SERVICE MANUAL

Repair Kit KK-4058-1

MBC - ZINC SPRAY GUN

MBC-ZINC-W (FOR WATERBASED INORGANIC ZINC)

MBC-ZINC-S (FOR SOLVENTBORNE ORGANIC ZINC)

I M P O RTA N T: B e f o r e u s i n g t h i s equipment, read all safety precautions and instructions. Keep for future reference.

Zinc solution – Follow manufacturers directions for mixing zinc powder into solution. Make sure adequate mechanical mixing is observed during and after zinc is mixed into liquid.

DESCRIPTION

The MBC-ZINC-W spray gun is intended for use with the new waterborne, zinc rich protective coatings. MBC-ZINC-S is used for solvent based zinc coatings.

The MBC-ZINC-W has all the features of the standard MBC-510 and consists of spray gun body and removable sprayhead. MBC-ZINC-W differs in the following components.

These instructions are found on both container label and Technical Data Sheets.

In addition to specific recommendations on handling the zinc, suppliers also have recommendations concerning operating pressures, air and fluid hose length and size.

Leather packings

Heavy duty needle spring

Acetal copolymer construction air cap

Fluid tip with composition insert

The MBC-ZINC-S is set up for solvent based ZINC and has the same features as the MBC-510. The MBC-ZINC-S includes:

GUN OPERATION

The MBC-ZINC guns are supplied with a D (.086”) size fluid tip. Extensive field testing of the various zinc formulations conclude that the use of smaller tip sizes require elevated fluid pressures, which in turn, increase the tendency of needle seat interference. These higher fluid pressures also cause the liquid material to pack out when the gun is triggered off. Lower fluid pressures help minimize both conditions.

Leather Packings

Heavy Duty Needle Spring

MB-4039-64HD Air Cap

Standard Fluid tip and needle

T h e s e c o m p o n e n t s h a v e p r o v e n very effective in handling the unique characteristics of waterborne zinc rich coatings. By using these components, the user will insure the longest and most reliable operation before major repair is required.

After first mixing, a fluid pressure of approximately 15 psi should provide satisfactory flow rates for normal production speeds. A reduction in flow output will be experienced as the viscosity increases and fluid pressures will have to be increased. Under most application conditions, atomizing air in the range of

50 psi will be satisfactory.

HANDLING OF ZINC COATING

Some zinc rich formulations can require up to 20 lbs. of dry zinc per gallon of liquid. Care must be taken when adding the zinc to insure complete suspension into the liquid. Mechanical agitation must be used when mixing, and during application, to prevent agglomeration and settling of the zinc particles. These larger clumps will interfere with needle seating and cause premature wear and leakage to the tip or needle.

Zinc rich formulations have limited pot life. Once the zinc is added, the liquid slurry begins to increase in viscosity.

Material should be used within 3-4 hours after mixing. If material is applied outof-doors, viscosity will increase faster as a result of heat buildup caused by environmental conditions.

Packing operation – The packing set consists of 3, pre-lubricated leather packings. Packing tension on needle is factory set. Lubricate packings twice daily by adding a few drops of •SSL-10 gun lube to the needle shaft. Retain proper packing tension to allow smooth needle travel.

This will insure minimal needle shaft and packing wear.

CLEANING

The fluid hose interior and gun fluid passages should be cleaned immediately after each zinc batch is used. Exterior metal surfaces of the gun body and head should be wiped clean before any accumulation is allowed to dry.

Waterborne zinc in its dried state will be extremely difficult to remove from any metal surface.

The DeVilbiss air cap GTI-1-100L, is constructed of Acetal copolymer. The zinc will not adhere to its surface. If zinc is allowed to dry, the film can be simply removed with a fiber brush or by soaking the cap in water. When the cap is removed, always wipe off the fluid tip exterior surfaces to prevent any zinc build up from drying.

PREVENTIVE MAINTENANCE

The MBC-ZINC spray gun is designed to provide the user trouble free service applying this unique protective coat ing, with only minimal care and maintenance.

There are certain steps the user can take to insure trouble-free service.

1.Never immerse or soak the entire spray gun in any liquid. These liquids are generally contaminated and can foul interior components and passages.

Immer sion over long periods can also dilute and remove lubricants necessary for smooth operation. Lubri cate gun components daily as indicated.

2. Mix dry zinc into solution using a mechanical agitator. Maintain agitation during application.

3. Mix only the amount to be used in 4 hours or less.

4. Refrain from using excessive fluid pressures. A range of 15-30 psi should be satisfactory during the 4 hour period of application.

5. Avoid longer than 25 ft. lengths of fluid and air supply hoses to the gun. Air hoses should be 5/16” I.D. minimum.

6. Do not allow zinc to dry on any interior, metal fluid passage in the gun or hose fittings. An appropriate cleaning agent should be used to purge the system as soon as a batch is used up.

7. Use a cleaning brush (see Accessories) to clean the air cap. Do not use a wire brush. Also avoid using metal objects such as drill bits to clean air hole jets.

•Safety Data Sheet available upon request.

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SAFETY PRECAUTIONS

This manual contains information that is improtant 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.

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 inury.

Note

Information that you should pay special attention to.

The following hazards may occur during the normal use of this equipment. Please read the following chart before using this equipment.

HAZARD CAUSE

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

SAFEGUARDS

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.

Solvent

Spray

Inhaling Toxic

Substances

Explosion Hazard -

Materials

General Safety

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 -

Trichloroethylene 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.

Wear eye protection.

Follow the requirements of the 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.

The MBC-510 can 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 & maintenance of the equipment (in accordance with the requirements of NFPA-33, Chapter 15). Users must comply with all local & national codes of practice & insurance company requirements governing ventilation, fire precautions, operation, maintenance and housekeeping. These are OSHA Sections 1910.94 and 1910.107 and NFPA-33.

Cumulative Trauma

Disorders (“CTD’s”) musculoskeletal disorders, involve damage to the hands, wrist,

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: elbows, shoulders, neck and back. Carpal 1. High frequency of the activity. tunnel syndrome and 2. Excessive force, such as gripping, pinching, tendinitis (such as or pressing with the hands and fingers. tennis elbow or rotator 3. Extreme or awkward finger, wrist, or arm.

cuff syndrome) are positions. examples of CTD’s.

4. Excessive duration of the activity.

5. Tool vibration.

6. Repeated pressure on a body part.

7. Working in cold temperatures.

Pain, tingling, or numbness in the shoulder, forearm, wrist, hands or fingers, especially during the night, may be early symptoms of a CTD’s, or

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 & hand can lead to serious disability.

Risk is reduced by avoiding or lessening factors 1-7.

CA PROP

65

PROP 65 WARNING

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

CTD’s can also be caused by such activities as sewing, golf, tennis bowling, to name a few.

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Note

When replacing the fluid tip or fluid needle, replace both at the same time. Using worn parts can cause fluid leakage. Also, replace the needle packings at this time.

Lightly lubricate the threads of the fluid tip before reassembling.

Torque to 20 - 25 ft. lbs.

To prevent damage to the fluid tip

(3) or fluid needle (3B), be sure to either 1 ) pull the trigger and hold while tightening or loosening the fluid tip or 2) remove fluid needle adjusting screw (27) to relieve spring pressure against needle collar.

TROUBLESHOOTING

Leakage from the tip can be caused by sluggish needle travel, improperly mixed zinc solution, or worn tip and/or needle.

If leakage occurs during application, clean the gun and hoses out and remove fluid tip. Inspect the interior seating surfaces.

If large particles appear to be imbeded into the tip seat, scrape the surfaces with a blunt object. Then, attempt to remove agglomerates from the balance of solution by straining.

Fluid Tip – If large imbedded clumps cannot be removed, or if the tip seating surface is worn, it will be necessary to replace the tip and needle. Satisfactory operation depends on the unique DeVilbiss tip design, smooth needle shaft, and lubricated and properly adjusted packings.

In order to insure proper operation, replace these parts when tip leakage occurs due to wear:

AV-4915-D Fluid Tip

MBC-496-DEX Fluid Needle

AV-1-K5 Gasket

(Zinc waterborne gun)

AV-2115-D Fluid Tip

MBC-496-DEX Fluid Needle

AV-1-K5 Gasket

(Zinc solvent-based gun)

MB-135-K9 pre-lubricated leather packings (3)

(both guns)

SPRAY GUN LUBRICATION

Daily, apply two drops of •SSL-10 spray gun lube (see Accessories) at trigger bearing stud (29) and the stem of the air valve (19) where it enters the air valve assembly.

The shank of the fluid needle (3B) where it enters the packing nut (7) should also be oiled. The fluid needle packing (3A) should be kept soft and pliable by periodic lubrication. Make sure the sprayhead (6) and retaining ring (1) threads are clean and free of foreign material. Before assembling retaining ring to sprayhead, clean the threads thoroughly, then add two drops of

SSL-10 spray gun lube to threads. The fluid needle spring (26) and air valve spring (20) 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.

• Safety Data Sheet available from

DeVilbiss upon request.

A. Trigger Points

B. Packing

C. Adjusting Valves

D. Threads

A

C

A

B

D

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PARTS LIST

Ref. Replacement

No. Part No. Description

Individual

Parts Req

1 MBC-368

2 GTI-1-100L

2A MB-4039-64HD

3 AV-4915-D

AV-2115-D

3A MB-135-K9

3B MBC-496-DEX

4 AV-1-K5

5 MBC-1225

6 P-MBC-402

7 MB-19-K5

8 MBC-1226-K10

9 MBC-67

10 MBC-498-1

11 ---

12 ---

13 ---

14 ---

15 ---

16 JGA-14-K25

17 JGA-15-K25

18 JGS-26-K25

19 JGS-431-K25

20 MBD-12-K25

21 JGS-72-K10

22 JGS-449-1

23 CV-5-K5

24 ---

25 MBC-33

26 MBC-70-K2

27 MBC-39

28 MBC-4247

29 ---

30 ---

31 JGS-478

32 JGS-477-1

33 P-MB-51

For Gun Repair order the following:

KK-4058-1 Repair Kit

MB-135-K9 Leather Packings

MBC-70-K2 Springs

Retaining Ring 1

Air Cap, Acetal copolymer (waterborne) 1

Air Cap, (solvent-based)

Fluid Tip (waterborne)

Fluid Tip (solvent-based)

Leather Packings (Kit of 9)

Needle

Gasket Kit (Kit of 5)

Baffle

Sprayhead Body

Packing Nut (Kit of 5)

Gasket Kit (Kit of 10)

1

1

1

3

Locking Bolt

Fan Adjustment Valve

Washer

Packing

Packing Nut

Knob

Screw

Snap Ring (Kit of 25)

Washer (Kit of 25)

U-cup (Kit of 25)

Air Valve (Kit of 25)

Spring (Kit of 25)

Gasket (Kit of 10)

Air Valve Assembly

Gasket Kit (Kit of 5)

Cylinder

Plunger

Spring (Kit of 2)

Screw

Cylinder Assy.

Trigger Bearing Stud

Screw

Stud & Screw Kit

(3 studs, 5 screws in kit)

Trigger, Stud & Screw Kit

(kit includes 1 each)

Air Inlet Adapter 1/4” NPS

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

1

1

1

1

1

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# 2A

#1

#2

#

3

4

5

6

#3A

7

3B

8

Torque to

150 inch lbs.

16

17

18

19

20

21

22

31

30

29

32

Torque to

20-25 ft. lbs.

9

Torque to

140 inch lbs.

Torque to

300 inch lbs.

11

12 13

14

15

10

•33

23

24

25

#26 27

28

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• Use medium strength thread sealant (i.e. Loctite 242 value, or equal) on threads.

# These components have proven very effective in handling characteristics of zinc rich coatings.

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TROUBLESHOOTING

CONDITION

Heavy top or

bottom pattern

Heavy center pattern

CAUSE

Horn holes plugged.

Obstruction on top or bottom of fluid tip.

Cap and/or tip seat dirty.

Heavy right or left side pattern Left or right side horn holes plugged.

Dirt on left or right side of fluid tip.

CORRECTION

Clean. Ream with non-metallic point.

Clean.

Clean.

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 paint by washing with solvent.

Too much material.

Material too thick.

Reduce fluid flow on suction guns. Reduce fluid pressure on pressure feed guns .

Thin to proper consistency.

Split spray pattern

Jerky or fluttering spray

Unable to get round spray

Not enough material.

*Loose or damaged fluid tip/seat.

Insufficient fluid in cup or pressure tank.

Gun (with cup) tipped at excessive angle.

Obstructed fluid passage or hose.

Loose or cracked fluid tube in cup or tank.

Too heavy fluid for suction feed. Dry or worn packing (14) or loose packing nut (15).

Fan adjustment screw not seating properly.

Air cap retaining ring loose.

Reduce air pressure or increase fluid flow by turning fluid needle adjusting screw counter clockwise on suction feed, increase fluid pressure on pressure feed guns.

Tighten or replace.

Fill cup or tank.

Do not tip excessively or rotate fluid tube.

Clean.

Tighten or replace.

Change to pressure feed.

Lubricate or replace. Tighten.

Clean or replace.

Tighten.

Will not spray No air pressure at gun.

Internal mix or pressure feed air cap and tip used with suction feed.

Fluid pressure too low with internal mix cap

Check air supply and air lines.

Change to proper suction feed air cap and tip.

Increase fluid pressure at tank.

and pressure tank.

Fluid needle adjusting screw not open enough. Open fluid needle adjusting screw.

Fluid too heavy for suction feed. Thin material or change to pressure feed.

Fluid leaking from packing nut Packing nut loose.

Packing worn or dry

Dripping from fluid tip Dry packing.

Sluggish needle.

Tighten, do not bind needle.

Replace or lubricate.

Lubricate. See “Preventive Maintenance”.

Lubricate. See “Preventive Maintenance”.

Tight packing nut. Adjust. See “ Preventive Maintenance”.

Sprayhead misaligned, causing needle to bind. Tap all around sprayhead with wooden mallet and retighten locking bolt.

*Most common problem.

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ACCESSORIES

WR-103 Wrench 42884-214-K5 3/8”

42884-215-K10 5/8”

Cleaning Brushes

HD-503

SolventSaver™

Hose/Gun

Cleaner

183GZ-5200

Hose/Gun Cleaner

SolventSaver™

HAF-507

Whirlwind™

In-Line Air Filter

Spray Gun Lube

SSL-10 (2 oz. bottle)

EN

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

HAV-500 OR

HAV-501

Adjusting Valve

(HAV-501 SHOWN)

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

P-H-5516 Air

Adjusting Valve

2 Qt. & 2-1/2 Gal hose/ gun cleaner used to clean the inside of hose, fluid passageways of gun & other paint equipment.

KB-555 (Aluminum) &

KB-545-SS (S/S)

2 qt. Pressure Feed Cup

With Regulator

2 gallon galvanized tank used to clean the inside of hose and material passages of the gun.

Removes water, oil, and debris from the air line.

Compatible with all paint materials: contains no silicone or petroleum distillates to contaminate paint. MSDA sheet available upon request.

JGA-444 Fluid Tube

This tube combines the fluid and air hoses at gun handle preventing dragging hoses over work, twisting line and improving overall gun handling.

TLC-576 Aluminum Cup

(Non-stick Lined) &

TSC-591Stainless Steel Cup

HAV-500 does not have pressure gage. Use to control air usage at gun.

Removes water, oil, and debris from the air line.

Provides greater degree of control over cup fluid pressure.

1 Qt. pressure feed cups.

3/8” NPS (F), cam lock lid.

Requires KK-4980 air regulator kit.

Quick Disconnect Approved for

HVLP Guns (Air)

High Flow Ball and Ring Type

HARG-510

Air Regulator

KK-5060 Air Cap

Cleaning Kit

192212 Professional Spray Gun

Cleaning Kit

HC-4419 1/4”

NPS(F)

HC-4719

1/4” NPT(M)

HC-4720

1/4” NPT(F)

29-3100 Scrubs ®

Hand Cleaner Towels

HC-1166

1/4” NPT(M)

Use to maintain nearly constant outlet pressure despite changes in inlet pressure and downstream flow.

Consists of: 2 brushes,

1 wire pick. Helps keep air cap clean and performing properly.

Contains six precision tools designed to effectively clean all DeVilbiss, Binks, Finishline and other brand spray guns.

Millennium 3000

Twin Cartridge

Paint Spray Respirator

Scrubs® are a premoistened hand cleaner towel for painters.

No water is needed.

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

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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 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 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.carlisleft.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

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