DeVilbiss GTI-500P, GTI-520P, EXL-520P Service Bulletin

SERVICE BULLETIN

SB-2-193-G

Replaces SB-2-193-F

Repair Kit KK-5058-2

GTI-500P and GTI-520P COMPLIANT PRESSURE FEED HVLP SPRAY GUNS

IMPORTANT: Before using this equipment,
read all safety precautions and instructions.
Keep for future use.

DESCRIPTION

These pressure feed high volume low pres­sure GTI guns are designed to apply a wide
variety of finishing materials. These guns
are manufactured to provide maximum
transfer efficiency by limiting air cap pres-

sure to 10 psi (complies with rules issued by
SCAQMD and other air quality authorities).

These guns will produce approximately 10
psi cap pressure at 30 psi gun inlet pres­sure. Air cap test kits are available (see
ACCESSORIES) which can be utilized to set
the exact air cap pressure. Air consumption
for the GTI-500P (#100 cap) is 16 SCFM
at 10 psi air cap pressure. Air consumption
for the GTI-520P (#2000 cap) is 15.5 SCFM
at 10 psi air cap pressure.

NOTE

These guns include 400 series
stainless steel fluid tips and
needles. Guns may be used with
chlorinated solvent materials. See
page 2 for additional warnings.

Important: These guns may be used with
most common coating and finishing mate­rials. They are designed for use with mildly
corrosive and non-abrasive materials. If
used with other high corrosive or abrasive
materials, it must be expected that fre­quent and thorough cleaning will be re­quired and the necessity for replacement of
parts will be increased.

INSTALLATION

For maximum transfer efficiency, do not
use more pressure than is necessary to
atomize the material being applied.

1. Connect the gun to a clean, moisture
and oil free air supply using a hose size
of at least 5/16" I.D. hose. Do not use
1/4" I.D. hose (25' x 1/4" hose at 18 CFM
has a pressure loss of 25 psi. 25' x 5/16"
hose at 18 CFM has a pressure loss of
8 psi).

NOTE

Depending on hose length, larger I.D.
hose may be required. Install an
HAV-501 air gauge at the gun handle
and air cap test kit over tip. When
gun is triggered on, adjust regulated
pressure to desired setting to provide
a maximum of 10 psi at the air cap.

Do not use more pressure than is
necessary to atomize the material

being applied. Excess pressure will

create additional overspray and re­duce transfer efficiency.

NOTE

If quick connects are required, use
only high flow quick connects ap­proved for HVLP use such as DeVil­biss HC-4419 and HC-4719. Other
types will not flow enough air for
proper gun operation.

NOTE

If an air adjusting valve is used at the
gun inlet, use DeVilbiss Model HAV­500 or HAV-501. Some competitive
adjusting valves have significant
pressure drop that can adversely
affect spray performance. Models
HAV-500 and HAV-501 have minimal
pressure drop, which is important for
HVLP spraying.

2. Attach the fluid hose to the material
inlet.

NOTE

Protective coating and rust inhibi­tors have been used to keep the
gun in good condition prior to ship­ment. Before using the gun, flush it
with solvents so that these materi­als will be removed from fluid pas­sages.

OPERATION

Mix, prepare and strain the material to be
sprayed according to the paint maufacturer's
instructions.

Strain material through a 60 or 90 mesh
screen.

1. Fill the pressure tank with the mate­rial.

2. Open the spreader adjustment valve
(10) (Fan) by turning the valve stem
counterclockwise.

3. Open fluid adjusting screw (17) by turn­ing counterclockwise.

4. Turn on air supply to gun and pressure
tank and set gun inlet pressure to
lowest recommended pressure for ma­terial being sprayed. Spray a test area.
Air pressure and paint flow should be
adjusted to provide a uniform disper­sion of atomized paint throughout the
pattern. Due to the unique cone shape
of the AV-2120 fluid tip, a slight back
pressure is created against the fluid
column. This will reduce the amount
of fluid output. To compensate, in­crease the fluid regulator pressure

slightly. With 10 psi cap pressure, back
pressure is approximately 2.0 psi. Keep
air pressure as low as possible to mini­mize bounce-back and overspray. Ex­cessive fluid flow will result in heavy
center spray patterns. Inadequate flows
may cause the patterrn to split. See
TROUBLESHOOTING, Page 5, if any
problems occur. If finer atomization is
required, increase gun inlet pressure.
If a reduced fluid flow rate is required,
turn fluid adjusting screw (17) clock­wise until desired fluid flow is obtained.

See Spray Gun Guide, SB-2-001 latest
revision, for details concerning setup of
spray guns.

PREVENTIVE MAINTENANCE

To clean air cap and fluid tip, brush exterior
with a stiff bristle brush. If necessary to
clean cap holes, use a broom straw or
toothpick if possible. If a wire or hard instru-

ment is used, extreme care must be used to
prevent scratching or burring of the holes
which will cauase a distorted spray pattern.

To clean fluid passages, remove excess
material from cup, then flush with a suitable
solvent. Wipe gun exterior with a solvent
dampened cloth. Never completely immerse
in solvent as this is detrimental to the lubri­cants and packings.

NOTE

When replacing the fluid tip or fluid
needle, replace both at the same
time. Using worn parts can cause
fluid leakage. See Chart 2. Also,
replace the needle packing at this
time. Lightly lubricate the threads
of the fluid tip before reassem­bling. Torque to 12-15 ft. lbs. Do
not overtighten the fluid tip.

To prevent damage to fluid tip (5)
or fluid needle (11), be sure to
either 1) pull the trigger and hold
while tightening or loosening the
fluid tip, or 2) remove fluid needle
adjusting screw (17) to relieve
spring pressure against needle
collar.

Page 2 SB-2-193-G

SAFETY PRECAUTIONS

This manual contains information that is important for you to know and understand. This information relates to USER SAFETY and
PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the following symbols. Please pay particular
attention to these sections.

NOTE

Important information that tells how to

Important safety information - A hazard
that may cause serious injury or loss of life.

prevent damage to equipment, or how to
avoid a situation that may cause minor
injury.

The following hazards may occur during the normal use of this equipment.

Please read the following chart before using this equipment.

HAZARD CAUSE SAFEGUARDS

Fire

Solvent Spray

Inhaling Toxic Substances

Explosion Hazard ­Incompatible Materials

General Safety

Cumulative Trauma
Disorders ("CTD's")

CTD's, or musculoskeletal
disorders, involve damage
to the hands, wrists,
elbows, shoulders, neck,
and back. Carpal tunnel
syndrome and tendonitis
(such as tennis elbow or
rotator cuff syndrome) are
examples of CTD's.

Solvent and coatings can be highly
flammable or combustible especially when
sprayed.

During use and while cleaning and flushing,
solvents can be forcefully expelled from
fluid and air passages. Some solvents can
cause eye injury.

Certain materials may be harmful if inhaled,
or if there is contact with the skin.

Halogenated hydrocarbon solvents - for
example; methylene chloride and 1,1,1, ­Trichloroethane are not chemically
compatible with the aluminum that might be
used in many system components. The
chemical reaction caused by these solvents
reacting with aluminum can become violent
and lead to an equipment explosion.

Improper operation or maintenance of
equipment.

Use of hand tools may cause cumulative
trauma disorders ("CTD's").

CTD's, when using hand tools, tend to affect
the upper extremities. Factors which may
increase the risk of developing a CTD include:

1. High frequency of the activity.

2. Excessive force, such as gripping,
pinching, or pressing with the hands and
fingers.

3. Extreme or awkward finger, wrist, or arm
positions.

4. Excessive duration of the activity.

5. Tool vibration.

6. Repeated pressure on a body part.

7. Working in cold temperatures.

CTD's can also be caused by such activities
as sewing, golf, tennis, and bowling, to name
a few.

Adequate exhaust must be provided to keep air free of
accumulations of flammable vapors.

Smoking must never be allowed in the spray area.

Fire extinguishing equipment must be present in the spray area.

Wear eye protection.

Follow the requirements of the Material Safety Data Sheet
supplied by your coating material manufacturer.

Adequate exhaust must be provided to keep the air free of
accumulations of toxic materials.

Use a mask or respirator whenever there is a chance of inhaling
sprayed materials. The mask must be compatible with the material
being sprayed and its concentration. Equipment must be as
prescribed by an industrial hygienst or safety expert, and be
NIOSH approved.

Guns with stainless steel internal passageways may be used with
these solvents. However, aluminum is widely used in other spray
application equipment - such as material pumps, regulators,
valves, and cups. Check all equipment items before use and make
sure they can also be used safely with these solvents. Read the
label or data sheet for the material you intend to spray. If in doubt
as to whether or not a coating or cleaning material is compatible,
contact your material supplier.

Operators should be given adequate training in the safe use and
maintenance of the equipment (in accordance with the require­ments of NFPA-33, Chapter 15). Users must comply with all local
and national codes of practice and insurance company
requirements governing ventilation, fire precautions, operation,
maintenance, and housekeeping. These are OSHA Sections

1910.94 and 1910.107 and NFPA-33.

Pain, tingling, or numbness in the shoulder, forearm, wrist, hands,
or fingers, especially during the night, may be early symptoms of
a CTD. Do not ignore them. Should you experience any such
symptoms, see a physician immediately. Other early symptoms
may include vague discomfort in the hand, loss of manual
dexterity, and nonspecific pain in the arm. Ignoring early
symptoms and continued repetitive use of the arm, wrist, and
hand can lead to serious disability. Risk is reduced by avoiding
or lessening factors 1-7.

Information that you should pay special
attention to.

SB-2-193-G Page 3

SPRAY GUN LUBRICATION

Daily, apply a drop of SSL-10* spray gun
lube at trigger bearing stud (28) and the
stem of air valve (20) where it enters air
valve assembly. The shank of fluid needle
(11) where it enters packing nut (9) should
also be oiled. Fluid needle packing (8)
should be lubricated periodically. Make
sure baffle (6) and retaining ring (3) threads
are clean and free of foreign matter. Before
assembling retaining ring to baffle, clean
the threads thoroughly, then add two drops
of SSL-10 spray gun lube to threads. Fluid
needle spring (14) and air valve spring (19)
should be coated with a very light grease,
making sure that any excess grease will not
clog the air passages. For best results, lubri­cate the points indicated, daily.

* Not for air tools or high RPM equipment.

A. Trigger Points
B. Packing
C. Adjusting Knobs
D. Baffle Threads
E. Air Valve Cartridge

A

D

PARTS REPLACEMENT

FLUID INLET GASKET (32) REPLACE­MENT INSTUCTIONS

1. Remove fluid inlet adapter (34) with

2. Clean Loctite from gun body inlet threads

3. Place gasket (32) squarely onto the

4. Use medium strength thread sealant

5. Torque fluid inlet adapter to 20-25 ft.

B

E

appropriate wrench.

and seal area.

fluid inlet adapter and push it down
until it is flat against the shoulder.

(i.e. Devcon 2242 blue, or equal) on
threads before installing fluid inlet
adapter.

lbs. and tighten locknut.

PARTS REPLACEMENT

Figure 1 Air Cap

Air Cap No.

XXX

HVLP: 30 PSI

MAX. INLET

Maximum air pressure required to
assure compliance of 10 PSI Max.
Cap Pressure - this reading must be
taken at the spray gun handle inlet
fitting.

Chart 1

No on Air Cap Air Cap With Ring
Order (Ref No. 4)

100 GTI-407-100

C

2000 GTI-407-2000

Chart 2

Fluid Tip and Needle

If this No. If This No. Matched Fluid Tip Size
is on Needle, is on Tip, Tip & Needle (I.D.)
Order Order Assembly In. mm.

JGA-402-FF AV-2120-FF JGA-4045-FF .055 1.4
JGA-402-FX AV-2120-FX JGA-4045-FX .042 1.1

Note: Do not use AV-1 copper gasket with
this spray gun.

GTI-33 Baffle Seal Replacement

1. Remove Fluid Tip (5).

2. Remove baffle (6).

3. Remove Seal (7) from baffle.

NOTE

The seal is designed to be a tight
fit on the baffle. The seal should be
able to be removed using your
fingers. If you are unable to re­move the seal using your fingers,
insert a small screwdriver between
the outer lip and the back of the
baffle and pry the seal off.

4. Assemble seal to baffle with angled
side up as shown below. NOTE: The
seal should be a tight fit on the baffle. If
it is a loose fit on the baffle, assure that
it is assembled with the angled side up.

5. Install baffle on gun.

6. Install fluid tip (5) and tighten to
12-15 ft-lbs.

ANGLED SIDE

SEAL

THICK SIDE

Pry here if
necessary

JGA-4035 Packing Replacement
Instructions

Gun Body

1. Remove adjusting knob and needle

spring from gun.

2. Partially withdraw needle from gun

body.

3. Loosen packing nut and remove.

4. Remove old packing.

5. Assemble packing nut to needle

6. Assemble packing in order shown to

needle.

7. Insert needle all the way into gun

body seating in tip.

8. Install needle spring and adjusting

knob.

9. Thread packing nut into gun body.

10. Tighten packing nut in equal

increments - no more than
1/6 turn at a time.

11. After each adjustment, pull needle

open and observe needle closure.

12. If needle snaps shut, continue

adjusting nut until there is evidence
of needle bind or slow closing.

13. Back off packing nut 1/12 turn to the

point where needle snaps shut.
Packing nut must remain tight
enough to prevent loosening by
hand.

14. Pull needle several times to verify

needle snaps shut and check
packing nut for looseness.

BAFFLE

Needle

Packing
(3 pieces)

Packing

Nut

Page 4 SB-2-193-G

PARTS LIST

18

17

16

15

14

10

13

12

11

36 37 38

39

6

7

5

4

3

2

1

Fluid Tip

(Torque to

9

8

*26 Air Inlet Nipple

1/4" NPS(M)

(torque to 15 ft. lbs.)

12-15 ft. lbs.)

24

23

22

21

20

25

32

33

12

19

*34

35

Fluid Inlet Nipple

3/8" NPS(M)

(torque to 20-25 ft.

lbs.)

28

27

29

31

30

*Use medium strength
thread sealant (i.e.
Devcon #2242 Blue, or
equal) on threads.

Ref. Replacement Parts
No. Part No. Description Req.

1 --- Air Cap 1
2 JGA-156-K10 Spring Clip (Kit of 10) 1
3 GTI-3 Air Cap Retaining Ring 1
4 See Chart 1 Air Cap & Retaining Ring 1
5 See Chart 2 Fluid Tip 1
6 GTI-425 Baffle Assembly 1

•7 GTI-33-K5 Baffle Seal (Kit of 5) 1

•8 JGA-4035-K5 Packing (Kit of 5) 1
9 34411-122-K10 Packing Nut 1

10 GTI-405 Spreader Valve 1
11 GTI-413 Fluid Needle 1

•12 JGS-72-K10 Gasket Kit (PTFE) 2
(Kit of 10)

13 --- Body Bushing 1

•14 --- Fluid Needle Spring 1

•15 --- Spring Pad 1

16 MBD-19-K10 Spring and Pad 1

(Kit of 10)

17 GTI-414 Needle Adjusting Screw 1
18 KK-5059 Bushing, Spring, Pad and 1

Knob Kit

•19 --- Air Valve Spring 1

•20 --- Air Valve 1

Ind.

Ref. Replacement Parts

Ind.

No. Part No. Description Req.

21 --- Air Valve Body 1

•22 --- U Cup Seal 1

•23 --- Washer 1

•24 --- Snap Ring 1
25 JGS-449-1 Air Valve Assembly 1
26 P-MB-51 Air Inlet Nipple 1

1/4" NPS(M)
27 --- Trigger Stud Screw 1
28 --- Trigger Stud 1
29 JGS-478 Stud and Screw Kit 1
30 --- Trigger 1
31 JGS-477-1 Trigger Stud, Screw Kit 1

•32 --- Fluid Inlet Gasket (PTFE) 1
33 --- Locknut 1
34 --- Fluid Inlet Adapter 1
35 JGA-4042 Fluid Inlet, Gasket, Nut Kit 1

•36 --- Retaining Clip 1

•37 --- Seal 1

•38 --- Pin 1
39 GTI-428-K5 Clip, Seal & Pin Kit (5 each) 1

• KK-5058-2 Gun Repair Kit includes a quantity of necessary parts.
Suffixes -K5, -K10 designate kits of multiple parts.
Example: JGA-4035-K5 is a kit of 5 packings.

TROUBLESHOOTING

CONDITION CAUSE CORRECTION

Heavy top or
bottom pattern

Horn holes plugged.
Obstruction on top or bottom of fluid tip.
Cap and/or tip seat dirty.

Clean. Ream with non-metallic point.
Clean.
Clean.

SB-2-193-G Page 5

Heavy right or left
side pattern

Heavy center pattern

Split spray pattern

Jerky or fluttering spray

Unable to get round spray

Will not spray

Runs and sags

Starved spray pattern

Excessive overspray

Excessive fog

Dry spray

Fluid leaking from packing nut

Fluid leaking or dripping from
front of gun

*Most common problem.

Left or right side horn holes plugged.
Dirt on left or right side of fluid tip.

Remedies for the top-heavy, bottom-heavy, right-heavy, and left-heavy patterns:

1. Determine if the obstruction is on the air cap or the fluid tip. Do this by making a test
spray pattern. Then, rotate the cap one-half turn and spray another pattern. If the defect
is inverted, obstruction is on the air cap. Clean the air cap as previously instructed.

2. If the defect is not inverted, it is on the fluid tip. Check for a fine burr on the edge of the
fluid tip. Remove with #600 wet or dry sand paper.

3. Check for dried paint just inside the opening; remove by washing with solvent.

Fluid flow too high for atomization air.
(Pressure Feed)

Material flow exceeds air cap's capacity.
Spreader adjustment valve set too low.
Atomizing pressure too low.
Material too thick.

Atomization air pressure too high.
Fluid flow too low.
Spreader adjusting valve set too high.

*Loose or damaged fluid tip/seat.
Baffle Seal installed incorrectly.
Material level too low.
Container tipped too far.
Obstruction in fluid passage.
Dry or loose fluid needle packing nut.
Loose or broken fluid inlet nipple.

Spreader adjustment screw not seating
properly.
Air cap retaining ring loose.

No air pressure at gun.

Fluid needle adj. screw not open enough.
Fluid too heavy.
Fluid pressure too low.

Too much material flow.
Material too thin.
Gun tilted on an angle or gun motion too
slow.

Inadequate material flow.

Low atomization air pressure.

Too much atomization air pressure.
Gun too far from work surface.
Improper stroking (arcing, gun motion too
fast).

Too much or too fast-drying thinner.
Too much atomization air pressure.

Air pressure too high.
Gun tip too far from work surface.
Gun motion too fast.
Gun out of adjustment.

Packing nut loose.
Packing worn or dry.

Packing nut too tight.
Dry packing.
Fluid tip or needle worn or damaged.
Foreign matter in tip.
Fluid needle spring broken.
Wrong size needle or tip.

Clean. Ream with non-metallic point.
Clean.

Balance air pressure and fluid flow. Increase
spray pattern width with spreader adjustment
valve.
Thin or lower fluid flow.
Adjust.
Increase pressure.
Thin to proper consistency.

Reduce at transformer or gun.
Increase fluid flow (increases gun handling
speed).
Adjust.

Tighten or replace.
Install per directions.
Refill.
Hold more upright.
Backflush with solvent.
Lubricate or tighten.
Tighten or replace.

Clean or replace.

Tighten.

Check air supply & air lines, blow out gun air
passages.
Open fluid needle adjusting screw.
Thin material.
Increase fluid pressure at tank.

Adjust gun or reduce fluid pressure.
Mix properly or apply light coats.
Hold gun at right angle to work and adapt to
proper gun technique.

Back fluid adjusting screw out to first thread,
or increase fluid pressure at tank.
Increase air pressure and rebalance gun.

Reduce pressure.
Adjust to proper distance.
Move at moderate pace, parallel to work
surface.

Remix properly.
Reduce pressure.

Reduce air pressure.
Adjust to proper distance.
Slow down.
Adjust.

Tighten, do not bind needle.
Replace or lubricate.

Adjust.
Lubricate.
Replace tip and needle with lapped sets.
Clean.
Replace.
Replace.

Page 6 SB-2-193-G

TROUBLESHOOTING (continued)

CONDITION CAUSE CORRECTION

Thin, sandy coarse finish drying
before it flows out

Gun too far from surface.
Too much air pressure.

Improper thinner being used.

Check distance. Normally approx. 6-8".
Reduce air pressure and check spray
pattern.
Follow paint manufacturer's mixing instrs.

Thick, dimpled finish "orange peel"

Gun too close to surface.

Air pressure too low.
Improper thinner being used.
Material not properly mixed.
Surface rough, oily, dirty.

ACCESSORIES

GTI-5033-100 & GTI-5033-2000

Air Cap Test Kits

The purpose of this test kit is to measure air
cap atomizing air pressure at the center air
port of the air cap. Used to confirm code
compliance and as a daily quality control
measure.

Automotive Quick Connects For HVLP Guns (Air)

High Flow Type.

HC-4419

Stem

1/4" NPT(F)

HC-4719

Coupler

1/4" NPT(M) /

NPS(M)

HC-1166

Stem

1/4" NPT(M)

HC-4720

Coupler

1/4" NPT(F)

Industrial Quick Disconnect Approved For
HVLP Guns (Air)

HC-4419

1/4" NPS(F)

High Flow Ball and Ring Type.

HC-4699

1/4" NPT(M)

HC-4700

1/4" NPT(M)

HC-1166

1/4" NPT(M)

KK-5060 Air Cap

Cleaning Kit

Consists of: 2 brushes,
1 wire pick. Helps
keep air cap clean and
performing properly.

Spray Gun
Lube SSL-10
(2 oz. bottle)

Compatible with all
paint materials; con­tains no silicone or
petroleum distillates to
contaminate paint.
MSDS Sheet available
upon request.

Check distance. Normally approx. 6-8".
Too much material coarsely atomized.
Increase air pressure or reduce fluid flow.
Follow paint manufacturer's mixing instrs.
Follow paint manufacturer's mixing instrs.
Properly clean and prepare.

JGA-156-K10

Spring Clips

Twin Cartridge,

Paint Spray

Respirator

Joins any single
piece DeVilbiss air
cap with latest
version MBC-368,
MSA-1 or GTI-3
retaining rings.
Helps prevent
parts loss and
provides easier
assembly.

NIOSH-Certified
(TC-84A-1623)
respiratory protection
in atmospheres not
immediately danger­ous to life.

192218 Scrubs

Hand Cleaner Towels

Scrubs® are a premoistened hand
cleaner towel for painters, body men
and mechanics that go where you go
and no water is needed.

MSP-524

®

for

HARG-510

Air Regulator

Use to maintain
nearly constant
outlet pressure
despite changes in
inlet pressure and
downstream flow.

WR-103 Wrench

Contains all necessary tip,
hose and nut sizes used
on or with gun.

HAF-507

Whirlwind™

In-Line Air Filter

Removes water,
oil, and debris
from the air line.

HAV-500 OR HAV-501

Adjusting Valve

(HAV-501 SHOWN)

HAV-500 does not
have pressure gauge.
Use to control air
usage at gun.

192212 Professional Spray

Gun Cleaning Kit

Contains six precision
tools designed to effec­tively clean all DeVilbiss,
Binks, Finishline and other
brand spray guns.

WARRANTY

This product is covered by DeVilbiss' 1 Year Limited Warranty. See SB-1-000 which is available upon request.

DeVILBISS WORLDWIDE SALES AND SERVICE LISTING - www.devilbiss.com

INDUSTRIAL FINISHING - DeVilbiss has authorized distributors throughout the world. FOR TECHNICAL ASSISTANCE OR THE
DISTRIBUTOR NEAREST YOU, CALL TOLL FREE 1-888-992-4657 (U.S.A. AND CANADA ONLY). FOR LOCAL CALLS, SEE LISTING BELOW.

U.S./Canada Sales & Customer Service Office Address Telephone No.
GLENDALE HEIGHTS, IL 60139 195 Internationale Blvd. [phone]

Toll Free Fax No. 1-877-790-6965

AUTOMOTIVE REFINISHING - DeVilbiss has authorized distributors throughout the world. For equipment, parts and service, check the
Yellow Pages under "Automobile Body Shop Equipment and Supplies". FOR TECHNICAL ASSISTANCE, CALL TOLL FREE 1-800-445-3988

(U.S.A. ONLY). FOR LOCAL CALLS, SEE LISTING BELOW.

U.S. Customer Service Office Address Telephone No.
MAUMEE, OH 4353 1724 Indian Wood Circle [phone]

Toll Free Fax No. 1-800-445-6643

5/02 ©Copyright 2002, DeVilbiss Printed in U.S.A.