SERVICE MANUAL EN
DV1 CLEARCOAT Gravity Spray Gun
II 2 G X
IMPORTANT! DO NOT DESTROY
It is the Customer's responsibility to have all operators and service personnel read and understand this manual.
Contact your local Carlisle Fluid Technologies representative for additional copies of this manual.
READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT.
SB-E-2-994 R1.0
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EN FUNCTIONAL DESCRIPTION
The DV1 spray gun is a professional quality spray gun designed to comply with all global legislations.
SPECIFICATIONS
AIR INLET PRESSURES P1 = Max. Static Air Input Pressure Gun Air Inlet Pressure with gun triggered Vibration Level: Sound Power Level: Sound Pressure Level: ENVIRONMENTAL Max. Ambient Operating Temperature See Table 1 Page 8 <2.5 m/s² Available On Request Available On Request 40°C Nominal [104°F] MATERIALS OF CONSTRUCTION Gun Body Material Fluid Tip, Fluid Needle and Trigger Stud Air Cap Material Retaining Ring, Sprayhead, Adjusting Knobs, Air Valve Cage, Sleeve Springs, Clips, Screws Seals and O-Rings Trigger Anodised Aluminium Stainless Steel Electroless Nickel Plated Brass Anodised Aluminium Stainless Steel Solvent Resistant Chrome Plated Steel 12 bar [175 psi] Valve Bodies, Rear Housing, Packing Nut, Sleeve Nut Chrome Plated Brass Air Valve Stem CONNECTIONS P1 = Air Inlet Size P2 = Fluid Inlet Size WEIGHT GUN ONLY DIMENSIONS L x H x W mm [inches] Electroless Nickel Plated Brass 1/4'' Universal 3/8" BSP 470g [16.6 oz] 161 x 177 x 44 [6.3 x 7.0 x 1.7 in] SB-E-2-994 R1.0
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Product Description / Object of Declaration: DV1 This Product is designed for use with: Suitable for use in hazardous area: Protection Level:
Solvent and water based materials Zone 1 / Zone 2 II 2 G X/Ex h II Gb X
Notified body details and role: This Declaration of conformity / incorporation is issued under the sole responsiblity of the manufacturer:
Element Materials Technology (0891) Lodging of Technical file 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 Atomising 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 atmospheres Basic 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".
Providing all conditions of safe use / installation stated within the product manuals have been complied with and also installed in accordance with any applicable local codes of practice.
Director of Sales (EMEA) Signed for and on behalf of Carlisle Fluid Technologies UK Ltd: SB-E-2-994 R1.0
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D Smith 1/8/18 www.carlisleft.com
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasise important safety information as follows:
WARNING CAUTION NOTE EN
Hazards or unsafe practices which could result in severe personal injury, death or substantial property damage.
Hazards or unsafe practices which could result in minor personal injury, product or property damage.
Important installation, operation or maintenance information.
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 material supplier's instructions and safety sheets before using this equipment.
INSPECT THE EQUIPMENT DAILY. Inspect the equipment for worn or broken parts on a daily basis. Do not operate the equipment if you are uncertain about its condition.
READ THE MANUAL. Before operating finishing equipment, read and understand all safety, operation and maintenance information provided in the operation manual. Users must comply with all local and national codes of practice 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 and result 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.
GLOVES. Must be worn when spraying or cleaning the equipment.
WEAR SAFETY GLASSES. Failure to wear safety glasses with side shields could result in serious eye injury or blindness.
STATIC CHARGE. Fluid may develop a static charge that must be dissipated through proper grounding of the equipment, objects to be sprayed and all other electrically conductive objects in the dispensing area. Improper grounding or sparks can cause a hazardous condition and result in fire, explosion or elecrtic shock and other serious injury.
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.
LOCK OUT / TAG-OUT. Failure to de-energise, disconnect, lock out and tag out all power sources before performing equipment maintenance could cause serious injury or death.
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.
NEVER MODIFY THE EQUIPMENT. Do not modify the equipment unless the manufacturer provides written approval.
PROJECTILE HAZARD. You may be injured by venting liquids or gases 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 EN PARTS LIST
REF.
5 6 1 2 3 4 PART No.
DESCRIPTION 704425 191972 RETAINING RING SLIP RING RETAINING RING SEAL RETAINING RING SUB ASSEMBLY AIR CAP SPRING CLIP (KIT OF 10) 7 SEE TABLE 1 AIR CAP & RETAINING RING 8 SEE TABLE 3 FLUID TIP SB-E-2-994 R1.0
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PARTS LIST (Continued)
REF.
PART No.
DESCRIPTION 18 19 20 21 22 23 24 25 26 27 28 29 30 31 13 14 15 16 9 10 11 12 17 + + + * * # # + 32 704402 704403 704401 704436 702731 704422 704423 704424 704437 DEFLECTOR PLATE SCREW (KIT OF 3) SPRAYHEAD GASKET (KIT OF 2) SPRAY HEAD KIT NEEDLE PACKING PACKING SPRING PACKING NUT PACKING, SPRING & PACKING NUT KIT O RING AIR VALVE CAGE SEAL SEAL GUIDE VALVE SEAT FRONT CAGE ASSEMBLY AIR VALVE STEM AIR VALVE SPRING REAR SEAL HOUSING REAR SEAL ASSEMBLY AIR VALVE ASSEMBLY IDENTIFICATION SLEEVE SLEEVE NUT SLEEVE KIT SEE TABLE 3 FLUID NEEDLE 41 42 43 44 45 46 37 38 39 40 33 34 35 #+ 36 704405 704404 704417 NEEDLE SPRING SPRING PAD NEEDLE SPRING KIT FLUID ADJUSTING KNOB O RING FLOW VALVE BODY FLOW VALVE KNOB CIRCLIP INLINE FLOW VALVE PLUG TRIGGER SCREW SPRING TRIGGER STUD TRIGGER SB-E-2-994 R1.0
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EN
QTY.
1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 www.carlisleft.com
PARTS LIST (Continued)
REF.
PART No.
DESCRIPTION 47 48 49 #+ 50 51 #+ 52 53 #+ 54 704406 55 704419 56 57 58 59 60 * 704418 704429 NOT REPLACEABLE TRIGGER, STUD, SPRING & SCREW KIT SCREW SPREADER VALVE PIN SPREADER VALVE STEM O RING VALVE BODY O RING SPREADER VALVE ADJUSTING KNOB SPREADER KNOB KIT (Not For Use With Digital Gauge) SPREADER VALVE ASSEMBLY VALVE TOOL TORX DRIVER TIP WRENCH TOOL KIT
CUPS AND GAUGES
GFC-501 61 702576 GRAVITY CUP PLASTIC GRAVITY CUP ALUMINIUM 704426 ATEX APPROVED (EU) 62 DIGITAL PRESSURE GAUGE
SERVICE PARTS
704430 704427 FM APPROVED (USA, CANADA) MINOR SERVICE KIT INCLUDES ITEMS MARKED # 704431 MAJOR SERVICE KIT INCLUDES ITEMS MARKED +
WARNING
QTY.
1 1 1 1 1 1 1 1 1 1 1 1 1 1
EN
The spray gun must be earthed to dissipate any electrostatic charges which may be created by fluid or 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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EN DV1 PART SELECTION GUIDE TABLE 1 DV1 AIR CAP PERFORMANCE GUIDE
Recommended Air Inlet Pressure (with gun fully triggered) Part Number Air Cap & Type 704434 DV1-C1 PLUS HVLP At Gun Handle 2.0 bar [29 psi] 704435 DV1-C2 PLUS HVLP 2.0 bar [29 psi] ** Fan pattern size @ 200mm [8"] distance.
TABLE 2 DV1 AIR CAP TEST KITS
At Digital Gauge 1.5 bar [22 psi] 1.5 bar [22 psi] Air Consumption Typical Fan Pattern Size** 285 L/min [10.0 scfm] 320 L/min [11.3 scfm] 325 mm [12.8 in] 310 mm [12.2 in] Recommended Air Inlet Pressure (with gun fully triggered) Part Number Air Cap & Type Atomisation Pressure 704438 704439 DV1-C1 PLUS HVLP DV1-C2 PLUS HVLP At Gun Handle 2.0 bar [29 psi] 2.0 bar [29 psi] At Digital Gauge 1.5 bar [22 psi] 1.5 bar [22 psi] 0.689 bar [10 psi] 0.689 bar [10 psi]
TABLE 3 DV1 FLUID TIPS & NEEDLES
Fluid Tip Part Number Fluid Tip Size 704440 704441 704442 704443 704444 1.0
1.1
1.2
1.3
1.4
Marking DV1-1.0 C DV1-1.1 C DV1-1.2 C DV1-1.3 C DV1-1.4 C Part Number Needle Marking 704416 DV1-300 SB-E-2-994 R1.0
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CAUTION
IMPORTANT: This spraygun is suitable for use with both waterbased and solvent based coating materials.
•
The gun is not designed for use with highly corrosive and/or abrasive materials.
EN •
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 material, 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 coating material to Manufacturer's instructions and strain material.
3. Turn fluid adjusting knob (36) clockwise to prevent fluid needle movement.
4. Turn spreader valve adjusting knob (54) 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 (36) clockwise. If atomisation is too coarse, increase air inlet pressure. If too fine, reduce inlet pressure.
9. The pattern size can be reduced by turning spreader valve knob (54) 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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EN 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 is necesarry to atomise the material being applied. Excess pressure will create additional overspray 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 tip, 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 care must 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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EN SPRAY GUN DISASSEMBLY / ASSEMBLY
#
KEY
Order for disassembly
(reverse for assembly)
DISASSEMBLY TIP & NEEDLE
22mm HEX 19 Nm [170 in-lbs] ✓
NOTE
When replacing the fluid tip or fluid needle, replace tip, needle and fluid packing at the same time. Using worn parts can cause fluid leakage. Do not overtighten.
NOTE
When removing air cap from retaining ring, do not remove slip ring or retaining ring seal from retaining ring. Damage to the parts may occur.
The slip ring and retaining ring seal are not available as replacement parts.
Simply wipe parts clean and reassemble with new or clean air cap.
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DISASSEMBLY PACKING EN DISASSEMBLY TRIGGER
T10 TORX 1 Nm [10 in-lbs] SB-E-2-994 R1.0
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DISASSEMBLY SPRAYHEAD
T10 TORX 1 Nm [10 in-lbs]
DISASSEMBLY FLOW VALVE
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7mm HEX 18.5 Nm [165 in-lbs] www.carlisleft.com
EN
DISASSEMBLY AIR VALVE
12 Nm [110 in-lbs] 6mm HEX 18 Nm [160 in-lbs]
EN
TO CHANGE IDENTIFICATION SLEEVE ONLY 1 2 4 5
SPREADER VALVE REPLACEMENT
11mm HEX 9 Nm [80 in-lbs] SB-E-2-994 R1.0
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T10 TORX 1 Nm [10 in-lbs] www.carlisleft.com
TROUBLESHOOTING MECHANICAL PERFORMANCE
GENERAL FAULTS CAUSE CORRECTION No air pressure at gun.
Check air supply and air line.
Will not spray.
EN
Fluid needle adjustment knob not open enough.
Open fluid needle adjustment knob.
Incorrect needle fitted to gun.
Gun spits paint when triggering on and off.
Excessive needle wear.
Excessive fluid tip wear.
Check fluid tip/needle selection chart and fit correct item.
Replace with new needle.
Replace with new fluid tip.
Gun 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.
Check for damage or blockage.
Fluid tip not fitted correctly in gun head.
Tighten.
Paint build-up on fluid tip.
Fluid tip/needle leakage.
Check for damage or blockage.
Damaged air cap holes.
Replace with new air cap.
Paint build-up on air cap.
Gradual build-up of bounce-back on gun head.
Thoroughly clean.
Unable to get round spray Fluid tip or sprayhead incorrectly fitted.
Remove, check components for damage and refit correctly.
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EN
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 CAUSE Fluid tip internal seat scored damaged or worn.
Fluid needle external profile damaged or worn.
Replace.
Replace.
CORRECTION Contamination on needle or tip mating surfaces preventing good seal.
Thoroughly clean.
Slow fluid leak from fluid tip and needle seat.
Incorrect fluid tip for fluid needle fitted to gun.
Check tip/needle selection chart and fit correct item.
Sluggish needle.
Lubricate packing. Tight packing nut.
Adjust.
Major fluid leak or fluid jetting from fluid tip and needle seat.
Contamination on needle or tip mating surfaces preventing good seal.
Remove tip and needle and thoroughly clean.
Incorrect fluid tip for fluid needle fitted to gun.
Check tip/needle selection chart and fit correct item.
Slow fluid leak from needle packing.
Fluid needle packing worn or loose.
Tighten or replace as necessary.
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EN
AIR FAULTS CAUSE CORRECTION Air Valve Stem contaminated and not correctly seating.
Remove Air Valve Stem and thoroughly clean valve shaft and seating surfaces.
Small air leak from air cap when gun is not triggered.
Air Valve Stem seal damaged or missing.
Replace.
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EN TROUBLESHOOTING SPRAY PERFORMANCE
CONDITION Heavy top or bottom pattern.
CAUSE CORRECTION Material build-up on air cap, plugged horn holes, centre holes or jets.
Soak cap or tip in suitable solvent and thoroughly clean.
Heavy right or left side pattern.
Material build-up on fluid tip exterior or partially plugged fluid tip.
Replace fluid tip or air cap if necessary.
Fluid tip or cap dirty or damaged.
Replace fluid tip or air cap if necessary.
Left or right side horn holes plugged.
Soak cap or tip in suitable solvent and thoroughly clean.
Dirt or damage on left or right side of fluid tip exterior.
Replace fluid tip or air cap if necessary.
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 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. 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 tip. Clean tip. If problem persists, renew tip.
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Heavy centre pattern.
Intermittent or 'fluttering' spray fan.
Split spray pattern Pattern adjustment valve set too low.
Turn out counter clockwise to achieve correct pattern.
EN
Too much material.
Reduce fluid flow by turning fluid needle adjusting screw clockwise. Reduce fluid pressure.
Material too thick.
Thin to correct consistency.
Atomising air pressure too low.
Increase air pressure.
Loose fluid tip.
Tighten.
Fluid tip not seated correctly in gun head.
Remove fluid tip, clean components, check cone seating on tip and gun for damage or contamination.
Partially obstructed fluid passage or hose.
Clean or replace.
Not enough material flow.
Increase fluid flow by changing fluid tip size, opening needle control knob or increase fluid pressure on pressure feed container.
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Too high horn pressure.
Reduce air pressure by rotating pattern control valve clockwise.
Too much air for fluid quanitity used.
Reduce input air pressure.
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Ball end heavy pattern.
Too much fluid flow.
EN
Change fluid tip for smaller size or change air cap for different specification air cap.
Excessive bounce-back.
Too much atomisation air pressure.
Reduce air pressure.
Gun too far from surface.
Check distance (normally 150 200mm [6-8"]).
Too much fluid flow.
Material too thin.
Runs and sags.
Gun tilted at an angle.
Gun too far from surface.
Thin, sandy coarse finish drying before it flows out.
Too much air pressure.
Fluid flow too low.
Adjust gun or reduce fluid pressure.
Mix properly or apply light coats/reduce fluid flow.
Mount gun at right angle to work.
Check distance.
Reduce air pressure and check spray pattern.
Increase fluid flow by changing fluid tip size, supply pressure or turning needle control knob counter clockwise.
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DIMENSIONS EN
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NOTES EN
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NOTES EN
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EN WARRANTY POLICY
This 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 maintenance guidance 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.
© 2019 Carlisle Fluid Technologies,Inc.
All rights reserved.
For technical assistance or to locate an authorised distributor, contact one of our international sales and customer support locations below.
Region Industrial / Automotive Automotive Refinishing Americas
Tel: 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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