DeVilbiss JGA-635G Reference manual

DEVILBISS
SERVICE BULLETIN
SB-2-362
Gun Repair Kit KK-5058-2
JGA-635G COMPliANT HIGH VOLUME lOW PRESSURE
GRAVITY FEED SPRAY GUN
IMPORTANT: Before using this equipment,
read all safetyprecautionsandinstructions.
Keep for future use.
DESCRIPTION
The complaint high volume !ow pressure
gravity feed JGA-635G gun is designed to
apply a wide variety of finishing 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).
This gun will produce approximately 10 psi
air cap pressure at 23psi gun inlet pressure.
An air cap test kit is available (see Acces-
sories)
which should be used to insure
10 psi cap pressure is not exceeded.
Air consumption for the JGA-635G (#350
cap) is 12.5 SCFM
at 10 psi air cap pressure.
WARNING I
Halogenated hydrocarbon solvents-
for example;
1, 1, 1 -trichloroethane
and methylene chloride- can chemi-
cally react with the aluminum in this
gun and cause an explosion hazard.
Read
the label or data sheet for
the material you intend to
spray. Do not use spray materials
containing
these solvents with this
spray gun.
Important: This gun may be used with
most common coating and finishing
materials. It is designed for use with mildly
corrosive and non-abrasive materials.
If used with other high corrosive or
abrasive 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" 1.0. hose. Do not use 1/4~ 1.0.
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
J.D. hose may be required. Install an
HAV-501 air gaugeat 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 material
being applied. Excess pressure will
create additional overspray and re-
duce transfer efficiency.
NOTE
If quick connects are required, use
.o.nl.'i high flow quick connects ap-
proved
for HVLP use such as DeVil-
biss HC-4419 and HC-4719. 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 competitive
adjusting valves have significant
pressure drop that can adversely
affect spray performance. Models
HAV-500 and HAV-501 have
minimal pressure drop, which is
important for HVLP spraying.
Attach
the gravity feed cup to the material
inlet.
NOTE
Protective coating and rust inhibi-
tors have been used to keep the
gun in
good condition prior to
shipment. Before using the gun,
flush it with solvents so that these
materials
will be removed from
fluid passages.
OPERATION
Mix, prepare and strain the material to be
sprayedaccording to the paint maufacturer's
·Instructions.
Strain material
through a 60 or 90 mesh
screen.
1. Fill the gravity feed cup with the mate-
ria!. Do not overfill. Make sure that the
cup lid vent hole is clear.
2. Open the spreader adjustment valve
(10) (Fan) by turning the valve stem
counterclockwise.
3. Close the fluid needle adjusting screw
(17) by turning clockwise.
4. Turn on air supply and set gun inlet
pressure
to lowestrecommended pres-
sure
for material being sprayed. Best
atomization will occur with 10 psig air
cap pressure. However, some materi-
als can
be sprayed at lower pressures,
improving transfer efficiency.
5. Sprayatestarea byturning fluid needle
adjusting screw ( 17) counterclockwise
until a full coat is obtained.
If the finish is too sandy and dry, the
material flow may be too low for the
atomization air pressure being used.
If the finish sags,there is too much material
flowing for the atomization air pressure
being used.
Both
of the above can be corrected by
increasing or decreasing the atomization air
pressure or the material flow. Pattern width
can be altered by turning spreader adjust-
ment valve (10), either clockwise to de-
crease
the width or counterclockwise to
increase the width.
See Spray Gun Guide, SB-2-001 latest
revision, for details concerning setup of
sprayguns.
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 if possible. If a wire or hard
instrument is used, extreme care must be
used
to preventscratching or burring ofthe
holes which will cause a distorted spray
pattern.
To clean
fluid passages, remove excess
material
from cup,then flush with asuitable
solvent.
Wipe gun exterior with a solvent
dampenedcloth. Nevercompletelyimmerse
in solvent as this is detrimental to the lubri-
cants and packings.
NOTE
When replacingthe fluidtip orfluid
needle, replace both at the same
time. Using
worn parts can cause
fluid leakage. See Chart
1. Also,
(continued on page 3)

Page 2 SB-2-362
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.
WARNING I NOTE
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 mi~
nor injury.
Information that you should pay special
attention to.
HAZARD
Fire
solvent Sp•:a
~
Inhaling Toxic Substances
Explosion Hazard •
Incompatible Materials
~
General Safety
Cumulative Trauma
Disorders ("CTD's")
CTD's,
or musculoskeletal
disorders,
involve da,mage
to the hands, wrists,
elbows, shoulders, neck,
and back. Carpal tunnel
syndrome and tendonitis
(such as tennis elbow or
rotator cuff syndrome) are
examples of CTD's.
WARNING I
The following hazards may occur during the normal use of this equipment.
Please read the following chart before using this equipment.
CAUSE
Solvent and coatings can be highly
flammable or combustible especially when
sprayed.
During use and
while cleaning and flushing,
solvents can be
forcefully expelled from
fluid and air passages. Some solvents can
cause eye injury.
Certain materials may be harmful if inhaled,
or if there is contact with the skin.
Halogenated
hydrocarbon solvents- for
example; methylene chloride and 1,1,1, ·
Trichloroethane are not chemically
compatible with the aluminum that might be
used in many system components. The
chemical reaction caused
by these solvents
reacting
with aluminum can become v'1o!ent
and lead to an equipment explosion.
Improper operation or maintenance of
equipment,
Use of hand tools may cause cumulative
trauma disorders (HCTD's").
CTD's,
when using hand tools, tend to affect
the upper extremities. Factors which
may
increase the risk of developing a CTD include:
1. High frequency of the activity.
2. Excessive force, such as gripping,
pmching, or pressing with the hands and
fingers.
3. Extreme
or awkward finger, wrist, or arm
positions.
4. Excessive duration of the activity.
5. Tool vibration.
6. Repeated pressure on a body part.
7. Working in cold temperatures.
CTD's can also be caused by such activities
as sewing, golf, tennis, and bowling, to name
a few.
SAFEGUARDS
Adequate exhaust must be provided to keep airfree of
accumulations
of flammable vapors.
Smoking
must never be allowed in the spray area.
Fire extinguishing
equipment must be present in the spray area.
Wear eye protection.
Follow the requirements of the Material Safety Data Sheet
supplied by
your coating 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. The mask must be compatible with the material
being sprayed and
its concentration, Equipment must be as
prescribed by an industrial hygienist or safety expert, and be
NIOSH approved.
Guns
with stainless steel internal passageways may be used with
these solvents. However, aluminum is widely used in other spray
application
equipment- such as material pumps, regulators,
valves, and
this gun and cup. Check all equipment items before
use and make sure
they can also be used safely with these
solvents.
Read the label or 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.
Operators should be
given adequate training in the safe use and
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.
Pain, tingling, or numbness in the shoulder, forearm, wrist, hands,
or fingers, especially during the night, may be early symptoms of a
CTD. Do not ignore them. Should you experience any such
symptoms, see a physician immediately. Other early
symptoms
may include vague discomfort in the hand, loss of manual
dexterity, and nonspecific pain in the arm. Ignoring early
symptoms and continued repetitive use
of the arm, wrist, and
hand can lead
to serious disability. Risk is reduced by avoiding or
lessening factors 1-7.

replace the needle packing at this
time. Lightly lubricate the threads
ofthefluid tip beforereassembling.
Torque to 15-20 ft. !bs. Do not over-
tighten the fluid tip.
To prevent damage to fluid tip (5)
or fluid needle {11), be sure to
either 1) pull the trigger and hold
white tightening or loosening the
fluid tip, or 2) remove fluid needle
adjusting screw {17) to relieve
spring pressure against needle
collar.
SPRAY GUN LUBRICATION
Daily, apply a drop of SSL-10*· spray gun
lube at trigger bearing stud (28) and the
stem of air valve (20) where it enters air
valve assembly. The shank of fluid needle
(11)
where it enters packing nut (9) should
also be oiled. Fluid needle packing {8)
should be lubricated periodically. Make
sure baffle {6) and retaining ring (3)
threads
are clean and free offoreign matter. Before
assembling retaining ring to baffle, clean
the threads thoroughly, then add two drops
of SSL-10 spray gun lube to threads. Fluid
needle spring
(14) and air valve spring (19)
should be coated with a very light grease,
making sure that anyexcess grease will not
clog the airpassages. Forbestresults, lubri-
cate the points indicated, daily.
*Not for air tools or high RPM equipment.
A. TriggerPoints
B. Packing
C. Adjusting Knobs
D. Baffle Threads
E.
D
E
Chart 1
PARTS REPLACEMENT
Figure 1 Air Cap
/;::::--~-::._~Air Cap No.
// No. 350 · ... <:- ..
;/ /~~~\ '\
I frro· ·,{ v-~ '""iT,
''.! o ·H 1.1'1/0IIi 11 1\
I
~··· ·, \.'~/ f )!...JlJ j
\ \, ~' );!
\
'• If
'--·· I
L
HVLP: 23 PSI #
.._MAX. INLE~<C ...
"~==:==:=:------
Maximum airpressure required to
assure .compliance of 10 PSI Max.
cap
pressure- this reading must
be taken at the spray gun handle
inlet fitting.
JGA~4035 Packing Replacement lnstrucM
tions
iT~
Gun Body . Packing
Packmg
Nut
{3 pieces)
1. Remove adjusting knob and needle
spring from gun.
2. Partially withdraw needle from gun
body.
3. Loosen packing nut and remove.
4. Remove old packing.
5. Assemble packing nut to needle
6. Assemble packing in order shown to
needle.
7. Insert needle all the way into gun
body seating in tip.
8. Install needle spring and adjusting
knob.
9. Thread packing nut into gun body.
1 0. Tighten packing nut in equal
increments -no more than
1/6 turn at a time.
11. After each adjustment, pull needle
open and observe needle closure.
SB·2·362 Page 3
12. If needle snaps shut, continue
adjusting nut until there is evidence
of needle bind or slow closing.
13. Back off packing nut 1/12 turn to the
point where needle snaps shut.
Packing nut must remain tight
enough to prevent loosening by
hand.
14. Pull needle several times to verify
needle snaps shut a~d check packing
nut for looseness. '
GTIM33 Baffle Seal Replacement
1. Remove Fluid Tip (5).
2. Remove Baffle {6).
3. Remove Seal {7) from baffle.
NOTE
The seal is designed to be a tight
fitonthe baffle.Theseal should be
able to be removed using your
fingers. lf you are unable to re-
move the seal using your fingers,
insertasmallscrewdriverbetween
the
outer lip and the back of the
baffle and pry the seal off.
\ANGLED SIDE
\~ SEAL~
R2 THICK SIDE . I'
:
I
I
: BAFFLE
Pry here if I
4. Assemble seal to baffle with angled side
up as shown above. NOTE: The seal
should be a
tight fit on the baffle. !fit is
a loose
flt on the baffle, assure that it Is
assembled with the angled side up.
5. Install baffle on gun.
6. Install fluid tip (5) and tighten to
15·20 ft-lbs.
Chart 2 - AIR FLOW
Fluid Tip (Ref. No. 51
Fluid Tip Fluid Tip Inlet Cap
Computer
Size Size Press. AirFlow
Press.
Part No. No.
(in.)
lmml Applications IPS II ISCFMI I PSI I
GTI-213·14 192044 0.055 1.4 (Std.) Basecoats,
low solids clears, general purpose.
15 9.5 6
GTI·213·12 192124 0.047 1.2 Stains, lacquers, and other thin materials.
19
11 8
GTI-213·13 192134 0.051 1.3 High solids clears.
23
12.5 10
GTI·213·15 192135 0.059 1.5 Enamels and
medium viscosity materials.
GTI·213·16 192045 0.063 1.6 Enamels and medium viscosity materials.
GT\·213·18 192046 0.070 1.8 Primers and medium -heavy viscosity materials.
GT\·213·20 192047 0.079 2.0 Latex and heavy materials.
GT\·213·22 192132 0.086 2.2 Latex and heavy materials.

Page 4 SB-2-362
4
PARTS LIST
Ref. Replacement
No. Part No. Description
1
--·
Air Cap
2 JGA-156-KtO Spring Clip (Kit of 101
3 GTI-3 Air Cap Retaining Ring
4 AV-440-350
Air Cap & Retaining Ring
5 See
Chart 1 Fluid
Tip
6 GTI-425 Baffle Assembly
·7 GTI-33-K5
Baffle Seal {Kit of 5)
·8 JGA-4035-K5 Packing I Kit of 5)
9 34411-122·K10 Packing
Nut
10 GTI-404 Spreader Valve
11
GTI-413 Fluid Needle
•12 JGS-72-K10 Gasket Kit (Teflon}
(Kit
of 10)
13
--·
Body Bushing
•14 ---
Fluid Needle Spring
•15
---
Spring Pad
16 MBD-19-K10 Spring and Pad
(Kit of 101
17
GTI-414 Needle Adjusting Screw
18 KK-5059 Bushing,
Spring, Pad
I and Knob Kit
•19
---
Air Valve Spring
18
Ind.
Parts
Req.
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
Ref.
Replacement
No. Part No.
•20
---
21
---
·22
---
·23
---
·24 ---
25 JGS-449-1
26 P-MB-51
27 ---
28 ---
29 JGS-478
30
---
31 JGS-477-1
•32 KGP-13-K5
•33
---
·34
---
•35
---
36 GTI-428-K5
*26 Air Inlet Nipple
1/4" NPS(M)
(Torque to 15 ft.lbs.)
Use mediumstrengththread
sealant(i.e. Devcon #2242
Blue,orequal)onthreads
Ind.
Parts
Description Req.
Air Valve 1
Air Valve Body 1
U~Cup Seal 1
Washer 1
Snap Ring 1
Air Valve Assembly 1
Air Inlet Nipple 1
1/4" NPS(MJ
Trigger Stud Screw 1
Trigger Stud 1
Stud and Screw Kit 1
Trigger 1
Trigger Stud, Screw Kit 1
Cup Gasket (Blue) (Kit of 51 1
Retaining Clip 1
Seal 1
Pin 1
Clip, Seal & Pin Kit (5 each) 1
• KK~5058~2 Gun Repair Kit includes a quantity of necessary parts.
Sufixes ~K5, -K10 designate kits of multiple parts.
Example: JGA~4035-K5 ls a kit of 5 packings.

SB-2-362 Page 5
TROUBLESHOOTING
CONDITION CAUSE CORRECTION
Heavy top or
'6 Hornholesplugged. Clean. Ream
with non-metallic point.
bottom pattern
Obstruction on top or bottom of fluid tip. Clean.
Cap and/or tip seat dirty.
Clean.
Heavy right or left Left
or right side horn holes plugged. Clean. Ream
with non-metallic point.
side pattern
Dirt on left or right side of fluid tip. Clean.
)(
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 atest 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.
Heavy center pattern
Fluid flow too high for atomization air. Balance air pressure and fluid flow. Increase
t spray pattern
width with spreader adjustment
valve.
Material
flow exceeds air cap's capacity. Thin or lower fluid flow.
Spreader adjustment valve set too low. Adjust.
Atomizing pressure too low. Increase pressure.
Materia!
too thick. Thin to proper consistency.
Split spray pattern
I Atomization
air pressure too high. Reduce at transformer or gun.
Fluid flow too low.
Increase fluid flow (increases gun handling
Spreader adjusting valve set too high. speed).
Adjust.
Jerky or flutterini~~ ~ u ~~
*Loose or damaged fluid tip/seat. Tighten
or replace.
Baffle seal installed incorrectly. Install per directions.
Material level
too low. RefilL
Container tipped too far. Hold more upright.
Obstruction in fluid passage. Backftush with solvent.
Dry or loose fluid needle packing nut. Lubricate or tighten.
Unable to get round spray Spreader
adjustment screw not seating Clean or replace.
properly.
Air cap retaining ring loose. Tighten.
Will not spray No air pressure
at gun. Check air supply and air Jines, blow out gun air
passages.
Fluid needle adjusting
screw not open Open
fluid needle adjusting screw.
enough.
Fluid too heavy for grav'1tyfeed. Thin material and/or change to larger tip size.
Paint
bubbles in cup Fluid
tip not tight.
Tighten tip to 12-15 ft-lbs.
Fluid leaking or dripping from
Cup lid loose. Push in or tighten lid.
cup lid
Dirty threads on cup or lid. Clean.
Cracked cup
or lid. Replace cup and lid.
Starved spray
pattern
Inadequate material flow.
Back fluid adjusting screw out to first thread,
or change to larger tip size.
Low atomization air pressure. Increase airpressureand rebalance gun.
Excessive overspray
Too much atomization air pressure. Reduce pressure.
Gun
too far from work surface. Adjust to proper distance.
Improper stroking (arcing, gun motion too
Move at moderate pace, parallel to work
fast). surface.
Excessive
fog
Too much or too fast-drying thinner. Remixproperly.
Too much atomization air pressure. Reduce pressure.
Dry spray
Air pressure too high. Reduce airpressure.
Gun
tip too far from work surface.
Adjust to proper distance.
Gun
motion too fast. Slowdown.
Gun out of adjustment. Adiust
Fluid leaking from packing nut
Packing nut ioose. Tighten, do not bind needle.
Packing
worn or dry. Replace or lubricate.
Fluid
leaking or dripping from
Packing nut too tight.
Adjust.
front of gun
Dry packing. Lubricate.
Fluid
tip or needle worn or damaged. Replace
tip and needle.
Foreign
matter in tip. Clean.
Fluid needle spring broken. Replace.
Wrong size needle or tip. Replace.
>)!·Most common problem.

Page 6 SB-2-362
TROUBLESHOOTING (continued)
CONDITION
Fluid dripping or leaking from
bottom of cup
Runs and sags
Thin, sandy coarse finish drying
before it flows out
Thiele, dimpled finish "orange peel"
ACCESSORIES
AV-5033-350
Air Cap Test Kit
The purpose of this test kit
is to measure air cap
atomizing air pressure at
thecenter air port of the air
cap. Used to confirm code
compliance and as a daily
quality control measure.
Automotive Refinish Quick Connects
For HVLP Guns (Air}
High Flow Type.
HC-4419 Stem
1/4" NPT(F)
~~
HC-1166 Stem
1/4" NPTIMI
'U{{' '':A
1'( f((f{.··.·
\ ! Jl£t;')
HC-4719 Coupler
1/4" NPT{M) /NPS(M)
(
~~
·- 'fl/;-~
·::~((/}
HC-4720 Coupler
1/4" NPT(F)
192212 Professional
Spray Gun Cleaning Kit
Contains six precision tools
designed to effectively clean
all DeVilbiss,
Sinks, Finishline
and other brand spray guns.
WR-1 03 Wrench
1)'-J--------~
Contains all necessary ,.§"".; l':'> ~ "" -;_c:.:e~Y
tlp, hose and nut sizes ~1:_~~;:::~
used on or with gun. ::::::l
WARRANTY
CAUSE
Cup loose on gun.
Cup gasket worn or missing below cup.
Cup threads dirty.
Too much material flow.
Material too thin.
Gun tilted on an angle, or gun
motion too slow.
Gun too far from surface.
Too much air pressure.
Improper thinner being used.
Gun
too close to surface.
Air pressure too low.
Improper thinner being used.
Material
not properly mixed.
Surface rough, oily, dirty.
GFC-501
!Acetal) 20 Oz.
Gravity Feed Cup
with Threaded lid
I
\~
HAV-500 OR
HAV-501
Adjusting Valve
(HAV-501 SHOWN)
HAV-500 does not
have pressuregauge.
Use to control air
usage at gun.
CORRECTION
Tighten.
Replace cup gasket.
Clean.
Adjust gun or reduce fluid flow.
Mix properly or apply light coats.
Hold gun at
right angle to work and
adapt
to proper gun technique.
Check distance. Normally approx. 8".
Reduce air pressure and check spray pattern.
Follow paint manufacturer's mixing instrs.
Check distance.
Normally approx. 8".
Too much materia! coarsely atomized.
Increase air pressure or reduce fluid flow.
Follow paint manufacturer's mixing lnstrs.
Properly clean and prepare.
KK-5060 Air Cap
Cleaning Kit
r'
\.~hi
\\
\
'•.
\\
Consistsof: 2 brushes,
1
wire pick. Helpskeep
air cap clean and per-
forming properly.
192218 Scrubs®
Hand Cleaner Towels
Scrubs'"' are a pre-
moistened hand cleaner
towel for painters, body
men and mechanics that
go where you go and no
water is needed.
MSP-524
Twin Cartridge£
Paint
Spray
Respirator
GH-505
Gun Holder 192219 Gun Holder Spray Gun Lube
SSL-10 (2 oz. bottle)
•
NIOSH-Certified
(TC84A-1623) for respira-
tory protection in atmos-
pheres not immediately
dangerous to life.
()~il
lJ~
I
=1
I
Gun holders are
made to hold stan-
dard paint cups, grav-
ity feed guns and
cups, and paintfilters.
Gun holder made
to hold guns with
gravity cups.
I~
.' I
[2]
Compatible with a!!
paint materials;
containsnosilicone
or petroleum distil-
lates to contami-
nate paint. MSDS
Sheet available
upon request.
OMX~70KK48 Paint Cup Liner Kit
Allows quick & easy clean-up.
Consists of: 1 - Piercing Tool, 48- Disposable
Liners,
48- Drain Bushings
HAF-507 Whirlwind™
In-Line Air Filter
Removes water, oil, and debris from
the air line.
' ;
""
This product is cove,red by a One Year Limited Warranty. See SB-1-000 which is available upon request.
AUTOMOTiVE REFINISHING
For equipment, parts and service, check the Yellow Pages under "Automobile Body Shop Equipment and Supplies".
FOR TECHNICALASSISTANCE, CAll TOll FREE 1-800-445-3988 (U.S.A. ONL YJ. FOR LOCALCALLS, SEE LISTING BELOW.
U.S. Customer Service Office
MAUMEE,
OH 43537
OEUILBISS
Address
17241ndian
Wood Circle Telephone No.
(4191 891-8100
Toll Free Fax No. 1-800-445-6643
3/03 ©Copyright 2003, www.devHbiss.com
Printed in U.S.A.