SERVICE MANUALEN

PROLiteGravity Spray Gun
II 2 G X/Ex h II Gb X

IMPORTANT! DO NOT DESTROY
It is the Customer's responsibility to have all operators and service personnel read and understandthis manual.
Contact your local Carlisle Fluid Technologies representative for additional copies of this manual.
READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT.

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FUNCTIONAL DESCRIPTION
The PROLite spray gun is a professional quality spray gun designed to comply with all global
legislations.

SPECIFICATIONSAIR INLET PRESSURES
P1 = Max. Static Air Input Pressure

12 bar [175 psi]

Gun Air Inlet Pressure with gun triggered

See Table 1
Page 8Vibration Level:<2.5 m/s²

Sound Power Level:

Available On Request

Sound Pressure Level:

Available On Request

ENVIRONMENTAL
Max. Ambient Operating Temperature

40°C Nominal [104°F]

MATERIALS OF CONSTRUCTION
Gun Body Material

Anodised Aluminum

Fluid Nozzle, Fluid Needle and Trigger Stud

Stainless Steel

Air Cap Material

Electroless Nickel Plated Brass

Air Cap Retaining Ring, Sprayhead, Adjusting Knobs

Anodised Aluminum

Springs, Clips, Screws

Stainless Steel

Seals and O-Rings

Solvent Resistant

Trigger

Chrome Plated SteelAir Inlet, Valve Body, Air Valve Body, Packing Nut

Chrome Plated Brass

Air Valve StemElectroless Nickel Plated Brass

CONNECTIONS
P1 = Air Inlet Size

1/4'' Universal

P2 = Fluid Inlet Size

3/8" BSP

WEIGHTGUN ONLY

445g [15.7 oz]

WITH CUP

625g [22.1 oz]

DIMENSIONS
L x H x W mm [inches]

186 x 317 x 108 [7.3 x 12.5 x 4.3 in]

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Product Description / Object of Declaration:

PROLite G, PROLite P/S, PROLite-S, GPG & FLG

This Product is designed for use with:

Solvent and waterborne materials

Suitable for use in hazardous area:

Zone 1 / Zone 2

Protection Level:

II 2 G X/Ex h II Gb X

Notified body details and role:

Element Materials Technology (0891)
Lodging of Technical file

This Declaration of conformity /incorporation is issued under the sole
responsiblity of the manufacturer:

Carlisle Fluid Technologies UK Ltd,
Ringwood Road,
Bournemouth, BH11 9LH. UK

EU Declaration of Conformity
The object of the declaration described above is in conformity with the relevant Union
harmonisation legislation:
ATEX Directive 2014/34/EU
Machinery Directive 2006/42/EC
by complying with the following statutory documents and harmonised standards:
EN 1127-1:2011 Explosive atmospheres - Explosion prevention - Basic concepts
BS EN 1953:2013 Atomizing and spraying equipment for coating materials - Safety requirements
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheresBasic methods and requirements.
EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres protection by methods "c", "b" and "k".
High volume, low pressure(HVLP) sprayguns are designed to reduce overspray and provide maximum transfer
efficiency by limiting air cap pressure to 0.7 bar [10 psi] (complies with rules issued by SCAQMD and otherauthorities)
HVLP and High Efficiency products comply with the requirements of PG6 from the EPA guidelines and offer
greater than 65% transfer efficiency.

Providing all conditions of safe use / installation stated within the product manuals have been complied with andalso installed in accordance with any applicable local codes of practice.

M Munoz
15/5/20Signed for and on behalf of Carlisle Fluid
Technologies UK Ltd:

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VP of Engineeringwww.carlisleft.com

In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasise important safety information as
follows:

WARNINGCAUTIONEN

NOTE

Hazards or unsafe practices which could result in Hazards or unsafe practices which could result in
Important installation, operation or maintenancesevere personal injury, death or substantial
minor personal injury, product or property
information.
property damage.
damage.

WARNING
Read the following warnings before using this equipment.
SOLVENTS AND COATING MATERIALS. Can be highly flammable or
combustible when sprayed. Always refer to the coating supplier's instructions
and safety sheets before using this equipment.

INSPECT THE EQUIPMENT DAILY. Inspect the equipment forworn or broken parts on a daily basis. Do not operate theequipment if you are uncertain about its condition.

READ THE MANUAL. Before operating finishing equipment, read andunderstand all safety, operation and maintenance information provided in theoperation manual. Users must comply with all local and national codes ofpractice and insurance company requirements governing ventilation, fire
precautions, operation and house-keeping of working areas.

EQUIPMENT MISUSE HAZARD. Equipment misuse can cause
the equipment to rupture, malfunction or start unexpectedly andresult in serious injury.

FIRE AND EXPLOSION HAZARD. Never use 1,1,1-Trichloroethane,
Methylene Chloride, other Halogenated Hydrocarbon solvents or fluids
containing such solvents in equipment with aluminium wetted parts. Such use
could result in a serious chemical reaction, with the posibility of explosion.
Consult your fluid suppliers to ensure that the fluids being used are compatible
with aluminium parts.

STATIC CHARGE. Fluid may develop a static charge that must be dissipatedthrough proper grounding of the equipment, objects to be sprayed and all otherelectrically conductive objects in the dispensing area. Improper grounding or
sparks can cause a hazardous condition and result in fire, explosion or electric
shock and other serious injury.

GLOVES. Must be worn when spraying or cleaning theequipment.

WEAR SAFETY GLASSES. Failure to wear safety glasses withside shields could result in serious eye injury or blindness.

WEAR RESPIRATOR. The use of respiratory protective
equipment is recommended at all times. The type of equipment
must be compatible with the material being sprayed.

TOXIC VAPOURS. When sprayed, certain materials may be poisonous, create
irritation, or are otherwise harmful to health. Always read all labels, safety
sheets and follow any recommendations for the material before spraying. If in
doubt contact your material supplier.

NEVER MODIFY THE EQUIPMENT. Do not modify theequipment unless the manufacturer provides written approval.

LOCK OUT / TAG-OUT. Failure to de-energise, disconnect, lock out and tagout all power sources before performing equipment maintenance could cause
serious injury or death.

PROJECTILE HAZARD. You may be injured by venting liquids orgases that are released under pressure, or flying debris.

NOISE LEVELS. The A-weighted sound level of pumping and spray equipment
may exceed 85 dB(A) depending on equipment settings. Actual noise levels
are available on request. It is recommended that ear protection is worn at all
times while equipment is in use.

PRESSURE RELIEF PROCEDURE. Always follow the pressure
relief procedure in the equipment instruction manual.

KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT
IN CASE OF AN EMERGENCY.
HIGH PRESSURE CONSIDERATION. High pressure can cause serious
injury. Relieve all pressure before servicing. Spray from the gun, hose leaks or
ruptured components can inject fluid into your body and cause extremely
serious injury.

OPERATOR TRAINING. All personnel must be trained before
operating finishing equipment.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT.

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EXPLODED VIEW

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PARTS LIST
REF.

PART No.

DESCRIPTION

QTY.

1

-

RETAINING RING

1

2

-

SLIP RING

1

3-

RETAINING RING SEAL

1

4905280RETAINING RING SUB ASSEMBLY

1

5

-

AIR CAP1

6905208SPRING CLIP (KIT OF 5)

1

7

SEE TABLE 1 AIR CAP & RETAINING RING

1

8

SEE TABLE 3 FLUID NOZZLE

1

9905297BAFFLE PLATE

1

10

-

SPRAYHEAD

1905287GASKET (KIT OF 2)112905303SPRAY HEAD KIT

1

13

-

NEEDLE PACKING

1

14

-

PACKING SPRING

1

15

-

PACKING NUT

1

PACKING, SPRING & PACKING NUT KIT

1

11

16

*

905294*

17-

FRONT VALVE SEAL

1

18

-

VALVE SEAT

1

19

-

AIR VALVE STEM

1

20

-

AIR VALVE SPRING

1

21

-

REAR VALVE SEAL

1

22905282

AIR VALVE ASSEMBLY

1

23905301

AIR VALVE BODY1

SEE TABLE 3 FLUID NEEDLE

24

1

25

-

NEEDLE SPRING

1

26

-

SPRING PAD

1905283

NEEDLE SPRING KIT

1

28905302FLUID ADJUSTING KNOB

129905200CIRCLIP (KIT OF 5)

1

30

-

VALVE HEAD

1

31

-

WASHER

1-

CIRCLIP2-

VALVE BODY

1-

O RING2-

VALVE ADJUSTING KNOB

1-SPREADER VALVE PIN

2AIRFLOW VALVE

1

27

32

*

*

33
34

*

35
36

*

37

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PARTS LIST (Continued)
REF.

PART No.

DESCRIPTION

QTY.

38

905289COLOUR ID RING KIT (4 COLOURS)

1

39905305AIR INLET

1-

TRIGGER SCREW

1-TRIGGER

1-

TRIGGER STUD

1

TRIGGER, STUD & SCREW KIT

1

40

*

41
42

*

43

90530644-

VALVE BODY

1

45

-

SPREADER VALVE ADJUSTING KNOB

1

46905275SPREADER VALVE ASSEMBLY

147905207FILTER (KIT OF 5)

1

48

-

GRAVITY CUP

1

49905203GRAVITY CUP LID

1

50905202DRIP CHECK LID (KIT OF 5)151905204GRAVITY CUP KIT

1-AIR VALVE SERVICE TOOL

1

53905307TORX DRIVER (KIT OF 2)1

54905296TOOL KIT152+

SERVICE PARTS
905281SPRAY GUN REPAIR KIT (INCLUDES ITEMS MARKED *)905206

SEAL AND PIN KIT, KIT OF 5 (ITEMS 32, 34 & 36)+ NOT INCLUDED IN THE GUN KIT, ONLY WITH REF 22

WARNING

The spray gun must be earthed to dissipate any electrostatic charges which may be created by fluidor air flows. This can be achieved through the spray gun mounting, or conductive air/fluid hoses.
Electrical bond from the spray gun to earth should be checked and a resistance of less than 10⁶ Ohms
is required.

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PROLite G
PART SELECTION GUIDETABLE 1
AIR CAP PERFORMANCE GUIDEAir Cap & TypePart Number

Air Consumption

Recommended Air Typical Fan Pattern
Inlet Pressure
Size**(L/Min)
HV30

HVLP

905238440 [15.5 cfm]

1.75 Bar [25 psi]

290-315mm

T110

High Efficiency

905245265 [9.4 cfm]

2.0 Bar [29 psi]

285-300mm

TE10High Efficiency

905240270 [9.5 cfm]

2.0 Bar [29 psi]

285-300mm

TE20High Efficiency

905241340 [12.0 cfm]

2.0 Bar [29 psi]

275-290mm

TE25High Efficiency

905242350 [12.4 cfm]

2.0 Bar [29 psi]

270-285mm** Fan pattern size @ 200mm [8"] distance.

TABLE 3FLUID NOZZLES & NEEDLESFLUID NOZZLES & NEEDLES

NeedlePart Number

Fluid Nozzle Size

Marking

905246

1.1

PRO-200-11

905247

1.2

PRO-200-12

9052481.3

PRO-200-13

9052491.4

PRO-200-14

9052501.5

PRO-200-15

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Part Number

Marking

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CAUTION
IMPORTANT: This spraygun is suitable for use with both waterborne and solevntborne paints &coatings.

• The gun is not designed for use with highly corrosive and/or abrasive materials.
• To avoid premature degradation of parts, DeVilbiss recommends the gun is washed in neutral
cleaning solution (pH 6 to 8).

• The gun is not designed to be cleaned within an ultrasonic bath.
If there is any doubt regarding the suitability of a specific paint or coating, contact your DeVilbiss
Distributor or DeVilbiss direct.
START-UP SEQUENCE
1. Connect the gun to a clean, moisture and oil free air supply using a conductive hose of at least 8mm
I.D.
2. Mix paint or coating to Manufacturer's instructions and strain material.
3. Turn fluid adjusting knob (28) clockwise to prevent fluid needle movement.
4. Turn spreader valve adjusting knob (45) counter clockwise to fully open.
5. Adjust inlet air pressure if required.
6. Turn fluid adjusting knob counter clockwise until first thread shows.
7. Test spray. If the finish is too dry, reduce airflow by reducing air inlet pressure.
8. If finish is too wet, reduce fluid flow by turning fluid adjusting knob (28) clockwise. If atomization is toocoarse, increase air inlet pressure. If too fine, reduce inlet pressure.
9. The pattern size can be reduced by turning spreader valve knob (45) clockwise.
10. Hold gun perpendicular to surface being sprayed. Arcing or tilting may result in uneven coating.
11. The recommended spray distance is 150-200mm.[6-8"]
12. Spray edges first. Overlap each stroke a minimum of 75%. Move gun at a constant speed.
13. Always turn off air supply and relieve pressure when gun is not in use.

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NOTE

Depending on hose length, larger I.D. hose may be required. Install an air gauge at the gun handle.
When gun is triggered on, adjust regulated pressure as required. Do not use more pressure than isnecesarry to atomize the paint or coating being applied. Excess pressure will create additionaloverspray and reduce transfer efficiency.

NOTE
If quick connect couplings are required, use only high flow quick connects. Other types will not flow
enough air for correct gun operation.

SPRAY GUN MAINTENANCE & CLEANING
To clean air cap and fluid nozzle, brush exterior with a stiff bristle brush. If necesarry to clean cap
holes, use a broom straw or toothpick if possible. If a wire or hard instrument is used, extreme caremust be taken to prevent scratching or burring of the holes which will cause a distorted spray pattern.
To clean fluid passages, remove excess material, then flush with gun wash solution. Wipe the gun
exterior with a dampened cloth. Never completely immerse in any solvent or cleaning solutions as
this is detrimental to the lubricants and life of the spray gun.

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SPRAY GUN DISASSEMBLY / ASSEMBLY#

KEY
Order for disassembly(reverse for assembly)

DISASSEMBLY NOZZLE & NEEDLE

NOTEWhen replacing the fluid nozzle or fluid needle, replace nozzle, needle and fluid packing at the sametime. Using worn parts can cause fluid leakage. Do not overtighten.

NOTE
To prevent damage to fluid nozzle or fluid needle, be sure to either:
1

Pull the trigger and hold while tightening or loosening the fluid nozzle, or,2

Remove the fluid adjusting knob to relieve spring pressure against needle collar.

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DISASSEMBLY AIR VALVEDISASSEMBLY PACKING

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ASSEMBLY AIR VALVE SEALS✓

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SPREADER VALVE REPLACEMENTNOTERemove and clean or replace the diaphragm (60) making sure the vent hole is clean and not blocked.
It is recommended to replace the cup lid gasket (59) to avoid leakage. Re-assemble the diaphragm
positioning the vent hole 180° to the vent hole in the lid (62), see diagram. Ensure the vent hole in
the lid is also not blocked before use.

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TROUBLESHOOTING MECHANICAL PERFORMANCE
GENERAL FAULTS

CAUSECORRECTION

No air pressure at gun.

Check air supply and air line.

Fluid needle adjustment knob
not open enough.

Open fluid needle adjustment
knob.

Incorrect needle fitted to gun.

Check fluid nozzle/needle
selection chart and fit correct
item.

Excessive needle wear.

Replace with new needle.

Excessive fluid nozzle wear.

Replace with new fluid nozzle.

Fluid nozzle not fitted correctly
in gun head.

Tighten.

Fluid nozzle/needle leakage.

Check for damage or blockage.

Fluid nozzle not fitted correctly
in gun head.

Tighten.

Fluid nozzle/needle leakage.

Check for damage or blockage.

Damaged air cap holes.

Replace with new air cap.

Will not spray.

Gun spits paint when triggering
on and off.

Gun spits paint when triggeringon due to paint build-up inside
air cap between spraying
operations.

Paint build-up on fluid tip.

Paint build-up on air cap.
Gradual build-up of bounce-backThoroughly clean.
on gun head.

Unable to get round spray

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Fluid nozzle or sprayhead
incorrectly fitted.

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Remove, check components fordamage and refit correctly.

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When removing air cap from retaining ring, do not remove the ring seat from the retaining ring.
Damage to the parts may occur. Simply wipe parts clean and reassemble with new or clean air cap.

FLUID FAULTS

CAUSECORRECTION

Fluid nozzle internal seat scoreddamaged or worn.

Replace.

Fluid needle external profile
damaged or worn.

Replace.

Contamination on needle or tip
mating surfaces preventing good Thoroughly clean.
seal.
Slow fluid leak from fluid nozzle
and needle seat.
Incorrect fluid nozzle for fluid
needle fitted to gun.

Check nozzle/needle selection
chart and fit correct item.

Sluggish needle.

Lubricate packing.

Tight packing nut.

Adjust.

Contamination on needle or tip
Remove nozzle and needle andmating surfaces preventing goodthoroughly clean.
seal.
Major fluid leak or fluid jettingfrom fluid nozzle and needle seat.

Slow fluid leak from needle
packing.

SB-E-2-996 R1.0

Incorrect fluid nozzle for fluid
needle fitted to gun.

Check nozzle/needle selection
chart and fit correct item.

Fluid needle packing worn or
loose.

Tighten or replace as necessary.

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AIR FAULTS

CAUSECORRECTION

Air Valve Stem contaminatedand not correctly seating.

Remove Air Valve Stem andthoroughly clean valve shaft andseating surfaces.

Air Valve Stem seal damaged or
missing.

Replace.

Small air leak from air cap whengun is not triggered.

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TROUBLESHOOTING SPRAY PERFORMANCECONDITION

CAUSE

CORRECTION

Heavy top or bottom pattern.
Paint or coating build-up on air cap,
plugged horn holes, centre holes orjets.

Soak cap or nozzle in suitable
solvent and thoroughly clean.

Paint or coating build-up on fluid
nozzle exterior or partially plugged
fluid tip.

Replace fluid nozzle or air cap if
necessary.

Fluid nozzle or cap dirty or damaged.

Replace fluid nozzle or air cap if
necessary.

Left or right side horn holes plugged.

Soak cap or nozzle in suitable
solvent and thoroughly clean.

Dirt or damage on left or right sideof fluid nozzle exterior.

Replace fluid nozzle or air cap if
necessary.

Heavy right or left
side pattern.

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

Determine if the obstruction is on the air cap or the fluid nozzle. 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. Also check for dried paint just inside the cap centre hole opening,
remove by washing with solvent.
If the defect is not inverted, it is on the fluid nozzle. Clean nozzle. If problem persists, renew nozzle.

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Heavy centre pattern.

Intermittent or 'fluttering'
spray fan.

Pattern adjustment valve set too low.

Turn out counter clockwise toachieve correct pattern.

Too much paint or coating.

Reduce fluid flow by turning fluid
needle adjusting screw clockwise.
Reduce fluid pressure.

Paint or coating too thick.

Thin to correct consistency.

Atomizing air pressure too low.

Increase air pressure.

Loose fluid nozzle.

Tighten.

Fluid nozzle not seated correctly in
gun head.

Remove fluid nozzle, clean
components, check cone seating on
tip and gun for damage orcontamination.

Partially obstructed fluid passage or
hose.

Clean or replace.

Not enough paint or coating flow.

Increase fluid flow by changing fluid
nozzle size, opening needle control
knob or increase fluid pressure onpressure feed container.

Too high horn pressure.

Reduce air pressure by rotating
pattern control valve clockwise.

Split spray pattern

Too much air for fluid quanitity used. Reduce input air pressure.

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Ball end heavy
pattern.

Too much fluid flow.

Change fluid nozzle for smaller sizeor change air cap for different
specification air cap.

Too much atomization air pressure.

Reduce air pressure.

Gun too far from surface.

Check distance (normally 150200mm [6-8"]).

Too much fluid flow.

Adjust gun or reduce fluid pressure.

Paint or coating too thin.

Mix properly or apply lightcoats/reduce fluid flow.

Gun tilted at an angle.

Mount gun at right angle to work.

Gun too far from surface.

Check distance.

Too much air pressure.

Reduce air pressure and check spraypattern.

Fluid flow too low.

Increase fluid flow by changing fluid
nozzle size, supply pressure or
turning needle control knob counterclockwise.

Excessive bounce-back.

Runs and sags.

Thin, sandy coarse finish drying
before it flows out.

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DIMENSIONS

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NOTES

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NOTES

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WARRANTY POLICYThis 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 maintenanceguidance provided, may invalidate any warranty.

For specific warranty information please contact Carlisle Fluid Technologies.
Carlisle Fluid Technologies is a global leader in innovative finishing technologies.
Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.

DeVilbiss®, Ransburg®, MS®, BGK®, and Binks® are registered trademarks of Carlisle Fluid
Technologies, Inc.
© 2020 Carlisle Fluid Technologies,Inc.
All rights reserved.
For technical assistance or to locate an authorised distributor, contact one of our international sales andcustomer support locations below.

RegionIndustrial / Automotive

Automotive Refinishing

AmericasTel: 1-888-992-4657
Fax: 1-888-246-5732

Tel: 1-800-445-3988
Fax: 1-800-445-6643

Europe, Africa,
Middle East,
India

Tel: +44 (0)1202 571 111
Fax: +44 (0)1202 573 488

China

Tel: +8621-3373 0108
Fax: +8621-3373 0308

Japan

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

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