DeVilbiss SB-2-001-F Operating manual

SERVICE BULLETIN
SB-2-001-F
Replaces SB-2-001-E
IMPORTANT: Beforeusingthisequipment,readall
safetyprecautionsandinstructionsinthismanual.
Keep for future use.
SPRAY GUN TROUBLESHOOTING AND
PREVENTIVE MAINTENANCE GUIDE

Page 2 SB-2-001-F
HAZARD CAUSE SAFEGUARDS
Fire Solvent and coatings can be highly Adequate exhaust must be provided to keep air
flammable or combustible free of accumulations of flammable vapors.
especially when sprayed.
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, Wear eye protection.
solvents can be forcefully expelled
from fluid fluid and air passages.
Some solvents can cause eye
injury.
Inhaling Toxic Certain materials may be harmful Follow the requirements of the Material Safety
Substances if inhaled, or if there is contact Data Sheet supplied by your coating material
with the skin. 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 hygienst or
safety expert, and be NIOSH approved.
Explosion Hazard Halogenated hydrocarbon solvents Guns with stainless steel internal passageways
Incompatible - for example; methylene chloride may be used with these solvents. However,
Materials and 1, 1, 1 - Trichloroethane are aluminum is widely used in other spray
not chemically compatible with application equipment - such as material pumps,
the aluminum that might be used cups and regulators, valves, etc. Check all
in many system components. The equipment items before use and make sure
chemical reaction caused by these they can also be ued safely with these solvents.
solvents reacting with aluminum Read the label or data sheet for the material
can become violent and lead to an you intend to spray. If in doubt as to whether
equipment explosion. or not a coating or cleaning material is com-
patible, contact your material supplier.
SAFETY PRECAUTIONS
Thismanualcontainsinformationthatisimprotantforyoutoknowandunderstand. Thisinformationrelates
toUSERSAFETYandPREVENTINGEQUIPMENTPROBLEMS. Tohelpyourecognizethisinformation,we
use the following symbols. Please pay particular attention to these sections.
Important information that tells
howtopreventdamagetoequip-
ment, or how to avoid a situation
that may cause minor inury.
Note
Information that you should
pay special attention to.
Important safety information -
A hazard that may cause
serious injury or loss of life.
The following hazards may occur during the normal use of this equip-
ment. Please read the following chart before using this equipment.

SB-2-001-F Page 3
Figure 3 Gravity Feed Gun With Cup on Top
Gravity feed guns are ideal for small applications
suchasspotrepair,detailfinishingorforfinishingin
alimitedspace.Theyrequirelessairthanasuction
feed gun and usually have less overspray.
Apressurefeedsystemisnormallyusedwhenlarge
quantities of material are to be applied, when the
materialistooheavytobesiphonedfromacontainer
or when fast application is required.
Figure 5 Pressure Feed Air Cap
PRINCIPLES OF AIR SPRAY
Sprayapplicationisperhapsthesimplestmethodof
coatingwhereasizeableareaorvolumeofmaterial
is involved or when intricate shapes and irregular
surfaces require painting. Spray will give the most
uniform film thickness making it easy to obtain a
smoothfinish.
The air spray gun is a tool which uses compressed
airtoatomizepaint,orothersprayablematerial,and
to apply it to a surface. Air and material enter the
gun through separate passages, and are mixed at
the air cap in a controlled pattern. Air spray guns
may be classified in various ways. Two ways of
classifyingguns are by thelocationofthe material
container and the material feed system. Figure 1
shows a gun with a cup attached below. This is
called Suction Feed which draws material to the
gunbysuction.Figure3isagunwithacupattached
above. This is called Gravity Feed - the material
travels down, carried by gravity. Figure 4 shows a
material container some distance away from the
spray gun. This is Pressure Feed - the material is
fed by positive pressure. Suction feed is easily
identifiedbythefluidtipextendingslightlybeyond
thefaceoftheaircap,asshowninFigure2. Suction
feed guns are suited to many color changes and to
small amounts of material, such as in touchup or
lower production operations.
Figure 2 Suction Feed Air Cap
Figure 4 Typical Pressure Feed Gun With Remote
Cup
Figure 1 Suction Feed Gun with Attached Cup
Fluid
Tip
Air Cap
Air Cap
Fluid
Tip

Page 4 SB-2-001-F
Internal and External Mix Guns
Anexternalmixgunmixesandatomizesairandfluid
outside the air cap. It can be used for applying all
types of materials, and it is particularly desirable
whensprayingfast-dryingpaintssuchaslacquer. It
is also used when a high quality finish is desired.
Figure 6 External Mix Gun
Figure 7 Internal Mix Gun
This gun mixes air and material inside the air cap,
beforeexpellingthem. Itisnormallyusedwherelow
air pressures and volumes are available, or where
slow-drying materials are being sprayed. A typical
exampleissprayingflatwallpaint,oroutsidehouse
paint, with a small compressor. Internal mix guns
are rarely used for finishing when a fast-drying
material is being sprayed, or when a high quality
finishisrequired.
HVLP (High-Volume/Low-Pressure)
HVLP uses a high volume of air (typically between
15-22 CFM) delivered at low pressure (10 psi or
less)toatomizepaintintoasoft,low-velocityspray
pattern.
As a result, far less material is lost in overspray,
bounce-backthanwithconventionalairspray.This
iswhyHVLPdeliversadramaticallyhighertransfer
efficiency (the amount of material that is actually
applied to the part) than higher pressure spray
systems.
Spray a horizontal test pattern (air cap horns in a
vertical position). Hold the trigger open until the
paintbegins to run. There should be evendistribu-
tion of the paint across the full width of the pattern
(seeFigure11).Adjustwithfanpatternadjustment.
Figure 9 Suction Feed & Gravity Feed System
Components
Figure 8 Air Cap Overspray, Conventional/HVLP
TheHVLPspraygunresemblesastandardspraygun
inshapeandoperation.
HVLP is growing in popularity and it has also been
judged environmentally acceptable due to its high
transfer efficiency.
HVLP can be used with low to-medium solid mate-
rials, including two-component paints, urethanes,
acrylics, epoxies, enamels, lacquers, stains, prim-
ers,etc.MorerecentlydevelopedHVLPaircapscan
alsosatisfactorilyatomizeevenhighsolidcoatings.
OPERATION
Suction and Gravity Feed Equipment Hook-Up
Connect the air supply from the compressor outlet
to the air filter regulator inlet. Connect the air
supplyhosefromtheregulatoroutlettotheairinlet
on the spray gun. After the material has been
reduced to proper consistency, thoroughly mixed
andstrainedintothecup,attachtheguntothecup.
HVLP
Conventional

SB-2-001-F Page 5
Figure 10 Horizontal Test Pattern with Even Mate-
rial Distribution
If the pattern produced by the above test appears
normal,rotatetheaircapbacktoanormalspraying
position and begin spraying (Example - a normal
pattern with a #9000 air cap will be about 9" long
whenthe gun is held 8"from the surface.) With the
fluid adjusting screw open to the first thread and
the air pressure set at approximately 30 psi, make
afewtestpasseswiththegunonsomecleanpaper.
Move the gun faster than usual when spraying the
test passes. If there are variations in particle size -
specks and/or large globs, the paint is not atomiz-
ing properly (See Figure 12). If the paint is not
atomizingproperly,increasetheairpressureslightly
and make another test pass. Continue this se-
quence until the paint particle size is uniform.
If the pattern seems starved for material and the
fluid adjusting screw is open wide (to the first
thread), the atomization air pressure may be too
high,orthematerialmaybetooheavy.Recheckthe
viscosity or reduce the air pressure.
If the material is spraying too heavily and sagging,
reduce the material flow by turning in the fluid
adjusting screw (clockwise).
Figure 11 Pattern with Uneven Particle Size
Pressure Feed Components
Apressurefeed system consists of a pressurefeed
spray gun, pressure feed tank, cup or pump, an air
filter/regulator,appropriate airandfluid hosesand
anaircompressor.
Connecttheairhosefromtheairregulatortotheair
inlet on the gun. Connect the mainline air hose to
the air inlet on the tank, cup or pump.
To avoid hazardous bursting or equipment
damage, do not exceed the container's maxi-
mum working pressure.
Connect the fluid hose from the fluid outlet on the
tank or pump to the fluid inlet on the gun.
Openspreaderadjustmentvalveformaximumpat-
ternsize. Openfluidadjustmentscrewuntilthefirst
threadis visible.
Shut off atomization air to the gun. Set the fluid
flow rate by adjusting the air pressure in the mate-
rialcontainer.Useabout6psiforaremotecupand
about 15 psi for a 2-gallon, or larger, container.
Adjust the fluid flow in the following ways:
Remove the air cap. With atomization air off, pull
thetrigger,flowingmaterialintoaclean,graduated
container for 10 seconds. Measure the amount of
material which flowed in that time and multiply
times6(orflowfor30secondsandmultiplytime2).
This is the fluid flow rate in ounces per minute. For
standard finishing, it should be about 14 to 16
ounces per minute. If the flow rate is less than this,
increase the air pressure in the container and re-
peat.
When the flow rate is correct, reinstall the air cap.
Iffluidpressureatthetank,cuporpumpexceeds20
psi, the next larger fluid tip size should be used.
Turn the atomizaton air to about 30 psi at the gun.
Spray a fast test pattern on a clean sheet of paper
and check the consistency of the particle size.
Increase or decrease the air pressure until even
particle size is achieved.
Spray a horizontal test pattern holding the trigger
openuntilthematerialbeginstorun. Paintdistribu-
tionacrossthefullwidthofthepatternshouldbethe
same (adjust with fan pattern adjustment). If it
cannot be adjusted, there may be a problem with
either the air cap or the fluid tip which must be
corrected. Refer to the Troubleshooting Section.
Hints for good spray technique.
Hold gun perpendicular 6" to 8" (HVLP guns) or 8"-
10" (suction, gravity or pressure conventional feed
guns) to surface being sprayed.
Don'ttiltthe gun in anydirection.Thiswillresult in
unevenpaint build causing runs and sags.
Triggergunjustbeforetheedgeofthesurfacetobe
sprayed.Thetriggershouldbeheldfullydepressed
andthegunmovedinonecontinuousmotion,until
theotheredgeof theobjectisreached.Releasethe
triggerbutcontinuethemotionforafewinchesuntil
it is reversed for the return stroke.
If distribution is not even, there is a problem with
either the air cap or the fluid tip. Refer to the
TROUBLESHOOTINGsectionforexamplesoffaulty
patterns to help diagnose the problem.

Page 6 SB-2-001-F
REPLACEMENT OF PARTS
FollowspecificgunServiceBulletinexplodedview
forreplacingparts.Thereareareasrequiringproper
sequence.
The fan adjustment assembly should only be in-
stalledafterturningtheknobout.Ifleftin,thestem
or needle could jam against the seat.
Pulltriggerorremovefluidadjustingscrewpriorto
tip tightening. Tip and needle damage can occur.
Spray guns have some combination of plastic,
copper, leather and soft packings and gaskets. It is
recommendedthatthese be replacediftheassem-
blyisremovedorwhendoinganoverallrepair.The
fluid needle packing must be replaced when the
packing nut bottoms out.
It is recommended to oil a new packing or needle
beforeassembly.Packingnutsshouldbetightened
justenoughtoseal(fluidleakageon pressurefeed,
suction of air on suction feed). Too tight will bind
the needle as well as shorten life of packing. When
replacing the fluid tip or fluid needle, it is recom-
Overlapeachstroke50%. Less than50%willresult
in streaks on the finished surface. Move the gun at
aconstantspeedwhiletriggeringsincethematerial
flows at a constant rate.
Another technique of triggering is referred to as
"feathering".Featheringallowstheoperatortolimit
fluidflow by applying only partial trigger travel.
Spray edges and corners first. This is called band-
ing. Bandingreducesoversprayyetprovidesgood
coverageoncorners.
Figure 12 Spray Techniques
Correct
Incorrect
mended to replace both at the same time. Lapped
sets are available for most guns on pressure feed
combinations.
MAINTENANCE
AIR CAP - Remove the air cap from the gun and
immerse it in clean solvent. Blow it dry with com-
pressed air.
If the small holes become clogged, soak the cap in
cleansolvent.Ifreamingtheholesisnecessary,use
a toothpick, a broomstraw or some other soft
implement.
Do not clean holes with a wire, a nail or a similar
hard object. Doing so could permanently damage
the cap by enlarging the jets, resulting in a defec-
tive spray pattern.
Figure 13 Cleaning Air Cap
Suction or Pressure Feed Cleaning - A suction or
pressure feed gun with attached cup should be
cleaned as follows:
Turnofftheairtothegun,loosenthecupcoverand
remove the fluid tube from the paint. Holding the
tubeoverthecup,pullthetriggertoallowthepaint
to drain back into the cup.

SB-2-001-F Page 7
This device incorporates a highly efficient fluid
header,whichmetersaprecisesolvent/airmixture.
The cleaner operates with compressed air and
sendsafinelyatomizedblastofsolventthroughthe
fluid passages of the hose, the spray gun, etc.
This simple, easy to use cleaner speeds up equip-
ment cleaning and saves solvent. It also reduces
VOCemissions.Be surethat boththe hosecleaner
and gun are properly grounded.
Wherelocalcodesprohibittheuseofahosecleaner,
manually backflush the hose into the cup or tank
with solvent and dry with compressed air.
Cleanthecontainerandaddcleansolvent.Pressur-
ize the system and run the solvent through until
clean. Atomization air should be turned off during
thisprocedure.Be sure to comply with local codes
regarding solvent dispersion and disposal.
Cleantheaircap,fluidtipandtank.Reassemblefor
future use.
Note
Never soak the entire gun in cleaning solvent. This
will dry out the packings and remove lubrication.
LUBRICATION
Lubricatethe fluid needle packing (A), the air valve
packing (B) the trigger bearing screw (C) and the
adjusting screw threads (D) with Spray Gun Lube,
*SSL-10, daily.
Thefluid needlespring(E) shouldbelightlycoated
withpetroleumjelly.
Thoroughlycleantheaircapandbaffle threads(F),
and lubricate with spray gun lube, SSL-10, daily.
Lubricate each of these points after every cleaning
in a gun washer.
*A Material Safety Data Sheet is available from
DeVilbissuponrequest.
Figure 14 Using a Hose Cleaner
Emptythecupandwashitwithcleansolventanda
clean cloth. Clean off the outside of the tube. Fill
halfwaywithcleansolventandsprayitthroughthe
gun to flush out the fluid passages. Be sure to
comply with local codes regarding solvent dis-
posal.
Then remove the air cap, clean it as previously
explained and replace it on the gun.
Wipe off the gun with a solvent soaked cloth, or if
necessary, brush the air cap and gun with a fiber
brushusingclean-upliquidorthinner.
Cleaning a pressure feed gun with remote cup or
tank - Turn off air supply to cup or tank. Release
materialpressurefromthesystembyopeningrelief
valve. Material in hoses may be blown back. Lid
must be loose and all air pressure off. Keep gun
higherthancontainer,loosenaircapapproximately
2-3turns,holdragoveraircap,andtriggergununtil
atomizing air forces all material back into the pres-
sure vessel.
A gun cleaner may be used for either type of gun.
This is an enclosed boxlike structure (vented) with
an array of cleaning nozzles inside.
Guns and cups are placed over the nozzles, the lid
isclosed,thevalveisenergized,and thepneumati-
callycontrolled solventspraysthroughthe nozzles
to clean the quipment. The solvent is contained,
and must be disposed of properly.
Somestates'codesrequiretheuseofaguncleaner
and it is unlawful to discharge solvent into the
atmosphere. Another efficient method of cleaning
the hose and gun passages is with a "Gun & Hose
Cleaner" device, such as the "SolventSaver".
Figure 15 Lubrications Points
F
B
E
D
D
CA

Page 8 SB-2-001-F
TROUBLESHOOTING
CONDITION CAUSE CORRECTION
Heavy top or bottom pattern Horn holes plugged. Clean. Ream with non-metallic
point.
Obstructionontoporbottomof Clean.
fluidtip.
Capand/ortipseatdirty. Clean.
Heavy right or left Left or right side horn holes plugged. Clean. Ream with non-metallic
side pattern point.
Dirtonleftorrightsideoffluidtip. Clean.
Remediesforthetop-heavy,bottom-heavy,right-heavyandleft-heavypatterns:
1)Determineiftheobstructionisontheaircaporthefluidtip. Dothisbymaking
atestspraypattern. Then,rotatethecapone-halfturnandsprayanother
pattern.Ifthedefectisinverted,obstructionisontheaircap.Cleantheaircap
aspreviouslyinstructed.
2)Ifthedefectisnotinverted,itisonthefluidtip.Checkforafineburronthe
edgeofthefluidtip.Removewith#600wetordrysandpaper.
3)Checkfordriedpaintjustinsidetheopening. Removepaintbywashingwith
solvent.
Heavy center pattern Fluid pressure too high for atomization Balance air and fluid pressure.
air (pressure feed)). Increase spray pattern width with
spreaderadjustmentvalve.
Materialflowexceedsaircap'scapacity. Thinorlowerfluidflow.
Atomizingpressuretoolow. Increasepressure.
Materialtoothick. Thintoproperconsistency.
Split spray pattern Fluid adjusting knob turned in too far. Back out counterclockwise to
achieveproperpattern.
Atomizationairpressuretoohigh. Reduceattransformer.
Fluidpressuretoolow(pressurefeedonly). Increasefluidpressure.
Spreaderadjustingvalvesettoohigh. Adjust.
Suction And Pressure Feed
Jerky or fluttering spray *Loose or damaged fluid tip/seat. Tighten or replace.
Materialleveltoolow. Refill.
Containertippedtoofar. Holdmoreupright.
Obstructioninfluidpassage. Backflushwithsolvent.
Looseorbrokenfluidtubeorfluid Tightenorreplace.
inletnipple.
Dryorloosefluidneedlepackingnut. Lubricateortighten.
*Mostcommonproblem.

SB-2-001-F Page 9
CONDITION CAUSE CORRECTION
Jerky or fluttering spray Suction Feed Only
(continued) Material too heavy. Thin or replace.
Container tipped too far. Hold more upright.
Air vent in cup lid clogged. Clear vent passage.
Loose, damaged or dirty lid. Tighten, replace or clean coupling
nut.
Dry or loose fluid needle packing. Lubricate or tighten packing nut.
Fluid tube resting on cup bottom. Tighten or shorten.
Damaged gasket behind fluid tip. Replace gasket.
Unable to get round spray Fan 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 lines.
Internal mix or pressure feed air cap Change to proper suction feed air
and tip used with suction feed. cap and tip.
Fluid pressure too low with internal Increase fluid pressure at tank.
mix 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.
Starved spray pattern Inadequate material flow. Back fluid adjusting screw out to
first thread, or increase fluid
pressure at tank.
Low atomization air pressure Increase air pressure and re-
(suction feed). balance 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 Move at moderate pace, parallel
too fast). to work surface.
Excessive fog Too much, or too fast-drying thinner. Remix properly.
Too much atomization air pressure. Reduce pressure.

Page 10 SB-2-001-F
CONDITION CAUSE CORRECTION
Dry Spray Air pressure too high. Decrease air pressure.
Material not properly reduced Reduce to proper consistency.
(suction feed).
Gun tip too far from work surface. Adjust to proper distance.
Gun motion too fast. Slow down.
Gun out of adjustment Adjust.
Fluid leaking from Packing nut loose. Tighten, do not bind needle.
packing nut Packing worn or dry Replace or lubricate.
Fluid leaking or dripping Packing nut too tight Adjust
from front of pressure
feed gun Dry packing. Lubricate.
Fluid tip or needle worn or Replace tip & needle with lapped
damaged sets.
Foreign matter in tip. Clean.
Fluid needle spring missing or Replace.
broken.
Wrong size needle or tip. Replace.
Needle bound by misaligned Tap sprayhead perimeter with a
sprayhead, (MBC guns only). wooden mallet. Retighten lock bolt.
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 Gun too far from surface. Check distance. Normally 6-8" - HVLP,
drying before it flows out 8-10" - conventional.
Too much air pressure. Reduce air pressure and check
spray pattern.
Improper thinner being used. Follow paint manufacturer's
mixing instructions.
Thick, dimpled finish Gun too close to surface. Check distance. Normally 6-8" - HVLP,
"orange peel". Too much 8-10" - conventional.
material coarsely
atomized Air pressure too low. Increase air pressure or reduce
fluid pressure.
Improper thinner being used. Follow paint manufacturer's
mixing instructions.
Material not properly mixed. Follow paint manufacturer's
mixing instructions.
Surface rough, oily, dirty. Properly clean and prepare.

SB-2-001-F Page 11
Morethanjustaspraygunmanufacturer,DeVilbiss
is your single source for practical solutions to all
yoursprayfinishingchallenges.
To maximize your production output, you need
consistent, reliable performance, high-quality re-
sults and a responsive service partner who knows
theindustryandyourbusiness. AndwithDeVilbiss,
you not only get the equipment, you also get the
expertise.
Since 1888, we've advanced the science of spray
finishing by introducing innovative products and
technologicaldevelopmentsthatsetthestandards
for the industry. These efforts help ensure that we
candeliverthebestsolutionforyourparticularspray
finishingapplications.
Spray Guns
•ConventionalairsprayandHVLP
•Standard-size,midsize,manualandautomatic
•Waterbornecompatible,stainlesssteelpassages
•Shadingandtouch-upgunsforprecisioncontrol
•Decorativegunsfortexturedfinish
•Dustergunsfortoughcleaningapplications
•Gravityfeed,suctionfeed,pressurefeed
•MAX™ the only true ergonomic spray gun
Cups and Tanks
•Pressure, gravity and suction feed cups
•Aluminum,stainlesssteelandpolyethylene
•ASME-certified galvanized and stainless tanks
•Tankcapacitiesfrom2gallonto15gallon
•Airmotordrives
Air Control
•Regulatorsandgauges
•Adjustingvalves
•Centrifugal,coalescing,in-lineanddesiccantfilters
Hose
•Fluidandairhose
•Ballandair-adjustingvalves
•Fittingsandconnections
Additional Accessories
•ThreadAdapters
• SolventSaver™ gun and hose cleaners
•Gun-mountedfluidstrainers
•Replacementpartskits
•Aircaptestkits
•Fluidregulators
SYSTEM SOLUTIONS FOR YOUR SPRAY FINISHING NEEDS

Page 12 SB-2-001-F
3/01 ©Copyright 2001, DeVilbiss Printed in U.S.A.
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NEAREST YOU, CALL TOLL FREE 1-888-992-4657 (U.S.A. AND CANADA ONLY). FOR LOCAL CALLS, SEE LISTING
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U.S./Canada Sales & Customer Service Office Address Telephone No.
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Toll Free Fax No. 1-877-790-6965
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U.S. Customer Service Office Address Telephone No.
MAUMEE, OH 43537 1724 Indian Wood Circle [phone]
Toll Free Fax No. 1-800-445-6643