switch ..................................................................................... 11

3.6 TECHNICAL DATA ..................................................................................................................................................... 12

4 COMMISSIONING ............................................................................................................................................ 13

4.1 MOUNTING AND INSTALLATION .................................................................................................................................. 13

4.2 ADJUSTING THE INCOMPLETE DEVICE .......................................................................................................................... 13

5 OPERATION ..................................................................................................................................................... 14

5.1 GENERAL INFORMATION ........................................................................................................................................... 14

5.2 OPERATING ELEMENTS ............................................................................................................................................. 14

6 TAKING OUT OF SERVICE ................................................................................................................................. 15

6.1 SHORT INTERRUPTION .............................................................................................................................................. 15

6.2 LONG-TERM INTERRUPTION ....................................................................................................................................... 15

6.3 SHUTDOWN OF DEVICE ............................................................................................................................................. 15

7 MAINTENANCE AND REPAIR ............................................................................................................................ 16

7.1 GENERAL INFORMATION ........................................................................................................................................... 16

7.2 ROUTINE TASKS ....................................................................................................................................................... 16

7.3 CLEANING .............................................................................................................................................................. 16

7.4 SPARE PARTS .......................................................................................................................................................... 16

7.5 CUSTOMER SERVICE / SUPPORT .................................................................................................................................. 17

8 TROUBLESHOOTING ........................................................................................................................................ 17

Rev. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 3 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
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8.1 GENERAL INFORMATION ........................................................................................................................................... 17

9 APPENDIX ........................................................................................................................................................ 18

9.1 DATA SHEET INDUCTIVE SENSOR (ARTICLE-NO. 9742369.01) ........................................................................................ 18

9.2 OPTION CABLE SOCKET FOR INDUCTIVE SENSOR (ARTICLE-NO. 9742369.11) .................................................................... 19

9.3 DATA SHEET PROXIMITY SWITCH, TYPE 102 160 (ARTICLE-NO. 9742451.01) .................................................................. 19

9.4 DIMENSIONED DRAWING DOSING VALVE STATION 9741970.00 ...................................................................................... 20

9.4.1 Spare Parts Drawing Dosing Valve Station 9741970.00 ............................................................................ 21

9.4.2 Spare Parts List Dosing Valve Station 9741970.00 .................................................................................... 22

9.5 DIMENSIONED DRAWING DOSING VALVE STATION 9741970.02 ...................................................................................... 23

9.5.1 Spare Parts Drawing Dosing Valve Station 9741970.02 ............................................................................ 24

9.5.2 Spare Parts List Dosing Valve Station 9741970.02 .................................................................................... 25

9.6 DIMENSIONED DRAWING DOSING VALVE STATION 9741970.03 ...................................................................................... 26

9.6.1 Spare Parts Drawing Dosing Valve Station 9741970.03 ............................................................................ 27

9.6.2 Spare Parts List Dosing Valve Station 9741970.03 .................................................................................... 28

9.7 DIMENSIONED DRAWING DOSING VALVE STATION 9741970.04 ...................................................................................... 29

9.7.1 Spare Parts Drawing Dosing Valve Station 9741970.04 ............................................................................ 30

9.7.2 Spare Parts List Dosing Valve Station 9741970.04 .................................................................................... 31

10 ACCESSORIES (OPTIONAL) ............................................................................................................................... 31

Rev. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 4 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [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
76726 Germersheim

Description

Dosing Valve Station, Article-No. 9741970.00/02/03/04

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, 1.5.9
EMC- Directive 2014/30/EU, dated 26. February 2014

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, 19 April 2016

(Place, Date) (Stefan Hirl, Walther Systemtechnik GmbH, Mgmt)

Rev. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 5 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

1 Safety Notes

CAUTION

We kindly request that the customer studies the assembly instructions carefully, in
order to acquaint himself with the safe and efficient operation of this device. Please
keep this manual at a safe place for future reference.
The assembly instructions include important instructions and details for the safe and
appropriate operation of the device. It supports the operating and maintenance staff,
thus helping to reduce safety hazards, repair costs and down times, as well as to
enhance reliability and service life considerably. Therefore, it is important that every
person in charge of the device has access to this document.

1.1 Symbols for Hazards, Directives and Information

Symbols are used indicate dangerous situations and specific behavior. These symbols are also used in the
assembly instructions. All warning, danger and information symbols describe situations which can be harmful
to persons, material or environment if rules are not followed.

The assembly instructions use the following signs and symbols for dangers:

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.

Rev. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 6 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

1.2 Basic Safety Directions

The basic requirements for safe handling and trouble-free operation of this device include:

CAUTION

 The device must not be used for purposes other than those intended.
 The device must not be modified. In case of modifications, the customer takes

on all responsibility for any incidents due to his modifications. In case a
modification of the device is required, please contact WALTHER
SYSTEMTECHNIK GMBH.

 Make sure that the device is always in safe operation condition. Qualified staff

shall perform functional tests and checks for damage at regular intervals.
Authorized staff only shall do disassembly, and according to these assembly
instructions only. To ensure appropriate expertise of the customer´s staff, we
offer training courses upon request.

 The customer is responsible for complying with all appropriate safety

measures.

 Never operate the device if outlets point towards a person.
 Always disconnect device from mains / air pressure supply / grease feed pipe

before beginning any maintenance work. All piping and hoses must be
pressureless.

 Check all pipes, hoses and screw connectors for leaks and visible damage at

regular intervals! Immediately remove any damage!

 Exposure of the sensors to magnetic fields may cause malfunction of the

sensors.

 Ensure that working place, device and environment are kept in clean and

clearly arranged state at regular intervals.

 Rules and regulations regarding the prevention of accidents that apply to the

working site must be observed.

1.3 Relevance of Assembly Instructions

The assembly instructions are only referring to the device as stated on the cover sheet of this manual.
The manufacturer of the device accepts responsibility for the safety, reliability and performance of the device

only if the user has read and signed the assembly instructions.
Kindly remember that the assembly instructions were designed for your personal protection and safety.
Reading and understanding the instructions may further help to avoid expensive service work and

inappropriate operation of the device, and hence substantially increase the customer´s benefit.

1.4 Responsibilities of Operating Company and Staff

 Reliable and trained staff only should be authorized to work with the device, and responsibilities

should be clearly assigned to individuals.

 Maintenance of electrical components of the device must be performed by a professional electrician,

or under supervision of a professional electrician, and according to electro-technical regulations.

 Maintenance of hydraulic equipment should be assigned to staff with hydraulics know-how and experi-

ence only!

1.5 Training of Staff

 Persons must not work with the device unless they have been respectively trained and made familiar

with the device.

 Responsibilities of personnel for assembly work, commissioning, operation, setting up, maintenance,

transport and repair should be clearly assigned to individuals.

 Persons in training may work with the device under supervision of an experienced person only.

Rev. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 7 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

1.6 Hazards when Working with the Device

All equipment and devices are built to the state of the art and according to accredited safety rules.
Nevertheless, safety hazards to the user or third persons, or deficiencies of the plant or its parts may occur, if
the device is not properly used.

The device must only be used:

 for its intended purpose;
 if working condition of device ensures full technical safety.

 Technical faults, which may degrade safety, must be repaired immediately!

1.7 Safety Hazards caused by Fluids

NOTE

Pay close attention to the safety directions specified by the fluid manufacturer and
observe his instructions.
The manufacturer of this device refuses to accept any liability for incidents caused by
disregarding directions, instructions or recommendations given by the manufacturer.

1.8 Safety and Protection Devices

 Make sure that all protection devices are installed properly and are in functional condition, prior to start-

up of the device.

 Protection devices must not be removed unless the device has been shut down and a safeguard against

restart has been established.

1.9 Personal Protective gear and Additional Measures

 The operator company is responsible for providing the required personal protective gear.
 All safety devices and installations should be checked at regular intervals.

1.10 Correct Use

The device must be used under the specified operating conditions only. The device must be used exclusively for
conveying lubricants according to the detailed specifications in chapter 2.1 of the assembly instructions. Any
usage other than or beyond that specified herein is regarded as not according to the intended purpose. The
manufacturer company assumes no responsibility for any damage resulting from such incorrect use.

Correct use of the device also includes:

 Observing and adhering to all assembly instructions stated in this manual.
 Adherence to inspection and maintenance tasks.

1.11 Incorrect Use

The manufacturer company assumes no responsibility for any damage resulting from inappropriate usage.
Incorrect use of the device includes but is not limited to:

 Conveying any medium not specified in this manual or in writing by the manufacturer;
 Using corrosive and / or curing agents;
 Conveying, handling or storing foods with the device.

1.12 Service, Maintenance, Troubleshooting

 The specified calibration and maintenance work should be performed timely according to the mainte-

nance schedule.

 Inform operators prior to execution of calibration and maintenance work.
 Disconnect device from mains supply and safeguard against unintentional restart (warning sign: “Do not

switch on!”).

 Make sure that all screw connections and fittings are fastened tightly.
 After completion of maintenance work, check all functions and all safety devices.

Rev. 1.1

Assembly Instructions - Dosing Valve Station 9741970.0x

Page 8 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

1.13 Warranty and Liability

In principle, our general business and delivery terms apply as well as any written agreements prior to
ordering. All warranty and liability claims in case of personal or material damage are excluded if they are
caused by one or more of the following reasons:

 Incorrect use of the device.
 Work on device by persons other than those authorized to work with the device.
 Improper transport, storage, assembly, commissioning, operation or maintenance of device.
 Operation of the device with faulty, not properly fitted or nonfunctional safety and protection devices.
 Disregard of instructions regarding safety, transport, storage, assembly, operation, commissioning,

maintenance and setting-up of the device as stated in the assembly instructions.

 Modifications of the device not authorized by the manufacturer company.
 Manipulation of the pressure control device or the supply pressure without authorization of the manufac-

turer company.

 Insufficient inspection of device parts subject to wear.
 Improper repairs and use of spare parts from other suppliers.
 Disasters, e.g. by forces of nature or foreign object damage.

1.14 Copyright

The copyright of the assembly instructions belongs to Walther Systemtechnik GmbH. The assembly
instructions are intended for use by the staff of the user company only.

Directions and instructions contained in this manual must not be copied, nor distributed, nor communicated
to third parties, neither completely nor partly.

1.15 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 under supervision of an experienced person only.

Personnel
Task

Trained
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

-

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Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

2 Transport

2.1 Packaging

The type of packaging will be selected according to the mode of transport. If not separately negotiated, the
packaging will be made in accordance with the packaging directive of company Walther Systemtechnik
GmbH. This directive complies with HPE Packaging Regulations.

2.2 Tasks before Transport

The following tasks have to be fulfilled before the actual transport.

 Disconnect energy supply lines

Extreme care has to be applied when transporting the incomplete machine and its individual parts in order to
avoid damages from external impacts or careless on- and off-loading. Depending on type and duration of
transport, appropriate transport securing devices have to be used. The incomplete device itself will be

adjusted and leveled by appropriate fastening elements.

3 Description of Function

3.1 Purpose of the Partly Completed Device

The special construction supplies the correct lubricant in the required quantity at a given time to a defined
location. The dosing valves are also suitable for the use with oil.

3.2 Type Label

The dosing Valve Station can be identified by an
engraving on the side of the casing which shows the
manufacturing date and also the article number.
Above that it has a type label; this contains more
information for indentifying the device.

IMPORTANT

Always use the engraved data and the data from the type label for spare part orders or
the technical service.

Type Label

Engraving

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Assembly Instructions - Dosing Valve Station 9741970.0x

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Walther Systemtechnik GmbH – D 76726 Germersheim
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3.3 Functional Description

The pneumatic part of the dosing valve is controlled by a pneumatic 5/2-way valve which is integrated in the
handle. Pulling the trigger initiates the grease dosing. The dosing pressure is depending on the pressure in
the grease (medium). The air and grease chambers are separated.
In order to obtain a high quality and precision of repeating during the actual dosing, the whole cycle has to
be completed. In other words, the control piston has to move from the initial position to the dosing position
and back into the initial position.
.

3.4 Versions

9741970.00 Standard Version

9741970.02 Magnetic Tape at air piston as front part for proximity switch

9741970.03 Initiator for controlling the dosing piston. This special construction increases the process
safety. The initiator will send an electric signal once the cycle has been completed, i.e. when
the grease has been released.
For a process-safe function of the initiator, the smallest selected dosing amount has to be
approx. 10% larger then minimum quantity indicated on the valve.
When dosing in the lower limit area, we recommend using the next small valve!

9741970.04 Magnetic Tape at air piston and proximity switch at valve. The special construction increases
the process safety. The proximity switch will send an electric signal once the cycle has been
completed; air piston in the initial position.

CAUTION

For a process-safe function of the initiator, the smallest selected dosing amount has to
be approx. 10% larger then minimum quantity indicated on the valve.

3.5 Total View / Description

3.5.1 9741970.00 Standard

Key

Pos.

Description

1

Connection grease

2

Ventilation

3

Adjusting sleeve

4

Connection air

Pneumatic Part

Grease

Part