Painter Training

1
Spray-Gun Operation

2
 How to set the spray-gun

1. Needle adjuster
• Amount of material

2. Pressure regulator
• Higher – lower pressure
4
1
2
3. Spray pattern control 3

• Round till wide

4. Air cap & fluid tip set-up

3
 Air pressure check

Air inlet 2 – 3 bar

30 – 40 PSI

4
 Spray pattern check

Adjustment screws fully open

• Apply ± 15 cm from the paper

Correct air pressure

± 15 cm

5
 Incorrect spray patterns

1 3

2 4

6
 Pressure drop in bar

Hose length
Inner diameter Pressure
5 Meter 10 Meter 15 Meter
(mm) (bar)
3 0.7 1.2 1.8
4 1.0 1.6 2.2
6 5 1.3 1.9 2.5
6 1.5 2.2 2.8
3 0.2 0.4 0.6
4 0.3 0.6 0.8
9 5 0.4 0.6 0.9
6 0.6 0.8 1.1

7
 Pressure drop in PSI

Hose length
Inner diameter Pressure
16.40 feet 32.80 feet 49.21 feet
(inch) (psi)
42.75 09.97 17.10 25.65
57.00 14.25 22.80 31.35
0.23 71.25 18.52 27.07 35.62
85.50 21.37 31.35 39.90
42.75 02.85 05.70 08.55
57.00 04.27 08.55 11.40
0.35 71.25 05.70 08.55 12.82
85.50 08.55 11.40 15.67

8
 Air hose & connectors

Air hose and connector diameter

• Preferably Ø 8 mm or >

9
 Maintenance

Use brand related maintenance tools

• Check with spray-gun supplier

10
Maintenance tools

11
Application Technique

1
 Gun technique

The right distance from spray-gun to object

± 150mm

No Yes

2
 Gun technique

Speed of movement

900 - 1200 mm/sec

3
 Gun technique

Follow the shape of the surface, keeping the same distance

No Yes

4
 Gun technique

Gun angle always 90º at the surface

No

5
 Gun technique

Gun angle always 90º at the surface

Yes

6
Routing total re-spray

7
 Cross-wise application

Application second coat on horizontal surfaces

• Crossed over the first coat

Better paint control

• Even flow on the panel

Less risk for

• Application pattern
• Runs at stand up surface

8
 Application technique

Basecoat application

Overlap next coats

• 50%

Panel application
• Half way each panel

9
 Application technique

Clearcoat application

Overlap next coats

• 50%

Panel application
• Half way each panel

10
 Application pressure

Application pressure Mist / drop coat

• Spray gun distance • Lower pressure
• 5 – 15 cm • Larger distance

22
Equipment

1
Equipment

2
Spraybooth

1
 Cleaning

Good housekeeping Poor housekeeping

• Clean and free of obstacles • Dirty, poor illumination

2
 Cleaning

Keep the interior clean

Use protection coating

• Replace frequently

3
 Open / closing doors

Keep the doors closed Fans on when doors are open

• Minimizing risk for dust • Keep dust particles out-side

4
 Moving cars

In and out the spray booth

• Cool down after drying cycle

5
 Temperature

Air temperature ± 60 Object temperature ± 50

6
 Air & object temperature

70 °C
Air
60 °C

50 °C Object

40 °C

30 °C

20 °C

1 °C 0

0
0 5 10 15 20 25 30 40 50 60 Time in minutes

7
 Pressure check

Maintain advised pressure

Pressure
indicator

Switch to adjust pressure

8
 Over & under pressure

Over-pressure Under pressure

• Leaking door seals • Dust in the spraybooth
• Dirty filters • Dust in the paint jobs
• Spray mist inside the shop
 Maintenance

Ceiling filter

Floor filter

Pre- and after filters

 Filter replacement

Floor filter Ceiling filter Pre- and after filter

Filters Frequency

Pre-filter each 4-6months

Ceiling filter once or twice a year
Paint-stop / Floor filter each 2-3-4 weeks
After filter each 4-6 months
Compressed Air

36
Compressed air

37
 Air conditioning

Filtering of contamination
• Oil & water

Polluted air result in defects in the paint film

Air in Air out

Dust particles Particle free

Water condense Water free
Compressor oil Oil free

38
Compressor

39
 Compressed air system
ring

Refrigerant
dryer

2
receiver filters 4
dryer 3
Compressor

ring
compressor 1
Lakukan pengecekan minyak paling tidak seminggu sekali.
Buang air secara teratur.
Lakukan pengecekan air inlet fillter.
Lakukan pengecekan filter secara teratur

40
 Air line

Main air line

• Slope ± 1%

Drop end connection on top

• Less risk for condensation

Air tap connection

• Half way drop end

41
Infra Red

42
 Why Infra Red

Reduction of drying cycle time resulting in

• Better use of bodyshop capacity

• More even workload for the spraybooth

• Ideal for small spot repairs; ½ day or 1 day repair

43
Various heat transfer

44
 Heat transfer - Conduction

Heat transfer by contact

• Heated metal

Physical contact

45
 Heat transfer - Convection

Heat transfer
• Inside the Spraybooth

Circulated Heated air

46
Heat transfer - Radiation

47
 Heat transfer efficiency

Amount of energy used

• 100% transfer

• % energy loss during transfer

• % energy which will be reflected

• % energy which will be absorbed

48
 Heat transfer efficiency

Reflection – Lighter colors

• Lower surface temperature
• Longer drying time

Absorption – Darker colors

• Higher surface temperature
• Shorter drying time

49
 Different radiations levels

Infra Red drying units – drying waves

Short Medium Long

50
 Infra Red drying information

Product and object related

• Product flash off times
• Distance IR drying equipment and object
• Total drying time needed for IR curing

Infra Red drying unit settings

1. Low potential
2. High potential

51
Polishing
 Why polishing?

Restoring color and gloss

• Old and weathered paint

Restoring gloss after application errors

• Dust – Runs – Orangepeel

Restoring gloss after blending

• Fade-out areas
 Points of attention

Respect recommended Additional IR curing in case of

T.D.S. drying times • Application error
• Blending area
 Points of attention

Clean surface prior to sanding

• Contamination causes additional scratches

Clean surface prior to polishing

• Remove sanding residues
 Points of attention

Correct sanding steps prior to polishing

The finer the sanding

• The easier to polish, which reduces the total polishing time
 Polishing tools

Electrical tools
• Constant rotation strength

Adjustable rotation speed

• Easy to handle
 Polishing tools

Air driven tools

• No constant rotation speed

Too much pressure on the tool

• Reduces rotation speed
 Polishing cloths

Use clean cloth

• Throughout polishing steps
• One cloth per separate polishing compound
 Polishing check

Clean or degrease after polishing

• Dedicated cleaner or M600

Removing polishing compound

• Check if all sanding scratches are removed
 General Polishing Advises

General polishing information

Dust – Runs – Orangepeel

• Process approach

Product selection
• Sanding materials
• Polishing materials

Polishing process steps

Masking Techniques

62
 Masking technique

Masking interior side

• Mask on sealant edge
• Accurate masking required; use fine line tape

63
 Masking technique

Pre-masking, final masking on edge with tape

• Easy to remove after spraying or drying

64
 Masking technique

Pre-masking, final masking on edge with tape

• Easy to remove after spraying or drying

65
 Fine line masking tape

Fine detail masking

• Taping curved lines
• Flexible, follows easily difficult contours

Vinyl backing
• For sharp paint line

66
 Soft masking foam tape

Easily applicable in
• Door jambs, bonnet, tailgate, etc.

67
 Masking technique

Folding the masking tape

• To gain minimum overspray on the panel edge

Edges on panel

Inside of panel, door

68
 Masking technique

Trim masking tape and Rubber string

• For lifting sealed window or screen rubbers

69
 Blending area

Covering blending area

70
Pre-masking

71
Pre-masking

72
Efficient masking

73
Efficient masking

74