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
WARNING 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- Solvent and coatings can be highly Adequate exhaust must be provided to
Fire Hazard flammable or combustible especially keep air free of accumulations of flammable
when sprayed. 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 Wear eye protection
can be forcefully expelled from fluid and
air passageways. Some solvents can
cause eye injury.

Toxic Substances Certain materials may be harmful if Follow the requirements of the Material
inhaled, or if there is contact with the Safety Data Sheet supplied by your coating
skin. 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- Halogenated Hydrocarbon solvents - for Guns with stainless steel fluid passages
Incompatible Materials example: Methylene Chloride and 1,1,1 - may be used with these solvents. However,
Trichloroethane are not chemically Aluminium is widely used in other spray
compatible with the aluminium which may application equipment - such as material
be used in many system components. pumps, cups and regulators, valves, etc.
The chemical reaction caused by these Check all other equipment items before use
solvents reacting with aluminium can and make sure they can also be used
become violent and lead to an equipment safely with these solvents. Read the label
explosion. 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.

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SPRAY FAULTS
Condition Cause Correction
Improper spray pattern Gun Improperly adjusted. Readjust gun, follow instructions carefully.

Clean air cap.

Dirty air cap
Clean
Fluid tip obstructed
Lubricate (see lubrication section) or
Sluggish needle loosen packing nut.

Heavy top or bottom pattern Material build-up on air cap, partially Soak cap or tip in suitable solvent and wipe
plugged horn holes, centre holes or jets. clean. To clean orifice, use a broom straw
Material build-up on fluid tip or partially or toothpick. Never use a wire or hard
plugged fluid tip 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 Reduce fluid flow by turning fluid needle
adjusting screw clockwise. Reduce fluid
pressure or increase atomisation pressure.

Thin
Material too thick

Intermittent or ‘fluttering’spray fan Loose fluid tip Tighten to 17 Nm (150 ibf/in)

Fluid tip not seated correctly in gun head Remove tip, clean components, check
cone seating on tip and gun for damage or
contamination
Gun (with cup) tipped at excessive angle.
Do not tip excessively or rotate fluid tube.
Obstructed fluid passage or hose.
Clean
Loose or cracked fluid tube in cup or
tank. Tighten or replace

Insufficient fluid in cup or pressure tank.

Fill cup or tank
Too heavy fluid for suction feed.

Thin material or change to pressure feed

Dry or worn packing or loose packing nut.
Lubricate or replace. Tighten
Plugged vent on suction feed cup.

Gun fluid inlet loose or not sealed/seated Clean vent hole in cup lid.
correctly
Tighten to 8 Nm (70 lbf/in)
Fluid hose or cup not fitted correctly to
gun fluid inlet connector
Remove, check mating surfaces and re-
tighten

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SPRAY FAULTS
Condition Cause Correction

Split spray pattern Not enough material or too high Reduce air pressure or increase fluid flow
atomisation pressure by turning fluid needle adjusting screw
counterclockwise or increase fluid
pressure on pressure feed container.

Excessive bounce-back Too much atomisation air pressure Reduce air pressure

Gun too far from surface Check distance (normally 6-8”)

Improper technique i.e. arcing, & fanning Move at moderate pace, parallel to work
the gun surface

FINISH FAULTS
Runs and sags Too much material flow Adjust gun or reduce fluid pressure

Material too thin Mix properly or apply light coats

Gun tilted on an angle Hold gun at right angle to work and adapt
to proper gun technique

Thin, sandy coarse finish drying before it Gun too far from surface Check distance (normally 6-8”)
flows out.
Too much air pressure Reduce air pressure and check spray
pattern

Improper thinner being used Follow paint manufacturers mixing

instructions

Thick dimpled finish “orange peel”. Too Gun too close to surface Check distance (normally 6-8”)
much material coarsely atomised.
Air pressure too low Increase air pressure or reduce fluid
pressure

Improper thinner being used Follow paint manufacturers mixing

instructions

Material not properly mixed Follow paint manufacturers mixing

instructions

Surface rough, oily, dirty Properly clean and prepare

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GUN FAULTS
Condition Cause Correction
Will not spray No air pressure at gun Check air supply and air lines

Internal mix or pressure feed air cap used Change to proper suction feed air cap
with suction feed

Fluid pressure too low with internal mix Increase fluid pressure at tank
A cap and pressure tank

Fluid needle adjusting screw not open Open fluid needle adjusting screw
enough

Fluid too heavy for suction feed Thin material or change to pressure feed.

Gun ‘spits’paint when triggering on Incorrect needle fitted to gun Check tip/needle selection chart and fit
and off correct item
A
Excessive needle wear Replace with new needle

Excessive fluid tip wear Replace with new fluid tip

Small air leak from air cap when Air valve contaminated and not correctly Remove valve and thorougly clean valve
gun is not triggered seating shaft and seating surfaces
A
Air Valve seal damaged or missing Replace

Gun ‘spits’paint when triggering on Fluid tip not fitted correctly in gun head Tighten to correct torque
due to paint build-up inside air cap
A between spraying operations Fluid tip/needle leakage
Check for damage or blockage

Slow fluid leak from fluid tip and Fluid Tip internal seat scored, damaged or Replace
needle seat worn

Fluid needle external profile damaged or Replace

worn

Contamination on needle or tip mating Thoroughly clean

surfaces preventing good seal
B
Incorrect fluid tip for fluid needle fitted to Check tip/needle selection chart and fit
gun correct item

Sluggish needle Lubricate packing

Tight packing nut Adjust

Major fluid leak or fluid jetting from Contamination on needle or tip mating Remove tip and needle and thoroughly
fluid tip and needle seat surfaces preventing good seal clean

Incorrect fluid tip for fluid needle fitted to Check tip/needle selection chart and fit
gun correct item

B Fluid needle stuck or ‘binding up’ Remove and clean fluid needle shaft, or
lubricate needle packing or loosen needle
packing

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GUN FAULTS
Condition Cause Correction
Paint build-up on fluid tip Fluid tip not fitted correctly in gun head Tighten to correct torque

B Fluid tip/needle leakage

Check for damage or blockage

Paint build-up on Air cap Damaged air cap holes Replace with new Air cap

B Gradual build-up of bounce-back on gun Thorougly clean

head

Slow fluid leak from needle packing Fluid needle packing worn or loose Tighten or replace as necessary
C
Air valve sluggish or slow to turn Air valve stem bent Replace damaged component
on/off when trigger is
D pulled/released Contamination on air valve stem Remove and clean

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

D
Air valve will not operate (air valve Air valve stem bent Remove air valve and replace damaged air
stem will not fully slide into valve valve stem
D body) when trigger is pulled
Contamination on air valve stem Remove air valve and thoroughly clean

Stiff trigger action Air valve stem bent Replace damaged component

Contamination on air valve stem Remove and clean

E Contamination on trigger bearing screw Remove and clean

Contamination on fluid needle shaft

Remove and clean
Fluid needle packing too tight
Loosen packing nut
Air leak from fluid needle exit point Seal damaged or missing Replace
in top of handle
F
Air cap retaining ring will not rotate Contamination on retaining threads Soak gun head in solvent to soften paint

G Cut retaining ring off of gun (probably

Deformed or damaged retaining ring replace retaining ring and baffle)

Unable to turn fan control knob on Internal O ring swollen or broken Replace O ring
top rear of gun
H Paint contamination on threads Remove and thoroughly clean

Unable to get round spray Fluid tip or air baffle incorrectly fitted Remove, check components for damage
and refit correctly

H Air baffle chinmey damaged Replace air baffle

Air leak from baffle seal Baffle seal swollen or damaged Replace
I
Unable to turn air control valve on Internal O ring swollen or broken Replace O ring
handle of gun
J Paint contamination on threads Remove and thoroughly clean

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Without a hose cleaner, remove excess material from cup or

Spray Gun Cleaning tank and clean. Set up cup, tank or pump to operate with clean
cleaning solvent. Turn off atomisation air to gun. Trigger gun
Suction Feed Clean Up:
into waste container. Continue flushing until cleaning solvent is
clear. Blow air through hose to dry. Wipe hose and gun with
Turn off air supply. Disconnect cup from lid. Raise tube out of
cleaning solvent dampened rag and lubricate gun.
material and pull trigger to allow remaining material to drain
back into the cup. Then empty the cup of material. Clean the
Cleaning the Air Cap:
cup, lid and tube. Add some thinner to cup.
Remove the air cap and, if dirtied with dry paint, let it soak in
Reassemble - Turn on air supply and spray with proper
clean solvent. Later, brush and wipe off the air cap. If any holes
cleaning solvent. Repeat with clean solvent if necessary.
in the cap are clogged, probe them with a whittled match-stick
Remove solvent, disconnect gun, remove air cap and clean.
or tooth pick. Don’t ream the air cap holes with wire, nails or
Wipe gun and cup with cleaning solvent dampened rag.
metal tools. This may damage the hole and result in imperfect
spray patterns.
Pressure Feed Clean Up:
Note - Never soak the entire gun in cleaning solvent. This will
First, turn off air supply to material source (cup, tank or pump).
dry out the packing and remove lubrication.
Release material pressure from the system by opening relief
valve or pulling trigger on gun.
Lubrication:
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 Daily, or after each use if intermittent, place a drop of SSL-10
solvent dampened rag, then lubricate. Use SSL-10 spray gun gun lube on the points shown. Springs behind the fluid needle
lube. and air valve should have a light coat of petroleum jelly.

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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
Steve Mannouch Oct96
BH11 9LH
Tel: 01202 571111

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