Ransburg 75785 Service Manual Download Page 1

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SERVICE MANUAL
AH-94-04.7

AH-94-04.7

AH-94-04.7
(Replaces AH-94-04.6)
May - 2008

IMPOR

IMPORT

TANT

ANT

ANT: Before using this equipment,

: Before using this equipment,

carefully read SAFETY PRECAUTIONS,

carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions in

starting on page 1, and all instructions in

starting on page 1, and all instructions in
this manual. Keep this Service Manual for

this manual. Keep this Service Manual for

this manual. Keep this Service Manual for
future reference.

future reference.

REA-90 and REA-90L

ELECTROST

ELECTROSTA

ATIC SPRA

TIC SPRA

TIC SPRAY

APPLICA

APPLICAT

TORS

ORS

Dual Atomization T

Dual Atomization Technology

echnology

MODELS:

75785 - ST

75785 - STANDARD (SOL

ANDARD (SOL

ANDARD (SOLVENT

VENT

VENT BASE)

BASE)

75786 - ST

75786 - STANDARD (W

ANDARD (W

ANDARD (WA

ATERBORNE)

TERBORNE)

75979 - A

75979 - AVIA

VIA

VIAT

TOR/MGS (SOL

OR/MGS (SOL

OR/MGS (SOLVENT

VENT

VENT BASE)

BASE)

75982 - A

75982 - AVIA

VIA

VIAT

TOR (W

OR (W

OR (WA

ATERBORNE)

TERBORNE)

Service Manual Price:

€

25.00 (Euro)

$30.00 (U.S.)

Summary of Contents for 75785

Page 1: ...REA 90L REA 90 and REA 90L REA 90 and REA 90L ELECTROST ELECTROST ELECTROST ELECTROST ELECTROSTA A A A ATIC SPRA TIC SPRA TIC SPRA TIC SPRA TIC SPRAY Y Y Y Y APPLICA APPLICA APPLICA APPLICA APPLICAT T...

Page 2: ...s been changed from revision AH 94 04 6 AH 94 04 6 AH 94 04 6 AH 94 04 6 AH 94 04 6 to revision AH 94 04 7 AH 94 04 7 AH 94 04 7 AH 94 04 7 AH 94 04 7 Reasons for this change are noted under Manual Ch...

Page 3: ...TECHNOLOGY CONVERSION PROCEDURE SPRAY PATTERN ADJUSTMENT APPLICATOR TO TARGET DISTANCE AIR CAP FLUID NOZZLE SELECTION CHART AIR CAP FLUID NOZZLE PERFORMANCE CHART MAINTENANCE MAINTENANCE MAINTENANCE M...

Page 4: ...NTENANCE continued MAINTENANCE continued MAINTENANCE continued MAINTENANCE continued MAINTENANCE continued BARRELASSEMBLY HOOK TRANSFORMER ASSEMBLY HOOK TRANSFORMER ON OFF SWITCH REPLACEMENT HANDLE FA...

Page 5: ...AH 94 04 7 REA 90 and 90L Spray Applicators Contents...

Page 6: ...evant to the A NOTE is information relevant to the A NOTE is information relevant to the A NOTE is information relevant to the A NOTE is information relevant to the procedure in progress procedure in...

Page 7: ...e supplied to the atomizer must be turned off prior to cleaning flushing or maintenance When using solvents for cleaning Thoseusedforequipmentflushingshouldhaveflash points equal to or higher than tho...

Page 8: ...alogenatedhydrocarbonsolvents for example methylene chloride and 1 1 1 Trichloroethane are notchemicallycompatiblewiththe aluminum that might be used in many system components The chemicalreactioncaus...

Page 9: ...xplosion is lost if safety circuits aredisabledduringoperation Frequent power supply shutdown indicates a problem in the system whichrequirescorrection Anelectricalarccanignitecoating materials and ca...

Page 10: ...should be cut out Operators must remove from themselves all metal objects that are not grounded NOTE NOTE NOTE NOTE NOTE REFER TO NFPA 33 REGARDING OPERATORGROUNDING B Parts being sprayed Resistance...

Page 11: ...ssary lock the power supply out so that it cannot be turned ON until the work is finished Whenever removing high voltage cables from equipment ground the contact end of the cable by holdingthecablesuc...

Page 12: ...sing with the hands and fingers 3 Extreme or awkward finger wrist or arm positions 4 Excessive duration of the activity 5 Tool vibration 6 Repeated pressure on a body part 7 Working in cold temperatur...

Page 13: ...ation 7 Componentstobeincorporatedintoorusedas replacement parts of the equipment shall be fitted by suitably trained personnel in accordance with the manufacturer s documentation 8 The certification...

Page 14: ...apply Special conditions for safe use The REA 90 and 90L75785 75786 75979 and75982Electrostatic Applicators shall only be used with associated 76580 7XXXX 76580 6XXXX 76789 and75983 Control Unit Prod...

Page 15: ...01 Label 77319 01 Label 77319 01 Label 77319 01 Label 77322 Label 77322 Label 77322 Label 77322 Label 77322 Label 77325 Label 77325 Label 77325 Label 77325 Label 77325 Label 79657 Label 79657 Label 79...

Page 16: ...zed spray particles under the influence of the electrostatic field become electrically charged The charged particles are attracted to and deposited on the target object The forces between the charged...

Page 17: ...quirements This allows moving the REA 90 power source inside most spray booths or areas where the standard control unit may not be conveniently located Examples are airplane hangars etc NOTES NOTES NO...

Page 18: ...D ANDARD SPECIFICA SPECIFICA SPECIFICA SPECIFICA SPECIFICATIONS TIONS TIONS TIONS TIONS 75979 SOL 75979 SOL 75979 SOL 75979 SOL 75979 SOLVENT VENT VENT VENT VENT BASE BASE BASE BASE BASE REA 90 A REA...

Page 19: ...R MGS Solventborne Figure 1 REA 90 and REA 90L Standard AVIATOR MGS Solventborne Figure 1 REA 90 and REA 90L Standard AVIATOR MGS Solventborne Electrostatic Spray Applicator Features Electrostatic Spr...

Page 20: ...REA 90 STANDARD ANDARD ANDARD ANDARD ANDARD SPECIFICA SPECIFICA SPECIFICA SPECIFICA SPECIFICATIONS TIONS TIONS TIONS TIONS 75982 W 75982 W 75982 W 75982 W 75982 WA A A A ATERBORNE TERBORNE TERBORNE T...

Page 21: ...ATOR Waterborne Figure 2 REA 90 and REA 90L Standard AVIATOR Waterborne Figure 2 REA 90 and REA 90L Standard AVIATOR Waterborne Electrostatic Spray Applicator Features Electrostatic Spray Applicator F...

Page 22: ...supply must be interlocked with it also Routing of Low V Routing of Low V Routing of Low V Routing of Low V Routing of Low Voltage Cable oltage Cable oltage Cable oltage Cable oltage Cable Positionth...

Page 23: ...rget Power Power Power Power Power Supply Supply Supply Supply Supply Booth Booth Booth Booth Booth The electrical discharge that is available from the charging electrode must not exceed 0 25 mJ of en...

Page 24: ...nd hand tighten the retaining nut If during the routing of the low voltage cable it is required to remove it from the spray applicator care should be taken when reinstalling it back that the retaining...

Page 25: ...nnelareworking close by FluidlinestotheapplicatorMUSTbeprotected from scraping and abrasion on the floor or sharpmetaledgesthatcouldleadtovoltagepin holing and loss of kV on the charged system Cleanli...

Page 26: ...htly score the inner sheath linearly and then radially 1 inch from the outer jacket Split the inner sheath along the linear score mark and peel it away from the core fluid hose Then remove the sheath...

Page 27: ...he appropriate fluid source Figure 4 Fluid Hose Assembly Figure 4 Fluid Hose Assembly Figure 4 Fluid Hose Assembly Figure 4 Fluid Hose Assembly Figure 4 Fluid Hose Assembly AIR HOSE FITTING AIR HOSE F...

Page 28: ...ssure reducer from the barrel by unscrewing it counter clockwise 4 Install the new pressure reducer 5 Installappropriatefluidnozzle gentlytightening intoplaceusingthespecialmulti purposeapplicator wre...

Page 29: ...rnaxisoffanatomizersfromhorizontal to vertical loosen the retainer ring rotate the air cap clockwise to the desired position and gently tighten the ring APPLICA APPLICA APPLICA APPLICA APPLICAT T T T...

Page 30: ...Orifice ID Fluid Nozzle Fluid Nozzle Fluid Nozzle Fluid Nozzle Fluid Nozzle Part Part Part Part Part 75600 01 75600 02 75600 03 AIR CAP FLUID NOZZLE SELECTION CHART AIR CAP FLUID NOZZLE SELECTION CHA...

Page 31: ...D NOZZLE PERFORMANCE CHART AIR CAP FLUID NOZZLE PERFORMANCE CHART 600 300 318 Spray Spray Spray Spray Spray T y p e T y p e T y p e T y p e T y p e Air Spray Air Spray HVLP Spray A i r A i r A i r A i...

Page 32: ...onents some oftheseitemsmaybesoakedinasuitablecleaning solvent The items that cannot be soaked are noted throughout this manual All o ring and electrical components cannot cannot cannot cannot cannot...

Page 33: ...2 Trigger the applicator gun high voltage ON 3 Slowly approach the applicator electrode to any grounded object and make contact 4 Monitorthecurrentoutputreadingonthevoltage supplymeterastheapplicator...

Page 34: ...aning Routine Cleaning Equipment Needed Equipment Needed Equipment Needed Equipment Needed Equipment Needed An appropriate solvent A solvent safety container grounded A small soft bristled brush The I...

Page 35: ...it clean A surface charge may build up on the plastic surface and discharge to the nearest grounded object Efficiency of the applicator will also be reduced and damage or failure of the applica tor co...

Page 36: ...h 7969 10 Plastic or Wood Dowel Rod 5 16 inch diameter TO REMOVE THE TO REMOVE THE TO REMOVE THE TO REMOVE THE TO REMOVE THE APPLICA APPLICA APPLICA APPLICA APPLICAT T T T TOR FROM THE OR FROM THE OR...

Page 37: ...id Hose Assembly 71 Air Hose Assembly 77 LowVoltageCable Item Item Item Item Item Description Description Description Description Description 4 Loosen the low voltage cable nut from the plug assembly...

Page 38: ...luid tube fitting 5 Pull the fluid hose assembly out of the barrel removing the spacer ferrule and fluid tube connector Then continue pulling the fluid hose assembly through the bracket removing the f...

Page 39: ...Nozzle and Nut Figure 7 Air Cap Fluid Nozzle and Nut Figure 7 Air Cap Fluid Nozzle and Nut Figure 7 Air Cap Fluid Nozzle and Nut Figure 7 Air Cap Fluid Nozzle and Nut 1 RetainingNut 2 Air Cap 3 Fluid...

Page 40: ...ing and Inspection Cleaning and Inspection Cleaning and Inspection Cleaning and Inspection 1 Use a suitable solvent to clean the needle electrode Referto SuitableSolventsforCleaning REA 90Applicatorsi...

Page 41: ...t completely and remove the air cap 3 Using a flat head screwdriver remove the two shoulder screws that retain the trigger to the applicatorhandle 4 While holding the grounding spring located under th...

Page 42: ...dge Seal Assembly Figure 9 Cartridge Seal Assembly Figure 9 Cartridge Seal Assembly Cleaning and Inspection Cleaning and Inspection Cleaning and Inspection Cleaning and Inspection Cleaning and Inspect...

Page 43: ...and over the external threads of the needle shaft Once both internal o rings have cleared the threads slide it onto the sealing area 2 Screwtheneedle electrodeontothefrontofthe needle shaft and hand...

Page 44: ...into the packing chamber from the rear of the barrel with the needle electrode forward 12 Push the needle shaft sub assembly forward until the packing nut will engage its mating thread in the barrel a...

Page 45: ...edle shaft spring into the spring retainer Align the electrical connectors of the barrel with the mating holes in the hook transformer assembly and the needle shaft spring with the spring recess in th...

Page 46: ...tage Cable Plug Assembly Item Item Item Item Item Description Description Description Description Description 7 Check the spacing between the back of the spring retainer and the handle It should be ab...

Page 47: ...Figure 17 6 Turn the control unit on and adjust the voltage knob clockwise to increase the voltage to the hook transformer 7 Watch the red lens at the rear of the hook transformer As the voltage is i...

Page 48: ...HOOK TRANSFORMER HOOK TRANSFORMER HOOK TRANSFORMER HOOK TRANSFORMER HOOK TRANSFORMER ON OFF SWITCH ON OFF SWITCH ON OFF SWITCH ON OFF SWITCH ON OFF SWITCH REPLACEMENT REPLACEMENT REPLACEMENT REPLACEM...

Page 49: ...edures should be completed Removal from Service Removal Fluid Tube and Fluid Hose forSolventBaseApplicators orFluidHose for Waterborne Applicators Removal Air Hose Removal Low Voltage Cable Removal Lo...

Page 50: ...eneedleforwear Replaceanydamaged or worn parts Assembly Assembly Assembly Assembly Assembly 1 Apply a light coating of dielectric grease to a new o ring and slide it over the threads of the retaining...

Page 51: ...ure 19 Air Valve Figure 19 Air Valve Figure 19 Air Valve Figure 19 Air Valve Figure 19 Air Valve 5 Witha3 8 inchwrench completelyremovethe retaining nut with the internal u cup seal Cleaning and Inspe...

Page 52: ...handle using a standard blade screwdriver The applicator trigger can be replaced ei ther with the applicator on line or removed from service If the following procedure is to be done online make sure t...

Page 53: ...el gasket 3 Check the spring to ensure it has seated into the handle recess and tighten the barrel retaining nut 4 Reinstall the trigger and ground spring refer to Trigger in the Maintenance section L...

Page 54: ...w voltage cable plug assembly to the handle The set screw is located toward the bottom of the handle on the front side see Figure 21 4 Hold the bottom of the plug assembly and pull it straight out of...

Page 55: ...to the air hose fluid hose bundle 3 Connect the low voltage cable assembly to the low voltage control unit FLUID TUBE FLUID TUBE FLUID TUBE FLUID TUBE FLUID TUBE SOL SOL SOL SOL SOLVENT VENT VENT VENT...

Page 56: ...damaged it should be replaced NOTE NOTE NOTE NOTE NOTE The accumulation of paint on the outer surface of the fluid tube can lead to reduced gun efficiency and or electrical damage C A U T I O N C A U...

Page 57: ...pply If the fluid hose will not flow solvent when the gun is removed from service it is plugged and must be replaced Fluid hoses should be replaced periodically depending on the type of materials bein...

Page 58: ...e assembly of this hose can only be done by certified ITW Ransburg Techni cians NOTE NOTE NOTE NOTE NOTE The conductive ferrule is black and is split down one side NOTE NOTE NOTE NOTE NOTE AIR LINE AI...

Page 59: ...come off with the air fitting and o ring attached 7 Remove the o ring from the air fitting stem and pull the air fitting through the fluid tube bracket Cleaning and Inspection Cleaning and Inspection...

Page 60: ...stance Be sure not to over adjust in either direction The following procedure is to set the sequence of operation for air and fluid as the trigger is actuated It is very important that atomizing air b...

Page 61: ...d End 1 Clogged or faulty air cap 2 Clogged or faulty fluid nozzle 1 Cleanorreplace 2 Cleanorreplace Pattern Will Not Pattern Will Not Pattern Will Not Pattern Will Not Pattern Will Not Shape Shape Sh...

Page 62: ...targetground 2 Improperspraytechnique 3 Improperboothexhaust 4 Excessive atomizing air 5 Excessive target distance 1 Trace and correct 1 megohm maxi mum ground to target resistance 2 See ITW Ransburg...

Page 63: ...tage Voltage Voltage Voltage Continued 6 Faulty control unit 7 Check fuses 8 Is the power turned on 9 Is the atomizing air turned on 10 Is the applicator triggered 11 Is the hook transformer on 12 Is...

Page 64: ...igure 26a 75785 Solvent Base Standard and 75979 Solvent Base AVIATOR MGS Figure 26a 75785 Solvent Base Standard and 75979 Solvent Base AVIATOR MGS Figure 26a 75785 Solvent Base Standard and 75979 Solv...

Page 65: ...ng Trigger 4 finger 1 Offset Bracket 2 45o Bracket Note Note Note Note Note The long trigger cannot be used with the 45o bracket 75979 SOL 75979 SOL 75979 SOL 75979 SOL 75979 SOLVENT VENT VENT VENT VE...

Page 66: ...Reducer Pressure HVLP White 74963 03 7 Nut Retainer Barrel 75323 00 8 Ring Retaining Barrel 75326 00 9 Electrode Assembly 70430 00 10 113 Seal Assembly Cartridge Non Adjustable REA 78626 00 12 133 Sh...

Page 67: ...5o Bracket 093 ID 8 15 16 Required 9704 16 56 Nut and Ferrule 3587 03 57 Nut Jam 10553 06 58 Fluid Tube Bracket Bulkhead Fitting Fluid Tube Bracket Bulkhead Fitting Fluid Tube Bracket Bulkhead Fitting...

Page 68: ...cription REA 90 90L REA 90 90L REA 90 90L REA 90 90L REA 90 90L SPRA SPRA SPRA SPRA SPRAY Y Y Y Y APPLICA APPLICA APPLICA APPLICA APPLICAT T T T TORS 75785 75979 ORS 75785 75979 ORS 75785 75979 ORS 75...

Page 69: ...AH 94 04 7 REA 90 and 90L Spray Applicators Parts Identification 64 64 64 64 64 NOTES NOTES NOTES NOTES NOTES...

Page 70: ...ne Standard and 75982 Waterborne AVIATOR Figure 26b 75786 Waterborne Standard and 75982 Waterborne AVIATOR Figure 26b 75786 Waterborne Standard and 75982 Waterborne AVIATOR Figure 26b 75786 Waterborne...

Page 71: ...odel No 75786A BB C 21 Model No 75786A BB C 21 Model No 75786A BB C 21 S Air Spray L HVLP 2 Short Trigger 2 finger 4 Long Trigger 4 finger 75982 W 75982 W 75982 W 75982 W 75982 WA A A A ATERBORNE REA...

Page 72: ...r Pressure HVLP White 74963 03 7 Nut Retainer Barrel 75323 00 8 Ring Retaining Barrel 75326 00 9 Electrode Assembly 70430 00 10 113 Seal Assembly Cartridge Non Adjustable REA 78626 00 12 133 Shaft Ass...

Page 73: ...08 00 62 Nut Connector Fluid Tube 72309 00 635 Nut Ferrule 3587 02 64 Ferrule Conductive 72315 00 65 Nut Jam 10553 05 66 Fitting Bulkhead Bracket Fluid Hose 72310 00 67 Connector 6241 06 68 Fitting Sw...

Page 74: ...AR AR AR ARTS LIST TS LIST TS LIST TS LIST TS LIST Figure 26b Figure 26b Figure 26b Figure 26b Figure 26b Rebuild Kit 78929 01 1 2 2 3 Wrench Nozzle 19749 00 2 2 4 4 Barrel Nut 75323 00 1 2 2 3 Fits h...

Page 75: ...Air Spray Conversion Kit 75733 00 Contains 74963 02 Black Pressure Reducers 18851 01 Fan Control Valve Assembly 4904 65R Air Cap 4907 45 Nozzle 73569 00 Retaining Ring REA 90 Applicator Rebuild Kit RE...

Page 76: ...ARRANTY IS TO REPLACE UNDER THIS WARRANTY IS TO REPLACE UNDER THIS WARRANTY IS TO REPLACE UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE PARTS THAT HAVE FAILED BECAUSE PARTS THAT HAV...

Page 77: ...4 04 6 REA 90 and 90L Spray Applicators Applicators Applicators Applicators Applicators to make the following changes 1 Replaced Label on the Front Cover 2 Replaced Labels72562 76180 76801 76856 76860...

Page 78: ...hnical Service Assistance Technical Service Assistance Automotive Assembly and Tier I Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns T...

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