DeVilbiss & &0 SERVICE BULLETIN SB-2-239-D Replaces SB-2-239-C Repair Kit KK-4987-1 JGHV-530 Suction Feed High Volume low Pressure Spray Gun IMPORTANT: Before using this equlpment,'read all safety precautions and Instructions Keep for future use DESCRIPTION All wetted surfaces are stainless steel and may be used with materials formulated with chlorinated solents, The suction feed JGHV gun is designed to apply a wide ariety of finishing materials This gun was manufactured to proide maximum transfer efficiency by limiting air cap pressure to 10 psi (complies with rules Issued by SCAQMD and other air quality authorities) The gun is intended tor use with suction feed paint supply This gun will produce approximately 10 psi cap pressure at 65 psi gun inlet pressure, as measured at the gun inlet An air cap test kit (see Accessories) should be used to insure 1 o psi air cap pressure is not exceeded INSTALLATION For maximum transfer efficiency, do not use more pressure than Is necessary to atomize the material being applied Connect the gun to a clean, moisture and oil free air supply using a hose size of at least 516" JD hose Aoid use of quick detachable connectors Do not use 14" ID hose (25' x 1 4" hose at 18 CFM has a pressure loss of 25 psi 25' x 516" hose at 18 CFM has a pressure loss of 8 psi) Depending on hose length, larger I D hose may be required Install an HAV-501 air gauge at the gun handle and air cap test kit oer tip When gun is triggered on, adjust regulated pressure to desired setting to proide a maximum of 1 0 psi at the air cap Do not use more pressure than Is necessary to atomize the material being applied Excess p;essure will create additional oerspray and reduce transfer efficiency OPERATION Strain material thru 60 or 90 mesh screen Best atomization will occur with 10 psig air cap pressure Howeer, some materials can be sprayed at lower pressures, improing transfer efficiency Make sure ent hole in suction cup is clean Open fluid adjusting screw (32) by turning counterclockwise Tum on air supply and set gun inlet pressure to lowest recommended pressure tor material being sprayed Spray a test area If finer atomization or increased fluid flow rates are required, increase gun inlet pressure If reduced fluid flow rates are required, turn fluid adjusting screw (32) clockwise until desired fluid flow is obtained If an air adjusting ale is used atthe gun inlet, use DeVilbiss Model HAV-500 or HAV-501 Some competnie adjusting ales hae significant pressure drop that can adersely affect spray performance Models HAV-500 and HAV-501 hae minimal pressure drop, which is important tor HVLP spraying See Spray Gun Guide, SB-2-001 latest reision, tor 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 Neer use a wire or hard Instrument This may scratch or burr holes causing a distorted spray pattern To clean fluid passages, remoe excess material from suction cup Wash out cup with solent Wipe off cup suction tube, then fill cup with solent Spray until fluid passages are clean Wipe gun exterior with a solent dampened cloth Neer completely immerse in solent as this is detrimental to the performance and gun life expectancy, as well as destroying the lubricants and packings
Page 2 SB-2-239-D 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 I WARNING Important safety Information A hazard that may cause serious Injury or loss of lite Important Information that tells how to preent damage to equipment, or how to aoid a situation that may cause minor lnury WARNING Information that you should pay special attention to The following hazards may occur during the normal use of this equip ment Please read the following chart before using this equipment I Area Hazard Tells what hazard Is Safeguard Tells how to aoid the hazard Solent Spray During cleaning and flushing, solents can be forcefully expelled from fluid and air passages Some solents can cause eye injury Smcking must neer be allowed in the spray area Fire extinguishing equipment must be present in the spray area Wear eye protection Explosion Hazard - Materials Certain materials may be harmful if inhaled, or if there is contact with the skin Halogenated hydrocarbon solents -tor example; methylene chloride and 1, 1, 1 -Trichloroethane can chemically react with aluminum The chemical reaction caused by these solents reacting with aluminum can become iolent and lead to an equipment explosion Follow the requirements of the Material Safety Data Sheet supplied by your coating material manufacturer Adequate exhaust must be proided to keep the air free of accumulations of toxic materials Use a mask or respirator wheneer there is a chance 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 hygienst or safety expert, and be NIOSH approed This gun can be used with these solents Howeer, aluminum is widely used in other spray application equipment - such as, material pumps, cups, regulators, ales, etc Check all other equipment items before use and make sure they can also be used safely with these solents Read the label or material 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
Figure 1 Baffle Page 3 SB-2-239-D When baffle (6) and fluid tip (3) are remoed, seal (4) and 0-ring (5) should be replaced For your conenience, an extra seal and 0-ring is included with this gun Be careful when reassembling baffle not to damage the 0-ring Apply SSL-1 0 gun lube to the 0-ring to help in reassembling Maximum air pressure required to assure compliance of 10 PSI Max Cap Pressure - this reading must be taken at the spray gun handle inlet fitting To preent damage to the fluid tip (3) or fluid needle (29), be sure to either 1) pull the trigger and hold while tightening the fluid tip or 2) remoe fluid needle adjusting screw (32) to reliee spring pressure JGHV-i i 6-K5 Gasket Replacement Instructions 1 Remoe fluid inlet adapter (9) with appropriate wrench 2 Clean loctite from gun body inlet threads and seal area 3 Place new gasket (7) squarely into the fluid inlet caity in the gun body Push the gasket (7) down with a blunt object, such asa pen or pencil, to guide and seat the gasket squarely into the gun body 4 Place a couple of drops of OH-130 (medium strength No 242 Loctite) on threads before installing fluid inlet adapter (9) 5 Torque fluid inlet adapter to 10ft lbs and tighten locknut (8) To preent serious gun damage, do not remoe tip (3) If the fluid Inlet adapter (9) has been remoed The stainless steel fluid Insert can break free (which Is non-repairable) Remoe the fluid tip (3) ~remoing the fluid inlet adapter (9) Chart 1 AIR CAP & BAFFLE COMBINATION NoStamped on Parts ' Set ~ '~ Air Cap Ref No2 Ref No6 Part No Baffle Air Cao Baffle 57 57-65 JGHV-101 57 JGHV-450 57-65 Air cap number located on face of cap - cap number must correspond with baffle number to assure 10 PSI cap pressure SPRAY GUN LUBRICATION Daily, apply a drop of gun lube at trigger bearing stud (19) and the stem of the air ale (14) where it enters the air ale assembly (1 7) The shank of the fluid needle (29) where ij enters the packing nut (23) should also be lubricated The fluid needle packing (22) should be kept soft and pliable by daily lubrication Make sure baffle and retaining ring threads are clean and free of foreign matter Before assembling air cap to baffle, clean the retaining ring and baffle threads thoroughly, then add two drops of SSL-10 spray gun lube to threads The fluid needle spring (31) and air ale spring (15) should be coated with a ery light grease, ensurtng that any excess grease will not clog the air passages For best results, lubricate the points indicated daily using SSL-10 spray gun lube A Trigger points B Packing C Adjusting ale D Baffle & retaining ring threads E Air ale cartridge A Chart 2 FLUID TIP AND NEEDLE If this Is No on Matched Fluid Tip TIP Size iidj Tip, Order, & Needle Assy ln mm AV-2125-D JGA-4046-22 086 22 : Do not use AV-1 gasket with this spray gun
Page 4 SB-2 239-0 JGHV-101-57 Air Cap Performance Charts Graph 1 25 25 10 25 30 35 40 45 50 55 60 65 Gun Inlet Pressure (PSI) Graph 2 10 9 ---- PARTSUST Ref Replacement Indiidual No Part No Description Parts Req * # 1 MBC-368 Retaining Ring 1 2 See Chart 1 Air Cap 1 3 See Chart 2 Fluid Tip 1 4 JGD-14-K10 Seal (Kit of 10) (Polyethylene) 1 5 SSG-8182-K5 "0" Ring (Kit of 5) 1 6 See Chart 1 Baffle, Gasket & Seal Kit 1 7 JGHV -116-K5 Gasket (Kit of 5) (Glass filled Teflon) 1 8 Locknut 1 9 - Fluid Inlet Adapter 3B" NPS 1 10 JGV-444 Fluid Inlet, Nut & Gasket Kit 1 11 Snap Ring 1 12 Washer 1 13 "UuCup 1 14 Air Vale 1 15 - Spring 1 16 JGS-72-K10 Gasket (Kit of 10) (Teflon) 2 17 JGS-449-1 Air Vale Assembly 1 18 Screw 1 19 - Trigger Bearing Stud 1 20 JGS-478 Stud & Screw Kit 1 (Kit includes 3 studs & 5 screws) 21 JGS-477 Trigger, Stud & Screw Kit 1 (Kit includes 1 each) 22 JGA-4035-K1 0 Packing (Kit of 10) 1 23 34411-122-K10 Fluid Needle Packing Nut (Kit of 10) 1 24 JGA-132 Plug 1 25 P-MB-51 Air Inlet Adapter 14" NPS 1 26 Retaining Ring 1 27 - "0" Ring (Vitron) 1 28 JGA-497-1 Fan Adjustment Assy 1 29 See Chart 2 Fluid Needle 1 30 - Gun Body Bushing 1 31 MBD-19-K10 Spring (Kit of 10) 1 32 JGS-16 Fluid Needle Adjusting Screw 1 33 JGA-4041 Bushing, Spring & Knob Ktt 1 30 35 40 45 50 55 60 65 Gun Inlet Pressure (PSI) A quantity of necessary parts is included in Gun Repair Kit KK-4987-1 which should be kept on hand for serice conenience Use JGS-449 1 ale assembly only Do JlQl use JGS-449 Pressure drop will occur Suffixes -K10, etc, designates kits of multiple parts Example: JGD-14-KiO is a kit of 10 seals
Page 5 SB-2-239-D 29 33 I 28---; 26 I 27 I \ ri -~-c==:: ==~ 6 \ -, 1 2 3 -D-A\'\1 Torque to 20-25 ft lbs <t> ~i l I I~ 10 Torque to 22 9 10 ftlbs 23 18 11 12 13 14 16 \ 1s I \ 17 21 ~ A (Ref No 22) Needle Packing Assy Detailed 3 Piece * Apply QH-130 (loctite #242 blue med strength) sealing 6 Drawing compound on threads
Page 6 SB-2-239-D TROUBLESHOOTING Condition Heay top or bottom pattern Cause Horn holes plugged Correction Clean Ream with non-metallic point ' ' Heay right or left side pattern )( Obstruction on top or bottom of fluid tip Cap andor lip seat dirty Left or right side horn holes plugged Dirt on left or right side of fluid tip Clean Clean Clean Ream with non-metallic point Clean Remedies for top-heay, bottom-heay, right-heay and left-heay patterns: 1) Determine if obstruction is on cap or fluid tip Do this by making a test pattern Then, rotate cap one-half turn and spray another pattern If defect is inerted, obstruction is on air cap Clean air cap as preiously instructed 2) If defect is not inerted, it is on fluid tip Check for a fine burr on edge of fluid lip Remoe with #600 wet or dry sand paper 3) Check for dried material just inside opening Remoe by cleaning Material flow exceeds air cap's capacity Thin or lower fluid flow Heay center pattern t Split spray pattern 1 Jerky or fluttering spray Atomizing pressure too low Material too thick Fluid adjusting knob turned in too far Atomization air pressure too high Increase pressure Thin to proper consistency Back out counterclockwise to achiee proper flow Reduce air pressure Loose or damaged fluid tip seat Tighten or replace m~,nu Material leel too low Container tipped too far Obstruction in fluid passage Refill Hold more upright Clean according to material supplier's recommendations Loose or broken fluid tube or fluid inlet nipple Tighten or replace Dry or loose fluid needle packing nut Lubricate or tighten Will not spray No air pressure at gun Check air supply and air lines Fluid needle adjusting screw not open enough Open fluid needle adjusting screw Excessie oerspray Too much atomization air pressure Reduce pressure Gun too far from work surface Adjust to proper distance Improper stroking (arching, gun motion to fast) Moe at moderate pace, parallel to work surface
Condition Cause Correction Dry Spray Air pressure too high Decrease air pressure Page 7 SB-2-239-D Gun tip too far from work surtace Gun motion too fast Gun out of adjustment Fluid leaking from packing nut Packing nut loose Packing worn or dry Adjust to proper distance Slowdown Adjust Tighten but do not bind needle Replace or lubricate Fluid leaking or dripping from Foreign matter in tip Cleanc front of gun Packing nut too tight Adjust Dry packing Fluid tip or needle worn or damaged Lubricate Replace tip & needle with lapped sets Fluid needle spring deformed or broken Replace Runs and sags Too much material flow Lower air pressure or turn needle adj screw {32) in clockwise Material to thin Gun tilted at an angle Mix properly or apply light coats Hold gun at right angle to work and adapt to proper gun technique Thin, sandy coarse finish Gun too far from surtace Check distance Normally 6-8" Drying before it flows out Too much air presure Reduce air pressure and check spray pattern Improper thinner being used Follow paint mfgr's mixing instructions Thick, dimpled finish "orange Gun too close to surface Check distance Normally 6-8" peel" Too much material, coarsely atomized Air pressure too low Increase air pressure or reduce flow by turning needle adj screw {32) in clockwise Improper thinner being used Material not properly mixed Surface rough, oily, dirty Follow paint mfgr's mixing instructions Follow paint mfgr's mixing instructions Properly clean and prepare Excessie fog Too much, or too fast-trying thinner Remix properly Too much atomization air pressure Reduce pressure Unable to get round spray Fan adjustment screw not seating Clean or replace property Most common problem Air cap retaining ring loose Tighten
Page 8 SB-2-239-D SERVICE BULLETIN REVISIONS R e f er to the f o II owmo c h art for Part N o L" ijerature chances Part No Chanaes Old Part Number New Part Number lnterchanaeablllt Literature Chances 1 Added Figure 1, Pg 3 infermation on checking max air pressure at cap 2 Added Safety Precautions and Toubleshooting into manual 3 Reised Wortdwide Sales and Serice Listino ACCESSORIES SPRAY GUN lube SSL-10 (2 oz bottle) Compatible with all paint materials: contains no silicone or petroleum, distihajes to contammate pa1nt TGC-&45 (Aluminum) TLC-555 (Teflon Uned) TSC-595 Stainlesa Steel Drip Free Suction Cups ~, ;,::-' Cup has a unique, two position ale which parm~s seleclion of either a drip!roo or conentional open ent mode HAV-501 Adjusting Vale Use to control air pres sure at gun KK-4974-57, Air Cap Test Kit The purpose of thls test kit Is to measure air cap atomizing air pressure at the center air port or the air cap Used to confirm code compliance and as a dally quallly control measure HD-503 SolantSaer'nll 2 Quart Hose Cleaner used to clean the in side of hose and material passagesofqun Other sizes aailable WR-103 Wrench MSP-521 Twin Cartridge, Paint Spray Respirator - NIOSH-Certified (TC-23C-863) for respiratory protection in atmospheres not immediately dangerous to life JGA-444 Fluid Tube- This tube combines the fluid and air hoses at gun handle preenting dragging hoses oer work, twisting lines and improing oerall gun handling Contains all neces Sf1ry tip, hose and r'jui s1zes used on or With gun KK-5004 Pressure Feed To Suction Feed Conersion Kit- Conerts JGHV-530 pressure feed spray gun to suction feed Includes air cap, baffle, matched fluid tip and needle 41677-205 (FX) 41677-206 (FF) Resilient Tipped Needle- Suited for use with organic finishing materials and many wood sealers containing silica VS-531 Low Pressure Fluid Strainer- This strainer proides a final filter for trapping foreign particles in the paint supply 42884-214-KS (38") & 42884-215-K10 (58") Cleaning Brushes- These brushes are helpful in cleaning threads and recesses of gun body WARRANTY This product is coered by DeVilbiss' 1 Year Limited Warranty See SB-1-000which is aailable upon request SERVICE NOTES For a complete guide on air spray equipment, order a free copy of SB-2-00 1 Worldwide Sales and Serice- DeVILBISS INDUSTRIAL SPRAY EQUIPMENT DeVilbiss has authorized distributorsthroughouttheworld For equipment, parts and serice, check the Yellow Pages under"spray Equipment" FOR TECHNICAL ASSISTANCE, CALL TOLL FREE 1-800-338-4448 (US ONLY) FOR LOCAL CALLS Worldwide Sales and Serice- DeVILBISS AUTOMOTIVE REFINISHING DeVilbiss has authorized distributors throughout the world For equipment, parts and serice, check the Yellow Pages under "Automobile Body Shop Equipment and Supplies" FOR TECHNICAL ASSISTANCE, CALL TOLL FREE 1-800-445-3988 (US ONLY) DeVilbiss 395 COCopyright 1995, DeVilbiss Printed in USA