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
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.
Page 3
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
Page 4
Page 4 SB-2-199-F
PARTS REPLACEMENT
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.
Note: Do not use AV-1 copper gasket with
this spray gun.
GTI-33 Baffle Seal Replacement
(For guns with #2000 cap only.)
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
15-20 ft-lbs.
ANGLED SIDE
SEAL
JGA-4035 Packing Replacement
Instructions
Needle
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 1/2 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.
Packing
(3 pieces)
Packing
Nut
FLUID INLET GASKET (32) REPLACEMENT INSTUCTIONS
1. Remove fluid inlet adapter (34) with
appropriate wrench.
2. Clean Loctite from gun body inlet
threads and seal area.
3. Place gasket (32) squarely onto the
fluid inlet adapter and push it down
until it is flat against the shoulder.
4. Use medium strength thread sealant
(i.e. Devcon 2242 blue, or equal) on
threads before installing fluid inlet
adapter.
5. Torque fluid inlet adapter to 20-25
ft. lbs. and tighten locknut.
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
THICK SIDE
BAFFLE
Pry here
if necessary.
A
C
D
B
E
Page 5
SB-2-199-F Page 5
18
17
16
15
14
13
12
10
11
36 37 38
See Note
below
39
6
7
5
4
3
2
1
Fluid Tip
(Torque to
15-20 ft. lbs.)
9
8
*26 Air Inlet Nipple
1/4" NPS(M)
(torque to 15 ft. lbs.)
32
33
12
19
20
21
22
23
25
24
PARTS LIST
Ind.
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 See Chart 1 Baffle Assembly 1
Suffixes -K5, -K10 designate kits of multiple parts.
Example: JGA-4035-K5 is a kit of 5 packings.
Note: Baffle seal NOT used with GTI-546P gun (46MP air cap).
Page 6
Page 6 SB-2-199-F
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.
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 7
TROUBLESHOOTING (continued)
CONDITION CAUSE CORRECTION
Thin, sandy coarse finish drying
before it flows out
Thick, dimpled finish "orange peel"
Gun too far from surface.
Too much air pressure.
Improper thinner being used.
Gun too close to surface.
Air pressure too low.
Improper thinner being used.
Material not properly mixed.
Surface rough, oily, dirty.
Check distance. Normally approx. 6-8".
Reduce air pressure and check spray
pattern.
Follow paint manufacturer's mixing instrs.
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.
ACCESSORIES
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)
192212 Professional Spray Gun Cleaning Kit
WR-103 Wrench
Contains all necessary
tip, hose and nut sizes
used on or with gun.
Spray Gun Lube
SSL-10 (2 oz. bottle)
JGA-156-K10
Spring Clips
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.
40-128
Twin Cartridge,
Paint Spray
HAV-500 OR
HAV-501
Adjusting Valve
(HAV-501 SHOWN)
Respirator
SB-2-199-F Page 7
HARG-510
Air Regulator
Use to maintain
nearly constant
outlet pressure
despite changes
in inlet pressure
and downstream
flow.
HAF-507
Whirlwind™
In-Line
Air Filter
KK-5060 Air Cap
Cleaning Kit
Contains six precision
tools designed to effectively clean all DeVilbiss,
Binks, Finishline and
other brand spray guns.
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.
Compatible with all paint
materials; contains
no silicone or petroleum distillates to contaminate paint. MSDS
Sheet available upon
request.
NIOSH-Certified
for respiratory
84A-1623)
protection in atmospheres not immediately
dangerous to life.
(TC-
Removes water, oil, and debris from the
air line.
Consists of: 2
brushes, 1 wire
pick. Helps keep
air cap clean and
performing properly.
Page 8
Page 8 SB-2-199-F
WARRANTY
This product is covered by DeVilbiss' 1 Year Limited Warranty.
DeVilbiss Sales and Service: www.devilbiss.com
DeVilbiss Automotive Refinishing
DeVilbiss has authorized distributors throughout the world.
For equipment, parts and service, check the Yellow Pages
under “Automotive Body Shop Equipment and Supplies.”
For technical assistance, see listing below.
U.S.A./ Canada Customer Service Office:
11360 S. Airfield Road, Swanton, OH 43558
Toll-Free Telephone: 1-800-445-3988 (U.S.A. and Canada only)
Toll-Free Fax: 1-800-445-6643