DeVilbiss Pro Lite E Service Manual

EN

IMPORTANT! DO NOT DESTROY

SERVICE MANUAL

READ ALL INSTRUCTIONS BEFORE OPERATING THIS DEVILBISS PRODUCT.

II 2 G X

Contact your local Devilbiss representative for additional copies of this manual.

It is the Customer's responsibility to have all operators and service personnel read and understand this

manual.

DEVILBISS Pro Lite™

Series:

Pro Lite™ E

Conventional, Air Atomisation Manual Spray Gun.

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EN

P1 =
P2 =

P1 = 1/4"
P2 = 3/8"

FLUID AND AIR INLET PRESSURES

ENVIRONMENTAL

Stainless Steel

Nitride Coated Stainless Steel

Tungsten Carbide

Air Inlet Size

Fluid Inlet Size

Universal

Universal

12 Bar [175 psi]

15 Bar [217 psi]

Max Air Input Pressure

Max Fluid Input Pressure

Fluid Tip and Needle Construction

Quickclean™ Coated Aluminium

HDPE, Viton Extreme

Seals and O-Rings

CONNECTIONS

DIMENSIONS

174 x 175 x 18

40°C Nominal [104°F]

Max Ambient Operating Temperature

Fluid Passageways

Electroless Nickel Plated Brass

Gun Body Material

Air Cap Material

MATERIALS OF CONSTRUCTION

WEIGHT

L x H x W mm

Gun Weight

500g

FUNCTIONAL DESCRIPTION

The DeVilbiss Pro Lite™ E Conventional hand gun is primarily designed for the application of Ceramic

and Enamel coatings in a high production environment. If used with such materials it must be
expected that the need for cleaning and or replacement of parts will be increased. Its particular
materials of construction make it suitable for materials supplied from pumped or pressure fed fluid
supply systems.
Available with a range of stainless steel, nitride hardened and tungsten carbide fluid tips and needles,

the gun features stainless steel fluid passageways and a QuickClean™ coated body, to give enhanced

corrosion protection in these arduous conditions.

Based on the Pro Lite™ drop forged aluminium gun body, the gun utilises an ‘in-line’ concentric air

valve which allows weight reduction and reduced fatigue to the operator.
The gun is designed as a flexible solution for the modern coating applicator.

SPECIFICATIONS

Stainless Steel

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EN

by complying with the following statutory documents and harmonised standards:

EN 12096:1997 Mechanical vibration - Declaration and verification of vibration emission values

Pro Lite™ E

EN ISO 11201:1995 Acoustics - Noise by machinery and equipment - Determination of emission sound pressure levels at a work station and
at other specified positions in an essentially free field over a reflecting plane with negligible environmental corrections

EN ISO 20643:2008 Mechanical vibration - Hand held and hand guided machinery - Principles for evaluation of vibration emission

EN ISO 28662-1 Hand-held portable power tools - Measurement of vibrations at the handle
BS EN 1953:2013 Atomising and spraying equipment for coating materials - Safety requirements

EN ISO 12100-1:2010 Safety of Machinery - Basic concepts, general principles for design - Basic terminology, methodology

Solvent and water based materials

EN ISO 12100-2:2010 Safety of Machinery - Basic concepts, general principles for design - Technical principles

08/09/14

D Smith

(General Manager)

Available on request

Sound Power Level:

Available on request

Manufacturer:

EN 13463-1: Non electrical equipment for use in potentially explosive atmospheres - Basic methods and requirements

EN 14462:2005+A1:2009 Surface treatment equipment - Noise test code for surface treatment equipment including its ancillary handling
equipiment - Accuracy grades 2 and 3

EU Declaration of Conformity

We: Finishing Brands UK, declare that the above product conforms with the Provisions of:

Machinery Directive 2006/42/EC

ATEX Directive 94/9/EC

Finishing Brands UK,
Ringwood Road,
Bournemouth, BH11 9LH. UK

Protection Level:

II 2 G X

N/A

Sound Pressure Level:

Suitable for use in hazardous area:

Zone 1 & 2

Vibration Level:

Product Description:

This Product is designed for use with:

EN1127-1: Explosive atmospheres - Explosion prevention - Basic concepts

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EN

GLOVES. Must be worn when spraying or cleaning the
equipment.

NEVER MODIFY THE EQUIPMENT. Do not modify the
equipment unless the manufacturer provides written
approval.

HIGH PRESSURE CONSIDERATION. High pressure can cause
serious injury. Relieve all pressure before servicing. Spray from
the gun, hose leaks or ruptured components can inject fluid into
your body and cause extremely serious injury.

OPERATOR TRAINING. All personnel must be trained
before operating finishing equipment.

LOCK OUT / TAG-OUT
Failure to de-energise, disconnect, lock out and
tag-out all power sources before performing
equipment maintenance could cause serious
injury or death.

WEAR SAFETY GLASSES. Failure to wear safety
glasses with side shields could result in serious eye
injury or blindness.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT.

NOISE LEVELS. The A-weighted sound level of pumping and
spray equipment may exceed 85 dB(A) depending on equipment
settings. Actual noise levels are available on request. It is
recommended that ear protection is worn at all times while
equipment is in use.

CAUTION

In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasise important safety information as
follows:

NOTE

Read the following warnings before using this equipment.

SOLVENTS AND COATING MATERIALS. Can be highly flammable
or combustible when sprayed. Always refer to the coating
material supplier's instructions and safety sheets before using
this equipment.

Hazards or unsafe practices which could result in

minor personal injury, product or property

damage.

EQUIPMENT MISUSE HAZARD. Equipment misuse can
cause the equipment to rupture, malfunction or start
unexpectedly and result in serious injury.

Important installation, operation or maintenance

information.

INSPECT THE EQUIPMENT DAILY. Inspect the
equipment for worn or broken parts on a daily basis.
Do not operate the equipment if you are uncertain
about its condition.

READ THE MANUAL. Before operating finishing equipment, read
and understand all safety, operation and maintenance
information provided in the operation manual. Users must
comply with all local and national codes of practice and
insurance company requirements governing ventilation, fire
precautions, operation and house-keeping of working areas.

FIRE AND EXPLOSION HAZARD. Never use 1,1,1­Trichloroethane, Methylene Chloride, other Halogenated
Hydrocarbon solvents or fluids containing such solvents in
equipment with aluminium wetted parts. Such use could result in
a serious chemical reaction, with the posibility of explosion.
Consult your fluid suppliers to ensure that the fluids being used
are compatibile with aluminium parts.

STATIC CHARGE. Fluid may develop a static charge that must be
dissipated through proper grounding of the equipment, objects
to be sprayed and all other electrically conductive objects in the
dispensing area. Improper grounding or sparks can cause a
hazardous condition and result in fire, explosion or elecrtic shock
and other serious injury.

TOXIC VAPOURS. When sprayed, certain materials may be
poisonous, create irritation, or are otherwise harmful to health.
Always read all labels, safety sheets and follow any
recommendations for the material before spraying. If in doubt
contact your material supplier.

PRESSURE RELIEF PROCEDURE. Always follow the
pressure relief procedure in the equipment instruction
manual.

Hazards or unsafe practices which could result in

severe personal injury, death or substantial

property damage.

PROJECTILE HAZARD. You may be injured by venting
liquids or gases that are released under pressure, or
flying debris.

WEAR RESPIRATOR. The use of respiratory
protective equipment is recommended at all times.
The type of equipment must be compatible with the
material being sprayed.

WARNING

WARNING

KNOW WHERE AND HOW TO SHUT OFF THE
EQUIPMENT IN CASE OF AN EMERGENCY.

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EN

- EC62 - 28C

C

C62

C64

C67

*

**

- - - - - - - - - - SNC

- - - - - - - - - SNC -

- - - - - SN SNC - - -

S =
N =
C =

PRO-250-18-K

PRO-250N-18-K

PRO-250C-18-K

PRO-350C-18-22-K

2.2

PRO-250-22-K

PRO-250N-22-K

PRO-250C-22-K

PRO-350-18-22-K

PRO-250N-14-K

C67

Conventional

For ceramic tip & needle part numbers, see table 3.

490mm

< 2.0 L/min

500mm

PRO-350N-18-22-K

--1.8

1.2mm

1.4mm

1.6mm

1.8mm

High quality stainless steel tips & needles available in this type & size.

Nitride hardened tips & needles also available in this type & size.

Tungsten carbide tips & needles also available in this type & size.

TABLE 3 - CERAMIC FLUID TIPS & NEEDLES

Fluid Tip Size

Stainless Steel

Nitride Hardened

Tungsten Carbide

Fluid Tip

Needle

Stainless Steel

Fluid Tip

Stainless Steel

Fluid Tip

C64

Conventional

2.2mm

2.8mm

< 2.5 L/min

430mm

C62

Conventional

AIR CAP

3 Bar [45 psi]

Conventional

Flow rates may vary according to paint/material and pressure used.

Fan pattern size @ 300mm distance.

TABLE 2 - Pro Lite™ E RECOMMENDED FLUID TIP / AIR CAP COMBINATIONS

0.5mm

0.7mm

0.85mm

1.0mm

PRO-350C-28-K

Air Cap

Atomisation Type

2.0mm

1.4

PRO-250-14-K

See table 1

TABLE 1 - Pro Lite™ E AIR CAP PERFORMANCE GUIDE

Air Cap & Type

Part Number

Air Consumption

Recommended

Air Inlet Pressure

See table 2

430 [15.2 cfm]

3 Bar [45 psi]

< 3.5 L/min

Conventional

PROC-120-C64-K

400 [14.1 cfm]

3 Bar [45 psi]

425 [15.0 cfm]

PROLT

Size & construction

PROC-120-C67-K

Conventional

FLUID TIP

Typical Fluid

Flow*

Typical Fan

Pattern Size**

Conventional

PROC-120-C62-K

GUN PART NUMBER FORMAT & PART SELECTION GUIDE

Pro Lite™ E

2.8

PRO-250-28-K

PRO-350-28-K

PRO-250N-28-K

PRO-350N-28-K

PRO-250C-28-K

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EN

EXPLODED VIEW

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EN

78*37

*38

SEE TABLE

SN-18-1-K2

*10--

SN-69-US-K

1

QTY.

--1

TRIGGER SCREW

PACKING NUT

-30-

AIRFLOW VALVE

421-31353641

PRO-407-BL-K

1

SN-421-K

-

SP-617-CR-K

PARTS LIST

SEE TABLE

-

-

SN-66-K

SN-67-BL-K

PRO-472-K3

-

-

SN-26-K4

1

TRIGGER

TRIGGER STUD

TRIGGER STUD & SCREW KIT

24

*40113911132

33

FLUID NEEDLE

18--

PRO-408-BL-K

---21222313

*141920

AIR VALVE KIT

25262728*29-1

1

AIR INLET

HOUSING

COLOUR ID RING KIT (4 COLOURS)

REAR VALVE SEAL

111-3412

3

SEE TABLE

-

SPRING CLIP (KIT OF 5)

PRO-405-K1491

2

SPRAY HEAD

GASKET (KIT OF 2)

SPRAY HEAD KIT

1

-

AIR CAP

AIR CAP & RETAINING RING

RETAINING RING SUB ASSEMBLY

SPINDLE

VALVE SEAT

51111111-

REF.

DESCRIPTION

FLUID TIP16

RETAINING RING

SLIP RING

RETAINING RING SEAL

-

JGA-156-K5

PART No.

CIRCLIP1*12-1

*15116

17

VALVE BODY

O RING

SPREADER VALVE PIN

SPREADER VALVE ADJUSTMENT KNOB

SPREADER VALVE ASSEMBLY

122

FRONT VALVE SEAL

-

PRO-471

AIR VALVE SPRING

1111111

1

GUN BODY

1

AIR INLET KIT

SPRING PAD

FLUID ADJUSTING KNOB

NEEDLE SPRING KIT

NEEDLE SPRING

NEEDLE PACKING

PACKING SPRING

1

SN-9-K

1

PACKING, SEAL AND PACKING NUT KIT

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EN

+

-

1

REF.

PART No.

DESCRIPTION

QTY.

-

-

11111

SERVICE PARTS

-

-

SN-419-K

SN-406

VALVE ADJUSTING KNOB

SEAL

LOCK NUT

FLUID INLET

52

+ 53

The spray gun must be earthed to dissipate any electrostatic charges which may be created by fluid or

air flows. This can be achieved through the spray gun mounting, or conductive air/fluid hoses.

Electrical bond from the spray gun to earth should be checked and a resistance of less than 10⁶ Ohms

is required.

WARNING

47--

CIRCLIP (KIT OF 5)

VALVE HEAD

WASHER1111

25746-007-K5

-

PARTS LIST CONTINUED

43444546484950

51

VALVE BODY

AIR VALVE SERVICE TOOL

1

FLUID INLET KIT

TOOL KIT

NOT INCLUDED IN THE GUN KIT, ONLY WITH REF 23

PRO-470

GTI-428-K5

SPRAY GUN REPAIR KIT (INCLUDES ITEMS MARKED *)

SEAL AND PIN KIT, KIT OF 5 (ITEMS 12, 14 & 15)

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EN

2. Connect the fluid supply hose to fluid inlet connector.

3. Mix coating material to Manufacturer's instructions and strain material.

10. The pattern size can be reduced by turning spreader valve knob (16) clockwise.

11. Hold gun perpendicular to surface being sprayed. Arcing or tilting may result in uneven coating.

12. The recommended spray distance is 150-200mm.

If quick connect couplings are required, use only high flow quick connects. Other types will not flow

enough air for correct gun operation.

Depending on hose length, larger I.D. hose may be required. Install an air gauge at the gun handle.

When gun is triggered on, adjust regulated pressure as required. Do not use more pressure than is

necesarry to atomise the material being applied. Excess pressure will create additional overspray and

reduce transfer efficiency.

14. Always turn off air supply and relieve pressure when gun is not in use.

13. Spray edges first. Overlap each stroke a minimum of 75%. Move gun at a constant speed.

9. If finish is too wet, reduce fluid flow by turning fluid adjusting knob (28) clockwise. If atomisation is
too coarse, increase air inlet pressure. If too fine, reduce inlet pressure.

START-UP SEQUENCE

1. Connect the gun to a clean, moisture and oil free air supply using a conductive hose of at least
8mm I.D.

NOTE

NOTE

4. Turn fluid adjusting knob (28) clockwise to prevent fluid needle movement.

5. Turn spreader valve adjusting knob (16) counter clockwise to fully open.

6. Adjust inlet air pressure if required.

7. Turn fluid adjusting knob counter clockwise until first thread shows.

8. Test spray. If the finish is too dry, reduce airflow by reducing air inlet pressure.

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EN

(reverse for assembly)

Order for disassembly

- see over page

Item Number

- see over page

KEY

SPRAY GUN DISASSEMBLY / ASSEMBLY

SPRAY GUN MAINTENANCE & CLEANING

To clean air cap and fluid tip, brush exterior with a stiff bristle brush. If necesarry to clean cap holes,
use a broom straw or toothpick if possible. If a wire or hard instrument is used, extreme care must be
taken to prevent scratching or burring of the holes which will cause a distorted spray pattern.

To clean fluid passages, remove excess material, then flush with gun wash solution. Wipe the gun
exterior with a dampened cloth. Never completely immerse in any solvent or cleaning solutions as this
is detrimental to the lubricants and life of the spray gun.

#

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EN

DISASSEMBLY TIP & NEEDLE

NOTE

When replacing the fluid tip or fluid needle, replace tip, needle and fluid packing at the same time.

Using worn parts can cause fluid leakage. Do not overtighten.

CAUTION

To prevent damage to fluid tip or fluid needle, be sure to either:

1. Pull the trigger and hold while tightening or loosening the fluid tip, or,

2. Remove the fluid adjusting knob to relieve spring pressure against needle collar.

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EN

DISASSEMBLY AIR VALVE

T20

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EN

ASSEMBLY AIR VALVE SEALS



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EN

DISASSEMBLY FLUID INLET

DISASSEMBLY PACKING

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EN

Fluid tip or sprayhead incorrectly
fitted.

Remove, check components for
damage and refit correctly.

When removing air cap from retaining ring, do not remove the ring seat from the retaining ring.
Damage to the parts may occur. Simply wipe parts clean and reassemble with new or clean air cap.

Fluid tip not fitted correctly in
gun head.

Tighten.

Check for damage or blockage.

Paint build-up on fluid tip.

Fluid tip not fitted correctly in
gun head.

Tighten.

Fluid tip/needle leakage.

Check for damage or blockage.

Paint build-up on air cap.

Damaged air cap holes.

Replace with new air cap.

Gradual build-up of bounce-back
on gun head.

Thoroughly clean.

Gun spits paint when triggering
on due to paint build-up inside air
cap between spraying operations.

TROUBLESHOOTING MECHANICAL PERFORMANCE

Unable to get round spray

Fluid tip/needle leakage.

GENERAL FAULTS

CAUSE

CORRECTION

Will not spray.

No air pressure at gun.

Check air supply and air line.

Fluid needle adjustment knob not
open enough.

Open fluid needle adjustment
knob.

Gun spits paint when triggering
on and off.

Incorrect needle fitted to gun.

Check fluid tip/needle selection
chart and fit correct item.

Excessive needle wear.

Replace with new needle.

Excessive fluid tip wear.

Replace with new fluid tip.

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EN

Fluid needle external profile
damaged or worn.

CAUSE

CORRECTION

CORRECTION

Slow fluid leak from fluid tip and
needle seat.

AIR FAULTS

Incorrect fluid tip for fluid needle
fitted to gun.

Check tiip/needle selection chart
and fit correct item.

CAUSE

Tight packing nut.

Adjust.

Major fluid leak or fluid jetting
from fluid tip and needle seat.

Thoroughy clean.

Remove tip and needle and
thoroughly clean.

Replace.

Contamination on needle or tip
mating surfaces preventing good
seal.

Spindle contaminated and not
correctly seating.

Fluid tip internal seat scored
damaged or worn.

FLUID FAULTS

Tighten or replace as necesarry.

Fluid needle packing worn or
loose.

Slow fluid leak from needle
packing.

Replace.

Sluggish needle.

Small air leak from air cap when
gun is not triggered.

Remove spindle and thoroughly
clean valve shaft and seating
surfaces.

Spindle seal damaged or missing.
Incorrect fluid tip for fluid needle

fitted to gun.

Check tiip/needle selection chart
and fit correct item.

Lubricate packing. (GL1)

Replace.

Contamination on needle or tip
mating surfaces preventing good
seal.

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EN

TROUBLESHOOTING SPRAY PERFORMANCE

Soak cap or tip in suitable solvent
and thoroughly clean.

CORRECTION

Replace fluid tip or air cap if
necesarry.

Heavy top or bottom
pattern.

CAUSE

Heavy right or left
side pattern.

Left or right side horn holes
plugged.

Replace fluid tip or air cap if
necesarry.

Fluid tip or cap dirty or damaged.

Dirt or damage on left or right
side of fluid tip exterior.

Replace fluid tip or air cap if
necesarry.

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

Material build-up on air cap,
plugged horn holes, centre holes
or jets.

Soak cap or tip in suitable solvent
and thoroughly clean.

Material build-up on fluid tip
exterior or partially plugged fluid
tip.

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. Also check for dried paint just inside the cap
centre hole opening, remove by washing with solvent.

If the defect is not inverted, it is on the fluid tip. Clean tip. If problem persists, renew tip.

CONDITION

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EN

Too much air for fluid quanitity
used.

Reduce input air pressure.
Atomising air pressure too low.

Increase air pressure.

Reduce air pressure by rotating
pattern control valve clockwise.

Turn out counter clockwise to
achieve correct pattern.

Not enough material flow.

Increase fluid flow by changing
fluid tip size, opening needle
control knob or increase fluid
pressure on pressure feed
container.

Too high horn pressure.

Thin to correct consistency.

Partially obstructed fluid passage
or hose.

Clean or replace.

Split spray pattern

Loose fluid tip.

Tighten.

Fluid tip not seated correctly in
gun head.

Remove fluid tip, clean
components, check cone seating
on tip and gun for damage or
contamination.

Too much material.

Heavy centre pattern.

Pattern adjustment valve set too
low.

Intermittent or 'fluttering'
spray fan.

Reduce fluid flow by turning fluid
needle adjusting screw clockwise.
Reduce fluid pressure.

Material too thick.

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EN

Reduce air pressure and check
spray pattern.

Too much fluid flow.

Reduce air pressure.

Thin, sandy coarse finish drying
before it flows out.

Increase fluid flow by changing
fluid tip size, supply pressure or
turning needle control knob
counter clockwise.

Ball end heavy
pattern.

Too much air pressure.
Gun too far from surface.

Check distance.

Fluid flow too low.

Material too thin.

Too much atomisation air
pressure.

Gun too far from surface.

Check distance (normally 150­200mm).

Excessive bounce-back.

Too much fluid flow.

Gun tilted at an angle.

Mount gun at right angle to work.

Adjust gun or reduce fluid
pressure.

Change fluid tip for smaller size
or change air cap for different
specification air cap.

Mix properly or apply light
coats/reduce fluid flow.

Runs and sags.

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EN

H-6065-B [BSP]

H-6065-B [NPS]

MPV-463

MPV-60-K3

GL-1-K10

Gun Lube Sachets (KIT OF 10)

10m x 8mm bore rubber air hose with 1/4" fittings.

QD Fittings (KIT OF 4)

MPV Swivels (KIT OF 3)

DGI PRO Digital Pressure Gauge.

Spanner.

Torx driver.

Cleaning Brush.

Cleaning Brush (KIT OF 3)

Torx Driver (KIT OF 2)

4900-5-1-K3

SPN-8-K2

ACCESSORIES

DESCRIPTION

PART No.

DGIPRO-502-BAR

SN-406

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EN

DIMENSIONS

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NOTES

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EN

NOTES

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EN

Finishing Brands reserves the right to modify equipment specifications without prior notice.

DeVilbiss, Ransburg, BGK, and Binks are registered trademarks of Finishing Brands.

www.finishingbrands.com.au
[e-mail]
Tel: [phone]
Fax: [phone]

www.binks.com
[e-mail]
Toll Free Tel: [phone]
Toll Free Fax: [phone]

USA/Canada

United Kingdom

www.finishingbrands.eu
[e-mail]
Tel: [phone]
Fax: [phone]

China

www.finishingbrands.com.cn
[e-mail]
Tel: [phone]
Fax: [phone]

Mexico

Australia

www.finishingbrands.com.mx
[e-mail]
Tel: [phone]
Fax: [phone]

France

www.finishingbrands.eu
[e-mail]
Tel: [phone]
Fax: [phone]

Japan

Brazil

www.devilbiss.com.br
[e-mail]
Tel: [phone]
Fax: [phone]

Germany

www.finishingbrands.eu
[e-mail]
Tel: [phone]
Fax: [phone]

© 2014 Finishing Brands

All rights reserved.

Devilbiss is part of Finishing Brands, a global leader in innovative spray finishing
technologies. For technical assistance or to locate an authorised distributor, contact one
of our international sales and customer support locations below.

www.ransburg.co.jp
[e-mail]
Tel: [phone]
Fax: [phone]

WARRANTY POLICY

Devilbiss products are covered by Finishing Brands one year materials and workmanship
limited warranty. The use of any parts or accessories, from a source other than Finishing
Brands, will void all warranties. For specific warranty information please contact the closest
Finishing Brands location listed below.

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