SERVICE BULLETIN SB-2-259-B Replaces SB-2-259-A Repair Kit KK-5058-2 JGA-504 CONVENTIONAL SPRAY GUN IMPORTANT: Before using this equipment, read all safety precautions and instructions. Keep for future use. Note Protective coating and rust inhibitors 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. DESCRIPTION The standard JGA-504 spray gun is a general purpose, heavy duty, high production spray gun suitable for use with most types of materials. The fluid passageway is plated brass and aluminum. The fluid tip and needle are 300 series stainless steel. OPERATION Mix, prepare and strain the material to be sprayed according to the paint manufacturer's instructions. Strain material through a 60 or 90 mesh screen. Halogenated hydrocarbon solvents - for example; 1, 1, 1 - trichloroethane and methylene chloride - can chemically react with the aluminum in this gun and cause an explosion hazard. Read the label 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 materials. It is designed for use with mildly corrosive and nonabrasive materials. If used with other high corrosive or abrasive materials, it must be expected that frequent and thorough cleaning will be required and the necessity for replacement of parts will be increased. INSTALLATION 1. Attach the air supply line to the air inlet (26). An air transformer installed as close as possible to the gun will provide filtered and regulated air. Note When larger diameter air hoses are used, it is advisable to use an 8' or 10' "whip end" or a smaller diameter hose at the gun for greater flexibility or movement. 2. Attach the suction feed cup or fluid hose to the material inlet. 1. Fill the suction or pressure feed cup with the material. Do not overfill. Make sure that the cup lid vent hole is clear, if using a suction cup. 2. Turn on the gun air at the source of supply. Adjust the atomization air pressure to 35 psi. 3. Turn on the supply air to the pressure cup if used. 4. Open the spreader adjustment valve (10) (Fan) by turning the valve stem counter-clockwise. 5. Open the fluid needle adjusting screw (17) by turning counter-clockwise. 6. Spray a test area. If the finish is too sandy and dry, the material flow may be too low for the atomization air pressure being used. If the finish sags, there is too much material flowing for the atomization air pressure being used. Both of the above can be corrected by increasing or decreasing the atomization air pressure or the material flow. Pattern width can be altered by turning the spreader adjustment valve (10), either clockwise to decrease the width or counter-clockwise to increase the width. See Spray Gun Guide SB-2-001 (latest revision) for details concerning set up 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. Never use a wire or hard instrument. This may scratch or burr holes causing a distorted spray pattern. To clean fluid passages, remove excess material at source, then flush with a suitable solvent using a device such as the SolventSaver™ (see Accessories). 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 Charts 1 and 2. Also, replace the needle packing at this time. Lightly lubricate the threads of the fluid tip before reassembling. Torque to 15-20 ft. lbs. Do not overtighten the fluid tip. To prevent damage to the 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 adjusting screw (17) to relieve spring pressure against needle collar. Page 2 SB-2-259-B SAFETY PRECAUTIONS This manual contains information that is improtant 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. Note Important safety information - 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. Information that you should pay special attention to. The following hazards may occur during the normal use of this equipment. Please read the following chart before using this equipment. HAZARD CAUSE SAFEGUARDS Fire 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 vapors. Smoking must never be allowed in the spray area. Fire extinguishing equipment must be present in the spray area. Solvent Spray During use and while cleaning and flushing, solvents can be forcefully expelled from fluid and air passages. Some solvents can cause eye injury. Wear eye protection. Inhaling 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 chanced 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. Explosion Hazard Incompatible Materials Halogenated hydrocarbon solvents - 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 an equipment explosion. Guns with stainless steel internal passageways may be used with these solvents. However, aluminum is widely used in other spray application equipment - such as material pumps, regulators, valves, this gun 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. General Safety Improper operation or maintenance of equipment. Operators should be given adequate training in the safe use and maintenance of the equipment (in accordance with the requirements 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. Cumulative Trauma Disorders (“CTD’s”) Use of hand tools may cause cumulative trauma disorders (“CTD’s”). CTD’s, or musculoskeletal disorders, involve damage to the hands, wrist, elbows, shoulders, neck and back. Carpal tunnel syndrome and tendinitis (such as tennis elbow or rotator cuff syndrome) are examples of CTD’s. CTD's when using hand tools, tend to affect the upper extremities. Factors which may increase therisk of developing a CTD include: 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 repetitive use of the arm, wrist and hand can lead to serious disability. Risk is reduced by avoiding or lessening factors 1-7. 1. High frequency of the activity. 2. Excessive force, such as gripping, pinching, or pressing with the hands and fingers. 3. Extreme or awkward finger, wrist, or arm positions. 4. Excessive duration of the activity. 5. Tool vibration. 6. Repeated pressure on a body part. 7. Working in cold temperatures. CTD’s can also be caused by such activities as sewing, golf, tennis bowling, to name a few. SB-2-259-B 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 not clog the air passages. For best results, lubricate the points indicated, daily. * Not for air tools or high RPM equipment. A. B. C. D. E. Page 3 Chart 1 Air Caps, Fluid Tips, Fluid Needles and Applications No. on Air Cap Order No. Suction Feed Air Cap With Ring (Ref. No. 4) Type of Fluid Delivery 80 MB-4039-80 SUCTION GTI-413 AV-213-16 OR AV-213-18 9000 AV-440-9000 SUCTION OR PRESSURE GTI-413 AV-213-16 OR AV-213-18 765 AV-440-765 PRESSURE GTI-449-12 AV-213-12 777 AV-440-777 PRESSURE GTI-449-12 AV-213-14 A Fluid Fluid Tips Fluid Fluid Tips Needle Used Needle Used (Ref. No. 11) (Ref. No. 5) (Ref. No. 11) (Ref. No. 5) Chart 2 Fluid Tips Available Tip Size in. mm 0.039 1.0 0.047 1.2 0.055 1.4 0.063 1.6 0.070 1.8 Trigger Points Packing Adjusting Knobs Baffle Threads Air Valve Cartridge Pressure Feed Fluid Tip (Ref. No. 5) Type of Fluid Delivery AV-213-10 AV-213-12 AV-213-14 AV-213-16 AV-213-18 Pressure Feed Pressure Feed Pressure Feed Suction Feed Suction Feed PARTS REPLACEMENT Figure 1 Air Cap Air Cap No. N o GTI-449-12 AV-213-10 OR AV-213-12 4. Assemble seal to baffle with angled side up as shown in diagram. 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. 6. Install fluid tip (5) and tighten to 15-20 ft-lbs. JGA-4035 Packing Replacement Instructions Needle XX C Gun Body DeVilbiss D B 1. Remove Fluid Tip (5). 2. Remove Baffle (6). 3. Remove Seal (7) from baffle. NOTE PARTS REPLACEMENT FLUID INLET GASKET (32) REPLACEMENT INSTUCTIONS 2. 3. 4. 5. Packing Nut E GTI-33 Baffle Seal Replacement 1. Packing (3 pieces) Remove fluid inlet adapter (34) with appropriate wrench. Clean Loctite from gun body inlet threads and seal area. Place gasket (32) squarely onto the fluid inlet adapter and push it down until it is flat against the shoulder. Use medium strength thread sealant (i.e. Devcon 2242 blue, or equal) on threads before installing fluid inlet adapter. Torque fluid inlet adapter to 20-25 ft. lbs. and tighten locknut. The seal is designed to be a tight fit on the baffle. The seal should be able to be removed using your fingers. If you are unable to 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. ANGLED SIDE SEAL THICK SIDE Pry here if necessary BAFFLE 1. Remove adjusting knob and needle spring from gun. 2. Partially withdraw needle from gun body. 3. Loosen packing nut and remove. 4. Remove old packing. 5. Assemble packing nut to needle. 6. Assemble packing in order shown to needle. 7. 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 increments - 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 adjusting 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 packing nut for looseness. Page 4 SB-2-259-B 18 17 16 15 14 13 12 10 11 36 37 38 39 4 6 7 5 OR 4 Fluid Tip (Torque to 15-20 ft. lbs.) 1 8 2 3 19 12 20 23 22 21 24 PARTS LIST Ref. No. Replacement Part No. 1 2 3 4 5 6 •7 •8 9 10 11 •12 --JGA-156-K10 GTI-3 See Chart 1 See Charts 1 & 2 GTI-425 GTI-33-K5 JGA-4035-K5 34411-122-K10 GTI-405 See Chart 1 JGS-72-K10 13 •14 •15 16 ------MBD-19-K10 17 18 •19 •20 21 GTI-414 KK-5059 ------- *26 Air Inlet Nipple 9 1/4" NPS(M) (torque to 15 ft. lbs.) 40 32 33 28 29 27 *34 30 *Use medium strength thread sealant (i.e. Devcon #2242 Blue, or equal) on threads. 35 25 Fluid Inlet Nipple 3/8" NPS(M) (torque to 20-25 ft. lbs.) Description Air Cap Spring Clip (Kit of 10) Air Cap Retaining Ring Air Cap & Retaining Ring Fluid Tip Baffle Assembly Baffle Seal (Kit of 5) Packing (Kit of 5) Packing Nut Spreader Valve Assembly Fluid Needle Gasket Kit (PTFE) 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 Ind. Parts Req. 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 31 Ref. No. Replacement Part No. •22 •23 •24 25 26 ------JGS-449-1 P-MB-51 27 28 29 30 31 •32 33 34 35 •36 •37 •38 39 40 ----JGS-478 --JGS-477-1 ------JGA-4042 ------GTI-428-K5 --- 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 Trigger Trigger, Stud & Screw Kit Fluid Inlet Gasket (PTFE) PTFE Locknut Fluid Inlet Adapter Fluid Inlet, Gasket, Nut Kit Retaining Clip Seal Pin Clip, Seal & Pin Kit (5 each) Plug Ind. Parts Req. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 • 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 packings. SB-2-259-B Page 5 TROUBLESHOOTING CONDITION CAUSE CORRECTION Heavy top or bottom pattern Horn holes plugged. Obstruction on top or bottom of fluid tip. Cap and/or tip seat dirty. Clean. Ream with nonmetallic point. Clean. Clean. Heavy right or left side pattern Left or right side horn holes plugged. Dirt on left or right side of fluid tip. Clean. Ream with nonmetallic point. 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 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. 3) Check for dried paint just inside the opening. Remove paint by washing with solvent. Heavy center pattern Fluid pressure too high for atomization air (pressure feed). Material flow exceeds air cap's capacity. Atomizing pressure too low. Material too thick. Split spray pattern Spreader adjusting valve set too high. Reduce at transformer or gun. Increase fluid pressure (increases gun handling speed). Adjust. Jerky or fluttering spray *Loose or damaged fluid tip/seat. Material level too low. Container tipped too far. Obstruction in fluid passage. Loose or broken fluid tube or fluid inlet nipple. Dry or loose fluid needle packing nut. Tighten or replace. Refill. Hold more upright. Backflush with solvent. Tighten or replace. Lubricate or tighten. Unable to get round spray Spreader adjustment screw not seating properly. Air cap retaining ring loose. Clean or replace. Tighten. Will not spray No air pressure at gun. Internal mix or pressure feed air cap and tip 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 and tip. Starved spray pattern Atomization air pressure too high. Fluid pressure too low (pressure feed only). Balance air and fluid pressure. Increase spray pattern width with spreader adjustment valve. Thin or lower fluid flow. Spreader adjustment valve set too low. Adjust. Increase pressure. Thin to proper consistency. Open fluid needle adjusting screw. Thin material or change to pressure feed. Low atomization air pressure (suction feed) Back fluid adjusting screw out to first thread or increase fluid pressure at tank. Increase air pressure and rebalance gun. Excessive overspray Too much atomization air pressure. Gun too far from work surface. Improper stroking (arcing, gun motion too fast). Reduce pressure. Adjust to proper distance. Move at moderate pace, parallel to work surface. Excessive fog Too much, or too fast-drying thinner. Too much atomization air pressure. Remix properly. Reduce pressure. Dry Spray Air pressure too high. Gun tip too far from work surface. Gun motion too fast. Gun out of adjustment. Reduce air pressure. Adjust to proper distance. Slow down. Adjust. Fluid leaking from packing nut Packing nut loose. Packing worn or dry. Tighten, do not bind needle. Replace or lubricate. Paint bubbles in cup. Fluid tip not tight. Tighten tip to 15-20 ft. lbs. *Most common problem. Inadequate material flow. Increase fluid pressure at tank. Page 6 SB-2-259-B Troubleshooting (continued) CONDITION CAUSE CORRECTION Fluid leaking or dripping from front of gun Packing nut too tight. Adjust. Dry packing. Fluid tip or needle worn or damaged. Foreign matter in tip. Fluid needle spring broken. Wrong size needle or tip. Lubricate. Replace tip and needle. Clean. Replace. Replace. Runs and sags Too much material flow. Material too thin. Gun tilted on an angle, or gun motion too slow. 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. Check distance. Normally approx. 6-8". Too much air pressure. Improper thinner being used. Reduce air pressure and check spray pattern. Follow paint manufacturer'smixing instructions. Gun too close to surface. Check distance. Normally approx. 6-8". Too much material coarsely atomized. Air pressure too low. Increase air pressure or reduce fluid pressure. Follow paint manufacturer'smixing instructions. Follow paint manufacturer'smixing instructions. Properly clean and prepare. Thick, dimpled finish "orange peel". Improper thinner being used. Material not properly mixed. Surface rough, oily, dirty. SB-2-259-B ACCESSORIES WR-103 Wrench HARG-510 Air Regulator HAV-500 OR HAV-501 Adjusting Valve MSP-524 Twin Cartridge, Paint Spray Respirator Spray Gun Lube SSL-10 Page 7 192212 Professional Spray Gun Cleaning Kit (HAV-501 SHOWN) Contains all necessary tip, hose and nut sizes used on or with gun. 192218 Scrubs® Hand Cleaner Towels Premoistened waterless hand cleaner towels for painters, body men and mechanics. Use to maintain nearly constant outlet pressure despite changes in inlet pressure and downstream flow. JGA-156-K10 Spring Clip Joins any single piece DeVilbiss air cap with latest version MBC-368, GTI-3 or MSA-1 retaining ring. Helps prevent parts loss and provides easier assembly. HAV-500 does not have pressure gauge. Use to control air usage at gun. TGC-545 (Alum.) TLC-555 (PTFE PTFE Lined), 2 Qt. Drip Free Suction Cup NIOSH-Certified (TC-84A-1623 for respiratory protection in atmospheres not immediately dangerous to life. Compatible with all paint materials: contains no silicone or petroleum distillates to contaminate paint. MSDS available upon request. Contains six precision tools designed to effectively clean all DeVilbiss, Binks, Finishline and other brand spray guns. GTI-415 Air Adjusting Valve HAF-507 Whirlwind™ In-Line Air Filter Automotive Quick Connects For HVLP Guns (Air) High Flow Type. HC-4419 Stem 1/4" NPT(F) Cup has a unique, two position valve which permits selection of either a dripfree or conventional open vent mode. Installs into gun to enable user to control and reduce air usage at the gun. Replaces JGA-132 plug. Removes water, oil, and debris from the air line. HC-1166 Stem 1/4" NPT(M) HC-4719 Coupler 1/4" NPT(M) / NPS(M) HC-4720 Coupler 1/4" NPT(F) Page 8 SB-2-259-B WARRANTY This product is covered by DeVilbiss' 1 Year Limited Warranty. DeVilbiss Worldwide Sales and Service Listing: www.devilbiss.com DeVilbiss Automotive Refinishing DeVilbiss has authorized distributors throughout the world. For equipment, parts and service, check the Yellow Pages under “Automotive Body Shop Equipment and Supplies.” For technical assistance, see listing below. U.S./Canada Customer Service Office: 1724 Indian Wood Circle, Suite J-K, Maumee, OH 43537 Toll-Free Telephone: 1-800-445-3988 (U.S.A. and Canada only) Toll-Free Fax: 1-800-445-6643 9/07 ©2007 Inc. All rights reserved. Printed in U.S.A.
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