SERVICE MANUAL

EXL-620G

HIGH VOLUME LOW PRESSURE

GRAVITY FEED SPRAY GUNS

EN

IMPORTANT: Before using this equipment, read all safety precautions and instructions.

Keep for future use.

DESCRIPTION

INSTALLATION

For maximum transfer efficiency, do not use more pressure than is necessary to atomize the material being applied.

OPERATION

Mix, prepare and strain the material to be sprayed according to the paint maufacturer's instructions.

The compliant high volume low pressure gravity feed EXL guns are designed to apply a wide variety of finishing materials.

These guns were manufactured to provide a maximum transfer efficiency by limiting air cap pressure to 10 psi (complies with rules issued by SCAQMD and other air quality authorities).

These guns will produce approximately

10 psi air cap pressure at 30 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 EXL-620G (#2000 cap) is 15.5 SCFM at

10 psi air cap presssure.

1. Connect the gun to a clean, moisture 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.

This gun should not be used with chlorinated solvent materials.

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 equipment explosion.

See page 2 for potential hazards.

NOTE

If quick connects are required, use only high flow quick connects approved for HVLP use such as

DeVilbiss HC-4419 and HC-4699.

Other types will not flow enough air for proper gun operation.

NOTE

Important: This gun may be used with most common coating and finishing materials. It is 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.

Strain material through a 60 or 90 mesh screen.

1. If used, install paint liner into cup. (See instructions included with cup.)

2. Fill the gravity feed cup with the material. Do not overfill. Make sure that the cup lid vent hole is clear.

3. Open the spreader adjustment valve

(10) (Fan) by turning the valve stem counterclockwise.

4. Close the fluid needle adjusting screw

(17) by turning clockwise.

5. Turn on air supply and set gun inlet pressure to lowest recommended pressure for material being sprayed. Best atomization will occur with 10 psig air cap pressure. However, some materials can be sprayed at lower pressures, improving transfer efficiency.

6. Spray a test area by turning fluid n e e d l e a d j u s t i n g s c r e w ( 1 7 ) counterclockwise until a full coat is obtained.

If the finish is too sandy and dry, the material flow may be too low for the atomization air pressure being used.

If the finish sags, there is too much material flowing for the atomization air pressure being used.

If an air adjusting valve is used at the gun inlet, use DeVilbiss Model HAV-

500 or HAV-501. Some competitive adjusting valves have significant pressure drop that can adversely affect spray performance. Models

H AV- 5 0 0 a n d H AV- 5 0 1 h a v e minimal pressure drop, which is important for HVLP spraying.

Both of the above can be corrected by increasing or decreasing the atomization air pressure or the material flow. Pattern width can be altered by turning spreader adjustment valve (10), either clockwise to decrease the width or counterclockwise to increase the width.

2. Attach the gravity feed cup to the material inlet.

PREVENTIVE MAINTENANCE

NOTE

See Spray Gun Guide, SB-2-001 latest revision, for details concerning setup of spray guns.

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.

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 cause a distorted spray pattern.

SB-2-202-H (11/2014) 1 / 8

EN

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 safety information - A hazard that may cause serious injury or loss of life.

Important information that tells how to prevent damage to equipment, or how to avoid a situation that may cause minor injury.

Information that you should pay special attention to.

CA PROP 65

The following hazards may occur during the normal use of this equipment.

Please read the following chart before using this equipment.

SAFEGUARDS HAZARD CAUSE

Fire Solvent and coatings can be highly flammable or combustible especially when sprayed.

Solvent Spray

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.

During use and while cleaning and flushing, solvents can be forcefully expelled from fluid and air passages. Some solvents can cause eye injury.

PROP 65 WARNING

WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Inhaling Toxic Substances

Explosion Hazard -

Incompatible Materials

General Safety

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.

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.

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.

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 hygienst or safety expert, and be NIOSH approved.

Due to the aluminum passageways in these guns, they must not be used with these solvents. Aluminum is also 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 requirements 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.

2 / 8 SB-2-202-H (11/2014)

EN

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.

PARTS REPLACEMENT

Figure 1 Air Cap

No. XXX

Air Cap No.

Chart 1

No. on Air Cap

Order

2000

Air Cap With Ring

(Ref. No. 4)

GTI-407-2000

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 (10), be sure to either 1) pull the trigger and hold while tightening or loosening the fluid tip, or 2) remove fluid needle adjusting screw (16) to relieve spring pressure against needle collar.

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

D

A

C

E

B

HVLP: 30 PSI

MAX. INLET

Chart 2

Fluid

Tip No.

Tip Size I.D.

In. mm

GTI-213-15 0.059 1.5

GTI-213-16 0.063 1.6

GTI-213-18 0.070 1.8

GTI-213-22 0.086 2.2

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 covered by U.S.A. Patent

No. 6,293,476.

#2000 Millennium Air Cap

Inlet Cap CFM

Pressure* Pressure Flow**

(PSI) (PSI) (CFM)

8

14.5

20

24.5

2

4

6

8

7.5

10.5

12.5

14.5

30 10 15.8

* At handle of gun.

** Fan fully open.

JGA-4035 Packing Replacement Instructions

GTI-33 Baffle Seal Replacement

Needle

1. Remove Fluid Tip (5).

2. Remove Baffle (6).

3. Remove Seal (7) from baffle.

Gun Body

Packing

(3 pieces)

Packing

Nut

NOTE

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. In needle snaps shut, continue adjusting nut until there is evidence of needle bind or slow closing.

13. Back off packing nut 1/12 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.

Pry here if necessary

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.

ANGLED SIDE

SEAL

THICK SIDE

BAFFLE

4. Assemble seal to baffle with angled side

up as shown above. 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.

SB-2-202-H (11/2014) 3 / 8

EN

12

13

18

16

14

15

17

10

11

32 33 34 35

36

3

4

1

6

7

5

2

Fluid Tip

(Torque to

15-20 ft.lbs.)

24

23

22

21

20

25

19

12

8

9

37

*26 Air Inlet Nipple

1/4" NPS(M)

(Torque to 15 ft.lbs.)

Use medium strength thread sealant (i.e. Devcon #2242

Blue, or equal) on threads

28

27

29

31

30

PARTS LIST

Ref. Replacement

No. Part No.

1 ---

2 JGA-156-K10

3 GTI-3

4 See Chart 1

5 See Chart 2

6 GTI-425

•7 GTI-33-K5

•8 JGA-4035-K5

9 34411-122-K10

10 GTI-404

11 GTI-413

•12 JGS-72-K10

13 ---

•14 ---

•15 ---

16 MBD-19-K10

17 GTI-414

18 KK-5059

•19 ---

•20 ---

Ind.

Description

Parts

Req.

Air Cap

Spring Clip (Kit of 10)

Air Cap Retaining Ring

Air Cap & Retaining Ring

Fluid Tip

Baffle Assembly

Baffle Seal (Kit of 5)

Packing (Kit of 5)

Packing Nut

Spreader Valve

Fluid Needle

Gasket Kit ( PTFE)

(Kit of 10)

Body Bushing

Fluid Needle Spring

Spring Pad

Spring and Pad

(Kit of 10)

Needle Adjusting Screw

Bushing, Spring, Pad

and Knob Kit

Air Valve Spring

Air Valve

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

Ref. Replacement

No. Part No.

Ind.

Description

Parts

Req.

21 ---

•22 ---

•23 ---

•24 ---

25 JGS-449-1

26 P-MB-51

27 ---

28 ---

29 JGS-478

30 ---

31 JGS-477-1

•32 KGP-13-K5

•33 ---

•34 ---

•35 ---

36 GTI-428-K5

37 192219

Air Valve Body

U-Cup Seal

Washer

Snap Ring

Air Valve Assembly

Air Inlet Nipple

1/4" NPS(M)

Trigger Stud Screw

Trigger Stud

Stud and Screw Kit

(Includes 3 Studs & 5 Screws)

Trigger

Trigger Stud, Screw Kit (1 each)

Cup Gasket (Blue) (Kit of 5)

Retaining Clip

Seal

Pin

Clip, Seal & Pin Kit (5 each)

Gun Holder, Coated

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

• KK-5058-2 Gun Repair Kit includes a quantity of necessary parts.

Sufixes -K5, -K10 designate kits of multiple parts.

Example: JGA-4035-K5 is a kit of 5 packings.

4 / 8 SB-2-202-H (11/2014)

TROUBLESHOOTING

CONDITION

Heavy top or bottom pattern

Heavy right or left side pattern

Heavy center pattern

Split spray pattern

Jerky or fluttering spray

Unable to get round spray

Will not spray

Paint bubbles in cup

Fluid leaking or dripping from cup lid

Starved spray pattern

Excessive overspray

Excessive fog

Dry spray

Fluid leaking from packing nut

Fluid leaking or dripping from front of gun

CAUSE CORRECTION

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.

Left or right side horn holes plugged.

Dirt on left or right side of fluid tip.

Clean. Ream with non-metallic point.

Clean.

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.

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.

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.

*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.

Spreader adjustment screw not seating properly.

Air cap retaining ring loose.

No air pressure at gun.

Fluid needle adjusting screw not open enough.

Fluid too heavy for gravity feed.

Fluid tip not tight.

Cup lid loose.

Dirty threads on cup or lid.

Cracked cup or lid.

Inadequate material flow.

Low atomization air pressure.

Tighten or replace.

Install per directions.

Refill.

Hold more upright.

Backflush with solvent.

Lubricate or tighten.

Clean or replace.

Tighten.

Check air supply and air lines, blow out gun air passages.

Open fluid needle adjusting screw.

Thin material and/or change to larger tip size.

Tighten tip to 12-15 ft-lbs.

Push in or tighten lid.

Clean.

Replace cup and lid.

Back fluid adjusting screw out to first thread, or change to larger tip size.

Increase air pressure and rebalance gun.

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.

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.

Clean.

Replace.

Replace.

EN

*Most common problem.

SB-2-202-H (11/2014) 5 / 8

EN

TROUBLESHOOTING (continued)

CONDITION

Fluid dripping or leaking from bottom of cup

Runs and sags

Thin, sandy coarse finish drying before it flows out

Thick, dimpled finish "orange peel"

CAUSE

Cup loose on gun.

Cup gasket worn or missing below cup.

Cup threads dirty.

Too much material flow.

Material too thin.

Gun tilted on an angle, or gun motion too slow.

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.

CORRECTION

Tighten.

Replace cup gasket.

Clean.

Adjust gun or reduce fluid flow.

Mix properly or apply light coats.

Hold gun at right angle to work and adapt to proper gun technique.

Check distance. Normally approx. 8".

Reduce air pressure and check spray pattern.

Follow paint manufacturer's mixing instrs.

Check distance. Normally approx. 8".

Too much material coarsely atomized.

Increase air pressure or reduce fluid flow.

Follow paint manufacturer's mixing instrs.

Properly clean and prepare.

6 / 8 SB-2-202-H (11/2014)

ACCESSORIES

GFC-501 (Acetal) 20 Oz. Cup

GFC-502 (Aluminum) 1-Liter Cup

Gravity Feed Cups

These gravity feed cups are designed to be used with EXL, FLG, GFG,

GFHV or GTI gravity feed spray guns.

GTI-5033-2000

Air Cap Test Kit

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.

Spray Gun Lube

SSL-10-K12 (2 oz. bottle)

Compatible with all paint materials; contains no silicone or petroleum distillates to contaminate paint.

MSDS Sheet available upon request.

EN

HAV-500 OR

HAV-501

Adjusting Valve

(HAV-501 SHOWN)

Cleaning Brushes

42884-214-K5 (3/8")

42884-215-K10 (5/8")

JGA-156-K10

Spring Clips

29-3100-K6 Scrubs ®

Hand Cleaner Towels

HAV-500 does not have pressure gauge.

Use to control air usage at gun.

These brushes are helpful in cleaning threads and recesses of gun body.

Joins any single piece DeVilbiss air cap with latest version MBC-368,

M S A - 1 o r G T I -

3 retaining rings.

Helps prevent parts loss and provides easier assembly.

Scrubs ® are a pre- moistened hand cleaner towel for painters, body men and mechanics that go where you go and no water is needed.

Industrial Quick Connects for HVLP Guns (Air)

HC-4419

1/4" NPS(F)

HC-4719

1/4" NPT(M)

HC-4720

1/4" NPT(F)

HC-1166

1/4" NPT(M)

WR-103 Wrench

Contains all necessary tip, hose and nut sizes used on or with gun.

OMX-70-K48 Paint Cup Liner Kit

Allows quick & easy clean-up.

Consists of : 1 - Piercing Tool,

48 - Disposable Liners, 48 - Drain Bushings

Paint Spray Respirators

40-141 (Sm) 40-128 (Med) 40-143 (Lg)

NIOSH-Certified for respiratory protection in atmospheres not immediately dangerous to life.

SB-2-202-H (11/2014) 7 / 8

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, BGK, and Binks are registered trademarks of

Finishing Brands. ©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 authorized distributor, contact one of our international sales and customer support locations below.

USA/Canada

www.devilbiss.com [email protected]

Tel: 1-800-992-4657

Fax: 1-888-246-5732

United Kingdom

www.finishingbrands.eu [email protected]

Tel: +44 (0)1202 571 111

Fax: +44 (0)1202 573 488

China

www.finishingbrands.com.cn [email protected]

Tel: +8621-3373 0108

Fax: +8621-3373 0308

Mexico

www.finishingbrands.com.mx [email protected]

Tel: 011 52 55 5321 2300

Fax: 011 52 55 5310 4790

France

www.finishingbrands.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.finishingbrands.eu [email protected]

Tel: +49 (0) 6074 403 1

Fax: +49 (0) 6074 403 281

Australia

www.finishingbrands.com.au [email protected]

Tel: +61 (0) 2 8525 7555

Fax: +61 (0) 2 8525 7500

8 / 8 SB-2-202-H (11/2014)