DeVilbiss FLG-615 User manual

DEVILBISS
SERVICE BULLETIN
SB-2-605-F
Replaces SB-2-605-E
Gun Repair Kit FLG-480
FLG-615 AND FLG-635 SPRAY GUN AND GFC-502 CUP
IMPORTANT: Before using this equip-
ment, read all safety precautions
on page 2 and instructions. Keep for
future use.
DESCRIPTION
The FLG-615 and FLG-635 are light weight,
Qflneral purpose gravity feed spray guns
for both conventional and HVLP spraying
applications suitable for use with a wide
variety
of common coating materials.
WARNING I
Halogenated hydrocarbon sol-
vents v for example; 1, 1, 1-
trichloroethane and methylene
chloride-canchemically react with
the aluminum in this gun and cause
an explosion hazard. Read the la-
bel or
data sheet for the material
you
intend to spray. Do not use
spray materials containing these
solvents with this spray gun.
IMPORTANT: This gun may be used with
most common coating and finishing mate-
rials. 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 fre-
quent and thorough cleaning will be re~
quired and the necessity for replacement of
parts will be increased.
OPERATION
Strain material thru 60 or 90 mesh screen.
Model FLG-615:
The No.1 (conventional) air cap requiresan
air supply at the gun inlet of approximately
45 psi, measured with the trigger pulled.
Model FLG-635:
The No, 3 (HVLP) air cap requires an air
supply at the gun inlet of 23 psi max.,
measured with the trigger pulled.
This gun was 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).
This
gun wil produce approximately 10 psi
c~p pressure at 23 psi gun inlet pressure, as
measured at the gun inlet. An air cap test kit
(see Accessories)
should be used to insure
10 psi cap pressure is not exceeded.
Adjust inlet air pressure to provide a uni-
form dispersion of atomized paint through-
out 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. See Spray Gun Guide,
SB-2-001, which is available upon request,
for details
concerning set up of sprayguns.
PREVENTIVE MAINTENANCE
To clean air cap and fluid tip, brush exterior
with a
stiff bristle brush. If necessary to
cleancap holes, use a broom straw ortooth-
pick if possible. If a wire or hard instrument
is used, extreme care must be used to pre-
ventscratching or burring ofthe holeswhich
will cause a distorted spray pattern.
To clean
fluid passages, remove excessma-
terial at source, then flush with a suitable
solvent.
Wipe gun exterior with a solvent
dampenedcloth.Never completely immerse
in solvent as this is detrimental to the lubri-
cants and packings.
Note
When replacing thef!uidtip orfluid
needle, replace both at the same
time.
Using worn parts can cause
fluid leakage. Using the supplied
fluid tip tool (16), tighten fluid tip
hand tight.
r-[ :CA--:uT!o~~~]
To prevent damage to the fluid tip
{3) or fluid needle (6), be sure to
either 1) pull the trigger and hold
while
tightening or loosening the
fluid tip or 2} remove fluid needle
adjusting screw (15) to relieve
spring pressure against needle
collar.
Spray Gun Lubrication
Daily, apply a drop ofSSL-10 spray gun lube
at trigger bearing stud ( 11) and the stem of
the air valve (17) where it enters the air
valve assembly (22). The shank of the fluid
need!e{6}where it enters the packing nut (8)
should also be oiled. The fluid needle pack-
ing (9) should be kept soft and pliable by
periodic lubrication. Make sure the baffle (5)
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 (14) and
air valve spring (18) should
be coated with a very light grease, making
sure
that any excessgrease will not clog the
air passages. For best results, lubricatethe
points indicated, daily.
Products shown covered by following U.S. Patents; 0386,654 & 5,582,350.
A Trigger Points A
B. Packing
C. Adjusting Valves
D. Bat
B
DESCRIPTION- 120175 IGFC-502)
This 32 oz. cup is designed to be used with
or without the DeVilbiss disposable cup
liner. The cup liner allows painting in any
position and
simplifies clean up.
This
gravity feed cup is designed to work
with the FLG, GFG and GFHV gravity feed
spray guns. The cup is constructed from
durable
aluminum to provide trouble-free
operation.The
cup insertis electroless nickel
plated brass. The disposablecup lid is
recy~
c!ableand isconstructed with recycled poly~
ethylene. The lid has a unique drip check to
prevent paint from dripping out of the vent
in the lid.
ASSEMBLY OF CUP TO GUN
1. Remove one of the cup gaskets (26)
from the poly bag.
2. Place this gasket in the fluid inlet of the
gun body. See drawing on page 4.
3. Store remaining cup gaskets in safe
place
for future use.
4. Place filter (25) in cup outlet atthis time
if desired. See drawing on page 4.
5. Assemble cup to gun and tighten hand
tight.
FILLING WITH PAINT
Fill the cup with paint to the full mark.
Do not overfill.
INSTALLING THE LID
Place plastic lid on the top of the cup, and
push in the center of the lid to assemble
lid. Fold vent cap and push onto center
portion
of lid (if vent cap is not already
assembled).
(Continued on page
4)

Page 2 SB-2-605-F SAFETY PRECAUTIONS
This manual contains information that is improtant for you to know and understand. This information relates to USER SAFETY and
PREVENTING EQUIPMENTPROBLEMS. To helpyou recognize this information, we use the following symbols. Please pay particular attention
to these sections.
WARNING I
importantsafetyinformation-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.
HAZARD
Fire
Solvent Spray
Inhaling Toxic
Substances
Explosion Hazard -
Incompatible Materials
WARNING I
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 flam~
mabie or combustible especially when
sprayed.
During cleaning and flushing, solvents can
be
forcefully expelled from fluid and air
passages. Some solvents can cause eye
injury.
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.
Certain materials may be harmful if inhaled, Follow the requirements of the Material Safety Data
or if there is contact with the skin. Sheet supplied by your coating material manufacturer.
Halogenated hydrocarbon solvents -
for
example; methylene chloride and 1, 1, 1-
Trichloroethane are not chemically com-
patible with the aluminum that
might be
used in many system components. The
chemica! reaction caused by these solvents
reacting with aluminum
can become violent
and lead to
an equipment explosion.
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
ln 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 safeiy with these solvents. Read the
label
or data sheet for the material you intend to spray.
If in doubt as to whether or not acoating or cleaning
material
is compatible, contact your material supplier,

Gun Drawing
16
I
~
3
~
@~;2;11
4~
·~
5 )
/
/
Use Fluid Tip Tool
(hand tight)
~
10
7
a
·
{Ref. No.9) Needle Packing Assembly
detailed
3~piece drawing.
.
PARTS LIST
Ref. Computer Replacement
No. Part No. Part No. Description
1 690002 FLG·101·K2 Retaining Ring (Kit
of 2)
2 ... See Chart 1
Air Cap
3
...
See Chart 1 Fluid Tip, Seal and
Tip Tool
*4 690015
FLG·4+K5
Fluid Tip Seal !Kit of 5)
5 690007 FLG-105 Baffle
6 690011
FLG-431 Fluid Needle
*7 690012 FLG·440-K5 Packing Kit {includes 1 Packing Nut
and 5 Packing Sets}
*8 ... .
..
Packing Nut
9 192109 JGA-4035-K5 Packing Kit (Kit
of 5)
10 519132 FLG-412 Trigger
*11 519029 FLG·8·K2 Trigger Stud Kit {Kit of 2)
*12
... ...
Circlip
13 690010 FLG-416 Spreader Adjustment Valve
7(•14
...
... Spring
15
690008 FLG·109·K2 Needle Adjusting Screw (Kit of 2}
*16 690009 FLG·111·K2 Fluid
T1p Tool (Kit of 2)
*17 ... .
..
Air Valve Stem and Seal
*18
...
...
Air Vaive Spring
*19 ... .
..
Air Valve Cap Body
?C·2o
.•.
. ..
Air Valve Cap
21
519054 FLG-40 Air Inlet Adapter
22 519134 FLG-414
Air Valve Service Kit
23 120175 GFC-502 Metal Gravity Feed Cup
I 24 190944 GFC·404·K2 Disposable
Lid Kit (Kit of 2)
25 190181 KGP+K5
Filter Kit (K"rt of 5)
I 26 192151 I
K~P-13·K5
Cup Gasket (Blue) (Kit of 5)
27 192219 I Gun Holder, Coated
Ind. Parts
Required
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*A quantity of necessary parts is included in Repair Kit FLG~480 (Computer No. 690013)
for complete gun repair and should be kept on hand for service convenience.
SB-2·605-F Page 3
GFC-502 Cup
"I
I
L
25---ir.•-~.
lJ
26--\0
View Showing Filter/Cup Installation
Cup Fitting
Gun Body
cuP Outlet

Page 4 SB-2-605-F
CLEANING
Note
For routine cleaning, it is not nee¥
essary to remove cup from gun.
Do
not remove washer (26) from
gun. If washer (26) is removed, it
must be replaced.
The cup lid is designed to be disposable
but may be cleaned and reused if slightly
contaminated with -overspray. If lid
becomes tight, or does not fit, it is due
to extended soaking in solvent, Let lid air
dry overnight and the lid should return to
its original size and fit.
some solvent to be flushed through gun.
Remove lid and pour out dirty solvent. Add
a small amount of clean solvent and repeat
procedure.
Wipe exterior of lid with aclean
doth and clean solvent.
[~~~T!?:~:J
Remove lid and properly dispose of any
excess paint. Pour in a small amount of
clean solvent. The amount will vary with
different coatings and solvents. Reinstall
lid. Shake cup to wash down the inside
surfaces. Hold
lid while shaking to prevent
lid from coming off. Pull trigger to allow
If a paint filter was used in the bottom of
the cup outlet, it should be removed and
cleaned or replaced at thfs time. Dispose
of used cup lid if contaminated and
replace with new.
Do not soak the lid in solvent for
extended periods of time. Doing
so could cause cup/lid sealing
problems and leakage.
Chart 1 For Model Numbers FLG-615 and FLG-635 Gravity Feed Spray Guns
Spray Gun Spray Gun No. on Ref. No.2
Ref. No.3 Fluid
Model Computer Air Air
Cap Fluid Tip Tip
Number Number Cap
Part No. Computer No. Part No. Computer No. Size
FLG-615-114 611101 1 FLG-1-1 690000 FLG-102-141< 690003 1.4 (Std.)
FLG-635-316 611103 3 FLG-1-3 690001 FLG-102-16K 690004 1.6 !Std.)
FLG-1 02-14K 690003 1.4 (Std.)
FLG-102-18K 690005 1.8 (Opt.)
FLG-102-22K 690006 2.2 (Opt.)
TROUBLESHOOTING
CONDITION CAUSE CORRECTION
Heavy top or
'
•·Horn holes plugged. Clean.
.Ream with non-metaHic point.
bottom pattern
Obstruction on top or bottom of fluid tip. Clean.
Cap and/or tip seat dirty. Clean.
Heavy right or left
Left or right side horn holes plugged. Clean.
Ream with non-metallic point.
side pattern
Dirt on left or right side of fluid tip. 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 atest 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 paintjust inside the opening; remove by washing with solvent.
Heavy center pattern
Fluid flow too high for atomization air. Balance air pressure and fluid flow. increase spray
t 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.
Split spray pattern
Atomization air pressure too high. Reduce at transformer
or gun.
Fluid
flow too low. Increase fluid
flow {increases gun handling speed).
Spreader adjusting valve set too high. Adjust.
Jerky or fluttering spray *Loose
or damaged fluid tip/seat. Tighten or replace.
~~~~~~~~
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.
I
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 and air lines, blow out gun air
passages.
Fluid needle adjusting screw not open enough. Open fluid needle adjusting screw.
Fluid too heavy
for gravityfeed. Thin material and/or change to larger
tip size.
*Most common problem.
I
I

SB-2-605-F Page 5
TROUBLESHOOTING !Continued)
CONDITION
CAUSE I CORRECTION
Paint bubbles in cup Fluid tip not tight. Tighten tip.
Fluid leaking or dripping from
Cup lid loose. Tighten lid.
cup lid
Dirty threads on cup or lid. Clean.
Cracked cup or !id. Replace cup and lid.
Starved spray pattern Inadequate material flow. Back fluid adjusting screw
out to first thread, or
change
to larger tip size.
Low atomization air pressure. Increase air pressure and rebalance gun.
Excessive overspray
Too much atomization air pressure. Reduce pressure.
Gun too farfrom work surface. Adjust
to proper distance.
Improper stroking (arcing, gun motion too Move at moderate pace, parallel to work surface.
fast).
Excessive fog
Too much or too fast-drying thinner. Remix properly.
Too much atomization air pressure. Reduce pressure.
Reduce air pressure.
Dry spray
Air pressure too high.
Adjust to proper distance.
Gun
tip too far from work surface. Slowdown.
Gun motion too fast. Adjust
Gun out of adjustment.
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.
Foreign
matter in tip. Clean.
Fluid needle spring broken. Replace.
Wrong size needle or tip. Replace.
Fluid dripping or leaking from
Cup loose on gun. Tighten.
bottom of cup Cup gasket
worn or missing below cup. Replace cup gasket.
Cup threads dirty. Clean.
Runs and sags
Too much material flow. Adjust gun
or reduce fluid flow.
Material too thin.
Mix properly or apply light coats.
Gun
tilted on an angle, ?r gun motion too slow. Hold gun at right angle to work and adapt to
proper gun technique.
Thin, sandy coarse finish drying Gun
too far from surface. Check distance. Normally approximately 8".
before it flows out Too much air pressure. Reduce air pressure and check spray pattern.
Improper thinner being used. Follow paint manufacturer's mixing instructions.
Thick, dimpled finish "orange Gun
too close to surface. Check distance. Normally
approximately a~.
peel" Too much material coarsely atomized.
Air pressure too low. Increase air pressure
or reduce fluid flow.
Improper thinner being used. Follow paint manufacturer's mixing instructions.
Material
not properly mixed. Follow paint manufacturer's mixing instructions.
Surface rough, oily, dirty. Properly clean and prepare.

Page 6 SB-2-605-F
ACCESSORIES
192212 Professional Spray Gun
Cleaning Kit
~ ·--~l-f~-~-----·_ol
! !i !" I~ J.l i
J j ~! { },i" J
l=r .. tj1JIT!t~!~i:,,. f ~~~ ltit/,1·
b-~~~~~
Contains six precision tools designed to effec·
tively clean all DeVilbiss, Sinks, Finish!ine and
other brand spray guns.
FLG-463
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 codecomplianceand
as a daily quality control
measure.
Automotive Quick Connects
For
HVlP Guns (Air)
~ghF!ow~
HC-4419 Stem
1/4n NPT(F)
HC-1166 Stem
1/4" NPT(M)
HC-4719 Coupler
1/4" NPT(M)/NPS{M)
HC-4720 Coupler
1/4" NPT{F)
GFC-501
(Acetal) 20 Oz.
Gravity Feed Cup
with Threaded Lid
Spray Gun
Lube
SSL-10
{2 oz.
bottle)
Compatible with aJ!
paint materials; con-
tains no silicone or
petroleum distillates
to contaminate paint.
MSDS available upon
request.
HARG~510 Air Regulator
HAV-500 OR HAV-501
Adjusting Valve
(HAV-501 SHOWN!
Use to maintain nearly constant outlet
pressure despite changes in inlet
pressure and downstream flow.
HAV-500 does not have
pressure gauge. Use to con-
trol air usage at gun.
MSP-524
Twin Cartridge,
Paint Spray
Respirator
NIOSH-Certified {TC84A-
1623) for respiratory
protection in atmos-
pheres not immediately
dangerous to life.
GH-505 Gun Holder
Gun holders are made to
hold standard paint cups,
gravity feed guns and
cups, and paint filters.
WR-103 Wrench
Containsall necessarytip,
hose
and nut sizes used
on
or with gun.
OMX-70-K48 PAINT CUP
LINER KIT
HAF-507 Whirlwind™
In-Line Air Filter 192218Scrubs® Hand Cleaner Towels
Allows quick and easy
clean-up.
Consists of :1 -Piercing
Tool,
48- Disposable Liners,
48- Drain Bushings
Removes@
water, oil,
and debris
from the air
line. §
Industrial Quick Connects For HVlP Guns (Air)
Gttto~((((lr(D~
HC-4419 Stem HC-4699 Coupler HC-1166 Stem HC-4700 Coupler
1/4" NPT(F) 1/4" NPT(M) /NPS{M) 1/4" NPT(M) 1(4" NPT{F)
Scrubs® are a premoistened hand
cleaner towel for painters, body
men and mechanics that go where
you go and no water is needed.
WARRANTY This product is covered by DeVilbiss' 1 Year Limited Warranty. See SB-1-000 which is available upon request.
DeVILBISS WORLDWIDE SALES AND SERVICE LISTING - www.devilbiss.com
INDUSTRIAL FINISHING
DeVilbiss has authorized distributors throughout the world. FOR TECHNICAL ASSISTANCE OR THE DISTRIBUTOR
NEARESTYOU,
CALl TOLL FREE 1-888-992-4657 (U.S.A. ANDCANADAONL YJ. FOR lOCAl CALLS, SEE LISTING BELOW.
U.S./Canada Sales & Customer Service Office
GLENDALE HEIGHTS, IL 60139
AUTOMOTIVE ~EFINISHING
Address
195 lnternationale Blvd. Telephone No.
[phone]
Toll Free
Fax No. 1-877-790-6965
DeVilbiss has authorized distributors
throughout the world. For equipment, parts and service, check the Yellow Pages
under "Automobile Body Shop Equipment and Supplies". FOR TECHNICAL ASSISTANCE, CALL TOLL FREE
1-800-445-3988 (U.S.A. ONLY), FOR lOCAL CALLS, SEE LISTING BELOW,
U.S. Customer Service Office
MAUMEE,
OH 43537
DEVILBISS
4/03
Address
1724 Indian
Wood Circle
©Copyright 2003,
Telephone No.
[phone]
Toll Free
Fax No. 1-800-445-6643
Printed in
U.S.A