DeVilbiss DV1 Basecoat Spray Gun Service Manual

SERVICE MANUAL
EN
DV1
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-2-992 R1.0
www.carlisleft.com
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
12 bar [175 psi]
See Table 1
Page 8
Vibration 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 Aluminium
Fluid Tip, Fluid Needle and Trigger Stud
Stainless Steel
Air Cap Material
Electroless Nickel Plated Brass
Retaining Ring, Sprayhead, Adjusting Knobs, Air Valve
Cage, Sleeve
Anodised Aluminium
Springs, Clips, Screws
Stainless Steel
Seals and O-Rings
Solvent Resistant
Trigger
Chrome Plated Steel
Valve Bodies, Rear Housing, Packing Nut, Sleeve Nut
Chrome Plated Brass
Air Valve Stem
Electroless Nickel Plated Brass
CONNECTIONS
P1 = Air Inlet Size
1/4'' Universal
P2 = Fluid Inlet Size
3/8" BSP
WEIGHT
GUN ONLY
470g [16.6 oz]
DIMENSIONS
L x H x W mm [inches]
SB-E-2-992 R1.0
161 x 177 x 44 [6.3 x 7.0 x 1.7 in]
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Product Description / Object of Declaration:
DV1
This Product is designed for use with:
Solvent and water based 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
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
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 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".
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.
D Smith
1/8/18
Signed for and on behalf of Carlisle Fluid
Technologies UK Ltd:
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Director of Sales (EMEA)
www.carlisleft.com
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasise important safety information as
follows:
WARNING
CAUTION
EN
NOTE
Hazards or unsafe practices which could result in Hazards or unsafe practices which could result in
Important installation, operation or maintenance
severe 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 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.
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.
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.
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 the
equipment 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 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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EN
EXPLODED VIEW
PARTS LIST
REF.
PART No.
DESCRIPTION
QTY.
1
-
RETAINING RING
1
2
-
SLIP RING
1
3
-
RETAINING RING SEAL
1
4
704425
RETAINING RING SUB ASSEMBLY
1
5
-
AIR CAP
1
6
191972
SPRING CLIP (KIT OF 10)
1
7
SEE TABLE 1 AIR CAP & RETAINING RING
1
8
SEE TABLE 3 FLUID TIP
1
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EN
PARTS LIST (Continued)
REF.
PART No.
9
704402
DEFLECTOR PLATE
1
10+
704403
SCREW (KIT OF 3)
3
11
-
SPRAYHEAD
1
12+
704401
GASKET (KIT OF 2)
1
13
704400
SPRAY HEAD KIT
1
14
-
NEEDLE PACKING
1
15
-
PACKING SPRING
1
16
-
PACKING NUT
1
17+
702731
PACKING, SPRING & PACKING NUT KIT
1
18
-
O RING
1
19
-
AIR VALVE CAGE
1
20
-
SEAL
2
21*
-
SEAL GUIDE
2
22*
-
VALVE SEAT
1
23#
704422
FRONT CAGE ASSEMBLY
1
24
-
AIR VALVE STEM
1
25#
-
AIR VALVE SPRING
1
26
-
REAR SEAL HOUSING
1
27
704423
REAR SEAL ASSEMBLY
1
28+
704424
AIR VALVE ASSEMBLY
1
29
-
IDENTIFICATION SLEEVE
1
30
-
SLEEVE NUT
1
31
704428
SLEEVE KIT
1
FLUID NEEDLE
1
32
SEE TABLE 3
DESCRIPTION
QTY.
33
-
NEEDLE SPRING
1
34
-
SPRING PAD
1
35#+
704405
NEEDLE SPRING KIT
1
36
704404
FLUID ADJUSTING KNOB
1
37
-
O RING
2
38
-
FLOW VALVE BODY
1
39
-
FLOW VALVE KNOB
1
40
-
CIRCLIP
1
41
704417
INLINE FLOW VALVE
1
42
-
PLUG
1
43
-
TRIGGER SCREW
1
44
-
SPRING
1
45
-
TRIGGER STUD
1
46
-
TRIGGER
1
47
704406
TRIGGER, STUD, SPRING & SCREW KIT
1
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EN
PARTS LIST (Continued)
REF.
PART No.
DESCRIPTION
QTY.
48
-
SCREW
1
49#+
-
SPREADER VALVE PIN
1
50
-
SPREADER VALVE STEM
1
51#+
-
O RING
1
52
-
VALVE BODY
1
53#+
-
O RING
1
54
-
SPREADER VALVE ADJUSTING KNOB
1
55
704419
56
704418
57
SPREADER KNOB KIT
1
(Not For Use With Digital Gauge)
SPREADER VALVE ASSEMBLY
1
-
VALVE TOOL
1
58
-
TORX DRIVER
1
59
-
TIP WRENCH
1
60
704429
TOOL KIT
1
* NOT REPLACEABLE
CUPS AND GAUGES
GFC-515
61
702576
704426
GRAVITY CUP
PLASTIC
GRAVITY CUP
ALUMINIUM
ATEX APPROVED (EU)
62
DIGITAL PRESSURE GAUGE
704427
FM APPROVED (US, CANADA)
SERVICE PARTS
704430
MINOR SERVICE KIT
INCLUDES ITEMS MARKED #
704431
MAJOR SERVICE KIT
INCLUDES ITEMS MARKED +
WARNING
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
Part Number
Air Cap & Type
Recommended Air Inlet Pressure
(with gun fully triggered)
At Gun Handle
At Digital Gauge
704407
DV1-B
HVLP
2.0 bar [29 psi]
1.0 bar [15 psi]
704408
DV1-B+
HVLP
2.0 bar [29 psi]
1.5 bar [22 psi]
Air
Typical Fan
Consumption Pattern Size**
400 L/min
330 mm
[14.1 scfm]
[13 in]
300 L/min
325 mm
[10.5 scfm]
[12.8 in]
** Fan pattern size @ 200mm [8"] distance.
TABLE 2
DV1 AIR CAP TEST KITS
Part Number
Air Cap & Type
Recommended Air Inlet Pressure
(with gun fully triggered)
At Gun Handle
At Digital Gauge
Atomisation Pressure
704432
DV1-B
HVLP
2.0 bar [29 psi]
1.0 bar [15 psi]
0.54 bar [8 psi]
704433
DV1-B+
HVLP
2.0 bar [29 psi]
1.5 bar [22 psi]
0.56 bar [8 psi]
TABLE 3
DV1 FLUID TIPS & NEEDLES
Fluid Tip
Needle
Part Number
Fluid Tip Size
Marking
704409
0.9
DV1-0.9 B
704410
1.0
DV1-1.0 B
704411
1.1
DV1-1.1 B
704412
1.2
DV1-1.2 B
704413
1.3
DV1-1.3 B
704414
1.4
DV1-1.4 B
704415
1.5
DV1-1.5 B
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Part Number
Marking
704416
DV1-300
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EN
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.
•
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
DISASSEMBLY TRIGGER
T10 TORX
1 Nm [10 in-lbs]
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DISASSEMBLY SPRAYHEAD
T10 TORX
1 Nm [10 in-lbs]
DISASSEMBLY FLOW VALVE
7mm HEX
18.5 Nm
[165 in-lbs]
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EN
DISASSEMBLY AIR VALVE
12 Nm
[110 in-lbs]
6mm HEX
18 Nm [160 in-lbs]
TO CHANGE IDENTIFICATION SLEEVE ONLY
1
2
4
5
SPREADER VALVE REPLACEMENT
11mm HEX
9 Nm [80 in-lbs]
T10 TORX
1 Nm
[10 in-lbs]
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EN
TROUBLESHOOTING MECHANICAL PERFORMANCE
GENERAL FAULTS
CAUSE
CORRECTION
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 tip/needle selection
chart and fit correct item.
Excessive needle wear.
Replace with new needle.
Excessive fluid tip wear.
Replace with new fluid tip.
Fluid tip not fitted correctly in
gun head.
Tighten.
Fluid tip/needle leakage.
Check for damage or blockage.
Fluid tip not fitted correctly in
gun head.
Tighten.
Fluid tip/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 triggering
on 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-back
Thoroughly clean.
on gun head.
Unable to get round spray
SB-E-2-992 R1.0
Fluid tip or sprayhead incorrectly Remove, check components for
fitted.
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
CORRECTION
Fluid tip internal seat scored
damaged 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 tip and
needle seat.
Incorrect fluid tip for fluid needle Check tip/needle selection chart
fitted to gun.
and fit correct item.
Sluggish needle.
Lubricate packing.
Tight packing nut.
Adjust.
Contamination on needle or tip
Remove tip and needle and
mating surfaces preventing good
thoroughly clean.
seal.
Major fluid leak or fluid jetting
from fluid tip and needle seat.
Incorrect fluid tip for fluid needle Check tip/needle selection chart
fitted to gun.
and fit correct item.
Slow fluid leak from needle
packing.
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Fluid needle packing worn or
loose.
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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.
Air Valve Stem seal damaged or
missing.
Replace.
Small air leak from air cap when
gun is not triggered.
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EN
TROUBLESHOOTING SPRAY PERFORMANCE
CONDITION
CAUSE
CORRECTION
Heavy top or bottom pattern.
Material build-up on air cap,
plugged horn holes, centre holes or
jets.
Soak cap or tip in suitable solvent
and thoroughly clean.
Material build-up on fluid tip exterior Replace fluid tip or air cap if
or partially plugged fluid tip.
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.
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 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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EN
Heavy centre pattern.
Intermittent or 'fluttering'
spray fan.
Pattern adjustment valve set too low.
Turn out counter clockwise to
achieve correct pattern.
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.
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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EN
Ball end heavy
pattern.
Too much fluid flow.
Change fluid tip for smaller size or
change air cap for different
specification air cap.
Too much atomisation 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.
Material too thin.
Mix properly or apply light
coats/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 spray
pattern.
Fluid flow too low.
Increase fluid flow by changing fluid
tip size, supply pressure or turning
needle control knob counter
clockwise.
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 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.
© 2018 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,
Middel 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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