SERVICE MANUAL

EN

FLG4 GRAVITY FEED SPRAY GUN AND

DEKUPS

®

DISPOSABLE CUP SYSTEM

MODELS: FLG-CNG-115 AND FLG-HVG-315

GUN DESCRIPTION

general purpose gravity feed spray gun for spraying applications suitable for use with a wide variety of common coating materials. Model

FLG-HVG-315 is an HVLP spray gun, and model

FLG-CNG-115 is conventional.

SPECIFICATIONS

Maximum Air Pressure: 100 psi

Gun Body:

Fluid Path:

Air Inlet:

Gun Weight:

Forged Aluminum

Anodized Aluminum

1/4" NPS male

18.13 oz / 514 g

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

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.

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.

NOTE

Information that you should pay special attention to.

HAZARD

Fire

Solvent Spray

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

Please read the following chart before using this equipment.

CAUSE

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.

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.

Inhaling Toxic Substances

Explosion Hazard -

Incompatible Materials

General Safety

Cumulative Trauma

Disorders ("CTD's")

CTD's, or musculoskeletal disorders, involve damage to the hands, wrists, elbows, shoulders, neck, and back. Carpal tunnel syndrome and tendonitis

(such as tennis elbow or rotator cuff syndrome) are examples of CTD's.

Certain materials may be harmful if inhaled, or if there is contact with the skin.

Halogenated hydrocarbon solvents - for example; methylene chloride and 1,1,1, -

Trichloroethane are not chemically compatible with the aluminum that might be used in many system components. The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion.

Improper operation or maintenance of equipment.

Use of hand tools may cause cumulative trauma disorders ("CTD's").

CTD's, when using hand tools, tend to affect the upper extremities. Factors which may increase the risk of developing a CTD include:

1. High frequency of the activity.

2. Excessive force, such as gripping, pinching, or pressing with the hands and fingers.

3. Extreme or awkward finger, wrist, or arm positions.

4. Excessive duration of the activity.

5. Tool vibration.

6. Repeated pressure on a body part.

7. Working in cold temperatures.

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

Follow the requirements of the Material Safety Data Sheet supplied by your coating material manufacturer.

Adequate exhaust must be provided to keep the air free of accumulations of toxic materials.

Use a mask or respirator whenever there is a chance of inhaling sprayed materials. The mask must be compatible with the material being sprayed and its concentration. Equipment must be as prescribed by an industrial hygienist or safety expert, and be

NIOSH approved.

Guns with stainless steel internal passageways may be used with these solvents. However, aluminum is widely used in other spray application equipment - such as material pumps, regulators, valves, and this gun and cup. 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.

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EN

FLG4 GRAVITY FEED SPRAY GUN AND DeKUPS ® DISPOSABLE CUP SYSTEM

IMPORTANT: Before using this equipment, read all safety precautions on page 2 and instructions. Keep for future use.

INSTALLATION

Note

Protective coating and rust inhibitors have been used to keep the gun in good condition prior to shipment. Before using the gun, flush it with solvents so that these materials will be removed from fluid passages.

Halogenated hydrocarbon solvents - for example; 1, 1, 1- trichloroethane and methylene chloride

- can chemically react with the aluminum in this gun and cause an explosion hazard. Read the label or data sheet for the material you intend to spray. Do not use spray materials containing these solvents with this spray gun.

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

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.)

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.

HVLP MODELS ONLY:

HVLP models of this gun were manufactured to provide maximum transfer efficiency by limiting air cap pressure to 10 psi (complies with rules issued by SCAQMD and other air quality authorities).

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 ap-

plied. Excess pressure will create additional overspray and reduce transfer efficiency.

Note

HVLP models of this gun will produce approximately 10 psi cap pressure at 23 psi gun inlet pressure, as measured at the gun inlet. An air cap test kit (see Accessories) should be used to ensure 10 psi cap pressure is not exceeded.

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

DeVilbiss HC-4419. Other types will not allow enough air flow for proper gun operation.

The No. 3 (HVLP) air cap requires a 14 scfm air supply at the gun inlet of 23 psi max., measured with the trigger pulled.

Note

CONVENTIONAL MODELS ONLY:

The No. 1 air cap requires 10 scfm air supply at a gun inlet of 40 psi, measured with the trigger pulled.

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 HAV-500 and

HAV-501 have minimal pressure drop, which is important for HVLP spraying.

OPERATION

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

Strain material through a 60 or 90 mesh screen.

PAINTING

Open the spreader adjustment valve (5) (Fan) by turning the valve stem counterclockwise.

Close the fluid needle adjusting knob (6) by turning clockwise.

Turn on air supply and set gun inlet pressure; 23 psi for HVLP, 40 psi for conventional use. Some materials can be sprayed at lower pressures, improving transfer efficiency.

Spray a test area. Turn the fluid needle adjusting knob (6) 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.

Turn the fluid needle adjusting knob (6) counterclockwise to increase fluid flow.

If the finish sags, there is too much material flowing for the atomization air pressure being used. Turn the fluid needle adjusting knob (6) clockwise to decrease fluid flow.

Pattern width can be altered by turning spreader adjustment valve (5), either clockwise to decrease the width or counterclockwise to increase the width.

Adjust inlet air pressure to provide a uniform dispersion of atomized paint throughout the pattern. Keep air pressure as low as possible to minimize bounce-back and overspray. Excessive pressure will result in split spray patterns. Inadequate pressures will cause heavy centered patterns and poor atomization.

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EN

FLG4 GRAVITY FEED SPRAY GUN AND DeKUPS ® DISPOSABLE CUP SYSTEM

CLEANING

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.

To clean fluid passages, remove excess material at source, 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.

PREVENTIVE MAINTENANCE

Spray Gun Lubrication

Daily, apply a drop of SSL-10 spray gun lube at trigger bearing stud (10) and the stem of the air valve (8). The shank of the fluid needle (7) where it enters the packing nut

(7) should also be oiled. The fluid needle packing (7) should be kept soft and pliable by periodic lubrication. Make sure the baffle (4) and retaining ring (1) 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. The fluid needle spring (6) and air valve spring (8) should be coated with a very light grease, making sure that any excess grease will not clog the air passages.

See Chart 1 for selecting the proper size fluid tip for the material you are spraying.

PARTS REPLACEMENT

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 packing and fluid tip seal at this time. Lightly lubricate the threads of the fluid tip before reassembling. Torque to 15-20 ftlbs. Do not overtighten the fluid tip.

The fluid tip part number and tip size are stamped around the outside of the fluid tip.

To prevent damage to the fluid tip (2) or fluid needle (7), be sure to either:

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

2. Remove fluid needle adjusting screw (6) to relieve spring pressure against needle collar.

Chart 1 – FLG4 HVLP and Conventional Models, Gravity Feed

Spray Gun

Model Number

Application Type

Number on

Air Cap

FLG-CNG-115

FLG-HVG-315

Gravity – Conventional

Gravity – HVLP

1

3

Air Cap Kit

(Ref. No. 1)

FLG4-1-1-k

FLG4-1-3-K

Fluid Tip

(Ref. No. 2)

FLG-332-15K

FLG-332-15K

Fluid Tip Size

Supplied With Gun

1.5 mm

1.5 mm

Chart 2 – Fluid Tips

Fluid Tip & Seal

(Ref. No. 2)

Part No.

FLG-332-13K

FLG-332-15K

FLG-332-18K

FLG-332-22K

Fluid Tip

Size

(in.)

0.051

0.059

0.070

0.086

Fluid Tip

Size

(mm)

1.3

1.5

1.8

2.2

Applications

Stains, lacquers, basecoats, clears.

General purpose, light to medium viscosity material.

General purpose, light to medium viscosity material.

Medium viscosity materials.

Chart 3 – HVLP Air Flows (#3 Cap)

Inlet Pressure

(PSI)

Air Flow

(SCFM)

15

19

23

10

11.5

13.5

Cap Presure

(PSI)

6

8

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DeKUPS

®

— HOW TO USE THE SYSTEM

EN

1 2 3 4

5 6 7 8

9

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EN

Gun Drawing

1

5

2

3

4 t

7 t t

8 t

10 t t

9

6

7

PARTS LIST

R

ef.

No.

1

2

Replacement

Part No.

Description

See Chart 1, p.4

Air Cap & Ring Kit

See Chart 2, p.4

Fluid Tip & Seal Kit

5

6

3

4

7

FLG-304-K5

FLG-305

FLG-465

FLG4-364-K

FLG4-366-K

Fluid Tip Seal (Kit of 5)

Baffle

Spreader Air Adjustment Valve

Needle Knob, Spring, Bushing & Gasket Kit

FLG4 Needle, Needle Packing & Nut Kit

8

9

10

FLG4-468-K

P-MB-51

FLG4-108-K

FLG-463

Air Valve & Gasket Kit

Air Inlet Nipple

Trigger, Trigger Stud & Screw

Air Cap #3 HVLP Test Cap

1

1

1

JGA-4035-K5 Needle Packing (Kit of 5)

FLG4-488-K t

FLG4 Gun Repair Kit (Contains 1 each: Fluid Tip Seal, Needle Packing,

Trigger Stud, Trigger Screw, and Gasket for Air Valve & Needle Bushing.)

Additional Spray Gun Accessories on page 9.

Ind. Parts

Required

1

1

1

1

1

1

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EN

DeKUPS ® ACCESSORIES

DPC-43

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

*Most common problem.

SB-2-779-R5 (1/2021)

CAUSE

Horn holes plugged.

Obstruction on top or bottom of fluid tip.

Cap and/or tip seat dirty.

CORRECTION

Clean. Ream with non-metallic point.

Clean.

Clean.

Left or right side horn holes plugged.

Dirt on left or right side of fluid tip.

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

1. Determine if the obstruction is on the air cap or the fluid tip. Do this by making a test spray pattern. Then, rotate the cap one-half turn and spray another pattern. If the defect is inverted, obstruction is on the air cap. Clean the air cap as previously instructed.

2. If the defect is not inverted, it is on the fluid tip. Check for a fine burr on the edge of the fluid tip.

Remove with #600 wet or dry sand paper.

3. Check for dried paint just inside the opening; remove by washing with solvent.

Fluid flow too high for atomization air.

Clean. Ream with non-metallic point.

Clean.

Balance air pressure and fluid flow. Increase spray pattern width with spreader adjustment valve.

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.

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.

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.

Tighten or replace.

Refill.

Hold more upright.

Backflush with solvent.

Lubricate or tighten.

Clean or replace.

Tighten.

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EN

TROUBLESHOOTING (Continued)

CONDITION

Will not spray

Paint bubbles in cup

CAUSE

No air pressure at gun.

Fluid needle adjusting screw not open enough.

Fluid too heavy for gravity feed.

Fluid tip not tight.

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

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"

Cup lid loose.

Dirty threads on cup or lid.

Cracked cup or lid.

Inadequate material flow.

Low atomization air pressure.

Too much atomization air pressure.

Gun too far from work surface.

Improper stroking (arcing, gun motion too fast).

Too much or too fast-drying thinner.

Too much atomization (air pressure.)

Air pressure too high.

Gun tip too far from work surface.

Gun motion too fast.

Gun out of adjustment.

Packing nut loose.

Packing worn or dry.

Packing nut too tight.

Dry packing.

Fluid tip or needle worn or damaged.

Foreign matter in tip.

Fluid needle spring broken.

Wrong size needle or tip.

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.

Too much material coarsely atomized.

Air pressure too low.

Improper thinner being used.

Material not properly mixed.

Surface rough, oily, dirty.

CORRECTION

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.

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.

Reduce pressure.

Adjust to proper distance.

Move at moderate pace, parallel to work surface.

Remix properly.

Reduce air 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.

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 approximately 8".

Reduce air pressure and check spray pattern.

Follow paint manufacturer's mixing instructions.

Check distance. Normally approximately 8".

Follow paint manufacturer's mixing instructions.

Increase air pressure or reduce fluid flow.

Follow paint manufacturer's mixing instructions.

Follow paint manufacturer's mixing instructions.

Properly clean and prepare.

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ACCESSORIES

HAF-507

Whirlwind™ In-Line Air Filter

Kit of 12

GFC-502 (Aluminum)1 Liter Cup

GFC-501 (Acetal) 20 Oz. Cup

Gravity Feed Cups

KGP-13-K5

Cup Gasket

HAV-500 OR HAV-501

Adjusting Valve

(HAV-501 SHOWN)

EN

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

FLG-463

HVLP Air Cap Test Kit

(#3 air cap)

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.

WR-103 Wrench

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

These gravity cups require KGP-13 Gasket between spray gun and cup.

Fluid inlet gasket necessary for use with metal gravity cups.

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

Spray Gun

Lube

SSL-10-12

(Twelve

2 oz. bottles)

Millennium 3000

Twin Cartridge

Paint Spray Respirator

192212 Professional Spray Gun

Cleaning Kit

192219

Gun Holder

Gun holder made to hold guns with gravity cups.

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

MSDS available upon request.

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

Medium 40-128

Quick Connects For HVLP Guns (Air)

High Flow Type

HC-4419 Stem

1/4" NPT(F)

Gun End

HC-4719 Coupler

1/4" NPT(M)

Hose End

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

29-3100-K6 Scrubs

Hand Cleaner

Towels

®

Scrubs

®

are a prem o i s t e n e d h a n d cleaner towel for painters, body men and mechanics that go where you go and no water is needed.

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EN

NOTES

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NOTES

EN

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WARRANTY POLICY

This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited warranty.

The use of any parts or accessories, from a source other than Carlisle Fluid Technologies, will void all warranties. Failure to reasonably follow any maintenance guidance provided may invalidate any warranty.

For specific warranty information please contact Carlisle Fluid Technologies.

For technical assistance or to locate an authorized distributor, contact one of our international sales and customer support locations.

Region

Americas

Industrial/Automotive Automotive Refinishing

Tel: 1-800-992-4657

Fax: 1-888-246-5732

Tel: 1-800-445-3988

Fax: 1-800-445-6643

Europe, Africa,

Middle East, India

China

Japan

Tel: +44 (0)1202 571 111

Fax: +44 (0)1202 573 488

Tel: +8621-3373 0108

Fax: +8621-3373 0308

Tel: +81 45 785 6421

Fax: +81 45 785 6517

Australia

Tel: +61 (0) 2 8525 7555

Fax: +61 (0) 2 8525 7575

For the latest information about our products, visit www.carlisleft.com

Carlisle Fluid Technologies is a global leader in innovative finishing technologies.

Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.

BGK™, Binks

®

, DeVilbiss

®

, Hosco

®

, MS

®

, and Ransburg

®

are all registered trademarks of Carlisle Fluid Technologies, Inc.

©2020 Carlisle Fluid Technologies, Inc.

All rights reserved.

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