SERVICE MANUAL

EN

DV1 CLEARCOAT
HVLP Gravity Spray Gun

II 2 G X

IMPORTANT! DO NOT DESTROY

It is the Customer's responsibility to have all operators and service personnel read and understand
this manual.

Contact your local Carlisle Fluid Technologies representative for additional copies of this manual.

READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT.

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FUNCTIONAL DESCRIPTION

The DV1 spray gun is a professional quality HVLP spray gun designed to comply with all global
legislations. Refer to Page 8, Table 1 & 2 for more detailed information.

SPECIFICATIONS

AIR INLET PRESSURES

P1 = Max. Static Air Input Pressure 12 bar [175 psi]

See Table 1
Gun Air Inlet Pressure with gun triggered
Page 8

Vibration Level: <2.5 m/s²

Sound Power Level: Available On Request
Sound Pressure Level: Available On Request

ENVIRONMENTAL
Max. Ambient Operating Temperature 40°C Nominal [104°F]

MATERIALS OF CONSTRUCTION
Gun Body Material Anodised Aluminium
Fluid Tip, Fluid Needle and Trigger Stud Stainless Steel
Air Cap Material Electroless Nickel Plated Brass

Retaining Ring, Sprayhead, Adjusting Knobs, Air Valve

Anodised Aluminium
Cage, Sleeve

Springs, Clips, Screws Stainless Steel

Seals and O-Rings Solvent Resistant
Trigger Chrome Plated Steel

Valve Bodies, Rear Housing, Packing Nut, Sleeve Nut Chrome Plated Brass

Air Valve Stem Electroless Nickel Plated Brass

CONNECTIONS
P1 = Air Inlet Size 1/4'' Universal
P2 = Fluid Inlet Size 3/8" BSP

WEIGHT
GUN ONLY 470g [16.6 oz]

DIMENSIONS
L x H x W mm [inches] 161 x 177 x 44 [6.3 x 7.0 x 1.7 in]

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Product Description / Object of Declaration: DV1 HVLP Gravity Spray Gun

This Product is designed for use with: Solvent and water based materials

Suitable for use in hazardous area: Zone 1 / Zone 2

Protection Level: II 2 G X/Ex h II Gb X

Notified body details and role: Element Materials Technology (0891)

Lodging of Technical file

This Declaration of conformity / Carlisle Fluid Technologies UK Ltd,

incorporation is issued under the sole Ringwood Road,
responsiblity of the manufacturer: Bournemouth, BH11 9LH. UK

EU Declaration of Conformity
The object of the declaration described above is in conformity with the relevant Union
harmonisation legislation:
ATEX Directive 2014/34/EU
Machinery Directive 2006/42/EC
By complying with the following statutory documents and harmonised standards:
EN 1127-1:2011 Explosive atmospheres - Explosion prevention - Basic concepts
BS EN 1953:2013 Atomizing and spraying equipment for coating materials - Safety requirements
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheres-
Basic methods and requirements.
EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres -
protection by methods "c", "b" and "k".
HVLP and High Efficiency products comply with the requirements of PG6 from the EPA guidelines and offer
greater than 65% transfer efficiency.

Providing all conditions of safe use / installation stated within the product manuals have been complied with and
also installed in accordance with any applicable local codes of practice.

Signed for and on behalf of Carlisle Fluid D Smith Director of Sales (EMEA)
Technologies UK Ltd: 1/8/18

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In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasise important safety information as EN
follows:

WARNING CAUTION NOTE

Hazards or unsafe practices which could result in Hazards or unsafe practices which could result in
Important installation, operation or maintenance
severe personal injury, death or substantial minor personal injury, product or property
information.
property damage. damage.

WARNING
Read the following warnings before using this equipment.

SOLVENTS AND COATING MATERIALS. Can be highly flammable or INSPECT THE EQUIPMENT DAILY. Inspect the equipment for
combustible when sprayed. Always refer to the coating supplier's instructions worn or broken parts on a daily basis. Do not operate the
and safety sheets before using this equipment. equipment if you are uncertain about its condition.

READ THE MANUAL. Before operating finishing equipment, read and

understand all safety, operation and maintenance information provided in the
operation manual. Users must comply with all local and national codes of EQUIPMENT MISUSE HAZARD. Equipment misuse can cause
practice and insurance company requirements governing ventilation, fire the equipment to rupture, malfunction or start unexpectedly and
precautions, operation and house-keeping of working areas. result in serious injury.

GLOVES. Must be worn when spraying or cleaning the

FIRE AND EXPLOSION HAZARD. Never use 1,1,1-Trichloroethane, equipment.
Methylene Chloride, other Halogenated Hydrocarbon solvents or fluids
containing such solvents in equipment with aluminium wetted parts. Such use
could result in a serious chemical reaction, with the posibility of explosion.
Consult your fluid suppliers to ensure that the fluids being used are compatible
with aluminium parts.
WEAR SAFETY GLASSES. Failure to wear safety glasses with
side shields could result in serious eye injury or blindness.

STATIC CHARGE. Fluid may develop a static charge that must be dissipated
through proper grounding of the equipment, objects to be sprayed and all other
electrically conductive objects in the dispensing area. Improper grounding or WEAR RESPIRATOR. The use of respiratory protective
sparks can cause a hazardous condition and result in fire, explosion or electric equipment is recommended at all times. The type of equipment
shock and other serious injury. must be compatible with the material being sprayed.

TOXIC VAPOURS. When sprayed, certain materials may be poisonous, create

irritation, or are otherwise harmful to health. Always read all labels, safety NEVER MODIFY THE EQUIPMENT. Do not modify the
sheets and follow any recommendations for the material before spraying. If in equipment unless the manufacturer provides written approval.
doubt contact your material supplier.

LOCK OUT / TAG-OUT. Failure to de-energise, disconnect, lock out and tag-
PROJECTILE HAZARD. You may be injured by venting liquids or
out all power sources before performing equipment maintenance could cause
gases that are released under pressure, or flying debris.
serious injury or death.

PRESSURE RELIEF PROCEDURE. Always follow the pressure

NOISE LEVELS. The A-weighted sound level of pumping and spray equipment relief procedure in the equipment instruction manual.
may exceed 85 dB(A) depending on equipment settings. Actual noise levels
are available on request. It is recommended that ear protection is worn at all
times while equipment is in use.
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT
IN CASE OF AN EMERGENCY.

HIGH PRESSURE CONSIDERATION. High pressure can cause serious

injury. Relieve all pressure before servicing. Spray from the gun, hose leaks or
ruptured components can inject fluid into your body and cause extremely OPERATOR TRAINING. All personnel must be trained before
serious injury. operating finishing equipment.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT.

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EXPLODED VIEW

PARTS LIST

REF. PART No. DESCRIPTION QTY.

1 - RETAINING RING 1
2 - SLIP RING 1
3 - RETAINING RING SEAL 1
4 704425 RETAINING RING SUB ASSEMBLY 1
5 - AIR CAP 1
6 191972 SPRING CLIP (KIT OF 10) 1

7 SEE TABLE 1 AIR CAP & RETAINING RING 1

8 SEE TABLE 3 FLUID TIP 1

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PARTS LIST (Continued)

REF. PART No. DESCRIPTION QTY.

9 704402 DEFLECTOR PLATE 1

10 + 704403 SCREW (KIT OF 3) 3
11 - SPRAYHEAD 1
12 + 704401 GASKET (KIT OF 2) 1
13 704436 SPRAY HEAD KIT 1
14 - NEEDLE PACKING 1
15 - PACKING SPRING 1
16 - PACKING NUT 1

17 + 702731 PACKING, SPRING & PACKING NUT KIT 1

18 - O RING 1
19 - AIR VALVE CAGE 1
20 - SEAL 2
21 * - SEAL GUIDE 2
22 * - VALVE SEAT 1
23 # 704422 FRONT CAGE ASSEMBLY 1
24 - AIR VALVE STEM 1
25 # - AIR VALVE SPRING 1
26 - REAR SEAL HOUSING 1
27 704423 REAR SEAL ASSEMBLY 1
28 + 704424 AIR VALVE ASSEMBLY 1
29 - IDENTIFICATION SLEEVE 1
30 - SLEEVE NUT 1
31 704437 SLEEVE KIT 1

32 SEE TABLE 3 FLUID NEEDLE 1

33 - NEEDLE SPRING 1
34 - SPRING PAD 1
35 #+ 704405 NEEDLE SPRING KIT 1
36 704404 FLUID ADJUSTING KNOB 1
37 - O RING 2
38 - FLOW VALVE BODY 1
39 - FLOW VALVE KNOB 1
40 - CIRCLIP 1
41 704417 INLINE FLOW VALVE 1
42 - PLUG 1
43 - TRIGGER SCREW 1
44 - SPRING 1
45 - TRIGGER STUD 1
46 - TRIGGER 1

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PARTS LIST (Continued)

REF. PART No. DESCRIPTION QTY.

47 704406 TRIGGER, STUD, SPRING & SCREW KIT 1

48 - SCREW 1
49 #+ - SPREADER VALVE PIN 1
50 - SPREADER VALVE STEM 1
51 #+ - O RING 1
52 - VALVE BODY 1
53 #+ - O RING 1
54 - SPREADER VALVE ADJUSTING KNOB 1
SPREADER KNOB KIT
55 704419 1
(Not For Use With Digital Gauge)
56 704418 SPREADER VALVE ASSEMBLY 1
57 - VALVE TOOL 1
58 - TORX DRIVER 1
59 - TIP WRENCH 1
60 704429 TOOL KIT 1
* NOT REPLACEABLE

CUPS AND GAUGES

GRAVITY CUP
GFC-501
PLASTIC
61
GRAVITY CUP
702576
ALUMINIUM

704426 ATEX APPROVED (EU)

62 DIGITAL PRESSURE GAUGE
704427 FM APPROVED (USA, CANADA)

SERVICE PARTS

704430 MINOR SERVICE KIT INCLUDES ITEMS MARKED #

704431 MAJOR SERVICE KIT INCLUDES ITEMS MARKED +

WARNING

The spray gun must be earthed to dissipate any electrostatic charges which may be created by fluid
or air flows. This can be achieved through the spray gun mounting, or conductive air/fluid hoses.
Electrical bond from the spray gun to earth should be checked and a resistance of less than 10⁶ Ohms
is required.

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DV1

PART SELECTION GUIDE

TABLE 1
DV1 AIR CAP PERFORMANCE GUIDE

Recommended Air Inlet Pressure

(with gun fully triggered) Air Typical Fan
Part Number Air Cap & Type
Consumption Pattern Size**

At Gun Handle At Digital Gauge

285 L/min 325 mm

704434 DV1-C1 PLUS HVLP 2.0 bar [29 psi] 1.5 bar [22 psi]
[10.0 scfm] [12.8 in]
320 L/min 310 mm
704435 DV1-C2 PLUS HVLP 2.0 bar [29 psi] 1.5 bar [22 psi]
[11.3 scfm] [12.2 in]
** Fan pattern size @ 200mm [8"] distance.

TABLE 2
DV1 AIR CAP TEST KITS

Recommended Air Inlet Pressure

(with gun fully triggered)
Part Number Air Cap & Type Atomisation Pressure

At Gun Handle At Digital Gauge

704438 DV1-C1 PLUS HVLP 2.0 bar [29 psi] 1.5 bar [22 psi] 0.69 bar [10 psi]

704439 DV1-C2 PLUS HVLP 2.0 bar [29 psi] 1.5 bar [22 psi] 0.69 bar [10 psi]

* For HVLP compliance in North America, air cap pressure must not exceed 0.69 Bar (10 psi). The gun inlet
pressures shown in Tables 1 & 2 above produce 0.69 Bar (10 psi) air cap pressure or less. Exact air cap
pressure can be set by using the air cap test kits shown in Table 2 above (sold separately).

TABLE 3
DV1 FLUID TIPS & NEEDLES
Fluid Tip Needle

Part Number Fluid Tip Size Marking Part Number Marking

704440 1.0 DV1-1.0 C

704441 1.1 DV1-1.1 C
704442 1.2 DV1-1.2 C 704416 DV1-300
704443 1.3 DV1-1.3 C
704444 1.4 DV1-1.4 C

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CAUTION
IMPORTANT: This spraygun is suitable for use with both waterbased and solvent based coating
materials.
• The gun is not designed for use with highly corrosive and/or abrasive materials.

• To avoid premature degradation of parts, DeVilbiss recommends the gun is washed in neutral
cleaning solution (pH 6 to 8).

• The gun is not designed to be cleaned within an ultrasonic bath.

If there is any doubt regarding the suitability of a specific material, contact your DeVilbiss Distributor
or DeVilbiss direct.

START-UP SEQUENCE
1. Connect the gun to a clean, moisture and oil free air supply using a conductive hose of at least 8mm
I.D.

2. Mix coating material to Manufacturer's instructions and strain material.

3. Turn fluid adjusting knob (36) clockwise to prevent fluid needle movement.

4. Turn spreader valve adjusting knob (54) counter clockwise to fully open.

5. Adjust inlet air pressure if required.

6. Turn fluid adjusting knob counter clockwise until first thread shows.

7. Test spray. If the finish is too dry, reduce airflow by reducing air inlet pressure.

8. If finish is too wet, reduce fluid flow by turning fluid adjusting knob (36) clockwise. If atomisation is too
coarse, increase air inlet pressure. If too fine, reduce inlet pressure.

9. The pattern size can be reduced by turning spreader valve knob (54) clockwise.

10. Hold gun perpendicular to surface being sprayed. Arcing or tilting may result in uneven coating.

11. The recommended spray distance is 150-200mm.[6-8"]

12. Spray edges first. Overlap each stroke a minimum of 75%. Move gun at a constant speed.

13. Always turn off air supply and relieve pressure when gun is not in use.

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NOTE

Depending on hose length, larger I.D. hose may be required. Install an air gauge at the gun handle.
When gun is triggered on, adjust regulated pressure as required. Do not use more pressure than is
necesarry to atomise the material being applied. Excess pressure will create additional overspray and
reduce transfer efficiency.

NOTE

If quick connect couplings are required, use only high flow quick connects. Other types will not flow
enough air for correct gun operation.

SPRAY GUN MAINTENANCE & CLEANING

To clean air cap and fluid tip, brush exterior with a stiff bristle brush. If necesarry to clean cap holes,
use a broom straw or toothpick if possible. If a wire or hard instrument is used, extreme care must
be taken to prevent scratching or burring of the holes which will cause a distorted spray pattern.

To clean fluid passages, remove excess material, then flush with gun wash solution. Wipe the gun
exterior with a dampened cloth. Never completely immerse in any solvent or cleaning solutions as
this is detrimental to the lubricants and life of the spray gun.

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SPRAY GUN DISASSEMBLY / ASSEMBLY

KEY
Order for disassembly
# (reverse for assembly)

DISASSEMBLY TIP & NEEDLE

22mm HEX
19 Nm
[170 in-lbs]

NOTE

When replacing the fluid tip or fluid needle, replace tip, needle and fluid packing at the same time.
Using worn parts can cause fluid leakage. Do not overtighten.

NOTE

When removing air cap from retaining ring, do not remove slip ring or retaining ring seal from
retaining ring. Damage to the parts may occur.

The slip ring and retaining ring seal are not available as replacement parts.

Simply wipe parts clean and reassemble with new or clean air cap.

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DISASSEMBLY PACKING

DISASSEMBLY TRIGGER

T10 TORX
1 Nm [10 in-lbs]

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DISASSEMBLY SPRAYHEAD

T10 TORX
1 Nm [10 in-lbs]

DISASSEMBLY FLOW VALVE

7mm HEX
18.5 Nm
[165 in-lbs]

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DISASSEMBLY AIR VALVE

12 Nm
[110 in-lbs]
6mm HEX
18 Nm [160 in-lbs]

TO CHANGE IDENTIFICATION SLEEVE ONLY

1 2 4 5

SPREADER VALVE REPLACEMENT

11mm HEX
9 Nm [80 in-lbs]

T10 TORX
1 Nm
[10 in-lbs]

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TROUBLESHOOTING MECHANICAL PERFORMANCE

GENERAL FAULTS CAUSE CORRECTION

No air pressure at gun. Check air supply and air line.

Will not spray.

Fluid needle adjustment knob Open fluid needle adjustment
not open enough. knob.

Check fluid nozzle/needle

Incorrect needle fitted to gun. selection chart and fit correct
item.
Gun spits paint when triggering
on and off.
Excessive needle wear. Replace with new needle.

Excessive fluid nozzle wear. Replace with new fluid nozzle.

Fluid nozzle not fitted correctly

Gun spits paint when triggering Tighten.
in gun head.
on due to paint build-up inside
air cap between spraying
operations.
Fluid nozzle/needle leakage. Check for damage or blockage.

Fluid nozzle not fitted correctly

Tighten.
in gun head.
Paint build-up on fluid tip.

Fluid nozzle/needle leakage. Check for damage or blockage.

Damaged air cap holes. Replace with new air cap.

Paint build-up on air cap.

Gradual build-up of bounce-back
Thoroughly clean.
on gun head.

Fluid nozzle or sprayhead Remove, check components for

Unable to get round spray
incorrectly fitted. damage and refit correctly.

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When removing air cap from retaining ring, do not remove the ring seat from the retaining ring.
Damage to the parts may occur. Simply wipe parts clean and reassemble with new or clean air cap.

FLUID FAULTS CAUSE CORRECTION

Fluid nozzle internal seat scored

Replace.
damaged or worn.

Fluid needle external profile

Replace.
damaged or worn.

Contamination on needle or tip

mating surfaces preventing good Thoroughly clean.
seal.

Slow fluid leak from fluid nozzle

and needle seat.
Incorrect fluid nozzle for fluid Check nozzle/needle selection
needle fitted to gun. chart and fit correct item.

Sluggish needle. Lubricate packing.

Tight packing nut. Adjust.

Contamination on needle or tip

Remove nozzle and needle and
mating surfaces preventing good
thoroughly clean.
seal.
Major fluid leak or fluid jetting
from fluid nozzle and needle seat.

Incorrect fluid nozzle for fluid Check nozzle/needle selection

needle fitted to gun. chart and fit correct item.

Slow fluid leak from needle Fluid needle packing worn or

Tighten or replace as necessary.
packing. loose.

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AIR FAULTS CAUSE CORRECTION

Remove Air Valve Stem and

Air Valve Stem contaminated
thoroughly clean valve shaft and
and not correctly seating.
seating surfaces.

Small air leak from air cap when

gun is not triggered.

Air Valve Stem seal damaged or

Replace.
missing.

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TROUBLESHOOTING SPRAY PERFORMANCE

CONDITION CAUSE CORRECTION

Heavy top or bottom pattern.

Paint or coating build-up on air cap,

Soak cap or nozzle in suitable
plugged horn holes, centre holes or
solvent and thoroughly clean.
jets.

Paint or coating build-up on fluid

Replace fluid nozzle or air cap if
nozzle exterior or partially plugged
necessary.
fluid tip.

Replace fluid nozzle or air cap if

Fluid nozzle or cap dirty or damaged.
necessary.

Heavy right or left

side pattern.
Soak cap or nozzle in suitable
Left or right side horn holes plugged.
solvent and thoroughly clean.

Dirt or damage on left or right side Replace fluid nozzle or air cap if
of fluid nozzle exterior. necessary.

Remedies for the top-heavy, bottom-heavy, right-heavy and left-heavy patterns.

Determine if the obstruction is on the air cap or the fluid nozzle. 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. Also check for dried paint just inside the cap centre hole opening,
remove by washing with solvent.

If the defect is not inverted, it is on the fluid nozzle. Clean nozzle. If problem persists, renew nozzle.

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Heavy centre pattern.
Turn out counter clockwise to
Pattern adjustment valve set too low.
achieve correct pattern.

Reduce fluid flow by turning fluid

Too much paint or coating. needle adjusting screw clockwise.
Reduce fluid pressure.

Paint or coating too thick. Thin to correct consistency.

Atomizing air pressure too low. Increase air pressure.

Intermittent or 'fluttering'
spray fan. Loose fluid nozzle. Tighten.

Remove fluid nozzle, clean

Fluid nozzle not seated correctly in components, check cone seating on
gun head. tip and gun for damage or
contamination.

Partially obstructed fluid passage or

Clean or replace.
hose.

Split spray pattern

Increase fluid flow by changing fluid

nozzle size, opening needle control
Not enough paint or coating flow.
knob or increase fluid pressure on
pressure feed container.

Reduce air pressure by rotating

Too high horn pressure.
pattern control valve clockwise.

Too much air for fluid quanitity used. Reduce input air pressure.

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Ball end heavy
pattern.

Change fluid nozzle for smaller size

Too much fluid flow. or change air cap for different
specification air cap.

Too much atomization air pressure. Reduce air pressure.

Excessive bounce-back.
Check distance (normally 150-
Gun too far from surface.
200mm [6-8"]).

Too much fluid flow. Adjust gun or reduce fluid pressure.

Mix properly or apply light

Runs and sags. Paint or coating too thin.
coats/reduce fluid flow.

Gun tilted at an angle. Mount gun at right angle to work.

Gun too far from surface. Check distance.

Reduce air pressure and check spray

Too much air pressure.
pattern.
Thin, sandy coarse finish drying
before it flows out.

Increase fluid flow by changing fluid

nozzle size, supply pressure or
Fluid flow too low.
turning needle control knob counter
clockwise.

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DIMENSIONS

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NOTES

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NOTES

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WARRANTY POLICY

This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited
warranty. The use of any parts or accessories, from a source other than Carlisle Fluid
Technologies, will void all warranties. Failure to reasonably follow any maintenance
guidance provided, may invalidate any warranty.

For specific warranty information please contact Carlisle Fluid Technologies.

Carlisle Fluid Technologies is a global leader in innovative finishing technologies.

Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.

DeVilbiss®, Ransburg®, MS®, BGK®, and Binks® are registered trademarks of Carlisle Fluid
Technologies, Inc.
© 2020 Carlisle Fluid Technologies,Inc.
All rights reserved.

For technical assistance or to locate an authorised distributor, contact one of our international sales and
customer support locations below.

Region Industrial / Automotive Automotive Refinishing

Tel: 1-888-992-4657 Tel: 1-800-445-3988

Americas
Fax: 1-888-246-5732 Fax: 1-800-445-6643

Europe, Africa,
Tel: +44 (0)1202 571 111
Middle East,
Fax: +44 (0)1202 573 488
India

Tel: +8621-3373 0108

China
Fax: +8621-3373 0308

Tel: +81 45 785 6421

Japan
Fax: +81 45 785 6517

Tel: +61 (0) 2 8525 7555

Australia
Fax: +61 (0) 2 8525 7575

For the latest information about our products, visit www.carlisleft.com

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