Evolv Sidekick & Spray Gun Troubleshooting Guide

Quick Solutions for Common Issues

Welcome to the Evolv Troubleshooting Guide! Whether you’re experiencing issues with your spray gun, solution cartridges, or the Sidekick unit itself, this guide is designed to help you quickly identify and resolve the most common problems.

Each section provides clear, step-by-step instructions to get your equipment back up and running smoothly. From connection issues to air pressure problems, we’ve got you covered with practical tips and part references.

Troubleshooting Guide: Spray Gun Not Spraying Solution

If your spray gun isn’t spraying solution, don’t worry—we’ll help you get it working again! Here are some common issues and how to fix them:

1. Check the Solution Cartridges

  • Possible Issue: Cartridges may be old, dirty, or faulty.
  • What to Do: Try using a new cartridge (Part #300456). If the gun sprays with a new one, the old cartridge was likely the problem.

2. Clean the Fluid Nozzle

  • Possible Issue: Old solution buildup can clog the nozzle.
  • What to Do: Remove and clean the fluid nozzle (Part #300454) using warm water. Use the nozzle tool for safe removal. Do not pour water directly into the gun. Make sure the nozzle is screwed back in properly.

Tip: Clean the nozzle every 1–2 weeks to prevent buildup.

3. Inspect the Trigger Mechanism

  • Possible Issue: Springs inside the trigger may be broken.
  • What to Do: Pull the trigger and check if the air flap inside the heat port moves. If not, open the gun casing and inspect the springs. Replace if needed (Part #201353).

4. Test the Fluid Coupler

  • Possible Issue: A faulty coupler can block solution flow.
  • What to Do: Use the purge tool (Part #101012) while holding down the trigger. Make sure the tool clicks into the coupler behind the green release button. If there’s resistance or no flow, the coupler may need replacing (Part #201361).

5. Check for Air Pressure Loss

  • Possible Issue: Cracks or holes in the gun, hose, or Sidekick air blower can reduce pressure.
  • What to Do: Turn on the machine and feel along the hose for air leaks—from the Sidekick to the gun base. If you detect a lot of escaping air, the equipment may need servicing. In our warehouse, we’ll inspect and repair/replace any cracked parts (nozzle body, heater cartridge, hose, or air blower).

Note: If the machine shuts off after running for a while, this could also be a sign of air pressure loss.

6. Check the Solution Quality

  • Possible Issue: Expired or temperature-damaged solution won’t spray properly.
  • What to Do: Look for the lot number and expiration date. Solution should be stored at room temperature. If it’s expired or has been exposed to extreme temperatures, offer a replacement.

Troubleshooting Guide: Spray Gun Leaking

If your spray gun is leaking, we’re here to help you pinpoint the issue and get it fixed quickly. Below are the most common causes and how to resolve them.

1. Check the Fluid Nozzle

  • Possible Issue: The nozzle may not be screwed in correctly, causing leaks around the green air collar.
  • What to Do: Make sure the fluid nozzle is fully screwed in and flush against the nozzle body. Avoid overtightening.

2. Inspect the Nozzle Seals

  • Possible Issue: Worn or damaged seals inside the fluid nozzle can cause leaks.
  • What to Do: Remove the nozzle and inspect the black Viton seal (Part #201350). You may need retaining ring pliers to access it. If the seal looks warped, torn, or misshaped, it should be replaced.

3. Examine the Fluid Coupler

  • Possible Issue: A damaged or worn fluid coupler can lead to leaks.
  • What to Do: If solution isn’t flowing properly, the coupler may need to be replaced (Part #201361).

4. Check the Solution Cartridge

  • Possible Issue: Cracks or damage in the cartridge can cause leaks at the back of the gun.
  • What to Do: Inspect the cartridge, especially where the green and clear plastic are joined. If leaking, replace the cartridge.

5. Inspect the Nozzle Body

  • Possible Issue: Cracks in the nozzle body (Part #100757) may cause internal leaks.
  • What to Do: This requires opening the spray gun casing. If cracked, the entire nozzle body must be replaced. The equipment will need to be shipped in for service.

6. Internal Component Issue

  • Possible Issue: A 3-piece component pressed into the nozzle body and fluid inlet may be damaged or misaligned.
  • What to Do: This part isn’t visible or replaceable by the customer. To identify the issue, purge the gun without the plastic housing. If you see a clear leak from this area, the component (Part #201364) needs to be replaced and properly seated.

Troubleshooting Guide: Spray Gun Sprays Without Trigger Being Pulled

If your spray gun is spraying solution on its own, it’s likely due to a mechanical or maintenance issue. Let’s walk through the most common causes and how to fix them.

1. Sticky Needle Mechanism

  • Possible Issue: The needle behind the fluid nozzle may be stuck due to dried solution or lack of cleaning.
  • What to Do: Remove and clean the fluid components:
    • Fluid nozzle
    • Needle and needle base
    • Actuator pin
    • Compression spring

    Customers can typically access the fluid nozzle and needle. After cleaning, the actuator pin should move freely when the trigger is pulled and released.

2. Worn Seals

  • Possible Issue: Damaged or worn seals can cause inconsistent sputtering or unintended spraying.
  • What to Do: Check the white O-rings (Part #201495) and the black Viton seal inside the fluid nozzle. If they appear torn, warped, or misshaped, replace them.

3. Damaged Nozzle Body Threading

  • Possible Issue: If the fluid nozzle was screwed in incorrectly, it may have damaged the threading, preventing a proper seal.
  • What to Do: Inspect the nozzle body to ensure the fluid nozzle sits correctly. If the threading is worn or damaged, the nozzle body will need to be replaced.

4. Incorrect Solution Type

  • Possible Issue: Non-Evolv solutions may be too thin, allowing them to bypass the needle even when the trigger isn’t pulled.
  • What to Do: Test the gun with both Evolv solution and the customer’s solution. If the issue only occurs with the non-Evolv solution, it may be due to viscosity differences.

Note: The Evolv system is designed specifically for Evolv solutions. Using other solutions may affect performance and is not covered under warranty.

Troubleshooting Guide: Sidekick Not Powering On

If your Sidekick isn’t turning on and no lights are showing, here are a few steps to help you identify and resolve the issue.

1. Check the Power Connection

  • Possible Issue: The power cord may not be plugged in.
  • What to Do: Make sure the power cord is securely plugged into a working outlet.

2. Reset the Breaker

  • Possible Issue: The Sidekick’s internal breaker may have tripped.
  • What to Do:
    • Pull the cabinet out and locate the blue switch on the roof of the inside area.
    • Make sure the switch is in the ON position.
    • For the Mini Sidekick, the switch is located on the back.
    • Also check your building’s circuit breakers to ensure power is flowing to the outlet.

3. Test the Power Cord

  • Possible Issue: The power cord assembly may have failed.
  • What to Do: Try using a different power cord. If the Sidekick powers on with a new cord, the original one needs to be replaced.

4. Internal Electrical Issue

  • Possible Issue: If the cord and breaker are fine, but the Sidekick still won’t turn on, there may be a deeper electrical issue.
  • What to Do: The unit will need to be inspected at the Evolv warehouse. Our technicians will:
    • Check all wiring from the power cord to the Power Control Board.
    • Use a testing station to identify failed components (e.g., power cord, EMI filter, PCB, LED touchpad).

Troubleshooting Guide: Sidekick Shuts Off During a Tan

If your Sidekick shuts off mid-session, especially when heat is on, it’s likely due to a connection or airflow issue. Here’s how to identify and fix the problem:

1. Check Spray Gun Connection

  • Possible Issue: The spray gun may not be properly attached to the hose.
  • What to Do: Make sure the cuff on the hose is securely screwed onto the bottom of the spray gun. If it’s loose, the heating circuit won’t complete, and the Sidekick may shut off with two flashing red lights on the touchpad.

Note: The Sidekick can spray air without heat even if the gun isn’t attached—but heat requires a full connection.

2. Look for Air Leaks

  • Possible Issue: A large air leak in the hose or air blower can cause overheating and automatic shutdown.
  • What to Do: If the hose or Sidekick feels unusually hot, it may be working too hard to compensate for lost air. The unit should be inspected at the warehouse:
    • Reattach or replace the hose if needed.
    • Inspect the air blower for cracks or leaks. Replace the blower assembly if necessary.

3. Check Air Brushes in the Blower

  • Possible Issue: The internal air brushes may be worn out.
  • What to Do: These components typically last 4–7 years depending on usage. The Sidekick and blower need to be opened to inspect and replace the brushes if they’re worn.

4. Inspect the Heater Cartridge

  • Possible Issue: The heater cartridge inside the spray gun may be cracked or electrically faulty.
  • What to Do:
    • Open the spray gun and check the heater cartridge (Part #510425) for visible damage.
    • If cracked, it can be rebuilt using a new garolite tube (Part #300478) or replaced entirely.
    • If no crack is visible but the cartridge still doesn’t work, it may need to be replaced due to internal failure.

Troubleshooting Guide: Cartridge Won’t Click Into Spray Gun

If you’re having trouble getting the cartridge to click into place, it’s usually a quick fix! Here’s how to get it working smoothly:

1. Press the Green Release Button

  • Possible Issue: The cartridge won’t insert unless the green release button is pressed.
  • What to Do:
    • Press the green release button firmly before inserting the cartridge.
    • This moves the metal mechanism inside the fluid coupler to the right, making space for the cartridge to lock in.

2. Check the Fluid Coupler Installation

  • Possible Issue: The fluid coupler may be screwed in incorrectly, preventing proper alignment.
  • What to Do:
    • Make sure the fluid coupler is screwed into the fluid inlet with exactly 7 full rotations from its seated position inside the gun.
    • This ensures the cartridge can align and click in properly.