DeVilbiss GTI-520P, GTI-546P Service Bulletin

Page 1
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
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.
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
(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
 •7 GTI-33-K5 Bafe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 See Chart 2 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
21 --- Air Valve Body 1
*34
35
Fluid Inlet Nipple
3/8" NPS(M)
(torque to 20-25 ft.
lbs.)
28
29
27
31
30
*Use medium strength thread sealant (i.e. Dev­con #2242 Blue, or equal) on threads.
Ind. Ref. Replacement Parts No. Part No. Description Req.
 •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.
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
4/12 © 2012 DeVilbiss Automotive Refinishing All rights reserved. Printed in U.S.A.
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