DeVilbiss JGA Operating instructions

HOW DOES YOUR SPRAY GUN SHAPE UP?

No matter how experienced the sprayer, merely

triggering and moving a gun in space will not

reveal any of the performance characteristics vital

to a top quality finish. A simple brief static spray

pattern test will immediately highlight any

potential problems before the gun is used on the

painstakingly prepared workpiece or vehicle.

Follow the procedure explained below and

compare the pattern to our examples. If your

result resembles the examples then look at the

corrective measures before you apply paint to the

workpiece.

(1) Ensure that you have the correct Air Cap, Fluid

Tip and Needle set-up on the gun to match the

material being applied.

(2) Tape a piece of brown paper (approx. ½ metre /

20” square) onto the spray booth wall at shoulder

height.

(3) Having set the gun at the recommended inlet or

atomising air pressure, hold it at he correct target

distance and spray at the paper without moving the

gun.

Normal Pattern – Ready

to Spray Intermittent Spray Fan or

Fluttering

Good balance and uniformity

?Symmetrical pattern shape

?Good working height and

width

?Uniform distribution of

material (Verify by

horizontal spray-out)

?Air in the fluid passageways

?Insufficient paint in the cup

?Fluid tip loose

?Fluid needle packing or packing

screw loose

?Cup vent hole clogged

Banana Pattern Heavy Top or Bottom

Pattern

?Air cap horn hole dirty or

damaged

?Test spray pattern, rotate

180oand test again to

isolate horn hole cause

location

?Clean air cap thoroughly

?Replace air cap if necessary

?Fluid tip or cap dirty or

damaged

?Test spray pattern, rotate 180o

and test again to isolate cause.

?Clean both items thoroughly

?Replace Fluid tip or Air cap if

necessary

Single Split Pattern Centre Heavy Ellipse

?Too much air for fluid

quantity used

?Reduce air pressure at

regulator

?Increase fluid flow by

changing fluid tip size

opening needle control

knob

?Bad air or paint setting

?Viscosity too high – thin with

solvent

?Fluid flow too high – reduce

?Air pressure too low – increase

Double Split Pattern Ball End Heavy Pattern

?Too much air for fluid

quantity used

?Reduce air pressure at

regulator

?Increase fluid flow by

changing fluid tip size or

opening needle control

knob

?Too much fluid flow

?Change fluid tip for smaller size

?Reduce flow using fluid needle

control

?Reduce fan size using fan

control

STATIC PATTERN TEST

Having examined the vertical spray pattern for uniformity of shape and size, now turn the air cap through 90oand static spray

a horizontal pattern making sure you trigger for long enough to load the shape with material. Then watch to see the formation

of the run-outs of material across the full width of the spray pattern.

This will highlight how well the material is distributed throughout the spray pattern. If the run-out is more obvious at the

centre or at the ends then this indicates a problem.

TYPICAL GOOD PATTERN RUN-OUT TYPICAL BAD PATTERN RUN-OUT

MAINTENANCE & TROUBLESHOOTING PAGE 1

Spray gun Maintenance and

Troubleshooting Guide

(JGA)

IMPORTANT: Before using the gun for the first time, tighten the needle

packing until the needle starts to bind. Then loosen the packing nut just

enough so that the needle moves freely.

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

following chart before using the equipment.

Area Hazard Safeguard

Tells where hazards may occur. Tells where hazard is. Tells how to avoid the hazard

Spray Area-

Fire Hazard Solvent and coatings can be highly

flammable or combustible especially

when sprayed.

Adequate exhaust must be provided to

keep air free of accumulations of flammable

vapours.

Smoking must never be allowed in the

spray area.

Fire extinguishing equipment must be

present in the spray area.

Solvent Spray During cleaning and flushing, solvents

can be forcefully expelled from fluid and

air passageways. Some solvents can

cause eye injury.

Wear eye protection

Toxic Substances Certain materials may be harmful if

inhaled, or if there is contact with the

skin.

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.

This mask must be compatible with the

material being sprayed and its

concentration.

Explosion Hazard-

Incompatible Materials Halogenated Hydrocarbon solvents - for

example: Methylene Chloride and 1,1,1 -

Trichloroethane are not chemically

compatible with the aluminium which may

be used in many system components.

The chemical reaction caused by these

solvents reacting with aluminium can

become violent and lead to an equipment

explosion.

Guns with stainless steel fluid passages

may be used with these solvents. However,

Aluminium is widely used in other spray

application equipment - such as material

pumps, cups and regulators, valves, etc.

Check all other 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 or cleaning material is

compatible, contact your material supplier.

WARNING

MAINTENANCE & TROUBLESHOOTING PAGE 2

SPRAY FAULTS

Condition Cause Correction

Improper spray pattern Gun Improperly adjusted.

Dirty air cap

Fluid tip obstructed

Sluggish needle

Readjust gun, follow instructions carefully.

Clean air cap.

Clean

Lubricate (see lubrication section) or

loosen packing nut.

Heavy top or bottom pattern Material build-up on air cap, partially

plugged horn holes, centre holes or jets.

Material build-up on fluid tip or partially

plugged fluid tip

Soak cap or tip in suitable solvent and wipe

clean. To clean orifice, use a broom straw

or toothpick. Never use a wire or hard

instruments. This damages holes and

distorts spray pattern.

Heavy right or left side pattern Note: To determine where material build-up is, invert cap and test spray. If pattern shape

stays in same position, the condition is caused by material build-up on fluid tip. If pattern

changes with cap movement, the condition is in the air cap.

Heavy centre pattern Too much material

Material too thick

Reduce fluid flow by turning fluid needle

adjusting screw clockwise. Reduce fluid

pressure or increase atomisation pressure.

Thin

Intermittent or ‘fluttering’ spray fan Loose fluid tip

Fluid tip not seated correctly in gun head

Gun (with cup) tipped at excessive angle.

Obstructed fluid passage or hose.

Loose or cracked fluid tube in cup or

tank.

Insufficient fluid in cup or pressure tank.

Too heavy fluid for suction feed.

Dry or worn packing or loose packing nut.

Plugged vent on suction feed cup.

Gun fluid inlet loose or not sealed/seated

correctly

Fluid hose or cup not fitted correctly to

gun fluid inlet connector

Tighten to 17 Nm (150 ibf/in)

Remove tip, clean components, check

cone seating on tip and gun for damage or

contamination

Do not tip excessively or rotate fluid tube.

Clean

Tighten or replace

Fill cup or tank

Thin material or change to pressure feed

Lubricate or replace. Tighten

Clean vent hole in cup lid.

Tighten to 8 Nm (70 lbf/in)

Remove, check mating surfaces and re-

tighten

MAINTENANCE & TROUBLESHOOTING PAGE 3

SPRAY FAULTS

Condition Cause Correction

Split spray pattern Not enough material or too high

atomisation pressure Reduce air pressure or increase fluid flow

by turning fluid needle adjusting screw

counterclockwise or increase fluid

pressure on pressure feed container.

Excessive bounce-back Too much atomisation air pressure

Gun too far from surface

Improper technique i.e. arcing, & fanning

the gun

Reduce air pressure

Check distance (normally 6-8”)

Move at moderate pace, parallel to work

surface

FINISH FAULTS

Runs and sags Too much material flow

Material too thin

Gun tilted on an angle

Adjust gun or reduce fluid pressure

Mix properly or apply light coats

Hold gun at right angle to work and adapt

to proper gun technique

Thin, sandy coarse finish drying before it

flows out. Gun too far from surface

Too much air pressure

Improper thinner being used

Check distance (normally 6-8”)

Reduce air pressure and check spray

pattern

Follow paint manufacturers mixing

instructions

Thick dimpled finish “orange peel”. Too

much material coarsely atomised. Gun too close to surface

Air pressure too low

Improper thinner being used

Material not properly mixed

Surface rough, oily, dirty

Check distance (normally 6-8”)

Increase air pressure or reduce fluid

pressure

Follow paint manufacturers mixing

instructions

Follow paint manufacturers mixing

instructions

Properly clean and prepare

MAINTENANCE & TROUBLESHOOTING PAGE 4

MAINTENANCE & TROUBLESHOOTING PAGE 5

GUN FAULTS

Condition Cause Correction

Will not spray No air pressure at gun

Internal mix or pressure feed air cap used

with suction feed

Fluid pressure too low with internal mix

cap and pressure tank

Fluid needle adjusting screw not open

enough

Fluid too heavy for suction feed

Check air supply and air lines

Change to proper suction feed air cap

Increase fluid pressure at tank

Open fluid needle adjusting screw

Thin material or change to pressure feed.

AGun ‘spits’ paint when triggering on

and off Incorrect needle fitted to gun

Excessive needle wear

Excessive fluid tip wear

Check tip/needle selection chart and fit

correct item

Replace with new needle

Replace with new fluid tip

ASmall air leak from air cap when

gun is not triggered Air valve contaminated and not correctly

seating

Air Valve seal damaged or missing

Remove valve and thorougly clean valve

shaft and seating surfaces

Replace

AGun ‘spits’ paint when triggering on

due to paint build-up inside air cap

between spraying operations

Fluid tip not fitted correctly in gun head

Fluid tip/needle leakage

Tighten to correct torque

Check for damage or blockage

Slow fluid leak from fluid tip and

needle seat Fluid Tip internal seat scored, damaged or

worn

Fluid needle external profile damaged or

worn

Contamination on needle or tip mating

surfaces preventing good seal

Incorrect fluid tip for fluid needle fitted to

gun

Sluggish needle

Tight packing nut

Replace

Thoroughly clean

Check tip/needle selection chart and fit

correct item

Lubricate packing

Adjust

Major fluid leak or fluid jetting from

fluid tip and needle seat Contamination on needle or tip mating

surfaces preventing good seal

Incorrect fluid tip for fluid needle fitted to

gun

Fluid needle stuck or ‘binding up’

Remove tip and needle and thoroughly

clean

Check tip/needle selection chart and fit

correct item

Remove and clean fluid needle shaft, or

lubricate needle packing or loosen needle

packing

MAINTENANCE & TROUBLESHOOTING PAGE 6

GUN FAULTS

Condition Cause Correction

BPaint build-up on fluid tip Fluid tip not fitted correctly in gun head

Fluid tip/needle leakage

Tighten to correct torque

Check for damage or blockage

BPaint build-up on Air cap Damaged air cap holes

Gradual build-up of bounce-back on gun

head

Replace with new Air cap

Thorougly clean

CSlow fluid leak from needle packing Fluid needle packing worn or loose Tighten or replace as necessary

DAir valve sluggish or slow to turn

on/off when trigger is

pulled/released

Air valve stem bent

Contamination on air valve stem

Replace damaged component

Remove and clean

DAir leak from around air valve stem Air valve seal damaged or missing Replace

DAir valve will not operate (air valve

stem will not fully slide into valve

body) when trigger is pulled

Air valve stem bent

Contamination on air valve stem

Remove air valve and replace damaged air

valve stem

Remove air valve and thoroughly clean

Stiff trigger action Air valve stem bent

Contamination on air valve stem

Contamination on trigger bearing screw

Contamination on fluid needle shaft

Fluid needle packing too tight

Replace damaged component

Remove and clean

Loosen packing nut

FAir leak from fluid needle exit point

in top of handle Seal damaged or missing Replace

GAir cap retaining ring will not rotate Contamination on retaining threads

Deformed or damaged retaining ring

Soak gun head in solvent to soften paint

Cut retaining ring off of gun (probably

replace retaining ring and baffle)

HUnable to turn fan control knob on

top rear of gun Internal O ring swollen or broken

Paint contamination on threads

Replace O ring

Remove and thoroughly clean

Unable to get round spray Fluid tip or air baffle incorrectly fitted

Air baffle chinmey damaged

Remove, check components for damage

and refit correctly

Replace air baffle

IAir leak from baffle seal Baffle seal swollen or damaged Replace

JUnable to turn air control valve on

handle of gun Internal O ring swollen or broken

Paint contamination on threads

Replace O ring

Remove and thoroughly clean

MAINTENANCE & TROUBLESHOOTING PAGE 7

Spray Gun Cleaning

Suction Feed Clean Up:

Turn off air supply. Disconnect cup from lid. Raise tube out of

material and pull trigger to allow remaining material to drain

back into the cup. Then empty the cup of material. Clean the

cup, lid and tube. Add some thinner to cup.

Reassemble - Turn on air supply and spray with proper

cleaning solvent. Repeat with clean solvent if necessary.

Remove solvent, disconnect gun, remove air cap and clean.

Wipe gun and cup with cleaning solvent dampened rag.

Pressure Feed Clean Up:

First, turn off air supply to material source (cup, tank or pump).

Release material pressure from the system by opening relief

valve or pulling trigger on gun.

On a pressure cup or tank, material in hoses may be drained

back. Lid must be loose and all air pressure off. Keep gun

higher than container and pull trigger. Allow material to drain

back into the container. Pour off remaining material.

A hose cleaner can be used to clean inside of fluid hose, gun

and fluid tube in cup or tank. Connect fluid hose to hose

cleaner,. Open air valve at hose cleaner. Pull trigger on gun and

slowly open cleaning solvent valve on hose cleaner. Flush until

clean. Shut off mixing valve when solvent and air discharge is

clear. Allow air to dry passages and then shut air valve at hose

cleaner. Repeat with hose to cup or tank connected to hose

cleaner. Lid on cup or tank should be set to one side of the shell

or on a waste container.

Note - This cannot be done with a pump. Pump must be run

with proper solvent to clean.

Clean inside of container and lid. Wipe down gun with cleaning

solvent dampened rag, then lubricate. Use SSL-10 spray gun

lube.

Without a hose cleaner, remove excess material from cup or

tank and clean. Set up cup, tank or pump to operate with clean

cleaning solvent. Turn off atomisation air to gun. Trigger gun

into waste container. Continue flushing until cleaning solvent is

clear. Blow air through hose to dry. Wipe hose and gun with

cleaning solvent dampened rag and lubricate gun.

Cleaning the Air Cap:

Remove the air cap and, if dirtied with dry paint, let it soak in

clean solvent. Later, brush and wipe off the air cap. If any holes

in the cap are clogged, probe them with a whittled match-stick

or tooth pick. Don’t ream the air cap holes with wire, nails or

metal tools. This may damage the hole and result in imperfect

spray patterns.

Note - Never soak the entire gun in cleaning solvent. This will

dry out the packing and remove lubrication.

Lubrication:

Daily, or after each use if intermittent, place a drop of SSL-10

gun lube on the points shown. Springs behind the fluid needle

and air valve should have a light coat of petroleum jelly.

MAINTENANCE & TROUBLESHOOTING PAGE 8

JGA Spray Gun Maintenance Schedule

A. Every Shift

1) Check front air cap face and all air cap holes are free from damage. Replace if necessary

2) Check fluid tip external profile is undamaged. Replace if necessary

4) Check fluid needle is seating correctly in fluid head allowing no seepage. Replace or lap-in if necessary.

5) Turn off pressure tank fluid cock and/or compressed air supply to gun. Trigger gun. Apply one drop of spray gun lubricant to

needle shaft immediately behind fluid needle packing screw. Release trigger. Repeatedly pull and release trigger to work

lubricant into fluid needle packing.

6) Check trigger operates smoothly and fluid needle does not stick or bind up during movement due to damage or paint build-up.

7) Apply single drop of lubricant to each side of trigger pivot screw. Repeatedly pull and release trigger to work lubricant into

trigger pivot.

8) Apply single drop of lubricant to air valve stem. Repeatedly pull and release trigger to work lubricant into air valve packing

seal.

9) Check air valve operates smoothly without sticking. Replace valve stem if necessary.

10) Check needle packing for fluid leakage. If required, tighten the needle packing by rotating packing screw until the needle

starts to bind, then loosen the packing nut just enough so that the needle moves freely. If screw bottoms without eliminating

fluid leak, replace packing with new item.

B. Additional end of week maintenance checks

1) Check air cap retaining ring and gun air baffle threads are free from damage (a smear of Vaseline on the threads will help

prevent binding).

2) Check air baffle seal is not leaking air badly or visibly damaged. Replace if necessary.

3) Apply smear of Vaseline to needle shaft front end for smooth operation.

4) Apply Vaseline to needle shaft rear end and needle spring to aid corrosion and contamination resistance.

5) Check Horn control valve is free to rotate with no stiff spots. Lubricate or replace O ring if necessary.

6) Check Air control valve, if fitted, is free to rotate with no stiff spots. Lubricate or replace O ring if necessary.

7) Check for air leaks from aircap when gun is not triggered. Clean or replace air valve stem or seat if necessary.

8) Check Trigger retaining screw is tight.

9) Check fluid and air inlet connectors are tight and sealed. Tighten if necessary.

C. Additional Bi-weekly maintenance checks

1) Check for air leakage from air valve body when trigger is pulled. Replace air valve seal if necessary.

2) Check fluid needle shaft is not badly worn and needle end profile and point are undamaged.

3) Apply a smear of Vaseline to all air O rings to aid fitting and easy rotation.

4) Check gun body for damage, particularly around air inlet connector port.

5) Check stainless steel head fluid insert, if fitted, for damage to fluid tip seat, swaging or leaks caused by rotation. This item is

not removable or replaceable, and a new gun body will be necessary.

6) Check for damage to air baffle chimney. Replace air baffle assembly if necessary.

7. Apply Vaseline to air valve spring to aid corrosion and contamination resistance.

ITW DeVilbiss

Ringwood Road

Bournemouth

BH11 9LH

Tel: 01202 571111

Steve Mannouch Oct96

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