De Havilland JGA-510 User manual

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SB-2-248-L (11/2014) 1 / 8
SERVICE MANUAL
JGA-510 (HVLP)
SUCTION/PRESSURE FEED
SPRAY GUN
MAJOR REPAIR KIT KK-4987-2
(GOVERNMENT NSN NO. 4940-01-046-9919 = KK-4987-2)
MINOR REPAIR KIT KK-5034
IMPORTANT: Before using this equipment,
read all safety precautions and instructions.
Keep for future use.
DESCRIPTION
The high volume low pressure JGA-HVLP gun
is designed to apply a wide variety of finish-
ing materials. This gun was manufactured
to provide 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 available in
both suction feed and pressure feed versions
of fluid delivery.
This gun will produce approximately
10 psi cap pressure at 50 psi gun inlet
pressure, as measured at the gun inlet.
An air cap test kit (see Accessories, Page
6) should be used to insure 10 psi air cap
pressure is not exceeded.
Note
This gun includes 300 series
stainless steel fluid passages
and 400 series tip and needle.
Guns may be used with chlorinated
solvent materials. See Page 2 for
additional warnings.
IMPORTANT: This gun may be used with
most common coating and finishing ma-
terials. It is designed for use with mildly
corrosive and nonabrasive materials. If
used with other high corrosive or abra-
sive materials, it must be expected that
frequent and thorough cleaning will be
required and the necessity for replacement
of parts will be increased.
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
5/16" I.D. Do not use 1/4" I.D. hose (25' x 1/4"
hose at 18 CFM has a pressure loss of 25 psi.
25' x 5/16" hose at 18 CFM has a pressure
loss of 8 psi.
Note
Depending on hose length, larger
I.D. hose may be required. Install a
HAV-501 air gauge at the gun handle
and air cap test kit over tip. When
gun is triggered on, adjust regulated
pressure to desired setting to pro-
vide a maximum of 10 psi at the air
cap. Do not use more pressure than
is necessary to atomize the mate-
rial being applied. Excess pressure
will create additional overspray and
reduce transfer efficiency.
Note
If quick connects are required,
use only high flow quick con-
nects approved for HVLP use
such as DeVilbiss HC-4419 &
HC-4699. Other types will not flow
enough air for proper gun operation.
Note
If an air adjusting valve is used
at the gun inlet, use DeVilbiss Model
HAV-500 or HAV-501. Some compet-
itive adjusting valves have signifi-
cant pressure drop that can adverse-
ly affect spray performance. Models
HAV-500 and 501 have minimal
pressure drop, which is important
for HVLP spraying.
OPERATION
Strain material thru 60 or 90 mesh screen.
Best atomization will occur with 10 psig
air cap pressure. However, some materials
can be sprayed at lower pressures, improving
transfer efficiency.
Open fluid adjusting screw (27) by turning
counterclockwise. If gun is a suction feed
version, make sure vent hole in suction
cup is clean. If gun is a pressure feed
version, turn on air to paint supply
and adjust fluid pressure to deliver the
desired paint volume.
Turn on air supply to gun and set gun
inlet pressure to lowest recommended
pressure for material being sprayed. Spray
a test area. Air pressure and paint flow
should be adjusted to provide a uniform
dispersion of atomized paint throughout
the pattern. Keep air pressure as low as
possible to minimize bounce-back and
overspray. Excessive fluid flow will result
in heavy center spray patterns. Inade-
quate flows may cause the pattern to split. See
TROUBLESHOOTING, page 5, if any problems
occur. If finer atomization is required, increase
gun inlet pressure. If a reduced fluid flow rate
is required, turn fluid adjusting screw (27)
clockwise until desired fluid flow is obtained
or reduce fluid pressure (pressure feed only).
Order a free copy of Spray Gun Troubleshoot-
ing and Preventive Maintenance Guide, SB-
2-001 latest revision, for details concerning
setup 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. See
page 6 for gun cleaning accessories.
To clean fluid passages, remove excess
material at source Then proceed as follows:
Suction Feed Guns - Wash out cup with
solvent. Wipe off cup suction tube, then
fill cup with solvent. Spray until fluid
passages are clean.
Pressure Feed Guns - Flush fluid delivery sys-
tem with a suitable solvent using a device such
as the SolventSaver™ (see ACCESSORIES).
Wipe exterior with a solvent dampened cloth,
or use 29-3100 Scrubs®(shown on page 6.)
Never completely immerse in solvent as this
is detrimental to the performance and gun
life expectancy, as well as destroying 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 Chart 1 for order-
ing information. Also, replace the
needle packing at this time. Lightly
lubricate the threads of the fluid tip
before reassembling. Torque to
20-25 ft. lbs.
To prevent damage to fluid tip
(3) or fluid needle (32), be sure
to either 1) pull the trigger and
hold while tightening or loos-
ening the fluid tip, or 2) re-
move fluid needle adjusting screw
(27) to relieve spring pressure
against needle collar.

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SB-2-248-L (11/2014)2 / 8
HAZARD CAUSES SAFEGUARDS
Fire Solvent and coatings can be highly flammable Adequate exhaust must be provided to keep air free of
or combustible especially when sprayed. accumulations of flammable vapors.
Smoking must never be allowed in the spray area.
Fire extinguishing equipment must be present in spray area.
Solvent Spray During use and while cleaning and flushing, Wear eye protection.
solvents can be forcefully expelled from fluid
and air passages. Some solvents can cause
eye injury.
Inhaling Toxic Certain materials may be harmful if inhaled, Follow the requirements of the Material Safety Data Sheet
Substances or if there is contact with the skin. supplied by your coating material manufacturer.
Adequate exhaust must be provided to keep the air free of toxic
materials.
Use a mask or respirator whenever 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 hygienist and be NIOSH
approved.
Explosion Hazard - Halogenated hydrocarbon solvents - for example; Guns with stainless steel internal passageways may be used
Incompatible methylene chloride and 1, 1, 1 - Trichloroethane with these solvents. However, aluminum is widely used in
Materials are not chemically compatible with the aluminum other spray application equipment - such as material pumps,
that might be used in many system components. regulators, valves and cups. Check all equipment items before
The chemical reaction caused by these solvents use and make sure they can also be used safely with these
reacting with aluminum can become violent and solvents. Read the label or data sheet for the material you
lead to an equipment explosion. 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 &
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 Use of hand tools may cause cumulative trauma Pain, tingling, or numbness in the shoulder, forearm, wrist,
Disorders (CTD's) disorders (“CTD’s”). hands or fingers, especially during the night, may be early
symptoms of a CTD. Do not ignore them. Should you
CTD's, or musculo- CTD’s, when using hand tools, tend to affect the experience any such symptoms, see a physician immediately.
skeletal disorders, upper extremities. Factors which may increase Other early symptoms may include vague discomfort in the
involve damage to the risk of developing a CTD include: hand, involve loss of manual dexterity, and nonspecific pain
the hands, wrists 1. High freequency of the activity. in the arm. Ignoring early symptoms and continued repetitive
elbows, shoulders, 2. Excessive force, such as gripping, pinching use of the arm, wrist and hand can lead to serious disability.
neck and back. or pressing with the hands and fingers.
Carpal tunnel 3. Extreme or awkard finger, wrist, or arm
syndrome and positions.
tendinitis (such 4. Excessive duration of the activity.
as tennis elbow or 5. Tool vibration.
rotor cuff syndrome) 6. Repeated pressure on a body part.
are examples of 7. Working in cold temperatures.
CTD's.
CTD's can also be caused by such activities as sewing, golf, tennis and bowling, to name a few.
SAFETY PRECAUTIONS
This manual contains information that is important 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
Information that you should pay special
attention to.
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 injury.
The following hazards may occur during the normal use of this equipment.
Please read the following chart before using this equipment.
CA PROP
65
PROP 65 WARNING
WARNING: This product contains chemicals
known to the State of California to cause
cancer and birth defects or other
reproductive harm.

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SPRAY GUN LUBRICATION
Daily, apply a drop of •SSL-10 spray gun
lube at trigger bearing stud (20) and the
stem of the air valve (12) where it enters
the air valve assembly (16). The shank of
the fluid needle (32) where it enters the
packing nut (18) should also be oiled.
The fluid needle packing (17) should be
lubricated periodically. Make sure the
baffle (5) and retaining ring (1) 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. The fluid needle spring (29) and
air valve spring (11) should be coated
with a very light grease, making sure that
any excess grease will not clog the air pas-
sages. For best results, lubricate the points
indicated, daily.
•A Material Safety Data Sheet is available
from DeVilbiss upon request.
A. Trigger Points
B. Packing
C. Adjusting
Valves
D. Baffle
Threads
E. Air Valve
Cartridge
PARTS REPLACEMENT - FLUID INLET
GASKET (6) REPLACEMENT INSTRUC-
TIONS
1. Remove fluid inlet adapter (8) with ap-
propriate wrench.
2. Clean Loctite from gun body inlet threads
and seal area.
3. Place gasket (6) squarely onto the fluid
inlet adapter and push it down until it
is flat against the shoulder.
4. Place a couple of drops of medium
strength thread sealant (i.e. Loctite 242
blue, or equal) on threads before install-
ing fluid inlet adapter.
5. Torque fluid inlet adapter to 20-25 ft. lbs.
and tighten locknut.
Figure 1 Baffle
C
A
E
DB
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.
Air cap number located on face
of cap - cap number must cor-
respond with baffle number to
assure 10 psi cap pressure.
57
50
Chart 1
FLUID TIP AND NEEDLE
Tip Size
Needle Tip (I.D.)
In. mm
JGA-402-DEX AV-2125-D .086 2.2
JGA-402-E AV-2125-DE .070 1.8
JGA-402-FX AV-2125-DFX .042 1.1
Note: Do not use AV-1 copper
gasket with this spray gun.
JGHV-101-57 Air Cap
Performance Charts
Gun Inlet Pressure (PSI)
Air Cap Pressure (PSI)
Graph 2
Gun Inlet Pressure (PSI)
Air Flow Rate (SCFM)
DISASSEMBLY INSTRUCTIONS -
NEW BAFFLE ASSEMBLY
The baffle design incorporates a tight,
press fit with the fluid tip, assuring a
positive air seal. With this design, the
baffle may pull away from the gun body
when the tip is removed and stay locked
onto the fluid tip. If this occurs, follow the
instructions below.
Note
A bench vise should be used for
convenience and to avoid damage
to the spray gun.
1. Secure the spray gun in a bench vise
with padded jaws, or use a rag to
avoid scratching the gun body.
2. Using a 1/2" socket, loosen the fluid
tip three (3) turns only, which will
leave about a 1/16" gap between the
baffle gasket and gun body. See
Figure 2. Do not loosen the fluid tip
more than three (3) turns, as
damage may occur.
Figure 2
Graph 1
3. Place a 1" socket (12 pt.) over the fluid
tip so that it rests on the top surface
of the baffle. See Figure 3.
4. Press downward on the socket with
sufficient force to free the baffle from
the tip. See Figure 3.
5. The fluid tip and baffle can now be
removed normally from the gun.
Figure 3
Loosen fluid tip
3 turns only.
1/16" gap
(approx.)
Fluid Tip
Baffle
Baffle
Gasket
Bench
Vise
Press Down
1" Socket
(12 pt.)
AIR CAP & BAFFLE COMBINATION
Set
No. Stamped on Part
Air Cap Ref. No. 2 Ref. No. 5
Part No. Baffle Air Cap Baffle
57 57 JGHV-101-57 JGHV-457-57
Chart 2

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Ref. Replacement Individual
No. Part No. Description Parts Required
1 MBC-368 Retaining Ring ......................................... 1
2 JGHV-101-57 Air Cap ......................................................1
3 See Chart 1 Fluid Tip ...................................................1
*4 JGD-14-K10 Gasket Kit, Polyethylene (Kit of 10) ........1
5 JGHV-457-57 Baffle and Gasket Kit ............................... 1
6 MSV-3-K10 Gasket, PTFE (Blue)(Kit of 10) .................1
7 — Lock Nut.................................................... 1
8 — Fluid Inlet Adapter ...................................1
9 JGA-4044 Fluid Inlet and Nut Kit.............................. 1
*10• JGS-72-K10 Gasket Kit, PTFE (Kit of 10) ....................2
*11 MBD-12-K25 Spring Kit (Kit of 25) ................................1
*12 JGS-431-K25 Air Valve Kit (Kit of 25) ............................1
*13• JGS-26-K25 U-Cup Seal Kit (Kit of 25) ........................1
*14 JGA-15-K25 Washer Kit (Kit of 25)............................... 1
*15 JGA-14-K25 Snap Ring Kit (Kit of 25) .........................1
16 JGS-449-1 Air Valve Assembly.................................. 1
*17• JGV-463-K3 Packing Kit (Kit of 3) ................................1
18 34411-122-K10 Packing Nut Kit (Kit of 10) .......................1
*19 — Screw ........................................................1
20 JGS-478 Stud and Screw Kit ..................................1
(Includes 3 studs and 5 screws)
PARTS LIST
**(Ref. No. 17) Needle Packing Detail (2 piece packing)
covered by U.S. Patent No. 5,209,501.
+Tapered edge faces out towards packing nut.
Fluid Packing
Nut
+Inner PTFE
Piece
Fluid
Needle
Outer U.H.M.W.
Poly. Piece
**17
18
9
6
7
8
1
2
3
4
5
22 23
15
14 16
10
11
12
13
33
21
20
19
30
10
29
31
27
28
25
24
32
26
Air Inlet Nipple
1/4" NPS(M)
(Torque to 15 ft. lbs.)
Torque to
20-25
ft.lbs.
Torque to
20-25
ft.lbs.
Fluid Inlet
Adapter
3/8" NPS(M)
* A quantity of necessary parts is included in Repair Kit
KK-4987-2 for complete gun repair and should be kept on hand for
service convenience. For more limited repair,
• "Soft Parts Kit" KK-5034 is also available (includes items 10, 13,
17, and 26).
#Ref. No. 34 includes Ref. Nos. 3 and 32. Copper tip gasket also
included but not used with JGA-510 gun.
Sufixes -K10 designates kit of multiple parts. Example:
JGD-14-K10 is a kit of 10 gaskets.
Government NSN No. 4940-01-046-9919 = KK-4987-2
Apply thread sealant (i.e.
Loctite blue No. 242, med.
strength or equal)
Ref. Replacement Individual
No. Part No. Description Parts Required
21 JGS-477-1 Trigger, Stud and Screw Kit
(Kit includes 1 each) 1
22 JGA-132 Plug 1
23 P-MB-51 Nipple 1
24 JGA-497-1 Fan Adjustment Assembly 1
*25 — Retaining Ring 1
*26• SSG-8069-K25 O-Ring, Viton (Kit of 25) 1
27 JGS-16 Adjusting Screw 1
*28 — Spring Pad
(Included with Nos. 29 & 31) 1
*29 MBD-19-K10 Spring Kit (Kit of 10) 1
30 — Bushing 1
31 JGA-4041 Bushing, Spring and Knob Kit 1
32 See Chart 1 Fluid Needle 1
33 — Gun Body
#34 See Chart 1 Fluid Tip &Needle Set (not shown) 1

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TROUBLESHOOTING
CONDITION CAUSE CORRECTION
Heavy top or
bottom pattern
Heavy right or left
side pattern
Heavy center pattern
Split spray pattern
Jerky or fluttering spray
Unable to get round spray
Will not spray
Runs and sags
Starved spray pattern
Excessive overspray
Excessive fog
Dry spray
Fluid leaking from packing nut
Fluid leaking or dripping from
front of gun
Horn holes plugged.
Obstruction on top or bottom of fluid tip.
Cap and/or tip seat dirty.
Left or right side horn holes plugged.
Dirt on left or right side of fluid tip.
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 by washing with solvent.
Clean. Ream with non-metallic point.
Clean.
Clean.
Clean. Ream with non-metallic point.
Clean.
Fluid flow too high for atomization air.
(Pressure Feed)
Material flow exceeds air cap's capacity.
Spreader adjustment valve set too low.
Atomizing pressure too low.
Material too thick.
Atomization air pressure too high.
Fluid flow too low.
Spreader adjusting valve set too high.
*Loose or damaged fluid tip/seat.
Material level too low.
Container tipped too far.
Obstruction in fluid passage.
Dry or loose fluid needle packing nut.
Loose or broken fluid tube or fluid inlet nipple.
Spreader adjustment screw not seating
properly.
Air cap retaining ring loose.
No air pressure at gun.
Fluid needle adjusting screw not open enough.
Fluid too heavy for gravity feed.
Fluid pressure too low.
Too much material flow.
Material too thin.
Gun tilted on an angle or gun motion too slow.
Inadequate material flow.
Low atomization air pressure (suction feed).
Too much atomization air pressure.
Gun too far from work surface.
Improper stroking (arcing, gun motion too
fast).
Too much or too fast-drying thinner.
Too much atomization air pressure.
Air pressure too high.
Gun tip too far from work surface.
Gun motion too fast.
Gun out of adjustment.
Packing nut loose.
Packing worn or dry.
Packing nut too tight.
Dry packing.
Fluid tip or needle worn or damaged.
Foreign matter in tip.
Fluid needle spring broken.
Wrong size needle or tip.
Balance air pressure and fluid flow. Increase
spray pattern width with spreader adjustment
valve.
Thin or lower fluid flow.
Adjust.
Increase pressure.
Thin to proper consistency.
Reduce at transformer or gun.
Increase fluid flow (increases gun handling speed).
Adjust.
Tighten or replace.
Refill.
Hold more upright.
Backflush with solvent.
Lubricate or tighten.
Tighten or replace.
Clean or replace.
Tighten.
Check air supply and air lines, blow out gun air
passages.
Open fluid needle adjusting screw.
Thin material and/or change to larger tip size.
Increase fluid pressure at tank.
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.
Back fluid adjusting screw out to first thread,
or increase fluid pressure at tank.
Increase air pressure and rebalance gun.
Reduce pressure.
Adjust to proper distance.
Move at moderate pace, parallel to work
surface.
Remix properly.
Reduce pressure.
Reduce air pressure.
Adjust to proper distance.
Slow down.
Adjust.
Tighten, do not bind needle.
Replace or lubricate.
Adjust.
Lubricate.
Replace tip and needle with lapped sets.
Clean.
Replace.
Replace.
*Most common problem.

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TROUBLESHOOTING (continued)
CONDITION CAUSE CORRECTION
Thin, sandy coarse finish
drying before it flow out
Thick, dimpled finish "orange
peel"
Gun too far from surface.
Too much air pressure.
Improper thinner being used.
Gun too close to surface.
Too much material coarsely atomized.
Air pressure too low.
Improper thinner being used.
Material not properly mixed.
Surface rough, oily dirty.
Check distance. Normally approx. 6-8".
Reduce air pressure and check spray pattern.
Follow paint manufacturer's mixing instructions.
Check distance. Normally approx. 6-8".
Increase air pressure or reduce fluid pressure.
Increase air pressure or reduce fluid pressure.
Follow paint manufacturer's mixing instructions.
Follow paint manufacturer's mixing instructions.
Properly clean and prepare.
ACCESSORIES
Contains all necessary
tip, hose and nut sizes
used on or with gun.
WR-103 Wrench
Joins any single piece
DeVilbiss air cap with
latest version MBC-368
or MSA-1 retaining ring.
Helps prevent parts loss
and provides easier
assembly.
JGA-156-K10
Spring Clips
42884-214-K5 (3/8") &
42884-215-K10 (5/8")
Cleaning Brushes
KK-5060 or 192212
Complete Cleaning Kit
These brushes are help-
ful in cleaning threads
and recesses of gun
body.
HAV-500 or HAV-501
Adjusting Valve
(HAV-501 shown)
HAV-500 does not have
pressure gauge. Use
to control air pressure
at gun.
Compatible with
all paint materials:
contains no silicone or
petroleum distillates
to contaminate paint. MSDS
available upon request.
Spray Gun Lube
SSL-10-K12
(2 oz. bottle)
HAF-507
Whirlwind™
In-Line Air Filter
Removes water, oil, and
debris from the air line.
TGC-545 Aluminum
TLC-555 (Non-Stick Coating Lined)
TSC-595 (Stainless Steel)
Drip Free Suction Cups
Cups have a unique, two
position valve which
permits selection of
either a drip free or
conventional open vent
mode.
KR-115-K5 Lid Protector
Kit keeps inside of lid
clean.
KK 5033-57
Air Cap Test Kit
The purpose of this test kit is to
measure air cap atomizing air
pressure at the center air port
of the air cap. Used to confirm
code compliance and as a daily
quality control measure.
Quick Disconnect Approved for
HVLP Guns (Air)
High Flow Ball and Ring Type
HC-4419 1/4"
NPS(F)
HC-4719
1/4" NPT(M)
HC-1166
1/4" NPT(M)
HC-4720
1/4" NPT(F)
NIOSH-Certified, for
respiratory protection
in atmospheres not
immediately dangerous
to life.
Provides greater
degree of control
over cup fluid
pressure.
KB-4006 6-Ft. Fluid
and Air Hose can
be used with these
cups.
40-128
Millennium 3000
Twin Cartridge
Paint Spray Respirator
KB-555 (Aluminum) &
KB-545-SS (S/S)
2 qt. Pressure Feed Cup
With Regulator
TLC-576 Aluminum Cup
(Non-Stick Coating Lined) &
TSC-591Stainless Steel Cup
1 Qt. pressure feed cups.
3/8" NPS (F), cam lock lid.
Requires KK-4980 air regula-
tor kit.
Scrubs® are a pre-
moistened hand clean-
er towel for painters.
No water is needed.
29-3100 Scrubs®
Hand Cleaner Towels

EN
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NOTES

EN
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prior notice. DeVilbiss, Ransburg, BGK, and Binks are registered trademarks of
Finishing Brands. ©2014 Finishing Brands. All rights reserved.
WARRANTY POLICY
DeVilbiss products are covered by Finishing Brands one year materials and workmanship limited warranty.
The use of any parts or accessories, from a source other than Finishing Brands, will void all warranties.
For specic warranty information please contact the closest Finishing Brands location listed below.
DeVilbiss is part of Finishing Brands, a global leader in innovative spray nishing
technologies. For technical assistance or to locate an authorized distributor,
contact one of our international sales and customer support locations below.
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