DeVilbiss GTI-520P, GTI-546P Service Bulletin
SERVICE BULLETIN
SB-2-199-F
Replaces SB-2-199-E
Repair Kit KK-5058-2
GTI-520P and GTI-546P 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
variety of finishing materials. These guns are
manufactured to provide maximum transfer
efficiency by limiting air cap pressure to 10
psi (complies with rules issued by SCAQMD
and other air quality authorities).
The GTI-520P (#2000 cap) gun will produce
approximately 10 psi cap pressure at 30 psi
gun inlet pressure. The GTI-546P (#46MP
cap) gun will produce approximately 10 psi
cap pressure at 50 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-520P (#2000 cap) is 16.5 SCFM
at 10 psi air cap pressure. Air consumption
for the GTI-546P (#46MP cap) is 22.5 SCFM
at 10 psi air cap pressure.
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
®
guns are designed to apply a wide
NOTE
These guns include 300 series
stainless steel fluid tips and
needles. Fluid passages are plated
brass and plated aluminum. Guns
may be used with chlorinated
solvent materials. See page 2 for
additional warnings.
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 pattern 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 instrument 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 15-20 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-2-199-F
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 hygienist or safety expert, and be NIOSH
approved.
Guns with stainless steel, anodized or electroless nickel plated
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
require- ments 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.
CA PROP
65
Information that you should pay special
attention to.
PROP 65 WARNING
WARNING: This product contains
chemicals known to the State of
California to cause cancer and birth
defects or other reproductive harm.
PARTS REPLACEMENT
Figure 1 Air Cap and Baffle Identification
NOTE:
The baffle is specially designed to
give the required performance for the
correct air cap. Use of incorrect baffle
and air cap will result in substandard
performance and/or improper air cap
pressures. (See Chart 1 for ordering
correct baffle.)
SB-2-199-F Page 3
No. 2000 Air Cap
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.
Baffle for #2000 Air Cap
Air Cap No.
No. 46MP Air Cap
The 46MP Air Cap doesn't have markings showing the maximum air pressure
required to assure compliance of 10
PSI max. cap pressure. That value is
located on the front of the baffle. (See
view below.)
Baffle for #46MP Air Cap
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.
Air Cap No.
The baffle used with the #2000 cap
doesn't have any markings on it. The
maximum air pressure required to
assure compliance of 10 PSI max. cap
pressure is located on the face of the
air cap. (See view above.)
NOTE:
Chart 1
Air Cap & Baffle Combinations
No. Stamped on Parts Set CFM@ Cap Pressure
Air Cap Ref. No. 4 Ref. No. 6
Part No. Baffle Air Cap Baffle Assy. 2 psi 4 psi 6 psi 8 psi 10 psi
2000
46MP 46
*Note: Baffle seal not used with JGPV-401-46-50 baffle.
(Not Stamped) GTI-407-2000
Air cap number located on face of cap.
Cap number must correspond with
baffle number to assure 10 PSI cap
pressure.
GTI-425 7.3 10.4 12.8 14.7 16.5
GTI-407-46MP *JGPV-401-46-50
8.5 13.0 16.5 19.8 22.5
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