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| Weird.
Few questions to hammer out whats going on:
1. Just to confirm it is leaking only while spraying. (Just ruling out that it wasn't a leak through the solenoid that'd have the nozzle dripping, but I'm pretty sure you said it only leaks between the two)
2. If you plug in those nozzles onto the non-PWM nozzle body, would it still leak?
As far as the o-ring, it is a metric o-ring (13mm x 3mm), so it wouldn't be a common thing to use the wrong one from the factory, but gotta investigate it anyways.
3. What color is the o-ring? (just to check vintage/year of the nozzles - as we have been swapping to a red FKM material to replace standard Buna-N o-rings in all nozzles - if it is red, it is FKM, if black - likely Buna-N)
4. Are these brand new caps? If they are old(er) and might have seen some swelling from chem additives/etc, they could potentially cause leaking issues.
5. By chance did you swap the o-ring from one of the non-leaking nozzles to the leaking one? Did that make a difference? (Just to try isolate if the o-ring was on the shy side of spec.)
6. What kind of pressures are you typically spraying at?
Conceivably, suppose it could be a situation where the o-ring is on the bottom end of tolerance, and the cap is on the upper end of tolerance, but that'd be pretty rare in itself as well.
Let me know what you can to try figure that out, as leaking bodies aren't good.
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Wilger Nozzle Bodies and Caps ?
