Carlisle GTi Pro Spray Gun Service Manual

SERVICE MANUAL

DEVILBISS GTi Pro

HVLP and High Efficiency

Gravity Spray Gun

II 2 G X

EN

IMPORTANT! DO NOT DESTROY

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

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

READ ALL INSTRUCTIONS BEFORE OPERATING THIS DEVILBISS PRODUCT.

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EN

FUNCTIONAL DESCRIPTION

The GTi PRO spray gun is a professional quality gun designed with EPA compliant, High Efficiency or high volume, low pressure (HVLP) technology. HVLP technology reduces overspray and limits air cap pressure to 0.7 bar [10 psi]. High Efficiency complies with EPA by obtaining transfer efficiency above 65%.

SPECIFICATIONS

AIR INLET PRESSURES

P1 =

Max Static Air Input Pressure

Gun Air Inlet Pressure with gun triggered

HVLP

High Efficiency

12 Bar [175 psi]

1.75 Bar [25 psi]

2.0 Bar [29 psi]

ENVIRONMENTAL

Max Ambient Operating Temperature 40°C Nominal [104°F]

MATERIALS OF CONSTRUCTION

Gun Body, Air Cap Retaining Ring, Knobs

Fluid Tip, Fluid Needle and Trigger Stud

Air Cap Material

Springs, Clips, Screws

Seals and O-Rings

Trigger

Air Inlet, Body Bushing, Spreader Valve Body, Air Valve

Nut

Air Valve Assembly

Anodised Aluminium

Stainless Steel

Electroless Nickel Plated Brass

Stainless Steel

Solvent resistant

Chrome plated steel

Chrome plated brass

Stainless Steel, HDPE

CONNECTIONS

P1 =

Air Inlet Size

P2 =

Fluid Inlet Size

WEIGHT

GUN ONLY

WITH CUP

DIMENSIONS

L x H x W mm

1/4"

3/8"

Universal

BSP

504g

681g

187 x 332 x 108

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EN

Product Description:

This Product is designed for use with:

Suitable for use in hazardous area:

Protection Level:

Vibration Level:

Sound Pressure Level:

Sound Power Level:

Manufacturer:

EU Declaration of Conformity

GTi PRO

Solvent and water based materials

Zone 1 & 2

II 2 G X

<2.5 m/s²

Available on request

Available on request

Finishing Brands UK,

Ringwood Road,

Bournemouth, BH11 9LH. UK

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

Machinery Directive 2006/42/EC

ATEX Directive 94/9/EC

by complying with the following statutory documents and harmonised standards:

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

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

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

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

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

EN 1127-1: Explosive atmospheres - Explosion prevention - Basic concepts

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

HVLP and High Efficiency products comply with the requirements of PG6 from the EPA guidelines and offer greater than 65% transfer efficiency.

D Smith

Director of Sales (EMEA)

21/03/16

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EN

WARNING CAUTION NOTE

Hazards or unsafe practices which could result in severe personal injury, death or substantial property damage.

Hazards or unsafe practices which could result in minor personal injury, product or property damage.

Important installation, operation or maintenance information.

WARNING

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.

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.

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

FIRE AND EXPLOSION HAZARD. Never use 1,1,1-Trichloroethane,

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 compatible with aluminium parts.

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

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

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.

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

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.

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

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

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.

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.

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

KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT

IN CASE OF AN EMERGENCY.

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

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

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EN

Gti PRO GUN PART NUMBER FORMAT & PART SELECTION GUIDE

PROGTI

G TE10 12 13 BK

Gravity

AIR CAP

T

TE

High Efficiency

High Efficiency

HV HVLP

See table 1

COLOUR

BK

BU

Black

Blue

GD Gold

FLUID TIP

Size

See table 2

TABLE 1

GTi Pro AIR CAP PERFORMANCE GUIDE

Air Cap & Type Part Number

Recommended Air Inlet

Pressure

HV30

T110

HVLP

High Efficiency

PRO-102-HV30-K

PRO-102-T110-K

TE10

High Efficiency PRO-102-TE10-K

TE20

**

High Efficiency PRO-102-TE20-K

Fan pattern size @ 200mm distance.

1.75 Bar [25 psi]

2.0 Bar [29 psi]

2.0 Bar [29 psi]

2.0 Bar [29 psi]

Air Consumption

465 L/min

270 L/min

275 L/min

350 L/min

Typical Fan Pattern Size**

280-310

260-290

265-290

265-285

TABLE 2

GTi Pro FLUID TIPS & NEEDLES

Fluid Tip Size

1.2

1.3

1.4

Fluid Tip

PRO-200-12-K

PRO-200-13-K

PRO-200-14-K

Needle

PRO-300-K

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EXPLODED VIEW

EN

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PARTS LIST

REF.

3

4

1

2

5

6

7

15

*16

*17

18

19

*20

21

*22

23

*24

30

31

32

33

25

26

27

28

*29

8

9

*10

11

*12

13

14

PART No.

DESCRIPTION

-

-

-

PRO-420-K

-

JGA-156-K5

SEE TABLE

RETAINING RING

SLIP RING

RETAINING RING SEAL

RETAINING RING SUB ASSEMBLY

AIR CAP

SPRING CLIP (KIT OF 5)

AIR CAP & RETAINING RING

SEE TABLE

-

SN-18-1-K2

SN-69-K

-

SN-6-K

-

SEE TABLE

PRO-5-K

-

-

-

-

-

-

-

-

PRO-406-K

-

-

-

SN-404-K

-

-

-

-

FLUID TIP

SPRAYHEAD

GASKET (KIT OF 2)

SPRAY HEAD KIT

BODY BUSHING SEAL

BODY BUSHING

BODY BUSHING & SEAL

FLUID NEEDLE

NEEDLE SPRING

SPRING PAD

FLUID ADJUSTING KNOB

FLUID ADJUSTING KNOB,SPRING & PAD KIT

CIRCLIP

VALVE BODY

O RING

SPREADER VALVE ADJUSTING KNOB

SPREADER VALVE PIN

SPREADER VALVE ASSEMBLY

NEEDLE PACKING

PACKING SPRING

PACKING NUT

PACKING, SPRING & PACKING NUT KIT

AIR VALVE BODY

AIR VALVE CAGE

AIR VALVE POPPET

AIR VALVE SPRING

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QTY.

1

1

1

1

1

1

1

1

1

2

1

2

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

EN

34

35

36

*37

38

*39

40

41

42

43

44

45

46

47

51

52

53

54

48

49

50

55

56

57

58

PARTS LIST (Continued)

REF.

PART No.

DESCRIPTION

SN-34-K5

SN-402-K

-

-

-

-

SN-21-K

SN-405-K5

SN-9-K

SN-26-K4

PRO-407-K

25746-007-K5

-

-

SN-41-K

-

-

GFC-501

GFC-2-K5

GFC-402

-

KGP-5-K5

-

SPN-8-K2

SN-406

AIR VALVE SPRING PAD

AIR VALVE SEAL

AIR VALVE ASSEMBLY

TRIGGER SCREW

TRIGGER

TRIGGER STUD

TRIGGER STUD & SCREW KIT

STUD AND SCREW KIT (KIT OF 5)

AIR INLET

COLOUR ID RING KIT (4 COLOURS)

AIRFLOW VALVE

CIRCLIP (KIT OF 5)

VALVE HEAD

WASHER

VALVE BODY

VALVE ADJUSTING KNOB

BAFFLE PLATE

GRAVITY CUP KIT

DRIP CHECK LID (KIT OF 5)

GRAVITY CUP LID

GRAVITY CUP

FILTER (KIT OF 5)

AIR VALVE SERVICE TOOL

TORX DRIVER (KIT OF 2)

TOOL KIT

SERVICE PARTS

PRO-415-1 SPRAY GUN REPAIR KIT (INCLUDES ITEMS MARKED *)

GTI-428-K5 SEAL AND PIN KIT, KIT OF 5 (ITEMS 20, 22 & 24)

WARNING

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.

QTY.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

EN

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CAUTION

IMPORTANT: This spraygun is suitable for use with both waterbased and solvent based coating materials.

•

The gun is not designed for use with highly corrosive and/or abrasive materials.

EN

•

To avoid premature degradation of parts, DeVilbiss recommends the gun is washed in neutral cleaning solution (pH 6 to 8).

•

The gun is not designed to be cleaned within an ultrasonic bath.

If there is any doubt regarding the suitability of a specific material, contact your DeVilbiss Distributor or DeVilbiss direct.

START-UP SEQUENCE

1

2

Connect the gun to a clean, moisture and oil free air supply using a conductive hose of at least

8mm I.D.

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

3 Turn fluid adjusting knob (18) clockwise to prevent fluid needle movement.

4 Turn spreader valve adjusting knob (23) counter clockwise to fully open.

5 Adjust inlet air pressure if required.

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

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

8 If finish is too wet, reduce fluid flow by turning fluid adjusting knob (18) clockwise. If atomisation is too coarse, increase air inlet pressure. If too fine, reduce inlet pressure.

9 The pattern size can be reduced by turning spreader valve knob (23) clockwise.

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

11 The recommended spray distance is 150-200mm.

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

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

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EN

NOTE

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.

NOTE

If quick connect couplings are required, use only high flow quick connects. Other types will not flow enough air for correct gun operation.

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.

SPRAY GUN DISASSEMBLY / ASSEMBLY

#

#

KEY

Order for disassembly

- see over page

(reverse for assembly)

Item Number

- see over page

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DISASSEMBLY TIP & NEEDLE

EN

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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DISASSEMBLY AIR VALVE

EN

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

SPREADER VALVE REPLACEMENT

EN

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DISASSEMBLY PACKING

EN

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TROUBLESHOOTING MECHANICAL PERFORMANCE

GENERAL FAULTS CAUSE CORRECTION

No air pressure at gun.

Check air supply and air line.

Will not spray.

EN

Fluid needle adjustment knob not open enough.

Open fluid needle adjustment knob.

Incorrect needle fitted to gun.

Gun spits paint when triggering on and off.

Excessive needle wear.

Excessive fluid tip wear.

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

Replace with new needle.

Replace with new fluid tip.

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

Fluid tip not fitted correctly in gun head.

Fluid tip/needle leakage.

Tighten.

Check for damage or blockage.

Fluid tip not fitted correctly in gun head.

Tighten.

Paint build-up on fluid tip.

Fluid tip/needle leakage.

Check for damage or blockage.

Damaged air cap holes.

Replace with new air cap.

Paint build-up on air cap.

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

Thoroughly clean.

Unable to get round spray

Fluid tip or sprayhead incorrectly fitted.

Remove, check components for damage and refit correctly.

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EN

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 FAULTS CAUSE

Fluid tip internal seat scored damaged or worn.

Fluid needle external profile damaged or worn.

Replace.

Replace.

CORRECTION

Contamination on needle or tip mating surfaces preventing good seal.

Thoroughy clean.

Slow fluid leak from fluid tip and needle seat.

Incorrect fluid tip for fluid needle fitted to gun.

Check tip/needle selection chart and fit correct item.

Sluggish needle.

Lubricate packing. (GL-1)

Tight packing nut.

Adjust.

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

Contamination on needle or tip mating surfaces preventing good seal.

Remove tip and needle and thoroughly clean.

Incorrect fluid tip for fluid needle fitted to gun.

Check tip/needle selection chart and fit correct item.

Slow fluid leak from needle packing.

Fluid needle packing worn or loose.

Tighten or replace as necesarry.

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EN

AIR FAULTS CAUSE CORRECTION

Air Valve Stem contaminated and not correctly seating.

Remove Air Valve Stem and thoroughly clean valve shaft and seating surfaces.

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

Air Valve Stem seal damaged or missing.

Replace.

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TROUBLESHOOTING SPRAY PERFORMANCE

CONDITION CAUSE

Heavy top or bottom pattern.

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

CORRECTION

Soak cap or tip in suitable solvent and thoroughly clean.

EN

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

Replace fluid tip or air cap if necesarry.

Fluid tip or cap dirty or damaged.

Replace fluid tip or air cap if necesarry.

Heavy right or left side pattern.

Left or right side horn holes plugged.

Soak cap or tip in suitable solvent and thoroughly clean.

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.

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.

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Heavy centre pattern.

EN

Pattern adjustment valve set too low.

Turn out counter clockwise to achieve correct pattern.

Too much material.

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

Intermittent or 'fluttering' spray fan.

Material too thick.

Thin to correct consistency.

Atomising air pressure too low.

Increase air pressure.

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.

Partially obstructed fluid passage or hose.

Clean or replace.

Split spray 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.

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Too high horn pressure.

Reduce air pressure by rotating pattern control valve clockwise.

Too much air for fluid quanitity used.

Reduce input air pressure.

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Ball end heavy pattern.

EN

Too much fluid flow.

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

Excessive bounce-back.

Runs and sags.

Too much atomisation air pressure.

Reduce air pressure.

Gun too far from surface.

Too much fluid flow.

Material too thin.

Gun tilted at an angle.

Gun too far from surface.

Check distance (normally 150-

200mm).

Adjust gun or reduce fluid pressure.

Mix properly or apply light coats/reduce fluid flow.

Mount gun at right angle to work.

Check distance.

Reduce air pressure and check spray pattern.

Thin, sandy coarse finish drying before it flows out.

Too much air pressure.

Fluid flow too low.

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

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DIMENSIONS

EN

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NOTES

EN

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NOTES

EN

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EN

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.

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

DeVilbiss®, Ransburg®, MS®, BGK®, and Binks® are registered trademarks of Carlisle Fluid

Technologies, Inc.,dba Finishing Brands.

© 2016 Carlisle Fluid Technologies,Inc., dba 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.

USA/Canada www.devilbiss.com

[email protected]

Toll Free Tel: 1-800-992-4657

Toll Free Fax: 1-888-246-5732

United Kingdom www.carlisleft.eu

[email protected]

Tel: +44 (0)1202 571 111

Fax: +44 (0)1202 573 488

China www.carlisleft.com.cn

[email protected]

Tel: +8621-3373 0108

Fax: +8621-3373 0308

Mexico www.carlisleft.com.mx

[email protected]

Tel: 011 52 55 5321 2300

Fax: 011 52 55 5310 4790

France www.carlisleft.eu

[email protected]

Tel: +33(0)475 75 27 00

Fax: +33(0)475 75 27 59

Japan www.ransburg.co.jp

[email protected]

Tel: 081 45 785 6421

Fax: 081 45 785 6517

Brazil www.devilbiss.com.br

[email protected]

Tel: +55 11 5641 2776

Fax: +55 11 5641 1256

Germany www.carlisleft.eu

[email protected]

Tel: +49 (0) 6074 403 1

Fax: +49 (0) 6074 403 281

Australia www.carlisleft.com.au

[email protected]

Tel: +61 (0) 2 8525 7555

Fax: +61 (0) 2 8525 7575

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