SB-2-280-E - DeVilbiss
Contents
1. DEVILBISS SERVICE BULLETIN SB 2 280 E Replaces SB 2 280 D Repair Kit KK 5058 2 EXL 520P PRESSURE FEED HVLP SPRAY GUNS IMPORTANT Before using this equipment read all safety precautions and instructions Keep for future use DESCRIPTION These pressure feed high volume low pressure EXL guns are designed to ap ply a wide variety of finishing materials These guns are 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 These guns will produce approximately 10 psicap pressure at 30 psi gun inlet pressure Air cap test kits are available see ACCES SORIES which can be utilized to set the exact air cap pressure Air consumption for the EXL 520P 2000 cap is 15 5 SCFM at 10 psi air cap pressure This gun should not be used with chlorinated solvent materials Halogenatedhydrocarbonsolvents 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 Important These guns may be used with most common coating and finishing materials They are designed for use with mildly corrosive and non abrasive materials If used with other high corrosive or abrasive2. 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 injury CAUTION Important information that tells how to prevent damage to equipment or how to avoid a situation that may cause minor NOTE Information that you should pay special attention to 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 The following hazards may occur during the normal use of this equipment Please read the following chart before using this equipment HAZARD CAUSE SAFEGUARDS Solvent and coatings can be highly flammable or combustible especially when sprayed 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 methy
3. 6 Install fluid tip 5 and tighten to 12 15 ft Ibs ANGLED SIDE SEAL THICK SIDE Pry here if BAFFLE necessary N JGA 4035 Packing Replacement Instructions Needle l Packing Packing Nut 3 pieces Gun Body 1 Remove adjusting knob and needle spring from gun Partially withdraw needle from gun body Loosen packing nut and remove Remove old packing Assemble packing nut to needle Assemble packing in order shown to needle 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 incre ments no more than 1 6 turn at a time 11 After each adjustment pull needle open and observe needle closure 12 If needle snaps shut continue ad justing 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 pack ing nut for looseness p E E Page 4 SB 2 280 E PARTS LIST Replacement Part No JGA 156 K10 MBC 368 See Chart 1 See Chart 2 GTI 425 GTI 33 K5 JGA 4035 K5 34411 122 K10 GTI 405 See Chart 2 JGS 72 K10 MBD 19 K10 GTI 414 KK 5059 ZG gt 7 A N EN i Y Fluid Tip Torque to Description Air C
4. mask must be compatible with the material being sprayed and its concentration Equipment must be as pre scribed 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 regu lators 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 require ments 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 repeti
5. materials it must be expected that frequent and thorough cleaning will be required and the necessity for replacement of parts will be increased INSTALLATION For maximum transfer efficiency do not use more pressure than is necessary to atomize the material being applied 1 Connect the gun to a clean moisture and oil free air supply using a hose size of at least 5 16 1 D hose Do not use 1 4 1 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 atthe gun handle and air cap test kit over tip When gun istriggered on adjust regulated pressureto desired settingto 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 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 Ifan air adjusting valve is used atthe 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 whichis important for HVLP sprayin
6. mixing instrs Follow paint manufacturer s mixing instrs Air pressure too low Improper thinner being used Material not properly mixed ACCESSORIES KB 555 Aluminum amp KB 545 SS S S 2 qt Pressure Feed Cup With Regulator f O 52 N a gt Spray Gun Lube SSL 10 K12 2 oz bottle Compatible with all paint materials con tains no silicone or petroleum distillates Surface rough oily dirty HAV 500 OR HAV 501 Adjusting Valve HAV 501 SHOWN Cleaning Brushes 42884 214 K5 3 8 42884 215 K10 5 8 HAV 500 does not These brushes are Provides greater degree of control over cup fluid pressure to contaminate paint MSDS Sheet avail able upon request have pressure gauge Use to control air usage at gun helpful in cleaning threads and recesses of gun body Properly clean and prepare JGA 156 K10 Spring Clips Joins any single piece DeVilbiss air cap with latest version MBC 368 MSA 1 or GTI 3 retaining rings Helps prevent parts loss and provides easier assembly 29 3100 K6 Scrubs Hand Cleaner Towels n gt Es SCRUBS IN A BUCKET Hand Cleaner Towels 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 GTI 5033 2000 WR 103 Wrench Air Cap Test Kit The purpose of this test kit is to measure air cap atomizi
7. ap Spring Clip Kit of 10 Air Cap Retaining Ring Air Cap amp 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 Air Valve Body a er 9 8 12 15 ft Ibs 8 aa N K y Tr Q28 29 31 A 30 S Fluid Inlet Nipple Use medium strength thread sealant torque to 20 25 ft 2 i e Devcon 2242 Blue 35 3 8 NPS M Ibs N e m m _ 77 gt lt 36 37 38 Mia e 39 fA Q S Y F A 26 Air Inlet Nipple 1 4 NPS M C torque to 15 ft Ibs or equal on threads Replacement Part No Description 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 amp 5 Screws Trigger Trigger Stud Screw Kit 1 each Fluid Inlet Gasket PTFE Locknut Fluid Inlet Adapter Fluid Inlet Gasket Nut Kit JGS 478 JGS 477 1 JGA 4042 Retaining Clip Seal Pin Clip Seal amp Pin Kit 5 each en est GTI 428 K5 e KK 5058 2 Gun Repair Kit includes a quantity of necessary parts Suffixes K5 K10 designate kits of multiple parts Example JGA 4035 K5 is a kit of 5 pac
8. d push it down until it is flat against the shoulder 4 Use medium strength thread sealant i e Devcon 2242 blue or equal on threads before installing fluid inlet adapter 5 Torque fluid inlet adapter to 20 25 ft lbs and tighten locknut PARTS REPLACEMENT Figure 1 Air Cap HVLP 30 PSI MAX INLET U S A Patent No 6 293 476 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 Chart 1 No on Air Cap Air Cap With Ring Order gt Ref No 4 Chart 2 Fluid Tip and Needle Tip Size Ref No 5 1 D Fluid Tip In mm AV 2120 D AV 2120 E AV 2120 FF AV 2120 FX Ref No 11 Fluid Needle JGA 402 DEX JGA 402 E JGA 402 FF JGA 402 FX GTI 33 Baffle Seal Replacement 1 Remove Fluid Tip 5 2 Remove baffle 6 3 Remove Seal 7 from baffle NOTE The seal is designed to be a tight fit on the baffle The seal should be ableto be removed using your fingers If you are unableto 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 Air Cap No Air Cap covered by SB 2 280 E Page 3 4 Assemble seal to baffle with angled side up as shown below 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
9. e at transformer or gun Fluid flow too low Increase fluid flow increases gun handling Spreader adjusting valve set too high speed Adjust Split spray pattern Loose or damaged fluid tip seat Tighten or replace Baffle Seal installed incorrectly Install per directions Material level too low Refill Container tipped too far Hold more upright Obstruction in fluid passage Backflush with solvent Dry or loose fluid needle packing nut Lubricate or tighten Loose or broken fluid inlet nipple Tighten or replace Jerky or fluttering spray Q Unable to get round spray Spreader adjustment screw not seating Clean or replace properly Air cap retaining ring loose Tighten Will not spray No air pressure at gun Check air supply amp air lines blow out gun air passages Fluid needle adj screw not open enough Open fluid needle adjusting screw Fluid too heavy Thin material Fluid pressure too low Increase fluid pressure at tank Runs and sags Too much material flow Adjust gun or reduce fluid pressure Material too thin Mix properly or apply light coats Gun tilted on an angle or gun motion too Hold gun at right angle to work and adapt to slow proper gun technique Starved spray pattern Inadequate material flow Back fluid adjusting screw out to first thread or increase fluid pressure at tank Low atomization air pressure Increase air pressure and rebalance gun Excessive overspray Too much atomization air p
10. g 2 Attach the fluid hose to the material inlet NOTE Protective coating and rust inhibi tors 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 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 1 Fill the pressure tank with the mate rial 2 Open the spreader adjustment valve 10 Fan by turning the valve stem counterclockwise 3 Open fluid adjusting screw 17 by turning counterclockwise 4 Turn on air supply to gun and pressure tank and set gun inlet pressure to low est recommended pressure for material being sprayed Spray a test area Air pressure and paint flow should be adjusted to provide a uniform disper sion of atomized paint throughout the pattern Due to the unique cone shape of the AV 2120 fluid tip a slight back pressure is created against the fluid column This will reduce the amount of fluid output To compensate increase the fluid regulator pressure slightly With 10 psi cap pressure back pres sure is approximately 2 0 psi Keep air pressure as low as possible to minimize bounce back and overspray Excessive fluid flow will result in heavy center spray patterns Inadequate flows may cause the patterrn to split See TROUBLESHOOTING Page 5 if any proble
11. kings SB 2 280 E Page 5 TROUBLESHOOTING CONDITION CAUSE CORRECTION Heavy top or bottom pattern Horn holes plugged Clean Ream with non metallic point Obstruction on top or bottom of fluid tip Clean Cap and or tip seat dirty Clean Heavy right or left side pattern Clean Ream with non metallic point Left or right side horn holes plugged Clean 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 Check for dried paint just inside the opening remove by washing with solvent Fluid flow too high for atomization air Balance air pressure and fluid flow Increase Pressure Feed spray pattern width with spreader adjustment valve Material flow exceeds air cap s capacity Thin or lower fluid flow Spreader adjustment valve set too low Adjust Atomizing pressure too low Increase pressure Material too thick Thin to proper consistency Heavy center pattern Atomization air pressure too high Reduc
12. lene 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 Extreme or awkward finger wrist or arm positions Excessive duration of the activity Tool vibration Repeated pressure on a body part Working in cold temperatures CTD s can also be caused by such activities as sewing golf tennis and bowling to name a few 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 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
13. ms occur If finer atomization is required increase gun inlet pressure If a reduced fluid flow rate is required turn fluid adjusting screw 17 clockwise until desired fluid flow is obtained See Spray Gun Guide SB 2 001 latest revision for details concerning setup of spray guns PREVENTIVE MAINTENANCE 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 cauase a distorted spray pattern To clean fluid passages remove excess material from cup then flush with a suit able solvent Wipe gun exterior with a solvent dampened cloth Never completely immerse in solvent as this is detrimental to the lubricants and packings 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 reas sembling Torque to 12 15 ft Ibs Do not overtighten the fluid tip CAUTION To prevent damage to fluid tip 5 or fluid needle 11 be sure to either 1 pull the trigger and hold while tightening or loosening the fluid tip or 2 remove fluid needle ad justing screw 17 to relieve spring pressure against needle collar Page 2 SB 2 280 E
14. ng air pressure at the center air port of the air cap Used to confirm code compliance and asa daily quality control measure HC 4419 1 4 NPS F HC 4720 1 4 NPT F Contains all necessary tip hose and nut sizes used HC 4719 on or with gun 1 4 NPT M HC 1166 1 4 NPT M 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 2 280 E Page 7 NOTES Page 8 SB 2 280 E WARRANTY This product is covered by DeVilbiss 1 Year Limited Warranty DeVilbiss Sales and Service www devilbiss com D VILBISS U S A Canada Customer Service Toll Free Customer Service E A 195 Internationale Blvd santas support Glendale Heights IL 60139 630 237 5000 Toll Free Fax 888 246 5732 5 12 2012 DeVilbiss All rights reserved Printed in U S A
15. ressure Reduce pressure Gun too far from work surface Adjust to proper distance Improper stroking arcing gun motion too Move at moderate pace parallel to work fast surface Excessive fog Too much or too fast drying thinner Remix properly Too much atomization air pressure Reduce pressure Dry spray Air pressure too high Reduce air pressure Gun tip too far from work surface Adjust to proper distance Gun motion too fast Slow down Gun out of adjustment Adjust Fluid leaking from packing nut Packing nut loose Tighten do not bind needle Packing worn or dry Replace or lubricate Fluid leaking or dripping from Packing nut too tight Adjust front of gun Dry packing Lubricate Fluid tip or needle worn or damaged Replace tip and needle with lapped sets Foreign matter in tip Clean Fluid needle spring broken Replace Wrong size needle or tip Replace Most common problem Page 6 SB 2 280 E TROUBLESHOOTING continued CONDITION CORRECTION Gun too far from surface Too much air pressure Thin sandy coarse finish drying before it flows out Check distance Normally approx 6 8 Reduce air pressure and check spray pattern Improper thinner being used Follow paint manufacturer s mixing instrs Thick dimpled finish orange peel Gun too close to surface Check distance Normally approx 6 8 Too much material coarsely atomized Increase air pressure or reduce fluid flow Follow paint manufacturer s
16. tive use of the arm wrist and hand can lead to serious disability Risk is reduced by avoiding or lessening factors 1 7 PROP 65 WARNING WARNING This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm CA PROP 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 notclog the air passages For best results lubricate the points indicated daily Not for air tools or high RPM equip ment A Trigger Points B Packing C Adjusting Knobs D Baffle Threads E Air Valve Cartridge DENE IM PARTS REPLACEMENT FLUID INLET GASKET 32 REPLACE MENT INSTUCTIONS 1 Remove fluid inlet adapter 34 with appropriate wrench 2 Clean Loctite from gun body inlet threads and seal area 3 Placegasket 32 squarely ontothe fluid inlet adapter an
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