DeVilbiss JGA-510 User Manual

SERVICE BULLETIN

SB-2-252-J

Replaces SB-2-252-I

■Major Repair Kit KK-4987-2

Minor Repair Kit KK-5034

JGA-510 CONVENTIONAL SPRAY GUN

IMPORTANT: Before using this equip­ment, read all safety precautions and in­structions. Keep for future use.

DESCRIPTION

The JGA-510 can be utilized with the wide
range of air caps and needles. It is a general
purpose, heavy duty, high production
spray gun suitable for use with most
types of materials. The fluid tip and needle
and internal fluid passages are stainless
steel.

Conversion to HVLP - The JGA-510, plus
JGA-503 models, can be converted to
HVLP if desired. Contact DeVilbiss for in­formation.

Note

This gun includes 300 series stain­less steel fluid passages and 300/400
series tip and needle. Guns may
be used with chlorinated solvent
materials, but see page 2 for
additional warnings.

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.

OPERATION

Note

Protective coating and rust inhibitors
have been used to keep the gun in
good condition prior to shipment.
Before using the gun, flush it with
solvent so that these materials will be
removed from fluid passages.

Page 6, if any problems occur.

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.

To clean fluid passages, remove excess
material at source, then flush with a suit­able solvent using a device such as the
SolventSaver™ (see Accessories). Wipe
gun exterior with a solvent dampened cloth.
Never completely immerse in solvent as
this is detrimental to 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. Matched sets are avail­able for most pressure feed combi­nations. See Chart 3. Matched sets
are particularly recommended with
thinner, less viscous materials. Also,
replace the needle packing at this
time. Lightly lubricate the threads
of the fluid tip before reassembling.
Torque to 20-25 ft. lbs. Do not over­tighten the fluid tip.

To prevent damage to the fluid tip
(4) or fluid needle (33), be sure to
either 1) pull the trigger and hold
while tightening or loosening the
fluid tip or 2) remove fluid needle
adjusting screw (28) to relieve
spring pressure against needle
collar.

FLUID INLET GASKET (7) REPLACEMENT
INSTRUCTIONS

1. Remove fluid inlet adapter with ap­propriate wrench.

2. Clean Loctite from gun body inlet
threads and seal area.

3. Place gasket (7) squarely onto the fluid
inlet adapter and push it down until it
is flat against the boss.

4. Place a couple of drops of medium
strength blue No. 242 Loctite on
threads before installing fluid inlet
adapter.

5. Torque fluid inlet adapter to 20-25 ft.
lbs., and tighten locknut.

SPRAY GUN LUBRICATION

Daily, apply a drop of SSL-10 spray gun
lube at trigger bearing stud (21) and the
stem of the air valve (13) where it enters
the air valve assembly (17). The shank of
the fluid needle (33) where it enters the
packing nut (19) should also be oiled. The
fluid needle packing (18) should be lubri­cated periodically. Make sure the baffle (6)
and retaining ring (1 or 2 ) 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 (30) and
air valve spring (12) should be coated with
a very light grease, making sure that any
excess grease will not clog the air pas­sages. For best results, lubricate the
points indicated, daily.

A. Trigger Points
B. Packing
C. Adjusting Valves
D. Baffle Threads
E. Air Valve Cartridge

A

Strain material thru 60 or 90 mesh screen.
Adjust fluid pressure to deliver the desired
paint volume. Adjust air pressure and flow
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. Inadequate flows may cause the
pattern to split. See “Troubleshooting”,

C

D

■

Government NSN No. 4940-01-046-9919 = KK-4987-2.

B

E

Page 2 SB-2-252-J

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.

Note

Important information that tells how 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 equipment.

Please read the following chart before using this equipment.

HAZARD CAUSE SAFEGUARDS

Fire

Solvent
Spray

Inhaling Toxic
Substances

Explosion Hazard ­Incompatible
Materials

General Safety

Cumulative Trauma
Disorders (“CTD’s”)

CTD’s, or musculo- CTD's when using hand tools, tend to affect any such symptoms, see a physician immediately. Other early
skeletal disorders, the upper extremities. Factors which may symptoms may include vague discomfort in the hand, loss of
involve damage to increase the risk of developing a CTD include: manual dexterity, and nonspecific pain in the arm. Ignoring early
the hands, wrist, symptoms and continued repetitive use of the arm, wrist and
elbows, shoulders, 1. High frequency of the activity. hand can lead to serious disability. Risk is reduced by avoiding
neck & back. Carpal 2. Excessive force, such as gripping, pinching, or lessening factors 1-7.
tunnel syndrome & or pressing with the hands and fingers.
tendinitis (such as 3. Extreme or awkward finger, wrist, or arm
tennis elbow or positions.
rotator cuff syndrome)
are examples of
CTD’s. 6.

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 the spray area.

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.

Certain materials may be harmful if inhaled, Follow the requirements of the Material Safety Data Sheet
or if there is contact with the skin. supplied by your coating material manufacturer.

Halogenated hydrocarbon solvents - for Guns with stainless steel internal passageways may be used
example; methylene chloride and 1, 1, 1 - with these solvents. However, aluminum is widely used in other
Trichloroethylene are not chemically com- spray application equipment - such as material pumps,
patible with the aluminum that might be used regulators, valves and cups. Check all equipment items before
in many system components. The chemical use and make sure they can also be used safely with these
reaction caused by these solvents reacting with solvents. Read the label or data sheet for the material you intend
aluminum can become violent and lead to to spray. If in doubt as to whether or not a coating or cleaning
an equipment explosion. material is compatible, contact your material supplier.

Improper operation or maintenance of Operators should be given adequate training in the safe use &
equipment. maintenance of the equipment (in accordance with the require

Use of hand tools may cause cumulative Pain, tingling, or numbness in the shoulder, forearm, wrist,
trauma disorders (“CTD’s”). hands or fingers, especially during the night, may be early

4.

Excessive duration of the activity.

5.

Tool vibration.
Repeated pressure on a body part.

7. Working in cold temperatures.

CTD’s can also be caused by such activities
as sewing, golf, tennis bowling, to name a few.

prevent damage to equipment, or how

to avoid a situation that may cause

minor inury.

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.

ments of NFPA-33, Chapter 15). Users must comply with all local
and national codes of practice and insurance company require
ments governing ventilation, fire precautions, operation,
maintenance and housekeeping. These are OSHA Sections

1910.94 and 1910.107 and NFPA-33.

symptoms of a CTD. Do not ignore them. Should you experience

Information that you should pay spe­cial attention to.

CHART 1

NOZZLE COMBINATIONS

Air Cap

Sizes

Order

From

Chart 2

Orifice

mm

AC D E EE EX FF FX FW GX

Tip

in./ .110 .080 .070 .070 .070 .055 .042 .063 .034

2.8 2.2 1.8 1.8 1.8 1.4 1.1 1.6 .9

Fluid Tip and Needle Size

Order From Chart 3

24 P P P
30 P S S S S
58 S P P P
62HD P
64HD P
67HD P
69HD P
80 S S S S
704 P P P
765 P P P
777 P P
797 P P
9000 S S S S

P = Pressure Feed Combination
S = Suction Feed Combinations

CHART 2

No. on Ref. No. (1) Ref. No. (3)

Cap Air Cap Air Cap Less Ring

Order With Ring

➞

24 AV-40-24
30 MB-4039-30
58 AV-439-58
62HD MB-4039-62HD
64HD MB-4039-64HD
67HD MB-4039-67HD
69HD MB-4039-69HD
80 MB-4039-80
704 AV-1239-704
765 AV-1239-765
777 31767-777
797 AV-1239-797

CHART 3

FLUID TIPS AND NEEDLES

Tip Orifice If this is *Ref. No. 5 Ref. No. 33 **Ref. No. 36
Size No. on tip Fluid Tip & Fluid Needle Matched Tip &
In. / (mm) order Gasket (No. on needle) Needle Set

.110 (2.8) AV-2115-AC AV-650-AC JGA-402-C JGA-4040-AC
.086 (2.2) AV-2115-D AV-650-D JGA-402-DEX JGA-4040-D
.070 (1.8) AV-2115-E AV-650-E JGA-402-E JGA-4040-E
.070 (1.8) AV-2115-EX AV-650-EX JGA-402-DEX JGA-4040-EX
.055 (1.4) AV-2115-FF AV-650-FF JGA-402-FF JGA-4040-FF
.042 (1.1) AV-2115-FX AV-650-FX JGA-402-FX JGA-4040-FX
.063 (1.6) AV-2115-FW AV-650-FW JGA-402-FF JGA-4040-FW
.034 (.9) AV-2115-GX - - - - - - JGA-4040-GX

OPTIONAL 300 GR. S.S. W/ U.H.M.W. POLYETHYLENE NEEDLE SEAT

.086 (2.2) AV-4915-D - - - - - - JGA-4056-D
.070 (1.8) AV-4915-E - - - - - - JGA-4056-E
.055 (1.4) AV-4915-FF - - - - - - JGA-4056-FF
.042 (1.1) AV-4915-FX - - - - - - JGA-4056-FX
.028 (.8) AV-4915-G - - - - - - JGA-4056-G

.086 (2.2) AV-1415-D AV-617-D JGA-409-D - - ­.070 (1.8) AV-1415-EE AV-617-EE JGA-409-DEEE - - ­.055 (1.4) AV-1415-FF AV-617-FF JGA-409-FF - - -

➞

400 GR. S.S. TIPS & 303 GR. S.S. NEEDLES

OPTIONAL CARBOLOY TIPS & NEEDLES

9000 AV-440-9000

SB-2-252-J Page 3

AIR CAPS

* AV-1 copper gasket included — DO NOT use with JGA-510 gun
** Matched tip & needle sets are recommended to assure leak-free operation

Page 4 SB-2-252-J

PARTS LIST

Ref. Replacement Individual
No. Part No. Description Parts Required

1 See Chart 2 Air Cap/Retaining Ring 1
2 MBC-368 Retaining Ring 1
3 See Chart 2 Air Cap Less Retaining Ring 1
4 See Chart 3 Fluid Tip 1

*5 GTI-33-K5 Seal Kit (Kit of 5) 1

6 GTI-425 Baffle Assembly 1
7 MSV-3-K10 Fluid Inlet Gasket (Kit of 10) Teflon (blue) 1
8 --- Lock Nut 1
9 --- Fluid Inlet Adapter 1

10 JGA-4044 Fluid Inlet and Nut Kit 1

*•11 JGS-72-K10 Gasket Kit (Kit of 10) (Teflon ) 2

*12 MBD-12-K25 Spring Kit (Kit of 25) 1
*13 JGS-431-K25 Air Valve Kit (Kit of 25) 1

*•14 JGS-26-K25 U Cup Seal Kit (Kit of 25) 1

*15 JGA-15-K25 Washer Kit (Kit of 25) 1
*16 JGA-14-K25 Snap Ring Kit (Kit of 25) 1

17 JGS-449-1 Air Valve Assembly 1

*•18 JGV-463-K3 Packing Kit (Kit of 3) 1

19 34411-122-K10 Packing Nut Kit (Kit of 10) 1

*20 --- Screw 1

21 JGS-478 Stud and Screw Kit (Kit includes 1

22 JGS-477-1 Trigger, Stud and Screw Kit 1

23 JGA-132 Plug 1
24 P-MB-51 Nipple 1
25 JGA-497-1 Fan Adjustment Assembly 1

*26 --- Retaining Ring 1

*•27 SSG-8069-K25 O-Ring (Viton) (Kit of 25) 1

28 JGS-16 Adjusting Screw 1

*29 --- Spring Pad (Included 1

*30 MBD-19-K10 Spring Kit (Kit of 10) 1

31 --- Bushing 1
32 JGA-4041 Bushing, Spring Pad and Knob Kit 1
33 See Chart 3 Fluid Needle 1
34 --- Gun Body 1

#35 See Chart 3 Fluid Tip and Needle Set 1

*A quantity of necessary parts is included in Major Repair Kit KK-4987-2 for complete

gun repair and should be kept on hand for service convenience.

•A quantity of necessary parts is included in Minor Repair Kit KK-5034 for gun repair.
# Ref. No. 35 includes Ref. Nos. 4 and 33. AV-1 copper gasket also included but not

used with JGA-510 gun.
Suffixes - K10 designates kits of multiple parts. (Example) JGS-72-K10 is a kit of 10 gaskets.

3 studs and 5 screws)

(Kit includes 1 each)

with # 30 and 32)

(Not shown)

■ Government NSN No. 4940-01-046-9919 = KK-4987-2.

GTI-33 Baffle Seal Replacement (5)

1. Remove fluid tip (4).

2. Remove baffle (6).

3. Remove seal (5) from baffle.

4. Assemble seal to baffle with angled

side up as shown at right.

NOTE

The seal should be a tight fit
on the baffle. If it is a loose fit
on the baffle, assure that it is
assembled with the angled
side up.

5. Install baffle on gun.

6. Install fluid tip (4) and tighten to 12-15
ft-lbs.

The seal is designed to be a tight fit
on the baffle. The seal should be
able to be removed using your
fingers. If you are unable to re­move the seal using your fingers,
insert a small screwdriver be­tween the outer lip and the back of
the baffle and pry the seal off.

NOTE

Pry here if
necessary

ANGLED SIDE

SEAL

THICK SIDE

BAFFLE

SB-2-252-J Page 5

32

33

11

31

30

29

28

25

2

3

See GTI-33 Baffle Seal Replacement

6

Instructions on Page 4.

4

1

Torque to
12-15 ft. lbs.

10

7

8

9

26

5

*

Torque to
20-25 ft. lbs.

∆

18

27

34

19

Fluid Inlet
Nipple
3/8 NPS (M)

* 24

16

14

13

12

15

17

Detail Ref. No. 18 - Two piece packing covered by

∆

U.S. Patent No. 5,209,501.

+ Tapered edge faces out towards packing nut.

+Inner Teflon Piece

Outer

U.H.M.W.

Poly. Piece

Fluid Packing

Fluid Needle

Nut

20

11

*23

21

22

*Apply QH-130 (Loctite #242 med. strength blue) sealing
compound on threads.

Air Inlet
Nipple
1/4 NPS (M)

Torque to
15 ft. lbs.

Page 6 SB-2-252-J

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

Horn holes plugged. Clean. Ream with non-metallic point.
Obstruction on top or bottom of fluid tip. Clean.
Cap and/or tip seat dirty. Clean.

Left or right side horn holes plugged. Clean. Ream with non-metallic point.
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 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 paint by washing with solvent.

Fluid pressure too high for atomization Balance air and fluid pressure.
air (pressure feed). Increase 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.
Material too thick. Thin to proper consistency.

Atomization air pressure too high. Reduce at transformer or gun.
Fluid pressure too low (pressure feed only). Increase fluid pressure (increases gun handling

speed).
Spreader adjusting valve set too high. Adjust.

*Loose or damaged fluid tip/seat. Tighten or replace.
Material level too low. Refill.
Container tipped too far. Hold more upright.
Obstruction in fluid passage. Backflush with solvent.
Loose or broken fluid tube or fluid inlet nipple. Tighten or replace.
Dry or loose fluid needle packing nut. Lubricate or tighten.

Unable to get round spray

Will not spray

Starved spray pattern

Excessive overspray

Excessive fog

Dry Spray

Fluid leaking from
packing nut

*Most common problem.

Spreader adjustment screw not seating properly. Clean or replace.
Air cap retaining ring loose. Tighten.

No air pressure at gun. Check air supply and air lines.
Internal mix or pressure feed air cap and tip Change to proper suction feed air cap and tip.
used with suction feed.
Fluid pressure too low with internal mix cap Increase fluid pressure at tank.
and pressure tank.
Fluid needle adjusting screw not open enough. Open fluid needle adjusting screw.
Fluid too heavy for suction feed. Thin material or change to pressure feed.

Inadequate material flow. Back fluid adjusting screw out to first thread

or increase fluid pressure at tank.
Low atomization air pressure (suction feed). Increase air pressure and rebalance gun.

Too much atomization air pressure Reduce pressure.
Gun too far from work surface. Adjust to proper distance.
Improper stroking (arcing, gun motion too fast). Move at moderate pace, parallel to work surface.

Too much, or too fast-drying thinner. Remix properly.
Too much atomization air pressure. Reduce pressure.

Air pressure too high. Reduce air pressure.
Gun tip too far from work surface. Adjust to proper distance.
Gun motion too fast. Slow down.
Gun out of adjustment. Adjust.

Packing nut loose. Tighten, do not bind needle.
Packing worn or dry. Replace or lubricate.

SB-2-252-J Page 7

TROUBLESHOOTING (continued)

CONDITION CAUSE CORRECTION

Fluid leaking or dripping Packing nut too tight. Adjust
from front of pressure
feed gun Dry packing. Lubricate.

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

Thin, sandy coarse finish Gun too far from surface. Check distance. Normally approximately 8".
drying before it flows out

Thick, dimpled finish Gun too close to surface. Check distance. Normally approximately 8".
"orange peel". Too much material coarsely atomized. Increase air pressure or reduce fluid pressure.

Fluid tip or needle worn or damaged. Replace tip and needle with lapped sets.
Foreign matter in tip. Clean.
Fluid needle spring broken. Replace.
Wrong size needle or tip. Replace.

Material too thin. Mix properly or apply light coats.
Gun tilted on an angle, or gun motion Hold gun at right angle to work and adapt to
too slow. proper gun technique.

Too much air pressure. Reduce air pressure and check spray pattern.
Improper thinner being used. Follow paint manufacturer's mixing instructions.

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 surface.

Page 8 SB-2-252-J

ACCESSORIES

P-H-5516 Air

Adjusting Valve

HAV-500 or

HAV-501

Adjusting Valve

(HAV-501 SHOWN)

HD-503

SolventSaver™

Hose/Gun Cleaner

HARG-510 Air

Regulator

JGA-4035-K5

Optional 3 Piece

Packings

JGA-52-K10

Leather Packings

Enables user to control
and reduce air usage at
the gun. Ideal for low
pressure spraying.

42884-214-K5 3/8"

42884-215-K10 5/8"

HAV-500 does not have
pressure gage. Use to
control air usage at gun.

Cleaning Brushes

The VS-531 Low Pres-

sure Fluid Strainer pro­These brushes are help­ful in cleaning threads
and recesses of gun
body.

vides a final filter for

trapping foreign par-

ticles in the paint sup-

ply.

JGA-156-K10

Spring Clip

In-Line Air Filter

Joins any single piece
DeVilbiss air cap MBC­368 or MSA-1 retaining
ring. Helps prevent
parts loss and provides
easier assembly.

TGC-545 (Aluminum) TLC-555

(Teflon Lined)

TSC-595 S.S. 2 Qt. Drip-Free

Suction Cup

Cup has a unique, two position
valve which permits selection of
either a drip-free or conventional
open vent mode.

Removes water, oil, and

debris from the air line.

VS-531 Low

Pressure
Strainers

HAF-507

Whirlwind™

2 Qt Hose/Gun Cleaner
used to clean the inside
of hose, fluid passage­ways of gun & other
paint equipment.

QMGZ

SolventSaver™

Use to maintain nearly
constant outlet pressure
despite changes in inlet
pressure and down­stream flow.

Hose/Gun Cleaner

2 Gallon galvanized tank
used to clean the inside
of hose and material
passages of the gun.

Quick Disconnect Approved for

HVLP Guns (Air)

High Flow Ball and Ring Type

HC-4419 1/4"

NPS(F)

HC-4700

1/4" NPT(F)

TLC-576 Aluminum Cup

(Teflon Lined) &

TSC-591Stainless Steel Cup

1 Qt. pressure feed cups.
3/8" NPS (F), cam lock lid.
Requires KK-4980 air regulator
kit.

Installs into gun to en­able user to control and
reduce air usage at the
gun. Replaces JGA-132
plug.

HC-4699

1/4" NPT(M)

HC-1166

1/4" NPT(M)

GTI-415 Air

Adjusting Valve

KB-545-SS (S/S) 2 qt. Pressure

Feed Cup With Regulator

Provides greater
degree of control
over cup fluid
pressure.

This 3 piece packing
can be used in place of
Ref. (18) JGV-463, 2
piece packing.

Spray Gun Lube

SSL-10 (2 oz.

bottle)

Compatible with all
paint materials: con­tains no silicone or pe­troleum distillates to
contaminate paint.
MSDS sheet available
upon request.

KB-555 (Aluminum) &

29-3100 Scrubs

Hand Cleaner Towels

Scrubs® are a pre­moistened hand cleaner
towel for painters.
No water is needed.

Used when abrasive
materials are sprayed
(i.e. porcelain enamel).
Use (2) JGA-52 packings
in place of JGV-463
packing.

MSA-4-K10 Fluid

Needle Spring

(replaces MBD-19)

Provides reduced
spring force (4 lbs.
verses 6 lbs.) for easier
trigger pull.

Millennium 3000

Twin Cartridge

Paint Spray Respirator

NIOSH-Certified, for
respiratory protection
in atmospheres not
immediately dangerous
to life.

®

WR-103 Wrench

Contains all necessary
tip, hose and nut sizes
used on or with gun.

JGA-444 Fluid Tube

This tube combines the
fluid and air hoses at gun
handle preventing drag­ging hoses over work, twist­ing line and improving
overall gun handling.

WARRANTY

This product is covered by DeVilbiss' 1 Year Limited Warranty.

DeVilbiss Worldwide Sales and Service Listing: www.devilbiss.com

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