DeVilbiss JGA Series Operation Manual

SB-E-2-251

Operation Manual

JGA – Pressure Feed Spraygun

ISS.05

E

E

P 2 - 8

EE

Operation Manual

JGA – Pressure Feed Spraygun

Important

Read and follow all instructions and Safety Precautions before using

this equipment

Description

The JGA Pressure Feed Spraygun Kit is approved to ATEX regulations 94/9/EC, protection level;

Important: These Sprayguns are suitable for use with most solvent based coating materials.

Nozzles and Needles are manufactured in Stainless Steel. These guns are not designed for use
with highly corrosive and/or abrasive materials and if used with such materials it must be
expected that the need for cleaning and/or replacement of parts will be increased. If there is any
doubt regarding the suitability of a specific material contact your local Distributor or ITW Finishing
direct.

II 2 G X Suitable for use in Zones 1, and 2

Model Part Number

Example: JGA-558FWH-797

Gun Number

Aircap No

Fluid Tip Size

EC Declaration of Conformity

We: ITW Finishing UK, Ringwood Rd, Bournemouth, Dorset, BH11 9LH, UK, as the

manufacturer of the Spraygun model JGA, declare, under our sole responsibility, that the

equipment to which this document relates is in conformity with the following standards or other

normative documents:

BS EN 292-1 PARTS 1 & 2: 1991, BS EN 1953: 1999; and thereby conform to the

protection requirements of Council Directive 98/37/EEC relating to Machinery Safety

Directive, and;

EN 13463-1:2001, council Directive 94/9/EC relating to Equipment and Protective

Systems intended for use in Potentially Explosive Atmospheres protection level II 2 G X.

ITW Finishing Systems and Products reserve the right to modify equipment specification without prior notice.

© 2007 ITW Finishing Systems and Products

B. Holt, General Manager

30th June 2003

2

SAFETY WARNINGS

EE

Fire and explosion

Solvents and coating materials
can be highly flammable or

combustible when sprayed. ALWAYS

refer to the coating material suppliers
instructions and COSHH sheets
before using this equipment

Users must comply with all local
and national codes of practice
and insurance company
requirements governing

ventilation, fire precautions, operation

and house-keeping of working
areas

This equipment, as supplied,
is NOT

Halogenated Hydrocarbons

Static Electricity can be

generated by fluid and/or air
passing through hoses, by the spraying
process and by cleaning non- conductive
parts with cloths. To prevent ignition
sources from static discharges, earth
continuity must be maintained to the
spraygun and other metallic equipment

used. It is essential to use
conductive air and/or fluid hoses.

suitable for use with

.

Personal Protective

Equipment

Toxic vapours – When sprayed,

certain materials may be
poisonous, create irritation or be
otherwise harmful to health. Always read
all labels and safety data sheets for the
material before spraying and follow any

recommendations. If In Doubt,

Contact Your Material Supplier

The use of respiratory protective

equipment is recommended at all
times. The type of equipment must be
compatible with the material being

sprayed.

Always wear eye protection when
spraying or cleaning the spraygun

Gloves must be worn when
spraying or cleaning the equipment

Training – Personnel should be given
adequate training in the safe use of
spraying equipment.

Misuse

Never aim a spraygun at any part of the
body

Never exceed the max. recommended
safe working pressure for the equipment

The fitting of non-recommended or non­original spares may create hazards

Before cleaning or maintenance, all
pressure must be isolated and relieved
from the equipment

The product should be cleaned using a
gun washing machine. However, this
equipment should not be left inside gun
washing machines for prolonged periods
of time.

Noise Levels

The A-weighted sound level of
sprayguns may exceed 85 dB
(A) depending on the set-up being used.
Details of actual noise levels are
available on request. It is recommended
that ear protection is worn at all times
when spraying.

Operating

Spray Equipment using high pressures
may be subject to recoil forces. Under
certain circumstances, such forces could
result in repetitive strain injury to the
operator.

3

© 2007 ITW Finishing Systems and Products

EE

Ref. No Description Part Number Qty

1 Air Cap/Retaining ring See Chart 2 1

1a Spring Clip - Kit of 5 JGA-156-K5 1

+2 Nozzle See Chart 3 1

3 Baffle + Seal JGD-402-K 1

+3a Baffle seal—Kit of 5 GTI-33-K5 1

+4 Spring Adjusted Needle Packing GTI-445-K2 1

5 Spreader Valve GTI-405-K 1

6 Stud and Screw - Kit of 5 GTI-408-K5 1

+7 Needle See Chart 3 1

+8 Spring - Kit of 5 GTI-409-K5 1

9 Bushing JGA-17 1

10 Needle Adjusting Screw GTI-414-K 1

11 Valve Assembly JGK-449 1

12 Trigger GTI-108 1

13 Connector JGA-158 1

14 Airflow Valve GTI-415-K 1

15 Lock Nut - Kit of 5 JGA-51-K5 1

16 Seal 23165-001 1

17 Fluid Inlet Connector and seal Kit JGA-159-K 1

18 Seal + Pin kit ( + SST-8434-K5) GTI-428-K5 2

19 Circlip - Kit of 5 2

20 Circlip - Kit of 5 25746-007-K5 1

+21 Seal - Kit of 5 JGS-72-K5 2

22 Air valve stem assembly 1

23 Spring JGV-262-K5 1

Parts List

+ - Parts included in service Kit KK-4502 (see accessories)

Aircap number and Nozzle size combinations Chart 2

G

FX

0.7

No Order No.

30+ AV-4239-30

43 AV-4239-43

62 MB-4039-62

64 MB-4039-64

78 MB-4039-78

80 MB-4039-80

186 AV-4239-186

704 AV-4239-704

765 AV-4239-765

777 AV-4239-777

797 AV-4239-797

© 2007 ITW Finishing Systems and Products

1.1

9

9
9

9 9 9 9

FZ

1.2

9

FF

FW

EE

EX

1.4

1.6

1.8

1.8

9
9

9
9

9
9

9

9
9

9

9

9

4

DE

2.0 D 2.2

9

AC

Air-

2.8
flow

301 3.0

307 3.0

449 3.0

9

432 3.0

457 3.0

311 3.0

344 3.0

418 3.0

476 3.0

462 3.0

463 3.0

Pressure
bar

EE

Chart 3

High Grade Stainless Steel (H)

Nozzle

size

2.8 AV-645-AC JGA-421-C-K —— —— AV-611-AC JGA-402-NAC-K

2.2 AV-645-D JGA-421-DEX-K

2.0 —— —— —— —— AV-611-DE JGA-402-NADEEE-K

1.8 —— ——

1.8 AV-645-E JGA-421-E-K

1.8 AV-645-EX JGA-421-DEX-K

1.6 AV-645-FW JGA-421-FW-K

1.4 AV-645-FF JGA-421-FFK

1.2 AV-645-FZ JGA-421-FZ-K

1.1 AV-645-FX JGA-421-FX-K

0.7 AV-645-G JGA-421-G-K

Nozzle Order No. Needle Order No.

Nozzle and Needle combinations

High Grade Stainless

Steel—Soft Seat

Nozzle

Order No.

AV-651-D JGA-421-DEX-K

—— ——

AV-651-E JGA-421-E-K

AV-651-FF JGA-421-FZ-K

AV-651-FZ JGA-421-FZ-K

AV-651-FX JGA-421-FZ-K

AV-651-G JGA-421-G-K

Needle Order No.

Nozzle Order

AV-611-D JGA-402-NADEX-K

AV-611-EE JGA-402-NADEEE-K

—— ——

—— ——

—— ——

AV-611-FF JGA-402-NAFF-K

AV-611-FZ JGA-402-NAFZ-K

—— ——

—— ——

Nitralloy (N)

No.

Needle Order No.

5

© 2007 ITW Finishing Systems and Products

EE

Specification

Air supply connection -

Universal
Fluid Supply Connection ­ Universal
Maximum static inlet pressure ­ P1 = 9 bar (130 psi)
Maximum static fluid pressure ­ P2 = 14 bar (200psi)
Gun Weight - 695 g

1

/4 BSP/NPS

3

/8 BSP/NPS

Installation

1. Attach air hose to connector (13).
Recommended hose size 8 mm
bore. The hose must be conductive
and electrical bond from the
spraygun to earth should be checked
with an ohmeter. A resistance of less

Operation

Maximum Service temperature - 40°C

Materials of Construction

Gun body- Polished Aluminium

Nozzle - See chart 3

Needle - See chart 3

than 106Ω is recommended. The air
supply should be filtered and
regulated.

2. Attach fluid supply hose to the Fluid
Inlet connector (17).

Mix, prepare and filter the coating
material to be sprayed to the
manufacturer’s instructions. Adjust the
spray gun controls, air and coating
material pressures before filling the cup
or turning on the material supply.

1. Needle adjustment. Fully open
needle adjusting screw (10) by turning
counter-clockwise until the first thread
shows.

2. Fan pattern adjustment. Turn
adjusting screw (5) to fully open
position, by turning counter-clockwise.

3. Air control valve. Open air adjusting
screw (14) fully by turning counter­clockwise (JGA-558 models only).

4. Air supply pressure. Regulate to 3.0
bar (43 - 45 lbf/in²).

5. Pressure feed coating material
supply. Regulate pressure to 0.5 bar
(7 lbf/in²).

6. Turn on coating material and air
supplies.

7. Test spray. If the finish is too dry or
application too slow, reduce air
pressure or increase coating material
supply pressure. If the finish is too
wet, reduce the coating material
supply pressure, or turn the needle
adjusting screw (10) fully clockwise
then gradually open until the desired
pattern is achieved.

8. If the atomisation is too coarse
increase the air pressure, if too fine,
reduce the air supply pressure or turn
air control valve (14) gradually
clockwise.

9. NOTE: The spray width can be
reduced from fan to round by turning
fan adjusting screw (5) clockwise.

10. Using the spray gun. Hold the gun
perpendicular to the spray surface
always. Arcing or tilting the gun will
result in an uneven deposit of coating
material. The recommended spray
distance is 150- 200 mm (6" - 8").
Spray the corners and edges first.

© 2007 ITW Finishing Systems and Products

6

EE

Overlap each stroke 50% as you coat
the area. Trigger just before the edge
of the surface to be sprayed. Move
the gun at a constant speed across
the surface and release the trigger.
Repeat the same method on the

Preventative Maintenance

1. Turn off air and relieve pressure in
the supply lines, or if using QD
system, disconnect from airline.

2. Release Cup and raise the tube out of
the material. Trigger the Gun and
allow material to drain back into the
cup.

3. Dispose of the surplus material and
clean the cup.

4. Remove air cap (1) and clean. If any
of the holes in the cap are blocked

return stroke.

11. To prevent accidental discharge of
coating material when the gun is not
in use, always turn off and release air
and fluid pressure.

with coating material use a toothpick
to clean. Never use metal wire which
could damage the cap and produce
distorted spray patterns

5. Ensure the tip of the nozzle (2) is
clean and free from damage. Build up
of dried paint can distort the spray
pattern.

6. Lubrication – stud/screw (6), needle
(7) and air valve (11) should be oiled
each day.

Replacement of Parts

Nozzle (2) and Needle (7) – Remove

parts in the following order: 10, 8, 7, 1
and 2. Replace any worn or damaged
parts and re-assemble in reverse order.
Recommended tightening torque for
nozzle (2) 17-20 Nm (150-180 lbf in)

Packing – Remove parts 10, 8, 7.
Unscrew cartridge (4). Fit new cartridge
finger tight. Re-assemble parts 7, 8, and
10 and tighten cartridge (4) with spanner
sufficient to seal but to allow free

movement of needle. Lubricate with gun
oil.

Air valve (11) – Remove Trigger, parts
6 and 12. Unscrew valve assembly. Re­assemble, fitting spring to valve head
before fitting valve.

Spreader valve (5) – Caution: always
ensure that the valve is in the fully open
position by turning screw fully counter­clockwise before fitting to body.

Accessories

Spanner – order SPN-5
Cleaning Brush – order 4900-5-1-K3
Service Kit – order KK-4502 add nozzle size as required

(i.e. KK-4502-FF-H)

Seal Kit - order KK-4558. Contains 3a, 4, 18, 19, 21
Pressure gauge Attachment – order GA-515
Gun Mounted Regulator – order DVR-501
Lubricant - order GL-1-K10

7

© 2007 ITW Finishing Systems and Products

ITW Finishing Systems and Products
Ringwood Road,
Bournemouth,
BH11 9LH,
England.
Tel. No. [phone]
Telefax No. [phone],
Website address http://www.itweuropeanfinishing.com

ITW Automotive Finishing UK
Anchorbrook Industrial Estate
Lockside
Aldridge,
Walsall,
UK.
Tel. No. [phone]
Telefax No. [phone],
Website address http://www.itweuropeanfinishing.com

ITW Finishing Systems and Products is a Division of ITW Ltd. Reg. Office:
Admiral House,
St Leonard’s Road,
Windsor,
Berkshire,
SL4 3BL,
UK
Registered in England: No 559693 Vat No 619 5461 24

ITW Oberflächentechnik GmbH & Co. KG
Justus-von-Liebig-Straße 31
63128 Dietzenbach
Tel [phone]
Telefax: (060 74) 403300
Website address http://www.itw-finishing.de

ITW Surfaces Et Finitions
163-171 avenue des Auréats B.P. 1453
26014 VALENCE CEDEX FRANCE
Tél. [phone]
Télex 345 719F DVILBIS
Téléfax: (33) 475-75-27-99

© 2007 ITW Finishing Systems and Products

8

July 07